Method and system for testing spas

Abstract

A test system and method for testing a spa system which includes a spa tub for holding water, an electronic controller system which controls the spa system functions, and one or more controlled devices. The system and method exercises the controlled devices during a testing regime, and monitors electrical current drawn by the spa system during the testing regime. The electrical current drawn by the spa system during the testing regime can be compared with an expected current draw specification.

1 . A method for testing a spa system which includes a spa tub for holding water, an electronic controller system which controls the spa system functions, a plurality of controlled devices controlled by the controller system including a pump for recirculating water in the tub, and a heater for heating water, the method comprising: 
 electrically coupling a test station to the spa system;    exercising the plurality of controlled devices during a testing regime;    monitoring an electrical current drawn by the spa system;    determining whether the electrical current drawn by the spa system during the testing regime is consistent with an expected current profile; and    disconnecting the test station from the spa system.    
   
   
       2 . The method of  claim 1 , further comprising: 
 filling the spa tub with water before exercising the plurality of controlled devices.    
   
   
       3 . The method of  claim 1 , wherein said exercising the plurality of controlled devices comprises: 
 conducting a pump cycle comprising turning the pump on, running the pump for a time, and turning the pump off.    
   
   
       4 . The method of  claim 1 , wherein said exercising the plurality of controlled devices comprises: 
 turning the heater on, and subsequently turning the heater off.    
   
   
       5 . The method of  claim 1 , wherein said exercising the plurality of controlled devices further comprises: 
 turning a blower fan on, and subsequently turning the fan off.    
   
   
       6 . The method of  claim 1 , wherein said exercising the plurality of controlled devices further comprises turning a spa light on, and subsequently turning the spa light off.  
   
   
       7 . The method of  claim 1 , wherein said exercising the plurality of controlled devices comprises: 
 sending a command or set of commands from a test station to the electronic controller of the spa system to turn on and turn off one or more of the controlled devices.    
   
   
       8 . The method of  claim 1 , wherein said exercising the plurality of controlled devices comprises: 
 operating each of said plurality of controlled devices one at a time to isolate the current drawn by each controlled device.    
   
   
       9 . The method of  claim 1 , wherein said exercising the plurality of controlled devices comprises operating all of said controlled devices simultaneously to measure a maximum current load of the spa.  
   
   
       10 . The method of  claim 1 , further comprising: 
 generating a test report indicative of operability of the spa under test during the test regime.    
   
   
       11 . The method of  claim 1 , wherein the test report includes listing of test results for each controlled device, and reflects a pass or fail test state.  
   
   
       12 . The method of  claim 1 , further comprising: 
 printing a certificate indicative of a successive test result if the spa under test operates normally during the testing regime.    
   
   
       13 . The method of  claim 1 , further comprising: 
 establishing a data communication link between the spa controller and the test station;    periodically passing spa status data over the data communication link from the spa controller to the test station indicative of a status of the spa and the controlled devices;    passing commands over the data communication link from the test station to the spa controller for execution by the spa controller.    
   
   
       14 . The method of  claim 1 , wherein the spa system further includes a spa control panel for entering spa commands, the method further comprising: 
 testing the spa control panel.    
   
   
       15 . A test system for testing a spa system which includes a spa tub for holding water, an electronic controller system which controls the spa system functions, a plurality of controlled devices controlled by the controller system including a pump for recirculating water in the tub, and a heater for heating water, the test system comprising: 
 a current sensor for sensing a spa current drawn by the spa system and providing a sensor signal indicative of the spa current;    a test computer system;    a data link between the spa controller system and the test computer system for transmitting spa system data to the test computer system and commands from the test computer system to the spa controller system;    a set of test instructions for execution by the test computer system for generating a set of commands to the spa controller to exercise the plurality of controlled devices during a testing regime;    the test computer system adapted to monitor said sensor signals during the testing regime and to determine whether the electrical current drawn by the spa system during the testing regime is within a predetermined specification, the test system being disconnected from the spa system during normal spa operation.    
   
   
       16 . The system of  claim 15 , wherein said set of test instructions comprises: 
 an instruction set for conducting a pump cycle comprising turning the pump on, running the pump for a time, and turning the pump off.    
   
   
       17 . The system of  claim 15 , wherein said set of test instructions comprises: 
 an instruction set for turning the heater on, and subsequently turning the heater off.    
   
   
       18 . The system of  claim 15 , wherein said set of test instructions comprises: 
 an instruction set for turning a blower fan on, and subsequently turning the fan off.    
   
   
       19 . The system of  claim 15 , wherein said set of test instructions comprises: 
 an instruction set for turning a spa light on, and subsequently turning the spa light off.    
   
   
       20 . A test system for testing a spa system which includes a spa tub for holding water, an electronic controller system which controls the spa system functions, a plurality of controlled devices controlled by the controller system including a pump for recirculating water in the tub, and a heater for heating water, the test system comprising: 
 means for sensing a spa current drawn by the spa system and providing a sensor signal indicative of the spa current;    a test computer system;    means for transmitting spa system data to the test computer system and commands from the test computer system to the spa controller system;    a set of test instructions for execution by the test computer system for generating a set of commands to the spa controller to exercise the plurality of controlled devices during a testing regime;    the test computer system adapted to monitor said sensor signals during the testing regime and to determine whether the electrical current drawn by the spa system during the testing regime is within a predetermined specification, said test system being disconnected from the spa system during normal spa operation.