PROGRAMMABLE DRAIN PUMP

Evaporative cooler apparatus includes two pumps, a primary pump which pumps water to an evaporative medium and a secondary pump for pumping water from the bottom of the cooler to drain the water reservoir of the cooler. The secondary, or drain pump includes a programmable timer that is operable by a user to select a run time duration for the pump motor from a plurality of possible run times. The programmable drain pump also includes a user control for selection of an off-state time from a plurality of available off-state times or intervals between run times of the drain pump motor. The programmable drain pump also includes a constant on control and a test control.

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Description
CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/871,798, filed Aug. 29, 2013, which is incorporated herein by reference.

FIELD

This disclosure relates to an evaporative cooler apparatus and, more particularly to a programmable drain pump for use with evaporative coolers in which a primary pump is used to supply water to an evaporative medium, and a secondary drain pump is used to drain the water pan of the evaporative cooler.

BACKGROUND

Evaporative cooler pumps have been known for many years. Typically, a single pump is used in an evaporative cooler to provide water for soaking an evaporative medium through which air is forced. The air is cooled evaporatively by giving up the latent heat of evaporation to the water in the evaporative medium.

An inherent problem with evaporative cooler pumps of the prior art is their limitation of pumping efficiently when the water level in the pan at the bottom of the evaporative cooler drops below a certain amount, which is typically an inch or so. As the water level decreases, there is cavitation caused by the pump design, namely the impeller of the pump, and the pump loses efficiency. Air is introduced into the stream of pumped water due to impeller cavitation, and the flow rate efficiency of the pump drops substantially. This is particularly important when the purpose of the pump is to evacuate the reservoir.

The evaporative cooler pump of certain embodiments includes an impeller design which greatly enhances the pumping flow rate efficiency by decreasing the cavitation and accordingly allowing the water level to drop substantially below that which is usable in the prior pumps, and still pumping efficiently without air bubbles in the pump water line.

A second feature of the pump apparatus of the present invention is the utilization of a secondary pump to periodically drain the evaporative cooler.

To decrease the dissolved solids (or salts) content of water used by evaporative coolers, a bleed system has been utilized by which a portion of the pumped water is continually bled off and drained out of the evaporative cooler. This requires the continual addition of new water to the evaporative cooler on a regular basis to replace the water that has bled off. The introduction of the fresh make-up water decreases the salt concentration content of the water in the cooler sump.

Since some of the water pumped to the evaporative medium drains down and returns to the sump, or bottom, of the evaporative cooler, that water includes the salts originally present in the water, and the buildup of salts in the cooler, and on the evaporative medium, causes a loss of efficiency of the evaporative medium and a buildup of the salts in the evaporative cooler housing itself The continuous bleed-off of the water requires the introduction of fresh water to help decrease the salinity concentration. On the other hand, the continuous bleed-off wastes a substantial amount of water.

A secondary pump, a drain pump, in the evaporative cooler apparatus of certain embodiments substantially decreases the waste of the water, such as heretofore bled off, by periodically draining the sump or bottom portion of the evaporative cooler housing, thus allowing for the introduction of fresh water on a periodic basis. This provides at least two advantages. The first advantage is the use of less water than the prior continual bleed systems, and a decrease in the salinity of the water due to the replenishment of the water on a regular basis.

A timer is used to actuate the drain pump on a regular basis. The salt or mineral buildup decreases, and the periodic changing of the water prevents a buildup or accumulation of stagnant water, and accordingly, there is a substantial decrease possibility of the breeding of mosquitoes in the evaporative cooler.

SUMMARY

The invention described and claimed herein comprises evaporative cooler apparatus in which a pair of evaporative cooler pumps is connected together. A primary, supply pump is used to provide water for the evaporative medium in the evaporative cooler. A secondary pump is used as a drain pump to periodically drain the water from the bottom of the evaporative cooler. The water is then replenished in the normal manner, such as by means of a float control valve. The pumps include impellers which allow the pumps to function efficiently in water depths as low as about a quarter of an inch or so without appreciable loss in flow rate. The impellers include vanes on both the bottom and the top of an impeller disk. The impeller design substantially increases the efficiency of the pumping process. A drain adapter is utilized to allow a drain pipe in the housing of the cooler apparatus to also be connected to the drain pump. The above-mentioned drain adapter also ensures the presence of an air gap to act as an anti-siphon protection.

In one aspect of the invention, the drain pump is a programmable drain pump having two modes of operation: a constant run mode wherein the drain pump continuously and indefinitely is in an on state and pumping water; and an alternating on/off, or intermittent run mode, whereby the motor turns on for a first programmed period of time and then turns off for a second programmed period of time, and then repeats the cycle.

Among the objects of certain embodiments of the present invention are the following:

  • To provide a new and useful evaporative cooler apparatus;
  • To provide a new and useful evaporative cooler pump apparatus;
  • To provide a pair of pumps in an evaporative cooler;
  • To provide a new and useful evaporative cooler pump apparatus having a high efficiency impeller for pumping in relatively low water level;
  • To provide a new and useful drain adapter for an evaporative cooler;
  • To provide an evaporative cooler pump apparatus having a primary pump for supplying water to an evaporative medium and a secondary pump for draining the water in the evaporative cooler on a periodic basis; and
  • To provide a new and useful high efficiency evaporative cooler apparatus utilizing two pumps.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a perspective view of an evaporative cooler such as may include a programmable drain pump of the present invention, showing the pump in its use environment;

FIG. 2 is a perspective view of a drain pump which may be a programmable drain pump of the present invention;

FIG. 3 is an exploded perspective view of a lower portion of the drain pump apparatus of FIG. 2;

FIG. 4 is a side view in partial section of a lower portion of the drain pump apparatus of FIG. 2;

FIG. 5 is a bottom plan view of an impeller portion of the drain pump apparatus of FIG. 2;

FIG. 6 is a view in partial section taken generally along line 6-6 of the impeller of FIG. 5;

FIG. 7 is a top plan view of the impeller of FIG. 5;

FIG. 8 is a perspective view of a drain adapter portion of the apparatus of FIG. 2;

FIG. 9 is a side view in partial section illustrating the drain adapter apparatus of FIG. 8 in its use environment;

FIG. 10 is a top, right side perspective view of an embodiment of a programmable drain pump;

FIG. 11 is a top, front perspective view of the programmable drain pump of FIG. 10;

FIG. 12 is a top, left side view showing the top panel of the programmable drain pump of FIG. 10;

FIG. 13 is a top isometric view of an embodiment of the programmable drain pump, showing a pump control panel on a top surface of the programmable drain pump, as disclosed herein;

FIG. 14 is a cross section view of the programmable drain pump of FIG. 13, showing the internal components thereof, as disclosed herein; and

FIGS. 15A and 15B are the two parts of a circuit diagram of the programmable circuit for an embodiment of the programmable drain pump as disclosed herein.

 DETAILED DESCRIPTION

FIG. 1 is a perspective view of evaporative cooler apparatus 10, which comprises the use environment of an evaporative cooler pump apparatus 70 and a programmable drain pump apparatus 100 of the present invention. The pumps 70 and 100 are shown disposed within an evaporative cooler housing 12, and on a bottom wall 14 thereof. The housing 12 also includes a pair of side walls 16 and 20, a back wall 24, and a front wall, not shown, and a top wall 34. The side walls 16 and 20 both include openings, and appropriate panels are disposed in the openings, and evaporative medium is in turn secured to panels in the openings. In FIG. 1, the evaporative medium 18 is shown disposed within the opening of the side wall 16. An opening 26 is shown extending through the back wall 24. The opening 26 may likewise include an appropriate panel for holding an evaporative medium.

Within the housing 12 is a blower housing 40. A blower or fan disposed within the housing 40 provides the air flow into the interior of the housing 12 through the evaporative medium pads and into the structure to which the evaporative cooler apparatus 10 is secured.

An electric outlet 50 is shown secured to the blower housing 40. A conductor 52 extends from the outlet 50 outwardly, as is well known and understood in the art.

A water input conduit 60 is shown extending to the side wall 16. The conduit 60 is appropriately connected to a valve 62. The valve 62 is controlled by a float 64. As the water level within the bottom of the housing 12 decreases, the float 64 opens the valve 62 to replenish the water supply. Such is well known and understood by those of skill in this art.

Two pumps, a primary or supply pump 70, and a secondary or drain pump 100, are shown disposed on the bottom wall 14 of the housing 12. The secondary or drain pump 100 is programmable as will be discussed in further detail hereinafter. A water conduit 72 extends from the supply pump 70 upwardly to a water distribution manifold or spider which in turn carries the water to the evaporative medium pads 18.

The secondary or drain pump 100 is connected to a drain conduit 102.

The conduit 102 extends and is connected to the drain adapter 200, indicated at 204 in FIG. 1, at a first end thereof, which adapter 200 is then connected at a second opposite end to an overflow pipe 190 which is appropriately secured to and extends through the bottom wall 14 to allow the water pumped by the pump 100 to drain from the housing 12.

An electrical cord 104 extends to a combination plug and receptacle 106. The plug portion of the plug receptacle 106 is appropriately connected to the outlet 50. The cord 74 and its plug 76 are in turn connected to the receptacle portion of the plug receptacle 106. The two pumps 70 and 100 accordingly require only a single outlet or receptacle for their operation.

The supply pump 70 and the drain pump 100 are similar to each other. In one embodiment, the primary difference between them is a timer unit 180 in the drain pump 100 that may not be present in the supply pump. This will be discussed in detail below. However, in an alternate embodiment, the drain pump may be a programmable drain pump with increased programmable functionality.

FIG. 2 is a perspective view, partially broken away, of the drain pump 100 illustrating its electrical elements, including a timer 180. The conduit 102 (see FIGS. 1 and 9) extends from an outlet 116 of the drain pump 100 to a drain pipe 190 for draining water from the bottom of the cooler housing 12, as discussed above and as will be discussed in detail below.

Details of the drain pump 100 are illustrated in FIGS. 2, 3, and 4. FIG. 3 is a bottom perspective view of the drain pump apparatus 100 particularly illustrating features of a pump impeller associated with both the supply pump 70 and the drain pump 100. FIG. 4 is a side view in partial section of the lower portion of the drain pump apparatus 100, specifically illustrating the impeller portion of the pump. For the following discussion, reference will primarily be made to FIGS. 2, 3, and 4.

The drain pump apparatus 100 includes a motor housing 110 in which is disposed an electrical motor 140. Beneath the motor housing 110 is a shaft housing 112. A motor shaft 142 extends from the motor 140 downwardly through the shaft housing 112 to an impeller 150. Located on the motor shaft 142 partially down within the shaft housing 112 is a “slinger” (not shown). The slinger is a disc-shaped washer concentrically affixed about the motor shaft 142, and located a short distance (e.g. 3-inches) above the impeller 150, which location is also a short distance (e.g. 0.5-inches) above the normal water level in the sump/reservoir. The slinger is configured to rotate with, and form a liquid tight seal around the circumference of, the motor shaft so that any water that may migrate up the motor shaft 142 during operation of the pump is prevented from migrating past the slinger. When water reaches the slinger, it contacts the flat bottom surface of the slinger and is redirected outward along the bottom surface thereof, and toward the outer edge of the slinger. As the water moves toward the outer edge of the rotating slinger, due to the action of centrifugal force, the water picks up speed as it moves further to the outer edge of the slinger, where the migrating water is finally slung off of the slinger and motor shaft 142. Beneath the shaft housing 112 is an impeller housing 114. The shaft 142 extends into the impeller housing 114. The impeller 150 is secured to the bottom of the shaft 142 within the housing 114.

Above the motor 140, and secured to the upper portion of the shaft 142, is a fan 144. The fan 144 provides a cooling flow of air for the motor 140 and the timer 180.

The motor housing 110 is closed by a cap 126.

At the bottom of the shaft housing 112 is a base 130. The base 130 extends outwardly to provide a relatively sturdy base support for the motor housing 110, the shaft housing 112, and the various elements associated with the apparatus. Extending downwardly from the base 130 is a plurality of feet 132. The feet 132 are spaced apart to allow water to flow between the feet and within the base 130 and to the impeller housing 114.

The outlet 116 extends from the impeller housing 114. The drain conduit 102 is connected to the outlet 116. From the outlet 116, the conduit 102 extends to a drain hose adapter 200. The adapter 200 will be discussed in detail below in conjunction with FIGS. 8 and 9.

The impeller housing 114 comprises a generally relatively short cylinder in which is disposed the impeller 150. The housing 114 includes an apertured top wall 118 and an apertured bottom plate 120. Water flows into the impeller housing 114 through the apertured bottom plate 120.

Details of the impeller 150 are shown in FIGS. 5, 6, and 7, in addition to FIGS. 3 and 4.

FIG. 5 is a plan view of the bottom of the impeller 150. FIG. 6 is a view in partial section of the impeller 150 taken generally along line 6-6 of FIG. 5. FIG. 7 is a plan view of the top of the impeller 150. For the following discussion of the impeller 150, reference will primarily be made to FIGS. 5, 6, and 7, in addition to FIGS. 3 and 4.

The impeller 150 comprises a relatively thin and generally circular disk 152. The disk 152 includes an outer periphery 154. The disk 152 also includes a bottom surface 156 and a top surface 166.

Disposed about the center of the disk 152, and extending outwardly from the bottom surface of the disk 152 is a shaft boss 158. A bore 160 extend through the shaft boss 158. The bore 160 receives the shaft 142 of the motor 140, as best shown in FIGS. 3 and 4.

Extending radially outwardly from the shaft boss 158 at the center of the disk 152 is a plurality of vanes 162. As illustrated in FIG. 5, the vanes 162 are spaced apart equally a relatively few degrees, in comparison with contemporary pump impellers. Ten vanes 162 are shown in FIG. 5 spaced apart equally from each other in the illustrated example. The distal tips or outer ends of the vanes 162 terminate inwardly from the outer periphery 154 of the disk 152.

The configuration of the vanes 162 is best shown in FIG. 6. The “upper” or “outer” surface of each vane 162 is farthest from the bottom surface 156 adjacent to the boss 158 and are closest to the surface 156 remote from the boss 158. In other words, the “height” of the vanes 162 tapers generally toward the surface 156 outwardly from the center portion of the disk 152.

On the top surface 166 are shown four vanes 168. The vanes 168 extend upwardly a relatively short distance from the top surface 166, and they extend radially inwardly from the outer periphery 154 of the disk 152. The vanes 168 terminate radially outwardly from the center portion of the disk 152. Moreover, as best shown in FIG. 7, the configuration of the vanes 168 is generally rectangular.

The vanes 168 on the top 166 of the impeller 150 help to prevent water from being pushed up through the aperture in top wall 118 of the impeller housing 114.

The disk 152 helps to prevent cavitation and accordingly allows the pump apparatus 100 to efficiently pump in water down to a depth of about a quarter of an inch Or so.

Returning again to FIG. 2, within the cap 126, and disposed above the motor 140, is the timer 180. The timer 180 in the drain pump 100 in certain embodiments works in conjunction with the supply pump 70 so that after a predetermined cumulative time period of the on operation in the primary supply pump 70, the timer 180 causes the motor 140 in the drain pump 100 to turn on, thus pumping the water from the bottom of the evaporative cooler housing 12 upwardly from the housing. The timer 180 in the drain pump 100 is preset so that it operates for a predetermined number of minutes before turning off.

For example, for every twelve hours of cumulative operation of the supply pump 70, the timer 180 in the drain pump 100 will cause the drain pump 100 to operate for a short period of time, such as seven minutes. During the seven minute time period that the drain pump 100 operates, the water in the bottom of the evaporative cooler housing 12 is effectively drained down to a minimum amount in the bottom of the cooler apparatus 10. At the same time, the demand for the water in the cooler apparatus 10 caused by the float 64 and the valve 62 causes fresh water to flow into the housing 12. The fresh water replenishes the water supply that had been drained off by the drain pump 100, and thus fresh water flows into the housing, substantially completely replacing the water in the housing 12 on a periodic basis.

It is apparent from the foregoing that when the water is pumped from the housing 12 by the drain pump apparatus 100, the float 64 will cause fresh water to flow into the evaporative cooler housing 12, thus diluting any old water that remains in the housing, such as any old water that has not been pumped out. The pump configuration ensures that most of the old water is pumped out and replaced by fresh water that is brought into the housing 12.

FIG. 8 is a perspective side view of a drain adapter 200 useable with the drain pump 100 and the evaporative cooler apparatus 10 and particularly with the bottom 14 of the housing 12. FIG. 9 is a side view in partial section showing the adapter 200 secured to the overflow and drain pipe 190 and to the conduit 102. For the following discussion, reference will primarily be made to FIGS. 1, 8, and 9.

As indicated above, the overflow and drain pipe 190 is appropriately secured to and extends through the bottom 14 of the housing 12. In prior art evaporative coolers, an overflow pipe serves as a safety feature for draining overflow water out of a cooler housing. In the apparatus of the present invention, the pipe 190 also serves as a drain pipe when the drain pump 100 is “on” for draining the housing 12.

To allow both functions to be accomplished by the pipe 190, the drain adapter 200 is used to connect the conduit 102 to the pipe 190. The adapter 200 is “open” so that overflow water may drain through the pipe 190. This opening also acts as an air gap providing an anti-siphon safety function. Water pumped through the conduit 102 flows downwardly along the adapter 200 to the pipe 190.

The adapter 200 comprises an elongated “X” configured or cross-shaped element, with outwardly extending tabs 204 centrally located along the length of the element. The element 200 includes four elongated arms. Phrased in another manner, two arm portions preferably bisect each other at right angles, defining a four armed element. The arms extend outwardly from a central longitudinal axis of the adapter.

The width or effective diameter of the element 200 above and below the tabs 204 is essentially the same as the inner diameter of the drain pipe 190 and as the inner diameter of the conduit 102. As shown in FIG. 9, the inner diameters of the pipe 190 and the conduit 102 are substantially the same.

The tabs 204 extend outwardly from the arm of the element 200. The outwardly extending tabs 204 have a greater width or diameter, which width or diameter is preferably at least the same as the outer diameter of the pipe 190 to allow the adapter 200 to be comfortably disposed in and on the pipe 190.

The “height” of the tabs 204 is sufficient to allow overflow water to flow into the pipe 190 between a top rim 192 of the pipe 190 and the bottom of the conduit 102 without problems of air flow or surface tension. Overflow water from the bottom of the housing 12 flows into the pipe 190 between the outwardly extending tabs 204 and the arms of the adapter element 200. The tabs 204 are simply extensions of the aims which comprise the element 200.

The tabs 204 essentially divide the arms of the adapter 200 into two portions, an upper portion 202 and a lower portion 206.

As shown in FIG. 9, the bottoms of the tabs 204 are disposed on the top rim 192 of the pipe 190. The upper arm portion 202 of the adapter 200 extends upwardly into the conduit 102, and the bottom arm portion 206 extends downwardly into the pipe 190 from the tabs 204.

An alternate embodiment of the adapter 200 is also illustrated in FIG. 8. In dash dot line is shown an arm 210. The use of the arm 210, with two of the four arms shown for the apparatus 200, comprises a three armed adapter. Preferably, the arms of the adapters are spaced apart from each other equal arcuate distances. The arms of the three armed embodiment are disposed apart an equal arcuate distance, providing a one hundred twenty degree separation, as opposed to a ninety degree separation for the arms of the four armed adapter 200.

In the three armed adapter, each arm has the same configuration as the arms illustrated for the four armed adapter 200, with tabs extending outwardly from the arms to be disposed on the top rim of the drain or overflow pipe. The three arms extend outwardly from a central longitudinal axis.

The evaporative cooler apparatus 10 shown in FIG. 1 is illustrated as being generally rectangular or square, but it will be understood that other configurations, such as round, may also be used.

While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, within the limits only of the true spirit and scope of the invention.

As previously disclosed above herein, in one embodiment the drain pump 100 includes a timer, such as a mechanical timer, that turns the motor of the drain pump 100 on after a predetermined permanently fixed length of cumulative run-time of the supply pump 70 (e.g. every twenty-four hours). However, referring to FIGS. 10-15, in an alternate embodiment the drain pump is a fully programmable drain pump 300. In use, the programmable pump 300 typically operates in a cycle, or alternating periods when the pump motor 140 is in an “on” state, so as to pump water to the drain pipe 190, and periods when the motor is in an “off” state, and no water is being pumped by the drain pump 300.

The programmable drain pump 300 of this alternate embodiment comprises the same mechanical components as previously disclosed above for the drain pump 100, but also further includes programmable control circuitry that includes a processor having programming configured to control the operation of the pump between the two alternating “on” and “off” states. Specifically, in one embodiment, the processor is configured to switch the pump between each of the two “on” and “off” states in an alternating manner for specified periods of time. The user specified input to the processor is in the form of setting a timer corresponding to each of the “on” and “off” states. A first timer is set for the “run time” of the motor, which specifies the length of time that the motor is to be operated in the “on” state, following the expiration of a specified period when the motor was previously in an “off” state. A second timer is set for the “clean frequency,” which specifies the length of time that the motor is to be turned to an “off” state between successive periods when the motor is “on.” The control circuitry allows a user to specify or input both the run time and the clean frequency and thereby control alternating operation of the programmable pump 300 between an “on” and an “off” state.

To permit the input of both the clean frequency and run time, the programmable drain pump 300 further includes a control panel 310 disposed in a wall of the pump housing, such as for example, the top surface of the cap 126 of the pump housing, for specifying the user selectable run time and clean frequency values (typically in increments of minutes or hours) for the pump 300.

In one embodiment, the clean frequency may be inputted by selecting one length of time from four pre-defined discreet lengths of time, such as for example two hours, four hours, six hours, or eight hours of “off” time for the programmable pump 300. The time period selected for the clean frequency will be the amount of time that the pump is turned “off” between successive periods when the pump is in an “on” state and pumping water to the drain pipe. While the clean frequency of the present exemplary embodiment is selectable from only four options (two hours, four hours, six hours, or eight hours of “off” time for the pump), in alternate embodiments, the programmable drain pump 300 may include more or less than four options for the clean frequency selection, and the actual time periods for the clean frequency may be the same or different than those previously disclosed herein without departing from the scope of the present disclosure.

In one embodiment, the run time, or length of time that the pump is “on,” may be inputted by selecting from one of two discreet pre-programmed periods of time, such as for example a period of 5-minutes or a period of 9-minutes. The time period selected for the run time will be the amount of time that the pump is turned “on” between successive periods when the pump is in an “off” state and no pumping is being performed. While the run time of the present exemplary embodiment is selectable between only two options (5-minutes and 9-minutes of “on” time for the pump), in alternate embodiments, the programmable drain pump 300 may include more or fewer than two options for the run time selection, and the actual time periods for the run time may be the same or different than those previously disclosed herein without departing from the scope of the present disclosure.

The run time may be selected by pressing a run time select button 320 in the control panel 310, which will highlight the specific labeled run time that has been selected, by lighting a corresponding light, LED, or other such similar indicator 322 positioned adjacent the label 324 for the chosen run time on the control panel 310. The illustrated example provides run time selections of 5 minutes and 9 minutes, although other run times may be provided and more or fewer run time options may be provided.

The clean frequency may be selected in a similar manner by pressing a clean frequency select button 330 in the control panel 310. As the clean frequency selection button 330 is selected, respective clean frequency selections are indicated by indicator lights 332, for example, which are identified by indicia 334 marked on the control panel 310. Each press of either the run time select button 320 or the clean frequency select button 330 will toggle the indicator associated with the respective button from one highlighted run time, or clean frequency, selection option to the next un-highlighted selection option. Once the indicator corresponding to the desired run time or clean frequency is highlighted, the indicated run time or clean frequency is respectively selected in the processor of the programmable drain pump.

Referring to FIG. 11, as an example, if the run time selection button 320 is pressed until the indicator light 322 corresponding to the five minute run time is highlighting as indicated by the “5 Min.” indicia, and the clean frequency selection button 330 is pressed until the indicator light 336 is highlighted corresponding to the clean frequency time of “4 Hrs.”, then in operation, the programmable pump 300 will alternate between being in the “on” state for 5 minutes, during which time the pump 300 is pumping water to the drain pipe 200, followed by 4 hours in the “off” state, where the pump is turned off and not pumping any water. The cycle then repeats indefinitely until the pump is reprogrammed or the cycle is interrupted.

Turning to FIG. 12, the programmable drain pump 300 also includes on the control panel 310 a constant on button 312 that may be selected by a user to keep the pump constantly on, such as during a cleaning or flushing operation. In addition, a test button 314 is provided to enable the user to test whether the programmable drain pump 300 is operational, for example, for the duration of the selected run time without having to wait for the clean frequency time to elapse.

The illustrated example permits user selection of either five minute or nine minute run times at intervals of two hours, four hours, six hours, or eight hours, as shown on the control panel 310. Of course, other run time durations may be available in other embodiments and other clean frequency intervals may be provided as options for user selection. More or fewer options may be provided in alternative embodiments.

In still further alternate embodiments (not shown), either of the run time or clean frequency may be infinitely, or nearly infinitely, variable, and inputted by a user entering the desired run time or clean frequency into the control circuitry with a numeric keypad, or changing the run time or clean frequency with “up” or “down” buttons that respectively and incrementally or continuously increase or decrease the particular time periods. In such embodiments, a display or digital readout would show the numerical length of time or other indicator that has been input to the processor. For example, a desired run time of 17 minutes would be inputted to the programmable drain pump by either keying in “1” “7” on a keypad, or pushing the “up” or “down” buttons for the run time until the number 17 is displayed on the display or readout. The selected indicator may instead refer to a hardness of the water, humidity in the air, or other condition or characteristic.

The programmable drain pump 300 may include the “constant on” selection button 312 that, when depressed, instructs the processor of the programmable pump to leave the motor of the programmable pump in the “on” state for an indefinite period of time, continuously pumping water, until the button is again depressed. This mode of operation is the constant on mode, and is useful, for example, if the programmable drain pump 300 must be used as a supply pump to supply water to the evaporative media of the evaporative cooler in the event that the primary supply pump 70 breaks down. The evaporative cooler will then not need to be shut down completely while the user procures a replacement supply pump. A subsequent depressing of the “constant on” button 312 will cease the operation of the pump 300 in the “constant on” mode and return the pump to operating in an alternating “on”/“off” mode where it is used as a drain pump as disclosed above.

In one embodiment, such a programmable drain pump 300 as disclosed herein may be configured to only be operational and tracking the clean frequency and run time of the drain pump 300 while the evaporative cooler is generating cool air. This means that the drain pump 300 is only operational when the recirculation pump 70 is simultaneously turned “on” and actively pumping water to the evaporative medium of the evaporative cooler. Therefore, in such an embodiment, the processor of the programmable drain pump 300 is also only tracking the length(s) of time that the drain pump 300 is in either of the “on” or “off” states while the recirculation pump 70 is also in an “on” state and pumping water to the evaporative medium. The supply pump 70 and the drain pump 300 are connected to one another either directly or indirectly to permit detecting of the supply pump operation by the drain pump.

For example, if the clean frequency on the programmable drain pump 300 is set to 2-hours (i.e. meaning 2-hours will pass between the end of one cleaning cycle and the beginning of the next cleaning cycle), and the recirculating pump 70 shuts down after 1-hour, the processor of the drain pump 300 will track/log the first hour of the drain pump's 300 “off” time, but will detect through the connection to the supply pump that the supply pump is off and will track no additional time until the recirculating pump 70 is again turned back “on” and pumping water. Once the recirculating pump 70 is turned back on, the processor of the programmable drain pump 300 will resume tracking time for the cleaning frequency until a total of 2-hours of cumulative time has elapsed, per the selected clean frequency period, after which the programmable drain pump 300 will then be turned “on” so as to operate to pump water to the drain pipe for the selected run time.

In alternate embodiments, the programmable drain pump 300 may be configured to track “on” and “off” time for each of the respective run time and clean frequency of the drain pump independently from the operation of the recirculating pump 70 without departing from the scope of the present disclosure.

Furthermore, in addition, the processor of the programmable drain pump 300 may be configured to track different time periods than those disclosed herein, such as for example, the length of time between the beginning of one cleaning cycle and the beginning of the next cleaning cycle (as opposed to the length of time between the end of one cleaning cycle and the beginning of the next cleaning cycle), without departing from the scope of the present disclosure.

Accordingly, there is disclosed herein a programmable drain pump for use in a dual pump evaporative cooling system, wherein the drain pump includes programming to permit adjustment of the run time and clean frequency of the drain pump and provide automatic operation of the drain pump at the selected intervals. This permits a user to set up customized cleaning schedules for an evaporative cooler, depending on the specific environmental factors in which the evaporative cooling system will operate. In addition, the programmable drain pump as disclosed herein may be used as a recirculation pump to allow for continuous operation of the evaporative cooler in the event that the primary recirculation pump breaks down. Accordingly, no run time of the evaporative cooling system is lost while the broken primary recirculating pump is repaired or replaced.

FIG. 13 shows the programmable pump 300 with the user operable buttons on the control panel 310. The programmable drain pump is configured to fit into the cooling apparatus. In FIG. 14, the pump has a printed circuit board 370 mounted within the pump housing. The printed circuit board 370 includes a processor and associated circuitry so as to be operable to perform the functions described herein. The user input to the programmable drain pump 300 is provided by controls, such as the button 312 that is mounted on an upper printed circuit board positioned beneath the control panel 310. A rubber seal is provided over the button 312 to keep water out of the electronics. A lower rubber seal 372 is provided below the circuit board 370 to prevent water from encroaching on the electronics from below. As noted above, the programmable pump 300 has a motor 140 that drives the impeller 150 via the shaft 142 and has a fan 144 for cooling the motor 140.

FIGS. 15A and 15B show a circuit 380 according to certain embodiments. The circuit 380 includes power conversion circuitry 381 and rectifying and filtering circuitry 382, switches 384 for user input of commands relating to continuous operation, run time selection, and clean interval time selection, and indicator LEDs 386 for continuous operation, 2 hour interval, 4 hour interval, 6 hour interval, 8 hour interval, 5 minute run time, and 9 minute run time. A microcontroller processor chip HR6P60HL is connected in the circuit for automated operation of the motor based on the user selection via the switches 384. A memory chip, such as a 24C04 chip, is connected to store the user settings. A test switch 388 is provided to test the operation of the drain pump. The illustrated circuit is but one example of a programmable circuit for operating the programmable drain pump.

Although other modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.

Claims

1. An evaporative cooler pump apparatus, comprising:

a shaft;
a motor connected to the shaft for rotating the shaft;
an impeller secured to the shaft remote from the motor for pumping water;
a housing for enclosing the motor and the impeller;
a programmable processor in operable communication with the motor, the processor including programming configured to selectively control the operation of the motor between, a constant-on mode, whereby the motor is turned on and runs indefinitely, and an intermittent run mode, whereby the motor continuously alternates between an on-state in which the motor is turned on for a first period of time, and an off-state in which the motor is turned off for a second period of time.

2. The apparatus of claim 1, further comprising:

a user control operable by a user for selection of an off-state period of time from a plurality of mutually different off-state periods of time available for selection.

3. The apparatus of claim 1, further comprising:

a user control operable by the user for selection of an on-state period of time from a plurality of mutually different on-state periods of time available for selection.

4. The apparatus of claim 3, wherein the user control for on-state periods of time is a first user control, and further comprising:

a second user control operable by a user for selection of an off-state period of time from a plurality of mutually different off-state periods of time available for selection.

5. An evaporative cooler apparatus, comprising:

an evaporative cooler housing, including a bottom wall, a side wall extending upwardly from the bottom wall, a top wall secured to the side wall, a water reservoir, and an evaporative medium secured to the side wall;
a water supply connected for providing water to the evaporative cooler housing;
a drain pipe connected for draining water from the evaporative cooler housing;
a first pump operative for pumping water from the water reservoir to the evaporative medium;
a second pump operative for pumping water from the water reservoir to the drain pipe, the second pump including a programmable processor in operable communication with a motor of the second pump, the processor including programming configured to selectively control the operation of the motor between a constant-on mode, whereby the motor is turned on and runs indefinitely, and a drain mode, whereby the motor continuously alternates between an on-state, in which the motor is turned on for a first period of time, and an off-state in which the motor is turned off for a second period of time.

6. The apparatus of claim 5, further comprising:

a user control operable by a user for selection of an off-state period of time from a plurality of mutually different off-state periods of time available for selection.

7. The apparatus of claim 5, further comprising:

a user control operable by the user for selection of an on-state period of time from a plurality of mutually different on-state periods of time available for selection.

8. The apparatus of claim 7, wherein the user control for on-state periods of time is a first user control, and further comprising:

a second user control operable by a user for selection of an off-state period of time from a plurality of mutually different off-state periods of time available for selection.

9. An evaporative cooler pump apparatus, comprising in combination:

a shaft;
a motor connected to the shaft for rotating the shaft;
an impeller secured to the shaft remote from the motor for pumping water;
a housing for enclosing the motor and the impeller;
a programmable processor in operable communication with the motor, the processor including programming configured to selectively control the operation of the motor in an intermittent run mode, whereby the motor alternates between an on-state in which the motor is turned on for a first period of time, and an off-state in which the motor is turned off for a second period of time;
a first user control operable by a user for selection of an off-state period of time from a plurality of mutually different off-state periods of time available for selection; and
a second user control operable by a user for selection of an off-state period of time from a plurality of mutually different off-state periods of time available for selection.
Patent History
Publication number: 20150059376
Type: Application
Filed: Aug 27, 2014
Publication Date: Mar 5, 2015
Applicant: PHOENIX MANUFACTURING, INC. (Phoenix, AZ)
Inventors: Gary Stephen Jouas (Phoenix, AZ), John Patrick Koponen (Chandler, AZ)
Application Number: 14/470,161
Classifications
Current U.S. Class: Time Or Program Actuator (62/157); Material Cooling Means Including Gas-liquid Contactor (62/304)
International Classification: F24F 5/00 (20060101); F24F 11/00 (20060101);