CIRCULATION AND DRAIN SYSTEM

Abstract

An evaporative cooler circulation and drain system including a fluid pump and a storage tank defining an interior volume for holding a fluid is disclosed. In one aspect, the system is operable between a circulation and drain-circulation operational modes. In the circulation mode, a drain valve is closed and the fluid pump is activated such that fluid is continuously circulated within the storage tank to discourage debris from settling by keeping debris in the tank in suspension. In the drain-circulation mode, the drain valve is opened and the fluid pump is activated such that fluid is both being continuously circulated within the interior volume of the storage tank and draining from the tank. In some embodiments, the system increases the drain flow rate by directing circulated fluid directly at a drain opening of the tank to flush debris through the drain piping and prevent plugging.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Application Ser. No. 61/928,740, filed on Jan. 17, 2014, entitled “Evaporative Cycles of Concentration Control,” the entirety of which is incorporated by reference herein. This application also claims priority to U.S. Application Ser. No. 61/928,764, filed on Jan. 17, 2014, entitled “Circulation and Drain System,” the entirety of which is incorporated by reference herein. This application claims priority to U.S. Application Ser. No. 61/928,775 filed on Jan. 17, 2014, entitled “Staging Control for an Evaporative Media System,” the entirety of which is incorporated by reference herein. This application also claims priority to U.S. Application Ser. No. 61/928,784, filed on Jan. 17, 2014, entitled “Staging Control for an Evaporative Media System,” the entirety of which is incorporated by reference herein. This application also claims priority to U.S. Application Ser. No. 61/928,800, filed on Jan. 17, 2014, entitled “Staged Dry Out Control for Evaporative Media Systems,” the entirety of which is incorporated by reference herein.

BACKGROUND

Direct evaporative coolers are frequently used in commercial and industrial HVAC systems, including applications for data centers and power plant turbine inlet cooling. Evaporative coolers consume less energy than mechanical refrigeration and air conditioning equipment and are increasingly being used to supplement and occasionally replace conventional cooling equipment. In operation, direct evaporative coolers use the enthalpy of vaporization of water as a means to cool and humidify air. Typically, this is accomplished by flowing air directly through a media wetted with water. As air passes through the wetted media, water evaporates by taking energy from the air to vaporize the water. Accordingly, the air temperature exiting the wetted media is reduced and the humidity is increased while the energy or enthalpy of the exiting air remains the same as the entering air. This type of a process is often referred to as adiabatic cooling.

Evaporative coolers typically use a water pump to transfer water in a tank below the media to the top of the media. The water flows down through the media wherein a portion of the water evaporates and the remaining portion drains out the media bottom into the tank below. The water continues to be recirculated using the water pump, or re-circulation pump, with make-up water added to replace the evaporated water. Tank water is periodically drained and replaced with additional make-up water to control tank water concentration and minimize scale fouling, biological fouling and corrosion.

However, evaporative coolers are subject to being plagued with mineral scale fouling, biological growth and corrosion of metal surfaces. As water evaporates the concentration of the minerals in the remaining water increases until the minerals precipitate and accumulate on surfaces of the evaporative cooler media and tank. Additionally, the media of the evaporative coolers act as effective air filters and trap dirt and debris in the air which is then flushed out of the media and settles in the tank as silt. Accordingly, tanks must be periodically cleaned to remove the minerals and the silt which have settled and adhered to tank surfaces. To clean the tank the unit must be shut down and drained so maintenance personnel can access and clean the tank. Unit cleanliness in general reduces mineral scale fouling, biological growth and corrosion.

Additionally, the debris and minerals that accumulate and settle in the tank may partially drain out and plug the drain valve, piping and p-trap in the drain system. Where minimal head pressure exists as water drains from a shallow tank into a drain pipe having a minimal slope, a low flow rate can exist which increases the likelihood of plugging in the drain piping. Such minimal drain flow rate also reduces effectiveness in draining debris and minerals from the tank. Improvements are desired.

SUMMARY

An evaporative cooler circulation and drain system is disclosed. In one aspect, the system includes a storage tank having a sidewall and a bottom side together defining an interior volume for holding a fluid. In another aspect, the system includes a fluid pump having an inlet and an outlet, wherein the inlet is in fluid communication with the interior volume of the tank. The storage tank may include a drain opening located in one of the storage tank sidewalls and bottom side, wherein the drain opening is in fluid communication with a drain pipe section. A drain valve may also be provided in fluid communication with the drain pipe section, wherein the drain valve allows the tank to drain fluid when in an open position regardless of the operational status of the pump and prevents the tank from draining when in a closed position.

In one aspect, the system is operable between a circulation mode and a drain-circulation operational mode. In the circulation mode, the drain valve is placed in the closed position and the fluid pump is activated such that fluid is continuously circulated within the interior volume of the storage tank. In the drain-circulation mode, the drain valve is placed in the open position and the fluid pump is activated such that fluid is both being continuously circulated within the interior volume of the storage tank and draining from the interior volume of the tank via the drain opening.

In one embodiment, the fluid pump outlet is in fluid communication with a discharge pipe section having an outlet opening within the tank interior volume that is facing and spaced from the storage tank drain opening such that water from the pump is injected into the drain pipe section.

In one embodiment, the pump outlet is connected to a discharge pipe section that is in fluid communication with the drain pipe section such that, when in the circulation mode, fluid is circulated from the pump outlet and back into the interior volume of the tank via flowing in a reverse direction through the drain. The discharge pipe section can be directly connected to the drain pipe section, or the two sections can be coupled together via a venturi flow device.

The system may also utilize an ultraviolet light in fluid communication with the pump outlet that can be configured to be on when the system is in the circulation mode and off when the system is in the drain-circulation mode. The system may also include a filter or cyclonic separator in communication with the fluid pump outlet to remove debris within the fluid.

Other embodiments include a system having a dedicated drain pump and a dedicated circulation pump, and a system wherein a reversible pump with two outlet ports is utilized to implement a drain mode and a circulation mode.

An electronic controller may be provided that is in communication with the pump(s), drain valve, and/or UV light, wherein the circulation, drain and/or drain-circulation operational modes are implemented by the electronic controller.

DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments are described with reference to the following figures, which are not necessarily drawn to scale, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

FIG. 1 is a schematic view of a first embodiment of a circulation and drain system in a circulation mode, the system having features that are examples of aspects in accordance with the principles of the present disclosure.

FIG. 2 is a schematic view of the first embodiment of a circulation and drain system shown in FIG. 1 in a drain-circulation mode.

FIG. 3 is a schematic view of a second embodiment of a circulation and drain system in a circulation mode, the system having features that are examples of aspects in accordance with the principles of the present disclosure.

FIG. 4 is a schematic view of the second embodiment of a circulation and drain system shown in FIG. 3 in a drain-circulation mode.

FIG. 5 is a schematic view of a third embodiment of a circulation and drain system in a circulation mode, the system having features that are examples of aspects in accordance with the principles of the present disclosure.

FIG. 6 is a schematic view of the third embodiment of a circulation and drain system shown in FIG. 5 in a drain-circulation mode.

FIG. 7 is a schematic view of a fourth embodiment of a circulation and drain system in a circulation mode, the system having features that are examples of aspects in accordance with the principles of the present disclosure.

FIG. 8 is a schematic view of the fourth embodiment of a circulation and drain system shown in FIG. 7 in a drain-circulation mode.

FIG. 9 is a schematic view of a fifth embodiment of a circulation and drain system in a circulation mode, the system having features that are examples of aspects in accordance with the principles of the present disclosure.

FIG. 10 is a schematic view of the fifth embodiment of a circulation and drain system shown in FIG. 9 in a drain mode.

FIG. 11 is a schematic view of a sixth embodiment of a circulation and drain system in a circulation mode, the system having features that are examples of aspects in accordance with the principles of the present disclosure.

FIG. 12 is a schematic view of the sixth embodiment of a circulation and drain system shown in FIG. 11 in a drain mode.

FIG. 13 is a schematic side view of an air handling system within which the circulation and drain systems of FIGS. 1-12 can be utilized.

FIG. 14 is a schematic end view of an evaporative media system within which the circulation and drain systems of FIGS. 1-12 can be utilized, the evaporative media system being usable in the air handling system shown in FIG. 13.

FIG. 15 is a schematic view of a control system usable with the systems shown in FIGS. 1-14.

FIG. 16 is a top view of a seventh embodiment of circulation and drain system, the system having features that are examples of aspects in accordance with the principles of the present disclosure.

FIG. 17 is a perspective view of the pump and discharge assembly related to the circulation and drain system shown in FIG. 16.

FIG. 18 is a side view of the discharge assembly shown in FIG. 17.

FIG. 19 is a front view of the discharge assembly shown in FIG. 17.

FIG. 20 is a rear view of the discharge assembly shown in FIG. 17.

FIG. 21 is a graph showing performance characteristics of a pump and discharge assembly suitable for use with the above described circulation and drain systems.

FIG. 22 is an exploded perspective view of the pump and discharge assembly whose performance is depicted in FIG. 21.

FIG. 23 is a bottom view of the pump and discharge assembly shown in FIG. 21.

FIG. 24 is a rear end view of the pump and discharge assembly shown in FIG. 21.

FIG. 25 is a front end view of the pump and discharge assembly shown in FIG. 21.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.

General System Description

FIG. 13 schematically shows an air handling system 1 comprising an evaporative cooler 10, which may be also referred to as an evaporative media system 10. FIG. 14 shows the evaporative media system 10 in additional detail. As shown, the air handling unit 1 of FIG. 13 may be additionally provided with a supply fan 5, a damper section 6, a filter 7, a heating coil 8, and a cooling coil 9. It should be understood that various other components and alternative configurations may be applied to air handling system 1 without departing from the concepts disclosed herein. In operation, the supply fan 5 draws air through the evaporative media system 10 to result in adiabatically cooled air when the evaporative media system 10 is activated.

As presented, evaporative media system 10 also includes a plurality of media stages 4A, 4B, 4C through which air is drawn via the operation of fan 5. Although three media stages are shown, it should be appreciated that the evaporative media system 10 may include fewer or more media stages without departing from the concepts disclosed herein. Furthermore, each media stage may include multiple sections of media. As shown, each media section 4A, 4B, 4C is separated from the other by a gap, or alternatively a barrier, to prevent moisture from communicating from one section to the other. This configuration allows for an individual media section to be dried out without being subjected to wicking moisture from an adjacent section.

Each of the media stages 4A, 4B, 4C is shown as being provided with an associated distribution pump 3A, 3B, 3C. While there is a one-to-one relationship shown between the media stages 4A, 4B, 4C and the pumps 3A, 3B, 3C, is should be understood that more than one media stage can be served by a single pump, with or without individual valves, to result in a larger media stage consisting of multiple media sub stages. Additionally, more than one pump may serve the same media stage.

In operation, when a pump 3A, 3B, 3C is activated (e.g. turned on or modulated to a speed greater than zero), the associated media stage 4A, 4B, 4C is wetted with fluid 12. When a media stage 4A, 4B, 4C is being actively wetted with water, for example when the associated pump 3A, 3B, 3C is in operation, that media stage 4A, 4B, 4C can be referred to as being activated. Likewise, when a media stage 4A, 4B, 4C is not being actively wetted with water, for example when the associated pump 3A, 3B, 3C is shut off and not in operation, that media stage 4A, 4B, 4C can be referred to as being deactivated.

Drain and Circulation System Description

Referring to FIGS. 1-12 and 16-20, seven embodiments of a circulation and drain system 10 in various operating states are disclosed for use as part of an evaporative cooling system 1. In each of the embodiments disclosed, water 12 can be continually circulated by a pump 20 (and/or 60, 80) within an evaporative cooler tank 14, having a sidewall 15 and a bottom 17, to discourage debris from settling by keeping the debris in suspension. The scrubbing action of the circulating fluid or water 12 also minimizes the adherence of debris to the tank sidewall 15. In some embodiments, the system increases the drain flow rate of the tank 14 by directing circulated fluid directly at a drain opening 16 of the tank 14 to flush debris through the drain piping and prevent plugging. In some embodiments, draining occurs while the water 12 is being circulated in the tank 14 so debris and minerals are in suspension while draining, thus being removed with the drain water.

Referring to FIGS. 1 and 2, a first embodiment of the circulation and drain system 10 is presented. As shown, the circulation and drain system 10 includes an evaporator tank 14 having a sidewall 15 and a bottom side 17 that together define an interior volume 11 for holding a fluid 12, such as water. The sidewall 15 may have various cross-sectional shapes as dictated by the requirements of the evaporator, for example square, rectangular, and circular cross-sectional shapes. The bottom side 17 may also be provided with various shapes to accommodate the perimeter defined by the sidewall 15.

The evaporator tank 14 may be provided with a drain opening 16 located in one of the bottom side 17 and the sidewall 15. In the particular embodiment shown, the drain opening 16 is provided at the bottom side 17 of the tank 14 and is connected to a drain pipe section 110.

In one aspect, a drain valve 30 having an inlet port 32 and an outlet port 34 is provided. As shown, the inlet port 32 is connected to the drain pipe section 110 while the outlet port is connected to a drain pipe section 112. The drain valve 30 is movable between a closed position (as shown at FIG. 1) and an open position (as shown at FIG. 2) so that fluid 12 can be selectively drained from the interior volume 11 of the evaporator tank 14. The drain valve 30 may be provided as an automatic control valve operated by a controller, such as electronic controller 500 discussed below.

Optionally, the storage tank 14 may be provided with an overflow pipe section 116 that is connected to the drain pipe section 112. The overflow pipe section 116 allows for fluid 12 in the storage tank 14 above a predetermined volume or level to be drained into common drain pipe 114.

As shown, the system may be provided with a first fluid pump 20 having an inlet 22 and an outlet 24. The fluid pump inlet 22 is in fluid communication with the interior volume 11 of the storage tank 14, preferably proximate the bottom side 17 such that virtually all fluid within the storage tank 14 can be drawn into the pump 20. The fluid pump outlet 24 is in fluid communication with a discharge pipe section 102 which is in turn connected to discharge pipe sections 104 and 106. As configured, both the discharge pipe sections 104, 106 direct respective portions of the pumped fluid back into the interior volume 11 of the storage tank 14 when the pump 20 is in operation.

As presented, the discharge pipe section 104 has a discharge opening 104a that directly faces and is spaced apart from the drain opening 16. This configuration allows pumped fluid leaving the discharge opening 104a to be injected towards the drain opening 16 and into the drain pipe section 110 which increases the drain flow rate of the tank 14 and flushes debris through the drain piping sections 110, 112, 114 and prevents plugging. As the discharge opening 104a is not directly coupled to the drain opening 16 or drain pipe 110, the fluid 12 can be referred to as being indirectly injected into the drain pipe sections. In one embodiment, the discharge opening 104a is spaced from the drain opening 16 by a distance of up to about 3 inches. In one embodiment, the discharge opening 104a is inserted such that it is installed about 1 inch into the drain opening 16. Distances between a 1 inch insertion and a 3 inch separation have been found to be preferable.

In one embodiment, an ultraviolet (UV) light 40 is provided and connected to the discharge pipe section 106 at an inlet 42 and connected to a discharge pipe section 108 at an outlet 44. The ultraviolet light 40 operates to kill bacteria that may be present in the fluid 12 as the fluid passes through the ultraviolet light 40.

FIG. 1 shows the system 10 operating in a circulation mode wherein the drain valve 30 is placed in the closed position and the fluid pump 20 is activated such that fluid is continuously circulated within the interior volume of the storage tank to minimize the settling of any debris in the tank by maintaining as much debris in suspension as possible.

FIG. 2 shows the system 10 operating in a drain-circulation mode wherein the drain valve 30 is placed in the open position and the fluid pump 20 is activated such that fluid 12 is both being continuously circulated within the interior volume 11 of the storage tank 14 and is draining from the interior volume 11 of the tank 14 via the drain opening 16. In this configuration, the fluid pump 20 aids in draining of the tank 14 by directing the pumped fluid 12 from the discharge pipe opening 104a into the drain opening 16 while still maintaining circulation within the tank 14 via discharge pipe sections 106, 108 to prevent solids or debris from settling. However, it is noted that the system 10 shown at FIGS. 1 and 2 is able to drain fluid 12 from the tank 14 without the operation of the fluid pump 20 by simply opening the drain valve 30, which would be a drain only mode of operation. The drain only mode is advantageous in the event that draining of the tank 14 is required, but where a failure of the fluid pump 20 has occurred.

Referring to FIGS. 3-4, a second embodiment of the drain and circulation system 10 is shown. As many aspects of the first and second embodiments are similar, the description for the first embodiment is applicable for this embodiment and does not need to be repeated for the second embodiment. The following description of the second embodiment is thus generally limited to the unique aspects of the second embodiment.

The primary difference of the second embodiment and the first embodiment is that the discharge pipe section 104 is directly connected to the drain pipe section 110 to form a common drain pipe into drain valve 30. This configuration allows for the drain pipe section 110 to act as a pathway for fluid 12 to recirculate back into the interior volume 11 of the tank 14 from the discharge pipe section 104 when the system is in the circulation mode (as shown in FIG. 3), and to also act as a secondary pathway for fluid 12 to drain from the tank 14 (as shown in FIG. 4). As it would be possible for pumped fluid to go back into the tank instead of being drained under certain circumstances, the pipe and drain valve sizing can be configured to reduce the chance of such an occurrence. Additionally, this configuration allows for the pump 20 to directly inject fluid 12 into the drain pipe sections 105, 112, 114 for enhanced flushing of any present debris.

Referring to FIGS. 5-6, a third embodiment of the drain and circulation system 10 is shown. As many aspects of the first, second, and third embodiments are similar, the descriptions for the first and second embodiments are applicable and do not need to be repeated for the third embodiment. The following description of the third embodiment is thus generally limited to the unique aspects of the third embodiment.

The third embodiment of the drain and circulation system 10 is very similar to the second embodiment, with the exception that the connection between the discharge pipe 104, the drain pipe 110, and the drain pipe 105 is accomplished with a venturi flow device 50 rather than a direct piping connection. As shown, the venturi flow device 50 has an inlet 52 connected to the discharge pipe section 104, an outlet 54 connected to the drain pipe section 105, and a port 56 connected to the drain pipe 110. As water is pumped through the venturi flow device 50 from the inlet 52 to the outlet 54 by the fluid pump 20, a low pressure at the port 56 is induced which causes fluid 12 to be drawn through the drain pipe 110 and drain opening 16, and into the venturi flow device 50 towards the outlet 54. It is noted that the fluid 12 can drain through the venturi flow device 50 via opening 16 and pipe section 110 without pump 20 in operation, provided that the drain valve 30 is in the open position.

Referring to FIGS. 7-8, a fourth embodiment of the drain and circulation system 10 is shown. To the extent that features of the previously described embodiments and the fourth embodiment are the same, the descriptions for the previous embodiments are fully applicable here and do not need to be repeated for the fourth embodiment. The following description is thus generally limited to the unique aspects of the fourth embodiment.

The fourth embodiment of the circulation and drain system 10 is different from previous embodiments in that a filter or cyclonic separator 70 is connected to the discharge pipe 104 at an inlet 72 wherein fluid is circulated back to the interior volume 11 of the tank 14 via an outlet 74. The filter or cyclonic separator 70 functions to remove and collect debris present in the fluid 12 to reduce potential settling and adherence of the debris to the surfaces of the storage tank 14. The fourth embodiment is also different in that a discharge opening 108a associated with discharge pipe section 108 faces and is separated from the drain opening 16 such that fluid 12 is indirectly injected into the drain pipe 110 via discharge pipe sections 106, 108 instead of discharge pipe section 104.

Referring to FIGS. 9-10, a fifth embodiment of the drain and circulation system 10 is shown. To the extent that features of the previously described embodiments and the fifth embodiment are the same, the descriptions for the previous embodiments are fully applicable here and do not need to be repeated for the fifth embodiment. The following description is thus generally limited to the unique aspects of the fifth embodiment.

The fifth embodiment of the circulation and drain system 10 is different from previous embodiments in that a reversible fluid pump 80 is provided that has two outlet ports 84, 86, and an inlet port 82. In this configuration, the first outlet port 84 is connected to the discharge pipe section 104 while the second outlet port 86 is connected to the discharge pipe section 106, with the inlet 82 being in fluid communication with the interior volume 11 of the storage tank 14. The configuration of the drain valve 30, the UV light, and the pipe sections 104, 105, 106, 110, 112, and 114 are the same as shown for the second embodiment shown in FIGS. 3-4, but may be configured similar to any other previously described embodiment as well.

In operation, the fluid pump 80 directs fluid 12 between the inlet 82 and first outlet 84 when rotated in a first direction and directs fluid 12 between the inlet 82 and the second outlet 86 when rotated in a second direction. As shown, the fifth embodiment of the drain and circulation system 10 is operable between a circulation mode and a drain mode. In the circulation mode, the fluid pump 80 is rotated in the second direction such that fluid 12 is continuously circulated within the interior volume 11 of the storage tank 14. In the drain mode, the fluid pump 80 is rotated in the first direction such that fluid 12 is drained from the interior volume 11 of the tank 14. Where a drain-circulation mode is desired, the discharge pipe section 104 can be reconfigured, for example by orienting the discharge pipe section outlet 104a within the interior volume 11 of the storage tank 14, as shown at FIGS. 1-2.

Referring to FIGS. 11-12, a sixth embodiment of the drain and circulation system 10 is shown. To the extent that features of the previously described embodiments and the sixth embodiment are the same, the descriptions for the previous embodiments are fully applicable here and do not need to be repeated for the sixth embodiment. The following description is thus generally limited to the unique aspects of the sixth embodiment.

The sixth embodiment of the circulation and drain system 10 is different from previous embodiments in that two fluid pumps are provided in a first fluid pump 20 and a second fluid pump 60, and in that no drain valve 30 is provided. The first fluid pump 20 is configured such that the discharge pipe section 104 is directly connected to drain pipe section 114 such that in order to drain the tank 14, the first fluid pump 20 must be activated. The second fluid pump 60 has an outlet 64 connected to the discharge pipe section 106 and has an inlet 62 that is in fluid communication with the interior volume 11 of the storage tank 14. Accordingly, fluid 12 can only be circulated within the tank 14 by operation of the second fluid pump 60 via inlet 62, discharge pipe sections 106, 108 and ultraviolet light 40.

As configured, the sixth embodiment of the circulation and drain system 10 has a circulation mode, a drain mode, and a drain-circulation mode. In the circulation mode, the first fluid pump 20 is deactivated and the second fluid pump 60 is activated such that fluid 12 is continuously circulated within the interior volume of the storage tank. In the drain mode, the first fluid pump 20 is activated and the second fluid pump 60 is deactivated such that fluid 12 is drained from the interior volume of the tank. In the drain-circulation mode, the first fluid pump 20 and the second fluid pump 60 are activated such that fluid 12 is both being continuously circulated within the interior volume 11 of the storage tank 14 and draining from the interior volume 11 of the tank 14.

As shown at FIGS. 16-20, a seventh embodiment of a circulation and drain system 10, and related subcomponents, are presented. The seventh embodiment of the circulation and drain system 10 is different from previous embodiments in two primary ways. First, the corners of the tank can be rounded (e.g. an obround, oblong, oval, or circular tank can be provided), or a rectangular tank can be provided with optional deflectors 19 located in each of the corners of the tank 14 to direct circulating fluid within the tank. Second, a dual outlet discharge assembly 90 is provided at the pump outlet 24. The discharge assembly 90 is horizontally oriented near one side of the tank 14 and parallel to the bottom 17 of the tank such that the discharging fluid 12 is directed towards one of the deflectors 19. The deflectors 19 are shown as being separately formed inserts into the tank 14, however, it should be understood that the deflectors 19 could be integrally formed as part of the tank 14 as well. Additionally, the tank 14 could be formed with curved sidewall 15 corners to achieve the same purposes. This configuration maximizes the circulation of fluid 12 within the tank 14 to aid in keeping debris and solids in suspension and preventing settling.

In one aspect, the discharge assembly 90 has an inlet 92 connected to the pump outlet 24 and a first outlet 94 connected to the UV light pipe section 106 and a second outlet 96 in fluid communication with the interior volume 11 of the tank 14. As most easily seen at FIGS. 17-20, the discharge assembly is shown as being constructed of an outer PVC sleeve 93 within which a reducing insert 91 is installed. The reducing insert 91 is configured with the first discharge outlet 94 as a central threaded connector to which a connector 108a of the UV light pipe section 108 is connected. As shown, the pipe section 108 is ½ inch tubing.

In the annular space surrounding the first discharge outlet 94, the second discharge outlet 96 is provided, as most easily seen at FIGS. 19 and 20. As shown, the second discharge outlet 96 is an arc shaped opening in the annular space that spans a portion of a full circle. FIG. 19 shows the arc of the outlet 96 spanning about one half of the circumference of the annular space while FIG. 20 shows a preferable embodiment wherein the outlet 96 spans about one third of the circumference. The total opening area defined by the outlet 96 is sized to result in the maximum kinetic energy or mass flow rate of the fluid leaving the outlet 96 which results in maximum circulation within the tank. If the opening is too large, the velocity of the fluid will be too low to induce adequate circulation while an opening that is too small will not circulate adequate volume. This opening area can be determined by using the pump flow curve to calculate the maximum mass flow rate or kinetic energy of the fluid outlet 96 while also accounting for the flow through the first outlet 94. Accordingly, the opening sizes of the outlets 94, 96 are each selected to provide the desired flow conditions through each outlet 94, 96. When installed, the discharge assembly 90 is oriented such that the second discharge outlet 96 is beneath the first discharge outlet 94 and such that the outlet 96 is nearest to the bottom 17 of the tank. This orientation minimizes splashing and noise.

As configured, the seventh embodiment of the circulation and drain system 10 has a circulation mode, a drain mode, and a drain-circulation mode. In the circulation mode, the first fluid pump 20 is activated and the drain valve 30 is closed such that fluid 12 is continuously circulated within the interior volume of the storage tank. In the drain mode, the first fluid pump 20 is deactivated and the drain valve 30 is opened such that fluid 12 is drained from the interior volume of the tank. In the drain-circulation mode, the first fluid pump 20 is activated and the drain valve is open such that fluid 12 is both being continuously circulated within the interior volume 11 of the storage tank 14 and draining from the interior volume 11 of the tank 14.

Referring to FIGS. 21-25, further disclosure is provided of a circulation pump assembly 220 suitable for use with the above described embodiments (e.g. the first and seventh embodiments) is shown. FIG. 21 shows a pump performance graph 200 for the pump assembly 220 in which a flow rate curve 202 and a kinetic energy curve 204 are shown. To derive at the optimal opening size for the discharge openings 296 back into the tank, the optimal flow rate (GPM) was measured for discharge orifice of various diameters and graphed as curve 202. The flow rate was used to calculate a mass flow rate (lbs/min) and a velocity (ft/min). The mass flow rate and the velocity were then used to calculate the Kinetic Energy of the water jet which is graphed as curve 204. As mentioned previously, to achieve the greatest mixing effect in the tank, it is desirable to maximize the energy of the water jet. The resulting kinetic energy curve 204 shows that the maximum energy is created when the discharge orifice is between about 0.4 and 0.6 inch, and is about 0.5 inch in diameter. In the example shown, four holes 96 are used as opposed to one single hole, primarily due to manufacturing constraints. The four holes used, which have a diameter of about 0.25 inch, have the equivalent area to that of a single 0.5 inch′ diameter hole in an effort to continue to maximize the kinetic energy of the water stream.

As can be seen at FIGS. 22-25, the circulation pump 220 has an outlet 224 and an inlet 222 connected to an elbow pipe section 226. In one embodiment, the elbow pipe section 226 is oriented facing downwards so as to draw water from as low in the tank as possible. The pump assembly 220 can also include a discharge assembly 290. In the example shown, the discharge assembly 290 includes a coupling member 291 that connects a discharge pipe section 292 to the pump outlet 224 and includes a tee section 293 coupled to the discharge pipe section 292. As configured, pumped fluid exits the pump outlet 224 and is directed through the discharge pipe section 292 and to the tee section 293, at which point the fluid flow splits and flows through first and second ends 293a, 293b of the tee section 293. At each end 293a, 293b, a cap 295, 297 is respectively provided. As shown, caps 295, 297 are threaded into the tee section 293, but any other suitable connecting means are possible. Each of caps 295, 297 is provided with two of the four total apertures 296 discussed above that direct pumped fluid back into the tank to maintain circulation in the tank. In the configuration shown, the flow through the apertures 296 in cap 295 is dispersed in the opposite direction of the flow through apertures 296 in cap 297, thus increasing the mixing effectiveness of the discharge assembly 290. In one configuration, the caps 295, 297 and apertures 296 are oriented such that the discharge flow is oriented generally horizontally and generally parallel with the bottom 17 of the tank 14.

Cap 297 may additionally be provided with a discharge outlet 294 which is in fluid communication with the UV light 40 via pipe or tube section 106. As with the embodiments shown at FIGS. 1-2 and 16, the discharge end of the tube or pipe section 106 may be oriented to discharge directly towards the drain opening for a power drain mode of operation. Although multiple components are shown in relation to the discharge assembly 290, it is noted that the discharge assembly 290 can be formed as a single, unitary component that attaches to the pump 220.

One suitable pump for pumps 3A-3C, 20, 60, 80, and/or 220 is a Little Giant F-Series F10-1200 (manufactured by Franklin Electric of Oklahoma City, Okla.). This type of pump has a wet rotor design without a shaft seal to separate the motor from the pump wherein water circulates around the armature.

Control System

Referring to FIG. 13, each embodiment of the circulation and drain system 10 may also include an electronic controller 500, as shown at FIG. 15. The electronic controller 500 is schematically shown as including a processor 500A and a non-transient storage medium or memory 500B, such as RAM, flash drive or a hard drive. Memory 500B is for storing executable code, the operating parameters, and the input from the operator user interface 502 while processor 500A is for executing the code. The electronic controller is also shown as including a transmitting/receiving port 500C, such as an Ethernet port for two-way communication with a WAN/LAN related to an automation system. A wireless communication interface may also be provided. A user interface 502 may be provided to activate and deactivate the system, allow a user to manipulate certain settings or inputs to the controller 500, and to view information about the system operation.

The electronic controller 500 typically includes at least some form of memory 500B. Examples of memory 500B include computer readable media. Computer readable media includes any available media that can be accessed by the processor 500A. By way of example, computer readable media include computer readable storage media and computer readable communication media.

Computer readable storage media includes volatile and nonvolatile, removable and non-removable media implemented in any device configured to store information such as computer readable instructions, data structures, program modules or other data. Computer readable storage media includes, but is not limited to, random access memory, read only memory, electrically erasable programmable read only memory, flash memory or other memory technology, compact disc read only memory, digital versatile disks or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and that can be accessed by the processor 500A.

Computer readable communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” refers to a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, computer readable communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, radio frequency, infrared, and other wireless media. Combinations of any of the above are also included within the scope of computer readable media.

Electronic controller 500 is also shown as having a number of inputs/outputs that may be used for implementing the above described operational modes of the circulation and drain system. For example, the electronic controller 500 provides an output to drain valve 30 to command the valve between an open position and a closed position and a command to activate and deactivate the pump(s) 20, 60, 80. As shown, the ultraviolet light 40 is activated upon the activation of the pump that delivers fluid to the ultraviolet light 40.

It is noted that electronic controller 500 may be configured with additional inputs and outputs for controlling other functions of the evaporator, such as outputs for commanding individual evaporator stage valves, an output for commanding a pump associated with the stage valves, an output for commanding a fan motor, an output for controlling a tank fill valve, and inputs for entering and leaving air temperature and humidity, tank water level, tank water temperature, and fan status.

The above described system and related embodiments each minimize maintenance by circulating water within the tank to keep debris in suspension and minimize debris adherence to tank walls so debris can be drained out of tank. These configurations improve reliability by minimizing the risk of a drain pipe plugging by using the pump to increase the drain flow rate, directly or indirectly, and flush debris through the drain piping.

The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the disclosure.

Claims

1. An evaporative cooler circulation and drain system comprising:

(a) a storage tank having a sidewall and a bottom side together defining an interior volume for holding a fluid;

(b) a fluid pump having an inlet and an outlet, the inlet being in fluid communication with the interior volume of the tank;

(c) a drain opening located in one of the storage tank sidewall and the bottom side, the drain opening being in fluid communication with a drain pipe section;

(d) a drain valve in fluid communication with the drain pipe section, the drain valve being operable between a closed position and an open position, the open position allowing the storage tank to drain fluid regardless of the operation of the fluid pump; and

(e) wherein the system is operable between a circulation mode and a drain-circulation operational mode: i. the circulation mode including the drain valve being in the closed position and the fluid pump being activated such that fluid is continuously circulated within the interior volume of the storage tank; ii. the drain-circulation mode including the drain valve being in the open position and the fluid pump being activated such that fluid is both being continuously circulated within the interior volume of the storage tank and draining from the interior volume of the tank via the drain opening.

2. The evaporative cooler circulation and drain system of claim 1, wherein the fluid pump outlet is in fluid communication with a discharge pipe section having an outlet opening that is facing and spaced from the storage tank drain opening.

3. The evaporative cooler circulation and drain system of claim 2, further comprising a UV light in fluid communication with the pump outlet, the UV light being configured to be on when the system is in the circulation mode and off when the system is in the drain-circulation mode.

4. The evaporative cooler circulation and drain system of claim 1, further comprising an electronic controller in communication with the pump and drain valve, wherein the circulation and drain-circulation operational modes are implemented by the electronic controller.

5. The evaporative cooler circulation and drain system of claim 3, further comprising an electronic controller in communication with the pump, the drain valve, and the UV light, wherein the circulation and drain-circulation operational modes are implemented by the electronic controller.

6. The evaporative cooler circulation and drain system of claim 1, further comprising a discharge assembly connected to the fluid pump outlet, the discharge assembly having a first outlet in fluid communication with a UV light and a second outlet in fluid communication with the interior volume of the tank.

7. The evaporative cooler circulation and drain system of claim 6, further comprising a third outlet in fluid communication with the interior volume of the tank.

8. The evaporative cooler circulation and drain system of claim 7, wherein the third outlet and the second outlet are oriented to direct circulation flow in opposite directions.

9. The evaporative cooler circulation and drain system of claim 7, wherein the third outlet and the second outlet are each formed by a plurality of holes.

10. The evaporative cooler circulation and drain system of claim 7, wherein the third outlet and the second outlet are each formed at opposite ends of a tee, and wherein the first outlet is formed at one of the ends of the tee.

11. An evaporative cooler circulation and drain system comprising:

(a) a storage tank having a sidewall and a bottom side together defining an interior volume for holding a fluid;

(b) a fluid pump having an inlet, a first outlet, and a second outlet, the inlet and the second outlet being in fluid communication with the interior volume of the tank, wherein the fluid pump directs fluid between the inlet and first outlet when rotated in a first direction and directs fluid between the inlet and the second outlet when rotated in a second direction;

(c) wherein the system is operable between a circulation mode and a drain operational mode: i. the circulation mode including the fluid pump being rotated in the second direction such that fluid is continuously circulated within the interior volume of the storage tank; ii. the drain mode including the fluid pump being rotated in the first direction such that fluid is drained from the interior volume of the tank.

12. The evaporative cooler circulation and drain system of claim 12, further comprising:

(a) a drain opening located in one of the storage tank sidewall and bottom side, the drain opening being in fluid communication with a drain pipe section;

(b) a drain valve in fluid communication with the drain pipe section, the drain valve being operable between a closed position and an open position, the open position allowing the storage tank to drain fluid regardless of the operation of the fluid pump;

(c) wherein, the circulation mode further includes the drain valve being in the closed position and the drain mode further includes the drain valve being in the open position.

13. The evaporative cooler circulation and drain system of claim 12, further comprising a second drain mode wherein the pump is rotated in the first direction and the drain valve being in the closed position.

14. The evaporative cooler circulation and drain system of claim 12, further comprising a UV light in fluid communication with the pump first outlet, the UV light being configured to be on when the system is in the circulation mode and off when the system is in the drain mode.

15. The evaporative cooler circulation and drain system of claim 14, further comprising an electronic controller in communication with the pump, the drain valve, and the UV light, wherein the drain and circulation operational modes are implemented by the electronic controller.

16. An evaporative cooler circulation and drain system comprising:

(a) a storage tank having a sidewall and a bottom side together defining an interior volume for holding a fluid;

(b) a fluid pump having an inlet and an outlet, the inlet being in fluid communication with the interior volume of the tank;

(c) a discharge assembly connected to the fluid pump outlet, the discharge assembly having a first outlet in fluid communication with a UV light and a second outlet in fluid communication with the interior volume of the tank;

(d) a drain opening located in one of the storage tank sidewall and bottom side, the drain opening being in fluid communication with a drain pipe section;

(e) a drain valve in fluid communication with the drain pipe section, the drain valve being operable between a closed position and an open position, the open position allowing the storage tank to drain fluid regardless of the operation of the fluid pump; and

(f) wherein the system is operable between a circulation mode and a drain-circulation operational mode: i. the circulation mode including the drain valve being in the closed position and the fluid pump being activated such that fluid is continuously circulated within the interior volume of the storage tank; ii. the drain-circulation mode including the drain valve being in the open position and the fluid pump being activated such that fluid is both being continuously circulated within the interior volume of the storage tank and draining from the interior volume of the tank via the drain opening.

17. The evaporative cooler circulation and drain system of claim 16, wherein the second outlet of the discharge assembly directs discharged fluid from the pump in a direction that is parallel with the bottom of the tank.

18. The evaporative cooler circulation and drain system of claim 17, wherein the tank is provided with curved corners.