Real world Hi-Pressure Aeroponics

haole420

Active Member
a lengthy post, as my posts usually are, but want to put this info out there to save others the trouble of learning the same lessons the hard way...

my aero setup consists of orbit nozzles and a 1HP shallow well pump with 6gal pressure tank (~$100 at harbor freight). out of the box, it pushes about 50psi, but i have it dialed up to maintain a pressure between 55psi and 75psi. crank it up to as high as you can go. higher pressure = smaller droplet size. my nozzles are rated up to 1500psi but my pump can't seem to generate more that 75psi, so if you want more pressure , get a bigger pump, but realize that 1HP pulls about 7amps (i think). you don't want that on the same 15amp household circuit as an HID lamp! granted, the pump only kicks on for about 30sec every once in a while, but for those 30sec, it's probably pulling 7amps. also keep an eye on the working pressure of you fittings. i have a quick coupling that is the weakest link, rated at 80psi, so 75psi is fine for me.

i went through about 7 different pumps: fountain pumps, sump pumps, you name it. avoid submersible pumps: they generate lots of heat. most sump pumps and such are equipped with a back pressure valve. when there's too much head or back pressure, the valve opens and water just squirts out the bottom. they're designed to drain basements, pools, ponds, etc. the only pressure they're designed to handle is a little head (weight of the water itself increased by height to which you're pumping). use a irrigation system pump if you want to go heavy duty or a shallow well pump if you want something that's reasonable suitable for a home system. pressure tank is absolutely necessary.

output goes through a spin down filter. using 150micron filter to allow larger fungus through. filter also has a purge valve that is handy for depressurizing the system within a few seconds. output then piped to a sprinkler solenoid valve powered by 24v adapter that's connected to day/night timer set to mist 5sec every minute during the day and every 2 minutes at night. cheaper cycle timer would do the trick too.

make sure you use a BRAIDED vinyl tube between the valve and your manifold/nozzles. standard clear vinyl tubing ballooned to diameter of about 6 inches and almost blew apart. i didn't have any pressure release mechanism at the time either. use a filter with purge valve or, at a minimum, install a simple pressure release valve. use metal clamps to connect tubing to barbs/bulkheads, as zip ties don't quite give you a solid seal and tend to allow for a slow drip. also, don't let the tubing crease, as it tends to stay that way. i used a clamp gently opposing the crease for several days to straighten it out. also, try to keep the distance between the valve and the manifold/nozzles to a minimum. the more tubing or pipe you have between them, the more water there is to act as a pressure reservoir and the nozzles will pee and dribble for a while (with bigger droplets at low pressure). ideally, each nozzle would have it's own valve right behind it, but whatever. i'm not going to go that far.

my manifold has orbit 10 nozzles spread around perimeter of 20"x30" rooting chamber. get 2X more nozzles than you plan on using. the require at cleaning at least weekly. overnight soak in vinegar will ruin the gasket. CLR works well too. i soak in CLR, agitate (while soaking) with vibrating massager for a minute, then blow air through the front of the nozzle using an air compressor. carefully plan your nozzle placement based on the pattern of the cut outs on your lid to allow for even spray distribution. also, get a tub with a lid that's not yellow (like mine). i had to cover it in foil HVAC tape.

rooting chamber is about 14" deep. i keep about 3" of solution in the bottom which functions as a shallow kind of DWC (SWC?). a triple fogger floats in the bottom and is on for 50sec, off for 150sec. running it all the time or even half the time heats up the res too much. the misting nozzles stir the fog in the chamber when they kick on every minute. when i have guests and have to switch to stealth mode, i turn off the pump/nozzles and leave the fogger on (still cycling it on/off). i use a 4" computer fan hooked up to 2 D-cell batteries to blow air through the lid to stir the fog, which would otherwise just sit at the bottom of the chamber when the pump is off. works beautifully and is virtually silent!

the rooting chamber spills over through a bulkhead (again, allowing for about 3" to remain in the bottom) and drains to my lower control res which is where the pump sucks up more solution when the pressure drops to 55psi. my particular pump requires a separate backflow valve ($10) on the input. one thing that will save you $$ and trips to the hardware store is to put threaded adapters on special/expensive slip PVC fittings like the backflow valve and spindown filter ($$$). when you first setup your system, you may want to rearrange stuff. you can only move stuff around so much when it's glued into PVC pipe. you can always cut the pipe and use a coupling, but you can only do that so many times. it also makes it nice when you want to replace those parts or yank them for assembly of a new system. this is my one major regret as far as design shortsightedness. i got the idea from the solenoid valve, which comes with threaded female connections and i did, in fact, end up moving around a few times.

upper root chamber solution temperature is still around 85F/30C. lower res a little lower. had a puny desktop water cooler with peltier plate in it and ran water through it using a submersible fountain pump, but that just didn't cut it. lowered temps about 0.5C. picked up a used water cooler with old school compressor in it just last night. going to gut it and hook it up to my system. hopefully i can get res temp down to ideal temp of 65-70F.

hope this helps. thanks to all the other posters for info!
 

Bob Smith

Well-Known Member
Thanks for the info, bro, but there's a lot that your setup leaves to be desired (IMO).

Firstly, get a diaphragm pump - mine uses 1 amp, self primes (up to 8 vertical feet, but who the hell would need that), and can deliver 160+PSI.

Secondly, get rid of that PVC/braided tubing and get some pressure rated PEX tubing - mine goes up to 230PSI, and the BEST part about it is, they go right into John Guest quick connect fittings for the ultimate in flexibility - takes two seconds to change something around, increase/decrease a run, etc.

Also not a hint of a leak, ever - you really can't beat them - also, smaller diameter means much less bleed after your cycle has stopped.

The weakest link in my system is my solenoids, which are rated to 140PSI, but I don't go over 125PSI, so everything else has a lot of "fudge room" before it's maxed out.

I use a 1 micron filter bag before my pump, and I haven't had any clogging issues yet (a few weeks in) - definitely not cleaning my misters once a week, that's for damn sure.

Just trying to save people some headaches if they choose to go this route - sounds like it's working for you though, so kudos on that :)
 

Atomizer

Well-Known Member
Typical lp aero roots due to overmisting, 20 seconds is way too much. It illustrates that without control even air atomising nozzles cant deliver true aero roots. Sooner or later the penny will drop that the key to aero is control.
 

pounce

Member
Typical lp aero roots due to overmisting, 20 seconds is way too much. It illustrates that without control even air atomising nozzles cant deliver true aero roots. Sooner or later the penny will drop that the key to aero is control.
Atomizer, lots of comments about what people are doing wrong. Do you have a post or thread somewhere where you discuss what you are doing and what you think works best?
 

Atomizer

Well-Known Member
There is a huge hp aero thread on RIU that discusses the parameters needed for hp aero and provides proof of the results. Compare the roots from the aerolife and the atomix and you`ll see the difference control can make.
I`ve never seen anything close from a 1000psi equipped setup as they overmist. There are a few on the net that are powered by 1000-1500psi pressure washer pumps. Maybe you could post some pics of the root structure your 1000psi setup grows to compare?
 

pounce

Member
There is a huge hp aero thread on RIU that discusses the parameters needed for hp aero and provides proof of the results
Can you link to where you are outlining what you think people should be doing?

I`ve never seen anything close from a 1000psi equipped setup as they overmist.
Overmist? I really don't understand that. What do you mean?

Note: it's been mentioned before up thread, but I actually don't grow what you guys grow.

You mostly post negative things. Are you trying to help people in a constructive way?
 

Atomizer

Well-Known Member
Overmist? I really don't understand that. What do you mean?
Its makes the difference between roots that have the aero structure and those that have the usual hydro structure, aka kept constantly wet or overwet..

Note: it's been mentioned before up thread, but I actually don't grow what you guys grow.
Roots are roots, the structural difference is related to the method used to grow them. Your plants must have some kind of roots to warrant using 1000psi mist irrigation coupled with foliar feeding?
 

haole420

Active Member
Thanks for the info, bro, but there's a lot that your setup leaves to be desired (IMO).

Firstly, get a diaphragm pump - mine uses 1 amp, self primes (up to 8 vertical feet, but who the hell would need that), and can deliver 160+PSI.

Secondly, get rid of that PVC/braided tubing and get some pressure rated PEX tubing - mine goes up to 230PSI, and the BEST part about it is, they go right into John Guest quick connect fittings for the ultimate in flexibility - takes two seconds to change something around, increase/decrease a run, etc.

Also not a hint of a leak, ever - you really can't beat them - also, smaller diameter means much less bleed after your cycle has stopped.

The weakest link in my system is my solenoids, which are rated to 140PSI, but I don't go over 125PSI, so everything else has a lot of "fudge room" before it's maxed out.

I use a 1 micron filter bag before my pump, and I haven't had any clogging issues yet (a few weeks in) - definitely not cleaning my misters once a week, that's for damn sure.

Just trying to save people some headaches if they choose to go this route - sounds like it's working for you though, so kudos on that :)
awesome. i think those are all upgrades that would let me crank up the pressure. is the diaphragm pump hooked up to a pressure tank? most of the tanks that i've seen at places like northern tool are all rated at around 80psi, if i remember correctly. clogging has to do with beneficials, i think, which aren't too water soluble. maybe i'll switch to ones that are. pump make/model?
 

pounce

Member
Its makes the difference between roots that have the aero structure and those that have the usual hydro structure, aka kept constantly wet or overwet..
I think you misunderstood. I understand too much mist. I don't understand saying:

Atomizer said:
I`ve never seen anything close from a 1000psi equipped setup as they overmist.
Why do you think a 1000psi system would innately lack or not be able to achieve perhaps the same control or better than a lower pressure system or a system that doesn't even use pressure?

Perhaps you haven't considered that what you think is limiting the system isn't actually a limit or that there are very simple solutions that provide control to systems of all pressures.

See my response to your other comment up thread.

https://www.rollitup.org/hydroponics-aeroponics/367969-real-world-hi-pressure-aeroponics-8.html#post5322482

It's very simple to control the pressure of any line 60psi or 1000psi. The concepts are the same. You have full control of the line pressure. If you want it to fall on it's own you can do that. If you want to force it to fall quickly you can do that as well....just open the line. Where is the "overmist" happening?

So, you seem to be attacking/criticizing many different approaches. Do you have some financial position with regard to a certain manufacturer or a certain approach? You still haven't shared what *you* think is the best setup. Care to share?
 

pounce

Member
awesome. i think those are all upgrades that would let me crank up the pressure. is the diaphragm pump hooked up to a pressure tank? most of the tanks that i've seen at places like northern tool are all rated at around 80psi, if i remember correctly. clogging has to do with beneficials, i think, which aren't too water soluble. maybe i'll switch to ones that are. pump make/model?
If you want to stay around average line pressure I'd imagine an Aquatec 8800 plus stainless Shurflo accumulator would be close to ideal. That combo might run you $325 or so.
 

Atomizer

Well-Known Member
So, you seem to be attacking/criticizing many different approaches. Do you have some financial position with regard to a certain manufacturer or a certain approach?
You seem to be misinterpreting the listing of shortfalls as criticism/attacks.

There is a big difference to slamming a solenoid closed with 60psi behind it and 1000psi, the pressure wave from 1000psi will be huge which produces water hammer issues.
Releasing 1000psi of pressure from the line in a split second is not something i`d want to do. Apart from that its very inefficient and wasteful as you use more power to regenerate that pressure at each misting (0-1000, 1000-0). An accumulator maintains a constant pressure behind the solenoid. It needs no regeneration so its cheaper, simpler and more effective.

Your pump runs into a closed pipe when the solenoid is closed, not great for the pump or your power bill as current increases with load. An accumulator uses stored pressure and is not the same thing.
I have ploughed a sizable amount of cash into aero of every type, i`m simply offering advice on the cheapest/ simpliest route to the end goal as hardware mistakes will get expensive (been there done that).

As for having any financial position with manufacturers or products..i`ll treat your comment with the contempt it deserves.
You skirted the 1000psi root structure pic request so maybe they are not upto hp aero standards?
 

pounce

Member
You seem to be misinterpreting the listing of shortfalls as criticism/attacks.
Not really. You are stating your opinion as fact without actually explaining yourself. I've looked through your posts and it's pretty common so I wont take it personally.

There is a big difference to slamming a solenoid closed with 60psi behind it and 1000psi, the pressure wave from 1000psi will be huge which produces water hammer issues.
Releasing 1000psi of pressure from the line in a split second is not something i`d want to do.
Commercial 1000psi misting systems run in public places all day long with solenoids. Not sure why you believe this is an issue.


I have ploughed a sizable amount of cash into aero of every type, i`m simply offering advice on the cheapest/ simpliest route to the end goal as hardware mistakes will get expensive (been there done that).
Have you actually run a 1000psi system? If yes, can you describe it and why you no longer use it? I think that would be interesting to talk technical and from experience.


As for having any financial position with manufacturers or products..i`ll treat your comment with the contempt it deserves.
So? I don't really care if you do or not. Would be useful to know if you do.

I'm in no way saying one way is better in all situations here.

If you had said "I'd imagine that a 1000psi system would be hard to control to the granularity of a second" I actually would have just shared again that it's possible and not that complex. Or maybe you could have said "I've tried to use a 1000psi system and had issues controlling the mist". We might have been able to discuss further.

For someone that wants to spend under $500 and grow in their basement I agree completely that 100psi is appropriate and adequate. When a person wants to experiment further with more precision there are other options.
 

Atomizer

Well-Known Member
I have never considered a 1000psi pump due to the issues of control and reliability as you need both for hp aero. I guess you are misting for a lot longer than 1 second as your method of control is too unwieldy to provide very short misting durations.
With the solenoid method you describe, your pump is either running 24/7 into a closed pipe most of the time or being switching on and off hundreds of times a day. Neither is good for the pump or your power bill.
Comparing apples to apples, a low flow nozzle at 1000psi will have the same flow rate as a higher flow nozzle at 100psi. Nozzles made from the same material need more frequent replacement with 1000psi of pressure compared to 100psi. The reason? all nozzle orifices are subject to erosion from water pressure. High pressure nozzles use very small orifice sizes. As the orifice enlarges the nozzle flow rate and droplet size increase and the mist pattern deteriorates.
If 1000psi works for you then thats fine but for me it has many too pitfalls in at least two important areas, control and reliability.
 

pounce

Member
I have never considered a 1000psi pump
That's fair. If you haven't tried then you really don't know. I'll take your comments as arm chair opinions.

I guess you are misting for a lot longer than 1 second as your method of control is too unwieldy to provide very short misting durations.
I don't have the issues you think I have. Sub second is possible.


Nozzles made from the same material need more frequent replacement with 1000psi of pressure compared to 100psi.
Honestly, in a commercial misting system you are running for hours and hours and hours without changing the misting heads. In an Aero system these misting heads are running in the seconds. Do the math. They last a long time. Even if you want to replace them they are not that expensive.

If 1000psi works for you then thats fine but for me it has many too pitfalls in at least two important areas, control and reliability.
You haven't tried it and you have a system you like I would guess. I'd just ask you not to keep posting your guesses as fact. It doesn't help anyone.
 

pounce

Member
Lets change the topic a bit. I'm curious to know if any of you have experimented with using a Surfactant in your nutrient solution.

Do your Nutrients contain a Surfactant and you don't know you are using one already?

Have you mixed your own Nutrients and purposefully added a Surfactant?

For those who don't know what a Surfactant is....it basically reduces surface tension. Basic soaps do this so that they work better. It makes water "wetter". They are frequently used in foliar sprays so that the solution doesn't bead up and instead covers the leaves etc. This helps penetration. You might see products like Wet Betty or Coco-Wet in your shops. You can add these to your own sprays as Surfactants.

When using a Surfactant with misters it actually helps to create a larger mist because you have lowered the surface tension on the water and sort of made it more slippery. The misters are much more efficient.

I'm curious about what people are using because if you lower the surface tension you also then make the droplets perhaps spread and join on the rootlets.

Theory is one thing, but I'm really interested in knowing if someone has actually looked at this and what they may have seen as a result.
 

Atomizer

Well-Known Member
fogco test.jpg

I have some Fogco 0.15mm orifice nozzles and 882psi (60 bar) of available pressure, not quite 1000 but close enough.
As you can see from the pic i can and do speak from experience, they have a very tight cone pattern and a very short throw distance. You need to use more nozzles to gain full coverage, each one delivers 0.6gph at 1000psi and they are prone to clogging. As you only use plain water and foliar feed, clogging issues are likely to be outside your experience.
Commercial misting systems have the nozzles mounted high up for a reason. You must have one picture that shows your mist quality?
 

pounce

Member
Its hard to tell what we are looking at in that pic.

Do you have clogging issue when using soluble non organic nutrients? Maybe something like Dutch Master? Is it due to the salts or the fact that you might be reusing nutrients? Do you filter and if so how fine do you filter?

If you are using an accumulator and not running a large number of misters your system could grow anaerobic bacteria. You could easily figure out how much volume you store and how long it takes to cycle fresh nutrients. You could even design it to flush every so many misting cycles. Just add a solenoid to the end of the line and open wide and dump back in your tank. Your misters likely wont spray with the low pressure you would get by opening the line.

A .15mm is about a .006 mister. I have some of these. I also run up to .014.

What are you looking for in a mist pattern? How large is your root chamber and are you using any sort of fan or air movement to distribute the mist?

FYI: You can use an ultrasonic jewelry cleaner and a cleaning solution to clean misters quickly. As many do...you can keep a second set and swap them to clean them.
 

Bob Smith

Well-Known Member
awesome. i think those are all upgrades that would let me crank up the pressure. is the diaphragm pump hooked up to a pressure tank? most of the tanks that i've seen at places like northern tool are all rated at around 80psi, if i remember correctly. clogging has to do with beneficials, i think, which aren't too water soluble. maybe i'll switch to ones that are. pump make/model?
Post #46 has links to (pretty much) everything I used in my setup (pump and 150PSI accumulator included).
 
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