DIY actuated surge valve - maintenance

[karimwassef]

About a year and a half ago, I posted my design for a cheap actuated PVC valve using a repair extension. I use these on my 100g surge and run from my Apex 10V channels through a DIY relay board.

Since the top and bottom and constantly submerged and no vortex can form, the surge is bubble free and the pipes and continuously primed.

<a href="http://s1062.photobucket.com/user/karimwassef/media/E1B84615-5132-47D9-A52A-8FA8E59B9F95_zpsjlojrgzu.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/E1B84615-5132-47D9-A52A-8FA8E59B9F95_zpsjlojrgzu.jpg" border="0" alt=" photo E1B84615-5132-47D9-A52A-8FA8E59B9F95_zpsjlojrgzu.jpg"/></a>

The concern was the long term viability of these valves with continuous use.

I have two calves and they run during the day on a schedule. When active, they surge every 5 minutes or so. So about 50x per day for 6 days a week ~ 23K operations (in + out). Saturday is calm day.

One valve has no issues, but the other one had a very slow drip. The one with the drip was a little off center so I think it was uneven wear on the two o rings inside.

I had designed it to be serviceable and this was the moment of truth...

I removed the actuator and clamps

<a href="http://s1062.photobucket.com/user/karimwassef/media/52A1B9A9-6A28-409F-9F2D-D27E607C8077_zpsjwiv2vqf.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/52A1B9A9-6A28-409F-9F2D-D27E607C8077_zpsjwiv2vqf.jpg" border="0" alt=" photo 52A1B9A9-6A28-409F-9F2D-D27E607C8077_zpsjwiv2vqf.jpg"/></a>

Inspected the shaft

<a href="http://s1062.photobucket.com/user/karimwassef/media/08B4913F-C477-47CF-B375-8F94F715D26E_zpsdyzrnvgg.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/08B4913F-C477-47CF-B375-8F94F715D26E_zpsdyzrnvgg.jpg" border="0" alt=" photo 08B4913F-C477-47CF-B375-8F94F715D26E_zpsdyzrnvgg.jpg"/></a>

The PVC plunger looked ok and moved freely but leaked a couple of drops.

Then I unscrewed the extension assembly and disconnected the inside shaft.

<a href="http://s1062.photobucket.com/user/karimwassef/media/A88EB040-DE8A-4DB4-9BAD-749942E45C56_zpsqj8dedgz.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/A88EB040-DE8A-4DB4-9BAD-749942E45C56_zpsqj8dedgz.jpg" border="0" alt=" photo A88EB040-DE8A-4DB4-9BAD-749942E45C56_zpsqj8dedgz.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/AF165DB6-2F0B-4059-9E6C-1DC3AE34C561_zpsro9btzgj.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/AF165DB6-2F0B-4059-9E6C-1DC3AE34C561_zpsro9btzgj.jpg" border="0" alt=" photo AF165DB6-2F0B-4059-9E6C-1DC3AE34C561_zpsro9btzgj.jpg"/></a>

That was fine too.

I removed the extension plunger with the o rings. This is the part I expected to service.

<a href="http://s1062.photobucket.com/user/karimwassef/media/EC37308F-36DD-4A5D-9A19-93AEF503AC8F_zpsxxk9spr3.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/EC37308F-36DD-4A5D-9A19-93AEF503AC8F_zpsxxk9spr3.jpg" border="0" alt=" photo EC37308F-36DD-4A5D-9A19-93AEF503AC8F_zpsxxk9spr3.jpg"/></a>

There are fine scratches in the rubber on one side.

Replaced it with a new one ($4 from Lowe's) and reassembled the actuator (1 screw, 3 large hose clamps).

<a href="http://s1062.photobucket.com/user/karimwassef/media/63303D52-1111-4A05-B9EC-230ADB26C25D_zpswyq3tvia.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/63303D52-1111-4A05-B9EC-230ADB26C25D_zpswyq3tvia.jpg" border="0" alt=" photo 63303D52-1111-4A05-B9EC-230ADB26C25D_zpswyq3tvia.jpg"/></a>

Running for 24hrs good as new.



Just felt like sharing - DIY is only good if it lasts.

 

[karimwassef]

I'm going to put these on a yearly maintenance. They're clearly over engineered as repair extensions, and given the minimal wear, I think that should give a decent margin.

 

[zachts]

Very nice follow up. I've been curious how these would hold up since reading about the build a long while ago.

 

[karimwassef]

They're excellent. I'm moving on to deliberate actuation ranges. Instead of on/off, I want to use the Apex analog output (0-10V) to control position. That way, I can vary the flow out of each and create an alternating wave flow and surge.

It'll take more than a relay box though.