Installation Instructions: Field Services

Pre-Installation

When scheduling an Altrac Pump installation, it is important to contact the irrigation manager for the site to determine that it is OK for techs to turn OFF and/or turn ON the pump at the planned date and time. Seasonal variations, such as equipment winterization, plant disease management, and fruit development may limit the times when Altrac equipment may be installed and tested. Check with the irrigation manager to confirm the operating pressure range of the pump system, to ensure that the appropriate pressure transducers are used.

 

When scheduling an electrical contractor, it is very helpful to provide them with photographs of the outside and inside of the pump controller electrical cabinet. Be sure to include detailed photos of the components inside the cabinet, as well as any wiring diagrams or spec sheets that may be inside the cabinet. This information is valuable to the contractor when planning the job and ordering parts. Planning ahead will reduce the need for additional site visits by the contractor and lower costs.

 

VFDs can be a large problem for installation. After the scouting form has been filled out the Altrac lead will contact a contractor that specializes in VFDs. Since VFDs are so complex we need to have a specialist work on it. If there is ever a reason that you have to use the display contact Heath or Neil on the Altrac Pumps And Valves channel FIRST. If the wrong settings are changed then the grower might not have access to water for their crops. It's crucial that we minimize the chance of a mistake by having a professional VFD technician work on it.  

 

If possible, obtain detailed photographs and measurements of the pump site to pre-plan mounting options for ST140, pump buddy(s), and sensor junction boxes. Be sure to measure distances for conduit runs to ensure techs can obtain sufficient supplies.

Turn Off Power to Pump

Flip the breaker on the pump cabinet to 'OFF'.

Install Battery 

Install Battery into Pump Station

Make sure orientation is correct. '-' to '-' and '+' to '+'

Battery is difficult to insert. Make sure you hear a click and the battery is flush with holder. 

Check Cellular Connectivity

Connect M12 patch cable to Pump Buddy.

Connect M12 patch cable to Pump Station.

Modem flashes green when searching for cellular signal.

Modem flashes blue when connected to cell network.

Check signal strength. If signal strength is over 100 RSSI you need to install a directional antenna. Directional antenna instructions can be found at the link below.

Directional Antenna User Manual – Altrac (zendesk.com)

Install Pressure Transducers

Identify ports for installing pressure transducers.

Pre-filter location

Post-filter location

Rules for Install

1. Pressure transducer must be oriented vertically. Horizontal sensors can freeze and stop working.
2. Sensor cable must be terminated in junction box. Do not extend cable. Cable is 6.5' (2m) long. Junction box must be located near enough to sensor for cable to reach.
3. Use Teflon tape on all thread.

Check thread size and install appropriate reducer.

Once sensor is tight tighten an addition quarter turn.

Example 1

 

Pressure transducer installed using a reducer and street elbow.  Note transducer orientation.

Example 2

Identify ports for installing pressure transducers.  Look for other existing pressure transducers, manual pressure gauges, pressure switches, or plugs in pre-threaded ports.  ¼” Tees can be used in combination with other plumbing fittings to install Altrac pressure transducers in parallel with existing equipment.  All pressure transducers must be mounted in a vertical position, with the cables facing upwards to prevent damage from freezing.

Check thread size and install appropriate reducer.  Altrac pressure transducers are ¼” pipe thread.  Once the sensor is tight, tighten an additional quarter turn.

Flow Meter 

The flow meter input accepts a pulse output from most flow meters such as McCrometer or Seametrics. Refer to your flow meter user manual to confirm pulse output capability. 

Wiring

(1) Connect the ‘Pulse +’ wire from your flow meter to the ‘Pulse +’ terminal on the ST140. 

(2) Connect the ‘Pulse -’ wire from your flow meter to the ‘Pulse -’ on the ST140. 

Calibration

The default calibration for the Altrac is 100 gallons per pulse. Most flow meters do not emit a pulse by default. You will need to check your flow meter settings to determine the gallons per pulse value. Some flowmeters require a magnet to adjust settings. 

If you need to use a pulse value that is not 100 gallons per pulse, adjust the calibration through the Altrac web app sensor adjustment page. 

Pulse Frequency

The ideal pulse frequency is not more than 1 pulse per second and not less than 1 pulse per 2 minutes while water is flowing

Maximum Pulse Frequency: 50 pulses per second

Minimum Pulse Frequency: If your pulse signal is infrequent (1 pulse per 10 minutes), the flow rate will not be accurate. 

Accuracy

Pulse Output: ±5% of total pulses sent by the flow meter. Flowmeter errors not included.

 

Dig Trench for Conduit

Rules

1. Trench to a depth of 6-8 inches.
2. All PVC must be glued to seal the pvc.
3. Flex conduit cannot be buried underground.

Electrical conduit is used to protect the cable running from the ST140 to the junction box.  Conduits must be buried 6-8 inches underground, or anchored securely to solid surfaces with clips and bolts.

Install Junction Box for Sensors

Rules

1. All wire terminations must occur in a junction box.

Junction boxes contain two terminal strips where sensor wires can be connected to the main cable wires which run to the ST140.  Use a screwdriver to attach the sensor wire to one side of the strip, and the main cable wire to the opposite side of the strip.  Cap or tape any unused wires inside the junction box.

Use a mounting plate to attach the junction box to a support post or pipe.  It must be located near enough for the PT cables to reach, and be out of the way of valves and other equipment.

Install cable glands and conduit fittings on the bottom side of the junction box. Make sure they are sealed with rubber gaskets and/or silicone sealant (E-6000). 

Junction Box Contact Position	Color	Altrac Station Terminal
1	White	Analog Sensor 1 - Power
2	Green	Analog Sensor 1 - GND
3	Purple	Analog Sensor 2 - Power
4	Yellow	Analog Sensor 2 - GND
5	Red	Analog Sensor 3 (Relay Feedback 1) - Power
6	Black	Analog Sensor 3 (Relay Feedback 1) - GND
7	Orange	Analog Sensor 4 (Relay Feedback 2) - Power
8	Grey	Analog Sensor 4 (Relay Feedback 2) - GND
9	Blue	Flow Meter - Positive
10	Brown	Flow Meter - Negative
11	Drain Wire	Digital Input 1 - GND

To attach wires use lever nuts. 

Install Pump Station

Rules

1. Pump station must be mounted at ~5' so an irrigation can easily push the button on the front of the pump station. 

In order to attach the conduit, drill a hole in the bottom of the pump station.

Install the flex conduit coupler and flex tubing. 

Run the appropriate wire and attach wires according to this table:

Input	Contact	Color
Analog Sensor 1	Power	White
Analog Sensor 1	GND	Green
Analog Sensor 2	Power	Purple
Analog Sensor 2	GND	Yellow
Analog Sensor 3 (Relay Feedback 1)	Power	Red
Analog Sensor 3 (Relay Feedback 1)	GND	Black
Analog Sensor 4 (Relay Feedback 2)	Power	Orange
Analog Sensor 4 (Relay Feedback 2)	GND	Grey
Flow Meter	Positive	Blue
Flow Meter	Negative	Brown
Digital Input 1	GND	Drain Wire

*Cap any unused wires so they don't touch the board and cause an electrical short. 

Mount Pump Station

Mount the Altrac Pump Station to a pole or flat surface using the included brackets and appropriate screws.

Rules

1. The station must be mounted between 4-6' (1.5-2m) so that the button on the front of the device is accessible the operator.

Turn Pump ON

Rules:

1. Leave the HOA switch in Manual until you are ready to test. 

Testing Procedure

Installation Testing Procedure (Field Services)

Dimensions and Components

Components

A: Waterresistent Vent 

B: Plug on .6” hole, PG9 Cable Gland

C: Accessory Port, 6-Pin, APT

Additional Components Shipped but Not Installed on Enclosure

PG13.5 Cable Gland (1)

PG9 Cable Gland (2)

Wall Mounting Brackets (4)

M5 x 10mm Lg. Truss Hd. Machine Screws (4)

Power Supply

We recommend powering the ST140 with a 15VDC power source. The Altrac provided option is described below.

Pump Station (ST140) Specifications:

Power Supply Voltage: 12-15VDC

Power Consumption: 2A peak usage

Installation:

Wire the power supply conductors to the terminals in the ‘Power’ section.  

Backup Battery

The ST140 includes a backup battery designed to power the device for up to 3 hours during a power outage. This battery will not allow the pump to continue operating, but it does allow the ST140 to notify the user when their pump has lost power.  The battery is not required for operation. 

Specifications:

Altrac Part Number: PW200

Battery Type: Lithium Ion Cell

Battery Size: 18650

Continuous Discharge Rating: >= 3A

Nominal Voltage: 3.6v

Nominal Capacity: >= 2000mAh

Rechargeable: Yes

Installation:

During setup you must remove the plastic strip protecting the battery terminal of the button.  

Removal:

To remove the battery, pull on the ribbon behind the battery. 

Relays

The ST140 has 2 onboard relays for controlling a primary and secondary pump. The relays are controlled independently through the Altrac web app or physically through the ‘test switches’ on the PCB.  

Relay Specifications

Contact Ratings: 6A, 250VAC, 85°C, Cycles: 30x10^3

Approvals: VDE Cert. No. 40023970, UL E214025, CQC 12002066685

Wiring

NC: Normally Closed

COM: Common

NO: Normally Open

Operation

The relays have a 60-second timeout between cycles to protect against damage to equipment

 

Relays Testing

To test the relay functionality without access to the Altrac web app, you can open the enclosure and check the relay status LEDs or physically switch the relays ON/OFF. When not testing, the relay switch should be in the left ‘OFF’ position. 

Analog Sensors

There are two analog sensors inputs on the ST140 Pump Station. These inputs are commonly used to monitor pressure sensors such as transducers (PSI reading) or switches (ON/OFF). 

The analog inputs by default are setup for pressure transducers with the following characteristics.

Power: VIN @ 30mA

Current Range: 4-20mA

PSI Range of Transducer: 0-100PSI

Pressure Transducer (SN210): 4-20mA Output

Wiring

POWER: RED, V+

INPUT: Black, Output

GND: Shield Drain Wire

Pressure Switch (24VDC Max)

Wiring

POWER: RED, V+

INPUT: Black, Output

GND: Shield Drain Wire (when applicable)

Analog Sensor Adjustment

If you need to adjust the default settings for the Analog Sensors, you must do so through the web app. 

Webapp Navigation:

Navigate to the ST140 device in question. Click on the gear icon in the top right corner of the device page to access the settings page. Click on the appropriate sensor tile to change settings. 

Digital Inputs

The digital inputs on the ST140 are used for monitoring switches and simple sensors. 

Default Input Specifications for Digital Inputs: 

DIN1: HOA Switch Auto Position - Pump 1

DIN2: HOA Switch Auto Position - Pump 2

DIN3: Not Defined

Power: VIN Pull Up

ON Threshold: Closed Contact (0V)

OFF Threshold: Open Contact (VIN)

Adjusting Digital Input Usage

No adjustment is necessary.

RS485/RS232

RS485/RS232 is an industrial digital communication protocol. It is frequently used for two or more devices to communicate and share information. The ST140 uses RS485/RS232 to communicate with various controllers such as VFDs and Soft Starts. 

Wiring

(1) Connect the ‘RS485 A’ input on the controller to RS485 ‘A’ terminal on the ST140. 

(2) Connect the ‘RS485 B’ input on the controller to RS485 ‘B’ terminal on the ST140.  

(3) Connect the ‘GND’ input on the controller to ‘GND’ terminal on the ST140.

Communication Settings

(1) You will need to update settings on your controller to enable RS485 communication. 

(2) Contact Altrac to learn more about which controllers are supported.