Installation Instructions for ST160 Valve station (Field Services) – Altrac

This document gives step by step instructions on how to install your Altrac multi-station (ST160/161) for valve control and pressure monitoring.

Tools and Materials	Size	Use
Phillips Screwdriver	Medium/Large	Attach mounting brackets
Flathead Screwdriver	Small (Terminal)	Inserting wires into station
Flathead Screwdriver	Medium/Large	Tightening hose clamps
Wire Strippers	Mid-range	Stripping 18 AWG wire
Mounting Pole	"Gateway" size	Mount Altrac Station and solar panel
Zip ties	11"	Cable management
Hose Clamps	"Repeater" size (32)	Mounting ST160 and solar panel

Building the Station

Use a hacksaw to remove the thin top part of a gateway pole.
Attach the Solar panel to the top of the pole with hose clamps.
Run the black cable provided with the solar panel along the backside of the fiberglass pole away from any pinch points and secure it to the pole with zip ties.
Screw on the two mounting brackets to the back of the Altrac enclosure. You will need a Phillips screwdriver.
Attach two hose clamps to the mounting brackets.
Fasten the ST160 directly below the solar panel at the top of the Repeater pole.
Drill a 3/4 inch hole directly under the Altrac ST160 box. This hole will be used to run your 4-conductor cables down the inside of the pole.
Add a gateway pole segment or segments to the bottom as necessary to achieve the desired station height.
Install your Galvanized fence post one tree away from the valve you will be installing the control device on. This will ensure that we don't damage any underground irrigation lines. Pour concrete footing and allow it to set.
Using a hole saw or unibit, drill 2 holes into the bottom of the junction box. Attach a PG13.5 cable gland on the left and a PG13.5 3-hole gland on the right.
Install your junction box directly next to the Valve. PTs have a 6' wire so the junction box will need to be near for it to reach. Junction boxes are bolted to mounting plates which can be hose clamped onto irrigation pipes. Be aware of the presence of underground irrigation pipes and use caution and your best judgment not to damage it.
Dig a small trench to run your 4 conductor cable from the galvanized pole to your Junction box.
Using your fish tape, run your 4 connector cable from the Altrac station to the junction box and lay the exposed cable inside the trench. Measure a length which will allow some extra to be buried at the base of the installed station, this will make it easier to take down the station in the future.
Make sure to leave plenty of slack on your 4 connector cable to ensure there will be enough cable to strip back the black insulation to expose the 4 separate wires.

Wiring

Open the ST160 Altrac Box.
Strip back the Black insulation to expose the separate wires.
Follow the table below to connect the wires to the PCB board. To connect the wires you will need to strip 1/4 inch off the end of the cable to expose the copper wire. Once this is done use a small flat head screwdriver to compress the green button on the terminals to insert the wire into the correct port.

Wire colors	Sensor connection	Port on PCB
Red (1)	Valve 1 Solenoid open	SOL1B+
Black (2)	Valve 1 Solenoid close	SOL1A+
Orange (3)	Valve 1 Pressure transducer hot	IN1+
Blue (4)	Valve 1 Pressure transducer ground	Port directly to the right of IN1+ (IN1-)
Red (5)	Valve 2 Solenoid open	SOL2B+
Black (6)	Valve 2 Solenoid close	SOL2A+
Orange (7)	Valve 2 Pressure Transducer hot	IN2+
Blue (8)	Valve 2 Pressure Transducer ground	IN2-
Silver	Bare drain wires for PTs	GND

PROTIP: Use a short section of insulated 18 gauge wire and a lever nut to connect the bare (silver) PT drain wires to GND.

Installing and Wiring the Solenoids

The Altrac Station controls up to two latching solenoid valves. Latching solenoids only require power to switch position (ON->OFF or OFF->ON), so they are suitable for low power applications. The latching solenoids each use two wires.

Install the solenoid onto your valve.
With the solenoid installed on the Valve run a piece of Flex conduit/wire protector to the junction box to prevent any wire damage and attach the two wires to the screw terminal inside the junction box. Make sure to match up the wiring for the solenoids with the Wiring table above. Note that some solenoids have different wire colors, like the Bermads which have Green(+) / Black(-) pairs. Wires can also be color coded backwards, if the valve is not working you might have a valve where Green/Red is (-) and Black is (+). Inform tech support and test that valves work correctly after wires have been properly matched in the junction box.

Valve 1:
Valve Station Red -> Solenoid Positive + (Usually RED or GREEN)
Valve Station Black -> Solenoid Negative - (Black)
Valve 2:
Valve Station Red -> Solenoid Positive + (Usually RED or GREEN)
Valve Station Black -> Solenoid Negative - (Black)

The solenoid wires are often very short, and may have to be extended in order to reach the junction box. You can use appropriately sized crimp butt splices, ¼” heat shrink tubing, and a length of 2-core gateway battery cable to extend the solenoid wires to the junction box.

Place the heat shrink tubing over the black solenoid wire.
Strip the end of the black wire in the battery cable and crimp it to the black solenoid wire.
Slide the tubing over the crimped splice junction, and carefully heat it with a propane torch. Allow it to cool, and check that it has fully sealed the connection.
Repeat the process for the red wires
Install split wire loom over the entire assembly and run the extension into the junction box.

Check the voltage range printed on the solenoid. Most solenoids can operate on a range of voltages from 9-24v or higher.
Check the position of the Solenoid Switches. By default they are set to 24V which will work on most solenoids so you should not have to adjust them.

However, if necessary you can adjust the switches labeled 'Solenoid Voltage' to match the voltage output of the Altrac Station to your solenoids.

VDC	SW1	SW2
24	OFF	OFF
15	OFF	ON
12	ON	OFF
9	ON	ON

Installing and Wiring the Pressure Sensor

The Altrac Station monitors up to two pressure sensors either switches (ON/OFF) or transducers (PSI). The pressure sensors each use two wires.

Install the Pressure Transducers on the downstream side of the Valve. This allows the ST160 to recognize when the valve is open. Use a tee or right/angle fitting to orient the PT with the wires facing up. This will prevent water freezing inside and damaging the unit.
With the Pressure Transducers installed on the Valve run a piece of flex conduit/wire protector to the junction box to prevent any wire damage and attach the two wires to the screw terminal inside the junction box. Make sure to match up the wiring for the Pressure Transducers with the wiring table and diagram below. (NOTE: This is an older picture left in for reference but is not the current configuration. Cable glands should be located on the bottom of the box as pictured in the diagram above, and the PT and solenoid wires share the same 3-hole PG13.5 gland.)

Pressure Sensor 1:

Valve Station Orange -> Pressure transducer Red

Valve Station Blue -> Pressure transducer Black

Valve Station Drain wire -> Pressure transducer Drain wire (silver)

Pressure Sensor 2: