User: Electromatic, Location: Virginia
Asked on: Friday, June 6, 2025 at 8:26 am EDT
Answered on: Friday, June 6, 2025 at 8:31 am EDT
Question: I have a water tank/booster station at the top of a mountain where the water is supplied by a pump station at the bottom of the mountain. There is a mechanical pressure switch at the top to call for water. For control at the bottom to turn the pumps on, there is a Wheelock CRT-T-40 telephone relay operating at 90V, 20Hz. The wiring between the stations is a telephone line. Is there a modern way to accomplish transmitting a signal here? The stations are about a mile apart through woods. The telephone line route is probably longer.
Okay, let's break down this challenge and explore some modern solutions for replacing your aging telephone relay-based control system. You're essentially trying to remotely start/stop a pump based on the water level sensed by the pressure switch. You have a few key constraints: Distance
Approximately a mile, possibly longer along the telephone line route.
Existing Infrastructure
You have a potentially usable (but likely old) telephone line.
Power Requirements
You need to consider power availability at both the pump station (bottom) and the booster station (top).
Reliability
This system needs to be dependable for water supply.
Modernization Goal
Replacing the outdated telephone relay.Here are a few modern approaches, ranked in terms of commonality and increasing complexity/cost:
1. Licensed Radio Telemetry (Most Likely Best Bet, Especially if the Phone Line is Unreliable)
How it works
This involves installing a licensed radio telemetry system at both locations.
Components
Transmitter (at the booster station)
Connected to the pressure switch. When the pressure switch closes (indicating low water), the transmitter sends a radio signal.
Receiver (at the pump station)
Receives the signal and activates a relay to start the pump.
Antennas
Necessary for reliable signal transmission. Higher gain antennas can extend the range and improve signal quality through wooded areas.
Power
Requires power at both locations to operate the radio equipment. Battery backup might be a good idea at the booster station in case of power outages.
Advantages
Reliable
Good quality radio telemetry systems are designed for industrial use and offer high reliability. Licensed frequencies avoid interference from other devices.
Secure
More secure than unlicensed options.
Independent
No longer reliant on the aging telephone line.
Two-way communication possible
You can often get models that allow two-way communication for status updates (e.g., pump running, high pressure).
Extendable
Easily expandable for adding more sensors or control points in the future.
Disadvantages
Licensing
Requires obtaining a radio license from your local regulatory agency (e.g., the FCC in the US). This can involve some paperwork and fees.
Cost
Typically more expensive upfront than other options (but often cheaper in the long run due to reliability).
Line of sight considerations
Woods can degrade radio signal. Antenna placement and type are critical.
2. Unlicensed Radio Telemetry (Less Reliable but Simpler Setup)
How it works
Similar to licensed radio telemetry, but uses unlicensed radio frequencies (e.g., 900MHz, 2.4GHz).
Components
Similar to licensed telemetry: Transmitter, Receiver, Antennas.
Advantages
No license required
Easier and faster to deploy.
Lower cost
Typically cheaper than licensed options.
Disadvantages
Less reliable
Susceptible to interference from other devices using the same frequency. This can be a significant problem in areas with many Wi-Fi networks or other radio equipment.
Shorter range
Often has a shorter range than licensed radio systems, especially in wooded environments.
Less secure
Easier to intercept signals.
Considerations
Only consider this if the environment is relatively free of radio interference, and reliable operation is not absolutely critical. Careful antenna placement is crucial.
3. Cellular Communication
How it works
Uses the cellular network to transmit data between the booster station and the pump station.
Components
Cellular Modem/Data Logger (at the booster station)
Connected to the pressure switch. When the switch closes, the modem sends a data message to a central server or directly to the pump station.
Cellular Modem/Controller (at the pump station)
Receives the message and activates a relay to start the pump.
Cellular Data Plan
Requires a cellular data plan for each modem.
Advantages
Wide coverage
Cellular networks generally cover a wide area.
Relatively easy to deploy
No need to run new wires or install radio towers.
Disadvantages
Cellular coverage
Requires reliable cellular coverage at both locations. This can be a problem in remote areas or if the booster station is in a valley or other area with poor signal strength.
Ongoing costs
Requires monthly cellular data plan fees.
Security
Requires careful security considerations to protect against unauthorized access.
Latency
Cellular networks can introduce latency (delay) in the communication, which may not be ideal for real-time control.
Power Consumption
Cellular modems can consume significant power, which may be a concern if the booster station has limited power.
4. Fiber Optic Cable (Probably Impractical)
How it works
Running a new fiber optic cable between the two locations.
Advantages
High bandwidth
Can transmit large amounts of data.
Immune to interference
Fiber optic cable is not susceptible to electrical interference.
Disadvantages
High cost
Very expensive to install, especially over a mile through woods. Requires trenching or aerial installation.
Specialized equipment
Requires specialized equipment to terminate and connect the fiber optic cable.
Impractical
Probably not feasible for this application due to the cost and complexity.
5. Utilizing Existing Telephone Line with Modern Equipment (Least Recommended)
How it works
Attempting to repurpose the existing telephone line.
Components
Modern Tone Remote Equipment: Devices exist that can send and receive tones over a telephone line. These tones can be interpreted by a controller at each end. Advantages
Potentially lower cost (initially)
Leverages existing wiring.
Disadvantages
Line Quality Concerns
Old telephone lines are often in poor condition, with splices, corrosion, and potential for noise and interference.
Bandwidth Limitations
Telephone lines have limited bandwidth, which can restrict the amount of data you can transmit.
Reliability Issues
This approach is highly susceptible to line problems.
Still Outdated Technology
While using "modern" tone control equipment, you're still building on a foundation of outdated technology.
Maintaining Legacy Equipment
If the telephone line needs repair, you're relying on technicians familiar with very old technology.
Unreliable: In most instances, the condition of the phone line will make this impractical.
Recommendation
Given the details, the
Licensed Radio Telemetry option is likely the best solution for your water tank/booster station application. It's designed for industrial environments and offers the best reliability. The initial cost is higher, but the long-term reliability and reduced maintenance costs will likely offset the initial investment.* Consider the long-term costs of maintaining a solution based on an aging telephone line.
Steps to Take
Site Survey
Conduct a site survey to assess radio signal propagation between the two locations. This will help determine the best antenna type and placement. A professional radio communication company can perform this.2.
Contact Radio Telemetry Vendors
Contact several vendors of licensed radio telemetry systems to get quotes and discuss your specific requirements.3.
Obtain a Radio License
Contact your local regulatory agency (e.g., the FCC in the US) to obtain a radio license.4.
Consider Backup Power
Implement battery backup or generator backup at the booster station to ensure continuous operation during power outages.5.
Implement Remote Monitoring
Consider integrating the system with a remote monitoring system so you can track water levels, pump status, and other critical parameters from a central location.6.
Document Everything: Thoroughly document the system configuration, settings, and troubleshooting procedures.By implementing a modern and reliable radio telemetry system, you can improve the efficiency and reliability of your water supply system and reduce the risk of costly downtime.I hope this detailed analysis helps! Let me know if you have any more questions. Flag for review