Step-by-Step Guide

Understanding OptiFlow's Purpose and Capacity Management

OptiFlow is designed to allow the shortest amount of irrigation time by optimizing your programs and stations across multiple controllers and points of connection. The system uses the full capacity of your mainline to irrigate as quickly as possible without exceeding any source or mainline limits.

The solution addresses a common challenge: managing irrigation when water demand exceeds available capacity. For example, on properties with limited water sources such as storage tanks, OptiFlow calculates what to irrigate based on priority settings. If there isn't enough water capacity on a given day, the system automatically moves lower-priority irrigation to the next day while ensuring the system irrigates at full capacity without exceeding pipe or pressure limits.

Before OptiFlow, many users experienced pressure problems caused by too many stations irrigating simultaneously and exceeding the flow capacity of the mainline. Previous systems only allowed users to set an arbitrary number of stations to run at once (one, two, or three stations) without any mathematical calculation behind it. OptiFlow replaces this guesswork with precise capacity-based optimization, allowing you to define the exact capacity (for example, 80 gallons per minute) and let the system decide how many stations to irrigate at any given time.

OptiFlow Training and Certification

HydroPoint provides a free, on-demand Certified OptiFlow Training program with three levels:

Level 1: Introduction to how the system works and how the network ties everything together.

Level 2: What you need to know about your site to qualify it as an OptiFlow site and understand your requirements.

Level 3: Installation and programming training covering hands-on implementation.

The complete training program consists of approximately three hours of instruction and is available free to all users. This training is provided as part of the OptiFlow purchase and helps ensure proper setup and ongoing management.

Data Requirements and Site Preparation

Programming OptiFlow requires detailed information about your irrigation system at multiple levels. You need to know the gallons per minute (GPM) capacity at every level of your system:

Source level: What happens before the mainline, before the point of connection. This includes understanding your water source capacity, whether it's from a municipal connection, well, or storage tanks.

Point of connection: Your flow sensor and master valve setup where data enters the system. This is where the system sees the actual gallons flowing and plugs them into the WeatherTRAK controller.

Mainline level: The capacity of your main irrigation lines throughout the property.

Station level: Individual station flow rates.

Much of this data may already exist in as-built drawings from your system designer. However, it's critical to verify these drawings against actual field conditions, as what's on paper is often different from what's in the ground. For example, if as-builts show a two-inch mainline but maintenance records indicate a three-inch pipe was installed during a repair, you need to verify the actual size because the difference significantly affects water capacity.

If you have a good relationship with your water provider, you can request drawings of their mainline infrastructure to understand capacity limits at the district level, not just at your controller level.

Starting from scratch and verifying all assumptions is recommended before deploying OptiFlow. For large, complex systems with hundreds of controllers, this verification process can take considerable time—up to two years for very large properties—but ensures accurate programming.

Accessing the OptiFlow Configuration Interface

1. Log into WeatherTRAK.net.

2. Once you are assigned OptiFlow privileges to any controller, an OptiFlow tab will appear in your WeatherTRAK.net account. If you don't see this tab, it means you don't yet have an OptiFlow controller assigned to your account.

3. Click on the OptiFlow tab, then select the Configure tab. This is where all system information is entered.

The OptiFlow workspace contains three main sections:

OptiFlow Controllers: Lists all controllers in your OptiFlow system.

Hydraulic Tree: This is where the bulk of programming work happens. You'll build your irrigation system structure here, including mainline sizes, sources, and flow zones.

Map: Shows where everything exists in the landscape.

Setting Up the Water Source

1. In the Hydraulic Tree section, begin by setting up the source of your system.

2. Click to add or edit a source. This is where you define the water capacity available behind your entire system.

3. Use the Max GPM Calculator (also called the Source Calculator) to determine your source capacity. This tool helps first-time OptiFlow users who may know their mainline size but not the gallons per minute it can provide.

4. In the calculator, select your pipe schedule (for example, Schedule 40).

5. Enter your pipe size (for example, 6 inches).

6. The calculator will recommend a value based on design velocity, which uses the industry rule of thumb of 5 feet per second. For example, a Schedule 40 six-inch pipe can deliver 534 gallons per minute at design velocity.

7. You can apply the recommended value, or adjust it based on your actual field conditions. The calculator provides a by-the-book answer, but real-world conditions may differ. Factors such as elevation changes (uphill runs lose pressure) or distance from the source can affect actual capacity.

8. Enter your actual source capacity in the threshold field. The calculator doesn't control the programming—what matters is the setting you enter in the capacity box.

9. Save your source settings.

The source capacity you set here represents the total water available to your system at all times. This is a critical baseline that OptiFlow will use to optimize all downstream irrigation.

Establishing Mainline Capacity

1. After setting up your source, add a new pipe to represent your mainline. Click to add a pipe onto the source in the hydraulic tree.

2. Name your mainline (for example, Main Number 1). If your site has names for different areas, use those names for easy identification rather than generic labels.

3. Open the Calculator tool for the mainline.

4. Select your pipe schedule (for example, Schedule 80).

5. Enter your mainline size (for example, 4 inches).

6. The calculator will display the recommended velocity. For a four-inch Schedule 80 pipe, this might show 175 gallons per minute at recommended velocity, or 246 gallons per minute at break threshold (the maximum before risking pipe damage).

7. Apply the appropriate value to your mainline settings, or adjust based on field conditions.

8. Save your mainline configuration.

This mainline capacity setting tells OptiFlow the maximum flow that can safely move through this section of pipe without causing pressure problems or exceeding hydraulic limits.

Assigning Points of Connection

1. Within your mainline settings, locate the section for assigning points of connection (POC).

2. Select which point of connection feeds this mainline from the dropdown menu. You can choose any point of connection from the controllers you manage.

3. Define what type of master valve is installed at this point of connection.

4. Define what type of flow sensor is managing this point of connection.

5. Save your point of connection settings.

The point of connection is where your flow sensor and master valve are located, and where the system gathers actual flow data to feed into the WeatherTRAK controller for optimization calculations.

Creating Flow Zones for Variable Hydraulic Conditions

Flow zones are used when a part of your system needs to operate under a different set of hydraulic rules. This commonly occurs when mainline size changes, elevation changes significantly, or distance from the source creates different pressure conditions.

1. Identify areas where your mainline size changes or hydraulic conditions differ. For example, if your four-inch mainline shrinks down to a two-inch line at the end of a run, you need a separate flow zone for that section.

2. In the hydraulic tree, click to add a Flow Zone onto your existing mainline.

3. Name your flow zone descriptively (for example, 2 Inch Section).

4. Open the calculator for the flow zone.

5. Select the pipe schedule (for example, Schedule 80).

6. Enter the pipe size for this section (for example, 2 inches).

7. The calculator will recommend a capacity (for example, 45 gallons per minute for a two-inch Schedule 80 pipe).

8. Apply the recommended value or adjust based on field conditions.

9. Save your flow zone settings.

Flow zones are a flexible tool that allows you to account for all the different variations in pressure, flow, and hydraulic variables throughout your system. Each flow zone can have its own capacity limits, and OptiFlow will optimize irrigation within each zone according to its specific constraints.

Assigning Programs and Stations to the Hydraulic Tree

1. Once you've built your hydraulic tree with source, mainlines, and flow zones, you'll see a list of your irrigation programs.

2. Each program contains stations, and each station displays its individual flow rate in gallons per minute.

3. To assign a program to a mainline, simply drag the program from the list and drop it onto the appropriate mainline in the hydraulic tree.

4. For programs that operate in areas with different hydraulic conditions (such as the end of your property where pipe size reduces), drag those programs onto the appropriate flow zone instead of the main line.

5. Continue dragging and dropping all programs onto their corresponding mainlines or flow zones until all programs are assigned.

Once programs are assigned to the hydraulic tree, OptiFlow can see the relationship between station flow rates and mainline capacity, and will begin optimizing irrigation schedules to use maximum capacity without exceeding any limits you've set.

Using the OptiFlow Inspector Tool

The OptiFlow Inspector is an analysis tool designed to identify any issues that would prevent stations from running properly. This tool should be used regularly—ideally daily when making system changes, and at minimum weekly for routine verification.

1. After completing your hydraulic tree setup and program assignments, click on the OptiFlow Inspector tool.

2. The tool will analyze your OptiFlow programming across multiple points of inspection (typically eight different checks).

3. Review the results. The inspector will show which checks passed and which failed. For example, you might see "6 passed, 1 failed" with details about the failure.

4. Click on any failed inspection to see details. Common issues include:

• Stations that exceed mainline capacity
• Stations that exceed flow zone capacity
• Stations that are turned off and won't irrigate
• Water window restrictions that prevent stations from fitting within available irrigation time

5. Address any issues identified by the inspector before running your irrigation schedule.

Daily and Weekly Inspector Tool Workflow

Establish a routine for using the OptiFlow Inspector tool to maintain system accuracy:

Daily use: Run the inspector tool at the end of every day when you've made any flow changes to the system. This includes retrofits, splitting valves, adding nozzles, new landscape installations, or repairs. Since OptiFlow's optimization is entirely based on flow rates, incorrect flows will cause the system to not work properly. The daily check ensures all flows are within limits and stations will irrigate as expected.

Weekly use: Run the inspector to identify stations that have been turned off. When managing hundreds of stations across a large property, it's easy to forget which stations were manually disabled for planting, maintenance, or other temporary reasons. The inspector will flag stations that are off and remind you to evaluate whether they need to be turned back on, preventing plant stress or die-back from forgotten shutoffs.

Every 2-3 weeks: Review other inspector warnings such as water window restrictions or capacity issues that may have developed over time as irrigation demands change seasonally.

Interpreting Inspector Results for Turned-Off Stations

1. When the inspector identifies stations that won't irrigate due to restrictions, click on the warning message.

2. The tool will identify which controller contains the problem (for example, Controller 205).

3. Click on the identified controller to open its settings.

4. Review the station list. Stations set to Auto will irrigate normally.

5. Look for stations that show as Off in the status column. These are the stations the inspector flagged.

6. Evaluate whether each off station needs to remain off or should be returned to service.

7. Change the status from Off to Auto for any stations that should resume irrigation.

This workflow replaces the old method of maintaining notebooks or spreadsheets to track which stations are disabled, providing an automated reminder system built into your daily routine.

Field Testing and Pressure Verification

While OptiFlow uses calculated capacities based on pipe size and design velocity, real-world conditions can differ from theoretical values. Establish a regular testing program to verify your system's actual performance:

Pressure-related capacity variations: A controller located downhill may theoretically receive more flow from a six-inch main due to gravity assist, while a controller at the end of an uphill mainline run will lose pressure and deliver less capacity than calculated. The actual capacity you can push through the system depends on measuring real pressure and conducting field tests.

Field testing procedure: Turn on the valve farthest from your source and measure how much flow it's actually receiving. Then turn on another valve and observe the combined flow. This physical testing reveals your true system capacity under actual operating conditions.

Quarterly pressure monitoring: Implement a program to measure pressure every quarter at key points:

• Right at the water meter (after the point of connection)
• At the end of mainline runs
• At four representative points throughout your system

Store this pressure information in your records. While there's ongoing debate about how often pressure monitoring is necessary, tracking pressure data over time helps you identify changes in system performance and can reveal issues with the water agency's supply or problems developing in your infrastructure. This data allows you to continually refine your OptiFlow settings for optimal performance.

Managing Flow Changes and System Updates

Any time you make changes to your irrigation system that affect flow rates, update your OptiFlow programming immediately:

Changes requiring updates:

• Retrofitting sprinkler heads or nozzles
• Splitting existing valves into multiple zones
• Adding new landscape areas
• Repairing or replacing mainlines with different pipe sizes
• Installing new points of connection
• Any modification to station components that changes GPM

1. After making any flow-related change in the field, log into WeatherTRAK.net.

2. Update the affected station's flow rate or modify the hydraulic tree as needed.

3. Run the OptiFlow Inspector tool to verify the changes don't create any capacity violations.

4. Address any warnings before the next irrigation cycle.

The basis of OptiFlow is flow-rate optimization. If your programmed flows don't match actual field conditions, the system cannot optimize properly. Maintaining accurate flow data is the single most important factor in OptiFlow performance.

Video Walkthrough

Video originally published April 2021.

If you have questions, here are 3 ways to get answers:

1. Search within this WeatherTRAK knowledgebase

2. Visit the WeatherTRAK support page

3. Call 800-362-8774 or email support@hydropoint.com, hours are Mon-Fri 3:00 AM – 6:00 PM PT and Sat 9:00 AM – 2:00 PM PT.