HyQuest Solutions HS40 II Series User manual

HS40 Series II
User Manual
04-2023 – 01-01-000

© 2023 HyQuest Solutions 2
Table of Contents
I Disclaimer 3
II Safety Instructions 4
Part I Introduction 5
1.1 Product Overview ............................................................................................................................................ 5
Part II Installation 7
2.1 Extending the Battery Cables ...................................................................................................................... 7
2.2 Adjusting the Bubble Rate ............................................................................................................................ 8
2.3 WL3100 Connection ..................................................................................................................................... 10
2.4 Compressor Diagnostic Interface and SDI-12 ..................................................................................... 10
Part III Operation 15
3.1 Description of Indicators ............................................................................................................................ 15
3.2 Startup Sequence .......................................................................................................................................... 16
3.3 Tank Pressurisation & Mist Separator Flushing .................................................................................. 16
3.4 Battery Size .................................................................................................................................................... 17
3.5 Battery Indication ......................................................................................................................................... 17
Part IV Maintenance 19
4.1 Automatic Moisture Extraction ................................................................................................................ 19
Part V Troubleshooting 23
Part VI Repair 25
Part VII Technical Data 26
Part VIII Obligations of the Operator and Disposal 27
8.1 Obligations of the Operator ....................................................................................................................... 27
8.2 Dismantling / Disposal ................................................................................................................................ 27
Part IX Appendices 29
9.1 Appendix A Installing Polyethelene Tubing and Orifice Fittings ................................................... 29
9.2 Appendix B Using Pressure to Measure Water Level ....................................................................... 30
9.3 Appendix C HS40 Series II-DO (Dual Orifice) ...................................................................................... 36
9.4 Appendix D Gas Chamber Orifice Assembly ......................................................................................... 36
9.5 Appendix E Typical Installations ............................................................................................................... 39
9.6 Appendix F Compressor Controller Bypass ............................................................................................ 40

Copyright Notice: No parts of this work may be
reproduced in any form or by any means without the
written permission of the publisher. HyQuest
Solutions waives copyright for users to print out
parts of the documentation in hard copy for their
own use only.
Trademark Notice: HyQuest Solutions (HS) and
KISTERS products and services referred to in this
document are trademarks or registered trademarks
of HyQuest Solutions or KISTERS AG. Other product
names used may or may not be the trademarks of
their respective owners.
© 2020 HyQuest Solutions, a KISTERS Group
Company. Any rights not expressly granted herein
are reserved.
The information provided in this manual was deemed
accurate as of the publication date. However, updates
to this information may have occurred.
This manual does not include all of the details of
design, production, or variation of the equipment
nor does it cover every possible situation which may
arise during installation, operation or maintenance.
HyQuest Solutions shall not be liable for any
incidental, indirect, special or consequential damages
whatsoever arising out of or related to this
documentation and the information contained in it,
even if HyQuest Solutions has been advised of the
possibility of such damages.
Any errors found in any HyQuest Solutions product
should be reported to HyQuest Solutions where
every effort will be made to quickly resolve the
problem.
This document is public.
3© 2023 HyQuest Solutions
I Disclaimer

§ Read the user manual including all operating instructions prior to installing, connecting and powering up the HyQuest
Solutions HS40S2. The manual provides information on how to operate the product. The manual is intended to be
used by qualified personnel, i.e. personnel that have been adequately trained, are sufficiently familiar with
installation, mounting, wiring, powering up and operation of the product.
§ Keep the user manual on hand for later reference!
§ If you encounter problems understanding the information in the manual (or part thereof), please consult the
manufacturer or its appointed reseller for further support.
§ HyQuest Solutions HS40S2 is intended to be used in hydrometeorological or environmental monitoring applications.
§ Before starting to work, you have to check the functioning and integrity of the system.
§ Check for visible defects on the HS40S2, this may or may not include any or all of the following mounting facilities,
connectors and connections, mechanical parts, internal or external communication devices, power supplies or
power supply lines, etc.
§ If defects are found that jeopardize the operational safety, work must be stopped. This is true for defects found
before starting to work as well as for defects found while working.
§ Do not use the HyQuest Solutions HS40S2 in areas where there is a danger of explosion.
§ The present user manual specifies environmental/climatic operating conditions as well as mechanical and electrical
conditions. Installation, wiring, powering up and operating the HyQuest Solutions HS40S2 must strictly comply with
these specifications.
§ Perform maintenance only when tools or machinery are not in operation.
§ If guards are removed to perform maintenance, replace them immediately after servicing.
§ Never make any electrical or mechanical diagnostics, inspections or repairs under any circumstances. Return the
product to the manufacturer’s named repair centre. You can find information on how to return items for repair in the
relevant section of the HyQuest Solutions website.
§ Disposal instructions: After taking the HyQuest Solutions HS40S2 out of service, it must be disposed of in
compliance with local waste and environmental regulations. The HyQuest Solutions HS40S2 is never to be disposed in
household waste!
§ Inputs and outputs of the device are protected against electric discharges and surges (so-called ESD). Do not
touch any part of the electronic components! If you need to touch any part, please discharge yourself, i.e. by touching
grounded metal parts.
II Safety Instructions
© 2023 HyQuest Solutions 4

© 2023 HyQuest Solutions 5
Introduction
1Introduction
Thank you for choosing our product. We hope you will enjoy using the device.
HyQuest Solutions manufactures, sells, installs and operates quality instrumentation, data loggers and communication
technology. Products are designed with passion for environmental monitoring and with a deep understanding of the
quality, accuracy and robustness needed to fulfil the requirements of measurement practitioners in the field.
The present User Manual will help you understand, install and deploy the device. If, however, you feel that a particular
information is missing, incomplete or confusing, please do not hesitate to contact us for further support!
The HS40 Series II Gas Purge Compressor and Bubbler System has been designed to replace conventional nitrogen gas
bottle supply to bubble units or gas purge systems. The HS40 is used for measuring water level in dams, rivers, canals
and tanks with up to 40 mH2O (130 ft) head.
1.1 Product Overview
The Air Force Model HS40 Series II is designed to replace conventional Dry Nitrogen bubbler systems for water level
measurement. It can operate with up to 40m (130ft) head of water. The system is low maintenance and has a low average
power consumption.

© 2023 HyQuest Solutions 6
Introduction

© 2023 HyQuest Solutions 7
Installation
2Installation
The HS40 Series II MUST be mounted in a vertical position (not laying flat as shown). The micro mist separator and auto
purge moisture feature will not function properly if the unit is in a horizontal position.
Before connecting 12V power to the HS40 Series II, fit the 3/8 inch river-line where shown (optional ¼ inch fitting).
Connect the 12V DC battery directly to the power cable shown, and add a mains or solar charger if required.
The status LED, at the bottom left of the cabinet, will cycle through its initial sequence, and then if the tank pressure is less
than 400kPa (58psi) [±20%], the compressor will start and pump the tank pressure up to 750kPa (110psi) [±20%]. This
initial pump up cycle may take up to 3 minutes.
This chapter contains the following subsections:
§ Extending the Battery Cables
§ Adjusting the Bubble Rate
§ WL3100 Connection
§ Compressor Diagnostic Interface and SDI-12
2.1 Extending the Battery Cables
The HS40 Series II is supplied with a 2m power cable, with each core being 6mm2. If the user needs to extend this cable,
extreme caution should be exercised, because whenever high currents are drawn through cables, there will be voltage
drops!!!
With the supplied cable (2m of 6mm2) there is a 0.18V drop on each conductor when the compressor draws 30A. Since
there is a positive and negative wire, the voltage seen by the HS40 Series II is 2 x 0.18V = 0.36V less than the voltage seen
at the battery terminals – and at 30A the battery voltage will also droop.
(This is before the cables are extended.)
7
8
10
10

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Installation
Use the following table to get an idea of the total cable voltage drop – keeping in mind the HS40 Series II will disconnect
the compressor when the voltage “it sees” drops below 10V.
Extended Cable
Length
Cable Size
(mm2 / AWG)
Vdrop1 on
extended cable
Vdrop2 on
supplied cable
Total
Vdrop
Actual Vbatt
when HS40 Series
II disconnects
compressor
2m (6ft)
6 / 9.5
0.36V
0.36V
0.72V
10.72V
4m (12ft)
6 / 9.5
0.72V
0.36V
1.08V
11.08V *
6m (18ft)
6 / 9.5
1.08V
0.36V
1.44V
11.44V *
4m (12ft)
10 / 7
0.42V
0.36V
0.78V
10.78V
6m (18ft)
10 / 7
0.6V
0.36V
0.96V
10.96V
10m (30ft)
10 / 7
1.02V
0.36V
1.38V
11.38V *
15m (45ft)
10 / 7
1.50V
0.36V
1.86V
11.86V *
15m (45ft)
16 / 5
0.96V
0.36V
1.32V
11.32V *
20m (60ft)
16 / 5
1.26V
0.36V
1.62V
11.62V *
* => Not Recommended
Note: A minimum battery capacity of 38Ah is recommended, to lessen battery voltage drop under heavy load.
2.2 Adjusting the Bubble Rate
§ Set the River Line control valve to the “Close” position. (Keep the Calibrate valve in the “Open” position)
§ Attach the HS23QC (supplied as standard) to the HS40 Series II Test Port and immerse the HS23QC in a beaker of
water.
§ Allow up to 10 minutes for the bubble rate and differential regulator to stabilise.

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Installation
§ Undo the bubble rate lock screw and adjust the bubble rate (to say 21 bubbles/min) The bubble rate at the Test Port
will be the same as would be at the River Line orifice. Nip up the lock screw and test the bubble rate again – it may
change slightly as the lock screw is done up.
Caution: Adjustment of the bubble rate higher than the maximum 45 BPM will void the manufacturer warranty on this
product.
§ Disconnect the HS23QC from the HS40 Series II Test Port.
§ Rotate the River Line control valve from the “Close” position to the “Open” position to direct the bubbles from the
“Test Port” back to the “River Line”.
Actual Bubble Rate setting at Test Orifice or River Line
(bubbles/min)
Suitability
10 Bubbles Per Minute.
(Recommended for GCO1P).
Suitable for Slow rising streams.
16 Bubbles Per Minute.
21 Bubbles Per Minute.
26 Bubbles Per Minute.
Factory Set Rate (Recommended for BU07).
For medium rising streams.
Maximum do not exceed 45 Bubbles Per Minute.
Suitable for Fast rising streams.
Exceeding the maximum bubble rate will cause excessive
wear to compressor pump.

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Installation
2.3 WL3100 Connection
The WL3100 measures the river-line pressure and provides water level information. Wiring connections to the WL3100
are via a 6 way plug-in terminal block underneath the HS40 Series II enclosure. You must have +12V and 0V power for
the WL3100 to operate. You may connect the SDI-12 and the 4-20mA interfaces at the same time. (These terminals are
“screwless” and keep a constant tension on the wire, thus producing a more reliable connection – simply use a
screwdriver to push on the orange lever to release the terminal spring tension, to insert or remove the wire.)
(Consult the WL3100 Manual for a detailed description of the WL3100 connection, operation and specific SDI-12
commands – available on the Hyquest Solutions website)
12
+12V DC Power
Da
SDI-12 Data
0V
0V DC Power
+S
+ve 4-20mA Signal
-S
-ve 4-20mA Signal
If connecting to the 4-20mA interface, make sure that the data logger (or RTU) powers up the 4-20mA loop long enough
for the WL3100 to recognize it, take a measurement and put the result back on to the 4-20mA loop. (1 sec when
“Continuous Mode” is set to “YES” and 15 secs when “Continuous Mode” is set to “NO”)
2.4 Compressor Diagnostic Interface and SDI-12
The wiring connections to the Compressor Controller is via the 5 way plug-in terminal block underneath the HS40 Series II
enclosure, and provides diagnostic information about the compressor. Notice that +12V is not required at these terminals,
as the Compressor Controller is powered from the heavy duty 6mm2 cables. (These terminals are “screwless” and keep a
constant tension on the wire, thus producing a more reliable connection – simply use a screwdriver to push on the
orange lever to release the terminal spring tension, to insert or remove the wire.)
Alm
Alarm O/C Output
CmprOn
Compr O/C Output
0V
0V Common
SDI
SDI-12 Data
0V
0V Common
This interface provides 2 x open collector style outputs that may be wired directly to a data logger or RTU digital inputs,
indicating when the compressor is operating (CmprOn), and if an alarm condition is present (Alm). The equivalent circuit is
shown below:

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Installation
SDI-12 is a standard used in the Hydrography industry for interfacing data recorders with microprocessor-based sensors.
SDI-12 stands for Serial/Digital Interface at 1200 baud.
The SDI-12 interface provides further diagnostic information such as :
§ System status – All OK, pump cycle in progress, compressor problem, Batt LV / HV.
§ How long the compressor was on for (in secs), during the last compressor pump cycle.
§ The time (in mins) since the compressor last operated.
§ Number of times the compressor has operated in the last 24 hours.
§ The min battery voltage during the last compressor pump cycle.
§ The max current during the last compressor pump cycle.
§ The present battery voltage.
SDI-12 Mode
The SDI-12 protocol has very strict ‘break’ and timing requirements – combined with 1200 baud, 7 bits and even parity.
When using a logger with native SDI-12, this timing is handled automatically.
Using RS232 Mode
The SDI-12 in the Compressor Controller has been implemented with a special feature that allows an SDI-12 to RS232
adaptor cable to be used so that communications via RS232 from a PC (or RTU). This special mode is enacted on each
command by proceeding each SDI-12 command with an ascii ‘*’ rather than a ‘break’. When the ascii ‘*’ is detected, all of
the timing/break requirements of the SDI-12 are removed. Commands may be typed from a terminal program such as
“Hyperterm”.
Note: RS232 mode requires each SDI-12 command to be preceded with a *
Note: If using Hyperterm à 1200 baud, 7 bits, even parity and no handshaking.
SDI-12 V1.3 Compliant Command Set (CRC commands are implemented)
(Please note the letter ‘a’ in the commands below refer to the SDI-12 address 0, 1, 2,….9)
Note: The default compressor controller SDI-12 Address ‘a’ is 9
Name
Command
Response
Break
Continuous spacing for at least 12
milliseconds
None
Acknowledge Active
a!
a<CR><LF>
Send Identification
aI!
allccccccccmmmmmmvvvxxx...xx<CR><L
F>

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Installation
Name
Command
Response
(Refer Note 1 )
Change Address
aAb!
b<CR><LF>
Address Query
?!
a<CR><LF>
Start Measurement
aM! or aMC!
atttn<CR><LF>
(Refer Note 2 )
Send Data
aD0!
a<values><CR><LF> or
a<values><CRC><CR><LF>
(Refer Note 3 )
Continuous Measurement
aR0! or
aRC0!
a<values><CR><LF>
(Refer Note 3,4)
a<values><CRC><CR><LF>
Start Verification
aV!
atttn<CR><LF>
Start Concurrent Measurement
aC! or aCC!
atttnn<CR><LF>
(Refer Note 2 )
Note 1.
Note 2.
The measurement command “M” and the concurrent command “C” will both return a time “ttt” of 000 indicating that the
measurement will be ready in 000 seconds and ‘n’ is 7 indicating there a 7 variables to be returned. Therefore a service
request is not supplied. (In accordance with the SDI-12 protocol).
Note 3.
Typical aD0! or aR0! response
12
12
12
12 13
12

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Installation
Note 4.
The Continuous Measurement command returns the same data as the Measure / Data combination in Note 3.
Compressor Status
The compressor status is retuned in the aM!-aD0! and aR0! commands:
0
All OK.
1
Compressor pump cycle is in progress.
2
Battery voltage low alarm (BattV < 10V and not risen above 12.5V yet)
3
Battery voltage high alarm (BattV > 16V)
4
Compressor pump cycle took too long (> 90 secs) – may be due to a pressure leak.
(Another pump cycle will be attempted automatically in 12 hrs)
5
Compressor duty cycle exceeded – (on for 4 mins total in a 15 min period)
(May have occurred if too many purges have been performed)
(The pump cycle will continue in 10 mins once the compressor has cooled down)
Please note:
For more information on SDI-12 commands, go to the www.sdi-12.org website and download the “SDI-12 Protocol
Specification” available on the home page.
Special Commands
The following commands conform to the SDI-12 protocol, and allow specific parameters within the Compressor Controller
to be configured.
Set/Get ID Number
aXID!
Get the Compressor Controller ID.
Replies with a+12345<CR><LF>
aXID+12345!
Set the Compressor Controller ID. Any
ascii character is acceptable. This value
appears in the Identify command.
Replies with a+12345<CR><LF>
Sample SDI-12 (RS232) Session
The following session is using the RS232 to SDI-12 interface to demonstrate the ‘*’ which removes the SDI-12 timing.

© 2023 HyQuest Solutions 14
Installation
Command
Response
Comment
*9I!
913HydrServHS40SII-
1.012345<CR><LF>
Get ID from addr 9
*9A2!
2<CR><LF>
Change address from 9 to 2
*2M!
20007<CR><LF>
Measure request on address 2
(7 variables avail in 000 secs)
*2D0!
2+0+16+235+1+11.8+32.2+12.7<CR><
LF>
Get data from address 2
(See data definition on prev page)
*2R0!
2+1+16+243+1+11.8+32.2+11.9<CR><
LF>
Contin Meas on address 2
(Same as 2M! and then 2D0!)

© 2023 HyQuest Solutions 15
Operation
3Operation
This chapter contains the following subsections:
§ Description of Indicators
§ Startup Sequence
§ Tank Pressurisation & Mist Separator Flushing
§ Battery Size
§ Battery Indication
3.1 Description of Indicators
When power is first applied, the Compressor Controller LED will flash each colour as a test – then the compressor may
start a pump up cycle, depending on the tank pressure and the state of the Condor pressure switch.
During normal operation, the status LED has the following meaning:
Status LED indicator:
Flash 1/sec (=1Hz) => Everything is operating normally. (Compressor + battery)
Flash 1/sec (=1Hz) => Battery voltage is low. (If the battery voltage falls below 10V, the
compressor will not operate and the LED will flash red. The LED will only return to a green
flash when the voltage rises above 12.5V. This allows the battery to be charged to a
reasonable level by solar, before attempting to operate the compressor again.)
Flash 5/sec (=5Hz) => Battery voltage is high. (If the battery voltage rises above 16V, the
compressor will not operate and the LED will flash red at 5Hz. The LED will only return to a
green flash when the voltage falls below 16V. This protects the compressor from overvoltage.)
Flash 1/sec (=1Hz) => The compressor took more than 90secs to pump up to full pressure.
Possible causes are:
§ Could be due to a leak in the tank / tubing.
§ The solenoid valve (normally open) is not operating or sealing properly during a pump up
cycle.
§ Compressor has lost its capacity to pump.
§ Compressor Controller is faulty, and not switching enough power to the compressor itself
or the in-line compressor connector is loose.
Note: Even when the LED is flashing blue, the system will attempt to pump up the tank
every 12 hours.
15
16
16
17
17

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Operation
Steady => A pump up cycle is in progress.
Flash 1/sec (=1Hz) => The compressor on/off duty cycle has been exceeded. The compressor
has been on for more than 4 minutes in the last 15 minutes. Wait 10 minutes for the
compressor to cool down, and it will automatically start again to complete the pump up cycle.
River Line Control Valve:
This Control Valve has 3 positions:
Open
In the Open position, the bubbler (regulator) is open to the River Line port and the transducer.
Close
In the Close position, the bubbler (regulator) is closed to the River Line. (If there is nothing
plugged into the Test Port Quick Connect, the transducer pressure will continue to increase
very slowly as the regulator reacts to a closed system – DO NOT leave it in this position for
extended periods as the internal pressure build up may exceed the burst pressure of the
transducer element !!!!) Note : The cabinet door has an interlock that prevents the door from
being closed while the valve is in the “Close” position.
Purge
In the Purge position, the receiver tank is directly connected to the River Line port to allow a
Purge of the River Line. After a River Line Purge is performed, rotate the control valve back to
the Close position and wait until the River Line pressure drops to a normal level (say 5
seconds) before rotating the control valve back to the Open position. (Otherwise the Purge
pressure may be introduced to the transducer and cause damage!!!)
Important: When purging, STOP when the tank pressure falls below 400kPa, otherwise the river-line pressure may fall
below the water head pressure resulting in water entering the River Line!
Calibrate Valve:
The Calibrate Valve is used to allow the “Bubble Rate Test Port” to be used to check the transducer (WL3100) calibration.
The procedure is as follows:
§ Set the “River Line Select” valve to the Close position.
§ Set the “Calibrate Valve” to the Calibrate position.
§ Set the pump up calibrator to “vent” so that the existing water head pressure is vented during the next step.
§ Connect the pump up calibrator to the Bubble Rate Test Port using the calibration hose assembly (can be purchased
separately from HS if required).
The pressure from the pump up calibrator can now be applied directly to the transducer (WL3100) input. Set a
required pressure (or water level) on the pump up calibrator, then read the water level from the transducer
(WL3100). After the transducer calibration has been verified, the system can be returned to normal operation by:
§ Remove the pump up calibrator from the Bubble Rate Test Port
§ Set the “Calibrate Valve” back to the Open position.
§ Set the “River Line Select” valve back to the Open Position.
3.2 Startup Sequence
After power-up the Compressor Controller status LED flashes all 3 colours, Green then Red then Blue to confirm the LED
is working OK.
3.3 Tank Pressurisation & Mist Separator Flushing
When the tank pressure falls below 400 kPa (58 psi) [±20 %], the Condor pressure switch will close, causing the controller
to operate the solenoid valve and initiate a compressor soft start. The compressor will then pump the pressure back up to
750 kPa (110 psi) [±20 %]. (While the compressor is on, the LED will be steady white. At the end of the pump up cycle, the
LED will flash green if completed successfully, or flash red or blue if there is a problem. At the end of each pumping cycle,
the solenoid valve is turned off so the collected moisture is blown out of the micro mist separator to atmosphere.

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Operation
3.4 Battery Size
The HS40 Series II consumes a quiescent of about 6 mA and draws about 30 A for 16 secs every 18 hours when the rate at
the test orifice is set to 26 bubbles/min.
This averages to: 30 A x 16 secs / (18 hr x 3600 secs/hr) = approx 8 mA.
The total average current is therefore:
HS40 Series II quiescent
6.0 mA
HS40 Compressor average
8.0 mA
WL3100 average
5.0 mA
Total consumption
19.0 mA
A 38 Ah battery will run for 38 Ah / 19.0 mA = 2000 hrs = 83 days = 2.6 months
(without any solar or additional charging)
The battery endurance will be dependent on the following:
§ The consumption of other equipment connected to the battery.
§ The frequency that the system wakes up to take a measurement.
§ The length of time the system is awake for each measurement.
§ The selected bubble rate – the higher the bubble rate, the more often the compressor will be required to replenish the
tank.
§ The battery Ah capacity – the minimum recommended battery capacity is 38 Ah.
3.5 Battery Indication
The battery voltage is monitored during all phases of operation. If the battery voltage falls below 10.0V then the status
LED will show the battery low indication and all compressor operation will stop immediately. The battery voltage must
then rise above 12.5V before clearing the battery low condition.

© 2023 HyQuest Solutions 18
Operation
A green LED flash indicates the battery is OK, a red LED flash indicates the battery low indication has been tripped. Once
the battery voltage rises above 12.5V the battery low condition will be cleared and the status LED will return to a green
flash.
A pump up cycle will be aborted if a battery low condition occurs. This condition is most likely to occur when the
compressor is on because it draws approximately 30A when operating – causing the battery voltage to drop.
A compressor soft start feature allows the compressor to slowly ramp up to speed, limiting the initial peak current draw
which always occurs when motors start up. This also helps prevent a battery low condition being registered as the
compressor starts.

© 2023 HyQuest Solutions 19
Maintenance
4Maintenance
The HS40 Series II requires little maintenance, however a yearly check of the moisture trap filter element is recommended
to ensure that moisture is being removed from the system effectively. You will also need to ensure that your battery /
power supply is sufficient for the equipment that you have installed and that both your battery and charging system are
working correctly. (See Specification page).
Note:
All fittings must be secure.
Even a minor leak will prevent the pressure from being maintained.
For more information, see the following subsection:
§ Automatic Moisture Extraction
4.1 Automatic Moisture Extraction
All HS40 Series II models have a system that automatically purges any built up moisture in the micro mist separator, at the
end of the pump up cycle, by controlling a solenoid release valve.
Filter Maintenance for the HS40 Series II
19

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Maintenance