NexSens CB-400 User manual

CB-400
Data
Buoy
User Manual

About NexSens Technology, Inc.
NexSens Technology, Inc. was founded in the late 1990s with a mission to advance the capabilities and
simplify the development of environmental monitoring systems. The company specializes in
environmental sensors, remote data acquisition and communications technology, easy-to-use computer
software, and web-based datacenters.
iChart Software is an easy-to-learn, easy-to-use Windows-based software program designed to interface
with the industry’s most popular environmental monitoring sensors and systems. A large, multi-vendor
instrument library makes setup quick and easy. iChart automates much of the tedious programming,
data collection, and manual data processing common with other environmental data collection systems.
The SDL500 (Submersible Data Logger) and iSIC (Intelligent Sensor Interface and Control) are state-of-
the-art data loggers that simplify the collection of real-time data from environmental sensors and
monitoring instruments. The data loggers support multi-vendor sensor connections and are specifically
designed for environmental data monitoring.
WQData LIVE is an enterprise class and business critical web-based software solution for environmental
data management. It assists with collecting, storing, analyzing, interpreting, sharing and publishing
environmental data. The datacenter effectively manages a wide variety of biological, physical, and
chemical parameters, along with many other environmental observations and project information.
Smart USB-based WQ Sensors include: Temperature, pH, ORP, Dissolved Oxygen, Ammonium, Bromide,
Calcium, Chloride, Fluoride, and Nitrate. An integral USB connector on the sensor cable offers a simple,
hassle-free connection to a computer without the need for a meter or batteries.
T-Node FR temperature systems, based on RS-485 Modbus technology, provide a simple, yet effective,
plug-and-play solution for developing multi-sensor networks and temperature strings. The T-Node FR
offers pass-through signals for SDI-12 and RS-485, allowing the user to connect Nodes and other
environmental measurement sensors along a string. This sensorBUS architecture has been designed so
researchers can easily build and customize multi-point temperature strings for more powerful
environmental monitoring networks.
Coastal Buoys are designed to support offshore monitoring systems. These buoys provide a robust
floating platform for coastal water or lake monitoring projects.
NexSens products and systems simplify the setup and operation of environmental monitoring networks
and help ensure quality data.

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TABLE OF CONTENTS
CHAPTER 1 - INTRODUCTION........................................................................................................................ 3
CHAPTER 2 –COMPONENTS AND SPECIFICATIONS...................................................................................... 4
2.1 CB-400 Components ..................................................................................................................... 4
2.2 CB-400S Components ................................................................................................................... 4
2.3 CB-400/CB-400S Specifications..................................................................................................... 4
2.4 Common Accessories .................................................................................................................... 5
CHAPTER 3 –GETTING STARTED................................................................................................................... 6
3.1 System Connections –Power, Communications and Sensors ...................................................... 6
3.2 Gathering Sample Data ................................................................................................................. 7
CHAPTER 4 –BUOY SETUP ............................................................................................................................ 9
4.1 Basic Setup.................................................................................................................................... 9
4.1.1 Running Sensor Cables.......................................................................................................... 9
4.1.2 Installing the SDL500 Submersible Data Logger ................................................................. 10
4.1.3 Securing Buoy Lid................................................................................................................ 11
4.1.4 Setting Pipe Caps................................................................................................................. 12
4.1.5 Connecting Bottom Sensors................................................................................................ 12
4.2 Accessories.................................................................................................................................. 13
4.2.1 Deployment Pipe................................................................................................................. 13
4.2.2 Instrument Cage..................................................................................................................14
4.2.3 Ballast Weight .....................................................................................................................14
CHAPTER 5 –MOORING THE BUOY ............................................................................................................ 16
5.1 Mooring Configurations.............................................................................................................. 16
5.1.1 Single-Point Mooring .......................................................................................................... 16
5.1.2 Two-Point and Three-Point Moorings.................................................................................17
5.2 Connecting Mooring Hardware .................................................................................................. 17
CHAPTER 6 –SAFELY DEPLOYING THE BUOY..............................................................................................19
6.1 Single-Point Mooring Deployment ............................................................................................. 19
6.2 Two-Point and Three-Point Mooring Deployment .....................................................................19
CHAPTER 7 –MAINTENANCE ...................................................................................................................... 20
7.1 Post-Season Cleaning.................................................................................................................. 20
7.2 Replacing an RBP500 Battery Pack ............................................................................................. 20

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CHAPTER 8 –WARRANTY & SERVICE..........................................................................................................23
8.1 Limitation of Warranty................................................................................................................ 23
8.2 Corporate Headquarters & Authorized Service Center ..............................................................23

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CHAPTER 1 - INTRODUCTION
NexSens CB-400 data buoy systems are designed for coastal or lake water monitoring applications. The
floating platform supports both topside and subsurface environmental monitoring sensors with options
for radio, cellular, and satellite data transmission. Temperature strings, multi-parameter sondes,
Doppler current meters, weather stations, and other monitoring instruments can all be quickly deployed
in protected coastal waters or lakes.
The 400 lb. buoyancy buoys are constructed of an inner core of cross-linked polyethylene foam with a
tough polymer skin. Three 4” diameter PVC pipes pass through the buoy hull for quick deployment of
subsurface instruments. On the topside, a removable tower supports weather monitoring stations and
beacons.
Multiple configurations are available for the CB-400 data buoy. The standard CB-400 package includes
the buoy with no power option. This configuration is designed for use with an SDL500 Submersible Data
Logger powered with D-cell alkaline batteries. CB-400S configurations are fitted with three 10-Watt solar
panels, which are harnessed together and connected to an RBP500 Rechargeable Battery Pack installed
inside the buoy hull. The RBP500 contains an 8.5 A-Hr battery to power the SDL500 and sensors.
The SDL500 is configured with five sensor ports for connection to industry-standard digital and analog
sensor interfaces, including RS-485, RS-232, SDI-12, 1-wire temp string, 0-2.5V, pulse count and more.
Each sensor port offers a UW receptacle with a double O-ring seal for a reliable, waterproof connection.
NexSens iChart Software is a Windows-based program for interfacing both locally (direct-connect) and
remotely (through telemetry) to a single data buoy or network of data buoys.

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CHAPTER 2 –COMPONENTS AND SPECIFICATIONS
2.1 CB-400 Components
Polymer-coated foam hull
Polymer-coated foam tower
Stainless steel frame
(3) 4” PVC instrument deployment pipes
(7) 3/4-inch stainless steel eye nuts, three on top and four on bottom
2.2 CB-400S Components
Polymer-coated foam hull
Polymer-coated foam tower
Stainless steel frame
(3) 4” PVC instrument deployment pipes
(7) 3/4-inch stainless steel eye nuts, three on top and four on bottom
(3) 10-watt solar panels
(1) RBP500 Rechargeable Battery Pack with 8.5 A-Hr SLA battery
(1) Power harness for connection of solar panels to RBP500
(1) UW-1P 1-meter cable for connection of RBP500 to SDL500 data logger
2.3 CB-400/CB-400S Specifications
Dimensions
Tower: 23” diameter, 26” height
Hull: 36” diameter, 12” height
Overall: 57” height (without instrument cage), 81” height (with
instrument cage)
Weight
CB-400: 95 Lbs. (with SDL500, cage and tower)
CB-400S: 120 Lbs. (with solar, RBP500, SDL500, cage and tower)
Materials
Hull: cross-linked polyethylene foam with polyurea coating
Tower: cross-linked polyethylene foam with polyurea coating
Maximum Buoyancy
400 lbs.
Mooring Attachments
(7) ¾” stainless steel eye nuts, (3) top-mounted and (4) bottom-
mounted
Suitable Environments
Freshwater lakes, protected coastal waters, rivers, reservoirs,
estuaries
Power Options
RBP500: 8.5 A-Hr Sealed Lead Acid (SLA) battery
SDL500 (not included): (8) D-cell alkaline batteries
Charging
CB-400S: (3) 10-Watt solar panels with solar regulator

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Figure 2-1: Buoy Components & Dimensions
2.4 Common Accessories
Item
Description
Details
RBP500
Rechargeable battery pack
Provides power to an SDL500 in a CB-400S. Optional
on CB-400.
CAGE
Instrument mooring cage
For water sensor deployments.
914
Deployment pipe
4” Sch. 80 PVC pipe with threaded adapter.
SDL500
Submersible data logger
Fully submersible data logger designed for use with
NexSens data buoys. Direct connect.
SDL500C
Submersible data logger
Cellular telemetry.
SDL500R
Submersible data logger
Radio telemetry.
SDL500I
Submersible data logger
Iridium satellite telemetry.
502-A15
LED Beacon
Mounts to buoy tower, 15 flashes per minute.
DOR35
Anchor
Pyramid anchor, 35 lb.
DOR70
Anchor
Pyramid anchor, 70 lb.
SSPA375-BOW
Shackle
Bow shackle, 3/8”
SSPA500-BOW
Shackle
Bow shackle, 1/2”
SSPA625-BOW
Shackle
Bow shackle, 5/8”
SS187
Stainless steel mooring line
Used for buoy and sensor mooring systems.
HGPC500i
Chain, ½”
Galvanized steel chain used for buoy moorings.
A-3-RED
Marker buoy, 18” diameter
Used for 2-point and 3-point mooring systems.

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CHAPTER 3 –GETTING STARTED
Before deploying a CB-400 data buoy , it is very important for the user to become familiar with the
hardware connections and operation of the system with iChart software. To begin, lay out the buoy,
sensors, data logger, and other components that make up the CB-400 system. Follow the steps in the
Chapters 3-5 to test and assemble the system.
3.1 System Connections –Power, Communications and Sensors
CB-400 data buoys are designed to accommodate the SDL500 Submersible Data Logger for connection
of monitoring instruments. On CB-400 systems without solar charging, the SDL500 is powered with D-
cell alkaline batteries. A communications antenna may be installed in the SDL500 top bulkhead port for
radio, cellular or satellite telemetry systems. Sensor connections are made on the top port and/or the
five ports on the bottom bulkhead. All sensors and devices must have a NexSens UW connector factory
installed in order to connect to the SDL500.
Consult the SDL500 manual for detailed information on the port characteristics to aid in assigning
sensors to the appropriate ports. The available ports are shown in Figure 3-1 below.
Figure 3-1: SDL500 Bottom (left) and Top (right) Bulkhead Ports
CB-400S systems include an RBP500 Rechargeable Battery Pack and a solar charging kit comprised of
three 10-watt solar panels and a power harness with solar regulator. Figure 3-2 is a schematic drawing
showing how these components are connected together along with the SDL500.
The three 10-Watt solar panels are harnessed together and connected to a solar regulator. This
assembly is connected to Port D on the RBP500. Pass-through signals are enabled on the bottom
bulkhead of the RBP500 by connecting UW-1P cables from the SDL500 to the RBP500 top bulkhead as
shown. The CB-400S package includes (1) UW-1P cable that connects from Port P0 on the SDL500 to
Port P0 on the RBP500 top bulkhead. This enables sensors to be connected to Port P0 and Port D on the
RBP500 bottom bulkhead.

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Figure 3-2: CB-400S Power & Communications Schematic
Additional ports can be enabled on the RBP500 by connecting additional UW-1P cables. For example, to
enable Port P1 on the RBP500, a UW-1P cable must connect the SDL500 Port P1 to the RBP500 top
bulkhead Port P1. To enable Port T on the RBP500, a UW-1P cable must connect the SDL500 Port T to
the RBP500 top bulkhead Port T.
Port A, the Analog sensor port, is not available on the RBP500 because it is used as a vent for the
battery. Sensors with analog outputs can only be connected to Port A on the SDL500.
3.2 Gathering Sample Data
Prior to buoy setup and deployment, it is essential to test the monitoring system (sensors, data logger
and telemetry) on shore. This is the most important part of the setup process because it allows users to
familiarize themselves with the system while confirming that everything is operating properly.
Connect all sensors, power the system, and gather sets of sample data with iChart software.
Refer to the SDL500 and iChart manuals for additional information on setup and testing of the software,
data loggers and sensors. Systems may also ship with project-specific startup documentation provided
by NexSens Customer Support.

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For troubleshooting assistance, the NexSens Knowledge Base contains detailed information on many of
the most common issues that may be encountered:
http://nexsens.com/knowledgebase/
NexSens tech support specialists may also be contacted for assistance:
NexSens Technology, Inc.
2091 Exchange Court
Fairborn, OH 45324
937-426-2151
[email protected]m

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CHAPTER 4 –BUOY SETUP
This section contains detailed instructions on the physical setup of a CB-400 buoy system. Directions are
included for a complete CB-400S package with solar panels and RBP500 battery pack. For standard CB-
400 systems without solar charging, the process is the same, but all sensor connections are made
directly to the SDL500 data logger.
4.1 Basic Setup
The basic setup for a CB-400 buoy system requires installing sensor cables, connecting sensors and the
RBP500 to the SDL500 data logger, installing the SDL500 in the buoy tower, securing the buoy lid, and
installing protective pipe caps. The following steps walk the user through this process.
Warning: The buoy is very heavy. Take care to lift properly and wear necessary lifting gear (e.g., back
braces). Always wear gloves when handling the buoy to protect hands as the buoy may have sharp edges
or points. Three people are required for safe lifting.
4.1.1 Running Sensor Cables
The buoy has three 4” PVC sensor deployment pipes for deployment of water monitoring instruments.
Starting at the bottom of a sensor deployment, feed sensor cables up and into the center chamber of
the buoy tower. The cables enter the center chamber through a small slot. Be careful to keep the slot in
the sensor deployment pipe lined up with the slot of the buoy tower throughout buoy setup.
Figure 4-1: Feeding Sensor Cable into Buoy Tower
After feeding sensor cables into the center chamber, reach down into the buoy tower. Grab the cables
and pull them through the buoy tower opening (top). On a CB-400S package, the chamber will also have
a UW-1P cable coming from the top of the RBP500.

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Figure 4-2: Sensor Cable and UW-1P Cable
4.1.2 Installing the SDL500 Submersible Data Logger
For SDL500 versions with wireless telemetry (radio, cellular or satellite), an antenna must be connected
to the top port. No antenna is needed for the direct-connect SDL500. Instead, the port is plugged or
used to connect a topside sensor.
Important: Double check that there is an O-ring installed on both the antenna plug and at the bottom of
the port. The double O-ring seal ensures that connections do not leak. Install the antenna carefully to
avoid damaging the pins. Consult the SDL500 manual for additional information on antenna installation.
Figure 4-3: Top Port Pins and O-ring and Connecting SDL500 Antenna
Unscrew the plugs from ports that will be used on the bottom of the SDL500. Store them with the
SDL500 maintenance kit for future use. For CB-400S systems, Port P0 will always be used to connect to
the RBP500 with the UW-1P cable. Remove the large orange O-ring at the bottom of the SDL500. Keep
with the SDL500 maintenance kit.

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Figure 4-4: SDL500 with Port Plugs and Bottom O-ring Removed
Connect the UW-1P cable running from Port P0 on the RBP500 to Port P0 on the SDL500. Connect
additional sensor cables to the appropriate ports. Refer to the SDL500 manual for additional information
on sensor-specific port selections. Again, double check for the O-rings on all UW plugs and ports.
Carefully slide the SDL500 into the center chamber of the buoy tower. Extra cable slack may need to be
drawn through the sensor deployment pipes as the SDL500 is lowered.
Figure 4-5: SDL500 Cable Connections and Installation
4.1.3 Securing Buoy Lid
Install the buoy lid to the tower cap using the (3) 3/8”-16 bolts provided with the system. Include a
washer and a lock washer between the bolt head and the lid (the washer sits under the lock washer).
Tighten the bolts until the lock washers are flattened, then an additional 1/8”turn. Do not over-tighten
the bolts to avoid stripping of the threading on the lid and cap.

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Figure 4-6: Buoy Lid Installation
Optional beacons or weather sensors to be mounted on the buoy lid can be installed once the lid is
securely in place.
4.1.4 Setting Pipe Caps
PVC caps are included for additional protection of sensor pass-through tubes. Place a cap over each
opening and secure with the provided bolts.
Figure 4-7: Pipe Cap on a Sensor Pass-through Tube
4.1.5 Connecting Bottom Sensors
On a CB-400S configuration, sensors may connect into Port 0 and Port D on the bottom of the RBP500
battery pack. The RBP500 acts as a pass-through, so the signal availability on enabled RBP500 ports is
the same as is available on the SDL500. For example, the RS-232 and SDI-12 signals on the SDL500 Port
P0 are also available on the RBP500 Port P0 when the UW-1P cable is attached.
Port P1 and Port T can be made available by connecting additional UW-1P cables between the battery
pack and SDL500 within the buoy. Port A is unavailable on the bottom side of the buoy because it serves
as a top-side battery vent. The SDL500 manual contains detailed information on selecting ports for
sensor connections.

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Double check that each UW plug and port have an O-ring installed. Missing O-rings will result in water
intrusion and sensor failure. See Section 4.1.2 for more information.
Figure 4-8: Sensor Connected to RBP500 Port P0
4.2 Accessories
Deployment pipes, instrument cages and ballast weights can be added to CB-400 buoy systems.
Deployment pipes and instrument cages provide options for secure mounting of sensors, and ballast
weights can help to balance the buoy and prevent overturning.
4.2.1 Deployment Pipe
Deployment pipe extensions are easily fitted to the built-in sensor deployment pipes to provide extra
protection for sensitive monitoring equipment. The 914 deployment pipe is a 4” Schedule 80 PVC pipe
section that attaches to the sensor deployment pipes with a threaded adapter. The bottom of the 914
pipe is fitted with a stop bolt to keep sensors in place.
To attach a 914 deployment pipe, lay the buoy on its side and thread the deployment pipe into one of
the three available pass-through sensor tubes. Take caution to avoid cross-threading of the adapter.
Also make sure the built-in deployment pipes do not rotate inside the buoy hull. The slotted top end
must be properly aligned with the slot in the buoy tower to allow sensor cables to run from the tower to
the deployment pipe assembly.
Figure 4-9: CB-400S with 914 Deployment Pipe

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4.2.2 Instrument Cage
The CB-400 buoy allows an instrument cage to be installed on the bottom. Sensors can be securely
attached to the instrument cage. To install the cage, first remove the 1-3/4”-10 x 4” bolt, 1-3/4” lock
washer and 1-3/4”-10 nut from the buoy frame.
Figure 4-10: Bolt on Buoy Frame
Run the bolt downward through the buoy frame and top of the cage. Place the lock washer and nut onto
the bolt.
Figure 4-11: Securing the Cage Assembly
Tighten securely with large crescent wrenches, and weld the connection to prevent the cage from
coming loose in rough water.
4.2.3 Ballast Weight
Proper ballast weight is essential to prevent buoy overturning. Carefully consider the site-specific ballast
requirements prior to deployment.

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A 25 lb. ballast weight is available for installation to the bottom of the instrument cage for additional
balance. Begin installation by inserting the 9-3/4” threaded rod section through the ballast weight and
bottom of the buoy frame or instrument cage assembly.
Figure 4-12: Inserting the Threaded Rod
On the bottom end of the rod, tighten a 1-3/4” eye nut with a 1-3/4” lock washer. Tighten the top end
of the rod securely to the buoy frame or instrument cage with a 1-3/4”-10 nut and 1-3/4” lock washer.
Weld the connections to prevent loosening in rough water.
Figure 4-13: Securing the Ballast Weight

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CHAPTER 5 –MOORING THE BUOY
This section contains only general information on the available mooring options. To develop an effective
mooring strategy, a variety of application-specific criteria must be thoroughly reviewed prior to
deployment. Adverse weather conditions, water level fluctuations, currents and wave action, debris
loads, and other factors can cause entanglement of mooring lines, submersion of the buoy, and damage
to sensors and other components. NexSens does not endorse any particular mooring strategy for any
application unless the end user performs a thorough review of the site conditions with the NexSens
engineering team.
5.1 Mooring Configurations
CB-400 buoys contain a total of four bottom-side eye nuts to accommodate single-point, two-point and
three-point mooring styles. Three of the eye nuts are arranged in a semi-circle directly at the bottom of
the hull for two- and three-point moorings. The final eye nut is located on the bottom of the buoy frame
or instrument cage if one is installed. This nut is used for single-point moorings or to deploy sensor
chains.
5.1.1 Single-Point Mooring
Single-point moorings are used in extremely calm waters when monitoring sensors are attached to the
instrument cage or housed in deployment pipes. The sensors are thus protected and less vulnerable to
damage caused by subsurface debris, high currents, and entanglement from anchor lines.
In a single-point configuration, a stainless steel mooring line connects the buoy directly to a bottom
chain and anchor. The anchor, bottom chain, and mooring line are assembled and attached to the buoy
prior to deploying the system.
Figure 5-1: Typical Single-Point Mooring Setup

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5.1.2 Two-Point and Three-Point Moorings
Two-point moorings are commonly used when monitoring sensors are deployed in the water column
below the buoy. In this setup, the mooring lines are pulled taut away from the buoy, freeing the water
column for a suspended sensor line.
In most two-point configurations, mooring lines connect the data buoy to small marine marker buoys.
These marker buoys are shackled to another mooring line that runs to the seafloor and connects via a
bottom chain to an anchor.
Three-point configurations are similar to two-point, but a third set of anchors, mooring lines and marker
buoys keep the buoy in place.
Figure 5-2: Typical Two-Point Mooring Setup
5.2 Connecting Mooring Hardware
Stainless steel bow shackles are used to connect the various mooring components (mooring lines,
marker buoys, chains and anchors) together and to the CB-400 buoy. Bow shackles must be properly
connected and secured to prevent hardware from loosening and becoming detached over time in rough
water conditions.
After hand-tightening a bow shackle, use a crescent wrench to tighten the connection. Then, run a cable
tie through the hole on the shackle pin and run this through the loop of the shackle. Pull tightly to
secure.

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Figure 5-3: Attaching Mooring Lines
Figure 5-4: Cable Tie Installed on Bow Shackle
A 1/2” bow shackle is used to connect mooring lines to the CB-400 buoy eye nuts and to 1/2” bottom
chains. Larger, 5/8” bow shackles are required for connection of marker buoys and anchors.
Figure 5-5: Mooring Components