HyQuest Solutions Pty. Ltd.

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1 INSTRUCTION MANUAL L GAS PURGE COMPRESSOR MODEL HS55V / HS55VDO/HS55VB Gas Purge Compressor- Model HS-55/DO/D DB HS Issue 2: 30/5/2014

2 CONTENTS Contents HS 55 & HS 55DO & HS 55DB GAS PURGE COMPRESSOR... 5 I GENERAL... 5 II PRODUCT OVERVIEW... 5 III UNPACKING YOUR HS 55/DO/DB... 6 IV TESTING YOUR SYSTEM... 6 V SPECIFICATION... 7 VI INSTALLATION... 9 Installing the Model HS 55/DO/DB... 9 Field Installation VII OPERATION (i) Normal Pumping Operation (ii) Manual Purge for HS 55 & HS 55DO (iii) Manual Purge for HS 55DB VIII MAINTENANCE IX BUBBLE RATE ADJUSTMENT X FAULT FINDING XI MOUNTING THE HS 55/DO/DB XII PART LIST HS 55 MAIN ASSEMBLY HS 55DO MAIN ASSEMBLY HS 55DB MAIN ASSEMBLY HS 55/DO REGULATOR ASSEMBLY HS 55DB REGULATOR ASSEMBLY HS 55/DO/DB COMPRESSOR HS 55/DO/DB DRYER MIST SEPARATOR HS 55/DO/DB DRYER MIST SEPARATOR AUTO PURGE VALVE HS

3 HS 55 RIVER LINE PURGE VALVE HS 55DO RIVER LINE PURGE VALVE XIII APPENDIX A GCO1P INSTALLATION GENERAL PERFORMANCE COMPARISON XIV APPENDIX B STANDARD ORIFICE INSTALLATION XV APPENDIX C HS 55/DO/DB TYPICAL INSTALLATIONS HS 55 TYPICAL INSTALLATION HS55 DO TYPICAL INSTALLATION HS55 DB TYPICAL INSTALLATION XV UPGRADING THE HS 55 DRYER/MIST SEPARATOR ASSEMBLY HS

4 HS

5 HS 55 & HS 55DO & HS 55DB GAS PURGE COMPRESSOR I GENERAL The HS-55/DO/DB has been designed to replace conventional nitrogen gas bottle supply bubble units/gas purge systems for water level measurement. The design of the unit centres on the tried and proven HyQuest Solutions Model HS23/DO/DB Dry Bubble Unit with Differential Regulator (BU07). The HS-55/DO/DB incorporates maintenance free Air Drying System that utilises an Auto Purge Valve for Auto Drain Moisture Traps to ensure the system is free of moisture. The effectiveness of the HS-55/DO/DB Dryer, Filter and Auto Purge Valve is such that the unit also removes all moisture is the air, thus helping to reduce aquatic growth at the river end. The unit is maintenance free for up to 5 years. II (i) PRODUCT OVERVIEW ORIFICE FEATURE The Model HS-55 comes with a single orifice and the HS-55DO comes with a dual orifice. The HS-55 is used in situations where siltation is not an issue and the level in the river can be measured using a single orifice. The HS-55DO consists of 2 orifices located at different heights from the river bed. Under normal condition the bottom orifice is active and the top orifice is inactive. The dual orifice application become beneficial in a situation where severe siltation appears and causes the blockage of the bottom orifice at which instance the valve of the bottom orifice (1) is closed and the valve of the inactive (top) orifice (2) is opened to keep the bubbler system operating. The Model HS-55DB comes with a dual bubbler application. It consists of bubbler systems with 2 orifices that can be operating simultaneously at different heights or same height from the river bed. The dual bubbler application becomes beneficial in a situation where water level need to be monitored at two different locations. (ii) MANUAL PURGE - MODEL HS-55/DO/DB The HS-55/DO incorporates a 3-Way switching valve for manual purging of the system. Continuous purging occurs when the valve is rotated to Purge, the river line is opened and the instrument line is closed. This is similar to Gas Bubbler Unit (Model HS23/DO) functions. The HS-55DB incorporates a lever for manual purging of the system. Continuous purging occurs when the purge valve is opened. This is similar to Gas Bubbler Unit (Model HS23) functions; when purge operation is performed ensure the instrument line is closed. HS

6 Voltage Regulator Protection If the compressor pump operates continuously for a long period of time or if the system voltage drops to 11V due to power supply failure, the voltage protection system will be activated. At 11V the compressor shuts down until the battery is recharged to 12V at which time the system will commence normal operation. This feature protects the system from continuous operation. III UNPACKING YOUR HS 55/DO/DB The carton should include: Model HS-55 or HS-55DO or HS-55DB Any Accessories you have ordered Please verify you have received these items. It is recommended that you visually inspect the HS-55/DO/DB to verify all components and connections are secure. For more details about HS-55/DO/DB Purge System (see the purge section in this manual). IV TESTING YOUR SYSTEM Before installing the HS-55/DO/DB, you may wish to test the system prior to going to the field. Testing the HS-55/DO/DB will familiarise you with the compressor in an environment where it is easy to work. The HS-55/DO/DB is designed to be mounted in a vertical position. The mist separator will not function properly if the unit is in a horizontal position. Once the HS-55/DO/DB is positioned, connect the power leads to an appropriate 12VDC power supply. Turn on power switch to start the compressor pumping. The pump will take approximately 4 minutes to fill the air tank to maximum pressure of 85 p.s.i, (600 Kpa) and will then automatically switch off. Connect to one of the outlet ports a short piece of river line tubing and secure the end into a container of water. Check the bubble rate setting as required (factory setting is equivalent to 80 bubbles per minute). If the bubble rate requires adjustment, (see page 16 for instructions). Please note, if the HS-55DO is not purchased with a WL2100D/WL3100 dry pressure transducer fitted, then the transducer used must be fitted or the sensor valves closed prior to the test operation commencing. There are two pressure gauges fitted to the HS-55/DO. The unit attached to the pressure regulator indicates the set feed pressure (factory set at 400 Kpa) this pressure should be retained at this setting, however, if adjustment is required, turn the supply regulator knob to achieve the required setting. The second pressure gauge is located on the side of the HS-55/DO indicates the air tank pressure. HS

7 V SPECIFICATION Power: Maximum Current: Average Current Draw: Compressor: Receiver Capacity: (Air Tank) Normal Operating Pressure Range: Duty Cycle: Maximum Head: Maximum Length: Maximum Purge Pressure: Minimum Purge Pressure: Differential Pressure: Purging: 12V d.c. (38 amp hour battery minimum). 30 Amps Approx. 50 ma (Based on 60 bubbles/min) Precision Piston 13.5 litres (3.5 U.S. Gallons) 60 p.s.i, (400 kpa) to 85 p.s.i, (600 kpa) Typically 12 hours per year at 60 bubbles/minute 30 Metres Water Level (River Line) 200 Metres (Using 3/8" O.D.x 1/8" I.D Tubing) 85 p.s.i, (600 kpa) 60 p.s.i, (400 kpa) 3 p.s.i, (20 kpa) to 5 p.s.i, (35 kpa) Manual - lever valve operation continuous Bubble Rate: Air Dryer/Auto Purge Valve: Environment: Pressure Connections: User selectable from 40 to 120 bubbles/minute. Bubble rate is set 40 bubble/min for GCO1 application (See page 15 for adjustment details). Up to 5 year maintenance free Automated Purge Valve Hydrophobic filter. -40 deg C to 60 deg C HS-55 1x Outlets 3/8" dia tube (River Line), instrument one 1/4 NPT Adaptor fittings available for most transducers HS-55DO 2 x Outlets 3/8" dia tube (River Line), instrument one 1/4 NPT Adaptor fittings available for most transducers HS-55DB 2 x Outlets 3/8" dia tube (River Line), instrument 2 x 1/4 NPT Adaptor fittings available for most transducers HS

8 Mass: Approx. 30 lbs, (13 kg) Dimensions: 24" H x 12" W x 15" D (610 mm x 305 mm x 380 mm) Packed Dimensions: Mass: 32" H x 16" W x 19" D (810 mm x 410 mm x 480 mm) Approx lbs, (32 kg) OPTIONAL ACCESSORIES: (i) Dry Pressure Transducer (Model WL3100/WL3100A). (Model WL2100D). (ii) ML1-420 Data Logger (iii) (iv) Pressure Line Orifice Fitting 1/8" I.D. x 3/8" O.D. heavy wall black polythene. SC M (1000 Ft) Roll SC M (328 Ft) Roll BU07 Small Diameter Orifice fitting OR GCO1P/SS Gas Chamber orifice fitting with adjustable stainless steel knuckle (v) Mounting Bench mounting bracket available ORDERING INFORMATION Model Details Pressure Transducer HS-55 Base Model Not available HS-55DO Dual Orifice Model Not available HS-55/WL2100D Base Model with Pressure WL2100D Transducer HS-55DO/WL2100D Dual Orifice Model with WL2100D Pressure Transducer HS-55/WL3100 Base Model with Pressure WL3100 Transducer HS-55DO/WL3100 Dual Orifice Model with Pressure Transducer WL3100 HS

9 VI INSTALLATION Installing the Model HS 55/DO/DB For proper installation of the HS-55/DO/DB, you will need: The HS-55/DO/DB Installation Kit (provided) Installation for your HS-55/DO/DB may vary according to your application. The Figures below illustrates the physical input/output connections on your HS-55/DO/DB. This drawing will help in determining where you should make your connections for power, ground, communications, and outlet to orifice and pressure to your sensor. HS 55 BASE MODEL (I/O) CONNECTIONS HS

10 MODEL HS 55DO (I/O) CONNECTIONS MODEL HS 55DB (I/O) CONNECTIONS HS

11 Field Installation (i) (ii) (iii) The HS-55/DO/DB must be wall mounted in a vertical position, with the compressor at the top. A mounting bracket can be provided for bench mounting (see drilling template in this manual). Connect your pressure sensor directly to the sensor valve or connect a pressure line between the valve and your pressure measurement device. If your measurement device has noncompatible connections, you will need to request adaptor fittings to suit. The manifold sensor valve for the transducer is ¼ NPT. The HS-55/DO/DB requires only one power source to power the compressor. This supply is typically a 12V, 38 amp hour minimum, long life re-chargeable battery with solar or mains charger. (iv) Connecting a Pressure Sensor The pressure sensor can be fitted directly to the sensor valve or connected using pressure fittings and connecting tube. The Figures below shows typical installations of a complete pressure measurement system. HS 55 TYPICAL INSTALLATION HS

12 NOTE: ONE ORIFICE IS IN OPERATION ONLY HS 55DO TYPICAL INSTALLATION NOTE: BOTH ORIFICES ARE IN OPERATION HS 55DB TYPICAL INSTALLATION HS

13 VII OPERATION (i) Normal Pumping Operation During normal operation, When the tank pressure drops to about 60 p.s.i (400 Kpa), the pressure switch powers up the compressor recharging the receiver to 85 p.s.i (600 Kpa). This should take about 2 minutes. At the end of the pumping cycle the air dryer/mist separator valve will automatically operate releasing all moisture out of the system and ensuring clean dry air continue to flow into the compressor tank on the next pumping operation. (ii) Manual Purge for HS 55 & HS 55DO This feature allows the operator to purge the system during routine service visits. WARNING: PLEASE READ THE FOLLOWING INSTRUCTIONS PRIOR TO OPERATION 1. The above diagram indicates the river orifice line is open for normal bubbler operation. 2. Close position indicates the river line is closed to the bubbler system. 3. Purge position permits the river line to be purged at full tank pressure for a short duration. Note: Ensure transducer valve is closed prior to purge operation. 4. Allow pressure to stabilise after purging for approximately 10 minutes prior to opening transducer valve. During the purge operation, the active orifice (1) or (2) should produce vigorous bubbling with the tank pressure falling to approximately 400Kpa (60 p.s.i.) after about 30 seconds. At this point the compressor will be activated to recharge the air receiver. If further purging is required, the compressor should be allowed to refill the tank to maximum pressure 600 kpa (85 p.s.i). At the completion of the purge sequence, the compressor will resume the normal bubble operation. WARNING: Ensure sensor valve is closed prior to purging. Reopen sensor valve approximately 5 to 10 minutes after purging to allow system pressure to drop to normal bubbling rate. HS

14 (iii) Manual Purge for HS 55DB This feature allows the operator to purge the system during routine service visits. A purge is carried out by turning the manual purge lever either left or right depending on which orifice line requires purging. During this time, the orifice should produce vigorous bubbling with the tank pressure falling to approximately 400Kpa (60 p.s.i.) after about 30 seconds. At this point the compressor will be activated to recharge the air receiver. If further purging is required, the compressor should be allowed to refill the tank to maximum pressure 600 kpa (85 p.s.i). At the completion of the purge sequence, the compressor will resume the normal bubble operation. WARNING: Ensure sensor valve is closed prior to purging. Reopen sensor valve approximately 5 to 10 minutes after purging to allow system pressure to drop to normal bubbling rate. HS

15 VIII MAINTENANCE The HS-55/DO/DB is almost maintenance-free. You will need to ensure e that your power supply is sufficient for the equipment that you have installed. As the compressor s dutyy cycle is a few f minutes every 24 hours, it willl last for many years. The voltage sensor prevents the HS-55/DO/DB from running continuously for long periods of time. This will protect thee pump andd many other components of the HS-55/DO/DB in case off a system leaks or other malfunctions. All fittings must be secure. At 80 bubbles/minutes, even a tiny leakk will alloww the entire gas flow to escape. It is recommended in yearly bases to check the compressor for the following: 1- Leaks: this is done by spraying a leek detector around the fitting and ensuring all fitting are tight. 2- Check all the wire terminals and battery voltage as battery life varies between 2-5 years depending on the manufacturer and the life span of the battery. 3- Check the mist separator filter status thiss is done as follows: a) Ensure compressor is off and batteryy is disconnected b) Push the quick release fitting to undoo the tube connected too the mist separator housing c) Undo the mist separator housing by turning anti-clockwise d) Check the mist separatorr state if require replacement part no. n is SC ; please turn the mist separatorr anti-clockwise to undoo and replace. e) To re-assemble reverse steps d,c, andd b and turn compressor back on. Step a Push & Hold Pull Gas Purge Compressor- Model HS-55/DO/D DB HS Issue 2: 30/ /5/2014

16 Step b Step c Gas Purge Compressor- Model HS-55/DO/DB HS Issue 2: 30/5/2014

17 IX BUBBLE RATE ADJUSTMENT The chart below has been prepared to show the relationship between the bubble rate at the test orifice and the equivalent rates that would be observed on a sight glass bubble unit. Once the desired bubble rate has been achieved tighten the screw to lock the Nupro valve. Actual Bubble Rate setting at Test Orifice or River Line (bubbles/min) Suitability Equivalent Site Glass Bubble Rate (bubbles/min) Suitable for low rising streams Suitable for Fast rising streams 200 Recommended setting for Gas Chamber Orifice, Model GC01P installations Note: Bubble rates detailed above are only an approximate guide for the purpose of conserving gas and have no influence on the performance of the transducer. Example: To adjust the HS-55DO to the equivalent of 80 bubbles per minutes, the Nupro valve should be rotated anticlockwise if the bubble rate is below this amount, or clockwise if bubble rate is above 80 per minute. There should be 21 bubbles per minute emerging from the test orifice. HS

18 X (i) (a) (b) (ii) FAULT FINDING HS-55/DO/DB Not Powering Up Check battery voltage Check all connections including POWER and GROUND. Both the compressor and control power sources must be connected. Intermittent Operation Check your power and ground connection. Moisture over time, will oxidize and corrode connectors and pins; Verify your power supply or battery voltage. XI MOUNTING THE HS 55/DO/DB DRILL HOLE SIZE HS

19 XII PART LIST HS 55 MAIN ASSEMBLY HS

20 HS

21 HS 55DO MAIN ASSEMBLY HS

22 HS

23 HS 55DB MAIN ASSEMBLY HS

24 HS

25 HS 55/DO REGULATOR ASSEMBLY HS

26 HS

27 HS 55DB REGULATOR ASSEMBLY HS

28 HS

29 HS 55/DO/DB COMPRESSOR HS

30 HS 55/DO/DB DRYER MIST SEPARATOR DRYER MIST SEPARATOR GPC07A HS

31 HS 55/DO/DB DRYER MIST SEPARATOR AUTO PURGE VALVE MIST SEPARATOR AUTO PURGE VALVE GPC07B HS

32 HS 55 RIVER LINE PURGE VALVE HS

33 HS 55DO RIVER LINE PURGE VALVE HS

34 XIII APPENDIX A GCO1P INSTALLATION GENERAL The HyQuest Solutions Gas Chamber Orifice (GCO1P/SS is designed to replace the standard orifice in a gas purge water level measurement system. The GCO1P /SS permits the use of extremely low bubble rates with increased sensitivity and near total reduction of lag between actual level rise and orifice pressure. It can also operate satisfactorily when buried under up to 1m of silt. Bubble rates as low as 10 bubbles per minute can be used, thereby reducing gas consumption and prolonging the life of the gas bottle, or reducing the duty cycle operation of the compressor pump on our HS 55/45/40/35 bubbler water level measurement systems. The main GC01P/SS chamber is constructed entirely of polyethylene with a copper coated brass screen to deter aquatic growth, and is supplied fitted with a 2" flexible stainless steel coupling to suit a standard 2 NB threaded pipe and to allow easy installation as the coupling allows up to 30 degrees of adjustment from horizontal. The GCO1P /SS has an in built 1/4 inch NPT hex brass coupling and is supplied with 1/4 inch NPT male to 3/8 inch. The bottom of the chamber includes a revolving copper coated brass screen for cleaning purposes the unit is designed to be fitted to existing installations preferably during low water condition. PERFORMANCE COMPARISON Based on 9 metres/hr of rise At 3 metres level of rise the standard orifice still lagged significantly whereas the gas chamber orifice exhibited no appreciable error. HS

35 Step 1: 2 BSP THREADED PIPE Step 2: Step 3: Gas Purge Compressor- Model HS-55/DO/DB HS Issue 2: 30/5/2014

36 Step 4: 30 Note: Ensure that the GCO1 is horizontally level as shown. Flexible coupling allows 2 Galvanised Pipe Flexible Coupling (L) GCO1 Body Volume = ml (H) Tube River Line Tube Back Front Orifice fitting Revolving Screen (for cleaning Purposes) (D) Dimension L D H GCO1P DIMENSIONSS Metric (mm) Imperial (inch) Gas Purge Compressor- Model HS-55/DO/D DB HS Issue 2: 30/ /5/2014

37 XIV APPENDIX B STANDARD ORIFICE INSTALLATION HS

38 XV APPENDIX C HS 55/DO/DB TYPICAL INSTALLATIONS HS 55 TYPICAL INSTALLATION HS

39 HS

40 HS55 DO TYPICAL INSTALLATION HS

41 HS

42 HS55 DB TYPICAL INSTALLATION HS

43 XV UPGRADING THE HS 55 DRYER/MIST SEPARATOR ASSEMBLY Note: Prior to starting disconnect the power and purge the tank. Step 1 Using a spanner undo the hose fitting (1a) and the Non Return valve fitting(1b). Once done undo the two mounting screws (1c) to remove the filter assembly. Step (1a) Step (1c) Step (1b) Step 2 The new dryer/filter kit is supplied in two sections, the first is the Dryer/Mist Separator and the second is the mist separator purge valve. HS

44 Step 3 Installation process 3b Using appropriate Allen Key loosens the two screws. Note do not fullyy undo. The purge valve bracket will be hooked to the back of the panel using the manifold screws. Once done tighten t the screws back on. 3d insert is still in position. Pull the quick release fitting back and push the tube all the way in and then release the fitting First ensuree the ¼ tube 3e Please connects your compressorr to12v power, once the tank is fully pressurised spray leak detector and check for any leaks. If no leaks are detected, your compressor is ready for use. Gas Purge Compressor- Model HS-55/DO/D DB HS a Screw the new Dryer/Mist Separator to the panel, re compressor c hose and assemble the the Non returnn valve ¼ tube. 3c shown Issue 2: 30/ Connect Wires as /5/2014