Nuvair Voyager II User manual

User Manual
Voyager II
&
Open Voyager II
Nitrox System
Rev 03.19

Voyager II& Open Voyager II Nitrox System
Nuvair Page 2 www.nuvair.com
If you have any questions on this equipment please contact Technical Support at:
Nuvair
1600 Beacon Place
Oxnard, CA 93033
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Hours: Monday through Friday
8:00 AM to 5:00 PM PST USA
If you lose this manual, you can download the latest version at www.nuvair.com.
This User Manual contains important safety information and should always be available to
those personnel operating this equipment. Read, understand and retain all instructions
before operating this equipment to prevent injury or equipment damage.
Every effort was made to ensure the accuracy of the information contained within. Nuvair, however,
retains the right to modify its contents without notice. If you have problems or questions after reading
the manual, stop and call Nuvair at [phone] for information.

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Table of Contents
Introduction
1.0 Introduction
2.0 Safety Warnings
3.0 Safety and Operation Precautions
4.0 Legal Precautions
5.0 Theory of Operation
6.0 Low Pressure Air Compressor Technical Data
7.0 High Pressure Compressor Technical Data
8.0 System Components
9.0 Nitrox System Specifications
10.0 Nitrox System Component Identification
11.0 System Drawing/Schematic
12.0 System Flow Chart
Setup, Operation, and Maintenance
13.0 Installing the Nitrox System
13.1 Precautions
13.2 Attaching Nitrogen Discharge Hose (Optional)
13.3 Electrical Power Connection
13.4 Air/Nitrox Quality Testing
14.0 Pre-Operation Instructions
14.1 Compressor Lubricant Levels
14.2 Membrane System Feed Air Regulator and Switch
14.3 Oxygen Analyzer Calibration
14.4 Attaching Scuba Cylinder
15.0 Producing Nitrox
15.1 Flow to Membrane
15.2 Setting Proper Pressure
15.3 Final Adjustments Before Pumping Nitrox
15.4 Pumping Nitrox
15.5 Pumping Air
15.6 Shutting Down
16.0 Nitrox Operational Notes
16.1 Correlation of Feed Air Pressure to Oxygen Content
16.2 Hot Fills
17.0 Maintenance
17.1 Daily Maintenance
17.2 Routine Maintenance
17.3 Compressor Lubricant
17.4 LP Feed Air Filtration
17.5 HP Compressor Filtration
17.6 Spare Parts List
17.7 Service Record Log
Appendix
Supply and Breathing Air Specifications
Filter Element Life Factors
Material Safety Data Sheets
Owner’s Warranty Responsibilities
Warranty
Additional Records of Change
Additional Manual Included:
Nuvair Pro O2Oxygen Analyzer User Manual

Voyager II& Open Voyager II Nitrox System
Nuvair Page 4 www.nuvair.com
1.0 Introduction
Nuvair has taken extreme care in providing you with the information you will need to operate this
system. However, it is up to you to carefully read this manual and make the appropriate decisions
about system safety.
This manual will assist you in the proper set-up, operation and maintenance of the Nuvair Voyager II
Nitrox System. Be sure to read the entire manual.
Throughout this manual we will use certain words to call your attention to conditions, practices or
techniques that may directly affect your safety. Pay particular attention to information introduced by
the following signal words:
Indicates an imminently hazardous situation which, if not avoided, will result in serious
personal injury or death.
Indicates a potentially hazardous situation which, if not avoided, could result in serious
personal injury or death.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices.
Notifies people of installation, operation or maintenance information which is important but
not hazard-related.

Voyager II& Open Voyager II Nitrox System
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2.0 Safety Warnings
This equipment is used to provide breathing gas for the purpose of underwater life support.
Read this manual in its entirety. Failure to heed the warnings and cautions contained in this
document may result in severe injury or death.
The equipment you will be using to manufacture Nitrox (oxygen rich air) will expose you to
both low and high-pressure gas. Gas, even under moderate pressures, can cause extreme
bodily harm. Never allow any gas stream to be directed at any part of your body.
Any pressurized hose can cause extreme harm if it comes loose or separates from its restraint
(or termination) while under pressure and strikes any part of your body. Use appropriate care
in making and handling all gas connections.
Pure nitrogen is a colorless, odorless, tasteless gas that will not support life.
Breathing gas mixtures containing more than 84% nitrogen at surface pressures
will lead to unconsciousness and may cause death.
The nitrogen discharge from the membrane system must be vented to the
exterior of any closed building, boat, or similar enclosed space. Breathing gas
mixtures containing more than 84% nitrogen at surface pressure will lead to
unconsciousness and may cause death.
Do not use any form of mineral oil or synthetic lubricant not rated for Nitrox in
any compressor in this system. Use only the recommended Nitrox compressor
lubricant. Never mix the Nitrox compressor lubricant with other lubricants.
Remove all existing lubricant and replace with the proper Nitrox compressor lubricant prior to
installing the membrane system. The use of improper lubricants can lead to fire or explosions,
which may cause serious personal injury or death.
Do not use this system to produce Nitrox mixtures containing more than 40%
oxygen. Pumping Nitrox mixtures with higher concentrations of oxygen may
lead to fires or explosions, which can cause serious personal injury or death.

Voyager II& Open Voyager II Nitrox System
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The use of enriched air Nitrox does not eliminate the risk of decompression sickness (DCS) in
diving. Decompression sickness can lead to permanent disability or death.
Do not pump Nitrox mixtures at pressures above the HP compressor
manufacturer’s rating, and never above 3600 psi (250 bar). The system is not
rated for pressures above 3600 psi (250 bar). Higher pressures may lead to
explosions which may cause serious personal injury or death.
Ambient room temperature should never exceed 100oF (38oC) during operation of the Nitrox
System. Operation at higher temperatures may lead to system damage and malfunction. A
damaged membrane will not produce the correct Nitrox mixture which can lead to severe
personal injury if the gas is used for diving purposes without proper analysis.
Warnings Graphics Defined:
Moving belts Electrocution Fire Eye protection Gas inhalation
Skin damage Explosion Explosion Electrocution Machinery
Abbreviations commonly used in this manual:
psi Pounds per Square Inch CFM Cubic Feet per Minute
HP High Pressure RPM Rotations per Minute
LP Low Pressure PPM Parts per Million
O2Oxygen L/min Liters per Minute
CO Carbon Monoxide O2% Oxygen Percentage of Gas
CO2Carbon Dioxide B.P. Back Pressure
N Nitrogen

Voyager II& Open Voyager II Nitrox System
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3.0 Safety and Operation Precautions
Because a compressor is a piece of machinery with moving and rotating parts, the same precautions
should be observed as with any piece of machinery of this type where carelessness in operations or
maintenance is hazardous to personnel. In addition to the many obvious safety precautions, those
listed below must also be observed:
1) Read all instructions completely before operating any compressor or Nitrox System.
2) For installation, follow all local electrical and safety codes, as well as the National Electrical Code
(NEC) and the Occupational Safety and Health Administration (OSHA) standards.
3) Electric motors must be securely and adequately grounded. This can be accomplished by wiring
with a grounded, metal-clad raceway system to the compressor starter; by using a separate
ground wire connected to the bare metal of the motor frame; or other suitable means.
4) Protect all power cables from coming in contact with sharp objects. Do not kink power cables and
never allow the cables to come in contact with oil, grease, hot surfaces, or chemicals.
5) Make certain that power source conforms to the requirements of your equipment.
6) Pull main electrical disconnect switch and disconnect any separate control lines, if used, before
attempting to work or perform maintenance. “Tag Out” or “Lock Out” all power sources.
7) Do not attempt to remove any parts without first relieving the entire system of pressure.
8) Do not attempt to service any part while System is in an operational mode.
9) Do not operate the System at pressures in excess of its rating.
10)Do not operate compressor at speeds in excess of its rating.
11)Periodically check all safety devices for proper operation. Do not change pressure setting or
restrict operation in any way.
12)Be sure no tools, rags or loose parts are left on the Nitrox System.
13)Do not use flammable solvents for cleaning the Air Inlet Filters or elements and other parts.
14)Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by
covering parts and exposed openings with clean cloth or Kraft paper.
15)Do not operate the compressor without guards, shields, and screens in place.
16)Do not install a shut-off valve in the compressor discharge line, unless a pressure relief valve, of
proper design and size, is installed in the line between the compressor unit and shut-off valve.
17)Do not operate in areas where there is a possibility of inhaling carbon monoxide, carbon dioxide,
nitrogen, or flammable or toxic fumes.
18)Be careful when touching the exterior of a recently run electric, gasoline, or diesel motor - it may
be hot enough to be painful or cause injury. With modern motors this condition is normal if
operated at rated load - modern motors are built to operate at higher temperatures.
19)Inspect unit daily to observe and correct any unsafe operating conditions found.
20)Do not “play around” with compressed air or direct air stream at body, this can cause injuries.
21)Compressed air from this machine absolutely must not be used for food processing or breathing
air without adequate downstream filters, purifiers and controls and periodic air quality testing.
22)Always use an air pressure-regulating device at the point of use, and do not use air pressure
greater than marked maximum pressure.
23)Check hoses for weak or worn conditions before each use and make certain that all connections
are secure.
The user of any compressor or Nitrox System manufactured by Nuvair is hereby warned that failure to
follow the preceding Safety and Operation Precautions can result in injuries or equipment damage.
However, Nuvair does not state as fact or does not mean to imply that the preceding list of Safety and
Operation Precautions is all-inclusive, and further that the observance of this list will prevent all
injuries or equipment damage.

Voyager II& Open Voyager II Nitrox System
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4.0 Legal Precautions
It is highly recommended that a Nitrox fill log be maintained when filling Scuba cylinders to document
the following information. This log must be of permanent binding style with no loose pages.
•Fill date and time of day
•Tank Number
•Supplier’s check of oxygen content (%O2) plus signature and date
•User’s check of oxygen content (%O2) plus signature and date
•Fill Pressure
•MOD (Maximum Operating Depth) in user’s handwriting
•Nitrox certifying agency and card number

Voyager II& Open Voyager II Nitrox System
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5.0 Theory of Operation
The Voyager II Nitrox System is a turnkey package that produces oxygen-rich air (Nitrox) and then
compresses it with a High Pressure (HP) Compressor to fill Scuba Tanks or storage cylinders. The
package is designed to be fully automatic, with a quieted enclosure for noise reduction and protection
from moving parts while it is running. Although it is described as the “Nitrox Compressor”, it can also
be used to pump air.
The Nitrox System allows for efficient and cost effective Nitrox production using electric power,
without the hazards or expense of blending with stored high-pressure oxygen (O2). Instead, the
system uses a Semi-Permeable Membrane to produce Nitrox from air. A portion of the nitrogen in air
is separated out, leaving an oxygen rich Nitrox mixture.
The Voyager II uses a Rotary Screw LP Compressor, Air/Oil Aftercooler, Refrigerated Air Dryer, and
Filtration to provide the Membrane System with a source of clean, pressurized feed air for separation.
The air is filtered to CGA Grade D or better air quality prior to entering the Membrane System so it will
not damage or plug the Membrane fibers. Specifications for Grade D air are provided in the
Appendix.
The Voyager II’s Membrane System is rated for a maximum feed air pressure of 300 psi (21 bar) and
has been configured to work well with the 175 psi (12 bar) maximum pressure delivered by the LP
Compressor. A Back Pressure Regulator is used to adjust the amount of air the screw compressor
produces to meet the appropriate levels for various %O2Nitrox production. The air is then heated to
a temperature that provides stability over a wide range of ambient conditions, is optimal for
Membrane permeation, and prevents moisture condensation.
The heated air enters the Membrane, which is made up of thousands of miniature hollow fibers. The
walls of these fibers are semi-permeable and designed for different gases to move through them (or
permeate) at different speeds. The resulting gas mixture is known as the “permeate”. As air flows
through the hollow fibers, both oxygen and nitrogen permeate through the fiber walls. The oxygen
permeates faster than the nitrogen, which produces permeate with oxygen content greater than air.
The gas that reaches the end of the hollow fibers without permeating is almost entirely nitrogen and is
discharged. The flow rate of this discharge is set by the factory via a fixed orifice, which controls the
permeate to contain a constant 43-44% O2under normal operating conditions.
The permeate is a concentrated mixture that must be diluted with additional air prior to entering the
HP Compressor. It exits the Membrane at ambient to slightly negative pressure and travels into the
Mixing Tube, where it mixes homogeneously with filtered outside air. The amount of dilution, and
thus final %O2, is obtained by adjusting the amount of air produced by the compressor and supplied
to the membrane, with the Back Pressure Regulator. As air flow to the membrane is increased,
permeate flow increases and a higher %O2Nitrox is produced. As air flow to the membrane is
decreased, permeate flow decreases, compressor intake air increases, and a lower %O2Nitrox is
produced.
This relationship between permeate flow and intake air flow exists because the total of these two flow
rates will always equal the intake flow rate demanded by the HP Compressor. The resulting Nitrox
mixture is analyzed for %O2before entering the HP Compressor for approximate content and again
when pumping Nitrox for precise content. The HP Compressor pumps the Nitrox to a maximum
pressure of 3600 psi (250 bar) to fill Scuba Tanks or storage cylinders.
A unique feature of Nuvair Nitrox Systems is that the feed air pressure that correlates to a specific
Nitrox %O2is repeatable. For example, if your HP Compressor pumps 36% O2when the feed air
pressure is at 125 psi (9 bar), then adjusting the Back Pressure Regulator to 125 psi (9 bar) during
the next use will produce the same mixture.

Voyager II& Open Voyager II Nitrox System
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6.0 Low Pressure Compressor Technical Data
Capacity and Power Consumption:
Normal working pressure – 80-175 psi (5.5-12 bar)
Capacity at normal working pressure – 30 CFM (850 L/min)
Shaft power at normal working pressure – 10.2 hp (7.65 kW)
Maximum working pressure – 175 psi (12 bar)
Minimum working pressure – 44 psi (3 bar)
Idling shaft power consumption – 2.3 hp (1.7 kW)
Transmission – Belt drive
Cooling:
Allowed ambient temperature – 32-104°F (0-40°C)
Motor and Electrical Values:
•Motor: F class ODP, 10 horse power (7.5 kW) three-phase or single phase
3-Phase Motor:
•Motor - F class, IP55, 10 hp (7.5 kW)
•Speed of rotation – 3480 rpm @ 60Hz
Compressor current : 14.1 amps @ 380 V / 50 Hz
32.125 amps @ 230 V / 60 Hz
14.5 amps @ 440 V /60 Hz
•Fuse (max) – 25 amps @ 380 V
45 amps @ 230 V
Single Phase Motor:
•Motor - F class, IP55, 10hp (7.5 kW)
•Speed of rotation – 3480 RPM @ 60 Hz
•Compressor current: 50 amps @ 230 V 60 Hz
•Fuse (max) – 60 amps @ 230 V
Control voltage – 230 V
General Technical Data:
Oil Capacity 4 L
Maximum Oil Content in Air– 3 mg/m3
Rotary screw compressors are continuous duty rated. They are not made to run for short
intervals or sit without use for long periods of time. The rotary screw compressor must be run
for a minimum of one continuous hour per week in tropical settings to insure moisture does
not build up in the compressor. The oil filter and oil/air separator must be changed every 2000
hours or a minimum of once per year. In tropical conditions the oil should be checked every
month for moisture by draining a small amount off the bottom of the compressor into a clear
glass. If moisture is found it can be drained off and a visual inspection should be done on all
filters checking for rust or corrosion.

Voyager II& Open Voyager II Nitrox System
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7.0High Pressure Compressor Technical Data
Capacity and Power Consumption:
•Normal working pressure – 3600 psi (250 bar)
•FAD Flow 9.3CFM (265 L/min)
•Charging Rate – 10.8 SCFM (307 L/min)
•Compressor speed of rotation – 1550 rpm
•Maximum working pressure – 5000 psi (354 bar)
•Transmission – Belt drive
Cooling:
•Allowed ambient temperature – 32-105°F (0-40°C)
•Air Cooled Interstage & Aftercooler
Motor and Electrical Values:
Single Phase Motor
•Motor - 7.5hp Single phase
•Speed of rotation – 3450 RPM
•Compressor current 35 amps @ 230 V / 60 Hz
Three-Phase Motor
•Motor - 7.5hp Three-phase
•Speed of rotation – 3450 rpm
•Compressor current 25 amps @ 230 V / 60 Hz
10.5 amps @ 380 V / 50 Hz
11 amps @ 460 V / 60 Hz
General Technical Data:
•Number Of Stages - 3
•Number Of Cylinders – 3
•Lubrication – Splash Lubricated
•Oil Quantity – 1.6 qt. (1.5 L)
•HP Filtration Rating – CGA Grade E, 30,000 cu ft at 68oF (20oC)
•Condensate Drains – Automatic & Manual Interstage & Final
•Fill Pressure Stop – Automatic & Manual
•Low Oil Level Shutdown
•High Temperature Shutdown
•Interstage Pressure Gauges

Voyager II& Open Voyager II Nitrox System
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8.0System Components
•Low Pressure Compressor, including:
•Magnet Motor Starter
•Hour Meter
•External Lubricant Sight Gauge, Fill, and Drain
•Nuvair 546 Food Grade Rotary Screw Compressor Lubricant
•Large oil/air cooler with exhaust fan
•Refrigerated Air Dryer
♦Automatic Condensate Drain
•Back Pressure Regulator that controls LP compressor feed air supply
♦Supply Air Pressure Gauge 90-165 psi (6-11 bar) depending on Nitrox %O2
•Low Pressure Feed Air Filtration, Grade D Breathing Air, including four stages:
♦Coalescing & Particle Removal to 1 micron, auto drain, liquid level indicator
♦Water & Oil Vapor Removal to 0.01 micron, auto drain, liquid level & service life indicators
♦Oil Vapor Removal to 0.003 PPM
•Heater including: (optional) not supplied with Nitrox Manager
♦Thermostat Control
♦Digital Temperature Gauge
♦Pressure Switch
♦200 psi (14 bar) ASME Over Pressure Relief
•Semi-Permeable Membrane
•Mixing Tube & Air Intake Filter
•Nuvair Pro O2Remote Permeate Oxygen Analyzer
•Nitrogen Discharge
•Nuvair Pro O2Fill Oxygen Analyzer,including:
♦High Pressure>Low Pressure Regulator
♦Flow Restrictor, 1 - 5 L/min
•High Pressure Compressor, including
♦Magnet Motor Starter
♦Hour Meter
♦Automatic Condensate Drains
♦Automatic Fill Pressure Stop
♦External Lubricant Sight Gauge, Fill, and Drain
♦Nuvair 455 Food Grade Compressor Lubricant
•High Pressure Filtration, Grade E Breathing Air
•Air/Nitrox Quality Analysis Kit

Voyager II& Open Voyager II Nitrox System
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9.0 Nitrox System Specifications
LP
Compressor
Delivery @ 175 psi (12 bar)
30 CFM FAD
(850 L/min)
Horsepower –
Electric
7.5 hp
(5.5 kW)
Physical
Specifications
Height
62 in
(157 cm)
Width
57 in
(145 cm)
Depth
32 in
(81 cm)
Weight
840 lb
(382 kg)
Full Load
Amps
230 V / E1 / 60 Hz
230 V / E3 / 50-60 Hz
380-415 V / E3 / 50 Hz
460 V / E3 / 60 Hz
95 amps
46 amps
23 amps
26 amps
Membrane Input
Operating Pressure Range
90-185 psi
(6-12 bar)
Maximum Input Pressure
300 psi
(21 bar)
Feed Air Volume Range
8-33 SCFM
(227-934 L/min)
LP Feed Air Quality
Grade D
Optimum Temperature
110 +/- 5oF
(43 +/- 3
o
C)
Nitrox %O
2
Range
24 - 40%
HP
Compressor
Charging Rate
10.8 SCFM
(305 L/min)
Horsepower –
Electric
7.5 hp
(5.5 kW)

Voyager II& Open Voyager II Nitrox System
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Motor Electrical Boxes
10.0 Nitrox System Component Identification
LP Back
Pressure
Regulator
Adjustment Knob
- Adjust Nitrox
O2% Here.
Fill Oxygen
Analyzer
Permeate
Oxygen
Analyzer
HP Fill Outlet
Condensate
Tank
Low
Pressure
Gauge
HP Filter
Pressure
Bleed
LP Oil
Temperature
HP Filter #
X65247
Container
Access
Latch
LP Filter Access
Power Supply Cord-
To Be Connected to by
Trained Electrician ONLY

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Cabinet Temp
And
Heater Control
Displays
HP & LP Oil
Drains
LP Feed Air
Filtration
(3 Stage)
HP Manual
Condensate
Drain Valves (3)
Final HP
Condensate
HP Motor
Control
Electrical Box
LP Motor
Control
Electrical Box
Refrigerated
Air Dryer
HP Oil Fill
LP Oil/Air
Separator
Stage Pressure
Gauges
Fill
Pressure
Gauge
High
Pressure
Compressor
On/Off
Switch
& Hour
Meter
Low
Pressure
Compressor
Momentary
On Switch
& Hour
Meter
LP Air Intake Filter

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Stage Pressure
Gauges
Refrigerated Air Dryer
Oil Drains
LP Filtration
O2Analyzers
HP Motor
Controls
LP Motor
Controls
LP Oil/Air
Separator
HP Filtration

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11. System Drawing / Schematic
Voyager II
Nitrox System Components
Shown Within Dashed Lines

Voyager II& Open Voyager II Nitrox System
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12. System Flow Chart
LP Aftercooler Removes
Moisture
LP Feed Air Filtration
Produces Grade D Air
BP Regulator Controls the
amount of Feed Air
pumped by the compressor
Moisture Separator in Drier
removes moisture
Thermostat Controlled Heater
Heats Air to 110ºF (43ºC)
Membrane Separates Supply
Air Into Permeate and
Nitrogen Rich Gas
Permeate Exits Membrane
Containing 43-44% O2
Nitrogen Rich Gas Exits
Through Fixed Orifice
located in exhaust cooling
air vent
Mixing Tube Mixes Air &
Permeate to Create Nitrox
Containing 24-40% O2
Air Intake Delivers Filtered
Ambient Air to Mixing Tube
Permeate O
2
Analyzer
Monitors Nitrox before
Compression to +/- 2% O2
HP Compressor with
Moisture Removal &
Filtration Compresses Nitrox
Fill O
2
Analyzer Monitors
Nitrox Mixture to +/- 1% O2
HP Nitrox Delivered to
Storage
HP Nitrox Delivered to
Scuba Cylinder
- OR -
Optional Vacuum Pump or
Blower
LP Compressor Produces LP
Feed Air
Refrigerated Air Drier cools
the air
Voyager II Nitrox System
Components Shown Within
Dashed Lines

Voyager II& Open Voyager II Nitrox System
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13.0 Installing the Nitrox System
If any information in this manual conflicts with any of the other manuals, call Nuvair before
proceeding.
The Nuvair Voyager II should never be operated in a facility where the room temperature
exceeds 104o F (40o C) while the system is in use. Operation at higher temperatures may lead
to system damage and malfunction. A damaged membrane will not produce the correct Nitrox
mixture which can lead to severe personal injury if the gas is used for diving purposes without
proper analysis.
13.1 Precautions
1) Please read all information supplied before physically installing the Nitrox System.
2) Unpack the system and remove from the pallet. Visually inspect the system to make sure there
has been no damage during shipping. If damaged, please call Nuvair to file a damage report.
Please take photos and supply detailed information about the damage.
3) Place the system in a location that allows a minimum spacing of 18” from adjacent walls. Select a
location where ambient room temperature will never exceed 100oF (38oC).
4) The Heater Thermostat has been set in the factory. Do not adjust.
13.2 Attaching Nitrogen Discharge Hose (Optional)
-The nitrogen discharge from the Membrane on the
Voyager II exits into the exhaust air fan. The fan
pushes over 3000 cfm of exhaust air. As long as the
fan is functioning there will be no need for an outside
optional discharge.
-The Nitrogen Discharge on the Membrane System for the
Open Voyager II can also have a hose attached to re-route Nitrogen flow to a remote outlet.
Pure nitrogen is a colorless, odorless, tasteless gas that will not support life.
Breathing gas mixtures containing more than 84% nitrogen at surface
pressures will lead to unconsciousness and may cause death.
The nitrogen discharge from the membrane should be vented to a well-
ventilated room or to open air with good circulation. Failure to isolate the
discharge from the air intake of the membrane system or LP compressor could
lead to incorrect Nitrox mixtures, resulting in serious personal injury or death.
If you allow this pure nitrogen to accumulate in an enclosed space, anyone entering this
space will quickly lose consciousness and will die if not immediately resuscitated.