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Nuvair Voyager II User manual

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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: +1 805 815 4044
Fax: +1 805 486 0900
Email: info@nuvair.com
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 +1 805 815 4044 for information.
Voyager II& Open Voyager II Nitrox System
Nuvair Page 3 www.nuvair.com
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
Nuvair Page 5 www.nuvair.com
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
Nuvair Page 6 www.nuvair.com
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
Nuvair Page 7 www.nuvair.com
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
Nuvair Page 8 www.nuvair.com
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
Nuvair Page 9 www.nuvair.com
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
Nuvair Page 10 www.nuvair.com
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.