Nuvair NSS Series User manual

Operation Manual
Fill Containment Station
SKU NSS-2P-OCA (as shown)

NSS Series
Nuvair
Page 2
www.Nuvair.com
If you have any questions about this equipment, please contact Technical Support at:
Nuvair
1600 Beacon Place
Oxnard, CA 93033 USA
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Hours: Monday through Friday
8:00 AM to 5:00 PM Pacific Time
WARNING
This Operation 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.
Under Nuvair’s system of continuous improvement, certain components may be updated or changed as higher
quality or more efficient parts and assemblies become available.
Nuvair will make every effort to update manuals as parts and functional aspects change. However, the look or
location of components on your product may differ from those in this manual if improvements have been made
that do not affect functionality or operational procedures.
Units pictured may also be equipped with different options than those on your product. In this case, the basic
operational and maintenance guidelines will still apply.
If you have problems or questions after reading the manual, stop and call Nuvair at +1.805.815.4044 for
information.

NSS Series
Nuvair
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Table of Contents
1.0 Introduction...........................................................................................................................................4
1.1 Symbol Conventions............................................................................................................................4
1.2 System Description .............................................................................................................................4
1.3 Required Operator Training .................................................................................................................4
1.4 Important Information for the User .......................................................................................................5
1.5 Foreword .............................................................................................................................................5
1.6 Assistance...........................................................................................................................................6
1.7 Responsibility ......................................................................................................................................6
2.0 Safety Warnings....................................................................................................................................7
2.1 Safety and Operation Precautions .......................................................................................................8
3.0 Fill Containment Station Layout ..........................................................................................................9
4.0 General Safety Rules ..........................................................................................................................11
4.1 Protective Clothing ............................................................................................................................ 11
4.2 Checks and Maintenance .................................................................................................................. 11
5.0 Safety Information Labels: Location & Description.......................................................................... 11
6.0 System Components .......................................................................................................................... 11
7.0 Fill Containment Station Specifications ............................................................................................ 12
7.1 Unpacking and Installation.................................................................................................................12
8.0 Checks for the Start of Each Working Day........................................................................................ 12
8.1 Check Refill Hoses ............................................................................................................................12
8.2 Storing Technical Documentation ...................................................................................................... 12
9.0 Fill Containment Station Operation ................................................................................................... 13
10.0 Maintenance ........................................................................................................................................19
10.1 Foreword ...........................................................................................................................................19
10.2 General .............................................................................................................................................19
10.3 Unscheduled Work ............................................................................................................................ 19
10.4 Scheduled Maintenance Table ..........................................................................................................20
10.5 Changing Air Filtration Cartridges......................................................................................................20
10.6 Temperature Effect on Filter Life .......................................................................................................21
10.7 Changing Flex Hoses ........................................................................................................................22
10.8 Dismantling and Putting the Fill Containment Station Out of Service ................................................. 22
11.0 Maintenance Register .........................................................................................................................23
11.1 Customer Service..............................................................................................................................23
11.2 Scheduled Maintenance .................................................................................................................... 23
11.3 Nuvair Customer Care Contact.......................................................................................................... 23
12.0 Spare Parts List...................................................................................................................................23
13.0 Service Log ......................................................................................................................................... 24
14.0 Appendix ............................................................................................................................................. 25
14.1 Supply and Breathing Air Specifications ............................................................................................ 25
14.2 Filter Element Life Factors.................................................................................................................25
15.0 Nuvair Fill Containment Station System Warranty ........................................................................... 26

NSS Series
Nuvair
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1.0 Introduction
This manual will assist you in the proper set-up, operation, and maintenance of the Nuvair NSS Series of fill
containment stations. Be sure to read the entire manual.
1.1 Symbol Conventions
This manual uses certain words and symbols to call your attention to conditions, practices or techniques that
may directly affect your safety. Pay particular attention to information introduced by the following symbols or
words:
SYMBOL
MEANING
DESCRIPTION
DANGER Indicates an imminently hazardous situation, which if not avoided, will
result in serious personal injury or death.
CAUTION Indicates a potentially hazardous situation, which if not avoided, could
result in serious personal injury or death.
WARNING
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.
NOTICE Notifies people of installation, operation or maintenance information
which is important but not hazard-related.
1.2 System Description
The Nuvair NSS Fill Containment Station Series is designed for use while filling high-
pressure gas cylinders (DIN, yoke, or SCBA). The all-steel construction of the fill
containment station (also referred to as a “blast cabinet” or “fragmentation cabinet)
offers protection for operators during the cylinder filling process. Its heads-up control
panel allows monitoring and adjustments from a standing position. The cabinet is
third-party tested to meet or exceed NFPA 1901 standard. Vertical blast tubes direct
air blast and debris away from the operator should a failure occur. The NSS Series
can handle, 2, 3, or 4 cylinders.
The model pictured is the NSS-2P-OCA. It is a 2-cylinder fill containment station with
pneumatic doors and oxygen compatible air filtration.
1.3 Required Operator Training
This manual must be read carefully and in its entirety.
•All fill station operators and maintenance personnel must read this entire manual with due care and
attention and observe the instructions/information contained herein.
•Company owners ensure that the operator has the required training for operation of the fill station and
that he/she has read the manual.
Figure 1. Model NSS-2P-OCA.

NSS Series
Nuvair
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1.4 Important Information for the User
The information/instructions for fill station use contained in this manual concern the Nuvair NSS Series of fill
containment stations.
•The instruction manual must be read and used as follows:
•Read this manual carefully; treat it as an essential part of the fill containment station.
•The instruction manual must be kept where it can readily be consulted by fill containment station
operators and maintenance staff.
•Keep the manual for the working life of the fill containment station.
•Make sure updates are incorporated in the manual.
•Make sure the manual is given to other users or subsequent owners in the event of resale.
•Keep the manual in good condition and ensure its contents remain undamaged.
•Do not remove, tear, or rewrite any part of the manual for any reason.
•Keep the manual protected from damp and heat.
•If the manual is lost or partially damaged and its contents cannot be read it is advisable to request a
copy from Nuvair.
1.5 Foreword
The regulations/instructions for use contained in this manual constitute an essential component of the supplied
fill containment station.
These regulations/instructions are intended for an operator who has already been trained to use this type of fill
containment station. The contained information is necessary and essential for the efficient and proper use of
the fill containment station.
Hurried or careless preparation leads to improvisation, which is the cause of accidents.
Before beginning work, read the following suggestions carefully:
1) Before using the fill containment station, gain familiarity with the tasks to be completed and the
allowable working position.
2) The operator should always have the instruction manual available.
3) Plan all work with due care and attention.
4) Operators must have a detailed understanding of where and how the fill containment station is to be
used.
5) Before starting work make sure that safety devices are working properly and that their use is
understood; in the event of any doubts do not use the fill containment station.
6) Observe the warnings given in this manual with due care and attention.
7) Constant and careful preventive maintenance will always ensure a high level of safety when using the
fill containment station. Never postpone repairs and have them carried out by specialized personnel
only; use only original spare parts.

NSS Series
Nuvair
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1.6 Assistance
Nuvair technicians are at your disposal for all routine/unscheduled maintenance work. Please forward your
request for assistance to Nuvair by phone, fax or e-mail:
Phone: [phone]
Fax: [phone]
Email: [e-mail]
1.7 Responsibility
Nuvair considers itself exonerated from any responsibility or obligation regarding injury or damage caused by:
•Failure to observe the instructions contained in this manual that concern the running, use and
maintenance of the fill containment station.
•Inappropriate incorrect actions during use or maintenance of the fill containment station.
•Modifications made to the fill containment station without prior written authorization from Nuvair.
WARNING
Maintenance and repairs must only be carried out using original spare parts and qualified
technicians. Nuvair cannot be held liable for any damages caused by failure to observe this
rule. The fill containment station is guaranteed as per the contractual agreements made at the
time of sale. Failure to observe the regulations and instructions for use contained in this manual shall
render the warranty null and void.
DANGER
•Use only tested, certified storage tanks: do not exceed the indicated working pressure.
•Use the fill containment station in areas free from dust, risk of explosion, corrosion, and fire.
•Improper use could have serious consequences for the user.
•Do not disconnect the hose from the fittings or the clamp when under pressure.
•Change the air purification filters regularly as described in section 10.0.
•Never pull a plug out by tugging the cord. Make sure the cord is not bent at a sharp angle and that it
does not rub against any sharp edges. Use of extensions is not advised.
•Never operate the fill containment station when the power cord is damaged, or the power supply
covers/guards are removed.
•All routine and unscheduled maintenance tasks must be carried out with the fill containment
station depressurized.
•The high-pressure flex hose that connects to external components must be in good condition,
especially in the areas near the fittings.
oThe plastic sheath that covers the hose must not show any signs of abrasion otherwise damp
could get in, corrode the steel braid and weaken it.
oThe hose must be changed periodically (yearly) or when it shows signs of wear.
oFailure to observe this rule could seriously endanger the users’ safety.
oMake sure the minimum bending radius of the hose is no less than 250 mm (9.8 inches).
To ensure maximum working efficiency, Nuvair has constructed the fill containment station with carefully
selected components and materials. The fill containment station is tested prior to delivery. Continued fill

NSS Series
Nuvair
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containment station efficiency over time will also depend on proper use and maintenance as per the
instructions contained in this manual.
All the components, connections and controls used in its construction have been designed and built to a high
degree of safety to resist abnormal strain or in any case a strain greater than that indicated in the manual.
Materials are of the finest quality; their introduction and storage in the company and their utilization in the
workshop are controlled constantly to prevent any damage, deterioration, or malfunction.
DANGER
Before carrying out any work on the fill containment station each operator must have a perfect
understanding of how the fill containment station works, know how to use the controls, and
have read the technical information contained in this manual.
•It is forbidden to use the fill containment station under conditions or for purposes other than
those indicated in this manual and Nuvair cannot be held liable for breakdowns, problems or
accidents caused by failure to observe this rule.
•Check that the fittings provide a proper seal by wetting them with soapy water: Stop using the
fill containment station and eliminate any leaks immediately when detected.
•Do not attempt to repair high pressure tubes by welding them or while the fill containment
station is pressurized.
•Do not empty storage tanks completely—not even for long term storage—as this practice allows
damp air to get in and eventually corrode the tank.
•It is forbidden to tamper with, alter or modify, even partially, the systems and equipment
described in this instruction manual, especially as safety guards and safety symbols are
concerned.
•It is also forbidden to carry out work in any way other than that described or to neglect the
illustrated safety tasks.
•The safety information and the general information given in this manual are very important.
2.0 Safety Warnings
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.
WARNING
This equipment is used to provide breathing air or nitrox for the purpose of 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.
WARNING
The equipment you will be using to fill air or nitrox cylinders will expose you to 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.
WARNING
Any pressurized hose can cause extreme harm if it comes loose or separates from its
connections while under pressure and strikes any part of your body. Use appropriate care in
making and handling all gas connections.

NSS Series
Nuvair
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WARNING
Do not use any form of mineral oil or synthetic lubricant not rated for the fill containment
station use. Use only the recommended fill containment station lubricant as necessary.
2.1 Safety and Operation Precautions
Because a fill containment station is a piece of machinery with moving parts and high-pressure gas, 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 fill containment station.
2. For installation, follow all local safety codes and the Occupational Safety and Health Administration
(OSHA) standards.
3. Protect all power cables from contacting sharp objects. Do not kink power cables and never allow the
cables to contact oil, grease, hot surfaces, or chemicals.
4. Make certain that power source conforms to the requirements of your equipment.
5. Do not attempt to remove any parts without first relieving the entire system of pressure.
6. Do not operate the system at pressures more than its rating.
7. Periodically check all safety devices for proper operation. Do not change pressure setting or restrict
operation in any way.
8. Be sure no tools, rags or loose parts are left on the fill containment station.
9. Do not use flammable solvents for cleaning.
10. Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by
covering parts and exposed openings with clean cloth or paper.
11. Do not operate the fill containment station without guards, shields, and doors secured in place.
12. Do not operate associated gas compressors in areas where there is a possibility of carbon monoxide,
carbon dioxide, nitrogen, or flammable or toxic fumes.
13. Inspect unit daily to observe and correct any unsafe operating conditions found.
14. Compressed air can be a serious hazard. Always use caution. Never direct air stream at any part of the
body as this can cause injuries.
15. Compressed air from this machine must not be used for food processing or breathing air without
adequate downstream filters, purifiers and controls and periodic air quality testing.
16. Always use an air pressure-regulating device at the point of use, and do not use air pressure greater
than marked maximum pressure.
17. Check hoses for weak or worn conditions before each use and make certain that all connections are
secure.
The user of any fill containment station 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 nor does it 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.

NSS Series
Nuvair
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3.0 Fill Containment Station Layout
Storage Bank 1
Gauge & Panel Valve
Storage Bank 2
Gauge & Panel Valve
Pneumatic Door
Open/Close Switch
Fill Station 1
Gauge & Valve
Regulated Fill Pressure Gauge
Fill Station 2
Gauge & Valve
HP to HP
Regulator
Unregulated Fill Pressure Gauge

NSS Series
Nuvair
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* WARNING
Turn off compressor input valve if transferring gas mixtures of more than 21% oxygen content
between Storage Bank 1 and Storage Bank 2.
Compressor
Input Valve*
OCA
Filtration
Vent