Nuvair Voyager IV, User And Maintenance Manual

Page 1: ...User and Maintenance Manual Voyager IV Nitrox System Rev 12 18 ...

Page 2: ...r 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 ...

Page 3: ...Connection 13 4 Check Compressor Lubricant Levels 13 5 Control Pane Description 14 0 Pre Operation Instructions 14 1 Oxygen Analyzer Calibration 15 0 Producing Nitrox 15 1 Flow to Membrane and Setting Proper Pressure 15 2 Final Adjustments Before Pumping Nitrox 15 3 Pumping Nitrox 15 4 Pumping Air 15 5 Shutting Down 16 0 Nitrox Operational Notes 16 1 Correlation of Feed Air Pressure to Oxygen Cont...

Page 4: ...rds 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...

Page 5: ...thing 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 ...

Page 6: ...ed 100o F 38o C 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 Expl...

Page 7: ...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 s...

Page 8: ...s 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 ...

Page 9: ...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 f...

Page 10: ...F ODP and Electrical Values Motor F class 20 hp 15 kW Speed of rotation 2930 RPM 50 Hz 3450 RPM 60 Hz Motor Amperage o 208 V 60 Hz 61 amps o 230 V 50 Hz 57 amps o 400 V 50 Hz 34 amps o 460 V 60 Hz 29 amps 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 l...

Page 11: ...ing Allowed ambient temperature 32 105 F 0 40 C Air Cooled Interstage Aftercooler Motor and Electrical Values Motor 15 hp 11kw 3 phase Speed of rotation 2930 RPM 50 Hz 3450 RPM 60 Hz Motor Amperage o 208 V 60 Hz 47 amps o 230 V 50 Hz 36 amps o 400 V 50 Hz 25 amps o 460 V 60 Hz 22 amps General Technical Data Number Of Stages 4 Number Of Cylinders 4 Lubrication Pressure Splash Lubricated Oil Quantit...

Page 12: ...vel 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 O2 Remote Permeate Oxygen Analyzer Nitroge...

Page 13: ...in 178 cm Weight 1625 lb 737 kg Full Load Amps 230 V E3 50 Hz 95 amps 230 V E3 60 Hz 95 amps 380 415 V E3 50 Hz 50 amps 460 V E3 60 Hz 55 amps Membrane Input Operating Pressure Range 90 185 psi 6 12 bar Maximum Input Pressure 300 psi 21 bar Feed Air Volume Range 13 60 SCFM 354 1700 L min LP Feed Air Quality Grade D Optimum Temperature 110 5o F 43 3o C Nitrox O2 Range 24 40 HP Compressor Charging R...

Page 14: ...gulator Adjustment Knob Adjust Nitrox O2 Here Low Pressure Compressor Momentary On Switch Hour Meter Fill Oxygen Analyzer Permeate Oxygen Analyzer HP Fill Outlet Fill Pressure Gauge HP Compressor Filter Canisters Condensate Container with Muffler Drain Low Pressure Gauge HP Filter Pressure Bleed LP Oil Temperature Cabinet Temperature Stage Pressure Gauges Filter X65677 Filter X65247 HP Oil Pressur...

Page 15: ...LP Oil Drains LP Feed Air Filtration 4 Stage HP Compressor Lubricant Level Sight Gauge Final HP Condensate Tower HP Motor Control Electric Box LP Motor Control Electric Box Refrigerated Air Dryer HP LP Oil Fill LP Air Intake LP Oil Filter LP Oil Air Separator ...

Page 16: ...Voyager IV Nitrox System Nuvair www nuvair com Page 16 11 0 System Drawing Schematic Voyager IV Nitrox System Components Shown Within Dashed Lines ...

Page 17: ...rogen Rich Gas Exits Through Fixed Orifice located by 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 O2 Analyzer Monitors Nitrox before Compression to 2 O2 HP Compressor with Moisture Removal Filtration Compresses Nitrox Fill Diver O2 Analyzer Monitors Nitrox Mixture to 1 O2 HP Nitrox Del...

Page 18: ...ng of 18 from adjacent walls Select a location where ambient room temperature will never exceed 100o F 38o C 4 The Heater Thermostat has been set in the factory Do not adjust 13 2 Nitrogen Discharge Hose The nitrogen discharge from the Membrane on the Voyager IV exits next to the exhaust air fan The fan pushes over 3000 CFM of exhaust air and as long as the fan is functioning there will be no need...

Page 19: ...tion for the Compressor Motor and Membrane System Heater located inside the motor starter compartment Amperage Load for System Approximately 95 amps for 230 V three phase service Approximately 50 55 amps for 400 460 V three phase service Compressor Rotation Check Always turn on bump starter for both LP and HP Compressors and run motor very briefly to check for proper direction of rotation see arro...

Page 20: ...into the air storage system could cause a diver to suffer from oxygen poisoning at depth Oxygen poisoning is extremely dangerous and can lead to death by drowning Do not allow air to be discharged into the Nitrox storage system Air introduced into the Nitrox storage system could cause a diver to suffer decompression sickness if the Nitrox mixture is not analyzed properly and is used underwater und...

Page 21: ...yzer may result in the use of incorrect Nitrox mixtures which may cause serious injury or death to the diver using the gas mixture At altitudes above sea level a correction factor must be used when calibrating the Fill Oxygen Analyzer may not be achievable See Fill Oxygen Analyzer manual for correcting analyzer readings at various altitudes Improper calibration of the Fill Oxygen Analyzer may resu...

Page 22: ...ay reading stabilizes at 20 9 d Reinstall the Flow Adapter Cap to the analyzer e The Fill Oxygen Analyzer is now ready for use Different settings may be used depending on location so verify your actual ambient conditions and refer to the Oxygen Analyzer manual for details 5 Turn on the LP Compressor and increase the pressure to a minimum of 90 psi 6 Allow the Compressors to run for a 10 Minute war...

Page 23: ...is increased a higher O2 Nitrox is pumped As pressure is decreased a lower O2 is pumped 1 Increase pressure by slowly turning the regulator Knob CW while monitoring the LP Pressure Gauge and Permeate Oxygen Analyzer As the pressure rises watch the corresponding increase in the analyzer O2 reading 2 Increase or decrease pressure slowly until the Permeate Oxygen Analyzer displays the O2 desired in t...

Page 24: ...si 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 No oxygen cleaning of standard cylinders or plumbing is mandatory when using the Nitrox System to produce Nitrox containing a maximum of 40 oxygen When filling oxygen clean cylinders hyper purification of the Nitrox is required using an op...

Page 25: ...he same cylinder more than once a day 15 3 Pumping Nitrox 1 When filling a Scuba cylinder follow all industry standards Do not exceed rated pressure of cylinder and do not exceed 3600 psi 250 bar under any condition 2 With fill whip bleed valve open and Nitrox flowing verify that Fill Oxygen Analyzer O2 reading equals the desired Nitrox O2 3 Close bleed valve open cylinder valve and fill cylinder ...

Page 26: ... Log every Nitrox fill to document the following information 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 9 When filling a HP Nitrox storage tank verify that Fill Oxygen Analyzer O2 ...

Page 27: ...i 9 bar and wait for the Oxygen Analyzer reading to stabilize You will find the analyzer reading to be very close to 36 O2 requiring only minor adjustments of the regulator to achieve the exact desired O2 Use the Fill Oxygen Analyzer to verify the Nitrox oxygen percentage prior to pumping When using the feed air pressure reading to obtain specific oxygen percentage minor adjustments of the feed ai...

Page 28: ...no condensate is present 3 Check LP Air Filtration for condensate and proper operation of condensate drains Use only the specified Nuvair lubricants in this system The use of incompatible lubricants presents a risk of fire and or explosion and may result in system damage This can lead to severe personal injury and death Be sure that all pressure has been relieved from the system prior to opening a...

Page 29: ... is operated in high humidity and or high temperature the Filter Element must be changed more often See Appendix for details on Filter Element Life Factors 6 Condensate Drain Container Check level and drain weekly or as needed 7 Semi Permeable Membrane No maintenance required Service life exceeds 20 years if LP Air Filtration is properly serviced to maintain Grade D standards 8 Membrane System Air...

Page 30: ...arry out these tasks if the compressor has only just shut down wait for the compressor to cool Pressure must be drained before opening LP Fill Plug Any oil spilt during the oil filter change could cause personnel to slip wear protective garments and anti slip footwear and remove traces of oil immediately Both oil and filters are classified as special wastes and must therefore be disposed of in com...

Page 31: ...pect as follows 1 Inspect Bowl for the presence of moisture A high level of moisture build up in the HF11 24 or HF7 24 Filter indicates improper operation of auto drain floats Evidence of any moisture in the HF1 24 Filter indicates air is not cooling properly and moisture is not properly being removed Check HF1 canister weekly for moisture Moisture indicates possible refrigerated dryer problem Exc...

Page 32: ...rvice indicators on the HF7 HF5 filters assist with monitoring replacement intervals 1 Push up on Filter Bowl rotate counter clockwise and lower to remove 2 Gently unscrew Filter Element and pull down off mounting post 3 Replace Element and reassemble in reverse order The interior of the Filter Bowls can be cleaned with a diluted solution of Simple GreenTM and flushed thoroughly with clean water T...

Page 33: ...nd or high temperature Filter Element must be changed more often See Appendix for details on Filter Element Life Factors 1 Shut down the Nitrox System 2 Open Manual Bleed Drain Valve to drain pressure Leave Valve open 3 Unscrew the Filter Canister Cap 4 Remove expended Element from Filter Canister 5 Install New Element place pressure on element to seat the element 6 Reinstall Cap to Canister 7 Clo...

Page 34: ...BA035 Air Intake Filter EK76 300KBA1446 HP Compressor Consumables HP Compressor Lubricant Food Grade Nitrox Compatible Nuvair 455 1 Gal 9406 HP Compressor Filtration Element Gas Drying Filter X65677 Breathing Air Filter Grade E X65247 Heater Assembly 1200 Watt 28 in Length H1200 Heater Thermostat Control 220 V Fahrenheit Gauge standard TS 13020 F TS 13021 C Heater Pressure Switch B16 947 Membrane ...

Page 35: ...Voyager IV Nitrox System Nuvair www nuvair com Page 35 17 7Service Record Log Date Technician Name Service Performed ...

Page 36: ...System must contain 0 003 PPM Oil Vapor All breathing Nitrox produced for diving must be purified to meet these same requirements except for oxygen content Nitrox oxygen content must measure within 1 O2 of the specified value of the mixture using a properly calibrated Oxygen Analyzer i e Nitrox produced with a target content of 32 O2 must measure in the range of 31 33 O2 Periodic air quality testi...

Page 37: ...ntake Hose provided If a longer hose is required contact Nuvair for assistance Compressors must be provided adequate ventilation to operate properly and prevent heat damage This requires an ambient temperature below 100o F 38o C sufficient clearance from adjacent walls and proper rotation direction Operation Do not use the Nitrox System to supply a HP or LP Compressor with Nitrox mixtures containi...

Page 38: ...list price A warranty registration card supplied with system documentation must be filled out and submitted to Nuvair for the warranty to be in full effect If the warranty registration card is not received within thirty 30 days of installation the thirty six 36 month warranty will begin with the date of shipment from Nuvair For warranty service to be considered customer s account must be current o...

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Page 40: ...Nuvair Phone 1 805 815 4044 Fax 1 805 486 0900 1600 Beacon Place Oxnard CA 93033 USA info nuvair com www nuvair com Rev 12 18 ...