User Manual
Titan
Nitrox System
Rev 01.19
Titan Nitrox System
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
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.
NUVAIR www.nuvair.com
Page
2
Titan Nitrox System
Table of Contents
Introduction
1.0 Introduction ...................................................................................................................................... 4
2.0 Safety Warnings .............................................................................................................................. 5
3.0 Safety and Operation Precautions ................................................................................................... 7
4.0 Legal Precautions ............................................................................................................................ 8
5.0 Theory of Operation ......................................................................................................................... 9
6.0 Low Pressure Air Compressor Technical Data …………………………………………………………. 10
7.0 High Pressure Compressor Technical Data ……………………………………………………..…...... 11
8.0 System Components ………………………………………...........……………………………………..... 12
9.0 Nitrox System Specifications ............................................................................................................ 13
10.0 Nitrox System Component Identification ..………………………........................................................ 14
11.0 System Drawing/Schematic …………………………………………….…………………………………. 15
12.0 System Flow Chart ……………………………………………………………………………………….… 16
Setup, Operation, and Maintenance
13.0 Installing the Nitrox System ............................................................................................................. 17
13.1 Precautions ......................................................................................................................... 17
13.2 Attaching Nitrogen Discharge Hose (Optional) ................................................................... 17
13.3 Electrical Power Connection ............................................................................................... 18
13.4 Air/Nitrox Quality Testing ………………………………………………………………………… 18
14.0 Pre-Operation Instructions ............................................................................................................... 19
14.1 Compressor Lubricant Levels ............................................................................................. 19
14.2 Membrane System Feed Air Regulator and Switch ............................................................ 19
14.3 Oxygen Analyzer Calibration ............................................................................................... 20
14.4 Attaching Scuba Cylinder .................................................................................................... 22
15.0 Producing Nitrox ............................................................................................................................... 23
15.1 Flow to Membrane .............................................................................................................. 23
15.2 Setting Proper Pressure ...................................................................................................... 24
15.3 Final Adjustments Before Pumping Nitrox .......................................................................... 24
15.4 Pumping Nitrox .................................................................................................................... 25
15.5 Pumping Air ......................................................................................................................... 27
15.6 Shutting Down ..................................................................................................................... 27
16.0 Nitrox Operational Notes .................................................................................................................. 28
16.1 Correlation of Feed Air Pressure to Oxygen Content .......................................................... 28
16.2 Hot Fills ............................................................................................................................... 28
17.0 Maintenance ...................... ......... ....... ...... ....... .................................................................................. 29
17.1 Daily Maintenance ............................................................................................................... 29
17.2 Routine Maintenance .......................................................................................................... 29
17.3 Compressor Lubricant ......................................................................................................... 31
17.4 LP Feed Air Filtration .......................................................................................................... 32
17.5 HP Compressor Filtration .............…………………………….............................................. 34
17.6 Spare Parts List ................................................................................................................... 35
17.7 Service Record Log ............................................................................................................. 36
Appendix ....................................................................................................................................................... 37
Supply and Breathing Air Specif icati ons ....... ................................................................................... 37
Filter Element Life Factors ............................................................................................................... 37
Owner’s Warranty Responsibilities ……… ……… ……… ………... .................................................... 38
Warranty ………………………………………………… ………… ……………………………………….. 39
Separate Manuals Included:
Nuvair Pro O
TM
Oxygen Analyzer Operation Manual
2
NUVAIR www.nuvair.com
Page
3
Titan Nitrox System
1.0 Introduction
This manual will assist you in the proper set-up, operation and maintenance of the Nuvair Titan 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.
NUVAIR www.nuvair.com
Page
4
Titan Nitrox System
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.
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) wil l expose you to
both low and high-pressure gas. Gas, even under moderate pressures, can cau s e ext r eme
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 car e
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 an d may caus e 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 conta ining 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 Lubrica nt 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.
NUVAIR www.nuvair.com
Page
5
Titan Nitrox System
Do not use this system to produce Nitrox mixtures containing more than 40% oxygen.
Pumping Nitrox mixtures with higher concentra tions of oxygen may lead to fires or
explosions, which can cause serious personal injury or death.
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.
NUVAIR www.nuvair.com
Page
6
Titan Nitrox System
3.0 Safety And Operation Precautions
Because a compressor is a piece of machinery with moving and rotating parts, the s am e precautions
should be observed as with an y piece of machinery of this type where carelessness in operations or
maintenance is hazardo us to personnel. In addition to t he many obvious safety precautio ns , those listed
below must also be observed:
1) Read all instructions co mpletely before operating any compressor or Nitrox System.
2) For installation, f oll ow 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 secur ely and adequately grounded. This can be accomplished by wirin g with a
grounded, metal-clad raceway system to the compressor starter; by using a s epar ate ground wire
connected to the bare m etal of the motor frame; or other suit abl e means.
4) Protect all power cables f r om coming in contact with sharp object s . Do not kink power cables and
never allow the cables to c ome in contact with oil, grease, hot s urfaces, or chemical s .
5) Make certain that power source conforms to the requirements of your equipment.
6) Pull main electrical disconnect switch and disconnec t any separate control lines, if used, before
attempting to work or perform maintenance. “Tag Out” or “ Loc k Out” all power sources.
7) Do not attempt to remove any parts without first relieving the entire system of pressur e.
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 par ts by
covering parts and exposed openings with clean cloth or K raft 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 i ns talled in the line bet ween the compressor unit and shut-off valve.
17) Do not operate in areas where there is a possibi lity 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 oper ated at
rated load - modern motors ar e bui lt 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, nor direct air stream at body, because this can cause
injuries.
21) Compressed air from this machine absolutely must not be used for food proces sing or breathing air
without adequate downstream filters, purifiers and controls and periodic air qual ity testing.
22) Always use an air pressure-regulating de vice 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 manufactur ed by Nu va i r is hereby warned that failure to
follow the preceding Saf ety and Operation Precautions c an r es ult 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 fur ther that the observance of this list will prevent all injuries or
equipment damage.
NUVAIR www.nuvair.com
Page
7
Titan Nitrox System
4.0 Legal Precautions
It is highly recommended that a Nitrox fill log be maintained when filling Scuba cylinders to document
the following inf ormation. 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
NUVAIR www.nuvair.com
Page
8
Titan Nitrox System
5.0 Theory of Operation
The Titan Nitrox System is a turnkey package that produces oxygen-rich air (Nitrox) and then
compresses it with a High Pressure (HP) Compressor to f ill 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 TitanTM uses a Reciprocating Piston LP Compressor, Air Aftercooler, Volume Tank, 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 Mem brane System so it will not
damage or plug the Membrane fibers. Specifications for Grade D air are provided in the Appendix.
The TitanTM’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 200 P.S.I (12 bar) maximum pressure delivered by the LP
Compressor. A Feed Air Pressure Regulator reduces the pressure to appropriate levels for various
%O2 Nitrox 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 diff erent gases to move through them (or
permeate) at different speeds. The resulting gas mixture is known as the “permeate”. As air f lows
through the hollow fibers, both oxygen and nitrogen permeate through the fiber walls. The oxygen
permeates faster than the nitrogen, which produces permeate with an 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 42-44% O2 under 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 Feed Air Pressure Regulator. As pressure is increased,
permeate flow increases, air flow decreases, and a higher %O2 Nitrox is produced. As pressure is
decreased, permeate fl ow decreases, air intake flow increases, and a lower %O2 Nitrox is produced.
This relationship between permeate flow and air intake flow exists because the total of these two f low
rates will alwa ys equal the intake flow rate demanded by the HP Compressor. The resulting Nitrox
mixture is analyzed for %O2 before 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 %O2 is repeatable. For example, if your HP Compressor pumps 36% O2 when the feed air
pressure is at 125 psi (9 bar), then adjusting the Feed Air Pressure Regulator to 125 psi (9 bar)
during the next use will produce the same mixture.
NUVAIR www.nuvair.com
Page
9
Titan Nitrox System
6.0 Low Pressure Compressor Technical Data
Capacity and Power Consumption:
• Normal working pressure – 165-175 psi (11-12 bar)
• Capacity at norm al working pressure – 23.5 CFM (666 L/min) Delivery
• 29.9 CFM (847 L/min) Di spl acem ent
• Compressor speed of rotation – 1035 rpm
• Maximum working pressure – 175 psi (12 bar)
• Transmission – Belt drive
Cooling
• Allowed ambient temperature – 32-100°F (0-38°C)
• Aftercooler heat rejection – outlet air temperature reduced to within 20ºF (11°C ) of ambient
Motor and Electrical Values:
• Motor - F class, IP55, 7.5hp 3 phase or 7.5 hp Single phase
• Speed of rotation – 1725 rpm
• Compressor current 230V-50/60 Hz/single phase – 40 amps
230V-50/60 Hz/three p hase – 20amps
General Technical Dat a:
• Oil Quantity – 2 qt. (1.9 L)
NUVAIR www.nuvair.com
Page
10
7.0 High Pressure Compressor Technical Data
Capacity and Power Consumption:
• Normal working pressure – 3600 psi (250 bar)
• Charging Rate - 9 SCFM (255 L/min) *
• Compressor speed of rotation – 1350 rpm
• Maximum working pressure – 5000 psi (354 bar)
• Transmission – Belt drive
Cooling:
• Allowed ambient temp er atur e – 32-105°F (0-40°C)
• Air Cooled Interstage & Aftercooler
Motor and Electrical Values:
• Motor - 7.5hp 3 phase or 7.5hp Single phase
• Speed of rotation – 3450 rpm
• Compressor current 230V-50/60 Hz/single phase – 40amps
230V-50/60 Hz/three p hase – 20amps
General Technical Dat a:
• Number Of Stages - 3
• Number Of Cylinders – 3
• Lubrication – Splash Lubricated
• Oil Quantity – 1.9 qt. (1.8 lL)
• HP Filtration Rating – CGA Grade E, 13,000 cu. ft. at 68oF (20oC)
• Condensate Drains – Automatic & Manual Interstage & Final
• Fill Pressure Stop – Automatic & Manual
• Low Oil Level Shutdown – Optional
• High Temperature Shu tdown – Optional
• Interstage Pressur e G aug es – Optional
*Based on filling an 80 Cu. Ft. Scuba Cylinder from 500 PSI to 3,000 PSI.
Titan Nitrox System
NUVAIR www.nuvair.com
Page
11
Titan Nitrox System
8.0 System Components
• Low Pressure Compressor, including:
♦ Magnet Motor Starter
♦ Hour Meter
♦ External Lubricant Sight Gauge, Fill, and Drain
♦ Nuvair 455 Food Grade Compressor Lubricant
• Low Pressure Volum e Ta nk:
♦ 120 Gallon Horizontal, other remote configurations available
♦ Automatic Condensate Drain
• Volume Tank Pressure Gauge
• Ball Valve Feed Air On/Off Valve
• Low Pressure>Low Pressure Feed Air Regulator with Pressure Gauge:
♦ Pressure input to regulator 165-175 psi (11-12 bar)
♦ Output Pressure from regulator 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
♦ Final Stage Carbon Particle Removal, auto drain, liquid level & service life indicators
• Heater including:
♦ 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
• Nitrogen Discharge Hose (optional)
• Nuvair Pro O2 TM Fill Oxygen Analyzer, including:
♦ High Pressure>Low Pressure Regulator
♦ Flow Restrictor, 1 - 5 L/min
• High Pressure Compressor, including
♦ Magnetic Motor Starter
♦ Hour Meter
♦ Automatic Condensate Drains
♦ Automatic Fill Pressure St op
♦ External Lubricant Sight Gauge, Fill, and Drain
♦ Nuvair 455 Food Grade Compressor Lubricant
• High Pressure Filtration, Grade E Breathing Air
• (2) Five Foot Fill Whips with International Yoke & Valve
TM
Permeate Oxygen Analyzer
NUVAIR www.nuvair.com
Page
12
9.0 Nitrox System Specifications
LP
Delivery @ 175 psi (12
23.5 CFM FAD
Horsepower –
7.5 hp
Physical
Height
52 in (132 cm)
Width
89 in (226 cm)
Depth
42in (107 cm)
Weight
1250 lb
(567 kg)
Full Load
230V/E3/50-60 Hz
45 amps
Membrane Input
Operating Pressure
Range
90-165 psi (6-11 bar)
Maximum Input
Pressure
300 psi (21 bar)
Feed Air Volume
Range
8-23.5 SCFM
(212-666 L/min)
LP Feed Air Quality
Grade D
Optimum Temperature
110 +/- 5oF
(43 +/- 3oC)
Nitrox %O2
Range
24 - 40%
HP
Compressor
Charging Rate
9 SCFM
Horsepower –
7.5 hp
Titan Nitrox System
bar)
Electric
Compressor
Specifications
230V/E1/50-60 Hz
Amps
(666 L/min)
(5.5 kW)
80 amps
NUVAIR www.nuvair.com
Electric
Page
(255 L/min)
(5.5 kW)
13
10.0 Nitrox System Component Identification
Fill Oxygen
Analyzer
Permeate
Analyzer
High Pressure
Feed Air Control
Switch
Heater
LP>LP Feed Air
O2% Here.
Fill Whip
HP Compressor
Filter Canister
LP Compressor
Volume
Gauge
Manual
Air Intake Filter
Air Intake Filter
Condensate
Container
Nitrogen
Outlet
Membrane
Heater
Heater Pressure Switch
Fill Pressure
Gauge
Feed
Valve
Intake
Hose
Oxygen
Titan Nitrox System
Tank
Pressure
Filtration
(3 Stage)
Air
Regulator Adjustment
Knob - Adjust Nitrox
Compressor
Controls
Thermostat
Control
Condensate
Drain Valve
Collection
Discharge
NUVAIR www.nuvair.com
Page
14
11.0 System Drawing / Schematic
Titan
Shown Within Dashed Lines
NUVAIR www.nuvair.com
Page
15
Titan Nitrox System
Nitrox System Components
12.0 System Flow Chart
LP Aftercooler Removes
Moisture
LP Feed Air Filtration
LP Volume Tank Collects
LP>LP Regulator Reduces
Desired Nitrox O2%
Thermostat Controlled Heater
Membrane Separates Supply
Nitrogen Rich Gas
Permeate Exits Membrane
Nitrogen Rich Gas Exits
Mixing Tube Mixes Air &
Air Intake Delivers Filtered
Permeate O2 Analyzer
Compression to +/- 2% O2
HP Compressor with
Filtration Compresses Nitrox
Fill/Diver O2 Analyzer Monitors
HP Nitrox Delivered to
HP Nitrox Delivered to
- OR -
Optional Vacuum Pump or
LP Compressor Produces LP
Feed Air (Supply Air)
LP Feed Air On/Off Flow
Valve Controls Feed Air
Titan
Shown Within Dashed Lines
Nitrox System Components
Titan Nitrox System
Moisture and Delivers
Feed Air
Pressure and Adjusts
Heats Air to 110ºF (43ºC)
Produces Grade D Air
Air Into Permeate and
Through Fixed Orifice
Containing 42- 44% O2
Ambient Air to Mixing Tube
Blower
Permeate to Create Nitrox
Containing 24-40% O2
Monitors Nitrox before
Moisture Removal &
NUVAIR www.nuvair.com
Nitrox Mixture to +/- 1% O2
Page
Scuba Cylinder
Storage
16
Titan Nitrox System
Fixed Factory Set
13.0 Installing the Nitrox System
If any information in this manual conflicts with any of the other manuals call Nuvair before
proceeding.
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 sever e
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 Attac hi ng Ni trogen Discharge Hose (Optional)
The nitrogen discharge from the Membrane must be
isolated from the air intakes of the Membrane System
and LP Compressor. This requirement will be met if
the Nitrox System is installed in a well-ventilated room
that meets industry sta ndards for compressor
installations. If the Nitrox System is installed in a
closed building, boat, or similar enclosed space, the
nitrogen discharge must be vented to the outside. An
optional Nitrogen Discharge Hose may be needed. If
your installation requires the use of a Nitrogen
Discharge Hose, please contact Nuvair for
assistance.
Nitrogen Discharge
Pure nitrogen is a colorless, odorless, tasteless gas that will not support life. Breathing gas mi xt ur es
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 ent ering this space will
quickly lose consciousness and will die if not immediately resuscitated.
NUVAIR www.nuvair.com
Page
17
Titan Nitrox System
Note Proper
Direction of Rotation
On/Off
Hour Meter
13.3 Electrical Power Connection
Never use extension cords to provide power to your Nitrox System. The system must be
properly wired according to national and local electrical codes by a qualified electrician.
Improper wiring may lead to fires, which can cause serious personal injury or death.
Prior to making the electrical power connection, check all system specifications provided in this
manual. When working on the Nitrox System the main breaker at the power source must be “locked
out” in the Off position. The Nitrox System has electrical protection for the Compressor Motor and
Membrane System Heater located inside the motor starter compartment.
Amperage Load for System
♦ Approximately 45 amps for 230 V three phase service
♦ Approximately 73 amps for 230 V single phase service
Compressor Rotation C heck
Always turn on (bump) starter for both LP and HP Compressors and run motor very briefly to check
for proper direction of rotation (see arrow on belt guard and flywheel).
Switches
Operation in reverse direction for extended peri ods of time will cause a Reciprocating
Compressor to run hot and perform poorly and may cause permanent damage.
13.4 Air/Nitrox Quality Testing
Before using your Nitrox System to pump Nitrox, test a sample of the Nitrox produced using the
Air/Nitrox Quality Analysis Kit provided to verify compliance with CGA standards. Quarterly testing is
mandatory once the System is operational.
NUVAIR www.nuvair.com
Page
18
14.0 Pre-Operation Instructions
Compressor
LP Feed Air
Lubricant
LP Feed Air
Do not allow Nitrox to be discharged into the air storage system. Nitrox introduced 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 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 under the assumption it is a different mix.
14.1 Compressor Lubricant Levels
Check lubricant levels before starting the LP
and HP Compressors, and add lubrican t as
required. Use only the lubricants specified.
14.2 Membrane System Feed Air Regulator and Switch
An LP>LP Feed Air Regulator is used to reduce feed air pressure to
the Membrane System to a typical range of 80-165 psi (6-11.5 bar).
An LP Feed Air Switch is used to contr ol t he fl ow of air into the
Membrane System. Prepare the Membrane System as follows:
1) Reduce feed air pressure to minimum
pressure setting by turning the regulator
adjustment knob counter-clockwise
(CCW)
until it spins freely.
2) Turn regulator knob clockwise (CW) until
you first
feel resistance, which means that the
spring is starting
to compress.
3) Make sure the LP Feed Air Switch is in
the Off position.
NUVAIR www.nuvair.com
Fill Plugs
Lubricant
Level Sight
Gauges
Regulator
Adjustment Knob
Page
19
Titan Nitrox System
Switch
Titan Nitrox System
Calibration Knob
Permeate Oxygen Analyzer
Provides Rough Reading
Fill Oxygen Analyzer
Provides Precise Reading
Oxygen Analyzer Calibration
Gas production may be monitored with the Permeate Oxygen Analyzer before entering the HP
Compressor to obtain a rough estimate of %O2 (+/- 2%); however, do not rely on this reading as an
indication of %O2 at the HP Compressor outlet. Prior to pumping Nitrox into a Scuba cylinder or
Surface Supply System, it must be monitored with the Fill Oxygen Analyzer to obtain a precise
measurement of %O2 (+/- 1%). Both Oxygen Analyzers must be calibrated prior to each use.
Oxygen Analyzers must be calibrated before each use. See Oxygen Analyzer manuals for
correct calibration procedures. Improper calibration of the Fill Oxygen Analyzer 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 result in
the use of incorrect Nitrox mixtures, which may cause serious injury or death to the diver
using the gas mixture.
The Permeate Oxygen Analyzer supplies oxygen readings that can vary +/- 2% O2 due to heat,
humidity, and pressure changes experienced in the Nitrox flow and therefore should only be
used for rough estimates of %O2. The Fill Oxygen Analyzer supplies more accurate oxygen
readings, within +/- 1% O2. For Scuba cylinder Nitrox fills, the user must always verify the final
fill with a third independent Oxygen Analyzer.
NUVAIR www.nuvair.com
Page
20
Titan Nitrox System
Insert Clean Rag
Adjust Fill Whip
Pressure
Optional Sound Muffler for HP Nitrox Compressor
LP Feed Air
LP Feed Air
HP Compressor
Hp Compressor
Gauge
Calibrate Oxygen Analyzers as follows:
1) Turn off the LP Feed Air by rotating the feed air supply valve slowly up to the closed.
2) Slightly open fill whip valve on HP
Compressor to relieve any
residual pressure, and then , i f
desired, insert clean rag in yoke
to act as sound muffler.
3) Turn on HP Compressor and drain condensate.
4) Adjust fill whip valve so the running HP Compressor maintains 1500-2000 psi (100-140 bar) outlet
pressure. Air will now be flowing past both Oxygen Analyzers for calibration purposes.
5) Monitor all gauges for proper operating range and check all connections for leaks.
6) Calibrate Oxygen Analyzers while the HP Compressor is pumping air. Refer to the Oxygen
Analyzer manual included with the Nitrox System for details. Note that special calibration
procedures may be required when operating at altitudes above sea level.
♦ Permeate Oxygen Analyzer - Calibrate analyzer so Display reads 20.9%.
♦ Fill Oxygen Analyzer - Calibrate analyzer so Display reads 20.9% to correlate with the Grade E
breathing air present at the Sensor. Different settings may be used depending on location, so
verify your actual ambient conditions and refer to the Oxygen Analyzer manual for details.
Switch
Supply Valve
(on position)
Valve to Maintain
in Fill Whip Yoke
On/Off Switch
NUVAIR www.nuvair.com
Page
21
Fill Oxygen Analyzer - Alternate Calibration Method
Sensor Cap
Removed
Calibration
Knob
Fill Whip Attached to
Scuba Cylinder
Fill Oxygen Analyzer
The Fill Oxygen Analyzer can also be calibrated in ambient air as an
alternative. This is especially useful during routine re-calibration
while the system is operating. Different settings may be used
depending on location, so verify your actual ambient conditions and
refer to the Oxygen Analyzer manual for details.
1) Remove the Flow Adapter Cap covering the Sensor.
2) Expose the Sensor to ambient air for approximately 15 seconds.
3) Adjust Calibration Knob until Display reading stabilizes at 20.9%.
4) Re install the Flow Adapter Cap to the analyzer.
5) The Fill Oxygen Analyzer is now ready for use.
14.3 Attac hi ng Scuba Cylinder
Titan Nitrox System
Only one fill whip is attached to a Scuba Cylinder at this point. The second whip will continue
to be used to control HP Compressor outlet pressure.
Attach one HP Compressor Fill Whip to a Scuba Cylinder.
Leave Cylinder Valve closed.
Additional cylinders or storage tanks can be attached after
the system is ready to pump Nitrox.
NUVAIR www.nuvair.com
Page
22
Titan Nitrox System
Reset
Button
LP Compressor Controls
Hours
Meters
HP Compressor Controls
On/Off
Switches
Feed Air
LP Feed Air
Knob
Heater
Control
LP Feed Air
LP Feed Air
15.0 Producing Nitrox
The equipment you will be using to manufacture Nitrox (oxygen rich air) wil l 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.
15.1 Flow to Membrane
1) Verify that Oxygen Analyzer calibration is complete, Make sure the LP Feed Air Supply Valve is
in the Off position, and Regulator is set to the minimum pressure setting.
2) With the LP Compressor running allow the Volume Tank to fill up to full pressure of approximately
175 psi (12 bar). The sound will change and the rpm will increase slightly, indicating that the
Compressor is unloading.
3) Turn on HP Compressor and allow the pressure to build to abo ut 20 00 psi (140 bar ) , t hen cr ac k
open the unconnected (page 21 image) fill whip to maintain 1500-2000 psi (100-140 bar).
4) Verify that Permeate Oxygen Analyzer reads 20.9%.
5) Turn on Membrane System by slowly opening the LP Feed Air Supply Valve ( rotate down)
6) Adjust feed air pressure to approximately 100 P.S.I (7 bar) to activate Heater Pressure Switch.
Increase pressure by slowly turning the regulator Knob CW or decrease pressure by turning the
Knob CCW. Heater will not turn on until Membrane System is pressurized to above 80 PSI.
7) Verify that Heater Thermostat Control green indicator light is on. The light will remain on until
operating temperature is reached and will then cycle on and off. When light turns off, check
Heater Temperature Gauge to verify air temperature is between 105-120 ºF (40-49 ºC). At any
time that temperature exceeds 120 ºF, green indicator light should be off.
Thermostat
Turn Valve up for
Closed position
(on position shown)
(on position shown)
Pressure
Gauge
Regulator
Adjustment
Supply Valve
Supply Valve
NUVAIR www.nuvair.com
Page
23
Titan Nitrox System
Fill Oxygen Analyzer
Permeate Oxygen
The Heater Thermostat Control green indicator l ight will sta y on until operating tempe rature is
reached.
Do not change the temperature setting on the Thermosta t Control without contacting Nuvair.
Changes in temperature settings may cause Membrane damage. 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.
15.2 Setting Proper Pressure
The Membr ane System feed air pressure determines the %O2 of the Nitrox mixture. As pressure is
increased, a higher %O2 Nitrox is pumped. As pressure is decreased, a lower %O2 is pumped.
1) Increase pressure by slowly
and Permeate Oxygen Analyzer. As the pressure rises, watch the corresponding increase in the
analyzer %O
reading.
2
2) Increase or decrease pressure slowly until the Permeate Oxygen Analyzer displays the %O2
desired in the final Nitrox mixture.
3) Allow system pressure and temperature to stabilize
(approximately 5-8 minutes).
♦ Volume Tank pressure rang e sho ul d be 165-175 psi (11-12
bar).
♦ Regulated Membrane System pressure range should be 80-
165 P.S.I (6-11.5 bar), depending on Nitrox %O
produced.
♦ Heater temperature range should be 105-120 ºF (40-49 ºC).
turning the regulator Knob CW while monitoring the Pressure Gauges
being
2
Analyzer
Feed air pressure will never be higher than Volume Tank pressure.
15.3 Final Adjustments Before Pumping Nitrox
1) As the Nitrox initially makes its way through the running HP
Compressor, the %O2 reading on the Fill Oxygen Analyzer will slowly
increase to read approximately the same %O2 as the Permeate
Oxygen Analyzer. This should happen within 3-5 minutes.
2) When the two analyzers read within +/- 1%, make any final
adjustments to the Membrane System feed air pressure necessary to
obtain the exact Nitrox %O2 desired as indicated on the Fill Oxygen
Analyzer.
3) The system is now ready to pump Nitrox.
NUVAIR www.nuvair.com
Page
24
Titan Nitrox System
15.4 Pumping Nitrox
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.
The Permeate O
pressure changes in the Nitrox flow and should only be used for rough estimates of %O
Analyzer supplies more accurate readings, within +/- 1% O2. For Scuba cylinder fills, the user must
always verify the fill with a third independent O
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.
Analyzer supplies oxygen readings that can vary +/- 2% O2 due to heat, humidity, and
2
. The Fill O
2
analyzer.
2
2
Do not pump Nitrox mixtures at pressures above the HP Compressor 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.
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, hyperpurification of the Nitrox is required using an optional Oxygen Compatible Air purification system
available from Nuvair.
This Nitrox System does not produce Nitrox mixtures acceptable for 100% oxygen service.
Never fill a cylinder that is marked, “For Oxygen Service,” with Nitrox that has been produced by
anything other than 100% oxygen clean system. Filling an oxygen clean cylinder with breathing gas
containing hydrocarbons can lead to explosions if the cylinder is subsequently fill ed w it h gas mixt ures
containing gas mixtures containing greater than 40% oxygen.
Only provide Scuba cylinder Nitrox fills to customers who have proof of Nitrox training and
certification. Improper use of Nitrox can be fatal.
This system is not cleaned for oxygen service and not all components are compatible with gas
mixtures containing greater than 40% oxygen. Pumping gas mixtures containing greater than 40%
oxygen will lead to explosions which may cause severe personal injury or death.
NUVAIR www.nuvair.com
Page
25
Titan Nitrox System
GAUGE
RECOMMENDED SETTING
Compressor Gauges
According to manufacturers recommendations
Heater Temperature
105-120o F (40-49o C)
Cabinet Temperature
Less than 100o F (38o C)
Volume Tank Pressure
165-175 PSI (11-12 bar)
Membrane Feed Air Pressure
80 - 165psi (6-11.5 bar) depending on Nitrox O2%
Fill Oxygen Analyzer
Showing the proper reading for intended fill
Nitrox Storage Pressure
DO NOT exceed rating of tank or 3600 P.S.I (250 bar)
Use Independent Oxygen
Each Scuba cylinder belonging to a customer must be analyzed by that customer at the Nitrox
filling facility, using an oxygen analyzer independent of those used with the Nitrox System. An
employee must witn ess that the customer has properly an alyzed the gas in each cylinder, noted
the maximum operatin g depth for that mi xture, and signed and dated the fill log. The time of day
must also be included wit h the date, since some customers may fill th e same cylinder more than
once a day.
Pump Nitrox as follows:
1) When filling a Scuba cylinder, follow all industry standards. Do not exceed rated pressure of
cylinder, and do not exceed 360 0 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. Monitor system for proper operation:
a) Monitor Oxygen Analyzers and recalibrate as required
b) Listen for proper operation of automatic condensate drains every 10-15 minutes.
c) Monitor all system gauges as shown in the table below.
The Oxygen Analyzers may require re-calibration after 10-20 minutes of operation due to
humidity and temperature change effects on the Sensor. To recalibrate, turn off the LP Feed
Air Switch and follow calibration instructions.
When the HP Compressor auto drain engages and dumps condensate, the Fill Oxygen
Analyzer reading will decrease momentarily due to the pressure drop in the system. It will
return to its previous reading within seconds after the auto drain sequence stops.
4) After filling is complete, close cylinder valve, vent the bleed valve,
and remove the cylinder.
5) T e st the Nitrox %O2 in the cylinder using an independent Oxygen
Analyzer such as the Nuvair O2 Quickstick. Calibrate analyzer before
use in accordance with manufacturer’s instructions.
6) Repeat steps 1-5 until you have f illed all Scuba cylinders.
7) Mark each tank with fill date, %O2, fill pressure, and MOD
(Maximum Operating D epth) .
Analyzer for Verification
NUVAIR www.nuvair.com
Page
26
Titan Nitrox System
LP Feed Air
LP Feed Air
Adjustment Knob
8) 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 reading equals the
desired Nitrox %O2. Open applicable line valves and tank valve, and fill with Nitrox. Do not
exceed rated pressure of cylinder, and do not exceed 3600 psi (250 bar) under any condition.
After filling is complete, close all valves and allow Nitrox Sys tem to shut down.
15.5 Pum ping Air
To use the System to pump air, simply turn the LP Flow Ball Valve to the off position. After about 2-3
Minutes the Nitrox will exit the system and No Nitrox will be supplied to the HP Compressor, and it will
pump air only. When the HP Compressor is pumping air, the Permeate Oxygen Analyzer and the Fill
Oxygen Analyzer should both read 20.9% O2.
Supply Valve
(on position shown)
Regulator
Always use Oxygen Analyzers to monitor oxygen content of any gas flowing through the
System. Both air and Nitrox are subject to variations in oxygen content.
15.6 Shutting Down
1) When tank filling is complete and tank valves are closed, the Nitrox System will automatically shut
down at the pressure set on the Auto shut off switch at the factory ( This is set based on
purchasers directions to Nuvair) .
2) Manually shut off the Membrane System by turning the Feed Air Regulator adjustment knob CCW
to reduce pressure to minimum setting and then tur n off the LP Feed Air Valve.
3) The system will automatically drain The LP Filters and HP Compressor. The Volume Tank
condensate MUST be manually drained daily.
NUVAIR www.nuvair.com
Page
27
Titan Nitrox System
16.0 Nitrox Operation Notes
16.1 Correlation of Feed air Pressure to Oxygen Content
After the 10 hour break-in period for your Nitrox System, you will notice that specific Nitrox %O2’s
always match specific feed air pressures once the System has warmed up. These pressures will be
repeatable. If you find that the Fill Oxygen Analyzer reads 36% O2 when the feed air pressure is at
125 psi (9 bar), record this pressure or make a mark on the feed air pressure gauge indicating the
%O2. Do this for each %O2 that you normally make, making sure System has warmed up first. The
next time Nitrox with 36% O2 is needed, adjust the regulator to 125 psi (9 bar) and wait for the
Oxygen Analyzer reading to stabilize. You wil l f ind 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 oxyge n percentage prior to pumping. When
using the feed air pressure reading to obtain specific oxygen percentage, minor adjustments
of the feed air pressure regulator may be required to obtain the exact percentage desired.
16.2 Hot Fills
While in the process of filling HP Nitrox Storage Tanks, you may have a need to supply a walk-in
customer with a Scuba Cylinder fill of a different Nitrox mix. You can change mixes as follo ws:
1) With the Nitrox System operating, isolate the HP Nitrox Storage Tanks from the HP Compressor
by closing the appropriate valves.
2) Record the Membrane System feed ai r pressure reading.
3) Slightly open fill whip valve on the HP Compressor, and adjust so the running Compressor
maintains 1500-2000 psi (100-140 bar) outlet pressure.
4) Adjust the feed air regulator to the pressure corresponding to the desired Nitrox %O2 for the
Scuba Cylinder fill.
5) Allow the Fill Oxygen Analyzer reading to stabilize, make any minor adjustments necessary to
achieve the desired %O2, and then fill cylinder in normal manner.
6) When finished return regulator to previous setting, and allow the Fill Oxygen Analyzer reading to
stabilize. Make any minor adjustments necessary to achieve the desired %O2, and then resume
filling Storage Tanks.
NUVAIR www.nuvair.com
Page
28
Titan Nitrox System
HP Manual
LP Manual
17.0 Maintenance
The following list of daily and routine maintenance items is intended as a guide. Refer to LP and HP
Compressor manuals for complete maintenance requirements.
17.1 Daily Maintenance
Be sure to check Compressor Lubricant levels prior to each day of opera tion. Fai l ure to
ensure the proper lubricant level will lead to system damage.
1) Check lubricant levels of both LP and HP
Compressors and add proper lubricants as
required. See Section 17.3 and Compressor
manuals for details.
2) Operate LP and HP Purge Buttons to verify proper
operation of automatic condensate drain valves,
then slightly open each HP and LP Manual
Condensate Drain Valve to verify that no
condensate is present.
3) Check LP Air Filtration for condensate and proper
operation of condensate drains.
17.2 Routine Maintenance
Condensate
Drain Valves
Condensate
Drain Valve
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 any filtration
canister. Failure to vent pressure from the system prior to opening the canister can lead to
serious personal injury or death.
If system is located in an area where there is high humidity and high heat, the life of all
Filtration Elements may be as little as 35% of rated operating capacity. Check the Compressor
manual and Appendix for details on Filter Element Life Factors.
1) LP Compressor Lubricant: Change Compressor Lubricant every 200 hours. Only use
lubricants rated for use with Nitrox, such as Nuvair 455 TM. Never mix Compressor Lubricants.
See Section 17.3 and LP Compressor manual for details.
2) HP Compressor Lubricant: Change Compressor Lubricant every 100 hours or annually,
whichever comes first. Only use lubricants rated for use with Nitrox, such as Nuvair 455 TM.
Never mix Compressor Lubricants. See Section 17.4 and HP Compres sor manu al for det ai l s.
NUVAIR www.nuvair.com
Page
29
Titan Nitrox System
Condensate Drain Container.
3) LP Air Filtration Inspection: On a weekly basis, inspect each Filter Bowl for the presence of
moisture and each Element for any unus ual degradation or wetness. See Section 17.5 for
details.
4) L P Air Filtration Elements: Change LP Filter Elements every 200 hours. When a dryer (see
page 33) is used with the system or hot and humid environment exists this number can vary to
maintain CGA Grade D air standards. Visual liquid level and service life indicators assist with
monitoring replacement intervals. See Section 17.5 for details. If the Nitrox System is
operated in high humidity and/or high temperature, Filter Elements must be changed more
often. See Appendix for details on Filter Element Life Factors.
5) HP C ompressor Filtration Element: Change HP Filter
Element every 13,000 cubic feet of air or Nitrox processing
to maintain CGA Grade E air standards. See Section 17.6
for details. If the Nitrox System 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 Intake Filter: Inspect filter element
every 3 months for visible particles. Change every 12
months or sooner if particles are visible.
9) Oxygen Analyzers: Replace Oxygen Sensor and Battery as
required. See manual included with Nitrox System.
Check & Drain Weekly.
Do not swallow (ingest) either the electrolyte from the Oxygen Sensor or the Sensor itself.
The Potassium Hydroxide chemical contained in the Sensor can cause severe injury or death.
If electrolyte or the Sensor is swallowed, seek medical attention immediately.
If after handling the Oxygen Analyzer or Sensor, you find that your fingers or other parts of
your body feel “slippery” or the skin or eyes sting, immediately flush affected area with clean,
fresh water for at least 15 minutes. The stinging or slippery sensation is an indication of a
leaking Sensor. The Potassium Hydroxide chemical contained in the Sensor can cause severe
injury or death. Seek immediate medical attention if eye contact is made or skin stinging
persists.
10) Air/Nitrox Quality Analysis: Take breathing air/Nitrox samples quarterly for analysis to assure
compliance with CGA Gr ade E breathing air standards.
NUVAIR www.nuvair.com
Page
30
17.3 Compressor Lubricant
LP Compressor
HP Compressor
Compressor
Compressor
The LP and HP Compressors in your Nitrox System comes standard with
Nuvair 455 TM Synthetic Food Grade Compressor Lubricant. Check lubricant
levels at each Sight Gauge and add lubricant as required through the
appropriate Fill Plug. Lubricant is removed through the Drain Plugs. See LP
and HP Compressor manuals for details on servicing Lubricant.
Lubricant
Fill Plugs
Lubricant Level
Sight Gauge
Lubricant
Drain Plugs
Lubricant Level
Sight Gauge
Titan Nitrox System
NUVAIR www.nuvair.com
Page
31
Titan Nitrox System
HF7-20
HF5-20
HF1-20
Partical
Coalescing
&
&Water/Oil
Moisture
Vapor
Removal
Removal
Removal
Replacement Element Part Number
E7-20
E5-20
E1-20
Air Flow
HF5-20 Filter
Gauge
Housing
Element
Bowl
HF1-20 Filter
Should not contain water
HF7-20 Filter
Gauge
17.4 LP Feed Air Filtration
Special attention needs to be given to the arrangement of the four LP Feed Air Filtration
Elements and Bowls. Properly reinstall each Element and Bowl to the correc t Housing.
Improper sequence can cause damage to downstream components
The use of Grade D or better feed air is critical to prevent the passing of any residual oil vapor into
the Membrane System. Three st ages of Hankinson LP filtration are used to produce Grade D air:
1) Particle and Water Removal to 1 micron
2) Coalescing & Water/Oil Vapor Removal to
0.01 micron
3) Oil Vapor Removal to 0.003 PPM
LP Filtration Inspection
Open each Filter and inspect as follows:
1) Inspect Bowl for the presence of moisture.
Evidence of moisture in the HF1-20 Filter
indicates air is not cooling properly and
moisture is not properly being removed.
Excess moisture will prevent the final filter
from operating properl y.
2) Inspect Elements for any unusual
degradation or wetness. Element
degradation can indicate more serious
problems. Contact Nuvair for assistance.
with Auto-Drain
Float & DP
with Auto-Drain
Float & DP
Oil
Vapor
NUVAIR www.nuvair.com
Page
32
Titan Nitrox System
Changing LP
Changing LP Filtration Elements
Change Filter Elem ents every 200 hours. When a dryer is used with the
system or hot and humid environment exists this number can vary.
Page 37 shows the manufacturers recommendations. If the Nitrox
System is operated in high humidity and/or high temperature, Filter
Elements must be changed more often. See Appendix for details on
Filter Element Life Factors.
1) Push up on Filter Bowl, rotate counter-clockwise, and lower to
remove.
2) Gently Pull Filter Element 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. This will assist to prolong the life of the element, bowl,
and auto drain.
Titan Refrigerated Air Dryer Option (pictured)
With the addition of a Refrigerated Air Dryer you will extend the life of your Low Pressure
Filters. Outlined on page 37 is the Manufacturers reference chart of how a filter life is extended
or decreased based on tempera t ure.
NOTE: The Particular Dryer Model and Visual Appearance will vary with the different installations.
Filtration Element
NUVAIR www.nuvair.com
Page
33
Titan Nitrox System
Manual Condensate
Drain Valves
Filter Canister Cap
Filter Element
HP Compressor
Filter Canister
Filter Canister Cap
17.5 HP Compressor Filtration
The HP Compressor comes standard with Triplex f iltration, utilizing a single Filter Eleme nt. Do NOT
use any substitute. Change Filter Element every 13,000 cubic feet of air or Nitrox processing. If the
Nitrox System is operated in high humidity and/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 Condensate Valves to drain pressure. Leave Valves open.
3) Unscrew the Filter Canister Cap per the HP Compressor man ual.
4) Remove expended Element from Filter Canister and unscrew from Canister Cap.
5) Install new Element to Canister Cap and reinstall Cap to Canister.
6) Close Manual Condensate Valves.
NUVAIR www.nuvair.com
Page
34
Titan Nitrox System
Nitrox System Components
Type
Part Number
LP Compressor Consumables
Reciprocating Compressor Lubricant, Food
Grade, Nitrox Compatible
Nuvair 455, 1 Gal
(Other Sizes Available)
9406
LP Filtration Element
Hankison HF 11-20
E11-20
Hankison HF 7-20
E7-20
Hankison HF5-20
E5-20
HP Compressor Consumables
HP Compressor Lubricant,
Food Grade, Nitrox Compatible
Nuvair 455, 1 Gal
(Other Sizes Available)
9406
HP Compressor Filtration Element
Breathing Air, Grade E
X302414
Membrane System
Heater Assembl y
1200 Watt, 28" Length
H1200
Heater Thermostat Control
110V/220V
A419
Heater Pressure Switch
3100-052
Membrane
230 Series
PPA230
Air Intake Filter Element
10-16 CFM
16CP
Mixing Tube Assembly
1.5 inch diameter, specify length
Oxygen Analyzer
Pro O2
9460
Pro O2 Remote
9462
Oxygen Sensor
Pro O
Pro O2 Remote
9505
9506
Compressor Hose Coupler
1-1/4"-1-1/2" to 1-1/4"-1-1/2"
018578000476
1-1/4"-1-1/2" to 1-1/2"
RDTC40X32
Related Equipment Components
Air/Nitrox Quality Analysis Kit
Specify: (1) CGA Grade Required
(2) Single Use or Program Use
17.6 Spare Parts List
See LP and HP Compressor manuals for Compressor parts lists. Other Nitrox System components
and related items are listed below.
2
NUVAIR www.nuvair.com
Page
35
Titan Nitrox System
Date
Technician Name
Service Performed
17.7 Service Record Log
NUVAIR www.nuvair.com
Page
36
Titan Nitrox System
Item
Grade D
Grade E
Oxygen
19.5-23.5%
20-22%
Carbon Dioxide (maximum)
1000 PPM
1000 PPM
Carbon Monoxide (maximum)
10 PPM
10 PPM
Hydrocarbons (maximum)
Not specified
25 PPM
Water Vapor (maximum)
Not specified
Not specified
Dew Point (maximum) (1)
Not specified
Not specified
Oil & Particles (maximum) (2 )
5 mg/m3
5 mg/m3
Odor
None
None
Filter
Temperature
Ambient
Temperature
Filter Element
Life Factor
53ºF (12ºC)
41ºF (5ºC)
2.6 x Life
62ºF (17ºC)
50ºF (10ºC)
1.8 x Life
71ºF (23ºC)
59ºF (16ºC)
1.35 x Life
80ºF (27ºC)
68ºF (20ºC)
1 x Life
89ºF (32ºC)
77ºF (25ºC)
0.8 x Life
96ºF (36ºC)
84ºF (29ºC)
0.55 x Life
105ºF (41ºC)
93ºF (34ºC)
0.45 x Life
114ºF (46ºC)
102ºF (39ºC)
0.35 x Life
Appendix
Supply and Breathing Air Specifications
All supply and breathing air must meet the following requirements of CGA G-7.1-1997. Supply air
delivered to the Membrane System must be purified to meet Grade D or E quality, and periodic air
quality testing to assure compliance is recommended. All breathing air for diving produced by the
downstream Compressor must be purified to meet Grade E quality, and periodic air quality testing to
assure compliance is mandatory.
Notes: (1) Dew Point of supply air must be >10oF (6oC) colder than coldest ambient air expected
(2) Supply air delivered to the Membrane System must contain <0.003 PPM Oil Vapor
All breathing Nitrox produc e d for diving must be purified to meet these same requ irements, 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 testing to assure compliance
is mandatory.
Filter Element Life Factors
Breathing air filter element life is typically rated by manufacturer based on an air temperature of 80ºF
at the filter inlet. Under normal operation this temperature is 12ºF (5ºC) warm er than the ambient air,
resulting in an equivalent ambient temperature rating at 68ºF (20ºC).
To determine element life at a different ambient temperature, multiply the rated life by the life factor
listed below:
NUVAIR www.nuvair.com
Page
37
Titan Nitrox System
OWNER’S WARRANTY RESPONSIBILITIES
Failure of the owner to prevent equipment damage by complying with the pr ocedures outlined below and in the
Operation Manual will void the Nitrox System warranty.
Installation:
• All set up requirements and procedures provided in the Nitrox System Operation Manual must be
followed in their entirety including supply air cleanliness, Compressor preparation, and installation of
the Nitrox System.
• Supply air to the Membrane must be properly filtered to CGA Grade D air quality or better to prevent
damage to the Membrane. Air quality testing of the supply air should be performed periodically and
documented to assure compliance.
• If there is any doubt regarding the suitability of a HP or LP Compressor for compressing Nitrox, contact
Nuvair or the Compressor manufacturer before you connect your Nitrox System.
• If an existing HP or LP Compressor is to be used for compressing Nitrox, all traces of the old lubricant
must be removed and replaced with a Nitrox Compressor Lubricant approved by Nuvair.
• Elect r ical wiring and connections should be made by a qualified electrician in accordance with all
national and local electrical codes.
• Do not change the temperature setting on the Heater Thermostat Control. Changes in temperature
settings may cause Membrane damage.
• To prevent Compressor damage, only use the Compressor Intake 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 100
and proper rotation direction.
Operation:
• Do n ot use the Nitrox System to supply a HP or LP Compressor with Nitrox mixtures containing more
than 40% oxygen. Compressing higher concentrations of oxygen may cause severe Compressor
damage.
• Do not pump Nitrox mixtures at pressures above the Compressor manufacturer’s rating, and never
above 3600 psi (250 bar). Compressing Nitrox at higher pressures may cause severe HP Compressor
damage.
• To prevent Membrane damage, drain all low pressure filter and volum e tank condensate on a daily
basis.
• If you become aware of an operational fault, stop using the equipment immediately and contact Nuvair
for assistance.
Maintenance:
• Chang e low pressure filter elements on a schedule determined by filter capacity and ambient
temperature and humidity. Contact Nuvair if you need assistance establishing a schedule for your
equipment and location.
• Replace Membrane System Air Intake Filter on a regular basis to prevent flow obstruction.
• Keep all nuts, bolts, fittings, connectors, and clamps tight.
• Keep a service record book showing that regular maintenance work has been carried out. If a warranty
claim becomes necessary, it will aid in demonstrating that damage has not been caused by insufficient
maintenance. Proof of maintenance may be required prior to determining the validity of a warranty
request.
o
F (38 oC), sufficient clearance from adjacent walls,
NUVAIR www.nuvair.com
Page
38
Titan Nitrox System
NUVAIR NITROX SYSTEM W ARRANTY
NUVAIR extends a limited warranty, which warrants the Nitrox System to be free from defects in materials and
workmanship under normal use and service for a limited period. The specific Membrane Component of the
Nitrox System is warranted according to the pro-rated terms as set forth below. All other Original Equipment
Manufacturer (OEM) components used in the system are warranted only to the extent of t he OEM’s warranty to
NUVAIR. NUVAIR makes no warranty with respect to these OEM components, and only warrants the
workmanship that NUVAIR has employed in the installation or use of any OEM component. This warranty is
not transferable.
NUVAIR will, at it’s discretion and according to the terms as set forth within, replace or repair any materials
which fail under normal use and service and do not exhibit any sig ns of improper maintenance, misuse,
accident, alteration, weather damage, tampering, or use for any other than the intended purpose.
Determination of failure is the responsibility of NUVAIR, which will work together with the customer to
adequately address warranty issues. When any materials are repaired or replaced during the warranty period,
they are warranted only for the remainder of the original warranty period. This warranty shall be void and
NUVAIR shall have no responsibility to repair or replace damaged materials resulting directly or indir ect ly from
the use of repair or replacement parts not approved by NUVAIR.
Pro-Rated Terms:
NUVAIR warrants the Membrane Component of the Nitrox System to be free from defects in material and
workmanship for a period of thirty-six (36) months from date of installation or forty-two (42) months from date of
shipment by NUVAIR, whichever may occur first. The warranty covers parts only and is pr orated as follows:
• Firs t Year Repair or replacement free of charge
• Second Year Warranty allowance of 70% of the current Membrane Component list price
• Third Year Warranty allowance of 40% of the current Membrane Component list price
A warranty registration card, supplied with system documentation, must be filled out and submitted t o NUVAIR
for the warranty to be in full effect. If the warranty registration card is not received within thirt y (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 or paid in full.
Maintenance Items:
Any materials which are consumed, or otherwise rendered not warrantable due to processes applied to t hem,
are considered expendable and are not covered under the terms of this policy. This includes maintenance and
consumable items listed as part of a suggested maintenance program included wit h system documentation.
Return Policy:
Application for warranty service can be made by contacting NUVAIR during regular business hour s and
requesting a Return Material Authorization number. Materials that are found to be defective mus t be shipped,
freight pre-paid, to the NUVAIR office in Oxnard, California. Upon inspection and determination of failure,
NUVAIR shall exercise its options under the terms of this policy. Warranty serviced materials will be r eturned
to the customer via NUVAIR’s preferred shipping method, at NUVAIR’s expense. Any expedit ed return
shipping arrangements to be made at customer’s expense must be specified in advance.
Limitation of Warranty and Liability:
Repair, replacement or refund in the manner and within the time provided shall const it ute NUV AIR’S sole
liability and the Purchaser’s exclusive remedy resulting from any nonconformity or defect. NUVAIR shall not in
any event be liable for any damages, whether based on contract, warranty, negligence, strict liability or
otherwise, including without limitation any consequential, incidental or special damages, arising with respect to
the equipment or its failure to operate, even if NUVAIR has been advised of the possibility thereof. NUVAIR
makes no other warranty or representation of any kind, except that of title, and all other warr ant ies, express or
implied, including warranties of merchantability and fitness for a particular purpose, are hereby expressly
disclaimed. No salesman or other representative of NUVAIR has authority to make any warr ant ies.
NUVAIR www.nuvair.com
Page
39
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 01.19
Loading...