User and Maintenance Manual
Voyager IV
Nitrox System
Rev. 12.18
Voyager IV 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
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Introduction
1.0 Introduction
2.0 Sa fety Warnings
3.0 Safety and Operation Precautions
4.0 Legal Precautions
5.0 Theory of Operation
6.0 Low Pressure Air Compressor Technical Data
7.0 High Pressure Compressor Technical Data
8.0 System Components
9.0 Nitrox System Specifications
10.0 Nitrox System Component Identification
11.0 System Drawing/Schematic
12.0 System Flow Chart
Setup, Operation, and Maintenance
13.0 Installing the Nitrox System
13.1 Precautions
13.2 Attaching Nitrogen Discharge Hos e (Optional)
13.3 Electrical Power 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 Content
16.2 Hot Fills
17.0 Maintenance
17.1 Daily Maintenance
17.2 Routine Maintenance
17.3 Compressor Lubricant
17.4 LP Feed Air Filtration
17.5 HP Compressor Filtrat ion
17.6 Spare Parts List
17.7 Service Record Log
Appendix
Supply and Breathing Air Specifications
Filter Element Life Factors
Owner’s Warranty Responsibilities
Warranty
Additional Manual Included:
Nuvair Pro O
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Oxygen Analyzer User Manual
2
Table of Contents
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Voyager IV Nitrox System
Voyager IV Nitrox System
1.0 Introduction
Nuvair has taken extreme care in providing you with the information you will need to operate this
system. However, it is up to you to carefully read this manual and make the appropriate decisions
about system safety.
This manual will assist you in the proper setup, operation and maintenance of the Nuvair Voyager IV
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.
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Voyager IV Nitrox System
2.0 Safety Warnings
This equipment is used to provide breathing gas for the purpose of underwater life support.
Read this manual in its entirety. Failure to heed the warnings and cautions contained in this
document may result in severe injury or death.
The equipment you will be using to manufacture Nitrox (oxygen rich air) will expose you to
both low and high-pressure gas. Gas, even under moderate pressures, can cause extreme
bodily harm. Never allow any gas stream to be directed at any part of your body.
Any pressurized hose can cause extreme harm if it comes loose or separates from its restraint
(or termination) while under pressure and strikes any part of your body. Us e appropriate care
in making and handling all gas connections.
Pure nitrogen is a colorless, odorless, tasteless gas that will not support life.
Breathing gas mixtures containing more than 84% nitrogen at surface pressures
will lead to unconsciousness and may cause death.
The nitrogen discharge from the membrane system must be vented to the
exterior of any closed building, boat, or similar enclosed s pace. Breathing gas
mixtures containing more than 84% nitrogen at surface pressure will lead to
unconsciousness an d may caus e death .
Do not use any form of mineral oil or s ynthetic 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 com pressor lubricant prior to
installing the membrane system. The use of improper lubricants can lead to fire or explosi ons,
which may cause serious personal injury or death.
Do not use this system to produce Nitrox mixtures containing more than 40%
oxygen. Pumping Nitrox mixtures with higher concentrations of oxygen may
lead to fires or explosions, which can cause serious personal injury or death.
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Voyager IV Nitrox System
The use of enriched air Nitrox does not eliminate the risk of decompression sickness (DCS) in
diving. Decompression sickness can lead to permanent disability or death.
Do not pump Nitrox mixtures at pressures above the HP compressor
manufacturer’s rating, and never above 3600 psi (250 bar). The system is not
rated for pressures above 3600 psi (250 bar). Higher pressures may lead to
explosions which may cause serious personal injury or death.
Ambient room temperature should never exceed 100oF (38oC) during operation of the Nitrox
System. Operation at higher temperatures may lead to system damage and malfunction. A
damaged membrane will not produce the correct Nitrox mixture which can lead to severe
personal injury if the gas is used for diving purposes without proper analysis.
Warnings Graphics Defined:
Moving belts Electrocution Fire Eye protection Gas inhalation
Skin damage Explosion Explosion Electrocution Machinery
Abbreviations commonly used in this manual:
psi Pounds per Square Inch CFM Cubic Feet per Minute
HP High Pressure RPM Rotations per Minute
LP Low Pressure PPM Parts per Million
O2 Oxygen L/min Liters per Minute
CO Carbon Monoxide O2% Oxygen Percentage of Gas
CO2 Carbon Dioxide BP B ack Pressure
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3.0 Safety And Operation Precautions
Because a compressor is a piece of machinery with moving and rotating parts, the same precautions
should be observed as with any piece of machinery of this type where carelessness in operations or
maintenance is hazard ous to personnel. In additi on to the many obvious saf ety precautions, those list ed
below must also be observed:
1) Read all instructions co mpletely before operating any compressor or Nitrox System.
2) For installation, follow all local electrical and safety codes, as well as the National Electrical Code
(NEC) and the Occupational Safety and Health Administr ation (OSHA) standards.
3) Electric motors must be securely and adequately grounded. This can be accomplished by wiring with a
grounded, metal-clad raceway system to the compressor starter; by using a separate ground wire
connected to the bare m etal of the motor frame; or other suitable means.
4) Protect all power cables from coming in contact with sharp objects. Do not kink power cables and
never allow the cables to c ome in contact with oil, grease, hot surfaces, or chemicals.
5) Make certain that power source conforms to the requirements of your equipment.
6) Pull main electrical disconnect switch and disconnect any separate control lines, if used, before
attempting to work or perform maintenance. “Tag Out” or “Lock Out” all power sources.
7) Do not attempt to remove any parts without first relieving the entire system of press ure.
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 exces s of its rating.
11) Periodically check al l safety devices for proper operation. Do not change pressure setting or res trict
operation in any way.
12) Be sure no tools, rags or loose part s are left on the Nitrox System.
13) Do not use flammable solvents for cleaning the Air Inlet F i lters 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 K r aft 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 ins talled in the line between the compressor unit and shut-off valve.
17) Do not operate in areas where there is a possibility of inhaling carbon monoxide, carbon dioxide,
nitrogen, or flammable or toxic fumes.
18) Be careful when touchi ng the exterior of a recently run e lectric, gasoline, or dies el motor - it may be
hot enough to be painful or cause inj ury. With modern mot ors this condition is normal if operated at
rated load - modern motors ar e bui lt to operate at higher temperatures.
19) Inspect unit daily to obser ve and correct any unsafe operating conditions f ound.
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 us ed for food processing or breathing a ir
without adequate downstream filters, purifi er s and controls and periodic air qual ity testing.
22) Always use an air pressur e-regulating device at t he point of use, and do not use air pressur e greater
than marked maximum pressure.
23) Check hoses for weak or worn conditions before each use and m ake certain that all connections are
secure.
The user of any compressor or Nitrox System manufactured by Nuvair is hereby warned that failure to
follow the preceding Safety and Operation Precautions can result in injuries or equipment damage.
However, Nuvair does not st ate as fact or does not mean to imply that the preced ing list of Safety and
Operation Precautions is all -inclusive, and f urther that t he observance of this list will prevent all inj uries or
equipment damage.
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Voyager IV Nitrox System
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Voyager IV 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 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
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Voyager IV Nitrox System
5.0 Theory of Operation
The Voyager IV Nitrox System is a turnkey package that produces oxygen-rich air (Nitrox) and then
compresses it with a High Pressure (HP) Compressor to fill Scuba Tanks or storage cylinders. The
package is designed to be fully automatic, with a quieted enclosure for noise reduction and protection
from moving parts while it is running. Although it is described as the “Nitrox Compressor”, it can also
be used to pump air.
The Nitrox System allows for efficient and cost effective Nitrox production using electric power,
without the hazards or expense of blending with stored high pressure oxygen (O2). Instead, the
system uses a Semi-Permeable Membrane to produce Nitrox from air. A portion of the nitrogen in air
is separated out, leaving an oxygen rich Nitrox mixture.
The Voyager IV uses a Rotary Screw LP Compressor, Air/Oil Aftercooler, Refrigerated Air Dryer, and
Filtration to provide the Membrane System with a source of clean, pressurized feed air for separation.
The air is filtered to CGA Grade D or better air quality prior to entering the Membrane System so it will
not damage or plug the Membrane fibers. Specifications for Grade D air are provided in the
Appendix.
The Voyager IV’s Membrane System is rated for a maximum feed air pressure of 300 psi (21 bar) and
has been configured to work well with the 175 psi (12 bar) maximum pressure delivered by the LP
Compressor. A Back Pressure Regulator is used to adjust the amount of air the screw compressor
produces to meet the appropriate levels for various %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 different gases to move through them (or
permeate) at different speeds. The resulting gas mixture is known as the “permeate”. As air flows
through the hollow fibers, both oxygen and nitrogen permeate through the fiber walls. The oxygen
permeates faster than the nitrogen, which produces permeate with oxygen content greater than air.
The gas that reaches the end of the hollow fibers without permeating is almost entirely nitrogen and is
discharged. The flow rate of this discharge is set by the factory via a fixed orifice, which controls the
permeate to contain a consta nt 44% O2 under normal operating con dit ions .
The permeate is a concentrated mixture that must be diluted with additional air prior to entering the
HP Compressor. It exits the Membrane at ambient to slightly negative pressure and travels into the
Mixing Tube, where it mixes homogeneously with filtered outside air. The amount of dilution, and
thus final %O2, is obtained by adjusting the amount of air produced by the compressor and supplied
to the membrane, with the Back Pressure Regulator. As air flow to the membrane is increased,
permeate flow increases and a higher %O2 Nitrox is produced. As air flow to the membrane is
decreased, permeate flow decreases, compressor intake air increases, and a lower %O2 Nitrox is
produced.
This relationship between permeate flow and intake air flow exists because the total of these two flow
rates will always equal the intake flow rate demanded by the HP Compressor. The resulting Nitrox
mixture is analyzed for %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 S ystems 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 P.S.I. (9 bar), then adjusting the Back Pressure Regulator to 125 psi (9 bar) during
the next use will produce the same mixture.
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6.0 Low Pressure Compressor Technical Data
Capacity and Power Consumption:
• Normal working pressure – 90-175 psi (6-12 bar)
• Capacity at normal working pressure – 60 CFM (1700 L/min)
• Shaft power at normal working pressure – 20 hp (15 kW)
• Maximum working pressure – 175 psi (12 bar)
• Minimum working pressure – 44 psi (3 bar)
• Idling shaft power consumption – 4.8 hp (3.6 kW)
• Transmission – Belt drive
Cooling:
• Allowed ambient temp er atur e – 32-104°F (0-40°C)
• Compressed air tempe r ature above cooling medium temperature – 50°F (10°C)
• Cooling air flow – 1692 CFM (0.8 m³/s)
• Maximum cooling air pressure drop – 0.12 in H2O (30 Pa)
• Cooling air temperature rise – 57°F (14°C)
• Oil cooler heat rejection – (12.2 kW)
• Aftercooler heat rejection – (1.7 kW)
3-Phase Motor Class 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 Dat a:
• Oil Capacity 4 L
•
Maximum Oil Content in Air– 3 mg/m
3
Voyager IV Nitrox System
Rotary screw compresso rs a re con tinu ou s duty rat ed. They are no t mad e to ru n for sh ort in terval s
or sit without use for long periods of time. The rotary screw compressor must be run for a
minimum of one continuous hour per week in tropical settings to insure moisture does not build
up in the comp ressor. The oil fil ter and oil/air separator must be changed ever y 2000 hours or a
minimum of once per year. In tropical conditions the oil should be checked every month for
moisture by draining a small amount off the bottom of the compressor into a clear glass. If
moisture is found it can be drained off and a visual inspection should be done on all filters
checking for rust or corrosion.
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Voyager IV Nitrox System
7.0 High Pressure Compressor Tech nical Data
See Separate Manual for Coltri HP Compressor
Specs reflect “MCH 30” Model
Capacity and Power Consumption:
• Normal working pressure – 3600 psi (250 bar)
• FAD Flow 17.5 CFM (495 L/min)
• Charging Rate – 21 SCFM (595 L/min)
• Compressor speed of rotation – 950 RPM
• Maximum working pressure – Air 6000 psi (425 bar), Nitrox 3600 psi (248 bar)
• Transmission – Belt drive
Cooling:
• Allowed ambient temp er atur e – 32-105°F (0-40°C)
• Air Cooled Inters t age & Aftercooler
Motor and Electrical Values:
• Motor – 15 hp (11kw) 3-phase
• Speed of rotation – 2930 RPM @ 50 Hz / 3450 RPM @ 6 0 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 Quantity – 3.7 qt. (3.5 L)
• HP Filtration Rating – CGA Grade E, 65,000 cu ft at 68oF (20oC)
• Condensate Drains – Automatic & Manual Interstage & Final
• Fill Pressure Stop – Automatic & Manual
• Low Oil Level Shutdown
• High Temperature Shutdow n
• Interstage Pressur e G aug es
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Voyager IV Nitrox System
8.0 System Components
• Low Pressure Compressor, including:
♦ Magnetic Motor Starter
♦ Hour Meter
♦ External Lubricant Sight Gauge, Fill, and Drain
♦ Nuvair 546 Food Grade Rotary Screw Compressor Lubricant
♦ Large oil/air cooler with exhaust fan
• Refrigerated Air Dryer
♦ Automatic Condensate Drain
• Back Pressure Regulator that controls LP compressor feed air supply
♦ Supply Air Pressure Gauge 90-165 psi (6-11 bar) depending on Nitrox %O2
• Low Pressure Feed Air Filtration, Grade D Breathing Air, including four stages:
♦ Coalescing & Particle Removal to 1 micron, auto drain, liquid level indicator
♦ Water & Oil Vapor Removal to 0.01 micron, auto drain, liquid level & service life indicators
♦ Oil Vapor Removal to 0.003 PPM
• Heater including: (optional) not supplied with Nitrox Manager
♦ Thermostat Control
♦ Digital Temperature Gauge
♦ Pressure Switch
♦ 200 psi (14 bar) ASME Over Pressure Relief
• Semi-Permeable Membrane
• Mixing Tube & Air Intake Filter
• Nuvair Pro O2 Remote Permeate Oxygen Analyzer
• Nitrogen Discharge
• Nuvair Pro O2 Fill Oxygen Analyzer, including:
♦ High Pressure>Low Pressure Regulator
♦ Flow Restrictor, 1 - 5 L/min
• High Pressure Compressor, including
♦ Magnet Motor Starter
♦ Hour Meter
♦ Automatic Condensate Drains
♦ Automatic Fill Pressure Stop
♦ External Lubricant Sight Gauge, Fill, and Drain
♦ Nuvair 455 Food Grade Compressor Lubricant
• High Pressure Filtration, Grade E Breathing Air
• Air/Nitrox Quality Analysis Kit
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9.0 Nitrox System Specifications
LP
Physical
Full Load Amps
Membrane Input
HP
Voyager IV Nitrox System
Delivery @ 175 psi (12 bar)
Horsepower –
Compressor
Electric
Length
Width
Height
Specifications
Weight
230 V / E3 / 50 Hz
230 V / E3 / 60 Hz
380-415 V / E3 / 50 Hz
460 V / E3 / 60 Hz
60 CFM FA (1700 L/min)
20 hp
(15 kW)
37 in (94 cm)
68 in (173 cm)
70 in (178 cm)
1625 lb (737 kg)
95 amps
95 amps
50 amps
55 amps
Operating Pressure Range
Maximum Input Pressure
Feed Air Volume Range
Optimum Temperature
Compressor
LP Feed Air Quality
Nitrox %O2 Range
Charging Rate
Horsepower –
Electric
90-185 psi (6-12 bar)
300 psi (21 bar)
13-60 SCFM (354-1700 L/min)
Grade D
o
110 +/- 5
F (43 +/- 3oC)
24 - 40%
21 SCFM (595 L/min)
15 hp
(11 kW)
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10.0 Nitrox Voyager IV System Component Identification
Heater
High
LP Back
Here.
Low Pressure
Fill
Permeate
HP Fill Outlet
Fill
HP Compressor
Filter Canister s
Condensate
Low
HP Filter
LP Oil
Cabinet
Stage
Filter #
X65677
Filter #
X65247
HP Oil
Gauge
Pressure
Gauges
Pressure
Pressure
Gauge
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Oxygen
Analyzer
Pressure
Bleed
Page
Compressor
Momentary
On Switch
& Hour
Meter
Pressure
Compressor
On/Off
Switch
& Hour
Meter
14
Voyager IV Nitrox System
Pressure
Regulator
Adjustment
Knob - Adjust
Nitrox O
Oxygen
Analyzer
2
Thermostat
Control
%
Pressure
Gauge
Temperature
Temperature
Container with
Muffler & Drain
HP & LP Oil
LP Feed Air
HP
Final HP
HP Motor
LP Motor
Refrigerated
HP & LP Oil
LP Air
LP Oil
LP Oil/Air
Condensate
Tower
Control Electric
Box
Compressor
Lubricant
Level Sight
Gauge
Air Dryer
Fill
Drains
Filtration
(4 Stage)
Voyager IV Nitrox System
Intake
Filter
Separator
Control Electric
Box
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11.0 System Drawing / Schematic
Voyager IV
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Voyager IV Nitrox System
Nitrox System Components
Shown Within Dashed Lines
12.0 System Flow Chart
LP Aftercooler Removes
Moisture
LP Feed Air Filtration
BP Regulator Controls the
Moisture Separator in Drier
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)
Refrigerated Air Drier cools
the air
Voyager IV
Shown Within Dashed Lines
Nitrox System Components
Voyager IV Nitrox System
amount of Feed Air
pumped by the compressor
removes moisture
Heats Air to 110ºF (43ºC)
Produces Grade D Air
Air Into Permeate and
Through Fixed Orifice
located by exhaust cooling
Containing 44% O2
Ambient Air to Mixing Tube
Blower
Permeate to Create Nitrox
Containing 24-40% O
2
Monitors Nitrox before
Moisture Removal &
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Nitrox Mixture to +/- 1% O2
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Scuba Cylinder
Storage
Voyager IV Nitrox System
13.0 Installing the Voyager IV 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 severe
personal injury if the gas is used for diving purposes without proper analysis.
13.1 Precautions
1. Please read all information supplied before physically installing the Nitrox System.
2. Unpack the system and remove from the pallet. Visually inspect the system to make sure there
has been no damage during shipping. If damaged, please call Nuvair to file a damage report.
Please take photos and supply detailed information about the damage.
3. Place the system in a location that allows a minimum spacing of 18” from adjacent walls. Select a
location where ambient room temperature will never exceed 100oF (38oC).
4. The Heater Thermostat has been set in the factory. Do not adjust.
13.2 Nitrogen Discharge Hose
The nitrogen discharge from the Membrane on the
Voyager IV exits next to the exhaust air fan. The f an
pushes over 3000 CFM of exhaust air and as long as
the fan is functioning there will be no need for an
outside optional discharge, unless installed in a
properly ventilated room.
Pure nitrogen is a colorless, odorless, tasteless gas that will not support life.
Breathing gas mixtures containing more than 84% nitrogen at surface
pressures will lead to unconsciousness and may cause death.
The nitrogen discharge from the membrane should be vented to a wellventilated room or to open air with good circulation. Failure to isolate the
discharge from the air intake of the membrane system or LP compressor could
lead to incorrect Nitrox mixtures, resulting in serious personal injury or death.
If you allow this pure nitrogen to accumulate in an enclosed space, anyone entering this
space will quickly lose consciousness and will die if not immediately resuscitated.
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Voyager IV Nitrox System
HP On/Off
HP Compressor Shown
LP Hour
Meter
HP Hour
Meter
LP On/Off
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 95 amps for 230 V three-phase service
♦ Approximately 50-55 amps for 400-460 V three-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).
Note Proper Direction
of Rotation
Switch
Switch
Operation in reverse direction for extended periods of time will cause a Reciprocating
Compressor to run hot and perform poorly and may cause permanent damage. Reverse
rotation for a rotary screw compressor for even a short period of time will cause damage.
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Voyager IV Nitrox System
HP
Oil Pressure
Compressor
Check Oil
Cabinet
Feed Air
LP
Temperature
Heater
Fill
On/Off
Switches
LP Feed Air
Knob
Stage
O2
Analyzers
13.4 Check Compressor Lubricant Levels
Check lubricant levels before start ing fill operations and add lubricant as required. Us e on l y the
lubricants specified. *To read LP oil level, turn the LP Compressor knob to Start position, then
immediately to the Off position. This will cycle the LP Compressor, distributing oil throughout the
system so an accurate reading may be made.
Lubricant
Level Sight
Gauges
Level*
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 extreme ly 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 under the assumption it is a different mix.
13.5 Control Panel Controls
Compressor
Regulator
Adjustment
Pressure
Gauge
Temperature
Gauge
Pressure
Gauges
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Pressure
Gauge
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Temperature
Gauge
Compressor
Oil
Voyager IV Nitrox System
14 Pre-Oper ation of Compressor Before Producing Nitrox
14.1 Calibrate Oxygen Analyzers
Gas production is 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 from the Compressor, 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.
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Voyager IV Nitrox System
Sensor Cap
Removed
Calibration
Knob
Compressor Controls
Fill Oxygen Analyzer
Calibration Knob
Permeate Oxygen Analyzer
Provides Rough Reading
Fill Oxygen Analyzer
Provides Precise Reading
On/Off Knob for
1) Turn on the High Pressure Compressor and allow to run for 1-2 minutes or until Analyzers
stabilize.
2) Crack open the bleed valve on the side of the compressor so that the running HP Compressor
maintains 1500-2000 psi (100-400 bar) outlet pressure. Air will now be flowing past both
Oxygen Analyzers for calibr ati on pur p os es.
3) Monitor all gauges for proper operating range and check all connections for leaks.(page 20)
4) Calibrate Oxygen Analyzers while the HP Compressor is pumping air. Refer to the Oxygen
Analyzer manual included with the Nitrox S ystem for details. Note that special calibration
procedures may be required when operating at altitudes above sea level.
♦ Permeate Oxygen Analyzer – Turn calibration knob so display reads 20.9%.
a. Fill Oxygen Analyzer – Remove the Flow Adapter Cap
covering the Sensor.
b. Expose the Sensor to ambient air for approximately 15
seconds.
c. Adjust Calibration Knob until Display reading stabilizes at
20.9%.
d. Reinstall the Flow Adapter Cap to the anal yzer.
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 w ar m up period for
the Membranes to warm up and stabilize. Check the Heater
Temperature Gauge to verify air temperature rises and is between 105-120 ºF (40-49 ºC).
7) Turn off LP Compressor and Re-Calibrate The Fill Analyzer..
8) Now that the System Temperature has stabilized You must Re-Calibrate the Fill O2 Sensors.
See Step 4a above.
HP Compressor
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 and follow calibration instructions.
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Voyager IV Nitrox System
Fill Oxygen Analyzer
Permeate Oxygen
15.0 Producing Nitrox
Before using your Nitrox Syst em 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.
The equipment you will be using to manufacture Nitrox (oxygen rich air) will expose you to
both low and high pressure gas. Gas, even under moderate pressures, can cause extreme
bodily harm. Never allow any gas stream to be directed at any part of your body.
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.
15.1 Flow to Membrane and Setting Proper Pressure
The Membrane System feed air pressure determines the %O2 of the Nitrox mixture. As pressure is
increased, a higher %O
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 the final Nitrox mixture.
♦ Regulated Membrane System pressure range should be
80– 175 psi(11-12 bar), depending on Nitrox %O2 being
produced.
♦ Heater temperature range should be 105-120 ºF (40 -49 ºC).
15.2 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.
4) Now you’re ready to close Bleed Valve and open Storage System.
Nitrox is pumped. As pressure is decreased, a lower %O2 is pumped.
2
Analyzer
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Voyager IV Nitrox System
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 O2 Analyzer supplies oxygen readings that can vary +/- 2% O2 due to heat,
humidity, and pressure changes in the Nitrox flow and should only be used for rough
estimates of %O2. The Fill O2 Analyzer supplies more accurate readings, within +/- 1% O2. For
Scuba cylinder fills, the user must always verify the fill with a third independent O2 analyzer.
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.
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, hyper-purification 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. Mixing Nitrox mixtures with 100% pure oxygen may lead to fires
and / or explosions, which may cause serious personal injury or death.
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 c ontaining hydrocarbons can lead to
explosions if the cylinder is subsequently filled with gas mixtures containing
gas mixtures containing greater than 40% oxygen. Explosions may cause serious injury or
death.
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Voyager IV Nitrox System
Only provide Scuba cy linder 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.
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 witness that the customer has properly analyzed the gas in each cylinder,
noted the maximum operating depth for that mi xture, and signed and dated the fill log. The
time of day must also be included with the date, since some customers may fill the 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 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.
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Voyager IV 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)
Membrane
Feed Air Pressure
80 - 175psi (6-12 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
On/Off Knob for
LP Compressor
On/Off Knob for
4) After filling is complete, close cylinder valve, vent the bleed valve
and remove the cylinder.
5) Test the Nitrox %O2 in the cylinder using an independent Oxygen
Analyzer such as the Nuvair O2 QuickstickTM. Calibrate analyzer
before use in accordance with manufacturer’s instructions.
6) Repeat steps 1-5 until you have filled all Scuba cylinders.
7) Mark each tank with fill date, %O2, fill pressure, and MOD
(Maximum Operating D epth) .
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 Syste m to shut down.
15.4 Pumping Air
To use the System to pump air, simply turn off the LP
Compressor. 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.
HP Compressor
Analyzer for Verification
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Voyager IV Nitrox System
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.
15.5 Shutting Down
1) When the Storage Banks are finished filling and tank valves are closed, the Nitrox System will
automatically shut down at the pressure set on the pressure switch (3600 psi).
2) Manually shut off the Membrane System by turning the Feed Air Regulator adjustment knob CCW
to reduce pressure to minimum setting and then turn of f the LP & HP compressors.
3) The system will automatically drain all Filter, Compressor, and Volume Tank condensate.
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 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 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 air 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 B.P. feed air regulator to the pressure corresponding to the desired Nitrox %O2 f or 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.
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Voyager IV Nitrox System
Condensate
Filter Pressure
Drain
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 operation. Failure 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) 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.
Tank
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.
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Voyager IV Nitrox System
Condensate Drain Container. Check
17.2 Routine Maintenance
1) LP Compressor Lubricant: Change Compressor Lubricant every 1000 hours or annually. Only
use lubricants rated for use with Nitrox, such as Nuvair 546. 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.
Never mix Compressor Lubricants. See HP Compressor manual for detai ls .
3) LP Air Filtration Inspection: On a weekly basis, inspect each Filter Bowl for the presence of
moisture and each Element for any unusual degradation or wetness. See Section 17.4 for
details.
4) LP Air Filtration Elem ents: Change LP Filter Elements every 500 hours or annually to maintain
CGA Grade D air standards. Visual liquid level and service life indicators assist with monitoring
replacement intervals. See Section 17.4 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 Compressor Filtration Element: Change HP Filter
Element every 60,000 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.
10) Air/Nitrox Quality An alysis: Take breathing air/Nitrox samples quarterly for analysis to assure
compliance with C GA Gr ade E bre athi ng air st and ar ds.
& 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.
1) 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.
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Voyager IV Nitrox System
Lubricant
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.
17.3 Compressor Lubricant
• The LP Compressor in your Nitrox System comes standard with Nuvair 546 Synthetic
Food Grade Compressor Lubricant for Rotary Screw Compressors.
• The HP Compressor comes with the Nuvair 455 Synthetic Food Grade 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.
Never mix lubricants, they are differ e nt.
-Do not carry 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
compliance with the anti-pollution laws in force.
-Filter changes and oil filling must be done with the compressors OFF.
*Oil in the LP compressor should only be changed after the unit has been allowed to sit and cool for
several hours, allowing all oil to drain from the cooler in to the compressor sump.
*When filling the LP compressor with oil:
1. Fill the sump until the oil level reaches the top of the sight tube
2. Follow the procedure for the daily oil level check, turning the compressor on and off
3. Continue filling as necessary to reach the appropriate oil level
Fill Plugs
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Voyager IV Nitrox System
HF1-24
HF5-24
HF7-24
HF11-24
Oil
Coalescing
Particle
Vapor
&Water/Oil
&
Coalescing
Removal
Vapor
Moisture
Removal
Removal
Replacement Element Part Number
E1-24
E5-24
E7-24
E11-24
Air Flow
HF5-24Filters
Housing
HF1-24
Moisture
HF7-24 Filter
Bowl
HF11-24
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 correct 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. Four stages of Hankison LP filtration are used to produce Grade D air:
1) Coalescing Filter
2) Coalescing & Water/Oil Vapor Removal to 1 Particulate micron
3) Coalescing & Water/Oil Vapor Removal to 0.01 Particulate micron
4) Final Stage - 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. 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.
Excess moisture will prevent the final filter from operating properly and can lead to damage of the
membrane.
Filter with
Auto-Drain
Float & Liquid
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Level
Indicator
Filter with
Manual
Drain –
Should not
Contain
with Auto-
Drain Float &
Liquid Level/
Service
Indicators
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31
with Auto-
Drain Float &
Liquid Level
Indicator
Voyager IV Nitrox System
Element
Changing LP
Element
Changing LP Filtration Elements
Change Filter Elements every 500 hours. 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. Visual service 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. This will assist to prolong the life of the element, bowl
and auto drain.
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Filtration
32
17.5 HP Compressor Filtration
Filter Canister Caps
Manual Bleed
Condensate
3
4
5
The HP Compressor comes standard with Triplex filtration. Do NOT use any substitute. Change Filter
Elements every 60,000 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 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) Close Manual Condensate Valves.
Drain Valve
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Tank
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Voyager IV Nitrox System
33
Voyager IV Nitrox System
Nitrox System Components
Type
Part Number
LP Compressor Consumables
Rotary Screw Compressor
Nuvair 546, 1 Gal
9409
LP Filtration Element
Hankison HF11-24
E11-24
Hankison HF7-24
E7-24
Hankison HF5-24
E5-24
Hankison HF1-24
E1-24
Oil Filter
EK76
A11207674
Air/Oil Separator
EK76
300KBA035
Air Intake Filter
EK76
300KBA1446
HP Compressor Consumables
HP Compressor Lubricant, Food
Nuvair 455, 1 Gal
9406
HP Compressor Filtration
Gas Drying Filter
X65677
Breathing Air Filter, Grade E
X65247
Heater Assembly
1200 Watt, 28 in Length
H1200
Heater Thermostat Co ntr ol
220 V
Fahrenheit Gauge standard
TS-13020 F
TS-13021 C
Heater Pressure Switch
B16-947
Membrane
230 Series
PPA230
Air Intake Filter Element
10-20 CFM
18P
Mixing Tube Assembly
1.5 in diameter, specify length
Call for part.
Oxygen Analyzer
Pro O2
9460
Pro O2 Remote
9462
Oxygen Sensor
Pro O2
9505
Related Components
Specify: (1) Single Use
Or (2) 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.
Lubricant, Food Grade, Nitrox
Compatible
Grade, Nitrox Compatible
Element
Pro O2 Remote
9506
Air/Nitrox Quality Analysis Kit CGA Grade Required
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Voyager IV Nitrox System
Date
Technician Name
Service Performed
17.7Service Record Log
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Voyager IV 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 expec te d
(2) Supply air delivered to the Membrane 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 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) warmer 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:
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Voyager IV Nitrox System
OWNER’S WARRANTY RESPONSIBILITIES
Failure of the owner to prevent equipment damage by complying with the procedures outlined below and in the
User Manual will void the Nitrox System warranty.
Installation:
• All set up r equirements and procedures provided in the Nitrox System User 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 f iltered to CGA Grade D air quality or better to prevent
damage to the Membrane. Air quality testing of the supply air should be perf ormed 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 com press ing Nitrox, all traces of the old lubricant
must be removed and replaced with a Nitrox Compressor Lubricant approved by Nuvair.
• Electrical 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.
• T o prevent Compressor dam age, only use the Compressor I 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 100
proper rotation direction.
Operation:
• Do not 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). Compr essing Nitrox at higher pressures may cause severe HP Compressor
damage.
• To prevent Membrane damage, drain all low pressure filter and volume 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:
• Change 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 ser vice record book s howing that regular maintenance work has been car ried 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 (38oC), sufficient clearance from adjacent walls, and
Nuvair www.nuvair.com
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Voyager IV Nitrox System
NUVAIR NITROX SY STEM WARRANTY
Nuvair extends a limited warranty, which warrants the Nitrox System to be free f rom defects in materials and
workmanship under normal use and service for a limited period. The specific Membrane Component of the
Nitrox System is warranted accor ding 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 the 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 its 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 signs 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 indirectly 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 prorated 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 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 or paid in full.
Maintenance Items:
Any materials which are consumed, or otherwise rendered not warrantable due to processes applied to them,
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 with system documentation.
Return Policy:
Application for warranty service can be made by contacting Nuvair during regular business hours and
requesting a Return Material Authorization number. Materials that are found to be def ective must 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 returned to the
customer via Nuvair’s preferred shipping method, at Nuvair’s expense. Any expedited 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 constitut e Nuvair’s sole l iabilit y
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 make s no
other warranty or representation of any kind, except that of title, and all other warranties, 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 warranties.
Nuvair www.nuvair.com
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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
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