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Summary of Contents for Nuvair Voyager II
- Page 1 User Manual Voyager II & Open Voyager II Nitrox System Rev 03.19...
- Page 2 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.
- Page 3 Voyager II & Open Voyager II Nitrox System Table of Contents Introduction Introduction Safety Warnings Safety and Operation Precautions Legal Precautions Theory of Operation Low Pressure Air Compressor Technical Data High Pressure Compressor Technical Data System Components Nitrox System Specifications 10.0...
- Page 4 However, it is up to you to carefully read this manual and make the appropriate decisions about system safety. This manual will assist you in the proper set-up, operation and maintenance of the Nuvair Voyager II Nitrox System. Be sure to read the entire manual.
- Page 5 Voyager II & Open Voyager II Nitrox System 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.
- Page 6 Voyager II & Open Voyager II 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).
- Page 7 Safety and Operation Precautions can result in injuries or equipment damage. However, Nuvair does not state as fact or does not mean to imply that the preceding list of Safety and Operation Precautions is all-inclusive, and further that the observance of this list will prevent all injuries or equipment damage.
- Page 8 Voyager II & Open Voyager II Nitrox System 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.
- Page 9 Specifications for Grade D air are provided in the Appendix. The Voyager II’s Membrane System is rated for a maximum feed air pressure of 300 psi (21 bar) and has been configured to work well with the 175 psi (12 bar) maximum pressure delivered by the LP Compressor.
- Page 10 Voyager II & Open Voyager II Nitrox System Low Pressure Compressor Technical Data Capacity and Power Consumption: Normal working pressure – 80-175 psi (5.5-12 bar) Capacity at normal working pressure – 30 CFM (850 L/min) Shaft power at normal working pressure – 10.2 hp (7.65 kW) Maximum working pressure –...
- Page 11 Voyager II & Open Voyager II Nitrox System 7.0 High Pressure Compressor Technical Data Capacity and Power Consumption: • Normal working pressure – 3600 psi (250 bar) • FAD Flow 9.3CFM (265 L/min) • Charging Rate – 10.8 SCFM (307 L/min) •...
- Page 12 Voyager II & Open Voyager II Nitrox System 8.0 System Components • Low Pressure Compressor, including: • Magnet Motor Starter • Hour Meter • External Lubricant Sight Gauge, Fill, and Drain • Nuvair 546 Food Grade Rotary Screw Compressor Lubricant •...
- Page 13 Voyager II & Open Voyager II Nitrox System 9.0 Nitrox System Specifications Delivery @ 175 psi (12 bar) 30 CFM FAD (850 L/min) Horsepower – 7.5 hp Electric (5.5 kW) Height 62 in (157 cm) Width 57 in (145 cm)
- Page 14 Voyager II & Open Voyager II Nitrox System 10.0 Nitrox System Component Identification Permeate Fill Oxygen Pressure Oxygen Analyzer Gauge Analyzer LP Oil Temperature Container LP Back Access Pressure Latch Regulator Adjustment Knob - Adjust Nitrox % Here. Motor Electrical Boxes...
- Page 15 Voyager II & Open Voyager II Nitrox System High Cabinet Temp Pressure Pressure Compressor Compressor Heater Control On/Off Momentary Displays Fill Switch On Switch Pressure & Hour & Hour Stage Pressure Gauge Meter Meter Gauges LP Oil/Air HP Oil Fill...
- Page 16 Voyager II & Open Voyager II Nitrox System Refrigerated Air Dryer Analyzers LP Motor Controls HP Motor Controls Stage Pressure Gauges LP Filtration LP Oil/Air Separator HP Filtration Oil Drains www.nuvair.com Nuvair Page...
- Page 17 Voyager II & Open Voyager II Nitrox System www.nuvair.com Nuvair Page...
- Page 18 Voyager II & Open Voyager II Nitrox System System Drawing / Schematic www.nuvair.com Nuvair Page...
- Page 19 Voyager II & Open Voyager II Nitrox System 12. System Flow Chart LP Compressor Produces LP LP Aftercooler Removes Feed Air Moisture BP Regulator Controls the amount of Feed Air pumped by the compressor Refrigerated Air Drier cools Voyager II Nitrox System...
- Page 20 -The Nitrogen Discharge on the Membrane System for the Open Voyager II can also have a hose attached to re-route Nitrogen flow to a remote outlet. Pure nitrogen is a colorless, odorless, tasteless gas that will not support life.
- Page 21 Improper wiring may lead to fires, which can cause serious personal injury or death. The electrical power to the Nuvair Voyager II must be off while wiring this system for service. Failure to ensure that the electrical power is off can lead to severe personal injury and death by electrocution.
- Page 22 Voyager II & Open Voyager II Nitrox System 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.
- Page 23 Voyager II & Open Voyager II Nitrox System 14.3 Oxygen Analyzer Calibration Gas production may be monitored with the Permeate Oxygen Analyzer before entering the HP Compressor to obtain a rough estimate of %O (+/- 2%); however, do not rely on this reading as an indication of %O at the HP Compressor outlet.
- Page 24 Voyager II & Open Voyager II Nitrox System Calibrate Oxygen Analyzers as follows: 1) Turn off LP compressor and return LP Feed Air BP Regulator to minimum pressure setting by turning adjustment knob CCW until it spins freely. LP Feed Air BP...
- Page 25 Voyager II & Open Voyager II Nitrox System Fill Oxygen Analyzer - Alternate Calibration Method 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.
- Page 26 Voyager II & Open Voyager II Nitrox System 15.0 Producing Nitrox 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.
- Page 27 Voyager II & Open Voyager II Nitrox System Do not change the temperature setting on the Thermostat 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.
- Page 28 Voyager II & Open Voyager II Nitrox System 15.3 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...
- Page 29 Voyager II & Open Voyager II Nitrox System 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.
- Page 30 Voyager II & Open Voyager II Nitrox System GAUGE RECOMMENDED SETTING According to manufacturers recommendations Compressor Gauges Heater Temperature 105-120 F (40-49 Less than 100 F (38 Cabinet Temperature Volume Tank Pressure 165-175 PSI (11-12 bar) Membrane Feed Air Pressure...
- Page 31 Voyager II & Open Voyager II Nitrox System 15.5 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 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 off the LP &...
- Page 32 Voyager II & Open Voyager II 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 %O ’s always match specific feed air pressures once the System has warmed up. These pressures will be repeatable.
- Page 33 Voyager II & Open Voyager II Nitrox System 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.
- Page 34 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 Section 17.4 and HP Compressor manual for details.
- Page 35 Voyager II & Open Voyager II Nitrox System 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. Customers may specify different lubricants, check lubricant page at the back of manual for accepted lubricants.
- Page 36 Lubricant fill ports shown below for each compressor installed in the Voyager II Lubricant Fill Plugs • 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.
- Page 37 Voyager II & Open Voyager II Nitrox System 17.4 LP Feed Air Filtration Special attention needs to be given to the arrangement of the three LP Feed Air Filtration Elements and Bowls. Properly reinstall each Element and Bowl to the correct Housing.
- Page 38 Voyager II & Open Voyager II Nitrox System Changing LP Filtration Elements Change Filter Elements every 250 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.
- Page 39 Voyager II & Open Voyager II Nitrox System 17.5 HP Compressor Filtration The HP Compressor comes standard with Triplex filtration, utilizing a single Filter Element. Do NOT use any substitute. Change Filter Element 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.
- Page 40 Voyager II & Open Voyager II Nitrox System 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. Nitrox System Components Type Part Number LP Compressor Consumables...
- Page 41 Voyager II & Open Voyager II Nitrox System 17.7 Service Record Log Date Technician Name Service Performed www.nuvair.com Nuvair Page...
- Page 42 Voyager II & Open Voyager II Nitrox System 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.
- Page 43 • 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.
- Page 44 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 signs of improper maintenance, misuse, accident, alteration, weather damage, tampering, or use for any other than the intended purpose.
- Page 45 Nuvair to contact the user regarding this product. The user must notify Nuvair of any change of address by the user or sale of the product. All changes or revisions to this manual must be recorded in this document to ensure that the manual is up to date.
- Page 46 Voyager II & Open Voyager II Nitrox System NOTES: www.nuvair.com Nuvair Page...
- Page 47 Voyager II & Open Voyager II Nitrox System www.nuvair.com Nuvair Page...
- Page 48 Voyager II & Open Voyager II Nitrox System Nuvair Phone +1 805 815 4044 Fax +1 805 486 0900 1600 Beacon Place Oxnard, CA 93033 info@nuvair.com www.nuvair.com Revision 03.19...
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