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Nuvair Voyager 315 Operation Manual

Nitrox system
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Operation Manual
Voyager 315 Nitrox System
SKU 7037.6

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Summary of Contents for Nuvair Voyager 315

  • Page 1 Operation Manual Voyager 315 Nitrox System SKU 7037.6...
  • 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: Table Of Contents

    Low Pressure Compressor Technical Data ................12 High Pressure Compressor Technical Data ................13 System Components ........................ 14 Voyager 315 Specifications ...................... 16 10.0 Nitrox System Component Identification .................. 17 11.0 System Drawing / Schematic ....................22 12.0 Nitrox System Flow Chart ......................23 13.0 Installing the Nitrox System ......................
  • Page 4 Links to Additional Relevant Manuals Nuvair Pro O [Oxygen] Analyzer User Manual · SKU 9462 (https://nuvair.com/manuals/Pro_O2_Manual08.17.pdf) Nuvair Pro CO [Carbon Monoxide] Analyzer User Manual · SKU 9624 (https://nuvair.com/manuals/ProCO_Manual_Rev_03.19.pdf) Nuvair Pro CO [Carbon Dioxide] Analyzer User Manual · SKU 9617 (https://nuvair.com/manuals/Pro_CO2_Manual_Re%2003.18.pdf) Beko RAC35 Refrigerated Air Dryer User Manual ·...

  • Page 5: Introduction

    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 315 Nitrox System. Be sure to read the entire manual.

  • Page 6: Safety Warnings

    Voyager 315 Nitrox System Safety Warnings WARNING 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 7 Voyager 315 Nitrox System WARNING 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.
  • Page 8 Voyager 315 Nitrox System Abbreviations Used in This Manual: Pounds per Square Inch Cubic Feet per Minute High Pressure Rotations per Minute Low Pressure Parts per Million Oxygen L/min Liters per Minute Carbon Monoxide Oxygen Percentage of Gas Carbon Dioxide B.P.

  • Page 9: Safety And Operation Precautions

    Voyager 315 Nitrox System 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 hazardous to personnel.

  • Page 10: Legal Precautions

    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 11: Theory Of Operation

    System so it will not damage or plug the Membrane fibers. Specifications for Grade D air is provided in the Appendix. The Voyager 315 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 12: Low Pressure Compressor Technical Data

    Voyager 315 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 13: High Pressure Compressor Technical Data

    Voyager 315 Nitrox System High Pressure Compressor Technical Data CAPACITY AND POWER CONSUMPTION Normal working pressure – 3600 psi (250 bar) FAD Flow 9.3 CFM (265 L/min) Charging Rate – 10.8 SCFM (307 L/min) Compressor speed of rotation – 1550 rpm Maximum working pressure –...

  • Page 14: 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 Large oil/air cooler with exhaust fan BEKO DRYPOINT® RAC35 REFRIGERATED AIR DRYER Automatic Condensate Drain BACK PRESSURE REGULATOR CONTROLLER OF LP COMPRESSOR FEED AIR...
  • Page 15 Magnet Motor Starter Hour Meter Automatic Condensate Drains Automatic Fill Pressure Stop External Lubricant Sight Gauge, Fill, and Drain Nuvair 455 or Nuvair 751 Food Grade Compressor Lubricant High Pressure Dual (2) CAN-35 Filtration, Grade E Breathing Air Nuvair Page 15 www.Nuvair.com...

  • Page 16: Voyager 315 Specifications

    Voyager 315 Nitrox System Voyager 315 Specifications Delivery @ 175 psi (12 30 CFM FAD bar) (850 L/min) Horsepower – 10 hp (7.4 kW) Electric 62 in Height (157 cm) 57 in Width (145 cm) 32 in Depth (81 cm)

  • Page 17: Nitrox System Component Identification

    Voyager 315 Nitrox System 10.0 Nitrox System Component Identification Final Gas Output Low Pressure Filter Pack CAN 35 High Pressure Filters Condensate Drains Figure 1. Voyager 315 front panel. All gauges are labeled. Nuvair Page 17 www.Nuvair.com...
  • Page 18 Voyager 315 Nitrox System Membrane Air Intake Nitrox Membrane Gas Mixing Tube Membrane Heater Condensate Trap Permeate Sensor CO2 Scrubber Refrigerated Air Dryer Nitrogen Outlet Figure 2. Voyager 315 rear view featuring modular frame. Nuvair Page 18 www.Nuvair.com...
  • Page 19 Voyager 315 Nitrox System Figure 3 and Figure 4. Voyager 315 control panel (above). Circuit panel open (below). Nuvair Page 19 www.Nuvair.com...
  • Page 20 Voyager 315 Nitrox System High Pressure Compressor Nitrox Outlet Hose Low Pressure Compressor Figure 5. Voyager 315 side view - panel doors removed. Nuvair Page 20 www.Nuvair.com...
  • Page 21 Voyager 315 Nitrox System Nuvair Page 21 www.Nuvair.com...

  • Page 22: System Drawing / Schematic

    Voyager 315 Nitrox System 11.0 System Drawing / Schematic Nuvair Page 22 www.Nuvair.com...

  • Page 23: Nitrox System Flow Chart

    Voyager 315 Nitrox System 12.0 Nitrox System Flow Chart Nuvair Page 23 www.Nuvair.com...

  • Page 24: 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.

  • Page 25: Electrical Power Connection

    WARNING The electrical power to the Nuvair Voyager 315 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 26 Voyager 315 Nitrox System HP Compressor LP Compressor Hour Meter Hour Meter Figure 9. Compressor hour meters. 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.

  • Page 27: Air/Nitrox Quality Testing

    Voyager 315 Nitrox System Compressor Rotation Check Always turn on (bump) starter for both LP and HP Compressors and run motor very briefly to check for proper direction of rotation (see arrow on belt guard and flywheel). To bump start the rotary low pressure compressor, switch on the press emergency stop button.

  • Page 28: Pre-Operation Instructions

    Voyager 315 Nitrox System 14.0 Pre-Operation Instructions WARNING 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 death by drowning.
  • Page 29 Voyager 315 Nitrox System Figure 12. Voyager 315 EK76 oil level sight gauge and high/low indicator decal. Figure 13. Two views of high pressure compressor oil level sight glass from both sides of cabinet. Nuvair Page 29 www.Nuvair.com...

  • Page 30: Start Refrigerated Air Dryer

    Voyager 315 Nitrox System 14.1 Start Refrigerated Air Dryer Power up the refrigerated air dryer 30 minutes before operating the Voyager 315. The refrigerated dryer extends the life of the nitrox membrane low pressure filters by 100 or more hours. 14.2...
  • Page 31 Voyager 315 Nitrox System WARNING The Permeate Oxygen Analyzer supplies oxygen readings that can vary ±2% O due to heat, humidity, and pressure changes experienced in the Nitrox flow and therefore should only be used for rough estimates of %O .

  • Page 32: Attaching Scuba Cylinder

    Voyager 315 Nitrox System 1) Remove the Flow Adapter Cap covering the Sensor. 2) Expose Sensor ambient approximately 15 seconds. 3) Adjust Calibration Knob until Display reading stabilizes at 20.9%. 4) Reinstall the Flow Adapter Cap to the analyzer. Flow Adapter Cap 5) The Fill Oxygen Analyzer is now ready for use.

  • Page 33: Producing Nitrox

    NOTICE 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 34: Final Adjustments Before Pumping Nitrox

    Voyager 315 Nitrox System 3) Allow system pressure and temperature to stabilize (approximately 5-8 minutes). ♦ Regulated Membrane System pressure range should be 90–165 psi (6–11 bar), depending on Nitrox %O being produced. ♦ Heater temperature range should be 105-120ºF (40-49ºC).

  • Page 35: Pumping Nitrox

    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. DANGER This Nitrox system does not produce Nitrox mixtures acceptable for 100% oxygen service.
  • Page 36 Voyager 315 Nitrox System 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. WARNING Only provide Scuba cylinder Nitrox fills to customers who have proof of Nitrox training and certification.

  • Page 37: Recommended Setting

    4) After filling is complete, close cylinder valve, vent the bleed valve, and remove the cylinder. 5) Test the Nitrox %O in the cylinder using an independent Oxygen Analyzer such as the Nuvair O Quickstick. Calibrate analyzer before use in accordance with manufacturer’s instructions.

  • Page 38: Pumping Air

    System. Both air and Nitrox are subject to variations in oxygen content. 15.5 Automatic Compressor Shutdown The Voyager 315 uses automatic controls to shut down the system when set pressure is reached. The Dial-a-Pressure Switch indicates the system’s fill pressure. Turn the gauge knob to dial-in the desired shutdown pressure.

  • Page 39: Nitrox Operation Notes

    Voyager 315 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 percentages match specific feed air pressures once the System has warmed up. These pressures will be repeatable.

  • Page 40: Maintenance

    WARNING 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.

  • Page 41: Routine Maintenance

    17.2 Routine Maintenance 1) LP Compressor Lubricant: Change Compressor Lubricant every 500 hours. 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.

  • Page 42: Compressor Lubricant

    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 43 Lubricant fill ports shown below for each compressor installed in the Voyager 315. Figure 20. Lubrication fill plugs for each compressor. (Representative image of HP compressor)

  • Page 44: Lp Feed Air Filtration

    Voyager 315 Nitrox System • 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 lubricant fill plug.

  • Page 45: Changing Lp Filtration Elements

    Voyager 315 Nitrox System HF7-20 HF5-20 HF1-20 Particle Coalescing & & Water/Oil Vapor Moisture Vapor Removal Removal Removal Replacement Element HF7-20 HF5-20 HF1-20 Part Number E7-20 E5-20 E1-20 Figure 21. Low pressure filtration and drain valves. 17.6 Changing LP Filtration Elements Change Filter Elements every 250 hours.

  • Page 46: Hp Compressor Filtration

    (b) of the plug (c) and rotate counterclockwise. If a filter wrench (SKU TL-033) is not available, a large screwdriver can be used to unscrew the filter plug (1, Figure 24). Figure 23. Voyager 315 HP filter cannisters. Nuvair Page 46 www.Nuvair.com...
  • Page 47 Voyager 315 Nitrox System • Remove the filter plug (2, Figure 24). • Remove the first cartridge (3, Figure 24) and the second cartridge; replace both with new cartridge elements. Place pressure on each cartridge (4, Figure 24) to seat the element fully into the canister.

  • Page 48: Co 2 Scrubber Maintenance

    Voyager 315 Nitrox System 17.8 CO Scrubber Maintenance The CO Scrubber (SKU 6070.5) is equipped with: Outer Scrubber Housing Scrubber Housing Vacuum Gauge Inner Media Containment Housing Dust Containment Mat Perforated Media Containment Housing Lid After Filter Outer Housing Lid Figure 26.
  • Page 49 Voyager 315 Nitrox System When reassembling the inner media containment housing after initial fill or media change, ensure that the dust containment mat is in place under the Perforated Lid. If a rise in vacuum in the scrubber housing is indicated, the media has been compromised or a blockage has occurred prior to the scrubber housing.

  • Page 50: Spare Parts List

    EK76 300KBA035 Air Intake Filter EK76 300KBA1446 HP Compressor Consumables Food Grade Lubricant, Nitrox Compatible Nuvair 455 or Nuvair 751, 1 Gal 9406 or 9403 HP Compressor Filtration Element Breathing Air, Grade E X65247 Optional Filter Breathing Air, Grade E...

  • Page 51: Service Record Log

    Voyager 315 Nitrox System 19.0 Service Record Log Date Technician Name Service Performed Nuvair Page 51 www.Nuvair.com...

  • Page 52: Appendix

    Voyager 315 Nitrox System 20.0 Appendix 20.1 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 53 Voyager 315 Nitrox System Filter Ambient Filter Element Temperature Temperature Life Factor 53ºF (12ºC) 41ºF (5ºC) × Life 62ºF (17ºC) 50ºF (10ºC) × Life 71ºF (23ºC) 59ºF (16ºC) 1.35 × Life 80ºF (27ºC) 68ºF (20ºC) × Life 89ºF (32ºC) 77ºF (25ºC) ×...

  • Page 54: Owner's Warranty Responsibilities

    • If there is any doubt regarding the suitability of an 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.
  • Page 55 Voyager 315 Nitrox System • 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.

  • Page 56: Nuvair Nitrox System Warranty

    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.
  • Page 57 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 warranties, express or implied, including warranties of merchantability and fitness for a particular purpose, are hereby expressly disclaimed.

  • Page 58: Additional Record Of Changes

    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 59 Voyager 315 Nitrox System NOTES Nuvair Page 59 www.Nuvair.com...
  • Page 60 Voyager 315 Nitrox System Nuvair Phone +1.805.815.4044 Fax +1.805.486.0900 1600 Beacon Place Oxnard, CA 93033 USA info@nuvair.com www.nuvair.com Revision 11.19.24 Nuvair Page 60 www.Nuvair.com...

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