LP 560 & 760 Silent Rotary 420 Rotair Nitrox Operations Manual 0912

User Manual: LP-420-Rotair-Nitrox-Operations-Manual-0912

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Operation Manual
LP 420 Nitrox Generator TM
Rev. 10.12
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 2
LP 420 Rotary Screw Nitrox Generator Manual
If you have any questions on this equipment please contact Technical Support at:
Nuvair
2949 West 5th St.
Oxnard, CA 93030
Phone: 1-805-815-4044
FAX: 1-805-815-4196
Email: info@nuvair.com
Hours: Monday through Friday
8:00 AM to 5:00 PM PST USA
This operation 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.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 3
LP 420 Rotary Screw Nitrox Generator Manual
Introduction
1.0 Introduction ........................................................................................... 4
2.0 Safety Warnings System Components ................................................. 5
3.0 Safety and Operation Precautions ........................................................ 7
4.0 Legal Precautions ................................................................................. 8
5.0 Theory of Operation .............................................................................. 9
6.0 Rotary Screw Compressor Technical Data …………………….............. 10
7.0 Nitrox System Components ……………………………………………….. 11
8.0 Nitrox System Specifications ................................................................. 12
9.0 Nitrox System Component Identification…………………………............ 13
10.0 System Drawing/Schematic …………………………………………. .. 15
11.0 System Flow Chart ……………………………………………………... 16
Setup, Operation, and Maintenance
12.0 Preparing Existing H.P. Compressors ........................................... 17
12.1 Purification System Air/Nitrox Quality............................... 17
12.2 Replacement of Compressor Lubricant ............................ 17
12.3 Installation of Fill Oxygen Analyzer .................................. 18
13.0 Installing the Nitrox System .......................................................... 18
13.1 Precautions ...................................................................... 19
13.2 Attaching Compressor Intake Hose ................................. 19
13.3 Attaching Nitrogen Discharge Hose (Optional) ................ 20
13.4 Output Pressure Adjustments .......................................... 21
13.5 Refrigerated Air Drier ………………………………………. 21
13.6 Electrical Power Connection ............................................ 22
14.0 Pre-Operation Instructions ............................................................ 23
14.1 Compressor Oil Levels ..................................................... 23
14.2 Membrane System O2% Control Knob and Flow Valve..... 23
14.3 Oxygen Analyzer Calibration.............................................. 24
14.4 Attaching Scuba Cylinder ................................................. 26
15.0 Producing Nitrox ............................................................................ 27
15.1 Flow to Membrane ........................................................... 27
15.2 Setting Proper Pressure ................................................... 28
15.3 Final Adjustments Before Pumping Nitrox ....................... 28
15.4 Producing Nitrox ............................................................... 29
15.5 Pumping Air ..................................................................... 32
15.6 Shutting Down ................................................................. 32
16.0 Nitrox Operational Notes .............................................................. 33
16.1 Correlation of Input Pressure to Oxygen Content ............ 33
16.2 Hot Fills ............................................................................ 33
17.0 Maintenance ................................................................................. 34
17.1 Daily Maintenance ........................................................... 34
17.2 Routine Maintenance ...................................................... 34
17.3 Compressor Lubricant ..................................................... 36
17.4 L.P. Filtration ................................................................... 38
17.5 Spare Parts List ............................................................... 39
17.6 Service Record Log ......................................................... 40
Appendix ........................................................................................................... 41
Supply and Breathing Air Specifications ............................................. 41
Filter Element Life Factors .................................................................. 41
Material Safety Data Sheets .............................................................. 42
Owner’s Warranty Responsibilities ………………………………......... 45
Warranty …………………………………………………………………… 46
Additional Records of Change ………………………………………….. 47
Separate Manuals Included:
Nuvair Pro O2 TM Oxygen Analyzer Operation Manual
Rotair S.p.A. Operating Manual
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 4
LP 420 Rotary Screw Nitrox Generator Manual
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 set-up, operation and maintenance of the Nuvair LP 420
Nitrox system. Be sure to read the entire manual.
Throughout this manual we will use certain words and symbols to call your attention to conditions,
practices, and / 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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NUVAIR rev. 10/12 Page 5
LP 420 Rotary Screw Nitrox Generator Manual
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. Use 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 space. Breathing gas
mixtures containing more than 84% nitrogen at surface pressure will lead to
unconsciousness and may cause death.
Do not use any form of mineral oil or synthetic lubricant not rated for nitrox in
any compressor in this system. Use only the recommended nitrox compressor
lubricant. Never mix the nitrox compressor lubricant with other lubricants.
Remove all existing lubricant and replace with the proper nitrox compressor lubricant prior to
installing the membrane system. The use of improper lubricants can lead to fire or explosions,
which may cause serious personal injury or death.
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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NUVAIR rev. 10/12 Page 6
LP 420 Rotary Screw Nitrox Generator Manual
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 H.P. compressor
manufacturer’s rating, and never above 3600 P.S.I. (250 bar). The system is not
rated for pressures above 3600 P.S.I. (250 bar). Higher pressures may lead to
explosions which may cause serious personal injury or death.
Ambient room temperature should never exceed 104o F (40o C) during operation of the nitrox
system. Operation at higher temperatures may lead to system damage and malfunction. A
damaged membrane will not produce the correct nitrox mixture which can lead to severe
personal injury if the gas is used for diving purposes without proper analysis.
Warnings Graphics Defined:
Moving belts Electrocution Fire Eye protection Gas inhalation
Skin damage Explosion Explosion Electrocution Machinery
Abbreviations commonly used in this manual:
P.S.I. Pounds Per Square Inch C.F.M. Cubic Feet Per Minute
H.P. High Pressure R.P.M. Rotations Per Minute
L.P. Low Pressure P.P.M Parts Per Million
O2 Oxygen L/min Liters Per Minute
CO Carbon Monoxide O2% Oxygen Percentage of Gas
CO2 Carbon Dioxide B.P. Back Pressure
N Nitrogen
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 7
LP 420 Rotary Screw Nitrox Generator Manual
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 hazardous to personnel. In addition to the many obvious safety precautions, those listed
below must also be observed:
1) Read all instructions completely 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 Administration (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 metal 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 come 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” and “Lock Out” all power sources.
7) Do not attempt to remove any parts without first relieving the entire system of pressure.
8) Do not attempt to service any part while system is in an operational mode.
9) Do not operate the system at pressures in excess of its rating.
10) Do not operate compressor at speeds in excess of its rating.
11) Periodically check all safety devices for proper operation. Do not change pressure setting or restrict
operation in any way.
12) Be sure no tools, rags or loose parts are left on the nitrox system.
13) Do not use flammable solvents for cleaning the air inlet filters or elements and other parts.
14) Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts by
covering parts and exposed openings with clean cloth or Kraft paper.
15) Do not operate the compressor without guards, shields, and screens in place.
16) Do not install a shut-off valve in the compressor discharge line, unless a pressure relief valve, of
proper design and size, is installed in the line between the compressor unit and shut-off valve.
17) Do not operate this compressor in any location where there is a possibility of toxic levels of carbon
monoxide (CO), carbon dioxide (CO2), nitrogen (N), or any flammable or toxic fumes being sucked into
the compressor intake.
18) Be careful when touching the exterior of a recently run electric, gasoline, or diesel motor - it may be
hot enough to be painful or cause injury. With modern motors this condition is normal if operated at
rated load - modern motors are built to operate at higher temperatures.
19) Inspect unit daily to observe and correct any unsafe operating conditions found.
20) Do not “play around” with compressed air, or direct air stream at body, because this can cause
injuries.
21) Compressed air from this machine absolutely must not be used for food processing or breathing air
without adequate downstream filters, purifiers and controls and periodic air quality testing.
22) Always use an air pressure-regulating device at the point of use, and do not use air pressure greater
than marked maximum pressure.
23) Check hoses for weak or worn conditions before each use and make certain that all connections are
secure.
The user of any compressor or nitrox system 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 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.
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LP 420 Rotary Screw Nitrox Generator Manual
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 serial 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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LP 420 Rotary Screw Nitrox Generator Manual
5.0 Theory of Operation
The LP 420 Nitrox Generator TM system is a system that produces oxygen-rich air (nitrox) ready for
delivery to a High Pressure (H.P.) compressor to fill scuba tanks or storage cylinders. The package is
designed to be fully automatic with an operator overseeing the production to maintain proper Nitrox
mixtures not to exceed 40% oxygen. 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 LP 420 Nitrox Generator TM uses a rotary screw L.P. compressor, air / oil aftercooler, (optional)
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 LP 420 Nitrox GeneratorTM membrane system is rated for a maximum feed air pressure of 300
P.S.I. (21 bar) and has been configured to work well with the 175 P.S.I (12 bar) maximum pressure
delivered by the L.P. 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.
The permeate is a concentrated mixture that is diluted with air prior to entering the H.P. 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 H.P. compressor. The resulting nitrox
mixture is analyzed for O2% before entering the H.P. compressor for approximate content and again
when pumping nitrox for precise content. The H.P. compressor pumps the nitrox to a maximum
pressure of 3600 P.S.I. (250 bar) to fill scuba tanks or storage cylinders.
A unique feature of Nuvair nitrox systems is that the feed air pressure that correlates to a specific
nitrox O2% is repeatable. For example, if your H.P. 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 P.S.I. (9 bar)
during the next use will produce the same mixture.
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NUVAIR rev. 10/12 Page 10
LP 420 Rotary Screw Nitrox Generator Manual
6.0 Low Pressure Rotary Screw Compressor Technical Data
RVK15
♦ Capacity and Power Consumption:
♦ Normal working pressure – 175 P.S.I. (12 bar)
♦ Capacity at normal working pressure – 44cfm (1.25 m³/min)
♦ Shaft power at normal working pressure – 15 hp (11.6 kW)
♦ Maximum working pressure – 175 P.S.I. (12 bar)
♦ Minimum working pressure – 44 P.S.I. (3 bar)
♦ Idling shaft power consumption – 3.35 hp (2.5 kW)
♦ Transmission – Belt drive
♦ Cooling
♦ Allowed ambient temperature – 32-104°F (0-40°C)
♦ Compressed air temperature above
cooling medium temperature – 50°F (10°C)
♦ Cooling air flow – (0.8 m³/s)
♦ Maximum cooling air pressure drop – 0.12 in H2O (30 Pa)
♦ Cooling air temperature rise – (14°C )
♦ Oil cooler heat rejection – (9.2 kW)
♦ Aftercooler heat rejection – (1.3 kW)
♦ Motor and electrical values:
♦ Motor - F class, IP55, 15 hp (11.2 kW)
♦ Speed of rotation – 60Hz 3500 RPM 50Hz 2930 rpm
♦ Fuse (max) 230/380/440V 100/50/25
♦ Compressor current 230/380/440V 17 A at 440 V E3 50 Hz or 60 Hz
22 A at 380 V E3 50 Hz or /60Hz
39 A at 220 V E3 50 Hz or /60Hz
♦ Control voltage – 230 V
♦ General technical data
♦ Oil Quantity – 4 liters
♦ Oil Content – 3 mg/m3 before filtration
♦ Noise level (Cagi Pneurop) - 70dB
♦ Compressor weight – 826lbs (375 kg)
Rotary screw compressors are continuous duty rated workhorses that that are not made to run for
short intervals 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 compressor. The oil filter and oil/air separator must be changed every 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.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 11
LP 420 Rotary Screw Nitrox Generator Manual
7.0 System Components
♦ Low Pressure Rotary Screw Compressor
♦ Refrigerated Air Dyer
♦ Nuvair 546 TM Food Grade Rotary Screw Compressor Lubricant
♦ On/Off Flow Valve
♦ L.P. Compressor Output Regulator with Pressure Gauge:
♦ Adjusted Pressure Output 90-175 P.S.I. (6-12 bar) depending on Nitrox %O2
♦ Low Pressure Filtration, Grade D Breathing Air, including three stages:
♦ Coalescing & Particle Removal to 1 micron, auto drain, differential pressure indicator
♦ Water & Oil Vapor Removal to 0.01 micron, auto drain, differential pressure indicator
♦ Oil Vapor Removal to 0.003 PPM, manual drain
♦ Heater including:
♦ Thermostat Control
♦ Digital Temperature Gauge
♦ Pressure Switch
♦ Semi-Permeable Membrane – compatible with H.P. compressors rated up to 15 cfm (420
L/min)
♦ F.A.D. for 40% O2 15 CFM (420 L/min)
♦ F.A.D. for 36% O2 19 CFM (530 L/min)
♦ F.A.D. for 32% O2 26 CFM (730 L/min)
♦ Mixing Tube & Air Intake Filter
♦ Nuvair Pro O2 Remote TM Panel Mount Inline Oxygen Analyzer
♦ Compressor Intake Hose for Nitrox Compressor
♦ Nitrogen Discharge Hose (optional)
♦ Nuvair Pro O2 TM Fill Oxygen Analyzer, including:
♦ High Pressure>Low Pressure Regulator
♦ Flow Restrictor, 1 - 5 L/min
♦ Nitrox Compressor Lubricant:
♦ Nuvair 455 TM Food Grade Lubricant (standard)
♦ Nuvair 751 TM Diester Based Lubricant (optional)
♦ High pressure compressor filtration, Grade E breathing air
♦ Air/Nitrox Quality Analysis Kit
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 12
LP 420 Rotary Screw Nitrox Generator Manual
8.0 Nitrox System Specifications
Nuvair Nitrox Generator
Model LP 420
Physical
Specifications
Height
(193 cm)
Width
Depth
Weight
Electrical
Specifications
Full Load Amps
440V/E3/50-60 Hz
380V/E3/50 Hz
230V/E3/50-60 Hz
21A
24A
48A
Membrane Input
Operating
Pressure Range
(6-12 bar)
Maximum Input
Pressure
(20 bar)
Supply Air
Volume Range
(280-1250 L/min)
LP Supply Air
Quality
Optimum
Temperature
(43 +/- 3oC)
Nitrox %O2
Supplied to
Compressor
HP Nitrox Compressor
@40% UP to
15.0 CFM
(≤420 L/min)
Charging Rate
@32% Up to
Charging Rate
Horsepower -
Electric
(4.0-11 kW)
Horsepower – Gas
or Diesel
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NUVAIR rev. 10/12 Page 13
LP 420 Rotary Screw Nitrox Generator Manual
9.0 Component Identification
Control Panel
Emergency Stop
Button
Start/Stop
Buttons
Air Pressure
Regulator
Adjust O2% Here
Compressor Oil
Temperature Gauge
Pressure Gauge
Refrigerated
Air Drier Power
Switch
Hour Meter
Mixing Tube
O2 Mixing with
Air
Air Intake for Nitrox
Compressor &
Membrane System
O
2
Analyzer with
Inline Sensor
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NUVAIR rev. 10/12 Page 14
LP 420 Rotary Screw Nitrox Generator Manual
Inline Sensor
Supplying o2%
Nitrogen Outlet
Factory Set Orifice
Heater
Thermostat
Control
Regulated
Air Pressure
to Membrane
System
Nitrox Supply to
Nitrox Compressor
Attach Hose Here
Filtration
HF20-7
Coalescing
HF20-5
Fine Polishing
HF20-1
Oil Vapor Removal
Membrane
Heater
Air Flow On/Off
Valve
In On Position
Compressor Oil
Drain Hose
Condensate Drain
Bucket Drain Daily
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NUVAIR rev. 10/12 Page 15
LP 420 Rotary Screw Nitrox Generator Manual
10.0 System
Drawing/Schematic
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NUVAIR rev. 10/12 Page 16
LP 420 Rotary Screw Nitrox Generator Manual
11.0 System Flow Chart
L.P. Aftercooler Removes
Moisture
L.P. Air Filtration Produces
Grade D Air
Refrigerated Dryer Removes
and Collects Moisture and
Delivers Supply Air
B.P. Regulator Adjusts L.P.
Compressor Production
and Desired Nitrox O2%
Thermostat Controlled Heater
Heats Air to 110ºF (43ºC)
Membrane Separates Supply
Air Into Permeate and
Nitrogen Rich Gas
Permeate Exits Membrane
Containing 42-44% O2
Nitrogen Rich Gas Exits
Through Fixed Orifice
Mixing Tube Mixes Air &
Permeate to Create Nitrox
Air Intake Delivers Filtered
Ambient Air to Mixing Tube
Inline O
2
Analyzer Monitors
Nitrox before Compression
to +/- 2% O2
H.P. Nitrox Compressor with
Moisture Removal &
Filtration Compresses Nitrox
Fill O
2
Analyzer Monitors
Nitrox Mixture to +/- 1% O2
H.P. Nitrox Delivered
to Storage
H.P. Nitrox Delivered
to Scuba Cylinder
- OR -
Optional Vacuum
Pump/Blower and CO2
Scrubber
L.P. Air Compressor Produces
L.P. Supply Air
L.P. Supply On/Off Flow
Valve Controls Supply Air
LP 420 Nitrox GeneratorTM
System Components Shown
Within Dashed Lines
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NUVAIR rev. 10/12 Page 17
LP 420 Rotary Screw Nitrox Generator Manual
12.0 Preparing Existing HP Compressors
Some compressors are not suitable for compressing oxygen-rich air, i.e.,
Nitrox. Use of an unsuitable compressor may lead to possible compressor
damage and/or fires or explosion. This can lead to serious personal injury or
death. If there is any doubt regarding the use of an existing compressor, contact Nuvair or the
compressor manufacturer before you connect your Nitrox System to your machinery.
12.1 Purification System
The purification system on the existing H.P. compressor to which the Nitrox System will be installed
must produce Grade E breathing air appropriate for diving use. This is the same standard applied to
all breathing air compressors. Please make sure you place extra caution on timely replacement of
the filters in the purification system to ensure these standards at all times. Specifications for Grade E
air is provided in the Appendix.
A recent air quality test from your existing Compressor is highly recommended prior to installing the
Nitrox System. After installation, test a Nitrox sample using the Air/Nitrox Quality Analysis Kit
provided. Quarterly testing is mandatory once the System is operational.
Breathing air compressors must produce breathing air appropriate for diving
use in accordance with the appropriate CGA Grade. Periodic air quality testing
is mandatory to assure compliance.
12.2 Replacement of Compressor Lubricant
For an existing Compressor to be used with the
Membrane System, all traces of old Lubricant must be
removed and replaced with Nitrox Compressor Lubricant.
Nitrox Compressor Lubricant is compatible with both air
and Nitrox.
1) Start Compressor and run for 10 minutes to warm
Compressor Lubricant. Shut off Compressor,
remove Lubricant, and replace Lubricant Filter if
any.
2) Refill Compressor with the Nuvair Air/Nitrox
Compressor Lubricant supplied. Do not overfill.
3) After 10 hours, repeat Steps 1 and 2.
Any oil spilled during the oil and oil filter change could cause personnel to slip
and fall. Wear anti-slip footwear. Remove any traces of spilled oil immediately.
Slips and falls may cause severe personal injury or death.
Nuvair™ 751
Premium Synthetic
Diester Based
Air/Nitrox
Nuvair™ 455
Premium Synthetic
Food Grade Air/Nitrox
Compressor
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 18
LP 420 Rotary Screw Nitrox Generator Manual
Do not carry out any maintenance tasks if the compressor has just shut down.
Wait for the compressor to cool to avoid skin burns.
Recommended Nitrox Compressor Lubricant change intervals after the 10-hour flush are at 25,
50, and 100 hours. After reaching 100 hrs, change lubricant in 100 hour cycles.
Wear eye protection, gloves, and skin protection when performing
oil changes. Although the oil is not classified as a dangerous
substance, the oil can be irritating to your eyes and skin.
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 or death.
Both oil and oil filter are classified as “special wastes” and must be disposed
of properly according to applicable national and local laws. Failure to dispose
of these wastes properly can lead to death of wildlife as well as government
fines and penalties.
12.3 Installation of Fill Oxygen Analyzer
The Fill Oxygen Analyzer is installed where the Nitrox is pumped (Compressor Fill Whip, Fill Panel,
etc.) to monitor the final oxygen content. A sample stream of Nitrox is delivered to the Analyzer to
provide accurate results and prevent damage to the Analyzer. A Regulator and Flow Restrictor are
used to control the pressure and flow of the sample stream. After installation, always use the Fill
Oxygen Analyzer when pumping Nitrox to ensure proper oxygen content.
Never expose the Oxygen Analyzer sensor to pressures other than ambient or you may
damage it and/or cause false readings. A damaged sensor will not provide accurate gas
analysis. Inaccurate gas analysis can lead to serious personal injury or death when the gas
mixture that was analyzed is used for breathing.
The Nitrox sample stream is obtained at the Fill Whip location on the Compressor or Fill Panel. Tap
into the Fill Whip manifold or install a H.P. “T” fitting, then attach the inlet of the Regulator/Flow
Restrictor Assembly using H.P. hose and fittings as required (hose and fittings not included).
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NUVAIR rev. 10/12 Page 19
LP 420 Rotary Screw Nitrox Generator Manual
Mount the Fill Oxygen Analyzer in a secure location, then attach the outlet of the Regulator/Flow
Restrictor Assembly to the Analyzer using the hose provided.
If any information in this manual conflicts with any of the other manuals call our headquarters
at 805-815-4044 before proceeding.
13.0 Installing the Nitrox System
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 permanent location near the existing HP Compressor. Allow a minimum
spacing of 18” from adjacent walls. Select a location where ambient room temperature will never
exceed 105oF (40oC).
4) The Heater Thermostat has been set in the factory. Do not adjust.
5) A 13 foot corrugated Compressor Intake Hose has been provided to connect the Nitrox System to
the HP Compressor intake. If a longer hose is required, the diameter must also be increased.
Contact Nuvair for assistance.
13.2 Attaching Compressor Intake Hose
1) Only use the corrugated Compressor Intake Hose provided with the Nitrox System. If a longer
hose is required, contact Nuvair for assistance.
2) Cut the Intake Hose to proper length to reach between the Nitrox System and HP Compressor.
Reattach end fittings
3) Attach the Intake Hose to the Membrane System outlet.
4) Attach the other end of the Intake Hose to the intake of the HP Compressor and secure with the
hose clamp provided.
Do not use a compressor Intake Hose longer than 13 feet to connect the Nitrox System to the
compressor intake. Use of a longer hose will increase the amount of suction the compressor must
generate which can cause overheating and damage to the compressor. Damaged compressors can
pump impurities into the diver’s breathing gas.
Pro O
2
TM
Fill O2 Analyzer
¼” NPT H.P. Tee Fitting -
Attach in Fill Flow Path
H.P.>L.P. (100psi) Pressure
Reducing Regulator
Flow Restrictor
(1-5 L/min at 100 P.S.I. input)
L.P. Hose to
Analyzer
H.P. Compressor Setup
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LP 420 Rotary Screw Nitrox Generator Manual
Do not substitute a compressor intake hose of a smaller diameter than the supplied by Nuvair. Use of
a smaller diameter hose will increase the amount of suction the compressor must generate which can
cause overheating and damage to the compressor. Damaged compressors can pump impurities into
the diver’s breathing gas.
13.3 Attaching Nitrogen Discharge Hose (Optional)
The nitrogen discharge from the Membrane must be isolated from the air intakes of the Membrane
System and L.P. Compressor. This requirement will be met if the Nitrox System is installed in a well-
ventilated room that meets industry standards for Compressor installations. If the Nitrox System is
installed in a closed building, boat, or similar enclosed space, the nitrogen discharge must be vented
to the outside. An optional Nitrogen Discharge Hose may be needed. If your installation requires the
use of a Nitrogen Discharge Hose, please contact Nuvair for assistance.
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 well-
ventilated room or to open air with good circulation. Failure to isolate the
discharge from the air intake of the membrane system or L.P. 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.
Attach one end of the suction hose
here and the other end to the
compressor intake.
Secure Hose to Nitrox Compressor intake with Hose
Clamp as shown on this Coltri H.P. Compressor.
Nitrogen gas outlet
factory set fitting
Air/Nitrox flow to
H.P. compressor
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13.4 Output Pressure Adjustments
The L.P. compressor output is adjusted with the control regulator located on top. The control regulator
can be used to adjust the output pressure from 90-175 PSI (6-12 bar).
This output adjustment allows the system to be used with a H.P. compressor having a rated capacity
up to (see page12). If your H.P. compressor is smaller, the inlet pressures required for the Membrane
System may be lower.
13.5 Refrigerated Air Drier
1. It is best to leave the drier on at all times. If your application requires turning the drier off
when not in use, turn the drier on at least 1 hour before using.
2. Check that during operation the temperature gauge is operating in the green.
3. Listen for the solenoid valve opening and draining condensate every 5 minutes or less.
4. L.P. filter life may change drastically if the drier is not operating properly.
On/Off Switch
Temperature Gauge
Regulated
Pressure
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13.6 Electrical Power Connection
Electrical wiring and connections should be made by a qualified electrician in accordance with all
national and local electrical codes. Check all System Specifications provided in this manual.
Do not use extension cords.
Amperage Load for System
L.P. Compressor Rotation Check
Always turn on (bump) starter and run motor very briefly to
check for proper direction of rotation before operating the
compressor initially. (see arrow above pulley).
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.
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.
The cabinet power switch must be in the off position to remove the front panel of the compressor.
This switch terminates power to the compressor and electrical panel. Store the compressor with this
switch in the off position. When working on the compressor the main breaker at the power source
must be “locked out” and “tagged out” in the “Off” position. The Nitrox System has circuit breaker
protection for the compressor motor and Membrane System heater located behind the front panel.
440 V 21Amp
380 V 24 Amp
230V 48 Amp
Note Proper
Direction of Rotation
Emergency Shut
Down Switch
Adjusted Pressure
Electrical Box
Located on right side behind panel.
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14.0 Pre-Operation Instructions
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.
Do not allow air to be discharged into the nitrox storage system. Air introduced into the nitrox
storage system could cause a diver to suffer decompression sickness if the nitrox mixture is
not analyzed properly and is used underwater under the assumption it is a different mix.
14.1 Compressor Oil Levels
Check oil levels before starting the L.P. and H.P.
Compressors, and add lubricant as required.
Use only the specified lubricants in section 17.3.
14.2 Membrane System Feed Air Regulator and Flow Valve
A low pressure feed air regulator is used to reduce supply pressure
to the Membrane System to a typical range of 90–175 P.S.I. (6-12
bar). An On/Off Flow Valve is used to control the flow of L.P.
supply air into the Membrane System. Prepare the Membrane
System as follows:
1) Reduce input pressure to minimum pressure setting by
turning the B.P. regulator adjustment knob counter-
clockwise (CCW) until it spins freely.
2) Turn B.P. regulator knob clockwise (CW) until you first feel resistance,
which means that the spring is starting to compress.
3) Make sure the ON/OFF feed air supply valve is in the off position.
On/Off Flow Valve
Handle in On Position
Check LP
Compressor
Oil Level
L.P. Feed Air
B.P. Regulator
Adjustment Knob
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14.3 Oxygen Analyzer Calibration
Gas production is monitored with the permeate oxygen analyzer before the compressed gas enters
the H.P. compressor to obtain a rough estimate of O2% (+/- 2%). Do not rely on this reading as a
proper indication of percentage of oxygen at the H.P. 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. It may not be possible to achieve all desired mixtures at altitude. 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 cylinder nitrox fills, the user must always verify the final fill
with a third independent oxygen analyzer.
In-line Oxygen Analyzer
Provides Rough Reading
Fill Oxygen Analyzer
Provides Precise Reading
Calibration Knob
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14.3 continued - Calibrate Oxygen Analyzers as follows:
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 H.P. compressor
maintains 1500-2000 P.S.I. (100-136 bar) outlet pressure. Air will now be flowing past both
oxygen analyzers for calibration purposes.
3) Monitor all gauges for proper operating range and check all connections for leaks.
4) Calibrate oxygen analyzers while the H.P. compressor is pumping air. Refer to the oxygen
analyzer manual included with the nitrox generator for details. Note that special calibration
procedures may be required when operating at altitudes above sea level.
5) Fill 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 analyzer.
e. The fill oxygen analyzer is now ready for use.
Different settings may be used depending on heat; humidity and
altitude verify your actual ambient conditions and refer to
the oxygen analyzer manual for details.
6) Turn on the L.P. compressor and increase the pressure to
a minimum of 90 P.S.I.
7) Allow the compressors to run for a 10 minute warm 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).
8) Now that the system temperature has stabilized, you must recalibrate the fill O2 analyzer.
See step (5a) above for calibration.
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 L.P. feed
air and follow calibration instructions.
Insert Clean Rag
in Fill Whip Yoke
Adjust Fill Whip
Valve to Maintain
Pressure
Optional Sound Muffler for H.P. Nitrox Compressor
Fill O2 Analyzer
Sensor cap
Calibration
knob
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14.4 Attaching Scuba Cylinder
Only one fill whip is attached to a Scuba Cylinder at this point. The second whip will continue
to be used to control H.P. Compressor outlet pressure.
1. Attach a H.P. compressor fill whip to a scuba cylinder.
Leave the cylinder valve closed.
2. Additional cylinders or storage tanks can be attached
after pre-operation is complete.
High-pressure cylinders that are filled quickly will become hot and due to the increased
internal temperature the cylinder pressure will increase. This will leave a diver with less
pressure inside the cylinder once cooling has occurred. This will decrease the amount of time
the diver may spend underwater which may be critical during a deep dive. Customers must be
warned of this possibility if cylinders are delivered for use while warm. Always fill all breathing
gas cylinders slowly to avoid overheating.
Fill Whip Attached to
Scuba Cylinder
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15.0 Producing Nitrox
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 or applicable
standards for intended use. 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 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.
15.1 Flow to Membrane
1) Verify that Oxygen Analyzer calibration is complete.
2) Check that On/Off Feed Valve is in the Off position.
3) Turn on L.P. Compressor using On/Off Switch and allow system
to build up pressure until it unloads
4) Turn on your H.P. compressor. Allow outlet pressure to build up
to approximately 2300 P.S.I., then crack open the unconnected
fill whip to maintain 1500-2300 P.S.I.
5) Verify that Inline oxygen analyzer reads 20.9%.
6) Turn on Membrane System by slowly opening the On/Off Flow
Valve.
7) Adjust input pressure to approximately 100 P.S.I to activate
Heater Pressure Switch. Increase pressure by slowly turning
the B.P. regulator knob clockwise or decrease pressure by
turning the B.P. knob counter clockwise.
8) Verify that heater thermostat control green indicator light is on.
The light will remain on until operating temperature is reached
and will then cycle on and off. When light turns off, check
Heater Temperature Gauge to verify air temperature is between
105-120ºF (40 -49oC). Temperature is preset at the factory and
changes to the thermostat control should not be required.
LP Compressor
On/Off Switch
Regulated
Pressure
Gauge
Heater Temperature
Gauge
Heater Thermostat
Control
Safety Pressure
Switch
Heater
On/Off Flow Valve
Handle in On Position
B.P. Regulator
Adjustment Knob
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LP 420 Rotary Screw Nitrox Generator Manual
The On/Off Flow Valve on the Nitrox Membrane System must be opened slowly. A sudden
rush of gas can damage the Membrane and other system components.
The Heater Thermostat Control green indicator light will stay on until operating temperature is
reached.
15.2 Setting Proper Pressure
The input pressure to the Membrane System determines the %O2 of the
Nitrox mixture produced. As input pressure is increased, a higher %O2
Nitrox is pumped. As pressure is decreased, a lower %O2 Nitrox is pumped.
1) Increase input pressure by slowly turning the Regulator knob
clock wise while monitoring the Pressure Gauges and Inline
Oxygen Analyzer. As the pressure rises, watch the
corresponding increase in the Analyzer %O2 reading.
2) Increase or decrease pressure slowly until the Inline Oxygen
Analyzer displays the %O2 desired in the final Nitrox mixture.
3) Allow system pressure and temperature to stabilize
(approximately 5-8 minutes).
♦ Regulated Membrane System pressure range should be
90– 175 P.S.I (6-12 bar), depending on Nitrox %O2 being
produced.
♦ Heater temperature range should be 105-120 ºF (40-49 ºC).
15.3 Final Adjustments Before Pumping Nitrox
1) As the Nitrox initially makes its way through the running Nitrox
Compressor, the %O2 reading on the Fill Oxygen Analyzer will slowly
increase to read approximately the same %O2 as the Inline 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 input 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.
Inline Oxygen Analyzer
Fill Oxygen Analyzer
Regulated
Pressure
Gauge
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15.4 Producing 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 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 H.P. compressor rating,
and never above 3600 P.S.I. (250 bar). The system is not rated for pressures
above 3600 P.S.I. (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 containing 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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Only provide scuba cylinder nitrox fills to customers who have proof of nitrox training and
certification. Improper use of nitrox can cause severe personal injury or death.
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 mixture, 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.
Pump Nitrox as follows:
1) When filling a scuba cylinder, follow all industry standards. Do not exceed rated pressure of
cylinder, and do not exceed 3600 P.S.I. (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 L.P. feed
air switch and follow calibration instructions.
When the H.P. 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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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
90 – 175 P.S.I. (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)
4) After filling is complete, close the 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 the 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 M.O.D.
(Maximum Operating Depth).
8) Log every nitrox fill to document the following information:
• Fill date and time of day
• Tank serial number
• Supplier checks oxygen content (O2%) adds signature and date
• User checks oxygen content (O2%) adds signature and date
• Fill pressure is noted
• M.O.D. (Maximum Operating Depth) is noted by user in their handwriting
• Nitrox certifying agency and card number is noted
9) When filling a H.P. 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 P.S.I. (250 bar) under any condition.
After filling is complete, close all valves and allow nitrox system to shut down.
High-pressure cylinders that are filled quickly will become hot and due to the increased
internal temperature the cylinder pressure will increase. This will leave a diver with less
pressure inside the cylinder once cooling has occurred. This will decrease the amount of time
the diver may spend underwater which may be critical during a deep dive. Customers must be
warned of this possibility if cylinders are delivered for use while warm. Always fill all breathing
gas cylinders slowly to avoid overheating.
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.
Use independent oxygen
analyzer for verification
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15.5 Pumping Air
To use the system to pump air, simply move the On/Off flow valve to the off position. No nitrox will be
supplied to the H.P. compressor, and it will pump air only. When the H.P. compressor is pumping air,
the permeate oxygen analyzer and the fill oxygen analyzer should both read 20.9% O2.
Always use Oxygen Analyzers to monitor oxygen content of any gas flowing through the
System. Both air and Nitrox are subject to variations in oxygen content.
15.6 Shutting Down
1) Shut off the Nitrox Membrane System by turning the regulator adjustment knob counter clockwise
to reduce input pressure to minimum setting and then closing the on/off flow valve.
2) Manually drain all filter, compressor, and optional volume tank condensate drains.
3) Turn off L.P. compressor on/off switch. The compressor will go into shut down mode.
4) Turn off H.P. compressor when it has returned to pumping air, as determined by a fill Oxygen
Analyzer reading close to 20.9% O2.
On/Off Flow Valve
Handle in On Position
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16 Nitrox Operation Notes
• Ensure all personnel who operate the system are properly trained in its use.
• Keep a log with details of each cylinder filled with nitrox, including the time and
date, name of operator of system, name and certification number of diver, gas
analysis, MOD, and cylinder pressure.
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 oxygen
percentages always match specific feed air pressures once the system has warmed up. These
pressures and percentages will be repeatable. If you find that the fill oxygen analyzer reads 36% O2
when the feed air pressure is at 125 P.S.I. (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
P.S.I. (9 bar) and wait for the oxygen analyzer reading to stabilize. You will find the analyzer reading
to be very close to 36% O2, requiring only minor adjustments of the regulator to achieve the exact
desired O2%.
Use the fill oxygen analyzer to verify the nitrox oxygen percentage prior to pumping. When
using the feed air pressure reading to obtain specific oxygen percentage, minor adjustments
of the feed air pressure regulator may be required to obtain the exact percentage desired.
16.2 Hot Fills
While in the process of filling H.P. 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 follows:
1) With the nitrox system operating, isolate the H.P. nitrox storage tanks from the H.P. compressor
by closing the appropriate valves.
2) Record the membrane system feed air pressure reading.
3) Slightly open fill whip valve on the H.P. compressor, and adjust so the running compressor
maintains 1500-2000 P.S.I. (100-136 bar) outlet pressure.
4) Adjust the backpressure feed air regulator to the pressure corresponding to the desired nitrox
O2% for the scuba cylinder fill.
5) Allow the fill oxygen analyzer reading to stabilize, make any minor adjustments necessary to
achieve the desired O2%, and then fill cylinder in normal manner.
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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17 Maintenance
The following list of daily and routine maintenance items is intended as a guide. Refer to L.P. and
H.P. 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 L.P. and H.P. compressors and add proper Lubricants as required.
See Section 17.3 and compressor manuals for details.
2) Check H.P. compressor filtration for condensate and proper operation of condensate drains.
Refer to H.P. compressor manual for details.
3) Check L.P. filtration for condensate and proper operation of condensate drains.
17.2 Routine Maintenance
Use only the specified Nuvair lubricants in this system. The use of
incompatible lubricants presents a risk of fire and/or explosion, and may result
in system damage. This can lead to severe personal injury and death.
Be sure that all pressure has been relieved from the system prior to opening
any filtration canister. Failure to vent pressure from the system prior to opening
the canister can lead to serious personal injury or death.
If system is located in an area where there is high humidity and high heat, the life of all
filtration elements may be as little as 35% of rated operating capacity. Check the compressor
manual and appendix for details on filter element life factors.
1) L.P. Compressor Lubricant: Change compressor lubricant after 50 hours and then every 1000
hours or annually. Only use lubricants rated for use with nitrox, such as Nuvair 546 TM. Never mix
compressor lubricants. See Section 17.3 and L.P. compressor manual for details.
2) L.P. 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
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Special attention needs to be given to the arrangement of the four L.P. Air Filtration Elements
and Bowls. Properly reinstall each Element and Bowl to the correct Housing. Improper
sequence can cause damage to downstream components.
3) L.P. Air Filtration Elements: Change L.P. filter elements every 500
hours or annually to maintain CGA Grade D air standards. Visual
liquid level and differential pressure 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.
4) Semi-Permeable Membrane: No maintenance required.
Service life exceeds 20 years if L.P. air filtration is properly
serviced to maintain oil free Grade D air standards.
5) Membrane System Air Intake Filter: Inspect filter element every 3
months for visible particles. Change every 12 months or sooner if
particles are visible.
6) Oxygen Analyzers: Replace oxygen sensor and battery as required.
See separate manual included with Nitrox System.
Do not swallow (ingest) either the electrolyte from the oxygen sensor or the sensor itself. The
Potassium Hydroxide chemical contained in the sensor can cause severe injury or death. If
electrolyte or the Sensor is swallowed, seek medical attention immediately.
If after handling the oxygen analyzer or sensor, you find that your fingers or
other parts of your body feel “slippery” or the skin or eyes sting, immediately
flush affected area with clean, fresh water for at least 15 minutes. The stinging
or slippery sensation is an indication of a leaking Sensor. The Potassium
Hydroxide chemical contained in the sensor can cause severe injury or death. Seek
immediate medical attention if eye contact is made or skin stinging persists.
Air Intake
Filter
DP Indicator Changes from
Green to Red as Filter Ages.
Do Not Use When Red.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 36
LP 420 Rotary Screw Nitrox Generator Manual
17.3 L.P. Compressor 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 or death.
The following items are not integral parts of the Nitrox System, but proper maintenance is required to
assure optimum performance.
1) H.P. Compressor Lubricant: Change H.P. compressor lubricant every 100 hours of operation in
accordance with manufacturer’s guidelines. Only use Lubricants rated for use with Nitrox, such as
Nuvair 455 TM or 751 TM. Never mix compressor lubricants. Refer to H.P. compressor manual for
details.
2) Breathing Air Filters: Change H.P. compressor filter elements in accordance with manufacturer’s
guidelines to maintain CGA Grade E breathing air standards.
3) Air/Nitrox Quality Analysis: Take breathing air/Nitrox samples quarterly for analysis to assure
compliance with CGA Grade E breathing air standards.
Lubricant
Level
Dipstick
Air/Oil
Separator
Compressor
Intake Filter
Oil Filter
Oil Drain valve is
behind pump and
requires you to reach
around right side to
drain. (picture above
shows rear panel off
for visual reference)
Lubricant
Drains at
the rear of
compressor
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 37
LP 420 Rotary Screw Nitrox Generator Manual
17.3 L.P. Compressor Lubricant
The L.P. compressor in your nitrox system comes standard with Nuvair 546TM 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.
To access the lubricant level sight gauge, filter, and drain, the front panel of the cabinet must be
opened. Turn off all electrical power to Nitrox System before opening cabinet. See L.P. compressor
manual for details on servicing lubricant and filter.
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 or death.
Nuvair 546
Rotary Screw Air Intake Filter
Rotair RVK 15 LP-420
162-0075-S
Rotary Screw Air Oil Separator
Rotair RVK 15 LP-420
157-170-S
Rotary Screw Pre-Filter
Rotair RVK 15 LP-420
157-172-S
Rotary Screw Oil Filter
Rotair RVK 15 LP-420
099-012-S
Lubricant
Filter
Oil Drain valve is
behind pump and
requires you to
reach around right
side to drain.
(picture right shows
rear panel off for
visual reference)
Lubricant
Level
Dipstick
Air/Oil
Separator
Compressor
Intake Filter
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 38
LP 420 Rotary Screw Nitrox Generator Manual
17.4 L.P. Filtration
Special attention needs to be given to the arrangement of the four L.P. 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. Three stages of Hankison L.P.
filtration are used to produce Grade D air:
1) Coalescing & Particle Removal to 1 micron
(Model No. HF7-20)
2) Water & Oil Vapor Removal to 0.01 micron
(Model No. HF5-20)
3) Oil Vapor Removal to 0.003 PPM (Model No.
HF1-20)
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 HF7 or HF5 filter indicates improper
operation of auto-drain floats. Any evidence of moisture in
the HF1 Filter indicates the air is not cooling properly and
moisture is not properly being removed. Excess moisture will
prevent the final filter from operating properly.
2. Inspect Elements for any unusual degradation or wetness.
Element degradation can indicate more serious problems.
Contact Nuvair for assistance,
Changing 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 DP indicators on
the HF7 and HF5 filters assist with monitoring replacement
intervals.
1) Push up on the Bowl, rotate CCW, and lower to remove.
2) Gently rotate 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.
HF7-20
Coalescing
& Particle
Removal to
1 micron
HF5-20
Water & Oil
Vapor
Removal to
0.01 micron
HF1-20
Oil Vapor
Removal
to 0.003
PPM
Air Flow
HF7 & HF5 Filters with Auto-
Drain Floats & Differential
Pressure Indicators.
Housing
Element
Bowl
HF1 Filter with
Manual Drain –
Should not
contain moisture
Differential Pressure Indicator
Changes from Green to Red as Filter
Ages. Do Not Use When Red.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 39
LP 420 Rotary Screw Nitrox Generator Manual
17.5 Spare Parts List
See Rotary Screw compressor manual for L.P. compressor parts list. Other Nitrox System
components and related items are listed below.
Nitrox System Components
Type
Part Number
Rotary Screw Compressor Lubricant, Food
Grade
Nuvair 546, 1 Gal
(Other Sizes Available)
9409
L.P. Filtration Element
Hankison HF 7-20
E7-20
Hankison HF 5-20
E5-20
Hankison HF 1-20
E1-20
Rotary Screw Air Intake Filter
Rotair RVK15 LP-420
162-0075-S
Rotary Screw Air Oil Separator
Rotair RVK15 LP-420
157-170-S
Rotary Screw Pre-Filter
Rotair RVK15 LP-420
157-172-S
Rotary Screw Oil Filter
Rotair RVK15 LP-420
099-012-S
Heater Assembly
2400 Watt, 38" Length
H2400
Heater Thermostat Control
110V/220V
A419
Heater Pressure Switch
3100-052
Membrane
250 Series
NUV250
Air Intake Filter Element
LP420
18P
Mixing Tube Assembly
2 inch
Oxygen Analyzer
Pro O2
9450
Pro O2 Remote Panel Mount
9460
Oxygen Sensor
See Analyzer Owners Manual
Compressor Hose Coupler
1-1/4"-1-1/2" to 1-1/2"
RDTC40X32
1-1/2" to 2"
RC50X40
Membrane to compressor suction hose
2” suction hose
2ARH
Related Equipment Components
Air/Nitrox Quality Analysis Kit
Specify: (1) CGA Grade Required
(2) Single Use or Program Use
Air/Nitrox Compressor Lubricant
Reciprocating Compressor, Food Grade
Nuvair 455, 1 Gal
9406
Reciprocating Compressor, Diester Based
Nuvair 751, 1 Gal
9403
(Other Sizes Available)
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 40
LP 420 Rotary Screw Nitrox Generator Manual
17.6 Service Record Log
Date
Technician Name
Service Performed
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 41
LP 420 Rotary Screw Nitrox Generator Manual
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 Nitrox 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.
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
Notes: (1) Dew Point of supply air must be >10oF (6oC) colder than coldest ambient air expected
(2) Supply air delivered to the Membrane System must contain <0.003 PPM Oil Vapor
All breathing Nitrox 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:
Filter Inlet
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
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 42
LP 420 Rotary Screw Nitrox Generator Manual
Material Safety Data Sheet
Nuvair™ 546 Premium Synthetic Food Grade Air/Nitrox Compressor Lubricant
Effective Date: 03/19/2010
Supersedes:
I. Product Identification:
Trade Name: …………………………………. Nuvair 546
Chemical Name: …………………………...... Polyalphaolefin
Chemical Family: ………………………...….. Synthetic hydrocarbon
II. Components & Hazard Statement:
This product is non-hazardous. This material is not considered hazardous by the OHSA Hazard Communication
Standard (29 CFR 1910.1200)
III. Physical Data:
Viscosity: ...................................................... 46 cSt. @ 40°C
Specific Gravity (Water = 1.0): ..................... 0.84
Boiling Point: ................................................ Not Determined
Vapor Pressure: ........................................... Negligible
Appearance & Odor: .................................... Clear & odor Mild
Solubility in Water: ....................................... Negligible
Other Data: ................................................ Non-Toxic USDA H-1 Approved
IV. Fire & Explosion Hazard Data:
Flash point: .................................................. 500°F / 260°C
Auto ignition Temperature: ........................... Not Determined
Flammability Limits: ..................................... Not Determined
Extinguishing Media: ................................... Dry Chemical; CO2 Foam; Water Spray
Special Fire Fighting Procedure: ………….. Burning may produce irritating/noxious fumes. Firefighters should use
NIOSH/MNSA approved self-contained breathing apparatus. Use water
to cool fire-exposed containers to prevent pressure build-up.
V. Reactivity Data:
Stability: ………………….…………………... Stable under normal conditions.
Materials to Avoid: ...................................... Incompatible with oxidizing agents.
Hazardous Decomposition Products: …...... Carbon monoxide, Carbon dioxide
VI. Health Information:
Eye Contact: ............................................... Flush eyes with water for 15 minutes. Call physician if irritation develops.
Skin Contact: ............................................... Wash skin with soap and water.
Inhalation: .................................................... Remove to fresh air.
Ingestion: ..................................................... First aid not normally required. If uncomfortable, call physician.
VII. Health Hazard Data:
Exposure Limit: ............................................ Not Applicable
Effects of Overexposure: ……………………. Low oral and dermal toxicity. Prolonged or repeated exposure may
cause irritation, nausea, and vomiting.
VIII. Employee Protection:
For general personal hygiene, wash hands thoroughly after handling material. Avoid contact with skin and eyes.
Chemical impervious gloves are not required, but may be recommended for prolonged exposure.
Use in a well ventilated area.
IX. Storage, Spill, & Disposal Procedures:
Storage: ………………………………………. Store in clean, dry area.
Spills: …………………………………………. Use absorbent materials to soak up fluid.
Disposal: ……………………………………… Incinerate this product and all associated wastes in a licensed facility in
accordance with Federal, state, and local regulations.
X. Hazard Rating Information:
NFPA Health: ………………………….. 0
Flammability: ……..................... 1
Reactivity: ……………….….….. 0
Personal Protection: ………….. B
This information contained herein is based on the data available to us and is believed to be true and accurate. Nuvair
makes no warranty, expressed or implied, regarding the accuracy of this data or the results to be obtained from the use
thereof. Nuvair assumes no responsibility for injury from the use of this product.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 43
LP 420 Rotary Screw Nitrox Generator Manual
Material Safety Data Sheets
Nuvair™ 455 Premium Synthetic Food Grade Air/Nitrox Compressor Lubricant
Effective Date: 03/19/2010
I. Product Identification:
Trade Name: …………………………………. Nuvair 455
Chemical Name: …………………………...... Polyalphaolefin
Chemical Family: ………………………...….. Synthetic hydrocarbons/Esters
II. Components & Hazard Statement:
This product is non-hazardous. This material is not considered hazardous by the OHSA Hazard Communication
Standard (29 CFR 1910.1200).
III. Physical Data:
Viscosity: ...................................................... 100 cst. @40°C
Specific Gravity (Water = 1.0): ..................... 0.85
Boiling Point: ................................................ N.A.
Vapor Pressure: ........................................... Negligible
Appearance & Odor: .................................... Clear – with Mild odor
Solubility in Water: ....................................... Negligible
IV. Fire & Explosion Hazard Data:
Flash point: .................................................. 464°F / 240°C / COC
Auto ignition Temperature: ........................... Not Established
Flammability Limits: ..................................... Not Established
Extinguishing Media: ................................... Dry Chemical; CO2 Foam; Water Spray
Special Fire Fighting Procedure: ………….. Burning may produce irritating/noxious fumes. Firefighters should use
NIOSH/MNSA approved self-contained breathing apparatus. Use water
to cool fire-exposed containers to prevent pressure build-up.
V. Reactivity Data:
Stability: ………………….…………………... This product is stable and will not react with water.
Materials to Avoid: ...................................... Avoid strong oxidizers
Hazardous Decomposition Products: …...... Carbon monoxide, Carbon dioxide
VI. Health Information:
Eye Contact: ............................................... Flush eyes with water for 15 minutes. Call physician if irritation develops.
Skin Contact: ............................................... Wash skin with soap and water.
Inhalation: .................................................... Remove to fresh air.
Ingestion: ..................................................... First aid not normally required. If uncomfortable, call physician.
VII. Health Hazard Data:
Exposure Limit: ............................................ Not Applicable
Effects of Overexposure: ……………………. Low oral and dermal toxicity. Prolonged or repeated exposure may
cause irritation, nausea, and vomiting.
VIII. Employee Protection:
For general personal hygiene, wash hands thoroughly after handling material. Avoid contact with skin and eyes.
Chemical impervious gloves are not required, but may be recommended for prolonged exposure. Use in a well
ventilated area.
IX. Storage, Spill, & Disposal Procedures:
Storage: ………………………………………. Store in clean, dry area.
Spills: …………………………………………. Use absorbent materials to soak up fluid.
Disposal: ……………………………………… Incinerate this product and all associated wastes in a licensed facility in
accordance with Federal, state, and local regulations.
X. Hazard Rating Information:
NFPA Health: ………………………….. 0
Flammability: ……..................... 1
Reactivity: ……………….….….. 0
Personal Protection: ………….. B
This information contained herein is based on the data available to us and is believed to be true and accurate. Nuvair
makes no warranty, expressed or implied, regarding the accuracy of this data or the results to be obtained from the use
thereof. Nuvair assumes no responsibility for injury from the use of this product.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 44
LP 420 Rotary Screw Nitrox Generator Manual
Material Safety Data Sheet
Nuvair™ 751 Premium Synthetic Diester Based Air/Nitrox Compressor Lubricant
Effective Date: 3/10/2010
Supersedes:
I. Product Identification:
Trade Name: ………………………………… Nuvair 751
Chemical Name: …………………………….. Diester
Chemical Family: ……………………………. Diester
II. Components & Hazard Statement:
This product is non-hazardous. This material is not considered hazardous by the OHSA Hazard Communication
Standard (29 CFR 1910.1200).
III. Physical Data:
Viscosity: ..................................................... 146 cst. @40°C
Specific Gravity (Water = 1.0): .................... 0.94
Boiling Point: ............................................... Not determined
Vapor Pressure: ........................................... Negligible
Appearance & Odor: .................................... Amber / Mild odor
Solubility in Water: ....................................... Negligible
Other Data: .................................................. Non-toxic USDA H-2 approved
IV. Fire & Explosion Hazard Data:
Flash point: .................................................. 520°F / 271°C COC ASTM D-92
Auto ignition Temperature: ........................... 765°F ASTM D-2155
Flammability Limits: ..................................... Not Established
Extinguishing Media: ................................... Dry Chemical; CO2 Foam; Water Spray
Special Fire Fighting Procedure: ………….. Burning may produce irritating/noxious fumes. Firefighters should use
NIOSH/MNSA approved self-contained breathing apparatus. Use water
to cool fire-exposed containers to prevent pressure build-up.
V. Reactivity Data:
Stability: ………………….…………………... Stable under normal conditions.
Materials to Avoid: ...................................... Incompatible with oxidizing agents.
Hazardous Decomposition Products: …...... Carbon monoxide, Carbon dioxide
VI. Health Information:
Eye Contact: ............................................... Flush eyes with water for 15 minutes. Call physician if irritation develops.
Skin Contact: ............................................... Wash skin with soap and water.
Inhalation: .................................................... Remove to fresh air.
Ingestion: ..................................................... First aid not normally required. If uncomfortable, call physician.
VII. Health Hazard Data:
Exposure Limit: ............................................ Not Applicable
Effects of Overexposure: ……………………. Low oral and dermal toxicity. Prolonged or repeated exposure may
cause irritation, nausea, and vomiting.
VIII. Employee Protection:
For general personal hygiene, wash hands thoroughly after handling material. Avoid contact with skin and eyes.
Chemical impervious gloves are not required, but may be recommended for prolonged exposure. Use in a well
ventilated area.
IX. Storage, Spill, & Disposal Procedures:
Storage: ………………………………………. Store in clean, dry area.
Spills: …………………………………………. Use absorbent materials to soak up fluid.
Disposal: ……………………………………… Incinerate this product and all associated wastes in a licensed facility in
accordance with Federal, state, and local regulations.
X. Hazard Rating Information:
NFPA Health: ………………………….. 0
Flammability: ……..................... 1
Reactivity: ……………….….….. 0
Personal Protection: ………….. B
This information contained herein is based on the data available to us and is believed to be true and accurate. Nuvair
makes no warranty, expressed or implied, regarding the accuracy of this data or the results to be obtained from the use
thereof. Nuvair assumes no responsibility for injury from the use of this product.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 45
LP 420 Rotary Screw Nitrox Generator Manual
OWNER’S WARRANTY RESPONSIBILITIES
Failure of the owner to prevent equipment damage by complying with the procedures outlined below and in the
Operation Manual will void the Nitrox System warranty.
Installation:
• All set up requirements and procedures provided in the Nitrox System Operation Manual must be
followed in their entirety including supply air cleanliness, Compressor preparation, and installation of
the Nitrox System.
• Supply air to the Membrane must be properly filtered to CGA Grade D air quality or better to prevent
damage to the Membrane. Air quality testing of the supply air should be performed periodically and
documented to assure compliance.
• If there is any doubt regarding the suitability of a HP Compressor for compressing Nitrox, contact
Nuvair or the Compressor manufacturer before you connect your Nitrox System.
• If an existing HP 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.
• 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.
• To prevent Compressor damage, only use the Compressor Intake Hose provided. If a longer hose is
required, contact Nuvair for assistance.
Operation:
• Do not use the Nitrox System to supply a H.P. 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 P.S.I. Compressing Nitrox at higher pressures may cause severe HP Compressor
damage.
• To prevent Membrane damage, drain all low pressure filter and optional volume tank condensate on a
daily basis.
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 service record book showing that regular maintenance work has been carried out. If a warranty
claim becomes necessary, it will aid in demonstrating that damage has not been caused by insufficient
maintenance. Proof of maintenance may be required prior to determining the validity of a warranty
request.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 46
LP 420 Rotary Screw Nitrox Generator Manual
NUVAIR NITROX SYSTEM WARRANTY
NUVAIR extends a limited warranty, which warrants the Nitrox System to be free from defects in materials and
workmanship under normal use and service for a limited period. The specific Membrane Component of the
Nitrox System is warranted according to the pro-rated terms as set forth below. All other Original Equipment
Manufacturer (OEM) components used in the system are warranted only to the extent of 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 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.
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:
• First 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.
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 defective 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 constitute NUVAIR’S sole
liability and the Purchaser’s exclusive remedy resulting from any nonconformity or defect. NUVAIR shall not in
any event be liable for any damages, whether based on contract, warranty, negligence, strict liability or
otherwise, including without limitation any consequential, incidental or special damages, arising with respect to
the equipment or its failure to operate, even if NUVAIR has been advised of the possibility thereof. NUVAIR
makes no other warranty or representation of any kind, except that of title, and all other 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.
LP 420 Nitrox Generator
NUVAIR rev. 10/12 Page 47
LP 420 Rotary Screw Nitrox Generator Manual
Additional Record of Changes
It is the responsibility of the owner of this product to register their ownership with Nuvair by
sending the warranty card provided to Nuvair. This card is to establish registration for any necessary
warranty work and as a means of communication that allows 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.
Change Date
Description of Change
10.2.12
Updated warnings and images from 12/07 orignal.
Nuvair™ All Rights Reserved
Phone 1-805-815-4044
Fax 1-805-815-4196
2949 West 5th Street,
Oxnard CA USA
Email : info@nuvair.com
Web : www.nuvair.com
Revision 10-12.2

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