NitroxMaker™ Commercial Series System (NM-CS)

TM
Brownie’s
M A R I N E
G R O U P
Commercial Series
NMCS-7.5
NMCS-10
NMCS-20
NMCS-30
940 NW 1st Street, Fort Lauderdale, FL 33311
PH. 954.462.5570 Fx. 954.462.6115
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This information is believed to be accurate by Brownie’s Marine Group as of it’s date of publication, but Brownie’s offers
NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth herein. Brownie’s shall not
be liable for inaccuracies in, or consequences resulting from, your use of this information. All information supplied is in
connection with sales of Brownie’s products, and is thus subject to Brownie’s standard terms and conditions of sale.
Brownie’s reserves the right to change this information and has no obligation to update these materials. This information
is Copyright © 2013 by Brownie’s Marine Group, and Brownie’s reserves to itself all rights to this publication. Brownie’s
customers have no right to reproduce, rewrite, modify, license or permit anyone else’s use of this information, without the
express written permission of Brownie’s Marine Group.
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NitroxMaker™ Commercial Series
Table of Contents
Chapter 1: Introduction...................................................................................................................4
1.1 How to Use this Manual.......................................................................................................4
1.2 Manual Safety Notices.........................................................................................................4
1.3 Components of a NitroxMakerTM System..............................................................................5
1.4 System Requirements..........................................................................................................6
1.5 Installation............................................................................................................................7
Chapter 2: Operations........................................................................................................................8
2.1 General.................................................................................................................................8
2.2 Pre-Start Checks..................................................................................................................8
2.3 Initial System Start-up Procedure.........................................................................................9
2.4 Controlling the Nitrox Mixture..............................................................................................10
2.5 Recalibrating the Oxygen Analyzer......................................................................................11
2.6 Shutdown NitroxMakerTM System........................................................................................11
NMCS Views.............................................................................................................................................12
NitroxMakerTM Commercial Series 7.5 .....................................................................................12-13
NitroxMakerTM Commercial Series 10 .....................................................................................14-15
NitroxMakerTM Commercial Series 20 .....................................................................................16-17
NitroxMakerTM Commercial Series 30 .....................................................................................18-19
Compressed Air Filters .............................................................................................................20
Specifications ...........................................................................................................................21
Log Pages ................................................................................................................................22-23
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NitroxMaker™ Commercial Series
WARNING
This Instruction Manual and Replacement Parts List contains safety information and instructions for the NitroxMaker™
System and Nitrox Membrane. You must read, understand and follow all safety precautions and instructions.
CHAPTER 1: INTRODUCTION
1.1 How To Use This Manual
This manual contains the operating and maintenance instructions for the Brownie’s Third Lung product(s) listed on the
front cover.
All instructions in this manual should be observed and carried out as written to prevent damage or premature
wear to the product or the equipment served by it.
If your unit is equipped with nonstandard accessories and/or options, supplemental information is normally
included in other documentation; i.e. OEM Manuals or additional Brownie’s Third Lung Manuals.
While every effort is made to ensure the accuracy of the information contained in this manual, Brownie’s Third Lung will
not, under any circumstances be held accountable for any inaccuracies or the consequences thereof.
1.2 Manual Safety Notices
Important instructions concerning the endangerment of personnel, technical safety or operator safety will be specially
emphasized in this manual by placing the information in the following types of safety notices.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This is
limited to the most extreme situations.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or injury.
CAUTION
CAUTION 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.
NOTE
NOTE advise of technical requirements that require particular attention by the operator or the maintenance technician
for proper maintenance and utilization of the equipment.
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NitroxMaker™ Commercial Series
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NitroxMaker™ Commercial Series
1.4 System Requirements
Grade E air is the quality/purity standard you should already be pumping for use as breathing air according to the CGA
standards. Please make sure you exercise extreme caution regarding the maintenance of the filter/purification system
to ensure this standard is maintained at all times. This is not only critical for the well-being of divers, but also to that of
the NitroxMakerTM components. If there is doubt in the quality of the air being compressed please discontinue use of the
NitroxMakerTM system and call Brownie’s Third Lung for service and an Air Quality Test.
Definition Grade E Air:
O2%: 20-22
CO2: 1000 ppm
CO: 10 ppm
Hydrocarbons: 25 ppm
Water: 67 ppm
Dew Point: -50 F
Oil & Particles: 5 mg/m3
Odor: none
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NitroxMaker™ Commercial Series
1.5 Installation
Place/install the machinery according to the guidelines in the Kaeser compressor manual.
Ensure you will have adequate space to:
-manipulate the machinery controls, including the Receiver IN & OUT valves
-manipulate the nitrox production controls
-change the LP filter cartridges
-remove service panels and service the machinery
Verify LP filter cartridges are installed in LP Filter Array canisters
Connect condensate drain line to drain port on the dryer. Route the drain line to a suitable location.
Make electric connections according to the Kaeser manual.
Install Nitrogen Waste Gas Lines.
The Waste Port Regulators include exposed barb fittings designed to accept ½ inch ID hose. Use only new hose in good
condition, without holes, breaks or cuts that could leak waste gas into the operational area of the compressor.
Route the Nitrogen Waste Gas Lines to a suitable location. Verify the hose is not kinked or crushed to reduce the flow of
waste gas.
DANGER
INGESTION OF NITROGEN WASTE GAS CAN CAUSE INJURY OR DEATH.
Make sure waste gas lines are routed to a well ventilated location (outside) where accumulation or ingestion
of the nitrogen waste gas will not occur.
Install Nitrox Transfer Hose
The Nitrox Transfer hose carries nitrox mix from the NitroxMaker™ to the intake port of the high-pressure compressor.
Use only non-collapsible hose suitable for breathing air applications.
Hose sizes: 1.5 inch ID – NMCS7.5 & NMCS10 2.0 inch ID – NMCS20 & NMCS30
Make sure hose ends have clean edge cuts, without loose shavings, dust or other foreign matter.
Install the nitrox sampling line (protruding from the end of the Mixing Tube) as far as possible into the Nitrox Transfer
Hose. Blowing the sampling line with compressed air will help distribute it along the interior dimension of the Nitrox
Transfer Hose.
Install the Nitrox Transfer Hose onto the output fitting at the base of the Mixing Tube and secure with a hose clamp.
Install the Nitrox Transfer Hose onto the intake fitting of the high-pressure compressor and secure with a hose clamp.
Install HP Compressor Sampling Regulator and hose
A sampling regulator assembly is included to route the output gas from the high-pressure compressor back to the
NitroxMaker Control Panel.
Install the sampling regulator assembly downstream of the purification filtration system if possible. Connect the hose from
the Tankfill Analyzer Selector Valve to the sampling regulator assembly.
When the sampling regulator valve is open, low-pressure gas will be routed to the Tankfill Analyzer.
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NitroxMaker™ Commercial Series
CHAPTER 2: OPERATIONS
2.1 General
The safety instructions applicable to this product are contained in the Appendix. They must be read, understood and
complied with prior to operating the product. All system checks, start-up and shut down procedures are based on standard
system configurations. Components may vary.
2.2 Pre-start Checks
High-Pressure Compressor
Check the condition and safe operating instructions of the high-pressure compressor to which the nitrox mix will be
supplied. Refer to the high-pressure compressor operator’s manual for any technical assistance.
Specifically check the following items:
-Compressor oil level
-Condition of intake and purification filter(s)
-Check for excessive moisture or carbon monoxide if an indicator is present in the system
-Verify the HP compressor sampling regulator control valve is in the OPEN position.
NitroxMaker™ Commercial Series
Follow all operating instructions in the operator’s manual for the associated Kaeser air system.
-Verify the nitrox supply hose is secured to the output of the nitrox mixing tube on the NitroxMaker. The other end
should be secured to the intake of the high-pressure compressor. Verify the hose is in good condition, without holes,
breaks or cuts that could compromise the gas mixture being produced.
-Verify nitrogen waste line(s) are secure on the Waste Port Regulator at the base of the membrane stick(s) and that
the waste lines are vented to an outside location where accumulation or ingestion of the nitrogen waste gas will not
occur.
DANGER
INGESTION OF NITROGEN WASTE GAS CAN CAUSE INJURY OR DEATH.
Make sure waste gas lines are routed to a well ventilated location (outside) where accumulation or ingestion
of the nitrogen waste gas will not occur.
Tanks
Inspect ALL tanks to be filled:
-Make sure the tanks are in good condition with no deep scratches, gouges or pitting.
-The tanks must be within current hydrostatic test and Visual Inspection dates.
-Do not fill empty tanks without first visually inspecting them for water intrusion.
-Make sure that the valves are in good condition and not in need of service. Do not fill tanks with damaged valves.
-Do not fill tanks that have been exposed to extreme heat, i.e.: tanks that have been in or near fires.
Records
-Add all pre-startup maintenance/inspection notations to the system log with date, hours and operator name.
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NitroxMaker™ Commercial Series
2.3 Initial System Start-up Procedure
1. Verify the circuits responsible to power the machinery are on at the breaker panel.
2. Verify the Air Receiver IN and OUT valves are in the open position. Air stored under pressure in the Air Receiver will
start to flow – this is normal.
3. Turn on the Kaeser system according to the instructions in the Kaeser manual.
Check the low-pressure filter array. The canisters have indicators to provide visual reference of the filter element
remaining life. AIR MUST BE FLOWING to get an accurate reading on the indicators. Change any filter cartridges
before total saturation is indicated.
4. Turn on the high-pressure compressor according to the manufacturer’s instructions. The high-pressure compressor
will consume the gas in the nitrox transfer hose. Allow the output of the high-pressure compressor to flow freely until
the desired nitrox mix has been achieved.
Failure to turn on the high-pressure compressor will cause a back-up of gas in the nitrox transfer hose. Excess gas
volume will flow out through the intake air filter at the top of the mixing tube, preventing an accurate reading of the
nitrox mix being produced.
5. Turn ON both gas analyzers and calibrate to AIR (20.9% oxygen)
a. Turn the Selector valve to the CALIBRATE position.
b. Using the control knob at the base of the FLOW METER, adjust the flow rate to 1-2 liters per minute (LPM).
c.
Calibrate both according to the analyzer manufacturer’s instructions. Lock in the calibration when the reading
is consistent at 20.9%.
6. Turn the Selector valves to the OUTPUT position.
7. Using the control knob at the base of the FLOW METER, adjust the flow rate to 1-2 liters per minute (LPM).
The NITROX ANALYZER will display the oxygen percentage in the gas flowing through the nitrox transfer hose to
the high-pressure compressor.
The TANKFILL ANALYZER will display the oxygen percentage in the gas provided by the sampling regulator,
downstream of the high-pressure compressor output.
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NitroxMaker™ Commercial Series
2.4 Controlling the Nitrox Mixture
Adjusting the pressure of the air supplied to the membrane sticks will change the oxygen percentage of the gas being
produced. Higher pressure produces higher concentrations of oxygen. As the pressure is reduced, the percentage
of oxygen will decrease as well.
As you gain experience with the system, you will learn the approximate percentage you can expect for a given range
of supply pressure. Keeping a log as you work with the system will provide a handy reference for later use.
WARNING
The performance of each membrane stick is unique. It may be possible to create nitrox mixtures with oxygen
concentrations greater the 40%. DO NOT SUPPLY GAS MIXTURES WITH OXYGEN CONCENTRATIONS
OVER 40% to the intake of any high-pressure compressor – combustion, equipment damage or component
failure may occur. Consult your high-pressure compressor manufacturer for additional information.
- Turn the NITROX MIX CONTROLLER knob clockwise or counter-clockwise to adjust the pressure.
- The SUPPLY PRESSURE GAUGE will indicate the gas pressure being supplied to the membrane stick(s).
- Adjust the pressure in 5 psi increments.
After adjusting the supply pressure, wait at least 60 seconds for the mixture change to be accurately displayed on the
NITROX ANALYZER.
Likewise, depending on the size and processing volume of the high-pressure compressor, you will need to wait 1-5
minutes for the mixture to work through the multiple stages of the high-pressure compressor and filtration to see an
accurate reading on the TANKFILL ANALYZER.
The high-pressure compressor output mixture may vary up to ±2% from the mixture displayed on the NITROX
ANALYZER.
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NitroxMaker™ Commercial Series
2.5 Recalibrating the Analyzer(s) While the System is Running
- Recalibration should be performed any time there is an unusual discrepancy between the analyzers.
- Perform steps 5, 6 and 7 in section 2.3 as necessary.
2.6 Shutting Down the NitroxMaker™ System
- Close the Air Receiver OUT valve to stop the flow of air to the NitroxMaker™ system. When the receiver reaches
the maximum programmed pressure, the Kaeser system will enter IDLE mode – the compressor will continue to
spin but air will not be produced. If air flow does not commence, the system will enter SLEEP mode to conserve
power until the flow of air resumes.
- Turn the Kaeser system OFF according to the instructions in the Kaeser manual. The pressure in the Air Receiver
will be retained, allowing you to restart nitrox production more quickly.
- Turn the high-pressure compressor OFF.
- Turn the HP compressor sampling regulator control valve to the CLOSED position.
The high-pressure compressor may be used WITHOUT the NitroxMaker™ system to fill scuba tanks or storage
bottles with AIR. The high-pressure compressor will ingest the required volume through the nitrox supply hose. If
the NitroxMaker™ system is not ON, the required volume will be supplied through the Intake Filter at the top of the
Mixing Tube.
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NitroxMaker™ Commercial Series 7.5
1
Compressor/Dryer
Control Panel
2
Emergency
OFF
3
Rotary Screw
Compressor
4
Dryer
Electronic
Demand Drain
Receiver
OUT Valve
11
ECO-DRAIN
12
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NitroxMaker™ Commercial Series 7.5
12
Intake Filter
18
Membrane
17
Mixing Tube
20
Receiver
Pressure Gauge
7
Air Receiver
(Tank)
6
Access Panel
(Cover)
Temperature Controller 21
Heater Element
Waste Port Regulators
22
11
Receiver
OUT Valve
19
9
LP Filter Array
9
Supply Pressure Gauge
16 Nitrox Mix Controller
13 Gas Analyzer
14 Flow Meter
15 Selector Valve
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NitroxMaker™ Commercial Series 10
Compressor/Dryer Control Panel
1
Emergency OFF
2
Rotary Screw Compressor
3
Nitrox Production
Control Panel
Dryer
5
4
Access Panel 6
Air Receiver
14
7
17
Membrane
12
Receiver Pressure
Gauge
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NitroxMaker™ Commercial Series 10
19 Waste Port Regulator
18 Intake Filter
20 Mixing Tube
21 Temperature Controller
8
LP Filter Array
20 Mixing Tube
12
Receiver OUT Valve
11
Receiver IN Valve
Emergency OFF 24
Nitrox Mix Controller 16
Gas Analyzer
13
Flow Meter
14
Selector Valve 15
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NitroxMaker™ Commercial Series 20
Compressor/Dryer
Control Panel
1
Emergency OFF
2
Nitrox Production
Control Panel
5
Rotary Screw
Compressor
3
Dryer
4
Access Panel
6
7 Air Receiver
LP Filter array
16
8
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NitroxMaker™ Commercial Series 20
Supply Pressure Gauge
9
Flow Meter 14
Gas Analyzer
13
Selector Valve 15
Nitrox Mix Controller 16
19 Waste Port
Regulator
Intake Filter 18
Mixing Tube 20
21
Temperature
Controller
Heater Element 22
17 Membrane
Condensate
Drain Port
23
Receiver IN Valve
10
Receiver OUT Valve 11
24 Nitrox Transfer Hose
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NitroxMaker™ Commercial Series 30
Compressor/Dryer Control Panel
Dryer
4
Emergency OFF
2
Nitrox Production
Control Panel
5
Access Panel
6
1
3
Rotary Screw
Compressor
Air Receiver 7
Receiver
Pressure Gauge
11
12
Receiver
OUT Valve
LP Filter Array
Receiver
Out Valve
18
8
9
10
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Receiver
In Valve
NitroxMaker™ Commercial Series 30
13 Gas Analyzer
9
14
Supply Pressure Gauge
Flow Meters
15 Selector Valves
16 Nitrox Mix Controller
Intake Filter 18
Waste Port Regulator 19
Mixing Tube 20
Membrane
17
Temperature
Controller
21
Heater Element
Nitrox Transfer
Hose
22
24
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NitroxMaker™ Commercial Series
Compressed Air Filters
Designed and developed using the latest innovations and manufacturing techniques, Kaeser filter housing are designed
with larger flow areas to ensure low pressure drop and to prove easier installation, operation and maintenance. The result
is consistent product quality while minimizing operating costs.
Standard Features and Benefits
1
Delta P Slide Indicator
2
Color Coded Elements
3
Internal Automatic Drain
4
Delta P Gauge
5
Modular Connections
6
Liquid Level Indicator
4
1
5
2
Ensures economical operation by changing color when filter element requires
replacement. Fitted as standard on filters
up to 60 scfm (excluding KVA).
Allows easy identification. Elements are
designed using the latest media innovations and manufacturing technology.
Reliably discharges collected condesate
(excluding KVA and KFS 250 & above).
Large, easy-to-read dual gauge faces
allow housings to be mounted in any flow
direction. Fitted as standard on filters from
100 scfm and up (except KVA).
Space-saving design allows housings to
be connected in series without additional
piping.
Visually monitor liquid level and verify
drain operation.
Visually monitor liquid level and verify drain
operation.
6
3
KOR/KOX filter elements should be replaced
at 10 psid (red area of Delta P gauge) or annually, whichever occurs first.
KVF filter elements should be replaced after
1,000 hours of operation or annually, whichever occurs first.
Model
NMCS-7.5
NMCS-10
NMCS-20
NMCS-30
20
Cannister 1
Cannister 2
Cannister 3
Kaeser Oil Removal
Element Kit
Kaeser Oil Removal
Element Kit
Kaeser Oil Removal
Element Kit
99.99+% liquid oil
removal
.01 micron solid
particle
1000 ppm max liquid
loading
OR 35
99.999+% liquid oil
removal
.01 micron solid
particle
100 ppm max liquid
loading
OX 35
0% liquid removal
.01 micron solid
particle
0 ppm max liquid
loading
VF 35
OR 35
OR 60
OR 100
OX 35
OX 60
OX 100
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VF 35
VF 60
VF 100
NitroxMaker™ Commercial Series
Specifications
NMCS7.5
NMCS10
NMCS20
NMCS30
Drive Motor Nominal Power
(HP)
7.5
10
20
30
Motor Style
TEFC
TEFC
TEFC
TEFC
Compressor rated pressure
(psig)
155
160
160
160
Capacity @ rated pressure
(CFM)
24
35
77
104.2
Airend Type (Sigma)
05
026
10
13
Noise Level
(dB(A))
69
66
66
71
110/1/60 dryer
208/3/60
240/3/60
460/3/60
208/3/60
240/3/60
460/3/60
208/3/60
240/3/60
460/3/60
208/3/60
240/3/60
460/3/60
Amp Draw
(5.5 @ 115v)
19.8
18.7
9.4
33
31
16
58
55
28
88
80
40
Compressor Oil Type
Capacity (gallons)
Kaeser FG-463
1.1 gallons
Kaeser FG-463
1.1 gallons
Kaeser FG-463
1.8 gallons
Kaeser FG-463
3 gallons
Air Receiver Capacity (gallons)
53
71
92.5
100
Dimensions
(inches)
27.5 x 52 x 58h
31 x 50 x 69h
36 x 55 x 74h
85 x 36 x 74h
Weight
(pounds)
750
1000
1250
1490
Ambient Operating Temp
(°F / °C)
40 - 115F
4.5 - 46C
41 - 115F
4.5 - 46C
42 - 115F
4.5 - 46C
43 - 115F
4.5 - 46C
Standard Elec Configuration
(V±10% acceptable)
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NitroxMaker™ Commercial Series
Date
22
Hours
Operator
Observations, Comments
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NitroxMaker™ Commercial Series
Date
Hours
Operator
Observations, Comments
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Brownie’s
M A R I N E
G R O U P
940 NW 1st Street, Fort Lauderdale, FL 33311
PH. 954.462.5570 Fx. 954.462.6115
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