Nuvair SKU PN-NITROX 4 Bank Air and Nitrox Fill Panel Instruction Manual

Nuvair SKU PN-NITROX 4 Bank Air and Nitrox Fill Panel Instruction Manual

WARNING

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.
Under Nuvair’s system of continuous improvement, certain components may be updated or changed as higher quality or more efficient parts and assemblies become available.
Nuvair will make every effort to update manuals as parts and functional aspects change. However, the look or location of components on your product may differ from those in this manual if improvements have been made that do not affect functionality or operational procedures.
Equipment pictured may also be manufactured with different options than those on your product, or components may be positioned differently. In both these cases, the basic operational and maintenance guidelines will still apply.
If you have problems or questions after reading the manual, stop and call Nuvair at +1.805.815.4044 for information.

Introduction

** This manual will assist you in the proper set-up, operation, and maintenance of the Nuvair 4 Bank Air/Nitrox Fill Panel**. Be sure to read the entire manual.
This Nuvair dive shop four (4) bank, five (5) whip air/nitrox fill panel with three-way switch valve is constructed of stainless steel and high quality fittings. It was built-to-order at our California production facility.
Based upon your customized order, the high-pressure air/nitrox input type may be 1/4″ tube or JIC fittings. Fill whips can be International (INT/Yoke), DIN 232 (DIN 200), DIN 300 (Europe), or another customized fill whip valve.

Symbol Conventions

This manual uses certain words and symbols to call your attention to conditions, practices or techniques that may directly affect your safety. Pay particular attention to information introduced by the following symbols or words:

System Description

Designed for use by dive shops with both air and nitrox banks, this four (4) bank, five (5) whip panel has a three-way valve that divides the panel into two (2) banks for air and two (2) banks for nitrox. The valve ensures the operator does not cross-contaminate banks. The panel includes:

• (2) Air storage control with valves and gauges
• (2) Nitrox storage control with valves and gauges
• (1) High pressure-high pressure (HP-HP) regulator for fill control
• (5) Fill outlet ports
• (5) Fill yokes of your choice (INT/Yoke, DIN 232*, DIN 300, or Custom)
• (5) Fill hoses – 4 ft long
• (1) 4 in fill pressure gauge
• (1) Nuvair Pro O2 Analyzer with high pressure-low pressure (HP-LP) regulator and flow restrictor

Required Operator Training

**NOTICE**

This manual must be read carefully and in its entirety. Properly trained and certified personnel should be the only operators of high pressure equipment like compressors and fill panels.

• All fill panel operators / maintenance personnel must read this entire manual with due care and attention and observe the instructions/information contained
• Company owners ensure that the operator has the required training for operation of the fill panel and that he/she has read the

Important Information for the User

** The information/instructions for fill panel use contained in this manual concern the 4 bank Air/Nitrox Fill Panel model** of high-pressure gas distribution panels.
The instruction manual must be read and used as follows:

• Read this manual carefully; treat it as an essential part of the fill
• The instruction manual must be kept where it can readily be consulted by fill panel operators and maintenance
• Keep the manual for the working life of the fill
• Make sure updates are incorporated in the
• Make sure the manual is given to other users or subsequent owners in the event of
• Keep the manual in good condition and ensure its contents remain
• Do not remove, tear or re-write any part of the manual for any
• Keep the manual protected from damp and
• If the manual is lost or partially damaged and its contents cannot be read it is advisable to request a copy from This manual is also available for download on our website.

Foreword

The regulations/instructions for use contained in this manual constitute an essential component of the supplied fill panel.
These regulations/instructions are intended for an operator who has already been trained to use high pressure compressed air equipment. The contained information is necessary and essential to efficient and proper use of the fill panel.
Hurried or careless preparation leads to improvisation, which is the cause of accidents. Before beginning work, read the following suggestions carefully:

• Before using the fill panel, gain familiarity with the tasks to be completed and the admissible working
• The operator must always have the instruction manual to
• Plan all work with due care and
• You must have a detailed understanding of where and how the fill panel is to be
• Before starting work make sure that safety devices are working properly and that their use is understood; in the event of any doubts do not use the fill
• Observe the warnings given in this manual with due care and
• Constant and careful preventive maintenance will always ensure a high level of safety when using the fill panel. Never postpone repairs and have them carried out by specialized personnel only; use only original spare parts.

Assistance

**** Nuvair technicians are at your disposal for all routine/unscheduled maintenance work. Please forward your request for assistance to Nuvair by sending a fax or e-mail to:

Phone:             +1.805.815.4044
Fax:                 +1.805.486.0900
Email:              [email protected]

NOTICE

Fill panels are a gas management tool. Fill panels do not generate compressed air. A source of compressed air is required to fill tanks..

Responsibility

**** Nuvair considers itself exonerated from any responsibility or obligation regarding injury or damage caused by:

• Failure to observe the instructions contained in this manual that concern the running, use and maintenance of the fill panel.
• Violent actions or incorrect maneuvers during use or maintenance of the fill
• Modifications made to the fill panel without prior written authorization from Nuvair.
• Incidents beyond the scope of routine, proper use of the fill

WARNING

Maintenance and repairs must only be carried out using original spare parts and qualified technicians. Nuvair cannot be held liable for any damages caused by failure to observe this rule. The fill panel is guaranteed as per the contractual agreements made at the time of sale.

Failure to observe the regulations and instructions for use contained in this manual shall render the warranty null and void.

Fill Panel Overview

** In this section are representative images of the 4 Bank Air/Nitrox Fill Panel. The layout of your fill panel** may be customized with optional equipment and/or made-to-order configuration. Because of this, the appearance of your fill panel may differ from what is represented in this manual.

Component Identification

** The 4 Bank Air/Nitrox Fill Panel** (Figure 1) is shown with standard components. Your fill panel may be customized and would appear differently, but the components operate in the same manner.
Air bank on/off valves (four in total) are adjacent to the bank pressure gauge (four in total) associated with that on/off valve and bank. If the air selector valve points left to the air placard, Banks 1 and 2 are selected. If the air selector valve points right to the nitrox placard, Banks 3 and 4 are selected.
Gas (air or nitrox) fill pressure is regulated by the output regulator. The regulated gas pressure of the output gas, leading to the five (5) fill whip connectors (Figure 3), is shown on the regulated fill pressure gauge.
The Nuvair Pro O2 Analyzer indicates the percentage of oxygen (O2) in the gas mix being fed to fill whip connections (Figure 3).

General Safety Rules

The fill panel must only be used by qualified personnel. Personnel must fully understand the arrangement and function of all the controls and instruments.

Protective Clothing

**** All operators may use accident prevention items such as gloves, hard hat, eye goggles, accident prevention shoes and ear defenders against noise from nearby compressor equipment (Figure 4).

Checks and Maintenance

When work is being performed on the fill panel or associated equipment, affix a “DO NOT START” signs on all sides of the affected equipment to prevent use while undergoing repair/maintenance (Figure 5).

Fill Panel Installation Mount the panel in a secure location. Utilize all mounting holes.

Mount to a load-bearing surface such as wood, metal, or concrete.
Attach the high pressure compressor input line and four (4) bank lines as indicated on the top edge of the panel.
Attach the five (5) fill whips to the panel outputs on the bottom edge of the panel. Attach high pressure lines by hand tightening first, then tighten with a wrench.

Fill Storage Banks

**** Turn on the high pressure compressor and open the bank fill on/off valve corresponding to the storage bank you wish to fill. Multiple banks can be filled simultaneously.
If so equipped, you may set the automatic shutoff on your compressor to the desired bank final pressure. Once the desired pressure has been reached, close the open on/off bank valve/s.

Tank Refill Procedure

**cooling.**

NOTICE

During refill, the operator must be in the work area. During the tank refill phase, it is advisable to submerge tanks in cold water to reduce the drop in pressure that accompanies tank

WARNING

During tank refill, those not involved in the refill procedure must maintain a safety distance of at least 9 feet (3 meters). Also, it is forbidden to disconnect the hoses from the fittings or the high-pressure out connection while the machine is under pressure. If an emergency occurs

during refill, shut down the compressor immediately.

DANGER

Should tanks show evident signs of internal or external corrosion, do not refill them even if they have been tested.

WARNING

Use only tested tanks (as proven by a test stamp and/or certificate). The working and tank refill pressures are stamped on the tanks themselves. It is forbidden to refill them at a pressure greater than that indicated.

Different fill valves are available at the time of purchase. Variations include INT (Yoke), DIN232, DIN300, and SCBA. To refill tanks, follow procedures described below and as illustrated in Figure 7:

• Check that the tanks to be refilled are in good
• Tanks must be inspected as required by local law and have evidence (stamped or label) attesting to said certification or
• Conduct a visual inspection of the tank/s
• Check that fill whips and associated fittings are in good
• Set the desired fill pressure using the output
• Fit the hose connector (a) to the fill valve (b).
• Screw in the fill valve knob (c) until it is tightened.
• Check that the bleed valve (f) is closed by rotating it
• Open the valve (d) by rotating it
• Open the desired fill bank
• Open the tank valve (e) by rotating it
• Once refilling has been completed close valves (d) and (e) by rotating them
• Close the on/off fill bank

Figure 7. Tank refill illustration (DIN valve pictured).

• Open the bleed valve (f) by rotating it anticlockwise until all the residual air in the whip has been
• Unscrew the fill valve knob (c) by rotating it
• Disconnect the tank fill

Never drain a tank completely, not even for seasonal storage or long periods of inactivity. Pressure prevents internal damage caused by moisture intrusion.

Spare Parts List

9450
Oxygen Sensor for Pro O2 Analyzer| Replacement Sensor| 9505
Pro Analyzer Single Port Flow Adapter Cap| Replacement Cap| BPM6
Coltri Thermoplastic Hose 4 ft (1.2m) 6090 psi (420 bar)| Replacement Fill Whip Hose| 13-04-0238
Coltri INT/Yoke Fill Valve with Bleed Valve| Replacement SCUBA Valve| SC000450B
Coltri BC DIN 300 bar Valve| Replacement DIN 300 Valve| SC000460
Coltri DRV DIN 232 bar Fill Valve with Gauge Port| Replacement DIN 232 Valve| DRV232

**** Service Log

Supply and Breathing Air Specifications

**** All supply and breathing air must meet the following requirements of CGA G-7.1-1997. Periodic air quality testing to assure compliance is recommended. All breathing air for diving produced by an upstream compressor must be purified to meet Grade E quality, and periodic air quality testing to assure compliance is mandatory.

Notes: ¹ Dew point of supply air must be >10oF (6oC) colder than coldest ambient air expected.
² Supply air delivered to the membrane system must contain <0.003 PPM oil vapor.

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References

• NUVAIR: Breathing Air Systems, Industrial Compressors, Nitrox
• Warranty | Nuvair

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