Brownie s M A R I N E G R O U P Tri-Ox MAKER TM Gas Mixing System Operator s Manual This manual is also available online 940 NW First Street, Fort Lauderdale, FL 33311 USA Ph 954-462-5570 Fx 954-462-6115 info@browniesmarinegroup.com
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READ ALL SAFETY RULES AND OPERATING INSTRUCTIONS CONTAINED IN THIS MANUAL AND FOLLOW THEM WITH EACH USE OF THIS PRODUCT. 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. 2013/09 3
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. 1.0 GENERAL INFORMATION AND SAFETY PRECAUTIONS 1.1 How To Use This Manual This manual contains the operating and maintenance instructions for the Brownie s Marine Group 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 Marine Group Manuals. While every effort is made to ensure the accuracy of the information contained in this manual, Brownie s Marine Group will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof. 1.1a 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. REGISTER YOUR PRODUCT ONLINE Go to to register your product. Registration will allow us to keep you informed about important issues and news about your system. 4
Table of Contents GENERAL INFORMATION AND SAFETY PRECAUTIONS 1.0 Introduction... 1.2 Illustrations... 1.2a Safety Precautions... 1.3 Equipment Description... 1.4 Equipment, Accessories, and Documents Supplied... 1.5 Equipment, Accessories Required but Not Supplied... UNPACKING AND INVENTORYING 2.1 Unpacking... INSTALLATION 3.1 Installing the Tri-Ox Maker Gas Mixing Tube... 12 3.2 Installing the Tri-Ox Maker Control Box... 13 3.2.a Installing Needle Valve or Pressure Regulator Controlled Models... 13 3.3 Installing the Compressor Gas Safety Relay... 14 3.4 Bypassing the Compressor Safety Relay... 15 3.5 Installing the Oxygen and Helium Supply Regulators... 15 3.6 Installing the Interconnecting Gas Tubing... 16 3.7 Initial Start-up and Preliminary Tests... 16 3.7.a Bypassing the Compressor Safety Relay... 16 3.7.b Testing the Helium Control Safety Circuit... 17 3.7.c Testing the Compressor Shut-Off Safety Circuit... 17 3.8 Oxygen Regulator Optimal Setting Procedures... 18 3.8.a Needle Valve Systems... 18 3.8.b Pressure Regulator Systems... 19 3.8.c Creating Helium Mixes... 20 3.8.d Connecting TECO Frequency Drive... 23 3.9 Installation Verification Tests... 25 OPERATION 4.1 Introduction... 4.2 Operating Limitations... 4.3 Controls and Indicators... 4.4 System Operation... 4.4.1 Prestart Procedures... 4.4.2 Startup... 4.4.3 Oxygen Sensor Auto-Calibration... 4.4.4 Oxygen Sensor Manual Calibration... 4.4.5 Starting Blending... 4.4.6 Adjusting the Gas Mixture... 4.4.7 Shutdown... GAUGING THE OUTPUT MIXTURE... 30 SCHEDULED MAINTENANCE 6.1 Cleanliness... 6.2 Oxygen Sensors... 6.3 Intake Air Filter... TROUBLESHOOTING... 31 FILL CHARTS... 32 4 6-7 9 10 11 11 11 26 26 26 26 26 27 27 27 28 28 29 31 31 31 5
1.2 Illustrations Tri-Ox Maker Gas Mixing System Tri-Ox Maker with Oxygen Inlet Air Intake Helium Mixing Chamber Helium Inlet Tri-Ox MAKER Control Unit Helium Regulator Oxygen Mixing Chamber Oxygen Sensor 1 Oxygen Inlet Oxygen Sensor 2 Oxygen Regulator Helium Storage Bottle(s) Oxygen Storage Bottle(s) Compressor Intake 6
Tri-Ox Maker with Nitrox Inlet Air Intake Helium Mixing Chamber Helium Inlet Tri-Ox MAKER Control Unit Helium Regulator Oxygen Mixing Chamber Nitrox Inlet Helium Storage Bottle(s) Tri-Ox Maker Air Intake and Mixing Chamber (Actual Image) Oxygen Storage Bottle(s) Oxygen Sensor 2 Compressor Intake 7
Intro Electrical The electrical voltages and currents associated with the Tri-Ox Maker Gas Mixing System are low enough to pose no personnel hazard. However, the control box and circuits are NOT explosion-proof. Do not operate the Tri-Ox Maker Gas Mixing System in an explosive-hazard atmosphere. The installation of the Tri-Ox Maker Gas Mixing System requires an electrical relay switch be installed in the owner s gas compressor which stops the flow of gases in the event the compressor stops or reaches final pressure. This relay must be installed by a competent electrician. Compressor Oils Due to the elevated Oxygen level that the Tri-Ox Maker Gas Mixing System introduces into your air compressor, it is essential that the lubricating oil in the compressor be a synthetic lubricant such as CF-2000 or as approved for your compressor by your compressor manufacturer. All hydrocarbons must be eliminated from your compressor system. Oxygen Although oxygen itself will not burn, it will enhance combustion. By its very nature, increasing the oxygen content in an enclosed space will increase the Intensity of a fire and can cause things which would not otherwise burn to do so. It is understood that the factors contributing to combustion in pressurized system including oxygen, heat, pressure, high speed gas flow, system design, shock waves and the presence of hydrocarbons. All of these factors are present to some degree in a high-pressure gas compressor. However, in concentrations below 40% oxygen, the North American diving industry has deemed that Nitrox can be treated the same as air with no special oxygen service requirements. The diving industry also recognizes that preparing and handling pressurized oxygen and oxygen/air mixtures is a skilled operation, not to be undertaken without proper training. There are inherent risks associated with pressurized oxygen systems. Failure to follow this Manual s instructions or other safety procedures increases the risk of an ignition source being introduced into the oxygen flow stream that could result in a fire, explosion, property damage, serious personal injury or death. In addition to following these safety precautions, remember to take appropriate safety measures with all components in the oxygen system. In no event shall Brownie s Marine Group or its owners be held liable for any property damage, injury or death in the event the Tri-Ox Maker Gas Mixing System is NOT installed, operated or maintained in strict accordance with this manual and other published oxygen service guidelines. Personnel Training ONLY individuals certified as Nitrox Gas Blenders are qualified to operate the Tri-Ox Maker. CAUTION It is mandatory that this instruction manual be read, understood and followed by all persons operating this Gas Mixing System. 8
1.2 Safety Precautions and Features of the Tri-Ox Maker Gas Mixing System 1) Breathing gas mixing inherently can be dangerous to the health and life of the breather of such mixed gases. All operators of the Tri-Ox Maker Gas Mixing System must be qualified Nitrox and/or Trimix gas blenders. 2) The following safety features are incorporated into the Tri-Ox Maker Control Module: If the air compressor stops running, the Control Module automatically closes the gas solenoids, which stops the flow of oxygen and helium into the Gas Mixing Tube and displays the message Compressor Turned Off. If the Gas Mixing Tube s lower (S2) sensor s plug is unplugged, the Control Module automatically closes the oxygen solenoid which stops the flow of oxygen into the Gas Mixing Tube and displays the message O2 level is too high. If the Gas Mixing Tube s upper (S1) sensor s plug is unplugged the Control Module automatically switches to Nitrox Only mode and displays Nitrox Only. When Auto Calibrate is pressed, the Control Module automatically closes both gas solenoids which stops the flow of both oxygen and helium into the Gas Mixing Tube. This ensures an accurate calibration to ambient 20.8% oxygen. If the power supply to the Control Module is interrupted, the gas solenoids automatically close which stops the flow of oxygen and helium into the Gas Mixing Tube. If the Control Module is turned off using the Power button, the gas solenoids automatically close which stops the flow of oxygen and helium into the Gas Mixing Tube. If the Control Module detects 39.9% oxygen, the Control Module automatically closes the oxygen solenoid which stops the flow of oxygen into the Gas Mixing Tube and displays Oxygen level too high. 9
1.3 Equipment Description The Tri-Ox Maker Gas Mixing Systems consist of three interconnected systems: 1) Gas Supply System: The Tri-Ox Maker Gas Mixing System includes two high quality, two-stage pressure regulators (one each for oxygen and helium). Color-coded tubing reduces the chance of mixing up the gas connections. 2) Tri-Ox Maker Gas Mixing Tube: The Gas Mixing Tube is a carefully engineered and tested device which will uniformly blend helium and oxygen into the air stream entering an air compressor. The Gas Mixing Tube includes an air intake muffler and air filter, internal baffles to blend the gases, gas injection points, and two oxygen sensor ports. The Gas Mixing Tube is to be connected to the air/gas compressor in the field using such fittings and devices as are needed for the particular installation. The field connection pieces of pipe, fittings, clamps, etc. are supplied and installed by the owner and must be air-tight. 3) Tri-Ox Maker Control Box: The Tri-Ox Maker Control Box consists of two sections: 1. The Control Module contains the computer which performs the following functions: a) calibrates the oxygen sensors b) senses whether the compressor is running c) does the calculations required to determine and display the percentages of oxygen and helium entering the compressor d) displays the results e) displays error messages f) starts and stops the flow of oxygen and helium gases by controlling the solenoid valves in the Control Valve Box 2. The Valve Box which contains the solenoid valves which start and stop the flow of oxygen and helium. In a Needle Valve controlled system, the Valve Box also contains the precision twenty (20) turn needle valves that allow you to accurately dial in the mix you want down to 0.1% (1/10th of a percent) for adjusting the flow rates of the oxygen and helium gases. In a Pressure Regulator controlled system, the Valve Box also contains the pressure regulators for adjusting the flow rates of the oxygen and helium gases. In a Remote Electrical controlled system, the Valve Box only contains the electronics and Potentiometer which control the remote electrical proportioning valve in the Remote Valve Box. 10
1.4 Equipment, Accessories, and Documents Supplied Tri-Ox Maker Control Module/Valve Box Interconnecting Blue Poly Tubing Interconnecting Green Poly Tubing Helium Supply Pressure Regulator Oxygen Supply Pressure Regulator Tri-Ox Maker Gas Mixing Tube Two Oxygen Sensors Compressor Running Relay 12 volt Power Supply Compressor Running Signal Connecting Wire Oxygen Sensor Connecting Wires (2) Fill Charts Instruction Manual 1.5 Equipment, Accessories required but not supplied: 1) Supply bottles of compressed oxygen 2) Supply bottles of compressed helium 3) Piping and fittings to connect the Tri-Ox Maker Gas Mixing Tube to the air compressor 2.0 UNPACKING AND INVENTORYING 2.1 Unpacking and Inventorying 1) Carefully unpack the components of your Tri-Ox Maker Gas Mixing System. Inspect for shipping damage. 2) Inventory the components received. Compare to the checked items on the enclosed packing list to ensure nothing has been omitted or lost in transit. If you find a discrepancy contact us right away. 11
3.0 INSTALLATION WARNING Synthetic oil must be used in the compressor!!! 3.1 Installing the Tri-Ox Maker Gas Mixing System 1) Mount the Tri-Ox Maker Gas Mixing Tube in a secure location as close to the compressor as reasonable. The Gas Mixing Tube may be mounted vertically, horizontally or at an incline as necessary. Position the Gas Mixing Tube so that the intake of the stick will receive clean air, as dry as possible, and do not restrict the airflow into the intake of the stick. The oxygen and helium inlet fittings can be re-located to the opposite side of the Gas Mixing Tube by swapping the bolt plugs with the inlet fittings if it makes them more convenient for your specific installation. 2) Remove the original fresh air intake filter from your compressor. 3) Field provide, route and install pipe, fittings, and hoses to connect the outlet end of the Gas Mixing Tube to the air intake of your air compressor as necessary. Compressor air intakes and installation conditions vary in size and configuration so we cannot supply you with the parts you might need. Be generous with the pipe tubing sizes to minimize airflow restrictions coming into your compressor. These connections must be air-tight but easily disconnected for compressor maintenance. A section of flexible hose between your PVC tubing and your compressor intake is desirable to isolate your piping, the Gas Mixing Tube, and the oxygen sensors from the compressor vibrations. 4) Unpack the supplied Oxygen Sensors. Do not unseal the packaging until you are ready to install the sensors. We recommend that you write the date on each sensor when you remove it from its packaging. The sensors normally last one year from the time they are unwrapped. 5) Press the Oxygen Sensors into the two fittings provided on the side of the Gas Mixing Tube in the locations marked Sensor 1 and Sensor 2. 6) Turn on your compressor and ensure that there are no leaks between the Gas Mixing Tube and the compressor intake which would allow air to leak into the gas flow after the Gas Mixing Tube. Any such leaks will dilute the gas mixture and lower the expected oxygen / helium content of the product gas. Turn OFF the compressor. 12
3.2 Installing the Tri-Ox Maker Control Module / Valve Box 3.2.a Needle Valve & Pressure Regulator controlled models 1) Mount the Tri-Ox Maker Control Module / Valve Box to a wall, post, or other suitable support in an easy to read location as close to the Gas Mixing Tube as reasonable and also close to a 120v, 60 cycle electrical outlet. Do not mount the Tri-Ox Maker Control Box directly to the frame of your compressor as the vibrations will result in shorter life expectancy of the control electronics. 2) Plug one end of one of the supplied Oxygen Sensor Cables into the top oxygen sensor (S1) of the Gas Mixing Tube and plug the other end into the Control Module jack marked S1. Coil excess wire neatly out of the way. Oxygen sensor cables 3) Plug one end of the other Oxygen Sensor Cable into the bottom oxygen sensor (S2) of the Gas Mixing Tube and the other end into the Control Module jack marked S2. Coil excess wire neatly out of the way. 4) Plug the supplied 12 volt power adapter into a 110/120VAC electrical outlet and plug the wire into the electrical jack on the right side of the Control Module. Coil excess wire neatly out of the way. Electrical jack on the Tri-Ox Maker Control Module 13
3.3 Installing the Compressor Gas Safety Relay Gas Safety Relay Switch Gas Safety Relay Switch Installation 1) If you were supplied with a RED Gas Safety Relay Switch, run any wire in your compressor which is energized only when the compressor is running through the hole in the relay. It can be 120 VAC, 220 VAC or DC. 2) Connect the Compressor Safety Relay Cable to the Gas Safety Relay Switch using the red/black modular connectors and plug the other end (RCA plug) to the RCA jack on the right side of the Valve Box. The jack on the Tri-Ox Maker Control Module Box is marked Compressor. CAUTION DO NOT connect the Compressor Safety Relay Cable to a power source! It will burn out the Tri-Ox Maker Control Module!!! 14
3.4 Bypassing the Compressor Safety Relay Jumper to bypass the Compressor Safety Relay If you cannot connect the Compressor Relay Safety Switch to your compressor you can install a jumper wire between the top two Tri-Ox Maker control module terminal block pins as shown above. The Tri-Ox Maker control module will operate normally but it will not shut off the supply gases automatically when the compressor stops. 3.5 Installing the Oxygen and Helium Supply Regulators 1) Locate the oxygen and helium supply cylinders in a convenient location within 30 ft (9.1 M) of the Tri-Ox Maker Control Box. WARNING The Oxygen and Helium Gas Supply Cylinders must be of breathing quality gases!!! 2) Install the provided Gas Pressure Regulators onto the respective supply cylinders. Screw the oxygen regulator onto the oxygen cylinder. Screw the helium regulator onto the helium cylinder. WARNING Take care to protect the connections from contamination which could result in fire or injury or death of the individual breathing the contaminated gas. 15
3) Ensure that the Gas Pressure Regulators adjustment knobs are turned all of the way out so there is no initial uncontrolled discharge pressure on the system 3.6 Installing the Interconnecting Gas Tubing 1) Cut a suitable length of the provided Green Poly Tubing and push one end into the discharge fitting of the Oxygen Pressure Regulator. Push the other end into the Oxygen In fitting at the bottom of the Tri-Ox Maker Valve Box. Should you need to remove the tube, push the colored plastic ring into the fitting while pulling the tube out. 2) Cut a suitable length of the provided Blue Poly Tubing and push one end into the discharge fitting of the Helium Pressure Regulator. Push the other end into the Helium In fitting at the bottom of the Tri-Ox Maker Valve Box. 3) Cut another suitable length of the provided Green Poly Tubing and push one end into the Oxygen Out fitting at the bottom of the Tri-Ox Maker Valve Box. Push the other end into the bottom Oxygen inlet fitting on the Gas Blending Tube. The Oxygen inlet fitting can be located on the opposite side of the tube by swapping the bolt plug with the inlet fitting if more convenient. 4) Cut another suitable length of the supplied Blue Poly Tubing and push one end into the Helium Out fitting at the bottom of the Tri-Ox Maker Valve Box. Push the other end into the top Helium inlet fitting on the Gas Mixing Tube. The Helium inlet fitting can be located on the opposite side of the tube by swapping the bolt plug with the inlet fitting if more convenient. 3.7 Initial Start-up and Preliminary Tests 3.7a Testing the Oxygen Control Circuits and Safeties 1) Slowly open the oxygen supply tank valve and then adjust the Oxygen Supply Pressure Regulator valve to 60 psi (4.1 Bar). Check for leaks. 2) Press the Power button on the Tri-Ox Maker Control Module. The Control Module will do a self-diagnosis test that will last a few seconds each time it is turned on. 3) Start your air compressor, discharging to a location where the gas mix doesn t matter such as to atmosphere. 4) Locate the Auto-Calibrate button on the Control Module. 16
Press and hold this button until the display reads Calibration Complete. This typically takes 5 seconds. 5) Press the UP arrow on the Control Module to start the flow of Oxygen. Turn the Oxygen needle valve, pressure regulator, or potentiometer on the Valve Box in or out to adjust the flow rate. Where installed, turning the needle valve to the right (clockwise) closes the valve and adjusts the oxygen percentage downward. Where installed, turning the pressure regulator or potentiometer to the right (clockwise) adjusts the oxygen percentage upward. 6) Raise the oxygen percentage above 40% to test the maximum oxygen percentage safety. The Control Module will shut off the oxygen solenoid and display O2 level too high. 7) Reduce the oxygen by adjusting the oxygen needle valve, pressure regulator, or potentiometer as described above and restart the flow of oxygen by pressing the UP arrow again. 8) Test the auto shutdown on loss of power by unplugging the power transformer from the Control Module. The solenoid valves should immediately close. Check by unplugging the green oxygen poly tube from the Gas Blending Tube and check for flow. There shouldn t be any flow. 9) Re-power the Control Module and plugging back in the power cord to restart the electronics and pressing the UP button to restart the flow of oxygen. 10) Test the disconnected oxygen sensor safety by unplugging the lower oxygen sensor (S2). The Control Module should immediately close the oxygen solenoid valve and will display O2 level too high. Check for flow at the poly tubing as previously. 11) Reconnect the green oxygen poly tube to the Gas Blending Tube. 3.7b Testing the Helium Control Safety Circuit 12) Slowly open the helium supply tank valve and then adjust the Helium Supply Pressure Regulator valve to 60 psi (4.1 bar). Check for leaks. 13) Press the UP arrow on the Tri-Ox Maker Control Module to start the flow of Oxygen and Helium. Adjust the Helium needle valve, pressure regulator, or potentiometer on the Tri-Ox Maker Control Module Box in or out to adjust the flow rate. 14) Test the disconnected helium sensor (upper oxygen sensor) safety by unplugging the upper sensor (S1). The Control Module should immediately close the helium solenoid valve. The screen should display Nitrox only. Check for flow at the helium poly tubing at the Gas Blending Tube as previously described above. 3.7c Testing the Compressor Shut-Off Safety Circuit 15) Shut off the air compressor. The Control Module should immediately shut off the oxygen and helium solenoids and display Compressor Stopped. Check for oxygen or helium flow by unplugging the oxygen and helium poly tubes from the Gas Blending Tube as before. 16) Safety tests complete. 17
3.8 Oxygen Regulator Optimal Setting Procedures for Use of External Oxygen Cylinders (ONLY) 3.8.a Needle Valve Systems If your Tri-Ox Maker Valve Box has silver or brass stem knobs follow the procedure below. 1) Start with the oxygen supply tank valve closed and the Oxygen Supply Pressure Regulator valve to zero. 2) Close the Tri-Ox Maker Control Module Box oxygen needle valve all the way by turning the knob clockwise until it seats. 3) Start the Tri-Ox Maker Control Module by pressing the Power button, allowing it to do its self-diagnosis. 4) Start the compressor. 5) Auto-calibrate the Oxygen Sensors. 6) Press the Up button to start reading the oxygen in the Gas Blending Tube. Ensure the calibration of the oxygen sensors was done correctly by reading the oxygen percentage in the natural air (should be 20.9%). 7) Open the Tri-Ox Maker Control Module Box oxygen needle valve all the way by turning the knob counter clockwise until it stops. 8) Slowly open the oxygen supply tank valve and then adjust the Oxygen Supply Pressure Regulator to 20 psi (1.4 Bar). Observe the initial percentage of oxygen in the Gas Blending Tube. 9) Slowly raise the Oxygen Supply Pressure Regulator pressure setting by turning the control knob clockwise, allowing time for the Tri-Ox Maker Control Module s oxygen reading to stabilize until the Control Module reaches 40% and shuts off the oxygen solenoid. This is the optimal pressure for the Oxygen Supply Pressure Regulator. 10) Repeat the procedure for the Helium except increase the supply pressure until you reach the highest percentage of Helium you expect to blend. 18
NOTE Both O2 and He regulators can be adjusted to higher pressures if necessary (maximum 90 psi). Such pressures are sometimes needed to make a high O2 or high He mix. 3.8.b Pressure Regulator Control Systems If your Tri-Ox Maker Valve Box has black STC pressure-lock knobs follow the procedure below 1) Start with the delivery valve on the oxygen supply tank closed and the Oxygen Supply Pressure Regulator set at zero pressure. 2) Open both needle valves at the injection points on the Gas Blending Tube all the way open. Lock setting by turning the locking nuts provided. 3) Unlock the Oxygen Delivery Pressure Regulator on the Tri-Ox Maker Control Module Box by pulling it out until you hear a click. Adjust the Oxygen Delivery Pressure Regulator all the way to zero by turning the knob all the way counter-clockwise. 4) Start the Tri-Ox Maker Control Module by pressing the Power button, allowing it to do its self-diagnosis. 5) Start the compressor. 6) Auto-calibrate the Oxygen Sensors. 7) Press the Up button to start reading the oxygen in the Gas Blending Tube. Ensure the calibration of the oxygen sensors was done correctly by reading the oxygen percentage in the natural air (should be 20.9%). 8) Adjust the Tri-Ox Maker Control Module Box Oxygen Delivery Pressure Regulator all the way to full open by turning the knob clockwise until it reaches its stop. 9) Slowly open the oxygen supply tank valve and then adjust the Oxygen Supply Pressure Regulator pressure to an initial setting of 20 psi (1.4 Bar). Observe the oxygen percentage in the Gas Blending Tube. 10) Slowly increase the pressure coming from the Oxygen Supply Pressure Regulator until the mixture in the Gas Blending Tube reaches 40% oxygen and shuts off the oxygen solenoid. This is the optimal setting for the Oxygen Supply Pressure Regulator. 19
3.8C Creating Helium Mixes with the Tri-Ox Maker and the NitroxMaker Tri-Ox Maker Gas Mixing System 1) The Tri-Ox Maker must be calibrated with atmospheric air entering the mixing tube (i.e 20.9%). The NitroxMaker should be OFF as no Nitrox should be entering the mixing tube. 2) Verify that the connection from the Helium supply regulator is complete to the Tri-Ox Maker. system. He Lines - Quick disconnect input located on the right rear of Tri-Ox Maker panel. - Helium output from low pressure. - Quick disconnect to low pressure Helium. - Helium input from low pressure. 20
3) Adjust the output pressure of the Helium regulator to between 30-60 psi. 4) Enable Power On to the Tri-Ox Maker by depressing the Red power on button located just below the left hand side of the display. 5) When the Tri-Ox Maker is powered up turn on the compressor to get clean air flowing through the mixing tube. Press and hold the calibration button located on the right hand side of the display until the system indicates that it is calibrated. S1 and S2 should read 20.8% Oxygen. 6) Turn ON the NitroxMaker and adjust the output flowing to the mixing tube to the desired percentage (i.e.32%). The S2 reading on the Tri-Ox Maker should now reflect the same percentage as that flowing from the NitroxMaker. 21
7) Press the Yellow up arrow button located beneath the right hand side of the display to enable gas flow to the Tri-Ox Maker. You should see a readout of the O2 percentage from the NitroxMaker next to the S2: line of the display. 8) Turn on the needle valve located to the right of the Helium label on the mixing tube. 9) View the calculated percentage of He located directly below the CALC. He label on the right hand side of the LCD readout. When the percentage is where you want the mix to be tighten down the lock nut on the needle valve. S1: 10.8 CALC. He S2: 32.0 / 30 % 10) Use the helium adjustment valve located to the lower right of the display to make fine adjustment to the helium percentage. When the precise percentage is reached depress the Helium control valve down to lock it into place. S1: 20.8 CALC. He S2: 20.8 / 0.0% 11) You may begin filling tanks with the tank fill compressor at this point. WARNING Must analyze your resulting mix for both Helium and Oxygen percentages before attempting to breath this gas. 22
3.8 D Connection of Teco 7200 20 HP Frequency Drive 1) With the faceplate of the Teco Drive open connect terminal block labeled L1 and L2 located on the lower left hand side of the Teco Drive to 220-230 VAC line 1 and line 2. L1 L2 240V T1 T2 T3 2) Connect the three phase output form T1/T2/T3 to the three phase input to the NitroxMaker (Kaeser) compressor motor. It is important to check for phase rotation on the Kaeser. The Kaeser will not start if the rotation is incorrect. The procedure to correct this involves removing two of the wires and switching them. If in doubt consult a professionally licensed electrician for installation. 3) Replace the cover plate and depress the Start button located centrally on the Teco Drive. 23
4) When the Teco Drive has started the Nitrox Maker may be energized. Tri-Ox Maker Gas Mixing System 5) When powering off it is necessary to first power down the NitroxMaker (Kaeser) compressor and then depress the Stop button on the Teco Drive. 24
NOTE Both O2 and He supply tank regulators can be adjusted to higher pressures if necessary (maximum 120 psi). Such pressures are sometimes needed to make a high O2 or high He mix. 3.9 Installation Verification Tests 1) Start and run your air compressor. 2) Power up your Tri-Ox Maker Gas Mixing System by pressing the Power button. Wait while the electronics does a self-diagnosis. 3) Press the Auto-calibrate button. Hold until display says Calibration Complete. 4) Press the UP button to start the flow of gases. 5) Adjust the gas flows using the needle valves, pressure regulators, or potentiometers on the Tri-Ox Maker Control Module Box to obtain the mixture you want. DANGER The Tri-Ox Maker system does not automatically adjust the flow for you, it only monitors the flow. It is the operator s responsibility to keep the flows where they want them. 6) Allow several minutes for the blend of gases to flush through the separators and purifiers on your compressor system before connecting it to an empty SCBA or SCUBA bottle. 7) Fill the test bottle with the mix coming from the compressor. 8) Shut-down the compressor or the Tri-Ox Maker Control Module and re-direct the compressor discharge as desired. 9) Measure the gas mix in the test bottle using your existing methods to confirm that the gas mixture produced was correct. 10) Assuming the results were correct, your Tri-Ox Maker Gas Mixing System is now ready to use. 11) Reduce the Oxygen Delivery Pressure Regulator pressure to zero. 12) Repeat the procedure for the Helium supply except raise the Helium supply pressure at the Helium Supply Pressure Regulator until the Helium reading on the Tri-Ox Maker Control Box reads 80% or whatever your maximum Helium blend will be. If you rarely will make high percent Helium mixes, you may wish to set the maximum flow by adjusting pressure at the Helium Supply Pressure Regulator to the minimum that will deliver the volume of Helium normally used. This will minimize your Helium losses. On the rare occasions when you need more, you need only to increase the pressure at the Helium Supply Pressure Regulator. 13) Reduce the settings of the Delivery Pressure Regulators at the Tri-Ox Maker Control Module Box to zero or whatever you wish your standard setting to be such as 32% Oxygen for making Nitrox. You should normally keep the Helium regulator turned down to zero when not making tri-mix gases. 25
4.0 OPERATION 4.1 Introduction 1) The Tri-Ox Maker Gas Mixing System is a precision gas blending device for mixing Nitrox and Trimix Diving Gas mixtures. It continuously monitors the oxygen and helium levels in the gas mixture entering the high-pressure air compressor system. The operator sets the desired gas mixture by adjusting the control valves or potentiometers on the Tri-Ox Maker Valve Box. The Tri-Ox Maker Gas Mixing System DOES NOT automatically adjust the flow rates it only monitors them. CAUTION The Tri-Ox Maker Control Box will not stop the compressor if a supply bottle runs out. It will display the percentage drop as the supply runs dry. It is the operator s responsibility to periodically monitor the Tri-Ox Maker control module display. 4.2 Operating Limitations 1) The Tri-Ox Maker Control Box is not waterproof. It must be protected from excessive moisture. If located where it would be exposed to the weather, it must be enclosed in a rain-tight box or otherwise protected from rain. 2) The Tri-Ox Maker Control Box is not electrically explosion-proof. It cannot be located in an explosive atmosphere environment. 3) The internal components of the Valve Box are rated for 120 psi (8.0 bar) maximum incoming gas pressure. 4) The Tri-Ox Maker Control Box has not been tested in temperature extremes. 4.3 Controls and Indicators 1) Supply Gas Pressure Regulators are adjustable and should be set at a maximum of 60 psi (4 bar). (See Oxygen Regulator Optimal Setting Procedures above.) 2) Gas flow control Needle Valves or Pressure Regulators or potentiometers are manually adjusted by the operator in order to obtain the desired gas mixture. They are located in the Tri-Ox Maker Control Module Box. The oxygen and helium percentages in the gas blend are displayed on the Tri-Ox Maker Control Module screen. The oxygen values of sensor 1 and 2 are on the left side, and calculated Helium partial pressure on the bottom right. 4.4 System Operation 4.4.1 Prestart Procedures 1) Ensure that adequate oxygen and/or helium supplies are in place and the Supply Pressure Regulators are connected to the supply tanks. 2) Ensure that the oxygen and helium supply tank valves are closed. 3) Inspect and ensure that all gas tubing is properly connected. 4) Inspect and ensure that Oxygen Sensor wires are properly connected. 26
4.4.2 Startup 1) Start the air compressor with discharge to atmosphere. 2) Turn on the Tri-Ox Maker Control Module by pressing the Power button. 4.4.3 Oxygen Sensor Auto-Calibration WARNING Calibrate the Oxygen Sensors every time the Tri-Ox Maker is turned on. 1) Press and hold the Calibrate button until the display shows Calibration Complete. (This usually takes about 5 seconds.) 2) Touch the UP arrow to activate the solenoids and get a reading on the Control Module screen. The reading should be 20.8-21% for atmospheric air. If not, press and hold Calibrate again and then the UP arrow again. 4.4.4 Oxygen Sensor Manual Calibration The sensors can be manually calibrated by performing the following steps: 1) Turn off the supply bottles. 2) Press the Calibrate button but do not hold it. The S1 reading will flash. 27
3) Press the UP or Down arrow to set the S1 reading to 20.9% 4) Press the Calibrate button again, the S2 reading will flash. 5) Press the UP or Down arrow to set the S2 reading to 20.9%. 4.4.5 Starting Blending 1) Open the discharge valves on the oxygen and/or helium supply tanks. 2) Adjust the oxygen and/or helium supply tank Gas Pressure Regulators to the pressures determined in the initial setup. 3) Touch the UP arrow on the Control Module on the Tri-Ox Maker Control Box to start the gas flow. 4.4.6 Adjusting the Gas Mixture 1) Turn the oxygen and/or helium knobs on the Tri-Ox Maker Control Module Box until the desired gas mixture is displayed. DANGER The oxygen and helium knobs on the Valve Box are attached to high precision needle valves, pressure regulators or potentiometers depending on the model you have purchased. The Tri-Ox Maker Control Module DOES NOT REGULATE THE GAS FLOW. It only reads the oxygen sensors, does the necessary calculations and displays the gas mixture that the operator manually sets with the controls. The gas mixture must be monitored by the operator and adjusted as necessary as the gas mixture is produced. 2) Gauge the output mixture to be sure when the correct gas mixture has flushed through the compressor filters and piping. This could be 4 minutes depending on how many filters, purifiers, length of piping, etc. that your particular installation has. See Section 5.0 28
3) When the desired mixture has been proven and stabilized at the fill whip or compressor output, attach a filling whip to a scuba cylinder or gas storage bank. 4) Continue to monitor the gas mixture at the Control Module and double-check the gas mixture with an oxygen helium analyzer before use. 5) Continue to monitor the pressure in the gas supply bottles to be sure you do not run out of gas supplies. This is particularly important where you are filling a large bank system. The system does not detect loss of supply gas pressures. 4.4.7 Shutdown CAUTION Stopping the air compressor will stop the flow of oxygen and/or helium due to the Gas Safety Relay Switch in the air compressor control cabinet. Using this method, however, will result in oxygen and/or helium enriched gas being left in the air compressor and the gas purification filters and could result in the enriched gas mixture being accidentally introduced into a SCUBA bottle or compressed air storage bank. For these safety reasons, it is best to flush the enriched gas mixture from the system before shutting down. Remember, the Tri-Ox Maker Gas Mixing System is merely a tool to assist you in blending gases. The operator is still responsible to be sure the mix is correct. 1) To turn off the Tri-Ox Maker Control Module, press and hold the Power button until the display shows Gas Off. To shut off the Tri-Ox Maker Module completely, again press and hold the Power button until the display shows Shutting Off. This takes about 5 seconds. Release the Power button while Shutting Off is displayed. 2) Shut off your compressor. 3) Shut off the oxygen and helium supply bottles. Shutting off the oxygen and helium supply bottles when not in use will prevent loss of valuable gases through any system leaks that you may not have detected. 29
5.0 GAUGING THE OUTPUT MIXTURE DISPLAY BEFORE FILLING TANKS Tri-Ox Maker Gas Mixing System We attached a pressure reducing nipple to a line valve and then to our air block which allows us to plug the portable sensor directly to the block and monitor the gas mixture before it goes into the tanks. Method #1 using Tankfill Analyzer Sample Regulator Output Install RA 12RP Hose Here HP Compressor Sample Regulator Install Downstream HP Compressor Final Filtration Method #2 Reducing Regulator for Output Sample 30
6.0 SCHEDULED MAINTENANCE 6.1 Cleanliness 1) When changing gas supply bottles, ensure that the bottle discharge port and the gas pressure regulator are clean and free from foreign matter. Cracking the valves on the supply bottles briefly will blow out any debris. 6.2 Oxygen Sensors 1) You can expect to get about a year of accurate readings from your oxygen sensors. We recommend that you replace your sensors every year to avoid the symptoms of failure. 6.3 Intake Air Filter 1) Depending on your environment, the Intake Air Filter will need to be cleaned periodically. Start out by checking / cleaning / replacing this filter at the same time as you check / replace your purifier filters. Increase or decrease the frequency depending on your local needs. 7.0 TROUBLESHOOTING GUIDE Symptom: When you try to Auto-Calibrate the Tri-Ox Maker Control Module, the readings won t hold 20.8-21%. Cause: One or both of the oxygen sensors are bad. Replace the oxygen sensors and recalibrate the Control Module. Symptom: Dialing an adjustment to the desired mix does not change the reading on the Control Module. (Usually this comes from the helium pressure.) Cause: There is too much incoming pressure from the supply tank Gas Pressure Regulator on the control solenoid. Turn down the regulator pressure to 30 psi (2 bar). Turn off the oxygen and helium supply tank valves. Remove the hoses from the Valve Box or the regulators and allow the pressure to bleed off. Then re-insert the hoses and turn on the oxygen and helium supply tank valves. 31
8.0 Fill Charts We have provided easy to read charts for partial-pressure blending using common banked gases: 21%, 32%, 34%, and 36%. By using these charts, in most cases, you will no longer have to empty your scuba cylinder and waste expensive gas to get the mix you want. Accurate fills are best accomplished using a digital pressure gauge. How to Use Pressure Fill Charts: 1) Analyze the existing mix and pressure in the scuba cylinder. 2) Refer to the chart that corresponds to the gas mixture that you keep in your bank. 3) Find the target mixture in the left column. 4) Follow the row across to the target pressure. 5) The number in the cell is the psi of 100% O2 that you should add to the scuba cylinder. 6) Top the scuba cylinder to the target pressure using your banked gas mixture. Hint: Target pressures that are not shown on the spreadsheet can be calculated by multiplying the existing pressure by the Base Number Multiplier (Multiplier) in the left column. Example: If we start with a tank that has 32% Nitrox in it and the customer wants to end up with 3000 psi of 40% Nitrox we would add 363 psi of O2 to whatever pressure is already in the tank then top off with our banked 32% to 3000 psi final pressure. 32
How to Use the Continuous Blending Chart: Only change the values on the spreadsheet that are in red. We have provided a sheet for psi and another sheet for bar in the same Excel spreadsheet. 1) Enter the existing mix and pressure in the scuba cylinder into the Contents in Tank section. 2) Enter the target mix and pressure in the Fill Info section. 3) Enter your banked mix in the Mix Top Off section. 4) Enter your prices in the Gas Prices section. 5) When completed, the Air Top Off section shows you what you will end up with if you add air to your existing mix. 6) The Mix Top Off section shows what you will end up with if you simply add your banked mix to the existing mix. 7) The Mixing Info section shows how to partial pressure blend the desired mix and the cost to do so. We ve provided target pressures when adding oxygen first and also when adding helium first so the blender can use the method they are most comfortable with. Most of the time, unless the target mix exceeds 40% oxygen, it is preferable to use the Tri-Ox Maker to obtain the desired mix. 8) The Tri-Ox Maker Mix section shows how to set the Tri-Ox Maker Control Box to continuously blend the desired mix. 9) Use the Dive Calculators to enter your maximum depth, Equivalent Nitrogen Depth and PO2. 10) Dive Calculator #1 shows you your ideal mix. Enter these values into Dive Calculator #2 and Calculator #3 NOTE If the numbers on the Continuous Blending Chart show negative numbers this indicates an impossible mix. On the spreadsheet, lower the PSI in Tank in the Contents in Tank section until the numbers are no longer negative. Then drain the tank pressure to match the pressure you arrived at on the spreadsheet and proceed with the fill. 33
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