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
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. 2 11/13
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 NitroxMaker TM 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 NitroxMaker TM System...11 NMCS Views...12 NitroxMaker TM Commercial Series 7.5...12-13 NitroxMaker TM Commercial Series 10...14-15 NitroxMaker TM Commercial Series 20...16-17 NitroxMaker TM Commercial Series 30...18-19 Compressed Air Filters...20 Specifications...21 Log Pages...22-23 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. 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. 4
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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 NitroxMaker TM components. If there is doubt in the quality of the air being compressed please discontinue use of the NitroxMaker TM 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 6
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. 7
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. 8
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. 9
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. 10
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. 11
7.5 1 Compressor/Dryer Control Panel 2 3 Emergency OFF Rotary Screw Compressor 4 Dryer Electronic Demand Drain Receiver OUT Valve 11 ECO-DRAIN 12
7.5 12 Receiver Pressure Gauge 7 Air Receiver (Tank) Intake Filter 18 Membrane 17 Mixing Tube 20 6 Access Panel (Cover) Temperature Controller 21 Heater Element 22 11 Receiver OUT Valve Waste Port Regulators 19 9 LP Filter Array 9 16 Supply Pressure Gauge Nitrox Mix Controller 13 Gas Analyzer 14 Flow Meter 15 Selector Valve 13
10 Compressor/Dryer Control Panel 1 Emergency OFF Rotary Screw Compressor Nitrox Production Control Panel Dryer 2 3 5 4 Access Panel 6 Air Receiver 7 17 Membrane 12 Receiver Pressure Gauge 14
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 15
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 8 16
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 Receiver OUT Valve 10 11 24 Nitrox Transfer Hose 17
30 Compressor/Dryer Control Panel 1 Dryer 4 3 Rotary Screw Compressor Emergency OFF 2 Nitrox Production Control Panel 5 Access Panel 6 Air Receiver 7 Receiver Pressure Gauge 12 11 Receiver OUT Valve LP Filter Array 8 Receiver Out Valve 9 10 Receiver In Valve 18
30 13 Gas Analyzer 9 Supply Pressure Gauge 14 Flow Meters 15 16 Selector Valves Nitrox Mix Controller Intake Filter 18 Waste Port Regulator 19 Mixing Tube 20 Membrane Temperature Controller 17 21 Heater Element 22 Nitrox Transfer Hose 24 19
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 4 1 Delta P Slide Indicator Ensures economical operation by changing color when filter element requires replacement. Fitted as standard on filters up to 60 scfm (excluding KVA). 1 2 Color Coded Elements Allows easy identification. Elements are designed using the latest media innovations and manufacturing technology. 5 3 Internal Automatic Drain Reliably discharges collected condesate (excluding KVA and KFS 250 & above). 2 4 Delta P Gauge 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). 5 Modular Connections Space-saving design allows housings to be connected in series without additional piping. 6 Liquid Level Indicator Visually monitor liquid level and verify drain operation. 3 6 Visually monitor liquid level and verify drain operation. 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 Cannister 1 Cannister 2 Cannister 3 Kaeser Oil Removal Element Kit Kaeser Oil Removal Element Kit Kaeser Oil Removal Element Kit NMCS-7.5 99.99+% liquid oil OR 35 99.999+% liquid oil OX 35 0% liquid removal VF 35 NMCS-10 removal removal.01 micron solid OR 35 OX 35.01 micron solid.01 micron solid particle VF 35 NMCS-20 particle OR 60 particle OX 60 0 ppm max liquid VF 60 NMCS-30 1000 ppm max liquid OR 100 100 ppm max liquid OX 100 loading loading loading VF 100 20
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) Capacity @ rated pressure (CFM) 155 160 160 160 24 35 77 104.2 Airend Type (Sigma) 05 026 10 13 Noise Level (db(a)) Standard Elec Configuration (V±10% acceptable) 69 66 66 71 110/1/60 dryer 208/3/60 240/3/60 460/3/60 Amp Draw (5.5 @ 115v) 19.8 18.7 9.4 208/3/60 240/3/60 460/3/60 33 31 16 208/3/60 240/3/60 460/3/60 58 55 28 208/3/60 240/3/60 460/3/60 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) Weight (pounds) Ambient Operating Temp ( F / C) 27.5 x 52 x 58h 31 x 50 x 69h 36 x 55 x 74h 85 x 36 x 74h 750 1000 1250 1490 40-115F 4.5-46C 41-115F 4.5-46C 42-115F 4.5-46C 43-115F 4.5-46C 21
Date Hours Operator Observations, Comments 22
Date Hours Operator Observations, Comments 23
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