OXYTRONIC 600 CONTINOUS FLOW NITROX SYSTEM COLTRI SUB OXYTRONIC 600 CONTINOUS FLOW NITROX SYSTEM

COLTRI SUB SAFETY

WARNINGS OPERATORS OF THE OXYTRONIC 600 NEED TO BE CERTIFIED GAS BLENDERS READ THE MANUAL BEFORE USING THE SYSTEM THE OPERATOR MUST STAY IN VISUAL RANGE OF THE SYSTEM THE MAXIMUM OXYGEN PERCENTAGE IS 40% OXYTRONIC 600 MUST BE MAINTAINED BY AUTHORIZED AND TRAINED PERSONNEL

ADVANTAGES OF SYSTEM OXYTRONIC 600 HAS A MAXIMUM APPLICATION OF 600L PER MINUTE NO WASTAGE OF OXYGEN LOW PRESSURE BLENDING MINIMIZES THE NEGATIVE AFFECTS OF REAL GAS LAWS SIMPLE SWITCHING BETWEEN BLENDS NO O2 CLEAN EQUIPMENT REQUIRED NO WASTAGE OF REMAINING GASES IN USED TANKS BLENDS CAN BE USED IMMEDIATELY. NO NEED TO WAIT EXTREMELY ACCURATE BLENDS CAN BE ACHIEVED

FEATURES OVERVIEW ACCUTRONIC INTELLIGENT SENSOR MAXIMUM PERCENTAGE SAFETY LIMITER MIXING RANGE ALARM NO FLOW ALARM MECHANICAL GAS VALVE EASY TO READ DISPLAY

COLTRI SUB ASSEMBLY

ASSEMBLY INSTRUCTIONS MOUNT THE STAINLESS STEEL PLATE TO THE WALL HANG THE OXYTRONIC 600 ON THE 4 MOUNTING BOLTS SCREW TO WALL HANG ON BOLT

ASSEMBLY INSTRUCTIONS ENSURE THAT THERE IS A POWER POINT NEARBY PREFERABLY WITH CURRENT SUPPLIED FROM THE COMPRESSOR. CONNECT THE POWER SUPPLY JACK PLUG TO OXYTRONIC 600 JACK PLUG

ASSEMBLY INSTRUCTIONS CONNECT THE OXYGEN CLEAN HOSE TO THE QUICK CONNECTOR OF THE OXYTRONIC 600. PUSH HOSE FIRMLY UNTILL YOU FEEL THE PIPE LOCATE QUICK CONNECT

ASSEMBLY INSTRUCTIONS CONNECT THE OTHER END OF THE OXYGEN CLEAN HOSE TO THE OXYGEN REGULATOR AND ATTACH TO O2 BOTTLE ENSURE ALL CONNECTIONS ARE CLEANED WITH COMPATIBLE CLEANING MATERIALS BEFORE CONNECTION PUSH TO CONNECT

ASSEMBLY INSTRUCTIONS CONNECT THE CORRUGATED HOSE TO THE INLET OF THE COMPRESSOR AND THE OTHER END TO THE OUTLET OF THE OXYTRONIC 600 CLAMP BOTH ENDS TIGHTLY WITH SUPPLIED CLAMPS

ASSEMBLY INSTRUCTIONS THE OXYTRONIC 600 IS NOW ASSEMBLED

COLTRI SUB SET UP

SET-UP PROCEDURES WHEN OPERATING FOR THE FIRST TIME OR AFTER CHANGING SENSORS, YOU NEED TO PAIR THE QXYGEN SENSOR TO THE OXYTRONIC UNIT PLEASE NOTE WHEN PERFORMING THE INITIAL SET –UP AS DESCRIBED IN THE FOLLOWING PAGES ANY RESIDUAL OXYGEN THAT MAYBE IN THE UNIT FROM PREVIOUS OPERATION IS TO BE FLUSHED OUT OF THE SYSTEM SO ONLY NORMAL AIR IS PRESENT IN THE INTERNAL PARTS. THIS CAN BE DONE BY RUNNING THE COMPRESSOR FOR 1 MINUTE WITH ALL OXYGEN VALVES CLOSED

SET-UP PROCEDURES BEGIN WITH ALL SWITCHES AND VALVES IN THE OFF/CLOSED POSITION ENSURE THE THE OXYGEN GAS VALVES ARE CLOSED AND THE OXYGEN REGULATOR VALVE IS FULLY UNSCREWED ANTI-COLCKWISE

SET-UP PROCEDURES CHECK POWER SWITCH IS IN THE OFF POSITION

SET-UP PROCEDURES WITH ALL SWITCHES AND VALVES CLOSED PRESS AND HOLD THE “ON/OFF” AND “PR” BUTTONS SIMULTANEOUSLY WITH BOTH BUTTONS HELD DOWN TURN THE POWER SWITCH TO THE ON POSITION CONTINUE TO HOLD DOWN THE TWO BUTTONS FOR 15 SECONDS OR UNTILL UNIT BEEPS TWICE

SET-UP PROCEDURES THE LCD SCREEN DISPLAY WILL NOW BEGIN TO RUN THROUGH A SERIES OF DIAGNOSTIC CHECKS AND SYMBOLS IF THE SET UP HAS BEEN PERFORMED CORRECTLY THE DISPLAY WILL SHOW THE CURRENT OXYGEN PERCENTAGE 20.9% THE CELL HAS NOW BEEN PAIRED WITH THE UNIT

CHECKING ELECTRO VALVE REPEAT TEST FREQUENTLY TO ENSURE VALVES ARE WORKING CORRECTLY

CHECKING ELECTRO VALVE SWITCH ON COMPRESSOR ENSURE MECHANICAL VALVE IS CLOSED ENSURE OXYGEN FLOW NEEDLE VALVE IS CLOSED OPEN O2 REGULATOR SET INTERMEDIATE PRESSURE ON O2 VALVE TO 5 BAR (SEE PAGE 32) TURN ON “ON/OFF” SWITCH RED LIGHT WILL COME ON PRESS “ON/OFF” BUTTON (GREEN FLOW LIGHT WILL COME ON)

CHECKING ELECTRO VALVE OPEN MECHANICAL GAS VALVE OPEN OXYGEN FLOW NEEDLE VALVE, O2% WILL SLOWLY INCREASE GAS WILL FLOW FROM THE OXYTRONIC 600 AND YOU WILL HEAR INTAKE NOISE OF GAS TURN “ON/OFF” SWITCH TO OFF, YOU WILL HEAR THE ELECTRO VALVE CLOSE AND OXYGEN WILL STOP FLOWING, O2 PERCENTAGE WILL DROP TO 21%

DO NOT USE HIGHER PERCENTAGES THAN 40% SETTING MAXIMUM O2% DO NOT USE HIGHER PERCENTAGES THAN 40%

SETTING MAXIMUM O2% THE OXYTRONIC 600 ALLOWS THE USER TO SET A RANGE ALARM PERCENTAGE SLIGHTLY ABOVE THE DESIRED OXYGEN FILL PERCENTAGE. WHEN THIS SETTING IS REACHED THE ELECTRO VALVE WILL AUTOMATICLY CLOSE AND STOP THE FLOW OF OXYGEN UNTILL THE PERCENTAGE DROPS 1% BELOW THE ALARM SETTING. AT WHICH POINT THE VALVE WILL RE OPEN. ALTERNATIVELY THIS ALARM MAY ALSO BE USED TO PROTECT AGAINST EXCEEDING THE MAXIMUM ALLOWABLE OXYGEN PERCENTAGE OF 40%

SETTING MAXIMUM O2% TURN ON UNIT WITH ON/OFF SWITCH. RED LIGHT WILL COME ON PRESS “ON/OFF” BUTTON FOR A FEW SECONDS UNTILL LCD READS ON AND PROCEEDS TO RUN THROUGH START UP DIAGNOSTIC. GREEN LIGHT WILL COME ON. PRESS AND HOLD “PR” BUTTON FOR 5 SECONDS. THE LCD DISPLAY WILL SHOW “PR” FOLLOWED BY “AL2” AND FINALY THE ALARM PERCENTAGE SETTING

SETTING MAXIMUM O2% TO ADJUST THIS SETTING PRESS “CAL” BUTTON, DIGITS WILL START TO FLASH USE “PR” BUTTON TO ADJUST SETTING AND “CAL” BUTTON TO SELECT DIGIT TO CHANGE WHEN THE DESIRED VALUE IS SET PRESS “ON/OFF” BUTTON, LCD WILL SHOW “END” TO INDICATE SETTING HAS BEEN SAVED NOTE, THIS SETTING REMAINS SAVED EVEN IF THE UNIT IS SWITCHED OFF

MEASUREMENT OF SENSOR DURING THE MIXING PROCESS A “REP” WARNING APPEARS ON THE LCD SCREEN WHEN THE OXYGEN SENSOR NEARS THE END OF ITS LIFE SPAN AND THE OPPERATOR IS ALERTED WITH THE FOLLOWING SIGNALS

MEASUREMENT OF SENSOR WHEN THE SENSOR IS 18% EXHAUSTED “REP” APPEARS EVERY 5 SECONDS. THIS IS ALARM 1 WHEN THE SENSOR IS 25% EXHAUSTED “REP” APPEARS EVERY 2 SECONDS. THIS IS ALARM 2 WHEN SENSOR IS 30% EXHAUSTED “REP” APPEARS PERMANENTLY. WHEN THIS WARNING IS SHOWN THE SENSOR MUST BE REPLACED AND THE NEW SENSOR START UP PROCEDURE CARRIED OUT

COLTRI SUB OPERATION

OPERATING PROCEDURES THIS PROCEDURE ASSUMES YOU HAVE ALREADY READ THE OPERATIONS MANUAL SUPPLIED WITH THE OXYTRONIC 600 AND ARE A CERTIFIED GAS BLENDER

OPERATING PROCEDURES START YOUR COMPRESSOR IN THE NORMAL MANNER CLOSE ALL THE OXYTRONIC GAS VALVES AND LEAVE OXYTRONIC 600 TURNED OFF AFTER COMPRESSOR HAS RUN FOR 1-2 MINIUTES CALIBRATE COMPRESSOR OUTPUT O2 ANALYZER TO AIR FLOW 20.9%

OPERATING PROCEDURES TURNING ON OXYTRONIC 600 TURN “ON/OFF” SWITCH TO ON RED LIGHT WILL COME ON PRESS “ON/OFF” BUTTON FOR A FEW SECONDS UNTILL LCD READS “ON” GREEN LIGHT COMES ON AND PROCEEDS TO RUN THROUGH START UP DIAGNOSTICS. PRESS AND HOLD “CAL” BUTTON FOR A FEW SECONDS. DISPLAY WILL BRIEFLY SHOW SENSOR VOLTAGE AND THEN SHOW O2 VALUE CALIBRATED TO AIR FLOW OF 20.9 % - 21%

SETTING INTERMEDIATE PRESSURE ON OXYGEN CYLINDER REGULATOR OPERATING PROCEDURES SETTING INTERMEDIATE PRESSURE ON OXYGEN CYLINDER REGULATOR BACK OFF REGULATOR “T” BAR ANTI CLOCKWISE OPEN O2 TANK VALVE UNTIL GAUGE ON RIGHT READS REMAINING GAS IN O2 TANK SLOWLY ROTATE INTERMEDIATE GAS REGULATOR “T” BAR CLOCKWISE UNTIL INTERMEDIATE PRESSURE GAS GAUGE READS 5 BAR DO NOT EXCEED 5 BAR. THIS CAN CAUSE DAMAGE TO THE O2 ELECTRONIC VALVE REMAINING GAS 5 BAR

OPERATING PROCEDURES DOUBLE CHECK OXYTRONIC NEEDLE VALVE IS FULLY CLOSED OPEN BALL VALVE BY MOVING HANDLE DOWN INLINE WITH VALVE BODY VERY SLOWLY OPEN NEEDLE VALVE UNTILL DESIRED O2 % IS REQUIRED. WHEN THE REQUIRED O2% READING IS REACHED AND STABILIZED ON THE COMPRESSOR IN LINE O2 ANALYZER YOU MAY PROCEED TO FILL CYLINDERS

OPERATING PROCEDURES CONSTANTLY MONITOR THE PERCENTAGE REQUIRED IF THE MAXIMUM O2 % RANGE ALARM SETTING IS REACHED THE RED LIGHT WILL COME ON THE ELECTRO VALVE WILL AUTOMATICLY CLOSE AND STOP THE FLOW OF OXYGEN UNTILL THE PERCENTAGE DROPS BY 1% BELOW THE ALARM SETTING, AT WHICH POINT IT WILL RE OPEN IF THE ELECTRO VALVE IS OPENING AND CLOSING THE O2 FLOW NEEDS TO BE REDUCED WITH THE NEEDLE VALVE

OPERATING PROCEDURES TURNING OFF OXYTRONIC 600 ONCE ALL TANKS ARE COMPLETED, THE USER MUST FOLLOW THESE STEPS IN ORDER CLOSE CYLINDER VALVES AND FILL COCKS CLOSE O2 TANK VALVE AND BACK OFF OXYGEN REGULATOR “T” BAR ALLOW COMPRESSOR TO RUN UNTILL INLINE COMPRESSOR ANALYZER READS 21%

OPERATING PROCEDURES TURNING OFF OXYTRONIC 600 WHEN LCD DISPLAY READS 21% CLOSE BALL VALVE CLOSE NEEDLE VALVE SWITCH OFF UNIT BY PRESSING “ON/OFF” BUTTON SWITCH OFF UNIT WITH “ON/OFF” SWITCH

OPERATING PROCEDURES NOTE IF A POWER FAILURE OCCURS, THE COMPRESSOR MUST BE RESTARTED BEFORE THE O2 CAN BE BLED FROM THE SYSTEM DUE TO THE NO FLOW SAFETY SYSTEM

ANOMALIES IN GAS BLENDING OPERATING PROCEDURES ANOMALIES IN GAS BLENDING DUE TO THE MECHANISM OF COMPRESSION O2 PERCENTAGE VALUE AT COMPRESSOR OUTPUT WILL BE SLIGHTLY LOWER THAN INPUT PERCENTAGE EXAMPLE:- A SETTING OF 36.5% ON THE OXYTRONIC WILL PRODUCE AN OUTPUT O2% OF APPROXIMATELY 36% THIS DIFFERENCE WILL VARY WITH DIFFERENT COMPRESSORS AND IS REPEATABLE ONCE ESTABLISHED

ANOMALIES IN GAS BLENDING OPERATING PROCEDURES ANOMALIES IN GAS BLENDING DUE TO RELATIVE HUMIDITY, THE ACTUAL ATMOSPHERIC O2 PERCENTAGE MAY NOT BE 20.9% PLEASE REFER TO COMPENSATION CHART IN INSTRUCTION MANUAL FOR MORE INFORMATION

COLTRI SUB SOFTWARE

BLENDING SOFTWARE THE OXYTRONIC 600 COMES SUPPLIED WITH A CD WHICH INCLUDES WITH AN EASY TO USE EXCEL FORMAT BLENDING CALCULATOR PLEASE LOOK AT THE FILE CALLED NITROX SOFTWARE.xls

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