Operation & Service Manual: Model: 18-4208-0010 Four Bottle Nitrogen Cart With Booster and Manifold/Regulator
Operation & Service Manual: Model: 18-4208-0010 Four Bottle Nitrogen Cart With Booster and Manifold/Regulator
Operation & Service Manual: Model: 18-4208-0010 Four Bottle Nitrogen Cart With Booster and Manifold/Regulator
Model: 18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
02/2004 - AB - Rev. 05
**CAUTION**
It is MANDATORY that this instruction manual be read and understood
by all persons operating this High Pressure Nitrogen Booster.
Includes Illustrated Parts List
Tronair, Inc.
1740 Eber Road
Holland, Ohio 43528-9794
USA
Telephone: (419) 866-6301 • 800-426-6301
Fax: (419) 867-0634
Web Site: www.tronair.com E-mail: [email protected]
18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
TABLE OF CONTENTS
PAGE
02/2004 - AB - Rev. 05
18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
This product can not be modified without the written approval of Tronair, Inc. Any modifications done without
written approval voids all warranties and releases Tronair, Inc., it suppliers, distributors, employees, or financial
institutions from any liability from consequences that may occur.
CAUTION!
It is MANDATORY that this instruction manual be read and understood by all persons
operating this High Pressure Nitrogen Booster.
The booster provides the capability of boosting remaining lower pressure Nitrogen from supply bottles to the
required higher aircraft system pressure; up to 4000 psig maximum.
WARNING!
To Avoid Serious Injury, Loss of Limb, or Death:
1. DO NOT use on Low Pressure aircraft components or systems such as tires, etc. This
is a Regulated Nitrogen Source equal to supply pressure.
2. DO NOT use with Oxygen or gases other than Nitrogen.
3. DO NOT exceed 4000 psig (276 bars) Nitrogen pressure.
2.0 SPECIFICATIONS/FEATURES
Dimensions:
• Height: 36-7/16 inches (92.5 cm)
• Length: 80-1/8 inches (203.5 cm)
• Width: 30-1/8 inches (77.5 cm)
• Weight: 360 lbs (163 kg)
Cart:
• Easy loading
• Use with all standard nine inch (9 in/22.9 cm) diameter Nitrogen bottles; CGA 580 connection
• Adjustable bottle stop
• Bottles fully captured
• Pneumatic tires
• Parking brake
• Hose compartment
• Instrument Panel
Booster:
• Output hose: 25 ft (7.6 m) long with #4, 37 JIC (female flared swivel fitting) at aircraft hook-up end
• Nitrogen output rating: 4000 psig (276 bars) maximum. (Do not exceed)
• Maximum supply bottle pressure: 1160 psig (78 bars)
• Minimum supply bottle pressure: 220 psig (15 bars)
• Nitrogen input to booster pump: 80 SCFM at 150 psig (10.3 bars) maximum
• Booster high pressure air pilot: 4000 psig (276 bars)
• Booster high pressure relief 4400 psig (303.4 bars)
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
CAUTION!
It is mandatory that this instruction manual be read and understood by all persons
operating this High Pressure Nitrogen Booster.
3.1 GENERAL
Information presented in this manual and on various labels, tags, and plates on the unit pertains to
equipment design, installation, operation, maintenance and trouble shooting which should be read,
understood, and followed for the safe and effective use of this equipment.
3.2 SAFETY
The operation, maintenance, and trouble shooting of this high pressure Nitrogen booster requires
practices and procedures which ensure personal operator safety and the safety of others. Therefore,
this equipment is to be operated and maintained only by qualified persons in accordance with this
manual and all applicable local codes.
NOTE: Safety instructions specifically pertaining to this unit appear throughout this
manual highlighted by the signal words WARNING, CAUTION, DANGER which
identify different levels of hazard.
WARNING: Denote practices which, if not carefully followed, could result in serious personal
injury and/or death.
CAUTION: Denote practices which, if not carefully followed, could result in minor personal injury
or damage to this equipment.
Nitrogen equipment must be kept clean and free from contaminants at all times. It is imperative that
all inspection, maintenance, testing and servicing of Nitrogen system components be done by trained
and qualified personnel using approved procedures.
CAUTION!
Maximum towing speed is 10 mph (16 km/h).
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Figure 1
Schematic
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
General: Information presented in this manual and on various labels on this unit pertains to equipment
Specifications, Installation, Operation, Maintenance and Trouble Shooting which should be
read, understood and followed for the safe and effective use of this equipment.
Training: Read this entire manual prior to operation of the unit. All personnel using this Nitrogen
Booster should understand and follow this manual and receive training. We encourage our
customers to call Tronair to discuss any operating or testing requirements. Telephone
419-866-6301 or 800-426-6301.
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
WARNING!
If there are any differences between the following instructions and the aircraft
maintenance manual, the aircraft maintenance manual will take precedence.
Reference Illustrated Parts Lists for replacement components.
1. Be sure all valves and controls are in the closed or “Off” position.
2. Decrease all pressure regulators to the minimum pressure setting. The regulator adjustment
knobs are the rotating type. Clockwise rotation of the knob increases pressure and counter-
clockwise rotation reduces pressure.
3. Connect Nitrogen fill line loosely to aircraft and purge line by slowly cracking open Nitrogen
supply bottle shutoff valve.
4. Tighten Nitrogen fill line connection at aircraft.
5. Generally check unit and assure the tightness of all fittings, nuts and bolts.
6. The high pressure Nitrogen booster is now ready to charge an aircraft Nitrogen system.
WARNING!
Be sure fill line is secured prior to purging the unit. This will prevent the hose end from
“whipping” if too much Nitrogen is allowed to flow through the unit.
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
1. If the Nitrogen supply bottle pressure is lower than the aircraft Nitrogen system pressure, check
valves in the Nitrogen booster will prevent back flow from the aircraft.
2. Connect the “RED” high pressure output hose from the booster to the aircraft.
3. Slowly open Nitrogen supply bottle valve.
4. Slowly adjust low-pressure regulator valve of the manifold assembly to send Nitrogen to the
Nitrogen booster.
5. Adjust the manifold low pressure regulator to prevent over-pressurization of the booster pump
regulator. Clockwise rotation increases pressure, and counter-clockwise rotation reduces
pressure. Since the Nitrogen booster pump compression ratio is 30:1, 135 psig (9.3 bars) of low
pressure regulator inlet will develop approximately 4000 psig (276 bars) of output Nitrogen
pressure.
6. Adjust the booster regulator to obtain desired output Nitrogen pressure required by the chart.
7. Close low pressure regulator valve when desired aircraft Nitrogen pressure level is obtained.
WARNING!
DO NOT use on low pressure Nitrogen system or components.
Continued operation of this Nitrogen booster at pressures above 4300 psi (296.5 bars) may
result in premature disc rupture.
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
6.0 MAINTENANCE
• Maintain 45 to 50 psi (3.1 to 3.4 bars) tire pressure.
• Grease wheel bearings quarterly.
• All maintenance performed on this high pressure Nitrogen booster shall be conducted in accordance
with all applicable codes governing the handling, operation, installation and trouble shooting for high
pressure Nitrogen operation. Maintenance is to only be done by qualified persons.
• See Appendix I Maxpro Operating & Maintenance Instructions.
• Twice a year, or sooner if driven with Nitrogen or used heavily, the air cycling valve in the booster pump,
should be lubricated. The air cycling valve is separate from the Nitrogen side of the pump and can be
serviced without danger of Nitrogen system contamination. Reference Appendix I, Maxpro Maintenance-
Air Valve Section and Air Cycling Valve seals kit
• The gauges on this unit should be inspected and calibrated annually to maintain and ensure accuracy.
• Manifold inlet hoses should be inspected weekly for signs of cracking or kinking, replace as necessary.
• Inspect Nitrogen output hoses prior to each use for signs of cracking or kinking, replace as necessary.
• Generally keep the entire unit clean and free from any contaminants. Visually inspect for any system
leaks or damage. Correction of any problems prior to unit operation is imperative for safe operation.
WARNING!
Never apply high pressure gas to the high pressure section of this booster whenever the
air driven section of this unit is disassembled or when maintenance is being performed on
unit.
6.0 Maintenance continued on following page
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Ensure that all hoses are capped. The unit should be covered for the duration of unit storage to
ensure Nitrogen system cleanliness for future aircraft system recharging.
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Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Parts List
WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL & SERIAL NUMBER OF YOUR UNIT.
02/2004 - AB - Rev. 05
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Parts List
WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL & SERIAL NUMBER OF YOUR UNIT.
02/2004 - AB - Rev. 05
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Parts List
WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL & SERIAL NUMBER OF YOUR UNIT.
02/2004 - AB - Rev. 05
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Parts List
WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL & SERIAL NUMBER OF YOUR UNIT.
* When ordering a replacement of TF-1043-07*180 High Pressure Output Hose, order EC-1057-02*120,
(qty.of 2) in addition.
** When ordering a replacement of TF-1043-07*300 Low Pressure Output Hose, order EC-157-05*120
(qty. of 2) in addition.
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Parts List
WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL & SERIAL NUMBER OF YOUR UNIT.
02/2004 - AB - Rev. 05
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Parts List
REPLACEMENT PARTS
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18-4208-0010
Four Bottle Nitrogen Cart with
Booster and Manifold/Regulator
Parts List
Refer to the Parts Illustration on Page 14.
REPLACEMENT KITS
♦ Each kit contains enough parts to install two (2) check valves.
♦♦ Standard Nitrogen bottle fittings.
♦♦♦ Optional high pressure Nitrogen bottle fittings.
REPAIR KITS
02/2004 - AB - Rev. 05
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APPENDIX I
MAXPRO
Operating & Maintenance
Instructions & Drawing
APPENDIX II
TESCOM
44-1100 Series Regulator
Operation & Service
Instructions
Piston Sensed Pressure
Reducing
Regulators
Operation & Service Manual
Safety, Installation & Operation
Precautions
APPENDIX III
Instrument
Certification
Notice
Instrument Certification Notice
The gauge Certificates of Calibration supplied for the gauge(s) on this unit contain the
calibration data for the actual instrument calibrated, along with the calibration date of the
STANDARD used to perform the calibration check.
The due date for re-calibration of the instrument should be based upon the date the instrument
was placed in service in your facility. Re-calibration should be done on a periodic basis as
dictated by the end user's quality system or other overriding requirements.
Note that Tronair, Inc. does not supply certificates of calibration on flow meters or pyrometers
unless requested at the time of placed order. These instruments are considered reference
indicators only and are not critical to the test(s) being performed on the aircraft.
Tronair, Inc.
1740 Eber Road
Holland, Ohio 43528-9794
Phone: (419) 866-6301 ! 800-426-6301
Fax: (419) 867-0634
Web Site: www.tronair.com E-mail Address: [email protected]