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
11/2013 - Rev. 12
**CAUTION**
It is MANDATORY that this instruction manual be read and understood by all persons operating this
High Pressure Nitrogen Booster.
TABLE OF CONTENTS
PAGE
11/2013 | Rev. 12
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., its suppliers, distributors, employees, or financial institutions from any liability
from consequences that may occur. Only Tronair OEM replacement parts shall be used.
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:
DO NOT EXCEED 3000 PSIG (276 BAR) NITROGEN SUPPLY BOTTLE PRESSURE.
DO NOT use High Pressure Nitrogen on Low Pressure aircraft components or systems such as tires,
etc.
DO NOT use with Oxygen or gases other than Nitrogen.
Servicing and maintenance if nitrogen systems shall be done by only trained and qualified personnel
using approved procedures.
2.0 SPECIFICATIONS/FEATURES
Dimensions:
Height: 36-7/16 in (92.5 cm)
Length: 80-1/8 in (203.5 cm)
Width: 30-1/8 in (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, 3000 psi max
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, 37º JIC (female flared swivel fitting) at aircraft hook-up end
Minimum supply bottle pressure: 250 psig (17 bar)
Nitrogen input to booster pump: 80 SCFM at 150 psig (10.3 bar) maximum
Booster high pressure air pilot: 4000 psig (276 bar)
Booster high pressure relief 4400 psig (303.4 bar)
Temperature Range:
0º to 200ºF (17.7º to 93.3º C)
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).
Figure 1 - Schematic
11/2013 | Rev. 12 Page | 2
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.
WARNING!
DO NOT use on low pressure Nitrogen system or components.
1. Connect the “RED” high pressure output hose from the booster to the aircraft.
2. Fully open Nitrogen supply bottles valve (250 min on bottle pressure gauges).
3. Slowly adjust low-pressure regulator valve to 140 psi (9.7 bar) max to send Nitrogen to the Nitrogen booster. Clockwise
rotation increases pressure, and counter-clockwise rotation reduces pressure. Since the Nitrogen booster pump
compression ratio is 30:1, 135 psi (9.3 bar) of low pressure regulator inlet will develop approximately 4000 psi (276 bar) of
output Nitrogen pressure.
4. Open booster pump supply valve.
5. With output valve closed, adjust the high pressure regulator to obtain
desired output Nitrogen pressure required by the chart.
6. Open booster output valve.
6.0 MAINTENANCE
Maintain 45 to 50 psi (3.1 to 3.4 bar) 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 Hydraulic International, Operation and Maintenance Instructions.
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.
6.1 STORAGE
Store the unit in a clean, dry area when not in use.
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.
The obligations of Tronair expressly stated herein are in lieu of all other warranties or conditions expressed or implied. Any
unauthorized modification of the Tronair products or use of the Tronair products in violations of cautions and
warnings in any manual (including updates) or safety bulletins published or delivered by Tronair will immediately
void any warranty, express or implied and Tronair disclaims any and all liability for injury (WITHOUT LIMITATION and
including DEATH), loss or damage arising from or relating to such misuse.
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
* When ordering a replacement of TF-1043-07*180 High Pressure Output Hose, also order EC-1057-02*12.0 (qty.of 2)
** When ordering a replacement of TF-1043-07*300 Low Pressure Output Hose, also order EC-1057-05*12.0 (qty. of 2)
Parts List
When ordering replacement parts/kits, please specify model, serial number and color of your unit.
Hydraulic International
Operation and Maintenance
Instructions
APPENDIX II
Smith’s
Installation &
Operation Guide
Pressure Regulators
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.
Declaration
of
Conformity
DECLARATION of CONFORMITY
The design, development and manufacture is in accordance with European Community guidelines
18-4208-0010