Tronair 20-4500-7000 Installation and operating instructions

OPERATION & SERVICE MANUAL
Tronair, Inc. Phone: [phone] | 800-426-6301
1 Air Cargo Pkwy East Web: www.tronair.com
Swanton, OH 43558 Email: [email protected]
Model: 20-4500-7000
Oxygen Booster
03/2009 Rev. 10

REVISION DATE TEXT AFFECTED
05 08/2005 Modified Parts List
06 10/2005 Modified 3.3 Assembly
07 03/2008 Added CE marling and Declaration of Conformity
08 07/2008 Major revision
09 02/2009 Major revision
10 03/2009 Major revision

Model: 20-4500-7000
Oxygen Booster
03/2009 | Rev. 10
TABLE OF CONTENTS PAGE
1.0 DESCRIPTION..................................................................................................................................................................2
1.1 OPTIONAL EQUIPMENT AVAILABLE TO ENHANCE UNIT..............................................................................2
2.0 SPECIFICATIONS/FEATURES........................................................................................................................................2
3.0 SAFETY............................................................................................................................................................................3
3.1 GENERAL SAFETY REQUIREMENTS..............................................................................................................3
4.0 PREPARATION FOR USE/ASSEMBLY INSTRUCTIONS...............................................................................................4
4.1 UNPACKING.......................................................................................................................................................4
4.2 ASSEMBLY.........................................................................................................................................................4
4.3 PREPARATION FOR OPERATION....................................................................................................................4
5.0 OPERATION.....................................................................................................................................................................5
5.1 FILL PROCEDURE.............................................................................................................................................5
5.2 CHARGING THE AIRCRAFT OXYGEN SYSTEM..............................................................................................5
5.3 DISCONNECT PROCEDURE.............................................................................................................................5
5.4 TO READ INDIVIDUAL BOTTLE PRESSURE....................................................................................................6
5.5 EFFICIENT USE OF SYSTEM............................................................................................................................6
6.0 MAINTENANCE................................................................................................................................................................6
6.1 STORAGE ..........................................................................................................................................................6
7.0 SAE AIRCRAFT OXYGEN SPECIFICATION INFORMATION.........................................................................................6
8.0 TROUBLE SHOOTING.....................................................................................................................................................6
9.0 PROVISION OF SPARES.................................................................................................................................................6
9.1 SOURCE OF SPARE PARTS.............................................................................................................................6
10.0 GUARANTEES/LIMITATION OF LIABILITY....................................................................................................................7
11.0 APPENDICES...................................................................................................................................................................7

Model: 20-4500-7000
Oxygen Booster
03/2009 | Rev. 10 Page | 1
Schematic

Model: 20-4500-7000
Oxygen Booster
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This product cannot 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. Only Tronair OEM replacement parts shall be used.
1.0 DESCRIPTION
The Tronair Model 20-4500-7000 Pneumatic Oxygen Booster provides the capability of boosting remaining lower pressure
oxygen from supply bottle to the required higher aircraft system pressure; up to 2,250 psig maximum.
Consumer Requirement: This Oxygen Booster utilizes an air driven pressure amplifier, requiring 145 PSIG maximum air
pressure input at 80 SCFM volume.
1.1 OPTIONAL EQUIPMENT AVAILABLE TO ENHANCE UNIT
Tronair offers the following Oxygen Regulators:
Single supply bottle: Model Number 20-4502-6000
Four bottle cart: Model Number 20-4504-7000
DANGER!
TO AVOID SERIOUS INJURY, LOSS OF LIMB OR DEATH:
1. DO NOT use on LOW PRESSURE aircraft systems.
2. DO NOT use with ANY GAS OTHER THAN OXYGEN.
3. DO NOT exceed 2250 PSIG inlet oxygen bottle pressure into booster.
4. All components used in the oxygen system shall be clean, dry and free of all contamination per SAE
SPEC. AIR 1176.
5. Servicing and/or maintenance of oxygen systems shall be done by trained and qualified personnel
using approved procedures per SAE SPEC. ARP 1532.
2.0 SPECIFICATIONS/FEATURES
Dimensions...........................................24-9/16 inches long x 19 inches high x 16 inches deep
Weight................................................... 80 pounds
Output Hose..........................................15 feet long with #4 37º JIC female flare swivel fitting at aircraft hook-up end
Oxygen Output Rating.........................2250 psi (155 bar)maximum
Input to Booster Pump......................... 80 SCFM at 150 psi (10.3 bar) maximum
Booster High Pressure Air Pilot.......... 2500 psi (172 bar)
Booster High Pressure Relief..............2750 psi (189.6 bar)
Temperature Range..............................0º to 200ºF (17.7º to 93.3º C)
All plumbing, fittings, and components are cleaned for oxygen use. The unit and hoses are cleaned, packaged and shipped
separately to avoid any possible system contamination.

Model: 20-4500-7000
Oxygen Booster
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3.0 SAFETY
The operation, maintenance, and trouble shooting of this unit requires practices and procedures which ensure personal 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.
Safety instructions specifically pertaining to this unit appear throughout this manual highlighted by the signal words WARNING
and CAUTION which identify different levels of hazard.
WARNING!
Denote practices which if not carefully followed, could result in SERIOUS injury and/or death.
CAUTION!
Denote practices which if not carefully followed, could result in minor personal injury or damage to
this equipment.
General: Information presented in this manual and on various labels, on this unit pertains to equipment specifications,
installation, operation, maintenance and troubleshooting 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 oxygen cart should understand
and follow this manual and receive training. We encourage our customers to call Tronair to discuss any operating
or testing requirements.
CAUTION!
It is mandatory that this instruction manual be read and understood by all persons operating this high
pressure oxygen booster.
WARNING!
TO AVOID SERIOUS INJURY OR DEATH OBSERVE THE FOLLOWING:
1. All components used in the oxygen system must be clean, dry, and free of all contamination per
SAE SPEC AIR 1176.
2. DO NOT use this equipment with nitrogen or gas other than oxygen.
3. DO NOT exceed 2250 PSIG bottle inlet pressure into booster.
4. Servicing and maintenance of the system should only be done by trained and qualified
personnel using approved procedures.
5. It is mandatory that this instruction manual be read and understood by all persons operating
this oxygen manifold.
3.1 GENERAL SAFETY REQUIREMENTS
Pressures: Gases under pressure are a potential hazard in the form of stored energy. Accidents can occur when this energy
is improperly handled. Be sure that all equipment used is compatible and designed to control the pressures
encountered.
Oxygen: Oxygen is an oxidizing gas and is chemically stable and nonflammable. However oxygen does support
combustion. High concentrations can accelerate the combustion of flammable materials up to and including an
explosion. It is important to understand that spontaneous combustion of organic materials can occur in oxygen
rich atmospheres.
Handling: Oxygen handling must be done with care to avoid any association with hydro-carbons, especially where fuels
and lubricants are present in aircraft service areas. It is imperative that oxygen systems be handled properly. Be
sure to keep all protective caps in position on equipment as long as possible, and replace them as soon as
possible.
Velocity: Oxygen flowing at a high velocity in a piping system can propel any foreign material particles with such force that
the impact friction can raise the particles temperature to a possible ignition point. It is, therefore, imperative that a
high degree of cleanliness be maintained in the oxygen system at all times.
Oxygen Servicing: The following list contains additional general safety precautions that should be adhered to during the
servicing process. However, always refer to the manufacturer's procedure for the airplane being serviced.
1. Always ground the system to be serviced and the servicing equipment before connecting the filler adapter.
2. Close the oxygen bottle manual shutoff valve.
3. Ensure that all aircraft electrical power is off. Do not operate electrical switches, or connect or disconnect
ground power generators during the oxygen charging operation.
4. Do not service the oxygen system if fueling or other flammable fluid servicing is in process.
5. Do not charge the system too fast. Rapid charging can create a dangerous overheating condition.
For information concerning specific SAE Aircraft Oxygen Equipment Oxygen Equipment Specifications, contact:
Society of Automotive Engineers
400 Commonwealth Drive
Warrendale, PA 15096-0001

Model: 20-4500-7000
Oxygen Booster
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4.0 PREPARATION FOR USE/ASSEMBLY INSTRUCTIONS
4.1 UNPACKING
The oxygen cart’s manifold system and oxygen booster have been thoroughly cleaned and inspected prior to packaging and
shipment. After opening the shipping container and removing the unit, inspect it thoroughly for shipping damage.
Though this unit has been functionally and pressure tested prior to leaving out facility, it is possible that some of the installed
fittings may have loosened during shipping. It is advised that all connections be checked for tightness as part of the installation
process.
Oxygen equipment should be kept clean, dry, and free from contaminants. It is imperative that all installation, inspection,
maintenance, testing, and servicing of oxygen system components be done by trained and qualified personnel using approved
procedures.
4.2 ASSEMBLY
1. Inspect all connections for contaminants before installation and
tightening. Remove any foreign materials. Be sure all oxygen
system components are clean per SAE specification AIR 1176.
2. Install 12 inch oxygen supply hose from regulator assembly to
gas outlet on Oxygen Booster per SAE spec. ARP 1532, being
careful not to contaminate the system during installation. (See
Figure 2).
3. Install 12 inch oxygen supply hose from manifold assembly to
gas inlet on Oxygen Booster per SAE specification ARP 1532,
being careful not to contaminate the system during installation
(See Figure 2).
4. Install and rotate the oxygen supply bottles so that the manifold
inlet hoses may be easily connected to the bottles. Tighten
bottle hoses 2 to 2½ turns after finger tight is reached. Make
sure the hoses are not kinked or damaged. Recheck all fittings
for tightness. (See Figure 2).
5. If less than four bottles are used, plug or cover unused inlet
hoses to ensure cleanliness.
6. Check that outlet shut off valve is closed. Carefully store outlet
hose in cart storage tray.
4.3 PREPARATION FOR OPERATION WARNING!
If there are any differences between the following instructions and the aircraft maintenance manual, the
aircraft maintenance manual will take precedence.
1. Attach one static discharge cable clamp to aircraft static ground. (See aircraft maintenance manual if any questions.)
2. Attach other static discharge cable clamp to earth static ground. (See aircraft maintenance manual if any questions.)
3. Be sure all valves and controls are in the closed or “OFF” position.
WARNING!
Be sure fill line is secured prior to purging the unit. This will prevent the hose from “whipping” if too much
oxygen is allowed to flow through the unit.
FIGURE 2 –Gas Inlet Connection for Output of
the Oxygen Supply Bottle Pressure Regulators

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Oxygen Booster
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5.0 OPERATION
5.1 FILL PROCEDURE
1. Connect shop air supply
2. Close high pressure oxygen gas output valve
3. Reduce output pressure regulator to minimum pressure (counter clockwise)
4. Remove cap from output hose and immediately loosely connect hose to aircraft component
5. SLOWLY open shut off valve on the oxygen bottle
6. Adjust output pressure regulator for 50 –100 psig on output pressure gauge
7. Open high pressure oxygen gas output valve slightly to purge output hose
8. Close high pressure oxygen gas output valve
9. Tighten output hose to aircraft component
10. Read aircraft system oxygen pressure required
11. Adjust output pressure regulator to required pressure
12. Slowly open high pressure oxygen gas output valve to fill aircraft component
13. Close high pressure oxygen gas output valve
14. Allow system to cool and recheck aircraft oxygen pressure prior to disconnecting.
Repeat stems 12 & 13 if necessary
5.2 CHARGING THE AIRCRAFT OXYGEN SYSTEM
If non-standard ambient temperatures are present at the time of oxygen system recharging, refer to Table 1 to determine the
proper filling pressure for oxygen cylinders.
TABLE 1
At Temperature
Degrees F
Fill to Working Pressure
Multiplied by Figure Below
110
1.10
105
1.0875
100
1.075
95
1.0625
90
1.05
85
1.0375
80
1.025
75
1.0125
70
1.000
65
0.9875
60
0.975
55
0.9625
50
0.95
45
0.9375
40
0.925
EXAMPLE: Ambient Temperature = 90F, Working pressure is 1800 PSIG:
Charge Pressure = (1800) x (1.05) = 1890 PSIG
5.3 DISCONNECT PROCEDURE WARNING!
When the aircraft fill line is pressurized or when oxygen is flowing through the system, the fill line hose will
“whip” if not secured.
1. Close the shut off valves on the oxygen bottle
2. Open high pressure oxygen gas output valve
3. Reduce high pressure output regulator to minimum pressure
4. SLOWLY disconnect the output hose from the aircraft to bleed remaining pressure within the system
5. Immediately reinstall the cap on the output hose
6. Close high pressure oxygen gas output valve
7. Disconnect shop air supply and close shop air shut off valve

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Oxygen Booster
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5.4 TO READ INDIVIDUAL BOTTLE PRESSURE
1. Close high pressure oxygen gas output valve
2. SLOWLY open a bottle shutoff valve
3. Read pressure on bottle supply pressure gauge
4. Close bottle shutoff valve
5. Open high pressure oxygen gas output valve and slightly adjust pressure regulator to bleed off system pressure
6. Repeat procedure for other bottles
5.5 EFFICIENT USE OF SYSTEM
Maximum oxygen may be removed from supply bottles if aircraft are serviced from the lowest pressure bottle first. In this
manner, the most oxygen may be removed from each bottle. Even bottles with relatively low pressures may be used to service
aircraft if the aircraft has a depleted system (250 psi minimum).
6.0 MAINTENANCE
The operation, maintenance, and trouble shooting of this unit require 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. Maintenance is only to be done by qualified persons.
All maintenance personnel must be familiar with the cautions and warnings associated with high pressure oxygen and high
pressure oxygen systems as outlined in Section 3 - Safety of this manual prior to performing any maintenance on the unit.
The inlet shop air filter should be inspected every 300 - 600 hours of service or every two years, whichever comes first. The
replacement air filter element is available from Tronair, part number PC-1145.
OXYGEN COMPONENTS: WARNING!
OXYGEN EQUIPMENT IS NOT FIELD OR CUSTOMER SERVICEABLE!
OEM repair or replacement is recommended.
The gauges on this unit should be inspected and calibrated annually to ANSI grade A accuracy, to maintain and ensure
accuracy.
Inspect oxygen manifold output hose prior to each use for signs of cracking or kinking, replace as necessary.
Replace oxygen inlet and output filters (Z-7011) after 2000 hours of use.
6.1 STORAGE
Store the unit in a clean, dry area when not in use.
Be sure that all hoses are capped and the unit is covered with lint free covering for the duration of unit storage to ensure
complete oxygen system cleanliness for future aircraft system recharging.
7.0 SAE AIRCRAFT OXYGEN SPECIFICATION INFORMATION
For information concerning specific SAE Aircraft Oxygen Equipment Oxygen Equipment Specifications, contact:
Society of Automotive Engineers
400 Commonwealth Drive
Warrendale, PA 15096-0001
8.0 TROUBLE SHOOTING
Refer to Appendix I and Appendix II
9.0 PROVISION OF SPARES
9.1 SOURCE OF SPARE PARTS
Spare parts may be obtained from the manufacturer:
TRONAIR, Inc. Telephone: [phone] or 800-426-6301
1 Air Cargo Pkwy East Fax: [phone]
Swanton, Ohio 43558 USA E-mail: [email protected]
Website: www.tronair.com
See Appendix I for Air Driven Gas Booster Compressor Replacement Parts.

Model: 20-4500-7000
Oxygen Booster
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10.0 GUARANTEES/LIMITATION OF LIABILITY
Tronair products are warranted to be free of manufacturing or material defects for a period of one year after shipment to the
original customer. This is solely limited to the repair or replacement of defective components. This warranty does not cover the
following items:
a) Parts required for normal maintenance
b) Parts covered by a component manufacturers warranty
c) Replacement parts have a 90-day warranty from date of shipment
If you have a problem that may require service, contact Tronair immediately. Do not attempt to repair or disassemble a product
without first contacting Tronair, any action may affect warranty coverage. When you contact Tronair be prepared to provide the
following information:
a) Product Model Number
b) Product Serial Number
c) Description of the problem
If warranty coverage is approved, either replacement parts will be sent or the product will have to be returned to Tronair for
repairs. If the product is to be returned, a Return Material Authorization (RMA) number will be issued for reference purposes
on any shipping documents. Failure to obtain a RMA in advance of returning an item will result in a service fee. A decision on
the extent of warranty coverage on returned products is reserved pending inspection at Tronair. Any shipments to Tronair must
be shipped freight prepaid. Freight costs on shipments to customers will be paid by Tronair on any warranty claims only. Any
unauthorized modification of the Tronair products or use of the Tronair products in violation 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.
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.
11.0 APPENDICES
APPENDIX I Maxpro Operation & Service Manual with Safety Precautions
APPENDIX II Declaration of Conformity
Additional Document:
DOC-1016 Oxygen Cleaned Certification