Operation & Service Manual

Transcription

1 Operation & Service Manual Model: Four Bottle Oxygen Cart with Booster CAUTION! It is mandatory that this instruction manual be read and understood by all persons operating this high pressure oxygen booster. Tronair, Inc Eber Road Holland, Ohio USA Telephone: (419) Fax: (419) Web Site:

2

3 TABLE OF CONTENTS PAGE Figure 1 - Oxygen Booster Components...1 Component Illustration General Description Specifications/Features High Pressure Oxygen Booster Component Description Safety General Safety Requirements Preparation For Use/Assembly Instructions Unpacking Assembly Preparation For Operation Operation Charging The Aircraft Oxygen System Disconnecting Oxygen Booster From Aircraft To Read Individual Bottle Pressure Efficient Use Of System Maintenance Storage Trouble Shooting...12 Parts List Index...13 APPENDIX I Tescom Series Regulator Operation & Service Instructions (Form 1119) APPENDIX II Haskel Air Driven Gas Booster Compressors Operation & Service Manual & Haskel/Linde Safety Precautions & Haskel Parts List

4

5 FIGURE 1 - Oxygen Booster Components ITEM DESCRIPTION 1 Relief Valve - Set at 2200 PSIG 2 Air Pilot Switch - Set at 350 PSIG 3 Air Pilot Switch - Set at 2000 PSIG 4 Oxygen Booster Pump 5 In-Line Oxygen Outlet Filter 6 Inlet Air Filter 7 Inlet Air Pressure Regulator 8 Pressure Gauge PSIG 9 Speed Control Valve 10 Pressure Gauge PSIG 11 Pressure Gauge PSIG - 1 -

6 Component Illustration Reference Parts List Descriptions, Page 1 and Section High Pressure Oxygen Booster Component Description FIGURE 2 - Oxygen Booster Schematic - 2 -

7 1.0 GENERAL DESCRIPTION The Four Bottle Oxygen Cart with the manifold and regulator allows the operator to manifold together up to four oxygen supply bottles and regulate the outlet pressure. Reverse flow check valves prevent back-flow from one supply bottle to another supply bottle. The Tronair Oxygen Booster provides the capability of boosting remaining lower pressure oxygen from supply bottles to the required higher aircraft system pressure; up to 2000 PSIG maximum. This Oxygen Booster utilizes an air driven pressure amplifier which cycles automatically with 90 PSIG maximum air pressure input at 80 SCFM volume. DANGER! TO AVOID SERIOUS INJURY, LOSS OF LIMB OR DEATH: 1. DO NOT use on LOW PRESSURE aircraft systems. This is an UNREGULATED OXYGEN SOURCE equal to supply bottle pressure. The use of a supply bottle pressure regulator is required with this unit. 2. DO NOT use with ANY GAS OTHER THAN OXYGEN. 3. DO NOT exceed 2000 PSIG inlet oxygen pressure into booster. 4. All components used in the oxygen system shall be clean, dry and free of all contamination per SAE SPEC. AIR Servicing and/or maintenance of oxygen systems shall be done by trained and qualified personnel using approved procedures per SAE SPEC. ARP SPECIFICATIONS/FEATURES Four Bottle Oxygen Cart: Height: 36-7/8 inches (94 cm) Length: 73 inches (186 cm) Width: 32-3/4 inches (83 cm) Weight: 225 lbs. (102 kg, approximately) Maximum Pressures: Inlet: 2000 PSI Outlet: 2000 PSI Bottle Connections: CGA-540 fittings Output Hoses: #4 x 3 foot with JIC fittings Oxygen Booster: Dimensions: 25 inches long x 18 inches high x 16 inches deep Output hose: 15 feet long with #4 37 degree JIC female flare swivel fitting at aircraft hook-up end Oxygen output rating: 2000 PSIG maximum Oxygen Booster: 30:1 volumetric displacement 06:1 maximum compression ratio 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. 2.0 Specifications/Features continued on following page

8 2.0 SPECIFICATIONS/FEATURES 2.1 HIGH PRESSURE OXYGEN BOOSTER COMPONENT DESCRIPTION Refer to Figures 1 & 2 on Pages 1 & 2 for component location. Item 1 Oxygen Over-Pressure Relief Valve set at 2200 PSIG; Safety Valve designed to pop off only if Item 3 fails to release. Item 2 Oxygen Inlet Air Pilot Switch set at 350 PSIG; Pilot Switch set to pop off if supply bottle pressure drops below 350 PSIG. Item 3 Oxygen System Air Pilot Switch set at 2000 PSIG; Relief Valve set to maximum oxygen output pressure. Item 4 Oxygen Booster Pump, 30:1 volumetric displacement pump; 6:1 maximum compression ratio. Item 5 Oxygen Output In-line Filter, 5 micron nominal, 15 micron absolute filtration. Item 6 Input Air Filter used to maintain clean shop air entering system, 150 PSIG maximum. Item 3.0 SAFETY 7 Input Shop Air Regulator used to control the amount of output oxygen pressure developed by the booster pump. Item 8 Regulated Air Pressure Gauge: PSIG Item 9 Speed Control Valve used to limit the volume of shop air input, thus controlling the speed of the booster pump operation. Item 10 Item 11 Oxygen Output Pressure Gauge: PSIG Oxygen Inlet Pressure Gauge: PSIG 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. 3.0 SAFETY continued on following page

9 3.0 SAFETY General: Training: 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. 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 DO NOT use this equipment with nitrogen or gas other than oxygen. 3. DO NOT exceed 2000 PSIG 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: Oxygen: Handling: Velocity: 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 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. 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. 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. Lubrication: The use of lubrication in an oxygen system shall be held to a minimum. No lubrication shall be applied in any area which will come into direct contact with oxygen during normal use. 3.1 GENERAL SAFETY REQUIREMENTS continued on following page

10 3.1 GENERAL SAFETY REQUIREMENTS WARNING! Only lubricants compatible with high pressure oxygen shall be used. SAE AIRCRAFT OXYGEN SPECIFICATION INFORMATION For more information concerning specific SAE aircraft oxygen equipment specifications, contact: Society of Automotive Engineers 400 Commonwealth Drive Warrendale, PA 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. 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 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 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 3) If less than four bottles are used, plug or cover unused inlet hoses to ensure cleanliness Place the High Pressure Oxygen Gas Booster on the Four Bottle Cart and secure with the supplied hardware (See Figure 4) Install 36 inch oxygen supply hose from regulator assembly to gas inlet on Oxygen Booster per SAE spec. ARP 1532, being careful not to contaminate the system during installation. (See Figure 3) Install the 180 inch oxygen output hose onto the Oxygen Booster per SAE spec. ARP 1532, being careful not to contaminate the system during installation Check that outlet shut off valve is closed. Carefully store outlet hose in cart storage tray. 4.2 Assembly continued on following page

11 4.2 ASSEMBLY FIGURE 3 - Component Identification FIGURE 4 - Oxygen Booster Assembly 4.0 PREPARATION FOR USE/ASSEMBLY INSTRUCTIONS continued on following page

12 4.0 PREPARATION FOR USE/ASSEMBLY INSTRUCTIONS 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 Attach one static discharge cable clamp to aircraft static ground. (See aircraft maintenance manual if any questions.) Attach other static discharge cable clamp to earth static ground. (See aircraft maintenance manual if any questions.) Be sure all valves and controls are in the closed or OFF position Decrease air pressure regulator to the minimum pressure setting Decrease the oxygen supply bottle pressure regulator to the minimum pressure setting Connect the oxygen fill line loosely to aircraft and purge line by SLOWLY cracking open oxygen supply bottle shutoff valve and adjusting the supply bottle pressure regulator to a low flow setting. 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. 5.0 OPERATION Tighten oxygen fill line connection at aircraft Verify the Speed Control Valve (See Figure 1 Item 9) is fully closed Connect shop air line to oxygen booster air drive inlet connection. (See Figure 1) The high pressure oxygen booster is now ready to charge an aircraft oxygen system. 5.1 CHARGING THE AIRCRAFT OXYGEN SYSTEM After the oxygen booster has been properly connected, fully open the oxygen supply bottle shut off valve. Adjust the oxygen supply bottle pressure regulator to the required aircraft oxygen system pressure. NOTE: If the supply bottle pressure is lower than the required aircraft oxygen system pressure, be careful not to over adjust the supply bottle pressure regulator once the maximum supply bottle pressure has been achieved. Increasing the oxygen supply bottle pressure regulator beyond this point will not increase the output and may damage the regulator spring. This will charge both the oxygen booster and the aircraft oxygen system to the set regulated pressure or to the lower available oxygen supply bottle pressure. If the oxygen supply bottle pressure is lower than the aircraft oxygen system pressure, check valves in the oxygen booster will prevent back flow of oxygen from the aircraft. 5.1 CHARGING THE AIRCRAFT OXYGEN SYSTEM continued on following page

13 5.1 CHARGING THE AIRCRAFT OXYGEN SYSTEM As a benchmark, adjust the shop air pressure regulator to the adjusted pressure as required by the chart located on the oxygen booster operating instructions label. NOTE: Since the oxygen booster pump compression ratio is 30:1, 60 PSIG of shop air inlet will develop approximately 1800 PSIG of output oxygen pressure Open the shop air speed control valve (see Figure 1 Item 9) to pressurize aircraft oxygen system. Close the shop air speed control valve when desired aircraft oxygen pressure level is obtained. NOTE: Because the oxygen booster operates theoretically at a 30:1 ratio, actual boosted oxygen pressures may vary slightly due to different physical conditions. The oxygen outlet pressure gauge (see Figures 1 & 2, Item 10) will show the aircraft system pressure developed by the oxygen booster. It is suggested that the unit system pressure be adjusted below the required aircraft pressure to prevent over-pressurization. If the set pressure that has been achieved is less than the required system pressure, increase the pressure of the shop air regulator to obtain the required final aircraft system pressure. If non-standard ambient temperatures are present at the time of oxygen system recharging, refer to Table 1 below to determine the proper filling pressure for oxygen cylinders. At Temperature Degrees F TABLE 1 Fill to Working Pressure X Figure Below EXAMPLE: Ambient Temperature = 90 F, Working pressure is 1800 PSIG: Charge Pressure = (1800) x (1.05) = 1890 PSIG 5.0 OPERATION continued on following page

14 5.0 OPERATION 5.2 DISCONNECTING OXYGEN BOOSTER FROM AIRCRAFT 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 Close the oxygen supply bottle shut off valve. This will stop inlet oxygen flow Decrease both the shop air inlet pressure regulator and the oxygen supply bottle pressure regulators to their respective minimum settings Disconnect shop air supply line SLOWLY loosen, bleed down, and disconnect aircraft oxygen fill line from the aircraft Cap aircraft oxygen fill line connection to prevent oxygen hose and system contamination Disconnect static discharge cable clamps from the aircraft static ground along with disconnection from the earth static ground. (See Aircraft Maintenance Manual if any questions.) 5.3 TO READ INDIVIDUAL BOTTLE PRESSURE Close outlet shut off valve Open a bottle shutoff valve Read pressure on manifold pressure gauge Close bottle shutoff valve Open outlet shutoff valve and slightly adjust pressure regulator to bleed off manifold pressure Repeat procedure for other bottles. 5.4 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. (Reference Figure 5)

15 5.4 EFFICIENT USE OF SYSTEM FIGURE 5 - Efficient Bottle Usage 6.0 MAINTENANCE The operation, maintenance, and trouble shooting of this unit 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. 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. 6.0 MAINTENANCE continued on following page

16 6.0 MAINTENANCE The gauges on this unit should be inspected and calibrated annually to ± 1/2 % full scale accuracy, to maintain and ensure accuracy. The inlet shop air filter should be inspected every hours of service or every two years, whichever comes first. The sintered bronze filter element can be cleaned using soap and water. The element should be dried with shop air blown from the inside out. The element may be cleaned multiple times before replacing, depending on cleanliness of operating environment. The replacement air filter element is available from Tronair, part number PC Maintain PSI tire pressure. Grease wheel bearings quarterly. Manifold inlet hoses should be inspected weekly for signs of cracking or kinking, replace as necessary. Inspect oxygen manifold output hose prior to each use for signs of cracking or kinking, replace as necessary. Generally keep the entire unit clean and free from contaminants. Visually inspect for any system leaks or damage. Correction of any problems prior to unit operation is imperative for safe operation. 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 a lint free covering for the duration of unit storage to ensure complete oxygen system cleanliness for future aircraft system recharging. 7.0 TROUBLE SHOOTING Will not run at low drive pressures (10-25 PSIG): PROBABLE CAUSE Excess friction of spool O-rings CORRECTIVE ACTION Re-lubrication or replacement of O-rings Booster will not cycle or slow cycling: PROBABLE CAUSE Excess friction of spool O-rings Leakage of flow and/or pilot tubes Indications that one or both pilot valves are malfunctioning Build-up of residue in muffler Oxygen inlet pressure too low CORRECTIVE ACTION Re-lubrication or replacement of O-rings Replace O-rings on flow or pilot tubes Remove pilot valves, inspect and/or replace Remove muffler and clean Increase inlet pressure to 350 PSIG minimum 7.0 TROUBLE SHOOTING continued on following page

17 7.0 TROUBLE SHOOTING False or double cycling, or continuous exhaust bleeding (air drive): PROBABLE CAUSE Small inlet supply line, restriction not allowing drive seals to function properly Rod seal leakage CORRECTIVE ACTION Increase air drive piping to ½" I.D. and test system. Replace O-rings in the following order: a: inside hex exhaust port b: spool O-rings c: sleeve O-rings Replace rod seals and O-rings Unit will not dead head (stall): PROBABLE CAUSE High pressure piston leakage Check valves contaminated Insufficient pressure at gas inlet CORRECTIVE ACTION Shut off air drive. Apply inlet oxygen supply. If leakage is audible out of oxygen seal vent port, replace gas piston seals. Remove, inspect, clean or replace as necessary. Increase inlet pressure to 350 PSIG minimum Excessive moisture or liquid outside of muffler: Air filter full of water PROBABLE CAUSE Drain air filter CORRECTIVE ACTION Oxygen will not flow through gas section with air drive Off : PROBABLE CAUSE Oxygen filters plugged or contaminated CORRECTIVE ACTION Clean or replace filter elements Parts List Index Description Page Oxygen Manifold/Regulator Assembly & Illustration Oxygen Booster Assembly & Illustration Four Bottle Cart & Illustration

18 Parts List Oxygen Manifold/Regulator Assembly ** WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL, COLOR & SERIAL NUMBER OF YOUR UNIT.** REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY 1 N SS Elbow, Male (Oxygen Cleaned) 1 2 SRP-1000 Valve, Needle (Oxygen Cleaned) 1 3 SRP-1001 Nipple, Pipe (Oxygen Cleaned) 1 4 N SS Tee, Street (Oxygen Cleaned) 1 5 PC Regulator, High Pressure (Oxygen Cleaned) 1 6 TF Pigtail (Oxygen Cleaned) 4 7 PC-1040 Nut (Oxygen Cleaned) 4 8 PC-1061 Nipple (Oxygen Cleaned) 4 9 Z-5387 Assembly, Oxygen Manifold (Oxygen Cleaned) 1 10 HC-1602 Gauge, Pressure (Oxygen Cleaned) 1 11 N SS Plug, Hex Head (Oxygen Cleaned) 2 12 Z-2519 Weldment, Mounting Bracket 1 13 HC-1601 Gauge, Pressure (Oxygen Cleaned) 1 14 TF *36.0 Assembly, Hose (Oxygen Cleaned) 1 REPAIR KITS 5 K-2745 Kit, High Pressure Regulator Standard Repair, for: PC (Non-Metallic and Metallic Parts)

19 Parts List Oxygen Booster Assembly ** WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL, COLOR & SERIAL NUMBER OF YOUR UNIT.** REPLACEMENT PARTS ITEM PART NUMBER DESCRIPTION QTY Filter, In-Line Oxygen Kit, Oxygen Outlet Filter Element Replacement 1 3 PC Gauge, Outlet Pressure ( PSIG) 1 4 PC Gauge, Outlet Pressure ( PSIG) 1 5 Z Assembly, Outlet Hose 1 6 PC-1065 Element, Filter Replacement

20 Parts List Four Bottle Cart ** WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL, COLOR & SERIAL NUMBER OF YOUR UNIT.** Reference Parts List Illustration on following page. REPLACEMENT KITS ITEM PART NUMBER DESCRIPTION QTY 1 K-2084 Kit, Wheel Replacement; consists of: G Jamnut, 3/4-16 Elastic 1 U-1041 Assembly, Wheel/Tire 1 2 K-2086 Kit, Red Reflector Replacement; consists of: G Rivet, 5/32 Open-End Aluminum 2 H Reflector, Red 1 3 K-2088 Kit, Aerofast Pin Replacement; consists of: G Pin, 3/8 x 1.8" long,model C Aerofast 1 G Rivet, 1/8 Open-End Steel 1 H-1026*07.0 Assembly, Lanyard 1 4 K-2087 Kit, Amber Reflector Replacement; consists of: G Rivet, 5/32 Open-End Aluminum 2 H Reflector, Amber 1 5 K-3309 Kit, Towbar Replacement; consists of: G Bolt, Hex Head, Grade 5, 1/2-20 x 2-1/4" long 1 G Stopnut, 1/2-20 Elastic 1 J-1626 Lever 1 Z Weldment, Towbar 1 6 K-2916 Kit, Static Reel Replacement; consists of: G Bolt, Hex Head, Grade 5, 5/16-24 x 1" long 4 G Stopnut, 5/16-24 Elastic 4 G N Flatwasher, 5/16 Narrow 8 H-1186 Reel, Static Discharge 1 REPAIR KIT See Page 15 K-2745 Kit, High Pressure Regulator Standard Repair, for: (Item 5) PC (Non-Metallic and Metallic Parts)

21 Parts List Illustration Four Bottle Cart ** WHEN ORDERING REPLACEMENT PARTS/KITS, PLEASE SPECIFY MODEL, COLOR & SERIAL NUMBER OF YOUR UNIT.**

22

23 APPENDIX I Tescom Series Regulator Operation & Service Instructions (Form 1119)

24

25 APPENDIX II Haskel Air Driven Gas Booster Compressors Operation & Service Manual Safety Precautions Parts List