NB/NBR NITROGEN BOOSTER

FOR AVIATION SERVICE

INSTALLATION, OPERATION
& MAINTENANCE MANUAL

INTERFACE DEVICES, INC. 230 Depot Road, Milford, CT 06460

Ph: (203) 878-4648, Fx: (203) 882-0885, E-mail: [email protected]
www.interfacedevices.com

IMPORTANT! FILE THIS MANUAL IN A SAFE PLACE FOR FUTURE SERVICE & PARTS NEEDS
ALWAYS REFERENCE THE SERIAL NUMBER FOR SERVICE & PARTS REQUESTS

Safety instructions specifically pertaining to this unit appear throughout this manual
highlighted by these signal words ** Warning** and **Caution ** to denote different
levels of hazard.
Warning: denotes practices, which if not carefully followed, could result in property damage,
SERIOUS personal injury and /or DEATH
Caution: denotes practices which if not carefully followed, could result in minor personal injury or damage to
equipment.

NB(R) Serial Number:___________________

STATEMENT OF WARRANTY

Interface Devices, Inc. (IDI) warrants it’s products to be free from defects in material and workmanship under normal
use and service for a period of one (1) year from date of shipment. Any defect discovered after the warranty period
has expired will be deemed to be outside the above coverage. No goods claimed to be under warranty shall be
accepted for return unless authorized by IDI.

Upon discovery of a defect (other than freight damage) or a shortage of an item received in the original shipping
container, the purchaser shall, within (10) calendar days, deliver notice of the defect or shortage. Damaged freight
claims must be placed with the freight carrier and will not be honored by IDI. If after due investigation of a claim of
defect or shortage is found valid, IDI, at it’s sole discretion, may discharge it’s entire obligations to the purchaser by
either repair or replacement of the defective product or component and for shortages by furnishing a replacement of
the missing quantity.

This express warrantee supersedes and is in lieu of all other remedies and warranties, including the implied
warranties of merchantability and fitness for a particular purpose, and liability for negligence. IN NO EVENT SHALL
IDI BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL LOSSES, EXPENSES OR DAMAGES INCLUDING
DAMAGES FOR PERSONAL INJURY OR COMMERCIAL LOSS.

N2 Booster Manual M99-1003-K November 2019

Table of Contents
1 General Description ..................................................................................................................................... 1
2 Specifications / Features .............................................................................................................................. 2
2.1 Component Description ......................................................................................................................... 3
3 Preparation for use ...................................................................................................................................... 4
3.1 Safety Instructions................................................................................................................................. 4
3.2 General Safety Precautions ................................................................................................................... 4
3.3 Assembly ................................................................................................................................................. 5
4 Operation ...................................................................................................................................................... 6
4.1 Preparation for Operation..................................................................................................................... 6
4.2 Charging the Nitrogen System ............................................................................................................. 6
4.3 Disconnecting Nitrogen Booster ........................................................................................................... 7
5 Maintenance ................................................................................................................................................. 8
5.1 General .................................................................................................................................................... 8
5.2 Storage ..................................................................................................................................................... 8
6 Troubleshooting ........................................................................................................................................... 9

Drawings and Schematics...………………………………………………………………………………10

 INTERFACE DEVICES INC
-NITROGEN BOOSTER NB(R)

1 General Description

NB(R) –

The ENB 45 Pneumatic Nitrogen Booster provides the capability of boosting remaining lower pressure Nitrogen
from supply bottles to the required pressure, from 400 to 4,500 psi.

The Nitrogen Booster is driven by compressed air or nitrogen. It cycles automatically to boost low-pressure nitrogen
to high pressure.

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** Warning **
To Avoid Serious Injury, Loss of Limb or Death

1. Use of a supply Bottle pressure regulator is required

with this unit.
2. Do not try to boost any gas other than nitrogen
3. Do not exceed 3000 PSIG inlet Pressure.
4. All Components used in the nitrogen system or shop air
system shall be clean, dry and free of all contamination.
5. Servicing and/or maintenance of nitrogen systems shall
be done by trained and qualified personnel using
approved procedures per SAE specifications.

2 Specifications / Features
Dimensions: 12.1” long, 9.4” high and 10.8” wide.
Weight: 24lbs. complete.
Output Rating: Adjustable from 500 to 4500 psi.
Nitrogen Booster Ratios: 20:1, 30:1 or 45:1.

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Fig. 1

2.1 Component Description

(Refer to Fig. 1 for component locations)

1. Pump on / off Air Switch.

2. Nitrogen Drive Pressure Gauge.
3. Nitrogen out Pressure Gauge.
4. Air or Nitrogen in Male Quick Connector half.
5. High Pressure Nitrogen Supercharge Regulator.
(Factory set to 125 PSIG)
6. Air/Nitrogen Regulator & gauge .
(Sets N2 Boost Pressure, (ie: 80 PSIG in yields 3,600 psi N2 Out).
7. Female Quick Disconnect Half (used when driving with nitrogen).
8. Air Inlet (1/2 npt, reference).
9. Gas In Port: ¼ npt 3,000 psi max..
10. Gas Out Port: ¼ npt, 400 to 4,500 psi max.

Typical Applications: Emergency gear blow-down bottle, hydraulic accumulator pre-charge, landing gear struts.

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3 Preparation for use

** Caution **
It is mandatory that this instruction manual be read, understood and
followed by all persons operating this high- pressure nitrogen booster.

3.1 Safety Instructions

3.1.1 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 safe and effective use of this
equipment.

3.1.2 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.

3.1.3 Safety instructions specifically pertaining to this unit appear throughout this manual
highlighted by these signal words **Warning** and **Caution** to denote different
levels of hazard.
**Warning** denotes practices which if not carefully followed, could result in
SERIOUS personal injury and /or DEATH.
**Caution** denotes practices which if not carefully followed, could result in minor
personal injury or damage to this equipment.

3.1.4 Training: Read through this entire manual prior to any Nitrogen booster operation. All
personnel using this Nitrogen Booster should understand and follow this manual and
receive training. We encourage our customers to call Interface Devices to discuss any
operating or testing requirements.

3.2 General Safety Precautions

3.2.1 Pressures: Gasses 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.

3.2.2 Nitrogen: Nitrogen is a stable gas and non-flammable.

3.2.3 Lubrication: the use of lubrication in a Nitrogen system should be kept to a minimum.
The booster requires no lubrication. An air line lubricator must not be used.

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** Warning **
Only Lubricants compatible with high-pressure nitrogen shall be used

No lubricant shall be applied in any area that will come into direct contact with Nitrogen
during normal use.

3.3 Assembly
3.3.1 Although the Nitrogen Booster is inspected prior to shipping, it could be damaged during
shipping. Therefore, it should be carefully unpacked and placed on a clean level surface
for inspection.

3.3.2 The Nitrogen booster is furnished with three ¼-20 by ½” deep tapped holes for mounting
to a bracket or cart.

3.3.3 Customer supplied parts:

 Two AN816-6, 3/8” AN to ¼” male pipe adapters.
 Two stainless steel/Teflon® –6 hose assemblies, rated to 5,000 psi working
pressure.
 Teflon® pipe tape.
 Pressurization attachment fitting.

3.3.4 Wrap 2-3 turns of Teflon® tape clockwise around the ¼” pipe thread ends of each
adapter fitting.

** Caution **
The customer supplied nitrogen supply must be complete with shutoff valves,
pressure gauges, pressure regulators and -6 hose assemblies. These
components must be rated for 5,000 psi operation.

3.3.5 Remove the protective plastic plugs from “GAS IN” and “GAS OUT” ports.

3.3.6 Insert ¼”nipple ends into their respective ports, and firmly tighten down, being careful
not to over-tighten. With supply regulator closed, connect one -6 swivel hose end to the
“GAS IN” fitting. Connect the other hose to the “GAS OUT” port.

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3.3.7 Attach the pressurization fitting to the other end of the nitrogen out hose.

3.3.8 Check all components for integrity. If all is well, you are ready to use NB(R) Booster.

4 Operation

4.1 Preparation for Operation

4.1.1 Be sure all valves and controls are in the closed position.

4.1.2 Decrease the item 6 (fig 1) inlet pressure regulator to its minimum pressure setting.

4.1.3 Inspect all connections for contaminants before installation and tightening. Remove any
foreign Materials. Be sure all Nitrogen components are clean as per SAE specifications.

4.1.4 Connect the output of the gas supply bottle to the “GAS IN” connection of the booster
(see figure 1a).

4.1.5 Decrease the nitrogen bottle regulator to its minimum pressure setting.

4.1.6 Connect the Nitrogen fill line and purge line by SLOWLY cracking open gas supply
bottle shutoff valve and adjusting the supply bottle pressure to a low-pressure setting.

** Warning **
Be sure fill line is secured prior to purging the unit. This will prevent the hose
from whipping about if too much N2 is allowed to flow through the unit

4.1.7 Tighten the N2 fill line connection.

4.1.8 The high pressure N2 Booster is ready to charge the system.

4.2 Charging the Nitrogen System

** Warning **
When nitrogen line is pressurized or when nitrogen is flowing through the
system, the fill line hose may “whip” about if not secured.

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4.2.1 After the nitrogen booster has been properly connected, fully open the N2 supply bottle
shut off valve. Adjust the gas supply bottle pressure regulator to the required N2 system
Pressure. Wait until the bottle pressure and the system pressure are equal. If the supply
bottle pressure is lower than the required system pressure, run the booster as follows:

4.2.2 Adjust the booster’s air pressure to attain a pressure slightly lower than the final required
N2 pressure (divide this nitrogen pressure by the pump ratio to find the initial required
regulated air pressure setting). Example for ENB-45: 3,000 psi final pressure minus 75
equals 2,925 psi divided by 45 equals 65 psi regulated air pressure.

4.2.3 Turn on the booster’s “PUMP RUN” toggle switch to the “ON” position to further
pressurize the nitrogen system. The nitrogen outlet pressure gauge will show the system
pressure developed by the booster. When the set pressure has been reached (i.e.: pump
stops pumping), increase the pressure of the air regulator to obtain the required final
system pressure. When the booster stops running, turn off the booster by switching the
toggle switch to the “OFF’ position.

4.3 Disconnecting Nitrogen Booster

4.3.1 Close the nitrogen bottle shut off valve. This will stop inlet nitrogen flow.

4.3.2 Decrease both the air inlet pressure regulator and the nitrogen supply bottle pressure
regulators to their respective minimum settings.

4.3.3 Disconnect air (or nitrogen) supply line.

4.3.4 Slowly loosen, bleed down, and disconnect nitrogen fill line. Disconnect the supply hose.

4.3.5 Cap both hose connections to prevent nitrogen hoses and booster contamination.

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5 Maintenance

** Warning **
Maintenance should be undertaken by qualified personnel only.
The operation, maintenance and troubleshooting of this high pressure Nitrogen Booster system
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 codes.

5.1 General
5.1.1 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 gas operation. Maintenance is to only be done by
qualified persons.

5.1.2 All maintenance personnel must be familiar with the cautions and warnings associated
with high pressure gas systems as outlined in sections 3.1 and 3.2 of this manual prior to
performing any maintenance on this unit.

5.1.3 The gauges on this unit are supplied for reference purposes. Calibrated and certified
gauges should be used for determining final pressure to the aircraft, which are available
from the factory at the time of purchase or upon request during repair.

5.2 Storage
5.2.1 Store the unit in a clean, dry and secure area when not in use.

5.2.2 Be sure all hoses are capped and the unit is covered with a lint free covering for the
duration of unit storage to ensure complete N2 system cleanliness for future system
recharging.

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6 Troubleshooting

** Warning **
Troubleshooting should be undertaken by qualified personnel only.

Troubleshooting Chart
Symptom Probable Cause Remedy

Pump will not cycle No air supply to pump Look for and fix
(Only regulated
nitrogen pressure at
out put.) Pump regulator set too Increase setting
low
Disconnect/ reconnect air supply (resets air spool to
Four way air end position)
reciprocating valve If spool still sticks, manually push spool to far end
spool stuck at mid with probe through hole in “spool stop cap”. If stuck
position or requires excessive force, disassemble air valve
assembly. Inspect for contamination or mechanical
bind. Repair or replace, lubricate seals with water-
proof grease

Pump makes one Faulty “2 way air Repair or replace

cycle then stops Valve” (Broken, leaks
or contaminated)

Pump cycles External leak at pump or Look for and correct

constantly when down stream high
Dead Headed pressure circuit

Contaminated or stuck Clean or replace

open check valve
cartridge

Internal leak in pump Check all dynamic and static seals and gaskets