Sierra PrecisionElectric Air Booster

Maintenance and Operating Manual

Sierra Precision

Table of Contents Page #

Introduction ………………………………………………………………………….. 1

General Information

Features …………………………………………………………………….. 2

Available Models …………………………………………………………… 3

Options ……………………………………………………………………… 4

Specifications ………………………………………………………………… 5

Typical Installations ………………………………………………………… 6

Operating & Maintenance Procedures

Operating Procedures ……………………………………………………….. 8

Maintenance Procedures ……………………………………………………. 10

Piston Seal Replacement Procedure ………………………………………… 11

Filter Element Replacement Procedure ……………………………………… 13

Replacement Parts

9000-00 Model ..………………………………………………………. 159000-A2 Model ..……………………………………………………….. 1712000 Models ……………………………………………… Contact FactoryRemote Option Models …………………………………… Contact Factory

Miscellaneous

Frequently Asked Questions (FAQs)…………………………………………. 19

Troubleshooting ……………………………………………………………….. 21

Warranty ……………………………………………………………………….. 23

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IntroductionWhat is an air booster?An air booster, sometimes referred to as an “air amp,” is a device that “boosts” airpressure from a low-pressure inlet air source to a high-pressure outlet destination.

Why use an air booster?The fire fighting and rescue industries are shifting to smaller SCBAs to reduce theoverall weight of equipment carried by firefighters and rescue workers. Consequently:♦ Smaller SCBA cylinders require higher pressure to maintain the same air usage time

and the existing in-house compressors may not be able to fill high-pressure SCBAs.♦ Replacement high-pressure, high-flow air compressors are costly and air storage

facilities often require costly modifications to accommodate new compressors.♦ Cascade systems cannot completely fill SCBA cylinders when the top cascade

cylinder falls below 4500 psi. An air booster ensures complete fills to 4500 psi.

When to use a Sierra Precision Electric Air Booster?RESCUE VEHICLES ♦ To maximize the use of breathing air in storage cylinders resulting in an increase in

the number of complete SCBA fills per storage cylinder.♦ To reduce fill times by eliminating the need to cascade air storage cylinders. When

used with a booster, all air storage cylinders can be fully opened and do not requirecascading.

♦ To eliminate the possibility of contaminated air at fire incidents when used inconjunction with an air storage system versus the use of mobile compressors.

FIRE STATIONS ♦ To enhance the capability of existing low-pressure compressors. For example, if a

fire department has a 3000 psi compressor and switches to 4500 psi air packs, anair booster is less costly than purchasing a new compressor.

♦ To extend the service life of existing compressors by operating at lower pressures.Running compressors at lower pressures extends compressor life.

HAZMAT♦ To avoid restrictions imposed by government regulations on the use of high-

pressure compressors at hazardous material manufacturing locations. Using acascade system in conjunction with a booster, and replenishing the air supply from alocal fire department or welding supply shop, maximizes the use of air from thecascade system and minimizes the costs of stored air and government compliance.

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FeaturesThe Sierra Precision Electric Air Booster has many unique features that make it ahigh performance, dependable yet cost-effective solution for high-pressure air systems.The Sierra Precision Electric Air Booster allows SCBA cylinders to be filled efficientlyand safely, whether at a fire incident or in the fire station.

Air filters… Eliminate any contaminants in the inlet and outlet air stream.

Oil-less seals… Reduce the chance of adding contaminants to air stream.

Electric motor… Conserves valuable stored air by allowing stored air to beused for filling cylinders and not for operating the pump.

Heat exchanger… Cools air before filling cylinders thereby minimizing pressuredrop. The airflow created by the fan prevents the motor andpump from overheating.

Reciprocating pistons… Assure smooth running operation. The unit is free standingand therefore does not need to be secured to supportingstructures. Please note: To ensure safety in transit, boltingdown is recommended for mobile installations.

Safety relief valves… Prevent cylinders from being over pressured.

Stainless steelcheck valves… Prevent back flow while filling SCBA cylinder(s). The Sierra

Precision proprietary design provides reliable, long-lifeperformance and durability.

Compact design… Allows the booster to be mounted with ease on rescuevehicles, fire apparatus or in the shop. The compact sizedoes not take up valuable workspace and cargocompartments.

Self-contained design… Allows the unit to operate without additional panels orsupport equipment. All that is needed is an electric outletand an inlet air source.

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Available Models--------------------------------------------------------------------------------------------------------------------9000-00 4500 psi Single Pressure9000-00R 4500 psi Single Pressure Remote Start/Stop

9000-A2 2216 psi / 4500 psi Dual Pressure Auto Start9000-A2R 2216 psi / 4500 psi Dual Pressure Auto Start Remote Start/Stop

12000-00 6000 psi Single Pressure12000-00R 6000 psi Single Pressure Remote Start/Stop

12000-A2 4500 psi / 6000 psi Dual Pressure Auto Start12000-A2R 4500 psi / 6000 psi Dual Pressure Auto Start Remote Start/Stop--------------------------------------------------------------------------------------------------------------------

9000-00 ModelThe 9000-00 is the standard model and is designed to fill cylinders to onepressure setting. Pressure settings are pre-set at the factory and adjustment inthe field, when necessary, is simple and straightforward. When filling cylinders,the unit pumps until the desired, pre-set air pressure is met and then shuts offautomatically. This eliminates any guesswork in determining when the cylinder isfull. Typical settings are 2216 psi or 4500 psi.

9000-A2 ModelThe 9000-A2 model maintains the same proven performance as the 9000-00model with the added features of two pressure settings and auto starting.

Changing between filling pressures only involves the turn of a valve handle. Forexample, after filling a cylinder, the operator conveniently turns a knob one-halfturn to fill a cylinder of a different pressure. No tools are needed and bothsettings are pre-set at the factory. This eliminates the guesswork involved infilling the different pressure-rated bottles and there is also no fear of overfillsbecause both circuits have “vent to atmosphere” safety relief valves. Whether inthe field or at the station, alternating between 2216 & 4500 psi cylinders is easy.

For more information regarding the Auto Start feature, please see “Auto Start” inthe Options section (next page).

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Available Models(continued)

12000 ModelsThe 12000-00, which is designed to fill cylinders to 6000 psi, enables fire stationswith 5000 psi compressors to recharge 6000 psi cascade storage tanks. The12000-A2 model allows the user to recharge storage bottles AND also fill SCBAcylinders. Typical settings for the A2 are 4500 psi and 6000 psi and switchingbetween pressure settings only requires the turn of a valve handle.

OptionsAuto Start

Why is the Auto Start option important? It can save time and energy.

The Auto Start option saves time and energy because its special circuitryautomatically starts the unit and this effectively allows the operator to remain inone place. For example, a remote fill station, with the auto-start option, allowsthe operator to remain at the fill station without having to move back and forthbetween the booster and the station. A shutoff valve on the manifold regulatesairflow to the cylinder(s). Upon re-opening the valve, the booster circuitry sensesthe “low-pressure” status and sends a signal to the start switch. The boosterthen starts and pumps until the pre-set pressure is reached. The operator thencloses the valve to the manifold, replaces the full cylinder(s) with empty ones,and repeats the cycle.

Remote Start/StopWhy is the Remote Start/Stop option important? It can help conserve space.

Rescue vehicles do not always have fill stations that are conveniently locatednear the booster. Since the Remote Start/Stop option allows the operator to startand stop the booster and to monitor fills at the control panel of the fill station, thebooster is not limited to where it can be installed. This frees up valuable, easyaccess cargo space for other critical fire fighting equipment.

Special ApplicationsThe Sierra Precision Electric Air Booster can be adapted for a variety ofapplications including argon, helium, nitrox (scuba) and oxygen. Contact SierraPrecision for more information regarding any special applications.

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SpecificationsSize…………………30.75” long x 19” wide x 15.50” highWeight………………145 poundsMotor………………..1.5 hp

110 or 220 voltSingle or three phaseThermal overload automatic shutoff – manual reset

High-pressureSection…….……….Non-lubricated

Contaminant freePiston seals (10,000 psi rating @ 700 F)Twin piston (hard chrome)Over pressure safety reliefStainless steel check valves

Drive Section………Sealed bearingsV-belt power transmission

Gauges……………. Inlet – 0 to 6000 psi Outlet – 0 to 8000 psi

Cooling……………..Fan cooled heat exchanger Maintenance…….…Periodic inspection of seals, filters and drive belt

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Typical Installations

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Photo courtesy ofmdenton Fire Departmen

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Operating Procedures1. Verify that all connections have been properly made.

2. Verify that the cylinder has been placed in an appropriate fill station.

3. Verify that the automatic shutoff is set no greater than the maximum pressure ofthe cylinder.

***WARNING***Pressure switch settings are pre-set at the factory and should not requireany adjustment. Improper adjustment of pressure switches could result inphysical injury. Please contact the factory in cases where pressure switchsettings do not meet fill station requirements.

4. Close both valves on the booster panel.

5. Slowly open valve on the cascade system or storage tank to full open.

6. Slowly open cylinder valve to full open.

7. Open the outlet valve on the air booster panel to full open.a. If the air in the cascade bottles or compressor storage tank is higher

than the cylinder being filled, it will free flow through the booster untilequalized.

b. The booster has stopped free flowing when the pressure indicated onboth booster gauges becomes equal and no sound is detected.

8. Turn the booster on with the starter switch on the booster panel.

9. Monitor the filling of the cylinder by the indicated pressure on the outlet gauge. a. There may be some normal decrease of indicated pressure on the inlet

pressure gauge, depending upon the size of the cascade system orcompressor storage tank.

b. The booster can be manually shut off, for any reason, at any time,before it reaches the pre-set pressure of the automatic shutoff switch.

c. If the booster has not been shut off manually, it will shut off at the pre-set pressure of the automatic shutoff switch.

d. If the shutoff switch should malfunction or has been tampered with, thesafety relief valve in the booster will automatically relieve the pressure.

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Operating Procedures(continued)

10. When the pressure has been reached and the booster has stopped, close thevalve on the cylinder being pressurized.

11. Close the outlet valve on the air booster.

12. Slowly open the outlet bleed valve on the air booster (this drops the pressure onthe hose between the booster and the cylinder being pressurized).

13. Disconnect the full cylinder and replace it with an empty one. Repeat steps 4-12.

14. At the end of the cylinder fill session:a. Close the valve on the cascade or compressor storage tank.b. Slowly open both valves on the booster to bleed booster air system.

The pressure indication on both booster gauges will return to zero.

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Maintenance Procedures*

1. Remove2. Check fa

a. Inb

b. Ifc. If

te3. Re-torqu4. Verify m

a. Bb. L

5. Check fia. Vb. Rc. Pd. “Be. C

pR

6. Removea. Vb. Sc. Bd. We. U

mf. W

7. Replace8. Wipe co9. Reconn10. Run boo

* A six-month maintenvary based upon total

** It is recommended bearing lubricant from

Rules Wear eye protection Of Disconnect all electrical connectionsThumb Bleed system air pressure

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cover.n belt.spect belt for cracks, uneven wear and side wall glazing. Replaceelt when any of above symptoms exist. belt should exhibit uneven wear, check alignment of pulleys. belt should exhibit side wall glazing or “squeals” on start-up, addnsion to belt by moving the motor out (further from pump).e head bolts to 175 inch pounds in an alternating crossing pattern.otor type.aldor – grease motor with one shot of grease in each end.eeson – no grease required.tting connections.erify electrical is disconnected.econnect air lines to booster.ressurize booster with 1800 to 2000 psi.ubble test” fittings by spraying with soapy water. heck for bubbles around the fittings. If bubbles are evident, relieveressure, tighten fitting(s), re-pressurize and recheck for bubbles.epeat until bubbles disappear. dust and debris.erify electrical is disconnected.hut off inlet pressure to booster.leed system pressure to zero psi.ear safety glasses.sing compressed air, blow out the heat exchanger coil and anyoisture or residue left from “bubble test”.ipe inside of booster enclosure until clean. cover.ver and front panel.ect inlet air lines and electrical plug.ster to verify operation.**

ance cycle is recommended; however, actual maintenance cycle requirements will operating time and environment.

that the booster be run at least 5 to 10 minutes each month in order to prevent becoming hard.

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Piston Seal Replacement Procedure

1. Disconnect power cord from 2. Bleed off or exhaust all air

electrical source. pressure from booster.

3. Remove all booster cover 4. Disconnect inlet and outlet screws and cover. tubes from each cylinder

head.

5. Remove the four cylinder head 6. Carefully slide, one at a time,bolts from each cylinder head each cylinder head from piston.(8 bolts total).

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Piston Seal Replacement Procedure (continued)

7. Lay each cylinder head on 8. Remove piston seal ring from

bench with piston seal up. each cylinder head with finger.Do not use any sharp-edged metal tools.

9. Blow out piston cavity and 10. Place tool No. T-1757 on wipe seal counter bore with cavity side of cylinder headlint-free cloth. (order tool from factory).

11. Gently press new seal, open 12. Place tool button on seal andside down, into tapered push seal through tool platebore of tool plate. into counter bore on cylinder

head.

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Piston Seal Replacement Procedure (continued)

13. Reassemble carefully, making 14. Torque cylinder head boltssure “inlet” side of cylinder to 175 inch pounds in an head is located closest to the alternating crossing pattern.front of the booster.

Filter Element Replacement Procedure

1. Disconnect power cord from 2. Bleed off or exhaust all air electrical sources. pressure from booster.

3. Remove all booster cover 4. Locate filter assembly screws and cover. scheduled for replacement.

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Filter Element Replacement Procedure(continued)

5. Loosen compression nut on 6. Loosen opposite compressionone side of the filter element nut from filter element housinghousing assembly. assembly.

7. Disassemble filter element 8. Check inside the housing seat. housing assembly. Remove Be sure to remove the washerall internal components. before installing the new one.

9. Replace all internal components 10. Reinstall filter element ensuring according to directions included that directional arrows are with replacement kit. pointing in the direction of flow.

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Replacement Parts – 9000-00Number Description Part #

1 Ball - Check valve (0.25" diameter) 2511-2502 Back-up ring – Check valve (new style) 1690-010103 Coil - Under voltage, 110V (00) 5534-1104 Coil - Under voltage, 220V (00) 5534-2205 Filter – Complete assembly (in-line) 44196 Filter – Element replacement kit (in-line) 64517 Gauge – Pressure (inlet) M-1070038 Gauge – Pressure (outlet) M-1070029 Head assembly – Cylinder (old style) 0559310 Head assembly – Cylinder (new style) 0596111 Head only – Cylinder (new style) 657312 Installation tool – Piston seal (old style) T-120313 Installation tool – Piston seal (new style) T-175714 Motor 2551-125160L15 O-ring – Check valve (old style) 1511-3516 O-ring – Check valve (new style) 1511-16417 O-ring, internal - Check valve (new style) 1511-2518 Seal – Piston (new style) 583119 Seal – Piston (old style) 251220 Seat – Outlet check valve (new style) 657221 Spring – Check valve (old style) 230422 Spring – Check valve (new style) 657823 Switch – Complete assembly, 110V (00) 05838-124 Switch – Complete assembly, 220V (00) 05838-225 Switch – On/Off, 110V (00) 5533-11026 Switch – On/Off, 220V (00) 5533-220

39* Switch – Pressure (00) (New style) 455427 Switch – Pressure (00) (Old style) 2556-128 Valve – Inlet check assembly (old style) 0563529 Valve – Inlet check fitting (new style) 657430 Valve – Outlet check fitting (old style) 236431 Valve – Outlet check fitting (new style) 657532 Valve – Outlet shutoff/Outlet bleed 2558-333 Valve – Pressure relief (2500 psi) 5001-134 Valve – Pressure relief (4800 psi) 5001-2

* denotes out of sequence numbers

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Replacement Parts Layout – 9000-00

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Replacement Parts – 9000-A2Number Description Part #

1 Ball – Check valve (0.25" diameter) 2511-2502 Back-up ring - Check valve (new style) 1690-010105 Filter – Complete assembly (in-line) 44196 Filter – Element replacement kit (in-line) 64517 Gauge – Pressure (inlet) M-1070038 Gauge – Pressure (outlet) M-1070029 Head assembly - Cylinder (old style) 0559310 Head assembly - Cylinder (new style) 0596111 Head only – Cylinder (new style) 657312 Installation tool – Piston seal (old style) T-120313 Installation tool – Piston seal (new style) T-175714 Motor 2551-125160L15 O-ring – Check valve (old style) 1511-3516 O-ring – Check valve (new style) 1511-16417 O-ring, internal – Check valve (new style) 1511-25

35* Relay – SS, 110V (A2) 4617 36* Relay – SS, 220V (A2) 456018 Seal – Piston (new style) 583119 Seal – Piston (old style) 251220 Seat – Outlet check valve (new style) 657221 Spring – Check valve (old style) 230422 Spring – Check valve (new style) 6578

37* Switch – On/Off, 110V (A2) 4553 38* Switch – On/Off, 220V (A2) 4552 39* Switch – Pressure, high (A2) 4554 40* Switch – Pressure, low (A2) 455528 Valve – Inlet check assembly (old style) 0563529 Valve – Inlet check fitting (new style) 657430 Valve – Outlet check fitting (old style) 236431 Valve – Outlet check fitting (new style) 657532 Valve – Outlet shutoff/Outlet bleed 2558-333 Valve – Pressure relief (2500 psi) 5001-134 Valve – Pressure relief (4800 psi) 5001-2

* denotes out of sequence numbers

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Replacement Parts Layout – 9000-A2

Pressure switches are notshown for clarity

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Frequently Asked Questions

1. Does Sierra Precision provide the interface hoses?2. What connections are required for interface hoses?3. What is the size of the booster?4. What is the weight of the booster?5. What size generator or power source is recommended?6. What inlet air pressure is needed to run the booster?7. What happens if the minimum inlet pressure required is not achieved?8. Can the booster be run from ambient air?9. Can the inlet air source be too high for the booster?10. How can the boosted be mounted or installed?11. Where can the booster be installed?12. What maintenance is required?

1. Does Sierra Precision provide the interface hoses? No, Sierra Precision does not supply these hoses. Both upstream anddownstream hoses that interface with the booster may be purchased from alocal, specialty hose fabricator.

2. What connections are required for interface hoses?Connections on the booster (both inlet and outlet) are standard ¼” male “AN”flare fittings with a standard 7/16-20 thread. Interface hoses will have thecorresponding ¼” female swivel “AN” crimp on flare fittings crimped to a hosesuch as Synflex 3800 series, or Parker 526BA. Hoses should be rated forbreathing air and appropriate pressures (5,000 or 6,000 psi). IDs should be ¼”.

3. What is the size of the booster?The booster envelope is 30 ¾” long x 19” wide x 15 ½” high.

4. What is the weight of the booster?135 pounds (net).150 pounds (shipping weight).

5. What size generator or power source is recommended? The booster requires a 6 kW power source for mobile applications or a 2.5 kWpower source for in-station applications. Larger generators (7.5 kW and up) maybe advisable, for mobile applications, in order to run additional accessoryequipment (lights, for example).

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Frequently Asked Questions (continued)

6. What inlet air pressure is needed to run the booster?The inlet pressure required varies depending on the outlet pressure desired.Generally, the higher the outlet pressure, the higher the inlet pressure required.For example, an inlet pressure of 800 psi is recommended to fill 2216 psi SCBAs;an inlet pressure of 2000 psi is recommended to fill 4500 psi SCBAs.

7. What happens if the minimum inlet pressure required is not achieved?If the minimum inlet pressure is not met, fill times will significantly increase. If theinlet pressure is too low, SCBA cylinders may not fill at all.

8. Can the booster be run from ambient air?No. The booster is designed to boost or amplify an existing air storage system orcompressor. It is not designed to perform without minimum inlet air pressure andwill prove quite inefficient when used as a compressor.

9. Can the inlet air source be too high for the booster?Yes. If the inlet air source is too high, relief valves inside the booster will ventpressure.

10. How can the boosted be mounted or installed?The booster can be mounted on a sturdy cart, solid workbench, or speciallyconstructed frame over a bank of cylinders. It is advisable for safety reasons,though not imperative, that the booster be bolted to the supporting surface. Formobile installations, bolting to the supporting surface is strongly recommended.

11. Where can the booster be installed?The booster should be located in an area that will allow a minimum of ten inchesof space between the back and right side of the booster and any adjoining wall orequipment. This clearance is necessary to allow adequate airflow through thebooster to cool the electric motor and other components. Additionally, havingspace in the back of the booster will greatly simplify any required maintenance orservice.

12. What maintenance is required?The booster is designed to be virtually maintenance free. Only normalmechanical system checks are necessary. Please refer to the “MaintenanceProcedures” section of this manual for specific details regarding maintenance.

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TroubleshootingSymptom Probable cause SolutionAir not passing through booster Outlet valve is closed or cannot be

opened because seats are crushedand/or valve handles are stripped.

Turn handle in proper direction and donot close outlet valve with excessiveforce. Replace valve if damaged.

Booster cycles on/off rapidly Outlet valve (or downstream shutoffvalve) not opened sufficiently to allowadequate airflow.

Open outlet valve (or downstreamshutoff valve) with at least 1½ turns.

Booster cycles on/off intermittently Back leakage through check valves orleak in outlet air system.

Replace cylinder heads (old style),replace check valves (new style) orcheck upstream air system for leaks.

Booster will not start (A2 Model) If unit is switched between pressuresettings without bleeding dischargepressure, air can become trapped inthe pressure switch housing andprevent the unit from starting.

Bleed the outlet air pressure lines priorto selecting a new output pressuresetting.

Booster will not start (00 Model) Outlet pressure has not been reduceda sufficient amount to overcome the“dead band” of the pressure switch.This prevents the switch from resetting.

Bleed outlet pressure lines untilpressure switch resets.

Inlet air lines hot Leaking check valves. Replace cylinder heads (old style) orreplace check valves (new style).

Inlet pressure drops during operation Inline air filters installed with flowarrows pointing in direction of airflow orfilters are clogged.

Reverse direction of installed filters orreplace clogged filter elements.

Noise – chattering (particularly above 3000 psi)

Sheaves loose. Tighten sets screws or bushings and/orreplace sheaves.

Noise – hissing around compressor unit with motor off and booster pressurized

Failed piston seals. Replace piston seals.

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Noise – hissing within booster compartment with motor off and booster pressurized.

Leaking compression fittings. ***WARNING*** Always bleed systempressure before making adjustments.Tighten fittings and connections.

Outlet air pressure does not increase Leaking check valves. Replace cylinder heads (old style) orreplace check valves (new style).

Pressure regulator (upstream) vents Leaking check valves. Replace cylinder heads (old style) orreplace check valves (new style).

Relief valves fail to close Dirt in relief valves. Clean or replace relief valves.

Relief valves “pop” open Upstream cascade system (boosterinlet pressure) exceeds the requireddownstream fill pressure (boosteroutlet pressure).

Install a pressure regulator betweensupply pressure system and thebooster inlet.

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WarrantySierra Precision warrants to the original purchaser, for a period of two years, that the airbooster (not including seals and electric motor) is free from defects in material andworkmanship. Sierra Precision warrants the piston seals in the air booster for anoperation time of 200 hours and the electric motor for a period of one year, as per themotor manufacturer’s warranty.

Sierra Precision’s sole obligation under this warranty, or under any other warrantyimplied by law, in the event of breach thereof, shall be as follows: for a period of twoyears after the date on which the air booster is originally purchased, Sierra Precision willeither, at its option, (a) repair, free of charge, any defect in material or workmanship inthe air booster, or (b) replace, free of charge, the air booster with an air booster ofcomparable quality.

This warranty is issued for the benefit of the original purchaser only and will not beavailable for the benefit of any transferee of the purchaser.

This warranty shall be inapplicable if the air booster has been tampered with, modified,misused, or altered in any way.

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Notes

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SPD009Rev NC

8/02

Sierra Precision has been in business since 1969 when it began manufacturing direct-drive pressure gauges for air cylinders for Self Contained Breathing Apparatus(SCBAs). Over the years, Sierra expanded its product line to include a complete line ofdirect-drive pressure gauges, electric air boosters, high and low-pressure air breathinghoses and a multitude of other life support products.

Sierra Precision strives for customer satisfaction by coupling engineering andmanufacturing capabilities with customer input to provide unique solutions at acompetitive price.

Sierra Precision11027 Arrow Route • Rancho Cucamonga, CA 91730

Phone 909-941-3900 • Fax 909-944-7303www.sierra-precision.com