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BioPak 240S - United States Mine Rescue Association

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1. Exhalation Breathing Hose The exhalation breathing hose is a flexible hose that will transfer user exhalation from the mask and into the breathing chamber Breathing Chamber The breathing chamber provides carbon dioxide absorption maintains system positive pressure maintains system volumetric control through venting and adding and provides anti anoxia protection The specific components of the breathing chamber are as follows Anti Anoxia Valve The anti anoxia valve an optional device is simply a plug that will restrict the exhalation hose connection to the breathing chamber in the event oxygen stores have not been installed or activated in the respirator Once the oxygen stores have been activated a pneumatic cylinder will withdraw the plug from the exhalation hose port When the plug is in the exhalation hose port the resulting breathing resistance will make it impossible for the user to breath the respirator thus providing a direct indication of no oxygen pressure Diaphragm and Diaphragm Spring The diaphragm and spring combine to form the counter lung The counter lung will react in an opposite direction from the user lungs and in combination with the spring will maintain positive pressure within the respirator Vent Valve The vent valve is located on the diaphragm and is mechanically actuated whenever the exhalation of the user exceeds the tidal volume of the respirator Once the respirator tidal volume has been exceeded the vent
2. Approval Biopak 240S Benchman Manual Part Number B5 06 6240 01 0 Revision K Self Contained Closed Circuit NIOSH rated for 4 hours as an entry and escape device Positive Pressure greater than 20 000 24 8 x 15 8 x 7 0 inches 630 x 401 x 178 millimeters 35 pounds 16 3 kilograms Including Facepiece Hoses Coolant Oxygen and Carbon Dioxide Absorbent 92dB 5mHz whistle sounding for 45 60 seconds to indicate 25 of rated duration approximately 1 hour remaining Red visual indication on chest mounted pressure gauge to indicate 25 of rated duration approximately 1 hour remaining DOT Approved Pressure Vessel Supplied with Pressure Gauge and Valve 21 cubic feet at 3000 psig fill 596 liters at 20 68 MPa fill above 15 F 9 C 32 to 85 F 0 to 30 C High impact fire retardant Noryl Fire retardant EPDM Silicone rubber polycarbonate lens ABS AGA Style Nylon copper brass Polypropylene housing Stainless steel cover Neoprene diaphragm ABS Delrin components NIOSH MSHA approved as entry into and escape from oxygen deficient atmospheres breathing apparatus Approval Number TC 13F 466 Reference Approval Label on Page 4 41 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 IX Warranty Statement Biomarine warrants subject to the terms below that the goods will be free from defects in design materials and workmanship for a period of three 3 years from the
3. BIOMARINE BIOPAK Model 240 8 240 S SELF CONTAINED BREATHING APPARATUS Biopak 240S Benchman Instruction Manual Biomarine Incorporated 456 Creamery Way Exton PA 19341 USA Phone 610 524 8800 Fax 610 524 8807 Email Neutronicsinc com Document A46D030 Revision K Part Number B5 06 6240 01 0 A46D030 Biopak 240S Benchman Manual Part Number B5 06 6240 01 0 Table of Contents Subject NIOSH Approval Label l Cautions and Limitations ll S Special or Critical User s Instructions ll Theory of Biopak Operation A Biopak Description B Breathing Loop C High Pressure Plumbing D Low Pressure Plumbing IV Turn Around Maintenance Procedure Turn Around Maintenance Tag Biopak Disassembly Washing and Disinfecting Oxygen Cylinder Charging Coolant Canister Charging Biopak Re Assembly Flow Test Carbon Dioxide Absorbent Charging and Installation Facepiece Concerns IO mmo ow J Final Re Assembly V Periodic Long Term Maintenance A Visual Inspection B High Pressure Leak Testing C Low Pressure Leak Testing D Flow Testing E Optional Facepiece Fit Testing Vi General Service Procedures A Scheduled Component Replacement B System Lubrication C Oxygen Cylinder D Regulator Assembly E Bypass Valve Assembly F Alarm Whistle Assembly G Flow Restrictor Assembly H Breathing Chamber Assembly l Harness and Straps J Facepiece Assembly K Factory Service and Training VI
4. damaged lens 2 Clean the inside lens of the facepiece with warm water and soap Dry the lens completely WARNING Do not use any alcohol or solvent based cleaners on the lens of the facepiece Such cleaning fluids may cause lens crazing and damage 3 Position a replacement lens on the inside of the facepiece Secure the lens into position by burnishing the seal material around the perimeter of the lens with a tongue depressor Note that replacement lenses are supplied with installation instructions 4 Apply anti fog solution to the facepiece and insert lenses as described in the Turn Around Maintenance procedures To Replace the AGA Style Wiper Chamois Reference Facepiece Wiper Assembly Illustrated Parts List 1 Pivot the wiper arm to access the self tapping screw 2 Remove the self tapping screw from one end of the assembly to disengage the flexible cable of the wiper Cut the nylon lacing away and slide the chamois off the flexible cable Slide a new chamois B2 02 7100 13 0 over the flexible cable and secure into position by tying with the nylon lacing supplied 5 Reattach the free end of the flexible cable to the pivot arm using the self tapping screw 35 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 K Factory Service and Training In the event Biopak problems arise that can not be corrected or repaired through the procedures provided in the Benchman Training Manual fa
5. 10 0 Foam Pad 4 1 B6 02 5000 33 0 Cover 5 1 B2 06 6000 02 0 Latch Stud 6 1 B3 03 2083 00 0 10 Split Lock Washer 7 1 B3 02 1080 00 0 10 32 Hex Nut 8 1 B5 06 6000 03 0 Turn Around Maintenance Tag Indicates Carbon Dioxide Absorbent material is supplied in bulk form in a 44 pound keg One keg will provide approximately 11 uses 52 A46D030 Biopak 240S Benchman Manual Part Number B5 06 6240 01 0 Revision K l Breathing Hose Assemblies ITEM QTY PART NUMBER DESCRIPTION REF 1 B2 02 7000 69 0 Connection Hose ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5001 49 0 Inhalation Hose Assembly 1 1 B2 02 7100 01 0 Hose Connector Gasket 2 1 B2 02 1300 01 0 Hose Connector Body 3 1 B2 02 1300 00 0 Hose Connector Nut 4 1 B2 06 6000 07 0 31 6mm Hose Clamp 5 1 B2 02 7000 74 0 Breathing Hose 6 1 B3 04 0300 06 0 Nylon 8 Green Cable Tie 7 1 B2 02 7000 77 0 Hose Connection Cuff 8 1 B2 02 7000 85 0 Inhalation Hose ID Label ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5001 48 0 Exhalation Hose Assembly 1 1 B2 02 7100 01 0 Hose Connector Gasket 2 1 B2 02 1300 01 0 Hose Connector Body 3 1 B2 02 1300 00 0 Hose Connector Nut 4 1 B2 06 6000 07 0 31 6mm Hose Clamp 5 1 B2 02 7000 74 0 Breathing Hose 6 1 B3 04 0300 05 0 Nylon 8 Red Cable Tie 7 1 B2 02 7000 77 0 Hose Connection Cuff 8 1 B2 02 7000 86 0 Exhalation Hose ID Label 53 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01
6. 245 OD x 114 ID Bypass Valve Mounting Washer 49 Revision K A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 F Breathing Chamber Assembly ITEM REF QTY 2NN Aa I bHNNNGOGNN TANGANI LG aaa aaa PART NUMBER B6 02 5001 40 0 B6 02 5001 40 1 B2 02 0000 07 0 B2 02 0000 09 0 B2 02 0000 10 2 B2 02 3300 04 0 B6 02 5000 49 1 B2 02 5000 25 0 B2 02 5000 26 0 B2 02 5100 02 0 B2 02 7100 03 0 B6 02 5001 55 0 B2 06 6000 02 0 B2 06 6000 09 0 B2 06 6000 19 0 B3 01 0043 00 0 B3 01 0043 01 0 B3 01 1061 04 0 B3 02 0040 00 0 B3 02 4060 00 0 B3 03 1043 00 0 B3 03 1063 00 0 B4 02 4012 00 0 B4 03 5204 04 0 B4 04 0000 00 0 B4 04 7060 01 1 B4 04 7060 02 0 B4 04 7060 03 1 B4 04 7070 01 0 B4 04 7070 03 1 B4 04 7070 07 1 B4 03 5004 04 0 B2 02 3300 18 0 V7 DESCRIPTION Breathing Chamber Assembly with Anti Anoxia Breathing Chamber Assembly without Anti Anoxia Constant Add Restrictor Fitting Add Valve Lever Center Section Housing Supply Connector Tube Anti Anoxia Valve Assembly 7 16 20 x 5 32 Tube Bushing Fitting 5 16 24 x 1 8 Tube Bushing Fitting Demand Housing Demand Housing Gasket Diaphragm Assembly Reference Section X G Latch Stud 10 Fitting Sealing Gasket Diaphragm Worm Gear Clamp 4 40 X 3 8 Flat Head Screw with O Ring 4 40 x 9 16 Flat Head Screw with O Ring 6 32 x 5 8 Pan Head Screw 4 40 ESNA Hex Nut 6 32 ESNA Hex Nut 4 Flat Was
7. Canister The carbon dioxide scrubber canister will remove user exhaled carbon dioxide through a chemical reaction It is essential to remove the carbon dioxide from the breathing loop as it will become toxic to the user over time and will lead to poisoning Carbon dioxide is a byproduct of the user metabolic consumption of oxygen The chemical reaction of the carbon dioxide absorption will release heat and moisture into the breathing loop and transform the scrubbing media into calcium carbonate as shown by the reaction below CO Ca OH Y CaCO H20 Carbon Dioxide Calcium Hydroxide Y Calcium Carbonate Water Connection Hose The short flexible connection hose supplies warm wet and carbon dioxide free gas from the breathing chamber to the coolant canister Coolant Canister The coolant canister is a housing that contains a frozen gel tube or pack Breathing gas from the connection hose will enter the canister at approximately 120 F and 100 moisture saturation The frozen gel will absorb much of the breathing gas heat to maintain the gas temperature and dew point below 90 F note that the NIOSH limit is 95 F Inhalation Breathing Hose The inhalation breathing hose is a flexible hose that will transfer carbon dioxide free cooled and condensed breathing air from the coolant canister into the inhalation port of the facepiece C High Pressure Plumbing The high pressure plumbing includes all components that are exposed to the high pr
8. G Flow Restrictor Assembly Should the Biopak fail the flow test of the Turn Around or Periodic Long Term Maintenance procedures the flow restrictor located in the demand housing of the breathing chamber may require replacement Reference the procedure outlined below and the Breathing Chamber Illustrated Parts List to replace the flow restrictor To Replace the Flow Restrictor Assembly 1 Verify that the oxygen cylinder valve is closed rotated to its full clockwise position and the chest mounted pressure gauge reads zero psi Depress the bypass valve to relieve any internal pressure in the Biopak Remove the upper housing breathing chamber lid and carbon dioxide scrubber canister from the Biopak CAUTION Do not use any tools to pry the breathing chamber cover or the carbon dioxide scrubber canister from the breathing chamber Damage may occur to the o ring seals or the components themselves Proper removal of the cover and scrubber is made by pulling up on the edge of the component with the fingers while pushing down with the thumbs on either the breathing hose stubs or rim of the breathing chamber Use a 9 16 open ended wrench to remove the flow restrictor fitting from the top of the demand housing located in the center of the breathing chamber well Use the combination pick supplied with the tool kit to remove the o ring seal from the flow restrictor fitting Inspect the o ring for signs of abrasions extrusion deforma
9. Harness Retaining Pin Harness Retainer Pin Cap Breathing Chamber Mounting Block 44 40 x 3 8 Flat Head Screw 6 32 x 3 8 Pan Head Screw 6 Flat Washer 44 40 ESNA Hex Nut Lower Housing with Hardware Flexible Draw Latch Style Carrying Handle Strap Flexible Draw Latch Catch Plate 6 32 ESNA Hex Nut Lower Housing with Hardware Rotational Latch Style 6 32 x 12 Pan Head Screw Note Lower housing style must match upper style in terms of latch type 7 7 7 yf sf NANANG fo HK 46 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 C Upper Housing Assembly ITEM REF REF 1 NOOR WP QTY at Nh a ahi adi PART NUMBER B6 02 5001 42 0 B6 02 5001 42 1 B2 02 7000 01 0 B2 06 6001 10 0 B6 02 5001 52 0 B3 01 1061 01 0 B2 06 2001 02 1 B3 02 4060 00 0 B6 02 5001 52 1 DESCRIPTION Biopak 240S Upper Housing Assembly Flexible Draw Latch Biopak 240S Upper Housing Assembly Rotational Latch Warning Label USA Label Upper Housing with Hardware Flexible Draw Latch Style 6 32 x 3 8 Pan Head Screw Flexible T Handle Draw Latch 46 32 ESNA Hex Nut Upper Housing with Hardware Rotational Latch Style Note Upper housing must match lower housing in terms of latch style AT A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 D Pneumatic Assembly ITEM REF QTY AS O aa DDD PART NUMBER B6 02 5001 41 0 B6 02 5001
10. burn more vigorously and at a higher temperature Oxygen will not cause materials to ignite unless there is an ignition source present A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 This SCBA is approved for respiratory protection during entry into and escape from oxygen deficient atmospheric gases and vapors at temperatures above 15 F This SCBA is approved only when the oxygen cylinder is fully charged with compressed oxygen meeting U S P specifications The oxygen cylinder shall meet applicable DOT specifications and shall be marked COMPRESSED BREATHING OXYGEN Do not use this apparatus near open flames or in high radiant heat After each use of this apparatus a fully charged breathing gas container and a recharge of carbon dioxide absorbent shall be installed Thorough cleaning and disinfecting of the facepiece breathing tube and breathing bag must be done in accordance with the manufacturer s instructions Use with adequate skin protection when worn in gases or vapors that poison by skin absorption for example hydrocyanic acid gas A good facepiece seal is important since facepiece leakage will severely reduce service time Use of pure oxygen or enriched air increases the flammability and lowers the ignition temperature of most materials Special handling procedures shall be instituted when utilizing the carbon dioxide scrubber material LimePak and the anti fog
11. center of the breathing chamber and press straight down so that the chamber studs protrude A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 through the cover through holes Slide the snap latches of the cover onto the studs to secure the cover in place 13 Check the CARBON DIOXIDE ABSORBENT REPLACEMENT box on the Turn Around Maintenance Tag l Facepiece Concerns 1 Complete the washing and disinfecting procedure to the facepiece before proceeding 2 Inspect the facepiece rubber components for signs of wear cuts nicks or abrasions Replace the facepiece as required 3 Inspect the perimeter seal of the anti fog lens Re burnish the seal edges if voids or gaps are evident 4 Use the anti fog cloth part number B6 02 5000 08 0 to apply a heavy coat of anti fog agent onto the exposed inside surface of the facepiece lens and or anti fog lens Best results are gained by storing the facepiece with the anti fog agent in place and un buffed on the lens CAUTION Do not ingest the anti fog solution or allow the anti fog solution to contact the eyes Refer to Appendix B for handling and first aid measures 5 Check the ANTI FOG AGENT APPLICATION box of the Turn Around Maintenance Tag J Final Re Assembly 1 If a test oxygen cylinder has been installed replace it with a freshly charged oxygen cylinder Open the cylinder valve and listen for leaks the alarm whistle chirping and verify tha
12. core into the center of the valve body Proper installation depth is achieved when resistance is felt during rotation Use the valve core installation tool to drive the core into position until it contacts the valve body seat Tighten the valve core an additional 1 8 turn using the valve core installation tool WARNING DO NOT over tighten the valve core during installation Excessive force on the add valve may strip the threads of the valve core or the demand valve Installation shall be made until the top of the valve is just even or slightly below the surface of the demand valve housing and the valve stem is completely above the demand housing surface 25 A46D030 5 6 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Reassemble the bypass valve spring o ring pushbutton washer and guard into the valve body using the bypass valve wrench Tighten the guard until snug Perform the Periodic Long Term procedures Replacing the Bypass Valve O Ring Part B4 04 7070 07 0 1 6 Verify that the oxygen cylinder valve is off rotated to its full clockwise position and the chest mounted pressure gauge reads zero psi Depress the bypass valve to relieve any internal pressure in the Biopak Use the bypass valve wrench included in the tool kit to remove the valve guard and washer from the lower housing The pushbutton with attached o ring mounting washer and spring will now fall out of the valve asse
13. date that the goods are purchased by buyer with the exception of rubber components Rubber and silicone rubber components are similarly warranted for a period of one 1 year from the date of purchase THIS WARRANTY DOES NOT APPLY TO OXYGEN CYLINDER HYDROSTATIC TESTING FOR PERIODIC RECERTIFICATION OF THE PRESSURE VESSEL THE SOLE LIABILITY OF BIOMARINE FOR ALL PURPOSES SHALL BE TO REPLACE AT THE SOLE OPTION OF BIOMAINRE DEFECTIVE PARTS APPEARING WITHIN THE THREE OR ONE YEAR PERIOD AS APPLICABLE BIOMARINE SHALL PROVIDE PARTS AT ITS OWN EXPNSE BUT ALL LABOR SHALL BE AT THE EXPENSE OF THE BUYER BIOMARINE SHALL HAVE NO OBLIGATION FOR REPLACEMENT UNLESS 1 BIOMARINE HAS RECEIVED WRITTEN NOTICE OF THE ALLEGED DEFECT WITHIN THIRTY 30 DAYS FOLLOWING THE DISCOVERY OF THE DEFECT OR THIRTEEN 13 MONTHS FROM THE DATE OF PURCHASE EHICHEVER OCCURS SOONER AND 2 THE BUYER SUBMITS PROOF OF DATE OF PURCHASE WITH INVOICE OR EQUIVALENT DOCUMENTATION AND 3 THE DEFECTIVE GOODS ARE PROMPTLY RETURNED BY BUYER AT THEIR SOLE EXPENSE TO BIOMARINE AT 456 CREAMERY WAY EXTON PA 19341 USA AND THE EQUIPMENT HAS NOT BEEN ALTERED AND THE DEFECT OCCURS UNDER CIRCUMSTANCES OF PROPER USE IN ACCORDANCE WITH ALL INSTRUCTIONS AND MANUALS PROVIDED TO THE BUYER It shall be the responsibility of the buyer to read carefully and abide by all instructions provided to the buyer in the instruction manual or elsewhere If buyer and the employees of the buyer did no
14. the chamber by depressing the face of the chamber fitting and pulling the tube end fitting straight out of the chamber fitting Release the breathing chamber from the lower housing by removing the four pushpins The pins are released by depressing the center button while pulling up on the pin Lift the entire breathing chamber out of the Biopak Turn the breathing chamber onto its cover and remove the large worm gear clamp that holds the diaphragm in place Pull the diaphragm from the breathing chamber by its edge Use the vent valve wrench supplied with the tool kit to disassemble the vent valve components from the center of the diaphragm Discard the damaged diaphragm Clean all components of the vent valve and inspect Replace any o ring seal or component that shows signs of wear or damage Re lubricate the o rings as per the Lubrication guidelines Section VI B Position the vent valve cap into the through hole of the replacement diaphragm so that the smooth flat surface of cap is on the same side of the diaphragm as the four guide plates Place the red vent spring onto the center screen of the cap and position the secondary seat and its o ring seal on top of the spring Carefully thread the secondary body and its o ring seal onto the cap threads to hand tight Be sure that the spring is properly seated in the seat and the seat button extends through the center through hole of the body Position the second vent spring on top
15. to stick Problem Alarm indications of remaining service time not functioning correctly Probable Causes 1 Chest mounted pressure gauge has failed or pressure line has been severed 2 Alarm whistle reguires tone adjustment 3 Alarm whistle has failed Remedy 1 Replace the chest mounted pressure gauge referencing the top assembly parts lists 2 Adjust the tone of the alarm whistle according to the procedure set forth in Section VL F 3 Replace the alarm whistle assembly according to the procedure set forth in Section VLF 38 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Problem Sounds of escaping gas heard during use Probable Causes 1 Poor facepiece fit is causing breathing loop leak Sound of escaping gas is being made by constant oxygen adds into the breathing loop by the demand valve 2 Sealing washer between the oxygen cylinder and the pressure regulator is missing or damaged resulting leakage of high pressure oxygen from the cylinder 3 Biopak has a leak in the breathing loop or the high or low pressure plumbing systems Remedy 1 Readjust the facepiece User should train for proper facepiece seal using the Facepiece Fit Test of Section V E The facepiece seal will be difficult if not impossible to achieve if the user has any facial hair or is wearing glasses that interfere with proper facepiece fit The user should be clean shaven and should utilize optional spectacle mountin
16. valve assembly Replace the spring if it appears damaged 3 Remove clean inspect and replace worn or damaged components in the vent valve according to procedures set forth in Section VI H Note that excessive lubrication on the primary and secondary vent seat o ring seals may cause valve sticking 4 Follow the procedures of Section VI H to replace the anti anoxia valve Before replacing the valve verify that no foreign particles have become jammed between the valve plug and the breathing hose port causing the valve to stick Problem High breathing resistance during inhalation Probable Causes 1 Facepiece inhalation check valve sticking closed 2 Diaphragm spring in breathing chamber is missing or damaged 3 Demand valve in breathing chamber has failed 4 Anti Anoxia valve in breathing chamber is not operating properly Remedy 1 Remove the check valve inspect clean and replace if required according to the procedures set forth in Section VI J 2 Follow the procedures of Section VI H to remove the breathing chamber from the Biopak Replace the spring if it appears damaged or install the spring if it is missing 3 Replace the valve core in the breathing chamber according to the procedures in Section VI H 4 Follow the procedures of Section VI H to replace the anti anoxia valve Before replacing the valve verify that no foreign particles have become jammed between the valve plug and the breathing hose port causing the valve
17. valve will be forced open to release excess gas This will insure that exhalation breathing resistances do not build up and cause user discomfort The valve is a two stage device providing dual seals for added protection Demand Valve The demand valve is a mechanically actuated valve located at the upper end of the diaphragm inhalation travel stroke In periods of heavy loads the user requirements may exceed those of the standard respirator function The demand valve will open to admit additional flow of oxygen into the breathing loop This device insures that the respirator will supply the user with additional oxygen as required and will also insure against the respirator going into a negative pressure situation during inhalation A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Breathing Chamber continued Flow Resirictor The flow restrictor admits a constant flow of oxygen directly into the breathing loop to replace volumes lost through user consumption and carbon dioxide absorption Oxygen will continually flow from the restrictor at 1 78 lpm which is 4 9 times greater than the metabolic consumption of oxygen by a human at rest Metabolic consumption rates of oxygen by human subjects can be characterized as listed below Body at Rest 0 2 to 0 5 Ipm Light Work Load 0 8 to 1 0 lom Moderate Work Load 1 0 to 1 5 lpm Heavy Work Load 1 5 to 2 0 Ipm Extremely Heavy Work Load 2 0 to 3 0 lpm Carbon Dioxide Scrubber
18. 0 J Coolant Canister Assembly ITEM REF REF 4 2 3 4 5 QTY a ee ee jami andha ndhi mi PART NUMBER B6 02 5001 44 0 B6 02 5000 66 0 B2 02 4100 66 0 B6 02 5001 58 0 B2 02 7100 15 0 B4 04 7060 09 0 B2 02 7000 73 0 DESCRIPTION Coolant Canister Assembly Coolant Canister Coo Tube Canister End Cap Canister Body Foam Moisture Absorbent Pad O Ring Seal 3 693 OD x 3 487 ID Coolant Canister Label CoolTube 54 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 K Oxygen Cylinder Assembly ITEM REF REF GTY sd du dd di dd OPT PART NUMBER B6 02 5000 93 0 B6 02 5000 48 0 B4 04 5500 00 0 B2 05 1000 00 0 B4 04 7060 00 0 B2 02 7000 56 0 B2 02 7000 21 0 B2 01 2000 04 0 B2 01 2000 04 1 B2 02 4000 04 0 B5 07 1000 00 0 DESCRIPTION Oxygen Cylinder Assembly Green Oxygen Cylinder Assembly Black White Oxygen Cylinder Valve Pressure Gauge O Ring Seal 1 012 OD x 0 734 ID Identification Label C17A003 03 Identification Label C17A003 04 Composite Pressure Cylinder Green Composite Pressure Cylinder Black White Oxygen Cylinder Extended Handle Optional Va wide Teflon Thread Tape for sealing threads of item 2 55 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 L Scott Style Facepiece Assembly ITEM QTY PART NUMBER REF 1 B6 02 5001 45 0 REF 1 B6 02 5001 45 1 REF 1 B6 02 5001 45 2 REF 1 B6 02 50
19. 0 B6 02 5001 40 0 B6 02 5001 40 1 B6 02 5001 46 0 B6 02 5001 44 0 B6 02 5000 93 0 B6 02 5000 05 0 B6 02 5001 36 0 B6 02 5001 48 0 B6 02 5001 49 0 B2 02 7000 69 0 B3 04 0300 00 1 B2 02 0000 15 0 B2 06 6000 12 0 B2 06 6000 74 0 B2 06 6000 01 0 B2 02 3300 34 0 B2 02 0000 03 0 B2 02 1300 11 0 B3 02 4060 00 0 B3 01 1041 00 0 B3 01 1061 02 0 B3 01 1061 03 0 B3 01 1082 01 0 B3 01 1082 00 0 B3 03 1042 00 1 B3 03 1063 00 0 B3 03 0006 00 0 B2 06 6000 17 0 B5 06 6240 00 0 B5 06 6240 01 0 B6 02 5001 50 0 DESCRIPTION Biopak 240S Complete Rebreather Assembly Upper Housing Assembly Reference Section X C Upper Housing Assembly Reference Section X C Lower Housing Assembly Reference Section X B Lower Housing Assembly Reference Section X B Pneumatics Assembly Reference Section X D Breathing Chamber Assembly Reference Section X F Breathing Chamber Assembly Reference Section X F Chest Mounted Pressure Gauge Assembly Coolant Canister Assembly Reference Section X J Oxygen Cylinder Assembly Reference Section X K Carbon Dioxide Scrubber Assembly Reference Section X H Tool Kit Assembly Reference SectionX O Exhalation Breathing Hose Assembly Reference Section K I Inhalation Breathing Hose Assembly Reference Section K I Connection Hose Assembly Reference Section K I Nylon 4 Cable Tie not depicted Alarm Whistle Mounting Clamp Chest Mount Pressure Gauge Line Clamp Breathing Chamber Lock Down Pin Breathing Hose Worm Gear Clam
20. 01 45 3 REF 1 B6 02 5001 45 4 REF 1 B6 02 5001 45 5 1 1 B2 06 6001 11 0 2 1 B2 06 6001 12 0 3 1 B2 06 6001 13 0 4 1 B6 02 5001 59 0 5 2 B2 02 1300 04 0 6 1 B2 02 4100 17 0 7 1 B2 02 4100 16 0 8 2 B2 02 7100 06 0 9 2 B2 02 7100 07 0 10 2 B2 06 6000 24 0 11 2 B2 06 6000 25 0 12 1 B2 06 6000 57 0 13 1 B3 04 0300 05 0 14 1 B3 04 0300 06 0 15 2 B2 02 7000 12 0 DESCRIPTION Standard Facepiece Assembly Small Standard Facepiece Assembly Large Standard Facepiece Assembly Extra Large Wipered Facepiece Assembly Small Wipered Facepiece Assembly Large Wipered Facepiece Assembly Extra Large Facepiece with Lens Small Facepiece with Lens Large Facepiece with Lens Extra Large Adapter Assembly Hose Adapter Fitting Inhalation Check Valve Holder Exhalation Check Valve Holder Check Valve Elbow Connector 38 1mm Hose Clamp 48 5mm Hose Clamp Anti Fog Lens Insert Nylon 8 Red Cable Tie Nylon 8 Green Cable Tie Check Valve Holder Sealing Gasket Note Items 4 through 15 can be purchased as a fully assembled component under part number B6 02 5001 68 0 49 KOOL 4 SS es RS NN A NN DOOR 56 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 M AGA Style Facepiece Assembly ITEM QTY PART NUMBER REF 1 B6 02 5000 25 0 REF 1 B6 02 5000 25 1 REF 1 B6 02 5000 25 2 REF 1 B6 02 5000 25 3 1 1 B2 06 6000 45 0 1a 1 B2 02 4400 00 0 1b 1 B2 06 6000 59 0 1c 1 B2 06 6000 58 0
21. 2 2 B2 02 7100 52 0 3 2ft B2 06 6000 46 0 4 1 B2 06 6000 44 0 5 1 B6 02 5001 01 0 6 1 B4 04 7060 08 0 7 1 B2 02 4100 31 0 8 1 B4 04 7070 05 0 9 1 B6 02 5000 80 0 10 2 B2 02 7000 12 0 11 2 B2 02 7100 06 0 12 1 B2 02 4100 17 0 13 1 B2 02 4100 16 0 14 2 B2 06 6000 25 0 15 2 B2 02 7100 07 0 16 1 B3 04 0300 06 0 17 1 B3 04 0300 05 0 18 2 B2 06 6000 24 0 19 2 B2 02 1300 04 0 20 1 B2 02 0000 30 0 21 1 B2 02 4100 74 0 22 4 B3 01 1041 05 0 23 1 B2 02 1300 17 0 24 1 B2 02 4000 00 0 25 2 B3 01 1021 03 0 26 4 B3 01 1041 04 0 27 1 B1 15 3000 01 0 28 1 B6 01 5000 00 0 29 1 B2 02 3300 27 0 30 1 B2 02 1300 09 0 31 1 B2 02 3100 09 0 32 1 B2 06 6000 63 0 33 1 B2 06 6000 64 0 DESCRIPTION AGA Style Facepiece with Speaking Diaphragm AGA Style Facepiece with Voice Amplifier AGA Style Facepiece with Wiper AGA Style Facepiece with Microphone AGA Facepiece Facepiece Lens Facepiece Frame with Screws Facepiece Head Strap Condensation Pad Ligarex Strap Ligarex Lock T Bone Adapter Assembly O Ring Seal 0 558 OD x 0 414 ID Adapter Plug O Ring Seal 1 943 OD x 1 737 ID Speaking Diaphragm Check Valve Holder Seal Gasket Check Valve Inhalation Check Valve Holder Exhalation Check Valve Holder 48 5mm Hose Clamp Elbow Connector Nylon 8 Cable Tie Green Nylon 8 Cable Tie Red 38 1mm Hose Clamp Hose Adapter Fitting Anti Fog Lens Insert Speaking Diaphragm Retainer 4 40 x7 16 Pan Head Screw Voice Amplifier Adapter
22. 34 4 5 6 7 8 9 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 PART NUMBER B6 02 5001 36 0 B6 02 5001 36 1 B6 02 5001 36 2 B2 02 7000 71 0 B2 03 1000 01 0 B2 03 1000 03 0 B2 03 1000 04 0 B2 03 1000 05 0 B2 03 1000 06 0 B2 03 1000 13 0 B2 03 1000 08 0 B2 03 1000 09 0 B2 03 1000 10 0 B2 03 1000 11 0 B2 03 3000 01 0 B2 03 3000 02 0 B2 03 3000 03 0 B2 03 1000 12 0 B2 03 1000 14 0 B6 02 5000 16 0 B6 02 5000 29 1 B5 07 1000 15 0 B5 07 3007 00 0 B3 06 5000 01 0 B6 02 5001 75 0 B4 04 7000 01 0 B5 01 3000 01 0 DESCRIPTION Biopak 240S Tool Kit Assembly Full Kit Biopak 240s Tool Kit Assembly Hand Tools Only Biopak 240s Tool Kit Assembly Specialty Tools Only Tool Kit Pouch 3 16 Slotted Screwdriver 1 Phillips Drive Screwdriver 3 8 x 5 16 Open End Wrench 5 8 x 9 16 Open End Wrench 7 16 Combination Wrench 1 2 Combination Wrench 1 16 Allen key Wrench 3 16 Nutdriver Combination Pick Tool Hose Clamp Ratchet Pincer Tool Vent Valve Wrench Bypass Valve Wrench Valve Core Tool 5 16 Nutdriver Needle Nose Pliers Flow Test Flowmeter Balloon Leak Test Fixture Test Key 6 Tongue Depressor Small Finger Cot Finger Cot Zip Lock Storage Bag Demand Housing Wash Plug Demand Housing Wash Plug Replacement O Ring Christo Lube O Ring Lubricant 2 ounce tube 17 18 2 gt 13 12 4 a 20 14 9 22 15 18 a 3 19 60
23. 40S has a Protection Factor greater than 20 000 that has been derived from a Quantitative Fit Test In the Quantitative Fit Test the rebreather is exposed to an ambient atmosphere heavily laden with particle contamination A measure of the particle concentration outside of the respirator is divided by a measure of the particle concentration in the respirator facepiece to establish the Protection Factor The Biopak has been utilized in mine rescue tunneling hazardous material remediation fire fighting chemical and biological warfare and numerous other applications Anywhere a potential exists for an oxygen deficient atmosphere or an atmosphere that may con ain a human health hazard agent can be considered an application of the Biopak Biopak 240S Benchman Manual Revision K A46D030 Part Number B5 06 6240 01 0 Exhalation Check Valve 7 nhalation Check UN gay VV halatio Y dl AN za F gt X Y nhalation Breathing Hose NI LS Coolant Canister UA mm gt a j Gel lube N Exhalation Breathing Hose Erase WE Exhalat B ng Hose o Anti Anoxia Volve kj a A a ES Connection Hos Carbon Dioxide Scrubber Canister Demand Valve aphragm Spring NG Di m Breathing Chamber sestrictor oO u Flow Vent Volve a Diaphragm Alarm Whistle Pressure Regulator Oxygen Cylinder CAL Chest Mounted N ine N Pr
24. 53 0 B6 02 5001 54 0 B6 02 5001 60 0 B2 02 6400 01 2 B2 02 5400 03 0 B2 02 3300 35 0 B6 02 5001 69 0 B3 01 1065 00 0 B3 03 0006 01 0 B2 02 5000 24 1 B4 02 1012 01 1 B4 02 4012 00 0 B4 02 4018 00 0 B6 02 5001 71 0 B6 02 5001 70 0 DESCRIPTION Biopak 240S Pneumatic Assembly Alarm Whistle Assembly Bypass Valve Assembly Reference Section X E Oxygen Cylinder Pressure Regulator with Fittings Oxygen Cylinder Yoke with Handle Oxygen Cylinder Regulator Jam Nut Oxygen Regulator Mounting Bracket Manifold Block Assembly 6 32 x 3 16 Hexagon Set Screw Oxygen Cylinder Sealing Washer High Pressure Tube Assembly 1 8 Outside Diameter Nylon Tubing 1 8 Outside Diameter Copper Tubing 3 16 Outside Diameter Copper Tubing 1 8 Tube Quick Disconnect Fitting Red 1 8 Tube Quick Disconnect Fitting Brass 48 A46D030 Biopak 240S Benchman Manual Part Number B5 06 6240 01 0 E Bypass Valve Assembly ITEM REF 1 NOOR O TO 8 10 11 QTY sadi eek ND eee IN ek a HU PART NUMBER B6 02 5001 54 0 B2 02 0000 12 0 B2 02 4100 18 0 B2 02 4100 19 0 B2 06 6000 13 0 B2 02 5100 04 0 B6 02 5001 77 0 B2 02 5400 01 1 B4 04 0000 00 0 B4 04 7070 03 1 B4 04 7070 07 1 B3 03 0006 00 0 DESCRIPTION Bypass Valve Assembly Push Button Valve Guard Valve Body Valve Spring 5 16 24 x 10 32 Bushing 1 8 Elbow Fitting Assembly Valve Holder Valve Core O Ring Seal 367 OD x 239 ID O Ring Seal
25. A46D030 Biopak 240S Benchman Manual Part Number B5 06 6240 01 0 P Miscellaneous Supplies DESCRIPTION Replacement Balloon for Leak Test Fixture Portion Pak Disinfectant 75 packets Cristo Lube O Ring Lubricant Dow 111 O Ring Lubricant Leak Tec Leak Detection Fluid 80Z Facepiece Lens Anti Fog Agent Biopak 240S Spare Parts Kit PART NUMBER B2 02 7000 17 0 B6 02 5000 42 0 B5 01 3000 01 0 B5 01 3000 11 0 B5 01 3000 03 0 B6 02 5000 08 0 B6 02 5001 78 0 Revision K Illustrated Parts List Note Greater detail of the presented illustrated parts lists can found on Biomarine assembly drawings as listed below Assembly drawings can be requested directly from Biomarine or through the local Biomarine representative Drawings can be supplied in paper or electronics format as desired Electronic formats are limited to AutoCAD 13 dwg files only Illustrated Parts List Top Assembly Section X A Lower Housing Assembly Section X B Upper Housing Assembly Section X C Pneumatic Assembly Section X D Bypass Valve Assembly Section X E Breathing Chamber Assembly Section X F Diaphragm Assembly Section X G Carbon Dioxide Scrubber Assembly Section X H Connection Hose Section K I Inhalation Hose Assembly Section X I Exhalation Hose Assembly Section K I Coolant Canister Assembly Section X J Oxygen Cylinder Assembly Section X K Scott Style Facepiece Assembly Section X L AGA Style Facepiece Assembl
26. Biopak to provide for immediate reuse and to prevent the growth of biological organisms in non disinfected eguipment A Turn Around Maintenance Tag The Turn Around Maintenance Tag provides an indication of completed procedures and inspections for user verification before subseguent Biopak uses Tags are supplied in bulk with each shipment of carbon dioxide absorbent and should be utilized throughout the procedures outlined in this section of the manual Without the completed tag in place on the Biopak the user will not know for certain that the Biopak is ready for use B Biopak Disassembly 1 Use a sponge and mild soap to wipe clean the entire exterior of the Biopak and harness Wipe dry or allow to air dry 2 Remove the upper housing from the Biopak by disconnecting the two latches to release and swing the housing up so that it can be lifted off of the hinge plates 3 Disconnect the hoses from the facepiece by unthreading the hose connectors Disconnect the connection and exhalation hoses from the breathing chamber by unthreading the worm gear clamps Remove the coolant canister from the Biopak by disconnecting the Velcro straps Remove the end cap from the coolant canister by rotating in a clockwise direction and pulling it straight out of the end of the housing Remove the coolant device from inside the canister Submit the coolant canister with hoses connected and the coolant device to the washing and disinfecting procedure Reta
27. E E T 2 8 T so a o E me N A46D054 REV HJ 03 28 2003 N Never substitute modify add or omit parts Use only exact replacement parts in the configuration as specified by the manufacturer O Refer to User s Instructions and or maintenance manuals for information on use and maintenance of these respirators S Special or critical User s Instructions and or specific use limitations apply Refer to User s Instructions before donning A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Cautions and Limitations Failure to properly use and maintain this product could result in injury or death All approved respirators shall be selected fitted used and maintained in accordance with MSHA OSHA and other applicable regulations Never substitute modify add or omit parts Use only exact replacement parts in the configuration as specified by the manufacturer Refer to User s Instructions and or maintenance manuals for information on use and maintenance of these respirators Special or critical User s Instructions and or specific use limitations apply Refer to User s Instructions before donning S Special or Critical User s Instructions All users of the Self Contained Breathing Apparatus SCBA must be trained by qualified instructors in donning operation inspection and emergency use procedures All repairs beyond the scope of this manual must be performed by Biomarine Incorporated or a q
28. I Troubleshooting Guide VIII Biopak Specifications Revision K A46D030 Biopak 240S Benchman Manual Part Number B5 06 6240 01 0 Warranty Statement Illustrated Parts Lists ozz MAS Y To mo ou Top Assembly Lower Housing Assembly Upper Housing Assembly Pneumatic Assembly Bypass Valve Assembly Breathing Chamber Assembly Diaphragm Assembly Carbon Dioxide Scrubber Assembly Breathing Hose Assemblies Coolant Canister Assembly Oxygen Cylinder Assembly Scott Style Facepiece Assembly AGA Style Facepiece Assembly AGA Style Facepiece Wiper Assembly Tool Kit Assembly Miscellaneous Supplies Appendix A Maintenance Log Sheet Appendix B Material Hazards Handling and First Aid Revision K BIOMARINE INCORPORATED 456 CREAMERY WAY EKTON PA 19341 USA PHONE 610 524 8800 FAX 610 524 8807 EMAIL Neutronicslnc com A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 i Cautions and Limitations Anti Fog Agent Cylinder Knob Extender Accessories Facepiece Voice Amplifier Facepiece Eyeglass Kit AGA Style w Wiper 201 228 G1 B17D190 B46D061 B46D060 400 471 G13 AGA Style w Voice Amplifer 400 471 G12 AGA Style w Speaking Diaphragm 400 471 G11 o prisas pr AGA Style w Microphone 400 471 G2 Scott Style Wipered Xlarge D46A0 Scott Style Wipered Large D46A0 o o o 5 Scott Style Wipered Small D46A0 Scott Style Standard Xlarge D46A0 Alternate Facepiec
29. T MEDICAL ATTENTION IMMEDIATELY Ingestion NEVER GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON If swallowed have conscious person drink several glasses of water or milk INDUCE VOMITTING GET MEIDCAL ATTENTION IMMEDIATELY Store in container supplied by manufacturer Respiratory No protection required when utilized as described in Biomarine Biopak manuals Skin Wear chemically protective gloves boots aprons and gauntlets to prevent prolonged or repeated skin contact during application to Biopak facepiece No protection required during normal Biopak use Eyes Wear protective eyeglasses or chemical safety goggles per OSHA eye and face protection regulations 29 CFR 1910 133 during application to Biopak facepiece No protection is required during normal Biopak use Hygiene Practice good personal hygiene after using this material especially before eating drinking smoking using the toilet or applying cosmetics 64
30. UENTIAL OR INCIDENTAL DAMAGES WHETHER IN CONTRACT TORT OR OTHERWISE OR FOR PERSONAL INJURY OR PROPERTY DAMAGE OR ANY FINANCIAL LOSS Any description of the goods contained in any documents to which these warranty provisions related including any quotations or purchase orders relating to the goods being delivered to buyer are for the sole purpose of identifying the goods and any such description as well as any sample or model which may have been displayed to or seen by buyer at any time have not been 42 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 made part of the basis of the bargain and have not created or amounted to any warranty express or implied that the goods would conform to any such description or any such sample or model EXCEPT AS SPECIFICALLY SET FORTH IN THESE WARRANTIES BIOMARINE MKES NO WARRANTIES EXPRESS OR IMPLIED WHETHER ARISING BYLAW CUSTOM CONDUCT OR USAGE OF TRADE INCLUDING WARRANTIES AS TO MERCHANTABILITY OR AS TO THE FITNESS OF THE GOODS FOR ANY PARTICULAR USE OR PURPOSE AND ANY WARRNTIES INCLUDING WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR PARTICULAR USE OR PURPOSE AND THE RIGHTS AND REMEDIES PROVIDED HEREIN ARE EXCLUSIVE THESE WARANTIES SHALL RUN TO THE BUYER ONLY AND SHALL NOT BE CONSTRUED AS A CONDITION Biomarine does not warrant that the goods are free from the rightful claim of any third person by way of infringement or patents or other proprietary informati
31. Voice Amplifier Adapter Retainer 2 56 x 14 Pan Head Screw 4 40 x 5 8 Pan Head Screw Voice Amplifier Module Microphone Assembly Microphone Flat Washer Microphone Retaining Nut Microphone Retainer Facepiece Nose Cup not depicted Facepiece Spectacle Kit not depicted 57 Revision K Biopak 240S Benchman Manual Part Number B5 06 6240 01 0 A46D030 NS a N ey NY g OA 5 ERIN y A eX a A Y V N 2 PATA y 58 A46D030 ITEM QTY REF 1 DNMNNNMNMNANNN Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 N AGA Style Facepiece Wiper Assembly PART NUMBER B6 02 5000 02 1 B2 02 4400 00 1 B3 05 3000 00 0 B2 02 3100 04 0 B2 06 6000 38 0 B3 03 1133 00 0 B3 04 0300 01 0 B2 02 3100 05 0 B4 04 7070 09 0 B3 01 3061 00 0 B2 02 3100 06 0 B2 02 7100 13 0 B2 02 3100 07 0 DESCRIPTION AGA Style Facepiece Wiper Assembly Modified AGA Style Facepiece Lens Spring Pin Wiper Handle 3 8 32 Thin Hex Nut Flat Washer Sealing Grommet 3 8 32 Bushing O Ring Seal 0 285 OD x 0 145 ID 6 32 x 5 8 Self Tapping Screw Wiper Pivot Arm Nylon Lacing Cord 0 09 Wide x 0 012 Thick Wiper Chamois Flexible Cable Lacing cord is supplied with each replacement chamois B2 02 7100 13 0 59 A46D030 O Tool Kit Assembly QTY 4 4 4 4 4 2 4 4 4 4 1 1 1 1 1 1 1 1 2 4 4 4 4 4 ITEM REF REF REF que
32. ace or skin when opening Oxygen cylinders should be filed and stored at ambient temperatures maintained at 70 F Filling a cylinder at high temperatures can result in final fill levels several hundred psig below the target pressure once the cylinder cools Conversely filling the cylinder at low temperatures may result in a final fill pressure of several hundred psig above the target pressure once the cylinder warms The variation of oxygen pressure with temperature is extreme and can result in hazardous conditions Therefore it is imperative that the oxygen cylinder storage temperature be maintained as close as possible to 70 F at all times During cylinder filling the temperature of the cylinder will rise in proportion to how quickly the cylinder is filled If the booster pump is heavily loaded the cylinder temperature will rise and cause increased oxygen expansion and pressure Therefore a two stage process is required to properly fill the oxygen cylinder After filling the cylinder to rated service pressure stamped on the cylinder the cylinder should be allowed to cool to approximately 70 F This will normally require a 15 20 minute cool down period if the cylinder is left in 70 F ambient temperatures The pressure as indicated on the cylinder pressure gauge will drop during this cool down period Once the cylinder has cooled a second fill stage to the proper fill pressure can be made The above guidelines must be followed in order to safe
33. age such as nicks cuts tears or rips When lubricating an o ring use the thumb and forefinger to work the lubricant over all surfaces while feeling for nicks or cuts Replace any o ring that has tears rips uneven spots nicks cuts rough spots or abrasions Cristo Lube MCG 111 or Dow 111 Silicone Lubricant are the only lubricants approved by the manufacturer for use in the Biopak Do not substitute any other lubricant WARNING Do not use an oil based lubricant or any other lubricant on the o ring seals other than Cristo Lube MCG 111 or Dow 111 Silicone Lubricant The use of other lubricants not approved by the manufacturer may result in fire hazards in the presence of the enriched oxygen atmosphere of the Biopak WARNING ALTHOUGH THE OXYGEN CYLINDER SEALING WASHER SERVES THE SAME PURPOSE AS AN O RING SEAL IT SHOULD NEVER BE LUBRICATED Lubrication of the sealing washer may result in regulator stem clogging rapid accumulation of dirt and will present a fire and explosion hazard due to the present of the high pressure enriched oxygen atmosphere It is recommended to inspect and lubricate the below listed o rings after a specified number of uses of the Biopak O ring locations and part numbers can be referenced on the Illustrated Parts Lists of this manual Breathing Chamber O Rings Inspect and re lubricate after every five 5 uses The large diameter o rings that seal the breathing chamber housing to the breathing cover an
34. an usual intake of oxygen Such situations may serve to shorten the duration of the Biopak below the 4 hour rating 5 Leaks in the breathing loop the low pressure system and the high pressure system will serve to shorten Biopak duration Inspect the Biopak systems to the procedures of the Periodic Long Term Maintenance Section V 6 Inthe rare event of pressure regulator failure the user should following the emergency procedures described in the User s Manual and immediately evacuate the area Replace the pressure regulator according to the procedure set forth in Section VI D of this manual Note that regulator failure can be diagnosed by a failure of the flow test with flows over 2 4 lpm 97S A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Problem High breathing resistance during exhalation Probable Causes 1 Facepiece exhalation valve sticking closed 2 Diaphragm spring in breathing chamber is not properly seated or damaged 3 Vent valve in breathing chamber not opening properly 4 Anti Anoxia valve in breathing chamber is not opening properly Remedy 1 Remove the check valve inspect clean and replace if required according to the procedures set forth in Section VI J 2 Follow the procedures of Section VI H to remove the breathing chamber from the Biopak Inspect the position of the diaphragm spring and verify that the free end of the spring is positioned over and around the diaphragm vent
35. athing chamber disconnecting the quick disconnect fittings at the chamber Remove the breathing chamber from the Biopak by disengaging the four pushpins located at the 3 6 9 and 12 o clock positions around the chamber Pressing the center button of the pin down while pulling the entire pin up disengages the pins Retain the pins for future reuse and submit the breathing chamber to the washing and disinfecting procedure C Washing and Disinfecting 1 2 Complete the Biopak disassembly procedure before washing and disinfecting Prepare a disinfecting solution by cutting open the disinfectant agent packet part number B6 02 5000 42 0 and pouring the contents into clean warm water Add one packet per each gallon of water CAUTION Do not substitute any other disinfectant agent Other agents may contain alcohol or chlorine that can deteriorate facepiece lens and rubber components Place the facepiece all coolant canister parts the breathing chamber lid and all the hoses into the disinfecting solution for a minimum of ten minutes Rinse the components thoroughly with the solution insuring that all surfaces have become wetted Be sure to introduce the solution into the internal volume of the breathing chamber NOTE Do not wash and disinfect the carbon dioxide scrubber components until after washing all other components to avoid contact of absorbent granules Cover the demand housing located in the center of the breathing chamber w
36. ature Remove the finger cot from the breathing chamber demand housing or remove the demand housing wash plug and re install the restrictor fitting to the top of the demand housing Check the WASHING DISINFECTING box on the Turn Around Maintenance Tag D Oxygen Cylinder Charging 1 2 For Charging of the Oxygen Cylinder by Third Parties Verify that the cylinder valve and seat are clean and cover with a clear plastic bag Secure the bag with a rubber band or tie Supply the cylinder to the third party filling vendor with instructions to fill between 2700 and 3000 psig as read by the cylinder gauge after the cylinder has cooled to 70 F with U S P medical grade oxygen For In House Charging Follow the guidelines outlined below a The filling area should be completely free of any grease or oil products If the filling is done in a small confined area adequate ventilation should be provided to prevent the build up of oxygen and the formation of an oxygen rich atmosphere b Only U S P medical grade oxygen is to be used to fill Biopak oxygen cylinders Other grades of oxygen may contain impurities and excess moisture that can affect the cylinder as well as the plumbing in the Biopak c To further protect the oxygen supply from possible contamination from moisture or dust it is recommended that each booster pump be equipped with a filter drier assembly installed on the gas inlet side of the booster pump The filter shall b
37. away from the center stud It is best to remove the top cover over a waste bin since the scrubbing media is in granular form and may spill out Submit the cover to the washing and disinfecting procedure Remove the foam pad from the scrubber and dump the internal granular contents into a suitable waste bin The granular scrubbing media is spent soda lime that is has been converted to limestone and is safe to dispose in regular trash Submit the canister body and foam pad to the washing and disinfecting procedure CAUTION Always wear rubber gloves and safety glasses when working with soda lime Reference Appendix B for details on the hazards of soda lime proper handling and first aid measures 9 Remove the oxygen cylinder from the Biopak by rotating the regulator yoke handle in a counterclockwise direction to loosen the connection Guide the cylinder up off of the center post and pins and out of the yoke Remove the sealing washer that seals the cylinder valve to the yoke and retain for reuse Submit the oxygen cylinder to the oxygen cylinder filling procedure It is acceptable to leave the oxygen cylinder in place during the duration of the washing and disinfecting procedure WARNING Before removing the oxygen cylinder verify that the cylinder valve is closed that the chest mounted pressure gauge reads 0 psi and depress the bypass valve to relieve any internal pressure 10 Disconnect the two nylon plumbing lines to the bre
38. ctory service may be obtained by contacting the manufacturer as direct below Additionally the manufacturer offers training programs for Biopak Benchmen and Users Training sessions will provide a complete review of all procedures provided in the Benchman Training Manual as well as use training The factory can be contacted as followed By Mail Biomarine Incorporated ATTN Service Department 456 Creamery Way Exton PA 19341 2532 USA By Phone 610 524 8800 Monday through Friday 9AM through 4PM By FAX 610 524 8807 By EMAIL NeutronicsInc com All service correspondence to the factory should include the below listed information Biopak Model Number Biopak Serial Number Date of Biopak Purchase Approximate Number of Biopak Uses Description of Biopak Problem Actions Taken to Correct Problem Contact Name Address and Phone Number 36 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Vil Troubleshooting Guide The following is provided as a guide for the Benchman to troubleshoot the Biopak Problems or issues that arise that can not be corrected by the Benchman with assistance from this manual should be referred to the factory Problem Mask fogging during use Probable Causes 1 Anti Fog lens insert not installed or damaged 2 Anti Fog agent not applied or applied incorrectly Remedy 1 Install or replace the Anti Fog lens according to procedures set forth in Section VI J 2 Reap
39. d the carbon dioxide scrubber canister will experience much abuse during repeated Turn Around Maintenance procedures These o rings shall be lubricated with either approved lubricant Vent Valve O Rings Inspect and re lubricate after every fifty 50 uses Reference the Diaphragm Assembly Illustrated Parts Lists for the location of the four o ring seals These seals may be lubricated with either approved lubricant 23 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Coolant Canister End Cap O Ring Inspect and re lubricate after every five 5 uses The o ring that seals the coolant canister end cap to the coolant canister housing will sustain much abuse from repeated insertion and removal of the coolant insert This o ring may be lubricated with either of the approved lubricants Other O Rings The remaining o rings of the Biopak will not be exposed to wear conditions and should not require regular lubrication Problems with these o rings will surface during high and low pressure leak testing Should one of the remaining o rings require replacement reference the Illustrated Parts Lists for its location and replacement part number Follow all guidelines presented above and use only the lubricants approved by the manufacturer as listed below WARNING Use only the approved lubricant as listed below when servicing o rings Use of the Dow 111 lubrication where Cristo Lube is specified may result in poor Biopak fu
40. de of the holder Cut away the tip of the check valve so that the remaining tip does not exceed Ya in length Slide the hose gasket over the check valve holder so that it is seated against the holder shoulder Position the holder and gasket into the open hose connector port of the adapter assembly Position the elbow onto the connector port of the adapter assembly and position it at the same angle as the inhalation side elbow Ensure that the holder gasket and elbow are fully engaged and seated onto the adapter assembly Secure the elbow into position using a new 48 5mm hose clamp and the hose clamp ratcheting tool supplied as an optional tool in the tool kit WARNING Do not attempt to re use the 48 5mm hose clamp The clamp is designed for a one time use only Attempts to reuse removed clamps may result in clamp disengagement during use 11 12 Reinstall the adapter assembly to the facepiece by pushing it straight into the facepiece port at a 90 angle from its final position rotating to the final position and securing by pushing in the silver retaining clip Perform the positive and negative test on the facepiece as described in the User s Manual 34 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 To Replace the Anti Fog Lens Insert Reference the Facepiece Illustrated Parts Lists 1 Remove the existing insert from the inside surface of the facepiece lens Discard the
41. der Discard the check valve 5 Insert the tip of the new check valve through the center hole of the check valve holder and pull through the other side until the shoulder of the valve has engaged on the holder Proper installation of the check valve will place it on the outside or convex side of the holder Caution Do not pull the check valve completely through the center hole of the check valve holder This may cause damage to the check valve 6 Cut away the tip of the check valve so that the remaining tip does do not extend past the edge of the check valve holder 7 Slide the hose gasket over the check valve holder so that it is seated against the holder shoulder 8 Position the holder and gasket into the open hose connector port of the adapter assembly 9 Position the elbow onto the connector port of the adapter assembly and position it at the same angle as the exhalation side elbow Ensure that the holder gasket and elbow are fully engaged and seated onto the adapter assembly 10 Secure the elbow into position using a new 48 5mm hose clamp and the hose clamp ratcheting tool supplied as an optional tool in the tool kit WARNING Do not attempt to re use the 48 5mm hose clamp The clamp is designed for a one time use only Attempts to reuse removed clamps may result in clamp disengagement during use 11 Reinstall the adapter assembly to the facepiece by pushing it straight into the facepiece port at a 90 angle
42. e Open the cylinder valve and verify that the alarm whistle produces a brief chirp Repeat the procedure to adjust the tone arm so that it will produce the loudest possible tone If the whistle will not produce the desired start up chirp then replace the alarm whistle assembly To Replace the Alarm Whistle Assembly 1 Verify that the oxygen cylinder valve is closed rotated to its full clockwise position and that the chest mounted pressure gauge reads zero psi Referencing the Top Assembly Illustrated Parts List remove the alarm whistle mounting clamp by unthreading the screw washer and nut from the lower housing Disconnect the copper high pressure tube assembly from the bottom of the alarm whistle assembly using two 7 16 open ended wrenches Disconnect the copper low pressure tubing from the top of the alarm whistle assembly using two 7 16 open ended wrenches 26 A46D030 9 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Reconnect the plumbing lines to the replacement alarm whistle Position the replacement alarm whistle into the lower housing so that the tone arm and holder extend out through the slot in the lower housing Secure the alarm whistle to the lower housing using the screw washer and hex nut Open the valve of the oxygen cylinder and verify the start up chirp Readjust the tone arm as required Perform the Periodic Long Term Maintenance procedures
43. e serviced at regular intervals as required d Before filling any cylinder visually inspect the cylinder under a bright light for signs of physical damage and the accumulation of contaminants such as dirt lint grease or oil Clean all contaminants from the cylinder before proceeding with filling Cuts in the outer wrapping of the cylinder require hydrostatic testing at a test facility as per CGA pamphlet C 6 2 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Before filling any cylinder inspect the hydrostatic test date stamped on the cylinder If the test date is over five 5 years old the cylinder may not be refilled Have the cylinder hydrostatically tested by an approved test facility or Biomarine as per CGA pamphlet C 6 2 before filling Make a special effort to prevent cylinders from being drained below 500 psig as indicated by the cylinder pressure gauge at all times to reduce the possibility of external contamination migration into the cylinder Oxygen cylinders that have pressure gauge readings of 0 psig must be purged and pulled into a vacuum to remove all traces of moisture before filling It is suggested that these cylinders be returned to Biomarine to insure proper purging and vacuum application Prior to connecting the cylinder to the refill pump the cylinder valve should be briefly opened to purge the valve seat of accumulated dust and or moisture Do not direct the valve opening towards the f
44. e Assemblies o o Scott Style Standard Large D46A0 o D o Scott Style Standard Small D46A0 D46A01 Ultra Lite Black White p o o M AII approved respirators shall be selected fitted used and maintained in accordance with MSHA OSHA and other applicable regulations D46A019 02 D46A0 o D46A018 B17A013 Biopak 240S Alternate Oxygen Cylinder C17A003 03 Assembly Ultra Lite Green C17A003 04 Coolant Device CoolTube Coolant Canister Assembly 0 Alternate Carbon Dioxide Scrubber RESPIRATOR COMPONENTS D17A038 D46A010 Factory Packed 300 887 G2 Standard 300 887 G1 without Anti Anoxia D46A006 02 ernate Center Section Pneumatic Assembly with Anti Anoxia D46A006 01 D46A007 with Rotational Latch D46A008 02 CLOSED CIRCUIT PRESSURE DEMAND ENTRY AND ESCAPE SELF CONTAINED BREATHING APPARATUS Alternate Upper Housing Assembly J Failure to properly use and maintain this product could result in injury or death 5 Z o lt 5 o LL z o o o lt o af x n D o with Fleixble Latch D46A008 01 o uu 3 au ternate Lower Housing with Rotational Latch D46A009 02 8 z a aa with Fleixble Latch D46A009 01 3 u o 2 al o E 2 Zz 6 P o o a o w o o z c E a 5 lt o S Z Ww cc o 8 9 a cc o o a o va gt D mr lt 23 a lt cz x s153 lt EE a Re 2 Ww 9 o e cl u o i s
45. e center post and pins of the regulator Tighten the regulator yoke against the cylinder to secure the connection Secure the cylinder in the Biopak with the Velcro strap G Flow Test 1 Slide a test flow meter part number B6 02 5000 16 0 over the demand valve housing located in the center of the breathing chamber well 2 Insert a wooden tongue depressor into one of the breathing chamber slots located around the chamber rim and press down to move the diaphragm away from contact with the demand valve Wedge the tongue depressor in the slot to maintain its position Install a second tongue depressor as per above into one of the breathing chamber slots located 180 from the first tongue depressor 3 Open the oxygen cylinder valve and verify a flow reading on the flow meter of at least 1 6 lpm with the oxygen cylinder at 3000 psig If the flow meter does not read at least 1 6 Ipm reference the Troubleshooting section of this manual Close the oxygen cylinder valve and remove the flow meter Remove the two tongue depressors from the breathing chamber slots Do not use excessive force to remove the tongue depressors If a tongue depressor becomes wedged in the breathing chamber use a second depressor installed into the next slot to free the wedged depressor 6 Check the FLOW TEST box of the Turn Around Maintenance Tag A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 H Carbon Dioxide Absorbent Chargin
46. eal integrity is acceptable It is recommended to perform the System Lubrication procedure at least once a year after the Biopak has aged five 5 years 22 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 B System Lubrication Proper lubrication of all o ring seals is essential to the reliable operation of the Biopak An o ring seal that has degraded will appear as leakage at its location during high or low pressure leak testing O ring damage can result from wear misalignment during seating or improper use of lubricant Observe the following precautions when servicing o rings Never pry an o ring from its seat with a screwdriver This can damage both the o ring and the seat Always carefully remove an o ring by hand or if required with the combination pick tool supplied in the Biopak 240S Tool Kit Do not attempt to lubricate an o ring while it remains in its seat This may result in excessive application of the lubricant and incomplete coating of the o ring Do not apply heavy coats of lubricant to the o ring Excessive lubrication does not provide greater sealing capability and may result in lubrication migration away from the o ring and into the breathing loop A properly lubricated o ring should have an even coating that appears as a dull sheen on the entire surface with no lumps or clumps Prior to lubricating and o ring visually inspect the o ring under a bright light source for any signs of dam
47. eplace the Padded Harness 1 2 3 4 Remove the upper housing Disconnect the plumbing lines and the breathing hoses to the breathing chamber Remove the breathing chamber from the lower housing as outline in Section H Remove the chest mounted pressure gauge from the harness by disconnecting the flow restrictor fitting located internal to the Biopak from the Biopak internal plumbing using 7 16 and 9 16 wrenches Pull the gauge and line from the harness and Biopak Pull the cap from each of the six harness retaining pins and remove each pin by sliding out of the harness loop Remove the harness from the Biopak Position a new replacement harness onto the lower housing and push the connection loops of the harness through the slots in the lower housing Anchor the harness into position using the six harness retainer pins and caps CAUTION Do not tubing to become trapped between the harness pin and cap when attaching the cap to the pin 10 11 12 13 Thread the gauge pressure line through the harness and Biopak lower housing Reconnect the pressure line to the flow restrictor fitting located internal to the Biopak using 7 16 and 9 16 wrenches Reinstall the breathing chamber into the lower housing Reattach the breathing hoses and plumbing lines to the breathing chamber Perform the Periodic Long Term Maintenance Procedures Reinstall the upper housing 32 A46D030 Biopak 240S Benchman Manual Re
48. essure oxygen stores Referring to Figure 1 this includes the oxygen cylinder oxygen cylinder pressure gauge oxygen cylinder valve pressure regulator and chest mounted pressure gauge These components serve to reduce the stored oxygen high pressure to a usable pressure level control the actuation of the oxygen stores and indicate the amount of remaining oxygen stores Oxygen Cylinder The oxygen cylinder is a lightweight carbon composite wrapped aluminum lined DOT approved pressure vessel that will contain the store of high pressure oxygen in the respirator The cylinder will hold 21 cubic feet of oxygen compressed to 3000 psi when fully charged This amount of oxygen will support the full four hour duration of the respirator The cylinder shall only be charged with U S P medical grade 100 oxygen and requires hydrostatic testing every five 5 years according to CGA pamphlet C 6 2 The cylinder is removable to permit recharging either in house or by a third party Oxygen Cylinder Valve The oxygen cylinder valve is attached directly to the oxygen cylinder and provides a mechanism for manually opening and closing the oxygen cylinder to the high pressure plumbing system Oxygen Cylinder Pressure Gauge The oxygen cylinder pressure gauge is connected directly to the oxygen cylinder and will provide a visual indication of the amount of oxygen A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 stored in the cylinder T
49. essure Gauge ax WI TL e NA Cyl alve A s Oxygen Cylinder Pressure Gouge gt Figure 1 Biopak 2405 Flow Diagram A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 B Breathing Loop The breathing loop consists of all components that are direct contact with the breathing atmosphere Referring to Figure 1 the breathing loop includes the facepiece the exhalation hose the breathing chamber the coolant canister and the inhalation hose These components all work to provide a positive pressure breathing atmosphere of 90 100 by volume oxygen and 90 100 relative humidity Facepiece The facepiece will fit directly onto the face of the user and will provide coverage from under the chin to the forehead Check valves are provided in the facepiece to force breathing atmosphere flow in the preferred direction The check valves will also insure that the breathing atmosphere does not hang up or remain in the facepiece which could result carbon dioxide build up and poisoning The facepiece is available in multiple sizes and styles Scott AGA and Drager to provide the best fit to the user Facepiece fit is critical in maintaining the positive pressure seal and conserving the duration of the respirator Standard facepieces are supplied with speaking diaphragms an anti fog lens insert and nosecup Optional features include lens wipers spectacle mounting kits voice amplification kits and voice communication systems
50. extended storage may be visually inspected flow tested and high and low pressure tested on a quarterly basis provided the following conditions have been met e Biopak is stored in an acceptable environment between 32 F 0 C and 85 F 30 C away from contact with contaminates such as dirt liquids etc e Turn Around Maintenance has been performed after each use in a timely manner e Biopak is stored sealed with all connections tight and the breathing hoses connected together with the hose coupling fitting NOTE A properly maintained and sealed Biopak can be stored up to one 1 year and placed directly into use Only under circumstances where the Biopak is to be stored for a 6 12 month period may the Periodic Long Term Maintenance schedule be extended to biannually or annually Periodic Long Term Maintenance must be performed on a monthly basis for Biopaks that have regular daily weekly or monthly use schedules Maintenance schedules should be tailored to the use schedule of the Biopak After completing the visual inspection the flow test the high pressure testing and the low pressure testing sign and date the back of the Turn Around Maintenance Tag and complete the Maintenance Log Sheet reference Appendix A to maintain a record of scheduled maintenance A Visual Inspection 1 Remove the upper housing from the Biopak 2 Visually inspect all components and housings for signs of wear abuse damage or loose connections
51. f discomfort persists Skin Drench with clean water Obtain medical attention if skin becomes inflamed Eyes Irrigate thoroughly with clean water Obtain medical attention Ingestion Wash out mouth thoroughly Obtain medical attention Store in a clean dry environment Avoid direct sunlight or temperatures in excess of 70 C 158 F Keep containers closed Respiratory Nuisance dust mask recommended Skin General purpose rubber gloves Eyes Glasses to protect against dust Hygiene Wash after skin contact 63 A46D030 Facepiece Anti Fog Solution Commercial Name Chemical Name Hazards Identification First Aid Measures Handling amp Storage Personal Protection Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Horizon Anti Fog Cloth mixture Avoid contact with eyes Dangerous by ingestion May cause nausea vomiting and diarrhea Inhalation Not Irritating Remove to fresh air If breathing is difficult have trained person administer oxygen If respiration stops administer artificial respiration GET MEDICAL ATTENTION Skin Relatively brief exposure causes no known adverse effects Flush thoroughly with cool water under shower while removing contaminated clothing and shoes SEEK MEDICAL ATTENTION Eyes IMMEDIATELY FLUSH EYES WITH A DIRECTED STREAM OF WATER for at least 15 minutes forcibly holding eyelids apart to ensure complete irrigation of all eye and lid tissue GE
52. facepiece solution Refer to Appendix B of this manual for details A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 lll Theory of Biopak Operation A Biopak Description The Biopak 240S is a four hour self contained closed circuit positive pressure breathing apparatus that is NIOSH approved for entry into and escape from oxygen deficient atmospheres The apparatus differs from open circuit devices in that all breathing air is recycled and confined within the device itself Only during periods of high volumetric exhalation will any breathing atmosphere be vented into the surround ambient atmosphere Breathing air is continually recycled in the device with exhaled carbon dioxide from the user captured by means of an absorbent media Breathing gas volumes lost through the absorption of carbon dioxide are directly replaced with a constant bleed of 100 oxygen from an on board supply Breathing is gas continually cooled through the use of a frozen gel to maintain user comfort throughout the four hour duration of the apparatus The apparatus is supplied with a full facepiece and is housed in a clamshell type backpack housing Hoses extend through the top of the housing to connect on either side of the facepiece to provide full mobility and viewing angles to the user The Biopak consists a three main sub systems the Breathing Loop The High Pressure Plumbing and the Low Pressure Plumbing The Breathing Loop consists of a
53. from its final position rotating to the final position and securing by pushing in the sliver retaining clip 33 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 12 Perform the positive and negative test on the facepiece as described in the User s Manual To Replace the Exhalation Check Valve Reference the Facepiece Illustrated Parts Lists 1 Remove the entire front adapter assembly from the Scott facepiece by pulling the silver retainer clip straight out away from the face piece rotating the assembly 90 and pulling the assembly straight out of the facepiece AGA style facepiece adapters are not removable and all procedures will be conducted with the adapter remaining installed on the facepiece Use a screwdriver to carefully pry the edge of the 48 5mm hose clamp up to disengage and remove the clamp from the inhalation side elbow A red band marks the exhalation side of the assembly Pull the elbow straight off the adapter assembly and retrieve the check valve and check valve holder and the check valve holder sealing gasket Remove the check valve from the check valve holder by pulling it through the holder Discard the check valve Insert the tip of the new check valve through the center hole of the check valve holder and pull through the other side until the shoulder of the valve has engaged on the holder Proper installation of the check valve will place it on the inside or concave si
54. g and Installation CAUTION Always wear rubber gloves and safety glasses when working with soda lime Reference Appendix B for details on the hazards of soda lime proper handling and first aid measures 1 Complete the washing and disinfecting procedure of all carbon dioxide scrubber components before proceeding with recharging 2 Using a Limepak keg part number B6 02 5000 32 0 refill the body of the scrubber canister with absorbent to the fill line indicated on the center post 3 Shake the canister back and forth on a smooth surface to promote settling of the absorbent into the canister 4 Add additional absorbent as required to fill to the indicated level WARNING Do not expose the absorbent material to the ambient atmosphere for more than a total of one 1 hour during recharging and or servicing Excessive exposure of the absorbent to ambient atmosphere will reduce the absorbent efficiency WARNING The carbon dioxide absorbent material has a maximum shelf life of five 5 years when sealed in its container Once the container seal has been broken the shelf life of the absorbent is reduced to one 1 year from the date of opening Always mark the date of container opening in the designated location on the container 5 Inspect the foam pad and verify that it not compressed Replace any foam pad that is less than 1 8 thick over the absorbent coverage area or 1 32 on the outside diameter Any foam pad that does not
55. g kits if glasses are worn 2 Replace or install the sealing washer onto the center stem of the pressure regulator 3 Perform the Periodic Long Term low and high pressure leak testing of Sections V B and V C Problem Breathing gas is uncomfortably warm during use Probable Causes 1 User is unfamiliar with conditions of Biopak supplied atmospheres 2 Frozen coolant insert has not been installed into the coolant canister 3 User is working in high ambient temperatures Remedy 1 The Biopak will supply breathing gas to the user at temperatures below 90 F throughout the 4 hour duration Breathing gas temperatures will be cool at the start of Biopak use and will continually rise as the user work load increases and as the frozen coolant insert begins to lose its charge 2 Install the FROZEN insert into the coolant canister The insert must be frozen for a period no less than eight 8 hours prior to use and should only be installed into the coolant canister just prior to donning the Biopak 3 Should the user be exposed to high ambient temperatures the temperature of the supplied breathing may rise above 90 F For cases of high ambient temperature it may be necessary to utilize a secondary cooling device in order to provide comfortable temperatures Problem Facepiece fails positive and or negative testing during user donning Probable Causes 1 Inhalation or exhalation check valve failure in the facepiece Remedy 1 Follow
56. he gauge will indicate the internal pressure of the cylinder regardless of the position of the oxygen cylinder valve This provides constant indication of cylinder fill conditions Pressure Regulator The pressure regulator consists of a pressure reducing mechanism and a 2 pin yoke The pressure regulating mechanism will reduce the high pressure of the oxygen cylinder to approximately 260 psig for delivery into the low pressure plumbing system The two pin yoke consists of a standard CGA oxygen valve connection format and a threaded handle to lock the valve of the oxygen cylinder into position onto the pressure regulator Chest Mounted Pressure Gauge The chest mounted pressure gauge mounts on the harness of the respirator and connects directly to the high pressure of the oxygen cylinder to provide the user with a real time visual indication of remaining oxygen stores during use Connection of the gauge to the oxygen cylinder is made via an armored plumbing line to protect it from damage during respirator use A flow restrictor is employed between the gauge and the cylinder to prevent the sudden release of oxygen stores in the event the connecting line becomes severed The gauge provides a direct indication of pressure remaining in the oxygen cylinder that can be translated into remaining respirator use time as listed below A red area on the gauge dial indicates to the user when approximately one hour of oxygen stores remain Gauge Reading psi Rema
57. he tongue depressors If a tongue depressor becomes wedged in the breathing chamber use a second depressor installed into the next slot to free the wedged depressor Turn off the oxygen cylinder and replace the carbon dioxide scrubber canister breathing chamber lid and upper housing C Low Pressure Leak Testing 1 2 Place the Biopak onto a flat service and remove the upper housing Disconnect the breathing hoses from the hose coupler fitting and connect the hoses to the leak test fixture part number B6 02 5000 29 0 Turn the Biopak over and insert a test key into the slotted hole on the rear of the lower housing and turn the key 1 4 turn to lock into position Turn the Biopak back over and open the oxygen cylinder valve Use the bypass valve to inflate the balloon of the leak test fixture to an approximate 45 angle If the balloon over inflates it can be vented through the vent valve of the test fixture WARNING Severe over inflation of the test balloon can cause damage to the balloon itself and to the vent valve of the breathing chamber Close the oxygen cylinder valve and depress the bypass valve to vent the internal pressure of the Biopak If gas escapes around the red pushbutton of the bypass valve the o ring of the button will require replacement Observe the test balloon for a period of 2 minutes The balloon should not significantly droop from 45 to 0 during the 2 minute period A droop to 35 is acceptable and on
58. he valve assembly making sure to save the fitting sealing gasket 7 Install the swivel elbow and gasket onto the replacement valve assembly and wrench tighten Position the valve assembly into the exhalation hose port of the breathing chamber Secure the valve into position using the retaining plate and mounting hardware 10 Reconnect the copper tubing from the demand housing to the swivel elbow fitting of the valve assembly 11 Open the oxygen cylinder to pressurize the Biopak The plug of the valve assembly should slide out of the exhalation hose port 12 Close the oxygen cylinder The valve shall slide back into position within the tube stub Replace the carbon dioxide scrubber the breathing chamber cover and the upper housing 13 Perform the Periodic Long Term Maintenance procedures of Section V I Harness and Straps The padded harness coolant canister straps and oxygen cylinder strap should be replaced when tears fraying or abrasions are evident Reference the procedures outlined below and the Lower Housing and Top Assembly Illustrated Parts Lists for replacement To Replace the Oxygen Cylinder or Coolant Canister Straps 1 Pull up on the strap end to disengage the Velcro connection 2 Remove the strap from the lower housing by pulling out by the metal loop end 3 Rethread a replacement strap through the lower housing slots 31 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 To R
59. her 6 Flat Washer 1 8 Outside Diameter Copper Tubing 10 32 x 1 8 Male Connector Fitting Demand Housing Valve Core O Ring Seal 505 OD X 299 ID O Ring Seal 10 145 OD x 9 725 ID O Ring Seal 10 895 OD x 10 475 ID O Ring Seal 423 OD x 351 ID O Ring Seal 367 OD x 239 ID O Ring Seal 245 OD x 114 ID Quick Connect Coupler Fitting Anti Anoxia Valve Mounting Bracket 26 19 16 14 50 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 G Diaphragm Assembly ITEM REF 1 NOOR O TO 8 10 QTY 1 1 1 1 1 1 1 1 2 2 1 PART NUMBER B6 02 5001 55 0 B6 02 5001 56 0 B6 02 5001 57 0 B2 02 4100 03 0 B2 02 4100 04 0 B2 02 4100 05 0 B2 02 4100 06 0 B2 06 6000 20 0 B4 04 7060 05 1 B4 04 7060 04 1 B2 02 3300 14 0 DESCRIPTION Biopak 240S Diaphragm Assembly Diaphragm with Hardware Vent Valve Cap with Screen Vent Valve Primary Body Vent Valve Secondary Body Vent Valve Primary Seat Vent Valve Secondary Seat Vent Valve Spring Silver O Ring Seal 2 193 OD x 1 987 ID O Ring Seal 1 005 OD x 799 ID Vent Valve Spring Red NO 51 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 H Carbon Dioxide Scrubber Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5000 05 0 Carbon Dioxide Scrubber Assembly 1 1 B6 02 5000 31 0 Scrubber Housing 2 AR B6 02 5000 32 0 Absorbent Agent Keg 3 1 B2 02 7100
60. in the worm gear clamps for reuse 4 Inspect the anti fog lens of the facepiece to verify that the perimeter seal is consistent and does not contain voids Re burnish the sealing edges if required 5 Remove the stainless steel cover from the breathing chamber as outlined below a Slide the snap latches of the cover to disengage them from the studs b Pull up on the lip of the cover with the fingers while pushing down on the breathing hose stubs of the breathing chamber with thumbs to remove the cover Submit the cover to the washing and disinfecting procedure CAUTION Do not use a screwdriver or any other instrument or tool to pry the cover away from the breathing chamber Such action will risk damage to the top edge of the breathing chamber as well as possibly damage the breathing chamber o ring seals 6 Lift the carbon dioxide scrubbing canister out of the breathing chamber by lifting on the canister edge with the fingers and pressing down on the breathing chamber rim with the thumbs CAUTION Do not use a screwdriver or any other instrument or tool to pry the canister out of the breathing chamber Such action will risk damage to the top edge of the breathing chamber as well as possibly damage the breathing chamber o ring seals A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Remove the carbon dioxide scrubbing canister from the Biopak work area and remove the top cover by pushing the latch
61. ining Use Time Hours 3000 4 2250 3 1500 2 750 1 D Low Pressure Plumbing The low pressure plumbing consists of all components that deliver the reduced pressure oxygen stores into the breathing loop and provide audible alarm features Referring to Figure 1 this will include the bypass valve alarm whistle and associated small diameter tubing Bypass Valve The bypass valve is a manually operated pushbutton located on the exterior of the respirator housing and will provide unrestricted flow of oxygen into the breathing loop when depressed The valve is intended for emergency uses only as described in the User Instruction Manual Alarm Whistle The alarm whistle will provide a 92 dB audible signal for 45 60 seconds whenever remaining oxygen stores are 25 of full capacity The alarm is a one time signal that signals the user when approximately one hour of oxygen remains The alarm is situated between the low pressure and high pressure plumbing components and functions on the differential pressure between the two systems Associated Plumbing The associated plumbing of the low pressure system is 1 8 diameter metal and plastic tubing that will connect the reduced pressure oxygen to the breathing loop and the alarm whistle A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 IV Turn Around Maintenance Procedure NOTE Turn Around Maintenance procedures should be preformed as soon as possible after each use of the
62. ith a finger cot or remove the restrictor fitting from the top of the demand housing and install the A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 demand housing wash plug supplied with the tool kit until it fully bottoms out on the top of the demand housing Pour disinfectant solution into the tube stubs of the breathing chamber Vigorously shake the breathing chamber with the tube stub end blocked to spread the solution throughout the chamber Allow all internal breathing chamber surfaces to remain wetted with the cleaning solution for a minimum of ten minutes CAUTION It is advised not to totally submerge the breathing chamber into the disinfectant solution to avoid contact of the solution with the demand housing flow restrictor Contact of the solution with the flow restrictor may cause restrictor clogging 10 Remove the components from the solution and rinse several times in clean fresh water Set the rinsed components aside to air dry or dry the components with a hair drier set for cool temperature Place the carbon dioxide scrubber canister body lid and pad into the solution for a minimum of ten minutes Rinse the components thoroughly with the solution to insure that all surfaces become weited Remove the carbon dioxide scrubber components from the solution and rinse several times in clean fresh water Allow the components to air dry or dry them with a hair drier set for cool temper
63. le observing the pressure measuring device Note the reading of the pressure measuring device when the facepiece seal begins to leak Stop exhaling and note where the pressure measuring device reading settles For a good facepiece seal the pressure measuring device should indicate a pressure reading of at least 6 water column Remove the test connection and doff the facepiece WARNING The above optional facepiece fit test IS NOT a substitute for quantitative fit testing Fit testing must be conducted to meet and federal state or local requirements such as required by MSHA or OSHA guidelines 21 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 VI General Service Procedures A Scheduled Component Replacement In order to maintain the Biopak in peak condition it is recommended by the manufacturer that the below listed components be replaced as listed Part Part Replacement Description Number Frequency Carbon Dioxide Scrubber Foam Pad B2 02 7100 10 0 every 20 uses Facepiece Anti Fog Lens Insert B2 02 0000 30 0 every 20 uses Oxygen Cylinder Sealing Washer B3 03 0006 01 0 every 50 uses Breathing Chamber ID O Ring Seal B4 04 7060 02 0 every 50 uses Breathing Chamber OD O Ring Seal B4 04 7060 03 1 every 50 uses Coolant Canister End Cap O Ring Seal B4 04 7060 09 1 every 50 uses The Biopak is designed for no mandatory component replacement during its lifetime However certain components will require re
64. lies as depicted by the Pneumatic Assembly Illustrated Parts List Section X D Secure the regulator to the lower housing using the five screws and the external support plate as referenced by the Top Assembly Illustrated Parts List Reinstall the oxygen cylinder and perform the Period Long Term Maintenance procedures E Bypass Valve Assembly The bypass valve will reguire service if the valve fails to provide emergency flow when depressed or if gas leaks around the perimeter of the pushbutton If the valve will not function correctly the valve core most likely requires replacement If leakage exists around the perimeter of the pushbutton the o ring seal most likely requires replacement Reference the procedures outlined below and the Bypass Valve Illustrated Parts List to service the bypass valve Replacing the Valve Core 1 Verify that the oxygen cylinder valve is off rotated to its full clockwise position and the chest mounted pressure gauge reads zero psi Depress the bypass valve to relieve any internal pressure in the Biopak Use the bypass valve wrench included in the tool kit to remove the valve guard and washer from the lower housing The pushbutton with attached o ring mounting washer and spring will now fall out of the valve assembly Use the valve core tool provided in the tool kit to remove the valve core from the center core of the valve body Immediately discard the valve core Install a replacement valve
65. ll components that are in direct contact with the breathing atmosphere to the user High Pressure Plumbing components work to reduce the high pressure of the on board oxygen supply to acceptable levels for use in breathing Low Pressure Plumbing components deliver the reduced pressure oxygen into the Breathing Loop Figure 1 provides a graphical representation of the complete respirator system Alarm features are provided to warn the user when oxygen stores are either running out or have not been activated A chest mounted pressure gauge will provide the user with a visual real time indication of remaining oxygen stores and will provide a visual alarm when only 1 hour of oxygen supply remains An alarm whistle will provide a 92dB sounding when remaining oxygen stores will provide one final hour of operation An anti anoxia feature will prevent use of the respirator whenever oxygen stores have not been installed or activated by the user A counter lung and spring arrangement is utilized to maintain positive pressure in the device during the exhalation and inhalation cycles of the respiration The positive pressure will insure that the entire breathing loop of the respirator is greater than the external ambient pressure This will insure that leakage such as around the facepiece seal is out of rather than into the respirator Outward leakage will lessen the potential for the migration of harmful external agents into the breathing atmosphere The Biopak 2
66. ly droops to 0 are considered significant If a significant droop is detected then inspect all hose connections coolant canister end cap and the breathing chamber cover for leakage and repair Disconnect the test fixture from the breathing hoses and reconnect them together with the hose coupler fitting Remove the test key from the rear of the Biopak and reinstall the upper housing WARNING Failure to remove the test key from the Biopak will result in excessively high breathing resistance improper Biopak function and may damage the diaphragm of the breathing chamber D Flow Testing 1 Remove the upper housing breathing chamber cover and carbon dioxide scrubber from the Biopak Slide a test flow meter part number B6 02 5000 16 0 over the demand valve housing located in the center of the breathing chamber well Insert a wooden tongue depressor one of the slots along the edge of the breathing chamber to push the diaphragm away from the demand valve Wedge the tongue depressor in the slot to maintain its position Install a second tongue depressor as per above into one of the breathing chamber slots located 180 from the first tongue depressor Open the oxygen cylinder valve and verify a flow reading on the flow meter of at least 1 6 lpm with the oxygen cylinder at 3000 psig If the flow meter does not read at least 1 6 lpm reference the Troubleshooting section of this manual 20 A46D030 5 6 Biopak 240S Be
67. ly fill the oxygen cylinder Oxygen can be a dangerous substance when not properly handled due its oxidation and flammability enhancement properties For further details of oxygen cylinder filling and supply of proper filling equipment contact the local Biomarine representative for assistance E Coolant Canister Charging 1 Complete the washing and disinfecting procedure of all coolant canister components before proceeding with recharging Place the washed disinfected and dried GelPak or Cool Tube into a standard freezer for at least eight 8 hours at a temperature not greater than 15 F 10 C and not lower than 159F 26 C Position the Cool Tube in the freezer in a horizontal position so that the internal gel mixture is distributed along the center axis of the tube Lay the GelPak in the freezer so that all sections of the GelPak are unfolded and flat 3 Check the COOLANT CANISTER IN FREEZER on the Turn Around Maintenance tag A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 F Biopak Re Assembly 1 Position the washed disinfected and dried breathing chamber into position in the lower housing of the Biopak Be sure to properly position the diaphragm spring over and around the vent valve of the breathing chamber during installation Secure the breathing chamber into position using the four pushpins The pins are installed by pressing the center button of the pin in while pushing the entire pi
68. mbly Use the combination pick supplied with the tool kit to remove the o ring seal from the groove on the stem of the pushbutton Immediately discard the o ring Lubricate a replacement o ring with Cristo Lube lubricant according to guidelines presented in Lubrication Section VI B Reassemble the bypass valve spring o ring pushbutton washer and guard into the valve body using the bypass valve wrench Tighten the guard until snug Perform the Periodic Long Term Maintenance procedures F Alarm Whistle Assembly If the alarm whistle does not provide a chirp when the oxygen cylinder valve is initially opened or if the whistle is difficult to hear it will require adjustment Alarm whistles that do not function at all should be replaced and the defective whistle returned to the factory To Adjust the Alarm Whistle Tone 1 2 Loosen the set screw in the tone arm holder and remove the tone arm Open the oxygen cylinder valve and verify that gas is escaping from the small hole in the side of the alarm body when the cylinder is opened The gas flow will only last for a few seconds If gas is escaping then continue with this procedure If gas is not escaping the alarm whistle assembly will require replacement Close the oxygen cylinder valve Reposition the tone arm into the holder so that the notch in the arm covers approximately 1 2 of the small hole in the alarm body Tighten the set screw in the tone arm holder to secur
69. n into position Pull up on each pin after installation to verify that it is securely locked into position Reconnect the two nylon plumbing lines to the fittings of the breathing chamber by connecting the quick disconnect fittings at the chamber Tug on each connection to verify that it is securely locked into position 2 Install the end cap onto the open end of the coolant canister by pressing it straight in and rotating clockwise to engage the locking pins Install the free end of the short hose to the breathing chamber hose stub closest to the 3 o clock position and secure with a worm gear clamp Position the coolant canister into the Biopak and secure with the two Velcro straps Route the inhalation hose around the left side of the breathing chamber and out of the housing top left through hole 3 Route the exhalation hose identified by a red band through the top right housing through hole and around the right side of the breathing chamber and over top of the short hose connecting the center section and coolant canister Secure the hose to the remaining hose stub of the breathing chamber and secure with a worm gear clamp 4 Connect the free ends of the inhalation and exhalation hoses together with a hose coupling fitting 5 Verify that the oxygen cylinder sealing washer is clean and install it onto the center post of the regulator Guide a recharged oxygen cylinder or a charged test cylinder into the regulator yoke and seat it onto th
70. nchman Manual Revision K Part Number B5 06 6240 01 0 Close the oxygen cylinder valve and remove the flow meter Remove the two tongue depressors from the breathing chamber slots Do not use excessive force to remove the tongue depressors If a tongue depressor becomes wedged in the breathing chamber use a second depressor installed into the next slot to free the wedged depressor Replace the carbon dioxide scrubber the breathing chamber cover and the upper housing into the Biopak E Optional Facepiece Fit Testing The Biopak is a positive pressure device that will leak outward in the event of poor facepiece sealing Leakage of gas from around the facepiece seal will significantly decrease the duration of the Biopak during use The procedure outlined below is provided as a guide for user testing to achieve and verify a good facepiece seal 1 Construct a test connector consisting of a stopper with a hole through it sized to fit into the hose connection ports of the facepiece and a length of tubing The tubing should connect to the stopper hole on one end and a pressure measuring device on the other end such as a water manometer capable of measuring 6 water column Don the facepiece without the breathing hoses attached and perform the negative and positive tests of facepiece donning Connect the test fixture to the exhalation port identified by a red band of the facepiece Take a deep breath and slowly exhale into the facepiece whi
71. nction General O Ring Location Lubricant Use Bypass Valve Cristo Lube Alarm Whistle Assembly Cristo Lube Flow Restrictor O Ring Seal Cristo Lube Connector Tube O Ring Seal Cristo Lube C Oxygen Cylinder There are no serviceable components on the oxygen cylinder The cylinder should be inspected regularly for signs of damage to the outer wrapping Cylinders that have cracks flaking or exposed fibers should immediately be removed from service Note that the cylinder is DOT approved pressure vessel and will require hydrostatic testing every five 5 years Every cylinder will have the date of the last test marked on the cylinder itself or on its label Testing shall be performed at a competent testing facility Contact the local Biomarine representative the local facility that may fill the oxygen cylinder or the factory for the location of a competent test facility D Regulator Assembly The regulator assembly can not be serviced or repaired in the field In the rare instance of regulator failure as marked by failure of the flow test after replacement of the flow restrictor and demand valve the regulator will require removal from service and replacement The procedure for regulator replacement is outlined below 1 Be sure that the oxygen cylinder valve is closed by rotating it to its full clockwise position 2 Verify that all pressure has been removed from the Biopak system as indicated by a zero psi reading on the chest mounted
72. of the secondary seat button and position the primary seat and its o ring seal on top of the spring Secure into position by threading the primary body and its o ring onto the threads of the secondary body making sure that the spring and primary seat are properly positioned WARNING DO NOT utilize the vent valve wrench to tighten the vent valve secondary and primary body threaded connections The connections only need to be made hand tight to generate the required sealing force Excessive force generated from over tightening may cause component damage and failure during use 28 A46D030 15 16 20 21 22 23 24 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Press the button of the primary seat and verify that the vent valve opens easily and completely Reinstall the diaphragm into the underside of the breathing chamber so that the vent valve button is in view Installation of the diaphragm is best achieved by first slipping a portion of the diaphragm over the chamber edge holding that portion in position and slowly easing the remaining portions of the diaphragm over the remainder of the chamber Inspect the diaphragm position and verify that the edge of the diaphragm is positioned against the first shoulder of the breathing chamber wall over the entire diaphragm circumference Secure the diaphragm into position using the large worm gear clamp It is suggested that the scre
73. on or disclaims any warranty against such infringement The terms of these warranties shall apply to the product sold by Biomarine except absorbent filters and anti fog lens inserts which are considered consumable item and as such are not covered by the terms of these warranties No waiver alteration or modification of the terms of these provisions shall be valid unless in writing and signed by an executive officer of Biomarine These warranties shall not apply to accessories or devices purchased by Biomarine and attached to or made part of the goods except that Biomarine warrants the the installation of such items in the completed product shall so conform to the installation instructions of the manufacturers thereof as not to invalidate such applicable warranties on such items as are obtained by Biomarine from such manufacturers and ii the workmanship incorporated in such installation shall be free from defects 43 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 X Illustrated Parts Lists Note Item numbers referenced with a designation throughout the Illustrated Parts Lists represent components supplied by the Biopak 240S Spare Parts Kit B6 02 5001 78 0 A Top Assembly ITEM REF 1 1A QTY Benen ANNO PH ONMNMNAHHA ARBAB I Y LY Yrs nh ueu iii E 4 PART NUMBER B7 07 2400 18 0 B6 02 5001 42 0 B6 02 5001 42 1 B6 02 5001 43 0 B6 02 5001 43 1 B6 02 5001 41
74. or parts that may impair the ability of the Biopak to function properly 3 Repair or replace any component that appears questionable 4 Replace the upper housing onto the Biopak B High Pressure Leak Testing 1 Place the Biopak onto a flat surface and remove the upper housing Verify that the breathing hoses are connected together with the hose coupler fitting Install a fully charged oxygen cylinder into the Biopak if one is not already in place Remove the breathing chamber lid and the carbon dioxide scrubber canister Wedge a wooden tongue depressor one of the slots along the edge of the breathing chamber to push the diaphragm away from the demand valve Wedge the tongue depressor in the slot to maintain its position Install a second tongue depressor as per above into one of the breathing chamber slots located 180 from the first tongue depressor Turn on the oxygen cylinder valve Inspect each plumbing connection joint with Leak Tec solution part number B5 01 3000 03 0 Inspection is performed by applying the Leak Tec solution to each joint allowing the solution to sit for a minimum of one minute and then visually inspecting each joint for signs of constant bubble formation 7 Tighten or replace any plumbing joint that shows signs of leakage A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Remove the two tongue depressors from the breathing chamber slots Do not use excessive force to remove t
75. overlap the outer edge of the canister body should also be replaced 6 Position the foam pad on top of the canister so that the center stud protrudes through the center hole of the pad and the pad overlaps the outside diameter of the canister body 7 Install the scrubber cover onto the top of the foam pad and secure into position by sliding the snap latch onto the center stud of the canister body 8 With the cover installed and locked into position shake the scrubber assembly If properly filled there shall be no sounds of absorbent shifting during shaking The foam pad should extend through the holes of the cover 9 Inspect the large o ring seal located on the inside diameter of the breathing chamber for nicks cuts or abrasions according to guidelines set forth in Section VI B Replace the o ring if signs of damage are evident Lightly lubricate the o ring with Dow 111 o ring lubricant 10 Position the charged carbon dioxide scrubber into the center of the breathing chamber well and press straight down and into the well until the scrubber bottoms out 11 Remove and inspect the large o ring seal located on the outside diameter of the breathing chamber for nicks cuts or abrasions according to guidelines set forth in Section VI B Replace the o ring if signs of damage are evident Lightly lubricate the o ring with Dow 111 o ring lubricant and re install 12 Position the washed disinfected and dried breathing chamber cover over the
76. p Regulator External Support Plate Chest Gauge Flow Restrictor Fitting Breathing Hose Coupler Fitting 46 32 ESNA Hex Nut 4 40 x 4 Pan Head Screw 6 32 x V2 Pan Head Screw 6 32 x 7 16 Pan Head Screw 410 32 x 1 2 Binder Head Screw with Locking Insert 10 32 x 3 8 Binder Head Screw with Locking Insert 4 Flat Washer 6 Flat Washer Bypass Valve Mounting Washer Biopak Storage Case Biopak 240S User Instruction Manual Biopak 240S Benchman Training Manual Breathing Chamber Cover A4 Revision K Biopak 240S Benchman Manual A46D030 Part Number B5 06 6240 01 0 45 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 B Lower Housing Assembly ITEM REF QTY O ANMHHWARWRDADNHWHHNH PART NUMBER B6 02 5001 43 0 B6 02 5001 43 1 B2 02 0000 04 0 B2 02 0000 05 0 B2 02 0000 26 2 B2 02 3300 01 0 B2 02 3300 37 0 B2 02 4100 20 0 B2 02 4100 21 0 B2 02 4100 22 0 B2 02 3000 02 0 B3 01 1043 00 0 B3 01 1061 01 0 B3 03 1063 00 0 B3 02 0040 00 0 B6 02 5001 51 0 B2 02 0000 02 0 B2 06 2001 02 1 B3 02 4060 00 0 B6 02 5001 51 1 B3 01 1061 02 0 DESCRIPTION Biopak 240S Lower Housing Assembly Flexible Draw Latch Biopak 240S Lower Housing Assembly Rotational Latch Coolant Canister Hold Down Strap Oxygen Cylinder Hold Down Strap Padded Harness Diaphragm Spring Hold Down Clamp Diaphragm Spring Short Harness Retaining Pin Long
77. place for 1 minute while observing for the formation of bubbles The formation of bubble around the valve core will indicate a leak that must be repaired through core tightening or replacement d Close the cylinder valve and allow the pressure to reduce by depressing the bypass valve e Remove the oxygen cylinder from the Biopak and remove the demand tube connection to the center section Reinstall the diaphragm into the underside of the breathing chamber so that the vent valve button is in view Installation of the diaphragm is best achieved by first slipping a portion of the diaphragm over the chamber edge holding that portion in position and slowly easing the remaining portions of the diaphragm over the remainder of the chamber Inspect the diaphragm position and verify that the edge of the diaphragm is positioned against the first shoulder of the breathing chamber wall over the entire diaphragm circumference Secure the diaphragm into position using the large worm gear clamp Turn the breathing chamber over and position it into the well of the lower housing making sure that the diaphragm spring is properly positioned over the vent valve Secure the breathing chamber to the lower housing using the four pushpins Installation of the pushpins is made by depressing the pin center button while pushing the pin straight in Re install the nylon plumbing connections to the breathing chamber by pushing each connector straigh
78. placement over time due to wear or damage The Long Term Maintenance procedures will aid the Benchman in the identification of worn or damaged components It is recommended that after a period of five 5 years the Benchman pay particular attention and provide additional inspection to the parts listed below for signs of wear or damage Breathing Diaphragm Remove the breathing chamber and disconnect the diaphragm from the center section housing by unthreading the diaphragm worm gear clamp Inspect the diaphragm for signs of wear cracking or rot Leak testing procedures will indicate leakage whenever the diaphragm has been perforated or torn Facepiece Inspect the rubber portions of the facepiece for signs of wear tears rips cracking or rot The mask fit test will identify if the face seal has degraded Inspect the anti fog lens insert for signs of cracking crazing hazing or wrinkling Inspect the seal around the perimeter of the anti fog lens to insure there are no voids Replace the lens if required Breathing Hoses Inspect for signs of wear cracking stiffness tears or rot The breathing hoses can incur substantial abuse during use due to contact with abrasive surfaces such as rock walls concrete walls etc Leak testing procedures will indicate leakage if the hoses have become perforated or torn O Ring Seals In general if the Biopak has passed the high and low pressure leak testing procedures then it can be assumed that the o ring s
79. ply the Anti Fog agent according to procedures set forth in Section IV I Problem Not achieving full 4 hour duration of Biopak during use Probable Causes 1 Poor or leaking facepiece seal 2 Oxygen cylinder opened prior to donning facepiece 3 Bypass valve utilized to clear facepiece lens or used excessively 4 User under heavy work loads or extreme ambient conditions 5 Leak in Biopak 6 Pressure Regulator Failure Remedy 1 Readjust the facepiece User should train for proper facepiece seal using the Facepiece Fit Test of Section V E The facepiece seal will be difficult if not impossible to achieve if the user has any facial hair or is wearing glasses that interfere with proper facepiece fit The user should be clean shaven and should utilize optional spectacle mounting kits if glasses are worn 2 Do not open the oxygen cylinder valve until after the facepiece has been donned If the oxygen cylinder valve is opened prior to donning the facepiece excessive loss of the oxygen stores will result 3 Use of the bypass valve in an attempt to clear the facepiece will result in excessive loss of oxygen stores and will not aid in clearing the lens The bypass valve should only be utilized in emergency situations since it will dump unrestricted flow directly into the breathing loop and will not conserve the oxygen stores 4 Whenever the user is under heavy workloads or placed into a hot environment the body will require a higher th
80. pressure gauge and by depressing the bypass valve to relieve any internal pressure 3 Remove the oxygen cylinder from the regulator yoke by disconnecting the Velcro strap around the cylinder and loosening the regulator yoke Lift the cylinder off of the regulator center post and pins and slide the cylinder from the Biopak 4 Reference the Top Assembly Illustrated Parts List Disconnect the copper high pressure tube assemblies from their connection to the regulator using two 7 16 open end wrenches 24 A46D030 10 11 14 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Unthread the five screws holding the regulator and external regulator support plate to the lower housing Carefully lift the regulator and yoke assembly from the lower housing Remove the two set screws from the yoke as referenced by the Illustrated Parts List for the Pneumatic Assembly Remove the regulator from the yoke by unthreading and lifting the yoke away Unthread the jam nut from the regulator and remove the mounting bracket Install the mounting bracket and jam nut onto the replacement regulator with fittings Position the replacement regulator with fittings into the yoke and secure with the two set screws It is recommended to immediately discard the replaced regulator so that it does not become mixed with good replacement parts Position the regulator into the lower housing and re connect the high pressure tube assemb
81. t abide by such instructions then the alleged defect shall not be deemed to have arisen under circumstances of proper use The instructions for use of the goods reflect the opinion of experts based on field use and tests The instructions should be followed carefully It is impossible however to eliminate all risks inherently associated with the use of the goods Unintended consequences may result because of factors as weather conditions the presence of other materials or the use or manner of application of the goods all of which are beyond the control of Biomarine All such risks shall be assumed by the buyer Buyer shall be responsible for insuring that the goods are functioning properly at all times and shall not use any goods which are not functioning properly If buyer uses goods when they are not functioning properly then buyer agrees to defend indemnify and hold Biomarine harmless against all losses damages and injuries to persons or property as a result of the use of the malfunctioning goods These warranties do not extend to the goods if they have been subjected to misuse neglect or accident including extended exposure to direct flames and or caustic chemical products after its delivery to buyer nor does it extend to any item that was modified or altered after its delivery to buyer IN NO EVENT WILL BIOMARINE BE LIABLE FOR ANY LOSS OR DAMAGE DIRECTLY OR INDIRECTLY ARISING FROM THE DEFECTS OR FROM THE USE OF THE GOODS OR FOR CONSEQ
82. t into the breathing chamber fitting Reconnect the hoses to the breathing chamber and secure each with a worm gear hose clamp Perform the Periodic Long Term Maintenance procedures Section V 30 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 To Replace the Anti Anoxia Valve Assembly Reference the Breathing Chamber Illustrated Parts List 1 Verify that the oxygen cylinder valve is closed rotated to its full clockwise position and the chest mounted pressure gauge reads zero psi 2 Remove the upper housing breathing chamber lid and carbon dioxide scrubber canister from the Biopak CAUTION Do not use any tools to pry the breathing chamber cover or the carbon dioxide scrubber canister from the breathing chamber Damage may occur to the o ring seals or the components themselves Proper removal of the cover and scrubber is made by pulling up on the edge of the component with the fingers while pushing down with the thumbs on either the breathing hose stubs or rim of the breathing chamber 3 Use two 7 16 open end wrenches to disconnect the copper tubing connection from the demand valve housing to the anti anoxia valve located in the well of the breathing chamber 4 Loosen the mounting hardware on the valve retainer plate and slide the plate out of the breathing chamber Slide the entire valve assembly out of the breathing hose port Remove the swivel elbow fitting from the end of t
83. t the chest mounted pressure gauge has the same reading as the oxygen cylinder pressure gauge after 90 seconds Close the cylinder valve after testing a If leaks are heard try reseating the oxygen cylinder on the regulator and inspect the sealing washing between the regulator and the cylinder Replace the washer if damaged or if leaking persists b If the alarm whistle does not chirp upon opening of the cylinder valve replace the alarm whistle c Ifthe chest mounted pressure gauge reading is incorrect replace the chest mounted gauge and pressure line 2 Verify that the oxygen cylinder is securely fastened to the Biopak at the regulator and with the Velcro strap Verify that the pressure gauge of the regulator reads between 2700 and 3000 psig Check the OXYGEN CYLINDER REPLACEMENT box on the Turn Around Maintenance Tag 3 Reinstall the upper housing to the Biopak and secure into position using the two housing latches 4 Sign and date the Turn Around Maintenance Tag and attach it to the handle of the oxygen cylinder valve 5 Place the Biopak in its designated storage location The Biopak is now ready for reuse A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 v Periodic Long Term Maintenance In addition the normal Turn Around Maintenance the Biopak should be visually inspected flow tested and high and low pressure tested on a monthly basis for units that are in constant use Biopaks that are in
84. the check valve replacement procedures for the inhalation and or exhalation check valves as set forth in Section VI J 39 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Problem Biopak fails leak testing Probable Causes 1 Component connections loose 2 System leak Remedy 1 Inspect the connections of components such as the coolant canister end cap breathing hose ends connection hose ends and breathing chamber plumbing connections to verify that they are properly made and tight 2 Leak test the system using Leak Tec inspection fluid as described in the Periodic Long Term Maintenance procedures Section V Problem Biopak fails flow test Probable Causes 1 Flow restrictor in breathing chamber has clogged 2 Demand valve of breathing chamber has failed 3 Pressure regulator has failed Remedy 1 Replace the flow restrictor according to the procedure of Section VI G 2 Replace the demand valve core according to the procedures of Section VI H 3 Replace the pressure regulator according to the procedure of Section VI D 40 A46D030 VIII Biopak Specifications Rebreather Type Rebreather Duration Protection Protection Factor PF Size Weight Fully Charged End of Service Alarms Oxygen Cylinder Operation Temperature Range Storage Temperature Range Materials of Construction Housing Shells Breathing Hoses Facepiece Plumbing Breathing Chamber
85. thing chamber out of the Biopak Turn the breathing chamber onto its cover and remove the large worm gear clamp that holds the diaphragm in place Pull the diaphragm from the breathing chamber by its edge Hold the flexible add valve lever back and use the valve core tool supplied with the tool kit to remove the valve core from the center of the breathing chamber housing with a counterclockwise rotation Discard the removed valve core Install a replacement valve core into the breathing chamber using the valve core tool 29 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 WARNING DO NOT over tighten the valve core during installation Excessive force on the add valve may strip the threads of the valve core or the demand valve Installation shall be made until the top of the valve is just even or slightly below the surface of the demand valve housing and the valve stem is completely above the demand housing surface 10 11 14 15 Reposition the add valve lever over the valve core and depress with the finger to verify valve core actuation Leak test the valve core installation as outlined below a Connect the nylon demand line brass quick disconnect to the center section brass quick disconnect fitting b Install a charged oxygen cylinder into the Biopak c Open the oxygen cylinder valve and apply Leak Tek leak detection fluid to the valve core Allow the Leak Tek to remain in
86. tion or tears Replace the o ring if necessary Immediately discard the flow restrictor fitting Lubricate the existing or replacement o ring with Cristo Lube lubricant and install it into the groove of the replacement restrictor fitting Do not allow the lubricant to contact the top surface of the fitting Reinstall the replacement fitting and o ring into the top of the demand housing using the 9 16 open end wrench Tighten snugly Perform the flow test of the Period Long Term Maintenance procedures Replace the carbon dioxide scrubber canister the breathing chamber cover and the upper housing 27 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 H Breathing Chamber Assembly Maintenance to the breathing chamber assembly may involve replacement of the diaphragm replacement of the vent valve replacement of the demand valve replacement of the anti anoxia valve or replacement of the flow restrictor The replacement of these components may be required should the Biopak fail the flow test the high pressure leak test or the low pressure leak test To Replace the Diaphragm and or Vent Valve Components Reference the Breathing Chamber and Diaphragm Assembly Illustrated Parts Lists 1 2 10 11 12 13 14 Remove the upper housing from the Biopak Disconnect the hoses to the breathing chamber by unthreading the worm gear hose clamp Disconnect the two nylon plumbing lines from
87. ualified Biomarine Service Center Prior to using the SCBA it must be determined that user is medically fit The following are some but not all medical and psychological conditions that could limit the use of the SCBA gt Emphysema Chronic Obstructive Pulmonary Disease Bronchial Asthma X ray evidence of Pneumonia Evidence of reduce pulmonary function Coronary Artery Disease Severe or progressive hypertension Epilepsy Grand Mal or Petit Mal Pernicious Anemia Diabetes Insidious or Mellitus Breathing difficulties when wearing a SCBA Claustrophobia or anxiety when wearing a SCBA V VV VV VV VV VV Y Abnormal or ruptured ear drum Compressed Oxygen Hazard Always handle oxygen cylinders with care to prevent rupture Do not allow oil grease or other combustible materials to come in contact with the cylinder or cylinder valve to prevent ignition Do not open the cylinder valve in the presence of open flame or sparks to prevent ignition Failure to heed this warning may result in personal injury or death due to sudden release of high pressure oxygen and or fire Oxidizing Agent Hazard Oxygen is a non flammable gas however it will enhance the combustion of other materials Oxygen enrichment will decrease the energy required for the ignition of materials In an oxygen rich environment oxygen concentration exceeding 23 by volume at sea level materials that normally will not burn in air may burn and materials that do burn in air will
88. vision K Part Number B5 06 6240 01 0 J Facepiece Assembly The check valves of the facepiece will require replacement whenever the user can not pass the positive and negative facepiece test as described in the User s Manual The Anti fog lens insert should be replaced whenever the insert has become scratched torn or voids have developed in the seal around the lens perimeter Replacement of the main facepiece lens is difficult and it is recommended that it be performed by the factory Replacement of any facepiece component not described herein shall be performed at the factory To Replace the Inhalation Check Valve Reference the Facepiece Illustrated Parts Lists 1 Remove the entire front adapter assembly from the Scott facepiece by pulling the silver retainer clip straight out away from the face piece rotating the assembly 90 and pulling the assembly straight out of the facepiece AGA style facepiece adapters are not removable and all procedures will be conducted with the adapter remaining installed on the facepiece 2 Use a screwdriver to carefully pry the edge of the 48 5mm hose clamp up to disengage and remove the clamp from the inhalation side elbow A green band marks the inhalation side of the assembly 3 Pull the elbow straight off the adapter assembly and retrieve the check valve check valve holder and the check valve holder sealing gasket 4 Remove the check valve from the check valve holder by pulling it through the hol
89. w head of the worm gear clamp be located directly under the hose stubs of the breathing chamber Turn the breathing chamber over and position it into the well of the lower housing making sure that the diaphragm spring is properly positioned over the vent valve Secure the breathing chamber to the lower housing using the four pushpins Installation of the pushpins is made by depressing the pin center button while pushing the pin straight in Re install the nylon plumbing connections to the breathing chamber by pushing each connector straight into the breathing chamber fitting Lightly tug on each connection to verify that it is fully engaged Reconnect the hoses to the breathing chamber and secure each with a worm gear hose clamp Perform the Periodic Long Term Maintenance procedures Section V Replace the upper housing onto the Biopak To Replace the Demand Valve Reference the Breathing Chamber Illustrated Parts List Section X F 1 2 Remove the upper housing from the Biopak Disconnect the hoses to the breathing chamber by unthreading the worm gear hose clamp Disconnect the two nylon plumbing lines from the chamber by depressing the face of the chamber fitting and pulling the tube end fitting straight out of the chamber fitting Release the breathing chamber from the lower housing by removing the four pushpins The pins are released by depressing the center button while pulling up on the pin Lift the entire brea
90. y Section X M AGA Style Facepiece Wiper Assembly Section X N 61 Assembly Drawing D46A013 D46A009 D46A008 D46A007 D46A007 D46A006 D46A006 300 887 D46A019 D46A019 D46A019 D46A010 C17A003 D46A01 1 400 471 D17A163 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Appendix A Maintenance Log Sheet Biopak Model Number Biopak 240 S Biopak Serial Number Long Term Maintenance Benchman s Signature Flow Test Visual High Pressure Low Pressure LPM Inspection Leak Testing Leak Testing Comments PASS FAIL PASS FAIL PASS FAIL 62 A46D030 Biopak 240S Benchman Manual Revision K Part Number B5 06 6240 01 0 Appendix B Material Hazards Handling and First Aid The following will provide the user with the potential hazards the proper handling methods and recommended first aid for the carbon dioxide scrubbing media LimePak and the facepiece anti fog solution Users are advised to consult the full Material Data Safety Sheet MSDS for each compound Material Safety Data Sheets can be supplied upon request directly from Biomarine LimePak Carbon Dioxide Scrubbing Media Commercial Name Chemical Name Hazards Identification First Aid Measures Handling amp Storage Personal Protection Sofnolime Soda Lime Can cause burns to eyes and skin Avoid inhaling dust Avoid skin and eye contact Inhalation Remove from exposure Obtain medical attention i

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