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EN Benchman Manual-Revision J - BioPak 240 Revolution 4

1. q aC 4g co g E I ta i u Ta 29 MN 21 n eta vu ii 24 CA 11 7 2 a i E 13 Ne ar 17 H p Page 43 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 16 Miscellaneous Supplies DESCRIPTION PART NUMBER Seal Kit includes all replacement seals amp lubricants B6 02 5002 14 0 Seal Kit includes all replacement seals without lubricants B6 02 5002 14 1 Christo Lube O Ring Lubricant 2 ounce tube B5 01 3000 01 0 Dow 111 O Ring Lubricant 5 3 ounce tube B5 01 3000 11 0 Oxygen Safe Leak Tec Leak Detection Fluid 8 ounce bottle B5 01 3000 03 0 Disinfectant 75 single use packets B6 02 5000 42 0 Wescodyne Plus Cleaner 1 gallon B5 01 5000 01 0 Turn Around Maintenance Tags B5 06 6000 17 0 7 17 Optional Attachments Breathing Hose Protective Sleeve B2 02 7001 22 0 A Kevlar sleeve that will slide over the exterior of the breathing hose to provide abrasion protection Hard Transit Case B6 02 5002 63 0 An injection molded style carrying storage case that provides exceptional BioPak 240R storage capabilities Soft Transit Case B2 02 7000 39 0 An armored cloth style carrying storage case that provides a shoulder strap Soft case is smaller and lighter than hard case but will not provide the same protection or storage space as the
2. 20a 1 B2 02 4001 50 0 PRO PP Storage Plug 20b 1 B2 02 4000 90 0 AV3000 Storage Plug 21a 1 B6 02 5002 54 0 Cylinder Fill Adapter CGA 540 Male 21b 1 B6 02 5002 55 0 Cylinder Fill Adapter CGA 540 Female 21c 1 B6 02 5002 53 0 Cylinder Fill Adapter G 34 A Male 21d 1 B6 02 5002 66 0 Cylinder Fill Adapter W21 8 Male 22 opt B6 02 5002 63 0 Hard Transit Case not depicted 23 opt B2 02 7000 39 0 Soft Transit Case not depicted Page 23 of 47 BioPak 240R User Instruction Manual A47D257 Revision J Note 1 The BioPak 240R respirator is supplied in a cardboard foam shipping box Reference the below listed key for BioPak configuration Code Description EN EN145 Certified FR Flame Rated Harness G Green Oxygen Cylinder BW Black White Oxygen Cylinder b bar Pressure Gauge Units p psi Pressure Gauge Units MPa Mega Pascal Pressure Gauge Units PRO Configured for PRO PP Facemask AV Configured for AV3000 Facemask 2 Facemasks are to be ordered separately 3 OrbSorb Scrubber is supplied in case form Each case will supply four sets of scrubber canisters four sets of scrubber moisture pads and four set of Turn Around Maintenance Tags 4 Manuals are provided standard in English language Other languages can be supplied by contacting Biomarine 5 Scrubber Moisture Pads are supplied with the CO2 Scrubber case but can be purchased separately 6 Cylinder Fill Adapters are required to connect the oxygen cylinder to a b
3. 7 1 B2 02 4000 89 1 Vent Valve Seat Note 1 Indicated components shall be lubricated with Dow 111 O Ring Lubricant B5 01 3000 11 0 prior to installation 2 Install Vent Body item 4 hand tight _ RUBBER Page 33 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 9 Pneumatic Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 Pneumatic Assembly 1 1 B6 02 5002 31 0 Bypass Feed Tube 2 1 B6 02 5002 32 0 Bypass Return Tube 3 1 B6 02 5002 30 0 Oxygen Feed Tube 4 1 B6 02 5002 03 1 Constant Add Center Section Feed Tube 5 1 B6 02 5002 02 1 Demand Add Center Section Feed Tube 6 1 B4 04 5000 00 0 Bypass Valve Push Button 7 1 B4 04 5570 00 0 Bypass Valve 8 1 B6 02 5002 00 1 Manifold Assembly See Section 7 10 9 1 B6 02 5002 26 1 Oxygen Regulator Assembly 10 1 B6 02 5002 43 0 Remote Gauge Shut Off Valve Assembly 11a 1 B6 02 5002 45 4 Remote Gauge Assembly bar 11b 1 B6 02 5002 45 0 Remote Gauge Assembly psi bar 12 1 B6 02 5002 44 0 Remote Gauge Feed Tube Assembly 13 1 B4 04 0030 00 0 Cylinder Seal Washer 14 1 B2 02 3300 14 0 Bypass Valve Spring 15 1 B4 04 7070 02 1 Constant Add Tube O Ring 16 1 B4 04 7070 00 1 Demand Add Tube O Ring Note 1 Oxygen Regulator Item 9 is supplied as a complete assembly only Regulator will mount to BioPak lower housing with two 8 x 3 8 Self Tapping Screws B3 01 4071 00 0 2 Bypass valve spring item 14 is to install between the bypas
4. Never pry o rings from glands with a screwdriver Remove o rings by hand or using the pick tool provided in the service kit e Unless otherwise directed do not lubricate o rings while they are still seated within their gland e Do not use heavy coats of lubrication Proper o ring lubrication will result in a shiny surface without lumps e Do not stretch or deform o rings during handling e Visually and by feel inspect o ring for signs of damage such as nicks cuts tears or abrasion e Christo Lube M and Dow 111 are the only lubricants approved for use in the apparatus e NEVER lubricate the sealing washer that sits between the oxygen cylinder and the pressure regulator 5 3 Oxygen Cylinder The cylinder should be inspected regularly for signs of damage to the outer wrapping Cylinders that are cracked flaking or show exposed fibres should be immediately retired from service Cylinders will require periodic hydro static testing per national requirements Typical intervals are every 5 years from the date of manufacture Cylinder testing should be conducted by an authorized testing facility Page 20 of 47 BioPak 240R User Instruction Manual A47D257 Revision J Cylinders that have been hydro static tested shall be cleaned for high pressure oxygen service as per national standards Cylinders are to be retired from service 15 years after the date of manufacture 5 4 Alarm Battery Replacement Pro
5. 02 3300 06 0 Constant Add Fitting 7 1 B2 02 3300 48 0 Demand Add Fitting 8 1 B4 04 7060 01 1 Demand Add Fitting O Ring 9 1 B2 02 7001 10 0 Demand Valve Gasket 10 1 B6 02 5002 23 0 Demand Valve Assembly 11 3 B3 01 0043 00 0 4 x 3 8 Sealed Flat Head Screw 12 1 B6 02 5002 05 0 Diaphragm Assembly See Section 7 8 13 1 B2 06 6001 47 0 Diaphragm Clamp 14 1 B4 03 5204 08 0 10 x 1 8 Tube Male Connector Fitting Note 1 Indicated components require lubrication with Dow 111 O Ring Lubricant B5 01 3000 11 0 prior to installation 2 Indicated components require lubrication with Christo Lube O Ring Lubricant B5 01 3000 01 0 prior to installation 3 Install indicated components to a torque of 25 30 in Ibs 4 Indicated components shall be installed with no lubricant 5 Center Section Body Assembly item 4 includes all depicted components with the exception of diaphragm item 12 and diaphragm clamp item 13 Page 31 of 47 BioPak 240R User Instruction Manual A47D257 Revision J Page 32 of 47 _11 12 _13 BioPak 240R User Instruction Manual A47D257 Revision J 7 8 Diaphragm Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5002 05 0 Diaphragm Assembly Complete 1 1 B6 02 5002 19 0 Flexible Diaphragm 2 1 B2 02 0000 08 0 Vent Cap 3 1 B4 04 7060 05 1 Vent Body O Ring 4 1 B2 02 4100 03 0 Vent Body 5 1 B4 04 7060 04 1 Vent Seat O Ring 6 1 B2 06 6001 53 0 Vent Valve Spring
6. Close the oxygen cylinder and allow the BioPak to slowly reduce pressure while observing the pressure gauge and LED indications The LED indication should turn to a flashing red with a horn sounding when the pressure gauge reads between 45 69 bar The LED indication will cease when the pressure gauge reads under 1 7 bar 5 Verify that the oxygen cylinder is fully charged to 207 bar and top off if necessary 6 Date and initial the maintenance tag under O2 Cylinder Replaced Filled Page 15 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 3 11 Upper Housing 1 Replace the upper housing onto the apparatus 2 If the carbon dioxide scrubbers have not been installed into the apparatus then leave the maintenance tag CO2 Cartridges Replaced field blank See section 3 12 concerning procedures for pre packing the carbon dioxide scrubber into the apparatus during turn around maintenance 3 Tie the completed maintenance tag across the waist belt connector or the carrying handle of the apparatus 3 12 Carbon Dioxide Scrubber Pre Packing Procedure The Biomarine carbon dioxide scrubbers can be pre packed into the apparatus during turn around maintenance if so desired Pre Packing the BioPak 240R with the carbon dioxide scrubbers is only permitted when utilizing OrbSorb carbon dioxide scrubber Pre packed carbon dioxide scrubbers may only be stored in the apparatus for a period no long than 1 year A
7. Hose Set includes all depicted items The Mask Adapter Assembly includes the check valves item 6 and o ring item 5 Lubricate the O Ring with Dow 111 prior to use DO NOT lubricate the check valves a F oO N Ratchet tool is required to close stepless ear clamp and is not provided in the standard service kit Stepless ear clamps are one time use only 3a or 3b 7 Page 28 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 5 AV3000 Breathing Hose Set ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5002 73 0 AV3000 Hose Set Complete 1 2 B2 02 7001 09 0 Breathing Hose 2a 2 B2 06 6002 19 0 Turn Key Hose Clamp 2b 2t B2 06 6000 01 0 Worm Gear Hose Clamp 3a 2 B2 06 6001 60 0 Stepless Ear Clamp 3b 2 B2 06 6002 30 0 Turn Key Hose Clamp 4 1 B6 02 5002 25 0 AV3000 Adapter Assembly 5 1 B2 06 6001 34 0 Facemask Adapter Gasket 6 2 B2 02 7001 11 0 Check Valve 7 10 B2 02 4101 22 0 Anti Crush Ring 8 1 B2 02 4000 90 0 AV3000 Storage Plug 9 B2 03 1000 11 0 Optional Stepless Ear Clamp Ratchet Tool Note 1 Hose Set includes 2 breathing hoses factory attached to AV3000 facemask adapter 1 gasket 10 anti crush rings 2 stepless ear clamps and 2 worm hose clamps Facemask adapter will contain check valves retaining clip and gasket Contact Biomarine for proper installation procedure of Check Valves item 6 3 Ratchet tool is required to close stepless ear clamp and is not provided in the sta
8. at scheduled intervals by qualified Benchman personnel who have completed a formal training course and hold a current certificate for the service and repair of Biomarine breathing apparatus Turn Around Maintenance shall be performed after each use of the BioPak 240R as detailed in the BioPak 240R Benchman Manual Long Term Maintenance must be performed on a monthly basis if the BioPak is in constant use or ona quarterly basis if the BioPak is being used less than once per month as defined in the BioPak 240R Benchman Manual Electronics Intrinsic Safety Assessment Procedure must be performed each time the batteries are replaced in the alarming system as defined in the BioPak 240R Benchman Manual Benchman training and service contracts can be provided by contacting Training amp Technical Support Services Page 5 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 1 5 Spare Parts Spare parts accessories general information and factory service can be obtained by contacting Training amp Technical Support Services Reference details provided in the BioPak 240R Benchman Manual concerning spare part identification accessory identification and BioPak factory service Training amp Technical Support Services Biomarine Inc 456 Creamery Way Exton PA 19341 United States of America Tel 1 610 524 8800 Fax 1 610 524 8807 Web BioPak240r com Customers can also contact their local authoriz
9. been rated for a 4 hour duration based upon machine testing at a breathing rate of 30 liters minute according to specifications of EN145 Actual duration of the apparatus will vary to factors such as o Workload high work rates will increase consumption rates of oxygen o Facemask Seal poor seal of mask will result in system leaks and high oxygen consumption rates Physical Fitness of Wearer System Leaks leaks in the BioPak system will result in high oxygen consumption It is important that all wearers are aware of the above factors and take account of them when assessing BioPak duration It is equally important that all wearers understand that the BioPak 240R respirator is a positive pressure apparatus Leaks in the apparatus itself or in the seal between the wearer s face and the facemask will lead to the apparatus adding additional oxygen to maintain positive pressure 1 3 Personnel Training Personnel who use closed circuit self contained positive pressure compressed oxygen breathing apparatus must be fully trained in accordance with these instructions and national regulations These instructions cannot replace an accredited training course provided by qualified instructors in the proper and safe use of Biomarine breathing apparatus Please contact Training amp Technical Support Services or your local distributor for training course details 1 4 Servicing The BioPak 240R must be serviced
10. for the sound of gas escaping into the breathing chamber The sound will last approximately 1 3 seconds This signals that the demand has properly opened 2 After 1 3 seconds the sound of gas escaping into the breathing chamber should cease This signals that the demand valve has properly closed 4 3 Constant Flow Test 1 Perform the test as described in Section 3 8 4 4 Vent Valve Functional Test 1 Fill the apparatus by depressing the emergency bypass valve in several short bursts Observe the pressure reading on the service kit The apparatus pressure should remain at or below 5 mbar 2 water column pressure after releasing the emergency bypass valve 4 5 Low Pressure Leak Test 1 Performthetestas described in Section 3 9 4 6 High Pressure Leak Test 1 Place the apparatus on a flat surface Ensure that the test keys of the Low Pressure Leak Test have been removed 2 Open the oxygen cylinder valve and wait until the apparatus pressure gauge has reached its final reading 3 Inspect each plumbing connection with oxygen safe leak detection fluid by wetting each joint waiting 60 seconds then inspecting each joint for the sign of bubble formation The presence of bubbles will indicate a leak 4 Repair any leaking joint or replace the leaking components 5 Close the oxygen cylinder valve and depress the emergency vent valve to depressurize the apparatus Page 18 of 47 BioPak 240R User Inst
11. numbered Item 2 through Item 4 The Valve Assembly shall be installed into the cylinder at a torque of 60 1 foot pound 3 Determine gauge manufacturer as WIKA or AMETEK before ordering replacement lens item 6a or 6b la Ib Page 38 of 47 7 13 ITEM ooN Ooh WH BioPak 240R User Instruction Manual A47D257 Revision J Lower Housing Assembly QTY N N NNN NN DAN WV pm OAs ll PART NUMBER B6 02 5002 29 0 B2 02 3300 46 1 B2 02 4000 68 0 B3 01 1071 03 0 B3 01 0008 00 0 B3 03 1073 00 0 B2 02 1300 27 0 B3 01 1063 00 0 B3 01 4011 00 0 3 01 1061 01 1 B3 03 3063 00 0 B2 02 7001 30 0 B3 01 1042 00 0 B2 02 1100 10 0 B3 03 3043 00 0 B3 01 1071 04 0 B3 02 4070 01 0 B2 02 7001 21 0 B2 02 4001 29 1 B3 01 1071 01 0 B3 02 4040 00 0 B2 02 1300 29 0 B2 02 1300 05 0 B2 02 1100 11 0 DESCRIPTION Lower Housing Shell Diaphragm Springs External Oxygen Knob Harness Waist Belt Fastening Screws 14 Turn Center Section Hold Down Pins Harness Mounting Washers Vent Spacer Vent Spacer Mounting Screw Oxygen Regulator Mounting Screw Manifold Mounting Screw Manifold Mounting Washer Latch Foam Pad Remote Gauge Mounting Screw Remote Gauge Mounting Bracket Remote Gauge Tooth Washer Remote Gauge Mounting Screw Remote Gauge Mounting Nut Oxygen Cylinder Hold Down Strap Kevlar Carrying Handle Handle Harness Shoulder Strap Mounting Screw Remote Gauge Hex Nut Regulator Support T
12. or wipe All facemasks connect to the apparatus via a push button bayonet hose connection Speech diaphragms are provided to allow verbal communication and all masks are a provided with a magnetic wiper the is for NN optional user utilization AV3000 Mask The polycarbonate visors of all facemasks conform to EN 166 Grade B for impact resistance 2 9 Optional Attachments Hydration systems provide the wearer with a source of drinking liquid without breaking the seal of the breathing loop to the external atmosphere Anti crush rings provide breathing hose crushing and restriction protection Kevlar breathing hose covers provide additional abrasion protection to breathing hoses Radiant heat guards provide additional breathing hose protection against high radiant heat and direct flame contact Page 10 of 47 BioPak 240R User Instruction Manual A47D257 Revision J Phase Change Module PCM provides cooling to the breathing gas when ice coolant is not utilized Note that the PCM is required when the ice coolant is not utilized Contact Biomarine or your local distributor for additional details and supply of optional attachments Page 11 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 3 Turn Around Maintenance Procedure 3 1 Maintenance Tag BIOPAK 240 REVOLUTION TURNAROUND MAINTENANCE TAG UNIT NO DATE INT WASHED DISINFECTED 02 CYLIN
13. ov 5E 2 2 z g S o s IL 7 a oe Date se ae A 41 33 Y SG Comments Benchman Signature S se SOME JE ME feleeleel esl eel E Z wn FS 22 53 58 53 28 58 53 se 5 E OF OF gt E asa ra r lt x EH Page 46 of 47 BioPak 240R User Instruction Manual A47D257 Revision J this page left intentionally blank Page 47 of 47
14. standard hard case PRO Mask Hydration System B6 02 5003 17 0 The Hydration System provides a 1 5 liter reservoir and an interface to the PRO facemask that will enable the user to drink liquid without breaking the breathing loop seal to the external ambient atmosphere AV3000 Mask Hydration System B6 02 5002 52 0 The Hydration System provides a 1 5 liter reservoir and an interface to the AV3000 facemask that will enable the user to drink liquid without breaking the breathing loop seal to the external ambient atmosphere Harness Shoulder Pads B2 02 7001 48 0 Constructed of flame rate materials the pads will provide additional padding on the shoulders of the main harness High Pressure Digital Leak Tester B6 02 5003 39 0 Provides a method to test the high pressure sections of the BioPak from cylinder valve to remote gauge and to demand housing and all connection in between utilizing pressure decay and eliminating the use of leak detection fluid Leak detection will be required if a leak is detected in order to locate the leak but leak detection fluid is not required for initial testing Page 44 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 8 APPARATUS SPECIFICTIONS Respirator Type Respirator Duration Size Weight Fully Charged Operational Conditions Storage Conditions Oxygen Delivery Oxygen Supply Battery Carbon Dioxide Scrubber Tidal Volume Note Self Contained Closed C
15. 09 5 AV3000 Complete Facemask Large 1 1 B6 02 5003 41 0 Replacement Front Lens with Anti Fog Film 2 1 B2 06 6002 31 0 Magnetic Lens Wiper 3 B2 06 6001 64 0 Optional Kevlar Neck Strap not depicted 4 1 B2 06 6001 70 0 Facemask Storage Bag not depicted 5 B6 02 5002 42 0 Optional Spectacle Kit 6 B6 02 5003 44 0 Optional Field Test Kit Note 1 The Complete Breathing Hose Set includes all depicted items The Mask Adapter Assembly includes the check valves item 6 and o ring item 5 Lubricate the O Ring with Dow 111 prior to use DO NOT lubricate the check valves pe N Page 27 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 4 PRO Breathing Hose ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5003 03 0 PRO Breathing Hose Set Turn Key Clamps REF B6 02 5003 03 1 PRO Breathing Hose Set Non Turn Key Clamps 1 2 B2 02 7001 09 0 Breathing Hose 2a 2 B2 06 6002 19 0 Turn Key Clamp requires no tool to operate 2b 2 B2 06 6000 01 0 Worm Gear Clamp requires tool to operate 3a 2 B2 06 6002 30 0 Turn Key Clamp requires no tool to operate 3b 2 B2 06 6001 60 0 Stepless Ear Clamp requires tool to operate 4 1 B6 02 5003 01 0 PRO Mask Adapter Assembly 5 1 B4 04 7060 25 0 Mask Adapter O Ring 6 2 B2 02 7001 11 0 Check Valves 7 10 B2 02 4101 22 0 Anti Crush Ring 8 1 B2 02 4001 50 0 Storage Plug 9 B2 03 1000 11 0 Optional Stepless Ear Clamp Ratchet Tool Note 1 The Complete Breathing
16. BIOPAFKL_ BUG REVOIEY TION BioPak 240R Closed Circuit Self Contained Breathing Apparatus Benchman Manual CE 1497 A47D257 Revision J B5 06 6000 23 0 ECO 9661 March 2013 WARNINGS BioPak 240R User Instruction Manual A47D257 Revision J 1 INTRODUCTION 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 Breathable Oxygen Apparatus Duration Personnel Training Servicing Spare Parts US DESCRIPTION General Harness Housing Breathing Loop Oxygen Delivery System Oxygen Cylinder Alarming System Facemask Optional Attachments 3 TURN AROUND MAINTENANCE PROCEDURE 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 Maintenance Tag Disassembly Cleaning Disinfection Coolant Canister Oxygen Cylinder Facemasks Assembly Constant Flow Test Low Pressure Leak Test Alarm Test Upper Housing Carbon Dioxide Scrubber Pre Packing Procedure 4 LONG TERM MAINTENANCE PROCEDURE 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 5 GENERAL 5 1 5 2 5 3 5 4 5 5 5 6 Visual Inspection Demand Valve Functional Test Constant Flow Test Vent Valve Functional Test Low Pressure Leak Test High Pressure Leak Test Emergency Bypass Valve Functional Test Alarm Test Maintenance Tag Validation SERVICE PROCEDURES Scheduled Component Inspection System Lubrication Oxygen Cylinder Alarm Battery Replacement Procedure Flow Restrictor Replacement Procedure Factory Service and Training 6
17. D257 Revision J 7 11 Alarm Monitor ITEM QTY PART NUMBER DESCRIPTION REF B6 01 5000 05 0 Alarm Monitor Complete 1 1 B6 02 5002 51 0 Replacement Battery Door 2 1 B1 14 2000 00 0 9VDC Battery 3 1 B1 10 3000 03 0 Center Section Cable Note 1 Only the below listed battery types are suitable for use in the Monitoring System Use of any other battery type will void intrinsic safety rating and certification Energizer 522 Panasonic 6AM6 Rayovac A1604 Duracell MN1604 Center Section Port Manifold Port Regulator Port Light Guide Port u ked Alarm Horn Main Housing Page 37 of 47 7 12 ITEM REF REF Note BioPak 240R User Instruction Manual A47D257 Revision J Oxygen Cylinder Assembly QTY dA Ad aoa dll PART NUMBER B6 02 5002 06 0 B6 02 5001 98 0 B2 01 2000 06 1 B2 01 2000 06 0 B4 04 7060 00 0 B2 02 3300 52 1 B4 04 7060 07 2 B6 02 5001 97 0 B2 06 6001 38 0 B2 06 6001 40 0 B2 02 4000 64 0 DESCRIPTION Black White Cylinder Assembly Empty Green Cylinder Assembly Empty Black White Cylinder Green Cylinder Exterior O Ring Valve Collar Interior O Ring Valve Assembly Replacement Gauge Lens WIKA Gauge Type Replacement Gauge Lens AMETEK Gauge Type Replacement Cylinder Valve Knob 1 Indicated O Rings require lubrication with Christo Lube Lubricant B5 01 3000 01 0 prior to installation 2 Valve Assembly Item 5 includes valve plus components
18. DER REPLACED FILLED FLOW TEST bm CO2 CARTRIDGES REPLACED SERIAL EXPIRATION DATE MASK INSPECTION ICE PLACED IN FREEZER LOW PRESSURE LEAK TEST WARNING INSTALL FROZEN ICE PRIOR TO USE REFER TO USER MANUAL AND OR MAINTENANCE MANUAL FOR INFORMATION ON USE AND MAINTENANCE OF THIS RESPIRATOR RESPIRATOR IS SUITABLE FOR USE ONLY BY PROPERLY TRAINED PERSONNEL FAILURE TO PROPERLY USE AND MAINTAIN THIS RESPIRATOR COULD RESULT IN INJURY AND DEATH Obtain a maintenance tag as supplied with replacement carbon dioxide scrubbers The maintenance tag shall be completed as directed in this procedure and then attached to the waist belt of the apparatus to show completion of all maintenance steps Record the apparatus identification onto the tag 3 2 Disassembly Immediately after completion of BioPak use remove the used CO2 scrubber canisters scrubber moisture pad and disconnect the demand and constant add lines to the center section to prevent migration of moisture into the manifold assembly Disassemble the apparatus to ready for cleaning and disinfection Note any apparatus damage and repair as needed Repairs beyond the scope of the Benchman should be referred to Biomarine 1 Remove the upper housing 2 Remove the coolant lids and coolant ice 3 Remove the oxygen cylinder making sure the seal washer remains in place and install the regulator wash cover su
19. G MPA PRO la 1 B6 02 5003 09 1 PRO PP Facemask Small See Section 7 2 1b 1 B6 02 5003 09 0 PRO PP Facemask Medium See Section 7 2 1c 1 B6 02 5003 21 1 PRO PP Facemask Small with Drink Port See Section 7 2 1d 1 B6 02 5003 21 0 PRO PP Facemask medium with Drink Tube See Section 7 2 le 1 B6 02 5002 09 3 AV3000 Facemask Small See Section 7 3 1f 1 B6 02 5002 09 4 AV3000 Facemask Medium See Section 7 3 1g 1 B6 02 5002 09 5 AV3000 Facemask Large See Section 7 3 2 1 B6 02 5002 18 0 Upper Housing Assembly 3 2 B2 02 4000 39 0 Coolant Lid 4 2 B6 02 5002 37 0 Ice Canister 5 2 B2 02 7001 09 0 Breathing Hose See Section 7 4 or 7 5 6 1 B6 02 5002 04 0 Center Section Lid Assembly See Section 7 6 7 1 B6 02 5003 69 0 OrbSorb Reduced Mass Scrubber 8 1 B6 02 5002 07 1 Center Section Assembly See Section 7 7 9 1 Pneumatics Assembly See Section 7 9 10 1 B6 01 5000 05 0 Alarm Monitor See Section 7 11 11a 1 B6 02 5001 98 0 Green Oxygen Cylinder See Section 7 12 11b 1 B6 02 5002 06 0 Black White Oxygen Cylinder See Section 7 12 12 1 B6 02 5002 29 0 Lower Housing Assembly See Section 7 13 13 1 B2 02 7001 24 0 Harness Assembly Flame Rated 14 2 B6 02 5002 40 0 Ice Canister Freeze Form See Section 7 14 15 1 B5 06 6000 22 0 User Manual ENGLISH 16 1 B5 06 6000 23 0 Benchman Manual ENGLISH 17 B2 02 7001 07 0 Moisture Control Set 18 1 B6 02 5003 34 0 Scrubber Moisture Pad 19 1 B6 02 5002 41 0 Phase Change Heat Exchanger PCM
20. IPTION REF B6 02 5003 09 1 PRO Facemask Small REF B6 02 5003 21 1 PRO Facemask Small with Drink Tube REF B6 02 5003 09 0 PRO Facemask Medium REF B6 02 5003 21 1 PRO Facemask Medium with Drink Tube 1 1 B6 02 5002 99 0 Interface Adapter Complete 2 1 B2 02 7100 22 0 Seal Ring 3 1 B2 06 6002 31 0 Magnetic Lens Wiper 4 1 B2 06 6001 70 0 Tote Bag not depicted 5 1 B2 06 6002 46 0 Replacement Drink Tube not depicted 6 1 B2 06 6002 50 0 Buckle Roller Kit Package of 5 7 1 B2 06 6002 51 0 Head Harness 8 1 B2 06 6002 52 0 Neck Strap not depicted 9 1 B6 02 5003 47 0 Replacement Lens with Anti Fog Film 10 B2 06 6002 37 0 Optional Spectacle Kit not depicted 11 B6 02 5003 43 0 Optional Field Test Kit not depicted 12 B5 06 6900 13 0 Optional Field Service Manual not depicted Note The complete Facemask Assembly includes the facemask itself plus the complete Adapter Coat the Seal Ring with Dow 111 lubricant before use The mask is supplied from the factory with a permanent anti fog film applied to the internal surface of the lens This film can not be applied to the mask in the field due to required conditions for installation Page 26 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 3 AV3000 Facemask ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5002 09 3 AV3000 Complete Facemask Small REF B6 02 5002 09 4 AV3000 Complete Facemask Medium REF B6 02 5002
21. R User Instruction Manual A47D257 Revision J 5 General Service Procedures 5 1 Scheduled Component Inspection Breathing Diaphragm Annually remove the center section and disconnect the diaphragm from the center section by loosening the clamp Inspect the diaphragm for signs of wear cracking or rot Disassemble the vent valve and inspect all components and lubricate as needed Reference the parts list for proper diaphragm alignment Diaphragm Alignment Proper diaphragm alignment is depicted below Note the positioning of the three large holes in the diaphragm plate in relation to the breathing chamber mounting feet and the breathing hoses Reference diagram in Section 7 8 n r Facemask Inspect all rubber components for signs of wear tears rips cracking or rot Breathing Hoses Inspect for signs of wear tears rips cracking or rot O ring Seals If the apparatus has passed the high and low pressure leak tests the o ring integrity is acceptable It is recommended to perform full system lubrication on an annual basis Otherwise inspect o rings at intervals of O Ring Uses or Description Age Center Section 25 uses annually Vent Valve 50 uses annually Other annually 5 2 System Lubrication Leaks discovered during high and low pressure testing are often caused by damaged or improperly lubricated o rings Replace faulty o rings and follow the guides below for o ring handling and lubrication e
22. STORAGE GUIDELINES Page 2 of 47 ooo NNN N On aaa Gi dA BioPak 240R User Instruction Manual A47D257 Revision J 7 PARTS LISTS 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 11 7 12 7 13 7 14 7 15 7 16 7 17 Top Assembly PRO Facemask Assembly AV3000 Facemask Assembly PRO Breathing Hose AV3000 Breathing Hose Center Section Lid Center Section Diaphragm Pneumatic Assembly Manifold Assembly Alarm Monitor Oxygen Cylinder Lower Housing Ice Canister Freeze Form Service Kit Miscellaneous Supplies Optional Attachments 8 APPARATUS SPECIFICATIONS 9 MAINTENACE LOG SHEET Page 3 of 47 23 23 26 27 28 30 31 34 36 38 39 42 44 44 45 46 BioPak 240R User Instruction Manual A47D257 Revision J A WARNINGS A Please Read Carefully and Fully Understand This manual is for use by personnel trained in the use and care of compressed oxygen closed circuit breathing apparatus and MUST NOT be used as a self teaching guide by untrained users Failure to understand or adhere to the BioPak User instructions and BioPak Benchman manual may result in injury or death Biomarine Inc has taken great care to ensure that the information in the manual is accurate complete and clear However Training amp Technical Support Services will be pleased to clarify any points in the manual and answer questions on Biomarine breathing apparatus The following warnings are in accordance with cert
23. cedure The alarm system battery shall be replaced after 200 hours of use after 6 months or after the alarm system low battery alarm RED GREEN BLUE flashes with corresponding horn sounding whichever occurs first Battery replacement can only be performed in an area known to contain non hazardous non explosive atmospheres 1 Remove the upper cover 2 Disconnect the electrical line to the center section 3 Use two 7 16 wrenches from the service kit to remove the light guide from the alarm monitor housing DO NOT allow the fitting anchored to the alarm housing to rotate 4 Remove the alarm housing from the apparatus Inspect the housing for cracks or damage Dust tight and water tight integrity are required for use in potentially explosive atmospheres The alarm module will require replacement if any damage to the housing is discovered 5 Remove the battery cover Inspect the cover and gasket for cracks or damage The battery cover door will need to be replaced if any damage is found 6 Remove the battery from the alarm housing and replace with a fresh battery Inspect the interior of the battery compartment for the presence of corrosion liquid or dust Clean if necessary or replace the alarm module Use only battery types as specified for replacement 7 Replace the battery cover making sure that the gasket is properly positioned and that the gasket is not damaged in any way 8 Install the ala
24. e between 4 C and 32 C to prevent degradation of the absorbent material e Carbon Dioxide Scrubbers must be utilized with the supplied Moisture Pad to prevent scrubber canister flooding that may lead to elevated carbon dioxide levels in the breathing gas DISCLAIMER Failure to comply with these instructions or misuse of the apparatus may result in death injury or material damage and invalidate any warranty or insurance claims This manual presents the minimum requirements for BioPak utilization Page 4 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 1 INTRODUCTION 1 1 Breathable Oxygen Oxygen used to supply or charge the breathing apparatus must be medical or aviation grade oxygen with moisture content less than 50 mg m at 207 bar The composition of suitable oxygen is given below and provides the maximum level of contaminates in the source oxygen acceptable for use in the BioPak Oxygen 99 5 minimum mole Carbon Dioxide 300 ppm maximum Carbon Monoxide 10 ppm maximum The purity quality of oxygen used to supply and charge breathing apparatus should be tested periodically in accordance with national regulations National regulations must be observed Personnel dealing with compressed oxygen and compressed oxygen cylinders must be fully trained in the use and handling of compressed oxygen 1 2 Apparatus Duration The apparatus will provide the user with 440 liters of compressed oxygen and has
25. e the following information when contacting Biomarine e Apparatus Model Number e Apparatus Serial Number e Date of purchase e Approximate number of uses e Description of problem e Actions taken to correct problem Storage plug shall be installed Never store a wet apparatus The apparatus must be fully dry before storage to prevent the growth of mold and bacteria Never store an apparatus that has not been fully cleaned and disinfected Store in a location free from impact that could cause damage to the apparatus Store in the stated conditions of ambient temperature relative humidity and air pressure Store in a location that will not submerge the apparatus Carbon Dioxide Scrubbers must be stored within the temperature limits of 4 C to 32 C e Contact name address and phone number with area or country code and email address e Please provide your current email address with all service correspondence Page 22 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 PARTS LIST 7 1 Top Assembly ITEM QTY PART NUMBER DESCRIPTION REF B7 07 2403 00 0 BioPak 240R Respirator EN FR BW b PRO REF B7 07 2403 01 0 BioPak 240R Respirator EN FR BW p PRO REF B7 07 2403 02 0 BioPak 240R Respirator EN FR BW MPa PRO REF B7 07 2403 03 0 BioPak 240R Respirator EN FR G b PRO REF B7 07 2403 04 0 BioPak 240R Respirator EN FR G p PRO REF B7 07 2403 05 0 BioPak 240R Respirator EN FR
26. ed Biomarine Distributor for training product support service or maintenance Reference documentation supplied with sales order for standard terms of warranty Page 6 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 2 APPARATUS DESCRIPTION 2 1 General BioPak 240R is a closed circuit positive pressure self contained breathing apparatus CCBA for use in long duration missions into atmospheres that are immediately dangerous to life and health IDLH Applications will include mine rescue fire fighting confined space entry domestic preparedness military tunnel rescue and HAZMAT All versions of the BioPak 240R feature a backpack style housing that is worn over the shoulders and hips of the wearer A pressure gauge is supplied to indicate remaining stores of oxygen and two visual alarms and one audible alarm is provided for system status The closed circuit design will recycle the wear s exhalation breath by removing carbon dioxide replacing consumed oxygen trapping condensation and cooling the breathing gas The positive pressure design will maintain internal breathing gas pressures slightly above external atmospheric pressure This feature will provide increased protection against the inward migration of external toxins to the wearer All external housing components are static dissipative and flame retardant BioPak 240R is approved to the following European Standards EN 136 1998 Respi
27. endent and redundant system status indications The pressure gauge is mounted on the harness and retained by a snap strap and magnet Remaining stores of oxygen will be indicated on the gauge and a red band of color will indicate to the wearer when oxygen stores have reached 25 of capacity The pressure gauge is protected against sudden loss of oxygen stores in the event of gauge line severing by a manual disconnect located at the gauge pass through point of the housing The electronic monitor will provide the wearer of indications of system status as listed below through the LED located on the pneumatic pressure gauge and via an alarm horn located on the monitor package Page 8 of 47 Condition System Ok System Fault End of Service Life Ice Reminder Low Battery BioPak 240R User Instruction Manual A47D257 Revision J Alarm Action Flashing Green Flashing Red Horn Sounding Flashing Red Horn Sounding Flashing Blue Flash Red Green Blue Horn Sounding Page 9 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 2 8 Facemasks BioPak 240R is approved for use with the PRO and AV3000 full facemasks all of which conform to EN136 Class 3 All facemasks are provided with five point fully adjustable head harnesses To prevent fogging during use the internal surface of the facemask lens is covered with a permanent anti fog film that will not require the application of any anti fog spray
28. ey 6 1 B2 03 3000 01 0 Vent Valve Hand Wrench 7 8 B2 06 6002 60 0 Demand Port Wash Plug 8 1 B2 02 5400 04 0 Regulator Wash Plug 9 1 B2 03 1000 10 0 Combination Pick Tool 10 1 B2 03 1000 15 0 00 Phillips Screwdriver 11 1 B2 03 1000 03 0 1 Phillips Screwdriver 12 1 B2 03 1000 16 0 2 Phillips Screwdriver 13 1 B2 03 1000 17 0 4 Hex Driver 14 1 B2 03 1000 09 0 3 16 Nut Driver 15 1 B2 03 1000 12 0 5 16 Nut Driver 16 2 B2 03 1000 04 0 3 8 x 5 16 Open End Wrench 17 2 B2 03 1000 06 0 7 16 Combination Wrench 18 1 B2 03 1000 13 0 Ye Combination Wrench 19 1 B2 03 1000 05 0 5 8 x 9 16 Open End Wrench 20 1 B5 01 3000 03 0 Oxygen Safe Leak Detection Fluid 8 ounces 21 1 B2 02 7001 28 0 Tool Pouch 22 1 B4 02 6037 00 0 Rubber Tubing 23 1 B2 03 1000 20 0 Stop Watch 24 opt B2 03 3000 08 0 Bypass Valve Tool 25 1 B2 03 1000 21 0 9 32 Nut Driver Note Replacement Case Assembly item 1 includes the tool kit case complete with internal pressure gauge and associated plumbing plus external shipping box 2 Order a minimum length of 6 feet of tubing Longer lengths are available upon request 3 The Bypass Valve Tool item 24 is not supplied with the Tool Kit The tool is utilized for installation and removal of the entire bypass valve assembly Page 42 of 47 BioPak 240R User Instruction Manual A47D257 Revision J DA n F E E
29. ifying authority requirements and apply to the use of breathing apparatus in general e Breathing apparatus user must be fully trained in the use and care of closed circuit self contained compressed oxygen breathing apparatus e Ensure that the selection of the apparatus type is sufficient for the tasks being undertaken and the hazards likely to be encountered Please refer to National Regulations for guidance e Adequate protection may not be provided in certain highly toxic atmospheres e The apparatus must be tested and serviced in accordance with the BioPak 240R Benchman Manual e The quality of oxygen used to supply and charge the breathing apparatus must be medical or aviation grade oxygen with a moisture content less than 50 mg m at 207 bar e Ensure that a good seal can be obtained between the face and facemask The wearing of beards side burns or spectacles may adversely affect the sealing of a facemask to the wearer s face e The apparatus is not designed for use underwater diving e The harness must not be used as a vehicle seat or fall arrest restraint e Replacement of the alarm system battery shall be performed in area atmospheres known to be safe and non explosive e The improper use of closed circuit breathing apparatus carries a risk of carbon dioxide poisoning of user Users shall be fully trained in recognizing the effects of carbon dioxide poisoning e Carbon Dioxide Scrubbers must be stored at a temperatur
30. ioPak harness is provided as a padded harness to increase wearer comfort The flame retardant harness is manufactured from Kevlar and Nomex materials with stainless steel hardware The harness is attached directly to the apparatus via locking stainless steel screws 2 3 Housing The backpack style housing is injection molded from a flame retardant polycarbonate stainless steel alloy that provides light weight high strength and static dissipation The housing consists of a lower portion and an upper portion that Page 7 of 47 BioPak 240R User Instruction Manual A47D257 Revision J snaps together in a secure fashion without the need for connection hardware 2 4 Breathing Loop The breathing loop consists of the breathing chamber breathing hoses facemask connector and facemask The breathing chamber consists of the center section center section lid and diaphragm The spring loaded diaphragm will maintain positive pressure within the apparatus All oxygen gas additions will occur within the breathing chamber as well as over pressure venting Carbon dioxide is removed from exhalation gas by the carbon dioxide scrubbers located within the breathing chamber Excessive moisture will be retained by the moisture containment sponges located within the center section Inhalation breathing gas cooling will be achieved as the gas travels around the two coolant canisters of the breathing chamber 2 5 Oxygen Delivery S
31. ion green colored line and connect the test flowmeter from the service kit to the open end of the feed line he WAR 2 Open the oxygen cylinder valve and observe flowmeter while holding it in a vertical and level position The flowmeter shall indicate a flow as per the table below when reading the center of the flowmeter ball The table provides flow readings for elevations of sea level to 1600 meters and above 1600 meters If the flow does not meet the requirements of the table below the flow restrictor will need replacement Cylinder Flow Flow Pressure 0 1600m 1600m bar lpm Ipm 100 150 1 8 2 4 1 9 2 6 150 207 1 9 2 5 2 0 2 8 3 Enter the measured flow rate date and initial the maintenance tag under Flow Test lom 4 Close the oxygen cylinder valve remove the test flowmeter and reconnect the constant add feed line to the center section Page 14 of 47 3 9 le 2 3 BioPak 240R User Instruction Manual A47D257 Revision J Low Pressure Leak Test Remove the storage plug from the breathing hoses and install the leak test adapter from the service kit Attach rubber tubing from the service kit between the leak test adapter and the input port of the service kit Insert two test keys from the service kit in the keyholes in the back of the lower housing Open the oxygen cylinder valve and depress the bypass valve until the test kit displays a pressure just under 7 mbar 3 5 water colum
32. ircuit Pressure Demand Certified as entry and escape 4 hour duration 584 x 439 x 178 mm 15 4 kg Maximum Temperature 5 C to 40 C Air Pressure 900 to 1200 hPa Relative Humidity 0 to 100 Temperature 4 C to 32 C Air Pressure 900 to 1200 hPa Relative Humidity 30 to 100 Constant Add 1 8 lpm Average Demand Add 80 lpm Minimum Emergency Add 80 lom Minimum gt 99 5 Oxygen by volume lt 300 ppm Carbon Dioxide lt 10 ppm Carbon Monoxide 50 mg m Water Content Maximum Tasteless and Odorless 440 liter storage at 207 bar pressure Power 9 Vdc Life 200 hours or six months Type Only the below types may be used Energizer 522 Panasonic 6AM6 Rayovac A1604 Duracell MN1604 Dual single use Solid Core canisters Non dusting Non settling Non channeling 6 0 liters 1 Operating temperature range provided above is the standard 4 hour duration with PCM installed For extreme temperature ranges the BioPak should be configured with ice coolers and utilized as directed below Ambient Temperature 41 to 60 C 61 to 90 C 90 C Recommended Safe Duration of Use 1 hour 15 minutes 6 minutes The above temperature duration figures are derived from human endurance limits and not from the endurance limit of the BioPak Page 45 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 9 MAINTENANCE LOG SHEET BioPak Model BioPak 240R BioPak Serial Number Long Term Maintenance
33. m so no application of anti fog agents of any kind are required 3 7 Assembly 1 Position the BioPak in a level position as depicted above by propping up the handle end of the lower housing 2 Install the center section making sure to properly seat the three springs onto the diaphragm 3 Lock the center section into position using the four quarter turn fasteners Page 13 of 47 BioPak 240R User Instruction Manual A47D257 Revision J Connect the electrical and pneumatic lines to the center section Verify the presence of an o ring seal on each pneumatic line connection Position the fully dry moisture sponges into the center section The sponges must be fully dry to prevent the growth of mold within the apparatus If utilized install the PCM into the breathing chamber opposite the moisture sponges Date and initial the maintenance tag under ce Placed in Freezer and enter PCM on the tag Install the center section lid and latch to secure If pre packing the carbon dioxide scrubbers complete section 3 12 then return to step 7 of this section Install the breathing hoses to the breathing chamber and secure with clamps making sure the flow direction arrows of the connector are facing up Install the storage plug into the facemask connector Install the oxygen cylinder and secure with the hold down strap 3 8 Constant Flow Test 1 Disconnect the constant add feed line to the center sect
34. n then immediately close the oxygen cylinder valve Activate the emergency bypass valve to empty all gas into the breathing chamber and raise the pressure reading to between 15 and 20 mbar 6 and 8 water column DO NOT overpressure After the test gauge stabilizes note the exact pressure reading of the service kit and allow the apparatus to sit undisturbed for 60 seconds The apparatus pressure shall not drop more than 0 5 mbar 0 2 water column in the 60 second period If the oxygen cylinder is not closed the pressure reading will continue to rise and potentially damage the breathing chamber If the apparatus pressure drops more than 0 5 mbar 0 2 in the 60 second there is a leak that must be located and repaired 7 Open the service kit bleed valve and or remove the leak test adapter to vent the apparatus Replace the storage plug Remove the two test keys from the rear of the lower housing 10 Date and initial the maintenance tag under Low Pressure Leak Test 3 10 Alarm Test 1 While observing the pressure gauge and TRIM indicator open the oxygen cylinder valve The cylinder must be filled with a minimum of 100 bar pressure for this test 2 When the oxygen cylinder is opened the TRIM indicator shall cycle RED GREEN BLUE with the horn sounding The TRIM will then flash GREEN and the horn will be silent 3 The pressure gauge will reach full reading in approximately 60 seconds 4
35. n elevated carbon dioxide levels in the breathing gas that may lead to injury or death 5 Install and secure the breathing chamber lid 6 Date and initial the maintenance tag under CO2 Scrubber Replaced The expiration date of pre packed carbon dioxide scrubbers will be the shorter time period between the following two factors 1 year from date of scrubber installation into BioPak or Use By date provided on packaging of carbon dioxide scrubber Page 17 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 4 Long Term Maintenance Procedure In addition to normal turn around maintenance the apparatus shall be visually inspected and pressure tested on a monthly basis if the apparatus is being used at least once per month or quarterly if the apparatus is used less than once per month or is in long term storage BioPaks that have been placed in long term storage should have the Long Term Maintenance Procedure conducted every 6 months A Maintenance Log Sheet is provided in this manual to assist in tracking long term maintenance procedures 4 1 Visual Inspection Remove the upper housing and visually inspect the apparatus for signs of wear abuse loose connections or other damage Repair as necessary Verify that the apparatus is properly sealed against the ambient environment by the presence of the storage plug 4 2 Demand Valve Functional Test 1 Open the oxygen cylinder and listen
36. ndard service kit Stepless ear clamps are one time use only 2a or 2b 2a or 2b Page 29 of 47 7 6 BioPak 240R User Instruction Manual A47D257 Revision J Center Section Lid Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5002 04 3 Center Section Lid Assembly Complete 1 2 B2 02 4000 39 0 Coolant Lid 2 1 B6 02 5002 04 4 Center Section Lid 3 1 B2 02 4000 72 1 Flow Baffle 4 4 B3 01 3064 00 1 6 x 1 2 Self Tapping Screws 5 8 B2 02 3100 17 0 Slide Fastener 6 8 B2 06 6000 06 0 Slide Top Washer 7 8 B2 06 6000 04 0 Slide Mechanism 8 8 B2 06 6000 05 0 Slide Guide Plate 9 8 B3 03 1023 01 0 Slide Bottom Washer 10 8 B3 01 1022 01 0 Slide Fastening Screw 11 8 B6 02 5002 92 0 Slide Kit Note 1 Center Section Lid item 2 is supplied with slide mechanisms installed coolant shells installed center section washers and instruction manual for installation The baffle and coolant lids are not supplied 2 Slide Kit item 11 will supply one each of items 5 through 10 oN O da 11 Page 30 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 7 Center Section Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5002 07 5 Center Section Assembly Complete 1 1 B4 04 7060 20 0 Lid O Ring 2 1 B6 02 5002 24 0 Demand Feed Tube 3 3 B3 02 0040 00 0 4 40 Locking Hex Nut 4 1 B6 02 5002 07 6 Center Section Body Assembly 5 1 B4 04 7070 03 1 Constant Add Fitting O Ring 6 1 B2
37. ooster pump The customer will only need as many adapters as there ports available on the booster pump Reference below for detail on adapter types da The above picture shows the CGA 540 Male and Female adapters connected together This arrangement will provide adaptation from a 1 4 NPT female port to the BioPak 240R cylinder w ps i IR Sa i cs i se Aa Item 21a Cylinder Fill Adapter CGA 540 Male B6 02 5002 54 0 This connector will adapt a CGA 540 female connection to the BioPak 240R cylinder De na Item 21c Cylinder Fill Adapter G A Male B6 02 5002 53 0 A i This adapter will provide direct adaptation from a female G 3 4 A connection commonly found on European booster pumps to the BioPak 240R cylinder Bet _ sme Female B6 02 5002 55 0 This connector will adapt a 4 NPT female port to a CGA 540 female connection Item 21d Cylinder Fill Adapter Drager Booster B6 02 5002 66 0 This adapter will provide direct adaptation from a female W21 8 connection commonly found on Drager booster pumps to the BioPak 240R cylinder Page 24 of 47 NO 0 GE 21a 21b ZC 21d D a f 4 DI amp E A47D257 Revision J B5 06 6000 23 0 ECO 9661 March 2013 PAD O BioPak 240R User Instruction Manual A47D257 Revision J 7 2 PRO PP Facemask Assembly ITEM QTY PART NUMBER DESCR
38. pparatus that are pre packed with the carbon dioxide scrubber shall be stored within the specified storage temperature and humidity levels and must be sealed air tight in the apparatus Moisture sponges must be installed dry when pre packing the BioPak 1 Inspect the expiration date of the carbon dioxide scrubber to ensure that it is not expired Record the carbon dioxide scrubber serial number and expiration date on the maintenance Page 16 of 47 tag or affix the scrubber label to the back of the tag Verify that each carbon dioxide scrubber canister has an o ring installed Install two carbon dioxide scrubber canisters into the breathing chamber making sure that they are properly aligned and fully seated into position as depicted below Position each canister so that the top indicator arrow is pointing to the center of the breathing chamber BioPak 240R User Instruction Manual A47D257 Revision J 4 Remove the moisture pad depicted below in sealed bag from the sealed pouch and install it into the breathing chamber as depicted Do not allow the pad to become pinched between the breathing chamber wall and the scrubber The pad shall be located right next to the baffle opening that leads to the coolant canisters COELI 999 29 72 5 PPP Sad Fe eo PRA 2890 s s s a a Proper moisture pad installation WARNING Failure to install the moisture pad can lead to scrubber flooding that will result i
39. pplied with the service kit It is acceptable to leave the oxygen cylinder in place until after washing and disinfecting has been completed to prevent the ingress of contaminants into the high pressure plumbing of the BioPak 4 Remove the facemask adapter from the breathing hoses 5 Remove the breathing hoses from the breathing chamber Remove the center section lid Remove and discard the two carbon dioxide scrubbers and the scrubber moisture pad 8 Remove the moisture sponges and the PCM if used 9 Disconnect the electrical line and both pneumatic connections to the center section Use care when handling the center section Avoid sharp objects and rough surfaces that could damage the rubber diaphragm 10 Remove the four quarter turn fasteners and remove the center section 3 3 Cleaning Disinfection Use only cleaners and disinfectants that are approved by Biomarine The apparatus must be cleaned and disinfected as soon as possible after each use If cleaning is not immediately possible after use at a minimum remove and discard the carbon dioxide scrubber and moisture pad remove the moisture control foam pads and temporarily store the BioPak with the center section lid open to prevent the growth of mold or mildew DO NOT submerge the electronic monitor housing DO NOT allow any fluids to contact the input port of the pressure regulator 1 Clean the upper and lower housings ice canisters and coolan
40. ratory protective devices Full face masks EN 145 2000 Respiratory protective devices Self contained closed circuit breathing apparatus compressed oxygen type Directive 97 23 EC Pressure Equipment Directive e EN 60079 0 2009 08 01 Electrical apparatus for explosive gas part 0 General Requirements o EN 60079 11 2007 01 01 Explosive Atmospheres Part11 Equipment protection by intrinsic safety I EN 60079 26 2007 03 01 Explosive Atmospheres Part 26 Equipment with protection level EPL GA o IEC 60079 0 2007 10 01 Ed 5 Explosive Atmospheres Part 0 equipment General Requirements o IEC 60079 11 2006 07 01 Ed 5 Explosive Atmospheres Part 11 Equipment protection by intrinsic safety 1 CORR 2006 12 08 o EN 60079 26 2006 08 01 Ed 2 Explosive Atmospheres Part 26 Equipment with protection level EPL GA BioPak 240R is CE marked in accordance with EEC Directive 89 686 EEC BioPak 240R Monitor is marked Ex ia I IIC T4 Ma Ga 20 c lt Tamb lt 60 c NOTIFIED BODIES Central Institute for Labour Protection Notified Body No 1437 Wierzbowa 48 90 133 Lodz Poland Intertek Testing amp Certification Ltd Intertek House Cleeve Road Leatherhead Surrey KT22 7SB United Kingdom TUV America Inc Industry Service 5 Cherry Hill Drive Danvers MA 01923 United States of America Please contact Biomarine Inc for further apparatus approval details 2 2 Harness The B
41. rm housing into the apparatus 9 Use two 7 16 wrenches from the service kit to install the light guide from the alarm monitor housing DO NOT allow the fitting anchored to the alarm housing to rotate 10 Connect the electrical line from the center section to the alarm housing 11 Conduct the Alarm Test as described in section 3 10 12 Install the upper housing 5 5 Flow Restrictor Replacement Procedure 1 E a i 2 Use the 4 hex driver from the service kit to the remove the flow restrictor 3 Use the 14 hex driver from the service kit to the install a replacement flow restrictor 4 Perform the high pressure leak test as directed in long term maintenance 5 Perform the constant add test as directed in turn around maintenance 6 Replace the upper housing Page 21 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 5 6 Factory Service and Training 6 STORAGE GUIDELINES Follow the guidelines below for proper storage of the apparatus Factory service and personnel User and or Benchman Training can be provided by contacting the location listed below or by contacting your local Biomarine Dealer or Distributor Biomarine Inc ATTN Service Department 456 Creamery Way Exton PA 19341 2532 USA Tel 610 524 8800 ext 123 Fax 610 524 8807 Web www BioPak240r com Contact Biomarine prior to returning any equipment To better serve your needs please provid
42. ruction Manual A47D257 Revision J 4 7 Emergency Bypass Valve Functional Test 1 Openthe oxygen cylinder and depress the emergency bypass valve for 1 2 seconds The of gas escaping into the breathing shall be heard whenever the valve is depressed and shall cease whenever the valve is released 2 Close the oxygen cylinder 4 8 Alarm Test 1 Perform the test as described in Section 3 10 4 9 Maintenance Tag Validation C47D138 REV B F x 03 2013 ES BIOPAK 240 REVOLUTION TURNAROUND MAINTENANCE TAG UNIT NO 0031246 WASHED DISINFECTED 02 CYLINDER REPLACED FILLED FLOW TeST__1 3 _ Ipm CO2 CARTRIDGES REPLACED seria R20135 728 1122544 _ EXPIRATION DATE YUNE 2014 MASK INSPECTION 6 24 13 ICE PLACED IN FREEZER 6 24 13 LOW PRESSURE LEAK TEST 6 24 13 N WARNING INSTALL FROZEN ICE PRIOR TO USE REFER TO USER MANUAL AND OR MAINTENANCE MANUAL FOR INFORMATION ON USE AND MAINTENANCE OF THIS RESPIRATOR RESPIRATOR IS SUITABLE FOR USE ONLY BY PROPERLY TRAINED PERSONNEL FAILURE TO PROPERLY USE AND MAINTAIN THIS RESPIRATOR COULD RESULT IN INJURY AND DEATH 1 Inspect the maintenance tag that should be attached to the apparatus waist belt or carrying handle Verify that all portions of the tag are properly completed 2 Verify that the apparatus oxygen cylinder is fully charged to 207 bar and top off if necessary 3 Replace the upper housing Page 19 of 47 BioPak 240
43. s valve and the bypass valve push button Spring shall seat around the actuator stem of the bypass valve 3 Indicated components require lubrication with Christo Lube O Ring Lubricant B5 01 3000 01 0 prior to installation Page 34 of 47 BioPak 240R User Instruction Manual A47D257 Revision J a GCC 11a i 15 11b 16 3000 3500 4000 psi 0 BIOPARKO BIOPAK Y OXYGEN ONLY Z OXYGEN ONLY USE NO OIL USE NO OIL psi bar Gauge Dial Face bar Gauge Dial Face Item 11b Item 11a Page 35 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 10 Manifold Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5002 00 1 Manifold Assembly Complete 1 1 B6 02 5002 21 1 Manifold Block w Pressure Switch amp Fittings 2 1 B6 02 5002 50 1 Flow Restrictor Assembly Complete 3 5 B4 03 5203 01 0 Swivel Elbow Fitting Note 1 2 Fittings Item 5 are supplied on spare tube assemblies Manifold assembly mounts to lower housing of BioPak using two each of 6 x 3 8 screws B3 01 1061 01 1 and tooth washers B3 03 3063 00 0 EN Assembly identified by RED band Pressure Switch supplied installed into block A EN Assembly identified by BLACK Hex Socket 2 SEE DETAIL A Extension Fitting supplied installed into block DETAIL A RESTRICTOR SCREW Safety Relief Valve supplied installed into block Page 36 of 47 BioPak 240R User Instruction Manual A47
44. ss 3 Date and initial the maintenance tag under Ice Placed in Freezer 4 If the frozen ice canisters are not going to be utilized in the BioPak do not date and initial the maintenance tag 3 5 Oxygen Cylinder The oxygen cylinder must be fully charged with oxygen before use Oxygen used to supply or charge the breathing apparatus must be medical or aviation grade oxygen with moisture content less than 50 mg m at 207 bar The composition of suitable oxygen is given below Oxygen 99 5 minimum mole Carbon Dioxide 300 ppm maximum Carbon Monoxide 10 ppm maximum The purity quality of oxygen used to supply and charge breathing apparatus should be tested periodically in accordance with national regulations National regulations must be observed Oxygen will enhance the combustion of other materials Personnel dealing with compressed oxygen and compressed oxygen cylinders must be fully trained in the use and handling of compressed oxygen 1 Obtain the proper cylinder fill adapter needed to connect the oxygen cylinder to the booster pump 2 Connect the cylinder to the booster pump and charge to 207 bar pressure with medical or aviation grade oxygen 3 6 Facemask 1 Inspect the components of the facemask and replace as required 2 Reinstall the magnetic wiper to facemask if utilized 3 Date and initial the maintenance tag under Mask Inspection NOTE The mask is supplied with a permanent anti fog fil
45. t lids and all connected components with a mild soap and water mixture if necessary 2 Mix the disinfectant with clean water as directed on the package 3 Submerge the facemask hoses with facemask connector center section lid center section PCM and moisture sponges into the disinfectant solution Allow the components to be wetted on all surfaces for a minimum of 10 minutes Install a Demand Port Wash Plug supplied with the service kit to the demand port of the center section to Page 12 of 47 BioPak 240R User Instruction Manual A47D257 Revision J keep water from migrating in the demand housing Do NOT allow the mask to soak in cleaning solutions for extended periods Extended soaking can cause delamination of the anti fog film 4 Thoroughly rinse all components in clean water to remove all disinfection solution It is extremely important to fully rinse the facemask of all cleaning solution 5 Allow all components to dry either by air drying heated drying or through the use of a dryer system Heat assisted drying temperatures shall not exceed 50 C 6 Date and initial the maintenance tag under Washed Disinfected 3 4 Coolant Canister The coolant canisters must be frozen before use 1 Place the cleaned and dried canisters into the freeze form and tighten the nuts securely 2 Place the freeze forms onto a level surface in a freezer for a minimum 8 hour period at a temperature of 12 C or le
46. ube Regulator Support Plate Oxygen Knob Retaining Bracket Diaphragm Springs Item 2 install into lower housing by threading onto spring retainer projections External Oxygen Knob Item 3 snaps into position within lower housing Indicated components are to be installed from the external side of the lower housing shell Oxygen Bottle Strap item 16 is to be threaded through the lower housing shell slots for installation Page 39 of 47 BioPak 240R User Instruction Manual A47D257 Revision J Page 40 of 47 7 14 ITEM REF RON BioPak 240R User Instruction Manual A47D257 Revision J Ice Canister Freeze Form QTY oo or ak PART NUMBER B6 02 5002 40 0 B6 02 5002 58 0 B2 02 4001 46 0 B2 02 1100 06 0 B3 02 4100 00 0 DESCRIPTION Ice Canister Freeze Form Complete Base Assembly Freeze Tube Top Plate Wing Nut Page 41 of 47 BioPak 240R User Instruction Manual A47D257 Revision J 7 15 Service Kit Assembly ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5002 16 0 Tool Test Kit Complete WC REF B6 02 5002 16 3 Tool Test Kit Complete milli bar la 1 B6 02 5002 57 0 Replacement Case Assembly WC 1b 1 B6 02 5002 57 1 Replacement Case Assembly milli bar 2a 1 B6 02 5002 15 0 AV3000 Flow Test Fixture 2b 1 B6 02 5003 00 0 PRO Flow Test Fixture 3 1 B6 02 5002 15 0 Flow Test Fixture 4 2 B6 02 5000 17 2 Test K
47. ystem Oxygen will be delivered from the oxygen cylinder to the breathing loop through a pressure regulator and manifold system in one of three different methods Pressure demand oxygen additions are provided whenever the diaphragm of the breathing chamber reaches the upper level of its travel and depresses the demand valve plunger Additions will be made at 80 liters minutes whenever the demand valve plunger is depressed Pressure demand additions occur whenever the wearer consumes more oxygen than is supplied by the constant add Constant add oxygen additions are continually added to the breathing loop at an average rate of 1 8 liters minute This oxygen addition rate is equivalent to the oxygen consumption rate of a wearer at a moderate work rate Emergency add oxygen additions occur whenever the wearer depresses and holds the red emergency bypass button This add will provide 80 100 liters minute of oxygen flow and is utilized only for emergency situations 2 6 Oxygen Cylinder The oxygen cylinder is a fully wrapped aluminum carbon fibre composite cylinder that is secured into the apparatus via connection to the pressure regulator and a hold down strap The cylinder will provide containment of the oxygen supply at a 207 bar to provide 440 liters of breathable oxygen to the wearer 2 7 Alarming System The alarming system consists of a pneumatic pressure gauge and an electronic monitor to provide the wearer with indep

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