User Manual
Contents
1. Step 1 10 MACK 3 SETUP OPERATION COMMON AIR SOURCES Step 1 Install the universal CGA 347 hand tight nuts Item 4 to the cylinders Step 2 Close all bleeder valves Item 3 by turning the knobs fully clockwise Step 3 Index the isolation valve Item 21 so the position arrow on the handle is inline with the plumb ing Step 4 Open one cylinder At this time the low pressure warning alarms Item 7 will sound until they set themselves at approximately 1000psi 69 bar Check the reading on the gauge Item 19 to verify that the cylinder is full Close the cylinder Step 5 Set the required tool pressure with the regulator control knob Item 18 Turn clockwise to increase counter clockwise to decrease pressure Step 6 Set the required respirator pressure s with the regulator control knob Item 15 Turn clock wise to increase counterclockwise to decrease pressure Step 7 Bleed the pressure at either the relief valve Item ft 11 or by partially engaging a male plug into one of the respirator tool couplings Item 12 12A This depressurizes the manifold and simu lates low cylinder pressure The low pressure warning alarms Item 7 will sound at approxi mately 500psi 35 bar Open the other cylinder s At this time the low pressure warning alarms Item 7 will sound until they reset themselves at approximately 1000 psi 69 bar2. Open the other cylinder At this time the low pressure warning alarm Item 6 will re sound until it sets itself at approximately 1000psi 69 bar Check reading on gauge Item 1 to verify cylinder is full Step 6 Couple respirators and lengths of hoses to the manifold and readjust pressure regulator Item 10 if necessary The system is now operational Step 7 Optional Install a high pressure connect whip to the high pressure inlet This step may be done after Step 5 or at anytime during operation of the system 5 MACK 1 PARTS IDENTIFICATION ITEM DESCRIPTION PART 1 INCOMING PRESSURE GAUGE 0 200PSI GA256KS LIGHT ASSEMBLY MACKLIGHT PRESSURE CAP SS347CAP 4 G4 MALE ADAPTER SS4F347AM SAT AS 14 MALE MALE CHECK VALVE VC4MMSS VA LOW PRESSURE WHISTLE AC PA25 7 CGA 347 HAND TIGHT NUT NIPPLE SSM7HT E A A RELIEF VALVE VR4150BR REGULATOR REG 5000 RESPIRATOR FITTING HANSEN QDH3SL6M a a dg gt p DUST CAP HANSEN QDH3DCAP m 12 RESPIRATOR FITTING SCHRADER QDSSL6M Ea FI DUST CAP SCHRADER ODSDCAP 13 OUTGOING PRESSURE GAUGE 0 6000PSI GA25200S SETUP OPERATION MACK 2 SETUP OPERATION Step 1 Install the universal CGA 347 hand tight nuts Item 3 to the cylinder valves and tighten Step 2 Close all bleeder valves Item 2 by turning the knobs fully clockwise Step 3 Open one cylinder At this time the low pressure warning alarm Item 7 w
3. designs and specifications are subject to change without notice Rev 2 12 98 Air leaks are not covered under warranty except when they result from a defective system component i e an on off valve or regulator or upon initial delivery due to poor workman ship Air leaks due to poor delivery or damage will be covered under delivery claims Minor air leaks are part of routine service and maintenance and are the responsibility of the cus tomer just as are filters and oil changes
4. 3 by turning the knobs fully clockwise Open the empty cylinder s valve Step 6 Adjust the fill regulator Item 8 to the desired pressure by turning the control knob clockwise to increase pressure Step 7 Slowly open the fill valve Item 2 by turning the knob counterclockwise Step 8 Once filling is complete close the full cylinder valve Step 9 Close the fill valve Item 2 Step 10 Open the relief valve This relieves the line pressure allowing removal of the universal CGA 347 hand tight nut See MACK 3 Parts Identification page 11 15 MACK 3 OPTIONAL FILL WHIP ASSEMBLY PART MACK 3FA 16 MACK NFPA1 PARTS IDENTIFICATION ITEM DESCRIPTION PART 6 LOW PRESSURE WHISTLE AC PA25 8 CHECK VALVE VC4MMSS 9 BLEEDERVALVE VAL030 MACK NFPA3 amp MACK NFPA3Q PARTS IDENTIFICATION 5 PRESSUREREGULATOR X REG 5000NG 6 LOW PRESSURE WHISTLE AC PA25 8 SUPPLY ISOLATION VALVE VALOZ3 9 CHECK VALVE VCAMMSS 10 BLEED VALVE VAL030 EUM 12 0 1 CGA 346 CGA 347 HAND TIGHT SS347HT 2 CGA 347 MALE ADAPTER SS4F347AM 4 5 1 1 1 1 PRESSURE CAP SS347CAP QUICK FILL PLUG OPTIONAL ST878MFST 17 MACK 1 6K PARTS IDENTIFICATION E SN FR FN Le 7 X N V y oh 2 KZ y X Y NZ CALIDA N s a ITEM 1 2 CHECK VALVE VC4SMMSS 3 HIGH PRES
5. Check read ing on gauge Item 19 to verify cylinder is full Step 8 Couple respirators tools and length of hoses to the corresponding couplings Readjust the pressure regulators if necessary The system is now operational Step 9 Optional Install a high pressure connect whip to the high pressure inlet This step may be done after step 7 or at any time during operation of the system 11 MACK 3 PARTS IDENTIFICATION or DESCRIPTION HIGH PRESSURE QUICK DISCONNECT QDHKSL4FSS ON OFF VALVE PART VAL020 BLEEDER VALVE CGA 347 HAND TIGHT NUT STEM VAL030 SS347HT CGA 347 MALE ADAPTER PRESSURE CAP SS4F347AM SS347CAP LOW PRESSURE WHISTLE AC PA25 FILL REGULATOR FILL WHIP CONNECTION REG001 QDHKPLAFSS FILL PRESSURE GAUGE RELIEF VALVE 150PSI GA256KS VR4150BR QUICK DISCONNECT HANSEN QDH3SL6M QUICK DISCONNECT SCHRADER ODSSL6M DUST CAP HANSEN ODH3DCAP DUST CAP SCHRADER OUTLET PRESSURE GAUGE 0 160PSI ODSDCAP GA20160S PRESSURE REGULATOR CHECK VALVE WLO14 VC4MMSS RELIEF VALVE 275PSI VR4275BR AIR SHORE REGULATOR REG007 INLET PRESSURE GAUGE 0 6000PSI GA206KS OUTLET PRESSURE GAUGE 0 1000PST SYSTEM ISOLATION VALVE GA201KS VAL073 PRESSURE REGULATOR OUTLET PRESSURE GAUGE 0 200PSI REG 5000 GA25200S LIGHT ASSEMBLY MACKLIGHT Step 8 MACK 3 SETUP OPERATON COMMON AIR SOURCES PE INLET P
6. Models MACK 1 MACK 2 MACK 3 MACK NFPA 1 MAC K NFPA3 MACK NFPA30 MAC K 1 6K Manual No POAOS1 Rev 1 March 2005 Operating Manual AIRSYSTEMS INTERNATIONAL INC 829 Juniper Crescent Chesapeake Va 23320 Telephone 757 424 3967 Toll Free 1 800 866 8100 Fax No 757 424 5348 http www airsystems cc e mail sales airsystems cc Air Systems International Inc Registered to ISO 9001 Printed in U S A Certificate No A5033 OCopyright Air Systems International Inc 2005 All Rights Reserved 2 TABLE OF CONTENTS A Pr A O 3 MACK 1 Setup Operation amp Parts IdentificatioN oooooommoms 4 5 MACK Setup Operation amp Parts IdentificatioN oooooomooms 6 7 MACK 2 Filing Cinderella 8 9 MACK 3 Setup amp Operation for Common Air Sources Parts Identification 10 11 MACK 3 Setup amp Operation for Isolated Air Sources cese eee eee e eere eene 12 13 MACK 3 Setup amp Operation for Optional Fill Whip Assembly MACK 3FA 14 15 MACK NFPA1 MACK NFPA3 Parts Identification ccce e eee ee esee reete e eere en een 16 MACK NFPA1 amp MACK NFPA3 Setup amp Operation eee eee e Leere eee ee eren ee eee 17 Chanems Cy NG S 18 Shutdown Procedure una 18 High Pressure Airline General Maintenance amp Inspection ssssssssssssssssssnssssssnsnssnnssnsssnnnn
7. PSI GA256KS 9 RELIEF VALVE 150PSI VR4150BR Ss 10 CHECK VALVE VC4MMSS NS 11 PRESSURE REGULATOR REG 5000 12 OUTLET PRESSURE GAUGE 0 200PSI GA25200S 13 QUICK DISCONNECT HANSEN QDH3SL6M 13A QUICK DISCONNECT SCHRADER QDSSL6M um I 14 DUST CAP HANSEN QDH3DCAP NE of 8 14A DUST CAP SCHRADER QDSDCAP d i M 15 FILL PRESSURE GAUGE 0 6000PSI GA256KS 16 LIGHT ASSEMBLY MACKLIGHT SETUP OPERATION S MACK 2 FILLING CYLINDERS Step 1 2216 4500psi cylinder fill Install the universal CGA 347 handtight nut Item 3 to the empty cylinder s valve and tighten Note An optional CGA 347 to CGA 346 adapter relief valve is available The relief valve is set to 2400psi Step 2 Close the fill and bleeder valves Item s 1 amp 2 Step 3 Open empty cylinder valve Step 4 Open the cascade air supply source Note It is highly recommended you use a high volume air source connected to the high pressure inlet Step 5 Adjust the fill regulator Item 4 to desired fill pressure by turning the control knob clockwise to increase pressure Step 6 Slowly open the fill valve Item 1 to a desired fill rate by turning the knob counterclockwise Step 7 Once filling is complete close the fill and cylinder valves Open the bleeder valve Item 2 to vent pressure Remove the CGA 347 hand tight nut Item 3 See MACK 2 Parts Identification page 7 9 MACK 2 FILLING CYLINDERS
8. RESSURE GAUGE 0 6000PSI GA256KS Optional Fill Assembly Part MACK 3FA Lower Whip Assemblies 12 MACK 3 SETUP OPERATION AIR SOURCES ISOLATED Step 1 Install the universal CGA 347 hand tight nuts Item 4 to the cylinders Note At least one cylinder on the upper and lower whip assemblies needs to be connected for independent operation Step 2 Close all bleeder valves Item 3 by turning the knobs fully clockwise Step 3 Index the isolation valve Item 21 so the position arrow on the handle is perpendicular to the plumbing Step 4 Open one cylinder from the upper and lower whip assemblies At this time the corresponding low pressure warning alarms Item 7 will soung until they set themselves at approximately 1000psi 69 bar Check the reading on the gauges Item s 19 amp 25 to verify that the cylinders are full Close the cylinders Step 5 Set the required tool pressure with the regulator control knob Item 18 Turn knob clockwise to increase or counterclockwise to decrease pressure Step 6 Set the required respirator pressure s with the regulator control knob Item 15 Turn clockswise to increase counterclockwise to decrease pressure Step 7 Bleed the pressure at either the relief valve Item ft 11 or by partially engaging a male plug into one of the respirator tool couplings Item s 12 12A This despressurizes the manifold and simulates low cylinder pressure The low pre
9. SURE INLET FITTING 6000 PSI MAX QDHKPLAFSS 4 BLEEDVAVE_________ VAL03 7 0 RESPIRATOR FITTING HANSEN QDH3SL4M 10A RESPIRATOR FITTING SCHRADER QDSSL4M 1 1 DUST CAP HANSEN QDH3DCAP 11A DUST CAP SCHRADER QDSDCAP 12 LIGHT ASSEMBLY NOT SHOWN MACKLIGHT 18 MACK NFPA1 amp MA CK NFPA3 Q SETUP amp OPERATION Note Low pressure 2216psi and high pressure 4500psi cylinders can be used Step 1 Install CGA 347 connections to cylinder valves and tighten with hand tight wheels Step 2 Make sure all bleeder valves are turned fully clockwise to prevent air loss and open one cylinder At this time the low pressure alarm whistle will sound It will continue until the pressure reaches approximately 1000psi 69 bar Low Pressure Alarm Test Set the required respirator pressure with the regulator control knob and bleed the pressure at either the relief valve or by partially engaging a male plug into one of the respirator couplings This depressurizes the manifold and simulates low cylinder pressure The low pressure warning alarm will sound at approximately 500psi 35 bar Open the other cylinder Check reading on gauge to verify cylinder is full Step 3 Couple respirators and lengths of hoses to the manifold and readjust pressure regulator if neces sary The system is now operational Step 4 Optional for MACK NFPA3 The CGA 347 inlet can be used as an alternate incoming air source Set the selector valve to th
10. e common vertical position or isolated horizontal position STEP2 STEP4 19 CHANGING CYLINDERS To change a cylinder while the unit is still in use 1 Open the second cylinder and note the gauge pressure 2 Close the drained cylinder 3 Open the bleeder valve to relieve line pressure Remove the CGA 347 hand tight nut 4 Remove the drained cylinder and install a full cylinder in its place Reinstall the CGA connections Close bleeder valves The cylinder is now ready for use when the other cylinder s pressure descends to 500psi Note The system is equipped with check valves that will prevent backflow from the other cylinder in use SHUTDOWN PROCEDURE 1 Cylinder valves must be shut and line pressure relieved through the relief valve 2 Remove CGA 347 connections from cylinders and reinstall valve covers for storage and transportation HIGH PRESSURE AIRLINE GENERAL MAINTENANCE amp INSPECTION Monthly 1 Check regulatos gauges and valves for external leakage 2 Inspect cylinder valves for proper closure 3 Check cylinder pigtails for cleanliness flexibility wear leakage blisters on hose and thread damage Replace damaged pigtails immediately 4 Inspect check valves for closure ability Annually 1 Check relief valve s pressure setting 2 Check regulator function by opening and closing regulator valve knob fully Every 4 years 1 Replace all flexible pigtails 20 Warranty Disclaimer Air Sy
11. e 18 Warranty Disclaimer 19 OVERVIEW The MACK series has been designed as a portable multifunctional air distribution system All MACK units are rated for 5000psi MACK 1 This version allows for one or two high pressure cylinders to be attached to the supply inlet whips A CGA 347 male inlet is provided for direct attachment to a bank of air cylinders All MACK series units have at least one air outlet manifold with pressure adjustments from 0 125psi MACK 2 This version has the same features as the MACK 1 with the addition of an adjustable fill regula tor pressure gauge and fill whip An optional second fill whip is available MACK 3 The MACK 3 contains two independent low pressure manifolds and regulator systems that each have their own cylinder supply hoses An isolation valve is located between the regulators to isolate the systems as well as provide common air flow from a single bottled air source One regulator is set to provide low pressure air 0 125psi for respirators and one for medium pres sure air 0 250psi for air shores and other rescue tools This medium pressure manifold has an additional low pressure regulator manifold system for additional respirators and tools A total of eleven outlets are provided The MACK 3FA version contains all of the above items with the addition of a complete bottle fill assembly model number MACK FA MACK NFPA1 This version contains two in dependent MACK 1 manifold and regulator systems
12. ill sound until it sets itself at approximately 1000psi 69bar Check reading on gauge to verify that cylinder is full Close the cylinder Step 4 Set the required respirator pressure with the regulator control knob Item 11 Turn clockwise to increase pressure counterclockwise to decrease pressure Step 5 Bleed the pressure at either the relief valve Item 9 or by partially engaging a male plug into one of the respirator couplings Item 13 14 This depressurizes the manifold and simulates low cylinder pressure The low pressure warning alarm Item 7 will sound at approximately 500psi 35bar Open the other cylinder At this time the low pressure warning alarm Item F7 will re sound until it sets itself at approximately 1000psi 69 bar Check reading on gauge Item 8 to verify cylinder is full Step 6 Couple respirators and lengths of hoses to the manifold and readjust pressure regulator if neces sary The system is now operational Step 7 Optional Install a high pressure connect whip to the high pressure inlet This step may be done after Step 5 or at anytime during operation of the system 7 MACK 2 PARTS IDENTIFICATION ITEM DESCRIPTION PART 1 ON OFF VALVE VAL020 BLEEDER VALVE VAL030 3 CGA 347 HAND TIGHT NUT AND STEM SS347HT 7 A 4 FILL REGULATOR REG001 AH 5 CGA 347 MALE ADAPTER SS4F347AM 6 PRESSURE CAP SS347CAP 7 LOW PRESSURE WHISTLE AC PA25 8 INLET PRESSURE GAUGE 0 6000
13. so that each one has its own cylinder supply hoses and low pressure whistle A total of 6 low pressure outlets are provided MACK NFPA3 This version of the MACK NFPA 1 contains two independent low pressure manifold and regula tor systems so that each has its own cylinder supply hoses An isolation valve is added between the systems to isolate the regulators as well as provide common air flow from a single bottled air source A CGA 347 high pressure inlet is provided on this version to allow for an external bank of air cylinders to operate the unit 4 MACK 1 SETUP OPERATION Step 1 Install the universal CGA 347 hand tight nuts Item 7 to the cylinder valves and tighten Step 2 Close all bleeder valves Item 8 by turning the knobs fully clockwise Step 3 Open one cylinder At this time the low pressure warning alarm will sound until it sets itself at approximately 1000psi 69bar Check reading on gauge Item 1 to verify that cylinder is full Close the cylinder Step 4 Set the required respirator pressure with the regulator control knob Item 10 Turn clockwise to increase pressure counterclockwise to decrease pressure Step 5 Bleed the pressure at either the relief valve Item 9 or by partially engaging a male plug into one of the respirator couplings Item 11 12 This depressurizes the manifold and simulates low cylinder pressure The low pressure warning alarm Item 6 will sound at approximately 500psi 35bar
14. ssure warning alarms will sound at approximately 500psi 35 bar Open the other cylinder s At this time the low pressure warning alarms Item 7 will sound until they reset themselves at approximately 1000psi 69 bar Check reading on gauge Item 19 to verify cylinder is full Step 8 Couple respirators tools and lengths of hose to the corresponding couplings Readjust the pressure regulators if necessary The system is now operational Step 9 Optional Install a high pressure connect whip to the high pressure inlet This may be done after Step 8 or at any time during operation of the system See MACK 3 Parts Identification page 11 13 MACK 3 SETUP OPERATION AIR SOURCES ISOLATED Step 9 Step 5 14 MACK 3 SETUP OPERATION OPTIONAL FILL WHIP ASSEMBLY PART MACK 3FA Step 1 If the system is to be used for breathing air and filling follow the procedures on page 10 for common air sources or page 12 for isolated air sources Continue to Step 2 Step 2 Close the high pressure fill regulator by turning the control knob Item 8 counterclockwise until no resistance is noticed Note Continuing to turn counterclockwise will result in the re moval of the knob Step 3 Install the fill whip onto the fill regulator by way of the quick disconnect Item 1 Step 4 Install the universal CGA 347 hand tight nut Item 4 to the cylinder to be filled Step 5 Close the bleeder and fill valves Item s 2 amp
15. stems manufactured equipment is warranted to the original user against defects in workman ship or materials under normal use for one year after date of purchase Any part which is deter mined by Air Systems to be defective in material or workmanship will be as the exclusive remedy repaired or replaced at Air Systems option This warranty does not apply to electrical systems or electronic components Electrical parts are warranted to the original user for 90 days from the date of sale During the warranty period electrical components will be repaired or replaced at Air Systems option NO OTHER WARRANTY EXPRESSED OR IMPLIED AS TO DESCRIPTION QUAL ITY MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER IS GIVEN BY AIR SYSTEMS IN CONNECTION HEREWITH UN DER NO CIRCUMSTANCES SHALL THE SELLER BE LIABLE FOR LOSS OF PROFITS ANY OTHER DIRECT OR INDIRECT COSTS EXPENSES LOSSES OR DAMAGES ARISING OUT OF DEFECTS IN OR FAILURE OF THE PRODUCT OR ANY PART THEREOF The purchaser shall be solely responsible for compliance with all applicable Federal State and Local OSHA and or MSHA requirements Although Air Systems International believes that its products 1f operated and maintained as shipped from the factory and in accordance with our op erations manual conform to OSHA and or MSHA requirements there are no implied or expressed warranties of such compliance extending beyond the limited warranty described herein Product
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