EN Benchman Manual-Revision I - BioPak 240 Revolution 4
Contents
1. 2b 1 AV3000 Facemask Assembly See Section 7 3 3 1 B6 02 5002 18 0 Upper Housing Assembly 4 2 B2 02 4000 39 0 Coolant Lid 5 2 B6 02 5002 37 0 Ice Canister 6 2 B2 02 7001 09 0 Breathing Hose See Section 7 4 or Section 7 5 7 1 B6 02 5002 04 0 Center Section Lid Assembly See Section 7 6 8a 1 B5 01 5000 00 0 ExtendAir Scrubber Canister 8b 1 B6 02 5003 05 0 Biomarine Scrubber Canister 9 2 B2 02 7001 15 0 CO Scrubber End Gasket 10 1 B6 02 5002 07 1 Center Section Assembly See Section 7 7 11 1 Pneumatic Assembly See Section 7 9 12 1 B6 01 5000 05 0 Alarm Monitor See Section 7 11 13a 1 B6 02 5001 98 0 Green Oxygen Cylinder Empty See Section 7 12 13b 1 B6 02 5001 98 1 Green Oxygen Cylinder Full See Section 7 12 13c 1 B6 02 5002 06 0 Black White Oxygen Cylinder Empty See Section 7 12 13d 1 B6 02 5002 06 1 Black White Oxygen Cylinder Full See Section 7 12 14 1 B6 02 5002 29 0 Lower Housing Assembly See Section 7 13 15a 1 B2 02 7001 25 0 Harness Assembly Standard 15b 1 B2 02 7001 24 0 Harness Assembly Flame Rated 16 2 B6 02 5002 40 0 Ice Canister Freeze Form See Section 7 15 17 1 B5 06 6000 22 0 User Manual ENGLISH 18 1 B5 06 6000 23 0 Benchman Manual ENGLISH 19a opt B6 02 5002 63 0 Hard Transit Case not depicted 19b opt B2 02 7000 39 0 Soft Transit Case not depicted 20a 1 B2 02 4001 50 0 PRO Storage Plug 20b 1 B2 02 4000 90 0 AV3000 Storage Plug 21a 1 B6 02 5002 54 0 Cylinder Fill Adapter CGA 540 Male2. 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 BioPak 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 5 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 moistur
3. column then immediately close the oxygen cylinder valve CTION MANUAL E RENCE BENCHMAN INSTRU PROPER MAINTENANCE PROCEDURES SYSTEM PRESSURE Activate the emergency bypass valve to empty all gas into the breathing chamber and raise the pressure reading to between 6 and 8 water column DO NOT overpressure BioPak 240R Benchman Manual A47D257 Revision 6 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 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 the apparatus pressure drops more than 0 2 in the 60 second there is a leak that must be located and repaired 7 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 oylinder 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 pres
4. 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 136 1998 Respiratory protective devices Full face masks 145 2000 Respiratory protective devices Self contained closed circuit breathing apparatus compressed oxygen type e Directive 97 23 EC Pressure Equipment Directive 60079 0 2009 08 01 Electrical apparatus for explosive gas part 0 General Requirements 60079 11 2007 01 01 Explosive Atmospheres Part1 1 Equipment protection by intrinsic safety I e EN 60079 26 2007 03 01 Explosive Atmospheres Part 26 Equipment with protection level EPL GA IEC 60079 0 2007 10 01 Ed 5 Explosive Atmospheres Part 0 equipment General Requirements IEC 60079 11 2006 07 01 Ed 5 Explosive Atmospheres Part 11 Equipment protection by intrinsic safety CORR 2006 12 08 60079 26 2006 08 01 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 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
5. 0 Check Valve Note 1 Complete Breathing Hose Set includes all depicted items 2 Mask Adapter Assembly includes the check valves and gasket 3 NOT lubricate the check valves Page 23 of 41 2b 2a BioPak 240R Benchman Manual A47D257 Revision 7 6 Center Section Lid Assembly ITEM QTY REF PART NUMBER B6 02 5002 04 0 B2 02 4000 39 0 B6 02 5002 27 0 B2 02 4000 72 0 B3 01 3064 00 1 B2 02 3100 17 0 B2 06 6000 06 0 B2 06 6000 04 0 B2 06 6000 05 0 B3 03 1023 01 0 B3 01 1022 01 0 B6 02 5002 92 0 gt OON OOF AMOK DESCRIPTION Center Section Lid Assembly Complete Coolant Lid Center Section Lid Flow Baffle 6 x 1 2 Self Tapping Screws Slide Fastener Slide Top Washer Slide Mechanism Slide Guide Plate Slide Bottom Washer Slide Fastening Screw Slide Kit 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 11 Page 24 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 7 Center Section Assembly ITEM QTY PART NUMBER REF 1 B6 02 5002 07 1 1 1 B4 04 7060 20 0 2 1 B6 02 5002 24 0 3 3 B3 02 0040 00 0 4 1 B6 02 5002 71 1 5 1 B4 04 7070 03 1 6 1 B2 02 3300 06 0 7 1
6. 21b 1 B6 02 5002 55 0 Cylinder Fill Adapter CGA 540 Female 21c 1 B6 02 5002 53 0 Cylinder Fill Adapter G A Male 21d 1 B6 02 5002 66 0 Cylinder Fill Adapter fits Drager Booster Pump 22 opt B6 02 5002 41 0 Phase Change Heat Exchanger PCM 23 1 B2 02 7001 07 0 Moisture Absorbent Pad Set Note 1 The BioPak 240R respirator is supplied with a cardboard foam shipping box Hard or soft transit cases are to be ordered separately Reference the below listed key for BioPak configuration as listed above DESCRIPTION Supplied as EN145 Certified Supplied with Standard non flame rated Harness Supplied with Flame Rated Harness Supplied with Green Oxygen Cylinder certified to DOT amp TC Supplied with Black White Oxygen Cylinder certified to PED DOT amp TC Remote Gauge supplied with bar pressure unit markings Remote gauge supplied with psi amp bar pressure unit markings 2 Scrubber Canister part number B5 01 5000 00 0 or B6 02 5003 05 0 will supply four sets of canisters and maintenance tags for four separate single uses 3 End Gasket part number B2 02 7001 15 0 can be purchased individually Gaskets are also supplied within each case of the ExtendAir CO Scrubber Canister 4 Alternate language manuals are available Contact Biomarine Representative for details CODE Page 18 of 41 BioPak 240R Benchman Manual A47D257 Revision Page 19 of 41 BioPak 240R Benchma
7. B2 02 3300 48 0 8 1 B4 04 7060 01 1 9 1 B2 02 7001 10 0 10 1 B6 02 5002 23 0 11 3 B3 01 0043 00 0 12 1 B6 02 5002 05 0 13 1 B2 06 6001 47 0 14 1 B4 03 5204 08 0 Note DESCRIPTION Center Section Assembly Complete Lid O Ring Demand Feed Tube 314 40 Locking Hex Nut Center Section Body Assembly Constant Add Fitting O Ring Constant Add Fitting Demand Add Fitting Demand Add Fitting O Ring Demand Valve Gasket Demand Valve Assembly 4 x 3 8 Sealed Flat Head Screw Diaphragm Assembly See Section 7 8 Diaphragm Clamp 10 x 1 8 Tube Male Connector Fitting 1 Indicated components require lubrication with Dow 111 O Ring Lubricant B5 01 3000 1 1 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 Center Section Body Assembly item 4 includes all depicted components with the exception of diaphragm item 12 and diaphragm clamp item 13 Page 25 of 41 BioPak 240R Benchman Manual A47D257 Revision Page 26 of 41 11 12 13 BioPak 240R Benchman Manual A47D257 Revision 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 Ven
8. Fogging Agent Applied NOTE The mask is supplied with a permanent anti fog film so no application of anti fog agents of any kind are required 3 7 Assembly 1 Install the center section making sure to properly seat the three springs onto the diaphragm 2 Lock the center section into position using the four quarter turn fasteners 3 Connect the electrical and pneumatic lines to the center section Verify the presence of an o ring seal on each pneumatic line connection 4 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 5 If utilized install the PCM into the breathing chamber on top of the moisture sponges Date and initial the maintenance tag under Canister Placed in Freezer and enter PCM on the tag 6 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 7 Install the breathing hoses to the breathing chamber and secure with clamps making sure the flow direction arrows of the connector are facing up 8 Install the storage plug into the facemask connector Page 9 of 41 BioPak 240R Benchman Manual A47D257 Revision 9 Remove the wash plug from the pressure regulator and install the oxygen cylinder Secure the cylinder with the hold down strap 3 8 Constant Flow Test Disconnect the
9. Solid Core canisters Non dusting Non settling Non channeling 6 0 liters Page 40 of 41 BioPak 240R Benchman Manual A47D257 Revision 9 MAINTENANCE LOG SHEET BioPak 240R BioPak Model BioPak Serial Number o d omments Benchman Signature 3591 jeuonouny ssed g yee yea 5 3591 JUBA 3591 jeuonouny Page 41 of 41
10. apparatus itself or in the seal between the 5 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 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 1 4 Servicing The BioPak 240R must be serviced at scheduled intervals by qualified benchmen 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 quarterly basis if the BioPak is being used less than once per month as defined in the BioPak 240R Benchman Manual Benchman trainin
11. freezer for a minimum 8 hour period at a temperature of 12 C or less 3 Date and initial the maintenance tag under Canister 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 a moisture content less than 50 mg m at 207 bar The composition of suitable oxygen is given below Oxygen 99 596 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 Connectthe 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 3 Date and initial the maintenance tag under Anti
12. hose to provide abrasion protection Breathing Hose Anti Crush Ring 2 02 4101 22 0 Injection molded hard plastic rings that slide over the exterior of the breathing hose Rings are to be positioned on the hose to sit on the shoulder of the user in order to prevent hose collapse when carrying items over the user s shoulder Facemask Neck Strap B2 06 6001 64 0 A Kevlar strap that connects to the lower rings of the facemask Strap will provide facemask support around the user s neck when facemask is not in the donned position Facemask Magnetic Wiper B2 06 6000 30 0 Wiper will provide single hand operation to wipe clean both the interior and exterior lens surface of the facemask at the same time Magnetic feature of wiper avoids need for facemask piercing Phase Change Heat Exchanger B6 02 5002 41 0 A wedge shaped canister that will fit between the ice canister housings internal to the respirator breathing chamber This canister is required whenever the BioPak is utilized without the ice canisters 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 standard hard case Hydration System B6 02 5002 52 0 The Hydration S
13. 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 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 Fill the apparatus by depressing the emergency bypass valve in several short burst Observe the pressure reading on the service kit The apparatus pressure should remain at or below 2 water column pressure after releasing the emergency bypass valve 4 5 Low Pressure Leak Test 1 Perform the test as described in Section 3 9 4 6 High Pressure Leak Test Place the apparatus 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 fo
14. BIOPAK 24 REVO TION BioPak 240R Closed Circuit Self Contained Breathing Apparatus Benchman Manual C d 1437 A47D257 Revision I B5 06 6000 23 0 April 2012 BioPak 240R Benchman Manual A47D257 Revision WARNINGS 1 INTRODUCTION 1 1 Breathable Oxygen 1 2 Apparatus Duration 1 3 Personnel Training 1 4 Servicing 1 5 Spare Parts 2 APPARATUS DESCRIPTION 2 1 General 2 2 Harness 2 3 Housing 2 4 Breathing Loop 2 5 Oxygen Delivery System 2 6 Oxygen Cylinder 2 7 Alarming System 2 8 Facemasks 2 9 Optional Attachments 3 TURN AROUND MAINTENANCE PROCEDURE 3 1 Maintenance Tag 3 2 Disassembly 3 3 Cleaning Disinfection 3 4 Coolant Canister 3 5 Oxygen Cylinder 3 6 Facemask 3 7 Assembly 3 8 Constant Flow Test 3 9 Low Pressure Leak Test 3 10 Alarm Test 3 11 Upper Housing 3 12 Carbon Dioxide Scrubber Pre Packing Procedure 4 LONG TERM MAINTENANCE PROCEDURE 4 1 Visual Inspection 4 2 Demand Valve Functional Test 4 3 Constant Flow Test 44 Vent Valve Functional Test 4 5 Low Pressure Leak Test 46 High Pressure Leak Test 4 7 Emergency Bypass Valve Functional Test 4 8 Alarm Test 4 9 Maintenance Tag Validation 5 GENERAL SERVICE PROCEDURES 5 1 Scheduled Component Inspection 5 2 System Lubrication 5 3 Oxygen Cylinder 5 4 Alarm Battery Replacement Procedure 5 5 Flow Restrictor Replacement Procedure 5 6 Factory Service and Training 6 STORAGE GUIDELINES 7 PARTS LISTS Top Assembly PRO Facemask Assembly AV3000 Facemask Assembl
15. NUMBER 6 02 5002 40 0 6 02 5002 58 0 2 02 4001 46 0 2 02 1100 06 0 B3 02 4100 00 0 KR ooo DESCRIPTION Ice Canister Freeze Form Complete Base Assembly Freeze Tube Top Plate Wing Nut Page 37 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 Page 38 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 17 Optional Attachments Harness Chest Belt Extender B2 02 7001 34 0 An extension strap for the standard harness chest belt for users of large size Harness Chest Belt Extender B2 02 7001 34 1 An extension strap for the flame rate harness chest belt for users of large size Harness Waist Belt Extender B2 02 7001 35 0 An extension strap for the standard harness waist belt for users of large size Harness Waist Belt Extender B2 02 7001 35 1 An extension strap for the flame rate harness waist belt for users of large size Breathing Hose Protective Sleeve B2 02 7001 22 0 A Kevlar sleeve that will slide over the exterior of the breathing
16. Page 16 of 41 BioPak 240R Benchman Manual A47D257 Revision 6 STORAGE GUIDELINES Follow the guidelines below for proper storage of the apparatus Storage plug shall be installed Never store a wet apparatus The apparatus shall be fully dry before storage 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 Store in case that may be supplied by Biomarine Do not store the apparatus pre packed with the ExtendAir carbon dioxide scrubber canisters Page 17 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 PARTS LIST 7 1 Assembly ITEM QTY PART NUMBER DESCRIPTION REF B7 07 2401 00 0 BioPak 240R Respirator EN FR BW P REF B7 07 2401 02 0 240R Respirator EN FR GR P REF B7 07 2401 06 0 BioPak 240R Respirator EN ST BW P REF B7 07 2401 08 0 BioPak 240R Respirator EN ST GR P REF B7 07 2401 09 0 BioPak 240R Respirator EN FR GR P REF B7 07 2401 14 0 BioPak 240R Respirator EN ST BW B REF B7 07 2401 15 0 BioPak 240R Respirator EN FR BW B REF B7 07 2401 16 0 240R Respirator EN ST GR B REF B7 07 2401 17 0 BioPak 240R Respirator EN FR GR B 2a 1 B2 06 6002 32 0 PRO Facemask Assembly See Section 7 2
17. Tube O Ring Demand Add Tube O Ring 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 01 407 1 00 0 2 Bypass valve spring item 14 is to install between the bypass 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 28 of 41 150 3000 50 3500 4000 psi OXYGEN ONLY USE NO OIL psi bar Gauge Dial Face Item 11a BioPak 240R Benchman Manual A47D257 Revision BIOPAK NS OXYGEN ONLY USE NO OIL P bar Gauge Dial Face Item 11b Page 29 of 41 ONS gt MARIN OXYGEN ONLY P USE NO OIL N MPa Gauge Dial Face Item 11c BioPak 240R Benchman Manual A47D257 Revision 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 Fittings Item 5 are supplied on spare tube assemblies 2 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 i
18. ask in the field due to required conditions for installation Page 21 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 4 Mask Breathing Hose ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5003 03 0 PRO Breathing Hose Set 1 2 B2 02 7001 09 0 Breathing Hose 2a 2 B2 06 6002 19 0 Turn Key Clamp 19 44mm 2b Opt B2 06 6000 01 0 Worm Gear Clamp requires tool to operate 3a 2 B2 06 6002 30 0 Turn Key Clamp 32 57mm 3b Opt 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 4 04 7060 25 0 Mask Adapter O Ring 6 2 B2 02 7001 11 0 Check Valves Note 1 Complete Breathing Hose Set includes all depicted items 2 The Mask Adapter Assembly includes the check valves and o ring 3 Lubricate the O Ring with Dow 111 prior to use 4 NOT lubricate the check valves 2b m 9 Y 2a Page 22 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 5 AV3000 Mask Breathing Hose ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5002 73 0 AV3000 Breathing Hose Set 1 2 B2 02 7001 09 0 Breathing Hose 2a 2 B2 06 6002 19 0 Turn Key Clamp 19 44mm 2b Opt B2 06 6000 01 0 Worm Gear Clamp requires tool to operate 3a 2 B2 06 6002 30 0 Turn Key Clamp 32 57mm 3b Opt B2 06 6001 60 0 Stepless Ear Clamp requires tool to operate 4 1 B6 02 5002 25 0 AV300 Mask Adapter Assembly 5 1 B2 06 6001 34 0 Facemask Adapter Gasket 6 2 B2 02 7001 11
19. constant add feed line to the center section smaller of the two pneumatic connections and connect the test flowmeter from the service kit to the open end of the feed line 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 gt 1600 bar 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 4 Close the oxygen cylinder valve remove the test flowmeter and reconnect the constant add feed line to the center section 3 9 Low Pressure Leak Test 1 Remove the storage plug from the breathing hoses and install the leak test adapter from the service kit Page 10 of 41 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 of 3 5 water
20. dentified by RED band Pressure Switch supplied installed into block x 4 EN Assembly identified by BLACK Hex Socket P di 2 SEE DETAILA 3 Extension Fitting 37 supplied installed into block DETAIL A RESTRICTOR SCREW Safety Relief Valve supplied installed into block Page 30 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 11 Alarm Monitor ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 01 5000 05 0 Monitoring System Complete 1 2 3 4 1 B6 02 5002 51 0 Battery Door Complete 1 1 B2 02 1300 20 0 Battery Door 2 1 B2 02 7001 16 0 Battery Door Gasket 3 1 B2 02 4001 11 0 Battery Door Warning Label 4 2 B2 02 3000 07 0 Battery Door Captive Screw 5 1 B1 14 2000 00 0 9Vdc Battery 6 1 B1 10 3000 03 0 Temperature Sensor Cable not depicted 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 1604 Page 31 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 12 Oxygen Cylinder Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5001 98 0 Green Cylinder Assembly Empty REF 1 B6 02 5001 98 1 Green Cylinder Assembly Full REF 1 B6 02 5002 06 0 Black White Cylinder Assembly Empty REF 1 B6 02 5002 06 1 Black White Cylinder Assembly Full 1 1 2 01 2000 06 0 Green Cylinder 1b 1 B2 01 2000 06 1 Black White C
21. e 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 System 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 conta
22. ents Page 7 of 41 BioPak 240R Benchman Manual A47D257 Revision 3 TURN AROUND MAINTENANCE PROCEDURE 3 1 Maintenance Tag BIOPAK 240 REVOLUTION TURNAROUND MAINTENANCE TAG UNIT c 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 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 supplied with the service kit 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 gaskets 8 Remove the moisture sponges and the POM if used 9 Disconnect the electrical line and both pneumatic c
23. et 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 Tube Regulator Support Plate Oxygen Knob Reatining Bracket 1 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 33 of 41 BioPak 240R Benchman Manual A47D257 Revision Page 34 of 41 Service Kit Assembly QTY Ba c Bae Aap BioPak 240R Benchman Manual PART NUMBER B6 02 5002 16 0 B6 02 5002 57 0 B6 02 5002 56 0 B6 02 5002 15 0 B6 02 5000 17 2 B2 03 3000 01 0 B6 02 5002 35 0 B2 02 5400 04 0 B2 03 1000 10 0 B2 03 1000 15 0 B2 03 1000 03 0 B2 03 1000 16 0 B2 03 1000 17 0 B2 03 1000 09 0 B2 03 1000 12 0 B2 03 1000 04 0 B2 03 1000 06 0 B2 03 1000 13 0 B2 03 1000 05 0 B5 01 3000 03 0 B2 02 7001 28 0 B4 02 6037 00 0 B2 03 1000 20 0 B2 03 3000 08 0 B2 03 1000 21 0 B6 02 5003 00 0 A47D257 Revision DESCRIPTION Tool Test Kit Complete Replacement Case Assembly AV3000 Lea
24. g and service contracts can be provided by contacting Training amp Technical Support Services 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 Page 4 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 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 5 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
25. he breathing apparatus must be medical or aviation grade oxygen with a moisture content less than 50 mg m at 207 bar The composition of suitable oxygen is given below Oxygen 99 596 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 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 Workload high work rates will increase consumption rates of oxygen 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
26. ided in the service kit e Unless otherwise directed do not lubricate o rings while they are still seated within their gland e Donotuse heavy coats of lubrication Proper o ring lubrication will result in a shiny surface without lumps e Donotstretch 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 and Dow 1117 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 oylinder 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 Cylinders that have been hydro static testing 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 Procedure 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 ho
27. inment 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 independent 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 80 dB horn located on the monitor package Condition Alarm Action System Ok Flashing Green System Fault Flashing Red Horn Sounding End of Service Life Flashing Red Horn Sounding No Coolant Ice Flashing Blue Low Battery Flashing Red Green Blue Horn Sounding Page 6 of 41 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 c
28. k Check Adapter Fitting Flow Test Fixture Test Key Tool Vent Valve Hand Wrench Center Section Port Plug Regulator Wash Plug Combination Pick Tool 00 Phillips Head Screwdriver 1 Phillips Head Screwdriver 2 Phillips Head Screwdriver 7 Hex Driver 3 16 Nut Driver 5 16 Nut Driver 3 8 x 5 16 Open End Wrench 7 16 Combination Wrench gt Combination Wrench 5 8 x 9 16 Open End Wrench Oxygen Safe Leak Tec Leak Detection Fluid 8 ounces Tool Pouch 3 8 OD Rubber Tubing Stop Watch not depicted Bypass Valve Tool not depicted 9 32 Nut Driver PRO Leak Check Adapter Fitting 1 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 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 35 of 41 BioPak 240R Benchman Manual A47D257 Revision Page 36 of 41 7 15 ITEM REF WN BioPak 240R Benchman Manual A47D257 Revision Coolant Canister Freeze Form QTY PART
29. leted 2 Verify that the apparatus oxygen cylinder is fully charged to 207 bar and top off if necessary 3 Replace the upper housing Page 14 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 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 Never pry o rings from glands with a screwdriver Remove o rings by hand or using the pick tool prov
30. likely to be encountered Please refer to National Regulations for guidance Adequate protection may not be provided in certain highly toxic atmospheres The apparatus must be tested and serviced in accordance with the BioPak 240R Benchman Manual 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 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 The apparatus is not designed for use underwater The harness must not used as a vehicle seat fall arrest restraint Replacement of the alarm system battery shall be performed in area atmospheres known to be safe and non explosive 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 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 3 of 41 BioPak 240R Benchman Manual A47D257 Revision 1 INTRODUCTION 1 1 Breathable Oxygen Oxygen used to supply or charge t
31. n Manual A47D257 Revision 7 2 Facemask Assembly ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5003 09 0 PRO Facemask Assembly Complete 1 1 B6 02 5002 99 0 BioPak PRO Facemask Adapter Complete 2 3 B3 01 1051 00 1 M4 x 12mm Locking Screws 3 1 B2 02 3300 69 0 Cowling 4 1 B6 02 5003 02 0 Hand Wheel Assembly 5 1 B2 02 3300 68 0 Retaining Clip 6 1 B2 02 4001 54 0 Push Button 7 1 B2 02 7100 22 0 Seal Ring 8 1 B2 06 6002 31 0 Magnetic Wiper 9 1 B2 06 6001 70 0 Tote Bag not depicted Note 1 complete Facemask Assembly includes the facemask itself plus the complete Adapter 2 complete Adapter includes parts 2 through 7 3 Coat the Seal Ring with Dow 111 lubricant before use 4 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 20 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 3 AV3000 Facemask Assembly ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5002 09 3 AV3000 Facemask Small REF B6 02 5002 09 4 AV3000 Facemask Medium REF B6 02 5002 09 0 AV3000 Facemask Large 1 1 B2 06 6001 70 0 Storage Bag not depicted 2 1 B2 06 6002 31 0 Magnetic Lens Wiper Note 1 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 m
32. ne 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 Remove the upper housing 2 Use the hex driver from the service kit to the remove the flow restrictor 3 Use the 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 5 6 Factory Service and Training 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 provide 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 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
33. onnections to the center section 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 after each use 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 coolant lids and all connected components with a mild soap and water mixture if necessary 2 Mixthe 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 4 Thoroughly rinse all components in clean water to remove all disinfection solution 5 Allow all components to dry either by air drying oven drying or through the use of the Biomarine dryer system Oven drying temperatures shall not exceed 50 C 6 Date and initial the maintenance tag under Washed Disinfected Page 8 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 2 Place the freeze forms onto a level surface in a
34. overed with a permanent anti fog film that will not require the application of any anti fog spray or wipe All facemasks connect to the apparatus via a push button bayonet hose connection Speech diaphragms are provided with each facemask types The polycarbonate visors of all facemasks conform to EN 166 Grade B for impact BioPak 240R Benchman Manual A47D257 Revision resistance 2 9 Optional Attachments Contact Biomarine or your local distributor for additional details and supply Hydration systems provide the wearer with a source of drinking liquid without breaking the seal of the breathing loop to the external atmosphere Hydration System Facemask magnetic wipers provide single hand wiping of the internal and external facemask lens to remove dirt condensation and fogging Wipers are provided with all masks Magnetic Wiper Anti crush rings provide breathing hose crushing and restriction protection Anti crush rings are provided with all BioPaks Keviar breathing hose covers provide additional abrasion Anti Crush Rings protection to breathing hoses Radiant heat guards provide additional breathing hose protection against high radiant heat and direct flame contact Phase Change Module PCM Radiant heat Guard 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 PCM Module of optional attachm
35. r 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 13 of 41 BioPak 240R Benchman Manual A47D257 Revision 4 7 Emergency Bypass Valve 4 9 Maintenance Tag Validation Functional Test 1 Open the oxygen cylinder and depress the emergency bypass valve for 1 2 seconds The of gas escaping into the BIOPAK 240 REVOLUTION breathing shall be heard whenever the TURNAROUND MAINTENANCE TAG valve is depressed and shall cease UNIT NO 246 whenever the valve is released 2 Close the oxygen cylinder re dag O2 CYLINDER REPLACEDIFILLED 0 2411 4 8 Alarm Test FLOW TEST 8 Ipm 1 Perform the test as described in REPLACED 3 Section 3 10 ANTI FOGGING AGENT APPLIED i ICE BAG PLACED IN FREEZER 5 LOW PRESSURE LEAK TEST N WARNING INSTALL FROZEN ICE BAGS 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 PA TO PROPERLY USE AND MAINTAIN TH on 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 comp
36. re packed carbon dioxide scrubbers may only be stored in the apparatus for a period no long than 1 year Apparatus 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 1 Inspect the expiration date of the carbon dioxide scrubber to ensure that itis not expired Record the carbon dioxide scrubber serial number onto the rear of the maintenance tag 2 Verify that each carbon dioxide scrubber canister has an o ring installed Page 11 of 41 BioPak 240R Benchman Manual A47D257 Revision Install two carbon dioxide scrubber canisters into the breathing chamber making sure that they are proper aligned and fully seated into position Install and secure the breathing chamber lid Date and initial the maintenance tag under CO2 Cartridges Replaced Page 12 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 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
37. rn sounding whichever occurs first 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 Page 15 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 alarm housing into the apparatus 9 Usetwo 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 li
38. sure gauge will reach full reading in approximately 60 seconds 4 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 Dateandinitial the maintenance tag under O2 Cylinder Replaced Filled 3 11 Upper Housing 1 Replace the upper housing onto the apparatus 2 Ifthe 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 Pre packing the BioPak 240R with the carbon dioxide scrubbers is only permitted when utilizing the Biomarine carbon dioxide scrubber Pre packing the BioPak with the ExtendAir carbon dioxide scrubber may lead to corrosion of the breathing chamber The Biomarine carbon dioxide scrubbers can be pre packed into the apparatus during turn around maintenance if so desired P
39. t Body O Ring 4 1 B2 02 4100 03 0 Vent 5 1 B4 04 7060 04 1 Vent Seat O Ring 6 1 B2 06 6001 53 0 Vent Valve Spring 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 1 1 0 prior to installation 2 Install Vent Body item 4 hand tight 2 3 RUBBER 2 7 22222 ZA X 24 SOA NEC IN 4 2 7 METAL 4 1 2 Page 27 of 41 BioPak 240R Benchman Manual A47D257 Revision 7 9 Pneumatic Assembly ITEM QTY PART NUMBER REF 1 1 1 6 02 5002 31 0 2 1 6 02 5002 32 0 3 1 B6 02 5002 30 0 4 1 B6 02 5002 03 1 5 1 B6 02 5002 02 1 6 1 B4 04 5000 00 0 7 1 B4 04 5570 00 0 8 1 B6 02 5002 00 1 9 1 B6 02 5002 26 1 10 1 B6 02 5002 43 0 11 1 B6 02 5002 45 0 11b 1 B6 02 5002 45 4 11 1 6 02 5002 45 2 12 1 6 02 5002 44 0 13 1 4 04 0030 00 0 14 1 2 02 3300 14 0 15 1 4 04 7070 02 1 16 1 4 04 7070 00 1 Note DESCRIPTION Pneumatic Assembly Bypass Feed Tube Bypass Return Tube Oxygen Feed Tube Constant Add Center Section Feed Tube Demand Add Center Section Feed Tube Bypass Valve Push Button Bypass Valve Manifold Assembly See Section 7 10 Oxygen Regulator Assembly Remote Gauge Shut Off Valve Assembly Remote Gauge Assembly psi bar Remote Gauge Assembly bar Remote Gauge Assembly MPa Remote Gauge Feed Tube Assembly Cylinder Seal Washer Bypass Valve Spring Constant Add
40. y PRO Breathing Hose AV3000 Breathing Hose Center Section Lid Center Section Diaphragm Pneumatic Assembly Manifold Assembly Alarm Monitor Oxygen Cylinder Lower Housing Service Kit Coolant Canister Freeze Form Miscellaneous Supplies Optional Attachments 8 APPARATUS SPECIFICATIONS 9 MAINTENACE LOG SHEET Page 2 of 41 ODDDDDADSH 40o000001001Q C BioPak 240R Benchman Manual A47D257 Revision WARNINGS 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 certifying authority requirements and apply to the use of breathing apparatus in general Breathing apparatus user must be fully trained in the use and care of closed circuit self contained compressed oxygen breathing apparatus Ensure that the selection of the apparatus type is sufficient for the tasks being undertaken and the hazards
41. ylinder 2 1 B4 04 7060 00 0 Exterior O Ring 3 1 B2 02 3300 52 1 Valve Collar 4 1 B4 04 7060 07 2 Interior O Ring 5 1 B6 02 5001 97 0 Valve Assembly Note 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 numbered Item 2 through Item 4 The Valve Assembly shall be installed into the cylinder at a torque of 60 1 foot pound Page 32 of 41 7 13 OOK WN BioPak 240R Benchman Manual A47D257 Revision Lower Housing Assembly QTY NAN NNN NMA OAN AW aa 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 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 Brack
42. ystem 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 Drier B6 02 5002 86 3 The Drier will provide a means to dry up to six BioPaks at a time Drier requires 240VAC power 115 VAC power is also available Contact Biomarine for full details Page 39 of 41 BioPak 240R Benchman Manual A47D257 Revision 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 Self Contained Closed Circuit Pressure Demand Certified as entry and escape 4 hour duration 584 x 439 x 178 mm 15 4 kg Maximum Temperature 5 C to 60 C 4 hour duration 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 Minimum Emergency Add 80 lpm 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
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