EN User Manual-Revision F - BioPak 240 Revolution 4
Contents
1. BIOP AK 2H4oO FR E2 VV Q J VION BioPak 240R Closed Circuit Self Contained Breathing Apparatus User Instructions CE ia A47D256 Revision F B5 06 6000 22 0 April 2012 BioPak 240R User Instruction Manual A47D256 Revision F Contents WARNINGS 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 9 Oxygen Delivery System 2 6 Oxygen Cylinder 2 7 Alarming System 2 8 Facemasks 2 9 Optional Attachments PREPARATION FOR USE 3 1 Maintenance Tag Inspection 3 2 Facemask Preparation 3 3 Moisture Sponge Preparation 3 4 PCM Installation 3 5 Carbon Dioxide Scrubber Installation ExtendAir 3 6 Carbon Dioxide Scrubber Installation Biomarine 3 7 Coolant Canister Installation DONNING THE APPARATUS 4 1 Donning the Apparatus 4 2 Donning the Facemask 4 3 Activate Oxygen Supply PRACTICAL USE 5 1 Breathing the Apparatus 5 2 Speaking 53 Alarming System 5 4 Coolant Replacement 5 9 Emergency Bypass 5 6 Emergency Operation Oil Facemask Fogging DOFFING THE APPARATUS 6 1 Doffing Instructions APPARATUS SPECIFICATIONS Page 2 of 16 COTO NNNNDOODD O aR HH A OW BioPak 240R User Instruction Manual A47D256 Revision F 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 b2. 16 of 16
3. a4 FAILURE TO PROPERLY IET AMD LANTAN IHG RESPIRATOR GOULD Pau IH IMUN Ata HATH Locate and inspect the maintenance tag that should be attached to the waist belt harness of the apparatus Verify that all items on the tag are properly dated and initialed If the maintenance tag is missing or not properly completed the apparatus MUST NOT be placed into service until full turn around maintenance has been completed as specified in the BioPak 240R Benchman Manual 3 2 Mask Preparation Do not apply anti fog agents of any kind to the facemask The facemask is supplied with a permanent anti fog film that will prevent fogging Soak both chamois surfaces of the wiper pieces with anti fog or water and install onto the lens of the facemask so that the chamois side of each piece in is direct contact with the lens The wiper is to be installed with the thinnest section positioned on the inside surface of the mask 3 3 Moisture Sponge Preparation Remove the moisture sponges from the breathing chamber and wet until supple Wring out excess water and replace into the breathing chamber If the sponges are not pre wetted prior to use the breathing air to the wearer will be warmer than usual 3 4 PCM Installation If the ice canisters are not utilized then install the PCM canister into the center section on top of the moisture sponges Note that early models of the BioPak will require a modification to the center section lid for p
4. attempt to use the emergency bypass to cool the breathing gas or clear the facemask of fogging Depress in 1 2 second periods for optimal use Continued use of the emergency bypass will shorten apparatus duration 5 6 Emergency Operation Follow the procedures below in event of the described emergency situation Equipment Failure Should any component of the apparatus experience a failure or should the apparatus upper housing become dislodged the wearer shall immediately retire to safe location to doff the apparatus Gauge Line Severing Should the gauge line feeding the pressure gauge become severed the apparatus will begin to leak oxygen To stop the loss of oxygen reach back and pull up on the quick disconnect fitting to release the gauge line and seal the leak The wearer shall immediately retire to a safe location and doff the apparatus Page 14 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 5 Facemask Fogging The facemask is provided with a permanent anti fog film There should be no issues with mask fogging during use as long as the film is intact on the internal surface of the lens Some initial sheeting of water from the film may blur vision at the onset of use This sheeting is easily cleared by using the magnetic wiper supplied with the mask 6 DOFFING THE APPARATUS 6 1 Doffing Instructions 1 Retire to a known safe location and doff the apparatus DO NOT remove the appara
5. acemasks 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 e Facemask magnetic wipers provide single hand wiping of the internal and external facemask lens to remove dirt condensation and fogging Wipers are provided with every facemask Anti crush rings provide breathing hose crushing and restriction protection Anti crush rings are provided with every BioPak e Kevlar breathing hose covers provide additional abrasion protection to breathing hoses e Radiant heat guards provide additional breathing hose protection against high radiant heat and direct flame contact Page 8 of 16 BioPak 240R User Instruction Manual A47D256 Revision F e 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 eat 4G SPR a aVSLL on Page 9 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 3 PREPARATION FOR USE Prior to donning the apparatus the wearer shall conduct the following procedures to ready the apparatus for use 3 1 Maintenance Tag Inspection BIDPAK 240 REVOLUTION TUANAROUND MAINTENANCE TAG
6. adjusted to rest either on the hips or shoulders of the wearer by adjustment of the shoulder straps 4 2 Donning the Facemask 1 Check that the head harness straps are fully slackened tq i 2 Hold the head harness lower straps place chin in chin cup and pull straps over back of head brushing hair away from faceseal 3 Adjust the facemask top strap so that the mask is at the correct level with the face and the head harness pad is in the center of the back of the head then tighten harness straps in sequence Bottom Middle Top DO NOT over tighten Page 12 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 4 Depress the push button of the facemask front port and insert the breathing hose adapter into the port Release the push button and tug and the breathing hose adapter to ensure that it securely anchored 4 3 Activate Oxygen Supply 1 Reach back and turn the green oxygen knob located on the right side of the apparatus house to its full counterclockwise position 2 Inspect the pressure gauge and LED The pressure gauge shall read a minimum of 200 bar pressure to achieve full apparatus duration The TRIM monitor shall initially flash RED GREEN BLUE with the horn sounding The LED shall then flash GREEN to signal acceptable system status If after 5 10 minutes of operation if the LED flashes BLUE this is an indication to check that the coolant canisters have been installed T
7. ained 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 EN 60079 11 2007 01 01 Explosive Atmospheres Part11 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 e IEC 60079 11 2006 07 01 Ed 5 Explosive Atmospheres Part 11 Equipment protection by intrinsic safety I CORR 2006 12 08 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 BioPak harness is provided as a padded harness to increase wearer comfort The flame retardant harness
8. ask to the wearer s face The apparatus is not designed for use underwater The harness must not be used as a vehicle seat or 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 16 BioPak 240R User Instruction Manual A47D256 Revision F 1 INTRODUCTION 1 1 Breathable Oxygen 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 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
9. ation accessory identification and BioPak factory service Page 5 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 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 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 Respiratory protective devices Full face masks e EN 145 2000 Respiratory protective devices Self cont
10. ed 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 Condition Alarm Action system Ok Flashing Green System Fault Flashing Red Horn Sounding End of Service Life Flashing Red Horn Sounding Ice Reminder Flashing Blue Flash Red Green Blue Horn Sounding Low Battery Page 7 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 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 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 f
11. his is a self cancelling alarm that will return the LED to flashing GREEN after 5 minutes DO NOT take the apparatus into service if the pressure gauge or TRIM indicator is not functioning as described above or if the TRIM indicator is flashing RED 3 With two hands collapse the inhalation hose and inhale Proper sealing of the exhalation check valve will result in the facemask being pulled in toward the face 4 With two hands collapse the exhalation hose and exhale Proper sealing of the inhalation check valve will result in the facemask being pushed away from the face DO NOT take the apparatus into service if the check valves do not pass the tests of steps 3 and 4 en 5 Depress the red emergency bypass for 1 2 seconds and release Verify the sound of oxygen gas additions into the breathing chamber while the button is depressed and that the oxygen additions cease when the button is released DO NOT take the apparatus into service if the emergency bypass valve does not pass the above test Page 13 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 5 PRACTICAL USE 5 1 Breathing the Apparatus There is no need to accelerate or deepen normal breathing rates The apparatus will automatically adjust oxygen additions to match the needs of the user 5 2 Speaking The facemasks are provided with speaking diaphragms that will transmit sound from the interior of the facemask to the external sur
12. ion of the BioPak Recommended Safe Duration with Respect to Ambient Temperatures The apparatus should be utilized with the coolant canisters installed for high ambient temperatures Recommended apparatus duration of use with the coolant canisters installed Ambient Recommended Temperature Safe Duration 40 60 C 4 hours 60 90 C 1 hour 90 C 15 minutes Page 11 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 4 DONNING THE APPARATUS 4 1 Donning the Apparatus Specialist Users such as Emergency Services may operate alternative donning procedures that conform to the relevant statutory regulations 1 Check that the shoulder and waist harness straps are fully slackened 2 Pass right arm through the shoulder strap and repeat for the left arm Ome 3 Bend over and pull down on the two shoulder strap adjustments to position the apparatus on the shoulders 4 Connect the waist belt straps together and pull the adjust straps forward to snug the apparatus to the hips 5 Connect and adjust the harness chest strap 6 Position and secure the pressure gauge to the magnet of the shoulder strap and secure with the snap strap An alternative magnetic location is positioned on the waist belt 7 Flip the breathing hoses over the shoulders and secure hose to the harness using the hose straps Position of the hose straps can be adjusted for optimal head movement The apparatus can be
13. 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 6 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 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 System Oxygen will be delivered from the oxygen cylinder to the breathing loop through a pressure regulato
14. 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 e Workload high work rates will increase consumption rates of oxygen e Facemask Seal poor seal of mask will result in system leaks and high oxygen consumption rates e Physical Fitness of Wearer e 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 Se
15. r 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 ata 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 independent and redundant system status indications The pressure gauge is mounted on the harness and retain
16. reathing 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 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 facem
17. roper PCM fit Om a reaa Seve elroy Page 10 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 3 5 Carbon Dioxide Scrubber Installation ExtendAir POA AUN ANIL AN AUN f Use By Se ptember 48 2012 WNW TULA YT AML oe 1h S Use By September 18 2012 Inspect the expiration date of the carbon dioxide scrubber to ensure that it is not expired Record the serial number of the scrubbers onto the back of the maintenance tag Install two 2 gaskets and carbon dioxide scrubbers into the breathing chamber Each scrubber shall be installed with the red end visible in the breathing chamber Do not use any scrubber that is missing the red end cap Replace the center section lid of the breathing chamber and lock to secure 3 6 Carbon Dioxide Scrubber Installation Biomarine ees Inspect the expiration date of the carbon dioxide scrubber to ensure that it is not expired Record the serial number of the scrubber onto the back of the maintenance tag Verify that each scrubber housing contains an o ring seal and install each into the breathing chamber making sure that each scrubber is fully seated and properly aligned 3 7 Coolant Canister Installation Remove the coolant lids from the center section lid and insert a fully frozen ice canister into each location Replace the coolant lids Coolant canisters are to provide wearer comfort but are not required for certified operat
18. rounding environment Speak slightly louder and slower than normal making every effort to clearly pronounce words Do not shout Optional voice amplification devices can be attached to the facemask prior to donning to enhance clarity of speech Contact Biomarine or your local distributor for details and supply 5 3 Alarming System The wearer should frequently inspect the pressure gauge and LED throughout the duration of the mission Should the pressure gauge indicate pressure in the RED colored area of the gauge the end of service life of the apparatus is near and the wearer shall retire to a safe location as quickly as possible to doff the apparatus Should the LED flash RED and or the horn sounds the wearer shall retire to a safe location as quickly as possible to doff the apparatus 5 4 Coolant Replacement If the breathing air becomes uncomfortable to the wearer the coolant canisters can be replaced without doffing the apparatus or breaking into the breathing loop Replacement of the ice canisters while wearing the apparatus will require assistance 1 Remove the coolant covers from the breathing chamber lid 2 Remove the spent coolant canisters from the breathing chamber lid 3 Install replacement fully frozen coolant canisters into the breathing chamber lid 4 Replace the coolant lids to the breathing chamber lid 5 5 Emergency Bypass The emergency bypass is for emergency use only DO NOT
19. rvices 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 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 4 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 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 identific
20. tus until well clear of the hazardous area If wearing a gas tight chemical suit DO NOT remove until decontamination procedures are complete To prevent the growth of germs bacteria and mold conduct turn around maintenance on the apparatus as quickly as possible Page 15 of 16 BioPak 240R User Instruction Manual A47D256 Revision F 7 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 6 C to 60 C 4 hour duration mission 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 lom Average Demand Add 80 Ipm 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 Solid Core canisters Non dusting Non settling Non channeling gt 6 0 liters Page
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