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NIOSH-Benchman Manual-Revision M

1. 1 T SONNI ppsie spe sw 2 5 a 84 25 9454 94 25 14 oooc NIW Ovt SONNY CAUTIONS AND LIMITATIONS porav on B47CO15 Anti Fog Hydration System Kit D47003 ACCESSORIES Wiper MONITORING 0470014 ALTERNATE HARNESS ASSEMBLY Non Flame Rated D47CO14 0 x isi 3500 Medium D47C054 02 E s 500 Small D47C054 0 ALTERNATE 047 013 0 47 013 02 047 013 0 047 012 FULL FACEPIECE Facepiece Spectacle 000 Medium North American ExtendAir 3000 Large ALTERNATE OXYGEN CYLINDER HEAT EXCHANGER BREATHING HOSE PROTECTION PNEUMATIC ASSEMBLY ALTERNATE CARBON DIOXIDE ABSORBENT SININOdWOD 5 JHL NI AINO GIAOUddY JUV SuOTVHIdS3H JS3HL ONIHLV9Y 8 3135 247253 ONY LIN IUI GISOTD R aotz HOP Ze dOtg 2088 75 019 Xv 1 0088 125 019 yyeay pue jeuonedn20 T gt VSN ZEST TREGT Vd NOLXJ 956 8 2 2 e Page 4 of 45 BioPak 240R Benchman Manual A47D135 Revision M xtendAir Carbon Dioxide Chemical Scrubber NIOSH Approval Label BIOMARINE INCORPORATED 456 CREAMERY WAY EXTON PA 1
2. US DOT E11194 per DOT CFFC Standards Transport Canada TC SU 5303 At ambient temperature above 40 F 4 C 200 hours or 6 months 1 Operating temperature range provided above is the standard 4 hour duration with PCM installed For extreme temperature ranges the BioPak should be configured with ice coolers and utilized as directed below Ambient Temperature 105 to 140 F 41 to 60 C 141 to 194 F 61 to 90 C 194 F 90 C Recommended Safe Duration of Use 1 hour 15 minutes 6 minutes The above temperature duration figures are derived from human endurance limits and not from the endurance limit of the BioPak Page 42 of 45 BioPak 240R Benchman Manual A47D135 Revision M 7 MAINTENANCE LOG SHEET BioPak Model BioPak 240R BioPak Serial Number Long Term Maintenance vv o gt L 28 S le amp z Be Date 5 z gt 9 gt Comments Benchman Signature 1388 8 2 8 27158 8 m oO ww x G t 5020155 gt sr 34 Da ae lt gt 43 45 BioPak 240R Benchman Manual A47D135 Revision M 8 WARRANTY Biomarine warrants subject to the terms below that the goods will be free from defects in design materials and w
3. 1 Perform the test as described in Section 1 9 2 6 High Pressure Leak Test Place the apparatus on a flat surface Ensure that the test keys of the Low Pressure Leak Test have been removed The oxygen cylinder must be fully charged to above 1500 psi 103 bar 2 Open the oxygen oylinder valve and wait until the apparatus pressure gauge has reached its final reading 3 Inspect each plumbing connection with oxygen safe leak detection fluid by wetting each joint waiting 60 seconds then inspecting each joint for the sign of bubble formation The presence of bubbles will indicate a leak 4 Repair any leaking joint or replace the leaking components Repairs must be performed with the BioPak fully vented of all internal pressure 5 Close the oxygen cylinder valve and depress the emergency vent valve to depressurize the apparatus Page 15 of 45 BioPak 240R Benchman Manual A47D135 Revision M 2 7 Emergency Bypass Valve Functional Test 1 Open the oxygen cylinder and depress the emergency bypass valve for 1 2 seconds The sound of gas escaping into the breathing shall be heard whenever the valve is depressed and shall cease whenever the valve is released 2 Close the oxygen cylinder 2 8 Alarm Test 1 Perform the test as described in Section 1 10 2 9 Maintenance Tag Validation 470138 REV B 03 2013 ET BIOPAK 240 REVOLUTION TURNAROUND MAINTENANCE TAG UNIT NO 0051246 WASHED DIS
4. 3 Install two carbon dioxide scrubber canisters into the breathing chamber making sure that they are proper aligned and fully seated into position Proper alignment of the scrubbers will have the canister arrows directed at the center point of the center section 4 Install the moisture pad supplied with the canister into the center section as depicted below WARNING Failure to install the moisture pad will result in scrubber flooding and caused elevated carbon dioxide levels in the inhalation gas that could lead to injury or death 5 Install and secure the breathing chamber lid 6 Date and initial the maintenance tag under CO2 Cartridges Replaced Record the expiration date of the scrubber onto the maintenance tag The expiration date of pre packed carbon dioxide scrubbers will be the shorter time period between the following two factors 1 year from date of scrubber installation into BioPak or Use By date provided on packaging of carbon dioxide scrubber Page 14 of 45 BioPak 240R Benchman Manual A47D135 Revision M 2 Long Term Maintenance Procedure In addition to normal turn around maintenance the apparatus shall be visually inspected and pressure tested on a monthly basis if the apparatus is being used at least once per month or quarterly if the apparatus is used less than once per month or is in long term storage BioPaks that have been placed in long term storage should have the Long Te
5. Pressure Switch amp Fittings 2 1 B6 02 5002 50 0 Flow Restrictor Assembly Complete 3 5 B4 03 5203 01 0 Swivel Elbow Fitting Note 1 Fittings Item 3 are supplied on spare tube assemblies 2 Manifold assembly mounts to lower housing BioPak using two each of 6 x 3 8 screws B3 01 1061 01 1 and tooth washers B3 03 3063 00 0 2 Pressure Switch E supplied installed into block di See Detail Li DETAIL SCREW Extension Fitting supplied installed into block Page 32 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 11 RMS Alarm Monitor ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 01 5000 05 0 Monitoring System Complete 1 1 B6 02 5002 51 0 Battery Door Complete 2 1 B1 14 2000 00 0 9 Battery 3 1 B1 10 3000 03 0 Temperature Sensor Cable Note 1 Only the below listed battery types are suitable for use in the Monitoring System Use of any other battery type will void intrinsic safety rating and certification Energizer 522 Panasonic 6AM6 Rayovac 1604 Duracell 1604 Center Section Port Manifold Port Regulator Port My Light Guide Port Alarm Horn Main Housing 1 33 45 BioPak 240R Benchman Manual A47D135 Revision M 5 12 Oxygen Cylinder Assembly ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5001 98 0 Green Oylinder Assembly Empty REF 6
6. 02 5001 98 1 Green Cylinder Assembly Filled REF B6 02 5002 06 0 Black White Cylinder Assembly Empty REF B6 02 5002 06 1 Black White Cylinder Assembly Filled 1 2 01 2000 06 0 Green Cylinder 1b 1 B2 01 2000 06 1 Black White Cylinder 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 6a 1 2 06 6001 38 0 Pressure Gauge Lens Cover WIKA 6b 1 2 06 6001 40 0 Pressure Gauge Lens Cover Ametek 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 3 Filled cylinder assemblies can not be shipped from Biomarine to locations outside the borders of the United States of America _ 1a OR 1b 34 45 BioPak 240R Benchman Manual A47D135 Revision M 5 13 Lower Housing Assembly ITEM QTY PART NUMBER DESCRIPTION 1 1 B6 02 5002 28 0 Lower Housing Shell 2 3 B2 02 3300 46 0 Diaphragm Springs 3 1 B2 02 4000 68 0 External Oxygen Knob 4 2 B3 01 1071 03 0 Harness Waist Belt Fastening Screws 5 4 01 0008 00 0 Center Section Hold Down Pins 6 8 B3 03 1073 00 0 Harness Mounting Washers 7 1 B2 02 1300 27 0 Vent Spacer 8 2 B3 01 1063 00 0 Vent Spac
7. PROPERTY DAMAGE OR ANY FINANCIAL LOSS Any description of the goods contained in any documents to which these warranty provisions related including any quotations or purchase orders relating to the goods being delivered to buyer are for the sole purpose of identifying the goods and any such description as well as any sample or model which may have been displayed to or seen by buyer at any time have not been made part of the basis of the bargain and have not created or amounted to any warranty express or implied that the goods would conform to any such description or any such sample or model EXCEPT AS SPECIFICALLY SET FORTH IN THESE WARRANTIES BIOMARINE MAKES NO WARRANTIES EXPRESS OR IMPLIED WHETHER ARISING BYLAW CUSTOM CONDUCT OR USAGE OF TRADE INCLUDING WARRANTIES AS TO MERCHANTABILITY OR AS TO THE FITNESS OF THE GOODS FOR ANY PARTICULAR USE OR PURPOSE AND ANY WARRANTIES INCLUDING WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR PARTICULAR USE OR PURPOSE AND THE RIGHTS AND REMEDIES PROVIDED HEREIN ARE EXCLUSIVE THESE WARRANTIES SHALL RUN TO THE BUYER ONLY AND SHALL NOT BE CONSTRUED AS A CONDITION Biomarine does not warrant that the goods are free from the rightful claim of any third person by way of infringement or patents or other proprietary information or disclaims any warranty against such infringement The terms of these warranties shall apply to the product sold by Biomarine except absorbent filters batteries and anti fog l
8. apparatus Install the PCM into the breathing chamber Install the center section lid and latch to secure If pre packing the carbon dioxide scrubbers complete section 1 12 then return to step 7 of this section Install the breathing hoses to the breathing chamber and secure with clamps making sure mask connector is sitting flat and the flow direction arrows of the connector are facing up Install the storage plug into the facemask connector Install the oxygen cylinder and secure with the hold down strap 1 8 1 Constant Flow Test Disconnect the 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 Open oxygen cylinder valve and observe flowmeter while holding it ina 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 5280 feet 1600 meters and above 5280 feet 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 5280 ft 5280 ft psi lpm lpm 1500 2000 1 8 2 4 1 9 2 6 2000 3000 1 9 2 5 2 0 2 8 Cylinder Flow Flow Pressure 0 1600m 1600m bar Ipm 100 150 1 8 2 4 1 9 2 6 150 207 1 9 2 5 2 0 2 8 3 Enter the measure
9. be completed as directed in this procedure and then attached to the apparatus in a prominent location to show completion of all maintenance steps Record the apparatus identification onto the tag 1 2 Disassembly Immediately after completion of BioPak use remove the used CO2 scrubber canisters scrubber moisture pad and disconnect the demand and constant add lines to the center section to prevent migration of moisture into the manifold assembly Disassemble the apparatus to prepare for cleaning and disinfection Identify 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 It is acceptable to leave the oxygen cylinder in place until after washing and disinfecting has been completed to prevent ingress of contaminates into the high pressure plumbing of the BioPak 4 Remove the facemask from the breathing hoses 5 Remove the breathing hoses from the breathing chamber 6 Remove the center section lid 7 Remove and discard the two carbon dioxide scrubber components and the scrubber moisture pad 8 Remove the moisture sponges and the PCM 9 Disconnect the electrical line and both pneumatic connections to the center section Use ca
10. if a leak is detected in order to locate the leak but leak detection fluid is not required for initial testing Page 41 of 45 BioPak 240R Benchman Manual A47D135 Revision M 6 APPARATUS SPECIFICTIONS Respirator Type Respirator Duration Size Weight Fully Charged Self Contained Closed Circuit Pressure Demand Certified as entry and escape 4 hour duration 23 0 x 17 3 x 7 0 inches 584 x 439 x 178 mm 34 pounds 15 4 kg Operational Conditions Temperature 5 F to 104 F 20 C to 40 C Storage Conditions Oxygen Delivery Oxygen Supply Battery Carbon Dioxide Scrubber Tidal Volume Apparatus Approval Monitor Approval Cylinder Approval Expected Battery Life Note Relative Humidity 0 to 100 Temperature 40 to 90 F 4 C to 32 C Relative Humidity 30 to 100 Constant Add 1 8 lpm Average Demand Add 80 lpm 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 300 psig 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 NIOSH TC 13F 541 AV3000 Mask NIOSH TC 13F 684 AV3500 Mask MSHA 18 A060028 0
11. pressure 2 Use the hex driver from the service kit to the remove the flow restrictor Be sure to remove and discard the existing head gasket of the existing flow restrictor 3 Use the 14 hex driver from the service kit to the install a replacement flow restrictor Use caution when installing the flow restrictor to insure that o ring does not roll out of its gland 4 Perform the high pressure leak test as directed in long term maintenance 5 Perform the constant add test as directed in turn around maintenance 6 Replace the upper housing Page 18 of 45 BioPak 240R Benchman Manual A47D135 Revision M 3 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 The BioPak 240R NIOSH User and Benchman manuals can be supplied in electronic format upon request Biomarine Inc ATTN Service Department 456 Creamery Way Exton PA 19341 2532 USA Tel 610 524 8800 Extensions 146 or 163 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 240R 2408 240 LW etc e Apparatus Serial Number Located internal to the BioPak beneath the oxygen cylinder e Date of purchase
12. torque of 25 30 in lbs Indicated components shall be installed with no lubricant Center Section Body Assembly item 4 includes all depicted components with the exception of diaphragm item Page 27 of 45 240R Benchman Manual A47D135 Revision 11 12 213 28 45 BioPak 240R Benchman Manual A47D135 Revision M 5 8 Diaphragm Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5002 05 0 Diaphragm Assembly Complete 1 1 B6 02 5002 19 0 Flexible Diaphragm 2 1 B2 02 0000 08 0 Vent Cap 3 1 B4 04 7060 05 1 Vent Body O Ring 4 1 B2 02 4100 03 0 Vent Body 5 1 B4 04 7060 04 1 Vent Seat O Ring 6 1 2 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 CLY LF LA ALLL 2 MEN WANT gt SONS wl rd METAL NOTE A S POSITION 2 Dia feo AN ALIGN ALIGN 4 1 2 ALIGN Page 29 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 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 0 9 1 B6 02 5002 26 0 10 1 B
13. 002 60 0 B2 02 5400 04 0 2 03 1000 10 0 2 03 1000 15 0 2 03 1000 03 0 2 03 1000 16 0 2 03 1000 17 0 2 03 1000 09 0 2 03 1000 12 0 2 03 1000 04 0 2 03 1000 06 0 2 03 1000 13 0 2 03 1000 05 0 5 01 3000 03 0 2 02 7001 28 0 4 02 6037 00 0 2 03 1000 20 0 2 03 3000 08 0 2 03 1000 21 0 2 03 1000 22 0 2 03 1000 01 0 BioPak 240R Benchman Manual A47D135 Revision M DESCRIPTION Service Kit Complete Replacement Case Assembly AV3000 Leak Check Adapter Fitting AV3500 Leak Check Adapter Fitting Flow Test Fixture Test Key Tool Vent Valve Hand Wrench Demand Port Wash Plug Regulator Wash Plug Combination Pick Tool 00 Phillips Head Screwdriver 1 Phillips Head Screwdriver 2 Phillips Head Screwdriver Hex Driver 3 16 Nut Driver 5 16 Nut Driver 3 8 x 5 16 Open End Wrench 7 16 Combination Wrench V 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 Bypass Valve Tool 9 32 Nut Driver 1 8 Slotted Screwdriver 3 16 Slotted Screwdriver Replacement Case Assembly item 1 includes the service kit case complete with internal pressure gauge and associated plumbing plus external shipping box 2 Order a minimum length 6 feet of tubing Longer lengths are available upon request 3 Bypass Valve Tool item 24 is not supplied with the Service Kit The tool
14. 6 02 5002 43 0 11 1 B6 02 5002 45 0 12 1 B6 02 5002 44 0 13 1 B4 04 0030 00 0 14 1 B2 02 3300 14 0 15 1 B4 04 7070 02 1 16 1 B4 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 5 10 Oxygen Regulator Assembly Remote Gauge Shut Off Valve Assembly Remote Gauge Assembly psi bar Remote Gauge Feed Tube Assembly Cylinder Seal Washer Bypass Valve Spring Constant Add 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 4071 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 30 of 45 BioPak 240R Benchman Manual A47D135 Revision M 150 psi BIOP A OXYGEN ONLY USE NO OIL psi bar Gauge Dial Face 11a Page 31 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 10 Manifold Assembly ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5002 00 0 Manifold Assembly Complete 1 1 B6 02 5002 21 0 Manifold Block w
15. 9 0 B2 06 6002 19 0 B2 06 6000 01 0 B2 06 6002 30 0 B2 06 6001 60 0 B6 02 5002 25 0 B2 06 6001 34 0 B2 02 7001 11 0 B2 02 4101 22 0 DESCRIPTION AV3000 Breathing Hose Set Breathing Hose Turn Key Clamp 19 44mm Worm Gear Clamp requires tool to operate Turn Key Clamp 32 57mm Stepless Ear Clamp requires tool to operate AV3000 Mask Adapter Assembly Facemask Adapter Gasket Check Anti Crush Ring 1 Complete Breathing Hose Set includes all depicted items G 3b 3a The Mask Adapter Assembly item 4 includes the check valves item 6 and gasket item 5 DO NOT lubricate the check valves Anti Crush Rings item 7 are optional components that will fit over the hose convolutions to prevent hose crushing Page 25 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 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 1 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 OON OU WN OOF HP 0 1 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
16. 9341 2532 USA E a 610 524 8800 K CLEAN AIR SCRUBBER Occupational Safety and Health CHEMICAL SCRUBBER CANISTER IOSH is TC 13F 541 and TC 13F 684 CAUTIONS AND LIMITATIONS 1 Approved for use only in replacing or refilling chemical scrubber part number C47C010 2 Not approved for use after indicated expiration date 3 Do not re use scrubber materials A47C024DLd REV D 12 07 2011 rbSorb Carbon Dioxide Chemical Scrubber NIOSH Approval Label BIOMARINE INCORPORATED 456 CREAMERY WAY EXTON PA 19341 2532 USA es PHONE 610 524 8800 K CLEAN AIR SCRUBBER atone Inet POr neon CHEMICAL SCRUBBER CANISTER IOSH TC 13F 541 and TC 13F 684 CAUTIONS AND LIMITATIONS 1 Approved for use only in replacing or refilling chemical scrubber part number D47C055 2 Not approved for use after indicated expiration date 3 Do not re use scrubber materials A47C077DLb REV B 12 07 2011 Page 5 of 45 BioPak 240R Benchman Manual A47D135 Revision M Remote Monitoring System RMS MSHA Electrical Approval BIOMARINE NTRON INC 456 Creamery Way Exton PA 19341 USA Model RMS Permissible Pressure and Temperature Monitoring Device United States Department of Labor Mine Safety Health Adminstration MSHA Approval No 18 A060028 0 Tested for intrinsic safety in methane air mixtures only Warnings The battery is to be changed in fresh air only MSHA
17. Always check the BioPak 240R oxygen cylinder for a current hydrostatic test date DOT requires carbon fiber wrapped aluminum cylinders be tested by an approved facility on a 5 year cycle from the date of manufacture Cylinder inspections by the user as outlined in CGA 6 2 must be done on a regular basis Prior to each use of the BioPak 240R a fully charged oxygen cylinder a fresh charge of carbon dioxide absorbent frozen ice canisters moisture control sponges and the phase change module PCM must be installed After each use of the BioPak 240R a thorough cleaning and disinfection of the facemask breathing hoses and breathing loop must be completed in accordance with procedures provided in the BioPak 240R Benchman manual Use with adequate skin protection when worn in atmospheres that contain gases or vapors that poison by skin absorption for example hydrocyanic acid gas Do not use an unapproved facemask Use only the facemasks approved for the BioPak 240R An unapproved facemask will compromise the protection provided to the user by the BioPak 240R A good facemask seal is important to achieving full protection and duration Users should conform to MSHA NIOSH guidelines concerning facial hair and use of the facemasks A clean shaven user will significantly increase the chances of achieving an adequate face seal The on going effectiveness and reliability of any protective breathing equipment is dependent upon the user owner s standard
18. BIOP AK Ho BioPak 240R NIOSH Closed Circuit Self Contained Breathing Apparatus Benchman Manual A47D135 Revision M B5 06 6000 15 0 ECO 9652 March 2013 BioPak 240R Benchman Manual A47D135 Revision M CERTIFICATION APPROVALS Respirator NIOSH Approval Label ExtendAir Scrubber NIOSH Approval Label OrbSorb Scrubber NIOSH Approval Label RMS MSHA Electrical Approval CAUTIONS AND LIMITATIONS S SPECIAL OR CRITICAL USER S INSTRUCTIONS 1 TURN AROUND MAINTENANCE PROCEDURE WH Maintenance Tag Disassembly Cleaning Disinfection Coolant Canister Oxygen Cylinder Facemask Assembly Constant Flow Test Low Pressure Leak Test Alarm Test Upper Housing Carbon Dioxide Scrubber Pre Packing Procedure 2 LONG TERM MAINTENANCE PROCEDURE 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 Visual Inspection Demand Valve Functional Test Constant Flow Test Vent Valve Functional Test Low Pressure Leak Test High Pressure Leak Test Emergency Bypass Valve Functional Test Alarm Test Maintenance Tag Validation 3 GENERAL SERVICE PROCEDURES 3 1 3 2 3 3 3 4 3 5 3 6 Scheduled Component Inspection System Lubrication Oxygen Cylinder Alarm Battery Replacement Procedure Flow Restrictor Replacement Procedure Factory Service and Training 4 STORAGE GUIDELINES 5 PARTS LISTS 5 16 5 17 Top Assembly AV3000 Facemask Assembly AV3500 Facemask Assembly AV3500 Breathing
19. Do NOT allow the mask to soak in cleaning solutions for extended periods Extended soaking can cause delamination of the anti fog film 4 Thoroughly rinse all components in clean water to remove all disinfection solution It is extremely important to fully rinse the facemask of all cleaning solution 5 Allow all components to dry either by air drying heated drying or through the use a dryer system Heat assisted drying temperatures shall not exceed 120 F 50 C 6 Date and initial the maintenance tag under Washed Disinfected 1 4 Coolant Canister The coolant canisters must be frozen before use 1 Place the cleaned and dried canisters into the freeze form and tighten the nuts securely 2 Place the freeze forms onto a level surface in a freezer for a minimum 8 hour period at a temperature of 10 F 12 C or less 3 Date and initial the maintenance tag under Placed in Freezer 1 5 oxygen cylinder must be fully charged to 3000 psi 207 bar with oxygen before use Oxygen used to supply or charge the breathing apparatus must be medical or aviation grade oxygen with moisture content less than 50 mg m at 3000 psi 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 perio
20. Hose AV3000 Breathing Hose Center Section Lid Assembly Center Section Assembly Diaphragm Assembly Pneumatic Assembly Manifold Assembly RMS Alarm Monitor Oxygen Cylinder Assembly Lower Housing Assembly Service Kit Assembly Coolant Canister Freeze Form Miscellaneous Supplies Optional Attachments 6 APPARATUS SPECIFICATIONS Page 2 of 45 7 MAINTENANCE LOG SHEET 8 WARRANTY BioPak 240R Benchman Manual A47D135 Revision M Page 3 of 45 43 44 BioPak 240R Benchman Manual A47D135 Revision M CERTIFICATION APPROVALS Respirator NIOSH A 2 G l gt Buiuuop a10jaqsuononasug 5 195 01 Jajay Adde suoneqiuin asn 5 1950 JEINLD 10 20 896 5 5401281131 ISAL JO PUP N 10 5 Jo pue SU NSU 5 1261 01 192 0 eui Aq pay p d se uoneinfiuoo ursjjed exe 251 ppe Ja eN N suonen8a1 pue vHSO HSIA ut pue pasn pany peus sJojeaidsa ry reap 19npojd sig pue Apadosd 4 4 9 A34 ONY SNOILNWO 2 596 023 29 25 1765914 04 105002 9
21. INFECTED 02 CYLINDER REPLACED FILLED FLOW TEST 1 8 CO2 CARTRIDGES REPLACED R2015 728 1122544 expiration pate YUNE 2014 MASK INSPECTION 6 24 13 ICE PLACED IN FREEZER 6 24 15 LOW PRESSURE LEAK TEST 2 24 15 WARNING INSTALL FROZEN ICE PRIOR TO USE REFER TO USER MANUAL AND OR MAINTENANCE MANUAL FOR INFORMATION ON USE AND MAINTENANCE OF THIS RESPIRATOR RESPIRATOR IS SUITABLE FOR USE ONLY BY PROPERLY TRAINED PERSONNEL FAILURE TO PROPERLY USE AND MAINTAIN THIS RESPIRATOR COULD RESULT IN INJURY AND DEATH 1 Inspect the maintenance tag that should be attached to the apparatus conspicuous and consistent location Verify that all portions of the tag are properly completed 2 Verify that the apparatus oxygen cylinder is fully charged to 3000 psi 207 bar and top off if necessary 3 Replace the upper housing Page 16 of 45 BioPak 240R Benchman Manual A47D135 Revision M 3 General Service Procedures 3 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 clean and inspect all components and lubricate as needed Reference the parts list for proper diaphragm alignment Diaphragm Alignment Proper diaphragm alignment is depicted below Note the positioning of the t
22. 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 11 Page 26 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 7 Center Section Assembly ITEM QTY PART NUMBER REF B6 02 5002 07 1 B4 04 7060 20 0 B6 02 5002 24 0 B3 02 0040 00 0 B6 02 5002 71 1 B4 04 7070 03 1 B2 02 3300 06 0 B2 02 3300 48 0 B4 04 7060 01 1 B2 02 7001 10 0 B6 02 5002 23 0 B3 01 0043 00 0 B6 02 5002 05 0 B2 06 6001 47 0 B4 03 5204 08 0 On WH DESCRIPTION Center Section Assembly Complete Lid O Ring Demand Feed Tube 4 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 5 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 12 and diaphragm clamp item 13 Indicated components require lubrication with Christo Lube O Ring Lubricant B5 01 3000 01 0 prior to installation Install indicated components to a
23. and Dow 111 are the only lubricants approved for use in the apparatus e NEVER lubricate the sealing washer that sits between the oxygen cylinder and the pressure regulator 3 3 Oxygen Cylinder The cylinder should be inspected regularly for signs of damage to the outer wrapping Oylinders that are cracked flaking or show exposed fibres should be immediately retired from service Oylinders will require periodic hydro static testing per national requirements Typical intervals are every 5 years from the date of Page 17 of 45 BioPak 240R Benchman Manual A47D135 Revision M manufacture Cylinder testing should be conducted by an authorized testing facility Cylinders that have been hydro static tested shall be cleaned for high pressure oxygen service as per national standards Cylinders are to be retired from service 15 years after the date of manufacture 3 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 horn 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 4 Remove the alarm housing from the apparatus In
24. and repaired 7 service kit bleed valve 8 Remove the leak test adapter to vent the apparatus 9 Replace the storage plug 10 Remove the two test keys from the rear of the lower housing 11 Date and initial the maintenance tag under Low Pressure Leak Test 1 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 1500 psi 100 bar pressure for this test 2 When the oxygen cylinder is opened the TRIM indicator shall cycle Red GREEN BLUE with the horn sounding The TRIM will then flash GREEN and the horn will be silent 3 The pressure gauge will reach full reading in approximately 60 seconds 4 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 650 1000 psi 45 69 bar The LED indication will cease when the pressure gauge reads less than 25 psi 1 7 bar 5 Verify that the oxygen cylinder is fully charged to 3000 psi 207 bar and top off if necessary 6 Date initial the maintenance tag under O2 Cylinder Replaced Filled Page 13 of 45 BioPak 240R Benchman Manual A47D135 Revision M 111 Upper Housing 1 Replace the upper housing onto the apparatus 2 Ifthe carbon dioxide scrubbers have not bee
25. approved for use with one of the following 9 Volt batteries only Eveready Inc Energizer 522 Panasonic Industrial Co 6AM6 Rayovac Corp 1604 or Duracell Inc MN1604 The connectors can only be connected to Biomarine BP240R Breathing Apparatus Page 6 of 45 BioPak 240R Benchman Manual A47D135 Revision M CAUTIONS AND LIMITATIONS 9 Failure to properly use and maintain this product could result in injury or death M All approved respirators shall be selected fitted and maintained in accordance with NIOSH MSHA OSHA and other applicable regulations N Never substitute modify add or omit parts Use only exact replacement parts in the configuration as specified by Biomarine O Refer to User s instructions and or maintenance manuals for information on use and maintenance of these respirators S Special or Critical User s Instructions and or specific use limitations apply Refer to User s instructions before donning S SPECIAL OR CRITICAL USER S INSTRUCTIONS Please Read Carefully and Fully Understand e All users of the Self Contained Breathing Apparatus SCBA must be trained by Biomarine Qualified Instructors in the donning operation inspection and emergency use procedures of the BioPak 240R Biomarine or a qualified Biomarine representative must perform all repairs beyond the scope of this or the BioPak 240R Benchman manual e Prior to using the BioPak 240R it must be determined tha
26. ator is supplied with a cardboard foam shipping box Hard or soft transit cases are to be ordered separately 2 Scrubber Canister part number B6 02 5003 69 0 will supply four sets of canisters four sets of moisture pads and maintenance tags for four separate single uses 3 Alternate language manuals are available Contact Biomarine Representative for details Page 20 of 45 BioPak 240R Benchman Manual A47D135 Revision M Page 21 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 2 AV3000 Facemask Assembly ITEM QTY REF REF REF 1 2 2 1 3 1 4 opt 5 opt 6 opt 7 opt 8 opt 9 opt Note PART NUMBER B6 02 5002 09 0 B6 02 5002 09 1 B6 02 5002 09 2 B2 02 7001 33 0 B2 02 4001 26 0 B2 06 6001 70 0 B2 06 6002 31 0 B6 02 5003 41 0 B2 06 6001 64 0 B6 02 5002 42 0 B6 02 5003 44 0 B6 02 5002 17 0 DESCRIPTION AV3000 Facemask Small AV3000 Facemask Medium AV3000 Facemask Large Nose Cup Pads Interface Tube Storage Bag not depicted Magnetic Lens Wiper Replacement AV3000 Lens with Anti Fog Film Kevlar Neck Strap Spectacle Kit AV3000 Field Test Kit Anti Fog Spray 1 Nose Pags item 1 fit internal to the mask nose cup 2 Contact factory for details concerning mask lens item 5 replacement 3 spray is not required for use of mask with anti fog film but can be utilized to lubricate the optional magneti
27. c wiper Page 22 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 3 AV3500 Facemask Assembly ITEM QTY PART NUMBER DESCRIPTION REF B6 02 5002 98 0 AV3500 Small Facemask Complete REF B6 02 5002 98 1 AV3500 Medium Facemask Complete REF B6 02 5002 98 2 AV3500 large Facemask Complete 1 1 B2 02 4001 26 0 Interface Tube 2 1 2 06 6001 34 0 Interface Gasket 3 1 B6 02 5003 04 0 Interface Fitting 4 1 B2 02 3300 68 0 Clip 5 1 B2 02 4001 54 0 Button 6 1 B2 02 4001 60 0 Cowling 7 3 B3 01 1061 07 1 Locking Pan Head Screw 8 1 4 04 7060 25 0 Hose Adapter O Ring 9 1 B6 02 5003 01 0 AV3500 Hose Adapter 10 1 B2 06 6002 31 0 Facemask Magnetic Wiper 11 1 B2 06 6001 70 0 Storage Bag not depicted 12 opt B2 02 7001 49 0 Chin Condensation Pad 13 opt B6 02 5003 41 0 Replacement AV3500 Lens with Anti Fog Film 14 opt B2 06 6001 64 0 Kevlar Neck Strap 15 opt B6 02 5002 42 0 Spectacle Kit 16 opt 6 02 5003 43 0 AV3500 Field Test Kit 17 opt B6 02 5002 17 0 Anti Fog Spray Note 1 Complete facemask does not include adapter assembly defined by items 8 9 Interface Fitting item 3 includes fitting with gasket item 2 installed Lubricate O Ring item 8 with Dow 111 prior to use Adapter Assembly item 9 includes check valves holders and check valve factory installed Chin Condensation Pad item 12 will fit internal to the facemask underneath the nose cup in the lens chin area The pad
28. d flow rate date and Page 12 of 45 initial the maintenance tag under Flow Test lom Close the oxygen cylinder valve remove the test flowmeter and reconnect the constant add feed line to the center section BioPak 240R Benchman Manual A47D135 Revision M 1 9 Low Pressure Leak Test 1 Remove the storage plug from the breathing hoses and install the leak test adapter from the service kit 2 Attach rubber tubing from the service kit between the leak test adapter and the input port of the service kit 3 Insert two test keys from the service kit in the keyholes in the back of the lower housing 4 Open oxygen cylinder valve and depress the bypass valve until the test kit displays a pressure of 3 0 water column then immediately close the oxygen cylinder valve 5 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 over pressurize 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 If the apparatus pressure drops more than 0 2 in the 60 second there is a leak that must be located
29. dically in accordance with national regulations National regulations must be observed Oxygen will enhance the combustion of other materials Personnel dealing with compressed oxygen and compressed oxygen cylinders must be fully trained in the use and handling of compressed oxygen 1 Obtain the proper cylinder fill adapter needed to connect the oxygen cylinder to the booster pump 2 Connect the cylinder to the booster pump and charge to 3000 psi 207 bar pressure with medical or aviation grade oxygen according to pump manufacturer s instructions 1 6 Facemask 1 Inspect the components of the facemask and replace as required 2 Do not apply anti fog solutions of any kind to the lens of the facemask 3 Date initial the maintenance tag under Mask Inspection 1 7 Assembly 1 Position the BioPak in a level position as depicted above by propping up the handle end of the lower housing Page 11 of 45 10 BioPak 240R Benchman Manual A47D135 Revision M Install the center section making sure to properly seat the three springs onto the diaphragm Lock the center section into position using the four quarter turn fasteners Connect the electrical and pneumatic lines to the center section Verify the presence of an o ring seal on each pneumatic line connection Position the fully dry moisture sponges into the center section The sponges must be fully dry to prevent the growth of mold within the
30. e Approximate number of uses e Description of problem e X 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 4 STORAGE GUIDELINES Follow the guidelines below for proper storage of the apparatus e Storage plug shall be installed e Never store a wet apparatus The apparatus shall be fully dry before storage e Never store an apparatus that has not been fully cleaned and disinfected Store a location free from impact that could cause damage to the apparatus e Storein the stated conditions of ambient temperature relative humidity and air pressure Store a location that will not submerge the apparatus e Do not store the apparatus pre packed with the ExtendAir carbon dioxide scrubber canisters e Long Term Storage storage of BioPak for periods exceeding 6 months without use Follow all of the above guidelines The BioPak should not be placed back into service until all the procedures associated with Turn Around and Long Term maintenance have been performed and passed Page 19 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 PARTS LIST 51 Top Assembly ITEM QTY PART NUMBER DESCRIPTION 1a 1 AV3000 Facemask Assembly See Section 5 2 1b 1 Wem AV3500 Facemask Assembly See Section 5 3 2 1 B6 02 5002 18 0 Upper Housing Assemb
31. ens inserts which are considered consumable items and as such are not covered by the terms of these warranties No waiver alteration or modification of the terms of these provisions shall be valid unless in writing and signed by an executive officer of Biomarine These warranties shall not apply to accessories or devices purchased by Biomarine and attached to or made part of the goods except that Biomarine warrants the the installation of such items in the completed product shall so conform to the installation instructions of the manufacturers thereof as not to invalidate such applicable warranties on such items as are obtained by Biomarine from such manufacturers and ii the workmanship incorporated in such installation shall be free from defects Page 44 of 45 BioPak 240R Benchman Manual A47D135 Revision M This page left intentionally blank Page 45 of 45
32. er Mounting Screw 9 2 B3 01 4011 00 0 Oxygen Regulator Mounting Screw 10 2 B3 01 1061 01 1 Manifold Mounting Screw 11 2 B3 03 3063 00 0 Manifold Mounting Washer 12 2 B2 02 7001 30 0 Latch Foam Pad 13 2 B3 01 1042 00 0 Remote Gauge Mounting Screw 14 1 B2 02 1100 10 0 Remote Gauge Mounting Bracket 15 2 B3 03 3043 00 0 Remote Gauge Tooth Washer 16 1 B2 02 7001 21 0 Oxygen Cylinder Hold Down Strap 17 1 B2 02 4001 29 1 Kevlar Carrying Handle 18 6 B3 01 1071 01 0 Handle Harness Shoulder Strap Mounting Screw 19 2 B3 02 4040 00 0 Remote Gauge Hex Nut 20 1 B2 02 1300 29 0 Regulator Support Tube 21 1 B2 02 1300 05 0 Regulator Support Plate 22 1 B2 02 1100 11 0 Oxygen Knob Retaining Bracket Note 1 Diaphragm Springs Item 2 install into lower housing by threading onto spring retainer projections 2 External Oxygen Knob Item 3 snaps into position within lower housing 3 Indicated components are to be installed from the external side of the lower housing shell 4 Oxygen Bottle Strap item 16 is to be threaded through the lower housing shell slots for installation Page 35 of 45 240R Benchman Manual A47D135 Revision Page 36 of 45 Service Kit Assembly QTY Ola 440 PART NUMBER B6 02 5002 16 0 B6 02 5002 57 0 B6 02 5002 56 0 B6 02 5003 00 0 B6 02 5002 15 0 B6 02 5000 17 2 B2 03 3000 01 0 B2 06 6
33. hree large holes in the diaphragm plate in relation to the breathing chamber mounting feet and the breathing hoses Reference diagram in Section 5 8 x 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 Itis 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 3 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 provided in the service kit e Unless otherwise directed do not lubricate o rings while they are still seated within their gland e Do not use heavy coats of lubrication Proper o ring lubrication will result in a shiny surface without lumps e Do not stretch or deform o rings during handling Visually inspect under bright lighting and inspect by feel o rings for signs of damage such as nicks cuts tears or abrasion e Christo Lube
34. is utilized for installation and removal of the entire bypass valve assembly Page 37 of 45 BioPak 240R Benchman Manual A47D135 Revision M m m 2 2b _ x E cr T A 20 eka 21 2 1 11 2 16 i E A oo 17 b 38 45 5 15 REF WN BioPak 240R Benchman Manual A47D135 Revision M Coolant Canister Freeze Form QTY PART NUMBER DESCRIPTION 6 02 5002 40 0 Ice Canister Freeze Form Complete 1 B6 02 5002 58 0 Base Assembly 1 B2 02 4001 46 0 Freeze Tube 1 B2 02 1100 06 0 Top Plate 3 B3 02 4100 00 0 Wing Nut Page 39 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 16 Miscellaneous Supplies DESCRIPTION Seal and Lubrication Kit Seal Kit includes all replacement seals without lubricants Christo Lube O Ring Lubricant 2 ounce tube Dow 111 O Ring Lubricant 5 3 ounce tube Oxygen Safe Leak Tec Leak Detection Fluid 8 ounce bottle Disinfectant Maintenance Tag PART NUMBER B6 02 5002 14 0 B6 02 5002 14 1 B5 01 3000 01 0 B5 01 3000 11 0 B5 01 3000 03 0 B5 06 6000 17 0 Page 40 of 45 BioPak 240R Benchman Manual A47D135 Rev
35. ision M 5 17 Optional Attachments Breathing Hose Protective Sleeve B2 02 7001 22 0 A Kevlar sleeve that will slide over the exterior of the breathing hose to provide abrasion protection Hard Transit Case B6 02 5002 63 0 An injection molded style carrying storage case that provides exceptional BioPak 240R storage capabilities Soft Transit Case B2 02 7000 39 0 An armored cloth style carrying storage case that provides a shoulder strap Soft case is smaller and lighter than hard case but will not provide the same protection or storage space as the standard hard case Hydration System B6 02 5002 52 0 The Hydration System provides a 1 5 liter reservoir and an interface to the AV3000 or AV3500 facemask that will enable the user to drink liquid without breaking the breathing loop seal to the external ambient atmosphere Drier Manifold B6 02 5002 87 0 The Drier Manifold will provide a connection of up to six BioPaks to a single line for connection to a user supplier blower for drying Harness Shoulder Pad B2 02 7001 48 0 Constructed of flame rated materials will provide additional padding on the shoulder of the main harness High Pressure Digital Leak Tester B6 02 5003 39 0 Provides a method to test the high pressure sections of the BioPak from cylinder valve to remote gauge and to demand housing and all connection in between utilizing pressure decay and eliminating the use of leak detection fluid Leak detection will be required
36. ly 3 2 B2 02 4000 39 0 Coolant Lid 4 2 B6 02 5002 37 0 Ice Canister 5 2 B2 02 7001 09 0 Breathing Hose See Section 5 4 or Section 5 5 6 1 B6 02 5002 04 0 Center Section Lid Assembly See Section 5 6 7 1 B6 02 5003 69 0 OrbSorb CO Scrubber 8 1 B6 02 5003 34 0 Scrubber Moisture Pad 9 1 B6 02 5002 07 1 Center Section Assembly See Section 5 7 10 1 Pneumatic Assembly See Section 5 9 11 1 B6 01 5000 05 0 Alarm Monitor See Section 5 11 12a 1 6 02 5001 98 0 Green Oxygen Cylinder Empty See Section 5 12 12b 1 B6 02 5001 98 1 Green Oxygen Cylinder Full See Section 5 12 13 1 B6 02 5002 28 0 Lower Housing Assembly See Section 5 13 14 1 2 02 7001 24 0 Harness Assembly Flame Rated 15 2 B6 02 5002 40 0 Ice Canister Freeze Form See Section 5 15 16 1 B5 06 6000 22 0 User Manual ENGLISH 17 1 B5 06 6000 23 0 Benchman Manual ENGLISH 18a opt B6 02 5002 63 0 Hard Transit Case not depicted 18b opt B2 02 7000 39 0 Soft Transit Case not depicted 19a 1 2 02 4001 50 0 AV3500 Storage Plug 19b 1 B2 02 4000 90 0 AV3000 Storage Plug 20a 1 B6 02 5002 54 0 Cylinder Fill Adapter CGA 540 Male 20b 1 B6 02 5002 55 0 Cylinder Fill Adapter CGA 540 Female 20 1 6 02 5002 53 0 Cylinder Fill Adapter 34 A Male 20d 1 B6 02 5002 66 0 Cylinder Fill Adapter fits Drager Booster Pump 21 1 6 02 5002 41 0 Phase Change Exchanger PCM 22 1 B2 02 7001 07 0 Moisture Absorbent Pad Set Note 1 The 240R respir
37. n installed into the apparatus then leave the maintenance tag CO2 Cartridges Replaced field blank See section 1 12 concerning procedures for pre packing the carbon dioxide scrubber into the apparatus during turn around maintenance 3 Tie the completed maintenance tag to the BioPak in a conspicuous and consistent location 1 12 Carbon Dioxide Scrubber Pre Packing Procedure Pre packing the BioPak 240R with the carbon dioxide scrubbers is only permitted when utilizing OrbSorb carbon dioxide scrubber The OrbSorb carbon dioxide scrubbers can be pre packed into the apparatus during turn around maintenance if so desired Pre packed carbon dioxide scrubbers may only be stored in the apparatus for a maximum period of 1 year Moisture sponges must be installed dry when pre packing the BioPak DO NOT pre pack any BioPak that will be stored at temperatures at or below freezing 32 F 0 C 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 f 2 74 1 Inspect the expiration date of the carbon dioxide scrubber to ensure that it is not expired Record the carbon dioxide scrubber serial number and expiration date onto the maintenance tag or affix the scrubber label to the back of the tag 2 Verify that each carbon dioxide scrubber canister has an o ring installed
38. of care in maintaining the equipment and the user s expertise in using the equipment Personnel who intend to use protective breathing equipment in a dangerous atmosphere must have the proper training temperament and experience to be able to function safely The user shall periodically inspect the TRIM display as described in this manual to determine the status of the respirator oxygen supply Intrinsic Safety Consideration for Model Type RMS permissible Pressure and temperature Monitoring Device Read manual before use e connectors of the monitoring device may only be connected to a Biomarine BioPak 240R Breathing Apparatus oxygen regulator manifold block and breathing chamber The fiber optic cable may only be connected to the BioPak 240R remote gauge assembly e Tested for intrinsic safety in methane air mixtures only e battery is to be changed in fresh air only Do not change battery in hazardous areas Approved for use only with the battery types specified in this manual Page 8 of 45 BioPak 240R Benchman Manual A47D135 Revision M use of the OrbSorb carbon dioxide chemical scrubbers must always include the installation of the moisture pad provided with the scrubber Failure to install the moisture pad as described in this manual can lead to scrubber flooding and elevated inhalation concentrations of carbon dioxide that may lead to injury or death DISCLAIMER This manual presents the minimum
39. orkmanship for a period of three 3 years from the date that the goods are purchased by buyer THIS WARRANTY DOES NOT APPLY TO OXYGEN CYLINDER HYDROSTATIC TESTING FOR PERIODIC RECERTIFICATION OF THE PRESSURE VESSEL OR CONSUMABLES THE SOLE LIABILITY OF BIOMARINE FOR ALL PURPOSES SHALL BE TO REPLACE OR REPAIR AT THE SOLE OPTION OF BIOMARINE DEFECTIVE PARTS APPEARING WITHIN THE THREE 3 YEAR PERIOD AS APPLICABLE BIOMARINE SHALL PROVIDE PARTS AT ITS OWN EXPENSE BUT ALL LABOR SHALL BE AT THE EXPENSE OF THE BUYER BIOMARINE SHALL HAVE NO OBLIGATION FOR REPLACEMENT UNLESS 1 BIOMARINE HAS RECEIVED WRITTEN NOTICE OF THE ALLEGED DEFECT WITHIN THIRTY 30 DAYS FOLLOWING THE DISCOVERY OF THE DEFECT OR THIRTY SEVEN 37 MONTHS FROM THE DATE OF PURCHASE WHICHEVER OCCURS SOONER AND 2 THE BUYER SUBMITS PROOF OF DATE OF PURCHASE WITH INVOICE OR EQUIVALENT DOCUMENTATION AND 3 THE DEFECTIVE GOODS ARE PROMPTLY RETURNED BY BUYER AT THEIR SOLE EXPENSE TO BIOMARINE AT 456 CREAMERY WAY EXTON PA 19341 USA AND 4 THE EQUIPMENT HAS NOT BEEN ALTERED AND 5 THE EQUIPMENT IS OPERATED AND MAINTAINED IN ACCORDANCE WITH ALL INSTRUCTIONS AND MANUALS PROVIDED TO THE BUYER It shall be the responsibility of the buyer to read carefully and abide by all instructions provided to the buyer in the instruction manual or elsewhere If buyer and the employees of the buyer did not abide by such instructions then the alleged defect shall not be deemed to have arisen
40. re when handling the center section Avoid sharp objects and rough surfaces that could damage the rubber diaphragm 10 Remove the four quarter turn fasteners and remove the center section 1 3 Cleaning Disinfection Use only cleaners and disinfectants that are approved by Biomarine The apparatus must be cleaned and disinfected as soon as possible after each use If cleaning is not immediately possible after use at a minimum remove and discard the carbon dioxide scrubber and moisture pad remove the moisture control foam pads and temporarily store the BioPak with the center section lid open to prevent the growth of mold or mildew DO NOT submerge the electronic monitor housing DO NOT allow any fluids to contact the input port of the pressure regulator 1 Clean the upper and lower housings ice canisters and 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 Page 10 of 45 BioPak 240R Benchman Manual A47D135 Revision M Install a Demand Port Wash Plug supplied with the service kit to the demand port of the center section to keep water from migrating into the demand housing
41. recommended procedures for maintaining the BioPak 240R End users are free to implement additional procedures and tests above and beyond the scope of this manual as they see fit or as may be required for specific locations or applications provided these procedures meet all criteria presented in the manual Failure to follow the minimum procedures presented in this manual may violate government or agency approvals as well as void the manufacturer s warranty Contact Biomarine with any questions pertaining to customized procedures or questions concerning the procedures stipulated in this manual Page 9 of 45 BioPak 240R Benchman Manual A47D135 Revision M 1 TURN AROUND MAINTENANCE PROCEDURE 1 1 Maintenance Tag 0 BIOPAK 240 REVOLUTION TURNAROUND MAINTENANCE TAG UNIT NO DATE INT WASHED DISINFECTED 02 CYLINDER REPLACED FILLED FLOW TEST 2 CARTRIDGES REPLACED SERIAL s EXPIRATION DATE MASK INSPECTION ICE PLACED IN FREEZER LOW PRESSURE LEAK TEST WARNING INSTALL FROZEN ICE PRIOR TO USE REFER TO USER MANUAL AND OR MAINTENANCE MANUAL FOR INFORMATION ON USE AND MAINTENANCE OF THIS RESPIRATOR RESPIRATOR IS SUITABLE FOR USE ONLY BY PROPERLY TRAINED PERSONNEL FAILURE TO PROPERLY USE AND MAINTAIN THIS RESPIRATOR COULD RESULT IN INJURY AND DEATH Obtain a maintenance tag supplied with replacement carbon dioxide scrubbers The maintenance tag shall
42. rm Maintenance Procedure conducted every 6 months A Maintenance Log Sheet is provided in this manual to assist in tracking long term maintenance procedures 2 1 Visual Inspection Remove the upper housing and visually inspect the apparatus for signs of wear abuse loose connections or other damage Repair as necessary Verify that the apparatus is properly sealed against the ambient environment by the presence of the storage plug 2 2 Demand Valve Functional Test 1 Vent the BioPak of all internal pressure 2 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 3 After 1 3 seconds the sound of gas escaping into the breathing chamber must cease This signals that the demand valve has properly closed 2 3 Constant Flow Test 1 Perform the test as described in Section 1 8 2 4 Vent Valve Functional Test 1 Replace the seal plug from the facepiece adapter with the leak test adapter from the test kit and connect the barb of the adapter to the barb of the service kit using rubbing tubing 2 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 2 5 Low Pressure Leak Test
43. spect 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 The battery door will only fit in one orientation on the module 8 Install the alarm housing into the apparatus 9 Use two 7 16 wrenches from the service kit to install the light guide from the alarm monitor housing DO NOT allow the fitting anchored to the alarm housing to rotate The light guide shall be positioned so that it is directed straight down towards the lower housing 10 Connect the electrical line from the center section to the alarm housing 11 Conduct the Alarm Test as described in section 3 10 12 Install the upper housing 3 5 Flow Restrictor Replacement Procedure 1 Remove the upper housing and vent the BioPak of all internal
44. ss of the user The user must be capable of determining when excessive ambient temperatures and high workloads will lead to physical exhaustion and or collapse Low Temperature Operation The 240R is suitable for respiratory protection during entry into and escape from oxygen deficient atmospheres in temperature as low as 5 F 20 C providing 1 the BioPak is stored in low temperatures it must be fully dry and NOT have the carbon dioxide scrubber pre packed into the breathing chamber and 2 the carbon dioxide scrubber is stored at temperatures above 32 F 0 C and is only installed into Page 7 of 45 BioPak 240R Benchman Manual A47D135 Revision M the BioPak just prior to use Prior to donning a cold BioPak verify that the cylinder is securely connected to the pressure regulator The BioPak 240R is approved only with the oxygen cylinder is fully charged with compressed medical or aviation grade oxygen with moisture content less than 50 mg m at 3000 psi 207 bar Allow the oxygen cylinder to cool after filling to determine the correct pressure Do not substitute any other gas type for the specified oxygen The user bears full responsibility for the purity of oxygen contained in the BioPak 240R oxygen cylinder The use of non approved gasses can result in injury or death If the oxygen cylinder is improperly filled with any gas other than oxygen the cylinder must be replaced A foreign gas may cause cylinder corrosion
45. t the user is medically fit The following lists some but not all medical and psychological conditions that could limit or prevent the use of the BioPak 240R Emphysema Chronic Obstructive Pulmonary Disease Bronchial Asthma X Ray evidence of Pneumonia Evidence of reduce pulmonary function Coronary Artery Disease Severe or progressive hypertension Epilepsy Grand Mal or Petit Mal Pernicious Anemia Diabetes Insidious or Mellitus Breathing difficulties when wearing a SCBA Abnormal or ruptured ear drum Claustrophobia or anxiety when wearing a SCBA Pacemaker or other Cardiac Conditions Compressed Oxygen Hazard Always handle oxygen cylinders with care to prevent damage Do not allow oil grease or other foreign materials to come in contact with cylinder cylinder valve or cylinder pressure regulator to prevent possible ignition Do not open the cylinder valve in the presence of open flame sparks or high radiant heat Failure to follow these recommendations could result in personal injury or death e Oxidizing Agent Hazard Oxygen will enhance the combustion of other materials so that materials that normally will not burn in air may burn in oxygen rich atmospheres and materials that do burn in air will burn more vigorously and at a higher temperature in oxygen rich atmospheres Oxygen will not cause materials to ignite without the presence of an ignition source e Work Load Stress Factors The use a SCBA will add to the work load and stre
46. under circumstances of proper use The instructions for use of the goods reflect the opinion of experts based on field use and tests The instructions should be followed carefully It is impossible however to eliminate all risks inherently associated with the use of the goods Unintended consequences may result because of factors as weather conditions the presence of other materials or the use or manner of application of the goods all of which are beyond the control of Biomarine The buyer shall assume all such risks Buyer shall be responsible for insuring that the goods are functioning properly at all times and shall not use any goods which are not functioning properly If buyer uses goods when they are not functioning properly then buyer agrees to defend indemnify and hold Biomarine harmless against all losses damages and injuries to persons or property as a result of the use of the malfunctioning goods These warranties do not extend to the goods if they have been subjected to misuse neglect or accident including extended exposure to direct flames and or caustic chemical products after its delivery to buyer nor does it extend to any item that was modified or altered after its delivery to buyer IN NO EVENT WILL BIOMARINE BE LIABLE FOR ANY LOSS OR DAMAGE DIRECTLY OR INDIRECTLY ARISING FROM THE DEFECTS OR FROM THE USE OF THE GOODS OR FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES WHETHER IN CONTRACT TORT OR OTHERWISE OR FOR PERSONAL INJURY OR
47. will absorb and retain moisture generated by the user in the facemask during use 6 Contact factory for details concerning mask lens item 13 replacement 7 Anti fog spray is not required for use of mask with anti fog film but can be utilized to lubricate the optional magnetic wiper Page 23 of 45 BioPak 240R Benchman Manual A47D135 Revision M 5 4 AV3500 Mask Breathing Hose ITEM QTY PART NUMBER DESCRIPTION REF 1 B6 02 5003 03 0 AV3500 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 AV3500 Mask Adapter Assembly 5 1 B4 04 7060 25 0 Mask Adapter O Ring 6 2 B2 02 7001 11 0 Check Valves 7 opt B2 02 4101 22 0 Anti Crush Ring Note 1 The Complete Breathing Hose Set includes all depicted items The Mask Adapter Assembly includes the check valves item 6 and o ring item 5 Lubricate the O Ring with Dow 111 prior to use DO NOT lubricate the check valves Anti Crush Rings item 7 are optional components that will fit over the hose convolutions to prevent hose crushing 2a 2b Page 24 of 45 5 5 REF BioPak 240R Benchman Manual A47D135 Revision M AV3000 Mask Breathing Hose QTY PART NUMBER B6 02 5002 73 0 B2 02 7001 0

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