AIR SYSTEMS INTERNATIONAL BB15-CO User manual

Printed in U.S.A
©Copyright Air Systems International, Inc. 2005. All Rights Reserved.
AIRSYSTEMSINTERNATIONAL,INC.
829JuniperCrescent,Chesapeake,Va.,23320
Telephone [phone]
Toll Free 1-800-866-8100
Fax No. [phone]
http://www.airsystems.com
e-mail: [email protected]
Operating Manual
Manual de instrucciones
Manuel d’utilisation
Models/Modelos/Modéles
BB15-CO, BB30-CO, BB50-CO,
BB75-CO, BB100-CO, BB150-CO
Manual No. BREBX013
(Rev 4 May 2005)
Air Systems International, Inc
Registered to ISO 9001
Certificate No. A5033

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TABLE OF CONTENTS
Breathing Air Quality Position Statement...................................................................................................................................................3
Filtration Efficiency.......................................................................................................................................................................................3
BoxSpecificationsandPartsIdentification....................................................................................................................................................................4
Monitor Overview, Specifications, Wiring Schematic & Identification...................................................................................................5
BoxSetup&Operation...................................................................................................................................................................................................6-7
System Shutdown...........................................................................................................................................................................................8
System Maintenance......................................................................................................................................................................................8
Monitor Battery Replacement......................................................................................................................................................................8
Sensor Replacement......................................................................................................................................................................................9
Calibration Procedure............................................................................................................................................................................10-11
Filter Replacement Breakdown
BB15-CO........................................................................................................................................................................................12
BB30-CO........................................................................................................................................................................................13
BB50-CO........................................................................................................................................................................................14
BB75-CO........................................................................................................................................................................................15
BB100-CO......................................................................................................................................................................................16
BB150-CO......................................................................................................................................................................................17
Warranty Disclaimer...................................................................................................................................................................................18
CONTIENDO
Calidad de Aire para Respiradores Política deAir Systems.....................................................................................................................19
Eficiencia de Filtraciòn..................................................................................................................................................................................19
Especificaciones y Indentificación del Partes..............................................................................................................................................20
Descripción General del Monitor, Especificaciones del Monitor, Esquemático delAlambrado,
y Identificación del Monitor..........................................................................................................................................................................21
Instalación y Operación...........................................................................................................................................................................22-23
Parada.............................................................................................................................................................................................................24
Mantenimiento del Sistema...........................................................................................................................................................................24
Sustitución de Baterías del Monitor.............................................................................................................................................................24
Sustitución del Detector.................................................................................................................................................................................25
Procedimiento de Calibración.................................................................................................................................................................26-27
Desglose de Filtro de Repuesto
BB15-CO..........................................................................................................................................................................................28
BB30-CO..........................................................................................................................................................................................29
BB50-CO..........................................................................................................................................................................................30
BB75-CO..........................................................................................................................................................................................31
BB100-CO........................................................................................................................................................................................32
BB150-CO........................................................................................................................................................................................33
Denegación de la Garantía............................................................................................................................................................................34
TABLE DES MATIERES
Exposé Concernant la Qualité de L’air Respirable....................................................................................................................................35
Efficacite du Filtrage.....................................................................................................................................................................................35
Specifications du Breather BoxTM et Identificacion des Pièces..................................................................................................................36
Vue d’Ensemble de la Appareil de Contrôle, Specifications, Schema du Cablage
et Identification de l’Appareil du Contrôle.................................................................................................................................................37
Installation et Fonctionnement................................................................................................................................................................38-39
Arret................................................................................................................................................................................................................40
Maintenance du Système...............................................................................................................................................................................40
Remplacement des Piles de l’Appareil de Contrôle....................................................................................................................................40
Remplacement des Capteurs.........................................................................................................................................................................41
Methode de Calibrage..............................................................................................................................................................................42-43
Decomposition des Filtres de Rechange
BB15-CO..........................................................................................................................................................................................44
BB30-CO..........................................................................................................................................................................................45
BB50-CO..........................................................................................................................................................................................46
BB75-CO..........................................................................................................................................................................................47
BB100-CO........................................................................................................................................................................................48
BB150-CO........................................................................................................................................................................................49
Limitations de la Garantie............................................................................................................................................................................50

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BREATHING AIR QUALITY POSITION STATEMENT
The responsibility for the quality of breathing air rests with the user. Compliance with federal, state, or local
regulations are the responsibility of the user and this recommendation does not supersede any existing rules,
regulations, or laws which may apply. Breathing air filtration products meet or exceed CGA Grade-D specifica-
tions for air quality as adopted by Federal OSHA. Compressor air quality standards meet or exceed OSHA
1910.134 requirements. When the components are used in accordance with the manufacturer's instructions and
recommendations, the "system" meets or exceeds federal regulations presently in force. It is incumbent upon the
user to comply with any changes in the regulations or law which may occur in future situations.
The air supply compressor should be located in a safe, clean ambient air environment. This "safe" loca-
tion should be tested periodically using proper instruments to ensure clean ambient air quality on a consistent
basis.TotalsystemGrade-D airqualityshouldbe testedatthetime of initialsetup.If the compressorismoved,retesting
airqualityisrecommended.Shouldthelocationorenvironmentsignificantlychange,theairqualityshouldberetested. The
compressorfilters andoillevel shouldbecheckeddailyandchangedwhencontaminated orwhenthemaximumnumber
of"run"hoursisachieved.
This seriesofair filtrationunitsshould beusedaccordingto therecommendationsspecifiedin themanual. The
standard filtration package is not explosion-proof and should be located in a non-explosive environment. (An
intrinsically safe model is available, please contact the factory for information.) The carbon monoxide monitor
should be calibrated monthly or if the accuracy of the monitor is in question. System air quality should be tested
for, but not limited to, the following Grade-D air components:
CO - Carbon Monoxide
O2- Oxygen
CO2- Carbon Dioxide
H2O - Water (Moisture Content)
Hydrocarbons (Oil Mist)
Total Particulates
The maximum allowable level of these air quality components varies depending on
Grade-D or E requirements. Contact sales for a copy of the latest standards.
Our Breathing Air compressors and filtration systems meet all of the following federal
specifications when used and serviced in accordance with our instructions.
Federal OSHA 29 CFR 1910.134
"Compressor Operations for Breathing Air"
Army Corps of Engineers EM385-1-1,
paragraph 07b-11-4,
"Compressed Breathing Air"
FILTRATION EFFICIENCY
1st Stage Particulate/Bulk Liquid Separation Auto Drain and Filter change indicator.
Removes 95% bulk particulate and liquids
@ 5 microns
2nd Stage Oil Coalescing and Ultra Fine
Particulate Auto Drain and Filter change indicator.
Removes oil and particulate to 99.9998%
@ 0.01 microns
3rd Stage Activated Charcoal Manual Drain and Filter change indicator.
Removes organic vapors, odors, and
tastes. Less than 0.003 pp/wt remaining
oil content
Note: Filter Change Indicators are standard on all models except the BB15 series.

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BREATHER BOXTM SPECIFICATIONS AND PARTS IDENTIFICATION
*Note: Some models may not have respirator connections. They can be ordered with NPT outlets for connection
to drop stations or point of attachments.
ITEM # DESCRIPTION
1INLETFITTING
2 1ST STAGE FILTER
3 2ND STAGE FILTER
4 3RD STAGE FILTER
5 PRESSURE GAUGE
6 RELIEF VALVE
7 RESPIRATOR CONNECTION
8FLOWMETER
9 115 VAC RECESSED PLUG
10 PRESSURE REGULATOR
11 CARBON MONOXIDE MONITOR
ITEM # DESCRIPTION
1 REMOTE ALARM JACK
2 HIGH CO AUDIBLE ALARM
3 HIGH CO INDICATOR
4 NORMAL INDICATOR
5INLETFITTING
6 1ST STAGE FILTER
7 FILTER CHANGE INDICATOR
8 2ND STAGE FILTER
9 3RD STAGE FILTER
10 PRESSURE GAUGE
11 RELIEF VALVE
12 RESPIRATOR CONNECTION
13 FLOWMETER
14 PRESSURE REGULATOR
15 CARBON MONOXIDE MONITOR
16 115 VAC RECESSED PLUG
MODELS BB30-150
MODEL BB15-CO
BB15 SERIES BB30 SERIES BB50 SERIES BB75 SERIES BB100 SERIES BB150 SERIES
Size 19"L x 13" H x 7"D 19"L x 13"H x 7"D 23.5"L x 16.75"L x 8.5"D 23.5"L x 16.75"H x 8.5"D 26.25"L x 20.75"H x 9" D 26.25"L x 20.75"H x 9" D
Weight 12.3 lbs/5.6 kg 19.7 lbs/8.0 kg 26.4 lbs/11.9 kg 34.2 lbs/15.5 kg 38.8 lbs/17.6 kg 38.8 lbs/17.6 kg
Inlet Size 1/4"Industrial
Interchange 1/2" Industrial Interchange 1/2"Industrial Interchange 1/2"Industrial Interchange 1/2"Industrial Interchange 1" Chicago Fitting
No. of Outlets 12 Standard
3 Optional 46 or Single 1/2"NPT Outlet 4-8 or Single 1/2"NPT Outlet Three 1/2" Industrial Interchange
Maximum Air
Flow (cfm/bar) 15scfm@ 110psi
425 lpm @ 7.5 bar 30scfm @ 110psi 850 lpm @ 7.5 bar 50scfm @ 110psi 1415 lpm @ 7.5 bar 75scfm @ 110psi 2124 lpm @ 7.5 bar 100scfm @ 110psi 4248 lpm @ 7.5 bar 150scfm @ 110psi 4955 lpm @ 7.5 bar
Remote
Alarm Signal No Yes Yes Yes Yes Yes
MaximumInlet
Pressure
Relief
Valve
Monitoring
Power
150psi(10.3 bar)
125psi(8.6 bar)
Inline Continuous Monitoring of Carbon Monoxide (CO)
9-16 VDC or 110-120 VAC 50/60 Hz

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Test Circuit Manually activated
Sensor Type Sealed electrochemical sensor for Carbon
Monoxide
Accuracy +/- 1% full scale
Response 90% in 10-15 seconds
Detectable Range 0 - 200ppm CO
Calibration Manual CO zero and span adjustments
Alarm Setting 10ppm CO (5ppm Canadian)
Warning Signals Normal operation - Green light
High CO - Red Light
High CO - Audible Alarm
Low Battery - Amber Light
Warranty 2 years from original date of purchase
MONITOR OVERVIEW
The monitor will analyze the air sample and display the CO concentration in parts-per-million (ppm). The system’s
green “NORMAL” operation light will illuminate and the red “HIGH CO” light will flicker faintly approximately
every second when the CO level is below 10ppm (5ppm Canadian). If the CO concentration level exceeds the alarm
set point, the green “NORMAL” light will turn off, the red “HIGH CO” light will illuminate, the audible alarm will
sound and the remote alarm connections (if used) will energize. Once the CO concentration levels drop below the
alarm set point, all alarm indicators will deactivate and the unit will return to “NORMAL” operation.
MONITOR IDENTIFICATION
MONITOR SPECIFICATIONS
WIRING SCHEMATIC
Size 2.75”H x 6.57”L x 5.1”W
Weight 2.8 LBS. (1.27KG)
Case Extruded aluminum - Anodized black
Voltage 115 VAC and/or 9 - 16 VDC
Shielding Internal RFI/EMI filters
Fuse 115 VAC 1 amp fast acting
Operating
Temperature 4 to 113 degrees F
(-15.5 to 45 degrees C)
Humidity
Range 10% to 90% RH
Flow
Requirement 50 - 100 cc
Display 3 digit LCD
(CO concentration)
ITEM # DESCRIPTION
1 LOW BATTERY INDICATOR
2 CALIBRATION TOOL
3 BATTERY HOLDER
4 REMOTE SIGNAL CONNECTOR
5 RECESS PLUG WITH FUSE HOLDER
6 AUXILIARY DC POWER JACK
7 ON/OFF/TEST SWITCH
8 AIR SAMPLE INLET
9 AIR DISCHARGE PORT (DO NOT BLOCK)

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BREATHER BOXTM SETUP AND OPERATION
STEP 1)
Secure a primary air source of sufficient air flow and discharge pressure.
The number and type of respirators being used determines the flow rate
and pressure required.
STEP 2)
Checkairlinemonitorforfresh9-voltbatteriesandturntheuniton. Connectthe
remotesignalcable,115VACplug,andairsample hose to the monitor.Note:
Remote signal cable does not apply to BB15 series. Place the “ON/OFF/
TEST” switch to the “ON” position. Allow 30 seconds for the readout to
stabilize.Ifareadingotherthan“ZERO”isdisplayed,calibrationofthemonitor
maybenecessary. Seecalibrationprocedure.
STEP 3)
Connect the extension cord to a 115 VAC receptacle. Note: The CO
monitor can run off the twin 9-volt batteries if noAC power is available.
STEP 4)
Connect the remote alarm assembly (optional) to the remote alarm jack.
Note: Does not apply to BB15 series.
STEP 5)
Close the flowmeter by turning the control knob fully
clockwise.
REMOTE SIGNAL
CABLE 115 VAC PLUG
AIR SAMPLE
HOSE
Note: Always operate the Breather BoxTM in the upright position. Failure to comply may result in one or all of the following:
• Auto drains will not function properly. This may result in the contamination of the CO monitor and cause water to be passed
through respirator hose and into the worker’s mask.
• Auto drains may become clogged, clean or replace auto drains (See Maintenance Instructions.)
• Filters may accumulate moisture and/or contamination, replace if necessary.

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STEP 6)
Connect the air source to the inlet fitting.
STEP 7)
Hold the “ON/OFF/TEST” switch in the “TEST” position. All local and
remote audible/visual indicators will activate. If indicators do not acti-
vate, check all electrical connections, then call factory repair department.
Note: An alarm function test can be performed at any time by lifting the
“ON/OFF/TEST” switch to the “TEST” position.
STEP 8)
Attach the desired respirators and lengths of hose to the quick connect
outlet couplings. Note: Some models may not have respirator connec-
tions. They can be ordered with NPT outlets for connection to points of
attachment.
STEP 9)
Adjust the outlet pressure to the setting recommended by the respirator
manufacturer. Turn the knob clockwise to increase pressure, counterclock-
wise to decrease pressure.
STEP 10)
Adjust CO monitor air sample flow rate by turning the flowmeter control
knob counterclockwise until the float hovers in the green bar area
(approximatley 50-100 cc/min). The box is now ready for operation.
The instrument will analyze the air sample and display the CO concen-
tration in parts-per-million (ppm). The system’s green “NORMAL”
operation light will illuminate, and the red “HIGH CO” light will flicker
faintly approximately every second when the CO level is below 10ppm
(5ppm Canadian).
When the CO concentration level exceeds the alarm set point, the green
“NORMAL” light will turn off, the red “HIGH CO” light illuminates,
the audible alarm will sound, and the remote alarm connections will
energize.
When CO concentrations drop below the alarm set point, all alarm
indicators will deactivate, and return to “NORMAL” operation.
MODEL # MIN. HOSE ID INLET FITTING
BB15-CO 3/8" 1/4" INDUSTRIAL INTERCHANGE
BB30-CO 1/2" 1/2" INDUSTRIAL INTERCHANGE
BB50-CO 1/2" 1/2" INDUSTRIAL INTERCHANGE
BB75-CO 1/2" 1/2" INDUSTRIAL INTERCHANGE
BB100-CO 1/2" 1/2" INDUSTRIAL INTERCHANGE
BB150-CO 3/4" 1" CHICAGO FITTING
INLET
FITTING

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SHUTDOWN
1)Make sure all personnel have egressed from the work area.
2)Shut off air source to the box.
3)Remove air pressure from the box by pulling the relief valve ring out.
4)Turn monitor “OFF” at the “ON/OFF/TEST” switch. Do not remove 9-volt batteries. These
are used to maintain a bias voltage to the sensors; this keeps the sensor ready for immediate future use.
5)Disconnect airline hoses.
6)Install dust caps if applicable.
CAUTION: Always depressurize the system before performing service.
Filter Housing/Bowls: Periodic cleaning of the polycarbonate bowls may become necessary. Remove the
auto drains. Clean the bowls with a mild soapy solution. Reinstall into the filter housing.
Auto Drains: The automatic drains are designed to remove bulk liquid contaminants. The drains (1st & 2nd
stages only) will automatically drain the liquids after the level has reached 1/3 of the bowl capacity. For periodic
cleaning, use a mild soapy solution.
Filter Change: The filtration system consists of a filter change indicator which will gradually change from
green to orange when filter life is spent. (Not available on BB15 series)
Note: Air must be flowing through the filtration unit before the filter change indicators will function.
Drain Lines: Make sure the auto drain tubes are placed in the holes at the bottom of the box to allow the
liquids to drain outside of the box.
Calibration: Monitor calibration should be done monthly or whenever the reading may be questionable. A
calibration date sticker should be affixed for future reference. To obtain an accurate calibration, we recommend
the use of Air Systems’ calibration kits.
Part Number:
BBK-20 Calibration kit for CO monitor, 20ppm CO, zero air, regulator and case - 17
liter size.
BBK-10 Canadian Calibration kit for CO monitor, 10ppm CO, zero air, regulator and case - 17
liter size.
BBK-20103 Calibration kit for CO monitor, 20ppm CO, zero air, regulator and case - 103
liter size.
To assure sensor accuracy, calibration of the monitor is required. If you cannot obtain an accurate calibration
sensor replacement may be necessary. Consult Repair Service Department before ordering.
Part Number:
CO-91NS NewReplacementCarbonMonoxide Sensor
Battery Replacement: Replace 9-volt batteries when the amber “LOW BATTERY” light illuminates. If the
monitor is not used for 90 days, check the 9-volt battery condition and replace if necessary.
SYSTEM MAINTENANCE
MONITOR BATTERY REPLACEMENT
These batteries continuously provide a required bias voltage to the CO sensor and
power the monitor in the event of AC power loss. If AC and DC power are removed
for a period of 2 hours or more, a 1 hour restabilization period is required on the
sensor as eratic readings may occur.
Batteries approved for use are:
1. Panasonic Industrial Alkaline Battery - 9 VDC Model No. 6AM - 6PI 9V
2. Duracell Alkaline Battery - 9 VDC Model No. MN1604B2
3. Eveready Battery (Energizer) Alkaline 9VDC - Model No. 6LR61-6AM6-9V

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SENSOR REPLACEMENT
STEP 4)
Removesensorfromsensorcupandremoveleads .Take
the new sensor and remove the metal spring. Reattach
leads to the proper colored terminals on the new sensor.
Install new sensor into sensor cup.
STEP 3)
Remove end plate to gain access
to the sensor cup from outside the
housing.
STEP 1)
Disconnect all external connections.
Remove CO monitor from the unit.
STEP 2)
Removethefourscrewsfromthemonitor’s
left end plate.
Note: Alarm location may vary.
Replacement sensors are shipped with a metal spring installed between the electrodes. Do not remove the clip
until the sensor is to be installed into the monitor.
STEP5)
Reassemble monitor and install back into system.
Connectallexternalconnections. Allow monitor to
stabilize30minutes to1hourand recalibrate.

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CALIBRATION PROCEDURE
Do not use inert gases to zero the monitor. This will cause premature failure of the sensor.
CO Zero Adjustment
To zero the instrument, follow the steps below. Zero calibration gas should be used to properly “zero” the
instrument and assure that a valid calibration is achieved. If zero adjustment cannot be made as indicated, sensor
replacement may be necessary. After each monitor adjustment outlined in the following steps, allow time for the
changes to stabilize.
Note:Acontrolledorificeinthe
regulatorwillallowthegastoflow
at approximately300cc/min.
6. Attach the clear tubing with male plug to the monitor
air sample inlet.
7. Open gas regulator fully by turning the knob at least
two (2) turns counterclockwise.
8. Allow digital readout to stabilize approximately 15 -
30 seconds.
9. Adjust "zero" pot adjustment screw (clockwise to
increase, counterclockwise to
decrease) until a "00" reading
is obtained.
10. Turn off the regulator and disconnect the tubing from
the zero air regulator.
1. Place the “on/off/test” switch to the “on” position.
2. Allow 30 seconds for the readout to stabilize.
The green indicator light will illuminate.
3. Hold the “on/off/test” switch in the “test”
position. The following will occur:
• Audible alarm will sound
• Green indicator LED will flash
• Amber low battery indicator
LED will illuminate
• Red lamp on
This test ensures the circuitry is operable and the
continuity to the sensor is proper. Release the switch.
4. Remove air sample inlet tube.
5. Install regulator on the zero air cylinder reference gas.