AIR SYSTEMS BB15-CO User manual

Manual No. BREBX013
(Rev. 8 Sept. 2012)
OPERATING MANUAL
MODELS:
BB15-CO
BB30-CO
BB50-CO
BB75-CO
BB100-CO
BB150-CO
AIR SYSTEMS INTERNATIONAL, INC.
829 Juniper Crescent, Chesapeake, Va 23320
Telephone [phone]
Toll Free 1-800-866-8100
Fax No. [phone]
hp://www.airsystems.com
e-mail: [e-mail]
French Canadian and Spanish versions of this manual are available online at www.airsystems.com

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 24”L X 17”H X 8.5”D 24”L X 17”H X 8.5”D 26.5”L X 21”H X 9”D 26.5”L X 21”H X 9”D
Weight 12.3 lbs/5.6 kg 19.7 lbs/8.9 kg 26.4 lbs/12 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
No. of Outlets 1 2 standard
3 op onal 46 or single 1/2” NPT outlet
4-8 or single
1/2” NPT outlet
(3) 1/2” industrial
interchange
Maximum Air
Flow (cfm/bar)
15 scfm @ 110 psi
425 lpm @ 7.6 bar
30 scfm @ 110 psi
850 lpm @ 7.6 bar
50 scfm @ 110 psi
1415 lpm @ 7.6 bar
75 scfm @ 110 psi
2124 lpm @ 7.6 bar
100 scfm @110 psi
2832 lpm @7.6 bar
150 scfm @110 psi
4248 lpm @7.6 bar
Remote
Alarm Signal No Yes Yes Yes Yes Yes
Maximum Inlet
Pressure 150 psi (10.3 bar)
Relief Valve 125 psi (8.6 bar)
Monitoring Inline Con nuous Monitoring of Carbon Monoxide (CO)
Power 9-16 VDC or 115 VAC 50/60 Hz
SPECIFICATIONS
Item # Descripon BB15 BB30 BB50 BB75 BB100 BB150
1Remote Alarm Jack N/A ELJP004 ELJP004 ELJP004 ELJP004 ELJP004
2Remote Alarm Jack Cover N/A ELJP005 ELJP005 ELJP005 ELJP005 ELJP005
3High CO Audible Alarm N/A ELLS004 ELLS004 ELLS004 ELLS004 ELLS004
4 High CO Indicator N/A MONC004 MONC004 MONC004 MONC004 MONC004
5 Clear LED Lens N/A ELDS013 ELDS013 ELDS013 ELDS013 ELDS013
6Normal Operaon Indicator N/A MONC005 MONC005 MONC005 MONC005 MONC005
7Inlet Fing QDH3PL6M QDH5PL8M QDH5PL8M QDH5PL8M QDH5PL8M QDCHI16M
8 Pressure Gauge GA20160B GA20160B GA20160B GA20160B GA20160B N/A
9 Relief Valve VR4125BR VR4125BR VR4125BR VR4125BR VR4125BR VR4125BR
10 Hansen Coupling QDH3SL6M QDH3SL6M QDH3SL6M QDH3SL6M QDH3SL6M QDH5SL12M
10a Schrader Coupling QDSSL6M QDSSL6M QDSSL6M QDSSL6M QDSSL6M N/A
11 Hansen Dust Cap QDH3DCAP QDH3DCAP QDH3DCAP QDH3DCAP QDH3DCAP N/A
11a Schrader Dust Cap QDSDCAP QDSDCAP QDSDCAP QDSDCAP QDSDCAP N/A
12 1st Stage Filter Assembly 15FLTRAW WL251 WL007 WL175 WL066 WL132
13 2nd Stage Filter Assembly 15FLTRCW WL253 WL008 WL177 WL017 WL059S
14 3rd Stage Filter Assembly 15FLTRDW WL255 WL009 WL179 WL018 WL060S
15 Flowmeter WL033NS WL033NS WL033NS WL033NS WL033NS WL033NS
16 Pressure Regulator 15REGW WL257 WL015 WL181 WL015 WL013A
17 Carbon Monoxide Monitor CO-91AB CO-91 CO-91 CO-91 CO-91 CO-91
18 115 VAC Recessed Plug ELJP006 ELJP006 ELJP006 ELJP006 ELJP006 ELJP006
BREATHER BOX™ PARTS IDENTIFICATION
2

BREATHER BOX™ PARTS IDENTIFICATION
MODEL BB15-CO MODEL BB30-CO
MODELS BB50-100-CO MODEL BB150-CO
3

Breathing Air Quality Posi on Statement
The responsibility for the quality of breathing air rests with the user. Compliance with federal, state,
or local regula ons are the responsibility of the user and this recommenda on does not supersede any
exist-
ing rules, regula ons, or laws which may apply. Breathing air  ltra on products
meet or exceed CGA Grade-D
speci ca ons 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 instruc-
 ons and recommenda ons, the "system" meets or exceeds federal regula ons presently in force. It is incum-
bent upon the user to comply with any changes in the regula ons or law which may occur in future situa ons.
The air supply compressor should be located in a safe, clean ambient air environment. This "safe" loca-
 on should be tested periodically using proper instruments to ensure clean ambient air quality on a consistent
basis. Total system Grade-D air quality should be tested at the  me of ini al setup. If the compressor is moved,
retes ng air quality is recommended. Should the loca on or environment signi cantly change, the air quality
should be retested. The compressor  lters and oil level should be checked daily and changed when contami-
nated or when the maximum number of "run" hours is achieved.
This series of air  ltra on units should be used according to the recommenda ons speci ed in the
manual. The standard  ltra on package is not explosion-proof and should be located in a non-explosive en-
vironment. (An intrinsically safe model is available, please contact the factory for informa on.) The carbon
monoxide monitor should be calibrated monthly or if the accuracy of the monitor is in ques on. 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 Par culates
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  ltra on systems meet all of the following federal
speci ca ons when used and serviced in accordance with our instruc ons.
Federal OSHA 29 CFR 1910.134
"Compressor Opera ons for Breathing Air"
Army Corps of Engineers EM385-1-1,
paragraph 07b-11-4,
"Compressed Breathing Air"
4

CARBON MONOXIDE MONITOR OVERVIEW
The monitor will analyze the air sample and display the CO concentra on in parts per million (ppm). The
system’s green “NORMAL” opera on light will illuminate and the red “HIGH CO” light will  icker approximately
every second when the CO level is below 10ppm (5ppm Canadian). If the CO concentra on level exceeds the
alarm set point, the green “NORMAL” light will turn o , the red “HIGH CO” light will illuminate, the audible
alarm will sound, and the remote alarm connec ons will energize. Once the CO concentra on levels drop be-
low the alarm set point, all alarm indicators will deac vate and the unit will return to “NORMAL” opera on.
1st Stage Par culate/Bulk Liquid Separa on
Auto drain and  lter change indicator. Re-
moves 95% bulk par culate and liquids @ 5
microns.
2nd stage Oil Coalescing and Ultra Fine Par culate
Auto drain and  lter change indicator. Re-
moves oil and par culate to 99.9998% @ 0.01
microns.
3rd Stage Ac vated Charcoal
Manual drain and  lter change indicator. Re-
moves organic vapors, odors, and tastes. Less
than 0.003 pp/wt remaining oil content.
FILTRATION EFFICIENCY
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  lters
Fuse 115 VAC/1 amp fast ac ng
Opera ng
Temperature
4° to 113° Fahrenheit
(-15.5° to 45° Celcius)
Humidity
Range 10% to 90% rela ve humidity
Flow
Requirement 50 - 100 cc/min
Display 3 digit LCD
CO concentra on
Test Circuit Manually ac vated
Sensor Type Sealed electrochemical sensor for
Carbon Monoxide
Accuracy +/-1% full scale
Response 90% in 10-15 seconds
Detectable
Range 0-200 ppm CO
Calibra on Manual CO zero and span adjustments
Alarm Se ng 10 ppm CO (5 ppm - Canadian)
Warning
Signals
Normal opera on - Green Light
High CO - Red Light
High CO - Audible Alarm
Low Ba ery - Amber Light
Warranty 2 years from original date of purchase
MONITOR SPECIFICATIONS
15 PIN CONNECTOR
WIRING DIAGRAM
5

CO MONITOR PARTS BREAKDOWN
6

ITEM # DESCRIPTION PART #
1LCD Display MONC703
2Span Potenometer MONC702A
3Alarm Set Point Potenometer MONC702A
4Zero Potenometer MONC702
5Air Sample Inlet Socket MONC001
6Air Sample Plug MONC002
7Air Exhaust Port MONC003
8On/O/Test Switch MONC007
9 Recessed Plug With Fuse Holder MONC020
10 1 Amp Fast Acng Fuse, 5 X 20Mm ELF001
11 15 Pin Socket MONC520
12 Faceplate/Endplate Screw MONC023
13 Main Circuit Board Assembly CO-91PCB
14 Power Supply Board CO-91PSB
15 Sensor Connector (Soldered To PCB) MONC509
16 Baery Box MONC006
17 9 Volt Baery ELB9V
18 Calibraon Tool MONC028
19 End Plate CO-91BEP
20 Aluminum Housing CO-91HOU
21 Led Socket MONC009LA
22 Yellow Led MONC008NS
23 Led Socket And Yellow Led CO-91LED
24 PPM/Serial No. Scker MONC031
25 Baery Box Connector (Soldered To PCB) MONC516
26 Led Connector (Soldered To PCB) MONC511
27 12 VDC Power Socket MONC522
28 12 Volt Power Plug (Oponal) ELJP018
29 12 Volt Cable (Order By The Foot) ELCB035
30 CO Sensor CO-91NS
31 CO Sensor Holder MONC810
32 CO Sensor Electrical Leads CO-91SL
33 90° Hose Barb MONC811
CO MONITOR PARTS BREAKDOWN
7

STEP 1)
Secure a primary air source of sucient air ow and discharge pres-
sure. The number and type of respirators being used determines the
ow rate and pressure required.
STEP 2)
Check airline monitor for fresh 9 volt baeries and turn unit on. Connect
the remote signal cable, 115 VAC plug, and air sample hose to the monitor.
Place the “ON/OFF/TEST” switch to the “ON” posion. Allow 30 seconds
for the readout to stabilize. If a reading other than “00” is displayed, cali-
braon of the monitor may be necessary. See calibraon procedure.
Note: Remote signal cable does not apply to BB15 series.
STEP 3)
Connect the extension cord to a 115 VAC receptacle.
Note: The CO monitor can run o the 9 volt baeries if AC power is not
available.
STEP 4)
Connect the oponal remote alarm (DC only) assembly to the remote
alarm jack.
Note: This step does not apply to BB15 series.
STEP 5)
Close the owmeter by turning the control knob fully clockwise. Do not
over-ghten.
BREATHER BOX™ SETUP AND OPERATION
Note: Always operate the Breather Box™ in the upright posi on. Failure to comply may result in one or all
of the following:
1) Auto drains will not func on properly. This may result in the contamina on of the CO monitor and cause
oil/water to be passed through respirator hose and into the worker’s mask.
2) Auto drains may become clogged.
3) Filters may accumulate moisture and/or contamina on.
8

MODEL # MIN. HOSE I.D. INLET FITING
BB15 SERIES 3/8” 1/4” INDUSTRIAL INTERCHANGE
BB30-100 SERIES 1/2” 1/2” INDUSTRIAL INTERCHANGE
BB150 SERIES 3/4” 1” CHICAGO FITTING
STEP 6)
Connect the air source, 150 psi max., to the inlet ng.
STEP 7)
Hold the “ON/OFF/TEST” switch in the “TEST” posion. All local and remote audi-
ble/visual indicators will acvate. If indicators do not acvate, check all electrical
connecons, then call factory repair dept.
Note: An alarm funcon test can be performed at any me by liing the “ON/
OFF/TEST” switch to the “TEST” posion.
STEP 8)
Aach desired respirators and hoses to the quick connect couplings.
Note: Some models may not have respirator connecons. They may be ordered
with NPT outlets for connecon to points of aachment.
STEP 9)
Adjust the outlet pressure to the seng recommended by the respirator man-
ufacturer. Turn the knob clockwise to increase pressure, counterclockwise to
decrease pressure.
STEP 10)
Adjust CO monitor air sample ow rate by turning the owmeter control knob coun-
terclockwise unl the ball hovers between 50 and 100 cc/min. The box is now ready
for operaon.
The monitor will analyze the air sample and display the CO concentraon in parts per
million (ppm). The system’s green “NORMAL” operaon light will illuminate, and the
red “HIGH CO” light will icker faintly approximately every second when the CO level is
below 10ppm (5ppm Canadian).
When the CO concentraon level exceeds the alarm set point, the green “NORMAL”
light will turn o, the red “HIGH CO” light illuminates, the audible alarm will sound,
and the remote alarm connecons will energize.
When CO concentraons drop below the alarm set point, all alarm indicators will deac-
vate and return to normal operaon.

SYSTEM MAINTENANCE
Filter Housing/Bowls: Periodic cleaning of the polycarbonate bowls may become necessary. Remove the auto
drains and clean the bowls with a mild soapy solu on. The auto drains may also be cleaned with a mild soapy
solu on at this  me. Dry and reinstall into the  lter housing.
Filter Change
: The  ltra on system consists of  lter change indicators which will gradually change from green to
orange when  lter life is spent.
Note: Air must be  owing through the  lters before the  lter change indicators will func on.
With system pressurized, close inlet ond outlet ball valves. Release the  lter trio pressure by pressing the manual
drain assembly to the side. Remove the bowl assemblies by releasing the lock ring.
Calibra on: Monitor calibra on should be done monthly or whenever the reading may be ques onable. A cali-
bra on date s cker should be a xed for future reference. To obtain an accurate calibra on, we recommend the
use of Air Systems calibra on kits.
Part Number:
BBK-10 Canadian calibra on kit for CO monitor; 10ppm CO, zero air, regulator and case - 17 liter size.
BBK-20 Calibra on kit for CO monitor; 20ppm CO, zero air, regulator and case - 17 liter size.
BBK-20103 Calibra on kit for CO monitor; 20ppm CO, zero air, regulator and case - 103 liter size.
DECAL085 Calibra on decal, sold in sheet of 14.
To assure sensor accuracy, calibra on of monitor is required. If you cannot obtain an accurate calibra on, sensor
replacement may be necessary. Consult Repair Service Department before ordering.
Part Number:
CO-91NS Replacement CO sensor
CAUTION: Always depressurize the system before performing service.
1) Make sure all personnel have egressed from the work area.
2) Shut o air source to the box.
3) Remove air pressure from the box by pulling the relief valve ring out.
4) Turn the CO monitor o . Do not remove the 9 volt ba eries. These are used to maintain a
bias voltage to the sensor; this keeps the sensor ready for immediate use.
5) Disconnect airline hoses.
6) Install dust caps if applicable.
SHUTDOWN
These ba eries provide the required con nuous 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 restabiliza-
 on period is required on the sensor as era c readings may occur.
Ba ery Replacement:
Replace 9 volt ba eries when the amber “Low Ba ery” light illuminates. If the monitor
is not used for 90 days, check the 9 volt ba eries and replace if necessary.
MONITOR BATTERY REPLACEMENT
10