AIR SYSTEMS MACK-1 User manual

Operating Manual
Models
MACK-1, MACK-2, MACK-3,
MACK-NFPA1, MACK-NFPA3, MACK-NFPA3Q, &
MACK-1-6K, MACK-3TV & MACKNFPATV
Manual No. POA051
(Rev 4 April 2011)
Air Systems International MACK-1 Multi Air Command Kit
Air Systems International MACK-2 Multi Air Command Kit
Air Systems International MACK-3 Multi Air Command Kit
Air Systems International MACK-NFPA1 Multi Air Command Kit
Air Systems International MACK-NFPA3 Multi Air Command Kit
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TABLE OF CONTENTS
Overview...........................................................................................................................................3
MACK-1 Setup, Operation & Parts Identification...................................................................4-5
MACK-2 Setup, Operation & Parts Identification...................................................................6-7
MACK-2 Filling Cylinders...........................................................................................................8-9
MACK-3 Setup & Operation for Common Air Sources, Parts Identification...................10-11
MACK-3 Setup & Operation for Isolated Air Sources.........................................................12-13
MACK-3 Setup & Operation for Optional Fill Whip Assembly MACK-3FA...................14-15
MACK-NFPA1 & MACK-NFPA3 Parts Identification.............................................................16
MACK-NFPA1 & MACK-NFPA3 Setup & Operation..............................................................17
Changing Cylinders.......................................................................................................................18
Shutdown Procedure......................................................................................................................18
High Pressure Airline General Maintenance & Inspection.......................................................18
Warranty Disclaimer......................................................................................................................19
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OVERVIEW
The MACK series has been designed as a portable multifunctional air distribution system. All
MACK units are rated for 5000psi.
MACK-1
This version allows for one or two high pressure cylinders to be attached to the supply inlet
whips. A CGA-347 male inlet is provided for direct attachment to a bank of air cylinders. All
MACK series units have at least one air outlet manifold with pressure adjustments from 0-125psi.
MACK-2
This version has the same features as the MACK-1, with the addition of an adjustable fill regula-
tor, pressure gauge, and fill whip. An optional second fill whip is available.
MACK-3
The MACK-3 contains two independent low pressure manifolds and regulator systems that each
have their own cylinder supply hoses. An isolation valve is located between the regulators to
isolate the systems, as well as provide common air flow from a single bottled air source. One
regulator is set to provide low pressure air (0-125psi) for respirators, and one for medium pres-
sure air (0-250psi) for air shores and other rescue tools. This medium pressure manifold has an
additional low pressure regulator/manifold system for additional respirators and tools. A total of
eleven outlets are provided. The MACK-3FA version contains all of the above items, with the
addition of a complete bottle fill assembly, model number MACK-FA.
MACK-NFPA1
This version contains two in dependent MACK-1 manifold and regulator systems, so that each
one has its own cylinder supply hoses and low pressure whistle. A total of 6 low pressure outlets
are provided.
MACK-NFPA3
This version of the MACK-NFPA1 contains two independent low pressure manifold and regula-
tor systems, so that each has its own cylinder supply hoses. An isolation valve is added between
the systems to isolate the regulators, as well as provide common air flow from a single bottled air
source. A CGA-347 high pressure inlet is provided on this version to allow for an external bank
of air cylinders to operate the unit.
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MACK-1 SETUP/OPERATION
Step 1)
Install the universal CGA-347 hand tight nuts (Item #7) to the cylinder valves and tighten.
Step 2)
Close all bleeder valves (Item #8) by turning the knobs fully clockwise.
Step 3)
Open one cylinder. At this time the low pressure warning alarm will sound until it sets itself at
approximately 1000psi (69bar). Check reading on gauge (Item #1) to verify that cylinder is full.
Close the cylinder.
Step 4)
Set the required respirator pressure with the regulator control knob (Item #10). Turn clockwise to
increase pressure, counterclockwise to decrease pressure.
Step 5)
Bleed the pressure at either the relief valve (Item #9), or by partially engaging a male plug into
one of the respirator couplings (Item # 11/12). This depressurizes the manifold and simulates low
cylinder pressure. The low pressure warning alarm (Item #6) will sound at approximately 500psi
(35bar). Open the other cylinder. At this time the low pressure warning alarm (Item #6) will re-
sound until it sets itself at approximately 1000psi (69 bar). Check reading on gauge (Item #1) to
verify cylinder is full.
Step 6)
Couple respirators and lengths of hoses to the manifold and readjust pressure regulator (Item #10)
if necessary. The system is now operational.
Step 7)
Optional
Install a high pressure connect whip to the high pressure inlet. This step may be done after Step 5,
or at anytime during operation of the system.
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MACK-1
ITEM # DESCRIPTION PART #
1 INCOMING PRESSURE GAUGE (0-200PSI) GA256KS
2 LIGHT ASSEMBLY MACKLIGHT
3 PRESSURE CAP SS347CAP
4 CGA-347 MALE ADAPTER SS4F347AM
5 ¼" MALE/MALE CHECK VALVE VC4MMSS
6 LOW PRESSURE WHISTLE AC-PA25
7 CGA-347 HAND TIGHT NUT/NIPPLE SS347HT
8 BLEED VALVE VAL030
9 RELIEF VALVE VR4150BR
10 REGULATOR REG-5000
11 RESPIRATOR FITTING--HANSEN QDH3SL6M
11A DUST CAP--HANSEN QDH3DCAP
12 RESPIRATOR FITTING--SCHRADER QDSSL6M
12A DUST CAP--SCHRADER QDSDCAP
13 OUTGOING PRESSURE GAUGE (0-6000PSI) GA25200S
PARTS IDENTIFICATION
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
SETUP/OPERATION
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MACK-2 SETUP/OPERATION
Step 1)
Install the universal CGA-347 hand tight nuts (Item #3) to the cylinder valves and tighten.
Step 2)
Close all bleeder valves (Item #2) by turning the knobs fully clockwise.
Step 3)
Open one cylinder. At this time the low pressure warning alarm (Item #7) will sound until it sets
itself at approximately 1000psi (69bar). Check reading on gauge to verify that cylinder is full.
Close the cylinder.
Step 4)
Set the required respirator pressure with the regulator control knob (Item #11). Turn clockwise to
increase pressure, counterclockwise to decrease pressure.
Step 5)
Bleed the pressure at either the relief valve (Item #9), or by partially engaging a male plug into
one of the respirator couplings (Item 13/14). This depressurizes the manifold and simulates low
cylinder pressure. The low pressure warning alarm (Item #7) will sound at approximately 500psi
(35bar).Open the other cylinder. At this time the low pressure warning alarm (Item #7) will re-
sound until it sets itself at approximately 1000psi (69 bar). Check reading on gauge (Item #8) to
verify cylinder is full.
Step 6)
Couple respirators and lengths of hoses to the manifold and readjust pressure regulator if neces-
sary. The system is now operational.
Step 7)
Optional
Install a high pressure connect whip to the high pressure inlet. This step may be done after Step 5,
or at anytime during operation of the system.
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MACK-2
ITEM # DESCRIPTION PART #
1 ON/OFF VALVE VAL020
2 BLEEDER VALVE VAL030
3 CGA-347 HAND TIGHT NUT AND STEM SS347HT
4 FILL REGULATOR REG001
5 CGA-347 MALE ADAPTER SS4F347AM
6 PRESSURE CAP SS347CAP
7 LOW PRESSURE WHISTLE AC-PA25
8 INLET PRESSURE GAUGE (0-6000PSI) GA256KS
9 RELIEF VALVE (150PSI) VR4150BR
10 CHECK VALVE VC4MMSS
11 PRESSURE REGULATOR REG-5000
12 OUTLET PRESSURE GAUGE (0-200PSI) GA25200S
13 QUICK DISCONNECT, HANSEN QDH3SL6M
13A QUICK DISCONNECT, SCHRADER QDSSL6M
14 DUST CAP, HANSEN QDH3DCAP
14A DUST CAP, SCHRADER QDSDCAP
15 FILL PRESSURE GAUGE (0-6000PSI) GA256KS
16 LIGHT ASSEMBLY MACKLIGHT
PARTS IDENTIFICATION
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6 Step 7
SETUP/OPERATION
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Step 1)
2216/4500psi cylinder fill: Install the universal CGA-347 handtight nut (Item #3*) to the
empty cylinder’s valve, and tighten.
Note: An optional CGA-347 to CGA-346 adapter/relief valve is available. The relief valve is set
to 2400psi.
Step 2)
Close the fill and bleeder valves (Item #s 1&2*).
Step 3)
Open empty cylinder valve.
Step 4)
Open the cascade/air supply source. Note: It is highly recommended you use a high volume air
source connected to the high pressure inlet.
Step 5)
Adjust the fill regulator (Item # 4*) to desired fill pressure by turning the control knob clockwise
to increase pressure.
Step 6)
Slowly open the fill valve (Item # 1*) to a desired fill rate by turning the knob counterclockwise.
Step 7)
MACK-2
FILLING CYLINDERS
Once filling is complete, close the fill and cylinder valves. Open the bleeder valve (Item #2*)to
vent pressure. Remove the CGA-347 hand tight nut (Item #3*).
*See MACK-2 Parts Identification, page 7.
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MACK-2
FILLING CYLINDERS
Step 1
Step 2 Step 3
Step 4
Step 5
Step 6
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MACK-3 SETUP/OPERATION
COMMON AIR SOURCES
Step 1)
Install the universal CGA-347 hand tight nuts (Item #4) to the cylinders.
Step 2)
Close all bleeder valves (Item # 3) by turning the knobs fully clockwise.
Step 3)
Index the isolation valve (Item #21) so the position arrow on the handle is inline with the plumb-
ing.
Step 4)
Open one cylinder. At this time, the low pressure warning alarms (Item #7) will sound until they
set themselves at approximately 1000psi (69 bar). Check the reading on the gauge (Item #19) to
verify that the cylinder is full. Close the cylinder.
Step 5)
Set the required tool pressure with the regulator control knob (Item # 18). Turn clockwise to
increase, counter clockwise to decrease pressure.
Step 6)
Set the required respirator pressure(s) with the regulator control knob (Item # 15). Turn clock-
wise to increase, counterclockwise to decrease pressure.
Step 7)
Bleed the pressure at either the relief valve (Item # 11), or by partially engaging a male plug into
one of the respirator/tool couplings (Item #12/12A). This depressurizes the manifold and simu-
lates low cylinder pressure. The low pressure warning alarms (Item #7)will sound at approxi-
mately 500psi (35 bar).Open the other cylinder(s). At this time the low pressure warning alarms
(Item #7) will sound until they reset themselves at approximately 1000 psi (69 bar). Check read-
ing on gauge (Item #19)to verify cylinder is full.
Step 8)
Couple respirators/tools and length of hoses to the corresponding couplings. Readjust the pressure
regulators if necessary. The system is now operational.
Step 9) Optional
Install a high pressure connect whip to the high pressure inlet. This step may be done after step 7,
or at any time during operation of the system.
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