Biomarine BioPak 240 REVOLUTION User manual

BioPak 240R Benchman Manual
A47D135 Revision J
A47D135, Revision N
B5-06-6000-15-0
ECO 9891, February 2014
BioPak 240R-NIOSH
Closed-Circuit, Self-Contained Breathing Apparatus
Benchman Manual

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CERTIFICATION APPROVALS 4
Respirator NIOSH Approval Label 4
ExtendAir®CO2Scrubber NIOSH Approval Label 5
OrbSorb®CO2Scrubber NIOSH Approval Label 5
RMS MSHA Electrical Approval 6
CAUTIONS AND LIMITATIONS 7
S-SPECIAL OR CRITICAL USER’S INSTRUCTIONS 7
1. TURN AROUND MAINTENANCE PROCEDURE 10
1.1 Maintenance Tag 10
1.2 Disassembly 10
1.3 Cleaning/Disinfection 10
1.4 Coolant Canister 11
1.5 Oxygen Cylinder 11
1.6 Facemask 11
1.7 Assembly 11
1.8 Constant Flow Test 12
1.9 Low Pressure Leak Test 13
1.10 Alarm Test 13
1.11 Upper Housing 14
1.12 Carbon Dioxide Scrubber Pre-Packing Procedure 14
2. LONG TERM MAINTENANCE PROCEDURE 15
2.1 Visual Inspection 15
2.2 Demand Valve Functional Test 15
2.3 Constant Flow Test 15
2.4 Vent Valve Functional Test 15
2.5 Low Pressure Leak Test 15
2.6 High Pressure Leak Test 15
2.7 Emergency Bypass Valve Functional Test 16
2.8 Alarm Test 16
2.9 Maintenance Tag Validation 16
3. GENERAL SERVICE PROCEDURES 17
3.1 Scheduled Component Inspection 17
3.2 System Lubrication 17
3.3 Oxygen Cylinder 17
3.4 Alarm Battery Replacement Procedure 18
3.5 Flow Restrictor Replacement Procedure 18
3.6 Factory Service and Training 19
4. STORAGE GUIDELINES 19
5. PARTS LISTS 20
5.1 Top Assembly 20
5.2 AV3000 Facemask Assembly 22
5.3 AV3500 Facemask Assembly 23
5.4 AV3500 Breathing Hose 24
5.5 AV3000 Breathing Hose 25
5.6 Center Section Lid Assembly 26
5.7 Center Section Assembly 27
5.8 Diaphragm Assembly 29
5.9 Pneumatic Assembly 30
5.10 Manifold Assembly 32
5.11 RMS Alarm Monitor 33
5.12 Oxygen Cylinder Assembly 34
5.13 Lower Housing Assembly 35
5.14 Service Kit Assembly 37
5.15 Coolant Canister Freeze Form 39
5.16 Miscellaneous Supplies 40
5.17 Optional Attachments 41
6. APPARATUS SPECIFICATIONS 42

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7. MAINTENANCE LOG SHEET 43
8. WARRANTY 44

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CERTIFICATION APPROVALS
Respirator NIOSH Approval Label:

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ExtendAir® Carbon Dioxide Chemical Scrubber NIOSH Approval Label:
BIOMARINE INCORPORATED
456 CREAMERY WAY, EXTON, PA 19341-2532 USA
PHONE: [phone]
CLEAN AIR SCRUBBER
CHEMICAL SCRUBBER CANISTER
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]
OrbSorb®Carbon Dioxide Chemical Scrubber NIOSH Approval Label:
BIOMARINE INCORPORATED
456 CREAMERY WAY, EXTON, PA 19341-2532 USA
PHONE: [phone]
CLEAN AIR SCRUBBER
CHEMICAL SCRUBBER CANISTER
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]

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Remote Monitoring System (RMS) MSHA Electrical Approval:
Eveready, Inc. Energizer #522
or Duracell, Inc. # MN1604
following 9-Volt batteries only:
MSHA approved for use with one of the
to Biomarine BP240R Breathing
The connectors can only be connected
Rayovac Corp. # A1604
Panasonic Industrial Co. # 6AM6
MSHA Approval No: 18-A060028-0
BIOMARINE - NTRON, INC.
Tested for intrinsic safety in methane-air
456 Creamery Way, Exton, PA19341 USA
Permissible Pressure and Temperature
Mine Safety and Health Adminstration
United States Department of Labor
The battery is to be changed in
Apparatus.
Warnings:
fresh air only.
mixtures only.
Monitoring Device
Model: RMS

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CAUTIONS AND LIMITATIONS
J - 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
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.
Prior to using the BioPak 240R it must be determined that 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.
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.
Work Load Stress Factors: The use of a SCBA will add to the work load and stress 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 BioPak 240R is suitable for respiratory protection during
entry into and escape from oxygen deficient atmospheres in temperature as low as -5oF
(-20oC) providing: 1) If 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 32oF (0oC) and is only installed into

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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/m3at 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.
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 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.
The 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.
Tested for intrinsic safety in methane-air mixtures only.
The 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.

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The 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.
Carbon Dioxide Chemical Scrubber: Users ARE NOT permitted to mix versions of the
OrbSorb®within a BioPak. Scrubber canisters installed into the BioPak for use must be of
exactly the same shape and type.
DISCLAIMER
This manual presents the minimum 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.

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1. TURN AROUND
MAINTENANCE PROCEDURE
1.1 Maintenance Tag
Obtain a maintenance tag supplied with
replacement carbon dioxide scrubbers.
The maintenance tag shall 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 care 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. Mix the 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.

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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.
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
120oF (50oC).
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 10oF
(-12oC) or less.
3. Date and initial the maintenance tag
under Ice Placed in Freezer.
1.5 Oxygen Cylinder
The 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/m3at 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 periodically 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 and 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.

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2. Install the center section making sure to
properly seat the three springs onto the
diaphragm.
3. Lock the center section into position
using the four quarter-turn fasteners.
4. Connect the electrical and pneumatic
lines to the center section. Verify the
presence of an o-ring seal on each
pneumatic line connection.
5. Position the fully dry moisture sponges
into the center section. The sponges
must be fully dry to prevent the growth
of mold within the apparatus.
6. Install the PCM into the breathing
chamber.
7. 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.
8. 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.
9. Install the storage plug into the
facemask connector.
10. Install the oxygen cylinder and secure
with the hold down strap.
1.8 Constant Flow Test
1. 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.
2. Open the oxygen cylinder valve and
observe flowmeter while holding it in a
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 lpm lpm
100-150 1.8-2.4 1.9-2.6
150-207 1.9-2.5 2.0-2.8
3. Enter the measured flow rate, date and
initial the maintenance tag under Flow
Test____ lpm.
4. Close the oxygen cylinder valve, remove
the test flowmeter and reconnect the
constant add feed line to the center
section.

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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 the 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 and repaired.
7. Open the 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 and initial the maintenance tag
under O2 Cylinder Replaced/Filled.

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1.11 Upper Housing
1. Replace the upper housing onto the
apparatus.
2. If the carbon dioxide scrubbers have not
been 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 (32oF/0oC).
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.
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.
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.
WARNING: Users ARE NOT permitted to
mix versions of the OrbSorb®within a
BioPak. Scrubber canisters installed into
the BioPak for use must be of exactly the
same shape and type.
5. Install and secure the breathing
chamber lid.

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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.
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 Term
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
1. Perform the test as described in Section
1.9.
2.6 High Pressure Leak Test
1. 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 cylinder 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.

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5. Close the oxygen cylinder valve and
depress the emergency vent valve to
depressurize the apparatus.
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
1. Inspect the maintenance tag that should
be attached to the apparatus in a
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.

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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 three large holes in the
diaphragm plate in relation to the breathing
chamber mounting feet and the breathing
hoses. Reference diagram in Section 5.8.
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. It is
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.
Never pry o-rings from glands with a
screwdriver. Remove o-rings by
hand or using the pick tool provided
in the service kit.
Unless otherwise directed, do not
lubricate o-rings while they are still
seated within their gland.
Do not use heavy coats of
lubrication. Proper o-ring lubrication
will result in a shiny surface without
lumps.
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.
Christo-Lube™ and Dow 111™ are
the only lubricants approved for use
in the apparatus.
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.
Cylinders that are cracked, flaking or show
exposed fibres should be immediately
retired from service.
Cylinders will require periodic hydro-static
testing per national requirements. Typical
intervals are every 5-years from the date of

BioPak 240R Benchman Manual
A47D135 Revision N
Page 18 of 45
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. Inspect 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 pressure.
2. Use the ¼” 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 ¼” 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.

BioPak 240R Benchman Manual
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Page 19 of 45
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: [phone]
Extensions 146 or 163
Fax: [phone]
Web: www.BioPak240r.com
Contact Biomarine prior to returning any
equipment.
To better serve your needs, please provide
the following information when contacting
Biomarine.
Apparatus Model Number
(240R, 240S, 240 LW, etc.)
Apparatus Serial Number
(Located internal to the BioPak,
beneath the oxygen cylinder)
Date of purchase
Approximate number of uses
Description of problem
Actions taken to correct problem
Contact name, address and phone
number with area or country code
and email address
Please provide your current email
address with all service
correspondence.
4. STORAGE GUIDELINES
Follow the guidelines below for proper
storage of the apparatus.
Storage plug shall be installed.
Never store a wet apparatus. The
apparatus shall be fully dry before
storage.
Never store an apparatus that has
not been fully cleaned and
disinfected.
Store in a location free from impact
that could cause damage to the
apparatus.
Store in the stated conditions of
ambient temperature, relative
humidity and air pressure.
Store in a location that will not
submerge the apparatus.
Do not store the apparatus pre-
packed with the ExtendAir® carbon
dioxide scrubber canisters.
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.

BioPak 240R Benchman Manual
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Page 20 of 45
5. PARTS LIST
5.1 Top Assembly
ITEM # QTY. PART NUMBER DESCRIPTION
1a 1 --- AV3000 Facemask Assembly-See Section 5.2
1b 1 --- AV3500 Facemask Assembly-See Section 5.3
2 1 B6-02-5002-18-0 Upper Housing Assembly
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 B6-02-5002-04-3 Center Section Lid Assembly-See Section 5.6
7 1 B6-02-5003-69-0 OrbSorb®CO2Scrubber Canister2
8 1 B6-02-5003-34-0 Scrubber Moisture Pad3
9 1 B6-02-5002-07-5 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 B6-02-5001-98-0 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 B2-02-7001-24-0 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-ENGLISH3
17 1 B5-06-6000-23-0 Benchman Manual-ENGLISH3
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 B2-02-4001-50-0 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
20c 1 B6-02-5002-53-0 Cylinder Fill Adapter, G ¾-A Male
20d 1 B6-02-5002-66-0 Cylinder Fill Adapter, fits Drager Booster Pump
21 1 B6-02-5002-41-0 Phase Change Heat Exchanger (PCM)
22 1 B2-02-7001-07-0 Moisture Absorbent Pad Set
Note:
1. The BioPak 240R respirator is supplied with a cardboard/foam shipping box. Hard or soft transit cases are to be
ordered separately.
2. CO2Scrubber 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.