Draeger PAS MAC8000 User manual

MAC8000 NOVEMBER 2010
MOBILE BREATHING-AIR
COMPRESSOR
PAS MAC8000
OPERATOR’S HANDBOOK
Draeger Safety UK Ltd
Ullswater Close, Kitty Brewster Industrial Estate,
Blyth, Northumberland, NE24 4RG, UK
Tel No: [phone] fax No: [phone]
E-mail: [email protected]
Website:www.draeger.ltd.uk

MAC8000 NOVEMBER 2010
1.0 INTRODUCTION
DREAGERprovides a range of breathing-airsystems which are completely
self-contained, fully mobile and specially designed to deliver breathing
quality compressed air to operatives wearing air-fed respiratory equipment
when working in hazardous atmospheres such as occur in the nuclear,
petrochemical, pharmaceutical and other industries. The Systems provide
breathable air conforming to EN 12021.
The MAC8000 is a fast towing unit with a two-cylinder, oil-cooled diesel
engine, driving a rotary screw compressor. A fully-automatic back-up
system is incorporated which maintains the air supply from reserves stored
in eight 9-litre cylinders.
When the air pressure or the reserve in the cylinders falls below a
permissible level, audible and visible alarms sound/flash at which time all
breathing-air apparatus wearers should immediately evacuate to a safe
area.
The unit has a centrally-mounted lifting eye and is enclosed within a steel
canopy which allows the correct air flow and access to all necessary parts
for both running and service. The unit is also sound attenuated to ensure
that the noise level is within the European regulations of <98LWA.
A hinged high-level air intake is provided which, in the operational mode, is
pivoted to the vertical. Off site the intake tube is lowered to the horizontal
position. The unit should be operated on reasonably level ground and sited
to prevent the re-entrainment of exhaust gases into the inlet. It should also
be kept well away from other polluted or toxic atmospheres.
All units are built for us in quality assured workshops under procedures
approved to ISO 9001:2000.
IMPORTANT
A qualified attendant should be in charge of the equipment during operation and
ensure that it is operated only, and strictly, in accordance with these instructions.
The attendant should check that all hoses are laid out without kinks or tangles, are
safe from interference or damage, and orifices of all couplings are clear of dirt.
If the unit switches over to cylinder supply, the attendant should immediately
instruct the operatives to leave the hazardous area.

MAC8000 NOVEMBER 2010
2.0 GENERAL ARRANGEMENT
2.1 MAC8000 ON SITE
Frontandrear viewshowingthe towingmechanism complete withjockey
wheel and handbrake applied. The hinged high-level air intake is shown
in the raised operational position.

MAC8000 NOVEMBER 2010
Shown open for service checks. Run engine only with canopy
lowered.

MAC8000 NOVEMBER 2010
2.2 TRAVELLING MODE
Picture shows the canopy, air intake and outlet cover in the lowered
position for travelling.
2.3

MAC8000 NOVEMBER 2010
INSTRUMENT PANELS
2.4 AUXILLARY INLET

MAC8000 NOVEMBER 2010
OUTLETS

MAC8000 NOVEMBER 2010
3.0 TECHNICAL DATA MAC8000
PORTABLE COMPRESSOR
SET - Atlas Copco XAHS37Dd
ENGINE - Deutz F2M2011 · oil-cooled · 2-cylinder diesel (low oil
pressure high oil temperature shutdown protected)
COMPRESSOR - Atlas Copco - oil injected · rotary screw
AFTERCOOLER - Outlet temperature within 5°C of ambient
FILTRATION - Purifies air to breathing quality conforming to BS EN 12021
CHASSIS - To full EEC regulations including brakes
TOWING HITCH - 50 mm ball or ring
BATTERY - 12 volt DC – Negative earth.
Earth bonding point on drawbar
NOISE LEVEL - <98 LWA. (Better than 78dBA @ 4 metres)
STANDARD FEATURES - Chalwyn engine overspeed valve · Lifting bale · Spark arrestor ·
Jockey wheel · High-level air intake · Hours run meter. Fully
automatic ‘fail-safe' reserve from high-pressure cylinders with start
up protection. Engine shut-downactivated by either high
temperature compressor oil or low engine oil pressure
GAUGES SHOW - HP cylinder pressure · Differential pressure · Compressor Pressure,
System pressure · Regulated pressure x 2
LAMPS SHOW - Alarm Type – Engine / Compressor Fault, HP alarm, LP alarm
AUDIBLE ALARMS - Primary air supply failure · Reserve pressure low
VISUAL INDICATOR - Shows changeover to HP reserves
OUTLETS - 8 off CEJN couplings (or alternatives) and 2 off ¾” Dynaquip
couplings
WASTES - Central tray for all oil/diesel drainageand spillage. All discharges from
filter autodrains are gathered into a container for proper disposal
QUALITY - The MAC8000 is manufactured in accordance with
Quality Assurance Procedures approved to ISO9001/EN29001
2
CYLINDER
OIL-
COOLED
DIESEL
FUEL
CAPACITY
Litres hrs
FREE
AIR DELD. At
10BAR
145psi
l/min cfm
WORKING
PRESSURE
Bar
psi
HP
CYLINDER
CAPACITY
Litres
DIMENSIONS (approx)
LENGTH
mm
WIDTH
mm
HEIGHT
mm
WEIGHT
kg
21.6 kW at
2400RPM approx 40 8
1700 60 8 115 1800 each
x 8 3300 1390 1240 1200

MAC8000 NOVEMBER 2010
4.0 OPERATING INSTRUCTIONS
4.1 SAFETY PRECAUTIONS GENERAL
For specific safety instructions see sections 9 (compressor) and 10
(engine)
Run the engine in a well-ventilated area. The machine should be as
level as possible in both planes whilst in operation.
Operate unit at least 1 metre away from buildings and flammable
objects.
Do not smoke or allow flames in the refuelling area.
Avoidinhaling the exhaustfumes. Diesel engineexhaust fumescontain
a variety of toxic and asphyxiant gases. Do not run the unit when it is
positioneddown-wind from anypotential sourceofpollutionincludingthe
work site.
If any fuel is spilt make sure the area is dry before starting the engine.
Many parts, especially the exhaust muffler and spark arrestor, become
very hot during operation and remain hot for a while after stopping the
engine. To avoid burns or fire hazards, always let the unit cool before
transporting, storing, or servicing.
Do not attempt any work on the compressor until the engine has been
stopped and the system completely depressurised. Wait until the
pressure gauge reads zero.
Donot insert any object through the fan guardrings. Serious damage to
the compressor and personal injury could result.
If changing the oil when the compressor is still warm, take necessary
precautions to avoid contact of hot oil with the skin. Dispose of used oil
with due regard to the environment.
Be aware of the location of the nearest fire extinguishers and their
method of operation. Great care should be taken not to spill fuel,
especially near a hot exhaust.
For safe operation prior to towing the compressor – see section 4.4.
This machine is only to be used by fully trained personnel in possession
of a current approved operator’s certificate.

MAC8000 NOVEMBER 2010
4.2 SITING
Never run the engine in an enclosed or confined area. The unit should
be operated on reasonably level ground and sited to prevent the re-
entrainment of exhaust gases and other toxic atmospheres. Taking
accountof thewind direction, the likelihood of pollutionfrom theworksite
andother local emissions, the compressorshould be positionedto avoid
ingesting these. A hinged high-level air intake is provided which, in the
operationalmode, ispivoted tothe vertical and should be fittedwith wind
directionindicatorsupplied. Communications between thestand-byman
and the BA wearer, and the routing of the supply hoses should also be
considered.
4.3 PRE-OPERATION DAILY CHECKS
Check for the following:-
the siting is still correct (see 4.2)
leaks
fuel level
engine oil level
compressor oil level
reserve air is adequate (see 4.4 for changing)
empty condensate container
Theunit shouldbe aslevel aspossible in bothplanes whilstin operation.
4.4 CHANGING HIGH-PRESSURE RESERVE CYLINDERS
If the cylinder pressure is below 138 bar (2,000 psi) replace with fully
charged cylinder as below:-
fully turn off cylinder valve (clockwise)
open cylinder connector bleed screw (anti-clockwise)
check pressure gauge reads zero pressure
remove cylinder DIN connector by turning handwheel anti-clockwise
remove cylinder from storage tube and replace with fully charged
equivalent cylinder
re-connect cylinder DIN connector and fully close bleed screw

MAC8000 NOVEMBER 2010
DIN Connector
Pressure Gauge
Bleed Screw
4.5 TOWING THE COMPRESSOR
Check the towbar, braking system and coupling. Check that wheels are
secure, tyres are in good condition and inflated correctly.
Connect lighting cable to towing vehicle if applicable. Check correct
operation of all lights.
Raise the jockey wheel fully and lock.
Ensure breakaway cable is secured to towing vehicle (where fitted).
Release the handbrake (where fitted).
Lower air intake and close the canopy and secure.

MAC8000 NOVEMBER 2010
5.0 MAINTENANCE AND SERVICE
(Refer to appropriate sections for specific details on how to carry out
the tasks)
5.1 MAINTENANCE SCHEDULE
Maintenance Schedule Daily Initially 6-
Monthly Yearly
50 hours
after initial
start-up
Or every
1,000
hours
Or every 500
hours Or every 2,000
hours
Service pack KIT 0273
Engine oil level Check
Compressor oil level Check
Fuel level Check/fill
Air filter vacuator valves Empty
Fuel filter water drain Drain
Air intake vacuum indicators Check
Drain water out of frame Check/drain
General conditions (leaks,
damaged parts, loose bolts,
trouble in previous operation)
Check
During operation (meters and
lamps, noise, the colour of the
exhaust fumes
Check
Electrolyte level and terminals of
battery Check Check
Tyre pressure Check Check
Leaks in air-, oil- or fuel system Check Check
Oil coolers Clean
Engine minimum and maximum
speeds Check Check
Torque of wheel nuts Check Check
Brake system Check/adjust Check/adjust
Safety valve Test
Door hinges Grease
Coupling head and all its moving
parts/shaft Grease
Shutdown switches Check
Pressure drop over separator
element Replace
Fan V-belt Adjust
Fuel tank Clean
Compressor oil Change
Compressor oil filter Replace
Air filter element Replace
Safety cartridges (option) Replace
Engine oil  Change
Engine oil filter Replace
Fuel filter Replace
Engine inlet and outlet valves  Adjust 

MAC8000 NOVEMBER 2010
Maintenance Schedule Daily Initially 6-Monthly Yearly
50 hours
after initial
start-up
Or every
1,000
hours
Or every
500 hours Or every 2,000
hours
Breathing-air filtration
Pre-filter element Replace
Coalescing filter element Replace
Activated carbon filter
element – main Replace Replace
Activated carbon filter
element – auxiliary Check Check
Hopcalite filter element Replace
Chalwyn intake valve Check
Engine intake filter element –
main Replace
Engine intake filter element –
secondary Replace
More frequently when operating in a
dusty environment Also drain engine oil from engine oil cooler (see Fig. 2.2 DPEC= Drain plug engine oil cooler)
Replace the element when the
pressure drop exceeds 0.8 bar In case of poor fuel quality, replace fuel filter more frequently
Refer to the Deutz operation manual The valves need to be adjusted for the first time
before 500 running hours
500 hours only valid when using
PAROIL SAE 15 W 40
Keep the bolts of the housing, the lifting eye, the towbar and the axle securely tightened.
Refer to section 8 ‘Technical specifications’ and section 3.1.3 for the torque values.
5.2 SERVICE SPARES
Description Quantity Part NoService interval
Pre-filter element 1 FIL0462 2000 hours/12 months
Coalescing filter element 1 FIL0461 2000 hours/12 months
Activated carbon filter element 1 FIL0440 1000 hours/6 months
Hopcalite filter element 1 FIL0463 2000 hours/12 months
Engine intake filter – main element 1 FIL0059 2000 hours/12 months
Engine intake filter – secondary element 1 FIL0449 2000 hours/12 months
Service pack – compressor and engine 1 KIT0273 500 hours/12 months
Service pack – unloading valve 1 KIT0271
Service pack – oil separator 1 KIT0274
Wind direction indicator 1 IND0061
Mineral compressor oil PAROIL M 5 litres OIL0031 500 hours/12 months
Mineral compressor oil PAROIL M 20 litres OIL0038 500 hours/12 months
Synthetic compressor oil PAROIL S 5 litres OIL0039 500 hours/12 months
Synthetic compressor oil PAROIL S 20 litres OIL0040 500 hours/12 months

MAC8000 NOVEMBER 2010
5.3 OILS
Engine:
30°C to 40°C PAROIL 15W40
30°C to -5°C PAROIL 15W40
-5°C to -20°C PAROIL 5W30
Compressor:
30°C to 40°C PAROIL S
30°C to -5°C PAROIL M/S
-5°C to -20°C PAROIL S
For detailed maintenance procedures consult the manufacturers’
manuals 9 section 4.3 and 10 section 4.1.
5.4 BREATHING-AIR FILTRATION
For further details see section 12.

MAC8000 NOVEMBER 2010
6.0 START UP PROCEDURE
Carry out pre-start checks (see 4.3)
Fit wind direction indicator and raise air intake
Raise canopy and ensure the safety support strut is in position
Push Circuit Breaker button (F1) once to allow starting
Ensure bleed screws are closed, turn on HP cylinders and check
pressures, HP alarm will sound
Pull safety support release, lower canopy and latch in position
Turn start switch to position 1 general alarm lamp will go on.
Turn start switch further clockwise to position 3, the starter will set
the engine in motion.
The maximum allowed starter time, where the starter motor is
running continuously is 20 seconds. If the engine does not catch, a
new attempt can be made after 30 seconds waiting. The
temperature alarm lamp H1 and the general alarm lamp H2 will go
out as soon as the engine has been started. The start switch
automatically springs back to position 1. Lamp H1 will only go on
when the compressor outlet temperature is too high.
The engine will run for 30 seconds OFF load on every start.
Check system status is ‘OK’ and alarms have ceased
The compressor is now ready for use
H1 Ignition switch
H2
Circuit breaker (F2)
Circuit breaker (F1)

MAC8000 NOVEMBER 2010
7.0 SHUTDOWN PROCEDURE
Ensure the machine is not supporting life
Disconnect all outlet hoses
Raise canopy and ensure safety support strut is in position
Turn off all HP cylinders
Stop engine by turning the ignition switch anticlockwise to ‘O’ stop
position (HP alarm will sound)
Depresssystem vent valveon maincontrol paneluntil all air pressure
has vented and alarms have ceased
Some outlet gauges may continue to show pressure
Push Circuit Breaker button (F1) once to prevent unintentional
starting
Pull the safety support release, lower canopy and latch in position
System Vent Valve
Circuit breaker (F2)
Circuit breaker (F1)

MAC8000 NOVEMBER 2010
8.0 WARNINGS
IF A WARNING ALARM SOUNDS, IMMEDIATELY EVACUATE ALL
BREATHING APPARATUS WEARERS TO A SAFE AREA
AN AUDIBLE AND VISUAL ALARM SHOWS:
1 Low compressor pressure
2 Malfunction of compressor or engine
3 Excessive demand
4 Restricted air intake
5 Low cylinder pressure
6 Residual pressure remains after ignition is turned off
FOR FURTHER INSTRUCTIONS AND DETAILED SERVICING
METHODS CONSULT OPERATOR’S HANDBOOK.
8.1 WARNING SEQUENCES
8.2 If the primary airline pressure drops to 7 bar (102 psi) the siren sounds
and the orange low-pressure alarm lamp will illuminate. If the drop
continues and reaches 6.8 bar (99 psi), the high-pressure cylinders
automatically come into operation and the status indicator turns from
green to red.
If the cylinder pressure drops below 138 bar (2,000 psi), the siren
sounds and the red high-pressure alarm will illuminate to warn that the
reserve supply is running low.
If the primary supply is restored, the system reverts to normal mode,
cylindersupply ceases andthe status indicator turns green. However, if
cylinder pressure has by then dropped below 138 bar (2,000 psi), the
siren and red lamp will continue to warn of low emergency supply.
Similarly, in the event of leakage from cylinders with a pressure drop
below 138 bar (2,000 psi), the siren sounds and the warning lamp
remains illuminated even though primary pressure is normal.

MAC8000 NOVEMBER 2010
8.3 If high engine temperature, low oil pressure or high compressor oil
temperaturesare detected,the primarysupply is shutdown becausethe
engine is stopped and the reserve automatically brought online.
8 x 9 litre @ 200 bar pressure cylinders

MAC8000 NOVEMBER 2010
10 DIESEL ENGINE
10.1 ENGINE INTAKE FILTER
Intake filter
assembly
Secondary filter
element FIL0449
Main filter element
FIL0059

MAC8000 NOVEMBER 2010
12.0 FILTERS
Activated carbon filter element rotation change sequence
Remove element from main activated carbon filter
Remove element from auxiliary activated carbon filter and refit to main filter
Fit replacement element to auxiliary activated carbon filter
A76 X1 Fine Filter assembly
E711 X1 Element kit
Change at 2,000 hours/yearly
A76 XA High Efficiency Filter assembly
E711 XA Element
Change at 2,000 hours/yearly
A76 AC Activated Carbon
Filter body - auxiliary
E711 AC Element
Change as detailed below
1,000 hours/half yearly
A77 HC Hopcolite Filter
E811HC Element
Change at 2,000 hours/yearly
A76 AC Activated Carbon
Filter body - main
E711 AC Element
Change if odour is detected
or 1,000 hours/half yearly
(see below)