BSI Operating Manual

Operations and Maintenance User Instructions
Life Support System

Breathing Systems Inc.
Breathing Systems, Inc.

8800 Grow Drive
Pensacola, Florida 32514
USA
0158
EC-Guideline 89/686/EWG
Certificate Nr. 5640 A/06/9 PSA
NIOSH Certificate TC-13F-360
Copyright November 2014

8800 Grow Drive
Pensacola FL 32514
USA
Operations and Maintenance Instructions

Type: Life Support System 5004
Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 2 of 39
Revision C (March 2014 Revision Reference NIOSH Label Only On Page 2)
Breathing Systems Inc. 8800 Grow Drive, Pensacola Fl 32514

www.breathingsystems.us Phone: +1 (850) 477 2324

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 3 of 39
Contents
CAUTIONS AND LIMITATIONS .................................................................................................................. 4
Introduction ............................................................................................................................................. 5
1. Product Description ............................................................................................................................. 5
1.1 Combination of Life Support System assemblies ........................................................................... 6
2. Safety information ............................................................................................................................... 6
3. Intended use ........................................................................................................................................ 6
4. Medical precautions............................................................................................................................. 6
5. Qualifications for operating the Life Support System.......................................................................... 6
6. Life Support System operations ........................................................................................................... 7
6.1. General .......................................................................................................................................... 7
6.2. Life Support System preparations................................................................................................. 7
6.3. Air control console ........................................................................................................................ 7
6.4. Using the Life Support helmet assembly .................................................................................... 11
6.5. Escape/Egress airline system 5000 ............................................................................................. 17
6.6. Completing operations with the Life Support System ................................................................ 18
7. Drawings ............................................................................................................................................ 19
7.1. Helmet connections (Model 2000) ............................................................................................. 19
7.2. Helmet side view (Model 2000) .................................................................................................. 20
7.3. Helmet regulators (Model 2000) ................................................................................................ 21
7.4. Helmet backs (Model 2000) ........................................................................................................ 22
7.5. Helmet interior (Model 2000) ..................................................................................................... 22
8. Maintenance ...................................................................................................................................... 23
8.1. Tools ............................................................................................................................................ 23
8.2. Testing accessories...................................................................................................................... 23
8.3. Air control console maintenance ................................................................................................ 24
8.4. Umbilical maintenance ............................................................................................................... 24
8.5. Life support helmet maintenance ............................................................................................... 24
8.7. Cleaning helmet assembly .......................................................................................................... 29
8.9. Final tests .................................................................................................................................... 34
9. Repairing ............................................................................................................................................ 36
9.1. Repairing air control console ...................................................................................................... 36

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 4 of 39
CAUTIONS AND LIMITATIONS

D - Air-line respirators can be used only when the respirators are supplied with breathing air
meeting the requirements of CGA G-7.1, Grade D or higher quality.
E - Use only the pressure ranges and hose lengths specified in the Users Instructions.
I - Contains electrical parts which have not been evaluated as an ignition source in flammable
or explosive atmospheres by MSHA/NIOSH.
J - Failure to properly use and maintain this product could result in injury or death.
M - All approved respirators shall be selected, fitted, used, and maintained in accordance with
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 the manufacturer.
O - Refer to Users Instructions, and/or maintenance manuals for information on use and
maintenance of these respirators.
S - Special or critical Users Instructions and/or specific use limitations apply. Refer to Users
Instructions before donning.
If temperature falls below 12 degrees Celsius or 50 degrees Fahrenheit the cold weather operations
heater should be connected. Heater voltage is optionally 110V or 220V, 60/50 Hz


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 5 of 39
Introduction
This manual describes the set-up, operation and maintenance of the Life Support System. It is intended
to guide the user through the safe operation and use of the Life Support System. The system is recognized
as Personal Protective Equipment pursuant to the guidelines of the European member states
(89/686/EWG) and is certified with the CE-Symbol. The system additionally is certified by United States
NIOSH (TC-13F-360) National Institute for Occupational Safety and Health.
1. Product Description
The Life Support System consists of the following components:
Air control console Model 5004 consisting of:

o
Control instruments for regulating the breathing air to helmet assemblies
Pressure reducers: high pressure (HP), low pressure (LP)
Visual and audible alarms
Communications system
Electrical heater for cold weather operations
Connections for communications
Connections for air supply cylinders
Umbilical connections
Umbilical assembly with two air supply lines, communication cable and steel safety cable
Life support helmet assembly Model 5000 consisting of :

o
Molded fiberglass and carbon fiber helmet assembly
Breathing regulators
Harness assembly
Exhalation valve
Communications headset
Connections for communication
Helmet latch assemblies
Operators communications headset
Egress cylinder assembly Model 5000
Egress regulator assembly
Egress airline system (optional) consisting of:

o Escape line (Egress Air Line)


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 6 of 39
1.1 Combination of Life Support System assemblies

The following combinations of the Life Support System are possible:
Control Helmet
Console Model
Model
5004
5000
Umbilical
Egress
Cylinder
100ft
30m
150ft
50m
200ft
60m
300ft
100m
External
Emergency
Air Cylinder
with
Connection
Escape Line
Optional
x
Pressure
Reducing
Regulator
and
Egress
Bottle
200-006
x = permissible combinations
Helmets are available in the following standard colors:
White Red Blue Yellow Brown Black Orange or custom colors
2. Safety information
The life support system may be operated when temperature does not fall below 0 degrees
Celsius (32F) and does not exceed 60C (140F).
The life support system should be stored in a closed and dry room and the storage
temperature should not be less than 0C (32F). Storage temperature should not exceed 60C
(140F). The life support system should be protected against moisture, dust and dirt.
Maintenance and repairs should be carried out by certified personnel trained by Breathing
Systems Inc., Pensacola, Florida (Refer to Figure 8.2).
The life support helmet should never be worn without air supplies connected and air control
console valves in the on position.
3. Intended use
The purpose of the Life Support System is to provide respiratory protection during entry into and egress
from oxygen deficient atmospheres.
4. Medical precautions
It is recommended that anyone wearing the life support helmet assembly receive a physical
examination by a medical doctor before using the system.
5. Qualifications for operating the Life Support System

Technician
Person entering confined space or vessels using life support helmet Model 5000.
Technician Assistant (Top Supervisor)
Person in charge of working the platform where the vessel or confined space is entered.
Safety Man
Person wearing life support helmet and standing by to assist persons entering confined space or
vessels.

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 7 of 39
Console Operator
Person in charge of all activities that apply to the life support system. The operator of the air control
console should be in continuous communications with all persons. The operator should not leave the air
control console when technicians and/or safety man are wearing life support helmet assembly.
Supervisor
Responsible for the entire operation
6. Life Support System operations

6.1. General
Prior to operations, the supervisor and technician should confirm that all required permits have been
issued.
6.2. Life Support System preparations
The following should be checked before operations:
Air supply cylinders are full and breathing air is of acceptable quality
Egress cylinders are full
Escape airline system is connected to separate regulated air supply
Current physical examination of workers
Certification of life support system operator
6.3. Air control console

Set up air control console on level surface
Open cover
Air Control Console Model 5004
Check the communications systems grounding connection on back of console
Strain relief of umbilical to be attached to solid structure
On/Off volume control


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 8 of 39
If temperature falls below 12 degrees Celsius or 50 degrees Fahrenheit the cold weather
operations heater should be connected. Heater voltage is optionally 110V or 220V, 60/50 Hz
Check to determine electrical requirements for air control console.
Frequent adjustment to volume control indicates battery replacement is required
Cold weather operations heater
Connect primary and secondary breathing air supplies to the back of air control console.
(Breathing air cylinder pressure should not exceed 200 bar/3000 PSI)
Primary Breathing Air Connection
Secondary Breathing Air Connection
Connect Umbilical to the back side of air control console. Umbilical connections are color
coded. Connect umbilical stainless steel plug to color matched stainless steel coupling.
Rotate coupling sleeve ninety degrees to safety lock. Connect umbilical brass plug to color
matched brass coupling. Rotate coupling sleeve ninety degrees to safety lock.

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 9 of 39
Back of air control console
Secondary Umbilical Air Hose Connection to Air Control Console
Connect communication connector

Check that all valves on control console are in OFF position
Open both valves for primary and secondary breathing air supplies on breathing air cylinders
Check air pressure on control panel
Pressure gauge display for air supply and regulated breathing air


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 10 of 39
Primary and Secondary outlet pressure is adjusted to 120 PSI 125 PSI. To increase pressure
settings, pull upward on black adjustment knob and turn clockwise to increase pressure
setting and turn counterclockwise to decrease pressure setting. After pressure is adjusted,
push knob back down to safety lock.
Knobs to adjust outlet pressure
6.3.1. Air control console

The Air control console displays operating information on the life support system.
Breathing air supply pressure from primary and secondary air supply cylinders are shown on
the air supply pressure gauges. If pressure for primary or secondary air supply reaches 500
PSI, a yellow LED warning light illuminates and an alarm sounds.
Display for air supply


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 11 of 39
Regulated air supply pressure has been pre-adjusted to 180 PSI 10 PSI.
Display for regulated air supply
Primary and secondary breathing air controls are provided. Units 1 4 are color coded and each
outgoing pressure is adjusted to 120 PSI 125 PSI. A green LED indicator illuminates in rhythm with
primary breathing in the helmet. If something should occur to the primary breathing circuit, helmet
breathing automatically transfers to the secondary breathing circuit which is indicated by the red LED
illuminating in rhythm with breathing.
Breathing indicator lights
6.4. Using the Life Support helmet assembly
It is recommended that a technician assist the life support technician preparing to use the life
support system.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 12 of 39
Model 5000
The life support technician with the assistance of a second technician should check to make
sure belts and buckles on the safety harness assembly are firmly connected. The egress
cylinder should be connected to the belt assembly at the left side of the technician and the
egress regulator and hose assembly connected to the harness. The steel safety cable should
be connected to the harness center D-ring.
Check that the egress cylinder valve hand wheel is fully closed.
Model 5000 front
Model 5000 side
Helmet air hose couplings should be at left side of harness
Model 5000 back
Model 5000 egress cylinder
Umbilical Connections
Connect umbilical strain relief cable to strain relief cable on harness. Connect primary and
secondary umbilical air couplings to the short length of umbilical on harness assembly.
Rotate ring on couplings ninety degrees to safety lock. Connect umbilical communications
connector to its mating connector.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 13 of 39
Hold life support helmet assembly in front of chest. Connect helmet hose with stainless steel
fitting to stainless steel coupling on left side of harness assembly. Rotate coupling sleeve
ninety degrees to safety lock. Connect helmet hose with brass fitting to brass coupling on left
side of harness assembly. Rotate coupling sleeve ninety degrees to safety lock.
Helmet
The life support helmet assembly includes three adjustments for sizing. With these adjustments the
helmet can be sized to comfortably fit head and face sizes to the 85th percentile. A pump and bladder
assembly is inflated to full pressure by applying thumb pressure until the bladder is full. Spacer pads in
the back of the helmet provide a comfortable fit. An adjustable net suspension with friction buckles
adjusts helmet and facemask for an air tight mask seal.
Pump for bladder assembly
To open the helmet, press on the latch assemblies at the lower right and left side.
With latch assemblies pressed, lift back of the helmet upward.
Release the friction buckles on the net suspension. Hold the helmet front in the left hand and
place face into helmet face mask.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 14 of 39
Helmet latch assemblies
Adjust net suspension for proper face seal
Open latch assemblies by pressing on side
Technician asks air control console operator to Turn Secondary Air On.
Console operator turns secondary air valve at control console to ON and red LED illuminates as
breathing air flows into the face mask. Console operator confirms Secondary Air On.
Secondary breathing red LED indicator lights
Technician senses air flow into face mask and presses the helmet to his face and breathes normally.

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 15 of 39
Adjust suspension net straps and friction buckles at back of head.
Adjusted suspension net
Technician checks communications. Technician, Technician Assistant (Top Supervisor) and

Console Operator confirm communications with each other.
If helmet is equipped with video communication system, Technician Assistant (Top
Supervisor) checks that Console Operators video communication system has clear picture.
The helmet is closed and latches connect firmly. Technician Assistant checks to confirm the
helmet is latched.
Helmet latch assemblies: LOCKED
After the helmet is latched, pressure in the helmet bladder can be reduced for better fit by
pressing the pressure relief valve at the back of the helmet.

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 16 of 39
Pressure relief valve
Once the technician is breathing normally, the technician assistant asks the Console operator
to turn Primary Air On.
The console operator turns the primary air valve on and the green LED flashes with each
breath. When the technician is breathing on primary air, the red LED on the secondary air
control turns off. Caution: Do not turn secondary control valve off as it is now in an
automatic standby position. If an interruption occurs to the primary breathing air, the
secondary operates automatically providing breathing air to the helmet assembly.
Primary breathing green LED indicator lights
Once primary air is flowing and the technician is breathing normally, the latch assemblies can
be safety locked.
Turn locking screw fully clockwise to safety lock.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 17 of 39
Locking screw Life Support Helmet
Note: The helmet lens meets impact resistance GGG-M-125d Oct.11, 1965 (amended July 30, 1969).
Antifog is not needed.
6.5. Escape/Egress airline system 5000
When a confined space requires five or more minutes for escape/egress, the emergency egress/escape
airline should be used.
The emergency egress airline is an air supply hose connected to a separate large volume air cylinder
with a pressure reducing regulator.
Caution: protect air cylinders from falling.
The large volume air cylinder should be located outside of the confined space entry but accessible to
the Technician Assistant/Top Supervisor.
The large volume air cylinder is always turned on. The hose assembly with quick connection coupling is
lowered into the confined space level with the life support helmet. If a complete interruption occurs to
the umbilical air supplies, the technician should be trained to turn on the egress cylinder worn on his
harness. Since this air supply is five minutes duration, the technician should breathe normally for a few
moments while he locates the emergency egress airline. In the Model 5000 Life Support System, the
egress airlines brass coupling connects to the brass fitting at the left front of the harness assembly.
Connection point Escape/Egress airline
The life support technician is ready to enter the confined space.

It is important to replace the air supply cylinders with full cylinders when supply pressure
reaches 500 PSI and the low pressure indicator LED illuminates and the alarm sounds.
Technicians, supervision and console operator should have clear intercom communications at

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 18 of 39
all times.
6.5.1. Automatic breathing system backup
The life support system is designed to provide an automatic breathing system back up.
Escape/Egress airline Connected
The escape/egress airline provides extended time for emergency exit for the life support technician.
Use of the escape/egress airline is essential whenever escape/egress will require five minutes or longer
to reach a safe environment.
6.6. Completing operations with the Life Support System
After the Technician has left the confined space and is in a safe environment, the Life Support
System should be taken out of service as follows:
Unlock helmet latch assemblies by turning lock screw counter clockwise.

Primary air supply should be turned off/closed by console operator at request of the top
supervisor.
Open both latch assemblies on life support helmet.
Secondary air supply should be turned off/closed by console operator at request of top
supervisor.
Remove helmet assembly from technicians head
Remove egress cylinder from harness assembly
Disconnect helmet primary and secondary airlines at couplings,
Disconnect helmet communications connector
Close breathing air supply cylinders
Turn off communications at air control console
Disconnect HP air supply manifolds between console and air supply cylinders
Disconnect umbilical and communications lines at air control console
Close top of air control console
Wind umbilical on to reel assembly
Clean and dry helmet assembly and conduct after job maintenance


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 19 of 39
7. Drawings
7.1. Helmet connections (Model 2000)
1. Helmet
5. Visor/lens Screw
9. Communication Cable
13. Primary Air Connection
2. Sensing Port
Screw
6. Secondary Air Hose Swivel

Connection
10. Safety Hook
14. Communication
Connection
3. Suspension Screw
7. Egress/escape Air Line Connection
11. Spiral Wrap Protection
4. Visor/lens
8. Primary Air Hose Swivel Connection
15. Umbilical
12. Secondary Air
Connection


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 20 of 39
7.2. Helmet side view (Model 2000)
1. Visor/Lens
4. Hinge Screws (10pcs)
7. Air Supply Hose
2. Sensing Port Screw
5. Visor/Lens Screws
8. Swivel Connection
3. Suspension Net Screw
6. Suspension Screws And Washers
9. Rubber Plug To Secondary Regulator


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 21 of 39
Model 5000
The Model 5000 helmet assembly hose connections are located on the chin area of the helmet.
7.3. Helmet regulators (Model 2000)
1. Sensing tube
2. Regulator mounting
3. Regulator
4. Air Tube
5. Swivel screws
6. Swivel Body
7. Air Inlet Fitting
8. Inlet manifold


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 22 of 39
7.4. Helmet backs (Model 2000)
1. Pump Cover
2. Pump & Bladder Assembly
3. Relief Valve
7.5. Helmet interior (Model 2000)
1. Microphone
5.Suspension pads
9. Pump and Bladder Assembly
2. Helmet latch assembly
6. Suspension
10 .Pressure relief valve
3. Latch screw
7. Comfort Pad Assembly
11. Suspension net
4.Helmet communications
8. Bayonet-Latch
12. Communication cable
13. Exhalation valve


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 23 of 39
8. Maintenance
Maintenance and repairs to Model 5000 life support systems should be performed by technicians
certified by Breathing Systems Inc., Pensacola, Florida.
8.1. Tools
The following tools are recommended during maintenance:
Adjustable wrench
Wire cutters
Phillips head screwdrivers of different sizes
Socket head screwdriver 3/32 and 3/16
Hexagon/Allen screwdriver 0,035 and 0.05
Hexagon/Allen screwdriver set 5/64 1/4
Liquid soap
Isopropyl alcohol
Soft cloth
Cleaning Brush
Bleach
8.2. Testing accessories

Testing Accessories
Drying oven
Helmet test instrument
Helmet regulator/exhalation valve test fixture
Breathing air supply regulated to 120 125 PSI
BSI communication system
Application
Dry the cleaned but wet helmet parts
Test static pressure and flow rates of regulators
Test and adjust static pressure setting of helmet
regulators and opening pressure of exhalation valve
For use during performance tests
Test helmet communications
Tests and maintenance should be performed as described in this manual.

Maintenance and tests to be performed according to following table:


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 24 of 39
Legend
0
1
2
3
4
5
No test
Visual test
Function test
Cleaning and disinfection
Test according legislation
Tested by Breathing Systems Inc
8.3. Air control console maintenance

Maintenance and repairs to the air control console should be carried out by Breathing Systems Inc.,
Pensacola, Florida or a certified technician.
8.4. Umbilical maintenance
Umbilical indicating possible damage should not be used without pressure and leak testing. Umbilical
should be visually inspected before use for damage to the exterior urethane cover, breathing air hoses,
safety cable, and communications connectors.
Figure: Umbilical connections (Model 2000)
Maintenance and repair to communication cables and communications connections should be

performed by certified technician.
8.5. Life support helmet maintenance
Maintenance and testing of life support helmet assemblies should be performed at the intervals
indicated in table 8.2. Maintenance and tests should be carried out by trained and certified technicians
and records should be maintained. Breathing Systems Inc. recommends that the helmet assembly be
visually inspected, cleaned and disinfected after each operation.
After use maintenance procedure should include the following:
Disassemble helmet assembly

Clean and disinfect
Dry and reassemble
Performance testing


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 25 of 39
8.6.1. Primary and secondary air breathing hose

Primary and secondary breathing air hoses are connected to the helmet with a swivel
assembly. Unscrew the swivel screw counterclockwise using a 3/16 Allen wrench tool.
Remove plastic wrap from the primary and secondary air hose, safety and communications
cables.
Figure: Remove plastic wrap (Model 2000)
The primary breathing air hose is connected to the swivel on the right side (technicians right
side) of the life support helmet. The secondary breathing air hose is connected to the swivel
on the left side of the life support helmet.
Figure: Unscrew swivel screw counterclockwise using 3/16 Allen wrench tool (Model 2000)
Replace O-Rings and plastic split-rings on the swivel screw

8.6.2. Helmet suspension pads and communications
Helmet suspension pads and comfort pads are held in place with hook and loop fasteners.
Model 2000
Remove suspension pads


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 26 of 39
Disconnect connecting plug between communications headset and microphone. Carefully lift
communications headset from hook and loop fasteners on suspension and remove from
helmet.
Model 2000
Remove communication headset
8.6.3. Communications testing

Connect helmet communication connector/plug to control console communications system.
Connect operators communications headset and turn volume control to ON.
Check communications reception from each helmet headset speaker
8.6.4. Helmet suspension and suspension net
Model 2000
Remove suspension net and plastic suspension

Remove four screws, washers and spacer washers securing plastic suspension.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 27 of 39
Model 2000
The holes for installing the plastic suspension are diagonal and the suspension must be
installed the same way. If the suspension is installed backwards the helmet will not
completely close.
For installation, mark the suspension R for right L for left.
8.6.5. Helmet back shell removal
Remove the five screws, washers and locknuts from the helmet front shell.
Models 5000, 2000
Helmet back shell removal
The center screw is longer than the other screws and there is a metal spacer between the
helmet hinge and helmet shell.
8.6.6. Remove and test exhalation valve

Press together the exhalation valve retaining ring while pulling the exhalation valve out of the
helmet.
Models 5000, 2000


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 28 of 39
Examine operation of exhalation valve.

Check movement of the spring underneath the blue diaphragm using slight pressure from
index finger.
If spring does not have free movement it should be replaced.
Examine blue diaphragm for damage. It should be replaced if damaged.
Examine o-ring for damage and replace o-ring if necessary.
Models 5000, 2000
Test movement of exhalation valve spring
If spring does not have free movement or if diaphragm is damaged the valve should be replaced or
returned to Breathing Systems Inc. for repair.
8.6.7. Remove primary regulator
Remove air manifold from regulator mounting.

Remove two socket head cap screws from inlet fitting
Remove four Phillips head screws from air manifold assembly
Remove large black hose from regulator mounting.
Remove small diameter black sensing tube from regulator mounting.
Remove small diameter black sensing tube from tube fitting below face mask.
Remove three silicone O-rings between regulator and mount.
Model 2000
8.6.8. Remove secondary regulator

Remove socket head cap screws from inlet fitting.
Remove air manifold from regulator mounting.
Remove four Phillips head screws from air manifold.
Remove large black hose from regulator mounting.
Remove small diameter black sensing tube from regulator mounting.
Remove small diameter black sensing tube from fitting below face mask.
Remove three silicone o-rings between regulator and mount.
O-Rings to be replaced during maintenance on Regulator, Manifold or Connections

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 29 of 39
8.6.9. Removing visor/lens

Remove visor/lens assembly only if the gasket is damaged or lens requires replacement.
Remove socket head cap screws from lens retainers. Remove visor/lens assembly from
helmet.
Model 2000
Remove four screws from the visor/lens frame.
Model 2000
8.7. Cleaning helmet assembly

All screws, washers, nuts and o-rings should be replaced during maintenance.
The following parts should be cleaned with a solution of warm water, liquid soap and two ounces of
bleach mixed in a large volume sink. After cleaning all parts should be rinsed in clean water and dried.
Helmet shell
Visor/lens
Visor/lens frame
Suspension pads
Suspension net
Suspension assembly
Exhalation valve
Face mask (cleaned in helmet assembly)
Manifold assembly
Inlet fitting and manifold
Clean visor/lens assembly with soap and water and a soft cloth.
All washed parts should be rinsed with clean water.

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 30 of 39
8.8.1. Helmet regulator/exhalation valve test fixture

The helmet test instrument enables the technician to test the static pressure of primary and secondary
helmet regulators using the regulator and exhalation valve test fixture. These tests determine if helmet
regulators and exhalation valve performance conforms to minimum specifications. Additionally, helmet
regulator flow can be checked to determine if the regulators provide minimum required breathing air
flow. Regulated breathing air supply should be 120 125 PSI (8.5 bar) connected to the test fixture.
CAUTION: Breathing air supply to the test fixture should not exceed 120 125 PSI (8.5 bar) or damage
may occur to the test fixture or injury to the operator.
BSI Helmet Test Instrument
Helmet regulator/exhalation test fixture

1. Air Pressure Indicator /
manometer
2 .Flow meter
3. Air supply valve on/off
5. Primary breathing air connection
4. Secondary breathing air

connection
6. Pressure sensing tube for helmet

regulators
7. Air supply connection


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 31 of 39
Install helmet regulator into test fixture as illustrated

Connect breathing air supply 120 125 PSI (8.5 bar) to helmet test instrument (7)
Connect test fixture to helmet test instrument (5) with hose assembly
Connect sensing tube (6) to test fixture)
Open valve clockwise (3)
Cover exhalation valve sensing tube fitting with index finger
Read static pressure of helmet regulator on manometer (1)
Primary helmet regulator setting is 1.8 to 2.2 inches water column pressure: To adjust
turn cover set screw clockwise using .050 Allen wrench screw driver to
increase
setting or counterclockwise to decrease setting
Secondary helmet regulator setting is 1.2 to 1.6 inches water column pressure. To adjust
turn cover set screw clockwise using ,050 Allen wrench screw driver to increase setting or
counterclockwise to decrease setting
Close valve (3) counterclockwise
Test adjustment complete
8.8.2. Exhalation valve test and adjustment
Install exhalation valve into test fixture as illustrated

Connect test fixture to helmet test instrument (5) with hose assembly
Connect sensing tube (6) to test fixture
Open valve counter clockwise (3)
Cover helmet regulator sensing tube fitting with index finger
Read pressure setting of exhalation valve on manometer (1)
Exhalation valve setting is 2.2 2.5 inches water column pressure. To adjust turn cover set
screw clockwise using a .050 Allen wrench screw driver to increase setting or
counterclockwise to decrease setting.
Replace exhalation valve if it cannot be adjusted to specification
Close valve (3)
Remove exhalation valve from test fixture
Test/adjustment complete.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 32 of 39
8.8.3. Installation of helmet regulators
Model 2000
Inside the helmet insert three silicone o-rings into primary regulator mounts in the lower
right side of the helmet
Position the primary regulator on the regulator mounts, insert and tighten two screws.
Attach large black regulator hose to the regulator mounts outlet and secure with small plastic
electrical tie.
Insert silicone o-ring into inlet manifold and fasten to regulator mounts and regulator with
two 1 screws.
Connect opposite end of large black regulator hose to chrome plated air tube bonded into
helmet and secure with electrical tie.
Connect air inlet fitting to helmet and inlet manifold with two cap head screws.
Connect one end of the small black regulator sensing tube to small aluminum tube on
regulator mounting.
Connect opposite end of small black regulator sensing tube to small aluminum tube below the
helmet face mask assembly.
Follow same procedure for assembling of secondary regulator in the lower left side of the
helmet.
8.8.4. Installation of exhalation valve

Position retaining ring on exhalation valve.
Squeeze together the exposed ends of the retaining ring and fit a length of ID hose over
the exposed ends to secure.
Insert exhalation valve and retaining ring into exhalation valve receptacle and align ends of
retaining ring with the notch in the receptacle.
Remove the ID hose from the ends of the retaining ring.
Retaining rings will position inside the notch, press down firmly and secure the exhalation
valve.
Models 2000, 5000
Caution: Confirm fit of exhalation valve by lightly pulling on the valve.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 33 of 39
8.8.5. Helmet assembly
Fit together helmet front and back with latch assemblies,

Insert five screws and washers into the top of helmet. The center screw is 3/8 and the four
side screws are screws. Between the helmet shell and hinge assembly, insert metal spacer
onto 3/8 screw.
Models 2000, 5000
8.8.6. Pump and bladder installation
Remove pump and bladder assembly from helmet

Inflate bladder assembly by rapid pressing of pump with thumb pressure
Place assembly under water and check for air leakage.
Replace pump and bladder assembly if leakage occurs.
If no leakage, depress pressure release valve to check deflation operation.
Replace pump and bladder assembly if pressure release valve is inoperable
Model 2000 picture
8.8.7. Suspension and suspension net installation

Position large spacer washers on suspension tee nuts.
Guide tee nuts through positioning holes in the side of helmet.
Secure with 6-32 X 3/8 screws and washers.
Suspension tee nuts must align with mounting holes on the side of helmet.
If helmet will not close and latch, the suspension has been installed backwards.
Secure suspension net in helmet with four 6-32 X 3/8 screws and washers.


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 34 of 39
Model 2000
8.8.8. Communications installation
Attach communications headset to helmet suspension

Plug microphone assembly into mating connector on headset.
Communications headset cable is threaded through notch in helmet.
Model 2000
8.8.9. Primary and secondary air hose installation
Primary air hose with stainless steel air connection is located on the right side of helmet
Secondary air hose with brass air connection is located on left side of helmet
8.9. Final tests

After assembly the following tests should be carried out with the Life Support Helmet using the Helmet
Test Instrument:
1. Regulator static test
2. Regulator flow test
Test to be performed with Helmet Test Instrument:
8.9.1. Helmet regulator static test
Open case and set helmet test instrument in an upright position

Remove sensing port screw from above helmet lens

8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 35 of 39
Screw sensing tube fitting (6) into helmet sensing port

Connect helmet primary air hose to connector (5) on helmet test instrument
Open valve counter clockwise (3)
Place face in helmet mask and breathe normally
Hold breath and read primary helmet regulator static pressure on manometer
Acceptable pressure range is 1.8 to 2.2 inches water column pressure
Remove face from mask
Close valve (3) clockwise to off and disconnect helmet primary air hose
Connect secondary air hose to connector (4) on helmet test instrument and follow same
procedure as above
Acceptable pressure range for secondary helmet regulator is 1.2 to 1.6 inches water
column pressure
Upon completion of test, close valve (3)clockwise to off and disconnect helmet secondary
air hose
Disconnect breathing air supply from helmet test instrument (7)
8.9.2. Helmet regulator flow test

The purpose of this test is to assure breathing regulators inside the helmet assembly flow at a minimum
rate.
Connect breathing air supply 120 125 PSI (8.5 bar) to helmet test instrument
Set helmet on table of level surface
Connect helmet primary air hose to connector (5)
Open valve clockwise (3)
Flow meter (2) weight should rise above blue indicator line
If flow meter weight does not rise above blue indicator replace helmet regulator and re-test.
Disconnect helmet primary air hose from connector (5)
Connect helmet secondary air hose to connector (4) and follow same procedure as above
Upon completion of test, close valve (3) counterclockwise
Disconnect helmet secondary air hose from connector (4)
Disconnect breathing air supply from helmet test instrument
If test is not successful, failures to be relieved and test to be repeated.

If measures are not achieved, the Regulator should be replaced.
Model 2000
Plastic spiral


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 36 of 39
After maintenance testing a record should be maintained in a record book and cross referenced with
helmet serial numbers. An approval label with date should be applied to the helmet.
Model 2000
9. Repairing
9.1. Repairing air control console
Connect air control console and helmet assembly according to manual. The following methods are for
trouble shooting possible console problems:
Problem:
Yellow LED lights do not illuminate after power/volume control is turned on.
Causes: Batteries require replacement

LED lights require replacement
9.1.1. Changing batteries

Remove four screws retaining battery box and open box.
Replace batteries and maintain polarity.
Close battery box, connect power terminals and replace four screws.
Turn power/volume control on and yellow LED lights should illuminate.
If LED lights do not illuminate replace LED lights


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 37 of 39
9.1.2. Cold weather heater

Problem: Heater does not power up, no warm air
Cause: Electrical failure of Heater
Remove Heater
Remove power plug and unfasten four screws in front.
Pull out Heater.

Check Connections
If Heater is defective, send heating system to Breathing Systems Inc. for replacement.
9.1.3. Leaking fittings

Problem: Air leaks in tube fittings of air control console:
Cause: Loose tube fittings
Leakage Test
Remove screws on panel front
Lift air control console from carrying case


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 38 of 39
Connect primary air supply to console primary connector and turn on air supply:
If leakage is not apparent, use soap and water solution on individual tube connections.
Leakage is indicated by formation of bubbles.
Tighten fitting with adjustable wrench and a second wrench to hold opposite fitting
Re-check for leakage with soap and water
Connect secondary air supply to console secondary connector and repeat above procedure
9.1.4. Breathing indicator LEDs
Problem: LEDs do not illuminate:
Cause: Flow switch is defective:
Replace LED indicator lights
Remove screws on front of panel
Lift panel from carrying case
Cut wire leads from LED and remove
Replace with new LED and reconnect wire leads
Install panel into carrying case
Fasten screws at front of panel
9.1.5. Low pressure alarm

Problem: Alarm does not operate:
Cause:
Electronic alarm is defective


8800 Grow Drive
Pensacola FL 32514
USA

Date:
November 18, 2014
Revision:
6
Approver:
Andrew Russell
Page 39 of 39
Remove screws
Lift air control console out of panel.
Cut wire leads and remove electronic alarm
Replace with new electronic alarm and reconnect wire leads
Confirm alarm function by turning power/volume control on
Install panel into carrying case and fasten screws at front of panel
Replace electronic alarm if it does not operate

9.1.6. Breathing indicator LEDs
Problem: Indicator LEDs do not illuminate
Cause: Piston in flow switch is not operating
Remove screws on top of panel
Lift panel out of carrying case
Remove flow switch and replace with new flow switch
Install panel into carrying case and fasten screws at front of panel


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Operations and Maintenance User Instructions

Life Support System

Breathing Systems, Inc.

Breathing Systems Inc.

Operations and Maintenance Instructions

Revision C (March 2014 Revision Reference NIOSH Label Only On Page 2)

Breathing Systems Inc. 8800 Grow Drive, Pensacola Fl 32514

Breathing Systems Inc.

Operations and Maintenance Instructions

Breathing Systems Inc.

Operations and Maintenance Instructions

CAUTIONS AND LIMITATIONS

Breathing Systems Inc. 8800 Grow Drive, Pensacola Fl 32514

Breathing Systems Inc.

Operations and Maintenance Instructions

Air control console Model 5004 consisting of:

Control instruments for regulating the breathing air to helmet assemblies

Pressure reducers: high pressure (HP), low pressure (LP)

Visual and audible alarms

Electrical heater for cold weather operations

Connections for communications

Connections for air supply cylinders

Life support helmet assembly Model 5000 consisting of :

Molded fiberglass and carbon fiber helmet assembly

Connections for communication

Helmet latch assemblies

Operators communications headset

Egress cylinder assembly Model 5000

Egress regulator assembly

Egress airline system (optional) consisting of:

Breathing Systems Inc. 8800 Grow Drive, Pensacola Fl 32514

Breathing Systems Inc.

Operations and Maintenance Instructions

1.1 Combination of Life Support System assemblies

5. Qualifications for operating the Life Support System

Breathing Systems Inc.

Operations and Maintenance Instructions

6. Life Support System operations

6.3. Air control console

Air Control Console Model 5004

Check the communications systems grounding connection on back of console

Strain relief of umbilical to be attached to solid structure

On/Off volume control

Breathing Systems Inc. 8800 Grow Drive, Pensacola Fl 32514

Breathing Systems Inc.

Operations and Maintenance Instructions

Check to determine electrical requirements for air control console.

Frequent adjustment to volume control indicates battery replacement is required

Cold weather operations heater

Primary Breathing Air Connection

Secondary Breathing Air Connection

Breathing Systems Inc.

Operations and Maintenance Instructions

Back of air control console

Secondary Umbilical Air Hose Connection to Air Control Console

Connect communication connector

Breathing Systems Inc. 8800 Grow Drive, Pensacola Fl 32514

Breathing Systems Inc.

Operations and Maintenance Instructions

Knobs to adjust outlet pressure