Bullard Clean Air Boxes (CAB) Series User Manual

Breathing Air Requirements

Respirable, at least Grade D breathable air must be supplied at all times to the Clean Air Box (CAB) Series units. This is the responsibility of the user or employer. Supplied High Pressure Compressed Air must AT A MINIMUM meet the requirements for Grade D breathable air as described in the Compressed Gas Association Commodity Specification G-7.1, and as specified by Federal Law 42 CFR Part 84, Subpart J, 84.141(b), and 29 CFR Part 1910, Subpart I, 1910.134(i)(1).

The requirements for Grade D breathable air include:

• Oxygen: 19.5-23.5%
• Hydrocarbons (condensed) in mg/m3 of gas: 5 mg/m3 max.
• Carbon monoxide: 10 ppm max.
• Carbon dioxide: 1,000 ppm max.
• Odor: No toxic contaminants at levels that make air unsafe to breathe.

*Specific measurement of odor in gaseous air is impractical. Air may normally have a slight odor. The presence of a pronounced odor should render the air unsatisfactory.

Contact the Compressed Gas Association at www.cganet.com for complete details on Commodity Specification G-7.1.

Air Source for Clean Air Boxes (CAB) Units

Locate the source of supplied air in a clean air environment containing at least Grade D breathable air at all times. Ensure the air source is far enough from your work site or hazardous exhaust emissions to guarantee the air remains contaminant-free and at least Grade D at all times.

Always use an inlet filter on your air source. Utilize suitable after-cooler/dryers with filters, and carbon monoxide monitors and alarms, as necessary to assure clean, at least Grade D breathable air at all times.

Industrial high pressure compressors that send compressed air into a storage air tank are typically used as the air source for Clean Air Boxes (CAB) units. These compressors usually include after-coolers, dryers, filters, CO monitors, and alarms. As compressed air is distributed, certain areas may require additional filtering and CO monitoring to meet Grade D breathable air requirements.

WARNING: Bullard Clean Air Boxes (CAB) MUST be supplied with at least Grade D breathable air. Clean Air Boxes (CAB) do NOT create Grade D breathable air. The air source should be regularly sampled to ensure it meets at least Grade D requirements at all times. Failure to regularly sample the air can result in death, serious injury, or life-threatening delayed lung disease, including silicosis, pneumoconiosis, or asbestosis.

Filtration Efficiency

The CAB units feature a multi-stage filtration system:

• 1st Stage: Particulate/Bulk Liquid Separation. Features an auto drain and removes 95% of solid contaminants and bulk liquids down to five (5) microns.
• 2nd Stage: Oil Coalescing and Ultra Fine Particulate. Features an auto drain and filter change indicator. Removes extremely fine oil mists down to .01 microns.
• 3rd Stage: Activated Charcoal. Features a manual drain and filter change indicator. Removes unpleasant oil and hydrocarbon vapors and odors from the air. Maximum remaining oil content is 0.003 ppm by weight.

WARNING: These units will not remove Carbon Monoxide (CO), Carbon Dioxide (CO2), Nitrogen, or other toxic gases or fumes. They do not increase the oxygen content of an air supply and should not be used when air entering the system is oxygen deficient. Air filtration systems must be operated in the upright position to allow auto drains to function correctly. Standard Clean Air Box (CAB) filtration units are not explosion proof and should not be located in an explosive environment. Failure to read, understand, and follow these instructions could cause death or serious injury.

California Proposition 65 Warnings

California Proposition 65 WARNING: Cancer and Reproductive Harm - www.P65Warnings.ca.gov.

Propuesta de California 65 ADVERTENCIA: Cáncer y Daño Reproductivo - www.P65Warnings.ca.gov.

Proposition de la Californie 65 AVERTISSMENT: Cancer et Troubles de l'appareil reproducteur - www.P65Warnings.ca.gov.

CAB Specifications

The Bullard Clean Air Box is supplied with up to 8 quick-disconnect fittings. The actual number of respirators that may be connected to the CAB depends on the inlet pressure to the Bullard air filtration system and the air flow and pressure requirements of the respirator being worn. Air supply pressure ranges and approved hose lengths for a respirator can be found in the manufacturer's User Manual for the respirator. Only NIOSH approved respirators should be used with this product.

Air Monitoring

The Grade D breathable air flows through the CO monitor. A small amount (~0.5 lpm) is diverted through a preset internal regulator and flow restrictor, delivering a continuous flow of sample air to the sensor chamber. The monitor analyzes the air and displays the CO concentration in parts-per-million (ppm).

A Green LED on the outside of the CAB illuminates during normal operation when the CO level is below the CO alarm point (10 ppm US and 5 ppm International). If the CO level rises above the alarm set point, the Red LED on the outside of the CAB illuminates, and an audible alarm sounds.

The red CO alarm and green LED lights indicating normal operation are located on the face of the monitor inside the CAB15 Clean Air Box.

Function Modes

The knob on the front of the CO monitor sets its functions and can be switched to RUN, TEST, and CAL.

• RUN mode: Operation/detection mode. The monitor must be in RUN mode to monitor supplied breathing air. Supplied air must be turned on and flowing to the instrument. If supplied air is off or interrupted, a low flow alarm will sound, and 'LF' will be displayed until the air is restored.
• TEST mode: Allows for bump testing of the sensor or silencing the low flow alarm when supplied air is shut off. To perform a bump test or zero gas test, place the monitor in TEST mode and flow calibration gas into the center of the knob. The reading should be 10 +/- 1 for CO gas or zero/1 for zero gas. Supplied air is not monitored in this mode.
• CAL mode: Calibration and zero calibration mode. Supplied air is not flowing to the sensor. '(AC) AutoCal®' will be displayed. Pressing the On/Off button changes the display to '(AO) AutoZero'. Refer to the Calibration section for instructions.

F1 (fault): Indicated on the display when the cam valve is not securely positioned in one of the three modes.

Monitor Specs

Error Codes

• rC: System requires recalibration.
• lb: Low battery.

Warning Signals

• Normal Operation: Green Light
• High CO: Red Light
• High CO: Audible alarm (90db)
• Low Battery: Amber Light (Blinking)
• Low Battery: Audible alarm (chirp)
• Low Flow Alarm: Audible alarm (90db)

Warranty

Two years on sensor.

Shielding

Internal RFI/EMI coating.

CAB Series Specifications Table

The following table details the specifications for the different CAB models:

CAB Clean Air Box Set Up and Operation

WARNING: Always operate the CAB Clean Air Box in the upright position. Failure to comply may result in improper auto drain function, filter contamination, or moisture passing into the respirator.

• Auto drains may not function properly, potentially leading to CO monitor contamination and water in the air supply hose.
• Auto drains may become clogged. Refer to user instructions for cleaning or replacement.
• Filters may accumulate moisture and/or contaminants. Refer to user instructions for filter replacement.

Set Up and Operation

1. Prior to connecting incoming air supply lines, purge all moisture by running air through the airlines before connecting the CAB.
2. Attach to an incoming air source containing at least Grade D breathable air; do not exceed 150 psi.
3. Connect the AC cord to the power inlet on the side of the CAB and plug it into an AC power source.
4. NOTE: This unit may also be operated using DC power or eight AA batteries if no AC power is available.
5. Flip the switch on the Control Box to the ON position. (See Figure 1)
6. Ensure the knob on the CO Monitor is rotated to the TEST position. This prevents the Low Flow alarm from sounding during start-up if no air is flowing. (See Figure 2)
7. Push the ON button located behind the front cover of the CO Monitor. (See Figure 2)
8. Wait for the 60-second countdown shown on the CO Monitor display screen.
9. Calibrate the CO Monitor if necessary. Refer to Calibration Instructions.
10. Connect the remote alarm assembly (optional) to the remote alarm jack.
11. NOTE: The knob must be in the RUN position for active monitoring of CO in the air supply.
12. Attach respirators and adjust regulators to the appropriate pressure per the respirator manufacturer's recommendation. For units with independent regulators, adjust each regulator as appropriate for each outlet being used.

Calibration and Zero-Point Process

Zero-Point Adjustment

NOTE: It is recommended that the Clean Air box be under pressure with no air going through the outlet fitting when performing zero point adjustment or calibration.

NOTE: If the monitor has been relocated to a different working area and ambient temperatures change, allow the unit to stabilize for 15-20 minutes prior to Zero Point adjustment and calibration. Zero calibration should be performed before calibrating the monitor with CO gas. Bullard recommends using impurity-free test gas to re-zero whenever the zero point has drifted.

1. Remove the front cover of the CO Monitor.
2. Push the ON button. The unit will beep and begin a 60-second countdown.
3. Rotate the knob on the front of the CO Monitor to the CAL position. 'AC' will appear on the display.
4. Press and hold the On/Off button until it beeps. 'AO' will now appear on the display.
5. Attach the regulator to the zero gas cylinder.
6. Insert the calibration connector fitting into the center of the knob on the front of the monitor.
7. Open the cylinder valve fully. The flow rate is preset.
8. The Red LED will continue to blink for approximately 90 seconds during the zero adjustment process. Watch for the Green LED to begin blinking, indicating a successful zero.
9. With the zero air flowing, rotate the knob to the TEST position. The reading should alternate between CO and 1 or 0. If any other reading is displayed, repeat Zero Point Adjustment.
10. Close the regulator on the zero gas cylinder completely and remove the calibration connector fitting.
11. With the incoming air flowing, turn the knob to RUN.

NOTE: Knob must be in RUN position for active monitoring of CO in the air supply.

Calibration Instructions

The COM5 and COM10 are Auto-Cal instruments; all calibration adjustments are made automatically. CO Monitor calibration should be performed monthly or whenever the reading may be questionable. A calibration schedule should be maintained for future reference. Bullard recommends the use of Bullard CABCK calibration kits for accurate calibration.

Calibration Procedure:

1. Remove the front cover of the CO monitor and push the ON button if necessary.
2. Rotate the knob on the front of the monitor to the CAL position. 'AC' will appear on the display.
3. Attach the regulator to the calibration gas cylinder (10 ppm CO required).
4. Insert the calibration connector fitting into the center of the knob.
5. Open the cylinder valve fully. The flow rate is preset.
6. The Red LED will blink for approximately 90 seconds during calibration. Watch for the Green LED to blink, indicating successful calibration.
7. With the 10ppm gas still flowing, turn the knob to TEST. The reading should alternate between CO and 10 (+/- 1). If any other reading is displayed, repeat both the Zero Point adjustment and CO calibration.
8. Close the regulator on the CO gas cylinder completely and remove the calibration connector fitting.
9. With the incoming air flowing, rotate the knob to the RUN position.

NOTE: Typical calibration takes approximately 90 seconds. If the unit will not calibrate within 3 minutes, repeat calibration steps with compressed air turned off. If the problem persists, contact Bullard Customer Service at 1-877-BULLARD (285-5273).

NOTE: Knob must be in RUN position for active monitoring of CO in the air supply.

Shut Down

1. Ensure all personnel have left the work area.
2. Shut off the incoming air to the Clean Air Box.
3. Release air pressure from the box by pulling the relief valve ring out.
4. Turn the CO Monitor OFF by pressing and holding the ON/OFF button for three seconds. Three short beeps will indicate the monitor is OFF.
5. Turn the control box switch to the OFF position.
6. Disconnect the airline hoses.
7. Install dust caps to prevent entry of debris into the outlet fittings.

System Maintenance

CAUTION: Always depressurize the system before performing service.

Filter Housing/Bowls

Periodic cleaning of the polycarbonate bowls may be necessary. Remove the auto drains. Clean the bowls with a mild soapy solution. Re-install into the filter housing.

Auto Drains

The automatic drains are designed to remove bulk liquid contaminants. They will automatically drain liquids after the level reaches 1/3 of the bowl capacity. For periodic cleaning, use mild soap and water.

Filter Change

The filtration system includes a filter change indicator that gradually changes from green to orange/red when the filter life is spent.

NOTE: Air must be flowing through the Clean Air Box for the filter change indicators to function.

Drain Lines

Ensure the auto drain tubes are placed in the holes at the bottom of the box to allow liquids to drain outside.

Battery Replacement

CO Monitor Battery

A 9-volt battery is installed under the front panel cover to power the CO monitor. The monitor may also run solely on DC power if the clean air box is not attached to an AC power supply. (See Figure 3)

To replace the 9-volt battery, remove the panel cover from the front of the CO monitor. Lift it off from either the left or right side. If a 9-volt battery is used for power, the monitor will indicate low battery ('LB') on the display when it is time to change the battery.

Optional DC Power Supply

The CAB Clean Air Box may be operated using 8 AA batteries to provide power to the external lights, CO alarm, and the CO monitor. Lights located on the top of the box indicate whether the box is operating on AC or DC power. If powered by DC (8 AA batteries), the amber light on top will burn steady. If battery power falls below the required voltage, the amber light will flash, indicating it is time to change the batteries. An audible alert of short intermittent beeps will also notify that batteries are low. The DC battery compartment is located inside the Clean Air Box. (See Figure 4)

WARNING: Removing the front of the housing by prying at the top will result in damage to the housing and render the product unsafe for use. This damage is not covered under warranty.

Sensor Replacement

NOTE: Before installing a replacement sensor, verify you have the correct sensor. The CABRS is the replacement sensor for COM10 or COM5 monitors with serial numbers ending in 'A' or no suffix. The CABRS2 is the replacement sensor for COM10 or COM5 monitors with serial numbers ending in 'B'. Monitors requiring CABRS2 will have an extra board for sensor mounting. (See Figure 5)

The sensor is accessible by removing the front of the housing from the COM5 or COM10 monitor.

1. To gain access to the sensor, remove the four screws on the front of the CO monitor.
2. After removing the screws, gently pry the front of the housing off from the bottom. (See Figure 6)
3. Gently pull out the old sensor.
4. Remove the shorting clip cover from the new sensor. Failure to remove this clip will result in an inability to calibrate.
5. Align the pins and gently push the new sensor into the sockets. (See Figure 7)
6. Replace the front cover of the monitor, ensuring LED lights align with the housing before securing with screws.
7. After replacing the sensor, allow the instrument to warm up for at least 30 minutes. The replacement sensor must be zeroed and calibrated before first use. Refer to Zero Point Adjustment and Calibration Instructions.

Replacement Parts Breakdown

The following tables list replacement parts for the CAB units.

CAB15 (15 cfm)

CAB30 (30 cfm)

CAB50 (50 cfm)

CAB100 (100 cfm)

Co Monitor Troubleshooting Guide

Warranty Information

One Year LIMITED Warranty

Bullard warrants to the original purchaser that the Clean Air Box will be free of defects in material and workmanship under normal use and service for a period of one (1) year from the date of purchase. Bullard's obligation under this warranty is limited to repairing or replacing, at its option, parts that are returned within the warranty period and that are, after examination, shown to Bullard's satisfaction to be defective, subject to the following limitations:

• Clean Air Box must be returned to the Bullard factory with shipping charges prepaid.
• Clean Air Box must not be altered from its original factory configuration.
• Clean Air Box must not have been misused, subjected to negligent use, or damaged in transport.
• The date of purchase must be within the one-year warranty period (a copy of the purchaser's original invoice showing the date of purchase is required to validate warranty coverage).

Bullard shall not be responsible for damages for loss of use or other indirect, incidental, consequential, or special costs, expenses, or damages incurred by the purchaser, even if Bullard has been advised of the possibility of such damages.

ANY IMPLIED WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE SPECIFICALLY EXCLUDED FROM THIS WARRANTY.

Some states do not allow the exclusion or limitation of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may have other rights which vary from state to state.

Return Authorization

The following steps must be completed before Bullard will accept any returned goods:

1. Contact Bullard Customer Service by telephone or in writing at:
   E.D. Bullard Company
   1898 Safety Way
   Cynthiana, KY 41031-9303
   Toll-Free: 877-BULLARD (285-5273)
   Phone: 859-234-6616
   Describe the problem as completely as possible. The representative will try to help correct the problem over the phone.
2. Verify with your representative that the product should be returned to Bullard. Customer Service will provide written permission and a return authorization number.
3. Before returning the product, decontaminate and clean it to remove any hazardous materials. Laws and/or regulations prohibit the shipment of hazardous or contaminated materials. Products suspected to be contaminated will be professionally discarded at the customer's expense.
4. Ship returned products, including those under warranty, with all transportation charges pre-paid. Bullard cannot accept returned goods on a freight collect basis.
5. Returned products will be inspected upon return. Bullard Customer Service will contact you with a quote for required repair work not covered by warranty. If the cost of repairs exceeds the quoted amount by more than 20%, your representative will call for authorization to complete repairs.

Contact Information

Bullard Center
2421 Fortune Drive
Lexington, KY 40509 • USA
877-BULLARD (285-5273)
Tel: +1-859-234-6616
Fax: +1-859-246-0243

Americas:
E.D. Bullard Company
1898 Safety Way
Cynthiana, KY 41031-9303
Toll free: 877-BULLARD (285-5273)
Tel: 859-234-6616
Fax: 859-234-8987

Europe:
Bullard GmbH
Dieselstrasse 8a
53424 Remagen • Germany
Tel: +49-2642 999980
Fax: +49-2642 9999829

Bullard Asia-Pacific Pte. Ltd.
51 Changi Business Park
Central 2
#03-04 The Signature
Singapore 486066
Tel: +65 6745 0556

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