operator’s manual for protective mask leakage tester (pmlt) · 2010. 1. 1. · protective mask...

Operator’s Manual for

Protective Mask Leakage Tester (PMLT) (U.S. Patent Nos. 6,435,009; 6,848,297; other patents pending)

Revision B

1 January 2010

Air Techniques International

Division of Hamilton Associates, Inc.

11403 Cronridge Drive

Owings Mills, MD 21117

USA

www.atitest.com

Copyright © 2010 Hamilton Associates, Inc.

Protective Mask Leakage Tester Manual No. 1800120

Air Techniques International Revision B

i

TNotice of Changes

The following pages of the PMLT manual have been revised and supersede the pages listed.

Change# Date Signature Date Change

Entered

The following changes have been entered via pen to the PMLT Operator’s Manual.

Change# Date Signature Date Change

Entered



ii

Protective Mask Leakage Tester Table of Contents

1 General Information.................................................................................... 1-1

1.1 Description ............................................................................................. 1-1

1.2 Specifications .......................................................................................... 1-1

1.3 Environmental Information........................................................................ 1-2

1.4 Storage Conditions................................................................................... 1-2

1.5 Labels .................................................................................................... 1-2

1.6 Warnings................................................................................................ 1-3

1.7 Cautions................................................................................................. 1-3

1.8 Symbols ................................................................................................. 1-4

1.9 Tests Conducted with the PMLT.................................................................. 1-4

1.9.1 Mask Leakage Test (MASK)..................................................................... 1-4

1.9.2 Drink Tube Flow Test (DRINK) ................................................................ 1-5

1.9.3 Drink Train Assembly Leakage Test.......................................................... 1-5

1.9.4 Drink Valve Seat Test ............................................................................ 1-5

1.9.5 Outlet Valve Test (VALVE) ...................................................................... 1-5

1.9.6 Quantitative Fit Test (FIT) ...................................................................... 1-5

1.9.7 Mask All Test (M ALL) ............................................................................ 1-5

1.9.8 All Test (ALL) ....................................................................................... 1-5

2 Components of the PMLT ............................................................................. 2-1

2.1 Control Unit ............................................................................................ 2-1

2.2 Power Unit .............................................................................................. 2-3

2.3 Aerosol Generator Assembly...................................................................... 2-5

2.4 Fit Test Kit .............................................................................................. 2-5

2.5 Accessories ............................................................................................. 2-6

3 Unpacking and Assembly ............................................................................. 3-1

3.1 Items Furnished With the PMLT.................................................................. 3-1

3.2 Additional Operator Supplies ..................................................................... 3-1

3.3 Unpacking .............................................................................................. 3-1

3.4 Assembling the PMLT................................................................................ 3-3

3.4.1 Aerosol Generator Assembly ................................................................... 3-3

3.4.2 Connecting Power Unit to Control Unit...................................................... 3-4

3.4.3 Attaching the Headform ......................................................................... 3-5

3.4.4 Assembling the Fit Test Kit ..................................................................... 3-6



iii

4 Initialization............................................................................................... 4-1

4.1 Power Up................................................................................................ 4-1

4.2 Setting the Altitude .................................................................................. 4-2

4.3 Selecting a Test....................................................................................... 4-3

5 Mask Testing ............................................................................................. 5-1

5.1 Mask Aerosol Setup.................................................................................. 5-1

5.2 Applying a Mask ...................................................................................... 5-2

5.3 Conducting a Test .................................................................................... 5-4

5.4 Mask Paused ........................................................................................... 5-5

5.5 Probe Mode............................................................................................. 5-5

5.6 Resume Testing....................................................................................... 5-7

5.7 Removing the Mask from the Headform....................................................... 5-9

5.8 Mask Testing Failures Flowcharts................................................................ 5-9

5.8.1 Leak Found in Mask Using Probe Flowchart ..............................................5-11

5.8.2 Leak Found at Seal Using Probe Flowchart ...............................................5-12

5.8.3 No Leak Found Using Probe Flowchart .....................................................5-13

6 Drink Tube Testing ..................................................................................... 6-1

6.1 Drink Tube Flow Test................................................................................ 6-1

6.2 Drink Train Assembly Leakage Test ............................................................ 6-2

6.3 Drink Valve Seat Test ............................................................................... 6-4

6.4 Drink Testing Failures Flowchart................................................................. 6-6

7 Outlet Valve Test........................................................................................ 7-1

7.1 Conducting a Test .................................................................................... 7-1

7.2 Outlet Valve Failures Flowchart .................................................................. 7-3

8 Quantitative Fit Test ................................................................................... 8-1

8.1 Selecting a Standard ................................................................................ 8-1

8.2 Fit Test Aerosol Setup .............................................................................. 8-2

8.3 Prepare the Subject ................................................................................. 8-3

8.4 Testing a Subject..................................................................................... 8-5

8.5 Fit Testing Serial Communications……………………………………………………………………… . 8-9

8.5.1 Connection Requirements………………………………………………………………………………….. 8-9

8.5.2 XData Serial Output Format…………………………………………………………………………….. 8-10

8.6 Fit Testing Failures Flowchart................................................................ 8-12

9 Powering Down and Packing the PMLT ........................................................... 9-1

9.1 Powering Down the PMLT .......................................................................... 9-1



iv

9.2 Packing .................................................................................................. 9-1

10 Preventive Maintenance Checks and Services (PMCS)....................................10-1

10.1 Preoperational PMCS .............................................................................10-1

10.1.1 Control Unit.......................................................................................10-1

10.1.2 Power Unit ........................................................................................10-2

10.1.3 Fit Test Kit ........................................................................................10-3

10.1.4 Aerosol Generator Assembly ................................................................10-4

10.1.5 Accessories .......................................................................................10-5

10.2 Periodic PMCS (Every 100 Operational Hours) ...........................................10-6

10.2.1 PMLT Case.........................................................................................10-6

10.2.2 Control Unit.......................................................................................10-6

10.2.3 Power Unit ........................................................................................10-7

10.2.4 Fit Test Kit ........................................................................................10-8

10.2.5 Accessories .......................................................................................10-9

10.3 Long Term PMCS (every 1500 operational hours or 2 years)........................10-9

10.3.1 End Item...........................................................................................10-9

11 Maintenance Procedures ...........................................................................11-1

11.1 Setting The Date and Time .....................................................................11-1

11.2 Adjusting The Altitude (Elevation)............................................................11-2

11.3 Fuse Replacement ................................................................................11-3

11.4 Universal Hold-Down Assembly Adjustment ..............................................11-3

11.5 Back Pressure Adjustment......................................................................11-8

11.6 Using the Mask Passing Tube ..................................................................11-8

11.6.1 Installation ........................................................................................11-8

11.6.2 Removal .........................................................................................11-10

11.7 External O-ring Replacement .................................................................11-8

11.8 Drink Tube Adapter O-ring Replacement ..................................................11-8

11.9 Outlet Valve Test Adapter Replacement ...................................................11-8

11.10 Shroud/Manifold Cleaning Procedure ....................................................11-10

11.11 Twin Tube Interface Trimming/Cutting ..................................................11-10

11.12 Drink Tube Adapter: Inner Adapter Cleaning .........................................11-10

12 Troubleshooting; Fault and Error Messages..................................................12-1

12.1 Symbols ..............................................................................................12-1

12.2 List of Flowcharts ..................................................................................12-2

12.3 Control Unit/Power Unit Errors ................................................................12-3

12.3.1 Display is Blank..................................................................................12-3



v

12.3.2 Single Dash on Display ........................................................................12-4

12.3.3 Pump Not Operating............................................................................12-5

12.3.4 Flow Error .........................................................................................12-6

12.3.5 Memory Error.....................................................................................12-7

12.3.6 Seal Failure........................................................................................12-8

12.4 Aerosol Errors.....................................................................................12-10

12.4.1 Remains in Loading During Aerosol Set Up or Mask Test ........................12-10

12.4.2 Remains in Loading During Fit Test Aerosol Set Up................................12-11

12.4.3 Aerosol Setup of 90 or Greater ...........................................................12-12

12.4.4 LSC Error ........................................................................................12-13

12.4.5 Low/High Aerosol Error .....................................................................12-14

12.5 Vacuum Errors....................................................................................12-16

12.5.1 Low Vacuum Failure..........................................................................12-16

12.5.2 High Vacuum Failure.........................................................................12-17

12.5.3 Persistent Penetration Failures ...........................................................12-18

12.6 Drink Test Errors.................................................................................12-19

12.6.1 Consistent Drink Tube Flow Failures ....................................................12-19

12.6.2 Consistent Drink Train or Seat Failures ................................................12-21

12.7 Valve Test Errors ................................................................................12-22

12.7.1 Consistent Outlet Valve Failures .........................................................12-22

12.8 Fit Test Errors.....................................................................................12-23

12.8.1 Remains in Setting During Fit Test ......................................................12-23

12.8.2 Consistent Low Fit Factors ..................................................................12-24

Appendix A Test Settings and Descriptions........................................................ A-1

Appendix B Testing a Mask with an Attached Hose ............................................. B-1

B.1 Components of Hose Test Adapter Kit ......................................................... B-1

B.2 Applying the Mask and Hose...................................................................... B-1

B.3 Conducting a Test.................................................................................... B-3

B.4 Mask Paused........................................................................................... B-4

B.5 Probe Mode............................................................................................. B-5

Appendix C Abbreviations and Acronyms .......................................................... C-1

Appendix D Repair Parts List ...........................................................................D-1

Appendix E PAO-4 Material Safety Data Sheet (MSDS)........................................ E-1

Appendix F Product Warranty.......................................................................... F-1



vi

List of Figures

Figure 1 Control Unit (Front View) ................................................................... 2-1

Figure 2 Control Unit (Rear View) .................................................................... 2-2

Figure 3 Control Unit (Side View)..................................................................... 2-2

Figure 4 Power Unit (Top View) ....................................................................... 2-3

Figure 5 Power Unit (Side Views)..................................................................... 2-4

Figure 6 Power Unit (Bottom View) .................................................................. 2-4

Figure 7 Aerosol Generator Assembly ............................................................... 2-5

Figure 8 Fit Test Kit ....................................................................................... 2-5

Figure 9 PMLT Accessories .............................................................................. 2-6

Figure 10 Headform....................................................................................... 2-7

Figure 11 PMLT Case ..................................................................................... 2-8

Figure 12 PMLT in Case .................................................................................. 3-2

Figure 13 Control Unit Unpacked ..................................................................... 3-2

Figure 14 Attaching Aerosol Generaor Assembly to Control Unit ........................... 3-3

Figure 15 Power Interface Cable to Power Unit .................................................. 3-4

Figure 16 Power Interface Cable to Control Unit................................................. 3-4

Figure 17 Control Unit and Power Unit Properly Connected .................................. 3-5

Figure 18 Headform and Pedestal Apart............................................................ 3-5

Figure 19 Headform and Pedestal Assembled..................................................... 3-6

Figure 20 Fit Test Support Rods Into Corner Nylon Pouch.................................... 3-7

Figure 21 Fit Test Rods Form Support Arc ......................................................... 3-7

Figure 22 Y-Hose Aerosol Extension Onto Brass Fittings ...................................... 3-7

Figure 23 Y-Hose Aerosol Extension Connecting to Aerosol Probe Hose.................. 3-8

Figure 24 Fit Test Interface Tubing Assembly .................................................... 3-8

Figure 28 Aerosol Setup ................................................................................. 5-1

Figure 29 Mask on Headform .......................................................................... 5-3

Figure 30 Mask Properly Attached With Adapters ............................................... 5-3

Figure 31 Mask Under Shroud ......................................................................... 5-4

Figure 32 Using the Probe .............................................................................. 5-7

Figure 33 Drink Flow Test Setup ...................................................................... 6-1

Figure 34 Plugging the Drink Tube .................................................................. 6-3

Figure 35 Outlet Valve Test............................................................................. 7-1

Figure 36 Fit Test Aerosol Setup ...................................................................... 8-2

Figure 37 Attaching the Fit Sampling Adapter .................................................... 8-4



vii

Figure 38 Attaching the Badge Clip .................................................................. 8-4

Figure 39 Fit Test Shroud ............................................................................... 8-5

Figure 40 Folding and Storing the Fit Test Shroud .............................................. 9-2

Figure 41 Control Unit Packed in Case .............................................................. 9-3

Figure 42 PMLT Properly Packed ...................................................................... 9-3

Figure 43 Replacing Fuses .............................................................................11-3

Figure 44 Properly Adjusted Mask and Clips .....................................................11-4

Figure 45 Back Pressure Adjustment ...............................................................11-6

Figure 46 Removing the Lint Screen................................................................11-7

Figure 47 Inserting Mask Passing Tube............................................................11-7

Figure 48 Mask Passing Tube Inserted.............................................................11-7

Figure 49 External O-Ring Replacement...........................................................11-8

Figure 50 Drink Adapter O-Ring Replacement ...................................................11-8

Figure 51 Removing the Retaining Bolt ............................................................11-9

Figure 52 Reinstalling the Bolt and Adapter ......................................................11-9

Figure 53 Outlet Valve Test Adapter................................................................11-9

Figure 54 Cleaning the Drink Tube Adapter ....................................................11-10

Figure 55 Hose Test Adapters ......................................................................... B-1

Figure 56 Installed Rubber Stopper.................................................................. B-1

Figure 57 Attaching Mask Hose Test Adapter ..................................................... B-2

Figure 58 Test Shroud Over Mask w/Hose......................................................... B-3

Figure 59 Using the Probe .............................................................................. B-6

Figure 60 Tamper Tape on Control Unit ............................................................ F-2



viii

List of Tables

Table 1 PMLT Specifications ............................................................................ 1-1

Table 2 Labels .............................................................................................. 1-2

Table 3 Symbols ........................................................................................... 1-4

Table 4 Control Unit (Front View)..................................................................... 2-1

Table 5 Control Unit (Rear View) ..................................................................... 2-2

Table 6 Control Unit (Side View)...................................................................... 2-2

Table 7 Power Unit (Top View) ........................................................................ 2-3

Table 8 Power Unit (Side Views) ...................................................................... 2-4

Table 9 Power Unit (Bottom View) ................................................................... 2-4

Table 10 Aerosol Generator Assembly .............................................................. 2-5

Table 11 Fit Test Kit ...................................................................................... 2-6

Table 12 PMLT Accessories ............................................................................. 2-7

Table 13 Headform Components...................................................................... 2-7

Table 14 PMLT Case....................................................................................... 2-8

Table 15 List of Items Furnished ..................................................................... 3-1

Table 16 Mask Testing Mode Descriptions ........................................................ 4-4

Table 17 Flowchart Symbols ..........................................................................5-11

Table 18 Flowchart Symbols ........................................................................... 6-6

Table 19 Flowchart Symbols ........................................................................... 7-3


Table 21 Fuse Descriptions and Locations ........................................................11-3


Table 23 List of Flowcharts ............................................................................12-2

Table 24 Test Settings and Descriptions ........................................................... A-1

Table 25 Hose Test Adapter Kit ....................................................................... B-1

Table 26 Abbreviations and Acronyms .............................................................. C-1



1-1

1 General Information This manual provides information and procedures for setup, operation, and maintenance of the Protective Mask Leakage Tester (PMLT).

1.1 DESCRIPTION

The PMLT is a portable device designed to test the serviceability and fit of protective masks. The PMLT will provide leak and serviceability testing of designated Nuclear, Biological and Chemical Defense (NBCD)/Chemical, Biological and Radiological Defense (CBR-D) masks and components without requiring the operator to wear the mask. The PMLT will provide quantitative fit testing while an individual is wearing his/her assigned protective mask. The PMLT is completely self-contained in a rugged Pelican™ case and can be set up in minutes by one person. The PMLT includes a universal hold-down assembly, inflatable mask seal, and various adapters which allow it to be used to test a variety of protective masks. The lightweight plastic headform is available in 2 different sizes and is easily interchanged to accommodate a wide range of mask sizes. The PMLT utilizes solid-state electronic circuitry with a user-friendly, menu-driven touch pad that provides an alphanumeric display on the screen.

1.2 SPECIFICATIONS

PMLT

Case Dimensions 32 in (L) x 22.5 in (W) x 20 in (H)

Weight ≈90 lbs when packed in PMLT Case

Input Power 110V AC 60Hz 2A

220V AC 50Hz 1A

Aerosol Detection Near-forward light scattering

Aerosol Generator Output Concentrations

Mask Test – test concentration ≈60 mg/mP

3 Fit Test – test concentration ≈35 mg/mP

3P

Aerosol Oil - Poly Alpha Olefin-PAO-4 (See Material Safety Data Sheet (MSDS) in HAppendix H E

Communication Port

Serial RS-232 (Null-modem cable required)

Baud Rate – 9600

Data Bits – 8

Parity – none

Stop Bit – 1

Flow control- X on/X off

Table 1. PMLT Specifications



1-2

1.3 ENVIRONMENTAL INFORMATION

The PMLT operates under the following environmental conditions:

NOTE

If operating the PMLT at temperatures greater than 100° F, it is recommended that a fan be used to circulate the

air around the PMLT. Do not point the fan directly at the PMLT as it may cause difficulties when setting up the

aerosol.

Temperature: 32°F to 120°F (0°C to 48.8°C)

Relative Humidity:

0% to 95%

Altitude: -500 ft to 10,000 ft (-152.4 m to 3048 m)

1.4 STORAGE CONDITIONS

Store the PMLT under the following conditions:

T

1.5 LABELST

The table below describes the common labels used in this manual:

LABEL DESCRIPTION

WARNING

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc, which, if not strictly observed, could result in injury to, or death of personnel.

CAUTION Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in damage to or destruction of equipment.

NOTE Highlights an essential operating or maintenance procedure, condition, or statement.

Table 2. Labels

Temperature: -38° F to 160° F (-38.8°C to 71.1°C)

Relative Humidity:

0% to 100%

Altitude: Any



1-3

1.6 WARNINGS

1. The PMLT is a heavy item when packed in its case. ALWAYS follow proper procedures when lifting a packed case; use two people to lift or carry. NEVER try lifting the packed case over your head. NEVER drop it into place—lower it carefully. 2. DO NOT ingest PAO oil. Refer to the Material Safety Data Sheet in Appendix E. 3. NEVER place the pressure and vacuum lines near your face. 4. To avoid eye injury, use care when handling the fit test support rods. 5. DO NOT connect the power cord if any wiring is frayed. 6. Isopropyl alcohol should be used only in accordance with supplier’s recommendation.

1.7 CAUTIONS 1. PAO is the only authorized challenge oil that should be used with the PMLT. Use of other liquids or challenge agents may damage or contaminate the internal optics of the light scattering chamber. 2. To avoid damage, when components are not being used, they should be stored in the plastic tray and/or case. 3. Failure to remove the power unit from the tray before lifting the tray from the case may result in damage to the tray. 4. PAO oil level must be between the top and bottom scribed fill lines on the aerosol generator bottle for the generator to work properly. 6. DO NOT cross-thread the generator cap to the bottle. Once assembled, the generator bottle should always be attached to the control unit. Damage to the generator cap or control unit may result if the generator bottle is not attached. 7. Failure to ensure the generator port snap tabs are depressed prior to inserting the aerosol generator assembly may cause damage to the control unit and/or aerosol generator assembly. 8. NEVER position the power unit upside down or with the fan opening obstructed. 9. Ensure that the power cable is unplugged during setup and prior to initialization to prevent damage to the PMLT. 10. During setup and prior to initialization, ensure that power switch is off to prevent damage to the PMLT. 11. NEVER disconnect the power interface cable prior to switching the power unit OFF. This action may corrupt the random access memory (RAM) within the control unit.



1-4

12. The fit test shroud and fit test interface tubing are easily damaged and should only be assembled prior to performing the fit tests. 13. DO NOT use a wrench when tightening the canister port plug. Damage may occur to the mask if the plug is over tightened. 14. NEVER plug or block the probe end (blue) of the aerosol probe hose while the aerosol generator is bubbling. Blocking the flow of aerosol may result in damage to internal components of the system. 15. Failure to remove the aerosol generator assembly from the control unit before packing may result in damage to the control unit and/or aerosol generator assembly. 16. Failure to disassemble the generator assembly prior to packing may result in oil spilling during shipping and damage the control and power units. 17. Failure to place the power unit upside down when packed may cause damage to the power interface cable connector and pressure/vacuum ports. 18. Ensure that no liquid is introduced to the inside of the PMLT as this may cause damage to the electronics. 19. Incorrect adjustment of the mask clips may cause disfiguring of or damage to the mask or insufficient sealing, leading to test failures. 20. NEVER attempt to access the internal components of the control unit or power unit. These units contain sensitive electronics that can be damaged if tampered with. Opening either of these units voids the factory warranty.

1.8 SYMBOLS

The table below describes the common symbols used in this manual:

SYMBOL DESCRIPTION

[Window] Indicates the information displayed in a window.

<Function> Indicates a function button.

Table 3. Symbols

1.9 TESTS CONDUCTED WITH THE PMLT

The following tests are conducted by the PMLT:

1.9.1 MASK LEAKAGE TEST [MASK]

This mode tests a variety of protective masks for leakage. Masks may be tested with or without an attached hose. When a failure is detected the system provides the operator with a probe option to help isolate the location of the leak(s). In the probe mode, aerosol is directed at various areas of the mask to identify which area or component of the mask is leaking. For more information refer to Chapter, Mask Testing.



1-5

1.9.2 DRINK TUBE FLOW TEST [DRINKTUBE/TURN IN]

This mode tests for any airflow obstruction via resistance through the mask drink tube. Connecting the mask drink tube to the drink tube test adapter on the control unit pedestal opens the quick-disconnect valve to allow airflow. The resistance is measured as the airflow is passed through the drink tube. For more information refer to Section 6.1, Drink Tube Flow Test [DRINKTUBE/TURN IN].

1.9.3 DRINK TRAIN ASSEMBLY LEAKAGE TEST

This mode tests the airflow leakage through the entire mask drinking assembly. Prior to initiating this test, the internal drink tube must be plugged. For more information refer to Section 6.2, Drink Train Assembly Leakage Test.

1.9.4 DRINK VALVE SEAT TEST [DRINKTUBE/TURN OUT]

This mode identifies leakage in the drink tube’s quick disconnect coupling valve. Once the mask’s drink tube is connected to the drink tube test adapter on the control unit pedestal, airflow leakage from the applied air pressure is measured. For more information refer to Section 6.3, Drink Valve Seat Test [DRINKTUBE/TURN OUT].

1.9.5 OUTLET VALVE TEST [VALVE]

This mode checks the leakage from the outlet valve on the mask. Air pressure is applied against the outlet valve and the airflow is checked. For more information refer to Chapter 7, Outlet Valve Test.

1.9.6 QUANTITATIVE FIT TEST [FIT]

This mode tests a mask for leakage when worn by an individual. While the subject is wearing the test mask, a shroud is placed over the head and on the individual's shoulders. For this test, aerosol is loaded inside the shroud. The amount of aerosol that breaches the seal of the mask is calculated and displayed as quantitative fit factor, along with a [PASSED] or [FAILED] message. For more information refer to Chapter 8, Quantitative Fit Test.

1.9.7 MASK ALL TEST [M ALL]

This mode tests all functions of the mask and includes the mask leakage test, drink tube flow test, drink train assembly leakage test, drink valve seat test, and outlet valve test, sequentially.

1.9.8 ALL TEST [ALL]

This mode tests the functionality and fit of the mask in succession. It includes the mask leakage test, drink tube flow test, drink train assembly leakage test, drink valve seat test, outlet valve test, and quantitative fit test, sequentially.



2-1

2 Components of the PMLT The PMLT consists of four (4) major components and several accessories. The major components are the control unit, power unit, aerosol generator assembly, and fit test kit.

2.1 CONTROL UNIT

The control unit comprises the microprocessor, which monitors and controls the PMLT. It enables the operator to respond to the software prompts by use of function keys, displays system parameters, and provides operator prompts for testing. The rear panel provides electrical power, vacuum and pressure connections, as well as a data/communications port for transferring data. The right-side panel houses the fit interface ports and aerosol generator ports.

Figure 1. Control Unit (Front View)

Control Unit (Front View)

1. Headform Ports Support the headform during testing.

2. Hose Test Port & Plug Port used for hose test option.

3. Display Screen Displays operator-prompted actions, system information, and function options.

4. Function Keys Used in the option menu to select or change options. The function of the key is displayed above in the display screen.

5. Outlet Valve Test Adapter

Used for testing the outlet valve of a mask. Different adapters may be required for different mask types.

6. Drink Tube Test Adapter

Used for testing the drink tube of the mask. Different adapters may be required for different mask types.

7. UID Label Bar code and electronic ID for inventory scanning purposes.

Table 4. Control Unit (Front View)

7

6 5 4

3 2 1



2-2

Figure 2. Control Unit (Rear View)

Control Unit (Rear View)

1. Pressure Port (Black) Used for connecting the twin tube interface hose to the power unit.

2. Vacuum Port (Brass) Used for connecting the twin tube interface hose to the power unit.

3. Power Cable Interface Port Supplies power to the control unit from the power unit.

4. Data Communication Port Used for connecting to PC serial port.

5. ID Label Identifies the control unit by serial number.

Table 5. Control Unit (Rear View)

Figure 3. Control Unit (Side View)

Control Unit (Side View)

1. Aerosol Generator Ports Used for connecting the aerosol generator assembly to the control unit.

2. Fit Test Interface Ports Used for connecting the fit test interface tubing to the control unit.

Table 6. Control Unit (Side View)

5

4 3 2 1

2

1



2-3

2.2 POWER UNIT

The power unit supplies vacuum, pressure, and electrical power to the control unit.

Figure 4. Power Unit (Top View)

Power Unit (Top View)

1. Power Interface Port

Supplies electrical power to the control unit.

2. Vacuum Port (Brass) Used for connecting the twin tube interface hose to the power unit.

3. Flow Port (Black) Used for connecting the twin tube interface hose to the power unit.

4. Fuse 3 Fuse for the system pump (4 amp. 250V slow-blow).

5. Fuse 2 Fuse for the control unit valves (2.5 amp. 250V slow-blow).

6. Fuse 1 Fuse for the control unit (2.5 amp. 250V slow-blow).

7. Fuse 4 Fuse for AC power input (4 amp. 250V slow-blow).

8. AC Power Input AC power cord connection to the PMLT.

9. On/Off Power Switch Turns the system on and off.

Table 7. Power Unit (Top View)

4

9

8

7 6 5

3

2

1



2-4

Figure 5. Power Unit (Side Views)

Power Unit (Side Views)

1. Air Vents Cooling air vents for the internal pump.

2. ID Label Identifies the power unit by serial number.

3. Fan Fan which draws air through the power unit to help cool internal pump.

Table 8. Power Unit (Side Views)

Figure 6. Power Unit (Bottom View)

Power Unit (Bottom View)

1. UID Label Bar code and electronic ID for inventory scanning purposes.

2. Support Leg Supports the power unit on tabletop or floor.

3. Warranty Label Displays warranty expiration date.

4. Service Tag Displays next due date for factory service.

5. Carrying Handle Used to lift and carry power unit.

6. Packing Instruction Reminder to store power unit this side up and forward inside PMLT Case Tray.

1 3

1

2

3

4

2

5

6 1



2-5

Table 9. Power Unit (Bottom View)

2.3 AEROSOL GENERATOR ASSEMBLY

The aerosol generator assembly is used to create the challenge aerosol when performing an overall mask leakage test or a quantitative fit test.

Figure 7. Aerosol Generator Assembly

Aerosol Generator Assembly

1. Generator Cap Used to connect the aerosol generator bottle to aerosol generator ports. Generates aerosol from the PAO test oil.

2. Aerosol Probe Hose Directs the generator’s aerosol output.

3. Generator Bottle Holds PAO oil. Marked with minimum and maximum fill lines.

Table 10. Aerosol Generator Assembly

2.4 FIT TEST KIT

The fit test kit contains all the necessary subcomponents required to perform a quantitative fit test. Refer to Figure 9 below and Table 11 on page 2-6.

Figure 8. Fit Test Kit

1

2

3

1

2 3

4

5



2-6

Fit Test Kit

1. Fit Test Bag Used to secure the fit test items when not in use.

2. Fit Test Interface Tubing Used for sampling aerosol leakage.

3. Fit Test Support Rods Used to support the fit test shroud.

4. Y-Hose Aerosol Extension Extends the aerosol probe hose to direct the generator aerosol output into the shroud.

5. Fit Test Shroud Used to contain the aerosol around a test subject.

Table 11. Fit Test Kit

2.5 ACCESSORIES

The accessories are all items not previously listed which may be provided with the PMLT. Refer to Figure 9 below and Table 12 on page 2-7.

Figure 9. PMLT Accessories

1 2 3

4 5 6

7

8

9

10 11

12 13

14

15

16

17

18

19

20



2-7

Item Description Item Description

1. Medium Headform 11. Spare Fuse Kit

2. Small Headform 12. Canister Port Plug

3. Oil Warmer (optional) 13. Outlet Valve Clamp

4. 100mL Bottle of PAO Oil 14. Hose Test Adapter

5. Mask Passing Tube 15. #2 Rubber Stopper

6. Power Cord 16. T-Handle Hex Wrench

7. Twin Tube Interface Hose 17. #2 Stubby Phillips Screwdriver

8. Power Interface Cable 18. 1/8” Flat Blade Screwdriver

9. Mask Test Shroud 19. #1 Phillips Screwdriver

10. Spare O-Ring Kit 20. QRLS Pin

Table 12. PMLT Accessories

Figure 10. Headform

Headform

1. Vacuum Port w/Lint Screen

Port for vacuum pressure with protective lint screen to filter debris from the LSC.

2. Peripheral Seal Inflates to provide seal against mask surface.

3. Flow Port Air flow port.

4. Eyelens Support Mount Used to secure the eyelens supports (optional) during flex testing¹.

5. Nosecup Channel Used to support the nosecup to facilitate airflow.

Table 13. Headform Components

¹ - Specialized testing conducted by a limited number of users.

3

1

2

5

4 4



2-8

Figure 11. PMLT Case

PMLT Case

1. PMLT Case Reusable case used for safekeeping, storage, and shipping the PMLT.

2. Retractable Handle Telescopes up and down for pulling PMLT Case.

3. Wheels To easily roll the PMLT Case from one place to another.

4. PMLT Case Tray Tray inside the PMLT case used for storage of the power unit and some PMLT accessories.

Table 14. PMLT Case

4

2

3

1



3-1

3 Unpacking and Assembly This chapter provides important information about unpacking and assembling the PMLT. Be sure to carefully check the furnished items list and become familiar with all locations and functions before operating the PMLT. Procedures should be followed correctly to ensure that the PMLT is properly unpacked and set up.

3.1 ITEMS FURNISHED WITH THE PMLT:

Qty Description Qty Description

1 PMLT Case with Foam 1 Fit Test Kit 1 PMLT Case Tray 1 Control Unit 1 Mask Test Shroud 1 Twin Tube Interface Hose 1 Operator’s Manual 1 Power Cord 1 Power Unit 1 Power Interface Cable 1 Small Headform 1 Mask Passing Tube 1 Medium Headform 1 Spare O-Ring Kit 1 Aerosol Generator Assembly 1 Spare Fuse Kit 1 QRLS Pin 1 Hose Test Adapter 1 Canister Port Plug 1 #2 Rubber Stopper 1 Outlet Valve Clamp 1 #2 Stubby Phillips Screwdriver 1 100 mL Bottle of PAO Oil 1 #1 Phillips Screwdriver 1 T-Handle Hex Wrench 1 1/8” Flat Blade Screwdriver

Table 15. List of Items Furnished

3.2 ADDITIONAL OPERATOR SUPPLIES

Few, if any, additional supplies are needed. However it is suggested that test operators use a sponge or lint free cloth to wipe masks and the peripheral seal of the headform prior to mask leakage testing. Operations will also require direct access to a 110/220V A/C power source.

3.3 UNPACKING

WARNING

The PMLT is a heavy item. Always follow proper procedures when lifting the PMLT; use two people to lift

or carry. Never drop it into place – lower it carefully.

CAUTION

To avoid damage, when components are not being used, they should be stored in the plastic tray and/or case.

NOTE

If any items are missing, contact ATI for replacement.

Preventive Maintenance Checks and Services (PMCS) should be performed during the unpacking and setup of

the PMLT. Refer to HChapter 10H.



3-2

1. Open the PMLT Case.

Figure 12. PMLT in Case

2. Remove the mask test shroud (1) from the case.

3. Remove the operator’s manual from the front storage section of the case.

CAUTION

Be sure to remove the power unit before lifting the tray from the case. Failure to do so may result in damage to

the tray.

4. Remove the power unit (3) from the tray.

5. Remove the fit test kit (4) from the PMLT case. Lift tray (5) out of the case.

Figure 13. Control Unit Unpacked

6. Remove the control unit from the case.

7. Remove the twin tube interface hose, the power interface cord, and the aerosol probe hose from around the headform pedestal and the power cord from behind the pedestal.

8. Place the tray and unused components back in the case and secure the case.

4

2

3

1

5



3-3

3.4 ASSEMBLING THE PMLT

3.4.1 AEROSOL GENERATOR ASSEMBLY

1. Remove the cap from the generator bottle, and place cap in the generator slot of the tray.

WARNING

Do not ingest PAO Oil. Refer to Material Safety Data Sheet in Appendix E.

NOTE

PAO oil level must be between the top and bottom fill lines on the generator bottle for the generator to work

properly.

2. Inspect the generator bottle to ensure that the oil level is between the top and bottom fill lines. If required, use the bottle of oil to fill the generator bottle or to store any excess oil.

CAUTION

Do not cross-thread the generator cap to the generator bottle. The generator bottle must always be

attached/installed on the control unit. Damage to the generator cap may result if the generator bottle is not

attached.

3. Hand-tighten the amber colored generator cap onto the generator bottle.

4. Snap the aerosol probe hose into the snap tabs on top of the generator cap.

Figure 14. Attaching Aerosol Generator Assembly to Control Unit

CAUTION

Failure to ensure the generator port tabs are depressed prior to inserting the aerosol generator assembly may

cause damage to the PMLT.

5. Attach the aerosol generator assembly to the control unit by depressing port tabs, and inserting the male adapters into the generator ports until locked.

Aerosol Generator Cap

Connector Port Tabs Aerosol Probe

Hose

Connector Ports



3-4

3.4.2 CONNECTING POWER UNIT TO CONTROL UNIT

CAUTION

Never position the power unit upside down or with the fan opening obstructed.

Ensure that power switch is off to prevent damage to the PMLT.

Ensure that power cord is not plugged in to prevent damage to the PMLT.

1. Position the power unit with rubber feet down, on a flat, solid surface near the control unit.

Figure 15. Power Interface Cable to Power Unit

2. Connect the male end of the power interface cable to the top of the power unit using alignment pins and twist locking ring until the detent is felt.

Figure 16. Power Interface Cable to Control Unit

3. Connect the female end of the power interface cable to the back of the control unit.

4. Connect the yellow-banded ends of the twin tube interface hose to the brass fittings on the control unit and power unit.

5. Connect the solid black ends of the twin tube interface hose to the black fittings on the control unit and power unit.

WARNING

Do not connect the power cord if any wiring is frayed.



3-5

6. Connect the power cord to the power unit.

Figure 17. Control Unit and Power Unit Properly Connected

3.4.3 ATTACHING THE HEADFORM

NOTE

When initialized, the PMLT conducts an inflation and seal test on the headform that is in place. If there is a failure,

a SEAL FAILED error message will appear. Refer to Section 12.3.6, Seal Failure, for troubleshooting. If the

headform is changed during operation, the PMLT must be restarted to allow the system to verify the inflation and seal process of the second headform. This seal check is only required once per headform per operating period.

1. Center the headform to be used over the pedestal with the chin (narrow portion) toward the front of the control unit. Refer to section 5.2, Applying A Mask, for recommended headform selection.

Figure 18. Headform and Pedestal Apart

2. Align the white fittings on top of the pedestal with the holes in the headform.



3-6

Figure 19. Headform and Pedestal Assembled

3. Press down on the headform until it is fully seated onto the pedestal.

4. Insert the QRLS pin (1) into the hole in the back of the headform to secure its position.

5. Ensure the lint screen is in place and clear of lint, dirt, or other debris.

NOTE

When the PMLT is unpacked and sitting idle, make sure the headform is attached and the mask test shroud is placed over the headform to prevent the ports from

collecting debris.

If fit testing is to be conducted, proceed to HSection 3.4.4, Assembling the Fit Test Kit.H If fit testing is not to be

conducted proceed to HChapter 4, InitializationH.

3.4.4 ASSEMBLING THE FIT TEST KIT

CAUTION

The fit test shroud and fit test interface tubing are easily damaged and should only be assembled prior to

performing the fit tests.

1. Unpack the fit test shroud, Y-hose aerosol extension, fit test interface tubing, and fit test support rods from the fit test bag.

WARNING

To avoid eye injury, use care when handling the fit test support rods.

2. Carefully unfold each fit test support rod and connect the aluminum tubing together so that the connected rods eventually form an arc.

1



3-7

Figure 20. Fit Test Support Rod Into Nylon Corner Pouch

3. Insert one end of a fit test support rod into the base of the fit test shroud and tuck it into one of the nylon corner pouches.

4. Flex the fit test support rod until the opposite end tucks into the diagonally opposite corner nylon pouch.

Figure 21. Fit Test Rods Form Support Arc

5. Repeat steps 2, 3 and 4 for other side of fit test shroud. When finished, both fit test support rods should form a crisscrossed support pattern inside the fit test shroud (Figure 21).

Figure 22. Y-Hose Aerosol Extension onto Brass Fittings

6. Attach the Y-hose aerosol extension to the brass fittings that connect through the grommets into the aerosol manifolds. (Two tubes in the top of the fit test shroud.)



3-8

Figure 23. Y-Hose Aerosol Extension Connecting to Aerosol Probe Hose

7. Connect the Y-hose aerosol extension to the aerosol probe hose.

Figure 24. Fit Test Interface Tubing Assembly

8. Connect the fit test interface tubing to the fit test interface ports on the control unit by depressing the port tabs and pushing the tubing on until they snap-lock in place.

9. Proceed to Chapter 4, Initialization.

100% Sample Line

(Blue)

Internal Sample line

(Clear)



4-1

4 Initialization This chapter provides step-by-step instructions for operating the PMLT efficiently. Descriptions of the menus are displayed on the display screen of the control unit.

4.1 POWER UP

WARNING


1. Plug the power cord into the power source.

NOTE

If the PMLT fails to initialize with the toggle switch in the “ON” (|) position, the operator should check all power

connections and then Fuse #4 for serviceability.

2. On the power unit, toggle the power switch to the ON (|) position.

NOTE

The PMLT requires no operator input for steps 3 to 5.

3. After power-up, the system version screen is displayed for approximately 10 seconds. The system version screen displays the software version number, security level, number of mask tests performed, number of fit tests performed, and number of operating hours since the last calibration of the PMLT. For more information on calibration and servicing refer to Section 10.3, Long Term Preventive Maintenance Checks and Services.

4. The [WARM UP] screen follows the system version screen and displays the current date and time along with the warm up interval. Refer to HSection 11.1, Date and TimeH, for instructions on setting the current date and time. The warm up interval will be displayed as a backward countdown from 120 to 0 seconds, in 5-second intervals, in the upper right corner of the display screen.

5. After the PMLT completes the internal warm-up, a [SYSTEM CHECK] screen is displayed. The [SYSTEM CHECK] screen indicates that the system is checking the internal sensors.

ATI PMLT V1.9 L1

1 0 5

Software Version

Security Level

Masks Tests Performed Fit Tests

Performed

Operating Hours

WARM UP 120

MM/DD/YY 00:00

Warm Up Time Remaining (seconds)

Adjustable Date/Time



4-2

NOTE

When initialized, the PMLT conducts an inflation and seal test on the headform that is in place. If there is a failure,

a SEAL FAILED error message will appear. Refer to Section 12.3.6, Seal Failure, for troubleshooting. If the

headform is changed during operation, the PMLT must be restarted to allow the system to verify the inflation and seal process of the second headform. This seal check is only required once per headform per operating period.

CAUTION

DO NOT press on the headform seal while it is inflating or once it is inflated. External pressure against the seal may cause a false SEAL FAILED error and require the

system to be re-initialized.

6. Upon completion of a successful system check, the following screen will appear:

4.2 SETTING THE ALTITUDE

<F1> CHANGE Sends the operator to the [ALTITUDE] adjustment screen.

<F4>CONT Continues on to the [SELECT TEST] screen.

1. Press <F1>, in order to change the present altitude.

<F1> UP Scrolls up through the available altitudes in 1000 foot increments

<F2> DWN Scrolls down through the available altitudes in 1000 foot increments.

<F4> CONT Continues on to the [SELECT TEST] screen.

SYSTEM CHECK

ALTITUDE NOW 0000FT

CHANGE CONT

ALTITUDE 0000FT

UP DWN CONT

ALTITUDE NOW 0000FT

CHANGE CONT



4-3

2. Using the <F1>UP and <F2>DWN keys, scroll to the nearest altitude in 1000 ft increments.

3. Press <F4>CONT to program the appropriate altitude into the PMLT and return to the [SELECT TEST] screen.

4. Continue on to the Section 4.3, Selecting a Test.

4.3 SELECTING A TEST

NOTE

The PMLT is equipped with internal temperature monitoring. If the internal temperature fluctuates +/- .9°F/.5°C, the PMLT will automatically enter into the [SYSTEM CHECK] mode. When the system check is

completed, the menu will return to the previous point of operation.

Extreme temperature fluctuations or variations in elevation could result in low vacuum failure readings

(4.0 – 5.49).

<F1> SYS Sends the operator to the System Diagnostics menu.

<F2> UP Scrolls up through the list of available tests.

<F3> DWN Scrolls down through the list of available tests.

<F4>Acpt Accepts the test type displayed.

NOTE

Scrolling up/down the list of tests, the display will start over at the end of the list. After power-up if MASK, M ALL, FIT, or ALL is selected an aerosol setup must be

conducted.

The display screen indicates the tests available. A more detailed description of the available tests is contained in HSection 1.9, Tests Conducted with the PMLT and in Table 16 on the following page.

SELECT TEST= M ALL

SYS UP DWN ACPT



4-4

TEST FUNCTION

[MASK] Performs a mask leakage test. Refer to Ch 5, Mask Testing and Appendix B, Testing a Mask With An Attached Hose.

[DRINK] Performs a drink flow, drink train, and drink seat test. Refer to Ch 6, Drink Tube Testing.

[VALVE] Performs a test on the outlet valve. Refer to Ch 7, Outlet Valve Test.

[M ALL] Performs the MASK, DRINK, and VALVE tests sequentially. Refer to Ch 5, Mask Testing; Ch 6, Drink Tube Testing; Ch 7, Outlet Valve Test. and Appendix B, Testing a Mask With An Attached Hose.

[FIT] Performs a quantitative fit test. Refer to Ch 8, Quantitative Fit Test.

[ALL]

Performs the mask, drink, valve, and fit tests sequentially. Refer to Ch, 5 Mask Testing; Ch 6, Drink Tube Testing; Ch 7, Outlet Valve Test; and Ch 8 Quantitative Fit Test.

Table 16. Mask Testing Mode Descriptions

1. Scroll to the appropriate test using <F2>UP and <F3>DWN.

2. Select the appropriate test by pressing <F4>ACPT and refer to the chapter related to that test for specific instructions.



5-1

5 Mask Testing A mask test allows the operator to test the serviceability of the face blank. This test is completed under negative pressure by challenging the mask with an aerosol mist.

5.1 MASK AEROSOL SETUP

An aerosol setup is used to set the 0% aerosol level (best seal) and 100% aerosol level (no seal) for any mask leakage test. These levels must be established every time the PMLT is setup in the MASK, FIT, M ALL, and ALL modes or if the PMLT is switched off and then restarted in one of those modes. It is also recommended that an aerosol setup be conducted whenever mask testing is resumed after the PMLT has been sitting idle for more than sixty (60) minutes.

NOTE

Ensure that the aerosol probe hose input grommet of the test shroud is located at the rear of the headform. Improper assembly may cause improper aerosol

distribution and possibly cause false test failures.

1. Place the test shroud over the headform. Ensure that the test shroud completely covers the headform and the aerosol probe hose input grommet is located at the rear of the headform. The headform should be exposed to the open air with no mask attached. Blocking the vacuum port of the headform during aerosol setup will result in a LOW AEROSOL ERROR.

Figure 28. Aerosol Setup

2. Place the test shroud over the headform. Ensure that the test shroud completely covers the headform and the aerosol probe hose input grommet is located at the rear of the headform.

<F1> YES

Starts the aerosol setup procedure.

AEROSOL SETUP

YES



5-2

3. Select <F1>YES to perform an aerosol setup. The following steps are then completed automatically by the PMLT:

[SETTING] Adjusting to test parameters.

[LOADING] Generator turns on and aerosol is loaded under the test shroud.

[SETTING] Setting 100% range.

[SETTING]

• With aerosol setup number displayed (-20 to 100+). • If the number displayed exceeds 90, refer to HSection 12.4.3,

Aerosol Setup of 90H or Greater, for troubleshooting recommendations.

NOTE

If the respirator being tested has a hose attached, refer to Appendix B, Testing a Mask With an Attached Hose.

4. At the completion of an aerosol setup, the following screen will be displayed:

NOTE

The PMLT should complete the aerosol setup and display the following screen within five minutes.

5. Remove the test shroud from the headform, leaving the aerosol probe hose inserted.

5.2 APPLYING A MASK

It is recommended that the SMALL headform be utilized for all mask leakage testing unless the test operator cannot obtain a seal against the mask. The MEDIUM headform may be used at the test operator’s discretion if a seal can not be obtained with the SMALL headform.

1. Ensure that the mask clips are properly adjusted for the type and size of protective mask being tested. Refer to HSection 11.12, Universal Hold-Down Assembly Adjustment H, for specific instructions.

2. Ensure that external components (hood, second skin, eyelens outserts, outlet valve cover, canister) are removed from the protective mask prior to testing. It is not necessary to remove the head harness or skull cap prior to testing.

3. Inspect the lint screen for debris. Clean as necessary.

4. Clean the mask seal area and peripheral seal on the headform with a sponge or lint free cloth, dampened with water.

APPLY MASK

SET ESC START

SETTING

6

Aerosol Setup Number



5-3

NOTE

If the head harness is attached to the protective mask, fully extend the harness straps and position the head

harness to the rear of the headform.

Ensure that mask nose cup does not cover the top flow port or airflow channel of the headform.

5. Position the mask on the headform, by placing it on chin first.

Figure 29. Mask on Headform

6. Hold down the chin of the mask while fastening the two temple/middle tabs (1) to their corresponding mask clips on the middle brackets of the headform pedestal.

7. Fasten the two cheek/bottom tabs (2) to their corresponding mask clips on the bottom brackets of the headform pedestal.

8. Fasten the two forehead/top tabs (3) to their corresponding mask clips on the top brackets of the headform pedestal.

9. Smooth the mask over the peripheral seal.

10. Ensure that the mask covers as much of the seal as possible. If this cannot be achieved, you may need to change to a different sized headform.

11. Ensure that even tension is applied from all of the straps of the mask to the clips.

Figure 30. Mask Properly Attached With Adapters

1

2

3

Outlet Valve Clamp

Canister Port Plug

Hose Test Port Plug



5-4

12. Retract the plunger on the outlet valve clamp and slide it over the outlet valve housing from the bottom. Then, release the plunger to seal the valve.

CAUTION

Do not use a wrench when tightening the canister port plug. Damage may occur to the mask if the plug is over

tightened.

13. Install the canister port plug into the canister port of the mask and hand-tighten until it is snug.

14. Ensure that the hose test port plug is installed.

Figure 31. Mask Under Shroud

15. Place the test shroud over the protective mask and headform with the aerosol probe hose at the rear of the headform.

16. Ensure the mask test shroud extends to the base of the headform pedestal and completely covers the mask.

5.3 CONDUCTING A TEST

<F1> SET Displays the [AEROSOL SETUP] menu. Section 5.1, Mask Aerosol Setup.

<F3> ESC Returns the operator to the [SELECT TEST] menu. Section 4.3, Selecting a Test.

<F4> START Starts the mask test procedure.

1. To begin the mask test, press <F4>START.

2. Wait approximately 10 seconds while the peripheral seal inflates. The following steps are then completed automatically by the PMLT:

APPLY MASK

SET ESC START



5-5

[SETTING] Indicates that the system is setting the test flow rate.

Indicates that the system is loading aerosol under the test shroud.

Indicates that the system is reading the aerosol leakage through the mask.

3. At the end of the test, either a [PASSED] or [FAILED] screen will appear:

A percentage of penetration (i.e.: .0001) is

displayed in the upper right corner. [PASSED] allows you to continue on to a new MASK test. If operating in either the M ALL or ALL mode, then testing continues on to the drink tube test.

Automatically stops testing. A steady tone indicates failure and a percentage of penetration (i.e.: 3.44%) is displayed.

Automatically stops testing. A steady tone indicates failure and either a LOW VAC or HIGH VAC message is displayed.

NOTE: Depressing the <F4>CONT key stops the audio alarm and advances to the [PAUSED] screen.

4. If [FAILED] or [FAILED VAC (HIGH or LOW)] appears, press <F4>CONT to continue and proceed to Section 5.4, Mask Paused, for further options.

5.4 MASK PAUSED

NOTE

If a mask test fails, refer to the flowchart diagrams in HSection 5.8, Mask Testing Failures, for guidance on which

steps to perform next.

SETTING

LOADING

TESTING

* PASSED* 0.0001

* FAILED * 3.44%

CONT

* FAILED * HIGH VAC

CONT

* FAILED * LOW VAC

CONT



5-6

The following screen is displayed after a mask failure:

<F1> RES Resumes normal testing.

<F2> PROB Allows the application of aerosol to the mask, using the aerosol probe hose to help isolate the leak.

<F3> REJ Rejects the mask and returns to the [APPLY MASK] screen.

<F4> DEFL

SEAL

Deflates the peripheral seal. Use if mask was applied incorrectly and adjustments need to be made. Returns operator to [APPLY MASK] screen.

5.5 PROBE MODE

The probe mode is used to help isolate the location of a leak.

NOTE

When the failure set point is exceeded in probe mode, a beep can be heard. The beep sounds only when the

failure threshold (.0030) is exceeded. When probing, the threshold may not be obtained since a lower

concentration of aerosol is being applied.

1. To begin probing, select, <F2>PROB from the [PAUSED] screen and the following screen will appear:

<F1> HIGH Switches from normal aerosol concentration to high aerosol concentration to help isolate small leaks. After [HIGH] is selected, the screen will display [NORM] in the <F1> position. Selecting [NORM] returns the user to the normal aerosol concentration for testing.

<F3> PAUSE Ends the probe test and returns to the [PAUSED] screen for further options. Refer to Section 5.4, Mask Paused, for further options.

<F4> REJ Rejects the current mask test and prompts the operator to confirm the rejection. Confirming the rejection by pressing <F4>REJ returns the PMLT to the [APPLY MASK] screen. Refer to Section 5.3, Conducting a Test.

2. Remove the test shroud from the headform, and remove the aerosol probe hose from the test shroud.

* TESTING 0.0089

HIGH PAUSE REJ

% Penetration

* PAUSED .0062% DEFL

RES PROB REJ SEAL



5-7

CAUTION

NEVER plug or block the probe end (blue) of the aerosol probe hose while the aerosol generator is bubbling. Blocking the flow of aerosol may result in damage to

internal components of the PMLT.

3. Hold the aerosol probe hose away from the mask until the numbers on the screen appear to stabilize at their lowest reading.

NOTE

When probing a mask, it is recommended that the hand not holding the probe be cupped around the area of the mask being checked. This will prevent excess aerosol from drifting over the mask, possibly leading to false

readings.

Figure 32. Using the Probe

4. Slowly pass the aerosol probe hose close to the mask surface. All potential areas for leaks should be probed (peripheral seal, lenses, recently replaced parts, etc.). The amount of time spent probing a leak is at the operator’s discretion. An increase in the value displayed on the screen indicates a probable mask leak in the area being probed.

5. When a suspected leak is isolated select <F3>PAUSE, then select <F1>RES or <F3>REJ from the [PAUSED] screen.

5.6 RESUME TESTING

1. Resume testing from the [PAUSED] screen by pressing the <F1> RES key.

* TESTING 0.0089

HIGH PAUSE REJ

% Penetration



5-8

<F1> RES Ends the probe test and returns to the [APPLY MASK] screen.

<F2> PROB Allows the application of aerosol to the mask, using the probe to help isolate the leak.

<F3> REJ Rejects the mask, deflates the seal, and displays the [REJECTED] screen. Pressing <F4>CONT returns you to the [APPLY MASK] screen.

<F4> DEFL

SEAL

Deflates the peripheral seal. Use if mask was applied incorrectly and adjustments need to be made.

<F4> CONT Returns to the [PAUSED] screen.

NOTE

If “Low Seal Pressure” screen is displayed, operator should select <F4> INFL SEAL to reinflate the peripheral

seal. This will redirect you to the <PAUSED> screen. Pressing the <F2> PROB key will allow the operator to

resume probing for the leak.




<F4> INFL SEAL

Re-inflates the peripheral seal after a [Low Seal Pressure] message. Allows user to retry mask probing or other leakage testing.

NOTE

Repeated [Low Seal Pressure] fault messages require troubleshooting. Refer to Section 12.3.6, Seal Failure,

for troubleshooting recommendations.

* PAUSED* DEFL

RES PROB REJ SEAL

Low Seal Pressure

CONT

* PAUSED* INFL

RES PROB REJ SEAL



5-9

5.7 REMOVING THE MASK FROM THE HEADFORM

When testing is complete, remove the mask from the headform as follows:

1. Remove the mask test shroud from the headform.

2. Disconnect the forehead buckles from the mask clips.

3. Disconnect the cheek buckles from the mask clips.

4. Disconnect the temple buckles from the mask clips.

5. Remove the protective mask from the headform.

6. Remove the canister port plug from the mask.

7. Remove the outlet valve clamp from the mask by retracting the plunger and sliding the clamp off.

NOTE

When mask testing is completed place the shroud over the headform to prevent debris from entering the

exposed ports.

To return to the [SELECT TEST] screen, Press <F3> ESC.

5.8 MASK TESTING FAILURES FLOWCHARTS

The symbols in the following table are used in the flowcharts on pages 5-11 through 5-14:

Indicates a step/action to be taken.

Indicates a point at which a decision must be made.

or

Indicates the path down which an answer leads.

Table 17. Flowchart Symbols

NOTE

Some protective mask failures can be resolved with the mask seated on the headform and some require the

protective mask to be removed.

The purpose of the following diagrams is to isolate the failure in the mask prior to troubleshooting the PMLT.



5-10

5.8 MASK TESTING FAILURES FLOWCHARTS (CON’T)

Does mask pass? Continue Testing.

Proceed to Section 12.5.1 Low Vacuum

Failure or 12.5.2 High Vacuum Failure

Probe for leakIAW Section 5.5

Proceed to Section 5.8.3, No Leak Found

Using Probe

Is leak at seal or in mask/hose?

Proceed to Section 5.8.1 Leak Found In Mask or Hose Using

Probe

Proceed to Section 5.8.2, Leak Found at Seal Using Probe.

Yes

VAC Failure

% Penetration

Leak

No leak found

Leak Found

In Mask/Hose

At Seal

No

Retest mask IAW procedures listed in Section 5.2 and 5.3

Does mask pass?

Are procedures being followed

IAW Chapter 5?

No

What type of failure is it?

Yes

Continue Testing.YesNo



5-11

5.8.1 LEAK FOUND IN MASK OR HOSE USING PROBE



5-12

5.8.2 LEAK FOUND AT SEAL USING PROBE



5-13

5.8.3 NO LEAK FOUND USING PROBE



6-1

6 Drink Tube Testing This chapter covers the procedures necessary to complete a comprehensive set of tests on the mask’s entire drink system.

6.1 DRINK TUBE FLOW TEST (DRINK TUBE/TURN IN)

The drink tube flow test utilizes air pressure to test the drinking system for blockage.

<F3> ESC Returns the PMLT to the [SELECT TEST] screen.

<F4> START Begins the Drink Tube Flow test.

1. Remove the mask test shroud from the headform, if installed.

Figure 33. Drink Flow Test Setup

2. Ensure the drink tube adapter is turned fully counterclockwise until it stops (“OUT” position).

3. Insert the mask drink tube to be tested into the drink tube adapter until it locks in place.

4. Turn the drink tube adapter fully clockwise until it stops (“IN” position).

5. Press <F4>START. The following step is then completed automatically by the PMLT:

[FLOW TEST] Signifies that the system is reading the resistance of the test.

6. At the end of the test, either a [PASSED] or [FAILED] screen will appear.

DRINK TUBE/TURN IN

ESC START

Drink Tube Adapter

Mask Drink Tube



6-2

Allows you to continue testing. The system-

automatically advances to the DRINK TRAIN test. Refer to Section 6.2, Drink Train Assembly Leakage Test, for further instructions.

Automatically stops testing; a steady tone indicates failure.

<F4> CONT NOTE: Depressing the <F4>CONT key stops the audio alarm and advances to the [PAUSED] screen.

<F2> RES reverts to [DRINK TUBE/TURN IN ] screen to reinitiate the drink system test sequence . The operator may then re-test the connected drink tube or test a different drink tube. <F3> REJ proceeds to [REJECTED] screen.

<F4>CONT reverts to [DRINK TUBE/TURN IN ] screen to reinitiate the drink system test sequence . The operator may then re-test the connected drink tube or test a different drink tube.

7. If failed, press <F4>CONT to continue and refer to the flowchart in HSection 6.4, Drink Testing Failures Flowchart, for further instructions.H

6.2 DRINK TRAIN ASSEMBLY LEAKAGE TEST

The drink train assembly leakage test utilizes air pressure to test the entire drink train for leakage. The internal drink tube must be plugged prior to starting this test.

1. Select either <F1>YES or <F2>NO.

<F1> YES Starts the DRINK TRAIN test after prompting you to [PLUG TRAIN]

<F2> NO Skips the DRINK TRAIN test and continues to the DRINK VALVE SEAT test.

TEST DRINK TRAIN?

YES NO

* PASSED *

* FAILED *

CONT

*PAUSED*

RES REJ

REJECTED

CONT



6-3

2. If <F1>YES is selected, the [PLUG TRAIN] screen appears as a reminder that the drink tube will need to be plugged inside the mask during this phase of the test sequence. Use the QRLS pin or place your thumb over the internal drink tube opening to prevent air from escaping and block flow.

Using the QRLS pin Using the thumb

Figure 34. Plugging the Drink Tube

NOTE

Ensure that the drink tube adapter is rotated fully clockwise before continuing.

3. Press <F4>CONT to initiate the test. The following step is then completed automatically by the PMLT:


Allows you to continue testing. The system- automatically advances to the DRINK TUBE/TURN OUT (DRINK SEAT) test. Refer to Section 6.3, Drink Valve Seat Test, for further instructions.



[D-TRAIN TEST] Indicates that the system is reading the airflow of the test.

PLUG TRAIN

CONT

* PASSED *

* FAILED *

CONT



6-4



3. If the test result is a failure, press <F4>CONT to continue. Refer to the flowchart in HSection 6.5, Drink Testing Failures Flowchart, for further instructions.

4. Remove the plug from the internal drink tube before continuing.

6.3 DRINK VALVE SEAT TEST (DRINK TUBE / TURN OUT)

The drink valve seat test utilizes air pressure to test for leaks at the drink valve seat (also known as the quick disconnect/QDC) while the valve is in its closed position.

1. Turn the drink tube adapter fully counterclockwise (turned “OUT”) until it stops.

2. Press <F4>CONT. The following step is then completed automatically by the PMLT:


Allows you to continue testing. The system- automatically reverts to the DRINK TUBE/TURN IN (DRINK FLOW) test to test the next drink system.



<F4> CONT Starts the DRINK VALVE SEAT test.

[SEAT TEST] Indicates that the system is reading the airflow of the test.

*PAUSED*

RES REJ

REJECTED

CONT

DRINK TUBE/ TURN OUT

CONT

* PASSED *

* FAILED *

CONT



6-5



4. Press <F4> to continue and refer to Section 6.5, Drink Testing Failures Flowchart.

5. If all the drink system tests were completed successfully, the following screen will be shown (dependent on test mode):

If testing in the DRINK mode:

If testing in M ALL or ALL mode:

<F3> ESC Returns the operator to the [SELECT TEST] menu. Refer to Section 4.2, Selecting a Test.

<F4> START Starts the VALVE test procedure. Refer to Chapter 7, Outlet Valve Test.

6. When drink system testing is complete, disconnect the protective mask drink tube from the drink tube adapter.

<F3> ESC Returns to the [SELECT TEST] screen.

<F4> START Begins another DRINK TUBE FLOW test.

VALVE TEST

ESC START

DRINK TUBE/ TURN IN

ESC START

*PAUSED*

RES REJ

REJECTED

CONT



6-6

6.4 DRINK TESTING FAILURES FLOWCHART

The symbols in the following table are used in this flowchart:



or



NOTE

Water inside the drink tube may cause repeated failures during the Drink Tube Flow Test.

The purpose of the following diagram is to isolate the failure in the mask prior to troubleshooting the PMLT.



6-7

6.4 DRINK TESTING FAILURES FLOWCHART (CON’T)

Drink Testing

Retest mask

Ensure that drink tube flow path is clear IAW mask TM/

TO

Does mask pass?Yes

Continue Testing

No

Test another mask if available or proceed to Section 12.6.1 or 12.6.2

for troubleshooting guidance

Clean drink tube IAW mask TM/TO and ensure that mating surfaces are dry

Does 2nd mask pass?

Proceed to PMLT Troubleshooting Section 12.6.1 or

12.6.2

Repair or reject 1st mask IAW

technical guidance

Does mask pass?Yes

Continue Testing

No

Is this the 4th time tested?

No

Yes

Yes

No



7-1

7 Outlet Valve Test This chapter covers the procedures necessary to complete outlet valve testing.

NOTE:

The default Outlet Valve Test Adapter provided with the PMLT does not accommodate all masks. If the mask(s) you are testing require a different adapter, contact the

ATI for further assistance.

<F3> ESC Returns to [SELECT TEST] screen.

<F4> START Starts the outlet valve test.

7.1 CONDUCTING A TEST

1. Ensure the mask test shroud is removed from the headform.

2. Verify that the outlet valve assembly cover has been removed from the protective mask.

3. Use a sponge or lint free cloth dampened with water to moisten the PMLT Outlet Valve Test Adapter.

NOTE

The outlet valve disk must remain dry during this test.

Figure 35. Outlet Valve Test

4. Align and insert the outlet valve assembly lug(s) into the notch(es) and gently apply pressure until it is fully seated.

5. Continue pressing the outlet valve assembly into the adapter until a click is felt.

6. Support the mask with your free hand while the outlet valve assembly is seated in the Outlet Valve Test Adapter during the test.

VALVE TEST

ESC START



7-2

NOTE

It may be necessary to periodically hand-tighten the PMLT Outlet Valve Test Adapter. Refer to HSection 11.3,

Outlet Valve Test Adapter Replacement,H for further instructions.

7. Press <F4>START. The following steps are automatically completed by the PMLT:

[VALVE TEST] Indicates that the system is reading the airflow of the test.


Allows you to continue testing. If an M ALL mode was selected, proceed to HSection 5.2, Applying a MaskH. If ALL mode was selected, proceed to HChapter 8, Quantitative Fit TestH. If VALVE test was selected you’ll be returned to the first [VALVE] test screen to begin another test.



<F2> RES returns PMLT to [VALVE] test screen. <F3> REJ proceeds to the [REJECTED] screen.

<F4>CONT reverts to [VALVE] screen to reinitiate a valve test on the same valve assembly as is or after cleaning or repairs/replacement of the disk.

9. If the outlet valve test was completed successfully, the following screen will be shown (dependent on test mode):

If testing in the VALVE mode:

<F3> ESC Returns to the [SELECT TEST] screen.

<F4> START Begins another Outlet Valve Test.

* PASSED *

* FAILED *

CONT

*PAUSED*

RES REJ

REJECTED CONT

VALVE TEST

ESC START



7-3

If testing in M ALL or ALL mode:

<F1> SET Displays the [AEROSOL SETUP] menu. Section 5.1, Mask Aerosol Setup.

<F3> ESC Returns the operator to the [SELECT TEST] menu. Section 4.3, Selecting a Test.


10. If outlet valve testing is complete, disconnect the protective mask from the Outlet Valve Test Adapter.

7.2 OUTLET VALVE FAILURES FLOWCHART




or



APPLY MASK

SET ESC



7-4

7.2 OUTLET VALVE FAILURES FLOWCHART (CON’T)

NOTE

The purpose of the following diagram is to isolate the failure in the mask prior to troubleshooting the PMLT.



8-1

8 Quantitative Fit Test This chapter describes the Quantitative Fit Test. This series of tests is designed to give a standard indication of the leakage rate of a mask while it is being worn by a subject.

NOTE

Fit testing must be conducted in accordance with specific NIOSH, industry, military service, and protective mask

technical directives.

Prior to conducting a fit test ensure that the PMLT has been operating at least 20 minutes to prevent the

condensation of human breath on the internal measuring optics.

Be sure that a fit test is performed with a known serviceable protective mask and canister.

An aerosol setup is required prior to performing the first fit test after initialization.

8.1 SELECTING A STANDARD

NOTE

The test operator is required to select the fit standard for the subject(s) being tested before the first aerosol setup

in the FIT or ALL test modes.

1. From the [SELECT TEST] menu, select <F4>ACPT to accept the FIT test.

<F1> UP Scrolls upward from 2 to 200,000

<F3> DOWN Scrolls downward

<F4> CONT Sets and saves the selected fit standard

2. Select the appropriate fit standard by pressing <F1> UP or <F2> DOWN until you arrive at the desired fit factor number. The standard can be set anywhere from 2 to 200,000. Pressing and holding either key will allow you to rapidly scroll through the numbers.

3. Press <F4> CONT to set and save your selection. The chosen fit standard will remain in memory until it is changed by the operator.

4. Proceed to Section 8.2, Fit Test Aerosol Setup.

SELECT TEST= FIT

SYS UP DWN ACPT

FIT FACTOR = 3000

UP DWN CONT



8-2

NOTE

Section 8.3, Prepare the Subject, may be completed simultaneously with Section 8.2, Fit Test Aerosol Setup.

8.2 FIT TEST AEROSOL SETUP

An aerosol setup is used to set the 0% aerosol level (best seal) and 100% aerosol level (no seal) for any mask leakage test. These levels must be established every time the PMLT is setup in the MASK, FIT, M ALL, and ALL modes or if the PMLT is switched off and then restarted in one of those modes. It is also recommended that an aerosol setup be conducted whenever mask testing is resumed after the PMLT has been sitting idle for more than sixty (60) minutes.

1. Use the attached badge clip to attach the drink adapter end of the fit test interface tubing to the inside the fit test shroud.

CAUTION

Do not lay the fit sampling tube (blue tubing with “v” cut end) directly onto the surface of a table, desktop, floor,

etc. during aerosol setup. Dirt and/or debris may be drawn through the open end directly into the internal optics and cause a system malfunction requiring ATI

factory service to repair.

Figure 36. Fit Test Aerosol Setup

2. Ensure the fit test shroud is standing upright (Figure 36).

<F1> YES Continues the aerosol setup procedure.

<F2> NO (not always active)

Bypasses the aerosol setup and continues with testing.

AEROSOL SETUP

YES NO



8-3

NOTE

<F2>NO selection is invisible (not active) unless PMLT has been previously setup in the FIT or ALL test mode.

3. At [AEROSOL SETUP] select <F1>YES. The following steps are then completed automatically by the PMLT:

[SETTING] Adjusting to test parameters.

[LOADING] Generator turns on and aerosol is loaded under the test shroud.

[SETTING] Setting 100% range.

[SETTING]

• With aerosol setup number displayed (-20 to 100+).

• If the number displayed exceeds 90, refer to HSection 12.4.3, Aerosol Setup of 90H or Greater, for troubleshooting recommendations.

NOTE

The PMLT should complete the aerosol setup and display the following screen within five minutes.

followed by:

5. Unclip the badge clip from the fit test shroud and remove the fit test interface tubing from beneath the fit test shroud.

6. Proceed to Section 8.3, Prepare the Subject

8.3 PREPARE THE SUBJECT

WARNING

It is critical to ensure that there are no obstructions in the drink tube during the test. An obstructed drink tube may result in FALSE PASSING scores. A DRINK test (IAW Chapter 6) should be conducted to verify that there are

no obstructions in the drink tube flow path prior to beginning the fit test.

1. Ensure that all protective mask components are attached to the mask. This includes a serviceable filter canister, the second skin, eyelens outserts, exhalation valve cover, etc.

2. Prepare the mask by removing the internal drink tube or by turning the internal drink tube away from the subject's mouth.

READY SUBJECT - 5

SET XDATA ESC CONT

SETTING

6

SETTING

6

Aerosol Setup Number



8-4

3. Instruct the test subject to sit down.

4. Have the subject don, clear, and check the seal of the mask in accordance with mask-specific technical procedures.

NOTE

It is critical to ensure that there are no obstructions in the drink tube during the test. A DRINK test can be conducted IAW Chapter 6 to verify that there are no

obstructions in the drink tube flow path.

Figure 37. Attaching the Fit Sampling Adapter

5. Attach the fit sampling adapter (blue adapter on the fit test interface tubing) to the subject’s drink tube. Make sure that the drink tube is inserted fully into the blue adapter.

Figure 38. Attaching the Badge Clip

6. Attach the badge clip to the excess material at the end of the head harness temple strap.

NOTE

Ensure the end of the sampling line is not resting near the exhalation valve.

7. Place the fit test shroud over the subject’s head, resting on the subject’s shoulders with the Y-hose aerosol extension in the back.



8-5

Figure 39. Fit Test Shroud

8. Adjust the straps of the fit test shroud to ensure that the subject can move his/her head without contacting the fit shroud.

9. Ensure that the green nylon apron of the fit test shroud extends below the subject’s shoulders.

8.4 TESTING A SUBJECT

<F1> SET Proceeds to the [AEROSOL SETUP] screen.

<F2> XDATA Starts loading the shroud with aerosol to conduct the fit test with serial data output and on-screen fit factor information

<F3> ESC Cancels the test and returns to the [SELECT TEST] screen.

<F4> CONT Starts loading the shroud with aerosol to conduct the fit test without serial data output.

1. Advise the subject to relax. Select <F2>XDATA or <F4>CONT. The PMLT will then load the shroud with aerosol and automatically advance to the first exercise screen. The following screens will be displayed:

then…

<F2> ABORT Aborts the current test and displays a [CANCEL DURING TEST] screen.

Y-Hose Aerosol Extension

READY SUBJECT - 5

SET XDATA ESC CONT

*LOADING*

ABORT

*SETTING*



8-6

NOTE

The <F2>ABORT option is available in every step of the fit test process. Selecting <F2>ABORT at any time during the fit test process will allow the test to immediately be

terminated and returns you to the [READY SUBJECT] screen.

2. <F4>CONT returns the user to the [READY SUBJECT -5] screen.

NOTE

The following fit test procedure is the default program. The number of fit test exercises, and their duration may be reprogrammed by the manufacturer. Contact ATI for

further assistance

3. Once the test aerosol has finished loading into the fit test shroud, the fit test is ready to begin and the exercise 1 screen is displayed.

4. Explain to the test subject that there are a total of five (5) exercises: normal breathing, deep breathing, head side to side, head up and down, and jaw rotation. Each exercise will last approximately 2 minutes. During the exercise interval the PMLT will obtain a minimum of 40 consecutive sample points.

5. Ensure the subject understands each exercise.

NOTE

After each exercise, a Fit Score will be displayed in the upper right corner of the screen.

Recording the Fit Scores may be a requirement, refer to local technical guidance.

A test subject may receive a low Fit Score for any single exercise and still receive an overall passing Fit Factor. The overall Fit Factor reflects a calculation based on all of the test subject’s individual Fit Scores and is not an

average.

Be sure the test subject does not over-exaggerate each exercise, as this may cause breaking of the seal and

cause inaccurate Fit Scores.

CANCEL DURING TEST

CONT

Displayed if <F2>ABORT is

selected

EXER= 1:60

ABORT START



8-7

NOTE

Be sure the test subject does not allow the filter canister to come in contact with their chest, shoulders, or the fit

test shroud. This may cause breaking of the seal and cause inaccurate Fit Scores.

6. First Exercise - Normal Breathing. Instruct the test subject to stay motionless and breathe normally. Have the test subject begin the exercise, and then select <F4>START.

NOTE

The instantaneous fit factor is calculated using the aerosol level within the mask and the initial challenge

aerosol level obtained just prior to the beginning of the exercise. The instantaneous fit factor reported may not reflect the intermediate fit score for any given exercise.

7. If F2<XDATA> was selected in step 1 the following screen will be displayed during Exercise 1. Data is refreshed approximately every second throughout the active sampling portion of the exercise routine. “Cur” represents the current instantaneous fit factor for the exercise in progress. “Min” will display the lowest instantaneous fit factor measured since the beginning of the current exercise. If F2 <XDATA> was not selected only the final factor will be displayed at the completion of the sampling period.

8. At the end of this exercise period the start screen for exercise 2 will appear. In addition, the fit score for exercise 1 will be displayed in the upper right corner of the screen. Record the fit score for exercise 1, if required, and proceed to the next step.

Second Exercise - Deep Breathing. Instruct the test subject to stay motionless and breathe in and out deeply for the duration of the exercise. Have the test subject begin the exercise, and then select <F4>START.


EXER= 1: 60

ABORT START

EXER= 1: Cur: 124903

ABORTMin: 90567

EXER= 2: 60 138097

ABORT START

EXER= 3: 60 91486

ABORT START

Fit Score for Exercise 1




8-8

EXER= 5: 60 200000

CONT

10. Third Exercise - Move Head Side to Side. Instruct the subject to slowly turn his/her head and look over each shoulder alternately. It should take a count of 3 to move from shoulder to shoulder. The subject should continue to breathe normally. Have the test subject begin the exercise, and then select <F4>START.


12. Fourth Exercise - Move Head Up and Down. Instruct the subject to slowly move his/her head up and down, from looking at the ceiling to looking at the floor, continuously. It should take a count of 3 to move from up to down. Have the test subject begin the exercise, and then select <F4>START.


14. Fifth Exercise – Jaw Rotation. Instruct the subject to rotate their jaw in a circular fashion being careful not to over extend the jaw. Have the test subject begin the exercise, and then select <F4>START.

15. At the conclusion of the final exercise the fit score for exercise 5 will appear in the upper right corner of the screen. Pressing <F4>CONT will cause the overall fit factor to appear along with [PASSED] or [FAILED].

16. If the test subject’s fit factor was at or above the selected standard, the following screen will appear:

17. If the test subject’s fit factor was below the selected standard, the following screen will appear:

<F4>CONT Allows you to continue testing. If ALL test was selected, proceed to HSection 5.2, Applying a MaskH. If a FIT test was selected, proceed to HSection 8.3, Preparing a SubjectH.

EXER= 4: 60 200000

ABORT START

EXER= 5: 200000

CONT




PASSED 150730 CONT

Overall Fit Factor



8-9

18. If the test failed, select <F4>CONT and proceed to HSection 8.5, Fit Testing Failures Flowchart.

19. At the conclusion of the fit test remove the fit test shroud, disconnect the fit test interface tubing, and direct the test subject to doff the mask.

NOTE Due to minor variances in how fit test exercises may be

performed, a subject’s overall fit factor may vary from fit test to fit test. This is normal and acceptable.

20. Prepare another subject for testing.

8.5 FIT TESTING SERIAL COMMUNICATIONS

8.5.1 CONNECTION REQUIREMENTS

Communication Port

Serial RS-232 (Null-modem cable required)

Baud Rate – 9600

Data Bits – 8

Parity – none

Stop Bit – 1

Flow control- X on/X off

Automatically stops testing; a steady tone indicates failure. After result is recorded, press <F4>CONT to advances to the [PAUSED] screen.

<F2> RES returns to [READY SUBJECT - 5] screen.<F3> REJ proceeds to [REJECTED] screen.

<F4> CONT returns to [READY SUBJECT - 5] screen.

FAILED 1250 CONT

*PAUSED* RES REJ

REJECTED CONT

Overall Fit Factor



8-10

8.5.2 XDATA SERIAL OUTPUT FORMAT

Data produced by the PMLT in an XDATA enabled fit test and sent to the serial RS-232 port is in TAB delimited format. The following is an abbreviated representation of what may be expected during the course of a series of exercises:

1 4218 2 1953 3 5075 4 2337 5 5941 6 2708 7 2153 8 976 9 1662 10 550 11 3338 12 2242 13 3992 14 1418 15 3630 16 1678 17 4650 18 1975 19 4725 20 1266 21 3136 22 696 23 2007 24 755 25 2638 26 843 27 1355 28 1014 29 2628 30 596 31 2132 32 604 33 1823 34 450 35 2343 36 601 37 1529 38 443 39 950 40 537 (END OF FIRST EXERCISE) 1 366 2 2979 3 497 4 2093 5 553 6 729 7 953



8-11

8 255 9 2247 (10….35) 36 1545 37 877 38 1324 39 4565 40 1485 (END OF SECOND EXERCISE) 1 11061 2 769 3 3627 4 2625 5 8897 6 2495 7 6001 8 6983 9 3391 (10…35) 36 1230 37 6452 38 1348 39 6789 40 2333 (END OF THIRD EXERCISE) |FIT,N,12/22/09,16:01,0,P,1114,#,1066,1349,988,%,~

Pipe sign (|)

Beginning of print string

FIT Type of test selected N Retest status - Y or N 12/22/09 Date (mm/dd/yy) 16:01 Time (hh:mm) 0 Accept (0) or Reject

(255) P Pass (P) or Fail (F) 1114 Overall Fit Score # Field separator 1066 Exercise 1 fit score 1349 Exercise 2 fit score 988 Exercise 3 fit score % Field separator Tilde (~) End of print string



8-12

8.6 FIT TESTING FAILURES FLOWCHART




or



NOTE

The purpose of the following flowchart is to isolate a failure in the mask prior to troubleshooting the PMLT.



8-13

8.6 (CONT’D) FIT TESTING FAILURES FLOWCHART



9-1

9 Powering Down and Packing the PMLT 9.1 POWERING DOWN THE PMLT

CAUTION

NEVER unplug the power interface cable prior to switching the power unit OFF. This action may corrupt the random access memory (RAM) within the control

unit.

1. Toggle the power switch to the “OFF” (0) position.

2. Unplug the power cord from the outlet.

3. Proceed to HSection 9.2, PackingH.

9.2 PACKING

1. Open the PMLT case and remove the tray.

CAUTION Failure to remove the aerosol generator assembly from the control unit before packing may result in damage to

the control unit and aerosol generator assembly.

2. Disconnect the aerosol generator assembly from the control unit.

CAUTION Failure to disassemble the aerosol generator assembly

may result in oil spilling during shipping and damage the control and power units.

Remove the aerosol probe hose from the generator cap.

WARNING

Do not ingest PAO oil. Refer to Material Safety Data Sheet in Appendix E.

3. Remove the generator cap from the generator bottle and wipe off excess oil using a wiping towel.

4. Place the bottle cap on the generator bottle, making sure it is tight but not cross-threaded.

5. Place the generator bottle and generator cap in the appropriate storage slot of the tray.

6. Remove the QRLS pin from the back of the headform, and place it in the tray.

7. Lift the headform off of the headform pedestal and place it in the tray.



9-2

8. Disconnect the power unit from the control unit.

8.1. Remove the power interface cable from both the control and power units.

8.2. Disconnect the twin tube interface hose from the control and power units.

9. Disconnect the fit test interface tubing from the control unit. If the PMLT was not setup for fit testing proceed to step 13. If the PMLT was setup for fit testing, proceed to step 10.

10. Disconnect the Y-hose aerosol extension from the aerosol probe hose and the fit test shroud.

WARNING

To avoid eye injury, use care when handling fit test support rods.

11. Carefully remove the fit test support rods from the fit test shroud and set them aside.

Figure 40. Folding and Storing the Fit Test Shroud

12. Fold the fit test shroud for storage IAW Figure 41.

12.1. Lay the fit test shroud flat, with the brass connectors facing down (1).

12.2. Fold the fit shroud in half so that the brass connectors are opposite each other (2).

5

3

4

1 2



9-3

12.3. Fold in half again, from the bottom up to the top, squeezing out as much air as possible (3).

12.4. Store the fit test shroud inside the fit test bag (4).

12.5. Once the fit test shroud is stored, place the Y-hose aerosol extension, fit test interface tubing, and fit test support rods inside the fit test bag and close the bag (5).

Figure 41. Control Unit Packed in Case

13. Wrap the twin tube interface hose, the power interface cable, and the aerosol probe hose around the headform pedestal.

14. Place the control unit into the bottom of the PMLT case.

15. Place the power cord between the pedestal and the temple strap bracket.

16. Place the mask passing tube between the headform pedestal and the display screen on top of the control unit.

Figure 42. PMLT Properly Packed

17. Place the tray into the PMLT Case.

CAUTION

Failure to store the power unit upside down may cause damage to the power cable interface port and

pressure/vacuum ports.

18. Place the power unit in the tray upside down (rubber feet & nylon handle up) with the power interface port facing forward and inside the cutout square.



9-4

19. Place the fit test bag in the space on the left side of the tray.

20. Place the small headform in the rear slot of the tray.

21. Place the medium headform in the front slot of the tray.

22. Place the rest of the PMLT accessories and tools in their appropriate storage locations on the tray.

23. Place the Operator's Manual and other documentation and support materials in the storage space at the front of the PMLT case.

24. Fold the test shroud in half and place it in the storage space at the front of the PMLT case.

WARNING

The PMLT is a heavy item. NEVER attempt to lift the PMLT over your head.

Always follow proper procedures when lifting the PMLT; use two people to lift or carry.

NEVER drop it into place; lower it carefully.

25. Close and secure the PMLT case.



10-1

10 Preventive Maintenance Checks and Services (PMCS) Preventive maintenance, checks, and services (PMCS) of the PMLT are broken down into 3 categories: • Pre-operational: A quick, but thorough inspection of components that should be

accomplished each time you setup and operate the PMLT. • Periodic: Accomplished at least once for every 100 operational test hours. • Long Term: Accomplished by ATI service technicians at least once for every 1500

operational hours or once every 2 years; whichever occurs first.

This chapter provides PMCS tables to assist in properly maintaining the PMLT. The PMCS tables cover the: • Control unit. • Power unit. • Aerosol generator assembly. • Fit test kit. • Accessories.

10.1 PREOPERATIONAL PMCS The following tables list all preoperational PMCS that should be conducted each time you setup and operate the PMLT.

10.1.1 CONTROL UNIT

ITEM TO CHECK PMCS PROCESS CORRECTIVE

ACTION

(IF NEEDED) Generator Ports Press and release snap tabs to

test function. Contact ATI if broken, damaged or not functional.

Fit Test Interface Ports Press and release snap tabs to test function.

Contact ATI if broken, damaged or not functional.

Pressure/Vacuum Ports

Visually inspect for obstructions, cracks or other physical damage.

Contact ATI if obstructed or damaged.

Power Cable Interface Port

Visually inspect for cracks in the fitting and broken or bent pins.

Contact ATI if damaged.

Display Screen Visually inspect for cracks or other physical damage.


Function Keys Visually inspect for physical damage.




10-2

Wing Nuts (6) Visually inspect for presence, corrosion, and tightness.

Tighten or replace, as necessary.

Mask Clip Screws (8) Visually inspect for presence, corrosion, and tightness.

Tighten or replace, as necessary.

Mask Bracket Clamps (2)

Visually inspect for cracks or bends.

Replace if damaged.

Mask Brackets (4) Visually inspect for cracks or bends.

Replace if damaged.

Mask Clips (6) Visually inspect for cracks or bends.

Replace if damaged.

Temple Strap Bracket Visually inspect for cracks or bends.

Replace if damaged.

Headform Ports Visually inspect for cuts or cracks. Inspect the O-rings for wear, cuts, or missing O-rings.

Contact ATI if cut or cracked. Replace damaged O-rings as necessary IAW Section 11.7

Headform Pedestal Screws (8)

Visually inspect for tightness. Screw should appear flush with surface.

Tighten, as needed.

Outlet Valve Test Adapter

Visually inspect to ensure it is not deformed or damaged.

Replace if deformed or damaged.

Calibration Sticker Visually inspect for presence and check to ensure scheduled calibration date has not passed.

Contact ATI if at or beyond calibration date.

10.1.2 POWER UNIT


ACTION

(IF NEEDED) Pressure/Vacuum

Ports Visually inspect for obstructions. Ensure ports are not cracked or crushed.

Contact ATI if obstructed or damaged.

Power Interface Cable Visually inspect to ensure it is not cracked and the pins are not crushed, bent, or broken. Verify that the cable is not cut and the wires are not visible.

Replace if damaged.

Service Tag Visually inspect for presence and check to ensure scheduled service date has not passed.

Contact ATI if beyond or within 60 days of service date.



10-3

10.1.3 FIT TEST KIT


ACTION

(IF NEEDED) Y-Hose Aerosol

Extension Visually inspect for oil, dirt, or debris and holes, cuts, or other damage.

Allow to drain, or rinse out with isopropyl alcohol. Replace if damaged.

Fit Test Shroud Visually inspect for cuts, tears, and damaged or loose stitching.

Repair with tape or replace shroud.

Fit Test Support Rods Visually inspect the rods to ensure the elastic banding is not ripped or heavily frayed. Ensure aluminum tubing is not abnormally bent, cracked or broken.

Replace if damaged.

Fit Test Interface Tubing

Visually inspect tubing for blockage, cuts or cracks and the presence of excess water or oil. Visually inspect the blue sampling tube to ensure the end has a “V” cut. Inspect O-rings for wear or cuts.

Clear blockage or replace tubing if damaged or unable to clear blockage. Allow to drain if excess water or oil are present or flush out with isopropyl alcohol. If “V” cut is missing, use knife to trim end into “V” or replace tubing. Replace damaged O-rings using spare O-ring kit IAW Section 11.7.

Fit Test Bag Visually inspect for rips, tears, torn stitching. Check velcro fasteners for function.

Repair with tape or replace if damage is excessive.



10-4

10.1.4 AEROSOL GENERATOR ASSEMBLY


ACTION

(IF NEEDED) Generator Cap Visually inspect for cracks or

other damage. Inspect the ports to ensure they are not damaged or obstructed.

Visually inspect the O-rings for wear or cuts.

Replace if damaged. Replace damaged O-rings using spare O-ring kit IAW Section 11.7.

Generator Bottle

Visually inspect for cracks or other damage. Inspect the threads to ensure they are continuous. Visually inspect the level of oil.

Replace if damaged. Refill or remove oil as necessary using spare supply of PAO oil.

Aerosol Probe Hose

Visually inspect to ensure the tubing is not cut or crushed. Inspect the metal probe tip to ensure it is not crushed or obstructed. Press and release snap tabs to test function.

Replace if damaged. Replace if damaged.



10-5

10.1.5 ACCESSORIES


ACTION

(IF NEEDED) Headforms Visually inspect overall and at the

interface ports for cracks. Visually inspect the peripheral seal for holes or cuts. Visually inspect the lint screen for dirt or damage.

Replace if headform or peripheral seal is damaged. Clean or replace lint screen.

Mask Test Shroud

Visually inspect for cuts, tears, or loose stitching. Inspect the drawstring and clasp for serviceability and function. Visually inspect for PAO oil residue.

Repair using tape. Replace if damaged. Remove oil residue with isopropyl alcohol and sponge or wiping towel.

Canister Port Plug Visually inspect to ensure that the threading is continuous and the plug overall is not dented or deformed.

Replace if damaged.

Outlet Valve Clamp

Visually inspect for the plastic portions for cracks and the rubber for dry rot, nicks or peeling. Make sure the spring is taut. Ensure retaining bolt is tight.

Replace if damaged. Tighten as necessary.

Twin Tube Interface Hose

Visually inspect for holes, cuts, or sharp bends. Ensure that the ends are not over stretched. Inspect to ensure that a yellow band is present on both sides of the same tube.

Trim the ends as necessary with knife IAW Section 11.11 or replace hose.

Power Cord Visually inspect to ensure the cord is not cut or frayed and the wires are not exposed. Ensure prongs on plug are not bent or damaged.

Replace if damaged.

Mask Passing Tube Visually inspect O-rings for wear or cuts. Visually inspect tube for the presence of debris, holes, damage, moisture, or blockage of any kind.

Replace damaged O-rings using spare O-ring kit IAW Section 11.7. Replace if damaged. Remove any blockage. Allow moisture to dry before use.



10-6

10.2 PERIODIC PMCS – EVERY 100 OPERATIONAL HOURS

The following is a list of all PMCS which should be conducted after every 100 hours of operation. This PMCS may be completed in conjunction with the preoperational PMCS.

10.2.1. PMLT CASE


ACTION

(IF NEEDED) Case

Visually inspect the locking clasps to ensure they are present and functional. Ensure clasps are not crushed or broken. Ensure the side carrying handles are securely attached and inspect the telescoping handle for function. Visually inspect the interior foam lining to ensure it is securely attached.

Inspect wheels for physical damage and function.

Contact ATI if there is any damage or permanent malfunction to the case body, wheels, or handles.

Tray Visually inspect the tray to ensure it is not cracked or broken and that the foam is securely attached.

Replace if damaged.

10.2.2 CONTROL UNIT


ACTION

(IF NEEDED) Fit Test Interface Ports Visually inspect the O-rings for

nicks, wear, and cuts. Replace damaged O-rings using spare O-ring kit IAW Section 11.7.

Data Communications Port

Visually inspect to ensure that the port is securely attached.

Secure, if loose, using #1 Phillips Screwdriver.

Serial Number Label Visually inspect to ensure it is securely attached.

Contact ATI if missing.

UID Label Ensure the UID Label is present and legible.




10-7

Hose Test Port Plug

Visually inspect O-ring for wear, nicks or cuts. Visually inspect to ensure that the metal plug is securely attached to white cover.

Replace damaged O-ring using spare O-ring kit IAW Section 11.7. Replace Plug.

Outlet Valve Retaining Bolt

Use stubby Phillips screwdriver to remove and then visually inspect threads for continuity and stripping. Hand-tighten when reattaching.

Replace if damaged.

Drink Tube Test Adapter

Inspect the inner adapter for dirt, oil, or debris. Visually inspect the O-ring for worn spots or cuts.

Use a wiping towel to clean as necessary IAW section 11.12. Replace O-ring using spare O-ring kit IAW Section 11.8.

Headform Pedestal Visually inspect for cracks. Contact ATI if damaged.

Light Scattering Chamber (LSC) Setting

Complete an aerosol setup to determine the setting number.

Contact ATI if setting number is 90 or higher.

10.2.3 POWER UNIT


ACTION

(IF NEEDED) Fuse Holders Visually inspect to ensure they are

flush with the top surface of the power unit.

Secure with flat blade screwdriver. If unable to secure, ATI.

Serial Number Label Visually inspect to ensure it is securely attached.


UID Label Ensure the UID Label is present and legible.




10-8

10.2.4 FIT TEST KIT


ACTION

(IF NEEDED) Y-Hose Aerosol

Extension Visually inspect tubing for cuts, cracks, sharp bends.

Replace if damaged.

Fit Test Interface Tubing

Visually inspect tubing for cuts, cracks, and sharp bends. Visually inspect the O-rings for worn spots or cuts. Visually inspect the drink tube adapter for cracks and to ensure it is not deformed. Visually inspect for blockage.

Replace if damaged. Replace damaged O-rings using spare O-ring kit IAW Section 11.7. Replace if damaged. If blockage cannot be removed, replace tubing.

Fit Test Shroud

Visually inspect for oil residue. Visually inspect for cuts or tears. Visually inspect the manifolds for oil buildup. Inspect brass connections to manifold ports to ensure they have not pulled through grommets.

Remove oil residue with and isopropyl alcohol and sponge or wiping towel. Repair using tape. Replace shroud if severely damaged. Flush with isopropyl alcohol. Contact ATI for repair.



10-9

10.2.5 ACCESSORIES


ACTION

(IF NEEDED) Headforms

Headforms (cont’d)

Visually inspect the screws which connect the peripheral seal interface port to ensure they are securely attached and flush with the surface. Visually inspect the clear inflation tubing on the underside of the headform for cuts.

Tighten, if loose, using #1 Phillips Screwdriver. Contact ATI if damaged or cut.

Bottle Of PAO Oil Visually inspect for oil. Visually inspect for cuts or cracks. Visually inspect to ensure the cap is present and secure.

Replenish PAO oil supply, as needed. Replace bottle, if damaged, or if cap is missing or damaged.

10.3 LONG TERM PMCS (EVERY 1500 OPERATIONAL HOURS OR 2 YEARS)

10.3.1 END ITEM


ACTION

(IF NEEDED) PMLT Check operational hours at

startup. If operational hours equal 1500 or greater, term maintenance is required. Operational hours are only displayed on power up. Refer to Section 4.1, Power Up.

If 1500 or greater, contact ATI to schedule factory maintenance and calibration.



11-1

11 Maintenance Procedures 11.1 SETTING THE DATE AND TIME

Date and Time is used to set the date in U.S. format (month/day/year) and the time in the 24-hour format.

1. From the [SELECT TEST] screen press <F1>SYS.

2. Press <F4>OPT, this opens the [OPTIONS] screen.

<F1> TIME Enters into the Date and Time screen.

<F2> ACF Enters into the Altitude Control Function.

3. Press <F1>TIME.

<F1> SET Enters into the Set Date and Time screen.

<F3> ESC Returns to the [SYS DIAG?] screen. 4. Press <F1>SET.

<F1> UP Increases the selected value.

<F2> DWN Decreases the selected value.

<F4> CONT Accepts the entered value and moves to the next entry.

SELECT TEST= M ALL

SYS UP DWN ACPT

MM/DD/YY 00:00

UP DWN CONT

SYS DIAG?

YES NO OPT

OPTIONS

TIME ACF

MM/DD/YY 00:00

SET ESC



11-2

5. Using either <F1>UP or <F2>DOWN, set the date in mm/dd/yy format, pressing <F4>CONT after each entry.

6. Using either <F1>UP or <F2>DOWN set the time in 24-hour format, pressing <F4>CONT after each entry.

7. Press <F4>CONT again after time and date are set to return to the Set Date and Time screen.

8. From the Set Date and Time screen, press <F3>ESC to return to the [SYS DIAG?] screen.

9. From the [SYS DIAG?] screen, press <F2>NO to return to the [SELECT TEST] screen.

11.2 ADJUSTING THE ALTITUDE (ELEVATION)

NOTE

Operational altitude (elevation) relative to sea-level must be known prior to operating the PMLT.

1. The PMLT should be set to the nearest 1000 foot increment of elevation at the testing location. It is possible to adjust the altitude setting without shutting down the PMLT.

2. Exit out of the current test screen and enter into the [SELECT TEST] screen.

3. Press <F1>SYS.

<F1> YES Proceeds to the [CHECK?] screen.

<F2> NO Proceeds to the [SELECT TEST] screen.

<F4> OPT Proceeds to the [OPTIONS] screen.

4. Press <F4>OPT.

5. Press <F2>ACF.

<F1> TIME Proceeds to the Set Date and Time screen.

<F2> ACF Proceeds to the Altitude Control Function screen.

SELECT TEST= M ALL

SYS UP DWN ACPT

SYS DIAG?

YES NO OPT

OPTIONS

TIME ACF



11-3

<F1> UP Scrolls up through the available altitudes in 1000 foot increments.

<F2> DWN Scrolls down through the available altitudes in 1000 foot increments.

<F4> CONT Programs the selected altitude and returns to the [SYS DIAG?] screen.

6. Using the <F1>UP and <F2>DOWN keys, scroll to the nearest altitude in 1000 ft increments.

7. Press <F4>CONT to program the appropriate altitude into the PMLT and return to the [SYS DIAG?] screen.

8. Press <F2>NO to return to the [SELECT TEST] screen.

11.3 FUSE REPLACEMENT

1. Turn off the PMLT.

2. Unplug the power cord from the power source.

3. Using a flat tip screwdriver, push down and turn the fuse holder cap counterclockwise. This will allow the spring loaded fuse holder cap to pop up.

Figure 43. Replacing Fuses

FUSE NO. DESCRIPTION

1 Fuse for the control unit (2.5 amp. 250V slow-blow)

2 Fuse for the control unit valves (2.5 amp. 250V slow-blow)

3 Fuse for the system pump (4 amp, 250V slow-blow)

4 Fuse for AC power input (4 amp, 250V slow-blow)

Table 21. Fuse Descriptions and Locations

4. Using your thumb and forefinger, lift the fuse holder cap out of its socket.

5. Remove the fuse from the fuse holder cap.

ALTITUDE 0000FT

UP DWN CONT

SYS DIAG?

YES NO OPT

Fuse 3

Fuse 4 Fuse 1 Fuse 2



11-4

6. Select a replacement fuse from the spare fuse kit and insert it into the fuse holder cap.

7. Using your thumb and forefinger, place the fuse and fuse holder cap back into its socket.

8. Using a flat tip screwdriver, push down and turn the fuse holder cap clockwise. This will lock it into place.

WARNING


9. Connect the power cord to the power source.

11.4 UNIVERSAL HOLD-DOWN ASSEMBLY ADJUSTMENT

Ensure that the universal hold-down assembly is properly adjusted. There are five hold-down brackets (four side brackets and one top bracket), six mask clips, and two side bracket clamps. Assembly can be adjusted to fit most mask styles.

CAUTION

Incorrect adjustment of the mask clips may cause disfiguring of or damage to the mask or insufficient

sealing, leading to test failures.

NOTE

The brackets may need to be adjusted for each size/type of mask to be tested. Failure to properly adjust the

brackets may cause false readings during a test.

1. Position the mask to be tested on the headform with the chin of the mask pulled down over the peripheral seal. Apply the mask in accordance with instructions detailed in HSection 5.2H, Applying a Mask.

Figure 44. Properly Adjusted Mask and Clips

Temple Strap

Bracket

Mask Clip Mask Clip

Screw

Mask Bracket

Mask Bracket Clamp



11-5

2. Mask brackets and mask clips should be adjusted to follow the angle and location of the mask straps. Adjust the mask clip for each strap to be approximately the distance of the width of one mask clip away from the mask buckle in the relaxed state.

3. If adjustments are necessary, use the stubby cross tip screwdriver to loosen the mask clip screws and then adjust the clips up or down the bracket. Tighten the mask clip screws with the stubby cross tip screwdriver when finished. Loosen the wing nuts to slide the mask brackets forward or backward then hand-tighten the wing nuts to secure the brackets in place.

11.5 BACK PRESSURE ADJUSTMENT

1. From the [SELECT TEST] screen, press <F1>SYS to enter the system diagnostics screen.

2. From the [SYS DIAG?] screen, press <F1>YES to enter the [CHECK?] screen.

3. Place the mask passing tube on the PMLT headform in accordance with HSection 11.6H, Using The Mask Passing Tube.

<F1> MSK Enters into the Mask Pressure and Flow screen.

<F2> VAL Enters into the Valve Pressure and Flow screen (Used only by ATI factory technicians).

<F3> MORE Enters into more diagnostic screens (Used only by ATI factory technicians).

<F4> EXIT Exits the [CHECK?] screen and returns to the [SYS DIAG?] screen.

4. At the [CHECK?] screen, select <F1>MSK to enter the mask pressure and flow diagnostics screen.

NOTE

When the left-most number (sample flow) reads 15.9 – 16.1, the right-most number (vacuum) should read 5.9 –

6.1. This should take no more than 30 seconds.

CHECK?

MSK VAL MORE EXIT

SELECT TEST= M ALL

SYS UP DWN ACPT

SYS DIAG?

YES NO OPT

MASK = 16.0 / 6.0

CONT



11-6

5. If the numbers displayed are in the proper ranges, press <F4>CONT and proceed to step 12.

6. If the numbers are not in the acceptable range, use the stubby cross tip screwdriver to remove the cover screw of the back pressure adjustment control. This is the largest diameter screw, located between two smaller cross tip screws on the upper right of the pedestal. (Do not lose this screw).

Figure 45. Back Pressure Adjustment

7. Place the T-handle hex wrench in the back pressure control adjustment screw.

8. Adjust the vacuum to 6.0 inches at a flow of 16.0 by turning the hex wrench clockwise or counterclockwise. Clockwise turns increase the vacuum while counterclockwise turns decrease the vacuum.

9. Allow the numbers to stabilize. This should take no more than 30 seconds.

10. Once the numbers read 15.9 – 16.1 and 5.9 – 6.1, respectively, press <F4>CONT.

11. Repeat from step 4 to verify that the vacuum is now set correctly.

12. Replace the cover screw, if removed, and press <F4>CONT to exit the mask pressure and flow screen into the [CHECK?] screen.

13. Press <F4>EXIT to return to the [SYS DIAG?] screen.

14. Press <F2>NO to return to the [SELECT TEST] screen.

T-Handle Hex Wrench

Back Pressure Adjustment

CHECK?

MSK VAL MORE EXIT

SELECT TEST= M ALL

SYS UP DWN ACPT

MASK = 16.0 / 6.0

CONT

SYS DIAG?

YES NO OPT



11-7

15. Select your next mask testing mode then press <F4>ACPT to continue.

16. Remove the mask passing tube and reinsert the lint screen into the vacuum port of the headform.

11.6 USING THE MASK PASSING TUBE

NOTE:

When using the mask passing tube, leakage should not exceed 0.0009% during a mask test. If leakage exceeds

0.0009% the mask passing tube is unserviceable.

11.6.1 INSTALLATION

1. Remove the mask test shroud.

Figure 46. Removing the Lint Screen

2. Using the flat tip screwdriver, carefully remove the lint screen from the headform.

Figure 47. Inserting Mask Passing Tube

3. Insert one end of the mask passing tube into the top (flow) port of the headform.

Figure 48. Mask Passing Tube Inserted



11-8

4. Insert the other end of the mask passing tube into the bottom (vacuum) port of the headform.

11.6.2 REMOVAL

1. Remove the mask passing tube from the headform.

2. Reinsert the lint screen into the vacuum port of the headform.

11.7 EXTERNAL O-RING REPLACEMENT

NOTE

The PMLT has external O-rings located in the following areas: headform pedestal, fit test interface ports,

generator cap, hose test port plug, mask passing tube, hose test adapter, and the fit test interface tubing. Using your index finger and thumb, remove the O-ring/gasket

by squeezing it inward while pulling upward.

Figure 49. External O-Ring Replacement

1. Place the new O-ring/gasket over or into the fitting and press down to secure.

11.8 DRINK TUBE ADAPTER O-RING REPLACEMENT

1. Using the flat tip screwdriver provided with the PMLT, carefully remove the drink tube adapter O-ring by inserting the flat tip of the screwdriver between the inside surface of the metal adapter and the O-ring.

2. Using a prying motion, carefully lift the O-ring out of its groove.

Figure 50. Drink Adapter O-Ring Replacement

3. Using the flat tip of the screwdriver, carefully insert the new O-ring into the groove.

4. Starting in one location and continuing around the circumference of the adapter, press down on the O-ring until is fully seated into the adapter.



11-9

11.9 OUTLET VALVE TEST ADAPTER REPLACEMENT

1. Remove the outlet valve retaining bolt from the Outlet Valve Test Adapter base using the No. 2 stubby cross tip screwdriver provided with the PMLT and then remove the outlet valve test adapter.

Figure 51. Removing the Retaining Bolt

2. To install a replacement outlet valve test adapter; first insert the outlet valve retaining bolt through the center of the outlet valve test adapter.

Figure 52. Reinstalling the Bolt and Adapter

NOTE

Over/under tightening the outlet valve retaining bolt may cause the outlet valve test to fail.

3. Reinstall the outlet valve retaining bolt and outlet valve test adapter into the base by turning clockwise until hand-tight, ensuring the notches are centered and facing up. The outlet valve test adapter should remain attached to the outlet valve base unless it becomes unserviceable or needs to be changed to accommodate other types of masks for testing.

Figure 53. Outlet Valve Test Adapter

Outlet Valve Retaining Bolt

Outlet Valve Adapter

Outlet Valve Adapter

Base



11-10

11.10 SHROUD/MANIFOLD CLEANING

WARNING

Isopropyl alcohol should be used only in accordance with supplier’s recommendations.

CAUTION

Be sure that no liquid is introduced to the inside of the PMLT as this may cause damage to the electronics.

1. Using a wiping towel very lightly dampened with isopropyl alcohol, carefully wipe all surfaces. Use care to avoid dripping alcohol on any adjacent surfaces.

2. Use a separate wiping towel to dry all surfaces.

11. 11 TWIN TUBE INTERFACE TRIMMING/CUTTING PROCEDURE

NOTE

When trimming the twin tube interface hose be sure that the yellow band is not cut and that it is securely attached

to the hose.

1. Place the tubing to be trimmed on a flat surface.

2. Using a knife carefully make a complete perpendicular cut as close to the end of tubing as possible.

11.12 DRINK TUBE ADAPTER: INNER ADAPTER CLEANING 1. Turn the drink tube adapter fully counterclockwise to the “OUT” position.

Figure 54. Cleaning the Drink Tube Adapter

2. Use a wiping towel to gently wipe between the drink tube adapter and the control unit.

3. Turn the drink tube adapter fully clockwise, to the “IN” position.



12-1

12 Troubleshooting; Fault and Error Messages

This chapter contains the troubleshooting flowcharts and fault and error messages you may encounter while operating the PMLT.

For technical support not specified or resolved by the following flowcharts you may call ATI during normal business hours (Mon-Fri, 8:30 am – 5 pm EST) at 410-363-9696 or email [email protected]. After-hours calls will be recorded and are normally returned within 2 business days.

CAUTION

Never attempt to access the internal components of the control unit or power unit. These units contain sensitive

electronics that can be damaged if tampered with. Opening either of these units voids the factory warranty.

12.1 SYMBOLS

The symbols in the following table are used in the flowcharts on pages 12-3 through 12-24:



or





12-2

12.2 LIST OF FLOWCHARTS

TYPE OF ERROR MANUAL SECTION

DESCRIPTION PAGE NUMBER

Control Unit/Power Unit 12.3.1 Display Is Blank 12-3

Control Unit/Power Unit 12.3.2 Single Dash On Display 12-4

Control Unit/Power Unit 12.3.3 Pump Not Operating 12-5

Control Unit/Power Unit 12.3.4 Flow Error 12-6

Control Unit/Power Unit 12.3.5 Memory Error 12-7

Control Unit/Power Unit 12.3.6 Seal Failure 12-8

Aerosol 12.4.1 Remains in Loading During Mask Aerosol Set Up or Mask Test

12-10

Aerosol 12.4.2 Remains in Loading During Fit Test Aerosol Set Up

12-11

Aerosol 12.4.3 Aerosol Set Up of 90 or Greater

12-12

Aerosol 12.4.4 LSC Error 12-13

Aerosol 12.4.5 Low/High Aerosol Error 12-14

Mask Test 12.5.1 Low Vacuum Failure 12-16

Mask Test 12.5.2 High Vacuum Failure 12-17

Mask Test 12.5.3 Persistent Penetration Failures 12-18

Drink Test 12.6.1 Consistent Drink Tube Flow Failures

12-19

Drink Test 12.6.2 Consistent Drink Train or Seat Test Failures

12-21

Valve Test 12.7.1 Consistent Outlet Valve Failures

12-22

Fit Test 12.8.1 Remains in Setting During Fit Test

12-23

Fit Test 12.8.2 Consistent Low Fit Factors 12-24

Table 22. List of Flowcharts



12-3

12.3 CONTROL UNIT/POWER UNIT ERRORS

12.3.1 DISPLAY IS BLANK

A common root cause of this problem can be attributed to a blown fuse (#1 or #4).

NOTE

A total lack of power could indicate a failure of Fuse 4 on the power unit. Check Fuse 4 and replace if defective IAW Section 11.3. If the power unit initializes when

toggled “on” and the display is still blank on control unit, use the flow chart below to troubleshoot the problem.

DISPLAY IS BLANK

Is power interface cable connected?

Connect power interface cable

Visually inspect fuse 1 IAW Section 11.3

Is fuse good?

Replace with known good power unit

Replace fuse IAW Section 11.3

Disconnect power cord

Reconnect power cord

Restart PMLT

Is display functioning?

Continue Testing

Yes

Yes

No

Yes

No

No


Yes

Turn PMLT off

NoContact ATI

Suspect Control Unit

Restart PMLT

Continue Testing

Is another power unit available?

Yes

NoContact ATI

Suspect Power Unit



12-4

12.3.2 SINGLE DASH ON DISPLAY

A common root cause of this problem can be attributed to a blown fuse (#2).

SINGLE DASH ON DISPLAY

Turn PMLT off

Visually inspect fuse 2 IAW Section 11.3

No

Yes



Repeat sequence a maximum of 5

times

Is this the 5th restart?

Contact ATISuspect

Control Unit

Yes

No

YesNo

No

Yes


Is fuse good?Replace fuse IAW Section 11.3

Restart PMLT

Continue Testing

Turn PMLT offfor 30 seconds

Restart PMLT




12-5

12.3.3 PUMP NOT OPERATING

A common root cause of this problem can be attributed to a blown fuse (#3).

Turn PMLT off


Is fuse good?

Contact ATISuspect Power Unit

Replace fuse IAW Section 11.3

Reconnect power cord.

Restart PMLT

Is pump operating?

Yes

Yes

No

Yes

No

No

Restart PMLT

Is pump operating?

No

Yes

PUMP NOT OPERATING

Is power cord properly

connected?

Turn PMLT off


Visually inspect fuse 3IAW Section 11.3

Continue Testing

Continue Testing



12-6

12.3.4 FLOW ERROR

The root cause of this problem can be usually be attributed to the control unit.

Is twin tube interface hose

properly connected?

Reconnect twin tube interface hose

IAW Section 3.4.2

Turn PMLT off

Is there a FLOW ERROR?

No

Yes

Yes

Disconnect twin tube interface hose

Restart PMLT

Reconnect twin tube interface hose IAW

Section 3.4.2

Conduct PMCS of twin tube interface hose IAW

Section 10.1.5

No

Repeat sequence a maximum of 5 times

Contact ATI.

Restart PMLT

Is this the 5th

restart?

YesNo

Turn PMLT off for 30 seconds



12-7

12.3.5 MEMORY ERROR

The problem may appear as a jumbled display screen and a common root cause is a corrupted RAM chip within the control unit. This problem can sometimes be attributed to a short-circuit or power surge.



12-8

12.3.6 SEAL FAILURE

The root cause of this problem can be attributed to either the power unit, control unit, or the peripheral headform seal itself.

SEAL FAILED

Can you hear the pump operating?

Turn PMLT off

Is headform properly seated?

QRLS pin installed?

Proceed To 12.3.3 Pump Not Operating

Suspect Power Unit

Reseat headform and insert QRLS

pin

Restart PMLT

Does seal still fail?

Continue Testing

No

No

Remove headform

Conduct PMCS on headform port O-rings IAW Section

10.1.1

Reseat headform and insert QRLS

pin

Restart PMLT


Yes

Yes

No

Yes

Continued onNEXT PAGE

No

Yes

Remove and replace headform with another then restart the PMLT



12-9

12.3.6 SEAL FAILURE (CONT’D)

Continue Testing

Contact ATISuspect Control

Unit

Disconnect twin tube interface

hose

Conduct PMCS on twin tube Interface hose IAW 10.1.5

Reconnect twin tube interface

hose IAW 3.4.2


Restart PMLT

Continue Testing with replacement

headform; 1st

headform is defective

Turn PMLT off

No

Yes

NoDoes seal still fail?

Yes

Continued fromPREVIOUS PAGE



12-10

12.4 AEROSOL ERRORS

12.4.1 REMAINS IN LOADING DURING MASK AEROSOL SET UP OR MASK TEST

The root cause of this problem may be related to operating altitude. Troubleshooting may isolate the problem to either the power unit or control unit.

LOADING

Turn off PMLT

Perform PMCS on twin tube interface hose IAW

Section 10.1.5

Disconnect twin tube interface hose

Reconnect twin tube interface hose

IAW Section 3.4.2

Complete an aerosol setup

Restart PMLT

Does it remain in LOADING?

Contact ATISuspect Control Unit


Replace with a known good power unit

Turn off PMLT

Restart PMLT

Does it remain in SETTING?

Continue Testing

No

Yes

Continue Testing

Yes Is a known good power unit

available?

Contact ATIFactory

Technician’s Evaluation

Needed

No

Yes



Replace with a known good control unit

Turn off PMLT

Restart PMLT

Does it remain in SETTING?

Is a known good control unit

available?

Was altitude properly adjusted

during setup?Yes

Set operating altitude IAW Section 11.2

No



Yes

Continue Testing

No

No (NOTE 1)

Yes

Yes

No (NOTE 2)

Yes

NOTE 1: Suspect first control unit is defective.

NOTE 2: Suspect first power unit is defective.

Contact ATIFactory


Needed

No



12-11

12.4.2 REMAINS IN LOADING DURING FIT TEST AEROSOL SET UP

Troubleshooting may isolate the problem to either the power unit or control unit.


LOADING

Turn off PMLT

Complete an aerosol setup IAW Section 8.2

Continue Testing

Disconnect both the twin tube interface hose

and the fit test interface hose

Perform PMCS on the fit test interface hose IAW Section

10.1.3, and the twin tube interface hose IAW

Section 10.1.5

Reconnect both the twin tube interface hose IAW Section

3.4.2, and the fit test interface hose IAW Section 3.4.4.

Turn on PMLT

Yes



Turn off PMLT

Restart PMLT



available?





Turn off PMLT

Restart PMLT


Yes

Continue Testing

Is a known good power unit

available?

No

No (NOTE 2)

No (NOTE 1)

Yes

Yes

Complete an aerosol setup IAW

Section 8.2

Complete an aerosol setup IAW

Section 8.2

NoYes

NoContact ATI

Factory Technician’s Evaluation

Needed

Contact ATITechnician’s Evaluation

Needed



12-12

12.4.3 AEROSOL SETUP OF 90 OR GREATER

After completing an aerosol setup, a number is displayed in the lower right corner of the screen. This number reflects the cleanliness of the optics within the control unit. While the PMLT will still operate until the number reaches 120, it is important to schedule higher-level maintenance when the number reaches 90. In order to minimize the amount of time that the PMLT will be out of service, it is essential that the following procedures are followed. The root cause of this problem can usually be attributed to a problem within the Light Scattering Chamber (LSC) of the control unit.



12-13

12.4.4 LSC ERROR

Troubleshooting may isolate the problem to either the power unit or control unit.

LSC ERROR

Turn off PMLT

Let PMLT sit for 30 seconds

Restart PMLT

Complete an aerosol setup IAW Section 5.1

Is there an LSC error?

Allow PMLT to run for 30 minutes


Conduct an aerosol setup


Turn off PMLT

Restart PMLT


Continue Testing

No

Yes

Continue Testing

Yes Is a known good power unit

available?

Contact ATIFactory


Needed

No


Conduct an aerosol setup


Turn off PMLT

Restart PMLT



available?

No (NOTE 1)

Yes

Yes

No (NOTE 2)



Contact ATIFactory


Needed

No

Yes Yes



12-14

12.4.5 LOW/HIGH AEROSOL ERROR

Troubleshooting may isolate the problem to the power unit, control unit, or aerosol generator.

LOW/HIGH AEROSOL Error

Remove generator cap from generator bottle

Conduct PMCS on generator cap

IAW Section 10.1.4

Check oil level in generator bottle

Is oil level between the lines?

Adjust the oil level as necessary

Restart PMLT

No

Yes

Aerosol setup being completed IAW

Section 5.1 for mask test or 8.2

for fit test?

Complete an aerosol setup IAW proper procedures

Yes

No

Is there still an aerosol error?

Continue Testing

Yes

No

Detach generator assembly

Attach generator assembly IAW Section 3.4.1

Yes

No

Turn off PMLT

Restart PMLT


Yes

Turn off PMLT

Detach generator assembly

Continue Testing


Restart PMLT

Allow the PAO to warm to room

temperature (72˚ F) (See NOTE 1)


No

Is the operating environment 45ºF/7ºC

or colder?





NOTE 1: Disconnect aerosol generator bottle until PAO is warmed to room temperature. PAO should be gradually and naturally warmed; NEVER use a microwave or other oven as this may change particle distribution.



12-15

12.4.5 LOW/HIGH AEROSOL ERROR (CONT’D)

Complete an aerosol setup IAW proper

procedures

No

Allow PMLT run for 20 minutes

Continue Testing

No

YesIs there still an aerosol error?

Continue Testing



Unit


Turn off PMLT

Restart PMLT



available?

Contact ATIFactory


Needed


Continue Testing

Yes

Contact ATISuspect Power

Unit


Turn off PMLT

Restart PMLT



available?

Contact ATIFactory


Needed


Continue Testing

YesYes



No (NOTE 1)

No (NOTE 2)

Yes

YesYes NoNo





12-16

12.5 VACUUM ERRORS

12.5.1 LOW VACUUM FAILURE

The root cause of this problem can always be attributed to the control unit.



12-17

12.5.2 HIGH VACUUM FAILURE




12-18

12.5.3 PERSISTENT PENETRATION FAILURES

These failures are often difficult to pinpoint and may be the fault of the operator, the mask, or a problem attributed to the control unit.

Install mask passing tube IAW Section 11.5 and then probe base of headform and hose test

port plug

Location of leak

Replace with another headform

Replace headform port O-rings IAW

Section 11.7


Unit

Hose Test Port Plug

Turn off PMLT

Remove headform

Conduct PMCS on headform IAW Section 10.1.5

Remove hose test port plug

Is the O-ring serviceable?

Replace O-ring IAW Section 11.7

Visually inspect the hose test

port plug

Yes

NoIs headform serviceable?

Conduct PMCS on headform pedestal ports IAW 10.1.1

Are the ports serviceable?

Yes Contact ATI;

possible defective

Headform PortsSuspect Control

Unit

Is it serviceable?

Replace hose test port plug

Turn on PMLT

Install mask passing tube IAW Section 11.5 and then conduct a mask test IAW

Section 5.3

Does test pass?

FAILED

No

Turn off PMLT

Turn on PMLT


headform; 1st

headform is defective

Continue Testing

Headform

Visually inspect the O-ring

No

Yes

Yes

Reinstall hose test port plug

No

Yes

No


Section 5.3

Does test pass?


hose test port plug; 1st hose

test port plug is defective

Yes


Section 5.3

Does test pass?

No

No

Yes



12-19

12.6 DRINK TEST ERRORS

12.6.1 CONSISTENT DRINK TUBE FLOW FAILURES

The root cause of this problem can be attributed to either the power unit or control unit.

Is test being conducted IAW

Section 6.1?

Retest using proper procedures

Disconnect drink tube from drink tube adapter

Conduct flow test IAW Section 6.1 without a mask

FAILED

Does it pass?

Does drink flow test pass?

Continue Testing

Continue Testing

Let PMLT sit for 30 seconds

Turn off PMLT

Restart PMLT


Yes

Yes

Yes

No

No

No




12-20

12.6.1 CONSISTENT DRINK TUBE FLOW FAILURES (CONT’D)

Continue Testing

Yes



Unit


Turn off PMLT

Restart PMLT



available?

Contact ATIFactory


Needed


Yes

Contact ATISuspect Power

Unit


Turn off PMLT

Restart PMLT



available?

Contact ATIFactory


Needed


Continue Testing(NOTE 1)

YesYes



No (NOTE 2)

No (NOTE 1)

Yes


NoNo No No

Continue Testing(NOTE 2)



12-21

12.6.2 CONSISTENT DRINK TRAIN OR SEAT FAILURES




12-22

12.7 VALVE TEST ERRORS

12.7.1 CONSISTENT OUTLET VALVE FAILURES




12-23

12.8 FIT TEST ERRORS

12.8.1 REMAINS IN SETTING DURING FIT TEST

The problem may be the result of blockage in the drink train or interface tubing. It may also be attributed to a fault in the control unit.



12-24

12.8.2 CONSISTENT LOW FIT FACTORS

This problem may be the result of a “hard-to-fit” test subject, the mask, or the PMLT. If it is the PMLT, the root cause of this problem can always be attributed to the control unit.

NOTE

Consistent low fit factor scores could be the result of the test subject being categorized as “hard to fit”. If

recommended troubleshooting does not resolve your problem, consider this possibility before assuming

defective equipment.



Appendices



A-1

APPENDIX A TEST SETTINGS AND DESCRIPTIONS

SETTING DESCRIPTION

Mask Leakage Test Sample flow = 16 slpm. Sample resistance = 6 in. WC (Vac) ± 0.5% Leakage Failure ≥ 0.0030%

Drink Tube Flow Test Set flow = 2 slpm. Failure resistance ≥ 2.2 in. WC (Press)

Drink Valve Seat Test Set resistance = 6 in. WC. (Press) Failure flow ≥ 0.5 sccm

Drink Train Leakage Test Set resistance = 6 in. WC. (Press) Failure flow ≥ 0.5 sccm

Outlet Valve Leakage Test Set resistance = 1 in. WC. (Press) Failure flow ≥ 15 sccm

Quantitative Face Fit Test Set flow = 4 slpm. Failure Quantitative Fit Factor programmable by operator. Five (5) default exercises. Exercise length = 60 seconds.

Table 24. Test Settings and Descriptions



B-1

APPENDIX B TESTING A MASK WITH AN ATTACHED HOSE

B. 1 HOSE TEST ADAPTERS

Figure 55. Hose Test Adapters

NOMENCLATURE

1. #2 Rubber Stopper Used to plug the air flow port of the headform so that air flow is redirected through the hose test port during leakage testing.

2. Hose Test Adapter Used to connect hoses to the hose test port on the PMLT headform pedestal.

Table 25. Hose Test Adapter Kit

NOTE

To prevent high vacuum failures, test operators should check/adjust the back pressure settings IAW Section

11.10 before initiating the first test of a mask with attached hose. Ensure the mask and hose are applied to

the headform in lieu of the mask passing tube when conducting the test.

B.2 APPLYING THE MASK

1. Plug the rear headform port with the #2 rubber stopper. Ensure the stopper is seated fully into the port or the test resistance may be affected.

Figure 56. Installed Rubber Stopper

#2 Rubber Stopper In Rear Headform Port

2

1



B-2

NOTE

A sponge, dampened with water, may be used to clean the surface of the headform and peripheral seal.

For sanitary reasons, users must discard cleaning sponges at the end of each mask testing day.

2. Ensure that external components (hood, second skin, eyelens outserts, outlet valve cover, and canister) are removed from the protective mask prior to testing. It is not necessary to remove the head harness/skull cap prior to testing.

3. Inspect the lint screen for debris. Clean as necessary.

4. Clean the mask seal area and peripheral seal on the headform with a sponge or lint free cloth dampened with water.

5. Position the mask on the headform and pull the chin down just over the peripheral seal IAW Section 5.2.

NOTE

If the head harness is attached to the protective mask, fully extend the harness straps and position the head

harness to the rear of the headform.

6. Hold down the chin of the mask while fastening the two temple (middle) tabs to their corresponding mask clips on the middle brackets of the headform pedestal.

7. Fasten the two cheek (bottom) tabs to their corresponding mask clips on the bottom brackets of the headform pedestal.

8. Fasten the two forehead (top) tabs to their corresponding mask clips on the top brackets of the headform pedestal.

9. Screw the hose test adapter onto the mask hose.

10. Remove the hose test adapter plug from the connection port and insert the mask hose test adapter.

Figure 57. Attaching Mask Hose Test Adapter

11. Retract the plunger on the outlet valve plug and slide it over the outlet valve housing, from the bottom upwards. Then, release the plunger to seal the valve.



B-3

12. Place the mask test shroud over the mask and hose. Ensure the hose remains free of kinks and completely inside the mask test shroud. (Figure 58)

Figure 58. Test Shroud Over Mask w/Hose

B.3 CONDUCTING A TEST

NOTE

To prevent high vacuum failures, test operators should check/adjust the back pressure settings IAW Section

11.10 before initiating the first test of a mask with attached hose. Ensure the mask and hose are applied to

the headform in lieu of the mask passing tube when conducting the test.

<F1> SET Displays the [AEROSOL SETUP] menu. Refer to Section 5.1, Mask Aerosol Setup.

<F3> ESC Returns the operator to the [SELECT TEST] menu. Refer to Section 4.3, Selecting a Test.


1. To begin the mask test, press <F4>START.

2. Wait approximately 10 seconds while the peripheral seal inflates. The following steps are then completed automatically by the PMLT:

[SETTING] Indicates that the system is setting the test flow rate.

(continued on next page)

APPLY MASK

SET ESC START

SETTING



B-4

(continued from previous page)

Indicates that the system is loading aerosol under the test shroud.

Indicates that the system is reading the aerosol leakage through the mask.


A percentage of penetration (i.e.: .0001) is

displayed in the upper right corner. [PASSED] allows you to continue on to a new MASK test. If operating in either the M ALL or ALL mode, then testing continues on to the drink tube test.

Automatically stops testing. A steady tone indicates failure and a percentage of penetration (i.e.: 3.44%) is displayed.

Automatically stops testing. A steady tone indicates failure and either a LOW VAC or HIGH VAC message is displayed.


4. If [FAILED] or [FAILED VAC (HIGH or LOW)] appears, press <F4>CONT to continue and proceed to HSection 5.4, MaskH Paused, for further options.

B.4 MASK PAUSED

NOTE

If a mask test fails, refer to the flowchart diagrams in HSection 5.8, Mask Testing Failures, for guidance on which

steps to perform next.

LOADING

TESTING

* PASSED* 0.0001

* FAILED * 3.44%

CONT

* FAILED * HIGH VAC

CONT

* FAILED * LOW VAC

CONT



B-5

The following screen is displayed after a mask failure:

<F1> RES Resumes normal testing.

<F2> PROB Allows the application of aerosol to the mask, using the aerosol probe hose to help isolate the leak.

<F3> REJ Rejects the mask and returns to the [APPLY MASK] screen.

<F4> DEFL

SEAL

Deflates the peripheral seal. Use if mask was applied incorrectly and adjustments need to be made. Returns operator to [APPLY MASK] screen.

B.5 PROBE MODE

The probe mode is used to help isolate the location of a leak.

NOTE

When the failure set point is exceeded in probe mode, a beep can be heard. The beep sounds only when the

failure threshold (.0030) is exceeded. When probing, the threshold may not be obtained since a lower

concentration of aerosol is being applied.

4. To begin probing, select, <F2>PROB from the [PAUSED] screen and the following screen will appear:

<F1> HIGH Switches from normal aerosol concentration to high aerosol concentration to help isolate small leaks. After [HIGH] is selected, the screen will display [NORM] in the <F1> position. Selecting [NORM] returns the user to the normal aerosol concentration for testing.

<F3> PAUSE Ends the probe test and returns to the [PAUSED] screen for further options. Refer to Section 5.4, Mask Paused, for further options.

<F4> REJ Rejects the current mask test and prompts the operator to confirm the rejection. Confirming the rejection by pressing <F4>REJ returns the PMLT to the [APPLY MASK] screen. Refer to Section B.3, Conducting a Test.

5. Remove the test shroud from the headform, and remove the aerosol probe hose from the test shroud.

* PAUSED .0062% DEFL

RES PROB REJ SEAL

* TESTING 0.0089

HIGH PAUSE REJ

% Penetration



B-6

CAUTION

NEVER plug or block the probe end (blue) of the aerosol probe hose while the aerosol generator is

bubbling. Blocking the flow of aerosol may result in damage to internal components of the PMLT.

6. Hold the aerosol probe hose away from the mask until the numbers on the screen appear to stabilize at their lowest reading.

NOTE

When probing a mask and hose, it is recommended that the hand not holding the probe be cupped around the

area of the mask/hose being checked. This will prevent excess aerosol from drifting over the mask/hose,

possibly leading to false readings.

Figure 59. Using the Probe

4. Slowly pass the aerosol probe hose close to the mask surface. All potential areas for leaks should be probed (peripheral seal, lenses, recently replaced parts, etc.). The amount of time spent probing a leak is at the operator’s discretion. An increase in the value displayed on the screen indicates a probable mask leak in the area being probed.

5. When a suspected leak is isolated select <F3>PAUSE, then select <F1>RES or <F3>REJ from the [PAUSED] screen.

B.6 RESUME TESTING

2. Resume testing from the [PAUSED] screen by pressing the <F1> RES key.

* TESTING 0.0089

HIGH PAUSE REJ

% Penetration



B-7




<F4> DEFL

SEAL

Deflates the peripheral seal. Use if mask was applied incorrectly and adjustments need to be made.

<F4> CONT

Returns to the [PAUSED] screen.

NOTE

If “Low Seal Pressure” screen is displayed, operator should select <F4> INFL SEAL to reinflate the peripheral

seal. This will redirect you to the <PAUSED> screen. Pressing the <F2> PROB key will allow the operator to

resume probing for the leak.




<F4> INFL

SEAL

Re-inflates the peripheral seal after a [Low Seal Pressure] message. Allows user to retry mask probing or other leakage testing.

NOTE

Repeated [Low Seal Pressure] fault messages require troubleshooting. Refer to Section 12.3.6, Seal Failure,

for troubleshooting recommendations.

* PAUSED* DEFL

RES PROB REJ SEAL

Low Seal Pressure

CONT

* PAUSED* INFL

RES PROB REJ SEAL



C-1

APPENDIX C ABBREVIATIONS AND ACRONYMS

The table below describes the common abbreviations and acronyms used in this manual.

ABBREVIATION OR ACRONYM DESCRIPTION

ACF Altitude Control Function

ATI Air Techniques International

BT Bottle

BX Box

CAGEC Commercial and Government Entity Code

CBRD Chemical, Biological and Radiological Defense

CFR Code of Federal Regulations

DOT Department of Transportation

EA Each

FOB Freight On Board

GAL Gallon

IAW In Accordance With

PMLT Protective Mask Leakage Tester

LEL Lower Explosive Limit

LPM Liters Per Minute

LSC Light Scattering Chamber

M Meter

Mg Milligram

Ml Milliliter

MPT Mask Passing Tube

MSDS Material Safety Data Sheet

NBCD Nuclear, Biological and Chemical Defense

NFPA National Fire Protection Association

NSN National Stock Number

OSHA Occupational Safety & Health Administration

OZ Ounce

PAO Poly Alpha Olefin

PC Personal Computer

PMCS Preventive Maintenance Checks & Services

PN Part Number

QRLS Quick Release Locking System

RO Roll

SARA Superfund Amendment & Reauthorization Act

SCCM Standard Cubic Centimeters per Minute

SLPM Standards Liters Per Minute

CONTINUED ON PAGE C-2



C-2

CONTINUED FROM PAGE C-1

TM Technical Manual

TO Technical Order

TSCA Toxic Substance Control Act

UEL Upper Explosive Limit

USAF United States Air Force

USMC United States Marine Corps

WC Water Column

Table 26. Abbreviations and Acronyms



D-1

APPENDIX D REPAIR PARTS LIST

PMLT

PMLT Case Control Unit

U/I: EA U/I: EA

Part #:1200136 Part #:9300170

SMR: PAOOO CAGEC: 0D1M0 SMR: PAOOO CAGEC: 0D1M0

Power Unit Fit Test Kit

U/I: EA U/I: EA

Part #:9300180 Part #:9300123

SMR: PAODD CAGEC: 0D1M0 SMR: PAOOO CAGEC: 0D1M0

PMLT Case Tray

U/I: EA

Part #:1200170

SMR: PAOZZ CAGEC: 0D1M0



D-2

CONTROL UNIT

Mask Clip Mask Bracket Clamp

U/I: EA U/I: EA

Part #: T104-0234 Part #: T99M-1337

SMR: PAOZZ CAGEC: 0D1M0 SMR: PAOZZ CAGEC: 0D1M0

Mask Bracket Temple Strap Bracket

U/I: EA U/I: EA

Part #: T99M-1346 Part #: T99M-1345


Outlet Valve Test Adapter Outlet Valve Retaining Bolt

U/I: EA U/I: EA

Part #:1200115 Part #: T99M-1318




D-3

Wing Nut Mask Clip Screw

U/I: EA U/I: EA

Part #:3100127 Part #:3300201


O-ring Replacement Kit:

Qty. 4 Part 4300134

Qty. 1 Part 4300143

Qty. 3 Part 4300172

Qty. 7 Part 4300176

O-Ring Replacement Kit

U/I: EA

Part #:0200297


Back Pressure Adjustment Screw

U/I: EA

Part #:3300388

SMR: XDOZZ CAGEC: 0D1M0

Hose Test Port Plug

U/I: EA

Part #:0600248

SMR: PAOOO CAGEC: 0D1M0



D-4

POWER UNIT

Fuse Replacement Kit:

Qty. 2 Part T2E0-0321

Qty. 2 Part T5A0-0319

Fuse Replacement Kit

U/I: EA

Part #: 0200298


ACCESSORIES

Medium Headform Small Headform

U/I: EA U/I: EA

Part #: T99M-1380 Part #: T99M-1479

SMR: PAOOO CAGEC: 0D1M0 SMR: PAOOO CAGEC: 0D1M0

Generator Cap Generator Bottle

U/I: EA U/I: EA

Part #:9300164 Part #:0600222

SMR: PAOOO CAGEC: 0D1M0 SMR: PAOZZ CAGEC: 0D1M0



D-5

Aerosol Probe Hose Mask Test Shroud

U/I: EA U/I: EA

Part #:0200316 Part #:1200116


Canister Port Plug Outlet Valve Clamp

U/I: EA U/I: EA

Part #:1000245 Part #:4800148


Bottle of PAO Oil 100ml Power Cord

U/I: EA U/I: EA

Part #:0200188 Part #: T2E0-0064

SMR: PCOZZ CAGEC: 0D1M0 SMR: PAOZZ CAGEC: 0D1M0



D-6

Twin Tube Interface Hose QRLS Pin

U/I: EA U/I: EA

Part #:0600225 Part #:3000156


Power Interface Cable Mask Passing Tube

U/I: EA U/I: EA

Part #:6700137 Part #:0600316


T-Handle Hex Wrench Stubby Phillips Screwdriver

U/I: EA U/I: EA

Part #:4800161 Part #:4800147




D-7

#1 Phillips Screwdriver Flat Blade Screwdriver

U/I: EA U/I: EA

Part #:4800229 Part #:4800230


FIT TEST KIT

Fit Test Bag Badge Clip

U/I: EA U/I: EA

Part #:1200230 Part #: 3500161


Fit Test Shroud Fit Test Support Rods

U/I: EA U/I: EA

Part #:1200121 Part #:1200220




D-8

Y-Hose Aerosol Extension Fit Test Interface Tubing

U/I: EA U/I: EA

Part #:0200208 Part #: T99M-1487

SMR: PAOZZ CAGEC: 0D1M0 SMR: PAOOO CAGEC: 0D1M0

HOSE TEST KIT

Hose Test Adapter #2 Rubber Stopper

U/I: EA U/I: EA

Part #:0200307 Part #:4300148

SMR: PAOOO CAGEC: 0D1M0 SMR: PAOZZ CAGEC: 0D1M0

HEADFORM REPAIR PARTS

Lint Screen

U/I: EA

Part #:5500112




E-1

APPENDIX E PAO-4 MATERIAL SAFETY DATA SHEET

Section I – CHEMICAL PRODUCT AND COMPANY INFORMATION PRODUCT NAME:

ATI PAO-4

Preparation Date: 11/21/00

Air Techniques International

Revision Date: 01/10/10

Address:

11403 Cronridge Drive

Owings Mills, MD 21117-2247

Telephone: (410) 363-9696

Emergency Telephone Number: Contact local HazMat officials

Section II – COMPOSITION INFORMATION

Chemical CAS Number

Concentration Exposure Limits

1-Decene, tetramer mixed with 1-decene

68649-12-7 100% None Established

Section III - HAZARDOUS INGREDIENTS/IDENTITY INFORMATION

None

Section IV - PHYSICAL/CHEMICAL CHARACTERISTICS

Boiling Point: 754˚F

Specific Gravity: 0.819 @ 60˚F

Vapor Pressure @ 20˚C: N/A

Vapor Density: N/A

Solubility in Water: Insoluble

Appearance and Odor: Colorless, Odorless Liquid

Freezing Point: N/A

pH @ 5%: N/A



E-2

Section V - FIRE & EXPLOSION DATA

Flash Point: 432˚F

Method Used: Cleveland open cup

Flammable Limits in air % by volume: N/A

Auto-Ignition Temp;

UEL: N/A

LEL: N/A

Extinguisher Media: Carbon dioxide, Dry chemical, Foam, Water spray

Special Firefighting Procedures: Use water spray, dry chemical, foam or carbon dioxide. Water may be ineffective but should be used to keep fire-exposed containers cool. If a spill or a leak has not ignited, use water spray to disperse the vapors. Water spray may be used to flush spills away from fire.

Unusual Fire and Explosion Hazards: Perform only those firefighting procedures for which you have been trained. Firefighters should wear self-contained breathing apparatus in the positive pressure mode with a full-face piece where there is a possibility of exposure to smoke, fumes or hazardous decomposition products.

National Fire Protection Association (NFPA):

Health – 1 Flammability - 1 Reactivity - 0 Other - not applicable

Section VI - PHYSICAL HAZARDS (REACTIVITY DATA)

Stability: Stable X Unstable

Conditions to Avoid: Contact with heat, sparks, flame and all sources of ignition.

Incompatibility: Strong acids, bases and oxidizing agents.

Hazardous Decomposition Products: Carbon dioxide and carbon monoxide

Hazardous Polymerization: May occur Will not occur X

Section VII - HEALTH HAZARDS

Signs and Symptoms of Exposure:

Eyes: This material is not classified as an eye irritant.

Skin Absorption: No acute effects known.

Skin Contact: This material is not classified as a skin irritant.

Inhalation: This material is not considered to be hazardous under normal conditions of use. Exposure to mist or spray may cause irritation of respiratory passages.

Ingestion: Considered to be non-toxic by animal tests. Oral LD 50 > 5.0 g/kg (Rat)

Chronic Effects: None known.



E-3

Emergency and First Aid Procedures:

Eyes: Flush with large amounts of cold water for at least 15 minutes. Do not let victim rub eyes. If irritation develops, contact a physician immediately.

Skin: Wash affected area with soap and water.

Inhalation: If inhaled, move to fresh air. If victim has stopped breathing give artificial respiration, preferably, mouth to mouth. Contact a physician immediately.

Ingestion: Do not induce vomiting. If victim is conscious and able to swallow, promptly have victim drink water to dilute. Do not give sodium bicarbonate, fruit juices or vinegar. Never give anything by mouth if victim is unconscious or having convulsions. Contact a physician immediately.

Section VIII - SPECIAL PRECAUTIONS/ SPILL & LEAK PROCEDURES

Handling: No special precautions necessary. Avoid container damage while handling.

Storage: Store in closed containers in a cool, dry well ventilated area. Maintain closure of bungs. Store at temperatures between 40˚F and 160˚F. Do not reuse container. Avoid container damage while storing.

Spill & Leak Response: Do not allow spilled material to enter sewers or streams. Add dry material to absorb (if large spill, dike to contain). Using recommended protective equipment, pick up bulk of spill and containerize for recovery or disposal. Flush area with water to remove residues.

Waste Disposal: All recovered material should be packaged, labeled, transported and disposed or reclaimed in conformance with Good Engineering Practices.

Comply with all applicable governmental regulations. Avoid land filling of liquids. Reclaim where possible.

Section IX - SPECIAL PROTECTION INFORMATION

Respiratory Protection: Not applicable with adequate ventilation.

Protective Gloves: Wear rubber gloves.

Eye Protection: Safety glasses with side shields or chemical goggles. Do not wear contact lenses.

Other Protective Wear: Wear impervious, protective clothing including rubber safety shoes to avoid skin contact.

Work Practices: Read label for instructions in use of product.

Section X - TOXICOLOGICAL INFORMATION

Eye Irritation (Rabbits): Practically non-irritating. Eye irritation score: 2.0 at 1 hour, 2.0 at 24 hours (Scale 0-110)

Skin Irritation (Rabbits): Practically non-irritating. Primary irritation score 1.3 (Scale 0-8)

Dermal Toxicity (Rabbits): LD50 > 5 g/kg Practically non-irritating

Oral Toxicity (Rabbits): LD 50 > 15 g/kg Practically non-irritating



E-4

Section XI - ECOLOGICAL INFORMATION

96 Hour LC 50 for Rainbow Trout is > 1,000 mg/liter

48 Hour EC 50 for Daphnia is 190 mg/liter

This material is not expected to be harmful to aquatic organisms.

Section XII - TRANSPORT INFORMATION

DOT Shipping Name: Not designated as a hazardous material by the Federal DOT

DOT Hazard Class: Not applicable

DOT Identification Number: Not applicable

DOT Packing Group: Not applicable

Section XIII - ADDITIONAL REGULATORY INFORMATION

OSHA (Occupational Safety, and Health Administration) 29 CFR 1910.1200 Hazardous Chemical: No SARA (Superfund Amendment and Reauthorization Act)

Section 311: Hazardous Chemical - no

Immediate - no

Delayed - no

Fire - no

Sudden Release - no

Reactive – no

Section 313: Toxic Chemical - no

TSCA (Toxic Substance Control Act)

All of the ingredients in this product are listed on the TSCA Inventory.

CALIFORNIA PROPOSITION 65

This product contains no listed substances known to the State of California to cause cancer, birth defects, or other reproductive harm, at levels that would require a warning under the statute.

DISCLAIMER: THIS DOCUMENT HAS BEEN PREPARED IN GOOD FAITH AND FROM INFORMATION

PROVIDED TO US BY OUR SUPPLIERS AND OTHER SOURCES CONSIDERED TO BE RELIABLE. NO

WARRANTY, EXPRESS OR IMPLIED IS GIVEN. THE BUYER IS RESPONSIBLE TO EVALUATE ALL

AVAILABLE INFORMATION WHEN USING THIS PRODUCT FOR ANY PARTICULAR USE. THE BUYER IS

ALSO RESPONSIBLE FOR COMPLYING WITH ALL FEDERAL, STATE, PROVINCIAL, AND LOCAL LAWS

AND REGULATIONS WHEN USING THIS PRODUCT.



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APPENDIX F PRODUCT WARRANTY

Product Warranty Air Techniques International, Division of Hamilton Associates, Inc.

Air Techniques International, (ATI), warrants the equipment purchased hereunder to be free from material defect in materials and workmanship under normal use and service, when used for the purpose for which it is designed, for a period of (1) one year from the date of shipment. The delivery of repair or replacement parts shall not interrupt or prolong the term of the warranty. ATI further warrants that the equipment will substantially perform in accordance with the technical specifications accompanying the formal equipment offer.

ATI, at its option, will either repair or replace any such items ATI finds to be defective within the stated warranty period, FOB ATI’s plant, PROVIDED:

1. That any claim of defect under this warranty is made in writing within thirty (30) days after

discovery thereof and that inspection by ATI, if required, indicates the validity of such claim to ATI’s satisfaction; and

2. That the defect is not the result of damage incurred in shipment to or from our factory; and 3. That the equipment has not been altered in any way whether as to design or use, whether

by replacement parts and/or services not supplied or approved by ATI, or otherwise; and 4. That the equipment has not been abused or neglected; and 5. That the user of the equipment has been properly trained and is operating the equipment in

accordance with the support documentation; and 6. That any equipment or accessories furnished but not manufactured by ATI, or not of ATI

design, shall be subject only to such adjustments as ATI may obtain from the supplier thereof; and

7. That the purchaser and user adhere to all maintenance procedures and schedules recommended by ATI in the support documentation

ATI’s obligation under this warranty is limited to the repair or replacement of defective parts with the exception noted above. If the equipment includes a scattering chamber, ATI’s warranty does not extend to contamination of the scattering chamber by foreign material.

At ATI’s option, any defective equipment which fails within the warranty period shall be returned to ATI’s factory for inspection, properly packed with shipping charges prepaid. No equipment shall be returned to ATI without prior issuance of a return authorization by ATI. If ATI determines that the equipment is not defective or that the customer did not perform user-level maintenance as defined in the support documentation, then ATI reserves the right to charge the customer for the unnecessary service work performed.

No warranties, express or implied, other than those specifically set forth herein shall be applicable to any equipment manufactured or furnished by ATI and the foregoing warranty shall constitute the Buyer’s sole right and remedy. This warranty applies to the original purchaser only and is non-transferable. In no event does ATI assume any liability for consequential damages, or for loss, damage or expense directly or indirectly arising from the use of ATI products, or any inability to use them either separately or in combination with other equipment or materials or from any other cause. The liability of ATI arising out of the manufacture, sale, or delivery of any product, whether in contract, tort, or otherwise – shall not exceed the value of the equipment. ATI shall not be responsible for



F-2

any claim against a customer or user of the equipment by a third party. No action, regardless of form, may be brought against ATI more than one year after the cause of action has accrued. The remedies of the purchaser herein are exclusive. EXCEPT FOR THE EXPRESS WARRANTY SET FORTH ABOVE, ATI MAKES NO OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED, WITH RESPECT TO THE EQUIPMENT. ATI SHALL DISREGARD AND NOT BE BOUND BY ANY REPRESENTATIONS OR WARRANTIES MADE BY ANY OTHER PERSON, INCLUDING EMPLOYEES, DISTRIBUTORS, RESELLERS, OR DEALERS OF ATI, WHICH ARE INCONSISTENT WITH THE WARRANTY SET FORTH ABOVE. FOR THE PURPOSES OF THE EXCLUSIVE REMEDIES AND LIMITATIONS SET FORTH IN THIS WARRANTY, “ATI” SHALL BE DEEMED TO INCLUDE HAMILTON ASSOCIATES, INC. AND ANY OTHER HAMILTON ASSOCIATES DIVISIONS OR SUBSIDIARIES, AND THEIR AFFILIATES, DIRECTORS, OFFICERS, EMPLOYEES, AGENTS, REPRESENTATIVES, SUBCONTRACTORS, AND SUPPLIERS OF ALL OF THEM.

NOTE

Each PMLT control unit has tamper tape applied over the front center screw. Removing this tape may void the

warranty. ATI does not assume liability for consequential damages or defects discovered on a control unit with the

tamper tape removed or missing.

Figure 60. Tamper Tape on Control Unit

Tamper Tape

(DO NOT Remove)

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operator’s manual for protective mask leakage tester (pmlt) · 2010. 1. 1. · protective mask...

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