TDA-99M Protective Mask Leakage Tester OPERATOR S MANUAL

Transcription

1 TDA-99M Protective Mask Leakage Tester OPERATOR S MANUAL ATI Part # (U.S. Patent Nos. 6,435,009; 6,848,297; other patents pending) Supersedes all previous versions 1 June 2008 Division of Hamilton Associates, Inc Cronridge Drive Owings Mills, MD U.S.A. Copyright 2008 by Hamilton Associates, Inc.

2 i

3 TDA-99M Protective Mask Leakage Tester Table of Contents 1 General Information Description Specifications Environmental Information Storage Conditions Labels Warnings Cautions Symbols Tests Performed By The TDA-99M Mask Leakage (MASK) Drink Tube Flow Test (DRINK TUBE/TURN IN) Drink Train Assembly Leakage Test Drink Valve Seat Test (DRINK TUBE/TURN OUT) The Outlet Valve Test (VALVE) Quantitative Fit Testing (FIT) Mask All Test (M ALL) All Test (ALL) Components of the TDA-99M Control Unit Power Unit Aerosol Generator Assembly Fit Test Kit Accessories Unpacking and Assembly List of Items Furnished Required Operator Supplies Unpacking Assembling the TDA-99M Aerosol Generator Assembly Connecting Power Unit to Control Unit ii

4 3.4.3 Attaching the Headform Assembling the Fit Test Kit Initialization Power Up Selecting A Test Mask Testing Mask Aerosol Setup Applying a Mask Conducting a Test Mask Paused Probe Mode Resume Testing Removing The Mask From The Headform Mask Testing Failures Flowcharts General Mask Testing Failures Leak Found in Mask or Hose Using Probe Leak Found at Seal Using Probe No Leak Found using Probe Drink System Testing Drink Tube Flow Test (DRINK TUBE/TURN IN) Drink Train Assembly Leakage Test Drink Valve Seat Test (DRINK TUBE/TURN OUT) Drink Testing Failures Flowchart Outlet Valve Testing Conducting a Test Outlet Valve Failures Flowchart Quantitative Fit Test Fit Test Aerosol Setup Prepare the Subject Test a Subject Test a Subject Fit Testing Failures Flowchart Powering Down and Packing the TDA-99M Powering Down the TDA-99M Packing iii

5 10 Preventive Maintenance Checks and Services Preoperational PMCS Periodic PMCS every 100 hours Long Term (every 1500 operational hours or 2 years) Maintenance Procedures Date and Time Outlet Valve Adapter Replacement Drink Tube Adapter O-Ring Replacement Procedure External O-ring Replacement Procedure Drink Tube Adapter: Inner Adapter Cleaning Procedure Fuse Replacement Procedure Tubing Trimming/Cutting Procedure Shroud/Manifold Cleaning Procedure Back Pressure Adjustment Universal Hold-Down Assembly Adjustment Using the Mask Passing Tube (if supplied) Troubleshooting; Fault and Error Messages List of Flowcharts Symbols Control Unit/Power Unit Errors Display Is Blank Single Dash on Display Pump Not Operating Flow Error Memory Error Seal Failure Aerosol Related Errors Remains in Setting During Mask Aerosol Setup or Mask Test Remains in Setting During Fit Test Aerosol Setup Aerosol Setup of 90 or Greater LSC Error Low/ High Aerosol Error Vacuum/Flow RelatedFailures Low Water Column (W.C. <5.5) Failure High Water Column (W.C. >6.5) Failure iv

6 Persistent Penetration Failures Drink Test Errors Consistent Drink Tube Flow Failures Consistent Drink Train or Seat Failures Valve Test Errors Consistent Outlet Valve Failures Fit Test Errors Remains in Setting During Fit Test Consistent Low Fit Factors Appendix A Test Descriptions and Specifications.... A-1 Appendix B Testing a Mask With An Attached Hose... B-1 B.1 Components of The 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 Expendable/Durable Supplies and materials List... C-1 Appendix D Repair Parts List...D-1 Appendix E PAO-4 Material Safety Data Sheet... E-1 Appendix F Product Warranty... F-1 v

7 List of Figures Figure 1 TDA-99M Control Unit Figure 2 TDA-99M Control Unit Front View Figure 3 Control Unit Rear View Figure 4 TDA-99M Control Unit Side View Figure 5 Power Unit Figure 6 Aerosol Generator Assembly Figure 7 Fit Test Kit Figure 8 TDA-99M Accessories Figure 9 Headform Figure 10 TDA-99M in Case Figure 11 Packed TDA-99M Tray Figure 12 Packed TDA-99M Lower Case Figure 13 Installing Generator into Control Unit Figure 14 Headform and Pedestal Apart Figure 15 Headform and Pedestal Assembled Figure 16 Fit Test Support Rod Installation Figure 17 Fit Test Rods Through Snap Loop Figure 18 Y-Hose Aerosol Extender Into Grommet Figure 19 Y-Hose Aerosol Extender Connected to Aerosol Probe Hose Figure 20 Fit Test Interface Tubing Connection Figure 21 Aerosol Setup Figure 22 Mask On Headform Figure 23 Mask With Adapters Figure 24 Mask With Shroud Figure 25 Using The Probe Figure 26 Drink Flow Test Setup Figure 27 Plugging The Drink Tube Figure 28 Outlet Valve Test Figure 29 Fit Test Aerosol Setup Figure 30 Attaching the Fit Sampling Adapter Figure 31 Attaching the Badge Clip Figure 32 Fit Test Shroud vi

8 Figure 33 Folding of Fit Test Shroud Figure 34 Packing the Fit Test Support Rods Figure 35 Control Unit in Case Figure 36 TDA-99M Properly Packed Figure 37 Removing the Retaining Bolt Figure 38 Reinstalling the Bolt and Adapter Figure 39 Outlet Valve Adapter Figure 40 Drink Adapter O-Ring Replacement Figure 41 External Oring Replacement Figure 42 Cleaning the Drink Tube Adapter Figure 43 Fuse Locations Figure 44 Back Pressure Control Cover Screw Figure 45 Back Pressure Adjustment Figure 46 Universal Hold Down Assembly Figure 47 Removing Headform Lint Screen Figure 48 Inserting Mask Passing Tube Figure 49 Mask Passing Tube Inserted Figure 50 Installed Rubber Stopper... B-1 Figure 51 Inserting Mask Hose Adapter... B-2 Figure 52 Test Shroud Over Mask and Hose... B-3 Figure 53 Using the Probe... B-6 Figure 54 Tamper Tape on Control Unit... F-2 vii

9 List of Tables Table 1 TDA-99M Specifications Table 2 Labels Table 3 Symbols Table 4 TDA-99M Control Unit Front View Table 5 TDA-99M Control Unit Rear View Table 6 TDA-99M Control Unit Side View Table 7 Power Unit Table 8 Aerosol Generator Assembly Table 9 Fit Test Kit Table 10 TDA-99M Accessories Table 11 Headform Components Table 12 List of Items Furnished Table 13 Flowchart Symbols Table 14 Flowchart Symbols Table 15 Flowchart Symbols Table 16 Flowchart Symbols Table 17 Fuse Location and Descriptions Table 18 List of Flowcharts & 2 Table 19 Flowchart Symbols Table 20 Test Descriptions and Specifications... A-1 Table 21 Hose Test Adapter Kit... B-1 Table 22 Expendable/Durable Supplies and Materials List... C-1 viii

10 1 General Information This manual provides information and procedures for setup, operation, and maintenance of the TDA-99M Protective Mask Leakage Tester. 1.1 DESCRIPTION The TDA-99M is a portable device designed to test the serviceability and fit of protective masks. The TDA-99M can provide leak and serviceability testing of designated negative pressure 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 TDA-99M can also provide quantitative fit testing while an individual is wearing his/her assigned protective mask. The TDA-99M is completely self-contained in a rugged shipping case and can be set up in minutes by one person. The TDA-99M includes a universal hold down assembly, headform(s) with inflatable mask seal, and various adapters which allow it to be used to test several types of protective masks. The lightweight plastic headform is available in two sizes, and can be quickly attached to accommodate a wide range of protective mask sizes. The TDA-99M utilizes solid-state electronic circuitry with a user-friendly menu driven touch pad controls and an alphanumeric display. 1.2 SPECIFICATIONS TDA-99M Dimensions Weight Input Power Aerosol Detection Aerosol Generator Communication Port 29 (W) x 16.5 (H) x 20 (D). 76 lbs when packed in shipping case 110V AC 60Hz 2A 230V AC 50Hz 1A Near-forward light scattering. Mask Test: test concentration 60 mg/m3 (milligrams per cubic meter). Fit Test test concentration 35 mg/m3 Aerosol Oil: Poly Alpha olefin-pao-4 (See Material Safety Data Sheet (MSDS) in Appendix E Serial RS-232 (Null-modem cable required) Baud Rate 9600 Data Bits 8 Parity none Stop Bit 1 Flow control- X on/x off 1-1

11 Table 1. TDA-99M Specifications Figure 1. TDA-99M Control Unit 1.3 ENVIRONMENTAL INFORMATION The TDA-99M operates best under the following environmental conditions: NOTE If operating the TDA-99M at temperatures greater than 100 F, it is recommended that a fan be used to circulate the air around the TDA-99M. Do not point the fan directly at the TDA-99M as it may cause aerosol dispersal and difficulties when attempting the aerosol setup. Temperature 32 F to 120 F / 0 C to 48.8 C Humidity 0% to 95% Altitude -500 ft to 10,000 ft ( m to 3048 m) 1.4 STORAGE CONDITIONS Store the TDA-99M under the following conditions: Temperature Humidity 0% to 100% -38 F to 160 F / C to 71.1 C) 1-2

12 Altitude Any 1.5 LABELS The table below describes the common labels used in this manual. LABEL WARNING CAUTION NOTE DESCRIPTION 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. 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. Highlights an essential operating or maintenance procedure, condition, or statement. Table 2. Labels 1.6 WARNINGS 1. The TDA-99M 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 TDA-99M. 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. 1-3

13 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 TDA-99M. 10. During setup and prior to initialization, ensure that power switch is off to prevent damage to the TDA-99M. 11. 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. 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. Do not attach the ends of the aerosol probe together during packing. Doing so may cause damage to the open end of the hose. 18. Failure to place the power unit upside down when packed may cause damage to the power interface cable and pressure/vacuum ports. 19. Ensure that no liquid is introduced to the inside of the TDA-99M as this may cause damage to the electronics. 20. Incorrect adjustment of the mask clips may cause disfiguring of or damage to the mask or insufficient sealing, leading to test failures. 1-4

14 21. 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 [Window] <Function> <<Start>> DESCRIPTION Indicates the information displayed in a window. Indicates a function key. Indicates the start of a system process. Table 3. Symbols 1.9 TESTS PERFORMED BY THE TDA-99M The following tests are performed by the TDA-99M 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.C 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] 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 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] 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. 1-5

15 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 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 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. 1-6

16 2 Components of the TDA-99M The TDA-99M consists of four (4) major components and several accessories. The major components are the control unit, power unit, aerosol generator assembly, and the fit test kit. 2.1 CONTROL UNIT The control unit comprises the microprocessor which monitors and controls the TDA- 99M. 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 (RS-232) for transferring data. The right-side panel houses the fit interface ports and aerosol generator ports Figure 2. TDA-99M Control Unit Front View FEATURE FUNCTION 1. Display Screen Displays operator-prompted actions, system information, and function options. 2. Function Keys Used in the option menu to select or change options. The function of the key is displayed above in the display screen. 3. Headform Ports Support the headform during testing. 4. Hose Test Port & Plug Port used for hose test option. 5. Drink Tube Test Adapter Used for testing the drink tube of the mask. Different adapters may be required for different mask types. 6. Outlet Valve Test Adapter Used for testing the outlet valve of a mask. Different adapters may be required for different mask types. Table 4. TDA-99M Control Unit Front View 2-1

17 FEATURE Figure 3. Control Unit Rear View FUNCTION 1. Data Communication Port Used for connecting to PC serial port. Primarily for technical service functions. 2. Power Interface Cable Port Used for connecting the power interface cable from the control unit to the power unit. 3. Vacuum Port (Brass Fitting) Used for connecting the twin tube interface hose from the control unit to the power unit. 4. Pressure Port (Black Fitting) Used for connecting the twin tube interface hose from the control unit to the power unit. 5. ID Label Identifies the control unit by serial number. Table 5. TDA-99M Control Unit Rear View 1 2 FEATURE Figure 4. TDA-99M Control Unit Side View FUNCTION 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 hose to the control unit. Table 6. TDA-99M Control Unit Side View 2-2

18 2.2 POWER UNIT The power unit houses the pump that supplies vacuum and pressure as well as electrical power to the control unit Figure 5. Power Unit FEATURE FUNCTION 1. Power Interface Cable Connects and provides power from the power unit to the control unit. 2. Pressure Port Used for connecting the twin tube interface hose from the control unit to the power unit. 3. Vacuum Port Used for connecting the twin tube interface hose from the control unit to the power unit. 4. Fuse 3 Fuse for the control unit (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 system pump (2.5 amp. 250V slow-blow). 7. Fuse 4 Fuse for A/C power input (4 amp. 250V slow-blow, 5 x 20mm) 8. AC Power Input Used for connecting the A/C power cable to the power unit. 9. On/Off Power Switch Toggle switch to turn the power unit on and off. Table 7. Power Unit 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. 2-3

19 CAUTION PAO is the only authorized challenge oil that should be used with the TDA-99M. Use of other liquids or challenge agents may damage or contaminate the internal optics of the light scattering chamber Figure 6. Aerosol Generator Assembly FEATURE FUNCTION 1. Generator Bottle Holds PAO test oil. Marked with scribed minimum and maximum fill lines. 2. Generator Cap Used to connect the aerosol generator bottle to aerosol generator ports on the control unit. Generates aerosol from the PAO test oil. 3. Aerosol Probe Hose Directs the generator s aerosol output. Table 8. Aerosol Generator Assembly 2.4 FIT TEST KIT The fit test kit contains all the necessary subcomponents required to perform a quantitative fit test Figure 7. Fit Test Kit 2-4

20 FEATURE FUNCTION 1. Fit Test Shroud Used to contain the aerosol around a test subject. 2. Y-Hose Aerosol Extender Extends the aerosol probe hose to direct the generator aerosol output into the shroud. 3. Fit Test Interface Tubing Used for sampling aerosol leakage. 4. Fit Test Bag Used to secure the fit test items when not in use. 5. Fit Test Rods Used to support the fit test shroud. 2.5 ACCESSORIES Table 9. Fit Test Kit The accessories are all items not previously listed which are also provided with the TDA-99M. They may be used in conjunction with mask testing or to maintain the system Figure 8. TDA-99M Accessories ITEM DESCRIPTION ITEM DESCRIPTION 1. Mask Test Shroud 7. QRLS Pin mL Bottle of PAO Oil 8. Medium Headform 3. Canister Port Plug 9. Small Headform 4. Outlet Valve Clamp 10. Power Cord 5. T-Handle Hex Wrench 11. Twin Tube Interface Hose 6. No. 2 Stubby Phillips Screwdriver Table 10. TDA-99M Accessories 2-5

21 Figure 9. Headform FEATURE 1. Vacuum Port w/lint Screen FUNCTION 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. Airflow Channel Used to support the nosecup to facilitate airflow. Table 11. Headform Components ¹ - Specialized testing conducted by a limited number of users. 2-6

22 3 Unpacking and Assembly This chapter provides important information about unpacking and assembling the TDA-99M. Be sure to carefully check the furnished items list and become familiar with all locations and functions of components before operating the system. Following these procedures correctly will ensure that the TDA-99M is properly unpacked and set up. 3.1 LIST OF ITEMS FURNISHED QTY NOMENCLATURE 1 Shipping Case 1 Hard Plastic Tray 1 Mask Test Shroud 1 TDA-99M Operating Manual 1 Power Unit 1 Small Headform 1 Medium Headform 1 Aerosol Generator Cap 1 Aerosol Generator Bottle 1 QRLS Pin 1 Canister Port Plug 1 Outlet Valve Plug ml Bottle of Oil (spare) 1 T-Handle Hex Wrench, 1/8 1 #2 Stubby Phillips Screwdriver 1 Fit Test Kit 1 Control Unit 1 Twin Tube Interface Hose 1 Aerosol Probe Hose 1 110V Power Cord Table 12. List of Items Furnished 3.2 OTHER REQUIRED OPERATOR SUPPLIES Sponge or Lint Free Cloth V power 3-1

23 3.3 UNPACKING WARNING The TDA-99M 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 the case 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 of the above listed items are missing, contact Customer Service for replacement. ( or NOTE Preventive Maintenance Checks and Services (PMCS) should be performed during the unpacking and setup of the TDA-99M. Refer to Chapter Open the shipping case. Figure 10. TDA-99M in Case 3-2

24 For Steps 2 through 5 refer to figure Remove the mask test shroud from the case. 3. Remove the manual and other documentation from the case. Figure 11. Packed TDA-99M Tray CAUTION Failure to remove the power unit from the tray before lifting the tray from the case may result in damage to the tray. 4. Remove the power unit from the tray. 5. Remove the fit test kit from the shipping case. Lift tray out of the shipping case. Figure 12. Packed TDA-99M Lower Case For Steps 6 and 7 refer to Figure Remove the control unit from the shipping case. 7. Remove the twin tube interface hose and the aerosol probe hose from around the headform pedestal. 8. Place the tray and unused components back in the case and secure the shipping case. 3-3

25 3.4 ASSEMBLING THE TDA-99M AEROSOL GENERATOR ASSEMBLY 1. Remove the plastic cap from the generator bottle, and place it in the generator bottle s slot in the tray. WARNING Do not ingest PAO Oil. Refer to Material Safety Data Sheet in Appendix E. CAUTION PAO oil level must be between the top and bottom scribed fill lines on the aerosol generator bottle for the generator to work properly. 2. Inspect the generator bottle to ensure that the test oil is between the two scribed fill lines. If required, use the spare bottle of oil to fill the generator bottle between the lines with test oil. CAUTION 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. 3. Screw the yellow generator cap onto the generator bottle. 4. Attach the aerosol probe hose to the top of the yellow generator cap by pressing the clear hose end into the hose port on the cap. CAUTION Failure to ensure the generator port snap tabs are depressed prior to inserting the generator assembly may cause damage to the TDA-99M. 3-4

26 Generator Port Snap Tabs Aerosol Probe Hose Connector Ports Aerosol Generator Cap Figure 13. Installing Generator into Control Unit 5. Plug the generator assembly into the TDA-99M unit by inserting the male adapters into the generator connector ports until locked CONNECTING POWER UNIT TO CONTROL UNIT CAUTION Never position the power unit upside down or with the fan opening obstructed. Ensure that the A/C power cord is unplugged to prevent damage to the TDA-99M. Ensure that power switch is off to prevent damage to the TDA-99M. 1. Position the power unit, with rubber feet down, on a flat, solid surface near the control unit. 2. Connect the power interface cable to the back of the control unit and screw the locking ring onto the control unit connection until it is completely secure. 3. Connect the yellow-banded twin tube interface hose to the brass ports on the back of the control unit and the top of the power unit. 4. Connect the solid black twin tube interface hose to the black ports on the control unit and power unit. 5. Connect the A/C power cord to the power unit. 3-5

27 3.4.3 ATTACHING THE HEADFORM NOTE When initialized, the TDA-99M 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 , Seal Failure, for troubleshooting. If the headform is changed during operation, the TDA-99M 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. 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. Center the headform to be used over the pedestal with the chin (narrow portion) toward the front of the TDA-99M. Figure 14. Headform and Pedestal Apart 2. Align the white fittings on top of the pedestal with the holes in the headform. QRLS Pin Figure 15. Headform and Pedestal Assembled 3. Press down on the headform until it is fully seated onto the pedestal. 3-6

28 4. Insert the QRLS Pin into the back of the headform to secure its position (Figure 15). NOTE When the TDA-99M is unpacked and sitting idle, make sure the headform is installed and the mask test shroud is over the headform to prevent the ports from collecting debris. If FIT testing is to be performed, proceed to Section Assembling the Fit Test Kit. If FIT testing is not to be performed proceed to Chapter 4, Initialization 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 extender, and fit test interface tubing from the fit test bag. WARNING To avoid eye injury, use care when handling the fit test support rods. Figure 16. Fit Test Support Rod Installation 3-7

29 2. Insert one end of the fit test support rod through the loops in the fit test shroud and thread it through until it is seated in the base holder of the fit test shroud. 3. Insert the other end of the rod in the base holder on the other end of the shroud. 4. Secure the reinforcement rods into place with the snap loop at the top of the fit test shroud. 5. Repeat Steps 4 and 5 for other side of fit test shroud. NOTE Ensure the Y-hose aerosol extender is passed through the grommets and into the manifolds. The manifolds provide even distribution of the aerosol inside the fit test shroud. Snap Loop Snap Loop Figure 17. Fit Test Rods Through Snap Loops Y-Hose through Grommet Figure 18. Y-Hose Aerosol Extender into Grommet 6. Install the Y-hose aerosol extender through the grommets into the aerosol manifolds. (Two tubes in the top of the fit test shroud.) 3-8

30 Figure 19. Y-Hose Aerosol Extender Connecting to Aerosol Probe Hose 7. Connect the Y-hose aerosol extender to the aerosol probe hose. Sample line (clear) 100% line (blue) Figure 20. Fit Test Interface Tubing Connection 8. Plug the fit test interface tubing into the fit interface ports on the control unit. 9. Proceed to Chapter 4, Initialization. 3-9

31 4 Initialization This chapter provides step-by-step instructions for operating the TDA-99M efficiently. Descriptions of the menus are displayed on the display window of the control unit. 4.1 POWER UP 1. Plug the power cord into the appropriate source of power. WARNING Do not connect the power cord if any wiring is frayed. 2. On the power unit, toggle the power switch to the ON ( ) position. NOTE The TDA-99M requires no operator input for steps 3 through After power-up, [SYSTEM VERSION] is displayed. The [SYSTEM VERSION] screen displays the software version number, security level, number of mask tests performed and number of operating hours since the last cleaning and verification of the unit, refer to Section 10.3, Long Term (PMCS). Security Level Masks Tests Performed ATI L1 VER 5A Software Version Operating Hours 4. The [WARM UP] screen displays the current date and time. See Section 11.1 Date and Time, to make changes. Adjustable Date WARM UP MM/DD/YY 00:00 Adjustable Time 5. After the TDA-99M goes through warm-up (approximately two to three minutes), a [SYSTEM CHECK] screen is displayed. The [SYSTEM CHECK] screen indicates that the system is checking its internal sensors. 4-1

32 SYSTEM CHECK NOTE When initialized, the TDA-99M 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. If the headform is changed during operation, the TDA-99M 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. 6. Following initial power up, a successful system check will advance the TDA-99M to the [SELECT TEST] screen. 4.2 SELECTING A TEST NOTE The TDA-99M is equipped with internal temperature monitoring. If the internal temperature changes (+/-.9 F/.5 C), the control unit 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 altitude variations could result in low water column (WC) failure readings ( ). SELECT TEST = M ALL SYS UP DWN ACPT <F1> SYS <F2> UP <F3>DWN <F4>ACPT Sends the operator to the [SYS DIAG] screen. Scrolls up through the list of available tests. Scrolls down through the list of available tests. Accepts the test type displayed. 4-2

33 NOTE Scrolling up/down the list of tests, the display will start over at the end of the list. After initial power-up or restart, if MASK, M-ALL, FIT, or ALL is selected, an aerosol setup must be performed. The display indicates the tests available. A more detailed description of the available tests is contained in Section 1.9 Tests Performed by the TDA-99M. TEST FUNCTION [M ALL] Performs the MASK, DRINK, and VALVE tests sequentially. Refer to Ch H5, Mask Testing; Ch H6, Drink Tube Testing; and Ch H7, Outlet Valve Testing. [MASK] [DRINK] [VALVE] [FIT] [ALL] Performs a mask leakage test. Refer to HCh 5, Mask Testing. Performs a drink flow, drink train, and drink seat test. Refer to HCh 6, Drink System Testing Performs a test on the outlet valve. Refer to HCh 7, Outlet Valve Testing Performs a quantitative fit test. Refer to HCh 8, Quantitative Fit Test. Performs the mask, drink, valve, and fit tests sequentially. Refer to Ch, H5 Mask Testing; Ch H6, Drink System Testing; Ch H7, Outlet Valve Testing; and Ch H8 Quantitative Fit Test. 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. 4-3

34 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 or fit test. These levels must be established every time the TDA-99M is setup in the MASK, FIT, M ALL, and ALL modes or if the TDA-99M 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 TDA-99M has been sitting idle for more than sixty (60) minutes. NOTE Make sure that the aerosol probe hose input grommet of the test shroud is located at the rear of the headform. Improper assembly may cause the aerosol to be improperly distributed and possibly cause a false test failure. 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 21. Aerosol Setup 2. Insert the aerosol nozzle into the grommet on the test shroud. 5-1

35 AEROSOL SETUP YES NO NOTE When setting up for the first test of the day or after a system restart, the <F2> NO selection is not visible or active. <F1> YES <F2> NO Starts the aerosol setup procedure. Bypasses aerosol setup and proceeds to APPLY MASK screen 3. Select <F1>YES to perform an aerosol setup. The following steps are then completed automatically by the TDA-99M: [SETTING] SETTING Adjusting to test parameters. LOADING Generator turns on and aerosol is loaded under the test shroud. SETTING Setting 100% range. NOTE The TDA-99M should complete the aerosol setup and display the following screen within 5 minutes SETTING 6 Aerosol Setting Number The aerosol setup number is displayed on the bottom line (-20 to 100+). If the number displayed exceeds 90, refer to HSection , Aerosol Setup of 90H or Greater, for troubleshooting recommendations. 5-2

36 NOTE If a protective mask 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: APPLY MASK SET ESC START 5. Remove the test shroud from the headform, leaving the aerosol probe hose inserted in the grommet. 5.2 APPLYING A MASK 1. 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 cannot be obtained with the SMALL headform. 2. Ensure that the mask clips are properly adjusted for the type and size of protective mask being tested. See Section 11.10, Universal Hold-Down Assembly Adjustment. 3. Ensure that all external components and accessories (hood, second skin, eyelens outserts, outlet valve cover, canister, etc.) are removed from the protective mask prior to testing. It is not necessary to remove the head harness or skull cap prior to testing. 4. Inspect the headform lint screen for debris. Clean as necessary. NOTE For sanitary reasons, users should discard cleaning sponges after each mask testing day. 5. Clean the mask seal area and peripheral seal on the headform with a sponge or lint free cloth, dampened with water. 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 block the top port of the headform or the channel between the two headform ports. 5-3

37 6. Position the mask on the headform, by placing it on chin first. 7. 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. Refer to Figure Fasten the two cheek (bottom) tabs (2) to their corresponding mask clips on the bottom brackets of the headform pedestal. 9. Fasten the two forehead (top) tabs (3) to their corresponding mask clips on the top brackets of the headform pedestal. 3rd 1st 2nd Figure 22. Mask on Headform 10. Smooth the mask over the peripheral seal. 11. Ensure that the mask covers as much of the seal as possible. If this cannot be achieved, ensure that the proper headform is installed for the mask being tested. 12. Ensure that even tension is applied from all of the straps of the mask to the clips. Canister Port Plug Outlet Valve Clamp Figure 23. Mask with Adapters 5-4

38 13. Retract the plunger on the outlet valve clamp and slide it over the outlet valve housing from the bottom. When the clamp is fully over the outlet valve assembly, 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. 14. Install the canister port plug into the canister port of the mask and hand-tighten until it is snug. 15. Ensure that the hose test port plug is installed into the side of the headform pedestal. Figure 24. Mask with Shroud 16. Place the test shroud over the protective mask and headform with the aerosol probe hose to the rear of the headform. 17. Ensure the mask test shroud extends to the base of the headform pedestal and completely encases the mask. 18. Use the drawstring to snug the mask test shroud around the base of the headform pedestal. 5.3 CONDUCTING A TEST APPLY MASK SET ESC START 5-5

39 <F1> SET <F3> ESC <F4> START Displays the AEROSOL SETUP menu. HSection 5.1, Mask Aerosol Setup.H Returns the operator to the SELECT TEST menu. HSection 4.2, Selecting a TestH. 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 TDA-99M: [SETTING] SETTING Indicates that the system is setting the test flow rate. LOADING Indicates that the system is loading aerosol under the test shroud. TESTING 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: * PASSED* Allows you to continue with a new test. If either the M ALL or ALL test was selected, then testing continues on to the drink tube test. If in the MASK test mode you will be prompted to begin a new mask leakage test. * FAILED * 3.44% CONT Automatically stops testing; a steady tone indicates failure. The tone is audible until <F4> CONT is depressed. * FAILED * WC CONT Automatically stops testing; a steady tone indicates failure. The tone is audible until <F4> CONT is depressed. 5-6

40 NOTE Depressing the <F4>CONT key stops the audio alarm and advances to the [PAUSED] screen. For further testing options refer to Section 5.4, Mask Paused, and Section 5.5, Probe Mode. 4. If FAILED or FAILED WC (HI or LOW) appears press <F4>CONT to continue and proceed to Section MASK PAUSED The following screen is displayed after acknowledging a mask failure: * PAUSED.1284% RES PROB REJ SEAL Percent Leakage Detected <F1> RES <F2> PROB <F3> REJ <F4> SEAL Resumes normal testing. Starts the aerosol generator and allows the operator to use the aerosol probe hose to manually direct the aerosol around the mask. Enhances leak detection and isolation capabilities. Rejects the mask and returns to the [APPLY MASK] screen. Deflates the peripheral seal. Use if mask was applied incorrectly and adjustments need to be made. Returns operator to [APPLY MASK] screen. 1. If a mask test fails, refer to the flowchart diagrams in HSection 5.8, Mask Testing Failures FlowchartsH, for guidance on which steps to perform next. 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. A leakage value of >.0030 indicates that an acceptable leak rate has been obtained. The beep sounds only when the failure threshold (.0030) is crossed. When probing, the threshold may not be obtained since a lower concentration of aerosol is being applied. 5-7

41 1. To begin probing, select, <F2>PROB from the [PAUSED] menu and the following screen will appear: * TESTING PAUSE REJ % Penetration <F1>PAUSE <F3>REJ Ends the probe test and returns to the [PAUSED] screen for further options. Refer to HSection 5.4, Mask PausedH, for further options. Rejects the current mask test and prompts the operator to confirm the rejection. Confirming the rejection by pressing <F4>REJ returns the system to the [APPLY MASK] screen. Refer to HSection 5.3, Conducting a TestH. 2. Remove the test shroud from the headform and remove the aerosol probe from the test shroud. 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 system. 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 part of the mask being checked. This will keep any excess aerosol from drifting over the mask, possibly leading to false readings. Figure 25. Using the Probe 5-8

42 4. Slowly pass the aerosol probe 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. * TESTING PAUSE REJ % Penetration 5. When a suspected leak is isolated select <F1>PAUSE. 5.6 RESUME TESTING *PAUSED* RES REJ 1. Select <F1>RES or <F3>REJ from the [PAUSED] screen to resume testing or reject the active test results. <F1> RES <F3> REJ Ends the probe test and returns to the [PAUSED] screen for further options. SeeH Section 5.4, Mask PausedH. Rejects the mask under test and prompts the operator for acceptance of the rejection. Accepting the rejection by pressing <F1> returns the TDA-99M to the [SELECT TEST] screen. See HSection 5.3, Conducting a TestH. NOTE When reaching the mask paused screen from the probe mode, the <F2> and <F4> keys are not active. 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. Remove the canister port plug from the mask by unscrewing it and remove the outlet valve clamp from the mask by pulling up on the plunger and sliding the clamp off. 3. Disconnect the forehead, cheek, and temple buckles from the mask clips. 4. Remove the protective mask from the headform. 5-9

43 NOTE If mask testing is completed, place the shroud over the headform or disassemble and store the system. 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 5-12 through 5-15: 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 13. Flowchart Symbols 5-10

44 5.8.1 GENERAL MASK TESTING FAILURES Does mask pass? Yes Continue Testing. No Are procedures being followed IAW Chapter 5? No Retest mask IAW procedures listed in Section 5.2 and 5.3 Yes No Does mask pass? Yes Continue Testing. What type of failure is it? WC Failure Proceed to Section , Low Water Column Failure or , High Water Column Failure % Penetration Leak No leak found Probe for leak Proceed to Section 5.12, No Leak Found Using Probe Leak Found Proceed to Section 5.11, Leak Found at Seal Using Probe. At Seal Is leak at seal or in mask/hose? In Mask/ Hose Proceed to Section 5.10 Leak Found In Mask or Hose Using Probe 5-11

45 5.8.2 LEAK FOUND IN MASK OR HOSE USING PROBE 5-12

46 5.8.3 LEAK FOUND AT SEAL USING PROBE *TESTING PAUSE REJ Press <F1>PAUSE Reseat mask/reattach hose Retest mask or hose Does mask or hose pass? Yes Continue Testing No Probe for leak Is leak isolated? No Yes Repair mask or hose IAW technical guidance Retest mask or hose No Replace mask or hose with mask passing tube (if supplied) IAW Section Perform mask test with mask passing tube (if supplied) IAW Section 5.3 No Does mask or hose pass? Yes Continue Testing Does mask or hose pass? No Yes Remove mask passing tube, reseat mask/reattach hose, and retest IAW Section 5.3 Proceed to Section , Persistent Penetration Failures Does mask or hose pass? No Yes Continue Testing REJECT MASK 5-13

47 5.8.4 No Leak Found Using Probe *TESTING PAUSE REJ Press <F3> REJ Remove mask or hose from headform Replace mask or hose with mask passing tube (if supplied) Perform leakage test with mask passing tube (if supplied) IAW Section 5.3 Proceed to section , Persistent Penetration Failures No Does it pass? Yes Remove mask passing tube Inspect and repair mask or hose IAW technical guidance Retest mask or hose IAW Section 5.3 No Does it pass? Yes REJECT MASK Yes Is this the 3 rd test? No Continue Testing 5-14

48 6 Drink System Testing This chapter covers the procedures necessary to complete drink system testing. 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. DRINK TUBE/ TURN IN ESC START <F3>ESC <F4>START Returns the system to the [SELECT TEST] screen. Begins the DRINK FLOW test. 1. If the mask test shroud is in place, covering the headform, remove it so that the headform is exposed to open air. 2. Ensure the drink tube adapter is turned fully counterclockwise (turned OUT ) until it stops. Figure 26. Drink Flow Test Setup 3. Insert the mask drink tube to be tested into the drink tube adapter until it locks in place. 4. Rotate the drink tube adapter fully clockwise (turned IN ) until it stops. 5. Press <F4>START. The following step is then completed automatically by the TDA- 99M: [FLOW TEST] Signifies that the system is measuring the resistance of the drink system. 6-1

49 6. At the end of the test, either a [PASSED] or [FAILED] screen will appear. * PASSED * * FAILED * CONT Allows you to continue testing. The systemautomatically 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. *PAUSED* RES REJ <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. REJECTED CONT <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 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 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. TEST DRINK TRAIN? YES NO <F1> YES <F2> NO Starts the DRINK TRAIN test after prompting you to [PLUG TRAIN]. Skips the DRINK TRAIN test and continues to the DRINK VALVE SEAT test. 6-2

50 1. Select either <F1>YES or <F2>NO. NOTE For the M40/M42 series protective masks, always select <F2>NO. 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. PLUG TRAIN CONT Using the QRLS pin Using the thumb Figure 27. Plugging the Drink Tube NOTE The drink tube adapter must be turned IN before continuing. 3. Press <F4>CONT to begin the test. The following step is then completed automatically by the TDA-99M: [D-TRAIN TEST] Indicates that the system is measuring the airflow of the test. 4. At the end of the test, either a [PASSED] or [FAILED] screen will appear. 6-3

51 * PASSED * * FAILED * CONT Allows you to continue testing. The systemautomatically advances to the DRINK TUBE/TURN OUT (DRINK SEAT) test. Refer to Section 6.3, Drink Valve Seat 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. *PAUSED* RES REJ <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. REJECTED CONT <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. 5. 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. 6. 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. DRINK TUBE/ TURN OUT CONT <F4> CONT Starts the DRINK VALVE SEAT test. 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 TDA- 99M: [SEAT TEST] Indicates that the system is reading the airflow of the test. 6-4

52 3. At the end of the test, either a [PASSED] or [FAILED] screen will appear. * PASSED * Allows you to continue testing. The systemautomatically reverts to the DRINK TUBE/TURN IN (DRINK FLOW) test to test the next drink system. * FAILED * CONT 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. *PAUSED* RES REJ <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. REJECTED CONT <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. 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: DRINK TUBE/ TURN IN ESC START <F3> ESC <F4> START Returns to the [SELECT TEST] screen. Begins another DRINK TUBE FLOW test. 6-5

53 If testing in M ALL or ALL mode: VALVE TEST ESC START <F3> ESC <F4> START Returns the operator to the [SELECT TEST] menu. Refer to Section 4.2, Selecting a Test. 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. 6.4 DRINK TESTING FAILURES FLOWCHART The symbols in the following table are used in the failure flowchart that follows: 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 14. Flowchart Symbols 6-6

54 6.5 DRINK TESTING FAILURES FLOWCHART 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 TDA-99M. Drink Testing Does mask pass? Ye s Continue Testing No Retest mask Does mask pass? Ye s Continue Testing No Repair or reject 1 st mask IAW technical guidance Yes Test another mask if available or proceed to Section or for troubleshooting guidance Does 2 nd mask pass? No Yes Is this the 4 th time tested? No Clean drink tube IAW mask TM/TO and ensure that mating surfaces are dry Proceed to Troubleshooting Section or Ensure that drink tube flow path is clear IAW mask TM/ TO 6-7

55 7 Outlet Valve Testing This chapter covers the procedures necessary to complete outlet valve testing. NOTE The outlet valve adapter provided with the TDA- 99M can be used to test the M40 Series and MCU-2 Series masks. If necessary to test other types of masks contact ATI for instructions or adapter info. VALVE TEST ESC START <F3> ESC <F4> START Returns to [SELECT TEST] screen. 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. Moisten the TDA-99M outlet valve adapter with a sponge dampened with water. NOTE The outlet valve disk must be dry during this test. Figure 28. 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. 7-1

56 5. Continue pressing the outlet valve assembly into the adapter until it is fully seated. 6. Support the mask with your free hand while the outlet valve assembly is seated in the outlet valve adapter during the test. NOTE It may be necessary to periodically hand-tighten the TDA-99M s outlet valve adapter. Refer to HSection 11.2, Outlet Valve Adapter Replacement for further instructions. 7. Press <F4>START. The following steps are automatically completed by the TDA- 99M: [VALVE TEST] Indicates that the system is measuring the airflow of the test. 8. At the end of the test, either a [PASSED] or [FAILED] screen will appear. * PASSED * * FAILED * CONT 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. 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. *PAUSED* RES REJECTED REJ CONT <F2> RES returns 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. 7-2

57 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: VALVE TEST ESC START <F3> ESC <F4> START Returns to the [SELECT TEST] screen. Begins another Outlet Valve Test. If testing in M ALL or ALL mode: APPLY MASK SET ESC START <F1> SET <F3> ESC <F4> START Displays the [AEROSOL SETUP] screen. HSection 5.1, Mask Aerosol Setup Returns the operator to the [SELECT TEST] screen. HSection 4.3, Selecting a Test. Starts the mask test procedure. 10. If outlet valve testing is complete, disconnect the protective mask from the outlet valve adapter. 7.2 OUTLET VALVE FAILURES FLOWCHART The symbols in the following table are used in the failure flowchart that follows: 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 15. Flowchart Symbols 7-3

58 The purpose of the following diagram is to isolate the failure in the mask prior to troubleshooting the TDA-99M. 7-4

59 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 performing a fit test ensure that the TDA-99M has warmed up for a minimum of 20 minutes. If the testing environment is less than 72 F up to 90 minutes may be required for warmup. Insufficient warmup may lead to FALSE test failures. An aerosol setup is required prior to performing the first fit test after initialization. Prior to performing a fit test, ensure that there is a serviceable canister attached to a serviceable protective mask in accordance with the appropriate mask technical manual. 8.1 FIT TEST AEROSOL SETUP NOTE Section 8.2, Prepare the Subject, may be completed simultaneously with Section 8.1, 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 or fit test. These levels must be established every time the TDA-99M is setup in the MASK, FIT, M ALL, and ALL modes or if the system 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 TDA-99M has been sitting idle for more than sixty (60) minutes. 1. Connect the fit test interface tube to a shoulder strap inside of the fit test shroud using the badge clip, which is included with the sampling tube. 2. Place the drink adapter end of the fit test interface tubing inside the fit test shroud. It may be exposed to open air or attached to a mask s drink tube. 3. Ensure the fit test shroud is standing upright (Figure 30). 8-1

60 Figure 29. Fit Test Aerosol Setup NOTE After initialization, <F2>NO selection is invisible (not active). AEROSOL SETUP YES NO 4. At [AEROSOL SETUP] select <F1>YES. The following steps are then completed automatically by the TDA-99M: [SETTING] [LOADING] [SETTING] Adjusting to test parameters. Loading aerosol into the fit test shroud. Setting to 100% range. NOTE The TDA-99M should complete the aerosol setup and display the following screen within five minutes. SETTING 6 <F1> SET <F3> ESC followed by: Proceeds to [AEROSOL SETUP] screen. Returns to [SELECT TEST] screen. If in M ALL mode, the testing progress is canceled and the unit will start a new test. F4> CONT Starts the fit test procedure. READY SUBJECT - 5 SET ESC CONT 8-2

61 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 8.2, Prepare the Subject. NOTE Section 8.2, Prepare the Subject, may be completed simultaneously with Section 8.1, Fit Test Aerosol Setup. 8.2 PREPARE THE SUBJECT 1. Ensure that all protective mask components are attached to the mask. This includes an outlet valve cover, a serviceable filter canister, the second skin, eyelens outserts, etc. 2. Prepare the mask by removing the internal drink tube or by turning the internal drink tube away from the subject's mouth. 3. Instruct the test subject to sit down. 4. Direct the subject to don, clear, and check the seal of the mask in accordance with mask-specific technical procedures. 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. Figure 30. Attaching the Fit Sampling Adapter 8-3

62 1. 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 31. Attaching the Badge Clip 2. Attach the badge clip to the excess material on the temple strap. NOTE Ensure the end of the sampling line is not resting near the mask s outlet valve. 3. Place the fit test shroud on the subject s shoulders with the Y-Hose Aerosol Extender in the back. Figure 32. Fit Test Shroud 8-4

63 4. Adjust the straps of the fit test shroud to ensure that the subject can move his/her head without hitting the fit test shroud s surface. 5. Ensure that the green nylon apron of the fit test shroud extends below the subject s shoulders. 8.3 TEST A SUBJECT 1. Advise the subject to relax. Select <F4>CONT. The shroud will then load with aerosol and automatically advance to the first exercise screen when complete. The following screens will be displayed: *SETTING* and then *LOADING* ABORT <F2> ABORT Aborts the current test and displays a [CANCEL DURING TEST] screen. 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. 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, jaw rotation. Each exercise will be performed for approximately 1 minute, followed by a 40 second evaluation period. 3. 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 overexaggerate each exercise, as this may cause breaking of the seal and cause inaccurate fit scores. NOTE 8-5

64 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 a break in the mask seal and cause inaccurate fit scores. EXER= 1:60 ABORT START <F2> ABORT <F4> START Aborts the current test and displays a [CANCEL DURING TEST] message. Selecting <F4>CONT from that screen returns the user to the [READY SUBJECT] screen. Starts the fit test procedure. 1. 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. 2. 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. Fit Score for Exercise 1 EXER= 2: ABORT START 3. 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. 4. At the end of this exercise period the start screen for exercise 3 will appear. In addition, the fit score for exercise 2 will be displayed in the upper right corner of the screen. Record the fit score for exercise 2, if required, and proceed to the next step. EXER= 3: ABORT START Fit Score for Exercise 2 5. 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. 8-6

65 6. At the end of this exercise period the start screen for exercise 4 will appear. In addition, the fit score for exercise 3 will be displayed in the upper right corner of the screen. Record the fit score for exercise 3, if required, and proceed to the next step. EXER= 4: Fit Score for Exercise 3 ABORT START 7. 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. 8. At the end of this exercise period the start screen for exercise 5 will appear. In addition, the fit score for exercise 4 will be displayed in the upper right corner of the screen. Record the fit score for exercise 4, if required, and proceed to the next step. EXER= 5: START Fit Score for Exercise 4 9. 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. 10. At the conclusion of the final exercise the fit score for exercise 5 will appear in the upper right corner of the screen. Pressing <F1>CONT will cause the overall fit factor to appear along with [PASSED] or [FAILED]. EXER= 5: CONT Fit Score for Exercise If the test subject s fit factor was at or above the 3000 (default pass/fail setting) the following screen will appear: PASSED Overall Fit Factor CONT [PASSED] Allows you to continue testing after pressing <F4>. If ALL test was selected, proceed to HSection 5.2, Applying a MaskH. If a FIT test was selected, proceed to HSection 8.2, Preparing a SubjectH. 12. If the test subject s overall fit factor score was below 3000 (default pass/fail setting), the following screen will appear: 8-7

66 FAILED 1250 CONT Overall Fit Factor FAILED 1250 CONT Automatically stops testing; a steady tone indicates failure. After result is recorded, press <F4>CONT to advances to the [PAUSED] screen. *PAUSED* RES REJ <F2> RES returns to [READY SUBJECT - 5] screen.<f3> REJ proceeds to [REJECTED] screen. REJECTED CONT <F4> CONT returns to [READY SUBJECT - 5] screen. 13. At the conclusion of the fit test remove the fit test shroud, disconnect the fit test interface hoses, 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 acceptable. 14. Prepare another subject for testing. 8-8

67 8.4 FIT TESTING FAILURES FLOWCHART The symbols in the following table are used in this flowchart: 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 16. Flowchart Symbols The purpose of the following flowchart is to isolate a failure in the mask prior to troubleshooting the TDA-99M. 8-9

68 8.4 FIT TESTING FAILURES FLOWCHART (CON T) 8-10

69 9 Powering Down and Packing the TDA-99M 9.1 POWERING DOWN THE TDA-99M 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. Switch the power switch to the off position. 2. Unplug the power cord from the outlet. 3. Proceed to Section 9.2, Packing. 9.2 PACKING 1. Open the shipping case and remove the storage tray. CAUTION 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. 2. Disconnect the aerosol generator assembly from the control unit. CAUTION Failure to disassemble the generator assembly may result in oil spilling during shipping and damage the control and power units. 3. Remove the aerosol probe from the aerosol generator cap. 4. Unscrew the aerosol generator cap from the aerosol generator bottle and wipe off excess oil. 5. Place the aerosol generator cap in the appropriate slot of the storage tray. 6. Screw the plastic cap onto the aerosol generator bottle, making sure it is tight and not cross-threaded. 7. Place the aerosol generator bottle in the appropriate slot of the storage tray. 9-1

70 8. Remove the QRLS pin from the back of the headform and place it in the storage tray. 9. Remove the headform from the control unit and place it into the storage tray. 10. Disconnect the power unit from the control unit Remove the power interface cable from both the control and power units Disconnect the twin tube interface hose from the control and power units. NOTE If the TDA-99M was not setup for fit testing proceed to step Disconnect the Y-hose aerosol extender from the aerosol probe and the fit test shroud. If the TDA-99M was setup for fit testing, proceed to step 12. If the TDA- 99M was NOT setup for fit testing, proceed to step 16. WARNING To avoid eye injury, use care when handling fit test support rods. 12. Remove the fit test rods from the fit test shroud

71 Figure 33. Folding and Storing the Fit Test Shroud 13. Fold the fit test shroud for storage IAW Figure Lay the fit test shroud flat, with the brass connectors facing down (1) Fold the fit shroud in half so that the brass connectors are opposite each other (2) Fold in half again, from the bottom up to the top, squeezing out as much air as possible (3) Store the fit test shroud inside the fit test bag (4). 14. Once the fit test shroud is stored, place the Y-hose aerosol extension and fit test interface hose inside the fit test bag and close the bag. Figure 34. Packing the Fit Test Support Rods 15. Carefully place the fit test support rods in the bottom of the shipping case. CAUTION Do not attach the ends of the aerosol probe together. Doing so may cause damage to the open end of the hose. 16. Wrap the twin tube interface hose and the aerosol probe hose around the headform pedestal. 17. Place the control unit in the bottom of the shipping case. 18. Fold the power cord and store it in the gap of the forehead strap bracket assembly. 19. Place the tray into the shipping case. 9-3

72 Power Cord Aerosol Probe Hose Twin Tube Interface Hose Figure 35. Control Unit in Case CAUTION Failure to place the power unit upside down may cause damage to the power interface cable and pressure/vacuum ports. 20. Place the power unit in the tray upside down with the power interface port facing forward. 21. Place the fit test storage bag on the left side of the tray. 22. Place the small headform in the rear slot of the tray. 23. Place the medium headform in the front slot of the tray. 24. Place the rest of the test accessories in their appropriate slots on the tray. SMALL Headform Operator s Manual Fit Test Kit MED Headform Mask Test Shroud Figure 36. TDA-99M Properly Packed 25. Place the mask test shroud on top of the power unit. 26. Place the Operator's Manual top of the mask test shroud and power unit. 27. Close and secure the shipping case. 9-4

73 10 Preventive Maintenance Checks and Services This chapter provides inspection tables to assist you in properly maintaining the TDA-99M. The PMCS tables cover the: -Control unit. -Power unit. -Generator Assembly -Fit Test Kit. -Accessories PREOPERATIONAL PMCS The following is a list of all Preventive Maintenance Checks and Services which should be conducted as you set up and prepare to initialize the TDA-99M. CONTROL UNIT Item to Check PMCS Process Corrective Action GENERATOR PORTS Push and release the tabs to Contact ATI ensure they are functioning FIT TEST INTERFACE PORTS Push and release the tabs to ensure they are functioning Contact ATI PRESSURE/VACUUM PORTS (REAR OF KEYPAD) POWER CABLE INTERFACE PORT Visually inspect for obstructions, ensure they are not cracked or crushed Visually inspect for cracks in the fitting, broken or bent pins Contact ATI Contact ATI Visually inspect pins for corrosion Clean with a lint free cloth DISPLAY WINDOW Visually inspect for damage Contact ATI KEYBOARD Visually inspect for damage Contact ATI WING NUTS (6) Visually inspect they are present Replace as needed on the universal hold down brackets MASK CLIP SCREW (8) Visually inspect they are present Replace as needed MASK BRACKET CLAMP (2) MASK CLIP BRACKETS (4) Visually inspect for presence and damage Visually inspect for presence and damage Replace as needed Replace as needed 10-1

74 MASK CLIPS (6) FOREHEAD STRAP BRACKET HEADFORM PORTS HEADFORM PEDESTAL SCREWS (8) OUTLET VALVE TEST ADAPTER Visually inspect for presence and damage Visually inspect for presence and damage Visually inspect for damage Visually inspect the o-rings for presence and damage Should appear flush with pedestal and be securely attached Visually inspect for damage or deformity. Replace as needed Replace as needed Contact ATI Replace O-rings as needed. Tighten as needed Replace Outlet Valve Adapter POWER UNIT ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION PRESSURE/VACUUM PORTS Visually inspect for obstructions, Contact ATI ensure they are not cracked or crushed POWER INTERFACE CABLE Visually inspect for general damage and that the pin ports are not crushed Contact ATI Verify that the cable insulation is not cut or frayed and the wires are not visible Contact ATI Visually inspect to ensure the pins are not bent, broken or corroded Contact ATI 10-2

75 FIT TEST KIT ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION Y-HOSE AEROSOL EXTENDER FIT TEST SHROUD FIT TEST RODS FIT TEST INTERFACE TUBING Visually inspect for oil, dirt, or debris Visually inspect for cuts, tears and stitching. Visually inspect the rods to ensure they are not cracked or splintering Visually inspect tubing for cuts or cracks Allow to drain or rinse out with Isopropyl Alcohol Replace Shroud or repair using Duct Tape. Replace Rods Replace Fit Test Interface Tubing Visually inspect tubing for excess water or oil Visually inspect o-rings for presence and damage Visually inspect tubing for blockage Allow to drain or flush out with Isopropyl Alcohol Replace as needed Remove Blockage GENERATOR ASSEMBLY ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION GENERATOR CAP Visually inspect for cracks Contact ATI Visually inspect o-rings for presence and damage Replace as needed Visually inspect the ports to ensure they are not damaged or obstructed Remove obstruction; contact ATI if unable to resolve GENERATOR BOTTLE Visually inspect the level of oil Visually inspect for cracks Visually inspect the threads to ensure they are continuous Refill or remove oil as necessary Replace Generator Bottle Replace Generator Bottle 10-3

76 AEROSOL PROBE Visually inspect to ensure the tubing is not cut or crushed Replace as needed Visually inspect the blue probe tip to ensure it is not crushed or obstructed Replace as needed Visually inspect the connection end (open) of hose to ensure it is not cracked, split, or frayed Trim the end of the tubing as needed ACCESSORIES ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION HEADFORMS Visually inspect for cracks Replace as needed MASK TEST SHROUD CANISTER PORT PLUG Visually inspect the interface ports (underside) for cracks Visually inspect the headform lint screen for presence, debris or damage Visually inspect the peripheral seal for holes, cuts, or general damage Visually inspect for oil residue Visually inspect for cuts or tears Check drawstring functionality Visually inspect to ensure it is not dented or deformed Replace as needed Clean or Replace Replace as needed Wipe out with isopropyl alcohol and sponge Repair using Duct Tape or Replace Repair or replace Replace as needed Visually inspect the threads to ensure they are continuous. Replace as needed OUTLET VALVE CLAMP Visually inspect for cracks Visually inspect the rubber for dry rot, nicks or separation from plunger Replace as needed Replace as needed 10-4

77 OUTLET VALVE CLAMP Visually inspect to ensure the spring is taut Replace outlet valve clamp TWIN TUBE INTERFACE HOSE Visually inspect the screw to ensure it is tight Visually inspect for holes, cuts, or sharp bends Tighten as necessary Replace as needed Visually inspect to ensure that the yellow band is present on opposite ends of the same tube Replace as needed POWER CORD Visually inspect to ensure hose tips are not cracked, split, or frayed Visually inspect to ensure the cord is not cut or frayed and the wires are not visible Visually inspect the pins to ensure they are not bent or broken Trim the ends as necessary Replace Cord Replace Cord 10.2 PERIODIC PMCS EVERY 100 OPERATING HOURS The following is a table of all PMCS which should be conducted after every 100 hours of operation. These tasks should be completed in conjunction with the preoperational PMCS. END ITEM ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION CASE Visually inspect the locking mechanisms to ensure they are present, and not crushed or broken Visually inspect the handles to ensure they are not missing Visually inspect the foam to ensure it is securely attached Contact ATI Replace Case Contact ATI TRAY Visually inspect the tray to ensure it is not cracked or broken Visually inspect the tray to ensure the foam is securely attached Replace as needed Replace tray 10-5

78 CONTROL UNIT ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION FIT TEST INTERFACE PORTS Visually inspect o-rings for Replace as needed presence and damage DATA COMMUNICATIONS PORT Visually inspect to ensure that the port is securely attached Tighten screws as needed SERIAL NUMBER LABEL HOSE TEST PORT PLUG Visually inspect to ensure it is securely attached Visually inspect for o-ring presence and damage Contact ATI Replace O-ring as needed Visually inspect to ensure that the metal plug is securely attached to white cover Replace Plug OUTLET VALVE BOLT Visually inspect threads for continuity Replace if stripped or damaged DRINK TUBE TEST ADAPTER Use a lint free cloth to clean the inner adapter see section 11.5 Visually inspect for o-ring presence and damage Clean as needed Replace as needed HEADFORM PEDESTAL LIGHT SCATTERING CHAMBER (LSC) SETTING Visually inspect for general damage Complete a mask test aerosol setup, to ensure the setting number is lower than 90 Contact ATI Contact ATI to schedule service if >90 POWER UNIT ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION FUSE HOLDERS Visually inspect to ensure they are Contact ATI not loose or damaged SERIAL NUMBER LABEL Visually inspect to ensure it is securely attached Contact ATI 10-6

79 FIT TEST KIT ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION Y-HOSE AEROSOL EXTENDER Visually inspect tubing for cuts, Replace hose cracks, sharp bends FIT TEST INTERFACE TUBING FIT TEST SHROUD Visually inspect tubing for cuts, cracks, sharp bends Visually inspect the o-rings presence and damage Visually inspect the drink tube adapter for general damage and for o-ring presence and damage Visually inspect tubing for blockage Visually inspect for oil residue Visually inspect for cuts or tears Visually inspect the manifolds for oil buildup Replace tubing Replace as needed Replace adapter or O ring as needed Remove blockage Wipe with Isopropyl Alcohol and sponge Repair using Duct Tape or Replace Shroud Flush with Isopropyl Alcohol ACCESSORIES Visually inspect the grommets for wear or cuts Replace Shroud ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION HEADFORMS Visually inspect the screws which connect the peripheral seal interface port to ensure they are securely attached Tighten with screwdriver, as needed SPARE BOTTLE OF OIL Visually inspect the clear inflation tubing on the underside of the headform for cuts. Check quantity Visually inspect for general damage to bottle and presence of cap Contact ATI if damaged Replace PAO as needed Replace Spare Bottle 10-7

80 10.3 LONG TERM (EVERY 1500 OPERATIONAL HOURS OR 2 YEARS) END ITEM ITEM TO CHECK PMCS PROCESS CORRECTIVE ACTION TDA-99M Check operational hours at startup. If operational hours equal 1500 or greater, term maintenance is required. Operational hours are only displayed on power up. Check calibration sticker for due date If 1500 or greater, contact ATI to schedule factory maintenance and calibration. 10-8

81 11 Maintenance Procedures 11.1 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. SELECT TEST= M ALL SYS UP DWN ACPT 1. From the [SELECT TEST] screen press <F1>SYS. SYS DIAG? YES NO OPT 2. Press <F4>OPT, this opens the [OPTIONS] screen. OPTIONS TIME DATE ESC <F1> TIME <F2> DATE <F3> ESC Enters into the time adjustment screen. Enters into the date adjustment screen. Escapes back to the [SYS DIAG?] screen 3. Press <F1>TIME. MM/DD/YY 00:00 SET ESC <F1> SET <F3> ESC 4. Press <F1>SET. Enters into the Set Date and Time screen. Returns to the [SYS DIAG?] screen. MM/DD/YY 00:00 UP DWN CONT <F1> UP <F2> DWN <F4> CONT Increases the selected value. Decreases the selected value. Accepts the entered value and moves to the next entry. 11-1

82 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 Time and Date screen. 8. From the Set Time and Date 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 OUTLET VALVE ADAPTER REPLACEMENT 1. Remove the outlet valve retaining bolt from the outlet valve base using a cross tip screwdriver and then remove the outlet valve adapter. Outlet Valve Base Outlet Valve Retaining Bolt Outlet Valve Adapter Figure 37. Removing the Retaining Bolt 2. To install a replacement outlet valve adapter; first insert the outlet valve retaining bolt through the center of the outlet valve adapter. Figure 38. Reinstalling the Bolt and Adapter 11-2

83 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 adapter into the base by turning clockwise until hand-tight, ensuring the notches are centered and facing up. The outlet valve 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 39. Outlet Valve Adapter 11.3 DRINK TUBE ADAPTER O-RING REPLACEMENT PROCEDURE 1. Using a flat tip screwdriver, carefully remove the drink tube adapter O-ring by inserting the flat tip of the screwdriver between the inside surface of the aluminum adapter and the O-ring. 2. Using a prying motion, carefully lift the O-ring out of its groove. Figure 40. Drink Adapter O-Ring Replacement 3. Remove a replacement O-ring from the spare O-ring kit. 11-3

84 4. Using the flat tip of the screwdriver, carefully insert the new O-ring into the groove of the aluminum adapter. 5. Starting in one location and continuing around the circumference of the adapter, press down on the O-ring until is fully seated into the groove EXTERNAL O-RING REPLACEMENT PROCEDURE NOTE The TDA-99M has external O-rings located in the following areas: headform pedestal, fit test interface ports, generator cap, hose test port plug, mask passing tube (if supplied), and the fit test interface hose. 1. Using your index finger and thumb, remove the O-ring by squeezing it inward while pulling upward. Figure 41. External O-Ring Replacement 2. Remove a replacement O-ring from the spare O-ring kit (if available). 3. Place the new O-ring over the fitting and press down to secure DRINK TUBE ADAPTER: INNER ADAPTER CLEANING PROCEDURE 1. Turn the drink tube adapter fully counterclockwise to the OUT position. Figure 42. Cleaning the Drink Tube Adapter 11-4

85 2. Use a lint free 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 FUSE REPLACEMENT PROCEDURE NOTE Steps 3 thru 8 refer to fuses 1, 2, and 3. For fuse 4 (A/C Power) refer to steps 1,2, and 9 thru Turn off the TDA-99M. 2. Unplug the power cord from the wall outlet or power source. 3. If replacing fuse 1, 2, or 3, use a flat blade screwdriver to push down and turn the fuse holder cap counterclockwise. This will allow the spring loaded fuse holder cap to pop up Figure 43. Fuse Locations LOCATION DESCRIPTION 1. Fuse 1 Fuse for the control unit (2.5 amp. 250V slow-blow) 2. Fuse 2 Fuse for the control unit valves (2.5 amp. 250V slow-blow) 3. Fuse 3 Fuse for the system pump (4 amp, 250V slow-blow) 4. Fuse 4 Fuse for the A/C power source (4 amp, 250V slow-blow 5 x 20 mm). Spare included inside holder. Table 17. Fuse Location and Descriptions 4. Using your thumb and forefinger, lift the fuse holder cap out of its socket. 11-5

86 5. Remove the bad fuse from the fuse holder cap. 6. Insert the replacement fuse into the fuse holder cap. 7. Using your thumb and forefinger, place the fuse and fuse holder cap back into its socket. 8. Use the flat blade screwdriver to push down and turn the fuse holder cap clockwise. This will lock it into place. 9. To replace fuse 4, wedge the flat blade of a screwdriver into the fuse cover and pry upwards to expose the fuse and the included spare. 10. Remove the bad fuse from the fuse holder cap. 11. Remove the spare fuse from the fuse holder cap and insert it in place of the bad fuse. 12. Press the fuse holder back into its socket until you feel it lock into place. WARNING Do not connect the power cord if any wiring is frayed. 13. Connect power cord to the TDA-99M TUBING 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. The fit test interface hose has a V Cut on the end of the 100% (blue) line to prevent it from sealing against the surface of the fit test shroud. This cut should always remain as a V. 1. Place the tubing to be trimmed on a flat surface. 2. Using a sharp cutting instrument (scissors, wire cutters, tubing cutters, etc), carefully make a complete perpendicular cut as close to the end of tubing as possible. 11-6

87 11.8 SHROUD/MANIFOLD CLEANING PROCEDURE 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 TDA-99M as this may cause damage to the electronics. 1. Using a sponge or lint free cloth very lightly dampened with alcohol, carefully wipe all surfaces. Use care to avoid dripping alcohol on any adjacent surfaces. 2. Using a dry, lint-free cloth, dry all surfaces BACK PRESSURE ADJUSTMENT NOTE The process below applies ONLY to systems supplied with a Mask Passing Tube. A known GOOD mask may be used as a substitute if a Mask Passing Tube is not supplied. 1. Exit the mask test menu on the TDA-99M and press <F1> (SYS) to enter the system diagnostics menu. 2. At the systems diagnostic screen, select <F1> (YES). 3. Place the Mask Passing Tube on the TDA-99M headform in accordance with Section CHECK? MSK VAL MORE EXIT <F1> MSK <F2> VAL <F3> MORE <F4> EXIT Enters into the Mask Pressure and Flow Screen Enters into the Valve Pressure and Flow Screen Enters into more diagnostic screens Exits the Diagnostics Menu returns the user to the Sys Diag screen. 11-7

88 4. Select the F1 (mask) key. NOTE When the left-most number (sample flow) reads , the right-most number (vacuum) should read The TDA-99M tests at a flow of and the vacuum must be in the range of MASK FLOW= 16.0 / 6.0 CONT 5. If the numbers displayed are in the proper ranges, press the <F4> CONT key and proceed to step 11. Back Pressure Port Cover Screw Figure 44. Back Pressure Control Cover Screw 6. If the numbers are not in the acceptable range, use a cross tip screwdriver to remove the cover screw of the back pressure adjustment control. The cover screw is the largest diameter screw, located between two smaller cross tip screws on the upper right of the headform pedestal base. (Do not lose this screw). T-Handle Hex Wrench Back Pressure Adjustment Figure 45. Back Pressure Adjustment 11-8

89 7. Place the T-Handle Hex wrench into the back pressure set screw to adjust the vacuum to 6.0 inches water column (WC) at a flow of 16.0 liters per minute (LPM). Slowly turn the wrench clockwise to increase the vacuum or counterclockwise to decrease the vacuum. 8. Allow the numbers to stabilize. This should take less than 30 seconds. 9. Once the numbers stabilize to read / , respectively, press the <F4> CONT key to return to the system diagnostic menu. 10. Repeat Steps 4 and 5 to verify that the vacuum is now set correctly. 11. Replace the cover screw and exit system diagnostics to return to mask testing. 12. Press <F4> EXIT to return to the System Diagnostics screen. 13. Press <F4> NO to return to the SELECT TEST screen. 14. Remove the mask passing tube from the headform and reinsert the lint screen UNIVERSAL HOLD-DOWN ASSEMBLY ADJUSTMENT Ensure that the universal hold-down assembly is properly adjusted. There are five holddown 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 Section 5.2, Applying a Mask, of this manual. 11-9

90 Temple Strap Bracket Mask Clip Mask Bracket Mask Bracket Clamp Figure 46. Universal Hold Down Assembly Mask Clip Screw 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 ( ½ ) from the mask buckle in the relaxed state. 3. If adjustments are necessary, use the 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 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 USING THE MASK PASSING TUBE (IF SUPPLIED) NOTE: When using the Mask Passing Tube the reading should not exceed during a Mask Test INSTALLATION 1. Remove the mask test shroud. Figure 47. Removing Headform Lint Screen Lint Screen over Vacuum Port 11-10

91 2. Use your index finger or a flat tip screwdriver to remove the lint screen from the headform s vacuum port. (Figure 48) Figure 48. Inserting Mask Passing Tube 3. Insert one end of the mask passing tube into the top (flow) port of the headform. Vacuum Port Flow Port Figure 49. Mask Passing Tube Inserted 4. Insert the other end of the mask passing tube into the bottom (vacuum) port of the headform REMOVAL 1. Remove the mask passing tube from the headform. 2. Reinsert the lint screen into the vacuum port of the headform

92 12 Troubleshooting; Fault and Error This chapter contains the troubleshooting flowcharts and fault and error messages you may encounter while operating the TDA-99M. For technical support not specified or resolved by the following flowcharts you may call the ATI for technical support , Monday thru Friday, 9 a.m. to 5 p.m. EST. After hours calls will be recorded and normally returned within 1 business day. 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 LIST OF FLOWCHARTS TYPE OF ERROR MANUAL SECTION DESCRIPTION PAGE NUMBER Initial Power Up Display Is Blank 12-3 Initial Power Up Single Dash On Display 12-4 Initial Power Up Pump Not Operating 12-5 Initial Power Up Flow Error 12-6 Initial Power Up Memory Error 12-7 Initial Power Up Seal Failure 12-8 Aerosol Set Up Remains in Setting During Mask Aerosol Set Up or Mask Test Aerosol Set Up Remains in Setting During Fit Test Aerosol Set Up Aerosol Set Up Aerosol Set Up of 90 or Greater Aerosol Set Up LSC Error Aerosol Set Up Low/High Aerosol Error Mask Test Low Water Column (WC) Failure CONT D ON PAGE

93 Mask Test CONT D FROM PAGE 12-1 High Water Column (WC) Failure Mask Test Persistent Penetration Failures Drink Test Consistent Drink Tube Flow Failures Drink Test Consistent Drink Train or Seat Test Failures Outlet Valve Consistent Outlet Valve Failures Fit Test Remains in Setting During Fit Test Fit Test Consistent Low Fit Factors Table 18. List of Flowcharts 12.2 SYMBOLS The symbols in the following table are used in the flowcharts on pages 12-3 through 12-24: 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 19. Flowchart Symbols 12-2

94 12.3 CONTROL UNIT/POWER UNIT ERRORS DISPLAY IS BLANK A common root cause of this problem can be attributed to a blown fuse (#1). 12-3

95 SINGLE DASH ON DISPLAY A common root cause of this problem can be attributed to a blown fuse (#2). 12-4

96 PUMP NOT OPERATING A common root cause of this problem can be attributed to a blown fuse (#3). PUMP NOT OPERATING Yes Is power cord properly connected? Switch Power Unit OFF Disconnect power cord No Switch Power Unit OFF Reconnect power cord Restart Power Unit Remove & visually inspect fuse 3 IAW Section 11.6 No Is pump operating? Replace fuse IAW Section 11.6 No Is fuse good? Yes Yes Continue Testing Reconnect power cord. Restart Power Unit Is pump operating? No Contact ATI Suspect Power Unit Yes Continue Testing 12-5

97 FLOW ERROR The root cause of this problem can be usually be attributed to the control unit. FLOW ERROR Yes Is twin tube interface hose properly connected? Switch Power Unit OFF No Reconnect twin tube interface hose IAW Section Continue Testing Disconnect twin tube interface hose Conduct PMCS of twin tube interface hose IAW Section 10.1 Reconnect twin tube interface hose IAW Section Restart Power Unit Is there a FLOW ERROR? No Continue Testing Yes Switch Power Unit OFF for 30 seconds Restart Power Unit Repeat sequence a maximum of 5 times No Is this the 5 th restart? Yes Contact ATI. Suspect Control Unit 12-6

98 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. 12-7

99 SEAL FAILURE The root cause of this problem can be attributed to either the power unit or control unit. 12-8

100 SEAL FAILURE (CONT D) Continued from PREVIOUS PAGE Does seal still fail? Yes Switch Power Unit OFF No Continue Testing with replacement headform; assume 1 st headform is defective Disconnect twin tube interface hose Conduct PMCS on twin tube Interface hose IAW 10.1 Reconnect twin tube interface hose IAW Restart Power Unit Does seal still fail? No Continue Testing Yes Contact ATI Suspect Control Unit 12-9

101 12.4 AEROSOL RELATED ERRORS REMAINS IN SETTING 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. SETTING Switch Power Unit OFF Disconnect twin tube interface hose Perform PMCS on twin tube interface hose IAW Section 10.1 Reconnect twin tube interface hose IAW Section Restart Power Unit Complete an aerosol setup Contact ATI Factory Technician s Evaluation Needed No Is a known good Control Unit available? Yes Yes Does it remain in SETTING? No Yes Is a known good Power Unit available? Yes No Contact ATI Factory Technician s Evaluation Needed Switch Power Unit OFF Continue Testing Switch Power Unit OFF Replace with a known good control unit Replace with a known good Power Unit Restart Power Unit Restart Power Unit Complete an aerosol setup Does it remain in SETTING? No (NOTE 1) Continue Testing Complete an aerosol setup No (NOTE 2) Does it remain in SETTING? Yes Yes Contact ATI Suspect Power Unit Contact ATI Suspect Control Unit NOTE 1: Suspect first control unit is defective. NOTE 2: Suspect first power unit is defective

102 REMAINS IN SETTING DURING FIT TEST AEROSOL SET UP Troubleshooting may isolate the problem to either the power unit or control unit

103 AEROSOL SETUP OF 90 OR GREATER After completing an aerosol setup, a number is displayed in the lower left corner of the screen. This number reflects the cleanliness of the optics within the control unit. While the TDA-99M will still operate until the number reaches 120, it is important to schedule ATI factory service when the number reaches 90. In order to minimize the amount of time that the TDA-99M 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

104 LSC ERROR Troubleshooting may isolate the problem to either the power unit or control unit. LSC ERROR Switch Power Unit OFF for 30 seconds Restart Power Unit and allow system to run for 30 minutes Complete an aerosol setup IAW Section 5.1 Contact ATI Factory Technician s Evaluation Needed No Is a known good control unit available? Yes Yes Is there an LSC error? No Yes Is a known good power unit available? Yes No Contact ATI Factory Technician s Evaluation Needed Switch Power Unit OFF Continue Testing Switch Power Unit OFF Replace with a known good control unit Replace with a known good power unit Restart Power Unit Restart Power Unit Complete an aerosol setup IAW Section 5.1 Is there an LSC error? No (NOTE 1) Continue Testing Complete an aerosol setup IAW Section 5.1 No (NOTE 2) Is there an LSC error? Yes Yes Contact ATI Suspect Power Unit Contact ATI Suspect Control Unit NOTE 1: Suspect first control unit is defective. NOTE 2: Suspect first power unit is defective

105 LOW/HIGH AEROSOL ERROR Troubleshooting may isolate the problem to the power unit, control unit, or aerosol generator. 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

106 LOW/HIGH AEROSOL ERROR (CONT D) 12-15

107 12.5 VACUUM/FLOW RELATED ERRORS LOW WATER COLUMN (W.C. < 5.5) FAILURE The root cause of this problem can always be attributed to the control unit. FAIL < 5.5 W.C. Retest following proper procedures No Is test being conducted IAW Section 5.3 Yes Yes Does low W.C. failure occur? Adjust back pressure IAW Section No Continue Testing Switch Power Unit OFF for 30 seconds No Was back pressure adjustable to standards IAW Section 11.10? Yes Complete mask test IAW Section 5.3 Restart Power Unit Yes Complete mask test IAW Section 5.3 using the mask passing tube (if supplied) IAW Section Does mask passing tube pass? Yes Continue Testing No Does mask pass? Repeat sequence a maximum of 5 times Continue Testing No No Repeat sequence a maximum of 5 times Is this the 5 th time? Yes Contact ATI Suspect Control Unit 12-16

108 HIGH WATER COLUMN (W.C. > 6.5) FAILURE The root cause of this problem can always be attributed to the control unit

109 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

110 12.6 DRINK TEST ERRORS CONSISTENT DRINK TUBE FLOW FAILURES The root cause of this problem can be attributed to either the power unit or control unit

111 CONSISTENT DRINK TUBE FLOW FAILURES (CONT D) 12-20

112 CONSISTENT DRINK TRAIN OR SEAT FAILURES The root cause of this problem can always be attributed to the control unit. FAILED No Is test being conducted IAW Section 6.2? Drink Train Test Which test is being conducted? Drink Seat Test Is test being conducted IAW Section 6.3? No Retest using proper procedures Did test pass? Yes No Yes Remove drink tube from drink tube adapter Conduct flow test, with no drink tube, IAW Section 6.1 Yes No Retest using proper procedures Did test pass? Yes Continue Testing Skip train test Continue Testing Seal the adapter with thumb Conduct drink seat test IAW Section 6.3 Did test pass? Yes Replace drink tube adapter O-ring No Continue Testing Switch Power Unit OFF for 30 seconds Restart Power Unit Conduct a drink test IAW Chapter 6 Continue Testing Yes Did test pass? No Contact ATI Suspect Control Unit 12-21

113 12.7 VALVE TEST ERRORS CONSISTENT OUTLET VALVE FAILURES The root cause of this problem can always be attributed to the control unit. FAILED Is test being conducted IAW Section 7.1? No Retest using proper procedures Yes Conduct PMCS on the outlet valve adapter IAW Section 10.1 Check the outlet valve adapter for tightness No Does it pass? Yes Continue Testing Hand-tighten adapter Retest outlet valve No Is the outlet valve adapter tight? Yes Does it pass? No Place thumb over hole in adapter and retest outlet valve IAW Chapter 7 Yes Does it pass? No Switch Power Unit OFF for 30 seconds Yes Restart Power Unit Continue Testing Place thumb over hole in adapter and retest outlet valve IAW Chapter 7 Yes Does it pass? No Contact ATI Suspect Control Unit 12-22

114 12.8 FIT TEST ERRORS 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. Stays in SETTING During Fit Test Ensure that the drink tube is fully seated in the adapter Ensure that nothing is blocking the drink tube flow path to include the fit test interface tubing IAW Sections 10.1 Is fit test interface tubing blocked? No Yes Unblock tubing Conduct fit test IAW Chapter 8 Remove mask and conduct drink tube flow test IAW Section 6.1 Yes Does it remain in SETTING? Switch Power Unit OFF for 30 seconds Yes Does test pass? No Restart Power Unit No Continue Testing Conduct fit test IAW Chapter 8 Repair drink tube IAW technical guidance and resume fit test Does it remain in SETTING? No Continue Testing Yes Switch Power Unit OFF for 30 seconds Restart Power Unit Conduct fit test IAW Chapter 8 No Does it remain in SETTING? Yes Contact ATI Suspect Control Unit 12-23

115 CONSISTENT LOW FIT FACTORS This problem may be the result of a hard-to-fit test subject, the mask, or the TDA- 99M. If it is the TDA-99M, the root cause of this problem can always be attributed to the control unit

116 Appendices

117 APPENDIX A: TEST DESCRIPTIONS AND SPECIFICATIONS DESCRIPTION Mask Leakage Test Drink Tube Flow Test SPECIFICATION Sample flow = 16 slpm. Sample resistance = 6 in. WC (Vac) ± 0.5% Leakage Failure >= % 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. Number of exercises = 5. Exercise length = 60 seconds Table 20. Test Descriptions and Specifications A-1

118 APPENDIX B TESTING A MASK WITH AN ATTACHED HOSE B.1 COMPONENTS OF HOSE TEST ADAPTER KIT QTY PN NOMENCLATURE Hose Test Adapter #2 Rubber Stopper Table 21. Hose Test Adapter Kit B.2 APPLYING THE MASK AND HOSE 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. #2 Rubber Stopper In Rear Headform Port Figure 50. Installed Rubber Stopper NOTE A sponge, dampened with water, may be used to clean the surface of the headform and peripheral seal. For sanitary reasons, users should discard cleaning sponges at the end of each mask testing day. 2. Ensure that external components (hood, second skin, eye lens outserts, outlet valve cover, canister, etc.) 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 dampened with water. B-1

119 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 canister end of the mask hose. 10. Remove the hose test adapter plug from the connection port and insert the mask hose test adapter. Figure 51. Inserting Mask Hose 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. 12. Double-check the tightness of the hose test adapter onto the mask hose. Ensure the adapter did not become loose when it was plugged into the hose test port. 13. Place the mask test shroud over the mask and hose. Ensure the hose remains kink-free and completely within the mask test shroud. (Figure 52) B-2

120 Figure 52. Test Shroud Over Mask & Hose B.3 CONDUCTING A TEST NOTE In the event of high water column failures, test operators should check/adjust the back pressure settings IAW Section If a back pressure adjustment is necessary, ensure the mask and hose are applied to the headform in lieu of the mask passing tube. APPLY MASK SET ESC START <F1> SET <F3> ESC <F4> START Displays the [AEROSOL SETUP] screen. Refer to Section 5.1, Mask Aerosol Setup Returns the operator to the [SELECT TEST] screen. Refer to Section 4.3, Selecting a Test. 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 control unit: [SETTING] [LOADING] [TESTING] Indicates that the system is setting the test flow rate. Indicates that the system is applying aerosol under the test shroud. Indicates that the system is measuring the aerosol leakage through the mask. B-3

121 3. At the end of the test, either a [PASSED] or [FAILED] screen will appear. * PASSED* Allows you to continue with a new MASK test. If either the M ALL or ALL test was selected, then testing continues on to the drink tube test. * FAILED* 3.44% CONT Automatically stops testing. A steady tone indicates failure and a percentage of penetration (i.e.: 3.44%) is displayed. * FAILED * WC CONT Automatically stops testing. A steady tone indicates failure and a WC message is displayed. <F4> CONT Proceeds to the [PAUSED] screen for further testing options and stops the alarm. Refer to HSection 5.4, Mask PausedH, for further options. 4. If [FAILED] or [FAILED x.xxx WC] appears, press <F4>CONT to continue and proceed to HSection 5.4, MaskH Paused, for further options. B.4 MASK PAUSED 1. The following functions are displayed after a mask failure. * PAUSED * DEFL RES PROB REJ SEAL <F1> RES <F2> PROB <F3> REJ <F4> SEAL Resumes normal testing. Allows the application of aerosol to the mask, using the probe to help isolate the leak. Rejects the mask and returns to the apply mask screen. Deflates the peripheral seal. Use if mask was applied incorrectly and adjustments need to be made. 2. If a mask fails, see Section 5.8, Mask Test Failures Flowcharts for guidance on which steps to perform next. B.5 PROBE MODE The probe mode is used to help isolate the location of a leak. B-4

122 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] menu and the following screen will appear: * TESTING PAUSE REJ % Penetration <F1> PAUSE <F3> REJ Ends the probe test and returns to the [PAUSED] screen for further options. Refer to HSection 5.4, Mask PausedH, for further options. Rejects the current mask test and prompts the operator to confirm the rejection. Confirming the rejection by pressing <F4>REJ returns the TDA-99M to the [APPLY MASK] screen. Refer to HSection 5.3, Conducting a TestH. 2. Remove the test shroud from the headform, and remove the aerosol probe hose from the test shroud. 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 TDA- 99M. 3. Hold the aerosol probe hose away from the mask and hose 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. B-5

123 4. Slowly pass the aerosol probe hose close to the mask and hose surfaces. All potential areas for leaks should be probed (peripheral seal, lenses, hose connections, 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 or hose leak in the area being probed. Figure 53. Using the Probe B-6

124 APPENDIX C: EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST The supplies listed in Table 22 are recommended for use with the TDA-99M. Suitable substitutes are acceptable. ITEM NUMBER NATIONAL STOCK NUMBER DESCRIPTION Cellulose Sponge, 2-1/4 Diameter or suitable substitute Towel, Machinery Wiping or suitable substitute Knife, Craftsman s or suitable substitute Tape, Pressure Sensitive, Adhesive: Black, 2 inch width, 60 yards length or suitable substitute Alcohol, Isopropyl, Rubbing: 16 ounce (unit of issue is optional) UNIT OF MEASURE DZ BX EA RO BT Table 22. Expendable/Durable Supplies and Materials List C-1

125 Appendix D: Repair Parts List Mask Clip NSN: U/I: EA Part #: T Mask Bracket Clamp NSN: U/I: EA Part #: T99M-1337 Mask Bracket NSN: U/I: EA Part #: T99M-1346 Temple Strap Bracket NSN: U/I: EA Part #: T99M-1345 Outlet Valve Adapter NSN: U/I: EA Part #: Outlet Valve Retaining Bolt NSN: U/I: EA Part #: T99M-1318 Wing Nut Mask Clip Screw NSN: U/I: EA NSN: U/I: EA Part #: Part #: D-1

126 O-ring Replacement Kit: Qty. 4 Part Qty. 1 Part Qty. 3 Part Qty. 7 Part O-Ring Replacement Kit NSN: U/I: EA Part #: Fuse Replacement Kit: Qty. 2 Part T2E Qty. 2 Part T5A Fuse Replacement Kit NSN: U/I: EA Part #: Hose Test Port Plug Back Pressure Adjustment Screw NSN: U/I: EA NSN: not available U/I: EA Part #: Part #: Medium Headform NSN: U/I: EA Part #: T99M-1380 Small Headform NSN: U/I: EA Part #: T99M-1479 D-2

127 Generator Cap Generator Bottle NSN: U/I: EA NSN: U/I: EA Part #: Part #: Aerosol Probe Hose 99M Mask Test Shroud NSN: U/I: EA Part #: Part #: Canister Port Plug Outlet Valve Clamp NSN: U/I: EA NSN: U/I: EA Part #: Part #: Bottle of PAO Oil 100ml NSN: U/I: EA Part #: Power Cord NSN: U/I: EA Part #: T2E D-3

128 Twin Tube Interface Hose QRLS Pin NSN: U/I: EA NSN: U/I: EA Part #: Part #: T-Handle Hex Wrench Mask Passing Tube NSN: U/I: EA NSN: U/I: EA Part #: Part #: No. 2 Stubby Cross Tip Screwdriver No. 1 Cross Tip Screwdriver NSN: U/I: EA NSN: U/I: EA Part #: Part #: /8 Flat Tip Screwdriver Lint Screen NSN: U/I: EA NSN: U/I: EA Part #: Part #: D-4

129 Fit Test Kit Fit Test Shroud NSN: U/I: KT NSN: U/I: EA Part #: Part #: Fit Test Bag Fit Test Support Rods NSN: U/I: EA NS N: U/I: EA Part #: Part #: Fit Test Interface Tubing Badge Clip NSN: U/I: EA NSN: U/I: EA Part #: T99M-1487 Part #: D-5

130 Y-Hose Aerosol Extension Hose Test Kit NSN: U/I: EA NSN: U/I: KT Part #: Part #: Hose Test Adapter #2 Rubber Stopper NSN: U/I: EA NSN: U/I: EA Part #: Part #: D-6

131 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 Revision Date: 02/29/08 Address: Cronridge Drive Owings Mills, MD Telephone: (410) Emergency Telephone Number: Contact local HazMat officials Section II Composition Information Chemical CAS Number Concentration Exposure Limits 1-Decene, tetramer mixed with 1-decene % None Established Section III - Hazardous Ingredients/Identity Information None Section IV - Physical/Chemical Characteristics Boiling Point: 754 F Specific Gravity: 60 F Vapor 20 C: N/A Vapor Density: N/A Solubility in Water: Insoluble Appearance and Odor: Colorless, Odorless Liquid Freezing Point: N/A 5%: N/A E-1

132 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-2

133 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. Storage at temperatures between -38 F and 160 F is acceptable for mask/filter testing applications. 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. E-3

134 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 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 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. E-4

135 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. E-5

136 APPENDIX F: PRODUCT WARRANTY Product Warranty, Division of Hamilton Associates, Inc., (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 F-1

137 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 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 TDA-99M control unit has tamper tape applied over the front center screw. Removing this tape voids the warranty. ATI does not assume liability for consequential damages or defects discovered on a control unit with the tamper tape removed or missing. Tamper Tape (DO NOT REMOVE) Figure 54. Tamper Tape on Control Unit F-2