Approvals: 1st Level 2nd Level 3rd Level 

National Institute for Occupational Safety and Health 

National Personal Protective Technology Laboratory 

P.O. Box 18070 

Pittsburgh, PA 15236 

Procedure No. NPPTL-STP-CBRN-PAPR-0551 Revision: 0.0 Date: 1 September 2006

DETERMINATION OF CBRN, POWERED AIR-PURIFYING RESPIRATOR (PAPR) 

PERFORMANCE DURING DYNAMIC TESTING AGAINST CHEMICAL AGENT DISTILLED 

SULFUR MUSTARD (HD) VAPOR AND DISTILLED SULFUR MUSTARD (HD) LIQUID 

CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) STANDARD TESTING 

PROCEDURE (STP) 

1 PURPOSE

1.1 This document establishes the procedures for ensuring the level of respiratory protection 

provided by Chemical, Biological, Radiological, and Nuclear (CBRN) Protection 

requirements for Powered Air-Purifying Respirator (PAPR) submitted for Approval, 

Extension of Approval, or examined during Certification Product Audits, meet the minimum 

certification standards set forth in Title 42 CFR, Part 84, Subpart G, Section 84.63(a)(c)(d); 

Federal Register Volume 60, Number 110, June 8, 1995 and the Statement of Standard for 

Chemical, Biological, Radiological, and Nuclear (CBRN) Powered Air- Purifying Respirator 

(PAPR). 

1.2 The purpose of this Standard Test Procedure (STP) is to describe the test conditions and 

procedures necessary to test and certify manufacturer submitted CBRN PAPR applications. 

A CBRN PAPR being a complete tight fitting or loose fitting facepiece or hood, properly 

outfitted with manufacturer unique components and a properly designed manufacturer 

specified PAPR blower and canisters which are installed per the manufacturer’s installation 

requirements outlined in current user’s instructions. This procedure is used to test CBRN 

PAPR systems against Distilled Sulfur Mustard (HD) vapor and liquid physical states, while 

the respirator is operated in dynamic mode by means of a breather pump connected to the 

breathing zone of a manikin headform. Instrumentation is integrated under this static 

chamber platform for the purpose of generating and controlling challenge concentrations and 

detecting agent permeation and penetration of a tested respirator. This procedure is a separate 

test under the NIOSH NPPTL heading of NPPTL-STP-CBRN-PAPR-0551 for challenge of 

Mustard (HD) Vapor and Liquid. This procedure is designed to rigorously test the evaluated 

respirator as a dynamic breathing system and generate repeatable independent pass or fail 

results under laboratory conditions. 

2 GENERAL:

2.1 The STP describes test procedures in sufficient detail that a team of persons knowledgeable 

in the appropriate technical field can select equipment with the necessary resolution, conduct 

the test and determine whether or not the product passes the test. 

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Procedure No. NPPTL-STP-CBRN-PAPR-0551 Revision: 0.0 Date: 1 September 2006 Page 2 of 35 

2.2 This STP shall be used to test HD agent permeation and penetration resistance for both tight 

and loose fitting PAPR models as well as both constant and demand response flow PAPRs. 

3 EQUIPMENT. List of necessary test equipment follows:

3.1 SMARTMAN, Head/upper torso form or equivalent (see picture 1). Manufactured by ILC 

Dover, Frederica, DE. The SiMulant Agent Resistant Test MANikin, a.k.a. SMARTMAN, 

is a cast zinc hollow shell headform representing a static uniform surface that outlines a 

medium sized human male head, neck, shoulders and upper chest stature. The head features 

an anatomically correct semi-static surface consisting of dimensional eyes, nose, ears, 

mouth orifice, forehead and chin. The features are on a movable section of the head to 

facilitate installing and removing a peripheral front face seal, which is made of butyl rubber 

and fits into a channel between the face and the permanent part of the head. See Picture 1: 

Head/Upper Torso Manikin, SMARTMAN. The seal is inflated to press against the inside 

of the facepiece seal area to assure against leakage. The face surface of the SMARTMAN 

is connected in several places to outside sampling ports by means of stainless steel tubing 

that is located inside the form and passes out the bottom. The largest tube, 3⁄4” inch in 

diameter, leads from the mouth area to the breather pump. Four smaller tubes are present. 

One tube connects to the center of the left eye; it is blocked off. A tube connects to the 

lower middle forehead above the bridge of the nose; it is blocked off. There are two metal 

tubes protruding outward from the oral/nasal region, they are in use. One is used to measure 

differential pressure by means of a Magnehelic® gauge, while the second one is used to 

monitor presence of agent. The four tubes are 1⁄4” diameter. The SMARTMAN is mounted 

and sealed to the floor of an exposure chamber, which is raised by four legs to allow the 

tubing to exit and connect to the external monitoring devices. A large channel is molded at 

the bottom of the SMARTMAN to allow the anchoring of respirator system shrouds as they 

are intended per manufacturer instructions. An illustration of the SMARTMAN is shown in 

Picture 1. 

Picture 1: Head/Upper Torso Manikin, SMARTMAN 

3.2 Leak detector Model TDA-99M or equivalent (see picture 2). Manufactured by Air 

Techniques, Inc., the TDA-99M is one of the primary tools for accessing aerosol leaks in 

the mechanical seals of the respirator and proper fit of a respirator to clean SMARTMAN 

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Procedure No. NPPTL-STP-CBRN-PAPR-0551 Revision: 0.0 Date: 1 September 2006 Page 3 of 35 

headform under non-toxic oil aerosol conditions. The device generates an Emery 3004 

mineral oil aerosol that is used to detect leakage in the respirator. With the respirator 

properly installed on the SMARTMAN and the breather pump operating at manufacturer 

specifications, the TDA-99M generates a liquid particulate aerosol at a concentration of 

100mg/m3

. This aerosol is introduced by the TDA 99M’s pump. The respirator interior is 

monitored for the presence of aerosol. The leak detector compares the concentration inside 

with the concentration outside, and calculates a digital percent penetration value. 

Picture 2: Leak detector Model TDA-99M 

3.3 MINIature Continuous Air Monitoring System, MINICAMS or equivalent (see picture 3). 

The MINICAMS, manufactured by OI Analytical, is a gas chromatograph equipped with a 

hydrogen flame emission detector and a preconcentrator tube. The preconcentrator tube is a 

small tube containing an adsorbent material to scrub out agent vapor contained in a sample 

of air drawn through it for a set time period. The tube is then heated to desorb the agent and 

introduce it into the column and subsequently the detector. By preconcentrating the agent, 

the detection limit is lowered. The MINICAMS unique software calculates the amount of 

agent detected over a specified period of time. The Limit of Detection (LOD) is equal to 

20% of the 8 hr Time Weighted Average for the specific chemical agent being detected. 

Residual contamination is the amount of challenge agent lingering in the breathing zone of 

the respirator when a new, clean respirator is mounted on the SMARTMAN. Residual

contamination is quantified at the beginning of each test and the MINICAMS output must 

remain stable for a period of 60 minutes prior to the initiation of any test. Two MINICAMS 

are required in order to continuously monitor the interior of the respirator for CBRN 

respirator certification.

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Picture 3: MINIature Continuous Air Monitoring System, (MINICAMS) 

3.4 Syringe pump, Sage Model M365 or equivalent (see picture 4). This multirange, variable 

rate infusion pump is used to inject liquid agent at a controlled rate into an air stream to 

generate a vapor challenge. The challenge concentration can be varied over a wide range to 

accommodate the requirements. The liquid agent is contained in a syringe connected by a 

flexible cannula, a small tube for insertion into a cavity or vessel, to the dilution airline. 

The plunger of the syringe is driven at a controlled rate by the pump to deliver a calculated 

constant flow of agent. The concentration of agent is adjusted by changing the speed 

setting of the pump. Rate Flow Range = 20.0 ml /min. to 0.3 ml/hr, Flow Accuracy = +/- 

5%. Laboratory technicians must be proficient in the pump’s uses. 

Picture 4: Syringe pump, Sage Model M365 

 

3.5 Flow-Temperature-Humidity Control System or equivalent (see picture 5). This system, 

referred to as the Miller-Nelson (MN) control system, manufactured by Miller-Nelson 

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Research, Inc., is an automated system to control the airflow, temperature, and humidity of 

an air supply for an operating respirator system. Laboratory compressed air and distilled 

water are supplied to the unit; the three sensors and controlling mechanisms are 

incorporated electronically, and the unit output is air of the required volume/flow (200-50 

L/min.± 2%), and relative humidity (20-80 ± 3%) and temperature (20-30 0

C ± 0.3%). 

Picture 5: Flow-Temperature-Humidity Control System 

3.6 Exposure Chamber or equivalent (see picture 6). The respirator exposure chamber is 

constructed of clear, chemical resistant material (Plexiglas® or Lexan®) or other equivalent 

material. The chamber floor must be adequate to support the 85-pound SMARTMAN. The 

front panel is removable and is held in place with clamps on each edge. The dimensions are 

approximately 2 ft. cubed. Four Plexiglas® legs are attached to the bottom and hold the 

chamber above the hood floor. This allows room for laboratory tubing and the face 

adjustment handle to pass beneath the camber. A M12A1 military specified air-purifying 

canister is installed on top of the chamber to filter the air that passes out of the chamber. 

There are ports in the sides to accommodate tubing for challenge concentration and clean 

purge air. An electric fan is installed near the top front to achieve a mixed challenge 

concentration. A “Clean Exposure Chamber/Cold Box” is a second chamber used to 

perform a fit and leak check on a respirator test unit (no agents used in this chamber) before 

it is installed in the agent exposure chamber. An “Agent Exposure Chamber/Hot Box” is a 

chamber used to perform testing of the respirator unit, using live agent. 

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Picture 6: Exposure Chamber 

3.7 Agent Mixing Chamber or equivalent (see picture 7). This chamber is fabricated of PVC 

pipe, with caps on both ends and three baffles fixed inside to ensure mixing of chemical 

warfare agent vapor and air. A pressure gauge, mounted on the mixing chamber, indicates 

internal mixture pressure and serves as a safety pressure indicator. Maximum pressure is 

indicated per laboratory standard operating procedures. A heating blanket is wrapped 

around the chamber to facilitate chemical vaporization. This is the primary mixing area that 

allows the chemical agent syringe pump flow and the regulated air flow from the Miller 

Nelson controller to mix and generate a specified concentration of chemical warfare agent. 

When the mixture is not being passed into the exposure chamber for a test, it is passed 

through a scrubber filter (an M18 military specified canister or equivalent). 

 

Picture 7: Mixing chamber 

3.8 Breather Pump, Model E1R1 or equivalent (see picture 8). Manufactured by Jaeco Fluid 

Systems, Inc., it is a breather pump used to replicate breathing. It is a double cylinder 

pump, operated by a single electric motor. The pump incorporates a variable speed motor 

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resulting in an adjustable stroke frequency. Planetary gears and a Scotch Yoke, producing a 

sinusoidal breathing pattern, control the pump. The sinusoidal pattern starts at zero flow 

rate, rises to peak flow of approximately π (3.1416) times the rated test certification flow 

rate in L/m and drops back to zero. The exhalation stroke of the pump is the same 

sinusoidal pattern. The volume per breath /tidal is adjustable up to 1.5 liters. 

Picture 8: Breather Pump 

3.9 Mass Flow Controllers or equivalent. Manufactured by Tylan Electronic or Brooks 

Instruments. Mass flow controllers are used to control the flow of sample to the 

MINICAMS and the flow of laboratory air to flush out the exposure chamber when the 

agent challenge is removed. The mass flow controllers are sized to meet the flow 

requirements. Flows are controlled to ± 2% of set point. Photo not provided. 

3.10 Hydrogen Flame Emission Detector (HYFED) Model SA 260 or equivalent. The HYFED 

Model SA 260, manufactured by Columbia Scientific, monitors the intensity of light 

emitted by sulfur or phosphorus chemical species as it passes through a hydrogen rich 

flame. A high detection specificity and sensitivity of the analyzer is achieved by a special 

geometric arrangement of the burner and the use of a narrow band pass optical filter (394 

nm for sulfur and 526 nm for phosphorus compounds). The chemiluminescent emission 

intensity is measured by a stabilized photomultiplier tube (PMT). The current output of the 

PMT is converted to voltage by a logarithmic electrometer amplifier, filtered, processed, 

and buffered to drive the instrument output. The HYFED can detect a wide range of agent 

concentration. Picture 9 is an illustration of the Hydrogen Flame Emission Detector 

(HYFED), Model SA 260. 

 

 

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Picture 9: Hydrogen Flame Emission Detector (HYFED), Model SA 260 

3.11 Respirator Systems Required for Testing. 

3.11.1 REQUIRED TIGHT FITTING PAPR QUANTITIES: Number of tight fitting 

PAPRs required for HD Live Agent Testing (LAT) is three (3) complete 

respirator systems. Initially, one (1) complete PAPR system which has not been 

subjected to Durability Conditioning is required for the HD “Qualifier 

Application”. Upon confirmation that the PAPR successfully passed the Qualifier 

Application HD Test, two (2) additional PAPRs shall be tested for HD 

“Remainder” LAT after they have been subjected to Durability Conditioning in 

accordance with CBRN PAPR Statement of Standard. 

Note: Canisters that were subject to the drop test during the durability 

conditioning shall be used in the remainder LAT. 

3.11.2 REQUIRED LOOSE FITTING PAPR QUANTITIES: Number of loose fitting 

PAPRs required for HD LAT is three (3) complete respirator systems. The loose 

fitting PAPRs shall not be subjected to durability conditioning prior to the LAT. 

3.11.3 PAPR Power Requirements: In order for the PAPR to be tested for the entire test 

duration of eight (8) hours, the laboratory shall integrate a power supply 

delivering the correct voltage and current so that the PAPR operates at the rated 

flow for the entire test duration. The manufacturer will be required to supply the 

correct rated battery voltage for their PAPR system. The manufacturer will also 

be required to supply a means to connect their PAPR system to the power supply 

(power leads), and wire termination instructions. The length of the power leads 

will range from 8 to 11 feet. The wire termination instructions will identify the 

PAPR model, instruction on wire termination, any special power limitations and 

clearly specify the correct rated battery voltage. 

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3.11.4 QUALIFIER LAT: HD Live Agent Test canisters, hoods, facepieces, blower 

units and accessories should be received from the appropriate NIOSH/NPPTL 

sanctioned source. No alterations to canisters are authorized prior to or during 

live agent systems testing. No use of duct tape or 100mph tape over inlet and 

outlet areas is authorized in lieu of no caps or missing caps. At NIOSH/Tenant 

Laboratory initial certification qualifier application inventory, canisters received 

in the Minimum Packaging Configuration are required to be plastic bagged, 

regardless of type of original packaging, and delivered to LAT lab upon 

completion of satisfactory certification inventory. 

3.11.5 REMAINDER LAT: Start of HD Remainder LAT is contingent upon testable 

PAPR systems completing all required NIOSH/NPPTL CBRN PAPR Durability 

Conditioning. Durability Conditioned canisters will be attached per 

manufacturer instructions to available compatible application PAPR assemblies 

prior to live agent testing by qualified and designated laboratory technicians only. 

Environmentally Durability Conditioned canisters should be received in an air 

tight durable re-sealable bag and administratively labeled with the date the 

Durability Conditioning test started, completed, type of damage if any observed, 

manufacturer and laboratory responsible individual for the Durability 

Conditioning, phone number and laboratory name. Only the manufacturer’s inlet 

and outlet plugs that come with the canister are to be used to seal up the canister 

after Durability Conditioning. If no plugs are provided, no other form of sealant 

is authorized Any canister damage during Durability Conditioning is required to 

be preserved, not altered, and noted on administrative markings for shipment to 

LAT lab. 

3.11.6 Annotation: HD Live agent systems test canisters and blower assemblies should 

be labeled prior to actual Live Agent Testing with the following administrative 

information: 

- NIOSH Task Number (TN Number) from NIOSH DEIMS. 

- Model of PAPR from NIOSH DEIMS. 

- Other routine information that will allow the lab to accurately track 

receipt, time in test, test results, noted observations, required retest, 

status of testing, disposal and trend analysis is required to be 

managed and available for review upon request by current 

representative of NIOSH/NPPTL. 

- Accurate labeling of post-tested respirators is mandatory in support 

of post-test incident investigations. 

4 TESTING REQUIREMENTS AND CONDITIONS:

4.1 Prior to beginning any testing, all measuring equipment and instruments to be used must have 

been calibrated using a method traceable to the National Institute of Standards and 

Technology (NIST) in accordance with the manufacturer's calibration procedure and 

schedule. 

 

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4.2 System Test Conditions: 

4.2.1 Breathing Machine: 

4.2.1.1 Breathing Machine Requirement (Both Constant Flow and Demand 

Response) 

Airflow = 40 liters per minute 

Respirations = 36 +/- 2 strokes per minute 

Tidal Volume = 1.1 liters 

 

4.2.2 Miller-Nelson airflow settings into exposure chamber: 

Airflow Rate: The actual value here is experiment/method 

dependent. The value eventually used must be documented. 

Determine an appropriate airflow rate based upon obtaining a stable 

concentration, the known volume of the exposure chamber, 

considering the agent challenge concentration desired, volume of 

chamber, breather air flow, PAPR blower rate and dilution air 

exhausted from the PAPR. 

 

Relative Humidity: 50 ±5% RH 

Temperature: 25 ± 3o

C 

4.2.3 SMARTMAN Sampling Point: 

 Breathing zone sampling point is a single SMARTMAN nasal port that 

allows sequential dual MINICAMS detections. 

4.2.4 Mustard (HD) Exposure Test: 

 

4.2.4.1 HD Vapor: General

Vapor Challenge Concentration = 50 mg/m3 ± 10% 

Time (disseminator on) = First 30 minutes, but no longer than 31 

minutes. 

Monitor & Hold Time = 7.5 hours 

Total Test Time = 8.0 hours 

Syringe Injection Rate = as required based upon syringe pump used 

and PAPR flow rate. 

Syringe Injected Volume = as required based upon syringe pump 

used and PAPR flow rate. 

4.2.4.2 Mustard (HD) agent vapor generated is required to be Chemical 

Agent Standard Analytical Reference Material (CASARM) grade. 

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Agent purity analysis must be NIST traceable, documented and meet 

CASARM agent purity requirements. Proper CASARM storage 

requirements per local regulation are required to be adhered to. 

4.2.4.3 Vapor test termination is at the indicated eight (8.0) hours plus 

required check shots before and after entire test period. In the interest 

of conserving agent quantities and preserving technician man-hours, a 

live agent test is terminated if at any point in the entire 8 - hour period 

the respirator detection methods for the breathing zone can show 

repeatable system failure within the pass/fail protocol described in 

this current STP. This failure is required to be witnessed by a 

minimum of two qualified laboratory personnel and noted in the 

laboratory journal for follow on documentation. 

4.2.4.4 Vapor challenge concentration exposure will start immediately after 

the test chamber has been sealed properly. 

4.2.4.5 HD LIQUID: GENERAL (ONLY TIGHT FITTING PAPR’S) 

Drop Size: 20 microliters (μl). 

Liquid Challenge Concentration: Minimum is 0.43 milliliters (22 drops 

of 20 μl each) and maximum is 0.86 milliliters (43 drops of 20 μl each) 

depending on type of respirator tested. 

Droplet Allocation: There shall be 25 drops applied to the facepiece 

whether it is a face-seal type or a neck-dam type with or without 

hydration facility. There shall be 7 to 18 applied to components such as 

the blower, breathing hose(s), multiple canisters, a communications 

device interface, an electrical power interface and other noted critical 

interfaces as determined by NIOSH/NPPTL during configuration 

analysis. 

Droplet Schematics: Three (3) NIOSH/NPPTL Schematics of HD Agent 

Droplet Placement for CBRN PAPR Application (Facepiece Mounted 

and Non-Facepiece Mounted) are attached. 

 

The listing is as follows: 

Appendix A: Tight Fitting Hood with Tight Fitting Neck Dam 

Type 

Appendix B: Chin/Cheek Style, Monocular 

Appendix C: Non-facepiece mounted blower assembly, Biocular, 

Multiple Canisters, Belt or Strap Mounted Canister Housing, 

Hose Assembly, Drink Component, Communications Interface, 

and Housing Power Source Interface with Battery/Power Source 

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installed. If respirator is monocular, substitute monocular droplet 

sequence for lens area as specified in Appendix B. 

 

External Shroud or Hood: Use of an external shroud or hood attached to 

the facepiece does not represent the worst case configuration and will 

therefore be removed, if possible, prior to live agent testing. Facepiece 

second or third skins or layers must be explicitly specified in the 

application submission as a required part of the CBRN PAPR 

configuration prior to live agent testing. If they are not, the worst case 

that will be tested is with the second skin removed. If a hood or shroud 

is permanently attached to the facepiece the respirator requires 

contamination droplets to be placed on those areas of the shroud 

covering the areas of the depicted facepiece diagram. Droplet 

application on a shroud stresses the same facepiece areas identified for 

the non-shrouded facepiece but instead of droplet applications being on 

bare facepiece material they are on the shroud covering that depicted 

area/seam/joint/interface. All other defined criteria apply. 

Total Test Time: The total test time of this test is 8 hours. Test start 

time, Time Zero, begins when the first confirmed vapor is applied to the 

interior of the agent exposure chamber. 

Liquid Time: HD liquid agent is applied to PAPR at hour six (6) mark of 

the Total Test Time. Total time that CBRN PAPR candidate system is 

exposed to both HD vapor and HD liquid (Liquid Time) is two (2) hours, 

the last two hours of the total eight (8) test time period. 

4.2.5 Test Termination Parameters: The termination of the HD liquid application test 

is in accordance with the total liquid/vapor test duration time of 8 hours plus the 

before and after test check shots. The test will be terminated to protect the 

detectors from over-saturation provided a candidate PAPR shows failing criteria 

prior to the eight (8) hour mark. The termination point should be set at or above 

the highest calibration point for each one of the MINICAMSs in use. 

4.3 Safety and Training: Normal laboratory safety practices are required. Laboratory specific 

regulations such as US Army Regulation 50-6, Chemical Surety apply as required. The 

practices include all safety precautions described in the current Occupational Safety & Health 

Facility Laboratory Safety Manual, the applicable US Army Regulations, the U.S. Army 

Soldiers and Biological Chemical Command Laboratory Safety Procedures, and any other 

equivalent manuals/periodicals. 

4.3.1 Safety glasses, lab coats, assigned respirator, butyl apron and butyl gloves are 

required to be available/worn as laboratory standard operating procedures apply. 

4.3.2 Work and walking surfaces must be maintained free of clutter and non-essential 

test equipment. 

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4.3.3 When handling any glass laboratory equipment, laboratory personnel must wear 

approved gloves, which are rated appropriately in accordance with current safety 

and hygiene plans. 

4.3.4 Laboratory personnel are required to be trained on this STP and documentation is 

required to be available for review of said training. Personnel are required to be 

trained and qualified per local requirements in all applicable standard operating 

procedures (SOP) appropriate for the test. 

4.3.5 Test personnel must be knowledgeable about the specific CBRN PAPR being 

tested and should be able to readily identify all CBRN PAPR hardware 

components, subassemblies and accessories and be able to support accurate 

troubleshooting of the CBRN PAPR and subassemblies to ensure it is operating 

properly in accordance with the manufacturer’s operating instructions. Test 

personnel must be able to properly align and fit the respirator facepiece on the 

SMARTMAN headform without malformation or destruction of any CBRN 

PAPR material. 

4.3.6 All LAT equipment passing or failing these NIOSH test protocols will be treated 

as hazardous materials in accordance with local laboratory procedures and 

methods. Disposal of such contaminated CBRN PAPR materials is the 

responsibility of the testing laboratory. In accordance with this STP, respirator 

manufacturers are released of equipment accountability in accordance with local 

testing lab test equipment procedures per Department of Defense HAZMAT 

protocol. 

4.3.7 Lab procedures outlined in applicable SOPs are required to be on hand. Annual 

training classes focus on the familiarization of required occupational safety and 

health subjects in accordance with specified surety lab procedures. 

4.3.8 Refer to appropriate Material Safety Data Sheets, manufacturer’s instructions and 

available current Health and Safety manuals, or other appropriate documentation 

for the proper protection and care in handling, storing, and disposing of the 

contaminated respirators, canisters, subassemblies and chemicals used in this 

procedure. 

4.4 EQUIPMENT PRE-TEST CONDITIONS : MINICAMS 

4.4.1 Background Reading: A Laboratory MINICAMS, as opposed to a Field 

MINICAMS, is used as the detector for agent penetration/permeation into the 

CBRN PAPR. It consists of a monitor, personal computer, Linear Mass 

Flowmeter and optional printer or recorder. Before the PAPR is placed on the 

exposure SMARTMAN, the MINICAMS are required to show steady state 

background readings lower than the lowest point on the current MINICAMS 

calibration curves. This is accomplished per local laboratory procedures but may 

involve the use of a clean M40 series protective mask mounted on the 

SMARTMAN head form. The SMARTMAN is then allowed to breathe for the 

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required time (8, 12, 48, 72 hours etc.) until a steady state background is 

achieved that is lower than the lowest current calibration curve point indicated on 

the respective MINICAMS performance results. The LAT for certification is not 

authorized to start without the background readings of the assigned 

SMARTMAN system (tested respirator and headform) being within the limits 

specified above. 

4.4.2 Unit of Measure: A small volume of air is drawn through a pre-concentrator tube 

containing an adsorbent material: HD sample volume is per determined value. 

Agent in the sample is adsorbed on the material. Later in the cycle the tube is 

heated to desorb the agent, which then flows through a gas chromatograph 

column to a flame emission detector. Because the total agent in the sample is 

detected at one time instead of continuously, the detection limit is much lower. 

The total quantity of agent detected is calculated back to the sample volume and 

is expressed as ng/L. 

4.4.3 Sample Cycle: Operation of the MINICAMS requires the use of compressed air, 

hydrogen, and nitrogen of a high purity in accordance with the users manual. 

The operating manual recommends operating parameters (temperature, timing, 

pressures, etc.) and cycle times (3, 5, 10 or 15 min.), depending on the laboratory 

application. CBRN PAPR HD analysis requires a total 6-minute cycle (3 minute 

sample followed by 3 minute purge per detector). The two MINICAMS are 

required to be synchronized so that one MINICAM sampling begins when the 

other MINICAM sampling ends. Raw data results confirm this requirement. 

4.4.4 HD Detection Principle: The MINICAMS is installed in accordance with the 

operating manual and local lab SOP. The appropriate optical filter for HD must 

be installed in front of the photomultiplier tube. In principle, when HD burns in a 

hydrogen flame, a chemical element (sulfur) is formed that emits radiation at a 

unique wavelength. The optical filter isolates the radiation and allows it to pass 

into the photomultiplier tube (PMT), whose output voltage is correlated with the 

quantity of agent burned in the flame. 

4.4.5 Standardization: MINICAMS are configured in accordance with the operating 

manual and the specific method for the chemical warfare agent that is being used. 

In order to quantify the agent in the sample, the MINICAMS must be 

standardized. Standardization is accomplished by injecting a small quantity (1.0 

or 2.0 uL) of a known standard solution of the agent onto the pre-concentrator 

tube during the INJECT segment of the test cycle IAW MINICAM calibration 

SOP. The standard solutions of agent are made in isopropanol, 

spectrophotometric grade. At least three injections of each quantity of agent 

should be injected per LAT sequence. 

4.4.6 Pretest activities for the MINICAMS are as follows: 

Set or verify operational parameters for appropriate agent 

Perform standardization 

Record ASCII file name on Data Sheet 

Standby for start of testing 

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4.5 EQUIPMENT PRE-TEST CONDITIONS: Syringe Pump 

4.5.1 A syringe pump is used to inject liquid agent into the dilution air stream at a 

controlled rate such that the concentration of agent in air is that required for the 

challenge specified for the test. Manual setting of the syringe pump controls 

allows the pump rate to be changed by using a turn knob. The syringe rate will 

depend on the airflow rate of the PAPR and must be set to maintain the required 

challenge concentration. 

4.5.2 Select the size syringe that will hold sufficient agent for the challenge period and 

the total volume of air required. Fill the syringe to the volume determined and 

attach the syringe to the fitting on the flexible cannula. The cannula is normally 

made of plastic with Luer locks on each end. One end of the cannula is attached 

to the heated tee in the dilution airline. Set the syringe in the holder and clamp it 

in place. Move the drive block until it is firmly against the end of the plunger. 

4.5.3 Set the switch on the pump to the setting required for the size syringe and the 

injection rate. Turning on the power switch will start the drive block pushing the 

plunger of the syringe to begin generating the agent challenge concentration. 

Turning off the power switch will stop the drive block from pushing against the 

plunger and stop the challenge agent concentration flow at the predetermined 

time. 

4.6 EQUIPMENT PRE-TEST CONDITIONS: SMARTMAN HD Vapor Generation 

4.6.1 Vapor Concentration: The vapor challenge for SMARTMAN testing is 

generated by injecting the required quantity of liquid agent into the volume of air 

that passes through the exposure chamber to give the challenge in mg/m3. This is 

accomplished by a combination of controlled airflow from the Miller- Nelson Air 

controller and a syringe pump for injecting the agent through a heated “tee” into 

the air stream. Determine the volume of air needed to pass through the exposure 

chamber per minute (flow rate) and the quantity of agent necessary to give the 

specified challenge concentration for this flow rate, taking into account the 

volume of air filtered and discharged into the chamber from the filtered and 

exhaled air of the PAPR. 

4.6.2 Ramp Up Time: Conditions for each individual system will have to be 

determined for each laboratory setup to achieve the required ramp up time for 

CBRN PAPR exposure concentration. The ability to accurately detect and 

quantify this agent ramp up time is a requirement for the testing laboratory and 

ramp up time and agent duration exposure time graphs will be available to 

confirm agent exposure duration in accordance with the procedures of this STP. 

4.6.2.1 Concentration Verification. (Both Constant Flow and Demand 

Response) 

- HD Setup (Mass Balance Analysis Concept or Demonstrated 

Equivalent) 

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- Chamber size = 8 ft3 

- Target Vapor Challenge Concentration = 50 mg/m3 ± 10%. 

- Ramp Up Time = 1-2 minutes (time from initial start of injection of 

HD air mixture to 50 mg/m3

, the lowest acceptable challenge 

concentration) 

- Dilution Air from Breather Pump = 40 l/m 

- Miller-Nelson Challenge Mixing Air = 50 l/m 

- Syringe Rate for Challenge Injection = [Flow Rate of PAPR 

Dependent] 

- Total HD Projected for Use in 30 minutes = 0.25 ml vapor plus 0.43 

to 0.86 ml of liquid drops (Drops are only applied to Tight Fitting 

PAPRs)

4.7 EQUIPMENT PRE-TEST CONDITIONS: Miller-Nelson (MN) Controller 

4.7.1 The Miller-Nelson unit receives compressed air from the laboratory house air 

supply system. Operate the Miller-Nelson according to the manufacturer’s 

instructions. The sensors for relative humidity and temperature must be 

calibrated, as well as the flow controller, since it is important that the total flow 

through the test system be known in order to supply the requisite amount of agent 

from the syringe pump. Insure the total flow, temperature and relative humidity 

values are logged in the technician’s lab logbook prior to commencing each live 

agent test. 

4.7.2 Set the readout panels on the Miller-Nelson according to paragraph 4.2.2. Ensure 

the Miller-Nelson is properly configured for current test procedure and all 

required airlines are secure to inlet ports of SMARTMAN and Miller Nelson 

systems. Allow the clean air to flow through the mixing chamber and the M18 

filter until it is time to start the test. 

4.8 EQUIPMENT PRE-TEST CONDITIONS: TDA-99M Aerosol Leak Detector 

4.8.1 The TDA-99M leak detector is used to detect oil particulate aerosol leaks into the 

CBRN PAPR after it has been installed on the SMARTMAN headform in the 

cold box. Ensure the canister and all components are correctly mounted and 

tightened per the current manufacturer instructions and specifications. The 

PAPR shall be operated throughout the test. Ensure that procedures for the 

PAPR follow the manufacturer’s installation procedures for gasket seal and 

facepiece donning and interface. Ensure the seal, threaded interface, inlet and 

outlet areas and canister housing are not changed in any manner prior to or 

during the live agent test. However, if the canister or canisters interface thread is 

deformed from Durability Conditioning (If applicable); continue with the test by 

attaching the canister per manufacturer instructions. Do not make any corrections 

for canister deformities at this time. Ensure the lab book is annotated and digital 

photos are taken / available for follow up incident review if necessary. 

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4.8.2 Turn on the power and let the leak detector equilibrate, according to the 

manufacturer’s instructions. The PAPR should be placed into operation mode 

(blower operating). Turn on the breather pump to activate the negative pressure 

test respirator. Connect the detector inlet to a sample line from the 

SMARTMAN. When aerosol is being generated, direct the wand to various 

portions of the facepiece and all mechanical seals or joints to detect any leak 

paths. If no localized leaks are found, replace the front panel of the exposure 

chamber and start the actual TDA 99M test. 

4.8.3 Connect the TDA-99M to a port on the exposure chamber and fill the chamber 

with aerosol. Maintain a constant aerosol concentration inside the exposure 

chamber for 30 minutes. Check the display on the TDA-99M for detection of 

aerosol inside the facepiece. When the detector indicates a maximum penetration 

of less than 0.0010% for 30 minutes which indicates no leakage, continue with 

the next item in the LAT procedure; however, if 0.0010% cannot be obtained and 

there are TDA-99 reading fluctuations due to residual particles from the PAPR 

manufacturing process, the laboratory manager shall make a determination 

whether a true leak exists or residual particles are being detected. If there is 

evidence of leakage, attempt to find and eliminate the leak. If leakage or 

contamination is detected, it is at the laboratory manager’s discretion whether or 

not to continue with the test. Annotate the lab book with description and 

decision. 

4.9 EQUIPMENT PRE-TEST CONDITIONS: Quality Control Measures. 

4.9.1 SMARTMAN Leak Test Without Respirator Mounted: Because the 

SMARTMAN is made of cast zinc, it is possible for leak paths, after extensive 

LAT or incorrect assembly, to form through the metal casting, allowing chemical 

warfare agent vapor to pass through the headform cavity into the interior of the 

respirator mounted on the headform. To check for these invisible leak paths, 

install a clean peripheral seal on the headform and inflate it to the recommended 

static pressure value. Flood the interior of the headform with a known rated 

helium concentration and purity. Use the probe of the helium leak detector to 

check the entire surface and the seal for presence of helium. Any leak found by 

the helium leak probe procedure must be diagnosed and eliminated, if possible. 

The leak test is to be performed initially on each new or reconditioned 

SMARTMAN and monthly on the SMARTMAN head-forms when they are in 

continuous daily use. 

4.9.2 Standardization of Instrumentation: Standardize the MINICAMS by using liquid 

standard solutions of the agents at various concentrations. These solutions are to 

be made in accordance with US Army, ECBC CAT IOP #214, “Preparing 

Standard Agent Solutions for Instrumentation”, or equivalent laboratory 

procedures. A stock solution is the primary solution made by weighing a 

quantity of agent into a volumetric flask and diluting to volume. This solution 

may be used for two weeks, unless deterioration is noted before that time. The 

stock solution is diluted further to make a series of standard solutions that are 

used to standardize the MINICAMS. The standard solutions may be used for one 

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week, unless MINICAMS analyses indicate that the solutions are deteriorating. 

Class A glassware must be used for all volumetric work. Calibration curves 

should have a minimum correlation of r2

 = 0.99 for HD. Agent solutions must be 

stored at recommended surety storage temperatures. 

4.9.3 Calibration of Flows: Since flow rates are used in several aspects of this test, it 

is necessary to use calibrated flow meters to set the flows used in the instruments. 

Flow meters are calibrated by the US Army Test Methods & Development 

Equipment (TM&DE) and Metrology Laboratory, in accordance with ISO 17025 

procedures or equivalent and use instruments traceable to NIST. Flow meters to 

be checked against calibrated meters are the Miller-Nelson Air Flow Controller, 

all electronic flow meters used for the MINICAMS pre-concentrator tube and the 

flow meters from the breather pump and the syringe pump agent injector. 

4.9.4 Aerosol Leak Testing: PAPR leak testing using the TDA-99M Aerosol Tester is 

performed on the facepiece after installation on the SMARTMAN and while the 

breather pump and PAPR are operating. Allow the TDA-99M to stabilize in its 

initial detection procedure. When readings are stable within ±2 end place digits 

of 0.0000, the TDA-99M Aerosol Tester is ready to begin detecting potential leak 

paths. If there is no leak, the display on the TDA-99M should read 0.0000 % 

penetration. Values of 0.0009 to 0.0001% penetration of particulate are 

acceptable. 

4.9.5 MINICAMS Detector Response: Check the response of the MINICAMS 

detector, before and after each LAT. This is done by injecting an aliquot of 

standard solution that contains a known concentration of agent near the midrange of the standard curve. Inject the aliquot into the end of the heated sample 

line from the oral-nasal sampling port; it is necessary to disconnect the line from 

the bottom of the chamber to do this. This is called a “check shot”. Repeat it at 

the end of the test to assure that the detector response has not changed during the 

test. The response of the detector should fall on the standard curve at the value 

expected for the amount of agent in the aliquot, or within 10% of that value. 

Record results of check shot in Laboratory Notebook. If the check shot does not 

reproduce a verifiable result, repeat the check shot. If the second check shot is 

not within the 10% parameter, the test is invalid. A quantifiable check shot 

should be made at the maximum, within 3 hours of the start of the actual test and 

at the PAPR end of test eight (8) hour mark. 

5 PROCEDURE (HD Liquid/Vapor Challenge (0551)):

5.1 HD LAT (0551) 

5.1.1 Assemble PAPR per manufacturer’s instructions. After Durability Conditioning, 

if applicable, conditioned canisters that were not stored in the PAPRs Minimum 

Packaging Configuration (Inside PAPR carrier or case) shall be placed on the 

PAPR and tested. With the house power supply delivering the rated voltage and 

current connect the PAPR and verify operation. 

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5.1.2 Take digital photographs of the assembled unit prior to start of LAT. These 

photographs are required to be available for NIOSH/NPPTL review and they 

should accurately and clearly indicate how the actual manual placement of the 

HD droplets occurred at the six (6) hour mark, prior to resumption of vapor 

testing. 

5.1.3 Mount the respirator on the SMARTMAN in the clean exposure chamber. The 

facepiece should be mounted to the SMARTMAN per the manufacturers’ 

operating/user instructions with special emphasis on head harness fitting and 

canister tightness. Ensure all parts of the facepiece are mounted / seated correctly 

on the headform. Turn on the PAPR blower: Refer to section 3.11.3 for PAPR 

power requirements. If a shroud or other accessory is being tested as part of the 

respirator system, ensure that they are mounted properly and serviceable. 

Visually inspect all accessories at the termination of the test for visible cracks 

and/or breaches of the airflow boundary, such as compromises of form, fit or 

function. 

5.1.4 Turn on the breathing pump (See Requirements in Paragraph 4.2.1. for the 

prescribed breathing rates). Use the integrated SMARTMAN Magnehelic®

pressure gauge as required as a qualitative indicator of PAPR performance, and 

can also serve as a tool for observation purposes. 

5.1.5 Using the TDA 99M, leak test the PAPR in the operational mode (blower 

operating). Connect the detector inlet to a sample line from the SMARTMAN, 

allow the PAPR to breath, and create a stable value on the TDA-99M. When the 

aerosol is being generated, direct the wand to various portions of the facepiece, 

blower, mechanical seals and joints to detect any leaks. The aerosol will be 

detected inside the facepiece if it finds a leak path. If any leaks are found, they 

must be corrected by the authorized laboratory technician or manager only. If a 

leak is found through the canister, connect a clean airline from outside the 

exposure chamber. If no localized leaks are found, replace the front panel of the 

exposure chamber. Connect the TDA-99M to a port on the exposure chamber 

and fill the chamber with the aerosol challenge. Maintain the aerosol challenge 

inside the chamber for thirty (30) minutes of continuous TDA-99M operations 

below 0.0010% penetration. If penetration exceeds 0.0010%, the TDA-99M 

alarm sounds, and/or the digital readout shows higher values, stop the 30 minute 

test, reanalyze the system and restart a new 30 minute test period. The PAPR 

must pass a continuous 30 minute test at ≤ 0.0009 % penetration parameters in a 

separate clean exposure chamber and an agent exposure chamber to be 

considered “qualified” to proceed with the agent testing. If after repeated 

attempts a successful leakage test cannot be achieved, the laboratory manager 

may use alternative means to seal the facepiece to the headform such as sealing 

the facepiece and nose-cup to the headform using non-toxic adhesive with the 

concurrence of NIOSH/NPPTL. Other methods such as allowing the respirator 

to purge itself of internal off-gassing particulates are acceptable provided the 

purge time is not excessively long. Repeated tests using the TDA-99M on the 

same tested respirator are not recommended and identified respirators are subject 

to being replaced to allow test progress. All adhesive designated for CBRN 

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certification use is required to undergo verification testing (V-Test) prior to use 

as a CBRN LAT capable substance (Successful performance to the given STP 

using three consecutive V-Test trial samples). If the respirator continues to fail 

the TDA 99M, the manufacturer must supply the MSDS on the type of 

particulate being picked up by the TDA 99M and a confirmation analysis by a 

third party laboratory must confirm the manufacturer’s MSDS and the 

particulates must be determined to be non-toxic in the acute and chronic human 

toxicology perspective before a NIOSH letter of approval is issued for a passing 

LAT respirator. If the applicant requests to continue despite the high TDA 99M 

readings, the testing laboratory manager has the option to continue the test or 

terminate the test based upon the inability of the respirator to pass the TDA 99M 

indicator screening test. 

5.1.6 Before the PAPR facepiece or hood can be placed on the SMARTMAN in the 

agent exposure chamber, the MINICAMS must have shown a steady state 

background lower than the lowest point on the calibration curves. This is 

accomplished by installing a M40 series protective respirator on the 

SMARTMAN. Ensure a new or sanitized/decontaminated M40 mask is used. 

The SMARTMAN should be allowed to breathe until a steady state background 

is achieved. The use of the M40 may or may not be equivalent to the actual use 

of a tested respirator on the headform, therefore in test situations were 

background is not stable use all means necessary to gain a steady state 

background before starting LAT. 

5.1.7 Remove PAPR from clean exposure chamber and install on SMARTMAN in the 

HD agent exposure chamber. 

5.1.8 Mount the respirator on the SMARTMAN in the agent exposure chamber. 

Conduct a TDA-99M 30 minute test by repeating steps of paragraph 5.1.5, with 

the exception that once the agent exposure chamber is sealed and no leaks are 

confirmed with the TDA-99M, the TDA-99M aerosol challenge is discontinued. 

Ensure the hotbox is purged of Emery Oil particulates for at least 15 minutes. 

Insure that the removal of the TDA-99M test hardware does not disturb the 

established seal of the PAPR facepiece to the SMARTMAN system. Remove the 

clean airline from the canister system, if it was used to isolate leaks. 

5.1.9 Turn on the Miller Nelson Flow temperature and humidity controller. 

5.1.10 MINICAMS Background Characterization. A background characterization must 

be run before every agent test. The MINICAMS should be monitored for a 

period of 60 minutes prior to the initiation of the chemical warfare agent test. 

Confirm that background level is less than the lowest point on the MINICAM 

calibration curve. If the background level is not less than required, troubleshoot 

the SMARTMAN system, do not start the test, advise laboratory manager and if 

necessary remove the PAPR facepiece or hood, rinse the headform with 

isopropyl alcohol, re-don the facepiece or hood and restart the procedure for 

characterization as necessary. If the PAPR is removed from the head form, 

restart the test procedure from paragraph 5.1.8. 

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5.1.11 Set up standard operational mode of test equipment. Ensure all test equipment is 

within calibration. 

5.1.12 Set Miller-Nelson for airflow into exposure chamber set to deliver required rates. 

See paragraph 4.2.2. 

5.1.13 Ensure MINICAMS are calibrated; check shot is complete and acceptable and 

ready for the operating mode. Annotate the check shot times and concentrations. 

5.1.14 Ensure that the challenge concentration instrument is calibrated and is ready for 

analysis. Monitor agent exposure chamber during the 60 minutes background 

characterization period. Characterization reading should reflect a steady state 

condition. Exposure chamber ambient atmosphere detector should be on during 

baseline determination. 

5.1.15 Load liquid agent in syringe and set syringe pump to correct flow rate to achieve 

the required agent challenge concentration. See paragraph 4.5. 

5.2 HD Vapor Application: (Both Tight and Loose Fitting PAPR’S)

The breathing rate requirement for both constant flow and demand response 

PAPRs is 40 lpm (36 +/- 2 strokes per minute) during the entire 8 hour test. 

5.2.1 Time zero + One second or start of the agent test is when the first confirmed 

vapor state of HD is applied to the interior of the exposure chamber while the 

MINICAMS are actively sampling. Vapor is pumped in for 30-minutes, turned 

off and agent decay cycle is monitored for 5.5 hrs. 

5.2.2 Ensure the breathing pump is set at 40 lpm for the entire duration of the test. Start 

of the 30 minute vapor exposure is when HD vapor is injected into the HD 

exposure chamber and initially detected. Annotate this starting time. Ensure 

time management is accomplished and allows the efficient tracking of two 

simultaneous events: one clock for total test time from start of HD exposure for 8 

hours and another clock for HD Vapor at 30-minutes. If necessary, the vapor 

clock can convert to the liquid agent clock at the six (6) hour mark. 

5.2.3 Introduce HD vapor agent challenge to the agent exposure chamber by first 

starting the syringe pump and turning the valve inline from bypass of the mixing 

chamber to direct flow from the mixing chamber to the internal ambient space of 

the agent exposure chamber. Using the appropriate Miran detector, monitor the 

concentration build up in the exposure chamber generated by the mixing 

chamber. The total flow to the mixing chamber from Miller Nelson is dependent 

on the airflow rate of the PAPR, which includes enough excess to make up for 

the clean air exhausted from the PAPR into the exposure chamber and maintain 

the constant challenge as required. The syringe flow rate is set to introduce the 

quantity of agent necessary to generate the challenge concentration required. 

Record when the MINICAMSs begin monitoring the interior of the facepiece.

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5.2.4 The vapor syringe pump should run for the prescribed challenge period of 30 

minutes, but no more than 31 minutes. At the end of the challenge period, turn 

off the syringe pump. Record the total volume used by the syringe pump, the 

elapsed time and the airflow rate delivered from the Miller-Nelson. These values 

will be recorded in the laboratory notebook. Ensure syringe flow is off and the 

mixing chamber airflow line is bypassed so Miller-Nelson uncontaminated air is 

flowing to the agent exposure chamber, simulating weathering. 

5.3 Liquid Application of HD droplets: (Tight Fitting PAPRs Only)

5.3.1 At the six (6) hour mark, liquid droplets are applied in a pre-defined manner to 

the PAPR. Liquid drops are delivered to the surface of the PAPR to test 

permeation of material surfaces. A minimum of 32 and maximum of 43 droplets 

(size of 20 micro liters each) are specified. Placement of the droplets, via syringe 

on to the system is specified in Appendices A, B or C. The droplets will be 

placed on the equipment per the numerical sequence and applicable 

note/nomenclature inserts on the enclosed appendices. Photographs of this 

manual droplet application must be maintained in the Task Folder. The exposure 

chamber is resealed as fast as possible and remaining test cycle time and 

detection operation proceeds up to the eight (8) hour mark. 

5.3.2 The droplet placement sequence will be starting at the top of the faceblank, 

working left to right, to the bottom of the face blank following the number 

sequence marked on Appendix A, B, or C. Prior to actual droplet application, 

technicians should prepare by marking location of actual droplets on a digital 

photograph of the equipment being tested and use this “dotted” schematic during 

the course of testing. If an external shroud is permanently mounted on the face 

blank, apply droplets per standard schematic based on respirator configuration 

but on surfaces of the shroud that mirror the routine face blank areas. If not 

permanently affixed, remove the shroud prior to test. Droplet application should 

be expeditious, safe and done in a timely manner. Annotate the Time Zero + One 

Second and the HD liquid application time period and liquid exposure time. 

Visual observation of the tested PAPR for the last two hours of testing is highly 

recommended. 

5.3.3 Actual guidelines for identification of test configuration for exposure to GB/HD 

are stated in the current version of the CBRN PAPR Statement of Standard. Two 

primary concepts are stated. The first is on unique parts, components and/or 

materials, that form an air pressure boundary between the breathing gas/air and 

the ambient environment, need to be tested. The second is unique parts, 

components and/or materials that have a direct effect on the ability of the 

respirator to provide respiratory protection, such as a facepiece head harness, 

exhalation valves, inhalation valves, head harness mounts, faceblank seals, 

canister interfaces, canister housings, eye lens interfaces with locking rings, side 

voicemeters and/or plugged areas, need to be LAT/tested. The test configuration 

should conform to one of the enclosed HD droplet schematic appendices. Slight 

variation is allowed provided it is clearly identified. If the test configuration does 

not conform, notify NIOSH/NPPTL, provide a digital photograph of the 

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respirator if required to NIOSH and await a new NIOSH droplet application 

schematic prior to LAT. 

5.3.4 Once the last droplet is applied, conduct a visual check of the breathing PAPR to 

ensure it is operating properly, no parts or accessories are out of place and that 

there is no immediate destruction of material due to the recent exposure to HD 

droplets. Mount the front panel of the agent exposure chamber. If PAPR starts 

to disintegrate immediately during or just after droplet application occurs, finish 

the droplet application process and close up the box immediately. Allow the test 

to run, monitoring the pass/fail criteria and terminate in accordance with 

paragraph 4.2.5. 

5.3.5 A detector is used to monitor the challenge concentration in the exposure 

chamber. This will be recorded on a computer with compatible software capable 

of accurately depicting the agent concentration versus time. 

5.3.6 System Hold or Agent Decay Monitor Time involves the continuance of flushing 

the agent exposure chamber with the Miller-Nelson uncontaminated air to allow 

the simulation of the natural effects of ambient environmental conditions 

including the persistent vapor effects of HD. 

5.3.7 Test Surveillance: The laboratory technicians should monitor the entire test to 

make sure all components of the system function, collect data as required and 

monitor the breakthrough concentration to protect the MINICAMS against 

saturation. If the system is failing, the MINICAMS must capture three maximum 

peak excursions (0.030mg/m3

) to document the PAPRs failure before 

MINICAMS can be taken off line from detecting. 

5.4 Procedures for Termination of Test: 

5.4.1 The test should be terminated when the full time for the test has elapsed or three 

confirmed quantifiable consecutive maximum peak excursions are verifiable. The 

pass/fail criteria on cumulative concentration (Ct) are determined after eight (8) 

hour completion and raw data tabulation. To terminate the test, turn off breather 

pump. Perform a check shot of agent to ensure that the detection system is still 

operating correctly. Take an aliquot of one of the mid-range standard solutions 

of agent with a micro-liter syringe and inject it into the nasal sampling port by 

injecting the line at the bottom of the exposure chamber. The MINICAMS 

response should be that indicated on the standard curve for the amount of agent 

contained in the aliquot. The response must be within 10% of the correct value 

for the final check shot test to be valid. 

5.4.2 Turn off the MINICAMS per laboratory SOP. Turn off Miller-Nelson airflow 

through the exposure chamber. Remove the test respirator; separate it into 

components as necessary and double-bag the components in accordance with 

laboratory SOP. Remove the bagged components to the decontamination hood 

for temporary storage. The test respirator will then be decontaminated, 

monitored and disposed according to laboratory SOP. Wipe down the interior of 

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the agent exposure chamber and the SMARTMAN using approved cleaning 

solution. Dispose of cleaning materials according to laboratory SOP. Test 

Service Agreements (TSA) between the manufacturer and the test laboratory on 

materials swatch testing or entire respirators is authorized off line from the 

timeline of the conduct of this standardized test procedure. However, in support 

of the TSA testing concept, the NIOSH/NPPTL CBRN Respirator Research and 

Development (R&D) Test Program, current letter, provides for prioritized use of 

dedicated NIOSH test equipment in support of research and development that is 

separate and distinct from certification. 

5.4.3 Example Step Sequence of activities for HD liquid and vapor CBRN PAPR test. 

Note: Loose fitting PAPRs are not durability conditioned prior to LAT 

testing. 

1. Conduct M40 preparation and background contamination 

assessment. 

2. Install PAPR in clean exposure chamber. 

3. Close clean exposure chamber, ensure PAPR blower is 

operating. 

4. Challenge clean PAPR with TDA-99M for 30 minutes 

5. Verify that clean PAPR has passed TDA-99M, retest/refit, go to 

next step or if failure, substitute failed PAPR with a new 

untested PAPR. Ensure an environmentally pre-tested canister 

or a qualifier canister is used and properly labeled for LAT. 

6. Install PAPR in agent exposure chamber. 

7. Photograph PAPR. 

8. Close agent exposure chamber, ensure PAPR blower is operating 

and start breathing pump. 

9. Challenge PAPR with TDA-99M for 30 minutes in the hot box. 

10. Start MINICAMS. 

11. Monitor background inside the mask and do chamber 

concentration/check shot. 

12. Conduct characterization for 60 min. 

13. Ensure front panel is readily available for replacement on agent 

exposure chamber 

14. Start makeup air using Miller-Nelson Controller while 

simultaneously starting ambient challenge concentration 

detection profile software, if not already started. 

15. Start syringe pump. 

16. Record start time of MINICAMS. 

17. Initiate challenge agent 

18. Record 30-minute vapor start time. 

19. Record challenge agent start time, vapor exposure. 

20. PAPR breathing rate will remain at 40 lpm (36 ± 2 strokes per 

minute) throughout the entire eight hour test. 

21. Ensure chamber ambient challenge concentration is ramping up 

as expected. 

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22. Monitor MINICAMS for detection, noted penetration peaks and 

saturation prevention. 

23. Stop syringe pump at 30-minute mark, but no later 31 minutes. 

24. Record stop time for challenge agent vapor exposure. 

25. Record hold time start (7.5 hours). 

26. At 5.5-hour mark conduct final preparations for HD droplet 

application. (Tight Fitting PAPRs Only)

27. At the six (6) hour mark apply droplets per required appendix. 

(Tight Fitting PAPRs Only)

28. Monitor PAPR for visible cracks, catastrophic breakage or 

failure criteria. Monitor clock exposure times, do not exceed 8 

hours total and ensure respirator does not convert to positive 

pressure for any reason. Testing laboratory is responsible for 

meeting all STP compliance requirements concerning test time; 

check shots, concentrations and pass/fail criteria assessment and 

determination. 

29. Eight (8.0) hours, end test. 

30. Record end time and local time at 8.0 hours 

31. Conduct check shot instrumentation 

32. Record check shot results and time of last end of test check shot. 

33. Prepare system for decontamination and removal of tested 

components. 

5.5 Data Analysis

5.5.1 Lead technician is responsible for accurately maintaining a laboratory notebook 

and all required records. Hardcopies of data should be annotated when pertinent 

events occur, such as a catastrophic failure, obvious airflow boundary cracks, 

accessory cracks/failure, check shots and test start/end times. Lab supervisor 

must gain NIOSH approval prior to pre-approving any deviation from NIOSH 

standard test procedure and sign off in the technician’s notebook as to the 

appropriate NIOSH approved change. Notebooks should be signed and dated, 

copies of all hardcopies of data that are generated shall be kept in the assigned 

task folder with NIOSH Task number. 

5.5.2 Laboratory manager and technician must complete all required Test Data Sheets 

in accordance with Appendix D. Originals of all test data sheets must be 

completed and retained in the task file. Test data sheets for CBRN PAPR 

candidates are managed by digital exchange of pre-formatted blank file forms 

easily transferred in standard email. No NIOSH DEIMS electronic forms exist 

for CBRN PAPR test data collection. NIOSH DEIMS, current version, will 

assign TNs, maintain the CBRN PAPR test queue and process all initial, lab and 

final reviews. NIOSH DEIMS for CBRN PAPR should be reviewed every three 

working days by the lab technician supervisor/principal investigator or 

equivalent. While an application is active and has information for update, the 

transfer of applicable files should be updated bi-daily with all applicable 

information to allow timely feedback and prevention of miscommunication. 

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5.5.3 Transfer the permeation data from the MINICAMS computer into a computer for 

analysis by Microsoft Excel. This table will contain data from the nasal area and 

associated time markers. The resulting table will each have four columns: 1) 

elapsed time 2) volume collected 3) sample collection time and 4) nanograms per 

sample. Convert the nanograms into a concentration, ng/L, by multiplying 

nanograms by a factor obtained by dividing the actual sample volume (typically 

200 mL but may be considerably less) into 1000 mL/L (Example: 1.73 ng x 

1/0.2 L = 8.65 ng/L). Convert nanograms/liter to milligrams/cubic meter by 

dividing by 1000 (Example: 8.65 ng/L / 1000 = 0.0865 mg/m3

). Ct 

(Concentration x Time) is calculated by multiplying the collection duration time 

times the concentration (Example: 0.0865 mg/m3

 x 2 min = 0.173 mg-min/m3). 

The cumulative Ct is calculated by adding the Ct value for each sample time. 

Using Excel’s Chart Wizard feature, a plot of concentration vs. time and the Ct 

vs. time can be generated and printed using all the data in the table. 

5.5.4 Challenge Concentration Data: Use the computations generated from paragraph 

5.5.3 above. Plot the challenge concentration versus time and produce two data 

graphs that track total detection events covering any maximum peak excursions 

over 8.0 hours and total concentration over time known, as Cumulative Ct, 

covering the total 8.0 hours of potential cumulative and instantaneous dosages. If 

the test is terminated prior to the completion of 8.0 hours due to PAPR failure, 

MINICAMS saturation preventive measures or other situations as outlined, 

laboratory technician supervisor or equivalent is responsible for accurately 

recording all applicable maximum peak excursions and cumulative Ct detected in 

the tested time. 

6 PASS/FAIL CRITERIA

6.1 The criterion for passing is set within the authority of 42 CFR, Part 84, Subpart G, Section 

84.63(a), (c) & (d); Volume 60, Number 110, June 8, 1995. A Two-fold pass/fail criterion 

is required for successful passing of HD testing. The criterion is as indicated in the 

Statement of Standard for Chemical, Biological, Radiological, and Nuclear (CBRN) 

Powered Air- Purifying Respirator (PAPR). 

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(i) Vapor-liquid sequential challenge of PAPR with distilled sulfur mustard (HD) 

Agent Challenge 

Concentration 

Duration of 

Challenge 

(min) 

Breathing 

Machine 

Airflow Rate 

(L/min) 

Maximum 

Peak 

Excursion 

(mg/m3

) 

Maximum 

Breakthrough 

(concentration 

integrated over 

minimum test time) 

(mg-min/m3

) 

Number of 

Systems 

Tested 

Minimum 

Test Time 

(hours) 

HDVapor 50 mg/m3* 30* 40 0.30‡

 3.0 § 3 8††

HDLiquid 0.43 to 0.86 

ml*,†, **

120* 40 0.30‡ 3.0 § 3 2 

* Vapor challenge concentration will start immediately after the test chamber has been sealed. Minimum Test Time 

for liquid exposure starts after the first liquid drop is applied. 

† Liquid Volume dependent on accessories used with the respirator. Minimum volume is 0.43 ml based on the 

respirator only. 

‡ Three consecutive sequential test data points at or exceeding 0.3 mg/m3

 will collectively constitute a failure where 

each test value is based on a detector sample time of approximately three (3) minutes. 

§ The cumulative Ct including all maximum peak excursion data points must not be exceeded for the duration of the 

test. 

** Liquid agent is applied to respirator at hour six (6) of the vapor test cycle. 

†† The test period begins upon initial generation of vapor concentration and ends at eight (8) hours. Supplemental 

electrical power to the PAPR is permissible to allow the system to run for the purpose of this test. 

6.1.1 Distilled Sulfur Mustard (HD) Penetration and Permeation Test: 

Challenge: 50 mg/m3 ± 10 % for 30 minutes (but not more than 31 minutes) 

followed by a maximum of forty three (43) 20 μl liquid droplet application at the 

6 hour mark. 

 

Test Time: 8.0 hours. 

Two-Fold Pass/Fail Criteria: 

a) Maximum Agent Breakthrough (Ct) = 3.0 mg-min/m3

. Concentration 

integrated over minimum service life is Ct and it is based on a detection 

sample time of approximately three (3) minutes for eight (8) hours. The 

Ct data value, including all maximum peak excursion data points, must 

not be exceeded for the duration of the test. 

b) Maximum Peak Excursions = 0.30 mg/m3. Three (3) consecutive data 

points at or exceeding the peak value constitutes a failure where each test 

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value is based on detection sample time of approximately three (3) 

minutes for eight (8) hours. 

NOTE: Any visible respirator deterioration in assigned material 

components such as breakage, distortion, hazing of lens, cracking or 

separation shall also constitute a system warning and qualify as a 

potential failure based upon assessment of NIOSH CBRN PAPR 

Guidelines for Identification of Test Configurations for Exposure to 

GB/HD, current version. 

NOTE: Any PAPR test that fails as a result of laboratory test equipment 

failure or malfunction, laboratory electrical power loss or incorrect 

technician operating procedures/actions will be considered by 

NIOSH/NPPTL as a test termination and requires an immediate 

mandatory retest upon lab supervisor confirmation. In this case, the 

testing laboratory, at no additional cost to NIOSH/NPPTL or the 

manufacturer concerned, retests the respirator. 

6.1.2 Precision and accuracy must be determined for each instrument in accordance 

with laboratory procedures and follow on NIOSH/NPPTL guidance to be 

published. Sound practice under NIOSH Manual of Analytical Methods supports 

a plus or minus 25% tolerance of a 95% confidence interval. NIOSH/NPPTL 

CBRN STP P&A tolerance can be higher but not lower. 

 

6.2 This test establishes the procedures for ensuring the level of respiratory protection provided 

under special Chemical, Biological, Radiological, and Nuclear (CBRN) requirements for 

Powered Air-Purifying Respirator (PAPR) submitted for Approval, Extension of Approval, or 

examined during Certification Product Audits, meet the minimum certification standards set 

forth in Title 42 CFR, Part 84, Subpart G, Section 84.63(a)(c)(d); Federal Register Volume 

60, Number 110, June 8, 1995. 

7 RECORDS/TEST SHEETS

7.1 All test data will be recorded in the NIOSH DIEMS and STP recognized formatted CBRN 

PAPR test data sheets (Appendix D). All applicable data, graphs and photographs 

taken/made by laboratory technicians, technician supervisors or the equivalent will remain on 

file at the actual lab where the test was conducted, is required to be retrievable within 24 hour 

notification and be maintained in accordance with local administrative SOPs and 

NIOSH/NPPTL Respirator Branch CET historical filing requirements. 

7.2 All videotapes and photographs of the actual test being performed by testing laboratory 

personnel, or of the test equipment shall be maintained in the task file as part of the 

permanent record. 

7.3 All equipment failing any portion of this test will be handled as follows; 

7.3.1 If a failure occurs on a new certification application (Qualifier or Remainder 

Application), testing laboratory will send a test report to the NIOSH Certification 

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Evaluation and Testing (CET) Branch Chief and await further instructions on 

required actions with any uncontaminated hardware for return to the 

manufacturer. 

7.3.2 If the failure occurs on hardware examined under NIOSH directed Off-the-Shelf 

Audit, the hardware will be examined by a technician and the Laboratory 

Manager for cause. All equipment failing or passing any portion of this test will 

be contaminated with chemical warfare agent and disposed of in accordance with 

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APPENDIX D: 

CBRN PAPR HD LAT Certification Test Data Summary Sheet; 

NIOSH Procedure No. NPPTL-STP-CBRN-PAPR –0551 

1. TEST TITLE: Determination of Powered Air-Purifying Respirator (PAPR) Performance During Dynamic 

Testing Against Chemical Agent Distilled Sulfur Mustard (HD) Vapor and Distilled Sulfur Mustard (HD) 

Liquid. 

A. Task Number (TN): _________________________________________ 

B. Manufacturer: ________________________________________ 

C. PAPR Model #/Type: ____________________________________ 

D. Test Start Date of Qualifier Application: ______________________ 

E. Test Start Date of Remainder Application: ______________________ 

F. Test End Date of Remainder Application: ______________________ 

G. Primary P/N and Subject for LAT Configuration:__________________ 

H. Gaining NIOSH CBRN Approval Numbers: ______________________ 

2. REQUIREMENT: 

Each of three CBRN (loose fitting PAPRs are not durability conditioned prior to LAT) Tight 

Fitting Facepiece, Loose fitting and Hood Style Powered Air-Purifying Respirator (PAPR) shall 

demonstrate no permeation or penetration of Distilled Sulfur Mustard (HD) vapor and Distilled 

Sulfur Mustard (HD) liquid (Tight Fitting PAPRS Only) equal to or greater than the stated 

maximum peak excursions and the stated cumulative concentration over time (Ct) including all 

maximum peak excursion data points for the duration of the eight (8) hour test. HD vapor 

challenge concentration will start immediately after the test chamber has been sealed. On Tight 

Fitting PAPRs Minimum Service Life for liquid exposure starts after the first liquid drop is 

applied. Liquid volume used is dependent on components used with the respirator. Minimum 

volume of 0.43mL and maximum volume of 0.86mL is based on the respirator final tested 

configuration as using one or multiple PAPR canisters on a specific respirator assembly. Three 

consecutive sequential test data points at or exceeding 0.3mg/m3 will collectively constitute a 

failure where each test value equals to or exceeds 0.3 mg/m3 and is based on a detector sample 

time of approximately 2 minutes. The cumulative Ct, including all maximum peak excursion data 

points, must not be exceeded for the duration of the test. Liquid agent is applied to the complete 

respirator at hour 6 of the test cycle. The test period begins upon initial generation of HD vapor 

concentration and ends at 8 hours. Tight fitting respirator systems are tested in the AS IS/Ready to 

Use configuration and remaining two respirator systems are tested in the environmentally preconditioned configuration prior to LAT. 

 OVERALL RESULT: PASS or FAIL

3. SUPPORTING REQUIRED DATA: 

A. Has Canister expired prior to LAT in accordance with User Instructions? YES or NO 

B. Is Canister bent, cracked or disfigured prior to any portion of LAT? YES or NO 

C. Does Canister to facepiece connection violate Form, Fit or Function? YES or NO 

D. Is Facepiece fully serviceable prior to any portion of LAT? YES or NO 

E. Are Sub Assemblies free of visible deformations or aberrations? YES or NO 

F. Are remainder components environmentally conditioned prior to LAT? YES or NO 

G. Does blower operate prior to LAT? YES or NO 

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HD CBRN PAPR LAT Certification Summary Continuum: 

Task Number: _______________________ STP No.: ___________________ 

Manufacturer: _______________________ Reference No.: ___________________ 

Test Title: Determination of Powered Air-Purifying Respirator (PAPR) Performance During Dynamic Testing 

Against Chemical Agent Distilled Sulfur Mustard (HD) Vapor and Distilled Sulfur Mustard (HD) Liquid. 

H. Did each PAPR pass or fail maximum peak excursions? PASS or FAIL 

I. Did each PAPR pass or fail Ct? PASS or FAIL 

J. Was all lab test equipment verified calibrated prior to LAT? PASS or FAIL 

K. Were the SAF Configuration Part Numbers verified on the actual testable hardware? 

PASS or FAIL 

i)

Test Total Test Time Max Peak Excursions Ct Result 

Qualifier Test #1 (e.g. TN-HD 1) 480 minutes or less Quantity Failing Value Pass/Fail 

Remainder Test #2 (e.g. TN-HD 2) 480 minutes or less Quantity Failing Value Pass/Fail 

Remainder Test #3 (e.g. TN-HD 3) 480 minutes or less Quantity Failing Value Pass/Fail 

4. COMMENTS: 

(e.g. CBRN PAPR candidate was tested in non-environmentally conditioned /Minimum Packaging 

Configuration for initial Qualifier Application. CBRN PAPR passed initial Qualifier Application LAT. 

However, when a Durability Conditioned PAPR was tested in Remainder Application tests, candidate 

CBRN PAPR failed max peak excursion criteria and exhibited canister thread dents and bends as a result of 

environmental pre – conditioning prior to Remainder LAT.) 

5. SIGNATURES: 

A. Laboratory Technician: _________________________ Date: _______________ 

B. Laboratory Supervisor: _________________________Date: _______________ 

Legible Signatures infer concurrence with test summary findings as indicated above. 

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Revision History 

Revision Date Reason for Revision 

0.0 1 September 2006 Original Issue 

 

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