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. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005

DETERMINATION OF OPEN CIRCUIT, SELF-CONTAINED BREATHING APPARATUS 

(SCBA) PERFORMANCE DURING DYNAMIC TESTING AGAINST CHEMICAL AGENTS

OF SARIN (GB) VAPOR AND DISTILLED SULFUR MUSTARD (HD) 

 VAPOR AND LIQUID STANDARD TESTING PROCEDURE (STP) 

1. PURPOSE

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

provided under special Chemical, Biological, Radiological, and Nuclear (CBRN) 

requirements for Open-circuit Self-Contained Breathing Apparatus (SCBA) with 

Full Facepiece 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). 

1.2 This procedure is used to test SCBA systems against Sarin (GB) vapor or 

Distilled Sulfur Mustard (HD) vapor and liquid, while the respirator is operated in 

dynamic mode by means of a breather pump connected to the mouth area of a 

manikin headform. Instrumentation is integrated under this static chamber 

platform for the purpose of generating and controlling challenge concentrations 

and detecting precise agent permeation of a tested respirator. 

1.3 Within this procedure, there are two separate tests: RCT-CBRN-STP-0200 for 

Challenge of Sarin (GB) Vapor and RCT-CBRN-STP-0201 for Challenge of 

Distilled Mustard (HD) Vapor and Liquid. This procedure is designed to 

rigorously test the evaluated respirator and generate repeatable independent pass 

or fail results. 

2. GENERAL

The STP describes a test entitled “Determination of Open Circuit, Self-Contained 

Breathing Apparatus (SCBA) Performance during Dynamic Testing against Chemical 

Agents of Sarin (GB) Vapor and Distilled Sulfur Mustard (HD) Vapor And Liquid” 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. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 2 of 46 

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, SMARTMAN, is a cast zinc, hollow shell and comprised of a head, 

neck, shoulders and upper chest. The head features an anatomically correct 

surface consisting of dimensional eyes, nose, ears, mouth orifice, forehead and 

chin. The facial features are on a movable section of the head to facilitate 

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

fits into a channel between the face and the permanent part of the head. The seal 

is inflated to press against the inside of the facepiece seal area to assure against 

leakage. The surface of the face 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, about 11⁄4” diameter, 

leads from the mouth area to the breather pump. One tube connects to the center 

of the left eye and can be used to monitor the upper, or eye, area of the interior of 

the mask. One tube connects to the lower middle forehead above the bridge of the 

nose and can be used to monitor pressure, or differential pressure when connected 

by means of a manometer to the nose area. There are two metal tubes protruding 

outward from the oral/nasal region; 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. 

Picture 1: Head/Upper Torso Manikin, SMARTMAN 

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3.2. Leak detector Model TDA-99M or equivalent (see picture 2). The TDA-99M is 

manufactured by Air Techniques, Inc. The TDA-99M is one of the primary 

technician tools for accessing aerosol leaks in the mechanical seals of the 

respirator and the correct fitting of a respirator face piece to the SMARTMAN 

headform. The TDA-99M is used to confirm the proper facepiece seal and 

integrity of the respirator after it has been mounted on the SMARTMAN. The 

device generates a mineral oil (Brand Name-“Emery 3004”) aerosol that is used to 

detect leakage into the interior of 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

 Aerosol is introduced into the agent exposure 

chamber. The interior of the mounted SMARTMAN mask is monitored for 

presence of the aerosol. The leak detector compares the concentration of aerosol 

inside with the concentration outside, and calculates a 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 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 4 of 46 

quantified at the beginning of each test / evaluation, the detection instrumentation 

must remain stable for a period of 60 minutes prior to the initiation of any test / 

evaluation. Two MINICAMS are required in order to continuously monitor the 

interior of the respirator.

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 body cavity or into a duct or vessel) to the dilution airline. The plunger of 

the syringe is driven at a controlled rate by the pump to deliver a 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% 

Nominal. 

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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 Research, Inc., is an automated system to control the airflow, 

temperature, and humidity of an air supply for an operating system. Laboratory 

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 exposure chamber is 

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

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 6 of 46 

equivalent material. The floor must be constructed to support the 85-pound 

weight of the 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 to hold the chamber above the floor of 

the hood and allow room for the tubing and the face adjustment handle. A 

M12A1 military air purifying collective filter 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 the challenge concentration and clean purge air. An 

electric fan is installed near the top front to achieve a well-mixed challenge 

concentration. A “Clean Exposure Chamber” is a unit 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” is a 

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

Picture 6: Exposure Chamber 

3.7 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 

chamber, indicates internal mixture pressure and serves as a safety pressure 

indicator. Maximum pressure is indicated per manufacturer pressure gauge 

instructions and markings. 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 filter or equivalent). A M18 (military air purifying collective filter) is positioned in-line between the 

exposure chamber and the breathing pump. 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 7 of 46 

Picture 7: Mixing chamber 

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

Jaeco Fluid Systems, Inc. This is the standard United States Army breather pump 

used to simulate breathing for testing of filters and other items. It is a double 

pump, operated by a single electric motor. The original pump design was 

modified by substituting a variable speed motor for the single speed motor, thus 

allowing the number of strokes per minute to be varied. The pump is controlled 

by a gearbox with planetary gears and a Scotch Yoke that produces the sinusoidal 

breathing pattern. The sinusoidal pattern starts at zero flow rate, rises to a 

maximum, or peak, flow of approximately π (3.1416) times the rated flow rate in 

liters per minute, and drops back to zero. The exhalation stroke of the pump 

follows the same sinusoidal pattern. The tidal volume (volume per breath) can be 

adjusted up to 1.5 liters. 

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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. 

3.10 Ambient Air Analyzer, MIRAN model 1A or 205B, or equivalent (see picture 9 

and 10). Manufactured by Thermo Environmental Instruments Inc. It is an 

infrared absorption based detector that uses a long path length cell up to 20 

meters, into which the air sample is introduced. This analyzer is used to monitor 

the challenge concentration of the vapor phase of the chemical warfare agents. 

Model 1A is used for the Sarin (GB) concentration and model 205B is used for 

the Distilled Mustard (HD) concentration. 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 9 of 46 

Picture 9: Miran Analyzer, Model 205B 

 NO PHOTO CURRENTLY AVAILABLE 

Picture 10: Miran Analyzer, Model 1A 

3.11 Air Compressor & Cascade System or equivalent (see picture 11). An aircompressor or a cylinder system capable of maintaining upper limit of 5000 psi 

and a lower limit of 500psi. The system must be capable of simulating the 

pressure decay curve from full rated air cylinder pressure to the lower limit air 

pressure range of 500 psig. At less than 500 psi, the tested SCBA system must be 

returned to fully rated cylinder pressure (4500, 2216 or 3000 psig, or the specified 

SCBA system air pressure under test). The cycle must be continued until the test 

is terminated at the end of six (6) hours. The decay cycles may be continuous or 

stepwise. 

NO PHOTO CURRENTLY AVAILABLE 

Picture 11: Air Compressor & Cascade System 

4. TESTING REQUIREMENTS AND CONDITIONS

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

been calibrated in accordance with its’ calibration procedure and schedule. 

 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 10 of 46 

4.2. System Test Conditions

4.2.1 Breathing Machine 

 Airflow = 40 liters per minute 

 Respirations = 36 +/- 2 strokes per minute 

 Tidal Volume = 1.1 liter 

 

4.2.2 High Pressure Compressed Air Supply, Grade D Compressed Air or Grade 

E Liquified Air (Source for SCBA Operating System) 

Pressure Decay Profile = Rated SCBA service pressure upper limit, with 

natural human respiratory decay over expected cylinder time and down to 

less than 500 psi before refreshing back to the upper limit of air pressure. 

Tank capacity = 2400 liters (minimum) 

Temperature = 25±5 0

C 

Oxygen: 19.5 to 23.5% 

CO by Volume: Less than 10ppm 

CO2 by Volume: Less than 1000ppm 

Dew Point: 24 ppm of H2O, Less than –65 degrees F at 1 atmosphere. 

Condensed Oil & Particulate: Less than 5 mg/m3. 

TVHC: Less than 25 ppm of Total Volatile Hydrocarbon Content. 

Odor: None to Slight OV 

GRADE D/E Air quality control certificates are required to be on file for 

the current compressor output air. Grade D/E air routine maintenance 

checks and procedures are required to be filed and capable of confirming 

the quality of used Grade D/E air in support of SCBA certification. 

4.2.3 Miller-Nelson air flow settings into exposure chamber 

 Airflow Rate: Determine an appropriate flow based upon obtaining a 

stable concentration, based upon the volume of the exposure chamber, 

considering the agent challenge concentration desired, volume of chamber, 

breather air flow, and dilution air discharged from the SCBA. 

 

 Relative Humidity = 50 ±5% 

 Temperature = 25 ± 3o

C 

4.2.4 SMARTMAN Sampling Point 

A single Nasal port to supply dual MINICAMS detectors. 

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4.2.5 Sarin (GB) Vapor Test 

 

4.2.5.1 Vapor Challenge Concentration = 2000 mg/m3

 ± 10 % 

 Vapor Challenge Time (disseminator on) = 30 minutes, but no 

longer than 31 minutes 

 Monitor & Hold Time = 5.5 hours 

 Total Test Time = 6 hours 

 Syringe Injection Rate = as required based upon syringe pump 

used 

 Syringe Injected Volume = as required based upon syringe pump 

used 

 

4.2.5.2 Liquid Sarin (GB) must be Chemical Agent Standard Analytical 

Reference Material (CASARM). Analysis must be NIST traceable. 

Proper CASARM storage requirements must be followed. 

 

 4.2.6 Distilled Sulfur Mustard (HD) Liquid and Vapor Test

4.2.6.1 HD Liquid Application 

 Drop Size = 20 microliters 

 Total Volume = 0.86 milliliters (43 drops of 20 micro liters) 

 Facepiece Droplet Diagram (Appendix A) = 25 drops 

 Associated Hardware Droplet Diagram (Appendix B) = 18 drops 

 

Use of an external shroud or hood attached to the facepiece 

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 

applications being on bare facepiece material they are on the 

shroud covering that depicted area/seam/joint/interface. 

Manual Liquid Droplet HD Application starts the total time from 

when the first droplet is applied while MINICAMSs are actively 

sampling. 

4.2.6.2 HD Vapor Challenge 

 Vapor Challenge Concentration = 300 mg/m3

 ± 10 % 

 Vapor Challenge Time 

(disseminator on) = 30 

minutes, but no longer 

than 31 minutes 

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 Monitor & Hold Time = 5.5 hours 

 Syringe Injection Rate = as required based upon syringe pump 

used 

 Syringe Injected Volume = as required based upon syringe pump 

used 

 Total Test Time = 6 hours (Manual 

Liquid Droplet HD Application starts the 

total time from when the first droplet is 

applied while MINICAMSs are actively 

sampling.) 

4.2.6.3 Liquid Distilled Mustard (HD) must be Chemical Agent Standard 

Analytical Reference Material (CASARM). Analysis must be 

NIST traceable. Proper CASARM storage requirements must be 

followed. 

 

4.2.7. Test Termination Parameters: The test will be terminated to protect the 

detectors from over-saturation. The termination point should be set at or 

above the highest calibration point for each one of the MINICAMSs in 

use. 

4.2.8. High Pressure Compressed Air Cycle. Compressed air inlet pressure is 

rated cylinder pressure per manufacturer instructions. Duration of test 

determines the amount of compressed air required to maintain the SCBA 

at manufacturer operating compressed air specifications. Compressed air 

source provides required high pressure air over the entire duration of the 

test. Maximum air cylinder pressure is 4500 psig but may vary depending 

on SCBA air cylinder ratings of 3000 psig or 2216/2200psi. Minimum air 

pressure required is 500psi. When the tested respirator unit alarms and 

reaches its testable low air minimum pressure of 500psig, efficient transfer 

of manual or processed standby air pressure is required to be initiated from 

second cylinder or built in house high pressure compressed air and isolate 

first cylinder for recharging. The compressed air cycle continues until the 

end of the specified test. 

4.3 Safety and Training: Normal laboratory safety practices must be observed. This 

includes all safety precautions described in the current Appalachian Laboratory 

for Occupational Safety & Health (ALOSH) Facility Laboratory Safety Manual, 

U.S. Army Soldiers and Biological Chemical Command Laboratory Safety 

Procedures, and/or equivalent manuals. 

4.3.1. Safety glasses, lab coats and assigned respirator must be worn as required. 

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4.3.2. Work surfaces must be maintained, free of clutter and non-essential test 

equipment. 

4.3.3. When, handling any glass laboratory equipment, lab technicians and 

personnel must wear gloves, which should protect against lacerations or 

punctures. 

4.3.4. Laboratory personnel must be trained in safe operating procedures 

appropriate for the test. 

4.3.5. The responsible technician must be knowledgeable about the specific Self 

Contained Breathing Apparatus (SCBA) being tested and should be able to 

readily identify all SCBA hardware accessories, components, 

subcomponents, noted accessories and be able to support accurate trouble 

shooting of the SCBA to ensure it is operating in the pressure demand 

mode. The responsible technician must be able to properly align and fit 

the respirator facepiece on the SMARTMAN headform. 

 

4.3.6. All equipment passing these NIOSH test protocols will be treated as 

hazardous materials in accordance with local laboratory procedures and 

methods. Disposal of such contaminated SCBA materials is the 

responsibility of the testing laboratory and respirator manufacturers are 

released of equipment accountability IAW NIOSH and local testing lab 

test equipment procedures per local testing lab procedures. 

 

4.3.7. Surety 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 Material Safety Data Sheets and appropriate Health and Safety 

manuals, or other appropriate documentation for the proper protection and 

care in handling, storing, and disposing of the chemicals and gases used in 

this procedure. 

4.4. MINICAMS 

4.4.1 A Laboratory MINICAMS is used as the detector for agent 

penetration/permeation of the SCBA. It consists of a monitor, PC 

computer, Linear Mass Flowmeter and optional printer or recorder. 

4.4.2. A small volume of air is drawn through a preconcentrator tube containing 

an adsorbent material: GB sample volume is approximately 200 mL and 

HD sample volume is approximately 200 mL. Agent in the sample is 

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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 Operation of the MINICAMS requires the use of compressed air, 

hydrogen, and nitrogen, of a high purity. The operating manual 

recommends operating parameters (temperature, timing, pressures, etc.) 

and cycle times (3, 5, 10 or 15 min.), depending on the application. GB 

analysis requires a 4-minute cycle and HD requires a 6-minute cycle. The 

two MINICAMS will be synchronized so that one minicam sampling 

begins when the other minicam sampling ends. 

4.4.4. The MINICAMS is installed in accordance with the operating manual. 

The appropriate optical filter for GB or HD must be installed in front of 

the photomultiplier tube. In principle, when GB or HD burns in a 

hydrogen flame, a chemical species (phosphorus or 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. 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 standard solution of the agent onto the 

preconcentrator tube during the INJECT segment of the test cycle. The 

standard solutions of agent are made in isopropanol, spectrophotometric 

grade. At least three injections of each quantity of agent should be 

injected. 

4.4.6 Pretest activities for the MINICAMS are as follows: 

Start the MINICAMS 

Set or verify operational parameters for appropriate agent 

Perform standardization 

Record ASCII file name on Data Sheet (Appendix A&B) 

Standby for start of testing 

4.5. Agent vapor generation for GB and HD. 

4.5.1. The vapor challenge for SMARTMAN testing is generated by injecting 

the required quantity of liquid agent into the volume of air that passes 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 15 of 46 

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

accomplished by a combination of controlled airflow from the MillerNelson 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 discharged into the chamber 

from the SCBA. 

Example: 

The conditions below are to be used as guidelines. Conditions for each 

individual system will have to be determined for each laboratory setup to 

achieve the required ramp up time.

GB Setup (mass balance) 

Chamber size = 8 ft3 

Target Challenge Concentration = 2000 mg/m3 + 200 

Ramp Up Time= 4 - 5 minutes (time from initial start of syringe pump to 

1800 mg/m3 lowest acceptable Challenge Concentration) 

 Dilution Air from Breather Pump = 40 l/m 

 Miller-Nelson Challenge Mixing Air = 90 l/m 

 Syringe Rate for Challenge Injection = 0.34 ml/m 

 Total GB in 30 minutes = 10.2 ml 

HD Setup (mass balance) 

Chamber size = 8 ft3 

Target Challenge Concentration = 300 mg/m3 + 30 

Ramp Up Time= 3-5 minutes (time from initial start of syringe pump to 

270 mg/m3 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 = 1 ml/hr 

 Total HD in 30 minutes = 0.5 ml

 

 From the pump operating manual select the syringe size and pump rate 

that will inject the required amount of agent per unit time. Draw up the 

total amount of agent needed into the syringe, with a small excess, connect 

one end of the cannula (the small flexible tube that is inserted into the air 

duct) to the syringe, and the other end to the heated tee in the air duct. 

Clamp the barrel of the syringe onto the pump and move the plunger drive 

until it contacts the end of the plunger. Turn on the power to the pump. 

The plunger will be activated and agent will be injected into the air stream 

as a vapor from the heated tee. The mixture passes into the mixing 

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chamber where it is thoroughly mixed, ready to be introduced into the 

exposure chamber for the test. 

 4.6. Miller-Nelson (MN) Controller

4.6.1. The Miller Nelson unit receives compressed air from the laboratory air 

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

instructions. The sensors for relative humidity and temperature must be 

calibrated, as must be 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. 

4.6.2. Set the readout panels on the Miller Nelson according to paragraph 4.2.3. 

Allow the clean air to flow through the mixing chamber and the M18 filter 

until it is time to start the test. 

 4.7. Syringe pump. 

 4.7.1. 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. 

 4.7.2. 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. 

 4.7.3. 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. 

4.8. TDA-99M Aerosol Leak Detector

4.8.1. The TDA-99M leak detector is used to detect leaks into the SCBA after it 

has been installed on the SMARTMAN headform. Connect the SCBA to 

the air supply system using a cylinder valve mounting fixture. See 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 17 of 46 

Appendix E for a drawing of the fixture. The SCBA is operated using air 

supplied to the SCBA from a cylinder air storage system. Ensure that 

procedures for the SCBA valve follow the manufacturer’s installation 

procedures for torque and that the seal (gasket or O-ring) is a new seal 

provided by the manufacturer. 

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

manufacturer’s instructions. The SCBA should be operating. Turn on the 

breather pump to activate the test mask. 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. Any leaks found must be 

corrected. Insure the SCBA does not go into negative pressure. If 

negative pressure is observed, terminate test and recheck/trouble shoot 

compressed air lines and face seal. If no localized leaks are found, 

replace the front panel of the exposure chamber. 

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

chamber with aerosols. Maintain a constant aerosol concentration inside 

the exposure chamber for 30 minutes. Check the display on the TDA99M for detection of aerosol inside the facepiece. If there is evidence of 

leakage, attempt to find and eliminate the leak. When the detector 

indicates a maximum penetration of less than 0.0010 %, continue with the 

next item in the test procedure. 

4.9. Quality Control Measures

4.9.1. SMARTMAN Leak Test: Because the SMARTMAN is made of cast zinc, 

it is possible for leak paths to form through the metal casting, allowing 

chemical warfare agent vapor to pass through from the headform cavity 

into the interior of the respirator mounted on the headform. Install a clean 

peripheral seal on the headform and inflate it. Flood the interior of the 

headform with helium. Use the probe of the helium leak detector to check 

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

must be eliminated. This test is to be performed on each new or 

reconditioned SMARTMAN and monthly on the head-forms when they 

are in 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 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 

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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 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 

value of r2

 = 0.999 for GB and r2 = 0.99 for HD. Agent solutions must be 

stored at 4o

F or lower. 

4.9.3. Determination 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 Army TM&DE and 

Metrology Laboratory, or equivalent, using instruments traceable to NIST. 

Flow meters to be checked against calibrated meters are the Miller-Nelson 

Air Flow Controller, electronic flow meters used for the MINICAMS 

preconcentrator tube, the breather flow from the breather pump and the 

syringe pump. 

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

performed on the facepiece after installation on the SMARTMAN and 

while the breather pump is 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 TDA99M should read 0.0000 % penetration. 

4.9.5 MINICAMS Detector Response: Check the response of the MINICAMS 

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

standard solution that contains a known concentration of agent near the 

mid-range of the standard curve. Inject the aliquot into the end of the 

heated sample line from the oronasal 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 checkshot does not 

reproduce a verifiable result, repeat the checkshot. If the second 

checkshot is not within the 10% parameter, the test is invalid. 

 

5. PROCEDURE (Vapor Challenge GB (0200) or Liquid/Vapor Challenge HD (0201)) 

5.1. Vapor Challenge GB (0200)

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 19 of 46 

5.1.1. Assemble SCBA per manufacturer’s instructions with the exception of the 

air cylinder. Air cylinders are not tested according to these standard 

testing procedures. Only the air cylinder neck valve and gaskets are tested 

using the high-pressure adaptor. 

5.1.2. Take a digital photograph of assembled unit for use later. 

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

facepiece should be mounted to the SMARTMAN per the manufacturers’ 

operating/user instructions. Ensure all parts of the facepiece are 

mounted/seated correctly on the headform. If a shroud or other accessory 

is being tested as part of the respirator system, ensure that they are 

mounted properly and serviceable. Batteries must be removed from the 

“PASS” device before testing begins. 

5.1.4 The test SCBA must be connected to the compressed air supply system 

using an air cylinder valve-mounting adapter. See Appendix E for a 

drawing of the adaptor. Different high-pressure air cylinders and rated 

SCBA respirators require different cylinder adapter dimensions. Ensure 

that the correct adapter is being used according to the manufacturer 

specifications. A calibrated torque wrench is used to exert the required 

foot-pounds of torque pressure. This adaptor will stay with the SCBA unit 

through out the complete testing process. Ensure that installation 

procedures for the valve follow the manufacturer’s installation procedures 

for torque and that the seal (gasket or O-ring) is a new seal provided by 

the manufacturer. Connect the compressed air system capable of 

supplying high pressure breathing air to the SCBA. Insure air inlet 

pressure gauge reads the SCBA rated service pressure ±10 psig. Insure 

SCBA air pressure gauge reads in the full range. The responsible 

technician must insure that the inlet air pressure gauge is at maximum 

rated pressure for the start of test and ample high-pressure air is available 

for the duration of the test. 

5.1.5 Insure inlet pressure gauge from high-pressure air source does not exceed 

the SCBA rated service pressure at any time. 

5.1.6 Turn on the breathing pump. Insure that the SCBA is in the pressure 

demand mode. This can be confirmed by visually checking the integrated 

SMARTMAN magnehelic pressure gauge needle movement. Magnehelic 

pressure gauge should be used only as a qualitative indicator of SCBA 

positive pressure. Lack of positive pressure in the SCBA will result in the 

magnehelic gauge reading in the negative pressure range. 

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5.1.7 Using the TDA-99M, leak test the SCBA in the operational pressure 

demand mode. Connect the detector inlet to a sample line from the 

SMARTMAN, allow the SCBA to breath and create stable value on the 

TDA-99M. When the aerosol is being generated, direct the wand to 

various portions of the facepiece and all 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 no localized leaks 

are found, replace the front panel of the exposure chamber. Connect the 

TDA-99M to a port into 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 SCBA must pass a continuous 30 minute test at ≤ 0.0009 % 

penetration parameters in separate clean exposure chamber and agent 

exposure chamber to be considered “qualified” to progress on in 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, with the concurrence of the applicant. 

Alternate means of sealing the facepiece must not compromise the normal 

use of the SCBA. 

5.1.8 Before the SCBA respirator facepiece 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 respirator on the SMARTMAN. 

The SMARTMAN should be allowed to breathe until the steady state 

background is lower than the lowest calibration curve point indicated on 

the respective MINICAMS. 

5.1.9 Remove SCBA from clean exposure chamber and install on SMARTMAN 

in the GB agent exposure chamber. The neck cylinder valve and assigned 

adaptor must stay together and transfer with the testing SCBA. 

5.1.10 Mount unit on the SMARTMAN in the agent exposure chamber. Conduct 

a TDA-99M 30 minute test by repeating steps 5.1.3 – 5.1.7, 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. Insure that the removal of the TDA-99M test hardware does 

not disturb the established seal of the SCBA facepiece to the 

SMARTMAN system. 

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

5.1.12 MINICAMS Background Characterization. A background 

characterization must be run before every chemical warfare agent test. 

The MINICAMS should be monitored for a period of 60 minutes prior to 

the initiation of the chemical agent warfare 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, trouble shoot the 

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

if necessary remove the SCBA facepiece, decon the headform, redon the 

facepiece and restart the procedure for characterization as necessary. . 

5.1.13 Set up standard operational mode of test equipment. Ensure all test 

equipment is within calibration. 

5.1.14 Set Miller-Nelson for air flow into exposure chamber set to deliver 

required rates. See paragraph 4.2.3. 

 

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 4.2.5 

(GB) 

 

5.1.16 Ensure MINICAM is calibrated, perform “check shot”, and ready for 

operating mode. Annotate the check shot time and concentration 

percentage. 

5.1.17 Ensure that the challenge concentration instrument is calibrated and it is 

ready for analysis. Monitor chamber concentration during the 60 minute 

Background Characterization period. Characterization readings should 

reflect steady state conditions. 

5.1.18 Time zero, or start of the agent test, is when the syringe pump is turned on 

and agent is allowed into the agent exposure chamber. Annotate this time. 

5.1.19 Introduce agent challenge [Sarin (GB)] to exposure chamber. Turn the 

valve in the line from by-pass to the mixing chamber to direct flow to the 

exposure chamber. The total flow to the chamber is approximately 80 

L/min from Miller Nelson, which includes enough excess to make up for 

the clean air exhausted from the respirator into the chamber and maintain 

the constant challenge as required. The concentration of challenge agent 

monitored using the appropriate Miran detector. The syringe flow rate is 

set to introduce the quantity of agent necessary to generate the challenge 

concentration required. Record the time when the MINICAMS begin 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 22 of 46 

monitoring the interior of the mask. It is required to start the MINICAMS 

before introducing agent into the chamber so that the first sampling period 

will coincide with the first agent challenge. 

5.1.20 The 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 air flow rate delivered from the MillerNelson. These values will be recorded in the laboratory notebook and test 

data sheets (Appendix C & D). Ensure the syringe flow is off and the 

mixing chamber airflow line is bypassed so Miller-Nelson uncontaminated 

air flow is going to the agent exposure chamber. 

5.1.21 The Miran Detector will be 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 verses time. 

5.1.22 System Hold or Monitor Time: Continue flushing the agent exposure 

chamber with the Miller-Nelson uncontaminated air to allow the 

simulation of the natural effects of ambient environmental conditions and 

the actual nonpersistent vapor effects of GB. Ensure the breathing 

machine operates at the same rate for the remaining 5.5 hours. 

5.1.23 Test Surveillance: The laboratory technicians should monitor entire the 

test to make sure all components of the system function, collect data as 

required and monitor the breakthrough concentration to protect the 

minicam against saturation. If the system is failing, the MINICAMS must 

capture three maximum peak excursions to document the SCBA’s failure 

before MINICAMS can be taken off the detection line. 

5.1.24 Termination of Test 

5.1.24.1 The test should be terminated when the full time for the test has 

elapsed. Turn off breather pump. Depressurize the SCBA by 

closing the compressed air feed or allowing the automatic highpressure air system to cycle down air pressure. Purge the air 

from the SCBA by opening the purge valve, and allow air to 

drain while the primary air cylinder valve is open. When gauge 

reads zero on SCBA, close purge valve and close air cylinder 

valve. Disconnect SCBA in accordance with local lab safety 

procedures Perform a check shot of agent to assure that the 

detection system is still operating correctly. Take an aliquot of 

one of the mid-range standard solutions of agent with a 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 23 of 46 

microliter syringe and inject it into the nasal sampling port by 

disconnecting the line from 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 test 

to be valid. 

5.1.24.2 Turn off the MINICAMS per laboratory SOP. Turn off MillerNelson airflow through the exposure chamber. Remove the test 

respirator, separate it into components and double-bag the 

components in accordance with local laboratory SOP. Remove 

the bagged components to the decontamination hood for 

temporary storage. If requested, a manufacture representative 

may review the items at this time to perform reverse engineering 

analysis. This review must be approved by the laboratory 

manager. The test respirator will then be decontaminated, 

monitored and disposed according to laboratory SOP. Wipe 

down the interior of the agent exposure chamber and the 

SMARTMAN using approved decontaminating solution. 

Dispose of cleaning materials according to laboratory SOP. 

5.1.25 Step Sequence of Activities for GB Vapor CBRN SCBA Test. 

1. Conduct M40 preparation and background contamination assessment. 

2. Install SCBA in clean exposure chamber. 

3. Close clean exposure chamber, ensure SCBA is breathing. 

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

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

step or if failure, substitute failed SCBA with a new untested SCBA. 

6. Install SCBA in agent exposure chamber 

7. Close agent exposure chamber, ensure SCBA is at maximum pressure 

limit and start breathing. 

8. Challenge SCBA with TDA-99M for 30 minutes 

9. Start MINICAMS 

10. Monitor background inside the mask and chamber concentration/check 

shot 

11. Conduct characterization for 60 min 

12. Start makeup air using Miller-Nelson 

13. Start syringe pump 

14. Record start time of MINICAMS 

15. Initiate challenge agent 

16. Record challenge agent start time, vapor exposure 

17. Simultaneously start ambient challenge concentration profile software 

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18. Monitor MINICAMS for detection, noted penetration peaks and 

saturation prevention. 

19. Stop syringe pump at 30-minute mark. 

20. Record stop time for challenge agent vapor exposure. 

21. Record hold time start (5.5 hours) 

22. End test 

23. Record end time at 6.0 hours 

24. Conduct check shot instrumentation 

25. Record check shot results. 

26. Prepare system for decon and removal of tested components. 

 

5.1.26 Data Analysis 

5.1.26.1 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 

checkshot or test start time. Supervisor must pre-approve any 

deviation from standard test method and signoff in technician’s 

notebook. 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. 

5.1.26.2 Laboratory manager and technician must complete all required 

Test Data Sheets (Appendix C & D). Originals of all Test Data 

Sheets must be completed and retained in the task file. NIOSH 

DEIMS is updated at the minimum, every three days by the lab 

technician supervisor/principal investigator or equivalent, while 

an application is active and has information for update, ideally, 

the DEIMS should be updated daily with all applicable 

information to allow timely feedback and prevention of 

miscommunication. 

5.1.26.3 Transfer the permeation data from the MINICAMS computer 

into a computer for analysis by Microsoft Excel. This analysis 

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) 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 Time) is calculated by multiplying the collection 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 25 of 46 

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 successively. 

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. 

5.1.26.4 Challenge Concentration Data: Using the computations 

generated from para 5.1.26.3 above. Plot the challenge 

concentration versus time and produce two data graphs that 

track total detection events covering any maximum peak 

excursions over 6 hours and total concentration over time 

known, as cumulative CT, covering the total 6 hours of potential 

cumulative and instantaneous dosages. If the test is terminated 

prior to the completion of 6 hours due to MINICAMS 

preventive measures, the laboratory technician supervisor or 

equivalent is responsible for accurately recording all applicable 

maximum peak excursions and cumulative CT detected in the 

tested time. 

5.2 Vapor Challenge HD (0201)

5.2.1 Assemble SCBA per manufacturer’s instructions with the exception of the 

air cylinder. Air cylinders are not tested according to these standard 

testing procedures. Only the air cylinder neck valve and gaskets are tested 

using the high-pressure adaptor. 

5.2.2 Take two digital photographs of assembled unit. One photograph is of the 

complete unit; the other is a close up of the facepiece with the regulator 

attached and all other tested accessories required by the application. 

5.2.3 Mount the unit on the SMARTMAN in the clean exposure chamber. The 

facepiece should be mounted to the SMARTMAN per the manufacturers’ 

operating/user instructions. Ensure all parts of the facepiece are 

mounted/seated correctly on the headform. If a shroud or other accessory 

is being tested as part of the respirator system, ensure that they are 

mounted properly and serviceable. Batteries must be removed from a 

PASS device before testing begins. 

5.2.4 The test SCBA must be connected to the compressed air supply system 

using an air cylinder valve-mounting adapter. See Appendix E for a 

drawing of the adaptor. Different high-pressure air cylinders and rated 

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SCBA respirators require different cylinder adapter dimensions. Ensure 

that the correct adapter is being used according to the manufacturer 

specifications. A properly calibrated torque wrench is used to exert the 

required foot-pounds of torque pressure. This adaptor will stay with the 

SCBA unit through out the complete testing process. Ensure that 

installation procedures for the valve follow the manufacturer’s installation 

procedures for torque and that the seal (gasket or O-ring) is a new seal 

provided by the manufacturer. Connect the compressed air system 

capable of supplying high pressure breathing air to the SCBA. Insure air 

inlet pressure gauge reads the SCBA rated service pressure ±10 psig. 

Insure SCBA air pressure gauge reads in the full range. The responsible 

technician must insure that the inlet air pressure gauge is at maximum 

rated pressure for the start of test and ample high-pressure air is available 

for the duration of the test. 

5.2.5 Insure inlet pressure gauge from high-pressure air source does not exceed 

the SCBA rated service pressure at any time. 

5.2.6 Turn on the breathing pump. Insure that the SCBA is in the pressure 

demand mode. This can be confirmed by visually checking the integrated 

SMARTMAN magnehelic pressure gauge needle movement. Magnehelic 

pressure gauge should be used only as a qualitative indicator of SCBA 

positive pressure. Lack of positive pressure in the SCBA will result in the 

magnehelic gauge reading in the negative pressure range. 

 

5.2.7 Using the TDA 99M, leak test the SCBA in the operational pressure 

demand mode. Connect the detector inlet to a sample line from the 

SMARTMAN, allow the SCBA to breath and create stable value on the 

TDA-99M. When the aerosol is being generated, direct the wand to 

various portions of the facepiece and all 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 no localized leaks 

are found, replace the front panel of the exposure chamber. Connect the 

TDA-99M to a port into 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 SCBA must pass a continuous 30 minute test at ≤ 0.0009 % 

penetration parameters in separate clean exposure chamber and agent 

exposure chamber to be considered “qualified” to progress on in the agent 

testing. If after repeated attempts a successful leakage test cannot be 

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achieved, the laboratory manager may use alternative means to seal the 

facepiece to the headform, with the concurrence of the applicant. 

5.2.8 Before the SCBA respirator facepiece 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 respirator on the SMARTMAN. 

The SMARTMAN should be allowed to breathe until the steady state 

background is lower than the lowest calibration curve point indicated on 

the respective MINICAMS. 

5.2.9 Remove SCBA from clean exposure chamber and install on SMARTMAN 

in the HD agent exposure chamber. The neck cylinder valve and assigned 

adaptor must stay together and transfer with the testing SCBA. 

5.2.10 Mount unit on the SMARTMAN in the agent exposure chamber. Conduct 

a TDA-99M 30 minute test by repeating steps 5.2.3 - 5.2.7, 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. Insure that the removal of the TDA-99M test hardware does 

not disturb the established seal of the SCBA facepiece to the 

SMARTMAN system. 

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

5.2.12 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 agent warfare 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, trouble shoot the SMARTMAN system, do 

not start the test, advise laboratory manager and if necessary remove the 

SCBA facepiece, decon the headform, redon the facepiece and restart the 

procedure for characterization as necessary. 

5.2.13 Set up standard operational mode of test equipment. Ensure all test 

equipment is within calibration. 

5.2.14 Set Miller-Nelson for air flow into exposure chamber set to deliver 

required rates. See paragraph 4.2.3 

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

achieve the required agent challenge concentration. See items 4.2.6.2. 

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5.2.16 Ensure MINICAMS is calibrated, performing “check shot”, and ready for 

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

5.2.17 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. 

5.2.18 Time Zero or start of the agent test is when the first drop of liquid HD is 

applied to the surface of the SCBA and the MINICAMS are actively 

sampling. Conduct of the liquid HD droplet application must be 

performed expeditiously to allow the agent exposure chamber to be closed 

and the total exposure of the SCBA under specified conditions. Annotate 

the starting time. 

5.2.19 Liquid Application of HD droplets: 

5.2.19.1 Liquid drops are delivered to the surface of the SCBA to test 

permeation of material surfaces. A total of 43 droplets (size of 

20 micro liters each) are specified. Placement of the droplets, 

via syringe on to the system is specified in (Appendix A & B). 

The droplets will be placed on the equipment starting at the top 

of the SCBA as it is mounted on the SMARTMAN, to the far 

back and working down to the bottom front. Photographs must 

be maintained in the Task Folder. Liquid application of HD 

occurs before the vapor challenge of HD begins. 

5.2.19.2 Twenty five (25) drops will be placed on the facepiece. This 

will follow the sequence in Appendix A. The droplet 

placement sequence will be starting at the top of the face blank, 

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

the number sequence marked on Appendix A. Prior to actual 

droplet application, technicians should prepare by marking 

location of actual droplets on a digital photograph of the 

equipment being tested. If an external shroud is mounted on 

the face blank, apply droplets per standard diagram but on 

surfaces of the shroud that mirror the routine face blank areas. 

5.2.19.2 The remaining eighteen (18) droplets are placed on the specific 

SCBA hardware equipment that is an obvious pressure 

boundary concern and any protective material surface that is a 

noted concern related to penetration or permeation. The 

droplet placement is performed following the sequence in 

Appendix B. 

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5.2.19.3 Once the last droplet is applied, conduct a visual check of the 

breathing SCBA to ensure it is in still in positive pressure 

mode, 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 SCBA starts to disintegrate immediately 

during or just after droplet application occurs, finish the droplet 

application process and close up the box immediately. If the 

disintegration of the SCBA presents a perceived safety hazard, 

the technician should terminate the test at his discretion. 

5.2.20 Start of the 30 minute vapor exposure is when the vapor HD is injected 

into the HD exposure chamber. Annotate this starting time. Ensure time 

management is accomplished that allows the efficient tracking of two 

simultaneous events: one clock for HD liquid for 6 hours and another 

clock for HD Vapor at 30 minutes. 

5.2.21 Introduce HD vapor agent challenge to the agent exposure chamber. Turn 

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. The total flow to the chamber is approximately 50 L/min from 

Miller Nelson, which includes enough excess to make up for the clean air 

exhausted from the mask into the chamber and maintain the constant 

challenge as required. The concentration of challenge agent monitored 

using the appropriate Miran detector. 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 mask. It is required to start the MINICAMSs before 

introducing agent into the chamber so that the first sampling period will 

coincide with the first agent challenge.

5.2.22 The 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 air flow rate delivered from the MillerNelson. These values will be recorded in the laboratory notebook and test 

data sheets (Appendix C & D). 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.

5.2.23 The Miran Detector will be used to monitor the challenge concentration in 

the exposure chamber. This will be recorded on a computer with 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 30 of 46 

compatible software capable of accurately depicting the agent 

concentration versus time. 

5.2.24 System Hold or Monitor Time: Continue flushing the agent exposure 

chamber with the Miller-Nelson uncontaminated air to allow the 

simulation of the natural effects of ambient environmental conditions and 

the persistent vapor effects of HD. Ensure the breathing machine operates 

at the same rate for the remaining 5.5 hours. 

5.2.25 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 to document the SCBA’s 

failure before MINICAMS can be taken off the detection line. If 

disintegration of the SCBA during the test is perceived as a safety hazard, 

the test technician may terminate the test at his discretion. 

5.2.26 Termination of Test 

5.2.26.1 The test should be terminated when the full time for the test has 

elapsed. To terminate the test, turn off breather pump. 

Depressurize the SCBA by closing the compressed air feed or 

allowing the automatic high-pressure air system to cycle down 

air pressure. Purge the air from the SCBA by opening the 

purge valve, and allow air to drain while the primary air 

cylinder valve is open. When gauge reads zero on SCBA, close 

purge valve and close air cylinder valve. Disconnect SCBA in 

accordance with local lab safety procedures Perform a check 

shot of agent to assure that the detection system is still operating 

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

solutions of agent with a microliter syringe and inject it into the 

nasal sampling port by disconnecting the line from 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 test to be valid. 

5.2.26.2 Turn off the MINICAMS per laboratory SOP. Turn off MillerNelson airflow through the exposure chamber. Remove the test 

respirator, separate it into components and double-bag the 

components in accordance with laboratory SOP. Remove the 

bagged components to the decontamination hood for temporary 

storage. If requested, a manufacture representative may review 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 31 of 46 

the items at this time to perform reverse engineering analysis. 

This review must be approved by the laboratory manager. The 

test respirator will then be decontaminated, monitored and 

disposed according to laboratory SOP. Wipe down the interior 

of the agent exposure chamber and the SMARTMAN using 

approved decontaminating solution. Dispose of cleaning 

materials according to laboratory SOP. 

5.2.27 Step sequence of activities for HD liquid and vapor CBRN SCBA test. 

1. Conduct M40 preparation and background contamination assessment. 

2. Install SCBA in clean exposure chamber. 

3. Close clean exposure chamber, ensure SCBA is breathing. 

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

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

step or if failure, substitute failed SCBA with a new untested SCBA 

6. Install SCBA in agent exposure chamber. 

7. Photograph SCBA. 

8. Close agent exposure chamber, ensure SCBA is at maximum pressure 

limit and start breathing. 

9. Challenge SCBA with TDA-99M for 30 minutes 

10. Start MINICAMS 

11. Monitor background inside the mask and chamber concentration/check 

shot 

12. Conduct characterization for 60 min 

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

exposure chamber 

14. Add drops of HD per digital photo 

15. Record 6 hour vapor start time 

16. Start makeup air using Miller-Nelson Controller 

17. Start syringe pump 

18. Record start time of MINICAMS 

19. Record 30 minute vapor start time 

20. Initiate challenge agent 

21. Record challenge agent start time, vapor exposure 

22. Simultaneously start ambient challenge concentration profile software 

23. Monitor MINICAMS for detection, noted penetration peaks and 

saturation prevention. 

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

25. Record stop time for challenge agent vapor exposure. 

26. Record hold time start (5.5 hours) 

27. End test 

28. Record end time at 6.0 hours 

29. Conduct check shot instrumentation 

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30. Record check shot results. 

31. Prepare system for decon and removal of tested components. 

5.2.28 Data Analysis 

5.2.28.1 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 

checkshot or test start time. Supervisor must pre-approve any 

deviation from standard test method and signoff in technician’s 

notebook. 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. 

5.2.28.2 Laboratory manager and technician must complete all required 

Test Data Sheets (Appendix C & D). Originals of all Test Data 

Sheets must be completed and retained in the task file. NIOSH 

DEIMS is updated, at the minimum, every three days by the lab 

technician supervisor/principal investigator or equivalent. While 

an application is active and has information for update, the 

DEIMS should be updated daily with all applicable information 

to allow timely feedback and prevention of miscommunication. 

5.2.28.3 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) 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 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. 

5.2.28.4 Challenge Concentration Data: Using the computations 

generated from para 5.1.28.3 above. Plot the challenge 

concentration versus time and produce two data graphs that 

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track total detection events covering any maximum peak 

excursions over 6 hours and total concentration over time 

known, as Cumulative CT, covering the total 6 hours of 

potential cumulative and instantaneous dosages. If the test 

is terminated prior to the completion of 6 hours due to 

MINICAMS preventive measures, 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 this test is set within the regulatory authority of 42 CFR, 

Part 84, Subpart G, Section 84.63(c); Volume 60, Number 110, June 8, 1995. A 

compound, two tier pass/fail criterion must be met for GB and HD testing. The 

criterion is: 

 6.1.1. Sarin (GB) Penetration Test: 

 Challenge: 2000 mg/m3

 ± 10 % for 30 minutes (but not more than 31 

minutes) 

 Test Time: 6 hours 

 Dual Pass/Fail Criteria: 

 a) Maximum agent breakthrough: 2.1 mg-min/m3 (integrated 

concentration 

 over time or cumulative CT) 

b) Maximum Peak Excursions: 0.087 mg/m3

: Three consecutive data 

points at or exceeding the peak value constitutes a failure. 

 Note: Overall CT limit of 2.1 mg-min/m3

 including peaks cannot be 

exceeded during the 6 hour test time. 

6.1.2. Distilled Sulfur Mustard (HD) Penetration and Permeation Test: 

 Challenge: 300 mg/m3

 ± 10 % for 30 minutes (but 

not more than 31 minutes) proceeded by a forty three (43) 20 

l liquid droplet application 

 Test Time: 6 hours 

 Dual Pass/Fail Criteria: 

 a) Maximum agent breakthrough: 6.0 mg-min/m3 (integrated 

concentration 

 over time or Cumulative CT) 

b) Maximum Peak Excursions: 0.60 mg/m3 Three consecutive data 

points at or exceeding the peak value constitutes a failure. 

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 Note: Overall CT limit of 6.0 mg/m3

 including all peaks 

cannot be exceeded during the 6 hour test time. 

6.1.3 Precision and accuracy must be determined for each instrument in 

accordance with laboratory procedures. 

 

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 Open-circuit Self-Contained Breathing Apparatus (SCBA) with 

Full Facepiece 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). 

7. RECORDS\TEST SHEETS

7.1. All test data will be recorded in the NIOSH DIEMS using on the test data sheet 

formats (Appendix C, D & F). 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 and will be 

retrievable within 24 hour notification to the storing lab and be maintained in 

accordance with local administrative SOPs. 

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

SBCCOM/NIOSH 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, or extension of 

approval application, SBCCOM will send a test report to the NIOSH 

Certification Team Leader and prepare any uncontaminated hardware for 

return to the manufacturer. 

7.3.2. If a failure occurs on hardware examined under an Off-the-Shelf Audit the 

hardware will be examined by the laboratory 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 

will be disposed of in accordance with SBCCOM chemical surety 

practices. 

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Procedure No. RCT-CBRN-STP-0200, 0201 Revision: 1.1 Date: 3 June 2005 Page 45 of 46 

TORQUE (ft 

lb) 

4500 / 2216 / 3000 

(psi) 

DEPTH & DIAMETER 

(inches) ADAPTER 

80 ± 10 4500 / 2216 / 3000 0.102 ± 0.002 / 1.126 ± 0.003 LABELED 

“C” 

95-115 

(average 100) 4500 0.102 ± 0.002 / 1.126 ± 0.003 LABELED 

“C” 

70-75 4500 0.107 ± 0.002 / 1.145 ± 0.003 LABELED 

“D” 

90 ± 10 4500 0.107 ± 0.002 / 1.145 ± 0.003 LABELED 

“D” 

75 ± 10 2216 / 3000 0.107 ± 0.002 / 1.018 ± 0.003 LABELED 

“B” 

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Revision History 

Revision Date Reason for Revision 

1.0 22 May 2002 Multiple clarifications and corrections to the STP based upon the 

initial SCBA testing and approval evaluation processes.

1.1 3 June 2005 Update header information and format 

No changes to method 

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