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. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005

DETERMINATION OF FULL FACEPIECE, TIGHT FITTING, NEGATIVE PRESSURE, AIRPURIFYING RESPIRATOR (APR) PERFORMANCE DURING DYNAMIC TESTING AGAINST 

THE CHEMICAL AGENT SARIN (GB) VAPOR CBRN STANDARD TESTING PROCEDURE (STP) 

1.0. PURPOSE 

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

provided under chemical, biological, radiological, and nuclear (CBRN) protection 

requirements for full facepiece, tight fitting, negative pressure, air-purifying respirators 

(APR) 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. 

1.2. The purpose of this standard test procedure (STP) is to describe the test procedure 

necessary to test and certify CBRN APR. This procedure is used to test CBRN APR 

against Sarin (GB) vapor while the respirator, as a system, is operated in a dynamic 

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

a given validated manikin headform. Instrumentation is integrated under this dynamic 

static chamber platform for the purpose of generating and controlling challenge 

concentrations and detecting precise agent penetration and permeation of a tested 

respirator system. 

1.3. The procedure is a separate test under the NIOSH National Personal Protective 

Technology Laboratory (NPPTL) heading of CET-APRS-STP-CBRN-0350 for challenge 

agent Sarin (GB) vapor. This procedure is designed to rigorously test the evaluated 

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

2. GENERAL

2.1. The STP describes a test titled “Determination of Full Facepiece, Tight Fitting, Negative 

Pressure, Air-Purifying Respirator (APR) Performance during Dynamic Testing against 

the Chemical Agent Vapor Sarin (GB)” 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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3. EQUIPMENT AND MATERIALS

3.1. SMARTMAN, Headform/Upper Torso or Equivalent (Figure 1). Manufactured by ILC 

Dover, Frederica, Delaware, the Simulant Agent Resistant Test Manikin, 

(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 silicone rubber and that fits into a channel between the face and 

the permanent part of the head. (See figure 1.) The seal is inflated to press against the 

inside of the facepiece seal area to assure against leakage. A face seal adjustment handle 

allows standard mechanical pressure to be exerted for securing the face seal. 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 headform and passes out the 

bottom of the headform. The largest tube, 11⁄4′′ in diameter, leads from the mouth area to 

the breather pump. Four smaller tubes are also present. 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. 

A second tube connects to the lower middle forehead above the bridge of the nose and 

can be used to monitor pressure or 

Figure 1. Headform/upper torso manikin, 

SMARTMAN. 

Differential pressure when connected by means of a manometer to the nose area. And 

finally, 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 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 3 of 30 

respirator system shrouds or other components as they are intended per manufacturer 

instructions. 

3.2. Leak Detector Model TDA-99M or Equivalent (Figure 2). Manufactured by Air 

Techniques International in Owings Mills, Maryland, the TDA-99M is one of the primary 

tools for accessing aerosol particulate leaks in the mechanical seals of the respirator and 

proper fit of a respirator to a clean SMARTMAN headform under non-toxic oil aerosol 

conditions. The TDA-99M generates a polyalphaolefin aerosol that is used to detect 

leakage in the respirator (Emery 3004 oil manufactured by the Henkel CorporationEmery Group or equivalent).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 100 mg/m3

. This aerosol is introduced by 

the TDA-99M’s pump. The respirator interior is quantitatively monitored for the presence 

of aerosol. The leak detector compares the concentration inside with the concentration 

outside, and calculates a digital read out percent penetration value. Dataport capabilities 

do exist for downloading data as software is published. 

3.3. Miniature Continuous Air Monitoring System, MINICAMS® or Equivalent (Figure 3). 

Manufactured by OI Analytical, the MINICAMS® is a gas chromatograph equipped with 

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

is a small tube containing an 

Figure 2. Leak detector model TDA-99M.

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 4 of 30 

Figure 3. Miniature Continuous Air Monitoring 

System, (MINICAMS®).

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, introduce it into the 

column and subsequently the detector. By pre-concentrating 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-

hour TWA 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. This is quantified at the beginning of 

each test, the detection instrumentation must remain stable for 60 minutes prior to the 

initiation of any test or evaluation. A minimum of two MINICAMS® are required in 

order to continuously monitor the interior of the respirator. NOTE: Next generation 

MINICAMS® and support equipment require successful NIOSH validation testing (Vtest) documentation before implementation. 

3.4. Syringe Pump, Sage® Model M365 or Equivalent (Figure 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. The rate flow range can be from 20.0 mL/min to 

0.3 L/hr, and flow accuracy of ± 5% nominal. 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 5 of 30 

Figure 4. Syringe pump, Sage® Model M365 

NOTE: Next generation syringe pumps or equivalent equipment and support equipment for data 

logging or automation, require successful NIOSH validation testing (V-test) documentation 

before implementation. 

3.5. Miller-Nelson® Flow-Temperature-Humidity Control System or Equivalent (Figure 5).

Manufactured by Miller-Nelson Research, Inc., this system, referred to as the MillerNelson® Control System, is an automated system to control the airflow, temperature, and 

humidity of an air supply for an operating respirator system. Laboratory specified 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 and flow 

(50–200 L/min ± 2%), and relative humidity (20%–80% ± 3%) and temperature (20°C–

30°C ± 0.3%)

Figure 5. Miller-Nelson® flow-temperature-humidity 

control system.

3.6. Exposure Chamber or Equivalent (Figure 6). The respirator exposure chamber is 

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

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 6 of 30 

equivalent material. The floor must be constructed efficiently 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 ft3

. Four legs made out of the same chemically 

resistant material are attached to the bottom to hold the chamber above the floor of the 

hood and allow room for laboratory tubing and the face adjustment handle. 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 mixtures. An electric fan is installed near the 

top front to achieve a mixed challenge concentration. A clean exposure chamber is a 

second chamber used to perform a fit and leak check on a respirator before it is installed 

in the agent exposure chamber (no agents are used in this chamber). An agent exposure 

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

Figure 6 shows a typical clean exposure chamber. 

3.7. Agent Mixing Chamber or Equivalent (Figure 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 airflow from the 

Miller-Nelson® Control System 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 filtration scrubber canister, a M18 military specification 

canister or equivalent. 

Figure 6. Exposure chamber.

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Figure 7. Mixing chamber.

3.8. Breather Pump, Model E1R1® or Equivalent (Figure 8). Manufactured by Jaeco Fluid 

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

operated by a single electric motor. The pump design is a modified variable speed motor 

generating varied strokes per minute. 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/min and drops back to zero. The exhalation stroke of the pump is the same 

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

Figure 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 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 8 of 30 

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 205B and Model 1A, or Equivalents (Figures 9 

and 10). Manufactured by Thermo Environmental Instruments, Inc. in Franklin, 

Massachusetts, these are 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. 

3.11. Test Material and Respirator System Quantities and Relevant Policy. 

3.11.1. Required Quantities: Quantity of respirators for GB Live Agent Testing (LAT) is 

per NIOSH/NPPTL CBRN APR Statement of Standard, Table 7, Test Sequence 

and Quantity Matrix. Overall GB LAT quantity is three complete respirator 

systems. One respirator system is tested as a qualifier in this STP and is 

commonly known as the Qualifier Live Agent Test (QLAT). Remaining two 

respirator systems are tested in sequence and are commonly known as the 

Remainder Live Agent Tests (RLAT). 

3.11.2. In the case of canisters, 125 canisters only go through hot, cold, humidity, 

vibration, and 117 of the 125 are manually dropped as a final conditioning 

process, before being tested in one of five types of follow on CBRN service life 

tests. RLAT penetration and permeation testing is one of those five types of 

service life tests for CBRN APR protocol. Initially, one respirator is required in a 

GB QLAT “as is/received”. Then, two environmentally conditioned canisters 

come out of environmental processing go to GB RLAT utilizing environmentally 

conditioned like respirators. Upon confirmation that the initial new application 

testing the QLAT samples are a success and completion of environmental 

conditioning, remainder LAT is completed by randomly selecting Task Number 

(TN) respirator systems for follow on remainder LAT, GB and HD, in 

accordance with CBRN APR Statement Of Standard, Paragraphs 4.7. and 4.9. 

Respirators designated as “spare queue” conditioned respirators are stored and 

available for use by the testing laboratory in situations where ongoing test 

processes are delayed or stopped by installation power failures, inaccurate test 

processing or other mid-test termination events identified by the test laboratory 

manager. In most cases, spare queue respirators are not to be used for additional 

certification testing because the applicant or manufacturer requests it. NIOSH 

should be informed of spare queue inventory testing conducted by the testing 

laboratory. 

3.11.3. Qualifier LAT (QLAT): New GB LAT canisters and face blanks should be 

received from NIOSH/NPPTL in a “as is/received” condition. No modifications 

to the tested canisters, components or APR are authorized prior or during live 

agent systems testing. At the NIOSH tenant laboratory initial certification 

qualifier application inventory conducted first, canisters received “as is” in the 

ready-to-use packaging are required to be inspected in accordance with the 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 9 of 30 

manufacturers user instructions (UI), kept in original packaging, and provided to 

testing laboratory upon completion of certification inventory. 

3.11.4. Remainder LAT (RLAT): Commencement of GB RLAT is contingent upon 

testable canisters completing all required NIOSH/NPPTL CBRN APR 

environmental durability processing prior to any live agent testing. 

Environmentally conditioned canisters can be attached per manufacturer 

instructions to available faceblanks prior to live agent testing by qualified and 

designated laboratory live agent testing technicians only. Environmentally 

conditioned canisters should be received in manufacturer specified minimum 

packaging and administratively labeled with a conditioning administrative 

number matching the task number. Only the manufacturer’s inlet and outlet plugs 

that come with the canister are to be used to seal up the canister after 

environmental testing. If no plugs are provided, no other form of sealant is 

authorized. Start of live agent testing must commence within 12 hours of 

receiving the environmentally pre-conditioned canisters and facepieces. Any 

canister damage during environmental processing is required to be preserved, not 

altered and noted on administrative reports to the NIOSH. 

3.11.4. If practical, GB live agent systems test canisters and respirators can be labeled 

prior to actual live agent testing with the following administrative information: 

— NIOSH task number (TN number) 

— Model of APR 

— 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 posttest investigations. 

4. TESTING REQUIREMENTS AND CONDITIONS

4.1. Any laboratory using this procedure to supply certification test data to NIOSH will be 

subject to the provisions of the NIOSH Supplier Qualifications Program (SQP). This 

program is based on the tenets of ISO/IEC 17025, the NIOSH Manual of Analytical 

Methods and other NIOSH guidelines. An initial complete quality system audit and 

follow on audits are requirements of the program. Additional details of the program and 

its requirements can be obtained directly from the NIOSH. 

4.2. Precision and accuracy (P&A) must be determined for each instrument in accordance 

with laboratory procedures and NIOSH/NPPTL guidance. Sound practice requires, under 

NIOSH Manual of Analytical Methods, demonstrating a tolerance range of expected data 

performance of a plus or minus 25% of a 95% confidence interval of the stated standard 

requirement. Actual NIOSH/NPPTL P&A tolerance can be higher but not lower. 

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

calibrated in accordance with its’ calibration procedure and schedule. At the minimum, 

all measuring equipment utilized for this testing must have been calibrated within the 

preceding 12 months or as required by manufacturer, using a quantifiable method 

traceable to the National Institute of Standards and Technology (NIST). 

4.4. System Test Conditions

4.4.1. Breathing Machine 

— Airflow = 40 liters per minute (Lpm) 

— Respirations = 36 ± 2 strokes per minute 

— Tidal Volume = 1.1 liters 

4.4.2. Miller-Nelson® Control System airflow settings into exposure chamber: 

Airflow Rate: The actual value here is to be determined based on laboratory test 

conditions and dependent method. The actual air flow value arrived at must be 

documented with a working equation showing supporting repeatable 

computations. Technicians determine an appropriate airflow rate based upon 

obtaining a stable concentration in the given volume of the exposure chamber 

and considering the agent challenge concentration desired, volume of chamber, 

breather pump airflow and dilution air exhaled from the APR. 

Relative Humidity: 50% ± 5% RH. 

Temperature: 25°C ± 3°C 

4.4.3. SMARTMAN Sampling Point: 

Breathing zone sampling point is a single SMARTMAN nasal port that allows 

sequential dual MINICAMS® detection monitoring. 

4.4.4. Sarin (GB) Vapor Test. 

4.4.4.1. GB vapor: General. 

— Vapor Challenge Concentration = 210 mg/m3

 ± 10% 

— Vapor Challenge Time (disseminator on) = 30 minutes, but 

no longer than 31 minutes 

— Monitor & Exposure Hold Time = 7.5 hours 

— Total Test Time = 8.0 hours 

— Syringe Injection Rate = as required based upon syringe 

pump used 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 11 of 30 

— Syringe Injected Volume = as required based upon syringe 

pump used 

NOTE: LAT vapor challenge concentrations for GB and HD are different. The 

GB vapor challenge concentration is 210 mg/m3 ± 10%, while that for HD is 50 

mg/m3 ± 10%. 

4.4.4.2. Liquid Sarin (GB) must be Chemical Agent Standard Analytical 

Reference Material (CASARM) grade. Agent purity analysis must be 

NIST traceable, documented and meet CASARM grade agent purity 

requirements. Proper CASARM storage requirements per local 

regulation are required to be adhered to. 

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

MINICAMS® detectors from over-saturation when a candidate APR shows 

failing criteria prior to the 8-hour mark. The decision termination point should be 

set at or above the highest calibration point for each one of the MINICAMS® in 

use. 

4.5. 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 Centers for Disease 

Control and Prevention (CDC) General Laboratory Health and Safety Manual, the 

applicable US Army Regulations, the U.S. Army Soldiers and Biological Chemical 

Command Laboratory Safety Procedures, and any other equivalent manuals and 

periodicals. 

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

required be available, worn and replaced as laboratory standard operating 

procedures apply. 

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

test equipment. 

4.5.3. When handling any glass laboratory equipment, lab technicians and personnel 

must wear approved gloves, which are rated appropriate in accordance with 

current safety and hygiene plans. 

4.5.4. 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. Training records are accountable 

during laboratory audits. 

4.5.5. The responsible technician must be knowledgeable about the specific CBRN 

APR being tested and should be able to readily identify all CBRN APR hardware 

components, subassemblies and accessories. Technicians are required to be able 

to support accurate trouble shooting of the CBRN APR and subassemblies to 

ensure it is operating in a correct negative pressure mode. The technician must be 

able to properly align and fit the respirator facepiece on the SMARTMAN 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 12 of 30 

headform, without malformation or destruction of any CBRN APR component or 

material. Correct nose-cup positioning is an example of one area that requires 

proper inspection per the UI. 

4.5.6. 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 APR materials is the 

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

manufacturers are released of equipment accountability once equipment is 

formally tested in the appropriate NIOSH recognized test laboratory. 

Manufacturer warning and caution statements for the respirators are subject to 

legal interpretation and most likely will not apply once the respirator has been 

contaminated by toxic chemical warfare agents and processed thru the 

decontamination procedure. 

4.5.7. 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. 

4.5.8. 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. 

4.6. Equipment Pre-Test Conditions: MINICAMS®

4.6.1. Background Reading: A laboratory MINICAMS®, as opposed to a field 

MINICAMS®, is used as the detector for agent permeation and penetration of the 

CBRN APR. It consists of a monitor, personal computer, linear mass flow meter 

and optional printer or recorder. Before the APR 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. A clean M40 

military specified respirator, mounted on the SMARTMAN head form, may be 

used. The SMARTMAN is then allowed to breathe for the required time (8, 12, 

48, 72 hours etc, however long it takes coupled with intermittent 

decontamination wipedowns as necessary.) 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) are within the limits 

specified. 

4.6.2. Unit of Measure. A small volume of air is drawn through a pre-concentrator tube 

containing an adsorbent material: GB sample volume is approximately 200 mL. 

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 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 13 of 30 

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. 

4.6.3. Sample Cycle. 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 minutes), depending on the application. GB analysis can require up to a 

4-minute cycle. The two MINICAMS® will be synchronized so that one 

MINICAMS® sampling begins when the other MINICAMS® sampling ends. 

Raw data results confirm this requirement. 

NOTE: LAT analysis cycles for GB and HD are different. GB analysis can require up to 

a 4-minute cycle whereas HD requires a 6-minute cycle. These times can be sub-divided 

into 2-minute cycles for each MINICAMS® during the LAT with GB and 3-minute 

cycles for each MINICAMS® during testing with HD. Raw data tables are required to 

demonstrate this repeatable process and the actual tables are required to be provide to the 

NIOSH in support of finalizing the NIOSH test report. 

4.6.4. GB Detection Principle. The MINICAMS® are installed in accordance with the 

operating manual. The appropriate optical filter for GB must be installed in front 

of the photomultiplier tube. In principle, when GB burns in a hydrogen flame, 

phosphorus 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. 

4.6.5. 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 μL) of a standard solution of the agent onto the pre-concentrator tube 

during the INJECT segment of the test cycle. The standard solutions of agent are 

made in spectrophotometric grade isopropanol. At least three injections of each 

quantity of agent should be injected. 

4.6.6. 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 internal lab work sheet/notebook 

— Standby for start of testing 

4.7. Equipment Pre-Test Conditions: SMARTMAN GB Vapor Generation. 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 14 of 30 

4.7.1. 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® 

Control System air controller and a syringe pump for injecting the agent through 

a heated “tee” into the air stream. Technicians 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 APR. 

4.7.2. Ramp-up Tome: Conditions for each individual system will have to be 

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

ARP exposure concentration. The ability to accurately detect and quantify this 

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

exposure time graphs should be available to confirm agent exposure duration in 

accordance with the procedures of this STP. 

4.7.3. Concentration Verification Summary:

GB Setup Variables: (Mass balance analysis method or another demonstrated 

equivalent method is used to confirm repeatable GB quantity sampling and 

amount of agent used per test.)

— Chamber size = 8 ft3

— Target Challenge Concentration = 210 mg/m3

 ± 21 mg/m3

— Ramp Up Time = 4–5 minutes (Time from initial start of syringe pump to 

189 mg/m3 lowest acceptable challenge concentration start point.) 

— Dilution Air from Breather Pump = 40 L/min 

— Miller-Nelson® Challenge Mixing Air = 50 L/min ± 2% 

— Syringe Rate for Challenge Injection = 0.34 mL/min 

— Total GB projected for use in 30 minutes = 10.2 mL

4.7.4. 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 chamber where it is thoroughly mixed, ready to be introduced 

into the exposure chamber for the test. Changes to this process require updating 

to NIOSH as necessary. 

4.8. Equipment Pre-Test Conditions: Miller-Nelson® Control System.

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 15 of 30 

4.8.1. The Miller-Nelson® receives compressed air from the laboratory air supply 

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

Insure it is calibrated correctly prior to starting the test. 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. Insure the total 

flow is logged in the technician’s logbook prior to commencing actual testing. 

Changes to this 

4.8.2. Set the readout panels on the Miller-Nelson® according to Paragraph 4.4.2. 

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

all required airlines are secure to inlet ports of SMARTMAN and MillerNelson® systems. Allow the clean air to flow through the mixing chamber and 

the M18 filter until it is time to start the test. 

4.9. Equipment Pre-Test Conditions: Syringe pump.

4.9.1. 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. 

4.9.2. 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. 

4.9.3. 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 a predetermined time. 

4.10. Equipment Pre-Test Conditions: TDA-99M Aerosol Leak Detector.

4.10.1. The TDA-99M leak detector is used to detect oil particulate aerosol leaks in the 

CBRN APR after it has been installed on the SMARTMAN headform cold 

box/clean chamber. Ensure the canister and all components are correctly 

mounted and tightened per the current manufacturer instructions and 

specifications. The APR is operated under negative pressure using air supplied to 

the APR from the Miller-Nelson® filtered house air of the laboratory. Ensure that 

procedures for the APR follow the manufacturer’s installation procedures for 

gasket seal, facepiece donning and interface. The canister and gasket, if provided, 

should be the same product that has undergone recent NIOSH/NPPTL 

environmental durability processing or in the “as is/received” condition. Ensure 

the seal, threaded interface inlet and outlet areas and canister housing are not 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 16 of 30 

changed in any manner prior to or after the LAT. However, if the canister or 

canister interface thread is deformed from environmental processing, 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 and available for follow up incident review 

if necessary. Advise NIOSH. 

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

manufacturer’s instructions. The APR 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. If no localized leaks are found, replace 

the front panel of the exposure chamber and start the actual TDA-99M test. 

4.10.3. 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 TDA-99M 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% for 30 minutes, the screening is complete. Continue with the next 

the test procedure. If a leak is detected by isolating the filter or canister, use a 

dedicated clean Teflon tube to draw clean air from the outside of the chamber to 

test the canister. Ensure Teflon tube data and configuration drawing is annotated 

in lab book. 

4.11. Equipment Pre-Test Conditions: Quality Control Measures.

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

unlikely, but possible, for leak paths to result. These may occur after extensive 

LAT or heavy dosage exposure due to incorrect APR assembly or mounting. 

They may form through the metal casting, allowing chemical warfare agent vapor 

to penetrate through the headform into the breathing zone 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 maximum pressure of 3 psi. 

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 headforms when they are in continuous daily use. 

4.11.2. Standardization of Instrumentation: Standardize the MINICAMS® by using 

liquid standard solutions of the agents at various concentrations. These solutions 

are made in accordance with US Army, 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 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 17 of 30 

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. Agent solutions must be stored 

at 4o

F or lower and periodically monitored with a calibrated thermometer. 

4.11.3 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® airflow controller, 

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

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

4.11.4. Aerosol Leak Testing: APR 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 TDA-99M should read 0.0000% 

penetration. 

4.11.5. 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 midrange 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 and preparations for a retest should 

start. A quantifiable check shot should be made within 3 hours of the start of the 

actual test and at the end of 8-hour mark. 

5. PROCEDURE 

5.1. Vapor Challenge GB (0350)

5.1.1. Assemble APR per manufacturer’s instructions. Ensure the packaged canister is 

received as specified in Paragraph 3.11 and CBRN APR Statement of Standard, 

Paragraph 4.10, Table 7, Note 2. The note here identifies the canisters only being 

in the “minimum manufacturer’s recommended packaging”, which is interpreted 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 18 of 30 

as the manufacturers specified packaging for storage of the canister. Facepieces 

will be tested “as is/received” when submitted in the qualifier application, 

conditioned in the remainder application and matched with appropriate 

conditioned canisters in accordance with CBRN APR Statement of Standard.

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 APR was configured with all 

components and tested. 

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 and 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. If 

batteries are required for communications devices, ensure they are available and 

easily fit into the device but do not expose them to live agent. Rather during 

TDA-99M aerosol testing, ensure the batteries are in the communications device 

and the device is turned on during aerosol screening but then take the batteries 

out for live agent testing. Contaminated batteries place an undue burden on the 

test laboratory and do not substantiate the use of extensive disposal methods to 

dispose of them. Properly close the communications device for malfunctions 

during the course of the test and visually check it and other accessories at the 

termination of the test for visible cracks or breaches of the airflow boundary or 

material detioration. 

5.1.4. Turn on the breathing pump. Insure that the APR is in the negative pressure 

mode by conducting negative pressure seal check(s) with protected hand over 

required surfaces of the tested respirator per on hand current manufacturer 

operating instructions or use instructions. Use the integrated SMARTMAN 

magnehelic pressure gauge as required to support confirmation of negative 

pressure cycles. Magnehelic pressure gauge is used only as a qualitative indicator 

of APR performance and it can serve as a tool for cyclic air flow observation to 

confirm the APR is “breathing”. Do not allow the tested CBRN APR to go into 

or maintain positive pressure for any reason, such as misdirected house air from 

air flow tubing cracks, kinks or line failure. 

5.1.5. Using the TDA-99M, leak test the APR in the negative pressure mode, connect 

the detector inlet to a sample line from the SMARTMAN, allow the APR to 

breathe, and create a stable value on the TDA-99M. If a communications device 

is present ensure batteries are installed and it is operational. 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 technicians 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 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 19 of 30 

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 30 minutes of continuous TDA-99M operations below 0.0010% 

penetration. If penetration exceeds 0.0010%, the TDA-99M alarm sounds or the 

digital readout shows higher values, stop the 30-minute test, re-analyze the 

system and begin a new 30-minute test period. The APR must pass a continuous 

30-minute test at ≤ 0.0009% penetration parameters in separate clean exposure 

chamber and an 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 such as sealing the facepiece and nosecup to the 

headform using non-toxic adhesive with the concurrence of the NIOSH/NPPTL. 

All adhesive designated for CBRN 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 confirmed MSDS to NIOSH, on the type of particulate being picked up by 

the TDA-99M. In addition, the manufacturer must obtain an analysis by a third 

party laboratory confirming the manufacturer’s MSDS and the toxicity of the 

particulates. 

5.1.6. Before the APR respirator facepiece can be placed on the SMARTMAN in the 

agent exposure chamber, the MINICAMS® must show 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®. 

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

GB agent exposure chamber. 

5.1.8. Conduct a second TDA-99M 30-minute test, but this time in the agent 

exposure/hot box chamber by repeating paragraphs 5.1.3.–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 agent exposure chamber 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 APR 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 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 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 20 of 30 

laboratory manager and if necessary remove the APR, decon the headform, redon 

the APR and restart the procedure for characterization as necessary. If the APR is 

removed from the headform, restart the procedure at Paragraph 5.1.8. 

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

within calibration. 

5.1.12. Set the Miller-Nelson® for air flow into exposure chamber set to deliver required 

rates. See Paragraph 4.7.3. 

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

the required agent challenge concentration. See Paragraph 4.8 (GB). 

5.1.14. Ensure MINICAMS® is standardized, perform check shot, and ready for 

operating mode. Annotate the check shot time and concentration percentage. 

5.1.15. Ensure that the challenge concentration instrument is calibrated and is ready for 

analysis. Monitor agent exposure chamber during the 60-minute background 

characterization period. Characterization reading should reflect a steady state 

condition. 

5.1.16. 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. 

5.1.17. Introduce GB vapor agent challenge 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 50 L/min from the MillerNelson®, 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 is monitored using the Miran 

detector or equivalent. 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 monitoring the interior of the APR. 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. 

5.1.18. 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 Miller-Nelson. These values will be 

recorded in the laboratory notebook and test sequence sheets. 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. 

5.1.19. The MIRAN® 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 and 

generating a final concentration detection graph per max peak attained and 

overall CT. 

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5.1.20. System Hold or Agent Decay 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 vapor effects of GB. Ensure the breathing machine operates at the same 

rate for the remaining 7.5 hours. 

5.1.21. 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 breathing zone breakthrough concentration to protect the 

MINICAMS® against saturation. If the APR is failing, the MINICAMS® must 

record three consecutive maximum peak excursions to document the APR’s 

failure before MINICAMS® can be taken off the detection line. Maximum peak 

values and overall Ct calculation and end point must be documented to show 

reliable and repeatable data collection. 

5.1.22. Procedures for Termination of Test: 

5.1.22.1. 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 or fail criteria on CT are determined 

after 8-hour completion and raw data tabulation. To terminate the test, 

turn off the breather pump. 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 agent contained in 

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

the final check shot test to be valid. 

5.1.22.2. Turn off the MINICAMS® per laboratory SOP. Turn off MillerNelson® 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. If 

requested, a manufacture representative may view the APR this time, 

in accordance with local surety safety standard operating procedures. 

The test respirator will then be decontaminated, monitored and 

disposed of 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. Test Service Agreements (TSA) between the 

manufacturer and the test laboratory on materials swatch testing or 

entire respirators is an option to the applicant.. However, in support of 

the TSA testing concept, the NIOSH/NPPTL CBRN Respirator 

Research and Development (R&D) Test Program does provide for use 

of dedicated NIOSH test equipment in support of research and 

development, R&D that is separate and distinct from certification. 

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5.1.23. Abbreviated Sequence 

1. Conduct M40 preparation and background contamination assessment. 

2. Install APR in clean exposure chamber. 

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

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

5. Verify that clean APR has passed TDA-99M, retest or refit, go to next step or 

if failure, substitute failed APR with a new untested APR. If RLAT, ensure 

an environmentally conditioned canister is used. 

6. Install APR in agent exposure chamber. 

7. Photograph APR. 

8. Close agent exposure chamber, ensure APR is in negative pressure mode and 

start breathing. 

9. Challenge APR with TDA-99M for 30 minutes in the agent exposure 

chamber. 

10. Start MINICAMS®. 

11. Monitor background inside the APR and chamber concentration/check shot. 

12. Conduct characterization for 60 minutes. 

13. Start makeup air using Miller-Nelson® while simultaneously starting 

ambient challenge concentration detection profile software. 

14. Start syringe pump. 

15. Record start time of MINICAMS®. 

16. Initiate challenge agent. 

17. Record challenge agent start time of vapor exposure. 

18. Simultaneously start ambient challenge concentration profile software. 

19. Monitor MINICAMS® for detection, noted penetration peaks and saturation 

prevention. 

20. Stop syringe pump at 30-minute mark. 

21. Record stop time for challenge agent vapor exposure. 

22. Record hold time start (7.5 hours). 

23. End test. 

24. Record end time at 8.0 hours. 

25. Conduct check shot instrumentation. 

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

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

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5.1.24. Data Analysis 

5.1.24.1. 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 or failure, check 

shots and test start and end times. Lab supervisor must gain NIOSH 

approval prior to pre-approving any deviation from NIOSH standard 

test procedure and signoff 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 and 

maintained in accordance with NIOSH policies concerning the FOIA. 

5.1.24.2. Laboratory manager and technician must complete all required test 

data sheets. Originals of all test data sheets must be completed and 

retained in the task file. Test data sheets for CBRN APR candidates 

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

easily transferred in standard email. NIOSH DEIMS, current version, 

will assign TNs, maintain the CBRN APR test queue and process all 

initial, lab and final reviews. While an application is active in testing 

and has information for update, no release of test information to third 

party agencies of any type is authorized. NIOSH is the only agency 

authorized to tell the applicant the status of final test results. The 

transfer of applicable files sent to NIOSH should be updated daily or 

weekly with all applicable information to allow timely feedback and 

prevention of miscommunication. Testing lab is required to insure all 

summary data sheets are reviewed for accuracy prior to final 

submission to NIOSH/NPPTL in a timely manner. NIOSH requires 

test data summary sheets, test data graphs showing max peaks and 

separate graphs showing CT, raw test data and one digital picture of 

before and after testing. 

5.1.24.3. Transfer the penetration and 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 x time) is calculated by multiplying the 

collection duration time by 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 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 24 of 30 

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

table. 

5.1.24.4 Challenge Concentration Data: Using the computations generated 

from Paragraph 5.1.24.3, plot the challenge concentration versus time 

and produce two data graphs that track total detection events covering 

any maximum peak excursions over 8 hours and total concentration 

over time known, as cumulative CT, covering the total 8 hours of 

potential cumulative and instantaneous dosages. If the test is 

terminated prior to the completion of 8 hours due to MINICAMS® 

preventive measures or the APR failing, the 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 OR FAIL CRITERIA

6.1. The criteria for passing this test is set within the regulatory authority of the U.S. 

Department of Health and Human Services, 42 CFR, Part 84, Subpart G, Section 

84.63(c); Volume 60, Number 110, June 8, 1995. A dual-pass-data criteria must be 

simultaneously met for GB passing test results. The criteria are: 

6.1.1. Sarin (GB) Test: 

Challenge: 210 mg/m3

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

Test Time: 8 hours 

Dual Pass or Fail Criteria: 

a) Maximum Agent Breakthrough (Ct) = 1.05 mg·min/m3

. Concentration 

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

time of approximately 2 minutes for 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 = 0.044 mg/m3. Three consecutive data points at or 

exceeding the peak value constitutes a failure where each test value is based on 

detection sample time of approximately 2 minutes for 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 lab manager final determination 

under advice from NIOSH/NPPTL. 

NOTE: Any APR test that fails as a result of laboratory test equipment failure or 

malfunction, laboratory electrical power loss or incorrect technician operating procedures 

or actions will be considered by NIOSH/NPPTL as a test termination and immediate 

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

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 25 of 30 

no additional cost to NIOSH/NPPTL or the manufacturer concerned, retests the 

respirator. 

Table 1, Vapor Challenge of CBRN APR with Sarin (GB), Chemical Warfare/Terrorism Nerve Agent:

Challenge 

Concentration

Vapor 

Concentration 

(mg/m3

) 

Vapor 

Challenge 

Time 

(minutes)

Breathing 

Machine 

Airflow 

Rate(L/min)

Maximum 

Peak 

Excursion 

mg/m3

Maximum 

Breakthrough 

(concentration 

integrated 

over minimum 

service 

life)(mgmin/m3)

Number 

of 

Systems 

Tested 

Minimum 

Service 

Life 

(hours)

GB 210(1) 30 40 0.044(3) 1.05(4) 3 8(2)

(1) The vapor challenge concentration generation will be initiated immediately after test chamber has been sealed.

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

(3) Three consecutive sequential test data points at or exceeding 0.044 mg/m3 will collectively constitute a failure where each test value is based on a detector sample time of approximately 2 

minutes. 

(4) The cumulative Ct including all maximum peak excursion data points must not be exceeded for the duration of the test. 

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 full facepiece, tight fitting, negative pressure air purifying respirator 

submitted for approval, extension of approval, or examined during certification product 

audits, meet the minimum certification standards set forth in 42 CFR, Part 84, Subpart G, 

Section 84.63(a)(c)(d). 

7. RECORDS AND TEST SHEETS

7.1. All test data will be recorded and transmitted to NIOSH using approved NIOSH test data 

sheet formats. 

7.2. Typical test data required by NIOSH for this STP is raw data of MINICAM readings, 

conversion of raw data into test trial graphs depicting agent concentration exposure curve 

over time and the official NIOSH test data sheet summarizing the test trials and results. 

7.3. A digital photograph is required to be taken at the beginning of each independent test. If 

observable defects are noted at the end of test, another digital photograph is required to 

be taken to document the observable defects. All applicable data, graphs and photographs 

taken or 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 from NIOSH and maintained in accordance with local 

administrative SOPs. 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 26 of 30 

7.4. 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. 

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

7.5.1. If a failure occurs on a new certification application, or extension of approval 

application, RDECOM will send a test report to the NIOSH Certification Team 

Leader and prepare any uncontaminated hardware for return to the manufacturer. 

7.5.2. 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 chemical surety practices. 

7.5.3. Sample information for a data test report is in Appendix A. Actual NIOSH test 

report, test data sheets, graphs and raw data are maintained separately from this 

STP for quality assurance requirements. 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 27 of 30 

APPENDIX A 

CBRN APR GB LAT Certification Test Data Summary Sheet 

(Test Data Sheet 1 of 3)

1. TEST TITLE: Determination of Full Facepiece, Tight Fitting, Negative Pressure, Air-Purifying 

Respirator (APR) Performance During Dynamic Testing Against Chemical Agent Sarin (GB) 

Vapor. 

A. Task Number (TN): __________________________________________ 

B. Manufacturer: __________________________________________ 

C. APR Model # and Components (Hydration device, communications device, shroud, etc.)

 _______________________________________ 

D. Qualifier Application Test Date: __________________________ 

E. Remainder Application Test Dates: ___________________ 

2. REQUIREMENT: 

Three of each CBRN full facepiece, tight fitting, negative pressure, CBRN Cap 1, 2, 3 or 4, 

consecutive air-purifying respirators (APR) shall demonstrate no permeation or penetration of 

Sarin (GB) vapor 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. GB vapor challenge concentration will start immediately 

after the test chamber has been sealed. Three consecutive sequential test data points at or 

exceeding 0.044 mg/m3

 will collectively constitute a failure where each test value equals to or 

exceeds 0.044 mg/m3 and is based on a detector sample time of approximately 2 minutes. The 

cumulative CT, 1.05 mg·min/m3

, including all maximum peak excursion data points, must not be 

exceeded for the duration of the test. The test period begins upon initial generation of GB vapor 

concentration and ends at 8 hours. 

OVERALL RESULT: PASS or FAIL

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 28 of 30 

APPENDIX A (Continued) 

CBRN APR GB LAT Certification Test Data Summary Sheet

(Test Data Sheet 2 of 3) 

3. SUPPORTING REQUIRED DATA: 

A. Has canister expired in accordance with user instructions? YES or NO. 

B. Is canister bent, cracked or disfigured prior to LAT? YES or NO. 

C. Is facepiece fully serviceable prior to LAT? YES or NO. 

D. Are sub-assemblies free of visible deformations or aberrations? YES or NO. 

E. Was all lab test equipment verified calibrated prior to LAT? YES or NO 

GB CBRN APR LAT Certification Test Report Continuum: 

Task Number: __________________ STP No.: ___________________ 

Manufacturer: __________________ Reference No.:___________________ 

A. Did each APR pass or fail maximum peak excursions? PASS or FAIL 

B. Did each APR pass or fail Ct? PASS or FAIL 

QUALIFIER TEST # 1 Total Test Time Max Peak Excursions Ct RESULT

 e.g., TN –GB 1 480 minutes or less Quantity failing Value PASS or FAIL 

REMAINDER TEST # 2 Total Test Time Max Peak Excursions Ct RESULT

 TN – GB 2 same as above(SAB). SAB SAB SAB 

REMAINDER TEST # 3 Total Test Time Max Peak Excursions Ct RESULT

 TN – GB 3. SAB SAB SAB SAB 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 29 of 30 

APPENDIX A (Continued) 

CBRN APR GB LAT Certification Test Data Summary Sheet

(Test Data Sheet 3 of 3) 

4. COMMENTS: 

For example, “CBRN APR XXXX was tested in the “as is” configuration for initial qualifier 

application and passed. However, when conditioned APR were tested in RLAT CBRN APR 

failed max peak excursion criteria, most likely due to canister thread dents and bends as a result 

of environmental conditioning prior to RLAT.” 

5. SIGNATURES: 

A. Laboratory Technician: _________________________ Date: _______________ 

 (Signature) 

 ________________________ 

 (Printed Name) 

B. Laboratory Supervisor: _________________________ Date: _______________ 

 (Signature) 

 ________________________ 

 (Printed Name) 

Legible signatures mean concurrence with test summary data and results as indicated. 

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Procedure No. CET-APRS-CBRN-STP-0350 Revision: 0.1 Date: 29 September 2005 Page 30 of 30 

Revision History 

Revision Date Reason for Revision 

0 24 December 2003 Interim Guidance Version: Initial version dated March 18, 2003 

was converted from an interim guidance STP to a draft final 

standard test procedure dated December 24, 2003. Integration of 

actual NIOSH DIEMS test data sheet was standardized between the 

STP and the NIOSH administrative project management system 

(DIEMS). 

0 30 September 2004 Final STP: Incorporated next generation equipment guidance on 

MINICAMS® and syringe pump into STP. Inserted GB 

performance values table from standard. Added registered 

trademarks. 

0.1 29 September 2005 Update header and format to reflect lab move from Morgantown, 

WV 

No changes to method 

 

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