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First Level Second Level Third Level Fourth Level 

National Institute for Occupational Safety and Health 

National Personal Protective Technology Laboratory 

P.O. Box 18070 

Pittsburgh, PA 15236 

Procedure No. TEB-CBRN-STP-0502 Revision: 0.0 Date: 21 November 2006

DETERMINATION OF CBRN ACID GASES (CYANOGEN CHLORIDE) SERVICE 

LIFE TEST, TIGHT-FITTING POWERED AIR-PURIFYING RESPIRATORS (PAPR) 

STANDARD TEST PROCEDURE (STP) 

1. PURPOSE

This test establishes the procedure for ensuring that the level of protection provided by the CBRN 

Acid Gases (Cyanogen Chloride) Service Life Test, Tight-Fitting Powered Air-Purifying 

Respirators Standard Test Procedure submitted for Approval, Extension of Approval, or 

examined during Certified Product Audits, meet the minimum certification standards set forth in 

42 CFR Part 84, Subpart G, 84.63(a)(c)(d); Volume 60, Number 110, June 8, 1995 and the 

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

Air-Purifying Respirator (PAPR). 

2. GENERAL

This STP describes Determination of CBRN Acid Gases (Cyanogen Chloride) Service Life Test, 

Tight-Fitting Powered Air-Purifying Respirators Standard Testing Procedure in sufficient detail 

that a person knowledgeable in the appropriate technical field can select equipment with the 

necessary resolution, conduct the test and determine whether the product passes the test. 

3. EQUIPMENT AND MATERIAL

3.1. The list of necessary test equipment and materials follows: 

3.1.1. Miller Nelson Research Model 401 Flow-Temperature-Humidity Control System 

or equivalent. This system 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 unit output is air of the 

variable volume/flow dependant on the size of unit (10% of max flow to max 

flow in Lpm ± 2%), and relative humidity (10-98 ± 3%) and temperature (20-30 

0

C ± 0.3%). 

3.1.2. EdgeTech Dew Prime II Hygrometer, Model 2000 or equivalent. A microprocessor based programmable chilled mirror dew point hygrometer. The 

hygrometer uses the dew point and ambient temperature to calculate the relative 

humidity. Ambient temperature range is: -50oC to 130oC ± 0.2oC; relative 

humidity is 1% to 95% ± 0.5% 
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3.1.3. Labview software developed for NIOSH Service Life Testing. 

3.1.4. California Analytical Instruments, Model 1314 Photoacoustic Multigas Monitor 

with UA0985 optical filter or equivalent. This monitor uses photoacoustic 

infrared detection to measure gases that absorb infrared light. A filter is used to 

select the wavelength specific for the gas being detected. Range for cyanogen 

chloride is 1000 to 0.1 ppm ± 0.01 ppm. Two detectors are used, one for 

challenge concentration and one for downstream concentration 

3.1.5. Mass Flow Controller, Brooks Instruments, variable flow rate depending on use. 

3.1.6. Read out and Control Electronics, Brooks Instruments, Model 0154. Power 

supply and controller for the Brooks Mass Flow Controller or equivalent. The 

flow controllers are an integrally mounted control valve module with which 

stable gas flows can be achieved. Various flow rates are used with an accuracy of 

± 0.7 % of rate and ± 0.2 % full scale. 

3.1.7. Dry Test Meter, American Meter Co., model and size depending on air flow to be 

measured. Must have NIST traceable calibration certificate. 

3.1.8. Cyanogen chloride cylinder, 99 % purity, with regulator and purge valve. 

3.1.9. Kin-Tek491 MB Basic Gas Standards Generator with cyanogen chloride 

permeation tubes that are certified to NIST standard or equivalent. 

3.2 Test fixture for mounting canisters. 

3.3 The test chamber consisting of an air tight box with door opening lined with gasket 

material. Two fittings located on the test chamber for the introduction of the test 

concentration and for the exit of the test fixture. This fixture is not commercially 

available 

3.4 Resistance tester equipment as described in standard test procedures RCT-APR-0003 and 

RCT-APR-0007. 

3.5 Airflow measurement equipment as described in standard test procedure RCT-APR0012. 

4. TESTING REQUIREMENTS AND CONDITIONS

4.1 For tight-fitting PAPR, this test procedure is only valid if the respirator system has first 

completed NIOSH Standard Test Procedure entitled Durability Conditions Process For 

Environmental, Transportation And Rough Handling Conditions On Chemical 

Biological, Radiological and Nuclear (CBRN) Respiratory Protective Devices (RPD) 

Standard Conditioning Procedure (SCP). 

4.2 Prior to beginning any testing, all measuring equipment to be used must have been 
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Procedure No. TEB-CBRN-STP-0502 Revision: 0.0 Date: 21 November 2006 Page 3 of 11 

calibrated in accordance with the manufacturer's calibration procedure and schedule. At a 

minimum, all measuring equipment utilized for this testing must have been calibrated 

within the preceding 12 months using a method traceable to the National Institute of 

Standards and Technology (NIST). 

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

subject to the provisions of the NIOSH Supplier Qualification 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 Institute. 

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

4.5 Compressed gas cylinders must meet all applicable Department of Transportation 

requirements for cylinder approval as well as retesting / requalification. 

4.6 Normal laboratory safety practices must be observed. This includes safety precautions 

described in the current NIOSH Pittsburgh Health and Safety Program. 

4.6.1. Safety glasses, lab coats and hard-toe shoes must be worn at all times. 

4.6.2. Workbenches must be maintained free of clutter and non-essential test 

equipment. 

4.6.3 When handling any broken glass laboratory equipment, lab technicians and 

personnel must wear special gloves, which protect against lacerations or 

punctures. 

4.7 Please refer to Material Safety Data Sheets and the NIOSH Health and Safety 

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

chemicals and gases used in this procedure.

5. PROCEDURE 

Note: Reference Section 3 for equipment, model numbers and manufacturers. For calibration 

purposes use those described in the manufacturer's operation and maintenance manuals. 

5.1 Follow individual instruction manuals for set up and maintenance of equipment used in 

this procedure prior to beginning testing. Malfunctioning equipment must be repaired or 

replaced and properly set up and calibrated before starting all tests. 

5.2 Calibrate both photoacoustic monitors for cyanogen chloride using the Kin-Tek gas 
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generator and cyanogen chloride permeation tubes. The challenge monitor is calibrated 

for the challenge concentration of 300 ppm and the downstream monitor is calibrated for 

the breakthrough concentration of 2 ppm. Make any necessary adjustments to the 

Labview software so that the concentration display on the software agrees with the 

detector. 

5.3 Set up test equipment as shown in Figure 1. The humidity reading controlled by the 

Miller Nelson system and monitored the Dew Point Hygrometer. The sample pickup for 

the hygrometer is place into the air stream via a tee after the Miller Nelson and before the 

introduction point of challenge agent. The thermocouple for the hygrometer is placed in 

the challenge gas stream immediately before the test chamber. 

5.4 Verify the following equipment is on: 

5.4.1 Air and water supplies. 

5.4.2 Miller Nelson Unit. 

5.5 Establish the correct humidity and temperature as per the test standard in paragraph 6.3. 

5.6 Set the required airflow for the system. Individual canisters will be tested by dividing 

115 Lpm by the number of air-purifying elements on the system. See appendix 8.2. 

Verify the airflow from the test fixture using the appropriate dry test meter. 

5.7 Weigh and record initial weight of the test canister on Test Data Sheet. 

5.8 Take and record initial airflow measurements in accordance with RCT-APR-012. See 

section 84.1152 (b) Title 42, Code of Federal Regulations, Part 84 for minimum airflow 

requirements. 

5.9 Take and record initial inhalation resistances for tight-fitting PAPR in accordance with 

RCT-APR-007. See Sections 84.122, 84.203, 84.1157 Title 42, Code of Federal 

Regulations, Part 84 for breathing resistance requirements. 

5.10 Mount canister onto test fixture and place in testing chamber. 

5.11 Ensure that the nitrogen gas is ready for immediate flushing of regulator through the 

purge valve. 

5.12 Turn on the cyanogen chloride cylinder. 

5.13 Establish the test concentration of 300 ppm ± 30 ppm cyanogen chloride. 

5.14 Once the cyanogen chloride concentration has been established, testing may begin. 

5.15 Direct challenge concentration airflow into test chamber. 

5.16 Start timer. Airflow out of the fixture is directed into the breakthrough detector. Monitor 
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Procedure No. TEB-CBRN-STP-0502 Revision: 0.0 Date: 21 November 2006 Page 5 of 11 

and record the upstream and downstream temperatures of the air stream throughout 

testing. Record breakthrough values and times. 

5.17 Run test until breakthrough of 2 ppm is observed or selected service life time is 

surpassed. Record this data on the test data sheet. 

5.18 Direct challenge concentration airflow out of test chamber. 

5.19 Weigh and record final weight of the test canister on Test Data Sheet. 

5.20 Take and record final airflow measurements in accordance with RCT-APR-012. See 

section 84.1152 (b) Title 42, Code of Federal Regulations, Part 84 for minimum airflow 

requirements. 

5.21 Take and record final inhalation resistances for tight-fitting PAPR in accordance with 

RCT-APR-007. See Sections 84.122, 84.203, 84.1157 Title 42, Code of Federal 

Regulations, Part 84 for breathing resistance requirements. 

5.22 Allow clean air to purge through system for 5 minutes. 

5.23 Repeat steps 5.5 through 5.21 for each test described in section 6.3. 

5.24 When all tests are completed turn off cyanogen chloride cylinder, set temperature and 

humidity to zero and allow air to pass through the system for 30 minutes. 

6. PASS OR FAIL CRITERIA

6.1. The criterion for passing this test is set forth in 42 CFR Part 84, Subpart G, 

84.63(a)(c)(d); Volume 60, Number 110, June 8, 1995. 

6.2. This test establishes the standard procedure for ensuring that: 

 84.63 Test requirements; general. 

(a) Each respirator and respirator component shall when tested by the applicant and 

by the Institute, meet the applicable requirements set forth in subparts H through 

L of this part. 

(c) In addition to the minimum requirements set forth in subparts H through L of this 

part, the Institute reserves the right to require, as a further condition of approval, 

any additional requirements deemed necessary to establish the quality, 

effectiveness, and safety of any respirator used as protection against hazardous 

atmospheres. 

(d) Where it is determined after receipt of an application that additional requirements 

will be required for approval, the Institute will notify the applicant in writing of 

these additional requirements, and necessary examinations, inspections, or tests, 
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Procedure No. TEB-CBRN-STP-0502 Revision: 0.0 Date: 21 November 2006 Page 6 of 11 

stating generally the reasons for such requirements, examinations, inspections, or 

tests. 

6.3. Acid Gases (Cyanogen Chloride) Test for CBRN Canisters 

6.3.1 Inhalation resistance to airflow of system will be taken before and after each test 

6.3.2 Airflow measurements of system must be taken before and after each test. 

6.3.3 Three canisters will be tested at the determined, continuous air flow, 25 % ± 2.5 

% relative humidity (RH), 25 o

C ± 2.5 oC and 300 ppm cyanogen chloride. 

6.3.4 Three canisters will be tested at the determined, continuous air flow, 80 % ± 2.5 

% relative humidity (RH), 25 oC ± 2.5 o

C and 300 ppm cyanogen chloride. 

6.3.5 Minimum service life will be 15, 30, 45, 60, 90 or 120 minutes as per 

manufacturer request. End of service life concentration is 2 ppm cyanogen 

chloride. 

7. RECORDS AND TEST SHEETS

7.1. All test data will be recorded on the DETERMINATION OF CYANOGEN CHLORIDE 

SERVICE LIFE test data sheet. 

7.2. All videotapes and photographs of the actual test being performed, or of the tested 

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 the failure occurs on a new certification application, or extension of approval 

application, send a test report to the TEB Team Leader and prepare the hardware 

for return to the manufacturer. 

7.3.2. If the failure occurs on hardware examined under an off-the-shelf audit the 

hardware will be examined by a technician and the TEB Team Leader for cause. 

All equipment failing any portion of this test may be sent to the manufacturer for 

examination and then returned to NIOSH. However, the hardware tested shall be 

held at the testing laboratory until authorized for release by the Branch Chief, or 

the Branch Chief’s designee, following the standard operating procedures 

outlined in Procedure for Scheduling, and Processing Post-Certification Product 

Audits, RB-SOP-0005-00. 

8. APPENDIXES

 8.1 Bench Top Set-Up 
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Procedure No. TEB-CBRN-STP-0502 Revision: 0.0 Date: 21 November 2006 Page 7 of 11 

 8.2 Airflow calculations 

 8.3 Test Data Sheet
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Procedure No. TEB-CBRN-STP-0502 Revision: 0.0 Date: 21 November 2006 Page 8 of 11 

Appendix 8.1: Bench Top Set-Up 
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Appendix 8.2: Service life testing airflow calculations. 

Tight-fitting PAPR 

___________ Number of filtering elements on a tight-fitting PAPR System. 

115 Lpm airflow 

Airflow for service life test = 115 Lpm / number of filtering elements 

Test Flow 

4 Canisters 3 Canisters 2 Canisters 1 Canister 

28.8 Lpm 38.3 Lpm 57.5 Lpm 115 Lpm 
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Appendix 8.3: Test Data Sheet 
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Revision History 

Revision Date Reason for Revision 

0.0 21 November 2006 Original Issue