National Institute for Occupational Safety and Health 

National Personal Protective Technology Laboratory 

P.O. Box 18070 

Pittsburgh, PA 15236 

Procedure No. TEB-CBRN-STP-0507 Revision: 0.1 Date: 2 June 2008

DETERMINATION OF CBRN BASE GASES (AMMONIA) 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 

Base Gases (Ammonia) 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, Section 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 the CBRN Base Gases (Ammonia) Service Life Test, Tight-Fitting Powered 

Air-Purifying Respirators Standard Test Procedure test 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 or not 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. 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. The capacity of the unit is airflow: 20 to 200 liters / 

minute +/- 2%), relative humidity: 20 to 90 +/- 3 % and temperature ambient to 

35 o

C +/- 1oC 

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%. 

Approvals: 

First Level Second Level Third Level Fourth Level 

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3.1.3. Air-Sentry IMS Ammonia Analyzer, Model 10R-NH3-4000M or equivalent. The 

analyzer is a system component that monitors the concentration of ammonia 

using the technology of Ion Mobility Spectroscopy. The analyzer range for 

ammonia is 1 to 3000 ppm ± 0.1 % of full scale. 

3.1.4. Air-Sentry IMS Ammonia Analyzer, Model 10R-NH3-50ppm or equivalent. The 

analyzer is a system component that monitors the concentration of ammonia 

using the technology of Ion Mobility Spectroscopy. The analyzer range for 

ammonia is 0.1 to 50 ppm ± 0.1 % of full scale. 

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 rate 

to be measured. Must have NIST traceable calibration certificate. 

3.1.8. Certified cylinder of approximately 12.5 ppm NH3 and 2500 ppm ammonia in 

Nitrogen. 

3.1.9. Ammonia cylinder, 99% purity. 

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-0007. 

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

4 TESTING REQUIREMENTS AND CONDITIONS

4.1. 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-0507 Revision: 0.1 Date: 2 June 2008 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. 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. 

4.4. 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. 

4.5. 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 may 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. After the manufacturer's specified warm-up period, adjust instruments to read zero and 

make adjustment for Labview software to read 0 ppm. Calibrate both ammonia analyzers 

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Procedure No. TEB-CBRN-STP-0507 Revision: 0.1 Date: 2 June 2008 Page 4 of 11 

using the certified gas cylinder containing approximately the 12.5 ppm and 2500 ppm 

ammonia. During calibration make adjustment for Labview software to read the 

appropriate concentration for 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. Miller Nelson Unit. 

5.4.2. Air and water supplies. 

5.4.3. NIOSH Service Life Apparatus Controller software program. 

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 worksheet 2 in 

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. Ensure that the diverter valve in the system is diverting the challenge concentration 

airflow to discharge and not into the testing chamber. 

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

5.12. Divert 0.8 Lpm airflow from airflow line to the ammonia challenge detector. 

5.13. Turn on ammonia cylinder. 

5.14. Establish the test concentration of 2500 ppm ammonia. 

5.15. Once the ammonia concentration has been established, testing may begin. 

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5.16. Direct challenge concentration airflow into test chamber. 

5.17. Start Timer. Airflow out of the fixture is directed into the breakthrough detector. Monitor 

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

testing. 

5.18. Run test until breakthrough of 12.5 ppm is observed or selected service life time is 

surpassed. Record this data on the test data sheet. 

5.19. Direct challenge concentration airflow out of test chamber. 

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

5.21. 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. 

5.22. 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 

5.23. Allow clean air to purge through test chamber for 5 minutes. 

5.24. Repeat steps 5.7 through 5.21 for each test described in section 6.3. 

5.25. When all tests are completed turn off ammonia 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, Section 

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 

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Procedure No. TEB-CBRN-STP-0507 Revision: 0.1 Date: 2 June 2008 Page 6 of 11 

additional requirements, and necessary examinations, inspections, or tests, stating 

generally the reasons for such requirements, examinations, inspections, or tests. 

6.3. Base Gases (Ammonia) 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 Lpm, continuous air flow, 25 % ±

2.5 % relative humidity (RH), 25 o

C ± 2.5 oC and 2500 ppm ammonia. 

6.3.4. Three canisters will be tested at the determined Lpm, continuous air flow, 80 % +

5 % relative humidity (RH), 25 o

C + 2.5 oC and 2500 ppm ammonia. 

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 12.5 ppm ammonia. 

7. RECORDS AND TEST SHEETS

7.1. All test data will be recorded on the determination of AMMONIA 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 CET Section Chief 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 CET Section Chief 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 CET Section 

Chief, or his designee, following the standard operating procedures outlined in 

Procedure for Scheduling, and Processing Post-Certification Product Audits, RBSOP-0005-00. 

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Procedure No. TEB-CBRN-STP-0507 Revision: 0.1 Date: 2 June 2008 Page 7 of 11 

8 APPENDICIES

8.1. Bench Top Set-up 

8.2. Test Data Sheet 

8.3. Service life testing airflow calculations

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Appendix 8.1: Bench Top Set-up Uncontrolled Copy 

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Procedure No. TEB-CBRN-STP-0507 Revision: 0.1 Date: 2 June 2008 Page 9 of 11 

Appendix 8.2: Test Data Sheet 

 

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Procedure No. TEB-CBRN-STP-0507 Revision: 0.1 Date: 2 June 2008 Page 10 of 11 

Appendix 8.3: Service life testing airflow calculations 

Tight-fitting PAPR 

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

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

Test Flow 

4 Cartridges 3 Cartridges 2 Cartridges 1 Cartridge 

28.8 Lpm 38.3 Lpm 57.5 Lpm 115 Lpm 

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Revision History 

Revision Date Reason for Revision 

0.0 21 November 2006 Original Issue 

0.1 2 June 2008 Editorial corrections – no change to technical content 

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