PORTACOUNT MODEL 8040 and 8048 Operation / User Manual Rev F May 2021

Contents Warranty... iii Safety ... v Description of Labels and Markings ... v RoHS ... vi ... vi Chemical Safety ...vii Laser Safety ... viii CHAPTER 1 Introduction and Overview ... 1 Why Fit Test ... 1 Preparations for Fit Testing ... 2 Identifying Parts ... 2 Reordering Supplies ... 7 Install FitPro™ Ultra Fit Test Software ... 7 Access and Install FitPro™ Ultra Fit Test Software ... 8 CHAPTER 2 Prepare the PortaCount® Fit Tester for Operation ... 9 Install the Twin Tube Assembly... 9 Prepare the Alcohol Cartridge ... 10 Connect the PortaCount® Fit Tester ... 13 Supply Power to the PortaCount® Fit Tester ... 14 Connect to FitPro™ Ultra Fit Test Software ... 15 Connect Wirelessly (optional)... 15 Using a Particle Generator (optional) ... 17 CHAPTER 3 FitPro™ Ultra Fit Test Software Operation ... 19 The Main Menu... 19 Fit Test History Feature and Multi-Respirator Fit Test Card Feature ... 29 CHAPTER 4 Daily Checks ... 33 Daily Check History Feature ... 35 CHAPTER 5 Real-Time FitCheck® Mode ... 37 Real-Time Training ... 37 Concentration Check ... 39 CHAPTER 6 Fit Testing ... 41 Precautions for Fit Testing ... 41 About Respirators and Fit Testing ... 42 Probed Test Respirators ... 42 i

Probes for Filtering-Facepiece (Disposable) Respirators... 44 Inserting a Test Probe in a Disposable Respirator with the TSI® Model 8025-N95 Probe Kit ... 44 Conducting a Fit Test... 48 Record/Print Results ... 55 CHAPTER 7 Manage Data... 57 Import/Export from CSV ... 57 Multiple Database Support ... 60 Custom Fields ... 62 CHAPTER 8 Preventive Maintenance, Service, and Troubleshooting ... 65 Maintenance ... 65 Troubleshooting ... 71 APPENDIX A Specifications ... 79 Model 8040 PortaCount® Respirator Fit Tester ... 79 Model 8048 PortaCount® Respirator Fit Tester ... 81 APPENDIX B The Rainbow Passage ... 85 Index ... 87

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Warranty Copyright© TSI Incorporated / 2017-2021 / All rights reserved. Part Number 6010633 / Revision F / May 2021 Address TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA Fax No. (651) 490-3824 LIMITATION OF WARRANTY AND LIABILITY (effective February 2015) (For country-specific terms and conditions outside of the USA, please visit www.tsi.com.) Seller warrants the goods, excluding software, sold hereunder, under normal use and service as described in the operator's manual, to be free from defects in workmanship and material for 24 months, or if less, the length of time specified in the operator's manual, from the date of shipment to the customer. This warranty period is inclusive of any statutory warranty. This limited warranty is subject to the following exclusions and exceptions: a. Hot-wire or hot-film sensors used with research anemometers, and certain other components when indicated in specifications, are warranted for 90 days from the date of shipment; b. Pumps are warranted for hours of operation as set forth in product or operator’s manuals; c. Parts repaired or replaced as a result of repair services are warranted to be free from defects in workmanship and material, under normal use, for 90 days from the date of shipment; d. Seller does not provide any warranty on finished goods manufactured by others or on any fuses, batteries or other consumable materials. Only the original manufacturer's warranty applies; e. This warranty does not cover calibration requirements, and seller warrants only that the instrument or product is properly calibrated at the time of its manufacture. Instruments returned for calibration are not covered by this warranty; f. This warranty is VOID if the instrument is opened by anyone other than a factory authorized service center with the one exception where requirements set forth in the manual allow an operator to replace consumables or perform recommended cleaning; g. This warranty is VOID if the product has been misused, neglected, subjected to accidental or intentional damage, or is not properly installed, maintained, or cleaned according to the requirements of the manual. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty with respect to, and shall have no liability in connection with, goods which are incorporated into other products or equipment, or which are modified by any person other than Seller. The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE. WITH RESPECT TO SELLER’S BREACH OF THE IMPLIED WARRANTY AGAINST INFRINGEMENT, SAID WARRANTY IS LIMITED TO CLAIMS OF DIRECT INFRINGEMENT AND EXCLUDES CLAIMS OF CONTRIBUTORY OR INDUCED INFRINGEMENTS. BUYER’S EXCLUSIVE REMEDY SHALL BE THE RETURN OF THE PURCHASE PRICE DISCOUNTED FOR REASONABLE WEAR AND TEAR OR AT SELLER’S OPTION REPLACEMENT OF THE GOODS WITH NON-INFRINGING GOODS.

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TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES, INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE GOODS. IN THE CASE OF SOFTWARE, SELLER WILL REPAIR OR REPLACE DEFECTIVE SOFTWARE OR IF UNABLE TO DO SO, WILL REFUND THE PURCHASE PRICE OF THE SOFTWARE. IN NO EVENT SHALL SELLER BE LIABLE FOR LOST PROFITS, BUSINESS INTERRUPTION, OR ANY SPECIAL, INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS OR CHARGES. No Action, regardless of form, may be brought against Seller more than 12 months after a cause of action has accrued. The goods returned under warranty to Seller's factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk of loss. Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY, which contains the complete and exclusive limited warranty of Seller. This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its terms waived, except by writing signed by an Officer of Seller. Disclaimer:

The measurement provided by the PortaCount® Respirator Fit Tester is an assessment of respirator fit during a fit test only. Respirator fit at other times will vary. The fit factor value is not intended for use in calculating an individual's actual exposure to hazardous substances.

Trademarks TSI, TSI logo, FitCheck, and PortaCount are registered trademarks of TSI Incorporated in the United States and may be protected under other country’s trademark registrations. FitPro Ultra, PortaCount Academy, PortaPunch, and N95-Companion Technology are trademarks of TSI Incorporated. Wi-Fi is a registered trademark of the Wi-Fi Alliance. Microsoft is a registered trademark of Microsoft Corporation. Service Policy Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our customers, our service policy is designed to give prompt attention to any problems. If any malfunction is discovered, please contact your nearest sales office or representative, or call TSI's Customer Service department at (800) 680-1220 (USA) or (001 651) 490-2860 (International) or visit www.tsi.com.

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Safety This section provides instructions to ensure safe and proper operation of the PortaCount® Respirator Fit Tester Models 8040 and 8048.

Description of Labels and Markings This section acquaints you with the advisory and identification labels on the instrument and used in this manual to reinforce the safety features built into the design of the instrument. It also identifies instrument markings.

Warning

WARNING WARNING means that unsafe use of the instrument could result in serious injury to you or cause irrevocable damage to the instrument. Follow the procedures prescribed in this manual to use the instrument safely.

Caution

CAUTION CAUTION means be careful. It means if you do not follow the procedures prescribed in this manual you may do something that might result in equipment damage, or you might have to take something apart and start over again. It also indicates that important information about the operation and maintenance of this instrument is included.

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Serial Number Label

WEEE Marking

Wi-Fi® Indicator

Status Indicator

Safety Label

Indicates item is nondisposable and must be recycled.

RoHS PortaCount® Respirator Fit Tester Models 8040 and 8048 instruments meet the intent for RoHS Directive 2011/65/EU.

PortaCount® Respirator Fit Tester Models 8040 and 8048 instruments meet the intent of standard IEC61326-1:2013 Accessories 804004 and 804005 meet Criteria C for Standard 61326-1:2014 Method IEC61000-4-5:2014 TUV-SUD Safety Mark, Certificate U8 18 04 41468 023, issued 2018-4-20 PortaCount issued a KC-ID string on 2018-04-30: R-REM-tSiPortaCount804 Both PortaCount models; 8040 & 8048 are designated with the same KC-ID

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WARNING These instruments must be used in the manner described in this manual. Failure to follow all of the procedures described in this manual can result in serious injury to you or can cause irrevocable damage to the instrument. There are no user-serviceable parts inside the instrument. Refer all repairs to a qualified factory-authorized technician.

Chemical Safety WARNING FLAMMABLE. HARMFUL IF SWALLOWED OR INHALED. CAUSES IRRITATION. May be poisonous if inhaled or absorbed through skin. Keep away from heat, sparks and flame. Avoid Contact with eyes, skin and clothing. Avoid breathing vapor. Keep in tightly closed container. Use with adequate ventilation. Wash thoroughly after handling. PRECAUTIONARY STATEMENT. Ingestion may cause nausea, vomiting, headaches, dizziness, or gastrointestinal irritation. FIRST AID PROCEDURES. If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. In case of contact, immediately flush eyes or skin with plenty of water for at least 15 minutes. If swallowed, and victim is conscious, have victim drink water or milk.

The alcohol used with these instruments is 99.5% pure or greater purity reagent grade isopropyl alcohol. It must be stored, cared for and disposed of properly. The use of other grades/types of alcohol will damage the instrument. Use these instruments in a clean area. •

DO NOT use in areas with corrosive or acidic atmospheres.

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Laser Safety The PortaCount® Models 8040 and 8048 are Class 1 laser-based instruments. During normal operation, the user will not be exposed to laser radiation. However, certain precautions must be taken or you may expose yourself to hazardous radiation in the form of intense, focused visible light. Exposure to this light can cause blindness.

DANGER DO NOT remove parts from the instrument unless specifically told to do so in this manual. DO NOT remove the instrument housings or covers while power is supplied to the instrument.

WARNING The use of controls, adjustments, or procedures other than those specified in this manual may result in exposure to hazardous optical radiation.

A급 기기 (업무용 방송통신기자재) 이 기기는 업무용(A급) 전자파적합기기로서 판매자 또는 사용자는 이 점을 주의하시기 바라며, 가정외의 지역에서 사용하는 것을 목적으로 합니다.

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CHAPTER 1

Introduction and Overview This manual describes both the PortaCount® Model 8040 and 8048 Respirator Fit Tester Hardware and FitPro™ Ultra Fit Test Software. The Model 8040 is designed to measure fit factors of respirators with a filter efficiency of 99% or greater. The Model 8048 includes N95-Companion™ Technology, which can fit test any tight-fitting respirators and all filtering facepiece air-purifying respirators including: NIOSH Series 100/99/95; and FFP3/FFP2/FFP1 disposables.

Why Fit Test There are two primary reasons for respirator fit testing: Verification of Training

After the individual has received respirator training, a fit test checks that the person has learned how to properly put on and wear a respirator without assistance.

Sizing

It is important to make sure that the individual is issued a properly sized respirator that is capable of providing protection when worn properly.

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Preparations for Fit Testing Training the Trainer

The person conducting the fit test must have a clear understanding of respiratory protection, respirators, and fit testing to be effective. Anyone can master the operation of the PortaCount® Respirator Fit Tester simply by studying this manual, but the background knowledge required to proficiently fit test cannot be obtained here. Consider attending a seminar on fit testing provided by TSI® PortaCount® Academy or from various consultants. Contact TSI® for PortaCount® Academy Scheduled training events.

Respirator Training

Respirator training is critical for any respiratory protection program. All employees who wear respirators must be taught how and why they are used. This training should be done prior to the fit test, not during the fit test. Consult the regulations or standards that pertain to your industry for information on training requirements.

Identifying Parts The following items are included with PortaCount® Respirator Fit Testers. If any are missing or damaged, please notify TSI® immediately. Use the photographs below to identify connectors, parts, and accessories of the PortaCount® Fit Tester. You need to be familiar with these items when following the instructions in this manual.

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Description

For use with

Respirator Fit Tester Model 8040/8048

8040 or 8048

Reference Picture

Chapter 1

Description

For use with

Alcohol Cartridge; a porous wick inside is soaked with alcohol.

8040 and 8048

Alcohol Fill Capsule; holds the isopropyl alcohol consumed by the PortaCount® Fit Tester.

8040 and 8048

Storage Cap; covers either the cartridge cavity of the PortaCount® Fit Tester or the alcohol fill capsule.

8040 and 8048

Zero Check Filter – 2 pieces; provides for the zero check and max fit factor check on the PortaCount® Fit Tester to make sure it is working properly. A spare filter is also provided.

8040 and 8048

Spare Alcohol Wicks – 2 pieces.

8040 and 8048

5 ft. (1.5 m) Twin Tube Assembly; consists of a pair of tubes: the clear sample tube and the blue ambient tube.

8040 and 8048

Introduction and Overview

Reference Picture

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4

Description

For use with

Spare Sampling Port Inlet Screens; used to help keep the PortaCount® Fit Tester internal flow path clean by capturing large or fibrous particles.

8040 and 8048

1/8 to 1/4 Tube Adapter; used to connect the sample tube to a respirator sample fitting (or probe) that has a ¼ inch (6.3 mm) fitting.

8040 and 8048

1/8 to 3/16 Tube Adapter; used to connect the sample tube to a respirator sample fitting (or probe) that has a 3/16 inch (4.8 mm) fitting.

8040 and 8048

AC Adapter; plugs into the external power connector on the PortaCount® Fit Tester and an AC wall outlet.

8040 and 8048

30 ml Isopropyl Alcohol Bottles 16 pieces (480 ml total).

8040 and 8048

Reference Picture

Chapter 1

Description

For use with

Quick Start Guide; for helping you get started quickly.

8040 and 8048

Carrying Case; provides protection and convenience. The case is designed to hold the PortaCount® Fit tester and standard accessories.

8040 and 8048

USB Cable: used to connect the PortaCount® Fit Tester to a tablet or computer.

8040 and 8048

Probe Assembly Tool: used to help assemble probes.

8048

Probe Kit (100 pieces).

8048

Neck Strap; to support twin tube when fit testing filtering facepiece respirators.

8048

Introduction and Overview

Reference Picture

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6

Description

For use with

Model 8026 Particle Generator; to supplement the ambient particle concentration in the fit testing area (optional).

8048

Package of 100 Salt Tablets (100 mg); for use with Model 8026 Particle Generator.

8048

Power Cord: for use with Model 8026 Particle Generator.

8048

Extra Lid: for use with Model 8026 Particle Generator.

8048

Durable Carrying Case; for use with Model 8026 Particle Generator.

8048

Reference Picture

Chapter 1

Reordering Supplies TSI® part numbers for consumable supplies, accessories, and miscellaneous replacement parts are: Model/Part No. 8016 8033 803X-ZFLTR 8017

800197 8034 6006456 8032 8032-FC 8032-SC 8032-CT WF-USBD 803X-CRDFRM 8025-N95 804004 804005

Description Box of 16, 30 ml Bottles of Isopropyl Alcohol (480 ml total) Box of 10 Alcohol Wicks Zero Check Filter Sampling Hose Kit with 3 Twin Tube Assemblies and 10 each 3/16 in. and 1/4 in. Tube Adapters. Twin Tube Assembly (Quantity 1) AC Adapter for PortaCount® Fit Tester (voltage sensing) PortaCount® Fit Tester Quick Start Guide Alcohol Cartridge and Fill Capsule Kit for PortaCount® Fit Tester Alcohol Fill Capsule with Storage Cap Storage Cap Alcohol Cartridge with Wick Wi-Fi® USB Dongle Punch-out Card Forms (250 sheets) Filtering Facepiece Probe Kit USB Hub, 4 USB-A Ports USB-A(M) to USB-A(F) Ext Cable, 6 ft/2 m

Install FitPro™ Ultra Fit Test Software The PortaCount® Fit Tester is controlled with FitPro™ Ultra Fit Test Software running on a tablet or a personal computer. The minimum requirements for a tablet or personal computer are:

Tablet Requirements •

Microsoft® Windows® 10 operating system.

•

1 free USB port.

Introduction and Overview

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Personal Computer Requirements •

Microsoft® Windows® 7 (32- and 64-bit) or Windows® 10 (32- and 64-bit) operating systems.

•

Microsoft.Net version 4 (installation software will install Microsoft.Net if necessary)

•

≥1 GHz processor.

•

≥1280 x 800 screen resolution.

•

1 free USB port.

•

500 MB free storage on hard drive

NOTICE An internet connection is required to install FitPro™ Ultra software and Microsoft.Net.

Access and Install FitPro™ Ultra Fit Test Software Use your tablet or computer to access the TSI® software and firmware wizard at: https://www.tsi.com/support/tsi-software-and-firmwarewizard/. Follow the instructions to download the software. Then run the FitPro™ Ultra Fit Test Software installer. For questions refer to detailed software installation instruction sheet included in your instrument case. Or call Customer Support at 1-800-680-1220 (USA), (651) 490-2860, or 001 651 490-2860 (International) or visit www.tsi.com/support. To start the FitPro™ Ultra Software, double-click on the icon. The software will present default configuration options that can be changed later if needed. See Chapter 2 to connect the instrument and begin fit testing.

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Chapter 1

CHAPTER 2

Prepare the PortaCount ® Fit Tester for Operation Install the Twin Tube Assembly The PortaCount® Fit Tester has two inlet fittings, one colored blue and one colored silver. Connect the twin tube assembly to the corresponding inlet fittings; the blue tube to the blue fitting and the clear tube to the silver fitting. The clear tube samples particles inside the respirator. Ambient particles outside the respirator are sampled through the blue tube.

NOTICE The twin tube MUST NOT be lengthened except for the few inches added by a tube adapter. NEVER split the ambient and respirator tubes, they must remain together and the two sample tubes must be nearly the same length for accurate fit testing.

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Prepare the Alcohol Cartridge The wick must be saturated with isopropyl alcohol for the PortaCount® Fit Tester to make particle measurements. Fill the alcohol cartridge as follows.

WARNING FLAMMABLE. HARMFUL IF SWALLOWED OR INHALED. CAUSES IRRITATION. May be poisonous if inhaled or absorbed through skin. Keep away from heat, sparks and flame. Avoid Contact with eyes, skin and clothing. Avoid breathing vapor. Keep in tightly closed container. Use with adequate ventilation. Wash thoroughly after handling. PRECAUTIONARY STATEMENT. Ingestion may cause nausea, vomiting, headaches, dizziness, or gastrointestinal irritation. FIRST AID PROCEDURES. If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. In case of contact, immediately flush eyes or skin with plenty of water for at least 15 minutes. If swallowed, and victim is conscious, have victim drink water or milk.

NOTICE Any dirt or debris that gets into the PortaCount® Fit Tester can plug the small internal nozzle and prevent operation. • DO NOT allow the black part of the alcohol cartridge to make contact with any surface that may be dirty. Keep the storage cap and alcohol cartridge clean. • The alcohol cartridge is inserted into the cartridge cavity during use. It is critically important to keep dirt and lint out of the cartridge cavity. • Cover the cartridge cavity with the storage cap (see Step 10) when the instrument is not being used and when transporting the PortaCount® Fit Tester.

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Chapter 2

1. Make certain the PortaCount® Fit Tester is turned off. 2. Remove the alcohol cartridge from the PortaCount® Fit Tester by twisting it counter-clockwise. 3. Open the alcohol fill capsule by twisting the storage cap off (counterclockwise). 4. Set the storage cap and alcohol cartridge down on a clean surface to prevent contamination. 5. Open a 30-ml bottle of alcohol. Invert the bottle and insert the nozzle end into the alcohol fill capsule as far as possible to make certain alcohol is not inadvertently sprayed anywhere except into the capsule. 6. Squeeze alcohol into the alcohol fill capsule. When 30 ml is added to an empty alcohol fill capsule, the alcohol level will rise to the fill-line when the wick is inserted. 7. Recap the empty alcohol bottle immediately.

Prepare the PortaCount® Fit Tester for Operation

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