corpro R1400 Operating manual

Core Protection Systems Ltd
1A Millfield Lane
Haydock
St Helens
WA11 9TW
United Kingdom
[phone]
[email protected]
www.corpro.systems
Registered in England & Wales
Company No 10002483, VAT No GB270 0319 41
© Copyright, 2021. Version: 1.1, May 2021
Training and Maintenance
A COMPREHENSIVE GUIDE

© Copyright, Core Protection Systems Ltd, 2021 Page 1
Contents
1. Document Scope and Structure ....................................................................................................4
2. Definitions ......................................................................................................................................6
3. Guidance.........................................................................................................................................7
3.1 HM1400 Half Mask......................................................................................................................7
3.1.1 General Training ....................................................................................................................7
3.1.1.1 Choosing your Mask size ................................................................................................8
3.1.1.2 Donning and Doffing your Half Mask ............................................................................. 9
3.1.1.3 Fit Checking your Half Mask......................................................................................... 10
3.1.1.4 During Use..................................................................................................................... 11
3.1.2 Maintenance ........................................................................................................................ 11
3.1.2.1 Shelf Life ....................................................................................................................... 11
3.1.2.2 General Maintenance ................................................................................................... 12
3.1.3 Cleaning and Disinfection ................................................................................................... 12
3.1.4 Storage................................................................................................................................. 13
3.1.5 Maintenance Intervals......................................................................................................... 13
3.1.6 Disposal................................................................................................................................ 14
3.2 FFM1600 Full Face Mask.......................................................................................................... 15
3.2.1 General Training .................................................................................................................. 15
3.2.1.1 Choosing your Mask size .............................................................................................. 15
3.2.1.2 Donning and Doffing your Full Face Mask ................................................................... 15
3.2.1.3 Fit Checking your Full Face Mask................................................................................. 16
3.2.1.4 During Use..................................................................................................................... 17
3.2.2 Maintenance ........................................................................................................................ 17
3.2.2.1 Shelf Life ....................................................................................................................... 18
3.2.2.2 General Maintenance ................................................................................................... 18
3.2.3 Cleaning and Disinfection ................................................................................................... 18
3.2.4 Storage................................................................................................................................. 19
3.2.5 Maintenance Intervals......................................................................................................... 19

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3.2.6 Disposal................................................................................................................................ 20
3.3 F1100 Filter Range ................................................................................................................... 20
3.3.1 General Training .................................................................................................................. 21
3.3.1.1 Fit your Filters............................................................................................................... 21
3.3.2 Maintenance ........................................................................................................................ 22
3.3.2.1 Shelf Life ....................................................................................................................... 22
3.3.2.2 General Maintenance ................................................................................................... 23
3.3.3 Cleaning and Disinfection ................................................................................................... 23
3.3.4 Storage................................................................................................................................. 24
3.3.5 Disposal................................................................................................................................ 25
3.4 Accessories................................................................................................................................ 25
3.4.1 Spectacle Kit........................................................................................................................ 26
3.4.1.1 Assembly, Attachment and Removal........................................................................... 26
3.4.1.2 Shelf Life, Cleaning and Storage .................................................................................. 28
3.4.1.3 Disposal......................................................................................................................... 28
3.4.2 Portacount Adapter............................................................................................................. 29
3.4.2.1 HM1400 Assembly, Attachment and Removal............................................................. 29
3.4.2.2 FFM1600 Assembly, Attachment and Removal ........................................................... 30
3.4.2.3 Shelf life, Cleaning and Storage................................................................................... 31
3.4.2.4 Disposal......................................................................................................................... 32
3.4.3 Spray Barrier........................................................................................................................ 32
3.4.3.1 Donning and Doffing..................................................................................................... 33
3.4.3.2 Shelf Life ....................................................................................................................... 33
3.4.3.3 Cleaning Procedures and Storage ............................................................................... 34
3.4.3.4 Disposal......................................................................................................................... 34
3.4.4 Exhale Barrier ...................................................................................................................... 35
3.4.4.1 Donning and Doffing..................................................................................................... 35
3.4.4.2 Storage and Disposal.................................................................................................... 36
3.4.5 Pre-filter and Pre-filter Holder ............................................................................................ 36
3.4.5.1 Donning and Doffing..................................................................................................... 37
3.4.5.2 Shelf Life ....................................................................................................................... 38

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3.4.5.3 Cleaning and Disinfection ............................................................................................ 38
3.4.5.4 Storage.......................................................................................................................... 38
3.4.5.5 Disposal......................................................................................................................... 39
3.5 Spares ........................................................................................................................................ 39
3.5.1 Component Identification................................................................................................... 40
3.5.2 Changing Components........................................................................................................ 41
3.5.2.1 HM1400 – Changing the Endoskeleton and/or Bayonets ........................................... 41
3.5.2.2 HM1400 – Changing the Elastic Strap, Harness and/or Buckles................................. 42
3.5.2.3 HM1400 – Changing the Valves .................................................................................... 43
3.5.2.4 FFM1600 – Changing the Endoskeleton and/or Bayonets .......................................... 44
3.5.2.5 FFM1600 – Changing the Valves ................................................................................... 45
3.5.2.6 FFM1600 – Changing the Bezel..................................................................................... 46
4. Further Advice .............................................................................................................................. 49
References ............................................................................................................................................ 50
Appendix 1............................................................................................................................................ 50

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1. Document Scope and Structure
The purpose of this document is to provide comprehensive guidance for the training and
maintenance of Corpro products. This document may be used and/or referenced by:
•Distributors of Corpro products who may provide product assistance to customers
•Those who act as a Corpro Service Centre
•Health and Safety / Infection Control Leads who are advising others on how to appropriately
wear and maintain Corpro products
•Individuals who wear Corpro products as part of their occupational uniform
The current scope of the Corpro product range is as follows:
•HM1400 Half Mask
•FFM1600 Full Face Mask
•F1100 Filter Range (with 9 filter variants)
•Range of Accessories (including the medical Barrier products and the Portacount adapter)
•Range of Spares for both the HM1400 half mask and the FFM1600 full face mask
Training may or may not be necessary for all products within the Corpro range.
The general structure of the document will be as follows:
1. HM1400 Half Mask
a. How to use/wear, shelf life, how to maintain, clean and store, disposal
2. FFM1600 Full Face Mask
a. How to use/wear, shelf life, how to maintain, clean and store, disposal
3. F1100 Filter Range
a. How to select and use/wear, shelf life, how to maintain, clean and store, disposal
4. Accessories
a. More detail on accessories which require certain procedures for effective usage
b. How to use/wear, longevity, how to maintain, clean and store, disposal
5. Spares
a. Spare identification and how to change certain spare parts
b. NB: This section does not cover all spares, but references the processes for the more
commonly used spares
To aid in customer training and support, we provide a wealth of instructional and informational
videos. If such a video exists for a certain procedure, a web link will be included in the appropriate
section. However, should you wish to browse the current selection of videos, you are able to here:
https://vimeo.com/corpro

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This document is purely for training and maintenance guidance and therefore does not cover the
following topics:
•The approvals, features and benefits of Corpro products
•Fit testing protocols
A Corpro Representative will be able to provide information and advice on the above points separately
to this document.
This guide is for information purposes only. Choices made are ultimately the responsibility of Health
and Safety personnel using or distributing the products due to their specific knowledge of their
area/working environment. If considering usage of Corpro products, it would be best to read the
entirety of this document as well as speak to a Corpro Representative to allow fully informed
respiratory safety equipment choices to be made.
Corpro reserves the right to update or amend this document at any time without prior notice. Version
number specified on the cover page footer, as applicable. Additionally, as part of Appendix 1, any
changes from previous versions will be referenced, explained and dated.

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2. Definitions
Certain terms and acronyms may be used throughout the document which are specific to the
respiratory / health and safety industries.
•Adequacy: According to the UK’s Health and Safety Executive (HSE) in their practical guide
‘HSG53’1, when we refer to RPE as ‘adequate’, we mean “it is right for the hazard and reduces
exposure to the level required to protect the wearer’s health”.
•Adjusting: ‘Adjusting’ a mask means to alter the positioning of one or many of the mask
components whilst wearing the mask with the aim of achieving a better fit.
•Fit: When discussing how well a tight-fitting respirator ‘fits’, it means how well the facepiece
seals onto the face. If a mask is poorly fitted, the mask is likely to allow air ingress.
•Fit test vs Fit check: Fit testing is different to fit checking. A fit test should be carried out as
part of the RPE selection process, before being worn in hazardous environments, to establish
the most adequate and suitable RPE for the wearer. This should be performed at least once a
year or after a long period of storage, and should be undertaken by an accredited fit tester. A
fit check is a procedure that should be performed by the wearer every time they don their RPE,
and this confirms whether a seal has been achieved.
•Leak test: Another name for a ‘fit test’ (see above). Other phrases which can be used are ‘leak
tightness test’ and ‘functional leak test’.
•Negative pressure check: Another name for ‘fit check’ (see above).
•Respirator: As defined by the HSE in HSG531, respirators (filtering devices) “use filters to
remove contaminants from the air being breathed in.”
oFurther, for context, ‘non-powered respirators’ rely “on the wearer’s breathing to
draw air through the filter”.
•PPE: Personal protective equipment.
•RPE: Respiratory protective equipment.
•Suitability: According to the HSE in HSG531, when we refer to RPE as ‘suitable’, we mean “it is
right for the wearer, task and environment, such that the wearer can work freely and without
additional risks due to the RPE”.
•Tight-fitting facepiece: As defined in HSG531, tight-fitting facepieces “rely on having a good
seal with the wearer’s face” and “a face fit test should be carried out to ensure the RPE can
protect the wearer”.

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3. Guidance
For your information, facial hair should be removed in advance of wearing tight-fitting respiratory
equipment such as the Corpro HM1400 half mask or the FFM1600 full face mask. This is because facial
hair will reduce the effectiveness of the seal between the mask and face. If an individual cannot clean-
shave for personal or religious reasons, they should speak to an appropriate Respiratory Health and
Safety individual within their organisation to discuss RPE options.
During cleaning procedures, be aware that the products may be contaminated before disinfecting.
Wear PPE before and during cleaning processes to reduce risk and dispose of/clean such PPE
appropriately and safely after use. All cleaning should be undertaken in a sterile or uncontaminated
environment.
Keep all Corpro products out of reach of children – small parts may be a choking hazard.
3.1 HM1400 Half Mask
The Corpro HM1400 Half Mask is a reusable, elastomeric respirator which requires an appropriate pair
of F1100 range filters attached (depending on airborne contaminants; both filters must be of the same
type and class). See section 3.3 for more information about the F1100 range filters. The mask can also
be used with various Corpro accessories (specified in section 3.4).
3.1.1 General Training
This section will cover the processes on how to appropriately select, wear, adjust and check the fit of
your HM1400.

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3.1.1.1 Choosing your Mask size
How to measure your face to establish the most likely HM1400 size for you. This process can be
undertaken in two ways.
NB: The most comfortable size for you, or the size which enables you to achieve a fit, may be different
from your recommended mask size depending on your facial features and preferences. Also, if in
between sizes (e.g., if you find your measurement to be between small and medium), both sizes
should fit but one size may be more comfortable than the other.
Instructional video: https://vimeo.com/corpro/choosing-your-mask-size
Pictorial instructions:
Written instructions:
Option 1 – Self measurement and sizing chart
1. Measure the distance from the bridge of your nose to the tip of your chin using any convenient
measuring tool. Do not follow the contour of your nose.
2. You can either download and print your mask sizing chart from
www.corpro.systems/resources, email [email protected]ms and ask for a downloadable
version, or request the chart directly from any Corpro Representative.
3. Use the sizing chart and map your measurements to find your most likely size.
Option 2 – Sizing calliper
The sizing calliper recommends your mask size without the need for explicit measurements. The
calliper can be purchased as an individual item.
1. Place the tip of the more curved, shorter side of the calliper on the tip of the chin and move
the other tip of the calliper gently towards the bridge of your nose until there is contact.

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2. Read the recommended size which is displayed on the calliper.
3.1.1.2 Donning and Doffing your Half Mask
How to put on and take off your half mask. Ensure you have established your recommended mask size
in advance of donning (see section 3.1.1.1).
Instructional video: https://vimeo.com/corpro/donning-and-doffing-your-half-mask
Pictorial instructions:
Donning –
Written instructions:
Step 1 – Donning
1. For first time use, ensure both your straps are released from the locked position. The strap is
‘unlocked’ when the strap is positioned over the locking tabs inside of the front cover.
2. Also loosen all straps prior to donning when using for the first time.
3. Fasten buckles around your neck and slightly tighten straps if necessary.
4. Securely locate the head cradle/harness on the crown of your head.
5. Adjust the mask and straps until secure and comfortable. The tension in the straps above and
below the oronasal should be balanced.

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6. Cover filter openings with your hands and perform a fit check. For fit checking procedure,
please see section 3.1.1.3.
Step 2 – Doffing
1. Remove head cradle/harness for temporary removal.
2. OR remove neck straps for temporary removal.
3. For full removal, release the head cradle/harness and then unlock the neck straps.
Locking the mask into position
1. To avoid refitting after each donning, lock the straps in place.
2. Open the front cover of the mask and secure the strap under the locking tabs.
3. Ensure tension in the straps above and below the oronasal in balanced and tug the straps
both above and below the front cover to make sure the locking was successful.
4. Repeat the process for both sides of the mask.
3.1.1.3 Fit Checking your Half Mask
The fit checking process for your half mask. A fit check should be performed each time you don your
mask.
Instructional video: https://vimeo.com/corpro/fit-checking-your-half-mask
Pictorial instructions:
Written instructions:
1. Don your mask. For the donning procedure, please see section 3.1.1.2.
2. Place the palm of your hands over the outward-facing openings on the filters.
3. Inhale and hold your breath for ten seconds to check the seal against your face. If fitted
adequately, the inhaled breath should cause the mask to press against your face and this

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should remain for the duration of the inhale/hold. Also move your head to test if the seal
holds.
4. If leakage occurs, adjust your mask and perform the fit check again.
3.1.1.4 During Use
WARNING: If you experience any of the following whilst wearing the product, leave the hazardous area
immediately and seek assistance.
•Breathing difficulty.
•Dizziness or nausea.
•You can smell or taste the contaminant.
•You experience any other noticeable side effects.
•Your equipment becomes damaged.
3.1.2 Maintenance
This section applies only to the mask itself and does not include the filters unless stated otherwise.
3.1.2.1 Shelf Life
It is recommended that the HM1400 product is fully serviceable for five years after the date of
manufacture. Manufactured date is on both the outer box and internal to the front cover on the mask
itself, below the exhale valve. After this time, it would be advisable to purchase a new mask.
It is wise to make a note of the manufactured date once the mask has been purchased, just in case the
outer box is lost or the front cover requires replacement. Shelf life may be reduced if damaged or not
adequately maintained. Replace mask immediately if damaged or showing visible signs of wear.

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3.1.2.2 General Maintenance
It is important to maintain RPE to ensure that it remains in good working order for wearer safety.
According to HSE guidance HSG531/ COSHH essentials R32, and in accordance with our manufacturer
instructions, RPE should be maintained at least once every three months (but ideally every month if
possible). Maintenance tasks include ensuring:
•RPE is generally free from dirt and cracks.
•Seals are fully intact.
•All components are in good condition, clean and free from breakages (for a full breakdown of
mask components, see section 3.5.1).
•The mask itself and the accompanying filters are within their expiration date.
Should any of your components on your mask need replacing, Corpro has a full range of spares which
can be purchased separately to the mask, along with instructions on how to change more commonly
purchased components. Please see section 3.5 for more information.
If you wear your respirator often, or if you work within an environment with high concentrations of
particulates and/or vapours, maintenance may be required on a more frequent basis. This should be
discussed with your organisational Respiratory Health and Safety personnel.
As part of your maintenance, it is advisable to fill in a Maintenance Log. This helps to keep track of
maintenance checks which have been performed and helps to identify when it would be beneficial to
act upon certain tasks. Corpro’s version of a Maintenance Log is available on the Corpro website
(https://corpro.systems/resources/), although if it is preferable, it is possible to generate your own
using HSE guidance.
NB: You should look over the mask and filters and perform a fit check (see section 3.1.1.3) each time
you don your mask. Do not wait for scheduled maintenance.
3.1.3 Cleaning and Disinfection
Ultimately, cleaning procedures, including cleaning frequency, depend on the working environment
and so this should be clarified based on organisational risk assessments. However, general advice can
be offered.
For thorough disinfection, it is advised to clean the respirator with one of the following solutions:
•Antibacterial soap and warm water (~ 40°C).
•10% bleach solution with water.
•60% or over isopropanol alcohol (IPA) products.

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•Hypochlorous acid products.
•Hydrogen peroxide solutions.
•Vapourised hydrogen peroxide (VHP).
•Equivalents to the above.
It does not matter how such cleaning solutions are administered. Once cleaned for at least five
minutes with one of the above, rinse the mask with plenty of water and leave to dry. Ensure products
are dry before use or storage.
At the very least, the respirator should be cleaned at the end of each working shift to benefit personal
hygiene, health and product longevity.
3.1.4 Storage
There may be particular required storage procedures depending on your working environment. This
should be confirmed with your organisational Respiratory Health and Safety Officer.
Corpro recommends the mask be stored in a cool, dry and sterile / uncontaminated place, out of
direct sunlight. Corpro can offer rigid, reusable storage containers if this is preferable, but if not,
somewhere safe and clean such as a disinfected personal locker will be sufficient.
The respirator should always be cleaned before storage, regardless of how long the respirator may
remain unused.
SPECIFICALLY FOR COVID-19:
NB: Make sure the mask and filters are dry in advance of storage.
Corpro recommends storing the mask (and filters) in a polythene bag, preferably zip-locked with some
form of desiccant (such as a dry silica gel sachet), when not in use. A polythene bag is included when
purchasing a HM1400 half mask or FFM1600 full face mask.
If the above storage method is not possible, it is suitable to store the mask and filters in a clean area
where there is no risk of contamination e.g., a disinfected personal locker.
3.1.5 Maintenance Intervals
To summarise, based on the information presented above, Corpro recommends the following
maintenance intervals:

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Interval
Task
Before Use After Use 3 months 6 months 12 months
Cleaning/Disinfecting
X
X
Fit Test / Leak
Tightness Test
X
(First Use)
X
Valve Replacement
X*
X*
X*
General User Checks
X
X
Fit Check
X
X
As previously mentioned, depending on your environment, risks and wear frequency, certain
maintenance tasks may be required more frequently. This needs to be established by an
organisational risk assessment.
If components have been replaced (e.g., valves), a fit check and a general user check must be carried
out in advance of mask’s next use.
All aforementioned tasks should be performed if a mask has been in storage for a long period, and at
least once a year.
* Either every 3, 6 or 12 months depending on wear frequency and working environment.
Organisational risk assessment required to establish.
3.1.6 Disposal
To establish the safest disposal method for the HM1400, this will require a risk assessment by your
organisation. However, Corpro can provide the following information and recommendations:
•All parts of the mask, other than the elastic strap, are recyclable as the mask’s materials
include thermoplastic elastomers (TPE), acrylonitrile butadiene styrene (ABS) or
polycarbonate/acrylonitrile butadiene styrene (PC/ABS) plastic, and silicone (valves only).
•Depending on your working environment, you may not be able to recycle the materials as the
mask may be classed as hazardous waste. This would need to be checked and, if classed as
hazardous waste, the appropriate disposal method should be outlined and followed.
•If the mask is not classed as hazardous waste, the product should be disposed of or recycled
as applicable in a controlled waste area at the occupational site / an agreed third-party site.

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3.2 FFM1600 Full Face Mask
The Corpro FFM1600 Full Face Mask is a reusable, elastomeric respirator which requires an
appropriate pair of F1100 range filters attached (depending on airborne contaminants; both filters
must be of the same type and class). See section 3.3 for more information about the F1100 range
filters. The mask can also be used with various Corpro accessories (specified in section 3.4).
3.2.1 General Training
This section will cover the processes on how to appropriately select, wear, adjust and check the fit of
your FFM1600.
3.2.1.1 Choosing your Mask size
The process of choosing a FFM1600 mask size is the same as the process for choosing the HM1400 half
mask size. Please see section 3.1.1.1 for the full procedure.
3.2.1.2 Donning and Doffing your Full Face Mask
How to put on and take off your full face mask. Ensure you have established your mask size in advance
of donning (see section 3.1.1.1).
Instructional video: https://vimeo.com/corpro/donning-and-doffing-your-full-face-mask
Pictorial instructions:
Donning –

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Written instructions:
Step 1 – Donning
1. For first time use, loosen all straps prior to donning.
2. Place the mask over your face and pull the harness over your head.
3. Starting with the bottom straps and working upwards, tighten the straps slightly (not fully).
4. Ensure no hair is trapped underneath the seal and adjust the mask’s positioning if necessary.
5. Tighten the straps fully. For a balanced fit, firstly tighten the bottom two straps in unison, then
the middle two straps in unison, and then the top strap.
6. Ensure the head harness is placed centrally at the back of the head and make sure your straps
are not twisted. Adjust your mask as appropriate.
7. Perform a fit check. For the full fit checking procedure, please see section 3.2.1.3.
Step 2 – Doffing
1. Undo the bottom two straps.
2. Pull the mask over your head.
3.2.1.3 Fit Checking your Full Face Mask
The fit checking process for your full face mask. A fit check should be performed each time you don
your mask, but at the very least should be performed once a year / after a long period of storage.
Instructional video: https://vimeo.com/corpro/fit-checking-your-full-face-mask

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Pictorial instructions:
Written instructions:
1. Don your mask. For the full donning procedure, please see section 3.2.1.2.
2. Place the palm of your hands over the outward-facing openings on the filters.
3. Inhale and hold for ten seconds to check the seal against your face. If fitted appropriately, the
inhaled breath should cause the inner and outer mask seals to press against your face and
this should remain for the duration of the inhale/hold. Also move your head to test if the seal
holds.
4. If leakage occurs, adjust your mask and perform the fit check again.
3.2.1.4 During Use
WARNING: If you experience any of the following whilst wearing the product, leave the hazardous area
immediately and seek assistance.
•Breathing difficulty.
•Dizziness or nausea.
•You can smell or taste the contaminant.
•You experience any other noticeable side effects.
•Your equipment becomes damaged.
3.2.2 Maintenance
This section applies only to the mask itself and does not include the filters unless stated otherwise.

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3.2.2.1 Shelf Life
It is recommended that the FFM1600 product is fully serviceable for five years after the date of
manufacture. Manufactured date is on both the outer box and internal to the outer seal, on the visor
and below the oronasal. After this time, it would be advisable to purchase a new mask.
It is wise to make a note of the manufactured date once the mask has been purchased, just in case the
outer box is lost or the fenestra/visor requires replacement. Shelf life may be reduced if damaged or
not adequately maintained. Replace mask immediately if damaged or showing visible signs of wear.
3.2.2.2 General Maintenance
It’s important to maintain RPE to ensure that it remains in good working order for wearer safety.
The same maintenance procedures apply for both the FFM1600 full face and the HM1400 half mask
(although as they are different types of masks, component and seal checks should be appropriate for
the mask type). For more detail on the recommended processes, see section 3.1.2.2.
3.2.3 Cleaning and Disinfection
Ultimately, cleaning procedures, including cleaning frequency, depend on the working environment
and so this should be clarified based on organisational risk assessments. However, general advice can
be offered.
The advice for the FFM1600 full face mask is the same as provided for the HM1400 half mask. Please
see section 3.1.3 for more information.

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3.2.4 Storage
There may be particular required storage procedures depending on your working environment. This
should be confirmed with your organisational Respiratory Health and Safety Officer.
Corpro’s storage recommendations are the same for both the HM1400 half mask and the FFM1600 full
face mask. Please see section 3.1.4 for storage advice.
3.2.5 Maintenance Intervals
To summarise, based on the information presented above, Corpro recommends the following
maintenance intervals:
Interval
Task
Before Use After Use 3 months 6 months 12 months 60 months
Cleaning/Disinfecting
X
X
Fit Test / Leak
Tightness Test
X
(First
Use)
X
Valve Replacement
X
A
X
A
X
A
Face Seal
Replacement
X
Inlet Gasket Change
X
Inner Mask
Replacement
X
General User Checks
X
X
Fit Check
X
X
As previously mentioned, depending on your environment, risks and wear frequency, certain
maintenance tasks may be required more frequently. This needs to be established by an
organisational risk assessment.
If components have been replaced (e.g., valves, gaskets, etc), a fit check and a general user check must
be carried out in advance of mask’s next use.
All aforementioned tasks should be performed if a mask has been in storage for a long period, and at
least once a year.