Factair SAFE-AIR TESTER F4501 User manual

F4501 & F4501ED SAFE-AIR TESTER
OPERATING MANUAL
FAC QAM 190 Issue D 09/18

1 FAC QAM 190 Issue D 09/18

2 FAC QAM 190 Issue D 09/18
Contents
Page No
Introduction
3
Calibration & Warranty
3
Equipment List
4
1
-
Pre Use
5
2
-
Start-Up
6
3
-
Selecting the test standard and configuring the
instrument.
7
4
-
Initiating a Breathing-Air Test
8
4.1
-
Completing a Breathing-Air Test
10
5
6
-
-
Continuous Oxygen Reading
Reviewing Test Results
14
15
7
-
Exporting Test Results and PC Software
16
Appendix 1 - Helpful Tips
18
Appendix 2 - Draeger Tube Tip Cutter
19
Appendix 3 - Reading the Draeger Oil Impactor and Chemical
Reagent Tubes
20
Appendix 4 –Breathing Air Standard
25
Appendix 5 –Breathing Air Quality Testing –Why?
26
Frequency of Breathing-Air Tests
Recording Breathing-Air Quality Test Results
27
28
A.4.5 Compressed Air for Breathing Apparatus
from EN529
29
COSHH L5 Sixth Edition
30
Respiratory Protective Equipment at Work
32

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Introduction
Safe-Air Testers are designed to provide a quick and easy method for carrying out accurate periodic
testing of breathing-air supplies. The European Standard for breathing-air quality is EN12021, which
should be referred to in conjunction with any overriding national standards.
The F4501 is designed specifically to test high pressure air breathing air cylinders and high pressure
charging systems up to 300bar.
The instrument has a colour touch screen display and is supplied in a hard weatherproof case with
storage provision for a wide range of accessories and equipment. It is primarily designed to be used
from within the case; however the tester can also be removed and operated separately where space
is at a premium.
The test is carried out using the Draeger Impactor for oil and chemical reagent tubes for carbon
monoxide, carbon dioxide and water*. These are supplied in packs of 10 per type and the chemical
reagent tubes show the degree of contaminant present as a colour change to the crystals that they
contain. The extent of this is read against the scale on the tube. For the Impactor the degree of oil
contamination is displayed on a screen.
Calibration and Warranty
Safe-Air Testers leave our factory with a 12-month warranty and calibration certificate. Our standard
turnaround on annual calibration is 10 working days providing there is no major damage that requires
an extensive rebuild. (Allow an extra 5 working days for calibration of ED versions.)
Note:- Please download all stored data before returning the Tester to Factair.
Temperature Parameters
Storage: -20/+50°C Operating Range: -10/+45°C
This tester is calibrated for the following approved reagent tubes/Impactor.
H2O (Water-reagent tube)* Draeger ref. 6728531
CO (Carbon monoxide-reagent tube) Draeger ref. 6728511
CO2(Carbon dioxide-reagent tube) Draeger ref. 6728521
Oil (Impactor) ** Draeger ref. 8103560
*Note:- A water reagent tube is not required with the F4501ED which will automatically record the
moisture and dewpoint readings
**Note:- The tester can also be used with the old type Draeger reagent tube for oil, ref 6728371.
(Refer to Appendix 2 at the rear of the manual for instructions.)
IMPORTANT –IT IS RECOMMENDED THAT YOUR SAFE-AIR TESTER IS RETURNED FOR
RECALIBRATION AND SERVICING WITHIN 12 MONTHS FROM THE ISSUE DATE OF ITS CALIBRATION
CERTIFICATE

4 FAC QAM 190 Issue D 09/18
Equipment List:
F4501 Safe-Air Tester
Hard Case
Mains Power Supply
USB Memory Cable
6 x AA Alkaline Batteries
Travel Container for used detector tubes
Tube Tip Cutter
F3002 High Pressure Regulator complete with connection hose
Stylus Pen
Optional Extras
F2216 Tube Kit Includes 10 of each: all Draeger Oil Impactor, H2O, CO & CO2
OR
F1798 Tube Kit Includes 10 of each: all Draeger Oil, H2O, CO & CO2
F2158 300 bar din to din adaptor. Enables connection of F3002 regulator to compressor charging
whip
Battery Tray
Mains Input
USB Connection
Power On
Air Inlet
Odour Check
Button
Colour Touch
Screen Display
Sintered Outlet
Oil
Water
Carbon
Dioxide
Carbon
Monoxide

5 FAC QAM 190 Issue D 09/18
1. Pre-Use
F4501 Safe-Air Testers are fitted with internal lithium rechargeable batteries and in addition also have
a battery tray which accommodates 6 off size AA alkaline type batteries packed separately and stored
underneath the tester within the case. In the event that the rechargeable batteries are not
sufficiently recharged then you can continue to use the instrument with either the Alkaline AA
batteries or mains power supply.
To install the alkaline AA batteries lift the tester out of its case, open the battery drawer at the rear of
the unit and place the batteries inside.
Note: - It is important to strictly observe polarity when fitting batteries and ensure that they are
correctly located.
During use the battery condition is displayed on the screen as shown below -
If the tester is to be used adjacent to a power socket, the mains adaptor may be used. Please note
the unit should be switched off prior to connection or disconnection of the mains supply.
When connected to a mains power supply the internal lithium batteries will be recharged.

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2. Start Up
To carry out a test first switch on the machine by pressing and holding the green “on” button, located
on the right-hand side of the unit, for approximately 3 seconds.
A splash screen will be displayed which shows the
instruments hardware and firmware versions.
Periodically the firmware is upgraded as part of
the recalibration process as improvements are
identified.
A stylus pen is provided for use with the touch
screen. The display will show the, date last
calibrated, serial number and a tick or cross
symbol will indicate whether it is within the
recommended calibration period.
The F4501 series has 2 battery level displays, the
left hand one is for the alkaline AA batteries, if
fitted. The right hand one is the rechargeable
internal lithium battery. Unless the instrument is
connected to a mains power supply the
instrument will use the highest of the 2 battery
power sources.
Please note if alkaline AAs are inserted whilst the
unit is on, their battery level will not be displayed
until the unit is turned off and back on again.
Press the arrow key to progress to the main
menu.
The main menu has 3 options available from left
to right these are: Begin Test, Review Previous
Tests and Set-Up Menu.
Each of these sub-menus are described in further
detail below
The instrument can also be turned off from this
menu by pressing the red power symbol in the
top right hand corner.

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Note –If the begin test icon is in greyed out this
will be because no test results are currently stored
on the tester.
Note –If the begin test icon is in greyed out this
will be because the instrument’s memory is full
(20 tests maximum) and you need to remove at
least 1 test before you can proceed. See Section 4
–Reviewing Test Results for further details.
3. Selecting the test standard and configuring the instrument
From the main menu press the Configure icon.
In the configuration sub menu there are 3 icons
available, from left to right these are:
Set Date
Set Time (the instrument uses a 24 hour clock)
Set units of measure and test standard
To set the date, press the calendar button on the
display as seen above.
In this menu you can then choose date format;
DD/MM/YYYY or MM/DD/YYYY

8 FAC QAM 190 Issue D 09/18
The times are set prior to the unit being supplied
but they can be adjusted as necessary.
To select the test standard or the units of
measure press the right hand icon.
In this menu you can then choose the following;
CO2sample rate, pressure and temperature units
of measure and the breathing-air test standard.
Once you have made your selection press the
arrow in the top right corner to exit. To then exit
from the configuration sub menu to the main
menu press the arrow at the top left of the
screen.
4. Initiating a Breathing-Air Test
To carry out a test press the “Begin Test” icon on
the main menu.
Should mains power not be connected and both
battery sources low, a battery icon shall be
displayed on-screen and it will not be possible to
proceed with a test.
Connect either the mains power or replace the
AA alkaline batteries, and restart the tester.

9 FAC QAM 190 Issue D 09/18
The unit will automatically calibrate the oxygen
cell against the surrounding atmosphere; the unit
therefore needs to be in a well ventilated area.
Note:- If the temperature is greater than 40°C
inside the instrument the calibration will operate
for an extended period to stabilise the Oxygen
cell.
You now have the option of entering a
description for the test location, if you wish to
use numbers press the “Function” button. Push
the right arrow button when you are ready to
proceed.
Choose between using a Draeger chemical
reagent tube or Draeger Oil Impactor in the test
port.
For further details on alternative chemical
reagent tubes see appendices 2 and 3.
For breathing-air tests the standard option is to
select a Draeger oil Impactor.
The unit has 3 breathing-air test programmes
available: High Pressure Charging Compressors
(top right) High Pressure Cylinders up to and
including 200bar and High Pressure Cylinders
above 200bar. All of the high-pressure tests
require the use of the F3002 regulator which has
a DIN connector that can accept input pressures
up to 300bar.

10 FAC QAM 190 Issue D 09/18
4.1 Completing an Air Quality Test
Select the required test to be undertaken from the 3 options
High-pressure charging compressors
High-pressure cylinder 200bar or lower
High-pressure cylinder greater than 200bar
Note: For cylinder tests please ensure the test is carried out on a recently filled, fully charged cylinder.
Note: For the high-pressure charging compressor test a DIN to DIN adaptor ref: F2158 is required to
connect the F3002 high-pressure regulator to a charging hose.
Connect the F3002 high-pressure regulator
assembly to the cylinder or charging hose to be
tested, ensuring that the regulator has the
correct type of connector for the cylinder.
Connect the regulator hose coupling to both the
regulator and the inlet of the tester.
Open the cylinder valve and check that the cylinder is fully charged by reading the contents gauge on
the regulator. (A partially discharged cylinder can give an incorrect water result.) The pressure
displayed on the tester will be that of the regulated supply from the cylinder and must not exceed
10 bar. Press the button in the top right hand corner to proceed.
Note:- if the unit is over-pressurised it will automatically shut down and display an overpressure
warning; it will then need to be returned to the manufacturer for checking and resetting.
Carry out the odour test by depressing the odour
test button and smelling the air exhausted from
the sintered outlet. If there is a serious odour
problem, fail the sample at this point of the test.
Initiating flows of seriously contaminated air
through the tube ports could result in damage to
the unit. If the odour test is satisfactory, press
the ‘pass’ icon.

11 FAC QAM 190 Issue D 09/18
The instrument will now commence a 5-minute
purge sequence, during which time an airflow will
be passed through the test port and across the
electronic cells. This clears contaminants from
previous tests and ensures that a representative
sample is being tested.
The F4501 incorporates a unique flow checking
system to ensure that the air is passing through
each of the 4 outlet ports, thus eliminating the
possibility of a false positive result.
If this screen appears the system has detected a
fault on one of the outlets, it is possible that this
could be due to a low battery. Replace the
batteries and repeat the test, if the screen
reappears then the unit should be returned to
Factair for investigation.
Once the purge has finished, the Water (not ED
version), CO, CO2and Draeger Impactor/oil tubes
should be inserted into the appropriate test ports
and tightened firmly; ensure the Impactor has an
intact protective seal.
This seal must remain in place for the duration of
the test.
Press the button in top right hand corner to start
the test.
The test will now commence and the duration will
be displayed as a countdown, together with
regulated pressure, ambient temperature and
oxygen content.
The unit can be left until the test time has
elapsed.

12 FAC QAM 190 Issue D 09/18
F4501ED only
If the instrument detects that the dewpoint
meter’s rate of change is still too high (>0.2°C per
minute) it will automatically continue the test
until this stabilises up to a maximum test time of
15 minutes.
The Impactor can now be removed and
evaluated.
To enter the results press the corresponding icon
on the screen.
Note:- Instructions on reading the Impactor can
be found in Appendix 3 at the back of the manual.
The tube readings should also then be entered,
push the button corresponding to each chemical
reagent tube.
Input the reading from the tube and press the
arrow icon in the top right hand corner of the
screen.

13 FAC QAM 190 Issue D 09/18
As each reading had been entered the input box
will turn green, once all the results have been
entered press the right had arrow to proceed.
The “test complete” screen displays all the
measurements recorded during the test. And
automatically determines whether the test was a
pass or fail against the standard displayed in the
top right corner of the screen. For water content
on high pressure tests both the measured value
in mg/m3and the atmospheric dewpoint are
provided.
If the test was a fail an orange exclamation mark
would be indicating those criteria which did not
meet the standard. The photograph opposite is
an example of a failed test where carbon dioxide
failed to meet the requirements of the selected
standard.
The test result is automatically recorded in the instrument’s memory, which can store up to
20 previous tests. To disconnect the Tester from the cylinder firstly turn off the cylinder valve, then
depress the odour test button until all the air is exhausted. It is now safe to disconnect the
connection hose and cylinder regulator.

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5.0 Continuous Oxygen Reading
The F4501 can also provide a continuous oxygen reading.
When you start a test press and hold the O2
cylinder for a few seconds when it is in its self
calibration mode.
Note:- If the temperature is greater than 40°C
inside the instrument the calibration will operate
for an extended period to stabilise the Oxygen
cell.
The instrument will then change operating modes
to continuously display the oxygen reading,
connect your air source and the instrument will
continue to provide a reading until you press the
back arrow key in the top corner.

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6.0 Reviewing Test Results
From the main menu button press the review
test button.
The F4501 & F4501ED can store up to 20 test
results and each individual test is titled by the
date and time when the test was completed.
To review a previous test select it then press the
right hand arrow.
To delete a test highlight it then press the trash
can button. All tests can be deleted by selected
the multiple trash can icon.
Note: Once the instrument has saved 20 results you will unable to complete further tests until you
have removed at least 1 of the stored tests.

16 FAC QAM 190 Issue D 09/18
7.0 Exporting test results and PC software
To transfer test results from the Safe-Air Tester to the PC software you must first install the software
on your PC. This is available in the download section of Factair’s website:
http://www.factair.co.uk/downloads
Then click on the File drop down menu and
select “Import test results from F4500 via USB
connection”.
You will then be able to choose the location
where you would like test results to be stored.
Individual test records can be opened from the
file drop down menu by selecting “Open an
F4500 test results file”.

17 FAC QAM 190 Issue D 09/18
Once loaded further information can be added
about the following:-
Test location.
Date next test due.
Test engineer and relevant address.
Note:- These details can be saved as default.
When complete you can save the test result file and if required print off a certificate. In the UK,
Health and Safety Executive guideline HSG53 recommends test results should be retained for a
minimum of 5 years.

18 FAC QAM 190 Issue D 09/18
Appendix 1 - HELPFUL TIPS
With detector tubes
Ensure that there are no fragments of glass in the tube glands prior to fitting detector tubes,
clean if required.
Always remove the ends of the detector tubes cleanly using the correct tube tip cutter. Do not
use pincers or other devices.
Always remove both ends of the detector tubes prior to fitting.
Always fit detector tubes with the arrows facing outwards.
Never break the glass ampoule in the oil tube before the test.
Only use the detector tubes that the Tester is calibrated for.
Once used, be aware that the tube tip cutter contains ground glass and glass fragments. Take
appropriate precautions for the disposal of these. Dispose of as sharps.
When using the tube tip cutter ensure only a light pressure is applied to the tube whilst
rotating for scoring.
General
Make sure the system flow control valve is closed after each test.
Connecting an air supply to the Tester with the system flow regulator in the open position can
damage the unit.
Never connect to a non-regulated supply from an HP cylinder or compressor.
Maximum inlet pressure to the Tester is 10 bar. If exposed to an overpressure the Tester will
display an overpressure warning necessitating its return to the manufacturer for checking and
resetting.
If the Tester has been used on an excessively wet supply it can be purged dry by running a full
test on a known dry source without any detector tubes fitted.
When using the mains power supply, ensure that the Tester is switched off prior to connection
and disconnection.
For any additional advice and information please contact Factair on: [phone].

19 FAC QAM 190 Issue D 09/18
Appendix 2
Draeger Tube Tip Cutter
The F2187 is especially designed to prevent glass from falling out of the opener by accident. The
reservoir for the broken-off tips is easy to empty.
Instructions
1. Place the end of the tube
between the 3 blades, and
turn to score the end.
2. Push the tube at an angle to
break the tip.
3. Repeat steps 1 and 2
with the other end of
the tube