Hornell Adflo User manual

93-0061-00 Rev. A
Turbo Unit Instruction Manual
Adflo®Turbo Unit Powered Air Purifier

93-0061-00 Rev. A
2
Adflo®Turbo Unit
2
Do not issue this product until the user reads
and understands this instruction manual which
is an essential part of this Adflo®Turbo Unit.
If equipment is not properly assembled,
connected, and used in strict conformance
with this instruction manual, contaminated air
could be drawn into the Unit, resulting in
exposure which may lead to serious bodily
injury or loss of life.
Use by unqualified or untrained persons, or
use other than in accordance with this
instruction manual, is dangerous and could
expose the user to serious bodily injury or loss
of life.
Do not make any modifications to any part of
this system, other than those specified in this
manual. Do not use any replacement parts
other than those specified in this manual.
Unauthorized modifications and replacement
parts will void the warranty and expose the
user to the risk of personal injury.
Final determination of Purifier applicability
and filter selection must be made by an on-
site safety specialist or industrial hygienist.
Not to be used in atmospheres classified as
IDLH.
Not to be used in atmospheres containing less
than 19.5% oxygen.
!WARNING

93-0061-00 Rev. A 3
Adflo®Turbo Unit
Table Of Contents
Chapter 1 General Information Page
1.1 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Respirator Approvals and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Headpiece Approvals and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 2 Adflo®Turbo Unit Use
2.1 Battery Charging/Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Pre-Operational Adflo®Unit Inspection & Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Headpiece Assembly Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Donning the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Fault Location Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 3 System Maintenance
3.1 Cleaning & Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Removing & Reinstalling the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Replacing the HE Filter, the Prefilter & the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Replacing/Installing the OV/HC/CL/SD Adflo®Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.5 Replacing the Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 4 Customer Information
4.1 Customer Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Adflo®Turbo Unit Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Warranty Return Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Out-of-Warranty Repairs and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Replacement Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5.1 Replacement Filters & Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5.2 Adflo®Turbo Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5.3 Headpiece Assembly Replacement Parts and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5.4 Miscellaneous Replacement Parts and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix A
Definition of Safety Signal Words per ANSI Z535.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Appendix B
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
List of Illustrations (Figures) Page
Figure 1 Exploded View of Adflo®Turbo Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2 Battery Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 3 Close-Up of Battery Charger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 4 The Four Different Charger Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 5 Turning On the Adflo®Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 6 Airflow Indicator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 7 Low Airflow Warning LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 8 Connecting the Breathing Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 9 Removing & Reinstalling the Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 10 Filter Cover Removal, Step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 11 Filter Cover Removal, Step 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 12 Filter Cover Removal, Step 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 13 Wrong Way 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 14 Wrong Way 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 15 Installing the Spark Arrestor, Prefilter and HE Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 16 Removing the HE Filter and OV/SD/CL/HC Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 17 Installing the OV/SD/CL/HC Cartridge into the Adflo®unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 18 Installing the Adflo®Turbo Filter Cover onto the OV/SD/CL/HC Cartridge. . . . . . . . . . . . . . . . . . . . . 15
Figure 19 Adflo®Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 20 Adflo®Unit Installed on Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 21 Exploded Adflo®Turbo Unit with Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

93-0061-00 Rev. A
4
Adflo®Turbo Unit
1.1 Principles of Operation
Adflo®Turbo Unit is a belt-mounted, powered air
purifier. Combined with the appropriate Hornell
headpiece, it helps to provide respiratory protection
from specific airborne contaminants.
The Adflo®Turbo Unit features a constant-flow blower
and filter cover that houses a spark arrestor, a prefilter,
and an HE particle filter. The Unit’s battery pack, belt,
breathing tube, airflow indicator, battery charger and
carry bag are all standard equipment. An
OV/SD/CL/HC Adflo®Cartridge is available and can
be added to the Adflo®unit.
The Adflo®Turbo Unit draws ambient air through its
filter/cartridge and supplies filtered air via a breathing
tube. The Adflo®Turbo Unit’s battery pack provides
5.5 to 13 hours of operation per charge, depending
upon particle filter loading and filter configuration.
The Adflo®Turbo Unit is equipped with automatic
flow control: the motor power is automatically
regulated during operation to compensate for the state
of the battery and the level of airflow resistance caused
by the HE filter and prefilter being loaded with
particles. This automatic control ensures a constant
airflow to the user. Should the airflow fall below the
manufacturer’s minimum design flow rate for any
reason, an audible alarm will sound and the red LED
on the on/off switch will flash to warn the user to
immediately leave the contaminated environment.
1.2 Respirator Approvals and Limitations
Refer to the (NIOSH 42 CFR 84) Approval Labels
supplied with the Adflo®Turbo Unit for the approved
purifier/headpiece combinations.
The Adflo®Turbo Unit has a new, exclusive design that
features a “stacked” filtration system. Unlike any other
design, the standard Adflo®configuration with the HE
particle filter can be “stacked” with the addition of an
Adflo®Cartridge for supplemental protection against
specific fumes and vapors.
In either configuration, the standard Adflo®Turbo
Filter Cover holds a spark arrestor, prefilter and
HE particle filter which always must be used. The
Adflo®Turbo Filter Cover snap-fastens directly onto
the turbo unit to provide high efficiency particle
filtration. When used with the Adflo®Cartridge, the
Adflo®Turbo Filter Cover snap-fastens to the
OV/SD/CL/HC cartridge. An on-site safety specialist
or industrial hygienist must review the HE filter label
to determine the applicability for a given
environment/application.
The Adflo®Cartridge consists of OV/SD/CL/HC
elements housed in a black plastic shell. The Adflo®
Cartridge snap-fastens onto the Turbo Unit. Then, the
Adflo®Turbo Filter Cover (with the installed spark
arrestor, prefilter and HE particle filter) snap-fastens
onto the Adflo®Cartridge to make a complete
Purifier/filtration unit. This “stacked” filtration
provides protection from particles, organic vapor, sulfur
dioxide, chlorine, and hydrogen chloride. An on-site
safety specialist or industrial hygienist must review the
HE filter label combined with the OV/SD/CL/HC
cartridge label to determine the applicability for a given
environment/application.
The following limitations apply to all Adflo®Turbo
Unit filter configurations:
•NOT for use in atmospheres Immediately
Dangerous to Life or Health (IDLH).
•NOT for use in atmospheres containing less than
19.5% Oxygen.
•NOT evaluated as an ignition source in flammable
or explosive atmospheres by NIOSH.
•NOT to be used without the Adflo®Turbo Unit
turned on since there is a risk of high concentration
of CO2and the oxygen level in the headpiece will
fall.
•NOT to be used if the Adflo®Turbo Unit does not
supply enough airflow (low flow alarm).
•NOT to be used in confined spaces with limited air
supply.
•NOT to be used if the user is not sure about the
contamination present in the ambient air.
•The Adflo®Turbo Unit is intended for use in the
temperature range of 23° to 131°F (-5°C to 55°C).
At temperatures below 50°F (10°C), the air inside
the headpiece can be perceived as being cold.
The following limitation applies to standard HE filter
configuration:
• NOT to be worn as protection against gases or
vapors.
The following limitation applies to HE filter plus the
OV/SD/CL/HC Cartridge configuration:
•Follow cartridge change schedule, as established by
an on-site safety specialist or industrial hygienist, to
ensure that cartridges are replaced before
breakthrough occurs.
Chapter 1 General Information

93-0061-00 Rev. A 5
Adflo®Turbo Unit
1.3 Headpiece Approvals and Limitations
For approved purifier/headpiece combinations, refer to
the (NIOSH 42 CFR 84) Approval Label that was
supplied with the Adflo®Turbo Unit.
For all other headpiece approvals—such as eye, face,
helmet protection standards—see the separate manual
that was supplied with the headpiece.
1.4 Unpacking
Open the cartons and inspect each item for shipping
damage. Replace all damaged items prior to use. Verify
that you have all of the components for a complete
Adflo®Turbo Unit as listed:
6
8
7
3
4
5
5A
5B
5C
911
10
Figure 1:
Exploded
View of Adflo®
Turbo Unit.
1) “Adflo®Turbo Unit Instruction Manual”
(this manual)
2) Hornell Respiratory Product Warranty Registration
(postcard)
3) Breathing Tube
4) Adflo®Turbo Unit (belt-mounted, motor-driven fan)
5) One Adflo®Turbo Filter Cover with the following
items installed:
A) Spark Arrestor
B) Prefilter
C) HE Particulate Filter
6) Adflo®OV/SD/CL/HC Cartridge (if ordered)
7) Belt
8) Battery Pack
9) Battery Charger
10) Carry Bag
11) Airflow Indicator
12) Approval Labels (not shown)

93-0061-00 Rev. A
6
Adflo®Turbo Unit
2.1 Battery Charging/Discharging
All new units must be charged before they are used for
the first time.
The charger must not be used in any circumstances for
any other purpose than that for which it was
manufactured. It is intended for indoor use only and
must not be exposed to moisture or damp
environments. It must not be used to charge non-
rechargeable batteries.
The charger controls the charging automatically. The
battery will be fully charged in approximately 3 hours,
depending upon its residual capacity. After charging,
trickle charging automatically starts and keeps the
battery at full capacity. The battery will discharge
during a long period in storage if not connected to the
charger. For this reason, always re-charge the battery if
it has been stored for more than 15 days.
To achieve maximum power when the battery is
new or has been stored for more than four weeks,
fully discharge/charge the battery for three
complete cycles. To discharge, run the unit until it
completely stops—DO NOT SHORT CIRCUIT
THE BATTERY TO DISCHARGE; DISCHARGE
THE BATTERY ONLY BY RUNNING THE UNIT
UNTIL IT STOPS. To fully charge the unit, follow
the steps listed below. Complete the
discharge/charge cycle three times.
The output of the battery pack is protected by an
automatic cut-out device which is activated when
excessive current is drawn. Once the cause of
excessive current is removed the device will reset after
a few seconds.
The battery pack is equipped with a separate charging
socket so that it can be charged without having to
remove it from the Adflo®Turbo Unit. The battery can
also be removed from the Adflo®unit for charging (see
Section 3.2: Removing and Installing the Battery Pack).
Recommended ambient temperature for charging is
32°F to 104°F (0°C to 40°C). If the charger’s LED
blinks very rapidly during charging, it means that the
environment is either too hot or too cold to charge.
1) Connect the charger output into the battery’s
charging socket (see Figure 2).
2) Plug the charger into a suitable source of AC power
(110-120V). The charger’s LED will stay on
continuously during the initial charging stage, as
symbolized by the unbroken line on the
charger’s label (see Figure 3).
Chapter 2 Adflo®Turbo Unit Use
3) When the battery is fully charged, the charger’s LED
will blink slowly, indicating that the charger is in the
trickle-charging stage, symbolized as a dashed line
on the charger’s label (see Figure 3). A fully charged
battery can be left in the trickle-charging stage for a
moderate amount of time (e.g. a weekend), but for
maximum battery life it is best to disconnect the
charger after a full charge has been received.
4) Disconnect the charger from the power source.
Disconnect the charger output from the battery’s
charging socket.
Figure 2:
Battery Charging.
Figure 3:
Close-Up of Battery Charger.

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Adflo®Turbo Unit
NOTE: If the Adflo®Turbo Unit starts to run during
charging, turn it off.
The Adflo®unit has a three-bar battery indicator (see
Figure 4) that is operational when the unit is turned on.
When all three bars are illuminated, the battery has 80-
100% capacity. Two bars indicate 20-80% capacity.
One bar indicates 5-20% capacity. During the last 30 to
60 minutes of charge, the bottom bar will flash
continuously one second ON then one second OFF and
the audible warning (beep) will beep four times in two
seconds, repeating every 30 seconds. The final 15 to 60
seconds causes the beeper to beep every 1/2 second.
NOTE: all airflow, lights and beeping will completely
stop when the battery is fully drained.
2.2 Pre-Operational Adflo®Turbo Unit
Inspection & Testing
Prior to beginning each work shift, perform the following
Pre-Operational Inspection to ensure the proper airflow
and alarm function of the Adflo®Turbo Unit.
1) Replace any missing or damaged parts.
2) Ensure that the HE filter is properly installed in the
Adflo®Turbo Unit. If using the OV/SD/CL/HC
cartridge, ensure that it is also properly installed in
the Adflo®unit. See Chapter 3 for instructions on
removing and replacing the HE filter and the
OV/SD/CL/HC cartridge.
3) Confirm that the battery pack is fully charged and
properly fitted to the Adflo®unit. See Chapter 3 for
instructions on removing and reinstalling the battery
pack.
4) If not already disconnected, disconnect the breathing
tube from the headpiece assembly’s airduct by
carefully twisting the breathing tube end connector
so it unlocks from the “J” channel on the airduct.
5) Insert the airflow indicator onto the end of the
breathing tube.
6) With the airflow indicator in a vertical position, turn
the Adflo®Turbo Unit on (see Figure 5). All three
LEDs located on the ON/OFF switch will turn on
for approximately one second; then the two green
LEDs should remain on.
7) Ensure that the bottom of the floating ball rests at, or
above, the minimum flow mark (see Figure 6).
NOTE: If the floating ball of the airflow indicator fails
to rest at or above the minimum flow level, refer to
Section 2.5 Fault Location of this manual.
Figure 4:
The Four Different Charge Indicators. Figure 5:
Turning On the Adflo Unit.
Figure 6:
Airflow Indicator Check.

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Adflo®Turbo Unit
8) Remove the airflow indicator from the end of the
breathing tube.
9) To check the low airflow/high particle load alarm,
you will simulate a low airflow condition as follows:
With the Adflo®unit turned on, tightly cover the end
of the breathing tube with the palm of your clean
hand; the motor will then automatically speed up,
attempting to compensate for the low airflow
condition. Continue to press your palm tightly
against the end of the breathing tube, making a tight
seal. When you have achieved a tight seal, the unit
will sound an audible alarm and the center, red LED
on the on/off switch will flash (see Figure 7).
Figure 7:
Low Airflow Warning LED.
10) Remove your hand from the end of the breathing
tube; the audible alarm and the flashing red LED
should both stop, while the motor returns to a
slower speed.
11) Reattach the airflow indicator and repeat steps
5 and 7 above to confirm the airflow rate.
12) If the unit does not operate as described in all of
the above procedures, perform the Fault Location
Procedures listed in Section 2.5.
13) To turn the unit off, press the off button for two
seconds.
14) After confirming adequate airflow, filter condition,
and alarm function, assemble breathing tube to the
airduct of the headpiece assembly (see Figure 8).
Make certain to twist the breathing tube end
connector until it locks into place in the “J”
channel of the headpiece’s airduct.
To ensure adequate protection, the
performance of this unit must be
monitored in a non-hazardous envi-
ronment. During user break periods,
confirm sufficient airflow: the air-
flow indicator float rests at the mini-
mum float level. Failure to confirm
sufficient airflow in a non-hazardous
environment could lead to contami-
nant exposure resulting in serious
bodily injury or loss of life.
!WARNING Figure 8:
Connecting the
Breathing Tube.
To avoid the disconnection of the
breathing tube, be certain to fully
insert and twist the breathing tube
end connectors until they lock into
place at the end of the “J” channels
found on both the headpiece’s
airduct and the Adflo®Turbo Unit.
!CAUTION

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Adflo®Turbo Unit
2.3 Headpiece Assembly Preparation
For all headpiece assembly preparation, see the
appropriate separate manual that was supplied with the
headpiece.
2.4 Donning the System
1) Install a fully-charged battery into the Adflo®Turbo
Unit (see Section 2.1 Battery Charging/Discharging
and Section 3.2 Removing & Reinstalling the
Battery Pack).
2) Check the installation of the Adflo®Turbo Filter
Cover, spark arrestor, prefilter and HE filter (see
Section 3.3 Replacing the HE Filter, the Prefilter &
the Spark Arrestor). Check the installation of the
OV/HC/CL/SD cartridge, if used (see Section 3.4
Replacing/Installing the OV/HC/CL/SD Adflo®
Cartridge).
3) The Adflo®unit is typically shipped already
installed on its belt. Inspect the belt for tears or rips.
Replace as needed (see Section 3.5 Replacing the
Belt).
4) Inspect the breathing tube for any kinks, breaks,
tears or holes. Insert the end connector of the
breathing tube into the Adflo®unit and twist it until
it locks into place in the “J” channel (see Figure 8).
!WARNING
Failure to properly adjust the
headpiece and the face seal could
result in an inadequate seal that
could lead to contaminant exposure
resulting in serious bodily injury or
loss of life.
5) Perform the Pre-Operational Adflo®Unit Inspection
& Testing (see Section 2.2 Pre-Operational Adflo®
Unit Inspection & Testing). After confirming
adequate airflow, filter condition, and alarm
function, assemble the breathing tube to the airduct
of the headpiece assembly. Make certain to twist the
breathing tube end connector until it locks into place
in the “J” channel of the headpiece’s airduct. Refer
to the appropriate separate manual that was supplied
with the headpiece.
6) Turn on the Adflo®Turbo Unit (see Figure 5).
7) Fasten the belt around the waist. Adjust the belt so it
fits comfortably and securely around the waist, with
the Adflo®Turbo Unit in the small of the back.
8) Put on the headpiece.
!WARNING
Failure to properly connect the
breathing tube to the headpiece
assembly and to confirm airflow
through the system to the breathing
zone could lead to contaminant
exposure resulting in serious bodily
injury or loss of life.

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Adflo®Turbo Unit
2.5 Fault Location Procedures
!WARNING
If, at any time during operation, the Adflo®Turbo Unit
stops, or the airflow to the headpiece stops or is
reduced, or if the user detects an odor or taste of gas,
or feels eye or throat irritation, or if either the battery
alarm or the low airflow/high particle load alarm is acti-
vated, the user must immediately leave the contaminat-
ed environment and perform the Fault Location
Procedures on the Adflo®Turbo Unit. Failure to perform
the Fault Location Procedures when any of the above
conditions occurs could lead to contaminant exposure
resulting in serious bodily injury or loss of life.
Fault Probable Cause Possible Solutions
Audible alarm and all three LEDs
are flashing (low airflow)
Bottom bar of battery indicator
flashes; battery alarm sounds
No airflow, no alarms
Low airflow, no alarms
User detects odor or taste of gas or
feels eye or throat irritation
1) Breathing tube is blocked
2) Filter is covered
3) Filter is fully loaded with
particles
Low battery voltage
1) Battery contact on battery pack
is damaged
2) Battery is completely flat (no
charge)
3) Damaged circuit board
4) Damaged motor
1) Damaged circuit board
2) Damaged motor
1) Incorrect Purifier for
application and/or environment
2) Time to change OV/SD/CL/HC
cartridge
1) Check & remove blockage or
obstruction
2) Check air filter & remove
obstruction
3) Change HE filter and prefilter
(see Chapter 3)
1) Fully charge the battery pack
2) Fully discharge & charge the
battery pack 3 times, as per
Section 2.1
3) Install a new, fully-charged
Adflo®battery pack
1) Check the battery contact (e.g.
is it bent or broken?)
2) Fully charge the battery pack
3) Return to Hornell for repairs
4) Return to Hornell
1) Return to Hornell
2) Return to Hornell
1) Consult on-site industrial
hygienist or safety director
2) Change cartridge & develop a
cartridge replacement schedule
with your on-site industrial
hygienist or safety director

93-0061-00 Rev. A 11
Adflo®Turbo Unit
Fault Probable Cause Possible Solutions
Battery pack’s charge lasts less
than 6 hours
The motor runs “faster than
normal”
The motor runs “slower than
normal”
1) Inadequate charging
2) HE filter is loaded with
particles, making the motor run
harder
1) The HE filter is loaded with
particles
2) Recent user change from HE
filter and OV/SD/CL/HC
cartridge to just the HE filter
1) Recent user addition of
OV/SD/CL/HC cartridge
1) Fully discharge & charge the
battery pack 3 times, as per
Section 2.1
2) Replace the HE filter &
prefilter, and examine the spark
arrestor
1) Replace the HE filter &
prefilter, and examine the spark
arrestor
2) Let the unit run for 2 minutes so
it can automatically adjust to
the new filter media or changes
to the filter configuration
1) Let the unit run for 2 minutes so
it can automatically adjust to
the new filter configuration
If further assistance is required, contact your Hornell distributor or the
Hornell technical support staff (see Chapter 4).

93-0061-00 Rev. A
12
Adflo®Turbo Unit
The Adflo®Turbo Unit must be stored in a dry, clean
area, in the temperature range of -4°F to +131°F (-20°C
to +55°C) and relative humidity of less than 90%RH.
The Adflo®Turbo Unit can withstand brief periods of
storage at +185°F (+85°C).
If the Adflo®Turbo Unit is stored at temperatures
below 32°F (0°C), the battery pack must be allowed to
warm up to achieve optimal battery performance. The
Adflo®Turbo Unit must be protected from dust,
particles, and other contamination when stored between
use, in a clean environment, in the Carry Bag.
3.2 Removing & Reinstalling the Battery
Pack
Hold the Adflo®Turbo Unit so the “Adflo®” logo faces
you; press in on the battery pack catch found
immediately to the right of the logo (see Figure 9A)
and lift out the battery.
To reinstall, hook the left edge of the battery pack into
its holder and then press the right side of the battery
until the catch fully engages (see Figure 9B).
3.1 Cleaning & Storage
The outer surfaces of the Adflo®Turbo Unit may be
cleaned with a soft cloth dampened in a mild solution
of clean water and mild detergent. Abrasive cleaners
or solvents must not be used.
Detach the breathing tube from the Adflo®Turbo Unit
and inspect for holes or tears. Wipe clean the
connection sites on the Adflo®Turbo Unit and the
headpiece assembly. If you suspect that the inside of
the breathing tube is dirty, it must be replaced with
a new breathing tube (see Chapter 4).
Chapter 3 System Maintenance
!WARNING
Do not allow contaminant to enter
into the breathing tube or Adflo®
Turbo Unit. Failure to prevent con-
taminant from entering into the
breathing tube or Adflo®Turbo Unit
could lead to contaminant expo-
sure resulting in serious bodily
injury or loss of life. Consult your
local safety professional in the
event contaminant entry into the
breathing tube or Adflo®Turbo Unit
is suspected.
Do not allow water to enter into the
Adflo®Turbo Unit or the battery
pack. Failure to prevent water from
entering into the Adflo®Turbo Unit
or the battery pack could cause
product failure leading to contami-
nant exposure resulting in serious
bodily injury or loss of life. Any fil-
ters or cartridges which have been
directly exposed to water must be
disposed of in accordance with
state, local and federal ordinances.
Do not clean any part of the system
with gasoline, organic-based sol-
vents, or chlorinated degreasing
fluids (such as trichloroethylene).
Failure to prevent cleaning with
any of these substances could lead
to contaminant exposure and/or
product failure resulting in serious
bodily injury or loss of life.
Figure 9:
Removing & Reinstalling the Battery Pack.
9A
9B

93-0061-00 Rev. A 13
Adflo®Turbo Unit
3.3 Replacing the HE Filter, the Prefilter
& the Spark Arrestor
The HE filter and prefilter must be changed if the
battery operating time becomes too short—or if the
airflow is diminished. The HE filter and prefilter
CANNOT be cleaned; do not attempt to remove
contamination from the HE filter or prefilter using
compressed air as this action will not work and it will
automatically void the Adflo®warranty.
To replace HE filter, the prefilter, or the spark arrestor,
the user must first remove the Adflo®Turbo Filter
Cover. Hornell designed the latch release for the
Adflo®Turbo Filter Cover so it would not accidentally
release if bumped into objects. The latch can be
released simply, and without the use of tools, using the
following method:
Figure 10: Filter Cover Removal, Step 1
Place the Turbo Unit upright on a stable surface, such
as a table. With the heel of your right palm, push
firmly on the second column of air holes of the silver
Filter Cover; the Cover will deflect slightly.
Figure 11: Filter Cover Removal, Step 2
While continuing to slightly deflect the silver Filter
Cover, press your fingers down on groove of the black
latch until it releases.
Figure 12: Filter Cover Removal, Step 3
Once the latch releases, the Filter Cover can be lifted
from the Turbo Unit.
Figure 13: Wrong Way 1
Do NOT push in the middle or the bottom edge of the
latch: the latch will not release.
Figure 14: Wrong Way 2
NEVER use tools to ply the latch; you can permanently
damage the latch or the Filter Cover, making the unit
inoperable.
Remove the used HE (particle) filter from the Adflo®
Turbo Filter Cover. NOTE: the HE filter CANNOT be
cleaned. Dispose of the used filter as per local and
federal regulations.

93-0061-00 Rev. A
14
Adflo®Turbo Unit
After you have removed the HE filter, the prefilter is
visible. The prefilter is designed to extend the service
life of the HE filter by capturing many of the particles
that would otherwise be captured by the HE filter. The
prefilter shall always be used and should be changed at
the same time the HE filter is changed. To remove it,
simply lift the soft prefilter out with your clean finger.
Note: the prefilter CANNOT be cleaned. Dispose of
the used prefilter as per local and federal regulations.
After you have removed the prefilter, the spark arrestor
(metal screen) is visible. Inspect the spark arrestor. If it
is dirty, remove it and clean with a mild solution of
clean water and mild detergent (dishwashing soap).
Completely dry the spark arrestor with a clean cloth. If
the spark arrestor does not come clean, or if it has any
damage to it, replace with a new spark arrestor (see
Chapter 4 for replacement parts).
Place the cleaned (or new) spark arrestor into the Adflo®
Turbo Filter Cover. Next, place the new prefilter into
the Adflo®Turbo Filter Cover. Then, place the new HE
filter into the Adflo®Turbo Filter Cover (see Figure 15).
To reinstall the Adflo®Turbo Filter Cover in the Adflo®
unit, hold the Adflo®unit so the “Adflo®” logo faces
you. Then hook the left side of the Adflo®Turbo Filter
Cover into the Adflo®unit. Press down on the right
side of the cover until the catch fully engages.
Figure 15:
Installing the Spark Arrestor, Prefilter and HE Filter.
Adflo Turbo Filter Cover
Spark Arrestor
Prefilter
HE Filter
3.4 Replacing/Installing the OV/HC/CL/SD
Adflo®Cartridge
The Adflo®Turbo Unit has an exclusive “stackable”
capability that allows it to extend its applicability into
welding environments requiring supplemental
respiratory protection against specific fumes and
vapors. This “stacked” filtration provides protection
from particles, organic vapor, sulfur dioxide, chlorine,
and hydrogen chloride. An on-site safety specialist or
industrial hygienist must review the HE filter label
combined with the OV/SD/CL/HC cartridge label to
determine the applicability for a given
environment/application (see Section 1.2 for Respirator
Approvals and Limitations).
Some users will buy Adflo®Turbo Units that already
have the OV/SD/CL/HC Adflo®cartridge installed from
the factory; other users will choose to install the
OV/SD/CL/HC Adflo®cartridge on their own to meet
changing applications and/or environments.
NOTE: IN ALL CASES, THE OV/SD/CL/HC
ADFLO®CARTRIDGE IS ALWAYS USED WITH
THE HE FILTER, PREFILTER, AND SPARK
ARRESTOR.
To replace or install an OV/SD/CL/HC Adflo®
cartridge, you must first remove the Adflo®Turbo Filter
Cover as follows: hold the Adflo®unit so the “Adflo®”
logo faces you; press in on the Adflo®Turbo Filter
Cover’s black catch on its right side, and lift off the
cover (see Figure 16).
Figure 16:
Removing the HE Filter and
OV/SD/CL/HC Cartridge.

93-0061-00 Rev. A 15
Adflo®Turbo Unit
If an OV/SD/CL/HC Adflo®cartridge is already
installed, remove it as follows: hold the Adflo®unit so
the “Adflo®” logo faces you; press in on the
OV/SD/CL/HC Adflo®cartridge’s black catch on its
right side, and lift it out of the Adflo®unit. The
OV/SD/CL/HC Adflo®cartridge CANNOT be cleaned.
Dispose of the used cartridge as per local and federal
regulations.
To install a new OV/SD/CL/HC Adflo®cartridge, hold
the Adflo®unit so the “Adflo®” logo faces you; hook
the left side of the new OV/SD/CL/HC Adflo®
cartridge into the left end of the Adflo®unit; press the
cartridge down on its right side until its catch fully
engages (see Figure 17).
Next, inspect the Adflo®Turbo Filter Cover and its
components. Replace as needed the HE filter, the
prefilter and the spark arrestor (see Section 3.3 for
complete instructions).
To reinstall the Adflo®Turbo Filter Cover, hold the
Adflo®unit so the “Adflo®” logo faces you. Then hook
the left side of the Adflo®Turbo Filter Cover into the
left side of the OV/SD/CL/HC Adflo®cartridge (see
Figure 18). Press down on the right side of the Adflo®
Turbo Filter Cover until the catch fully engages.
Figure 17:
Installing the
OV/SD/CL/HC Cartridge into the Adflo unit.
Figure 18: Installing the Adflo Turbo Filter Cover
onto the OV/SD/CL/HC Cartridge.
3.5 Replacing the Belt
Remove the old belt from the Adflo®Turbo Unit by
unfastening the belt’s two Velcro®straps and pulling
the Adflo®unit away from the unfastened belt.
To attach the Adflo®unit to the belt, first arrange the
belt so its two ends are higher than its middle; the belt
will look like a smile. Next, thread each Velcro®strip
through the slot on the back of the Adflo®unit, and then
on through the slot on the leather belt (see Figure 19).
Tightly pull the two Velcro®strips prior to fastening
them to one another. When attached properly, the
Adflo®unit is tight against the belt: it will not slide
around. When worn by the user, the buckle will be on
the left side and the belt’s tongue will be on the right
side.
Figure 19:
Adflo®Belt Installation.
Figure 20:
Adflo®Unit Installed on Belt

93-0061-00 Rev. A
16
Adflo®Turbo Unit
4.1 Customer Service
If you have any questions about your Hornell products,
contact our Customer Service at: 800-628-9218 or
Fax: [phone]. (Canada: 800-676-6930 or
Fax: [phone]).
4.2 Adflo®Turbo Unit Warranty
Hornell, Inc. warrants all Adflo®Turbo Units obtained
hereunder to be free from defects in material and
workmanship in normal service and under normal
conditions for 12 months from the date of delivery.
This warranty is void in the case of operator misuse,
abuse, or neglect. Read your instruction manual to
avoid certain situations which could void this warranty.
The foregoing warranty shall not apply, and Hornell,
Inc. shall be held harmless and relieved of any
obligation or liability to the buyer, if the equipment has
been repaired or altered in a manner not authorized by
Hornell, including the use of replacement components
not approved by Hornell, or if the equipment has been
subject to abuse, negligence or accidental mishandling.
The foregoing warranties are in lieu of all other
warranties expressed, implied, or statutory, including
warranty of merchantability or fitness for a particular
purpose.
4.3 Warranty Return Procedure
1) Make a photocopy of your proof-of-purchase;
include the serial number of the product being
returned.
2) Call the Hornell Warranty Department toll-free at
888-773-3345 (Canada: 800-676-6930) to describe
the warranty problem and receive a warranty return
number.
3) Write the warranty return number on the proof-of-
purchase photocopy and fax to Hornell Warranty
Department at 330-487-5326 (Canada Fax: 905-
664-1402). Upon receipt, Hornell will send out a
replacement product that will, in most cases,
arrive the next business day. Send the original
product via UPS third party billing or a call tag
issued by Hornell; clearly write the warranty
return number on the outside of the package.
Chapter 4 Customer Information
4.4 Out-Of-Warranty Repairs and Service
Hornell offers out-of-warranty repairs on all current
models. For repair pricing and procedures, call the
Service, Repair & Warranty Dept. toll-free: 888-773-
3345 or Fax: [phone]. (Canada: 800-676-6930 or
Fax: [phone]).
4.5 Replacement Parts and Accessories
When ordering replacement parts and/or accessories,
use the part numbers and descriptions listed below.
Failure to use only Hornell parts and accessories will
void the product warranty and will expose the user to
the risk of serious bodily injury or loss of life. Hornell,
Inc. is not responsible for system performance if other
than Hornell parts are used to repair or refurbish the
equipment.
4.5.1 Replacement Filters and Cartridges
Part Number Description
15-0099-99X06 6-pack Adflo®Prefilter
15-0099-99X12 12-pack Adflo®Prefilter
15-0199-99X02 2-pack Adflo®HE Particle Filter
15-0199-99X06 6-pack Adflo®HE Particle Filter
15-0199-99X36 36-pack Adflo®HE Particle Filter
15-0399-99X02 2-pack Adflo®OV/SD/CL/HC
Cartridge
15-0399-99X06 6-pack Adflo®OV/SD/CL/HC
Cartridge
15-0009-99X02 2-pack Adflo®Spark Arrestor
4.5.2 Adflo®Turbo Replacement Parts
Part Number Description
15-1099-01 Adflo®Turbo Assembly and Filter
Cover without Filter or Cartridge
or Battery
15-1099-81 Adflo®Turbo Filter Cover
15-5401-01 Adflo®Turbo, complete with Breathing
Tube Assembly, Flow Indicator, Belt,
Spark Arrestor, Adflo®Turbo Filter
Cover, Prefilter, HE Particle Filter,
Battery and Smart Charger.

93-0061-00 Rev. A 17
Adflo®Turbo Unit
4.5.3 Headpiece Assembly Replacement
Parts and Accessories
See the manual that came with the headpiece assembly
for a listing of replacement parts and accessories.
4.5.4 Miscellaneous Replacement Parts
and Accessories
Part Number Description
15-0099-05 Flow Indicator
15-1099-07 Adflo®Battery Pack
15-0099-08 Adflo®Battery Smart Charger
15-0099-10 Adflo®Breathing Tube Assembly
(Rubber)
15-0099-16 Adflo®Leather Belt
18-0099-16 Comfort Belt
15-0099-06 Adflo®Leather Belt Front Piece
Replacement
18-0099-33 Carry Bag
The only user-serviceable parts on
the Adflo®Turbo Unit are the
Adflo®Turbo Filter Cover, HE Filter,
Prefilter, Spark Arrestor, the
OV/SD/CL/HC Adflo®Cartridge and
the Battery Pack.
The Blower Unit is supplied as a
seal-tested unit. Any attempt to
detach the flexible air inlet
molding or fan scroll will result in
the termination of the limited
warranty contained in Chapter 4.1
!CAUTION
18-0099-33
15-0399-99
15-0099-10
Turbo
15-0099-06
15-0099-16
15-0199-99
15-0099-99
15-0009-99
15-1099-81 15-1099-07
15-0099-08 15-0099-05
15-1099-01
Figure 21:
Exploded Adflo®Turbo Unit with Part Numbers.

Appendix A
Definition of Safety Signal Words per
ANSI Z535.4
indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
93-0061-00 Rev. A
18
Adflo®Turbo Unit
Appendix B
Technical Specifications for Adflo®Turbo
Unit Powered Air Purifier:
Assigned Protection Factor
(for approved purifier/
headpiece combination): 25
Airflow: 6+ cfm (170+ lpm)
Noise: <70 db at maximum
airflow
Weight, Adflo®unit with
battery, belt, breathing tube: 4.48 lbs (2.03 kg)
Weight, OV/SD/CL/HC
Adflo®Cartridge: 1.62 lbs (0.74 kg)
Operating Temperatures: 23° to 131°F
(-5° to 55°C)
Respirator Approval: refer to the (NIOSH 42
CFR 84) Respirator
Approval Label for all
approved purifier/
headpiece combinations.
Battery Life: Approximately 520
charges
Belt Size: 75-115 cm
!CAUTION
!WARNING

93-0061-00 Rev. A 19
Adflo®Turbo Unit
Notes

93-0061-00 Rev. A
HORNELL, INC.
2374 EDISON BLVD. • TWINSBURG, OH 44087 USA
800-628-9218 • 330-425-8880 • FAX: [phone]
[email protected] • www.hornell.com
HORNELL CANADA INC.
43 TEAL AVE. UNIT 1 • STONEY CREEK, ONTARIO L8E 3B1 CANADA
800-676-6930 • 905-664-6239 • FAX: [phone]
[email protected] • www.hornell.com
All proprietary designs protected by patents worldwide. Speedglas
®
, Adflo
®
, Fresh-air
®
and SideWindows
™
are trademarks of Hornell.
All other trademarks are the property of their respective owners. Hornell, Inc. reserves the right to make changes in specifications or
products at any time without prior notice. ©2003 Hornell, Inc. Printed in USA.