KAPPLER Frontline 500 Operation manual

Certied Models NFPA 1990 (1991) – 2022 Edition
F5H582-91 • F5H583-91
User Information
for Frontline® 500
Vapor and Liquid
Protective Ensemble
RM 00863 Rev 01-2023

THIS INFORMATION PACKET MAY NOT BE REMOVED EXCEPT
BY THE END USER
Kappler, Inc.
P.O. Box 490 | 115 Grimes Drive
Guntersville, AL 35976
256-505-4005 Phone
800-600-4019 Toll free
256-505-4151 Fax
[e-mail]
User Information for
Frontline® 500 Vapor and Liquid Protective Ensemble
Certified Model
NFPA 1990 (1991) - 2022 Edition
22-KAP-111

CONTENTS
Safety Considerations..............................................................................................................................1
Safety Symbols Used In This Manual...................................................................................................1
Warnings and Limitations ......................................................................................................................2
Additional Equipment ....................................................................................................................................... 3
Wearers Must Be Physically Fit ...................................................................................................................... 3
Always Use the Buddy System����������������������������������������������������������������������������������������������������������������������������� 4
Manage and Prevent Heat Stress������������������������������������������������������������������������������������������������������������������������ 4
Chemical Permeation Data ������������������������������������������������������������������������������������������������������������������������������������ 5
Static Electricity ���������������������������������������������������������������������������������������������������������������������������������������������������������� 5
Avoid Continuous Exposure���������������������������������������������������������������������������������������������������������������������������������� 6
Supplied Airline Applications ..........................................................................................................................6
Sock Booties ��������������������������������������������������������������������������������������������������������������������������������������������������������������� 6
Provide Hearing Protection ............................................................................................................................. 7
Communications���������������������������������������������������������������������������������������������������������������������������������������������������������7
Inspection of the Garment .....................................................................................................................7
Full Visual Inspection ..............................................................................................................................8
Pressure Testing the Garment ..............................................................................................................9
Conducting the Test ................................................................................................................................9
Returning the Garment ......................................................................................................................... 13
Instructions For Field Replaceable Compontents ......................................................................... 13
Storage Life and Service Life.............................................................................................................. 14
Storage Life.........................................................................................................................................................14
Storage Conditions .......................................................................................................................................... 15
Visor Anti-Fog Treatment ..................................................................................................................... 15
Closure Lubricants ................................................................................................................................. 15

Marking Recommendations and Restrictions ................................................................................. 16
Recommended Undergarments......................................................................................................... 16
Respirator Consideration for Ensembles ......................................................................................... 16
Sizing Considerations ........................................................................................................................... 16
Donning the Garment............................................................................................................................ 17
Dong the Garment.............................................................................................................................. 19
Interface Issues......................................................................................................................................20
Decontamination and Cleaning of Chemical and Biological Contamination ........................20
Decontamination Solutions........................................................................................................................... 20
Field Decontamination................................................................................................................................... 20
Decontamination before Reuse..........................................................................................................21
Maintenance & Cleaning ............................................................................................................................... 22
Retirement Considerations................................................................................................................. 23
Disposal ................................................................................................................................................... 23
Warranty information ............................................................................................................................ 24
Appendix A - Technical Data Package ............................................................................................25
NFPA 1991 Performance Data ...................................................................................................................... 25
Sizing Information............................................................................................................................................ 25
Garment Material and Component Descriptions..........................................................................26
Garment Material............................................................................................................................................. 26
Visor/Faceshield Material.............................................................................................................................. 26
Glove Material and Assembly ...................................................................................................................... 26
Sock Bootie Material ...................................................................................................................................... 26
Physical Foot Protection................................................................................................................................ 26
Zipper/Closure Type and Material .................................................................................................... 27

Material Seam Types and Composition........................................................................................... 27
Garment Material..............................................................................................................................................27
Garment Material - Visor.................................................................................................................................27
Garment Material - Glove .............................................................................................................................. 28
Garment Material - Footwear ....................................................................................................................... 28
Garment Material - Garment Closure ......................................................................................................... 28
Exhaust Valve Type and Materials.................................................................................................... 28
Respiratory Equipment ........................................................................................................................28
Testing Devices......................................................................................................................................29
External Gasket Types and Materials...............................................................................................29
Head Protection Accommodated with this Garment...................................................................29
Frontline® Glove Sizing Chart ............................................................................................................29
Appendix B - Garment Sizing Chart .................................................................................................30
Appendix C - Frontline® 500 Inspection Log.................................................................................. 31

User Information for Frontline® 500
1
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SAFETY CONSIDERATIONS
It is the user’s responsibility to read, understand and follow the information in this
manual and on Kappler’s website, www�kappler�com and all applicable Federal,
state and local occupation safety and health statutes� For users outside the United
States, please consult national or other applicable personal protective equipment
regulations� Proper use should be consistent with NFPA 1500, Standard on Fire
Department Occupational Safety and Health Program, and 29 CFR 1910�132�
The Authority Having Jurisdiction (AHJ) responsible for approving equipment
must comply with the requirements of NFPA 1891 for the selection, care, and
maintenance of protective ensembles and elements�
SAFETY SYMBOLS USED IN THIS MANUAL
While reading this manual, you will come across a number of warnings concern-
ing some of the risks and dangers you may face while using the device� These
warnings contain “signal” words that will alert you to the degree of hazard you
may encounter� These words, and the hazards they describe, are as follows�
warning
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
caution
Indicates a potentially hazardous situation which, if not avoided,
could result in physical injury or damage to the product. It may
also be used to alert against unsafe practices.

User Information for Frontline® 500 2
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WARNINGS AND LIMITATIONS
NOTICE
Indicates additional information on how to use the garment.
caution
This garment must be used in combination with additional PPE,
which include the following:
Separate full-face respiratory protection such as a self-contained
breathing apparatus (SCBA) or an external breathing air supply
(airline system with garment pass-through) with escape bottle.
NFPA compliant garments must use NIOSH CBRN approved SCBA.
Separate foot and lower leg protection such as chemical
protective boots.
warning
There are uses, environments, and chemicals for which these
garments and/or fabrics are unsuitable. It is the responsibility of
the user to review available data and verify that the garment and/
or fabric is appropriate for the intended use and meets all
specified and/or industry standards.

User Information for Frontline® 500
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caution
Additional Equipment
Additional personal protective equipment that might also be considered includes:
●Head protection�
●Hearing protection may be required due to high levels of external noise or
high noise levels generated by supplied air systems�
●Other protective equipment that may be warranted based on the situation�
Wearers Must be Physically Fit
Garments should only be worn by persons who are in good
physical condition. Working in a totally encapsulating garment
is strenuous. In an emergency situation or hot environment, the
wearer may experience heat stress. Persons who show
symptoms of heat stress such as nausea, dizziness, or excessive
heat build-up should leave the work area immediately and do
the garment as quickly as possible. Persons in doubt about their
physical condition should check with a physician before wearing
these garments.
If any of the following symptoms develop during use of this
garment, immediately leave the hot zone, undergo field
decontamination (if exposed), and do the garment:
●Fever
●Diculty breathing
●Nausea
●Excessive tiredness continued

User Information for Frontline® 500 4
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continued
●Dizziness
●Numbness
●Any unusual odor or taste
●Eye or skin irritation
●Narrowing or dimming of vision
●Claustrophobia
●Loss of balance or orientation
Always Use the Buddy System
Never work in this garment alone� A minimum of two people should enter con-
taminated areas together� It is important to have someone available to assist in
the event of an emergency� That person will require the same level of protection
as the person needing emergency assistance�
Manage and Prevent Heat Stress
This garment interferes with the natural regulation of body temperature� This can
lead to a rise in core body temperature and heat stress� The wearer should be
aware of the symptoms and treatment of heat stress� The wearer can take several
steps to limit and/or prevent heat stress, such as use of a cooling system, and
working in accordance with a conservative work/rest schedule� The maximum
time the garment can be worn depends on such variables as the air supply, ambi-
ent condition, climate inside the garment, physical and psychological condition of
the wearer, work rate and work load� The TLV™ pocket guide from the American
Conference of Governmental Industrial Hygienists (ACGIH, Cincinnati) provides
corrected heat stress limits for totally encapsulating garments� Similar information
is available on the federal OSHA website (www�OSHA�gov)�

User Information for Frontline® 500
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Chemical Permeation Data
Before using a garment in a chemical situation, consult the chemical permeation
data appropriate to the garment material� This information is to be used as a
guide only� The permeation performance of any material depends on a number
of factors including chemical concentration, temperature, time and amount of
exposure, etc� Due to the large number of variables, it is impossible for all garment
materials to be tested against all chemicals, all combinations or mixtures, and all
temperatures at which the chemical might be encountered�
Chemical permeation tests are performed under laboratory conditions – not
actual workplace conditions� They address chemical breakthrough characteristics
and do not account for physical performance characteristics that aect barrier
such as abrasion, flex fatigue, puncture, tear, oxidative degradation, or degraded
performance due to previous contamination�
No single protective material will protect against all chemicals for all situations�
The best course of action is to test the primary garment materials against the
specific chemical hazard, at the temperature and in the concentrations to be
encountered� Kappler, Inc� will provide free swatches of primary garment materials
for testing and help arrange to have these tests performed�
Static Electricity
Under certain conditions, such as cold and dry weather, it is possible for garments
to build and discharge static electricity� Discharges are not normally dangerous
except in situations where generation of an electrical spark could ignite a flamma-
ble atmosphere� When working around flammable chemicals, steps to eliminate
potential static discharges should be used� In these situations, recommended
precautionary steps include raising humidity level of the work area and/or using
a commercial, anti-static application�