Kappler Zytron 300 Operation manual

Certied Models NFPA 1992 - 2018 Edition

Z3H426 92 • Z3H427 92 • Z3H428 92 • Z3H432 92

Z3H437 92 • Z3H576 92 • Z3H577 92

Z3H579 92 • Z5H577 92 • Z3H452 92

Z3H452 92 5B • Z3H456 92 • Z3H456 92 5B

User Information for

Zytron®300 and 500

Liquid Splash

Protective Garment

RM 00893 Rev: 12-2021

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

info@kappler.com

User Information for

Zytron 300 and 500 Liquid Splash Protective Garments

Certiﬁed Models

NFPA 1992-2012 Edition

21-KAP-232

CONTENTS

Safety Considerations.............................................................................................................5

Safety Symbols used in this manual....................................................................................5

Warnings and Limitations ....................................................................................................... 6

Additional Equipment ��7

Chemical Permeation Data �� 9

Static Electricity�� 9

Avoid Continuous Exposure��10

Inspection of Garment ............................................................................................................11

Full Visual Inspection ..............................................................................................................11

Returning the Garment ..........................................................................................................12

Storage�� 13

Visor Anti-fog Solution...........................................................................................................13

Closure Lubricants ..................................................................................................................13

Marking Recommendations and Restrictions ..................................................................14

Recommended Undergarments..........................................................................................14

Sizing Considerations ............................................................................................................14

Donning the Garment (Z3H427 92, Z3H432 92 and Z3H437 92).............................14

Dong the Garment (Z3H427 92, Z3H432 92 and Z3H437 92) ...............................16

Donning the Garment (Z3H428 92 and Z3H426 92) ....................................................16

Dong the Garment (Z3H428 92 and Z3H426 92) ......................................................18

Donning the Garment (Z3H576 92, Z3H577 92 and Z5H577 92) .............................19

Dong the Garment (Z3H576 92, Z3H577 92 and Z5H577 92) ...............................21

Donning the Garment Z3H579 92.................................................................................... 22

Dong the Garment Z3H579 92.......................................................................................24

Interface Issues.......................................................................................................................24

Decontamination and Cleaning of Chemical and Biological Contamination ........ 25

Decontamination before Reuse��26

Maintenance and Cleaning��26

Retirement Considerations�� 27

Disposal ....................................................................................................................................27

Warranty information .............................................................................................................28

APPENDIX A - Technical Data Package ......................................................................... 29

NFPA 1992 Performance Data��29

Sizing Information ��29

Garment Material and Component Descriptions.......................................................... 29

Physical Foot Protection........................................................................................................31

Zipper/Closure Type and Material .....................................................................................31

Material Seam Types and Composition............................................................................33

Exhaust Valve Type and Material.......................................................................................34

Type and Style of Head Protection Accommodated with this Garment..................34

Zytron®Glove Sizing Chart..................................................................................................34

APPENDIX B - Zytron®Sizing Chart ..................................................................................35

APPENDIX C - Zytron®Inspection Test Log....................................................................36

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SAFETY CONSIDERATIONS

Be sure to read, understand and follow the information in this manual

and all applicable federal, state and local occupational safety and health

statutes. For users outside the United States, please consult national or

other applicable personal protective equipment regulations. Proper use,

consistent with NFPA 1500, Standard on Fire Department Occupational

Safety and Health Program, and 29 CFR 1910.132 is required.

SAFETY SYMBOLS USED IN THIS MANUAL

While reading this manual, you will come across a number of warnings

concerning 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.

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WARNINGS AND LIMITATIONS

NOTICE

Indicates additional information on how to use the device.

Thisgarment mustbe usedin combinationwith additional

PPE, which include the following:

Separate full-face respiratory protection such as a self-

contained breathing apparatus (SCBA), an external

breathing air supply (airline system with garment pass-

through) with escape bottle or a re- breather system. NFPA

compliant garments must use NIOSH CBRN approved

SCBA.

Separate foot and lower leg protection such as chemical

protective boots.

caution

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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;

caution

Additional Equipment

Additional personal protective equipment that might also be consid-

ered includes:

►Head protection.

►Hearing protection may be required due to high levels of exter-

nal noise or high noise levels generated by supplied air systems.

►Other protective equipment that may be warranted based on the

situation.

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●Fever

●Diculty breathing

●Nausea

●Excessive tiredness

●Dizziness

●Numbness

●Any unusual odor or taste

●Eye or skin irritation

●Narrowing or dimming of vision

●Claustrophobia

●Loss of balance or orientation

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 the 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, ambient 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).

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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; 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 take into consideration physical performance

characteristics that e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 ﬂammable atmosphere. When working around

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ﬂammable chemicals, steps to eliminate potential static discharges

should be used. In these situations, recommended precautionary steps

include the use of an over-cover, raising humidity level of the work area,

and/or using a commercial anti-static application.

Avoid Continuous Exposure

This garment should not be immersed in chemicals. This garment

should not be exposed to continuous hazardous liquid chemical splash

or deluge. Do not wade through liquid pools of hazardous chemicals if

not necessary. Direct chemical exposure to the garment should be as

limited as possible. If exposed to direct splash or deluge of hazardous

chemicals, leave the area immediately and decontaminate.

Sock Boots

The sock boots attached to this garment are designed to be worn inside

outer chemical boots. These sock boots do not have sucient durability

or slip resistance to be worn as outer boots.

Provide Hearing Protection

If noise levels inside the garment exceed regulatory noise levels, hearing

protection must be provided. Use hearing protection recommended by

a safety professional and which does not interfere with the operation or

use of the garment.

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INSPECTION OF GARMENT

FULL VISUAL INSPECTION

To perform a full visual inspection:

►Choose a clean, dry area that is free of potential sources of

snags, tears and punctures.

►Mark suspected defects with colored adhesive tape.

►Check the visor for scratches or ﬂaws.

►Visually inspect seams for tape lift or delamination.

►Visually inspect for surface damage or discoloration on

material,visor, gloves and zipper closure.

The garment should undergo a full visual inspection

at the following times:

• Upon receipt to ensure no damage has occurred

during shipment.

• After a garment is worn and before the garment is

made available for reuse.

• Annually.

However, most performance properties of a liquid-

splash clothing item or ensemble cannot be tested by

the user in the ﬁeld.

caution

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►Check zipper closure for worn or damaged parts.

►Check function of zipper and zipper ﬁtting. If zipper is dicult

to operate, it can be lubricated lightly on the outer and inner

components with paran (wax). After lubrication, the zipper

should be closed and opened a number of times to assure that

all excess lubricant has been removed. Garment should be

stored with zipper open.

Garments with visible holes, tears, rips, punctures, serious discoloration

or abrasions should not be used.

Note any remarks in the inspection log. If the garment is unsuited for

use by visual inspection, the garment may be retired and designated for

training use after being permanently labeled “For Training Use Only” or

disposed of properly.

RETURNING THE GARMENT

In some instances the garment may be returned for inspection and possible

replacement. If a garment fails a visual inspection or pressure test, contact

Kappler Inc., to authorize the return. Contaminated garments will not be

accepted for repair. Discoloration or odors are evidence of contamination.

Garments being returned must be accompanied by the usage log and

The Returned Good Authorization Form from Kappler, stating the suit has

not been contaminated. Note: Charges may be incurred� See warranty

information pg� 18�

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Storage

Storage Life

Kappler Zytron® 300 garments contain materials for which there is no

speciﬁc storage life data available. Garments may be used as long as

they pass the ASTM F1052 pressure test and pass a full visual inspection.

It is recommended that garments be labeled, retired and designated

to “Training Use Only” if they do not pass the visual inspection and/or

pressure test.

Storage Conditions

Garments should be stored away from direct sunlight, preferably

in a cool, dry location that is not subjected to extreme hot or cold

conditions. Garments should be stored in their original boxes, in bags

or on hangers. Garments should be stored with the zipper open.

VISOR ANTI-FOG SOLUTION

Kappler oers an Anti-Fog solution especially for use in chemical

garment visors. Refer to part number A00RS.

CLOSURE LUBRICANTS

There are no lubricants recommended for the closure system.

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MARKING RECOMMENDATIONS AND RESTRICTIONS

Ensembles may be marked with the Kappler ChemTape® Kit for

identiﬁcation. Refer to part number 99415.

RECOMMENDED UNDERGARMENTS

The wearer should consider wearing inherently ﬂame resistant, woven

clothing, with full sleeves, and trousers under this garment.

SIZING CONSIDERATIONS

The Zytron® 300 garment sizing chart should be used to determine accurate

ﬁt. The correct size garment should be worn. See Appendix B pg� 23�

DONNING THE GARMENT (Z3H427 92, Z3H432 92 AND Z3H437 92)

1. Conduct a brief visual inspection of the garment before

beginning donning procedure.

a. garment should be free of discoloration, or physical damage

b. inner gloves should be fully inserted in outer gloves

c. inside and outside of exhaust values should be free of caps

and plugs

2. An assistant should help the wearer don the garment.

3. Before donning remove all jewelry and personal items

(pens, key rings, badges, pagers, knife cases, etc.) that might

damage the garment.

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4. Check function of respirator and place near donning location.

5. Visually check size and condition of outer boots and place near

the donning location.

6. Open garment zipper closure completely.

7. Read garment size label to assure proper ﬁt.

8. Remove shoes. The sock boots on this garment are worn inside

outer chemical boots. These sock boots do not have adequate

durability or slip resistance to be worn over footwear as an outer

covering.

9. While sitting, insert feet into garment legs and down into sock

boots. Stretch legs out to maximum extension while pulling

garment up around hips.

10. Pull boot splash ﬂaps up and don outer boots. Fold splash ﬂaps

down over boots as far as possible.

11. Place one hand in the sleeve and pull garment sleeve to

shoulder. Make sure hand is securely inside the glove.

12. Place other hand in the opposite sleeve and glove as before.

13. Don respirator face piece and tighten head straps to secure.

14. Pull hood over the head and secure, ensure proper ﬁt and seal.

15. Slowly close the zipper. After checking that the zipper is completely

closed, the ﬂaps should be closed and sealed over the zipper.

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DOFFING THE GARMENT (Z3H427 92, Z3H432 92 AND Z3H437 92)

1. If the garment has been contaminated or is suspected of being

contaminated, the wearer should continue to use his respirator

until the garment has been doed and removed.

2. An assistant should help the wearer do the garment after

ﬁeld decontamination. If the garment has been contaminated,

the assistant should wear protective clothing and respiratory

equipment.

3. While the wearer stands, the assistant should open the storm

ﬂap and zipper closure, and then peel the garment down and

away from the wearer’s shoulders. To prevent inner gloves from

inverting, grasp the ﬁngers of both gloves while the other hand is

being removed. The assistant should help the wearer remove his

arms from the sleeves. External airlines should be disconnected

from the garment and from the wearer’s respirator, while the

wearer switches to his escape bottle.

4. Lower the garment below the hips and sit down. Have the

assistant remove the boots, pull the garment o the legs and

remove the garment to a remote location.

5. Once the garment has been removed, the wearer can do the

respiratory face piece.

DONNING THE GARMENT (Z3H428 92 AND Z3H426 92)

1. Conduct a brief visual inspection of the garment before

beginning donning procedure.

a. garment should be free of discoloration, or physical damage

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b. inner gloves should be fully inserted in outer gloves

c. inside and outside of exhaust values should be free of caps

and plugs

2. An assistant should help the wearer don the garment.

3. Before donning remove all jewelry and personal items

(pens, key rings, badges, pagers, knife cases, etc.) that might

damage the garment.

4. Check function of respirator and place near the donning location.

5. Visually check size and condition of outer boots and place near

the donning location.

6. Open garment zipper closure completely.

7. Read garment size label to assure proper ﬁt.

8. Remove shoes.

9. While sitting, insert feet into garment legs and down into sock

boots. Stretch legs out to maximum extension while pulling

garment up around hips.

10. Put on boot and pull elastic ankle openings over the boots.

Placeone hand in the sleeve and pull garment sleeve to shoulder.

11. Place other hand in the opposite sleeve. Put on gloves and

attach to garment sleeves with ChemTape®.

12. Slowly close the zipper closure. After checking that the closure

iscompletely closed, the storm ﬂaps should be closed and sealed

over the zipper closure. Do this by removing the double sided

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tape release paper pressing to top storm ﬂap to bottom storm ﬂap.

Fold the top of the storm ﬂaps inside the garment at chin.

13. Put on respirator face piece and pull garment hood back over

the top of the face piece.

DOFFING THE GARMENT (Z3H428 92 AND Z3H326 92))

1. If the garment has been contaminated or is suspected of being

contaminated, the wearer should continue to use his respirator

until the garment has been doed and removed.

2. An assistant should help the wearer do the garment after

ﬁeld decontamination. If the garment has been contaminated,

the assistant should wear protective clothing and respiratory

equipment.

3. While the wearer stands, the assistant should open the storm

ﬂap and zipper closure, and then peel the garment down and

away from the wearer’s shoulders. To prevent inner gloves from

inverting, grasp the ﬁngers of both gloves while the other hand is

being removed. The assistant should help the wearer remove his

arms from the sleeves. External airlines should be disconnected

from the garment and from the wearer’s respirator, while the

wearer switches to his escape bottle.

4. Lower the garment below the hips and sit down. Have the

assistant remove the boots, pull the garment o the legs and

remove the garment to a remote location.

5. Once the garment has been removed, the wearer can do the

respiratory face piece.

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DONNING THE GARMENT (Z3H576 92, Z3H577 92 AND Z5H577 92)

1. Conduct a brief visual inspection of the garment before

beginning donning procedure.

a. garment should be free of discoloration, or physical

damage

b. inner gloves should be fully inserted in outer gloves

c. inside and outside of exhaust values should be free of

caps and plugs

2. An assistant should help the wearer don the garment..

3. Before donning remove all jewelry and personal items (pens, key

rings, badges, pagers, knife cases, etc.) that might damage the

garment.

4. Check function of respirator and place near the donning location.

5. Visually check size and condition of outer boots and place near

the donning location.

6. Open garment zipper closure completely.

7. Read garment size label to assure proper ﬁt.

8. Apply anti-fog to inside to visor.

9. Remove shoes. The sock boots on this garment are worn inside

outer chemicals boots. These sock boots do not have adequate

durability or slip resistance to be worn over footwear as an

outercovering.

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10. While sitting, insert feet into garment legs and down into sock

boots. Stretch legs out to maximum extension while pulling

garment up around hips.

11. Pull boot splash ﬂaps up and don outer boots. Fold splash ﬂaps

down over boots as far as possible.

12. While standing, with garment at waist level, don SCBA respirator

harness and back piece.

13. Don respirator face piece and check its function. To conserve

SCBA air supply, disconnect the air supply from the face piece,

if possible, as long as the wearer retains access to fresh air. In

the case of an airline breathing system, complete all connections

and adjustments.

14. Place one hand in the sleeve and pull garment sleeve to

shoulder Make sure hand is securely inside the glove.

15. Place other in the opposite sleeve and glove as before.

16. Pull the garment over respirator backpack towards head, making

sure nothing will constrict or hamper air ﬂow for your breathing

apparatus or airline.

17. Attach the SCBA regulator air supply to the face piece, activate

the air supply and ensure proper function of air supply before

closing the zipper. If using an airline breathing system, ensure

breathable air is now being supplied to the suit.

18. Have your assistant slowly close the gas-tight zipper closure.

After checking that the zipper is completely closed, the storm

ﬂaps should be closed and sealed over the zipper closure.

KAPPLER Zytron 300 Operation manual

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