KAPPLER AKMOC User manual
Instructions for
Pressure
Testing
A Gas TightGarment
Test Kit:
AKMOC
RM
00847 Rev: 08-2021
CONTENTS
Safety Symbols used
in
this manual.....................................................................
1
Helpful
YouTube
Videos available for your AKMOC
use ............................
2
Self-Test
Instructions ............................................................................
6
ASTM and
CE
Testing Procedure ......................................................... 9
Instructions for
Locating Leaks ..................................................................
15
Pressure Test
Kit Verification...................................................................... 16
Items Needed for Pressure Test Kit
Verification
...........................................
16
Verification Procedure ...............................................................................
17
DuraChem® 500 Instructions for Using the Face Seal
Blank
to
Pressure Tes
t Kappler
Adapter
Item #
AK
M007 ......................... 18
Replacement
P
art
s
and Acce
sso
rie
s
..................................................... 19
Nomenclature ...........................................................................................
19
APPENDIX
A – Testing Procedure Screen
Sho
t
s
...................................... 20
Troubleshooting & Other Tips ............................................................. 22
Frequently Asked Questions. .............................................................. 26
USB
Data Program Instructions................................................................... 28
Disclaimer ......................................................................................... 28
I
ns
ta
lling
t
he
Pressure Test
Kit USB
Data
Program application
................. 30
Using
the USB Data Program application .............................................. 31
Exporting
the
test
result data..................................................................... 33
Exit and
Close
the USB Data Program
application
.................................. 34
Warranty information................................................................................. 35
Caution
Do Not Connect Power or Air Supply to this pressure test
kit without fully reading and understanding the User
Instructions. Kappler recommends using 100- 150 psi
Grade
D
breathing
air for
testing
as a
minimum with
200 psi
Maximum.
Always
use
a
source
of
clean
and
dry
air
to operate
this pressure test kit.
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,
ifnot
avoided, could result in serious injury or death.
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.
NOTICE
Indicates
additional
information
on
how
to
use
the
device.
HELPFULYOUTUBE VIDEOS AVAILABLE FOR YOURAKMOC USE.
PRESSURE TESTING A GAS TIGHT GARMENT USING THE AKMOC TEST KIT
https://www.youtube.com/watch?v=Hv5k2srzdEw
PRESSURE TEST KIT SELF-TEST
https://www.youtube.com/watch?v=U89O5youy0o
REPLACEMENT AND USE OF THE UNIVERSAL ADAPTER
https://www.youtube.com/watch?v=MUMqckDIHGU
R
E
MO
VA
L
AN
D R
EPLACE
M
EN
T
OF
TH
E
EXHAUS
TVALVE
BODY ON A FRONTLINE 500
https://www.youtube.com/watch?v=9khzKO_PVFw
R
E
MO
VA
L
AN
DRE
P
L
ACE
M
EN
T
OF
TH
E
PI
R
E
LLIEXHAUST
VALVE ON A ZYTR
ON
500
https://www.youtube.com/watch?v=gWZxRzP8Vnc
T
ECHN
I
QUE
FOR
C
L
OS
I
NG
A
GAS
TI
GH
TZIPPER
https://www.youtube.com/watch?v=Vupn0CH0wks
PROPER FOLDING AND STORAGE OF ZYTRON 500
https://www.youtube.com/watch?v=ST2n51PMqAU
PROPER FOLDING AND STORAGE OF FRONTLINE 500
https://www.youtube.com/watch?v=QFRIqkckmGg
Garment
3
Warning
DO NOT CONNECT SUPPLIED AIR TO THE TEST
KIT DURING A SELF-TEST. CONNECTION OF
SUPPLIED AIR DURING TH
IS
T
E
ST
COULD
RESULT
IN SER
IOU
S I
NJ
URY OR
DA
M
A
GE
TO
TH
E
T
E
ST
KIT.
NOTICE
During the assembly and testing of the Kappler
AKMOC pressure
test kit, several steps are taken to
ensurethereliabilityandaccuracyofthekit.
The kit is subjected to a self-test to ensure the
connections inside the kit are complete and leak
free.ThekitisthemsubjectedtoanASTMF1052 test
with a testing pillow.
Upon successful completion of these tests, the
pressure transducer inside
the kit is
verified against
a
pressure calibrator.
If the
transducer
is out of
tolerance
during
the
verification, slight adjustments are
made to
bringthereadoutintotolerance.
Kappler is not in the position to produce calibration
records for these kits because we are not an
accredited calibration company.
If the authorityhaving
jurisdiction
(AHJ) or company
policies require calibration of the kit, then an
accredited calibration company should be consulted
forcalibration.
4
Garment
Caution
This pressure test kit is recommended for an inlet
pressureof100-150psi. Anypressurehigherthan 200
psiwilldamagethepressuretestkit.Ifasource greater
than 200 psi is used, a pressure regulator must be
installed
in-line
to
prevent
damage
to
the
kit.
Kappler strongly recommends the use of a clean air
source to prevent contamination of the pressure test
kit. If a clean and dry air source cannot be verified,
an in-line air filter should be installed.
If hoses are removed from the test kit while the
test is in process there is a possibility of over-
inflating and/or damage to the garment being
tested. If hoses are removed during a pressure
test Kappler recommends immediately stopping
the testing process and completely restarting the
pressure test.
Garment
5
A.
Pair
of
Valve
Adapters
(AKM003)
B. Aspirator
for
Self-Test
C. USB Drive
D. PairofAirSupplyHoses
with
Quick
Disconnect
Fittings
(AKM004)
E. Power Cord
Figure 1: Labeled
Components
F.
Male
Quick
Disconnect
Hose
Fittings
(D)
G.
Male
Quick
Disconnect
Fitting
for
Aspirator
(B)
H.
Pressure
Relief
Valve
I. Swivel Connector for
User
Supplied
Air
Fitting
J.
Touch
Screen
K. USB Port
L. Power Switch and
Power Cord Plug (E)
Figure 2: Test Kit
Layout
6
Garment
SELF-TEST INSTRUCTIONS
Warning
DO NOT CONNECT SUPPLIED AIR TO THE
PRESSURE TEST KIT DURING THE “SELF-TEST”.
RELEASE ANY RESIDUAL PRESSURE BEFORE
ATTACHING ASPIRATOR
1.
Ensure there
is
no residual pressure in the test kit by using
your
finger to press the white inner tube
of
the
Male
Quick
Disconnect
Fitting (Part G) and releasing any stored air.
2. Locate the power supply cord (Part E) and insert into the AC
receptacle
(L)
on
the
test
kit
face.
Connect
the
power
supply
cord
to
a
110 volt power source. Use
of
this
kit
outside
the
United States
will
require special adapters and/or converters.
3.
Connect
the
two
supplied
air
hoses
(Part
D)
together
by
attaching
one male quick disconnect to one female quick disconnect and
then
connecting
the
other
ends
to
the
male
quick
disconnect
fittings
(Part
F) mounted on the top center of the test kit face plate.
4.
Attach the female quick disconnect on the self-test aspirator (Part
B)
to the male quick disconnect (Part G) located on the face plate
adjacent to the other quick disconnect fittings. Close the
thumb
screw on theaspirator.
5.
Turn
test kit on with power switch (L). Wait until the test kit
program
has loaded and the Touch Screen (J) shows the Set-up Page
(Figure
3
).
Insert
USB
drive
into
the
USB
port
(K).
Note:
It
will
take
a
few moments for the drive to connect with the software.
8
Garment
9.
Input the user and test kit information in the appropriate fields
and
pressthe “SELF-TEST” buttonto returntothe self-test page.
10.
Press the “START” button, and then firmly squeeze the
aspirator
one
(1)
time
to
fill
the
kit
and
hoses
with
air.
The
self-test
requires
minimal
air,
DO
NOT
continue
to
squeeze
the
aspirator
or
this
will
further extend the time to complete the
test.
11. The self-test will take several minutes to complete.
12.
The
results
of
the
testing
will
be
displayed
with
an
indication
of
PASS/
FAIL.
To
complete the self-test and record the test data, press
the
“STOP” button and then press the “COPY
DATA
TO USB” button
to
transfer
data
to
the
USB
drive.
When
the
red
button
“Accessing
USB
Drive Do Not Remove” stops flashing,
the
USB drive can
be
removed.
Kappler offers
a
data conversion program
to
access the data
on
the USB drive and allow conversion into an Excel spreadsheet
for
further
use.
The
executable
file
for
this
program
can
be
located
at
https://www.kappler.com/files, USB Data Program. Instructions
for
downloading the Data Program can be found on page
30.
13.
If
the
test
kit
passes
the
self-test, remove
the
aspirator
bulb
from
the
kit,
disconnect
the
hose
ends
from
each
other
and
attach
the
valve
adapters to perform garment testing.
14.
If
the
test
kit
fails
the
self-test,
ensure
the
kit
has
obtained
ambient
temperature
for
at
least
30
minutes.
Verify
all
connections
for
proper
fit, relief valve seating, and has appositive seal on all
connections.
Perform
the test 2-3
more times allowing
for
plenty
of
time
for
temperature adjustment of the kit to reach
ambient temperature.
If
the
test
kit
still
will
not
self-test,
contact
Kappler
Customer
Service
at
1-800-600-4019
for
a
Return
Goods
Authorization
(RGA)
to
return
the test kit for inspection and
repair.
Garment
9
15.
If
the self-test results
in
an
ending pressure
of
4.25 inches or
higher,
the
message
“Pressure
rose
during
test.
Please
retest”
will
appear.
Allow
the kit to
remain
in the test area at
least
30
minutes
and
perform
the
test
again.
If
the
result
of
the
retest
is
high
again,
contact
Kappler Customer Service
at
1-800-600-4019
for
a
Return
Goods
Authorization (RGA)
to
return
the
test kit for inspection and
repair.
NOTICE
The ASTM and CE Testing Procedure SHOULD NOT
be performed near heating or cooling vents. Air can
expand and/or contract, leading to a false pass or fail
of the garment.
ASTM AND CE TESTING
PROCEDURE
1.
Insert
the
two
test
kit
valve adapters (Part
A)
into
the
matching
quick
disconnect fittings
on
the
Supplied
Air
Hoses
(Part
D).
Listen
for
a
distinct click to ensure disconnect
fittings
are
inserted
correctly.
2.
Locate the power supply cord (Part E) and insert into theAC
receptacle (L)
on
the test kit face. Connect the power supply
cord
to
a
110
volt
power
source.
Do
not
turn
on
the
power
to
the
test
kit
at this time. (Use of this kit outside the United States will
require
special adapters and/or converters.)
3.
The user must supply
a
suitable quick disconnect fitting, that
is
compatible with their air supply
system,
and
install
the
fitting
into
the
supplied
air
fitting
connection
(I)
located
on
the
upper
right of
the test kit face. Use thread sealant or sealing tape
on
the
fitting
10
Garment
Threads
to ensure
proper seal.
If
sealing
tape
is used,
insure
none is over the end of the male fitting.
4.
Connect
to
a
clean
and
dry
air
source,
preferably
Grade D
breathing
air,
to
the
test kit. Kappler recommends
an
inlet pressure
of
between 100-150
psi.
Do not exceed 200 psi inlet pressure.
5.
Turn
on
the
test
kit
with
power
switch
(L)
and
wait
until
the
test
kit
program has loaded and the Touch Screen (J) shows the Set-up
Page
(Figure
3).
Insert
USB
drive
into
USB
port
(K).
Note:
It
will
take
a
fewmoments forthe USBdriveto connect withthesoftware.
6.
Cut the pull tie
that attaches
the
inspection
tag to the garment
storage
bag
(Figure
7),
open
the bag and
remove
the gas tight
garment. Unfold the garment and place face down on
a smooth
clean surface where
it
can
be
inflated without
obstruction.
7.
Locate
the two
exhaust valves
on
the back of
the garment.
Remove the exhaust valve covers (M) and the diaphragms (N)
from
inside the exhaust
valves.
(Figure 8)
Visually inspect
the
valve
diaphragms
(N) for
signs
of
deterioration
to
ensure pliability
and
proper
performance.
8.
Place
each
valve
cover
(M)
and
diaphragm
(N)
in
a safe place until
testing is completed.
9.
Install
the test kit valve
adapters (A)
into each
exhaust valve,
while reaching inside garment
to
support
the
exhaust valve
from
the
inside.
Firmly
insert
the valve
adapters
(A)
into
the
exhaust
valves sitting level with respect
to
the
exhaust valve with
a
slight
even
twist to ensure
a
tight seal.
Visually
inspect the connection to
confirm
the
valve
adapters
(A)
are
securely
in
place.
Close
the
garment
zipper ensuring
the
slider
is
firmly
engaged
against
the
zipper
end
stop.
For
instructions
on
proper
zipper
closing
techniques
refer
to
https://www.kappler.com/files “Technique for Closing a Gas
Tight
Zipper”.
10.
Onthetest kit touch screen Set-up Page, press “TESTSELECTION”.
Garment
11
10.
On the test kit touch screen Test Selection Page (Figure 4),
press
the “ASTM TEST or CE (EUROPEAN) TEST, depending on the test
needed. On the Test Page, press the “INPUT USER AND
GARMENT INFORMATION” dialog box to reach the User
and
Garment Information
Page
(Figure
5
).
The
information
for
the
tester,
the
style/color/size
of
the
garment,
garment
serial
number,
garment
manufacturing
date
and
test
kit
serial
number
can
be
recorded.
After
the necessary information has been entered, press the
appropriate
button and return to the ASTM or CE test page.
11.
Press the START button to begin the test. The button will light
up
if
pressed correctly
to
indicate testing has started. The test
will
perform automatically. The garment will inflate until the
settling
pressure
is
reached.
You
will hear continued short bursts of air
from
the
kit
during
this
time,
which
is
normal.
During
this
time,
flatten
out
any
wrinkles
or
folds
in
the
garment,
such
as
the
sock
boot
folded
under
the
boot flap.
Also
use
this
time
to
perform
a
visual
inspection
to
check
for
cuts,
abrasions,
seam
lifts
and
other
visual
defects.
12.
After the settling pressure
is
reached (5 inches for ASTM/
6.8
inches
for
CE),
the
settling
phase
of
the
test
will
begin
and
will
continue
for
the
appropriate
time.
(3
minutes
for
ASTM/10
minutes
for
CE).
13.
After settling is complete, the test kit will reduce the pressure
to
the
initial
test
pressure
(4
inches
for
ASTM
/6.6
inches
for
CE)
and
begin
the
testing
phase.
After
the
testing
begins,
do
not
touch
the
garment ortheSuppliedAirHosesforthedurationofthetest.
14.
At the end of the test, the screen will display messages at the
top
and bottom of the
page.
The top message will
indicate a
pass
or
fail
of
the
pressure
test.
The
bottom
message
will
provide
the
ending
test
pressure.
These
messages
will
remain
until
the
“STOP”
button
is pressed to end the testing.
12
Garment
Figure 5: User and Garment Information
Page
15.
When testing
is
complete, press the red “STOP” button and
then
the “COPY DATA TO USB” button to transfer the test data to the
USB
Drive.
(Figure
6)
Do
not
remove
the
USB
Drive
until
the
flashing
red
“Accessing
USB
Drive
Do
Not
Remove”
stops
flashing.
If
“COPY
DATA TO USB” is pressed and the flashing icon does not appear,
then all data has been transferred.
Figure 6: Copy Data to USB Button and
Red
“Accessing
USB Drive Do Not
Remove” Alert
Garment
13
NOTICE
The pressure testing data must be downloaded to the
USB before the power is turned off to the pressure
test kit or the stored data will be lost.
16.
Disconnect the valve adapters (A) from the garment.
17.
Fill
out
the
inspection
tag;
see
Figure
7
(A),
which
came
attached
to
the bag with the results of the test and the user
information.
A
B
Figure 7: (A) Pull Tie and
Inspection
Tag
(B)
Pull Tie and
Inspection
Tag
binding
the
handles together.
18.
Replace the diaphragms and the valve covers, (Part M and N)
in
Figure
8
.
For
the
Zytron®
diaphragm
pull
on
the
stem to secure
the
14
Garment
diaphragm
to the
valve
and for the
Frontline® diaphragm
insert
the
protrusion located in the center of the valve into the hole
of the diaphragm.
M. Exhaust
Valve
Covers
N. Diaphragms
Figure 8:
Exhaust
Valve Covers and
Diaphragms
19.
Fully unzip the garment to exhaust the air, fold the garment
and
return it to the bag as stated in garment User Manual.
NOTICE
Kappler recommends that all garments be stored with
the zipper unzipped completely.
20.
Using
a
pull
tie,
attach
the
inspection
tag
to
the
bag
while
binding
the handles together; see Figure 7 (B).
Garment
15
Caution
Do not allow the kit to come in contact with water as
it may damage the pressure test kit.
INSTRUCTIONS FOR LOCATING LEAKS
1.
With the garment still connected to the test kit, Press the
“Start”
button on the ASTM test to begin the test again.
2.
During
the
settling
time
where
the
pressure
is
maintained
at
5
inches
of water column, brush or wipe sections of the garment, one at
a
time, with a mild soap and water solution.
3.
Check seams, zippers,
visor
seams,
glove
interfaces
and valve
bodies, as well as between the valve and valve adapter.
4.
Observe
these
areas
for
the
presence
of
soap
bubbles,
which
is
an
indication of aleak.
If more time is needed for inspection, press the “STOP” button and
repeat steps 1 through4until leak is found.
NOTICE
All Kappler garments are designed for multi-use,
single exposure and must be replaced when
damaged or chemical contamination occurs.
16
Garment
PRESSURE TEST KIT VERIFICATION
NOTICE
Verification should not be performed near heating or
cooling vents. Air can expand and/or contract, leading
to incorrect readings. This test should be performed
with a third party calibrated manometer.
Warning
WARNING: DO NOT REMOVE the testing unit from
the outer case. Inside the kit there are exposedwires
that could shock the user and cause serious injury
or death if the user makes contact with the power
supply or power switch. Removal of the testing unit
from the case is NOT RECOMMENDED ANDVOIDS
THE WARRANTY.
ITEMS NEEDED FOR
PRESSURE TEST
KIT VERIFICATION
►
Calibrated Pressure
Test
Device
capable
of
reading
between
0 and 10 inches of water column
►Female Quick Disconnect Coupling Sockets
►¼ Inch Diameter Hose
►
Other
parts
may
be
needed
depending
on
the
calibrated
device being used as a reference.
Table of contents
