RPB PX4 AIR PAPR User manual

0194
INSTRUCTION MANUAL

2
INTRODUCTION 3
PAPR COMPONENT CONCEPT 5
WARNINGS 6
RESPIRATOR OPERATIONS 8
PAPR SETUP AND USE 10
APPARATUS CLASSIFICATION AND PROTECTION FACTOR 18
RESPIRATOR OPERATIONS CONTINUED 19
PRODUCT SPECIFICATIONS AND DATA 21
TROUBLE SHOOTING 22
PARTS AND ACCESSORIES 24
PARTS LIST 25
CONTENTS
Read all instructions and warnings before using this product.
Keep this manual for future reference.
RPB® Safety Global Headquarters 2807 Samoset Rd, Royal Oak, MI 48073, USA.
T: 1-866-494-4599 F: 1-866-494-4509 E: [e-mail] rpbsafety.com
RPB® Safety Asia Pacic Headquarters 652 Halswell Junction Road, Hornby South 8042
New Zealand. T: [phone] F: [phone] E: [e-mail] rpbsafety.com
RPB®, Advancing Your Safety, Nova, Nova 3, Radex, and Zytec are registered trademarks of RPB®
Safety LLC
For technical assistance contact our Customer Service Department
on 1-866-494-4599 or email: [email protected]om
Form #: 7.20.526
Rev: 1

3
INTRODUCTION
The RPB® PX4 AIR is approved in two
congurations, 03-911 to EN 12941:
1998 + A1: 2003 + A2: 2008 as a
Powered Air Purifying Respirator Fan
Unit only when used in conjunction with
the following Respirators:
- Nova 3 Respirator - (EN 12941:
1998 + A1: 2003 + A2: 2008 TH3
P R SL)
- Z3 Welding Respirator - (EN
12941: 1998 + A1: 2003 + A2:
2008 TH2 P R SL)
- Z-LINK Respirator - (EN 12941:
1998 + A1: 2003 + A2: 2008 TH3
P R SL)
This Respirator System is intended to
be used only in conjunction with an
“Organised Respiratory Protection
Program” which complies with the
Requirements of National and Local
Governments.
The RPB® PX4 AIR belt mounted
assembly consists of a motor/blower
unit, high eciency lter, waist belt and
lithium ion battery pack. The motor/
blower unit draws ambient air through
its high eciency lter and supplies
air to the headgear via a breathing
tube. The blower unit is equipped with
automatic ow control; the motor
speed is monitored and regulated
during operation to compensate for the
charge state of the battery pack and
the increasing level of airow resistance
caused by lter blocking. Should the
airow fall below the minimum ow rate
an audible alarm will sound and the fan
indicator light bar will turn red and ash
on the control panel. The user should
leave the work area immediately should
this occur. In like manner, the Battery
indicator bar will turn red and sound
the audible alarm when the battery has
approximately 10 -15 minutes of charge
left, to give sucient warning to the
wearer that the power will shut o soon.
When selecting a Powered Air Purifying
Respirator (PAPR), the following factors
need to be considered:
1. Possible occurrence of
explosive atmosphere.
2. Types of pollutants.
3. Concentrations.
4. Intensity of work.
5. All other protective
requirements other than
respiratory.
All risk analysis should be carried out
by a person trained to make suitable
decisions on these matters.
The RPB® PX4 AIR has been designed
for use in atmospheres that are NOT
IMMEDIATELY DANGEROUS TO LIFE OR
HEALTH (IDLH).
The RPB® PX4 AIR 03-911 are approved
to EN 12941: 1998 + A1: 2003 + A2: 2008
TH2/TH3 P R SL for use in environments

4
where hazards are known and
characterized and oxygen deciency is
not present. It is only approved in the
congurations indicated on page 4 of
the manual. Refer to the Instruction
Manual provided with the appropriate
RPB® Respirators for more information.
Note: the EN 12941: 1998 + A1: 2003 + A2:
2008 standard is a requirement for lose
tting respirators such as helmets and face
shields (03-911) and the 12942: 1998 + A1:
2004 + A2: 2008 standard is a requirement
for tight tting respirators such as full
face masks and half face masks (03-912
Low Flow). For more information on the
respirator refer to the specic Respirators
User Instruction Manual.
Service Life of HE Filter,
Prelter and Spark Arrestor
The HE lter should be replaced if the
airow alarm is activated, or the ow
indicator reading falls below the 6cfm
(170 slpm) for the 03-911 and 4.2cfm
(120 slpm) for 03-912 minimum airow.
The HE lter should also be replaced
if there is damage to the lter media,
such as a tear or puncture, etc… or the
lter media becomes wet. The PX4 AIR is
approved to only be used with genuine
RPB® lter cartridges.
The Prelter is recommended to be
replaced when it is dirty or damaged
or at the same time as the HE Filter. The
Spark Arrestor should be replaced if
it becomes damaged or clogged with
debris.
WARRANTY
All RPB® products are covered by a
manufactures warranty of 3 months. The
manufacturer warranty covers defects
in material, workmanship and does not
cover damage caused by misuse or abuse.
RPB®’s only obligation and your exclusive
remedy shall be to repair, replace or
refund the purchase price of such parts or
products upon the presentation of proof of
purchase. Maximum liability is in no case
to exceed the value of the RPB® Product
involved.
APPROVAL
The RPB® PX4 AIR meets the
requirements of the European
Community Directive
89/686/EEC, (Personal Protective
Equipment Device).
The RPB® PX4 AIR is approved as an EN
12941: 1998 + A1: 2003 + A2: 2008 TH2/
TH3 P R SL Respirator by:
Apave Sudeurope SAS (0082)
8 rue Jean-Jacques Vernazza
CS 60193
13322 Marseille Cedex 16
France
Under Article 10 and the quality systems
are approved under Article 11b by
INSPEC International (0194)
Salford University Business Park
56 Leslie Hough Way

5
PAPR COMPONENT CONCEPT
The RPB® PX4 AIR is part 3 of the 3 main components that constitute a respirator (Note
the T100 has been used in the below diagram as an example):
Figure 1.1
!WARNING! Failure to use genuine parts and components that are part of the
approved respirator assembly will void the approval of the entire respirator
assembly.
Respirator Hood
Breathing Tube Assembly
Air Supply
1
2
3

6
!WARNINGS!
1. Do not use this respirator until you
have been trained in the respirators’
use, maintenance and limitations
by a qualied individual (appointed
by your employer) who has
extensive knowledge of the RPB®
PX4 AIR.
2. Before using this respirator ensure
your employer has determined
that airborne contaminant
concentrations do not exceed
those allowed by applicable
National and Local Government
regulations and recommendations
for Power Air Purifying Respirator.
Government law requires that the
employer measures and monitors
airborne contaminant levels in the
work area.
3. DO NOT WEAR this respirator if any
of the following conditions exist:
- Atmosphere is immediately
dangerous to life or health.
- You CAN NOT escape without
the aid of the respirator.
- Atmosphere contains less than
19.5% Oxygen.
- Work area is poorly ventilated.
- Contaminants are in
excess of regulations or
recommendations.
4. Do not modify or alter this
respirator. Use only parts and
components that are part of the EN
12941: 1998 + A1: 2003 + A2: 2008
TH2/TH3 P R SL approved respirator
assembly. The use of non RPB®
parts voids the EN 12941: 1998 +
A1: 2003 + A2: 2008 TH2/TH3 P R
SL approval of the entire respirator
assembly.
5. Inspect all components daily for
signs of damage or wear that may
reduce the level of protection
originally provided.
6. Do not wear this respirator until
you have passed a complete
physical exam, maybe including a
lung X-ray conducted by qualied
medical personnel.
7. Improper use of this respirator
may cause injury or death.
Improper use may also cause life
threatening delayed lung disease
such as silicosis, pneumoconiosis or
asbestosis.
8. This respirator, when properly tted
and used, signicantly reduces but
does not completely eliminate the
breathing of contaminants by the
respirator wearer.
9. DO NOT use this respirator in poorly
ventilated areas or conned spaces
unless the area is well ventilated
and that the contaminant
concentrations are below those
recommended for this respirator.
Follow all procedures for conned
space entry, operation and exit as
dened in applicable National and
Local Government regulations and
recommendations.

7
10. The RPB® PX4 AIR PAPR is not
intrinsically safe. Do not use
in ammable or explosive
atmospheres. Doing so may result
in serious injury or death.
Always correctly use and maintain
the lithium ion battery packs.
Failure to do so may cause re or
explosion or could adversely aect
the respirator performance and
result in injury, sickness or death.
- Do not charge batteries with
unapproved chargers, in
enclosed cabinets without
ventilation, in hazardous
locations, or near sources of
high heat.
- Do not immerse in water or
other liquids.
- Do not use, charge, or
store batteries outside the
recommended temperature
limits.
11. LEAVE WORK AREA IMMEDIATELY IF:
- Any respirator component
becomes damaged.
- Airow stops or slows down
- Breathing becomes dicult
- You become dizzy, nauseous,
too hot, too cold, or ill.
- Vision is impaired.
- When the Warning Alarm
Sounds
12. The materials that the respirator
is made of may create static
electricity under low humidity. For
more information on this, please
call our Customer Care Team on
1-866-494-4599 or visit rpbsafety.
com.
13. For information on the Respirators’
head protection properties
i.e. EN397, please refer to the
respective Respirator’s Instruction
Manual.
14. For information on the Respirators’
hearing protection properties
i.e. EN352, please refer to the
respective Respirator’s Instruction
Manual.
15. For information on the Respirators’
eye protection properties i.e.
EN166, please refer to the
respective Respirator’s Instruction
Manual.
16. Incorrect use could be dangerous.
Caution should be taken for the
possibility of looped hoses and/or
cables becoming caught up.
17. At very high work rates the
pressure in the device may become
negative at peak inhalation ow.
18. Power o state gives little or no
respiratory protection and this is
considered an abnormal situation.
In the power o state a rapid
build-up of carbon dioxide and
depletion of oxygen within the
hood may occur.
!WARNINGS! CONTINUED

8
RESPIRATOR OPERATIONS
Unpacking
Inspect the package contents for
shipping damage and ensure all
components are present. The product
should be inspected before each
use following the procedures in the
inspection and cleaning section of this
Instruction Manual.
Battery Pack
The battery pack must be inspected
before each time it is charged. If there
are any cracks or evidence of damage
to the case do not charge the battery
pack. All batteries must be disposed of
in a correct and responsible manner,
in accordance with local government
ordinances.
Before using the RPB® PX4 AIR make
sure that the battery is fully charged, as
per the following instruction steps on
page 10.
Note: For problems with the Battery
Pack, see the Trouble Shooting section
on Page 22.
High Eciency (HE) Filter
Before unpacking the 03-985 HE lter
make sure that the sealed plastic
packaging is still intact. Once the
seal is broken the lter is exposed to
the environment and may become
contaminated. Before inserting the lter
make sure that the following points are
checked:
1. Check the Fan unit is switched o
and the fan is not running before
opening the Door.
2. Inspect the lter for tears or any
sign of damage to the lter media.
3. Inspect the seal on the back side of
the lter is clean and free of cuts or
distortions.
Equipment Marking
The RPB PX4 and its lters are marked in
accordance with the EN 12941: 1998 +
A1: 2003 + A2: 2008 TH2/TH3 P R SL.
TH1, TH2, and TH3 – Indicate the class
designation for complete device.
P, R, and SL – reusable Particle Filter
against liquid and solid particles.
A1, B1, E1 and A2 Gas Filter class
designation
(Note: the “A”, “B” and “E” indicates that
the lter provides protection against
organic. Inorganic and acid gases, as per
the standard and the number following
the letter indicates the lter capacity).
Note: see table 1-1 on page 18 for
details on the lter selection.
There are two models of the PX4 AIR:
03-911 - Standard air ow - light gray
fan cover
03-912 - Low ow model for tight tting
respirators - Dark Gray fan cover and
model label on back.

9
Markings and Symbols on
the Equipment
- Read all instructions before
use.
Li-Ion - Lithium Polymer Batteries.
- Batteries shall be disposed
of as electronic waste.
- Recycle
- RoHS compliant.
ALARMS AND DEVICE
WARNINGS
Filter Blockage
A pulsing alarm sounds when the
airow to the hood falls below the
minimum requirement of 170slpm
(180slpm Nominal) for 03-911 and
120slpm (130slpm Nominal) for 03-912
more than 5-10 seconds in duration.
Battery Level
A pulsing alarm sounds when
approximately 10-15 minutes of charge
is left in the battery. Power the unit o
and remove the battery (in a safe area)
and place on the charger. If you have
a second battery you can connect it to
the device to continue operation. The
continuous alarm will also sound if the
battery is overheating.
Alarm volume is 85 dBA at 4”(104mm).
Note: When the alarm sounds it is
recommended that you leave the work
area immediately. Once outside of the
work area power the unit down and
resolve the problem.
When the alarm sounds there will be a
vibration activated as well. This will help
notify the operator of the warning even
in noisy environments or when using
hearing protection.

10
PAPR SETUP AND USE
To remove the battery from the
charging station, press the release latch
on the bottom of the battery and lift the
battery from the station.
Fit the battery to the charging station by
connecting the left side and rotate the
battery down and latch into place.
Follow the indicators from left to right
on the front of the charging station to
know the status of the charge process.
The triangle warning light will indicate
if there is problem charging. When all
three lights display green, the battery is
fully charged.
Connect the Power Pack to the charging
station. Connect the Power Pack to the
Mains Electrical Source (110 - 240v),
charging will begin.
CHARGING THE BATTERY PACK
Figure 1.1
Figure 1.3
Figure 1.2
Figure 1.4

11
The battery has a power capacity
indicator showing the level of charge
from 20% to 100%, press the test button
to reveal the result.
Now attach the battery to the RPB PX4
AIR by connecting the left hand edge
to the base of the unit and rotate up
into position, making sure that the latch
snaps into place.
Figure 1.6
Figure 1.5

12
Mount the 03-985 HE Filter into the
Door, note the logo on the front of the
Filter should be to the bottom.
Slide the Door on to the hinge block on
the right side of the fan unit as you face
it, rotate the door to the left and latch
inplace.
Figure 3.3 Figure 3.4
Check your environments. For use in
environments with Sparks or molten
metal, use the 03-982 Spark Arrester in
front of the 03-981 Pre-lter. This will
reduce the risk of re.
A 03-981 Pre-lter is mounted in front of
the 03-985 HE lter to prolong the life of
the Filter.
HIGH EFFICIENCY FILTER
Figure 3.1 Figure 3.2

13
TO REPLACE THE HE FILTER
Make sure the 03-911 fan unit is
switched o before attempting to open
the Door. (Note: Press and hold button
to power o.)
(1.) Depress the latch, (2.) rotate the
door to the right and lift the door o
the latch.
Figure 4.1 Figure 4.2
1. 2.
Remove the 03-985 lter from the Door
and dispose of it in a suitable way.
(Note: treat the old lter with care as the
contaminants on the outside of the lter
may be dangerous to your health).
Install the new replacement 03-985
lter as per Fig 3.3 and 3.4. Inspect the
03-981 Pre-lter and replace as needed.
Figure 4.3 Figure 4.4

14
The Power button is on the right of the
unit as you look at the front of the PX4.
POWER ON: Press and hold the power
button (for about 1 second). Note the
unit will always start up in the low speed
setting and should reach nominal ow
within 5-10 seconds. Allow the unit
to warm up for 5 minutes or until the
ow meter (04-091) is in the safe range
before use.
POWER ON/OFF BUTTON AND SPEED CONTROL
Figure 2.1
POWER OFF: Press and hold the power
button (for about 1 second) and the unit
will turn o. See Fig 6.3.
Figure 2.4
When the battery is out of charge the
top row of lights will ash red and the
alarm will sound. Immediately return
to a safe environment and remove
the respirator and change/charge the
battery.
The top row of green lights indicate the
charge of the battery. 3 lights is fully
charged. 1 light means the battery is
getting low. When it is time to change or
charge the battery, there will be 1 light
ashing alternately green and red.
Figure 2.1
Figure 2.3

15
Speed 1 - 170 slpm (03-911)
[120 slpm (03-912)]
Speed 2 - 210 slpm (03-911)
[135 slpm (03-912)]
Speed 3 - 240 slpm (03-911)
[150 slpm (03-912)]
FAN SPEED AND AIR BLOCKAGE INDICATION
Normal - Speed 1
Mild Blockage - Speed 1
Moderate Blockage - Speed 1
Heavy Blockage - Speed 1
Blocked - Speed 1
cannot be achieved
Normal - Speed 2
Mild Blockage - Speed 2
Moderate Blockage - Speed 2
Heavy Blockage - Speed 2
cannot be achieved
Blocked - Speed 1
cannot be achieved
Speed ~ 170 slpm (03-911)
120 slpm (03-912)
Speed ~ 210 slpm (03-911)
135 slpm (03-912)
Normal - Speed 3
Mild Blockage - Speed 3
Moderate Blockage - Speed 3
cannot be achieved
Heavy Blockage - Speed 2
cannot be achieved
Blocked - Speed 1
cannot be achieved
Speed ~ 240 slpm (03-911)
150 slpm (03-912)
OPERATION LEGEND
Speed Settings: Cycle through the 3
speed settings by pressing the Power
Button. Each button press will advance
through these speed settings.
The blue lights indicate the selected fan speed. The red lights indicate the level of
blockage. When the lights ash red and blue, the selected fan speed cannot be
reached, but sucient air supply (170slpm 03-911, 120slpm 03-912) can still be
reached. When 3 lights ash red, the alarm will sound indicating insucient air supply
is being produced. Return to a safe environment and check the lter and/or the airway
for blockage. If the lter is contaminated, replace with a new cartridge.
Figure 2.5
Figure 2.6

16
Now take the bayonet end, insert the
connection into the PX4 and make sure
the 2 small pegs line up with the slots in
the PX4 outlet.
Twist the breathing tube to the right a ¼
turn to lock into position. Make sure that
it is fully locked in position.
Figure 5.3 Figure 5.4
BREATHING TUBE
Select the Flexible breathing tube that
suits your respirator (check the tting
connects to your respirator type). Ensure
that the seal is in place.
Take the end that ts to the Respirator
and connect it securely.
Figure 5.1 Figure 5.2

17
Thread the belt through the support in
a left to right ow when looking at the
front of the PX4.
Choose the appropriate belt for
the working environment; (07-765
Polyethylene Belt and Buckle {Standard}
or 07-765-FR Nomex® Belt and Buckle
{Welding and High Heat Applications}).
BELT AND SUPPORT ATTACHMENT
Figure 6.1 Figure 6.2
Take the loose end of the Belt and
thread from behind through the outer
slot (slot furthest out from the PX4) in
the left support and then back through
the inner slot (Closest to the PX4).
Figure 6.3
Thread the belt through the belt loop so
that it passes between the loops and the
support.
Figure 6.4

18
European Device
Classication
APPARATUS
MODEL
NOMINAL
PROTECTION
FACTOR
PARTICULATE
FILTER 03-985
EN 12941 TH3 NOVA 3 500 X
EN 12941 TH2 Z3 50 X
EN 12941 TH3 Z-LINK 500 X
APPARATUS CLASSIFICATION AND PROTECTION FACTOR
TABLE 1.1
Thread the belt through the inner slot
from the back and then back through
the outer slot, see Fig 5.5.
Now thread the clip end of the buckle
on to the belt and pull to the desired
length, see Fig 5.6.
Figure 5.5 Figure 5.6
BELT AND SUPPORT ATTACHMENT CONTINUED

19
RESPIRATOR OPERATIONS CONTINUED
Inspection, Disinfecting and
Cleaning
Before each use, the unit should be
inspected for the following points.
This helps to determine that the unit is
operating as it was designed and it is
suitably protecting the operator:
1. PX4 AIR PAPR SYSTEM: Make a
visual inspection of the entire unit,
which includes the motor housing,
lter door and door cover, lter
and pre-lters, battery, belt and
breathing tube. Also inspect that
the correct hood or face pieces is
attached.
2. BATTERY PACK: Check that the
battery has a full charge (see the
battery test strip on the top of
the battery, Fig 1.5) to conrm
that there is sucient charge for
the work period that you need to
accomplish. Make sure that the
battery is securely tted to the PX4
AIR PAPR.
3. BREATHING TUBE: Inspect the
breathing tube completely, looking
for splits and cracks in the tube,
the ttings are held securely in
the tube and that the O-ring is in
place on the bayonet tting that
inserts into the PX4. Make sure that
the breathing tube ts rmly into
the PX4 unit and seals without any
leaks around the connection.
See Fig 4.3 and 4.4
4. HE FILTER: Inspect the lter casing
for cracks and distortions that will
aect the seal to the PX4 unit.
Inspect the lter paper and the seal
carefully for any of the following
defects; dirt, cuts and tears,
distortions or indentations. The seal
can be wiped clean with a damp
cloth to remove dirt particles, (do
not use solvents or detergents. The
HE lter paper must not be cleaned
or submersed in water at any time.
Damage to the HE lter paper will
aect its ability to lter the air and
could expose users to harmful
environments. All damaged lters,
pre-lters and spark arresters must
be replaced before using the PX4.
5. AIRFLOW METER: Check the ball in
the 04-091 airow meter is moving
freely. Insert the ow meter into the
outlet of the PX4 and rotate ¼ turn
to lock in place so that it is sitting
vertical. Turn on the PX4 and let
the air stabilize over a 30 second
period. With the meter still in the
vertical position check that the ball
Figure 7.1

20
is sitting above the minimum ow
rate marker.
WARNING! Do not use the PX4 if the
meter does not reach the minimum
airow rate of the ow meter. Low
airow will increase the level of
protection provided.
Ser Fig. 7.1
6. ALARM SIMULATION: Check the
operation of the airow alarm is
functioning correctly. Power on the
PX4and place the palm of your
hand over the outlet of the PX4.
Continuing to hold your hand
tightly over the outlet, with the
airow restricted until the alarm
sounds, (audible alarm and Red
LED indicators on the button) after
5-10 seconds, indicating the airow
is below the minimum airow.
Remove your hand and the alarm
and LED should return to normal
operation once the airow is back
to safe levels.
7. CLEANING & DISINFECTING: The
PX4 unit can be cleaned with a
damp cloth and mild detergent on
the external surfaces and the face
of the fan motor housing.
WARNING! DO NOT submerse in
Water or use solvents on any parts
of the PX4. This device has electrical
components and could cause injury
or death if put in contact with
water.
8. STORAGE: The PX4 should not be
stored with the Filter or battery
attached if not being used for long
periods of time, store in a clean, dry
environment, away from direct heat
sources between -10°C and +45°C,
at a relative humidity of less than
90%. All batteries must be stored in
a cool dry atmosphere.
DO NOT use, store or charge a
battery in ambient temperatures
that exceed (40°C). All lters must
be stored in an airtight plastic bag
or container so that they are not
exposed to contamination.
9. BELT LOOPS/SUPPORTS: Check
the Belt Supports and Belt Loops
for cracks. If cracks or excessive
wear is present, they should be
replaced. To replace the Belt
Supports (03-965) and the Belt
Loops (03-924), unthread the Belt
from the Belt Supports and the Belt
Loops. Remove the Belt Loops by
removing the two screws in each
Belt Loop. Remove the old Belt
Supports and place the new ones.
Place the new Belt Loops and screw
in tight until secure. Do not over
tighten.
RESPIRATOR OPERATIONS CONTINUED