TSI Incorporated PORTACOUNT PRO+ 8038 Operation manual

PORTACOUNT®PRO 8030 AND
PORTACOUNT®PRO+ 8038
RESPIRATOR FIT TESTERS
OPERATION AND SERVICE MANUAL
P/N 6001868, REVISION P
MARCH 2015

i
Copyright©
TSI Incorporated / 2008-2015 / All rights reserved.
Part Number
6001868 / Revision P / March 2015
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA
Fax No.
[phone]
LIMITATION OF WARRANTY AND LIABILITY (effective February 2015)
(For country-specific terms and conditions outside of the USA, please visit www.tsi.com.)
Seller warrants the goods, excluding software, sold hereunder, under normal use and
service as described in the operator's manual, to be free from defects in workmanship and
material for 24 months, or if less, the length of time specified in the operator's manual,
from the date of shipment to the customer. This warranty period is inclusive of any
statutory warranty. This limited warranty is subject to the following exclusions and
exceptions:
a. Hot-wire or hot-film sensors used with research anemometers, and certain other
components when indicated in specifications, are warranted for 90 days from the date
of shipment;
b. Pumps are warranted for hours of operation as set forth in product or operator’s
manuals;
c. Parts repaired or replaced as a result of repair services are warranted to be free from
defects in workmanship and material, under normal use, for 90 days from the date of
shipment;
d. Seller does not provide any warranty on finished goods manufactured by others or on
any fuses, batteries or other consumable materials. Only the original manufacturer's
warranty applies;
e. This warranty does not cover calibration requirements, and seller warrants only that
the instrument or product is properly calibrated at the time of its manufacture.
Instruments returned for calibration are not covered by this warranty;
f. This warranty is VOID if the instrument is opened by anyone other than a factory
authorized service center with the one exception where requirements set forth in the
manual allow an operator to replace consumables or perform recommended cleaning;
g. This warranty is VOID if the product has been misused, neglected, subjected to
accidental or intentional damage, or is not properly installed, maintained, or cleaned
according to the requirements of the manual. Unless specifically authorized in a
separate writing by Seller, Seller makes no warranty with respect to, and shall have no
liability in connection with, goods which are incorporated into other products or
equipment, or which are modified by any person other than Seller.
The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS
stated herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR
PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE. WITH RESPECT TO
SELLER’S BREACH OF THE IMPLIED WARRANTY AGAINST INFRINGEMENT, SAID
WARRANTY IS LIMITED TO CLAIMS OF DIRECT INFRINGEMENT AND EXCLUDES
CLAIMS OF CONTRIBUTORY OR INDUCED INFRINGEMENTS. BUYER’S
EXCLUSIVE REMEDY SHALL BE THE RETURN OF THE PURCHASE PRICE
DISCOUNTED FOR REASONABLE WEAR AND TEAR OR AT SELLER’S OPTION
REPLACEMENT OF THE GOODS WITH NON-INFRINGING GOODS.
TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR
BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES,
INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED
ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL

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BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE
PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE
GOODS. IN THE CASE OF SOFTWARE, SELLER WILL REPAIR OR REPLACE
DEFECTIVE SOFTWARE OR IF UNABLE TO DO SO, WILL REFUND THE PURCHASE
PRICE OF THE SOFTWARE. IN NO EVENT SHALL SELLER BE LIABLE FOR LOST
PROFITS, BUSINESS INTERRUPTION, OR ANY SPECIAL, INDIRECT,
CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE
RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS
OR CHARGES. No Action, regardless of form, may be brought against Seller more than
12 months after a cause of action has accrued. The goods returned under warranty to
Seller's factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk
of loss.
Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY
AND LIABILITY, which contains the complete and exclusive limited warranty of Seller.
This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its
terms waived, except by writing signed by an Officer of Seller.
C a u t i o n
This instrument is a Class I laser device. Adjustments or
performance of procedures other than those specified
herein may result in hazardous radiation exposure.
W A R N I N G
This instrument contains (1) non-rechargeable Lithium
battery which is not user serviceable. Return to factory
for replacement.
Disclaimer: The measurement provided by the PortaCount Pro Respirator Fit Tester
is an assessment of respirator fit during a fit test only. Respirator fit at
other times will vary. The fit factor value is not intended for use in
calculating an individual's actual exposure to hazardous substances.
Patents
Model 8038 PortaCount®Pro+ Respirator Fit Tester is patented under U.S. Patent No.
6,125,845.
Trademarks
TSI, TSI logo, and PortaCount are registered trademarks of TSI Incorporated. FitPro+
and N95-Companion are trademarks of TSI Incorporated.
Service Policy
Knowing that inoperative or defective instruments are as detrimental to TSI as they are
to our customers, our service policy is designed to give prompt attention to any
problems. If any malfunction is discovered, please contact your nearest sales office or
representative, or call TSI's Customer Service department at [phone] (USA) or
(001 651) 490-2811 (International) or visit www.tsi.com.

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Contents
Contents....................................................................................................... iii
Introduction and Overview .......................................................................... 1
Database Operation When Operating in Stand-Alone Demo Mode......... 1
Registration ............................................................................................. 1
Why Fit Test ............................................................................................ 2
Preparations for Fit Testing ..................................................................... 2
Precautions for Fit Testing....................................................................... 3
Chapter 1 Unpack and Verify Shipment..................................................... 5
Chapter 2 Getting to Know the PortaCount Pro Respirator Fit Tester.... 7
The Touch Screen Display ...................................................................... 7
Sampling Ports........................................................................................ 8
Electrical Connections............................................................................. 9
Alcohol Related Parts............................................................................ 11
Miscellaneous Parts .............................................................................. 12
Chapter 3 About Respirators and Fit Testing.......................................... 17
Probed Test Respirators........................................................................ 17
Probes for Filtering-Facepiece (Disposable) Respirators...................... 19
Inserting a Test Probe in a Disposable Respirator with the TSI
Model 8025-N95 Probe Kit................................................................. 19
Positive Pressure Respirators ............................................................... 23
Chapter 4 Conducting a Fit Test with the PortaCount Pro
Respirator Fit Tester ........................................................................... 25
Step 1—Prepare the PortaCount Pro Respirator Fit Tester for
Fit Testing.......................................................................................... 26
Step 2—Attach Flash Drive and Select Database (optional) ................. 29
Step 3—Run Daily Checks.................................................................... 30
Step 4—Conducting Fit Tests................................................................ 32
Step 5—Record Results........................................................................ 39
Step 6—Using a Printer with the PortaCount Pro Fit Tester.................. 41
Step 7—Stand-Alone Fit Testing—Data Handling Best Practices......... 43
Step 8—Advanced Database Tools....................................................... 44
Chapter 5 Operating Modes and User Interface...................................... 47
Modes of Operation............................................................................... 47
User Interface........................................................................................ 48
New Exercise Name.............................................................................. 55
Chapter 6 Service and Maintenance ........................................................ 61
Recalibration Interval............................................................................. 61
Status Messages................................................................................... 61

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Reordering Supplies...............................................................................62
Shipping & Storage Precautions ............................................................63
Changing the Alcohol Wick ....................................................................63
Nozzle Cleaning.....................................................................................66
Chapter 7 Troubleshooting........................................................................69
On-line Troubleshooting Guides.............................................................69
Appendix A Specifications........................................................................77
Flow Rate...............................................................................................78
Appendix B Theory of Operation ..............................................................81
How the PortaCount Pro Respirator Fit Tester Works............................81
How the PortaCount Pro Fit Tester Counts Particles .............................82
Appendix C Calculating Fit Factor............................................................85
Appendix D Calculating Particle Concentration......................................87
Appendix E Timing in Fit Test Mode.........................................................89
Appendix F Using the PortaCount®Pro Respirator Fit Tester to
Fit Test Positive Pressure Respirators...............................................91
Appendix G The Rainbow Passage ..........................................................95
Index ........................................................................................................97

1
Introduction and Overview
This manual describes both the Model 8030 PortaCount®Pro and
8038 PortaCount®Pro+ Respirator Fit Tester hardware and operation
of the tester without the use of FitPro+™Fit Test Software.
The Model 8030 is designed to measure fit factors of masks with an
efficiency of 99% or greater. The Model 8038 includes N95-
Companion™technology, which lets you measure any tight-fitting
respirator including N95, P2, and P1 disposables.
Regardless of whether you intend to use the PortaCountPro
Respirator Fit Tester with or without the FitPro+ Fit Test software,
become familiar with this manual first. Many of the details in this
manual that concern PortaCount Pro fit test operations are not
repeated in the FitPro+ Fit Test Software Manual.
Database Operation When Operating in Stand-Alone
Demo Mode
The PortaCountPro Respirator Fit Tester has an on-board (Demo-
Training) database that lets you perform all available operations,
including adding data. Any changes you make to this Demo-Training
database, however, are lost when you power off the PortaCountPro
fit tester, unless you manually save them using the new Advanced
Database Tools (introduced in firmware version 2.0).
To save fit test results or other data when using the PortaCount Pro
Respirator Fit Tester in stand-alone mode (not controlled by the
FitPro+ Fit Test Software), you must have a USB flash drive
containing a valid database attached to one of the USB ports. (See
the FitPro+ Fit Test Software User Manual for instructions on how to
configure the USB flash drive.)
Registration
Please fill out and mail the registration card that came with your
instrument or register it online at http://register.tsi.com. You may re-
register at any time to update our records. You will need your
instrument model number and serial number.
Registration allows TSI to keep in touch with you regarding important
information concerning the TSI instrument(s) and software you own.

2 Introduction and Overview
Why Fit Test
There are two primary reasons for respirator fit testing:
Verification of Training. After the individual has received
respirator training, a fit test checks that the person has learned
how to properly put on and wear a respirator without assistance.
Sizing. It is important to make sure that the individual is issued a
respirator that is capable of providing protection when worn
properly, that is, it is the right size.
Preparations for Fit Testing
Training the
Trainer
The person conducting the fit test must have a
clear understanding of respiratory protection,
respirators, and fit testing to be effective. Anyone
can master the operation of the PortaCountPro
Respirator Fit Tester simply by studying this
manual, but the background knowledge required
to proficiently fit test cannot be obtained from
here. Consider attending a one-, two- or three-
day seminar on fit testing provided by various
consultants. Contact TSI for references.
Respirator
Training
Respirator training is critical for any respiratory
protection program. All employees who wear
respirators must be taught how and why they are
used. This training should be done prior to the fit
test, not during the fit test. Consult the
regulations or standards that pertain to your
industry for information on training requirements.
The PortaCountPro Respirator Fit Tester
includes a Real-time Fit Factor display that
allows you to see the results of changes he or
she makes to the mask.

Introduction and Overview 3
Precautions for Fit Testing
The following is a discussion of several precautions to consider prior
to conducting a fit test:
Fit Testing
People Who
Smoke
Cigarettes or
Cigars
Smokers exhale particles for at least 30 minutes
after they have smoked a cigarette or cigar. The
PortaCountPro fit tester can count these particles
and will interpret them as if they were caused by
face seal leakage. It is very important to instruct
individuals not to smoke for at least 30 minutes
prior to fit testing. Fit factors for anyone who has
smoked recently will be lower than that individual
deserves and may even cause him or her to fail the
fit test entirely.
Fit Testing
with
Generated
Aerosols
The PortaCountPro fit tester is designed to operate
using the microscopic particles in the ambient air. It
can measure particle concentrations and fit factors
when generated aerosols (like corn oil, salt or
DOP) are used; however, these aerosols may
cause the PortaCount Pro fit tester to need more
frequent cleaning and calibration.
Fit Testing
Near Irritant
Smoke
Do not conduct fit tests in close proximity to
sources of irritant smoke like those used for
qualitative fit testing. The irritant smoke is corrosive
and can damage the PortaCount Pro Respirator Fit
Tester. Fit testing near sources of amyl-acetate
(banana oil) is not a problem.
The TSI Web site http://fittest.tsi.com contains additional useful
resources.
Disclaimer: The measurement provided by the PortaCount Pro
Respirator Fit Tester is an assessment of respirator fit
during a fit test only. Respirator fit at other times will
vary. The fit factor value is not intended for use in
calculating an individual's actual exposure to hazardous
substances.

4 Introduction and Overview
(This page intentionally left blank)

5
Chapter 1
Unpack and Verify Shipment
The following items are included with the PortaCount®Pro/Pro+
Respirator Fit Tester. If any are missing or damaged, please notify
TSI immediately. Refer to Chapter 2 for photos and descriptions of
each item.
Standard Items PortaCount Pro/Pro+ Fit Tester
(Models 8030 and 8038)
Qty
Description

1
PortaCount Pro Respirator Fit Tester Model 8030/8038
1
Stylus
1
Alcohol Cartridge
1
Alcohol Fill Capsule
1
Storage Cap
2
Zero Check Filter
2
Spare Alcohol Wicks
1
5 ft (1.5 m) Twin Tube Assembly
1
1/8 to 3/16 Tube Adapter
1
1/8 to 1/4 Tube Adapter
1
AC Adapter

6 Chapter 1
Standard Items PortaCount Pro/Pro+ Fit Tester
(Models 8030 and 8038)
Qty
Description

16
30 ml Alcohol Bottles (480 ml total)
1
PortaCount Pro/Pro+ Respirator Fit Tester Quick Start Guide
1
Carrying Case
1
FitPro+ Fit Test Software CD and case
1
USB Cable
1
USB Flash Drive
Additional Items PortaCount PRO+Fit Tester (Model 8038 only)
Qty
Description

1
Probe Assembly Tool
1
Probe Kit (100 pieces)
1
Neck Strap
1
Package of 100 Salt Tablets (100 mg)
1
Model 8026 Particle Generator Operation and Service Manual

7
Chapter 2
Getting to Know the PortaCount Pro
Respirator Fit Tester
Use the numbered paragraphs and correspondingly numbered arrows
to identify the touch screen display, connectors, parts, and
accessories of the PortaCount®Pro fit tester. You need to be familiar
with these items when following the instructions in this manual.
The Touch Screen Display
The touch screen display provides the interface to all operations.
Select items on the touch screen using your finger or the stylus that is
provided. Do not use a pen, pencil or other sharp instrument, as this
may damage the screen.
Stylus
On/Off
Button

8 Chapter 2
Sampling Ports
Sampling ports permit air to flow into and out of the PortaCount Pro
fit tester.
1 The Sample Port is used when sampling air from a respirator
during a fit test. The clear tube marked "SAMPLE" of the Twin
Tube Assembly (3) connects here. The Sample Port fitting is
silver and marked with the letter "S".
2 The Ambient Port is used to sample ambient air during a fit test.
The blue tube marked "AMBIENT" of the Twin Tube Assembly (3)
connects here. The Ambient Port fitting is blue and marked with
the letter "A".
3 The Twin Tube Assembly consists of a pair of tubes: the Sample
Tube and the Ambient Tube. The Twin Tube Assembly is about
5.5 feet (1.7 meters) long. The Sample Tube is 7 inches (18 cm)
longer than the Ambient Tube.
The Twin Tube must not be lengthened except for the few inches
added by a Tube Adapter. Never split the ambient and sample
tube, they must remain together and the two sample tubes must
be nearly the same length for accurate fit testing.
2
3
1

Getting to Know the PortaCount Pro Respirator Fit Tester 9
Electrical Connections
4 The USB Series “B” receptacle provides for communication
between the PortaCount Pro fit tester and a USB port on the
personal computer. The USB cable provided with the PortaCount
Pro fit tester connects here.
5 Two USB Series “A” receptacles let you connect a USB mouse,
USB keyboard, compatible USB printer, or a USB flash drive
(thumb drive).
6 The External Power Connector connects the AC Adapter to the
PortaCount Pro fit tester.
4
5
6

10 Chapter 2
7 The AC Adapter plugs into the External Power Connector on the
PortaCount Pro fit tester and an AC wall outlet. The AC Adapter
senses the input voltage automatically.
7

Getting to Know the PortaCount Pro Respirator Fit Tester 11
Alcohol Related Parts
8 The Alcohol Cartridge holds the isopropyl alcohol consumed by
the PortaCount Pro fit tester. A porous wick inside is soaked
with alcohol.
9 The Cartridge Cavity is where the Alcohol Cartridge is inserted
during use. Make certain dirt and lint do not enter the Cartridge
Cavity. Cover the Cartridge Cavity with the Storage Cap (10)when
the instrument is not being used.
10 The Storage Cap is used to cover either the Cartridge Cavity of the
PortaCount Pro fit tester or the Alcohol Fill Capsule, whichever does
not currently hold the Alcohol Cartridge.
11 Two spare Alcohol Wicks are included with the PortaCount Pro
fit tester.
12 The Alcohol Fill Capsule is used to store and fill the Alcohol
Cartridge.
13 The PortaCount Pro fit tester is shipped with 16 bottles of reagent
grade (99.5% or better) isopropyl alcohol. Each bottle contains
30 ml. The instrument consumes alcohol at approximately 2 ml per
hour and the alcohol wick holds approximately 13 ml ofalcohol. Do
not use isopropyl alcohol that is less than 99.5% pure.
8
10
11
12
13
9

12 Chapter 2
Miscellaneous Parts
14 The Spare Sampling Port Inlet Screens are used to help keep the
PortaCount Pro fit tester internal flow path clean by capturing
large or fibrous particles.
15 Two Tube Adapters are shipped with each PortaCount Pro fit
tester. The adapters are used to connect the Sample Tube to a
respirator sample fitting (or probe) that is larger than the 1/8 inch

Getting to Know the PortaCount Pro Respirator Fit Tester 13
(3 mm) inside diameter of the Sample Tube. One of the Tube
Adapters fits 3/16 inch (4.7 mm) fittings and the other fits 1/4 inch
(6.3 mm) fittings. An adapter is not needed for respirators
equipped with a 1/8 inch (3 mm) fitting.
16 The Zero Check Filter is provided for the Zero Check and Max Fit
Factor Check on the PortaCount Pro fit tester to make sure it is
working properly. A spare filter is also provided.
Note
TSI recommends that the Zero Check Filter be left attached to
the sample line whenever the PortaCount Pro fit tester is turned
on but not in use. This prevents lint and debris from being drawn
into the instrument and blocking the airflow.
17 The PortaCount Pro/Pro+ Respirator Fit Tester Quick Start Guide.
18 The Compact Disc (CD) contains FitPro+™Fit Test Software for
Windows in addition to manuals and other information related to
TSI fit testing products and fit testing in general. There is no
printed FitPro+ software manual in lieu of the online help. Visit the
TSI Web site http://fittest.tsi.com to download the current version
of most TSI manuals. The CD is located in a convenient storage
case.
19 The Carrying Case provides protection and convenience. The
case is designed to hold the PortaCount Pro fit tester and
standard accessories.
20 The USB Cable is used to connect the PortaCount Pro fit tester to
a computer. It is needed whenever the FitPro+ Software is used
to interface and control the PortaCount Pro fit tester.
21 The USB Flash Drive holds active databases and lets you select
and use the active database in the PortaCount Pro fit tester in
stand-alone mode. Without a flash drive, you cannot store
information and test data collected or updated when using the
PortaCount Pro fit tester in stand-alone mode. The flash drive is
used to exchange database data between the PortaCount Pro fit
tester and the FitPro+ software. (See the FitPro+ Fit Test
Software User Manual for instructions on how to configure the
USB flash drive.)

14 Chapter 2
Additional Items (Model 8038 only)
22 The Probe Assembly Tool is
used to install the sampling
probes in filtering-facepiece
(disposable) respirators.
23 The Probe Kit includes 100
disposable probes.
24 The Neck Strap supports the
Twin Tube assembly when
sampling running fit tests on
filtering-facepiece (disposable)
respirators.
25 Model 8026 Particle Generator. If you do not have the minimum
ambient particle concentration needed for the PortaCount Pro fit
tester to do a fit test, this optional particle generator supplements
naturally occurring room concentration with non-toxic salt (NaCl)
particles in the appropriate size range for the PortaCount Pro fit
tester. Refer to the Model 8026 Particle Generator information on
the TSI Web site http://software.tsi.com.
22
23
24
25