TSI Instruments PortaCount Plus 8020 Operation manual

PORTACOUNT®Plus
Model 8020
Operation and Service Manual
P/N 1980092, Revision M
August 2006
SHIP/MAIL TO:
TSI Incorporated
500 Cardigan Road
Shoreview, MN 55126-3996
USA
E-mail address:
[email protected]
Website:
http://www.tsi.com
U.S.
Technical Support:
1-800-874-2811
1-651-490-2811
Fax:
1-651-490-3824
INTERNATIONAL
Technical Support:
(001 651) 490-2811
Fax:
(001 651) 490-3824
Respirator Fit Testing

ii
Copyright©
TSI Incorporated / 1997–2006 / All rights reserved.
Part Number
1980092 / Revision M / August 2006
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA
Fax No.
[phone]
LIMITATION OF WARRANTY AND LIABILITY (effective July 2000)
Seller warrants the goods sold hereunder, under normal use and service as described in the operator's manual, shall be
free from defects in workmanship and material for twenty-four (24) months, or 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:
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. 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.
c. 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.
d. 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.
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 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 NO EVENT
SHALL SELLER BE LIABLE FOR ANY SPECIAL, 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.
Caution
This instrument is a Class I laser device. Adjustments or performance of
procedures other than those specified herein may result in hazardous radiation
exposure.
Disclaimer: The measurement provided by the PORTACOUNT®Plus 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.
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.

iii
CONTENTS
CHAPTERS
1. UNPACKING.......................................................................................................................1
2. IDENTIFYING THE PARTS ................................................................................................3
Keypad.................................................................................................................................3
Display.................................................................................................................................4
Status Messages.................................................................................................................4
11. SERVICE.............................................................................................................4
12. LOW BATTERY Warning ....................................................................................5
13. LOW PARTICLE..................................................................................................5
Sampling Ports....................................................................................................................5
Electrical Connections.........................................................................................................6
Alcohol Related Parts..........................................................................................................7
Miscellaneous Parts ............................................................................................................8
3. CONDUCTING A FIT TEST..............................................................................................11
Why Fit Test? ....................................................................................................................11
Preparations for Fit Testing...............................................................................................11
Respirators for Quantitative Fit Testing.............................................................................11
Precautions........................................................................................................................13
Fit Testing with FitPlus Fit Test Software (version 2.12 or higher) ...................................14
Fit Testing Without Computer Software ............................................................................15
Conducting a Fit Test in Stand-alone Mode......................................................................16
Common Problems Resulting in Low Fit Factors..............................................................18
4. OPERATING THE PORTACOUNT PLUS........................................................................19
Connecting Power.............................................................................................................19
Connecting the Optional Printer........................................................................................21
Modes of Operation...........................................................................................................21
Count Mode..................................................................................................................21
Fit Test Mode ...............................................................................................................22
External Control Mode..................................................................................................24
Checking/Setting the Fit Factor Pass Level for Stand-alone Operation ...........................24
Checking/Setting the Number of Exercises for Stand-alone Operation............................24
Changing/Checking the Exercise Duration for Stand-alone Operation.............................25
Status Messages...............................................................................................................26
Low Battery Warning Message....................................................................................26
Low Particle Message..................................................................................................26
Service Message..........................................................................................................27
Shipping & Storage Precautions .......................................................................................27
5. MAINTENANCE................................................................................................................29
Registration .......................................................................................................................29
Recalibration Interval.........................................................................................................29
Reordering Supplies..........................................................................................................29
Adding Alcohol...................................................................................................................29
Alcohol Cartridge..........................................................................................................32
Changing the Alcohol Wick..........................................................................................33
Removing the Wick from the Alcohol Cartridge...........................................................33

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Re-assembling the Alcohol Cartridge ..........................................................................34
Drying the Alcohol Wick ...............................................................................................34
Daily Checks......................................................................................................................35
Particle Check..............................................................................................................35
Zero Check...................................................................................................................35
Max FF Check..............................................................................................................36
Battery Maintenance..........................................................................................................37
Shipping & Storage Precautions .......................................................................................38
6. TROUBLESHOOTING......................................................................................................39
Troubleshooting the PORTACOUNT Plus ............................................................................39
On-line Troubleshooting Guide .........................................................................................39
Nozzle Cleaning ................................................................................................................44
APPENDICES
A SPECIFICATIONS ............................................................................................................45
B THEORY OF OPERATION...............................................................................................47
C CALCULATING FIT FACTOR..........................................................................................49
D CALCULATING PARTICLE CONCENTRATION.............................................................51
E INTERNAL TIMING IN FIT TEST MODE..........................................................................53
F USING THE TSI PORTACOUNT PLUS TO FIT TEST POSITIVE PRESSURE
RESPIRATORS.................................................................................................................55
G THE RAINBOW PASSAGE..............................................................................................57
INDEX................................................................................................................................59

v
INTRODUCTION
This manual discusses all aspects of the PORTACOUNT®Plus Respirator Fit Tester except for topics that
concern the use of the Fit Test Software with a computer. Regardless of whether you intend to use the
PORTACOUNT Plus with or without software, you should become familiar with this manual first. Many of
the details in this manual that concern PORTACOUNT Plus operations are not repeated in the Fit Test
Software Manual.
This manual does not cover the use of the Model 8095 N95-Companion or Model 8026 Particle generator.
Consult their respective manuals for operating instructions.
Registration. Please fill out and mail the registration card that came with your instrument or register 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.
Refer to Chapter 1: “Unpacking,” and Chapter 2: “Identifying the Parts,” to familiarize yourself with the
PORTACOUNT Plus and the included accessories.
Chapter 3: “Conducting a Fit Test,” contains the information you will need to get started using the
PORTACOUNT Plus.
Chapter 4: “Operating the PORTACOUNT Plus,” provides detailed instructions on how to use the instrument,
what each function does and how it works. This chapter is mandatory reading for anyone who uses the
PORTACOUNT Plus. Although you need not read Chapter 4 before you try the instrument out, you will find
the information to be indispensable later on.
Chapter 5: “Maintenance,” describes how to maintain the PORTACOUNT Plus. This is information you must
know in order to successfully use the instrument.
Chapter 6: “Troubleshooting,” contains guidance for resolving problems you may encounter. Always
consult this chapter first if a problem arises. The TSI Web site http://fittest.tsi.com contains additional
resources that you may find useful.
Finally, the many appendices contain additional technical information. Take a few minutes to look at the
list of appendices in the Table of Contents. The TSI Web site http://fittest.tsi.com contains additional
resources that you may find useful including the PORTACOUNT Plus Model 8020 Technical Addendum
which contains detailed information on computer interfacing and remote control.
Disclaimer: The measurement provided by the PORTACOUNT Plus 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.

1
Chapter 1
UNPACKING
The following items are included with the PORTACOUNT®Plus Respirator Fit Tester. If any are missing or
damaged, notify TSI immediately.
Standard items included with the PORTACOUNT Plus
Model 8020
Qty Description
1 PORTACOUNT Plus Model 8020
1 Alcohol Cartridge
1 Alcohol Fill Capsule*
1 Storage Cap
2 Zero Check Filter
2 Spare Alcohol Wicks
1 1/8 to 3/16 Tube Adapter
1 1/8 to 1/4 Tube Adapter
1 AC Adapter
1 Training Video
16 30 ml Alcohol Bottles (480 ml total)
1 Operation & Service Manual (this manual)
1 Carrying Case
1 FitPlus for Windows Fit Test Software**
1 CD Holder
1 RS-232 Interface Cable (9-pin)
1 9-Pin to 25-Pin Serial Cable Adapter
1 USB-to-Serial Converter
*The Training Video makes reference to a black sponge located inside the
Alcohol Fill Capsule. That sponge is no longer provided.
**Visit the TSI Web site at http://software.tsi.com to download the latest
version of FitPlusTM Software.

3
Chapter 2
IDENTIFYING THE PARTS
Use the numbered paragraphs with the correspondingly numbered arrows to identify the various parts of
the PORTACOUNT®Plus Respirator Fit Tester and its accessories. It will be necessary for you to be familiar
with the part names in order to follow the instructions in this manual.
Keypad
"Keypad" refers to all the keys on the front panel as a group.
1. ON/OFF Key
The ON/OFF key turns the instrument ON or OFF.
2. FIT TEST Key
Pressing the FIT TEST key puts the PORTACOUNT Plus into Fit Test Mode. The indicator light on
the FIT TEST key will be on when in Fit Test Mode.
3. COUNT Key
Pressing the COUNT key puts the PORTACOUNT Plus into Count Mode. The indicator light on the
COUNT key is on when in Count Mode.
4. EXTERNAL CONTROL Indicator
When the indicator light next to EXTERNAL CONTROL is on, the PORTACOUNT Plus is being
controlled through the Data Port by an external computer. All keypad controls except the
ON/OFF key will be disabled.
5. TEST START/STOP Key
In Fit Test Mode, the TEST START/STOP key is used to start a fit test and also to terminate a fit
test early (a fit test will automatically stop when the preset number of exercises is completed).
When in Count Mode, the TEST START/STOP key is used to toggle between 1-Second Count
Mode and 15-Second Count Mode.
6. PASS LEVEL Key
Use the PASS LEVEL key to view and change the fit factor pass level. Press the key momentarily
to check the fit factor pass level without changing it. Press and hold the key down to scroll
through the available fit factor pass level values. Release the key to set the level at the value
shown on the display at that moment.
1
2 3
4
567

4
7. NO. OF EXER Key
Use the NO. OF EXER key to view and change the number of exercises to be used in the fit test
protocol. Press the key momentarily to check the number of exercises without changing it. Press
and hold the key down to scroll through the available values. Release the key to set the number of
exercises at the value shown on the display.
Display
The Display is a liquid crystal display (LCD) used to present numeric data and status information to you.
The elements that can be shown on the Display are:
NOTE: The Display is always blank when FitPlus for Windows Software is controlling the PORTACOUNT
Plus.
8. Numeric Values
Numeric values for fit factor, overall fit factor and particle concentration are displayed as full digit
numbers truncated to 3 significant digits. Fit factor pass levels are displayed as integers. The units
associated with the numeric value are displayed to the right of the number. The units that can be
displayed are:
•FIT FACTOR
•OVERALL FIT FACTOR
•PARTICLE/cm3
•FIT FACTOR PASS LEVEL
9. Exercise Number
The exercise number display is used to check or set the number of exercises needed for a complete
fit test and to display the exercise number in progress during a fit test. During a fit test, the "IN
PROGRESS" message will appear next to the exercise number and will flash on and off.
10. PASS/FAIL Message
A "PASS" or "FAIL" message will appear in the lower-right hand corner of the Display every
time a fit factor or an overall fit factor is displayed. "PASS" will appear if the displayed fit factor
is equal to or greater than the fit factor pass level and "FAIL" will appear if the displayed fit factor
is less than the fit factor pass level. The fit factor pass level is set with the PASS LEVEL key.
Status Messages
There are three warning indicators that can be displayed by the PORTACOUNT Plus. They are:
11. SERVICE
When the message: "SERVICE" is displayed, the PORTACOUNT Plus is usually low on alcohol;
however, there can be other reasons. Consult the section on status messages in Chapter 4,
“Operating the PORTACOUNT Plus.”
8
9
10
11
12
13

5
12. LOW BATTERY Warning
The flashing message: "LOW BATTERY" warns you that there are about 15 minutes remaining
before the PORTACOUNT Plus turns itself off due to lack of sufficient battery power. Finish the fit
test in progress and then install a fresh battery, or plug in the AC adapter.
13. LOW PARTICLE
The "LOW PARTICLE" message indicates that the PORTACOUNT Plus has measured a particle
concentration during the ambient sample that is below the pre-programmed cut off of 1000
particles/cm3(the cut off is 70 particles/cm3when the optional N95-Companion is in use). This
message can only appear during operation in Fit Test Mode.
Sampling Ports
There are three ports that permit air to flow into and out of the PORTACOUNT Plus. They are:
14. Sample Port
The Sample Port is the inlet used by the PORTACOUNT Plus when sampling air from a respirator
during a fit test in Fit Test Mode and at all times while in Count Mode. The clear tube marked
"SAMPLE" of the Twin Tube Assembly connects here. The Sample Port fitting is silver in color
and marked with the letter "S".
15. Ambient Port
The Ambient Port is used to sample ambient air during a fit test in Fit Test Mode. It is never used
in Count Mode. The blue tube marked "AMBIENT" of the Twin Tube Assembly connects here.
The Ambient Port fitting is colored blue and marked with the letter "A".
16. Exhaust Port
The Exhaust Port is where all sampled air exits the PORTACOUNT Plus.
17. Twin Tube Assembly
The Twin Tube Assembly consists of a pair of tubes. The Sample Tube is clear in color, has the
word "SAMPLE" marked on it in several places along its length, and connects to the silver
colored Sample Port. The Ambient Tube is blue in color, has the word "AMBIENT" marked on it,
and connects to the blue colored Ambient Port. The Twin Tube Assembly is about 5.5 feet
(165 cm) long and must never be lengthened by more than a few inches for fit testing. The Sample
Tube is 1.5 inches (40 mm) longer than the Ambient Tube.
14
15
16 17

6
Electrical Connections
18. Battery Cover & Battery Cover Latch
The battery compartment is located underneath the PORTACOUNT Plus behind the Battery Cover.
Slide your finger under the Battery Cover Latch and lift to remove the cover. Tools are not
required.
19. Battery Connector
The Battery Connector is located inside the battery compartment. The connector is polarized (one
pin is larger than the other) so that it cannot be plugged into a battery pack backwards. A TSI
Model 8903 Rechargeable Battery Pack must be used for battery operation of the PORTACOUNT
Plus. If the AC Adapter is used, a battery pack need not be installed and the connector can be
loose inside the battery compartment.
Note: As of January 2003, battery packs are no longer available from TSI.
20. Data Port
The Data Port allows RS-232C serial communication with the PORTACOUNT Plus. It is used to
transmit data to a printer like the TSI Portable Printer or for communications with a
microcomputer. The Data Port uses a standard RJ-45 modular connector.
21. Accessory Port for Optional Model 8095 N95-Companion
This port is used to connect the optional Model 8095 N95-Companion accessory used for fit
testing lower efficiency disposable respirators. N95-Companion capability can be added to older
PORTACOUNTs that do not have this port. Contact TSI.
22. External Power Connector
The External Power Connector is on the back of the PORTACOUNT Plus. The coaxial metal
connector is labeled "POWER" just above it. The voltage requirement and polarity are also
marked. The connector used is 5.5 mm x2.5 mm. Many instruments on the market use similar
connectors. Always be certain that you are connecting the AC Adapter that was supplied with the
PORTACOUNT Plus.
18
19
20
22 21

7
23. AC Adapter Model 8024
The AC Adapter plugs into the External Power Connector on the PORTACOUNT Plus and your AC
wall outlet. The AC Adapter senses the input voltage automatically. Older PORTACOUNTswere
shipped with single voltage AC Adapters.
24. Computer Interface Cable with 9/25 Pin Adapter
The Computer Interface Cable (Model 8927) is used to connect the PORTACOUNT Plus to an
IBM-PC compatible computer. It is needed whenever the FitPlus Fit Test Software is used with
the PORTACOUNT Plus. The cable has a RJ-45 modular connector on the PORTACOUNT Plus end
and a 9-pin D-connector on the other. The 9/25-Pin Adapter is used when the computer is
equipped with a 25-pin serial connector instead of a 9-pin serial connector.
NOTE: If your computer has no RS-232 serial port you can use your USB port instead by
purchasing a USB to Serial Converter.
Alcohol Related Parts
25. Alcohol Cartridge
The Alcohol Cartridge holds isopropyl alcohol that is consumed by the PORTACOUNT Plus. There
is a porous wick inside that is soaked with alcohol.
26. Cartridge Cavity
The Cartridge Cavity is where the Alcohol Cartridge is inserted during use. It is very important to
make certain that dirt and lint do not enter the Cartridge Cavity. Cover the Cartridge Cavity with
the Storage Cap when the PORTACOUNT Plus is not being used.
23
24
25
26
27
28
29
30

8
27. Storage Cap
The Storage Cap is used to cover the Cartridge Cavity of the PORTACOUNT Plus or to cover the
Alcohol Fill Capsule, whichever does not currently hold the Alcohol Cartridge.
28. Spare Alcohol Wicks
Two spare Alcohol Wicks are included with the PORTACOUNT Plus. They can be used to replace
the wick inside the Alcohol Cartridge.
29. Alcohol Fill Capsule
The Alcohol Fill Capsule is used to store and fill the Alcohol Cartridge.
NOTE: The Training Video refers to a black sponge located inside the Alcohol Fill Capsule.
That sponge is no longer necessary or provided.
30. Alcohol Supplies
The PORTACOUNT Plus is shipped with 16 bottles of reagent grade (99.5% or better) isopropyl
alcohol. Each bottle contains 30 ml. The PORTACOUNT Plus consumes alcohol at the approximate
rate of one ml per hour and the alcohol wick holds approximately 8 ml of alcohol. Do not use
isopropyl alcohol that is less than 99.5% pure.
Miscellaneous Parts
31. Excess Filter
The Excess Filter cleans the air that goes through the internal bypass, before it reaches the pump.
NOTE: It is unlikely that either filter will need to be replaced except during factory service.
32. Sensor Filter
The Sensor Filter cleans air that has passed through the internal sensor, before it reaches the
pump.
31
32

9
33. Tube Adapters
There are two Tube Adapters shipped with each PORTACOUNT Plus. The adapters are used to
connect the Sample Tube to a respirator sample fitting (or probe) that is larger than the 1/8 inch
(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.
34. Zero Check Filter
The Zero Check Filter is provided for the purpose of performing a Zero Check and Max FF Check
on the PORTACOUNT Plus to make sure it is working properly. A spare filter is also provided.
35. PORTACOUNT Plus Operation & Service Manual (this manual)
The PORTACOUNT Plus Operation & Service Manual provides detailed instructions on operating,
servicing and troubleshooting. It covers all aspects of the instrument with the exception of use
with FitPlus Fit Test Software. It also does not cover use of the Model 8095 N95-Companion or
Model 8026 Particle Generator. Visit the TSI Web site 1http://fittest.tsi.com to download the
current version of most TSI manuals.
36. FitPlus Fit Test Software and Technical Reference CD
This Compact Disc (CD) contains FitPlus 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
longer a printed FitPlus manual in lieu of the built-in online help functions.
The latest version of FitPlus software can be downloaded from the TSI Web site
http://software.tsi.com.
37. Compact Disc (CD) Storage Case
The CD that contains the Fit Test Software is located in one of these convenient storage cases.
38. Carrying Case
The Carrying Case is a rugged case that provides protection and convenience. The case is
designed to hold the PORTACOUNT Plus and standard accessories as well as the optional Portable
Printer and Model 8021 Battery Kit.
39. USB-to-Serial Converter
If your computer does not have an RS-232 serial port, use the USB-to-Serial Converter supplied
with the PORTACOUNT to convert an USB port into a virtual RS-232 port. Note that the converter
includes a software CD and installation instructions. It will not function unless installed.
34 33
35
36 & 37
38
39

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40. Optional—Model 8095 N95-Companion
The N95-Companion is an optional accessory that allows the PORTACOUNT Plus to fit test lower
efficiency filtering-facepiece (disposable) respirators such as class N95, R95 and P95 varieties
available in the USA and P1 and P2 classes available in many other countries. Class-99, class-100
(USA), and P3 (other countries) disposables can be fit tested with the PORTACOUNT Plus alone.
Older PORTACOUNTs can be made “N95-Companion Ready” via a factory upgrade.
41. Optional Model 8026 Particle Generator
Some locations do not have the minimum 1000 particles/cm3ambient particle concentration
needed for the PORTACOUNT Plus to do a fit test. The optional particle generator supplements the
naturally occurring room concentration with non-toxic salt (NaCl) particles in the right size range
for the PORTACOUNT to use.
40
41

11
Chapter 3
CONDUCTING A FIT TEST
NOTE: This chapter describes how to conduct a quantitative respirator fit test using the PORTACOUNT®
Plus Respirator Fit Tester. This procedure assumes that the mask being tested is a negative-pressure air-
purifying respirator or a positive-pressure mask temporarily converted to function like a negative-pressure
air-purifying respirator. For additional details see Appendix F of this manual and Application Note ITI-070
Introduction to Respirator Fit Testing located on the TSI Web site http://fittest.tsi.com.
Why Fit Test?
There are two primary reasons for respirator fit testing:
1 Verification of Training
After the individual has received respirator training, you perform a fit test to make certain that the
person has learned how to properly put on and wear a respirator without assistance.
2 Sizing
It is important to make sure that the individual will be issued a respirator that is capable of
providing protection when worn properly, i.e., 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 PORTACOUNT
Plus 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.
Respirators for Quantitative Fit Testing
Probed Test Respirators
The conventional way to quantitatively fit test is through the use of probed test respirators. A
probed respirator has a fitting (probe) installed that allows air from inside the respirator to be
sampled by an instrument like the PORTACOUNT Plus. The probed respirator is only used for fit
testing and cannot legally be used in a hazardous environment. You will need at least one
respirator of each make, model and size your company issues. After the fit test, the individual
should be issued a respirator with the identical facepiece, only without the probe.
Most probed respirators are obtained from the respirator manufacturer or distributor. You should
be able to buy probed versions of most if not all models. Be sure to buy class-100 or class-99
filters also if you don't already stock them. You must use class-100, class-99 or P3 filters for fit
testing even if you use another type of cartridge in the workplace.

12
Probes for filtering-facepiece (disposable) respirators
Disposable respirators can be fit tested by inserting a test probe through the filter material. The
optional TSI Model 8025-N95 Probe Kit includes disposable probes and insertion tools. Order
TSI Model 8025-N95R Probe Refill Kit for additional probes (no tools).
NOTE: The PORTACOUNT Plus Model 8020 can successfully fit test class-100, class-99 and P3
disposable respirators. Lower efficiency disposable respirators such as class 95, P2 and
P1 will usually require use of the optional TSI Model 8095 N95-Companion accessory.
Fit Testing with the Person's Own Assigned Respirator
Some respirators, especially older models, do not have fit test adapters available. In that case, a
permanently probed test respirator is the only option.

13
Respirator manufacturers' technique
There is a growing number of respirator manufacturers who provide sampling adapters that permit
fit testing in one's own respirator. Contact your distributor or call the manufacturer direct and ask
if such accessories are available.
TSI fit test adapter kits
TSI Sampling Adapters allow you to fit test using the respirator that is actually used by that
individual. Sampling Adapters for most major brands of respirator are available. A complete list
of fit test adapters available from TSI and from respirator manufacturers is posted on the TSI Web
site http://fittest.tsi.com.
Homemade adapters
A sampling adapter can be made by modifying a respirator cartridge. This usually involves
running a tube through the cartridge and into the respirator. TSI recommends that you avoid this
option because it is so easy to do poorly. The most fundamental mistake that is often made is to
not extend the sampling tube through the inhalation valve and into the breathing zone. This
combined with problems sealing around the outside of the tube make this option unattractive.
Precautions
The following is a discussion of several precautions that should be considered 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
PORTACOUNT Plus 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 PORTACOUNT Plus 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 Plus 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 Plus. Fit
testing near sources of amyl-acetate (banana oil) is not a problem.
Sample Tube Length
The Twin Tube Assembly is about 5½ feet long and must not be lengthened except for the few
inches added by a Tube Adapter. The two sample tubes must be nearly the same length for
accurate fit testing.
TSI recommends that the Zero Check Filter be left attached to the sample line whenever the
PORTACOUNT Plus is turned on but not in use. This prevents lint and debris from being drawn into
the instrument and blocking the airflow.

14
Fit Testing with FitPlus Fit Test Software (version 2.12 or higher)
Most PORTACOUNT Plus users conduct fit testing with the included FitPlus Fit Test Software because it
makes the fit test process easy and provides documentation and record keeping functions. When used,
FitPlus software controls all PORTACOUNT functions making it unnecessary to use the keypad controls
other than the ON/OFF key. For detailed help using FitPlus software, please use the online help functions
built into FitPlus. If you want to conduct fit testing without computer software, skip to the next section in
this chapter. For more detailed instructions on the operation of FitPlus software use the online help
function built into the software.
1. Install FitPlus for Windows Software from the provided CD.
2. Connect the AC Adapter (or battery) to the PORTACOUNT Plus and turn it on by pressing the
ON/OFF key. The PORTACOUNT Plus will go through a 60-second warm-up period before it’s
ready to go.
3. Connect the PORTACOUNT’s Data Port to your computer’s RS-232 serial port using the cable
provided. If the computer port has 25 pins instead of 9, use the provided 25 to 9-pin adapter.
Computers that do not have an RS-232 serial port can use the USB-to-Serial Converter provided
with the PORTACOUNT.
4. Add alcohol to the PORTACOUNT Plus. Follow the instructions under “Adding Alcohol” located in
the chapter on maintenance.
5. Start FitPlus for Windows software by double-clicking the PORTACOUNT icon or selecting FitPlus
for Windows from the Start Menu.
6. FitPlus software starts and asks if you want to do the Daily Checks. TSI recommends that you
Click YES the first time you use the PORTACOUNT Plus each day. Subsequent Daily Checks are
optional. You can have FitPlus software perform the Daily Checks at any time by using the drop-
down menus.
7. Perform the Daily Checks as directed by the software when it first starts or by selecting Daily
Checks from the PORTACOUNT Menu. You will need to use the Zero Check Filter provided. See
Chapter 6, “Troubleshooting,” if any of the tests fail.
8. Next, FitPlus will offer to begin the fit test process at Step 1. Type in the information about the
person you will be fit testing. Next time you fit test that person you will be able to pick the name
off a list. Click NEXT when done.
9. Step 2 (on screen) requires you to select a respirator. Type in the information about the respirator
that will be used. Next time you use that same respirator you will be able to pick it off a list. In the
USA, OSHA requires a fit factor pass level of 100 and 500 for half masks and full-face masks,
respectively. Click the Help button if necessary. Click NEXT when done.
10. Step 3 (on screen) requires you to enter the size of the mask being used and the fit test operator’s
name or initials. You can also review the other settings to make sure they are correct. Pay special
attention to the current default fit test exercise protocol to make sure it’s the one you are required
to use. USA protocols and some non-USA protocols are pre-defined. If yours is not on the list you
can create it by duplicating an existing protocol and editing it. Use the online help if necessary.
Click NEXT when done.
11. Now you are ready to start the fit test itself. Attach the clear sample hose to the respirator worn by
the person being fit tested. When ready, click START. You will then be guided through the entire
fit test exercise protocol automatically. Just have the person being fit tested perform each exercise
as directed by the computer. The computer automatically performs the fit test, calculates all fit
factors and saves the information to the database. After each fit test is completed, you may review
the results, print a report, or start another fit test.