F4504 MULTI-AIR TESTER

OPERATING MANUAL

FAC QAM 173 Issue A 03/16

0
1
 Contents
Page No

Introduction 3

Calibration & Warranty 4

Equipment List 4

1 - Pre Use 5

2 - Start-Up 6

3 - Selecting the test standard and configuring the 7

instrument.
4.1 - Breathing-Air Tests – airline up to 10 bar 8

4.2 Breathing-Air Tests - HP systems 200 & 300 bar 14

5 - Medical Air Tests – Pharmacopeia and HTM02-01 17

6 - Continuous Oxygen Reading 21

7 - Exporting Test Results and PC Software 22

Appendix 1 - Helpful Tips 23

Appendix 2 - Draeger Tube Tip Cutter 24

Appendix 3 - Reading the Draeger Oil Impactor and Chemical 25

Reagent Tubes

Appendix 4 – Breathing Air Standard 30

Appendix 5 – Breathing Air Quality Testing – Why? 31

Frequency of BA Tests / Recording results 32

A.4.5 Compressed Air for Breathing Apparatus 34

from EN529

COSHH L5 Sixth Edition 35

Respiratory Protective Equipment at Work 37

Appendix 6 – Medical Air Standards 39

Conversion chart mg/m3 to ppm v/v 40

2
Introduction

Multi-Air Testers are designed to provide a quick and easy method for carrying out accurate periodic
testing of breathing and medical-air supplies. The instrument can test against a range of standards,
for breathing air the European Standard is EN12021, which should be referred to in conjunction with
any overriding national standards. For medical and surgical air the F4504 is programmed to test
against the requirements of European Pharmacopoeia and in the UK, HTM 02-01.

The F4504, is designed primarily for use on airline systems up to 10bar when used in conjunction with
the F3005 regulator can also test systems up to 20 bar. For testing high pressure cylinders or charging
systems the F3002 High Pressure Regulator is available which has a 200/300 bar 5/8” DIN thread.

For some of the medical tests the F4504 uses alternative test methods to those described in the
narrative of the standard.

Standards which the F4504 can test against are:

Breathing Air:
 EN12021:2014

Medical:
 HTM02-01 Medical and Surgical Air
 HTM02-01 Dental Air
 European Phamacopeia Medical and Surgical Air
 European Phamacopeia CO2
 European Phamacopeia N2
 European Phamacopeia N2O

The F4504 has a colour touch screen display and is supplied in a hard weatherproof case with storage
provision for a wide range of accessories and equipment. It is primarily designed to be used from
within the case; however the tester can also be removed and operated separately where space is at a
premium.

As well as test ports for chemical reagent tubes/Impactors the F4504 incorporates an electronic
dewpoint meter, electrochemical oxygen cell, digital flowmeter and pressure transducer.

Depending on the standard selected tests are carried out using the Draeger Impactor for oil and
chemical reagent tubes for carbon monoxide, carbon dioxide, sulphur dioxide, nitrous fumes,
hydrogen sulphide and polytest. These are supplied in packs of 10 per type and the chemical reagent
tubes show the degree of contaminant present as a colour change to the crystals that they contain.
The extent of this is read against the scale on the tube. For the Impactor the degree of oil
contamination is displayed on a screen.

Results from the F4504 can be downloaded to PC software which can be downloaded from Factair’s
website (www.factair.co.uk/downloads). The software allows you a convenient way to easily store,
retrieve and print previous test results.

3
Calibration and Warranty

Multi-Air Testers leave our factory with a 12-month warranty and calibration certificate. Our
standard turnaround on annual calibration is 10-15 working days providing there is no major damage
that requires an extensive rebuild.
Note:- Please download all stored data before returning the Tester to Factair.

Temperature Parameters
Storage: -20/+50°C Operating Range: -10/+45°C

This tester is calibrated for the following approved reagent tubes/Impactor.

Test Draeger ref. Factair Part Sensitivity

No:
Carbon Monoxide CO 6728511 TUB0004 5-150 ppm
Carbon Dioxide CO2 6728521 TUB0005 100-3000 ppm
Oil (Impactor) 8103560 TUB0053 0.1 mg/m3
Oil (chemical reagent tube)* 6728371 TUB0003 0.1 mg/m3
Nitrous Fumes NOx 8103661 TUB0068 0.2-6 ppm
Sulphur Dioxide SO2 6728491 TUB0014 1-25 ppm
Polytest CH28401 TUB0017 Sensitivity dependant on
compound present
Hydrogen Sulphide H2S 6728041 TUB0020 0.5-15ppm

**Note:- The tester can also be used with the old type Draeger reagent tube for oil, ref.6728371.
(Refer to Appendix 2 at the rear of the manual for instructions.)

IMPORTANT – IT IS RECOMMENDED THAT YOUR MULTI-AIR TESTER IS RETURNED FOR

RECALIBRATION AND SERVICING WITHIN 12 MONTHS FROM THE ISSUE DATE OF ITS CALIBRATION
CERTIFICATE

Equipment List:
F4504 Multi-Air Tester
Hard Case
Mains Power Supply
USB Memory Cable
6 x AA Alkaline Batteries
Travel Container for used detector tubes
Tube Tip Cutter
F1946 Connection ¼ BSP inlet adaptor
Stylus Pen
Optional Extras
F3005 20 Bar Regulator
F3002 200/300 Bar 5/8” DIN thread High-Pressure Regulator
F2193 Connection adaptor terminating in a CEJN Plug

4
1. Pre-Use

Multi-Air Testers are fitted with internal rechargeable batteries and in addition also have a battery
tray which accommodates 6 off size AA alkaline type batteries packed separately and stored
underneath the tester within the case. In the event that the rechargeable batteries are not
sufficiently recharged then you can continue to use the instrument with either the Alkaline AA
batteries or mains power supply,

To install the alkaline AA batteries lift the tester out of its case, open the battery drawer at the rear of
the unit and place the batteries inside.

Note: - It is important to strictly observe polarity when fitting batteries and ensure that they are
correctly located.

During use the battery condition is displayed on the screen.

If the Tester is to be used adjacent to a power socket, the mains adaptor may be used. Please note
the unit should be switched off prior to connection or disconnection of the mains supply.

5
2. Start Up

To carry out a test first switch on the machine by pressing and holding the green “on” button, located
on the right-hand side of the unit, for approximately 3 seconds.

A splash screen will be displayed which shows the

instruments hardware and firmware versions.
Periodically the firmware is upgraded as part of
the recalibration process as improvements are
identified.

A Stylus pen is provided for use with the touch

screen. The display will show the, date last
calibrated, serial number and a tick or cross
symbol will indicate whether it is within the
recommended calibration period.

Press the arrow key to progress to the main

menu.

The main menu has 3 options available from left

to right these are:
Begin test, Review Previous Tests and Set-Up
Menu.

Each of these sub-menus are described in further

detail below

The instrument can also be turned off from this

menu by pressing the red power symbol in the
top right hand corner.

Note – If the begin test icon is in grey this will be

because the instrument’s memory is full (20 tests
maximum) and you need to remove at least 1 test
before you can proceed. See Section 4 –
Reviewing Test Results for further details.

6
3. Selecting the test standard and configuring the instrument

From the main menu press the configure icon.

In the configuration sub menu there are 3 icons

available, from left to right these are:
Set Date
Set Time (the instrument uses a 24 hour clock)
Set units of measure and test standard

The date and time are set prior to the unit being
supplied but they can be adjusted as necessary.

To select the test standard or the units of

measure press the right hand icon.
In this menu you can then choose date format;
pressure and temperature units of measure and
the breathing-air test standard.

Once you have made your selection press the

arrow in the top right corner to exit. To then exit
from the configuration sub menu to the main
menu press the arrow at the top left of the
screen.

7
4. Breathing-Air Tests- Airline up to 10 bar

Having selected the breathing-air standard

EN12021 in the configuration screen, to carry out
a test press the “begin test” icon on the main
menu

The unit will automatically calibrate the oxygen

cell against the surrounding atmosphere; the unit
therefore needs to be in a well ventilated area.

Note:- If the temperature is greater than 40°C

inside the instrument the calibration will operate
for an extended period to stabilise the Oxygen
cell.

You now have the option of entering a

description for the test location, if you wish to
use numbers press the “function” button. Push
the right arrow button when you are ready to
proceed.

Choose between using a Draeger chemical

reagent tube or Draeger oil Impactor in the test
port.

For further details on alternative chemical

reagent tubes see appendices 2 and 3.

For breathing-air tests the standard option is to

select a Draeger oil Impactor.

8
 The unit has 4 breathing-air test programmes
available: Airline Systems up to 40 bar (top left);
High Pressure Charging Compressors (top right)
High Pressure Systems up to and including 200bar
and High Pressure Cylinders above 200bar. All of
the high-pressure tests require the use of the
F3002 regulator which has a DIN connector that
can accept input pressures up to 300bar.

4.1 Completing an Airline Test

Select (Airline < 40 bar) – note the maximum
pressure the instrument is rated to is 10 bar.

With the flow control valve in the closed position

connect to the air supply to be tested. Ideally this
should be done by using the hose which normally
supplies the breathing apparatus. Fit the
appropriate adaptor to the Tester first and then
connect the supply hose to the adaptor.

A test can be carried out at any pressure between

2 and 10 bar.

Note:- If the unit is over-pressurised it will

automatically shut down and display an
overpressure warning; it will then need to be
returned to the manufacturer for checking and
resetting.

Input pressure will be displayed on the measured

pressure bar graph and the adjacent display.
System pressure will automatically default to this
reading.

Note:- The pressure dewpoint at the end of the test will be calculated on the recorded system
pressure.

For the majority of applications the system pressure can be left at this default setting, however if the
breathing-air system is distributed as breathing air at a different pressure to that being displayed this
should be entered at this stage.
9
To enter press the right hand side (Set) icon use the keypad to enter the required value, press the
right arrow to return. The (Reset) button will automatically reset the system pressure back to the
measured pressure.

Press the arrow key to proceed.

We can now confirm the flow and pressure is

adequate for your respiratory protective device.
Adjust the system’s flow control valve so that the
flow meter registers the required level*, check
the pressure is sufficient for the breathing-air
equipment being used. It is recommended that
this flow is left running for the duration of the
test to simulate the conditions of use. Press the
arrow key to proceed if the flow and pressure
meet the minimum requirements for your RPD.
*Note:- At high flow rates hearing protection should be considered.

Carry out the odour test and smell the air

exhausted from the sintered outlet. If there is a
serious odour problem, fail the sample at this
point of the test by pressing the ‘fail’ button.
Initiating flows of seriously contaminated air
could result in damage to the instrument. If the
odour test is satisfactory, press the ‘pass’ button.

The instrument will now commence a 5-minute

purge sequence, during which time an airflow will
be passed through the test port and across the
electronic cells. This clears contaminants from
previous tests and ensures that a representative
sample is being tested.

10
 Once the purge has finished, the CO, CO2 and
Draeger Impactor/oil tube should be inserted into
the test port and tightened firmly; ensure the
Impactor has an intact protective seal. This seal
must remain in place for the duration of the test.
Press the button in top right hand corner to start
the test.

The test will now commence and the duration will

be displayed as a countdown, together with
pressure, flowrate, ambient temperature, carbon
dioxide, carbon monoxide and oxygen content.

During the test the flowmeter should be set to

simulate the requirements of the respiratory
protective device RPD.

The unit can be left until the test time has

elapsed.

If the instrument detects that the dewpoint

meter’s rate of change is still too high (>0.2 dec C
per minute) it will automatically continue the test
until this stabilises (maximum test time 15
minutes).

Once the test is complete close the flow control

valve, the readings from the Impactor can now be
entered.

To enter the results press the corresponding icon

on the screen.
Note:- Instructions on reading the Impactor can
be found in Appendix 3 at the back of the manual.

11
 The tube readings should also then be entered,
push the button corresponding to each chemical
reagent tube / Impactor.

Input the reading from the tube / Impactor and

press the arrow icon in the top right hand corner
of the screen.

The “test complete” screen displays all the

measurements recorded during the test. And
automatically determines whether the test was a
pass or fail against the standard displayed in the
top right corner of the screen. The water content
on low pressure tests is displayed as a pressure
dewpoint. The test result is recorded in the
instrument’s memory, which can store up to
20 previous tests.

If the test was a fail an orange exclamation mark

would be indicating those criteria which did not
meet the standard. The photograph opposite is
an example of a failed test where carbon dioxide
failed to meet the requirements of the selected
standard.

12
For airline systems less than 40 bar the pressure dewpoint, i.e. the point at which water will begin to
condense into a liquid form in the airline, must be at least 5 degrees centigrade below the lowest
temperature at which the system will be used. The F4504 automatically calculates the pressure
dewpoint from the measured water content and system pressure, it then compares this to the
ambient temperature to determine whether it was a pass or fail.

This test result is automatically recorded in the instrument’s memory, which can store up to
20 previous tests. To view these tests return to the main menu and press the “Review Tests” button.
Test results are stored accordingly to the date and time they were completed. From this menu
previous tests can be viewed or deleted as required.

To disconnect the Tester from the system make sure you leave the inlet adaptor on the instrument
and only disconnect at the end of the supply hose. The adaptor can then be disconnected afterwards
if required.

To turn off the Tester use the return arrows to return to the main menu screen and press the X in the
top right hand corner of the screen.

Note: - The unit will automatically turn off after a few minutes if left unused at the main menu screen.

13
3.2 Completing a High Pressure Test
For high pressure tests there are 3 different test options available. All of the high-pressure tests
require the use of the F3002 regulator which has a DIN connector which can accept input pressures of
up to 300 bar.
High-pressure charging compressors

High-pressure cylinder less than 200bar

High-pressure cylinder greater than 200bar

Note: For cylinder tests please ensure the test is carried out on a recently filled, fully charged cylinder.

Note: For the high-pressure charging compressor test a DIN to DIN adaptor ref: F2158 is required to
connect the F3002 high-pressure regulator to a charging hose.

To carry out a test press the appropriate button.

Ensure that the flow control valve is fully closed
and then connect the F3002 high-pressure
regulator assembly to the cylinder or charging
hose to be tested, ensuring that the regulator has
the correct type of connector for the cylinder.
Connect the regulator hose coupling to both the
regulator and the inlet of the Tester.

Open the cylinder valve and check that the cylinder is fully charged by reading the contents gauge on
the regulator. (A partially discharged cylinder can give an incorrect water result.) The pressure
displayed on the tester will be that of the regulated supply from the cylinder and must not exceed
10 bar. Press the button in the top right hand corner to proceed.

Note:- if the unit is over-pressurised it will automatically shut down and display an overpressure
warning; it will then need to be returned to the manufacturer for checking and resetting.

Carry out the odour test by gently opening the

flow control valve and smelling the air exhausted
from the sintered outlet, then close the valve. If
there is a serious odour problem, fail the sample
at this point of the test. Initiating flows of
seriously contaminated air through the tube ports
could result in damage to the unit. If the odour
test is satisfactory, press the ‘pass’ icon.

14
 The instrument will now commence a 5-minute
purge sequence, during which time an airflow will
be passed through the test port and across the
electronic cells. This clears contaminants from
previous tests and ensures that a representative
sample is being tested.

Once the purge has finished, the Draeger

Impactor should be inserted into the test port
and tightened firmly; ensure the Impactor has an
intact protective seal. This seal must remain in
place for the duration of the test. Press the
button in top right hand corner to start the test.

The test will now commence and the duration will

be displayed as a countdown, together with
pressure, ambient temperature, carbon dioxide,
carbon monoxide and oxygen content.

The unit can be left until the test time has

elapsed.

If the instrument detects that the dewpoint

meter’s rate of change is still too high (>0.2 dec C
per minute) it will automatically continue the test
until this stabilises (maximum test time 15
minutes).

15
 The Impactor can now be removed and
evaluated.

To enter the results press the corresponding icon

on the screen.

Note:- Instructions on reading the Impactor can

be found in Appendix 3 at the back of the manual.

The “test complete” screen displays all the

measurements recorded during the test. And
automatically determines whether the test was a
pass or fail against the standard displayed in the
top right corner of the screen. For water content
on high pressure tests both the measured value
in mg/m3 and the atmospheric dewpoint are
provided.

If the test was a fail an orange exclamation mark

would be indicating those criteria which did not
meet the standard. The photograph opposite is
an example of a failed test where carbon dioxide
failed to meet the requirements of the selected
standard.

The test result is automatically recorded in the instrument’s memory, which can store up to
20 previous tests. To disconnect the Tester from the cylinder firstly turn off the cylinder valve, open
the flow control valve until all the air is exhausted then close the valve. It is now safe to disconnect
the connection hose and cylinder regulator.

16
5 Medical Air Tests – Pharmacopeia and HTM02-01

Having selected the appropriate medical-air

standard in the configuration screen, to carry out
a test press the “begin test” icon on the main
menu

The unit will automatically calibrate the oxygen

cell against the surrounding atmosphere; the unit
therefore needs to be in a well ventilated area.

Note:- If the temperature is greater than 40°C

inside the instrument the calibration will operate
for an extended period to stabilise the Oxygen
cell.

You now have the option of entering a

description for the test location, if you wish to
use numbers press the “function” button. Push
the right arrow button when you are ready to
proceed.

For EU Phamacopeia – Medical Air and HTM02-01

Medical and Surgical Air and Dental Air only

Choose between using a Draeger oil Impactor or

oil tube.
For further details on alternative chemical
reagent tubes see appendix 3.
The standard option is to select a Draeger oil
Impactor.

17
 With the flow control valve in the closed position
connect to the air supply to be tested. Ensure the
supply hose has non hydroscopic properties to
ensure it will not retain excessive moisture and
effect the result. Fit the appropriate adaptor to
the Tester first and then connect the supply hose
to the adaptor.
A test can be carried out at any pressure between
2 and 10 bar.

Note:- If the unit is over-pressurised it will

automatically shut down and display an
overpressure warning; it will then need to be
returned to the manufacturer for checking and
resetting.

Input pressure will be displayed on the measured

pressure bar graph and the adjacent display.
System pressure will automatically default to this
reading.

Note:- The pressure dewpoint at the end of the test will be calculated on the recorded system
pressure.

For the majority of applications the system pressure can be left at this default setting, however if the
medical-air system is distributed at a different pressure to that being displayed this should be entered
at this stage.

To enter press the right hand side (Set) icon use the keypad to enter the required value, press the
right arrow to return. The (Reset) button will automatically reset the system pressure back to the
measured pressure.

Press the arrow key to proceed.

The instrument will now commence a 5-minute

purge sequence, during which time an airflow will
be passed through the test port and across the
electronic cells. This clears contaminants from
previous tests and ensures that a representative
sample is being tested.

18
 Once the purge has completed the chemical
reagent tubes / Impactor should be inserted into
the test port and tightened firmly. The
tubes/Impactors to be used are shown at the top
of the screen and will be dependent on the test
standard selected earlier.
If using an Impactor ensure it has an intact
protective seal. This seal must remain in place for
the duration of the test.
Press the button in top right hand corner to start
the test.

The test will now commence and the duration will

be displayed as a countdown, together with test
standard. The pressure, ambient temperature,
and oxygen content will also be displayed.

During the test the flowmeter should be kept

closed.

Test port volumes are automatically adjusted for

different gas mediums. The unit can be left until
the test time has elapsed.

Depending on the standard and therefore the

chemical reagent tubes / Impactor being used
some will complete at different test times and
the instrument will automatically stop the flow to
these tubes. Each complete test port will be
shown with a green tick.

If the instrument detects that the dewpoint

meter’s rate of change is still too high (>0.2 dec C
per minute) it will automatically continue the test
until this stabilises (maximum test time 15
minutes).

19
 Once the test is complete push the button
corresponding to each chemical reagent tube /
Impactor.

Input the reading from the tube / Impactor and

press the arrow icon in the top right hand corner
of the screen.

For the oil and polytest tubes select the

appropriate pass or fail icons.

After you have entered each result that box will

change from red to green. Once you have
completed entering all the results press the arrow
icon in the top right hand corner of the screen.
you enter each result the

Note:- Instructions on reading the Impactor can be found in Appendix 4 at the back of the manual.

20
 The “test complete” screen displays all the
measurements recorded during the test. And
automatically determines whether the test was a
pass or fail against the standard displayed in the
top right corner of the screen. The water content
is automatically also displayed, together with
oxygen content, ambient temperature and test
pressure. The test result is recorded in the
instrument’s memory, which can store up to
20 previous tests.

To disconnect the Tester from the system make sure you leave the inlet adaptor on the instrument
and only disconnect at the end of the supply hose. The adaptor can then be disconnected afterwards
if required.

To turn off the Tester use the return arrows to return to the main menu screen and press the X in the
top right hand corner of the screen.

Note: - The unit will automatically turn off after a few minutes if left unused at the main menu screen.

6.0 Continuous Oxygen Reading

The F4504 can also provide a continuous oxygen reading.

When you start a test press and hold the O2

cylinder for a few seconds which it is in its self
calibration mode.

Note:- If the temperature is greater than 40°C

inside the instrument the calibration will operate
for an extended period to stabilise the Oxygen
cell.

The instrument will then change operating modes

to continuously display the Oxygen reading,
connect your air source and the instrument will
continue to provide a reading until you press the
arrow key in the top corner.

21
7.0 Exporting test results and PC software

To transfer test results from the Safe-Air Tester to the PC software you must first install the software
on your PC. This is available in the download section of Factair’s website:

http://www.factair.co.uk/downloads

Further details to follow.

22
 Appendix 1 - HELPFUL TIPS
With detector tubes

 Ensure that there are no fragments of glass in the tube glands prior to fitting detector tubes,
clean if required.

 Always remove the ends of the detector tubes cleanly using the correct tube tip cutter. Do not
use pincers or other devices.

 Always remove both ends of the detector tubes prior to fitting.

 Always fit detector tubes with the arrows facing outwards.

 Never break the glass ampoule in the oil tube before the test.

 Only use the detector tubes that the Tester is calibrated for.

 Once used, be aware that the tube tip cutter contains ground glass and glass fragments. Take
appropriate precautions for the disposal of these. Dispose of as sharps.

 When using the tube tip cutter ensure only a light pressure is applied to the tube whilst
rotating for scoring.

General

 Make sure the system flow control valve is closed after each test.

 Connecting an air supply to the Tester with the system flow regulator in the open position can
damage the unit.

 Never connect to a non-regulated supply from an HP cylinder or compressor.

 Maximum inlet pressure to the Tester is 10 bar. If exposed to an overpressure the Tester will
display an overpressure warning necessitating its return to the manufacturer for checking and
resetting.

 If the Tester has been used on an excessively wet supply it can be purged dry by running a full
test on a known dry source without any detector tubes fitted.

 When using the mains power supply, ensure that the Tester is switched off prior to connection
and disconnection.

For any additional advice and information please contact Factair on: +44 (0) 1473 746400.

23
Appendix 2

Draeger Tube Tip Cutter

The F2187 is especially designed to prevent glass from falling out of the opener by accident. The
reservoir for the broken-off tips is easy to empty.

Instructions

1. Place the end of the tube 2. Push the tube at an angle to 3. Repeat steps 1 and 2
between the 3 blades, and break the tip. with the other end of
turn to score the end. the tube

24
Appendix 3
Reading the Draeger Oil Impactor and Chemical Reagent Tubes

Oil Impactor

The Oil Impactor’s protective seal must be kept in place for the duration of the test and only
removed after the test has been completed.

With a standard measurement range of 0.1 to 1.0 mg/m3 the Impactor has a limit of detection of
0.05 mg/m3. The Impactor can detect all mineral and synthetic oils, it features a series of 3 horizontal
lines, each formed by a series of precision manufactured nozzles. These horizontal lines of nozzles
are calibrated to a different concentration of oil. When air is passed through these nozzles any oil
present in the air is deposited on the glass plate prior to the air being exhausted by vents around its
circumference, this allows the user to easily and quickly identify minute quantities of oil.

For tests that pass with an oil concentration of less than 0.05mg/m3, the screen will remain blank. For
tests above that read as follows:

The bottom line represents an oil concentration of 0.1 mg/m3. When the oil deposited forms a
continuous line then the concentration is in excess of 0.1 mg/m3. The middle line represents a
concentration of 0.5 mg/m3, again when the oil deposited forms a continuous line the concentration
is in excess of 0.5 mg/m3. The top line represents a concentration of 1.0 mg/m3, again when this
forms a continuous line the concentration is in excess of 1.0 mg/m3.

Pass - Pass -
greater greater
than than
0.05mg/m3 0.1mg/m3
but less but less
than than
0.1mg/m3 0.5mg/m3

Fail - greater Fail -

than greater
0.5mg/m3 than
but less than 1.0mg/m3
1.0mg/m3

25
Each pack of tubes has its own instruction leaflet but the following notes should help you take
readings after the tests have been completed.

Each tube has an expiry date which is located on the back of its storage box.

Oil (67 28371)

REQUIREMENT - THE AIR SHOULD HAVE A MAXIMUM OIL CONTENT OF 0.5 MG/M³
AND SHOULD BE WITHOUT SIGNIFICANT ODOUR OR TASTE.

1. Using the Tube Tip Cutter, 2. With one hand holding the 3. Place your used
place the ampoule section in cutter, the other holding the detector tubes in the
the platform at the bottom. tube and with your thumb F2154 Travel Container,
Note: Make sure the tube is against the base of the cutter,
until they can be disposed
against the back wall of the apply pressure to the tube, this
cutter. Line up the black dot should break the inner tube. of properly as “sharps” or
nearest the end of the tube with glass.
dot on the cutter.

Ensure the oil tube is kept vertical throughout this process.

Satisfactory test: - The white crystals will turn translucent and show at worst a slight discoloration.

Failed test: - (Mineral oil) - The white crystals will show a light brown or darker
discoloration.
- (Synthetic oil) - The white crystals will show a yellow discoloration [Note: best
seen by comparing with an unused tube].

26
 Carbon Dioxide (CO2) (67 28521)
REQUIREMENT - MAXIMUM READING OF 500 PPM. (300 PPM EU Pharmacopoeia N2/N2O)
The media in the detector tube will discolour to show the presence of carbon dioxide. The total
length of the discoloration read from the printed scale at that point is a measure of the concentration
in parts per million.

Carbon Monoxide (CO) (67 28511)

REQUIREMENT - MAXIMUM READING OF 5 PPM.
The media will discolour to show the presence of carbon monoxide in the air sample. The total length
of the discoloration is the measure of concentration read directly from the scale in parts per million.

Nitrous Fumes (NOx) (8103661)

REQUIREMENT - MAXIMUM CONCENTRATION OF 2 PPM.

The media in the detector tube will discolour to show the presence of nitrous fumes. The total length
of the discoloration is the measure of concentration read directly from the scale in parts per million.

27
Sulphur Dioxide (SO2) (67 28491)

REQUIREMENT - MAXIMUM READING OF 1 PPM. ( 2PPM EU Pharmacopoeia – in CO2)

The media in the detector tube will change from grey blue to white to show the presence of sulphur
dioxide. The total length of the white section is the measure of concentration read directly from the
1-25ppm scale in parts per million.

Polytest (CH 28401)

REQUIREMENT - NO DISCOLORATION.
The media in the detector tube will discolour to provide qualitative determination of easily oxidizable
substances in air. Refer to Polytest data sheets for more specific information.

If discoloration occurs further investigation will be required to determine the source of the
contamination.

IMPORTANT – IT IS RECOMMENDED THAT YOUR MULTI-AIR TESTER IS RETURNED FOR

RECALIBRATION AND SERVICING WITHIN 12 MONTHS FROM THE ISSUE DATE OF ITS CALIBRATION
CERTIFICATE

28
Disposal of Draeger-Tubes
When Draeger tubes have been used, or unopened tubes have exceeded their expiry date, they
should be disposed of using one of the following methods:

Used Tubes
Submerge the tube(s) in a beaker or metal container filled with water and allow to soak for 24 hours.
Treat the residual water in accordance with local authority waste regulations (some tube aqueous
waste may require neutralisation prior to disposal). Place the tubes in a “sharps” or glass bin wearing
protective gloves and safety spectacles. Dispose of the bin via the company’s normal industrial waste
disposal method(s) i.e. landfill or incineration.

OR

Place the tubes in a “sharps” or glass bin wearing protective gloves and safety spectacles. Dispose of
the bin via the company’s normal hazardous waste disposal method(s) i.e. landfill or incineration.

OR

Place the tubes in a “sharps” or glass bin wearing protective gloves and safety spectacles. Dispose of
the container via incineration.

Unused Tubes
Open the Draeger tube at both ends using the special tube opener or the cutter on the hand pump.
Break any ampoules where applicable. Dispose of the tubes as stated in Methods 1, 2 or 3.

NOTE: As an alternative a local authority approved waste disposal contractor can be employed to
collect used and unused tubes from site and dispose of them in a safe manner.

29
Appendix 4 Breathing-Air Standard

BS EN12021 & EN12021:2014

Odour The gas shall be free from unsatisfactory odour or taste.
Oxygen (21 ± 1)%

Carbon ≤ 500 PPM

Dioxide
Carbon ≤ 5 PPM
Monoxide
Oil ≤ 0.5 mg/m3

Water Where the apparatus is used and stored at a known

Airline temperature the pressure dewpoint shall be at least 5°C
<40Bar below likely lowest temperature. Where the conditions of
usage and storage of any compressed air supply is not
known the pressure dewpoint shall not exceed -11°C.
Water 40 to 200 bar ≤50 mg/m3
High >200 bar ≤35 mg/m3
Pressure HP Charging Comp ≤25 mg/m3

Above is an extract only for full details refer to the individual standard.

30
Appendix 5 - Air Quality Testing – Why?

The required quality of breathing air is stated in EN12021 is to provide information on the safe limits
of potential contaminant gases within breathing air and to ensure that the life support gas of oxygen
is of an adequate level.

Compressed air for breathing normally originates from a compressor system installed or operating at
the place of use and there are various factors that can affect the quality and safety of this air.

 The air intake to the compressor can ingest airborne contamination from local processes and
vehicle exhaust fumes which are not removed by standard breathing air filtration. Such air borne
contamination may not be continuous but the pollution of the air supply may persist for hours or
days.
 Malfunctioning compressors, especially reciprocating type, can produce unsafe levels of both
carbon monoxide and carbon dioxide.
 Breathing air filtration has a finite life and can fail causing high levels of oil and water
contamination to be present in the air.
 The performance of desiccant filters is dramatically affected by operating temperature.
Infrequent validation may result in poor quality air being supplied for an extended period
 Failure of the compressed air aftercooling will result in air entering the filtration at too high a
temperature, this will cause the filtration to prematurely fail and pass excess levels of oil and
water.
 Malfunctioning dryers can disturb the oxygen concentration to outside safe levels within the
breathing air.
 High levels of water in breathing air can freeze within RPD demand valves causing the air supply to
fail.
 Insufficient air flow or pressure to the RPD will reduce the protection factor of the RPE and
potentially expose the user to ingress of external contaminants.
 The effects of contaminants when breathed at elevated pressure can have a much greater effect
on users than it would at normal pressure.
 Changes in the performance of compressor and filtration equipment are usually rapid in nature.
Any failure affecting outlet air quality may injure users for an extended period if quality validation
is infrequent.
 Odour alone is a poor indicator of air quality, toxic as asphyxiant gasses are often odourless, the
limits for oil pollution are lower than the threshold detection level that most people will notice.

All employers have a duty of care to their employees to ensure that the breathing air they are
supplied with is adequate for the RPD they are using and safe to breathe. The points raised above
may form the basis of the risk assessment called for in the European guidance document for the
selection and use of respiratory protective devices EN 529.

31
Frequency of Breathing-Air Tests

Low Pressure Systems

The purpose of periodically testing air quality is to make sure that the control measures you have put
in place are delivering the air quality required.

In the UK national forward to EN12021 advises that samples should be taken and analysed at least
every three months or more frequently if there has been a change in, or concerns relating to, the
production process.

In the HSE guideline document Respiratory Equipment at Work (HSG53) it states you should base the
frequency of such tests on a risk assessment, but again they should take place at least every three
months, and more often when the quality of air cannot be assured to these levels.

For mobile breathing-air compressors, in the UK, COSHH stipulates that, the employer should ensure
that wherever a compressor is located, the quality of air it supplies is not compromised by nearby
contaminants. We strongly therefore recommend that for mobile compressors the air quality is
tested whenever it is first moved into a new position or prevailing wind conditions change.

The final decision on frequency of test is the responsibility of the Employer and needs to not only
reflect local legislation but also the task and frequency of use. It should be incorporated into their risk
assessment and updated regularly to reflect results from ongoing breathing-air tests to maintain a
robust control system.

High Pressure Systems

Whilst up to a 3 month periodicity for testing may be suitable for low pressure breathing-air systems,
further consideration should be given to high pressure compressors where the life of filter elements
are normally much shorter, typically 50 hours for a HP filter cartridge and this is reduced further in
high ambient temperatures.

Accordingly for these systems we recommend that your risk assessment for testing HP systems
should be based on the expected filter life and an air quality test should first be completed when new
filter elements are fitted and then again when they reach 50% of their life based on the hours run
usage. Subsequent tests would then be dependent on usage with a maximum interval between tests
of 3 months.

32
Recording Breathing-Air Quality Test Results

When undertaking breathing-air quality tests, results should be retained. In the UK the regulations
COSHH stipulates the information retained should include:

 the name and address of the employer responsible for the RPE;
 particulars of the equipment and of the distinguishing number or mark, together with a
description sufficient to identify it, and the name of the maker;
 the date of examination and the name and signature or other acceptable means of identifying
the person carrying out the examination and test;
 the condition of the equipment and details of any defect found, including for canister or filter
respirators, the state of the canister and the condition of the filter;
 for self-contained compressed air/gas breathing apparatus, the pressure of air/gas in the
supply cylinder; and
 for powered/power-assisted respirators and breathing apparatus, the volume flow rate to
ensure that they can deliver at least the manufacturer's minimum recommended flow rate.

Records can be in paper or electronic format but should be kept readily accessible and retrievable at
any reasonable time for examination by safety representatives or inspectors etc.

In the guideline document Respiratory Protective Equipment, a practical guide (HSG53) it advises
results should be kept for 5 years.

33
 A.4.5 Compressed air for breathing apparatus
from EN529

A.4.5 Compressed air for breathing apparatus (EN12021)

A.4.5.1 General

A compressor system will have produced the compressed air supplied to a breathing apparatus. The compressor system
may be used for filling individual high-pressure pressure vessels or those on a mobile trolley or to supply air direct to
breathing apparatus and other air-tools used in the workplace.

Contaminants can mix in compressed air at various stages of its production and supply. Any presence of contaminants in
acceptable quantities will render the air unsuitable as “breathable air” and can threaten the health and safety of the
respiratory protective device wearer. For this reason quality assured compressed air should be supplied to a breathing
apparatus. EN12021 stipulates the minimum quality standards for breathable compressed air and includes the levels for
oxygen, carbon monoxide, carbon dioxide, lubricants, water and other types of contaminant and odour.

A.4.5.2 Compressor system

A.4.5.2.1 General

A competent person should be consulted when planning or installing a compressed air system for producing breathable
air. This will help to minimise problems associated with compressors and the down stream effects on the quality of the
air supplied. Table A.2 provides a summary of the main elements associated with a compressor system for producing
breathable air. In addition to the careful and installation of the system it should be maintained by a competent person
to ensure the safe operation of the system.

The compressor should be installed in an area providing sufficient space on all side to ensure good ventilation. The area
should be cool as possible but avoid place where freezing is possible. The air intake point should be located in open air
and away from potential contaminants (e.g. not close to ventilation outlets or in down stream of the outlets or near
vehicle exhaust emission points).

A.4.5.2.2 Air purification elements

The air purification elements should be placed in the correct sequence to ensure the delivery of acceptable quality
breathing air. These purification elements should be replaced in accordance with the advice provided by the competent
person and the manufacturers of these elements.

A.4.5.2.3 Testing and inspection

The volume flow and quality of the supplied air should be thoroughly tested as specified by a competent person after
risk assessment.

Permission to reproduce extracts of EN529 is granted by BSI. British Standards can be obtained from BSI Customer
Services, 389 Chiswick High Road, London W4 4AL. Tel: +44 (0)20 8996 9001. email: cservices@bsi-global.com

Contains public sector information licensed under the Open Government Licence v3.0

34
 COSHH L5 (Sixth Edition 2013)
EXTRACTS FROM CODE OF PRACTICE RELATING TO

RESPIRATORY PROTECTIVE EQUIPMENT (RPE)

178. The maintenance, examination and tests should be in accordance with the manufacturer's instructions.
Examinations should comprise a thorough visual examination of all parts of the respirator or breathing
apparatus, to ensure that all parts are present, correctly fltted, and the equipment is in good working order. In
particular, the examination should ensure that the straps, facepieces, filters and

valves are sound and in good working condition. For powered and power-assisted respirators, tests should:

• be made on the condition and efficiency of those parts;

• ensure that the battery pack is in good condition;

• ensure that the respirator delivers at least the manufacturer's recommended minimum volume flow rate.

179. For RPE incorporating compressed gas cylinders, tests should include the condition and efficiency of all
parts, the pressure in the cylinders and the volume flow rate. Frequency of examination and tests

180. The quality of the air supplied to a breathing apparatus should be tested at suitable intervals, depending
on the task and the frequency of use. When the air supply is from mobile compressors, the employer should
ensure that wherever a compressor is located, the quality of air it supplies is not compromised by nearby
contaminants. In every case, the air supplied to a breathing apparatus should meet the relevant quality
standard. As it is not reasonably practicable to test for all contaminants, the risk assessment made under
regulation 6 should guide what other contaminants will require testing.

181. Thorough maintenance examinations and, where appropriate, tests of items of RPE, other than one-shift
disposable respirators, should be made at suitable intervals. The frequency should increase where the health
risks and conditions of exposure are particularly severe.

182. In situations where respirators are used only occasionally, an examination and test should be made
before their next use and maintenance carried out as appropriate. The person who is responsible for
managing the maintenance of RPE should determine suitable intervals between examinations. Emergency
escape-type RPE should be examined and tested in accordance with the manufacturer's instructions.

183. Suitable arrangements should be made to ensure that no employee uses RPE which has previously been
used by another person, unless it has been thoroughly washed and cleaned in accordance with the
manufacturer's instructions.

35
Suitable records

184. The record of each thorough examination and test of RPE carried out should include:

 the name and address of the employer responsible for the RPE;
 particulars of the equipment and of the distinguishing number or mark, together with a description
sufficient to identify it, and the name of the maker;
 the date of examination and the name and signature or other acceptable means of identifying the
person carrying out the examination and test;
 the condition of the equipment and details of any defect found, including for canister or filter
respirators, the state of the canister and the condition of the filter;
 for self-contained compressed air/gas breathing apparatus, the pressure of air/gas in the supply
cylinder; and
 for powered/power-assisted respirators and breathing apparatus, the volume flow rate to ensure that
they can deliver at least the manufacturer's minimum recommended flow rate.

Keeping records

185. Employers may keep records in any format, eg on paper or electronically. Records should be kept readily
accessible and retrievable at any reasonable time for examination by safety representatives or inspectors etc.

Accommodation for, and checking of, PPE

186. Employers should ensure that accommodation is provided for PPE so that it can be safely stored or kept
when it is not in use. The adequacy of the accommodation will vary according to the quantity, type and its
use, eg pegs, (labelled) lockers, shelves or containers etc. The storage should be adequate to protect the PPE
from contamination, loss or damage by, for example, harmful substances, damp or sunlight. Where quantities
of PPE are stored, equipment which is ready for use should be clearly segregated from that which is awaiting
repair or maintenance. Where PPE becomes contaminated during use, and especially by biological agents, the
accommodation should be separate from any the employer provides for ordinary clothing and equipment.
Employers may also have duties under the Workplace (Health, Safety and Welfare) Regulations 1992 to
provide accommodation for PPE.14.

187. All PPE should be checked regularly to ensure that it continues to function and provide protection. The
types of checks should be suited to that item of PPE and be able to detect significant deterioration. The more
likely the performance of a particular item of PPE is to deteriorate, the more often it needs checking. Whoever
does this work should be sufficiently knowledgeable and trained to identify deterioration and significant
faults. Equipment that has deteriorated significantly or is faulty should be effectively repaired or disposed of
safely.

Reproduced from COSHH Approved Codes of Practice L5 by Factair Ltd with the permission of the Controller of
HMSO.
Contains public sector information licensed under the Open Government Licence v3.0

36
 Respiratory Protective Equipment at Work
A practical guide
HSG53 (Fourth edition, published 2013)

Dos and don’ts

Do’s Don’t’s
Always ensure the breathing apparatus is in Never place the hose inlet near to potential
good working order before putting it on, sources of contamination, eg vehicle
even when new. exhausts.
Always look after your supply hose during Never use the equipment without the waist
use – your life may depend on it. belt.
Always use all the straps provided, making Never use a light-duty airline hose where
sure they are correctly positioned and there is any potential for crushing by
adjusted. Follow the manufacturer’s vehicles or passers-by etc.
instructions.
Never keep working if the airflow rate drops
Ensure that an adequate clean air supply is or any warning devices are activated. Leave
available for all users. the work area immediately.

Ensure that the compressed air quality

meets the minimum requirements of BS EN
12021.15

Always plan your exit from the

contaminated area so you don't run out of
air.

Ensure the other PPE you need to wear is

compatible with the BA.

Appendix 3 Quality of air for breathing apparatus

Air quality
1. Air supplied to breathing apparatus (BA) should be clean and safe to breathe, whether it is
supplied via a fresh air hose or a source of compressed air.

Fresh air hose

You should securely anchor the inlet for fresh air hose BA in an area that is free of contaminant. This
can usually be achieved by siting the inlet well away from the work area (eg in free air outside the
building), and upwind of any local sources of airborne contamination (eg vehicle exhaust).

37
Compressed air
2. Compressed air for BA normally originates from a compressor system. The maintenance,
examination and testing of compressors should be carried out according to the manufacturer’s
instructions. The siting of air inlets to compressors should follow the same principles as for
fresh air hose. However, because compressors themselves can generate and concentrate a
wide range of contaminants, you should take extra care in assuring air quality.

3. As the BA wearer’s life and health depend on the air supplied by the compressor, you should
ensure that the air supplied meets the quality requirements in British Standard BS EN 12021
Respiratory protective devices. Compressed air for breathing apparatus,* in addition to the
pressure and airflow rate requirements of the BA manufacturer.

4. Compressors which are moved from site to site, such as those used by the emergency services
or on construction sites, will require a higher standard of maintenance and should be sited so
that the quality of air they provide is not compromised by nearby contaminants.

* BS EN 12021 states: ‘Compressed air for breathing apparatus shall not contain any contaminants at
a concentration which can cause toxic or harmful effects. In any event all contaminants shall be kept
to as low a level as possible and shall be far below the national exposure limit. Combination effects of
more than one contaminant shall be taken into account.’ (1999)Respiratory protective equipment at
work Page 48 of 59

Periodic testing of air quality

5. The purpose of periodically testing air quality is to make sure that the control measures you
have put in place are delivering the air quality required by BS EN 12021. You should base the
frequency of such tests on a risk assessment, but they should take place at least every three
months, and more often when the quality of air cannot be assured to these levels.

6. As part of the risk assessment, if a mobile compressor is being used consideration should be
given as to how often the air supply should be checked when the compressor is moved. Testing
for these components may be carried out using any appropriate method, eg:
simple colour change tubes;
on-line gas testers;
sample collection for laboratory analysis elsewhere.

7. The supplier of your compressor or BA should be able to advise you on the best method for
you. You should keep records of air quality tests for five years.

© Crown copyright material is reproduced with the permission of the Controller of HMSO and Queen’s Printer
for Scotland.

Source Acknowledgement:
HSG53 Respiratory Protective Equipment at Work ISBN 978 0717 6454 2 Health and Safety Executive 2013
Contains public sector information licensed under the Open Government Licence v3.0

38
Appendix 6 - Medical Air Standards

HTM02-01
Medical & Surgical Air Dental Air Synthetic Air
Oil ≤ 0.1 mg/m3 ≤ 0.1 mg/m3

Water ≤ 67 vpm (≤ 0.05 mg/L, ≤ 1020 vpm (≤ 0.78 mg/L, ≤ 67 vpm (≤ 0.05 mg/L,
50mg/m3, atmospheric 78mg/m3, atmospheric 50mg/m3, atmospheric
dewpoint -46°C) dewpoint -20°C) dewpoint -46°C)
Carbon ≤ 5 mg/m3 ≤ 5 PPM v/v 3
≤ 5 mg/m ≤ 5 PPM v/v
Monoxide
Carbon ≤ 900 mg/m3 ≤ 500 PPM ≤ 900 mg/m3 ≤ 500 PPM v/v
Dioxide v/v
Carbon ≤ 5 PPM ≤ 10 PPM
Monoxide
NO and ≤ 2 PPM v/v ≤ 2 PPM v/v
NO2
SO2 ≤ 1 PPM v/v ≤ 1 PPM v/v
Polytest No discoloration No discoloration No discoloration
(Optional)
Odour None None
Note – There is also a requirement to conduct a visual particulate test and this should be free from
visible particles in a 75 L sample (175 L for surgical air)
Above is an extract only for full details refer to the HTM02-01 standard.

European Pharmacopoeia 5.0

Air, Medicinal N2O CO2 N2
Oxygen 20.4% v/v to 21.4% v/v
Oil ≤ 0.1 mg/m3

Water ≤ 67 vpm (≤ 0.05 mg/L, ≤ 60 vpm (≤ 0.45 ≤ 60 vpm (≤ 0.45 ≤ 60 vpm (≤ 0.45
50mg/m3, atmospheric mg/m3) mg/m3) mg/m3)
dewpoint -46°C)
Carbon ≤ 5 PPM v/v ≤ 5 PPM v/v ≤ 5 PPM v/v
Monoxide
Carbon ≤ 500 PPM v/v ≤ 300 PPM v/v ≤ 300 PPM v/v
Dioxide
Carbon ≤ 5 PPM v/v ≤ 5 PPM v/v ≤ 5 PPM v/v
Monoxide
NO and ≤ 2 PPM v/v ≤ 2 PPM v/v ≤ 2 PPM v/v
NO2
SO2 ≤ 1 PPM v/v ≤ 2 PPM v/v
H2S ≤ 1 PPM v/v
Odour None

39
Water – mg/m3 to PPM v/v Conversion Charts

40
 Factair Ltd
49 Boss Hall Road
Ipswich
Suffolk
IP1 5BN
UK

Tel Sales: +44 (0) 1473 746400

Tel Hire: +44 (0) 1473 746444
Fax: +44 (0) 1473 747123

Email: enquiries@factair.co.uk
www.factair.co.uk

41