8030 8038 PortaCountPro Manual 6001868

PORTACOUNT® PRO 8030 AND
PORTACOUNT® PRO+ 8038

RESPIRATOR FIT TESTERS
OPERATION AND SERVICE MANUAL
P/N 6001868, REVISION P

MARCH 2015
Copyright©
TSI Incorporated / 2008-2015 / All rights reserved.
Part Number
6001868 / Revision P / March 2015
Address
TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA
Fax No.
(651) 490-3824
LIMITATION OF WARRANTY AND LIABILITY (effective February 2015)
(For country-specific terms and conditions outside of the USA, please visit www.tsi.com.)
Seller warrants the goods, excluding software, sold hereunder, under normal use and
service as described in the operator's manual, to be free from defects in workmanship and
material for 24 months, or if less, the length of time specified in the operator's manual,
from the date of shipment to the customer. This warranty period is inclusive of any
statutory warranty. This limited warranty is subject to the following exclusions and
exceptions:
a. Hot-wire or hot-film sensors used with research anemometers, and certain other
components when indicated in specifications, are warranted for 90 days from the date
of shipment;
b. Pumps are warranted for hours of operation as set forth in product or operator’s
manuals;
c. Parts repaired or replaced as a result of repair services are warranted to be free from
defects in workmanship and material, under normal use, for 90 days from the date of
shipment;
d. Seller does not provide any warranty on finished goods manufactured by others or on
any fuses, batteries or other consumable materials. Only the original manufacturer's
warranty applies;
e. This warranty does not cover calibration requirements, and seller warrants only that
the instrument or product is properly calibrated at the time of its manufacture.
Instruments returned for calibration are not covered by this warranty;
f. This warranty is VOID if the instrument is opened by anyone other than a factory
authorized service center with the one exception where requirements set forth in the
manual allow an operator to replace consumables or perform recommended cleaning;
g. This warranty is VOID if the product has been misused, neglected, subjected to
accidental or intentional damage, or is not properly installed, maintained, or cleaned
according to the requirements of the manual. Unless specifically authorized in a
separate writing by Seller, Seller makes no warranty with respect to, and shall have no
liability in connection with, goods which are incorporated into other products or
equipment, or which are modified by any person other than Seller.
The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS
stated herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR
PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE. WITH RESPECT TO
SELLER’S BREACH OF THE IMPLIED WARRANTY AGAINST INFRINGEMENT, SAID
WARRANTY IS LIMITED TO CLAIMS OF DIRECT INFRINGEMENT AND EXCLUDES
CLAIMS OF CONTRIBUTORY OR INDUCED INFRINGEMENTS. BUYER’S
EXCLUSIVE REMEDY SHALL BE THE RETURN OF THE PURCHASE PRICE
DISCOUNTED FOR REASONABLE WEAR AND TEAR OR AT SELLER’S OPTION
REPLACEMENT OF THE GOODS WITH NON-INFRINGING GOODS.
TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR
BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES,
INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED
ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL
i
BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE
PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE
GOODS. IN THE CASE OF SOFTWARE, SELLER WILL REPAIR OR REPLACE
DEFECTIVE SOFTWARE OR IF UNABLE TO DO SO, WILL REFUND THE PURCHASE
PRICE OF THE SOFTWARE. IN NO EVENT SHALL SELLER BE LIABLE FOR LOST
PROFITS, BUSINESS INTERRUPTION, OR ANY SPECIAL, INDIRECT,
CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE
RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS
OR CHARGES. No Action, regardless of form, may be brought against Seller more than
12 months after a cause of action has accrued. The goods returned under warranty to
Seller's factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk
of loss.
Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY
AND LIABILITY, which contains the complete and exclusive limited warranty of Seller.
This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its
terms waived, except by writing signed by an Officer of Seller.
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.
WARNING
This instrument contains (1) non-rechargeable Lithium
battery which is not user serviceable. Return to factory
for replacement.
Disclaimer: The measurement provided by the PortaCount Pro Respirator Fit Tester
is an assessment of respirator fit during a fit test only. Respirator fit at
other times will vary. The fit factor value is not intended for use in
calculating an individual's actual exposure to hazardous substances.
Patents
®
Model 8038 PortaCount Pro+ Respirator Fit Tester is patented under U.S. Patent No.
6,125,845.
Trademarks
TSI, TSI logo, and PortaCount are registered trademarks of TSI Incorporated. FitPro+
and N95-Companion are trademarks of TSI Incorporated.
Service Policy
Knowing that inoperative or defective instruments are as detrimental to TSI as they are
to our customers, our service policy is designed to give prompt attention to any
problems. If any malfunction is discovered, please contact your nearest sales office or
representative, or call TSI's Customer Service department at (800) 874-2811 (USA) or
(001 651) 490-2811 (International) or visit www.tsi.com.
ii
Contents
Contents ....................................................................................................... iii
Introduction and Overview .......................................................................... 1
Database Operation When Operating in Stand-Alone Demo Mode......... 1
Registration ............................................................................................. 1
Why Fit Test ............................................................................................ 2
Preparations for Fit Testing ..................................................................... 2
Precautions for Fit Testing ....................................................................... 3
Chapter 1 Unpack and Verify Shipment ..................................................... 5
Chapter 2 Getting to Know the PortaCount Pro Respirator Fit Tester .... 7
The Touch Screen Display ...................................................................... 7
Sampling Ports ........................................................................................ 8
Electrical Connections ............................................................................. 9
Alcohol Related Parts ............................................................................ 11
Miscellaneous Parts .............................................................................. 12
Chapter 3 About Respirators and Fit Testing.......................................... 17
Probed Test Respirators ........................................................................ 17
Probes for Filtering-Facepiece (Disposable) Respirators ...................... 19
Inserting a Test Probe in a Disposable Respirator with the TSI
Model 8025-N95 Probe Kit................................................................. 19
Positive Pressure Respirators ............................................................... 23
Chapter 4 Conducting a Fit Test with the PortaCount Pro
Respirator Fit Tester ........................................................................... 25
Step 1—Prepare the PortaCount Pro Respirator Fit Tester for
Fit Testing .......................................................................................... 26
Step 2—Attach Flash Drive and Select Database (optional) ................. 29
Step 3—Run Daily Checks .................................................................... 30
Step 4—Conducting Fit Tests ................................................................ 32
Step 5—Record Results ........................................................................ 39
Step 6—Using a Printer with the PortaCount Pro Fit Tester .................. 41
Step 7—Stand-Alone Fit Testing—Data Handling Best Practices ......... 43
Step 8—Advanced Database Tools....................................................... 44
Chapter 5 Operating Modes and User Interface ...................................... 47
Modes of Operation ............................................................................... 47
User Interface ........................................................................................ 48
New Exercise Name .............................................................................. 55
Chapter 6 Service and Maintenance ........................................................ 61
Recalibration Interval ............................................................................. 61
Status Messages ................................................................................... 61
iii
Reordering Supplies ............................................................................... 62
Shipping & Storage Precautions ............................................................ 63
Changing the Alcohol Wick .................................................................... 63
Nozzle Cleaning ..................................................................................... 66
Chapter 7 Troubleshooting........................................................................ 69
On-line Troubleshooting Guides ............................................................. 69
Appendix A Specifications ........................................................................ 77
Flow Rate ............................................................................................... 78
Appendix B Theory of Operation .............................................................. 81
How the PortaCount Pro Respirator Fit Tester Works ............................ 81
How the PortaCount Pro Fit Tester Counts Particles ............................. 82
Appendix C Calculating Fit Factor ............................................................ 85
Appendix D Calculating Particle Concentration ...................................... 87
Appendix E Timing in Fit Test Mode ......................................................... 89
Appendix F Using the PortaCount® Pro Respirator Fit Tester to
Fit Test Positive Pressure Respirators ............................................... 91
Appendix G The Rainbow Passage .......................................................... 95
Index ........................................................................................................ 97
iv
Introduction and Overview
This manual describes both the Model 8030 PortaCount® Pro and
8038 PortaCount® Pro+ Respirator Fit Tester hardware and operation
of the tester without the use of FitPro+™ Fit Test Software.
The Model 8030 is designed to measure fit factors of masks with an

efficiency of 99% or greater. The Model 8038 includes N95-
Companion™ technology, which lets you measure any tight-fitting
respirator including N95, P2, and P1 disposables.
Regardless of whether you intend to use the PortaCount Pro

Respirator Fit Tester with or without the FitPro+ Fit Test software,
become familiar with this manual first. Many of the details in this
manual that concern PortaCount Pro fit test operations are not
repeated in the FitPro+ Fit Test Software Manual.
Database Operation When Operating in Stand-Alone

Demo Mode
The PortaCount Pro Respirator Fit Tester has an on-board (Demo-
Training) database that lets you perform all available operations,
including adding data. Any changes you make to this Demo-Training
database, however, are lost when you power off the PortaCount Pro
fit tester, unless you manually save them using the new Advanced
Database Tools (introduced in firmware version 2.0).
To save fit test results or other data when using the PortaCount Pro
Respirator Fit Tester in stand-alone mode (not controlled by the
FitPro+ Fit Test Software), you must have a USB flash drive
containing a valid database attached to one of the USB ports. (See
the FitPro+ Fit Test Software User Manual for instructions on how to
configure the USB flash drive.)
Registration
Please fill out and mail the registration card that came with your
instrument or register it online at http://register.tsi.com. You may re-
register at any time to update our records. You will need your
instrument model number and serial number.
Registration allows TSI to keep in touch with you regarding important

information concerning the TSI instrument(s) and software you own.
1
Why Fit Test
There are two primary reasons for respirator fit testing:
 Verification of Training. After the individual has received
respirator training, a fit test checks that the person has learned
how to properly put on and wear a respirator without assistance.
 Sizing. It is important to make sure that the individual is issued a
respirator that is capable of providing protection when worn
properly, that is, it is the right size.
Preparations for Fit Testing

Training the The person conducting the fit test must have a
Trainer clear understanding of respiratory protection,
respirators, and fit testing to be effective. Anyone
can master the operation of the PortaCount Pro
Respirator Fit Tester simply by studying this
manual, but the background knowledge required
to proficiently fit test cannot be obtained from
here. Consider attending a one-, two- or three-
day seminar on fit testing provided by various
consultants. Contact TSI for references.
Respirator Respirator training is critical for any respiratory
Training protection program. All employees who wear
respirators must be taught how and why they are
used. This training should be done prior to the fit
test, not during the fit test. Consult the
regulations or standards that pertain to your
industry for information on training requirements.
The PortaCount Pro Respirator Fit Tester
includes a Real-time Fit Factor display that
allows you to see the results of changes he or
she makes to the mask.
2 Introduction and Overview

Precautions for Fit Testing
The following is a discussion of several precautions to consider prior
to conducting a fit test:
Fit Testing Smokers exhale particles for at least 30 minutes
People Who after they have smoked a cigarette or cigar. The
Smoke PortaCount Pro fit tester can count these particles
Cigarettes or and will interpret them as if they were caused by
Cigars 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 The PortaCount Pro fit tester is designed to operate
with using the microscopic particles in the ambient air. It
Generated can measure particle concentrations and fit factors
Aerosols when generated aerosols (like corn oil, salt or
DOP) are used; however, these aerosols may
cause the PortaCount Pro fit tester to need more
frequent cleaning and calibration.
Fit Testing Do not conduct fit tests in close proximity to
Near Irritant sources of irritant smoke like those used for
Smoke qualitative fit testing. The irritant smoke is corrosive
and can damage the PortaCount Pro Respirator Fit
Tester. Fit testing near sources of amyl-acetate
(banana oil) is not a problem.
The TSI Web site http://fittest.tsi.com contains additional useful

resources.
Disclaimer: The measurement provided by the PortaCount Pro

Respirator Fit Tester is an assessment of respirator fit
during a fit test only. Respirator fit at other times will
vary. The fit factor value is not intended for use in
calculating an individual's actual exposure to hazardous
substances.
Introduction and Overview 3

(This page intentionally left blank)
4 Introduction and Overview

Chapter 1
Unpack and Verify Shipment

The following items are included with the PortaCount® Pro/Pro+
Respirator Fit Tester. If any are missing or damaged, please notify
TSI immediately. Refer to Chapter 2 for photos and descriptions of
each item.
Standard Items PortaCount Pro/Pro+ Fit Tester

(Models 8030 and 8038)
Qty Description 
1 PortaCount Pro Respirator Fit Tester Model 8030/8038
1 Stylus
1 Alcohol Cartridge
1 Alcohol Fill Capsule
1 Storage Cap
2 Zero Check Filter
2 Spare Alcohol Wicks
1 5 ft (1.5 m) Twin Tube Assembly
1 1/8 to 3/16 Tube Adapter
1 1/8 to 1/4 Tube Adapter
1 AC Adapter
5
Standard Items PortaCount Pro/Pro+ Fit Tester
(Models 8030 and 8038)
Qty Description 
16 30 ml Alcohol Bottles (480 ml total)
1 PortaCount Pro/Pro+ Respirator Fit Tester Quick Start Guide
1 Carrying Case
1 FitPro+ Fit Test Software CD and case
1 USB Cable
1 USB Flash Drive
Additional Items PortaCount PRO+ Fit Tester (Model 8038 only)

Qty Description 
1 Probe Assembly Tool
1 Probe Kit (100 pieces)
1 Neck Strap
1 Package of 100 Salt Tablets (100 mg)
1 Model 8026 Particle Generator Operation and Service Manual
6 Chapter 1
Chapter 2
Getting to Know the PortaCount Pro

Respirator Fit Tester
Use the numbered paragraphs and correspondingly numbered arrows
to identify the touch screen display, connectors, parts, and
accessories of the PortaCount® Pro fit tester. You need to be familiar
with these items when following the instructions in this manual.
The Touch Screen Display

The touch screen display provides the interface to all operations.
Select items on the touch screen using your finger or the stylus that is
provided. Do not use a pen, pencil or other sharp instrument, as this
may damage the screen.
Stylus
On/Off
Button
7
Sampling Ports
Sampling ports permit air to flow into and out of the PortaCount Pro
fit tester.
2 1
1 The Sample Port is used when sampling air from a respirator

during a fit test. The clear tube marked "SAMPLE" of the Twin
Tube Assembly (3) connects here. The Sample Port fitting is
silver and marked with the letter "S".
2 The Ambient Port is used to sample ambient air during a fit test.
The blue tube marked "AMBIENT" of the Twin Tube Assembly (3)
connects here. The Ambient Port fitting is blue and marked with
the letter "A".
3 The Twin Tube Assembly consists of a pair of tubes: the Sample
Tube and the Ambient Tube. The Twin Tube Assembly is about
5.5 feet (1.7 meters) long. The Sample Tube is 7 inches (18 cm)
longer than the Ambient Tube.
The Twin Tube must not be lengthened except for the few inches
added by a Tube Adapter. Never split the ambient and sample
tube, they must remain together and the two sample tubes must
be nearly the same length for accurate fit testing.
8 Chapter 2
Electrical Connections
4 5 6
4 The USB Series “B” receptacle provides for communication

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

7
7 The AC Adapter plugs into the External Power Connector on the

PortaCount Pro fit tester and an AC wall outlet. The AC Adapter
senses the input voltage automatically.
10 Chapter 2
Alcohol Related Parts
12
13
8
10
11
8 The Alcohol Cartridge holds the isopropyl alcohol consumed by

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

Miscellaneous Parts
14 The Spare Sampling Port Inlet Screens are used to help keep the
PortaCount Pro fit tester internal flow path clean by capturing
large or fibrous particles.
15 Two Tube Adapters are shipped with each PortaCount Pro fit
tester. The adapters are used to connect the Sample Tube to a
respirator sample fitting (or probe) that is larger than the 1/8 inch
12 Chapter 2
(3 mm) inside diameter of the Sample Tube. One of the Tube
Adapters fits 3/16 inch (4.7 mm) fittings and the other fits 1/4 inch
(6.3 mm) fittings. An adapter is not needed for respirators
equipped with a 1/8 inch (3 mm) fitting.
16 The Zero Check Filter is provided for the Zero Check and Max Fit
Factor Check on the PortaCount Pro fit tester to make sure it is
working properly. A spare filter is also provided.
Note
TSI recommends that the Zero Check Filter be left attached to
the sample line whenever the PortaCount Pro fit tester is turned
on but not in use. This prevents lint and debris from being drawn
into the instrument and blocking the airflow.
17 The PortaCount Pro/Pro+ Respirator Fit Tester Quick Start Guide.
18 The Compact Disc (CD) contains FitPro+™ Fit Test Software for
Windows in addition to manuals and other information related to
TSI fit testing products and fit testing in general. There is no
printed FitPro+ software manual in lieu of the online help. Visit the
TSI Web site http://fittest.tsi.com to download the current version
of most TSI manuals. The CD is located in a convenient storage
case.
19 The Carrying Case provides protection and convenience. The
case is designed to hold the PortaCount Pro fit tester and
standard accessories.
20 The USB Cable is used to connect the PortaCount Pro fit tester to
a computer. It is needed whenever the FitPro+ Software is used
to interface and control the PortaCount Pro fit tester.
21 The USB Flash Drive holds active databases and lets you select
and use the active database in the PortaCount Pro fit tester in
stand-alone mode. Without a flash drive, you cannot store
information and test data collected or updated when using the
PortaCount Pro fit tester in stand-alone mode. The flash drive is
used to exchange database data between the PortaCount Pro fit
tester and the FitPro+ software. (See the FitPro+ Fit Test
Software User Manual for instructions on how to configure the
USB flash drive.)

Additional Items (Model 8038 only)
22 The Probe Assembly Tool is
used to install the sampling
probes in filtering-facepiece
(disposable) respirators. 22
23 The Probe Kit includes 100
disposable probes.
23
24 The Neck Strap supports the
Twin Tube assembly when
sampling running fit tests on
filtering-facepiece (disposable)
respirators.
24
25
25 Model 8026 Particle Generator. If you do not have the minimum

ambient particle concentration needed for the PortaCount Pro fit
tester to do a fit test, this optional particle generator supplements
naturally occurring room concentration with non-toxic salt (NaCl)
particles in the appropriate size range for the PortaCount Pro fit
tester. Refer to the Model 8026 Particle Generator information on
the TSI Web site http://software.tsi.com.
14 Chapter 2
Important Considerations
 Keep the Particle Generator or any other sources of particle

generation at least 6 feet away from the PortaCount Pro fit
tester during operations.
 For the Particle Generator to function properly, you must
operate the generator and conduct the fit tests in an enclosed
area. A room smaller than 400 sq. ft. would provide the best
conditions. Particle generation will not function as efficiently in
an open cubicle area or a very large room.
 Use the Particle Generator and other forms of particle
generation sparingly, when needed. Often they are only
needed in the morning hours or at the beginning of fit testing.
Do not operate any form of particle generation if ambient
particle concentrations are above 8,000 particles/cm3 for the
Model 8030 or 8038 when testing masks with 99% efficiencies
or greater, or above 800 pt/cc for the Model 8038 when testing
masks with <99% efficiencies.

16 Chapter 2
Chapter 3
About Respirators and Fit Testing

The conventional way to quantitatively fit test is through the use of
probed test respirators, but fit tests can also be performed on
disposable respirators and positive pressure respirators. This chapter
discusses the types of respirators and provides instructions on
installing a sampling port to a disposable filtering-facepiece.
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® Pro fit tester. 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, issue the individual 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 do not already stock them. Class-100, class-99,
or P3 filters must be used for fit testing even if you use another type
of cartridge in the workplace.
17
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.
Adapter’s
To PORTACOUNT PRO Inhalation
Valve Sample Inlet
Class-100 Filter Sample Tube Cap Suction Cup

Cartridge Sampling
Adapter
Respirator Manufacturers' Technique

There are 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 this option be avoided 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.
18 Chapter 3
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 Pro Model 8030 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 PortaCount Pro+ Model 8038.
Inserting a Test Probe in a Disposable Respirator with

the TSI Model 8025-N95 Probe Kit
To perform a quantitative fit test, the PortaCount Pro fit tester must
draw an air sample from inside the respirator while it is being worn by
the person being fit tested. The tools, sampling probes and push nuts
contained in the probe kit lets you install a sampling port onto any
disposable filtering-facepiece respirator.
WARNING
Once a sampling probe has been installed, the respirator
cannot be used for respiratory protection. Ported
respirators are for quantitative fit testing only. Discard (or
sanitize) the respirator after each fit test is completed.
(Follow the respirator manufacturer’s recommendations.)
1. Choose a location to install the sample probe.
For proper fit testing, the sampling point must be in the “breathing
zone” of the respirator user. For most respirators, this is in the
center of the respirator between the person’s nose and mouth.
About Respirators and Fit Testing 19

For flat “duckbill” style respirators, install the probe near the
outer edge of the bottom panel where it cannot be blocked by
the person’s chin.
Bottom panel shown
For respirators with center-mounted exhalation valves, install

the probe to the left or right of the valve. Do not install the probe
above or below the valve because this risks having the probe
blocked by the person’s nose or chin.
Correct probe location to left

(or right) of valve
Wrong probe location

below (or above) valve
20 Chapter 3
For respirators with an outer mesh, install the probe normally
as if the mesh was not present. The sampling probe and push nut
will seal properly right through the mesh.
2. Slide the sampling probe onto the piercing tool. As the pointed
end of the piercing tool is very sharp, be extremely careful
when handling it!
Sampling Probe
3. Choose a location on the mask that is in front of the person's

nose/mouth region. Avoid seams and folds in the mask.
4. Pierce the mask at the selected location, using the piercing tool
with the loaded sampling probe. Be sure to pierce the mask
from the inside!

Push Nut
Positioned on
Anvil Tool
Sampling Probe
Pushed Through
Mask
5. Push the sampling probe through the mask until the end of the
tool point is visible from the outside of the mask. Leave a few
millimeters of the tool point visible.
6. Place the push nut on the anvil tool with the "dished" side up. A
magnet prevents the push nut from falling off.
7. Position the anvil tool, with the loaded push nut, over the
protruding point. The mask should now be pinched between the
two tools.
8. Press the two tools firmly together to force the push nut as far as
possible onto the probe. The mask material should be tightly
pinched and the mask, sampling probe, and push nut should be
joined together as illustrated.
Push the Tools

Together to
Fasten the
Probes
22 Chapter 3
9. Inspect the sampling probe to be sure it is not plugged. Try to
rotate the probe with your fingers. If it moves freely, use the probe
insertion tool kit to press the push nut firmly onto the sampling
probe and pinch the mask material more tightly.
Correctly
Positioned
Sampling Probe
Note
Once a sampling probe is installed into a disposable mask, the
mask cannot be used for respiratory protection. Probed masks
are to be used for quantitative fit testing only. Discard each
probed disposable mask after a fit test is completed.
Positive Pressure Respirators

Refer to Appendix F for a discussion on Fit Testing positive pressure
respirators with the PortaCount Pro Respirator Fit Tester.

24 Chapter 3
Chapter 4
Conducting a Fit Test with the PortaCount Pro

Respirator Fit Tester
This chapter describes how to use the PortaCount® Pro fit tester as a
stand-alone instrument to conduct a quantitative respirator fit test.
Learn to operate the PortaCount Pro fit tester in this manner even if
you plan to use the FitPro+™ software. After becoming familiar with
manual operation, to automate fit testing with a computer and the fit
test software, refer to the FitPro+ software online help for
detailed instructions.
Note
The PortaCount Pro Respirator Fit Tester has an on-board
Demo database that lets you perform all available operations,
including adding data. However, any changes you make to this
Demo database are lost when the PortaCount Pro fit tester Is
powered off and must be manually recorded if a permanent
record is desired.
To save fit test results or other data when using the PortaCount
Pro Respirator Fit Tester in Stand-Alone mode (not controlled by
the FitPro+ Fit Test Software), a flash drive containing a valid
database must be attached to one of the USB ports.
The fit test procedure1 is broken down into the following steps.
1. Prepare the PortaCount Pro Respirator Fit Tester for testing by
filling the Alcohol Cartridge.
2. Attach a flash drive and select a database (optional). If a
database is not selected from the flash drive, the Demo database
is used by default.
3. Run daily checks.
4. Conducting fit tests.
1
The 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.
25
5. Record the results.
6. Using a Printer with the PortaCount Fit Tester.
7. Stand-Alone Fit Testing.
8. Advanced Database Tools.
Step 1—Prepare the PortaCount Pro Respirator Fit

Tester for Fit Testing
Follow the steps below to setup the PortaCount Pro fit tester for fit
testing without using the FitPro+ Fit Test Software (stand-alone
mode).
Fill the Alcohol Cartridge

WARNING
Isopropyl alcohol is hazardous material. Do not ingest or
allow alcohol to contact your eyes or skin. Refer to the
Material Safety Data Sheet (MSDS) located in the box of
alcohol for handling precautions and first aid
procedures.
Always recap alcohol fill capsule and other containers
immediately to prevent absorption of moisture and the
escape of alcohol vapors.
Dispose of any alcohol with visible contamination.
Because the Alcohol Cartridge is inserted into the Cartridge Cavity of

the instrument, it is critically important to keep it clean. Any dirt or
debris that gets into the PortaCount Pro fit tester can plug the small
internal nozzle and prevent operation. Do not allow the black part of
the Alcohol Cartridge to make contact with any surface that may be
dirty. Keep the storage cap and alcohol cartridge clean.
Maintaining an adequate alcohol supply inside the PortaCount Pro fit

tester is critical to its operation and requires strict adherence to the
directions that follow.
1. Make sure the PortaCount Pro fit tester is turned off.
2. Remove the Alcohol Cartridge from the PortaCount Pro fit tester
by twisting it counter-clockwise.
3. Open the Alcohol Fill Capsule by twisting the Storage Cap off
(counter-clockwise).
26 Chapter 4
4. Set the Storage Cap and Alcohol Cartridge down on a clean
surface to prevent contamination.
5. Open a bottle of alcohol. Invert the bottle and insert the nozzle
end into the Alcohol Fill Capsule as far as possible to make
certain alcohol is not inadvertently sprayed anywhere except into
the Capsule.
Fill Line
6. Squeeze alcohol into the Alcohol Fill Capsule until it is even with
or slightly above the fill-line.
7. Recap the alcohol bottle immediately.
Conducting a Fit Test with the PortaCount Pro Respirator Fit Tester 27
8. Make certain the alcohol cartridge is clean. If it has been
contaminated, refer to the Service and Maintenance chapter and
follow the instructions to replace it. If it is clean, insert the Alcohol
Cartridge into the Alcohol Fill Capsule and turn the capsule
clockwise until it locks in place.
9. Set the Alcohol Fill Capsule down and wait at least 2 minutes
while the alcohol wick inside the Alcohol Cartridge soaks up
alcohol.
10. Remove the Alcohol Cartridge from the Capsule and gently shake
it to allow excess alcohol to drip back into the Alcohol Fill
Capsule. Stop when excess alcohol is no longer dripping; it is not
necessary to wait until the outside surface of the Alcohol
Cartridge is dry.
11. Insert the Alcohol Cartridge into the Cartridge Cavity of the
PortaCount Pro Respirator Fit Tester. It should slide in with little
effort. DO NOT FORCE IT (see Note below). As you approach full
insertion, firmly twist the Alcohol Cartridge clockwise until it locks
into position.
28 Chapter 4
12. Recap the alcohol fill capsule with the storage cap.
Remember: Always recap alcohol fill capsule and other

containers immediately to prevent absorption of moisture and the
escape of alcohol vapors.
Note
Always store the Alcohol Cartridge in the Alcohol Fill Capsule.
The Alcohol Fill Capsule is designed to be a safe transportation
and storage container for alcohol. The Alcohol Cartridge can be
left soaking in alcohol indefinitely. Install the Storage Cap into
the Cartridge Cavity to prevent dirt or lint from getting inside the
Step 2—Attach Flash Drive and Select Database

(optional)
To save fit test results or other data when using the PortaCount Pro
Respirator Fit Tester in stand-alone mode, you must have a flash
drive containing a valid database in the root directory attached to one
of the USB ports.
1. Using the FitPro+ software, load the database or databases you
want to use onto the flash drive. (See the FitPro+ Fit Test
Software User Manual for instructions on how to configure the
USB flash drive.)
2. Insert the flash drive into one of the USB ports of the PortaCount
Pro fit tester.
3. Press the Database tab.
4. Press Select Database icon.
5. Select the database you want to use as the active database and
press Load.
6. When the database is loaded, select Done. The database you
selected is now the active database and will remain the active
database until you select another one or remove the flash drive.
Step 3—Run Daily Checks

TSI recommends maintenance checks be performed once each day
before the PortaCount Pro Respirator Fit Tester is used and
whenever a problem is encountered.
These daily checks are:

 Particle Check
 Classifier Check (only for the PortaCount Pro+ 8038 with
N95 enabled)
 Zero Check
 Max Fit Factor Check
Completed daily checks provide confidence that the PortaCount Pro

fit tester is working properly. Failure of any of the daily checks
requires immediate attention. See Troubleshooting chapter. If the
PortaCount Pro Respirator Fit Tester passes the daily checks, and
you have difficulty fit testing, the problem is probably NOT in the
PortaCount Pro fit tester. Examine the respirator carefully for leaks or
pinched tubes.
To start the daily checks:

1. Connect the AC Adapter to the instrument and turn on the
PortaCount Pro fit tester using the O/I button. The PortaCount
Pro fit tester goes through a warm-up period before it is ready to
use.
30 Chapter 4
2. From the Activities Tab, select the Daily Checks icon [ ].
3. Press Yes with the stylus or your finger tip, and follow the
directions on the screen.
4. If you are using a PortaCount Pro+ 8038 and plan to fit test
respirators that are less than 99% efficiency, select the “N95
Enabled” box. This test is only necessary if you will be testing
disposable masks with efficiency less than 99% (such as class
95, P2, and P1 respirators)."
5. Click Settings if you want to change or view the Daily Check
settings, then Save or Cancel to return to the Test Status dialog.
Caution
Changing the Daily Checks settings is not
recommended. Factory settings are optimal.
6. As instructed on the display, remove the HEPA filter or mask (if

one is attached to the sample intake hose) and press START.
The first check is the Particle Check, which determines if the
PortaCount Pro fit tester is working and if the concentration of
particles in the ambient air is sufficient to conduct fit testing.
When the test begins, progress is shown in the “Test Status” box
on the screen. For the Model 8030, the Particle Check passes if
the particle concentration is 1000 or above, and fails if the particle
concentration is below 1000. For the Model 8038, the Particle
Check passes if the particle concentration is 30 or above, and
fails if the particle concentration is below 30. If the test fails, refer
to the Troubleshooting chapter.
7. If the “N95 enabled” box is selected, the Particle Check is
immediately followed by the Classifier Check. The Classifier
Check verifies the classifier is functioning properly.
8. The next check is the Zero Check, which provides assurance that
there are no leaks in the system. As instructed on the touch
screen, attach the Zero Check filter to the clear Sample Tube and
press START. The test begins. The particle concentration should
drop to zero (0.00) in less than 30 seconds. An occasional value
of 0.60 or 1.20 is acceptable, but it should read 0.00 most of the
time. If the Zero Check fails, see the Troubleshooting chapter. By
default for the model 8030 and 8038, the Zero Check passes if
the particles counted individually over 30 seconds do not exceed
a total of 30. If the PortaCount Pro fit tester fails the Zero Check,
any fit tests you conduct may result in lower fit factors than would
be measured otherwise. The risk is that you may fail people who
have good fits, thereby wasting time and effort. There is no
possibility that failing the Zero Check could result in overstated fit
factors. This is because any particles leaking into the PortaCount
Pro fit tester are interpreted as mask leakage, resulting in lower fit
factors.
9. The Max Fit Factor Check is after the Zero Check. This check
determines if the PortaCount Pro is capable of measuring high fit
factors and if the internal switching valve is functioning properly.
The test is essentially a fit test on a HEPA filter which simulates a
perfectly fitting respirator. A very high fit factor should result if the
instrument is working properly. The Max FF Check actually
measures the maximum fit factor that can be determined by the
PortaCount Pro fit tester given the local ambient particle
concentration and the mask sample time programmed into the
PortaCount Pro fit tester. Assuming the Zero Check Filter is
perfect, the maximum fit factor will be the local ambient particle
concentration divided by a mask concentration equivalent to one
particle during the mask sample time. When the PortaCount Pro
fit tester actually measures zero particles during the mask
sample, one particle is artificially added to prevent division by
zero when calculating the fit factor. Performing this test is futile if
there are leaks in the system. If this test fails refer to the
Troubleshooting chapter.
10. Press EXIT when the tests are complete. If the PortaCount Pro fit
tester passed all tests, proceed to Step 4 – Conducting Fit Tests.
If the instrument failed any test, refer to the Troubleshooting
chapter to resolve the problem and then run the Daily Checks
again.
Step 4—Conducting Fit Tests

1. Make sure the instrument is turned on, and the database you
want to work with has been selected (in order to save fit test
results and other information).
2. Instruct the person being tested to put on the respirator 5 minutes
before the fit test starts to purge the particles trapped inside the
respirator and permit the wearer to make certain the respirator is
comfortable. Have the subject don the mask without assistance.
Fit test results depend on the subject knowing how to properly
don the mask. Train all subjects in proper mask-donning
techniques before being fit tested. Do not allow the subject to
adjust the mask during the exercises, as this invalidates previous
results.
32 Chapter 4
If testing a disposable respirator (with the Model 8038), have the
fit-test subject hang the tubing support neck strap around his or
her neck, adjusting it to a comfortable position. Position the tubing
support neck strap so that the tubing does not pull the mask off
the person’s face. Have the person tilt his or her head up and
down, turn side to side, and bend over to see if the tubing pulls
the mask away from their face. If it does, readjust the neck strap
or the tubing and repeat check the fit again.
3. On the Activities tab, press Fit Test [ ]. The People List dialog
appears.
4. Select the person to fit test as follows:
a. If the person shown on the dialog is the one you want to fit
test, press Next to select the respirator for the fit test. Press
Next to continue.
b. If the person shown on the dialog is not the one you want to
fit test, click the arrow on the People List field to display the
names in the People Table, click on the name of the person
you want, verify the correct name is displayed then press
Next to select the respirator for the fit test.
Note
If the person you want to fit test is not in the database, press
New and create a new record by typing in the information
required. To add information, press the field you want to
enter and an on-screen keyboard appears. Use the stylus to
type the information. (Alternatively, you can plug a USB
keyboard into one of the available USB ports and enter
information using the keyboard.) When done, press Next
and confirm that you want to save the new entry and use it
for this fit test.
34 Chapter 4
5. After pressing Next, the Respirator List dialog appears.
a. If the respirator you want to use is displayed, click Next.
b. To select a different respirator, click the arrow on the
Respirator List field to display a list of all the respirators in
the database. Use the stylus to select the respirator you want
to use, click Next to continue.
Note
Respirator records to the database cannot be entered here.
If the respirator you want to use for fit tests is not in the
database, or if no records are in the database, you must exit
the Fit Test function and use the Database tab to access the
respirator database (see Chapter 5). FitPro+ software can
also be used to update the database to include the
respirator.
6. After pressing Next, the Current Protocol dialog box appears,
the mask size and operator fields are blank. These fields must be
filled in before you can continue.
7. Make certain the exercise protocol shown in the Current Protocol
field is the one you want to use. To select a different protocol,
click the arrow on the Current Protocol field to display a list of all
the Protocols in the database. Use the stylus to select the
protocol you want to use
Note
A protocol cannot be added to the database here. If the protocol
you want to use for fit tests is not in the database, or if no
records are in the database, you must exit the Fit Test function
and use the Database tab to access the protocol database (see
Chapter 5). FitPro+ software can also be used to update the
database to include the protocol.
8. Click on the Mask Size field and use the on-screen keyboard to
type in the mask size, for example: SMALL, MEDIUM, or LARGE.
Abbreviations such as S, M, or L can also be used.
9. Click on the Operator field and fill in your name or initials.
10. To change the Due Date for this person’s next fit test, click on the
down arrow and select a different date from the calendar.
11. When you have filled in this dialog, click Next to proceed.
12. After clicking Next, the Run Test: Fit Test Step 4 of 4 dialog
appears, and you are ready to begin the fit test. Before clicking
START to begin the test, verify the information at the top left of
the screen and make certain the PortaCount Pro sample tube is
connected to the respirator (Use one of the Tube Adapters if
necessary.), and ask the test subject if they are ready to begin
the exercise protocol immediately.
13. Press START. Fit testing begins immediately, and the first
exercise name appears. The elapsed exercise time also appears
as a graphic progress bar. As each exercise completes, the result
appears in the Fit Factor column. The Ambient and Mask
Concentration Values fields show the ambient and mask particle
concentrations as they are measured.
14. When a fit test starts, the PortaCount Pro Respirator Fit Tester
begins a preprogrammed test sequence, sampling alternately
from the Sample Tube and the Ambient Tube. Each exercise
includes an ambient sample, a mask sample, and then another
ambient sample. Refer to Chapter 5 for more information on
creating a new protocol with altered sampling times. Refer to the
Appendixes for technical details on exercise/sample timing,
calculating exercise fit factors, and calculating overall fit factors.
15. PortaCount Pro fit tester beeps to alert the person being tested
that it is time to begin the next exercise. The exercises proceed
one after another without pause. Exercises that pass are
highlighted in green. Exercises that fail are highlighted in red.
Have the test subject follow the exercises one after another when
prompted by the instrument. Each exercise takes approximately
60 seconds to complete.
Exercise Name Description
Normal breathing Remain still and breathe as usual.
Deep breathing Take long deep breaths as if working hard.

Do not overdo it.
Head side to side Breathe normally while slowly turning the

head from side to side. Turn far enough to
each side to stretch the neck muscles. Each
cycle from left to right should take several
seconds, pausing momentarily at each side to
take a breath.
36 Chapter 4
Exercise Name Description
Head up and down Breathe normally while slowly alternating

between looking up at the ceiling and down at
the floor. Each up and down cycle should
take several seconds.
Talking out loud Read a prepared paragraph (like the Rainbow

Passage located in Appendix G of this
manual) or count out loud to simulate the
workplace.
Grimace Grimace by smiling and/or frowning to create

a leak in the respirator face seal. This
exercise will often result in a failed fit factor,
which is why the OSHA standard allows you
to exclude that fit factor when computing the
overall fit factor. When performing the
grimace, you are intentionally creating a
break in the face seal in order to see if the
mask re-seals itself afterwards. Successful
re-sealing is proven by achieving a passing fit
factor on the next exercise.
Notes: The OSHA protocol includes special
provisions for the grimace exercise. It is
allowed to be 15 seconds long and the
resulting fit factor may be discarded
(excluded) before calculating the overall fit
factor. This is allowed because the grimace
exercise is done to intentionally break the
face seal in order to make sure the mask
reseats itself before the next exercise.
Bend and touch Bend at the waist as if you were touching

toes your toes while breathing normally.
Normal breathing Remain still and breathe as usual.
16. PortaCount Pro Respirator Fit Tester alerts you when the fit test
is complete. The PortaCount Pro fit tester beeps three times and
calculates and displays the overall fit factor for the set of
exercises. The upper section of the dialog box displays either a
pass or fail status. Pass or fail is determined by comparing the
overall fit factor to the Fit Factor Pass Level. The overall fit factor
is displayed at the lower left.
Note
In the USA, OSHA requires a minimum fit factor of 100 for half
masks and 500 for full-face masks. If necessary, consult the
appropriate regulation or standard.
 If the test was a Pass, the fit test is over. Keep a record of the
test on file if you are not using a database on the flash drive.
Also, if the fit test passed, issue that exact size and model
respirator to the test subject.
 If the fit test failed, determine the reason and repeat the test.
Some common reasons for failure are described below.
 If you are fit testing with a disposable respirator, discard it
when the fit test is complete. Probed respirators are intended
for fit testing only and are never to be reused. You may be
able to sanitize and reuse other types of respirators. Contact
the respirator manufacturer for specific information.
 If the fit test is terminated before the last exercise is
completed (by pressing Stop), the display indicates the test
has stopped. No overall fit factor is displayed.
17. You can now begin to test another person, by pressing Next >
New Test.
(continued on next page)
38 Chapter 4
Step 5—Record Results
If you use the PortaCount Pro Respirator Fit Tester in stand-alone
mode and do not have an active database on the flash drive attached
to one of the USB ports, you have to manually record the fit test
results and information about the person and respirator being fit
tested. If using a database from the flash drive, the results are
automatically stored in the database. Use FitPro+ software to view
and print the results.
In the default configuration, only passed fit test results are stored into
the database, but this can be changed in the Global Settings screen
so that all fit test results are saved. Refer to Chapter 5 for more
information on Global Settings. Record the following information if no
database is used.
Ambient concentration
Mask concentration
Fit factor exercise 1
.
.
Fit factor exercise X
Overall fit factor
Pass or Fail
The overall fit factor is the most important data item. It is the overall
result of the fit test and usually the only fit factor value that must be
retained as part of your record keeping. The fit factors for the
individual exercises are not as important. It is possible to have a
passing overall fit factor even though one of the exercises resulted in
a failing fit factor.
The overall fit factor is not simply an average of all the exercise fit
factors. It is a weighted average related to the amount of airborne
hazard that the person might have inhaled if he or she were in the
workplace. For example; one fit test exercise with a fit factor of 100
and then another with a fit factor of 1000 does not equal an overall fit
factor of 550, rather they have an overall fit factor of about 180. This
is because the fit factor of 100 contains 10 times the amount of
hypothetical hazard as the fit factor of 1000. See the appendix on
“Calculating Fit Factors” for more details.
Common Problems Resulting in Low Fit Factors
Some of the most common problems that result in lower than
expected fit factors are described below. Assuming the PortaCount
Pro fit tester passes the Daily Checks, explore the following
possibilities.
Not using high If high-efficiency class-99 or class-100

efficiency filters filters (P3 for non-USA users) are not
being used on the respirator, you may
never get a high fit factor. Filters such as
class-95. P1 and P2 (for non-USA users)
allow some ambient air particles to get
through and be interpreted as face seal
leakage by the PortaCount Pro Respirator
Fit Tester.
Note: The Model 8038 fit tests lower
efficiency respirators including
class-95, P1, and P2 filtering-
facepieces (disposables).
Alcohol cartridge is Make sure the alcohol cartridge is installed
not tightly inserted properly and all O-rings are in position.
or an O-ring is
missing
Starting fit test too When the mask is first donned, ambient air
soon after mask is particles are trapped inside. These
donned. particles clear out as the person breathes.
According to all fit testing protocols, a fit
test subject must wait 5 minutes after
donning the mask before beginning the fit
testing exercises.
Sample tubes too No more than the few inches should be
long added to the Sample tube (use a Tube
Adapter). Longer sample tubes prevent
proper purging between the ambient and
mask sample.
Leaking respirator Make certain the respirator probe (if used)
probe or fit test or fit test adapter does not leak around the
adapter outside.
PortaCount Pro fit Cut a short piece off the end of the tube to
tester sample tube expose a fresh end.
leaks where attached
to probe or adapter
due to wear
40 Chapter 4
Hair interfering with Make sure there is no hair between the
face seal respirator face seal and the individual's
skin.
Hair or foreign Make sure the exhalation valve is clear. A
material in single hair can make a big difference.
exhalation valve
Cigarette smoker Do not allow the individual to smoke for at
least 30 minutes prior to the fit test.
Suspiciously High Fit Factors

When fit testing full or half face respirators in most ambient
environments, fit factors greater than 100,000 are considered
suspicious, and should be verified using the Real-time Fit Factor
function after the fit test has been completed. While still donning the
respirator, have the person being fit tested purposefully break the
seal of the mask to their face by sliding an object (i.e. a pen or their
finger) through the sealing surface. Even with a small leak, the fit
factor calculated should be very low. If the Real-time calculated fit
factor drops in value as expected, the reported high fit factors are
valid. If the Real-time calculated fit factor does not drop in value when
the seal is broken, there may be a block or kink in the Mask Sample
tubing, usually as it enters the mask.
Step 6—Using a Printer with the PortaCount Pro

Fit Tester
Version 2.0 and greater PortaCount firmware adds the ability to
connect a compatible printer directly to the PortaCount Pro fit tester
for printing Fit Test Reports in stand-alone (no computer required)
testing mode.
Printer Compatibility
The PortaCount Pro fit tester supports the printing of fit test reports on
printers compatible with the HP PCL3/PCL5e/PCL3GUI printer
languages, including many DeskJet, LaserJet and DesignJet models.
It is recommended that the Print Test function be used to confirm
compatibility for the printer.
Connecting and Testing the Printer

There are two USB ports on the back panel of the PortaCount unit.
With the PortaCount Pro fit tester powered off, connect the removable
media device used to import/export and store the fit test database
files to the first USB port and connect the printer to the second
USB port.
To test the connection, power up the PortaCount Pro fit tester and the
printer. Allow the printer to boot completely and make sure there is no
error condition (refer to the printer manufacturer’s documentation).
Once the printer is online and idle, follow the Printer Setup procedure
outlined in Chapter 5, “Operating Modes and User Interface.”
It is also possible to configure the system to print out fit test reports
automatically at the end of each fit test. Refer to Chapter 5 for more
information on adjusting these options in the Global Settings menu.
Printing Fit Test Reports

There are two places in the PortaCount Pro fit tester workflow where
Fit Test Reports can be printed:
1. At Fit Test Step 4, after a fit test has been completed, click the
Next > button to access the pop-up option menu.
42 Chapter 4
At the top of that menu, select Print to print a report of the fit test
that was just completed.
Note
If the test is stopped by the user before it completes, or if it fails
due to a fault condition such as low ambient concentration, the
fit test will not be saved to the database and will not be available
for printing, unless the option to “save all fit test” results has
been enabled under Global Settings. See Chapter 5 for further
information.
2. In the “Fit Test Reports” screen, available through the “Database”
page, you can print Fit Test Reports for records that you select
from the currently loaded database.
It is also possible to configure the PortaCount Pro to print fit test

reports automatically at the end of each fit test. Refer to Chapter 5 for
more information on adjusting these options in the Global Settings
menu.
Step 7—Stand-Alone Fit Testing—Data Handling

Best Practices
TSI’s PortaCount Pro Respirator Fit Tester is designed to provide a
robust solution for stand-alone fit testing. As with any computing
application, care must be taken by users to ensure that precious data
is not lost due to mishap or mishandling. This section recommends
some basic and advanced guidelines for good data handling and
instructions on how to use the PortaCount Pro fit tester “Advanced
Database Tools” introduced in firmware version 2.0.
 In stand-alone mode, all important fit test data
is stored on the removable media device (flash
drive) that is connected to the PortaCount unit.
Note
The flash drive provided with the
PortaCount Pro fit tester does not include
the necessary PortaCount Pro database.
This must be created through the FitPro+
software, please refer to the FitPro+
software user’s manual.
 Do not lose or damage the flash drive! All fit test data is stored in
files on the flash drive.
 Only connect one flash drive to the PortaCount Pro fit tester at a
time. The PortaCount Pro fit tester does not support operation
with two flash drives simultaneously.
 Never remove the flash drive while data is being written to it at
the end of a Daily Check or Fit Test or anytime you see this
message on the PortaCount screen:
 Backup the file(s) on the flash drive to a host computer as often

as practical.
Step 8—Advanced Database Tools

The “Advanced Database Tools” introduced in firmware version 2.0
are intended for use by advanced users or as instructed by TSI
technical support personnel during a phone support session. The
“Advanced Database Tools” can be accessed through the Setup tab.
44 Chapter 4
Advanced
Database Tools Description
Statistics Allows the advanced user to determine how many
records of each type (people, respirators, protocols,
fit test results and daily checks) are in the selected
database file and reports the file size in bytes.
Clean Copy Allows the advanced user to make a “clean” copy of
an existing database file. A “clean” copy retains the
people, respirator, protocol, and daily check records,
of the original database, but does not copy fit test
results. This tool can be used when your working
database file is becoming too large to create a
second, working copy.
Copy Allows the advanced user to make a copy of an
existing database file. One typical use might be to
create a “master database” using FitPro+ software
that contains commonly used respirator and protocol
information, then using “Copy” to make working
copies that you can customize by adding people,
additional protocols or respirators using the
PortaCount Fit Tester user interface as needed.
Save This command writes the database that is active in
memory to a file on the flash drive. This is usually
not necessary because the file is saved
automatically at the end of each test, but can be a
useful tool in some situations. For example, in the
unlikely event that your primary flash drive fails and
you receive an error message that the data was not
saved, you could swap out the primary drive with a
backup and use “Save” to write the database from
memory to the backup flash drive. You could then
continue working with the backup flash drive in
place.
Advanced
Database Tools Description
Save As This command is like Save, but allows you to save
the currently loaded database under a different file
name. This would not usually be necessary, but you
could use this tool to make a backup copy of your
database under a different name as an additional
precaution.
This tool is also capable of saving the “Demo-
Training” database to a flash drive, providing a
method for creating a new database in stand-alone
mode without using FitPro+ software. The steps in
creating a new database based on the “Demo-
Training” database are:
1. Insert a blank flash drive into the PortaCount Fit
Tester (or remove the flash drive from the
PortaCount Fit Tester).
2. Use “Select Database” from the Database page
to load the “Demo-Training” database into
memory.
3. Replace the flash drive, if you had previously
removed it, and use the “Save As” tool in the
Advanced Database Tools to save the database
from memory to flash drive.
4. Use “Select Database” from the Database page
to load the new database into the PortaCount Fit
Tester’s memory. The newly created database
can be used just like a database exported from
FitPro+ software and you can customize it by
adding protocols, respirators and people using
the PortaCount Fit Tester user interface.
Delete Allows advanced users to delete database files
from the flash drive. Use this tool with caution
because it permanently deletes a database file
from the flash drive!
46 Chapter 4
Chapter 5
Operating Modes and User Interface
This chapter describes the operating modes of the PortaCount® Pro

Respirator Fit Tester and describes the options available through the
user interface (touch screen).
Modes of Operation
There are two modes of operation:
 External Control mode – using FitPro+™ software or another TSI
product such as TSI’s Mask Integrity Test Accessory (MITA)
 Stand-alone mode
Note
Switching between External Control and Stand-alone control during
an active fit test or a daily check may prevent the active record from
being saved.
External The PortaCount Pro Respirator Fit Tester is operating

Control in External Control Mode when it is being controlled by
Mode FitPro+ software running on your computer. To start
External control mode, place the PortaCount fit tester
touch screen on the main Activities menu. Connect the
PortaCount fit tester to the computer and initiate control
from the software.
If you do not have the PortaCount fit tester on the main
Activities menu, FitPro+ software may display a
message instructing you to unlock the PortaCount fit
tester. Return the PortaCount fit tester to the main
Activities menu and then reinitiate External Control
Mode from the software.
47
External If using a PortaCount fit tester with version 2.9 firmware
Control or greater, a black screen appears on the PortaCount
Mode Pro Fit Tester with a Lock button. This screen prevents
(cont.) you from inadvertently returning the PortaCount fit
tester to Stand-alone mode. However, you can still
return to Stand-alone mode by pressing the Lock
button and accepting the prompt to Unlock.
Refer to the online help of the FitPro+ software for
operating details.
Stand- The PortaCount Pro Respirator Fit Tester is operating
alone in Stand-alone Mode when it is first powered on. It
Mode automatically begins a warm-up period and when that
is over, a beep sounds and the main Activities menu
displays on the touch screen display. The PortaCount
Pro fit tester is now ready for Fit Testing and other
stand-alone operations.
If you attempt to perform an operation from the
PortaCount Pro fit tester touch screen while it is in
External Control Mode, a message may appear on the
PortaCount fit tester asking if you want to unlock the
instrument. If you choose to unlock the PortaCount Pro
fit tester, it begins to operate in stand-alone mode.
User Interface
The touch screen provides the user interface to all functions when the
instrument is operating in stand-alone mode. These functions are
accessed through the tabs at the bottom of the display. The functions
available through each tab are described below.
Activities Tab
The Activities tab lets you perform three functions: Fit Testing, Daily
Checks, and Real-time fit factors.
Fit Test
Press Fit Test [ ] to start a fit test in stand-alone mode. Refer
to Chapter 4 for a complete description.
Daily Check
Press Daily Check [ ] to start the Daily Checks of the
instrument. Refer to Chapter 2 for a complete description.
48 Chapter 5
Realtime
Press Realtime [ ] to view a graph showing real-time fit
factors or perform an ambient concentration check.
The real-time fit factor display is generally used for respirator

training and troubleshooting. It allows a test subject to experiment
with strap tension and other adjustments while watching the effect
these efforts have in real time.
The test subject learns how each adjustment affects the fit, and
learns how to achieve a fit that is comfortable and has minimum
leakage.
Note
This feature is intended for training. It should not be used
immediately before a fit test. Using the feature to help the test
subject don the respirator immediately before the official fit test
defeats one of the main purposes of fit testing: to prove that the test
subject knows how to don the mask properly without help. Use the
Real-time Fit Factor feature for training and practice only.
You can use the real-time fit factor display prior to a fit test as
long as you have the test subject remove the mask and put it on
again (without the use of the real time display or other
assistance) before the final test.
Before starting the real-time fit factor display, have the test
subject put on the respirator and make sure it is properly attached
to the PortaCount Pro Respirator Fit Tester.
When you press Realtime [ ] the Real-Time Fit Factor Display

appears.
Operating Modes and User Interface 49

The PortaCount Pro Respirator Fit Tester takes an ambient
concentration reading and stores the value. Next it purges the
mask and then begins continuous monitoring of the mask
concentration.
The line graph lets you (and the test subject) observe the Fit
Factor reading as it fluctuates in near real time. (There is a delay
of a few seconds between when a change in fit occurs and when
the graph displays the change in fit factor.)
The graph pauses every 5 minutes while the PortaCount Pro fit
tester takes a fresh ambient air measurement. Press Restart to
force a new ambient reading sooner.
The Real-time Data Display page also has an “Ambient

Concentration Check” mode.
50 Chapter 5
In this mode, the PortaCount Pro fit tester continuously measures
the particle concentration through the ambient inlet port allowing
the user to easily check ambient concentration in preparation for
testing.
Press Exit to close the Real Time display.

Database Tab
The Database tab lets you select an active database to use for fit
testing or view the People, Respirator, Protocols, and Fit Test records
of the active database. (See the FitPro+ Fit Test Software User
Manual for instructions on how to configure the USB flash drive.)
Note
Unless a flash drive with valid database files is inserted in one of the
USB ports, you cannot use an active database. There is a database
available in the PortaCount Pro fit tester for demonstrations and
training purposes only. But this database cannot be permanently
modified and adding new records or making other modifications to
this internal database does not permanently change them. All
changes and additions are lost when you turn off the PortaCount Pro
fit tester.
Select Database
Press Select Database, to display a dialog of available
databases on the flash drive. If there is no flash drive attached to
the PortaCount Pro fit tester, a warning message appears. If you
do not want to use a database from a flash drive, press Exit;
otherwise, insert a flash drive with a valid database (or
databases) in the root directory and press Refresh.
Note
Unless a flash drive with valid database files is inserted in one of
the USB ports, you cannot use a real database. The database
stored in the PortaCount Pro fit tester is for demonstration/
training purposes only. Adding new records or making other
modifications to the internal database does not permanently
change (save) them and information cannot be exchanged with
FitPro+ software.
1. Use the down arrow to select the database you want to use.
2. Verify the database you want to use displayed in the
“Available Databases” field.
3. Press Load. The database is imported and becomes the
active database. All changes, additions, fit test results and so
on are stored to this database. The database can be exported
to your computer running FitPro+ software by inserting the
flash drive in one of your computer’s USB ports.
4. Press Done to exit this function.
52 Chapter 5
Fit Test Reports
Select Fit Test Reports [ ] to view the Fit Test records of
those individuals in the active database. Use the arrow at the
right of the Selected Fit Test field to show all the records and
select a record by pressing on the person’s name in the
dropdown box.
If a compatible USB printer is connected, you will have the option

to print a report for the record you have selected.
When you are done viewing records, press Exit to end this
function.
People
Select People [ ] to view the records of people in the active
database or add a new person to the database.
1. To view records, press the arrow at the right of the People
List. Select a record by pressing the name in the dropdown
box.
2. To add a new record, press New, and fill in the required fields
using the on-screen keyboard, then press Save. If necessary,
refer to the FitPro+ Fit Test Software User’s Manual for a
description of these fields.
3. Press Exit to close the People list.
Respirators
Select Respirators [ ] to view the records of the respirators in
the active database or add a new respirator to the database.
1. To view the records, press the arrow at the right of the
Respirator List. Select a record by pressing the respirator
name in the dropdown box.
2. To add a new record, press New, and fill in the required fields
using the on-screen keyboard, then press Save. If necessary,
refer to the FitPro+ Fit Test Software User’s Manual for a
description of these fields.
3. Press Exit to close the Respirator list.

Protocols
Select Protocols [ ] to view the current protocol or access
other protocols in the active database or add a new protocol to
the database.
1. To select a different protocol, press the arrow at the right of
the Current Protocol field. Select the protocol by pressing the
Protocol name in the dropdown box. This now becomes the
active protocol for fit tests.
2. To add a new Protocol, press New, enter a name using the
on-screen keyboard, edit the fields using the up/down arrows
in the Protocol Details dialog, and then press OK.
3. When the Create New Entry dialog appears, click on an
Exercise Name field to open the Exercise # Parameters
dialog and enter information for that exercise (you can also
modify any information you entered on the Protocol Dialog in
step 2 by clicking on the specific parameter). Up to 12
exercises can be entered.
The following table describes the fields.
Button or Field
Name Description
Ambient Purge Use the up/down arrows to set the time (in seconds)
Time the ambient air is purged before an ambient sample
measurement is made.
Ambient Sample Use the up/down arrows to set the time (in seconds)
Time the ambient air is sampled before the Mask purge
time begins.
Cancel Closes the dialog without saving any changes.
Exercise Name A list of all the exercises in the protocol (up to 12
exercises).
Exclude Check this box if you want PortaCount Pro fit tester
to exclude this exercise when calculating the fit
factor. This exercise then is essentially a “time-out.”
It is typically used for the OSHA 29CFR1910.134
grimace exercise. Do not exclude exercises unless
you are absolutely certain they are not required for
the overall fit factor result.
Note: When an exercise is excluded, the value
stored as the mask sample time becomes the time
used for the entire exercise. No actual measurement
is made.
OK Closes the dialog box and saves your values.
54 Chapter 5
Button or Field
Name Description
Mask Purge Time Use the up/down arrows to set the time (in seconds)
the mask is purged before the Mask sample time.
New Exercise Enter a name for the exercise using the on-screen
Name keyboard.
Next Test In _ Number of months before the next fit test is due.
months This is typically 12 months, although some
regulations call for 6 or 24 months. Consult the
applicable regulations for additional information.
Valid range from 1 to 99. Use the up/down arrows to
set this field.
N95 (Model 8038 If this protocol will be used for testing masks with <
only) 99% filter efficiencies such as N95, P2, and P1
respirators, check this box.
Protocol Name Enter the name for the exercise protocol you are
creating using the on-screen keyboard.
Mask Sample Use the up/down arrows to set the Mask Sample
Time Time for the exercise.
Save Saves the current protocol information and adds the
record to the database.
Stop Fit Test If the protocol requires all exercises to pass, check
immediately when this box. Most regulations allow an exercise to fail as
any exercise fails long as the overall fit factor passes. Default is
unchecked.
Refer to the regulation or standard that applies to your

industry or hazard for guidance on which exercises should be
performed and how many there should be.
4. Press Save to save the new protocol.
5. Press Exit to close the Protocol database.

Setup Tab
Use the Setup tab to set the PortaCount Pro fit tester’s date and time, get
information about the model number and firmware version of your
instrument, calibrate the touch screen, set up a printer and verify the
connection and set global options such as the high concentration limit.
Date and Time

Select Date and Time [ ] to set the date, time, and date
format on the instrument. The date and time need to be set to
accurately bookmark when a fit test is done.
1. Press Date and Time, to open a dialog with the default date
and time. Use the arrows to the right of the Date field to pick
the date from the pop-up calendar.
2. To change the time, select the segment of time you want to
change (hour, minute, second), then use the arrows to
increase or decrease the value.
3. Select the Date Format from the Date Format box.
Note
When you set the date format here it does not change the date
format that FitPro+ software uses. When data is exchanged with
FitPro+ software, it is exchanged in a universal date format.
4. Press OK to close this dialog and save your settings or
Cancel to close the dialog without changing it.
Device Info
Press Device Info [ ] to view the model number, serial
number and version level of your PortaCount Pro fit tester and
verify USB printer connection. The box that appears also contains
other information that may be helpful with troubleshooting the
instrument with a TSI representative.
Touch Screen Calibration

Press Touch Screen Calibration [ ] to recalibrate the touch
screen. The touch screen needs recalibration when you touch
one area of the screen and the wrong action is performed. This is
most noticeable when using the on-screen keyboard. For
example, you touch the “u” and “j” appears. Use the stylus for
calibration, not your finger.
56 Chapter 5
As instructed on the touch screen, “Carefully press and briefly
hold stylus on the center of the target. Repeat as the target
moves around the screen.”
When the calibration is complete, you are notified that the

settings have been measured. Press anywhere on the screen to
end the calibration.
Printer Setup
The PortaCount Pro fit tester supports the printing of fit test
reports on printers compatible with the HP PCL3/PCL5e/
PCL3GUI printer languages, including many DeskJet, LaserJet
and DesignJet models. When setting up printing for the first time
it is important to configure the printer setup correctly.
Select the printer type as specified by the printer manufacturer.
The fit test report is designed to print best on letter sized paper or
card-form paper that includes a punch-out fit test card (TSI part
number 803X-CRDFRM). If using the card-form paper, select
Report Format, “Report with card.”
Use the Top Margin and Left Margin settings to position the fit
test report on the page or position the card text onto the card
form.

Press the Print Test button to perform a printing test using the
currently selected settings. Adjust the Top Margin and Left Margin
to position the report properly on the paper.
 If the message “Printer Not Detected” appears, check the
printer connection and try again. If the problem continues, it is
possible that the printer is not compatible with the PortaCount
Pro fit tester.
 If the system appears to print but no page comes out, the
page is blank or the print out is garbled, check that the correct
Printer Type is selected or try the other Printer Type
selections.
 If you have tried all of the suggestions above and the test
page will not print, it is possible that the printer is not
compatible with PortaCount Pro fit tester.
Press Save to commit the configuration changes to the

PortaCount persistent storage.
Press Exit to close the Printer Setup screen.
Advanced Database Tools

These tools provide a means for advanced users to manage the
fit test result database files stored on removable media devices.
Refer to Chapter 4, “Step 7—Stand-Alone Fit Testing—Data
Handling Best Practices” for details.
Global Settings
58 Chapter 5
Note
nd
There is a 2 High concentration warning level setting for N95
mode on the PortaCount Pro+ Model 8038.
High The high concentration warning notifies

Concentration when the ambient air particle concentration
Warning Level exceeds the target range during Daily
Checks and Fit Tests. Prolonged exposure
to excessive concentration levels could
degrade the performance of the PortaCount
over time, resulting in failed daily checks or
a “Low Particle Message.” By default, the
high concentration warning displays when
the ambient concentration is above 30,000
particles/cm3 for the Model 8030 or 8038
when testing masks with 99% efficiencies
or greater, or above 1,500 pt/cm3 for the
Model 8038 when testing masks with <99%
efficiencies. These default values can be
varied from the Global Settings screen to
accommodate environments where particle
concentration is necessarily elevated. To
troubleshoot this warning, refer to
Chapter 6, Service and Maintenance.
Save fit tests to By default, fit test result will only be saved
database to the flash drive database if the fit test
passes. Use this option to allow saving of
all fit test results including failed fit tests.
When “Save all fit tests” is selected, those
fit tests which are stopped prematurely by
either the user or due to a fault condition
such as low ambient concentration will be
saved to the database.
Automatically If this option is enabled, a fit test report will
print report for automatically be printed for each saved fit
saved fit tests test result. Make sure that the printer has
been configured correctly using the Printer
Setup screen before enabling this option.
Refer to Chapter 5 for more information on
Printer Settings menu.

Terminate fit When this option is enabled, the instrument
test early if a will calculate the best case overall fit factor
passing overall at the end of each exercise and if a passing
fit factor is overall fit factor value is not achievable, the
impossible to test will terminate early.
achieve
Save Press Save to commit the configuration
changes to the PortaCount fit tester
persistent storage.
Exit Press Exit to close the Global Settings
screen.
60 Chapter 5
Chapter 6
Service and Maintenance
Recalibration Interval
TSI recommends that the PortaCount® Pro Respirator Fit Tester be
cleaned and recalibrated annually. Try to arrange your fit testing
schedule to allow for annual factory recalibration. If you have a fit
testing schedule that is seasonal or you expect heavy usage during
an upcoming period (such as an outage), TSI recommends that you
have the PortaCount Pro fit tester serviced prior to that time. TSI's
Customer Service Department provides fast service in order to
minimize your down time. Contact TSI on the Internet at www.tsi.com
or send e-mail to PortaCount@tsi.com.
Status Messages
Two status messages can be displayed by the PortaCount Pro
Respirator Fit Tester.
Low Particle The PortaCount Pro fit tester is factory

Message programmed not to allow fit testing when the
ambient particle concentration is below 1000
particles/cm3 for the Model 8030 or 8038 when
testing masks with 99% efficiencies or greater,
and 30 particles/cm3 for the Model 8038 when
testing masks with <99% efficiencies. If the
ambient sample in Fit Test Mode is below these
levels, the “Low Particle” message appears on
the touch screen display and the fit test is
automatically terminated.
This message appears in Fit Test Mode only, for
one of the reasons described below. Consult the
Troubleshooting chapter if necessary.
61
High When the “High concentration warning” is
Concentration displayed, it means that the PortaCount fit tester
Warning detects ambient concentration levels higher than
recommended. Prolonged exposure to excessive
concentration levels could degrade the
performance of the PortaCount fit tester over
time, resulting in failed daily checks or a “Low
Particle Message.” This message does not
necessarily mean that the PortaCount Pro fit
tester will stop working soon. Fit test results are
accurate even when this message is displayed.
Refer to the Troubleshooting chapter for other
possible causes and solutions for this message.
Low Alcohol When the "Low Alcohol Level" message is
Level Message displayed, it means that the PortaCount Pro fit
tester may be low on alcohol. This message
does not necessarily mean that the PortaCount
Pro fit tester will stop working soon. Fit test
results are accurate even when this message is
on. Refer to the Troubleshooting chapter for
other possible causes and solutions for this
message.
Reordering Supplies
TSI part numbers for consumable supplies and miscellaneous
replacement parts are:
Model/Part No. Description

8016 Box of 16, 30 ml bottles of isopropyl alcohol
(480 ml total)
8033 Box of 10 Alcohol Wicks
803X-ZFLTR Zero Check Filter
8017 Sampling Hose Kit with 3 Twin Tube Assemblies and
10 each 3/16 in. and 1/4 in. Tube Adapters.
800197 Twin Tube Assembly (Quantity 1)
8034 AC Adapter for Model 8030/8038 (voltage sensing)
6006456 PortaCount Pro/Pro+ Fit Tester Quick Start Guide
8032 Alcohol Cartridge and Fill Capsule Kit for Model
8030/8038
8032-FC Alcohol Fill Capsule with Storage Cap
8032-SC Storage Cap
8032-CT Alcohol Cartridge with wick
62 Chapter 6
Shipping & Storage Precautions
When transporting or storing the PortaCount Pro Respirator Fit
Tester, it is important to remove all alcohol. Transporting or storing
the PortaCount Pro fit tester with the alcohol cartridge inside may
cause flooding of the optics.
When putting the PortaCount Pro fit tester back into the carrying
case, follow the steps below:
1. Remove the Alcohol Cartridge from the PortaCount Pro fit tester
and store it in the Alcohol Fill Capsule. The Alcohol Fill Capsule is
designed to be a safe transportation and storage container for
alcohol. The Alcohol Cartridge can be left soaking in alcohol
indefinitely.
2. Cover the Cartridge Cavity with the Storage Cap. Installing the
Storage Cap into the Cartridge Cavity prevents dirt or lint from
getting inside the PortaCount Pro fit tester.
NEVER ship the PortaCount Pro Fit Tester back to TSI with
any alcohol bottles.
Changing the Alcohol Wick

The wick inside the Alcohol Cartridge may be changed in the field.
Two spare wicks are included with the PortaCount Pro Respirator Fit
Tester. Normally, the wick does not need to be changed unless one
of the following problems develops:
 Moisture accumulates in the wick and causes the Low Alcohol

Level message to come on even when there is an adequate
alcohol supply. This may happen when the PortaCount Pro fit
tester is used extensively for weeks on end. Especially if fit
testing in an area with high humidity.
If moisture accumulation occurs, the Alcohol Wick can be

removed, allowed to dry, and then re-installed into the Alcohol
Cartridge.
Service and Maintenance 63

 The wick becomes contaminated with dirt, oil, or other foreign
substances. This should not happen unless the instrument is
used to sample aerosols other than those normally found in
ambient air.
If the Alcohol Wick is contaminated, discard it and replace it with

a new one. Note that some discoloration of the wick is normal and
will not influence performance.
To remove the Alcohol Wick from the Alcohol Cartridge:

1. Grasp the cartridge with both hands. With the knob in one hand
and the Wick Retainer Cap in the other, twist and pull apart the
assembly. The cartridge should snap apart exposing the end of
the white Alcohol Wick.
2. After separating the two halves, push the Alcohol Wick out of the
Wick Retainer Cap from the opposite end with the Wick Removal
Tool (wood dowel) provided with each new alcohol wick. Do not
use a pencil point because bits of lead could break off.
3. Examine the white Alcohol Wick. Discard wicks that are severely
discolored or physically damaged. Some light brownish-yellow
discoloration of the wick is normal.
If the wick is in good condition, dry it by placing it on a clean
surface in a well-ventilated area and allow it to dry for at least
two days.
64 Chapter 6
4. Before re-installing the alcohol wick, make certain that all parts
are clean. Small bits of the wick or lint can cause serious
problems if they get into the PortaCount Pro fit tester.
5. Inspect the inside surfaces of the Alcohol Cartridge and the Wick
Retainer Cap. Blow air into them, if necessary, to make certain
that there are no dust particles present.
6. Blow air onto all surfaces of the Alcohol Wick that will be used to
make certain that any loose particles that may have shed from
the wick are removed.
7. Check both ends of the wick. If one end is smoother than the
other, slide the smooth end of the wick into the Wick Retainer
Cap first. Otherwise, simply insert the wick and push firmly until
the wick hits bottom.
8. Blow everything off again.
9. Align the two halves of the Alcohol Cartridge and press firmly until
they snap together.
Operation in High Humidity

When using a Model 8030/8038 in a high humidity environment, the
wick assembly will retain water moisture more rapidly than normal
and will require more frequent wick replacements. Water moisture
collecting in the wick is a normal occurrence, but is greatly increased
with a rise in humidity. Under normal conditions with a dry wick freshly
charged with isopropyl alcohol, the PortaCount fit tester will operate
approximately 6.5 hours before the “Low Alcohol Warning” appears.
This average run time will start to decrease when operating the
PortaCount fit tester in higher humidity. To keep this average run time

as long as possible, replace the wick each day with a dry one. To dry
out the wick you removed from the PortaCount fit tester, place it in a
well-ventilated area that has a humidity level of 50% or lower and let it
set overnight (approximately 16 hours). The wick should then be dry
and ready to be used again. The 16-hour dry time is based on an 8-
hour operation in a humid environment. The total dry time will vary
depending on the number of operation hours on the wick in high
humidity environment.
Nozzle Cleaning
If the small (pin-hole size) internal nozzle becomes clogged with lint
or other debris, the following procedure should clear it. The symptom
of a clogged nozzle is a low (perhaps zero) ambient particle count.
This usually, but not always, causes the Particle Check and/or Max
Fit Factor Check to fail. There are two procedures. Perform
Procedure A first, then Procedure B if necessary.
Procedure A
Obtain a source of clean compressed gas,
such as Chemtronics® or equivalent. It must
have a long nozzle (straw) in order to reach
deep into the PortaCount Pro Respirator Fit
Tester.
 Turn the PortaCount Pro fit tester off and
remove the alcohol cartridge.
 Insert the long nozzle inside the
PortaCount Pro fit tester as shown. Keep
the end of the nozzle centered in the cavity and gently push it in
as far as possible. The internal nozzle is located just at the far
end of the cavity and cannot be seen.
 Apply two or three bursts of gas. This will not damage the
PortaCount Pro Respirator Fit Tester.
66 Chapter 6
Reinsert the alcohol cartridge. Turn the PortaCount Pro Respirator Fit
Tester on. Perform the Daily Checks. If the problem persists, try
Procedure B.
Procedure B
Use this procedure only if Procedure A fails to clear the internal
nozzle.
 Turn the PortaCount Pro fit tester off and remove the alcohol
cartridge.
 Turn and hold the PortaCount Pro fit tester up on end so that you
can look down into the cartridge cavity.
 Take a bottle of the alcohol used to operate the PortaCount Pro fit
tester and drip 3 to 4 drops down into the cartridge cavity. Try to
keep the drops centered so they hit the bottom without touching
the sides. Do not use too much. One drop is enough if it all
reaches the nozzle.
 Keep the PortaCount Pro fit tester in this vertical position for
about 5 minutes so the alcohol can soften or dissolve the
blockage.

Put the PortaCount Pro Respirator Fit Tester down in normal
operating position and perform Procedure A.
68 Chapter 6
Chapter 7
Troubleshooting
This chapter lists a series of symptoms, their possible causes and

recommended solutions for problems with the PortaCount® Pro/Pro+
Respirator Fit Tester. If your symptom is not listed, or if none of the
solutions solves your problem, please contact TSI. Additional help is
available from the TSI Web site www.tsi.com or by sending e-mail to
PortaCount@tsi.com.
Always replenish the alcohol supply as the first step in solving a

problem. Alcohol can be added to the fill line at any time.
Eventually, the Alcohol Wick inside the Alcohol Cartridge will absorb
enough moisture to prevent proper operation. Symptoms of excess
moisture are low particle counts even though there is plenty of alcohol
and plenty of particles in the room, and also having to frequently
replenish the alcohol supply (such as every hour or less). Changing
the Alcohol Wick is the best way to solve the problem. The wick can
also be dried by leaving the Alcohol Cartridge in the PortaCount Pro
and then running it overnight, or by removing the wick from the
cartridge and letting it dry for 48 hours.
Always perform the Daily Checks as described in Chapter 4 as the

first troubleshooting step. Passing the Daily Checks usually indicates
that the PortaCount Pro Fit Tester is working properly and that the
problem is elsewhere, such as the connection to the respirator and/or
the respirator itself.
On-line Troubleshooting Guides

Additional application notes on troubleshooting are located on the
FitPro+™ software CD or visit TSI’s website at http://fittest.tsi.com.
69
Symptom Possible Causes Solution
Low Particle Low on alcohol. Replenish alcohol.
message
Hoses are reversed on Verify the hoses are
Twin Tube Assembly. connected properly to the
PortaCount Pro and mask.
Wrong tube is connected Connect the proper tube
to respirator. to the respirator (clear
tube).
Twin Tube Assembly is Straighten out the Twin
kinked, pinched, or Tube Assembly or remove
blocked. the obstruction.
Particle count in area Move to another location
really is low. or use a particle generator
(such as the 8026 Particle
Generator or an ultrasonic
humidifier).
Moisture build-up inside Change Alcohol Wick
PortaCount Pro fit tester. inside the Alcohol
Cartridge. Dump old
alcohol from the Alcohol
Fill Capsule and add fresh
alcohol. Run 2 hours to
dry optics (remove the
alcohol cartridge and
install storage cap).
Inferior or contaminated Change Alcohol Wick
alcohol. inside the Alcohol
Cartridge. Use only
approved alcohol (99.5 %
or better isopropyl).
Plugged internal nozzle. See Nozzle Cleaning in
chapter.
Unit needs recalibration Return the instrument to
and cleaning. TSI for service.
Does not switch AC Adapter not plugged Connect AC Adapter.
on in to unit or AC outlet.
70 Chapter 7
Fails Zero Check Alcohol Cartridge is Tightly close the Alcohol
loose. Cartridge.
Twin Tube Assembly Repair or replace the Twin
leaks. Tube Assembly.
Filter leaks. Repeat the test with a
different filter.
Ends of Twin Tube Cut off the worn ends on
Assembly are poorly the Twin Tube Assembly.
sealed.
Twin Tube Assembly is Connect the Twin Tube
disconnected. Assembly to the
Slightly flooded with Remove Alcohol Cartridge
alcohol. and run for 15 minutes,
then try again.
Switching valve is not Return to TSI for service.
functioning.
O-ring on alcohol Replace O-ring. Smear a
cartridge is not sealing. very small amount of
grease (such as
petroleum jelly) on the
O-ring.
Tube fittings on Tighten fittings with pliers.
PortaCount Pro fit tester
are loose.
Troubleshooting 71
Fit factor of 1 or Respirator is not Install proper filter for fit
very low equipped with HEPA, testing.
class-99, class-100, or
(If the PortaCount P3 filters.
fit tester passes Respirator leaks, has Repair the respirator.
the Daily Checks, loose filters, or a
the problem is with malfunctioning exhalation
the respirator, not valve.
the PortaCount fit
tester.) Twin Tube Assembly is Connect the Twin Tube
disconnected. Assembly to the
Twin Tube Assembly is Connect the Twin Tube
not connected to Assembly to the respirator
respirator sampling port. sampling port (clear tube).
Twin Tube Assembly Repair or replace the Twin
Leaks. Tube Assembly.
Sample Tube too Long. Use standard 5-foot Twin
Tube Assembly.
PortaCount Pro fit tester Run 2 hours to dry optics
is flooded with alcohol. (remove the Alcohol
Cartridge and install
Storage Cap).
Alcohol level is low. Add alcohol to the
Switching valve is not Return to TSI for service.
functioning.
72 Chapter 7
Suspicious PortaCount Pro fit tester Run 2 hours to dry the
readings is flooded with alcohol. optics (remove cartridge
and install storage cap).
(If the PortaCount Tube fittings on Tighten with pliers.
fit tester passes PortaCount Pro fit tester
the Daily Checks, are loose.
the problem is the
respirator, not the PortaCount Pro fit tester Zero-Check the
PortaCount fit leaks. PortaCount Pro fit tester
tester.) and fix any leaks.
Sample lines too long. Use standard 5-foot Twin
Tube Assembly.
Alcohol Cartridge is Tightly close the Alcohol
loose. Cartridge.
Respirator is not Install HEPA filters for fit
equipped with HEPA tests.
filters.
Twin Tube Assembly is Straighten out the Twin
kinked, pinched, or Tube Assembly or remove
blocked. the obstruction.
Leaking respirator probe. Tighten or seal probe.
Tubing in fit test adapter Straighten out tubing.
is kinked or pinched.
Respirator is faulty. Fix or replace the
respirator.
Suspiciously High Twin Tube Assembly is Use the Real-time Fit
Fit Factors kinked, pinched, or Factor function to verify
blocked. the fit factor.
Refer to Straighten out the Twin

Suspiciously High Tube Assembly or remove
Fit Factors the obstruction.
section.
Troubleshooting 73
Particle count is Alcohol level is low. Replenish alcohol.
zero or near zero
Sampling through HEPA Remove filter.
Filter.
Twin Tube Assembly is Remove the blockage.
blocked.
Moisture build-up in Change Alcohol Wick
Alcohol Wick. inside Alcohol Cartridge.
Run 2 hours to dry optics
(remove the alcohol
cartridge and install
storage cap).
Inferior or contaminated Change Alcohol Wick
alcohol. inside the Alcohol
Cartridge. Use only
approved alcohol.
PortaCount Pro fit tester Run 2 hours to dry optics
is flooded with alcohol. (remove Alcohol Cartridge
and install Storage Cap).
Filter cover leaking. Replace cover and O-ring.
Plugged nozzle. See Nozzle Cleaning in
chapter.
Requires frequent Moisture build-up inside Change Alcohol Wick
refill of alcohol Alcohol Wick. inside cartridge. Run 2
(every hour or hours to dry optics
less) (remove the alcohol
cartridge and install
storage cap) Use only
approved alcohol.
Alcohol visible in PortaCount Pro fit tester Run overnight to dry
Twin Tube is flooded with alcohol. optics (remove Alcohol
Assembly or Cartridge and install
coming out of storage cap).
Exhaust Port
74 Chapter 7
High A near-by particle Turn off or turn down any
Concentration generator is elevating particle generators
message ambient concentration operating in the vicinity
levels. such as humidifiers or the
Model 8026 Particle
Generator.
Keep all forms of particle
generation at least 6 ft
(1.8 m) from the
PortaCount fit tester
during fit testing.
The room ventilation Increase room ventilation.
system is reduced or
turned off.
Ambient concentration is In situations where the
naturally elevated, ambient concentration is
elevated through pollution,
construction, or other
means where it cannot be
controlled, the trigger
threshold for the warning
may be raised as
described in Chapter 5
Operating Modes and
User Interface. Note that
prolonged exposure to
excessive particle
concentration levels could
degrade the performance
of the PortaCount fit tester
over time, requiring more
frequent maintenance.
Troubleshooting 75
76 Chapter 7
Appendix A
Specifications
(Specifications are subject to change.)
Model 8030 PortaCount Pro Respirator Fit Tester

Size ......................................................... 9.5 x 8.5 x 6.75 in.
(24 x 22 x 17 cm)
Weight
Unit only ............................................ 5.0 lb. (2.7 kg)
With standard accessories and case .. 16 lb. (7.3 kg)
Fit Factor Range .................................... 1 to greater than 10,000

Concentration Range............................ 0.01 to 2.5 x 105
particles/cm3
Particle Size Range ............................... 0.02 to greater than
1 micrometer
Typical Fit Factor Accuracy ................. 10% of reading up to fit
factors of 10,000
Temperature Range
Operation .......................................... 32 to 100°F (0 to 35°C)
Storage ............................................. -40 to 160°F (-40 to 70°C)
Flow Rate
Sample ............................................. 350 cm3/min
Total .................................................. 1000 cm3/min (nominal)
Power Requirements ................................... 100 to 250 VAC, 50 to 60 Hz
Alcohol
Hours per charge .............................. 6 hours at 70°F (21°C)
Alcohol type ...................................... Reagent grade isopropyl
(99.5% or better)
Carrying Case
Size ................................................... 19.5 x 13.7 x 9 in.
(49.5 x 34.8 x 23 cm)
Pass/Fail Settings ................................. User-selectable: 0 to 10000
Factory Recalibration Interval ............. 1 year
Warranty................................................. Two years on workmanship
and materials
77
Respirator Facepieces that can be Fit Tested
Full-face elastomeric
Half-face elastomeric
NIOSH series-100 filtering-facepiece
NIOSH series-95 filtering-facepiece (8038 upgrade required for
series-95 only)
Fit Factor Measurement

Direct measurement of fit factor (Cout/Cin)
(Mask leakage is measured simultaneously while test subject moves
and breathes.)
Model 8038 PortaCount Pro+ Respirator Fit Tester

Size ......................................................... 9.5 x 8.5 x 6.75 in.
(24 x 22 x 17 cm)
Weight
Unit only ............................................ 6.8 lb. (3.1 kg)
With standard accessories and case .. 18 lb. (8.2 kg)
Fit Factor Range .................................... 1 to greater than 10,000;

1 to 200 for < 99% efficiency
masks
Concentration Range ............................ 0.01 to 2.5 x 105
particles/cm3
Particle Size Range ............................... 0.02 to greater than
1 micrometer
Typical Fit Factor Accuracy ................. 10% of reading up to fit
factors of 10,000
Temperature Range
Operation .......................................... 32 to 100°F (0 to 35°C)
Storage ............................................. -40 to 160°F (-40 to 70°C)
Flow Rate
Sample .............................................. 350 cm3/min
Total .................................................. 1000 cm3/min (nominal)
Power Requirements.................................... Autosensing 100 to 250
VAC, 50 to 60 Hz
78 Appendix A
Alcohol
Hours per charge .............................. 6 hours at 70°F (21°C)
Alcohol type ...................................... Reagent grade isopropyl
(99.5% or better)
Carrying Case
Size ................................................... 19.5 x 13.7 x 9 in.
(49.5 x 34.8 x 23 cm)
Pass/Fail Settings ................................. User-selectable: 0 to 10000
Factory Recalibration Interval ............. 1 year
Warranty................................................. Two years on workmanship
and materials
Respirator Facepieces that can be Fit Tested
Full-face elastomeric
Half-face elastomeric
Fit Factor Measurement

Direct measurement of fit factor (Cout/Cin)
(Mask leakage is measured simultaneously while test subject moves
and breathes.)
Specifications 79
80 Appendix A
Appendix B
Theory of Operation
How the PortaCount Pro Respirator Fit Tester Works

The PortaCount® Pro fit tester measures respirator fit by comparing the
concentration of microscopic particles outside the respirator to the
concentration of particles that have leaked into the respirator. The ratio of
these two concentrations is called a fit factor. A fit factor of 100 means
that the air inside the respirator is 100 times as clean as the air outside.
Outside Concentration
Fit Factor 
Inside Concentration
Since the microscopic

particles in the air
cannot pass through
the class-100 or
class-99 filters used
on the respirator, any
particles that get into
the respirator must
have come in through
a leak.
The PortaCount Pro fit

tester has two sample
tubes, one samples
ambient air and the
other attaches to the
respirator and samples
from inside it. A valve
inside the PortaCount
Pro fit tester switches
from one tube to the
other according to a
programmed
sequence.
81
How the PortaCount Pro Fit Tester Counts Particles
The PortaCount Pro fit tester is based on a miniature, continuous-flow
Condensation Nucleus Counter (CNC), also known as a Condensation
Particle Counter (CPC). A CNC takes particles that are too small to be
easily detected, grows them to a larger, easily detectable size, and then
counts them.
The idea of CNCs/CPCs is not new. As early as 1888, Aitken

described a dust counter that grew particles to detect them. In 1943
the Nolan-Pollack photoelectric CNC was described. In the 1950s and
1960s, commercial, automatic CNCs were available. However, none
were of the continuous-flow type, and the PortaCount Respirator Fit
Tester is the first highly portable continuous-flow CNC.
The concept of using a condensation nucleus counter (CNC) for the

purpose of quantitative respirator fit testing was first demonstrated in
1981 by Dr. Klaus Willeke of the University of Cincinnati.
Reference: Willeke, K., H.E. Ayer, J.D. Blanchard. “New

Methods For Quantitative Respirator Fit Testing With
Aerosols,” American Industrial Hygiene Association
Journal, Feb. (1981).
The PortaCount Pro Respirator Fit Tester grows submicron particles

to supermicron alcohol droplets and then measures the concentration
of the alcohol droplets. This makes the PortaCount Pro Fit Tester
sensitive to particles with diameters as small as 0.015 microns, but
insensitive to variations in particle size, shape, composition, and
refractive index. Thus, quantitative fit testing can be performed with
virtually any aerosol, including ambient air.
Aerosol is drawn through the instrument by a diaphragm vacuum

pump operating at a flow rate of 1.0 liter per minute. The flow enters
the instrument through either the ambient port or the sample port. The
switching valve determines which port is used. The outlet of the
switching valve leads to the saturator end cap, where the flow splits.
A flow rate of 0.35 liters per minute enters the saturator and passes
through the condenser, nozzle, and sensing volume. The remaining
flow passes through the excess airline and is recombined with the
sampled flow down-stream of the sensing volume.
82 Appendix B
The PortaCount Pro sensor consists of a saturator, condenser, and
optical elements. The saturator is lined with an alcohol-soaked wick.
A thermoelectric device is mounted between the saturator and
condenser which cools the condenser and heats the saturator. After
passing through the saturator, the aerosol (now saturated with alcohol
vapor) enters the condenser tube. The alcohol vapor condenses on
the particles, causing them to grow into droplets. The droplets then
pass through the nozzle and into the sensing volume as depicted in
the schematic diagram below.
The focusing optics in the sensor consists of a laser diode and a

series of lenses that focus the laser light into a sensing volume just
above the nozzle. Each particle passing through the sensing volume
scatters light. The light is collected by the receiving optics and
focused onto a photodetector. The photodetector generates an
electrical pulse from the scattered light as each droplet passes
through the sensing volume. The particle count is determined by
counting the number of pulses generated during a given time period.
Knowing the particle count, time period and flow rate allows particle
concentration to be computed.
Theory of Operation 83
84 Appendix B
Appendix C
Calculating Fit Factor
Fit factor is defined as the particle concentration outside the respirator

divided by the particle concentration inside the respirator.
Because ambient concentration can vary over time, the PortaCount®

Pro Respirator Fit Tester calculates the fit factor by taking the average
of the ambient concentrations measured before and after the
respirator sample and then dividing by the concentration measured in
the respirator. This is why the first test cycle (exercise) is longer than
additional test cycles in Fit Test Mode. It is necessary to measure the
required additional ambient concentration sample before the first fit
factor can be calculated.
Both the ambient and respirator concentrations are determined by

integration. The integrated concentrations are determined by the total
number of particles counted during the sample periods.
Fit factor is actually calculated by:
CB  CA
FF 
2CR
where: FF = fit factor

CB = particle concentration in the ambient sample before
the respirator sample
CA = particle concentration in the ambient sample after
the respirator sample
CR = particle concentration in the respirator sample.
If no particles are counted in the respirator sample, the PortaCount

Pro fit tester automatically adds one particle. This prevents dividing
the ambient concentration by zero. At the end of a fit test, the overall
fit factor is calculated and displayed, based on the individual fit factors
for each test cycle.
85
The following equation is used to calculate the overall fit factor in the
PortaCount Pro fit tester:
n
Overall FF 
1 1 1 1 1
   ...  
FF1 FF2 FF3 FFn 1 FFn
where: FFx = fit factor for test cycle

n = number of test cycles (exercises).
Disclaimer: The measurement provided by the PortaCount Pro

Respirator Fit Tester is an assessment of respirator fit
during a fit test only. Respirator fit at other times will
vary. The fit factor value is not intended for use in
calculating an individual's actual exposure to hazardous
substances.
86 Appendix C
Appendix D
Calculating Particle Concentration
Particle concentration is calculated by counting the number of

particles passing through the sensor in a given period of time. Since
the flow rate is known (5.83 cm3/sec), the particle concentration can
be determined.
In 1-Second Count Mode the equation is:
N1
ParticleConcentration 
(1 sec) 5.83 cm3 / sec
where N1 is the number of particles counted in a 1-second period
Note that the total flow rate of air through the PortaCount® Pro is a
nominal 16.7 cm3/sec. The reason that we use 5.83 cm3/sec. in the
calculations above is because the flow path inside the PortaCount
PRO is divided into two branches, the sensor flow and the bypass
flow. The sensor flow is set at precisely 5.83 cm3/sec and the bypass
flow is approximately 10.8 cm3/sec.
Using the equation above, you can see that the minimum measurable
concentration is 0.17 particles per cm3 in 1-Second Count Mode.
The equations above can also be used to determine the minimum

measurable mask concentration that can be measured in Fit Test
Mode given the mask sample time that is used. For example, with a
40 second mask sample (factory setting), the minimum measurable
concentration is 0.004 particles per cm3.
87
88 Appendix D
Appendix E
Timing in Fit Test Mode

Test Sequence
When performing a fit test, PortaCount® Pro Respirator Fit Tester
automatically samples both the ambient air and the particles inside
the respirator. An internal switching valve automatically switches
between the two sampling ports. In each test cycle, (exercise) both an
ambient sample and a respirator sample are taken. Also, time is
allowed for purging of the sensor between each of the samples.
The PortaCount Pro fit tester uses the ambient sample taken before
and after each exercise to compute the fit factor. The two ambient
particle concentrations are averaged together and then divided by the
mask particle concentration to yield the fit factor for that exercise.
Averaging the before and after ambient particle concentrations is
done to offset any ambient particle concentration drift that may have
occurred during the mask sample.
Caution
Do not lengthen the Twin Tube Assembly more than a
few inches unless the mask sample purge time has also
been extended accordingly. Insufficient purging between
mask and ambient samples will result in unrealistically
low fit factors. Shortening the Twin Tube Assembly is
never a problem.
89
90 Appendix E
Appendix F
Using the PortaCount® Pro Respirator Fit

Tester to Fit Test Positive Pressure
Respirators
On January 8, 1998, OSHA released the long-awaited revision to the

Respiratory Protection Standard 29CFR1910.134. It replaces the
standard with the same name and number that was released in 1971.
This new revision has far reaching impact on a large number of
existing OSHA standards in that it replaces certain provisions related
to respirator use.
One of the new requirements is that OSHA now requires all tight-
fitting respirator facepieces to be fit tested annually. This includes air-
supplied and positive-pressure respirators such as Powered Air
Purifying Respirators (PAPR), airline respirators, and Self Contained
Breathing Apparatus (SCBA). With few exceptions, these respirator
styles were previously exempted from OSHA's fit testing
requirements. For detailed information regarding the new standard
and to download your own copy, see TSI Application Note ITI-056
Respirator Fit Testing Highlights for OSHA Respiratory Protection
Standard 29CFR1910.134 on our website http://fittest.tsi.com.
Self-Contained Breathing Apparatus (SCBA) are respirators that

supply breathing air from a backpack mounted tank. The most
common application for SCBA is firefighting. There are other types of
positive-pressure respirators also, including air-line and recirculating
respirators.
Powered Air Purifying Respirators (PAPRs) are a special class of

respirator that utilizes a battery operated blower motor to pump air
into the mask through an air-purifying cartridge. The blower/filter
assembly is usually either belt mounted or fastened to the front of the
facepiece.
The OSHA fit testing requirement is only for tight-fitting masks. Tight
fitting respirators utilize a facepiece similar to the facepiece on a
conventional negative-pressure air-purifying respirator with filter
cartridges. In fact, many respirator manufacturers use the identical
facepiece for negative and positive-pressure respirators. Tight-fitting
masks form a tight seal around the wearer's face.
91
Loose fitting respirators usually employ a hood that fits over a
person's head and loosely seals around the neck. The quality of the
seal is not dependent on a close physical match with the wearer's
body. Since there is no "seal" to test, there is no requirement to do a
fit test. Note that some hood-type respirators are classified as tight-
fitting and, therefore, require fit testing.
Respirator fit testing (testing facepiece leakage) cannot be done while

the pressure inside the facepiece is maintained positive by some
outside air supply. The positive-pressure will alter the seal and the
measurement will not reflect how well the shape of the facepiece
matches the person's face. For this reason, all fit testing of positive-
pressure respirators must be done in negative-pressure mode, or in
other words, without a forced air supply. Any tests done in positive
pressure mode are overall performance tests, not fit tests. Hood-style
respirators can be performance tested but not fit tested because there
is no face seal to test.
There are two ways to accomplish fit testing positive-pressure masks

in negative-pressure mode. The method preferred by many is to
temporarily convert the employee's assigned mask into a negative-
pressure mask. This is accomplished through the use of special fit
test adapters that temporarily attach to the mask and allow the use of
filter cartridges. Added benefits of this method are that an integrity
test of the mask is performed simultaneously with the fit test and also,
the hygienic concerns associated with sharing a test mask are greatly
reduced. Fit Test Adapters are available from the respective
respirator manufacturer and from TSI for many popular respirators.
When an adapter is not available, the only alternative is to use a

surrogate mask or test mask. This involves purchasing a negative-
pressure air-purifying mask that has the same sealing surfaces as the
positive-pressure mask that will actually be used for respiratory
protection. For quantitative fit testing, the mask will need a sampling
port so that a sample can be drawn from the breathing zone. Most
respirator manufacturers have these available. If the mask comes in
multiple sizes, you will need at least one test mask in each size.
Using this technique, fit testing for positive-pressure respirators
becomes identical to fit testing for negative-pressure respirators.
For those people who wish to conduct performance tests on positive-

pressure respirators using a PortaCount fit tester, there are a few
special precautions. The primary concern is aerosol particulates in the
air supply. The PortaCount fit tester will measure these particles as
leakage and report performance factors (fit factors) that are
92 Appendix F
significantly lower than actual. Most PAPRs have a blower motor on
the clean side of the filter. Most of these motors generate small
particles that the PortaCount fit tester can easily measure. Likewise,
air from SCBA tanks, and from compressors, contains significant
numbers of particles. Grade D breathing air is by no means particle
free. The only way to overcome this problem is to pass the air through
a HEPA filter just before it reaches the facepiece. There is no OSHA
requirement to do this type of performance testing.
Related information located on the TSI Web site: http://fittest.tsi.com:

 TSI Application Note ITI-070, Introduction to Respirator Fit
Testing
 TSI Application Note ITI-029, What You Need to
Quantitatively Fit Test Various Brands of Self-Contained
Breathing Apparatus Available in the USA
 Fit test adapter list
 TSI Application Note ITI-056, Respirator Fit Testing Highlights
for OSHA Respiratory Protection Standard 29CFR1910.134.
Using the PortaCount Pro to Fit Test Positive Pressure Respirators 93

94 Appendix F
Appendix G
The Rainbow Passage
95
96 Appendix G
Index
8 B E
8025-N95 probe kit, 19 B receptacle, 9 electrical connections, 9
bend and touch toes, 37 error messages
A blue tube, 8 high concentration, 75
bottle low particle, 61, 70
A receptacle, 9
alcohol, 6, 27, 62, 63, exclude, 54
AC adapter, 5
67 exercise name, 54
AC Adapter, 10
breathing zone, 18 exercised, 36
activities menu, 47
button, O/I, 30 external control mode,
activities tab, 31, 34, 48
47, 48
daily check, 48
C external power
fit test, 48
connector, 9
realtime, 49 calculating
adapter fit factor, 85
homemade, 18 particle concentration, F
advanced database tools, 87 fit factor
44, 58 cancel, 54 calculating, 85
clean copy, 45 carrying case, 6, 13 fit factor of 1 or very low,
copy, 45 cartridge cavity, 11 72
delete, 46 changing fit test, 48
save, 45 alcohol wick, 63 conducting, 32
save as, 46 clean copy, 45 fit test adapter
statistics, 45 clear tube, 8 kit, 18
alcohol common problems, 40 fit test mode
supplies, 11 conduct a fit test, 25 test sequence, 89
alcohol capsule conduct fit test, 36 fit test report
fill line, 27 conducting fit test, 32 printing, 43
alcohol cartridge, 5, 11, connections fit test reports, 53
26, 27 electrical, 9 fit testing
reassembling, 65 copy, 45 personal respirator, 18
removing wick, 64 current protocol, 35 without computer
warning, 26 software, 26
alcohol coming out of D FitPro+™ software CD,
exhaust port, 74 13
daily check, 48
alcohol fill capsule, 5, 11, flash drive, 1, 9, 29
daily checks, 30, 31
26, 63
data handling, 43
alcohol visible in twin G
database tab, 52
tube assembly, 74
date and time, 56 generated aerosol, 3
alcohol wick, 5, 11
deep breathing, 36 generator. (see particle
changing, 63
delete, 46 generator)
high humidity, 63, 65
demo database, 1 global settings, 58
ambient concentration
device info, 56 exit, 60
check, 50
dialog box save, 60
ambient port, 8
select a respirator, 35 grimace, 37
ambient purge, 54
disclaimer, ii, 3, 86
ambient sample time, 54
does not switch on H
ambient tube, 8
message, 70
anvil tool, 22 head side to side, 36
duckbill style respirator,
automatically print report head up and down, 37
20
for saved fit tests, 59 high concentration
due date, 35
message, 75
97
high concentration factory recalibration people table, 53
warning, 62 interval, 79 piercing tool, 21
high concentration fit factor measurement, PortaCount
warning level, 59 79 theory of operation, 81
high humidity, 63, 65 fit factor range, 78 troubleshooting, 69
homemade adapter, 18 flow rate, 78 positive pressure
particle size range, 78 respirator, 23
I–J pass/fail settings, 79 powered air purifying
power requirements, 78 respirators (PAPRs),
introduction, 1
size, 78 91
irritant smoke, 3
specifications, 78 precautions, 3
temperature range, 78 print
K typical fit factor test, 58
keyboard accuracy, 78 printer, 41
on-screen, 34, 35, 53, warranty, 79 compatibility, 41
54, 55, 56 weight, 78 connecting/testing, 41
USB, 9, 34 modes of operation, 47 fit test reports, 42
setup tab, 56
L N printer setup, 57
printer test, 58
low alcohol level, 62 N95 (Model 8038 only),
printer test function, 41
low fit factors 55
printing fit test reports, 42
common problems, 40 N95 enabled, 31
probe assembly tool, 6,
low particle, 61 neck strap, 6, 14
14
low particle message, 70 new exercise name, 55
probe kit, 6
next test due in __
probed test respirators,
M months, 55
17
normal breathing, 36, 37
maintenance, 61 probes for filtering
nozzle cleaning, 66
mask purge time, 55 facepiece respirators,
mask sample time, 55 19
mask size, 35
O product registration, 2
max FF check, 32 OK, 54 protocol information, 35
Model 8030 operating modes, 47 protocol name, 55
alcohol, 77 operation in high protocol table, 54
carrying case size, 77 humidity, 65
concentration range, 77 OSHA requirements, 38, Q
factory recalibration 91
quantitative fit testing
interval, 77 overall fit factor, 39
respirators, 17
fit factor measurement, equation, 86
78 overview, 1
fit factor range, 77
R
flow rate, 77 P rainbow passage, 95
particle size range, 77 realtime data display, 50
packing list, 5
pass/fail settings, 77 realtime fit factors, 49
particle check, 31
power requirements, 77 reassembling alcohol
particle concentration
size, 77 cartridge, 65
calculating, 87
specifications, 77 recalibration interval, 61
particle count is zero or
temperature range, 77 recalibration touch
near zero message,
typical fit factor screen, 56
74
accuracy, 77 record information, 39
particle generator, 14, 70
warranty, 77 record results, 39
important
weight, 77 registration, 1
considerations, 15
Model 8038 removing wick from
parts
alcohol, 79 alcohol cartridge, 64
identifying, 7
carrying case size, 79 reordering supplies, 62
patent, ii
concentration range, 78 report format, 57
people list, 34
98 Index
requires frequent refill of stop fit test immediately Z
alcohol, 74 when any exercise
respirator fails, 55 zero check, 31
center mounted storage, 63 fails, 71
exhalation valve, 20 storage cap, 5, 11 zero check filter, 5, 13
duckbill style, 20 stylus, 5
fit testing with personal supplies
respirator, 18 reordering, 62
manufacturers’ suspicious readings, 73
technique, 18 suspiciously high fit
outer mesh, 21 factors, 41, 73
probed test, 17
probes for filtering T
facepiece, 19
talking out loud, 37
quantitative fit testing,
terminate fit test early, 60
17
test sequence, 89
testing positive
testing a disposable
pressure, 91
respirator, 33
respirator list field, 35
theory of operation, 81
respirator table, 53
thumb drive. (see flash
respirator training, 2
drive)
touch screen, 7, 47, 48
S calibration, 56
salt tablets, 6 trademarks, ii
sample port, 8 training the trainer, 2
sample timing field, 55 transporting or storing, 63
sample tube, 8 troubleshooting, 69
length, 8 tube adapter, 5, 8
sampling hose kit, 62 tube adapters, 12
sampling port inlet twin tube assembly, 5, 8,
screens, 12 62
sampling ports, 8
save, 45, 55 U
save as, 46
unpacking, 5
save fit tests to database,
USB cable, 13
59
USB flash drive, 13, 29,
select a respirator
52
dialog box, 35
USB keyboard, 9
select database, 30, 52
USB printer, 9, 53
self-contained breathing
USB receptacles, 9
apparatus (SCBA), 91
user interface, 47, 48
service, 61
service policy, ii
set the date, time, and V
date format, 56 verification of training, 2
setup tab, 56
shipping, 63 W–X–Y
sizing, 2
smokers, 3 warranty, i
software why fit test, 2
technical reference CD, wick
13 removing, 64
stand-alone fit testing, 43 wick retainer cap, 64
stand-alone mode, 47, 48
statistics, 45
status messages, 61
Index 99
TSI Incorporated – Visit our website www.tsi.com for more information.
USA Tel: +1 800 874 2811 India Tel: +91 80 67877200

UK Tel: +44 149 4 459200 China Tel: +86 10 8219 7688
France Tel: +33 1 41 19 21 99 Singapore Tel: +65 6595 6388
Germany Tel: +49 241 523030
P/N 6001868 Rev. P ©2015 TSI Incorporated Printed in U.S.A.

8030 8038 PortaCountPro Manual 6001868

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8030 8038 PortaCountPro Manual 6001868

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PORTACOUNT® PRO 8030 AND

PORTACOUNT® PRO+ 8038

P/N 6001868, REVISION P

The Model 8030 is designed to measure fit factors of masks with an

Regardless of whether you intend to use the PortaCount Pro

Database Operation When Operating in Stand-Alone

Registration allows TSI to keep in touch with you regarding important

Preparations for Fit Testing

2 Introduction and Overview

The TSI Web site http://fittest.tsi.com contains additional useful

Disclaimer: The measurement provided by the PortaCount Pro

Introduction and Overview 3

4 Introduction and Overview

Unpack and Verify Shipment

Standard Items PortaCount Pro/Pro+ Fit Tester

Additional Items PortaCount PRO+ Fit Tester (Model 8038 only)

Getting to Know the PortaCount Pro

The Touch Screen Display

1 The Sample Port is used when sampling air from a respirator

4 The USB Series “B” receptacle provides for communication

Getting to Know the PortaCount Pro Respirator Fit Tester 9

7 The AC Adapter plugs into the External Power Connector on the

8 The Alcohol Cartridge holds the isopropyl alcohol consumed by

Getting to Know the PortaCount Pro Respirator Fit Tester 11

Getting to Know the PortaCount Pro Respirator Fit Tester 13

25 Model 8026 Particle Generator. If you do not have the minimum

 Keep the Particle Generator or any other sources of particle

Getting to Know the PortaCount Pro Respirator Fit Tester 15

About Respirators and Fit Testing

Probed Test Respirators

Most probed respirators are obtained from the respirator

Class-100 Filter Sample Tube Cap Suction Cup

Respirator Manufacturers' Technique

TSI Fit Test Adapter Kits

Inserting a Test Probe in a Disposable Respirator with

1. Choose a location to install the sample probe.

About Respirators and Fit Testing 19

Bottom panel shown

For respirators with center-mounted exhalation valves, install

Correct probe location to left

Wrong probe location

3. Choose a location on the mask that is in front of the person's

About Respirators and Fit Testing 21

Push the Tools

Positive Pressure Respirators

About Respirators and Fit Testing 23

Conducting a Fit Test with the PortaCount Pro

Step 1—Prepare the PortaCount Pro Respirator Fit

Fill the Alcohol Cartridge

Because the Alcohol Cartridge is inserted into the Cartridge Cavity of

Maintaining an adequate alcohol supply inside the PortaCount Pro fit

Remember: Always recap alcohol fill capsule and other

Step 2—Attach Flash Drive and Select Database

Step 3—Run Daily Checks

These daily checks are:

Completed daily checks provide confidence that the PortaCount Pro

To start the daily checks:

6. As instructed on the display, remove the HEPA filter or mask (if

Step 4—Conducting Fit Tests