Testor Training Manual
Contents
1. Series Pressure Reducer 3 2 PA9OPIus Series Pressure Reducer te 16142 May 2000 i gt Drager Testor 3 2 3 Test Hoses If the equipment to be tested has a continuous hose from the pressure reducer to the lung demand valve then to perform full functional testing using the Testor the hose must be disassemble from the reducer and replaced with the following test hoses as required PA90 Pressure Reducer 3339620 Plus Pressure Reducer 3337650 3 1 PA90 Series Pressure Reducer Tools Required 5mm AF Hexagon Socket Key 3335738 Medium Pressure Test Hose 3339620 Ensure the cylinder valve is Closed and the pressure vented from the system 2 Using the socket key unscrew and remove the blanking plug from the secondary medium pressure port in the end face of the pressure reducer 3 Inspect test hose and ensure that the O ring is fitted to the end fitting and is not damaged Screw the end fitting of the hose into the secondary medium pressure port in the end face of the pressure reducer hand tight 4 Proceed to either Section 2 1 Leak Testing Testor or Section 2 2 Testing the Breathing Apparatus 5 Following satisfactory testing of the equipment remove the test hose inspect O ring of the blanking plug and re fit plug to secondary port Tighten using socket key Carry out a high pressure leak test of the equipment 3 2 Plus Series Pressure Reducer Tools Required 2mm AF Socket Key 3337900 Medium Pressure Test H2. clockwise from the high pressure air source Disconnect the hose coupling of the separate lung demand valve hose from the left hand female coupling of the Testor and connect to the female coupling of the medium pressure hose of the pressure reducer Activate the lung demand valve to switch Off positive pressure then refit the lung demand valve to the facepiece ensuring a secure connection If the equipment tested has a continuous hose from the lung demand valve to the pressure reducer remove the test hoses as required Refer to Section 3 Carry out a high pressure leak test of the equipment Following satisfactory Tests complete the test details in the Log Book for the compressed air respiratory equipment Store the equipment in designated area Ready for Use te 16142 May 2000 lt lt gt Dr ger Testor 2 12 2 3 Testing Equipment Fault Finding The following test sequence should be carried out following any Failure identified during Functional Tests as described in Section 2 2 Reference should be also made to the Fault Location Section Aand the appropriate Training Service Manual 2 3 1 Facepiece This fault analysis is for guidance reference must be made to the Fault Location Section A and the appropriate Training Service Manual for the facepiece 2 3 1 1 Facepiece Negative Pressure Leak Test This fault analysis is for guidance reference must be made to the Fault Location Section A and the appr
3. i CAUSE REMEDY Inward outward leak 1 Damaged faulty Replace O ring when in facepiece port connection O ring 2 Damaged bore in front Replace Front Port port of facepiece Leak Test Positive 1 Banjo Seals Leaking Replace Seals pressure off 2 Balanced Piston Unit Replace Balanced Leaking Piston Unit High Static pressure Balanced piston lever Replace Springs springs too strong Low Static pressure Balanced piston lever Replace Springs springs too weak Demand Valve fails to 1 Bent damaged Balanced Replace Balanced switch automatically to Piston Lever Piston Unit positive pressure mode 2 Bent damaged retaining Replace Balanced spring plate Piston Unit te 16142 May 2000 lt j gt Dr ger Testor 4 4 4 3 Facepiece It is important to refer to the relevant Training Service Manual for full details of Service Maintenance recommendations with regard to the product in use Important Note This table is for guidance only reference must be made to the Fault Location section of the appropriate Training Service Manual FAULT CAUSE REMEDY Inward Leak 1 Exhalation valve Clean and or replace silicone leaking disc Inspect exhalation valve seat in front port for damage Clean and or replace Face seals leaking Inspect for damage 4 Facepiece rubber Replace facepiece rubber body perforated body pin holes cracking Will not Weak exhalation Replace exhalation valve hold maintain valve spring spring assembly p
4. port unless RH lever is held back otherwise a positive overpressure will be shown on the mbar gauge 9 Carefully push LH lever forward towards the sign until the needle of the mbar gauge rotates anti clockwise and indicates a negative pressure of 10mbar Release the LH lever then Start the timer the gauge reading should remain at 10mbar for 30 seconds Note Ifan under pressure occurs when pushing the lever forward then carefully pull the lever away from the sign until 10mbar is achieved then start leak test as above 10 Pull and hold the RH lever away from the sign and remove the blanking plug from the port at rear of the test head Release the RH lever The needle of the mbar gauge should return to 0 11 Close the cylinder valve then press and hold the LH lever towards the sign to vent pressure from system When vented activate the lung demand valve to switch off positive pressure Leak testing of the Testor now completed 12 Proceed to test the compressed air respiratory protection equipment see Section 2 2 mbar Medium Pressure 5 High Pressure Gauge Gauge Timer Air Source Mouthpiece LH Centre RH Male Connector Fig 3 1269 Dr ger Testor 2 6 2 2 Testing the Breathing Apparatus This procedure covers the functional testing requirement ofthe complete assembly of the compressed air respiratory prote
5. Drager Testor Training Manual Testor Drager Index Section 1 Section 2 Section 3 Section 4 Introduction and Safety Warnings Test Procedures Test Hoses Fault Location te 16142 May 2000 Qj f r Dr ger Testor 1 1 1 1 Introduction The Dr ger Testor test equipment provides an efficient means of testing the Functional features of the Dr ger range of compressed air respiratory protection equipment For details of the following reference should be made to the Instructions for Use supplied with the Testor Unit e Cleaning and Storage e Technical Data e Maintenance Intervals e Trouble Shooting It is recommended that the Testor Instructions for Use and this manual be read and fully understood before proceeding with any Functional Testing of compressed air respiratory protection equipment 1 2 For Your Safety Approved Drager compressed air respiratory protection equipment incorporate a Dr ger pre set and sealed pressure reducer A range of Lung Demand Valves Facepieces and associated ancillary units are approved for use with the equipment The Dr ger guarantee is void should original seal caps of the pressure reducer or any sealed component assemblies of the ancillary units be tampered with removed or broken Use of compressed air respiratory protection equipment requires wearer and service training knowledge and observance of the instructions contained in the Training Service Manual an
6. LH Centre RH Male Connector Fig 3 1269 Testor 2 9 10 Fully extend the straps of the head harness of the facepiece Moisten the inner face sealing lip and exhalation valve of the facepiece with clean water Place facepiece over rubber test head pulling the harness down the back of the head and positioning the head harness centrally with back of the head While holding down the harness towards the back of the head tighten each of the lower straps evenly towards back of head and repeat with the upper side straps See Fig 4 If necessary adjust the centre strap Fig 4 as required 1273 1 Carefully push the centre lever forward towards the sign to very carefully inflate the rubber head to achieve complete contact around the face seal of the facepiece Safety Note Do Not over inflate test head 12 Insert the blanking plug into the inlet inhalation port of the facepiece Ensure a secure assembly 13 Facepiece Negative Pressure Leak Test Set the timer to one minute Carefully push the LH lever forward towards the sign until the needle of the mbar gauge rotates anti clockwise and indicates a negative pressure of minus 6mbar Release the LH lever Immediately Start the timer The needle of the mbar gauge should not move from minus 6mbar to 3mbar in less than one minute If a fault is highlighted refer to Section 2 3 1 1 14 Exhalation Valve Lift Off Test Push and hol
7. cepiece Proceed to Section 2 3 2 18 If test satisfactory Close the valve of the high pressure air source Whistle Warning Unit Test Carefully push the LH lever towards the sign to slowly vent pressure from the system During slow venting observe the high pressure gauge of the equipment and check that the whistle activates an audible signal at between 60bar to 50bar mbar Medium Pressure High Pressure Gauge Gauge Timer Air Source Mouthpiece LH Centre RH Male Connector Fig 3 1269 Testor 2 11 Note 20 21 22 Note 23 As soon as the whistle activates an audible signal release the LH lever to allow the whistle to N vent the air Remove the lung demand valve from the facepiece Pull and hold the centre lever towards the sign to deflate the test head to average size and until the mbar and medium pressure gauges indicates 0 Release and extend the side straps of the head harness of the facepiece and remove the Fig 5 facepiece from the rubber test head If necessary reset the centre strap as shown in Fig 5 0017 If the equipment Passes the tests disconnect female coupling of the medium pressure hose from the coupling of the Testor If the reducer is fitted to an independent air source grip firmly the outer diameter of the handwheel of the pressure reducer and unscrew anti
8. ct the male coupling of the hose of separate lung demand valve units to the female quick release connector located at the left side of the Testor 7 Open the valve of the high pressure air source mbar Medium Pressure High Pressure Gauge Gauge Timer Air Source Mouthpiece LH Centre RH Male Connector Fig 3 1269 Dr ger Testor 2 8 8 Full Flow Test Press the centre of the rubber cover of the lung demand valve A and AE types will switch On to positive pressure Check that an unobstructed airflow vents from the lung demand valve See Safety Note Safety Note During the full flow test Do Not direct the outlet of the lung demand valve onto the face or skin This test should take a minimum of 3 5 seconds Following the test re activate the lung demand valve A and AE to switch Off positive pressure then immediately observe the medium pressure gauge Medium Pressure Test At an inlet pressure of gt 100bar the medium pressure gauge should indicate a pressure of between 6bar to 9bar after 5 seconds After one minute it is acceptable for the medium pressure to rise to 9 7bar During the timing of the medium pressure test check for audible leak s If a fault is highlighted refer to Section 4 mbar Medium Pressure High Pressure Gauge Gauge Timer Air Source Mouthpiece
9. ction equipment i e pressure reducer lung demand valve and facepiece 2 2 1 High Pressure Leak and Whistle Warning Unit Test Important Note The following is a general procedural sequence reference must be made to the appropriate Pre Operational Checks section of the Instructions for Use or the Test Procedure section of the Training Service Manual for the equipment Note If equipment has a quick release coupling on medium pressure hose then attach the lung demand valve to the coupling A and AE Activate the lung demand valve to switch Off positive pressure 2 Open cylinder valve slowly but fully to pressurise the pneumatic system Check the pressure reading of the high pressure gauge Close the cylinder valve and observe high pressure gauge Cylinder content should be at least 80 of maximum charge i e 160bar for 200 units or 240bar for 300 units 3 High Pressure Leak Test The high pressure gauge reading should not drop more than 10bar in one minute During the timing of the high pressure leak test check for audible leak s If the equipment fails to conform to test parameters vent the pressure from the system investigate source of the leak rectify and repeat test Until the leak is rectified Do Not carry out any further test If test is satisfactory proceed to Instruction 4 4 Whistle Warning Unit Test While slowly venting pressure from the system observe the high pressure gauge As the pressure decreases ch
10. d the Instructions for Use supplied with equipment e Use of equipment requires compliance with National Regulations Laws and Standards governing the use of respiratory equipment in the country of use e Use equipment only for the purpose specified in the Instructions for Use supplied with equipment or as confirmed in writing by Dr ger Trained and competent personnel should inspect and service equipment at regular intervals and a record kept of such inspections and servicing e Dr ger recommends a service contract be obtained from your Dr ger Branch or Agent e Contact Dr ger for details of Service Contracts and Service Training Courses e Notify Drager in the event of component fault or failure Use only original Drager Spare Parts for service and maintenance fe 16142 May 2000 a gt Dr ger Testor 2 1 Section Description 2 Test Procedures 2 1 Leak Testing Testor 2 2 Testing Breathing Equipment 2 3 Testing Equipment Fault Finding te 16142 May 2000 PA Dr ger Testor 2 2 2 Test procedures Standard test procedures for compressed air respiratory protection equipment are as follows Cylinder Pressure Check High Pressure Leak Test Whistle Warning Unit Test e t c Details of these tests are covered in the Functional Test Procedure Section of the relevant Service Training Manual for the equipment Having completed the Functional Test Procedures as defined in the relevant Service Train
11. d the RH lever forward towards the sign The needle of the mbar gauge rotates clockwise and will stop when the exhalation valve in the front port of the facepiece lifts from its sealing rim Keep the RH lever pushed forward the needle of the gauge should remain stable between the following values Front Port Facepiece 4 5mbar and 5 7mbar Side Port Facepiece 5 8mbar and 7 0mbar Release the RH lever If a fault is highlighted then refer to Section 2 3 1 2 15 Remove the blanking plug from the inhalation port of the facepiece then connect the lung demand valve to the inhalation port ensuring a secure connection Dr ger Testor 2 10 16 Balanced Piston Leak Test Pull the RH lever away from the sign to zero 0 the mbar gauge Release the RH lever The needle of the mbar gauge should not move from 0 to 4mbar in less than 5 seconds Note Ifa fault is highlighted this indicates a faulty Balanced Piston Unit stop the test service lung demand valve then re test 17 Static Pressure Test Push and hold the LH lever forward towards the sign The lung demand valve should activate to positive pressure mode audible activation Release the LH lever The mbar gauge should indicate a positive pressure reading of between Imbar to 3 9mbar No audible leak Note Ifa fault is highlighted activate the lung demand valve to switch Off positive pressure remove the lung demand valve from the fa
12. eck that the whistle activates an audible alarm signal at between 60bar to 50bar Vent pressure from system as follows A and AE Cover the outlet port of the lung demand valve with palm of the hand then press the centre of the rubber cover of the demand valve to switch On positive pressure Slowly vent pressure by carefully lifting palm of hand to maintain a slow steady decrease in pressure N Slowly vent equipment by carefully pressing centre of the rubber cover of the demand valve maintaining a slow steady decrease in pressure Note Before proceeding to test the equipment with the Testor ensure that the Testor Unit is satisfactory and has Passed the leak test as described in Section 2 1 Dr ger Testor 2 7 Tools Required Adaptor Rd40 to A R50028 Blanking Plug 3335421 Important Note If the equipment to be tested incorporates a lung demand valve that is connected directly to the pressure reducer then remove the demand valve from the reducer and assemble the following test hose as required Refer to Section 3 5 Connect the pressure reducer to a fully charged cylinder assembly or an independent high pressure air source then connect the female coupling of the medium pressure hose of the equipment to the male connector located at the right hand side of the Testor 6 Remove the lung demand valve from the inhalation port of the facepiece Activate the lung demand valve to switch Off positive pressure Conne
13. ing Manual and if the integrity of the lung demand valve facepiece or set has been broken due to repair and or replacement of components the following additional tests should be carried out using the Testor Test Equipment Full Flow Test Medium Pressure Test Facepiece Leak Test Facepiece Exhalation Valve Lift Off Test Balanced Piston Leak Test Positive Pressure Switch Over Static Pressure Test Refer to Section 2 2 for detailed instructions for the Functional Tests These functional tests should also be carried out in line with the Drager recommendations as outlined in the Maintenance and Test Interval Chart of the Instructions for Use and the Test Procedure Section of the appropriate Training Service Manual for the equipment to be tested It is recommended that this manual be read and fully understood before proceeding with any Functional Testing of compressed air respiratory protection equipment te 16142 May 2000 Qj f r Dr ger Testor 2 3 2 1 Leak Testing Testor Before starting any test or series of tests of compressed air respiratory protection equipment it is recommended that the Testor Unit be leak tested as described in the following instructions Tools Required Adaptor Rd40 to A R50028 Blanking Plug 3335421 Safety Note Connect only breathing quality air to the Testor Unit from a supply pressure source of maximum pressure 10bar Disconnect the lung demand valve from the female coupling of the medi
14. ng is fitted then insert the connector of the manifold into the outlet port of the reducer Insert retention staple into holes in reducer body Fully insert retention staple ensuring correct location into groove of manifold connector 1270 Dr ger Testor 3 4 Note Check manifold securely retained by pulling manifold away from reducer body 6 Locate groove of the retaining cap over the protruding portion of retention staple align screw holes insert screws and using 2mm socket key tighten screws 7 Proceed to either Section 2 1 Leak Testing Testor or Section 2 2 Testing the Breathing Apparatus 8 Following satisfactory testing of the equipment remove the test hose from the reducer Remove the lung demand valve from the manifold of the test hose and re assemble to the pressure reducer Carry out a high pressure leak test of the equipment te 16142 May 2000 Qj f r Testor Drager Section Contents 4 1 4 2 4 3 4 4 Pressure Reducer Lung Demand Valve Facepiece Whistle Warning Unit te 16142 May 2000 i Testor 4 1 Pressure Reducer Compressed air respiratory protection equipment manufactured by Drager incorporate a pre set and sealed pressure reducer assembly The Dr ger warranty conditions and guarantee is void should original seal caps be tampered with or removed Correct operational condition of the pressure reducer is guaranteed only if the unit is serviced and re sealed by Dr ge
15. opriate Training Service Manual for the facepiece e Check integrity of fit of facepiece to rubber test head Re fit facepiece and re test e Damage O ring on blanking plug Inspect Fit new O ring and re test e Check exhalation valve rubber disc is clean and not damaged Inspect Wash and clean Re fit and re test e Check sealing rim for exhalation valve rubber disc is clean and not damaged Inspect Wash and clean re test If damaged replace port assembly re test e Speech diaphragm locking ring not tight Inspect Tighten replace as necessary and re test e Speech diaphragm and or sealing ring damaged Inspect Replace as necessary and re test 2 3 1 2Exhalation Valve Lift Off Test High or Low Lift Off value High value Strong spring Low value Weak spring Inspect and fit new spring If an initial high reading is indicated but then settles to within the test parameter this indicates a sticky exhalation valve disc and or sealing rim Remove clean rinse in clean water re fit and re test te 16142 May 2000 Qj f r Dr ger Testor 2 13 2 3 2 Lung Demand Valve Pull the centre lever of the Testor towards the sign to reset the internal shuttle valve of the Testor Unit then release the lever Pull and hold the RH lever away from sign then insert the lung demand valve into the adaptor port at the rear of the test head Release the RH lever The needle of the mbar gauge sh
16. ose 3337650 Close the cylinder valve of the equipment and ensure the system is vented Unscrew reducer handwheel from cylinder valve Loosen cylinder strap slide cylinder away from reducer and remove cylinder from equipment te 16142 May 2000 Qj f r Testor 3 3 Refer to Figure 1 2 Using 2mm socket key unscrew anti clockwise and remove two screws 1 from reducer body remove retaining cap 2 and retention staple 3 Grip and pull the lung demand valve hose 4 to remove the hose from the outlet port of the reducer Note Component parts of relief valve i e spring O ring retainer and O ring remain attached to nozzle of the lung demand valve hose Do Not remove components Refer to Figure 2 3 Using 2mm socket key unscrew anti clockwise and remove two screws 1 from the manifold block of the test hose remove retaining cap 2 and retention staple 3 Insert the end fitting of the lung demand valve hose into manifold port push and hold against the compression spring insert retention staple 3 through holes in manifold Fully insert retention staple ensuring correct location into groove in hose end fitting Note Check hose securely retained by Fig 2 pulling hose away from manifold 0306 4 Locate groove of retaining cap over protruding portion of retention staple align holes insert screws and using 2mm socket key tighten screws Refer to Fig 3 5 Ensuring O ri
17. ositive pressure maintain headstrap adjustment 2 Buckle rollers Assemble correctly incorrectly fitted Unable to Strap ratchets worn Replace headstrap te 16142 May 2000 Qj f r Dr ger Testor 4 5 4 4 Whistle Warning Unit It is important to refer to the relevant Training Service Manual for full details of Service Maintenance recommendations with regard to the product in use Important Note This table is for guidance only reference must be made to the Fault Location section of the appropriate Training Service Manual FAULT u CAUSE REMEDY Whistle sounds at Incorrect whistle setting Reset whistle wrong pressure Whistle sounds Damaged H P piston seat 1 2 or 3 Remove continuously Piston seal leak H P hoses from reducer Plunger housing seal leak M P and return reducer to Drager REX Poor sounding Blocked whistle tube flute Clean or replace whistle and or jet whistle tube Blocked Filter Replace filter filters Split or perforated rubber hose Replace hose of dual pressure hose leaking Faulty activation Remove hoses from reducer and return reducer to Drager REX Whistle does not Blocked whistle tube flute Clean or replace sound and or jet whistle tube Blocked Filter Replace filter filters Split or perforated rubber hose Replace hose of dual pressure hose leaking Faulty Activation Remove hoses from reducer and return reducer to Drager REX te 16142 May 2000 lt j gt
18. ould return to 0 2 Leak Test Lung Demand Valve Carefully push the RH lever forward towards sign The needle of the mbar gauge rotates clockwise Set the needle of the gauge to 7mbar Release the RH lever Note f an over pressure occurs when pushing the RH lever forward then carefully pull the LH lever away from the sign until 7mbar is achieved then start leak test as follows Needle of the mbar gauge should not move from 7mbar to 6mbar in less than one minute If a failure occurs refer to Section 4 Following the test pull the RH lever back away from sign until the needle of the mbar gauge indicates 0 Release the RH lever 4 Static Pressure Test Push and hold the LH lever forward towards the sign The lung demand valve should activate to positive pressure mode audible activation Release the LH lever The mbar gauge should indicate a positive pressure reading of between 1mbar to 3 9mbar If a failure occurs refer to Section 4 Vent pressure from system Important Note If any failures occur during these tests service the equipment as necessary Refer to the appropriate Training Service Manual Retest equipment with the facepiece mbar Medium Pressure High Pressure Timer U y ee kS Mouthpiece LH Centre RH Male Connector Fig 3 1269 Dr ger Testor 3 1 Section Contents 3 Test Hoses 3 1 PA90
19. r Dr ger 4 2 Return faulty units less hoses and any accessories to Dr ger Service Refer to the relevant Training Service Manual for full details of Service Maintenance recommendations with regard to the product in use Important Note This table is for guidance only reference must be made to the Fault Location section of the appropriate Training Service Manual High Pressure Leak Valve Leak from pressure relief valve Leak from pressure relief valve components o k High or Low Medium Pressure High Pressure Leak at connection Damaged valve plunger seat Gauge Seal Damaged O Ring Weak Spring Damaged O Ring Retainer Reducer Failure Reducer out of specification Damaged HP O Ring Damaged Metal Components te 16142 May 2000 Overhaul Valve Return to Dr ger Service Replace O Ring Replace O Ring Replace Spring Replace Retainer Remove hose and replace reducer Return suspect reducer to Dr ger Service Remove hose and replace reducer Return suspect reducer to Dr ger Service Replace O Ring Refer to Dr ger Service de Dr ger Testor 4 3 4 2 Lung Demand Valve It is important to refer to the relevant Training Service Manual for full details of Service Maintenance recommendations with regard to the product in use Important Note This table is for guidance only reference must be made to the Fault Location section of the appropriate Training Service Manual FAULT
20. um pressure hose of the equipment pressure reducer and connect the separate lung demand valve to the female quick release connector located at the left side of the Testor Refer to Fig 1 Connect the female coupling of the medium pressure hose of the equipment to the male Fia I connector located at the right Ig hand side of the Testor Unit Refer to Fig 2 Note If the equipment to be tested incorporates a lung demand valve that is connected directly to the pressure reducer then it is necessary to assemble the following test hoses as required Refer to Section 3 PA90 Pressure Reducer 3339620 ePlus Pressure Reducer 3337650 Important Note If using a test hose lung Fig 2 demand valve connected 1271 activate the lung demand valve to switch Off the positive pressure 2 Set the timer to one minute Fully open the cylinder valve or independent air supply source Allow the needle of the medium pressure gauge of the Testor to stabilise 3 Close the cylinder valve then start the timer Observe the high pressure gauge of the equipment the gauge reading should not drop more than 10bar in one minute During the timing of the pressure leak test check for audible leak Dr ger Testor 2 4 Refer to Fig 3 4 Reset the timer to one minute Fully open the cylinder valve Carefully push the centre lever forward towards the sign and very carefull
21. y inflate the rubber head to approximately average head size Safety Note Do Not over inflate test head 5 Start the timer At the end of the timing sequence the test head should show no signs of reduction in size deflation 6 Reset the timer to 30 seconds With the test head still inflated moisten the end of the finger or thumb with water and place and hold over the hole in the mouth fitting of the test head Carefully push the RH lever forward towards the sign until the mbar gauge indicates 20mbar If an over pressure reading occurs when pushing lever forward then pull carefully on the LH lever away from the sign until the pressure reading reduces to 20mbar Start the timer The gauge reading should remain at 20mbar for 30 seconds After 30 seconds remove thumb from mouth fitting of test head the needle of the mbar gauge should return to 0 Press the timer Stop button 7 Pull and hold the centre lever towards the sign to deflate the rubber test head to approximately average head size mbar Medium Pressure High Pressure Gauge Gauge Timer Air Source Mouthpiece LH Centre RH Male Connector Fig 3 1269 Dr ger Testor 2 5 8 Pull and hold the RH lever back away from sign and insert male blanking plug into port at rear of test head Release the RH lever Note Do Not insert the blanking plug into
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