Top level protection for demanding hazmat response.
Zytron® 500 is the classic emergency responder choice for hazmat response and other demanding situations. It’s tough, built for mobility, and based on patented technology that created the first material to survive eight full hours against the ASTM F1001 Test Battery with no breakthrough. Choose from coveralls, splash and vapor total encapsulating suits, and NFPA-certified styles.
Zytron 500 is available in a wide range of styles from coveralls to total encapsulating suits. Start with the garment type, then pick entry, back style and gloves in the model chooser below.
Also in the line: training suits and the Zytron 500 overhood.
Style drawings are illustrationsEvery style is listed by its Kappler style code. Construction features, colors and sizes are shown on each card; open a style to see sizes and pricing, or ask us for a quote on a mixed order.
The letters and digits in a Kappler style number spell out the fabric, seam type, garment type and any NFPA certification or option.
Attached hood with elastic face opening and the LongNeck™ Respirator-Fit Closure.
Expanded back, Expanded View AntiFog Visor System and 1 exhaust port, in front or rear entry.
AquaSeal® Gas-Tight Zipper, Expanded View AntiFog Visor System and Attached Field Replaceable Butyl Gloves, in flat back or expanded back.
Pass-thru options: request a quote
2N1® Glove System on Hazmat styles eliminates the problem of inner glove inversion. Visor with additional FEP overlay and knee reinforcements.
Pass-thru options: request a quote
Pass-thru options: request a quote
NFPA 1990 (1994) Class 2 and NFPA 1990 (1992) styles available.
Zytron 500 training suits with serged seams and a large PVC visor, plus the Zytron 500 hood.
Greater than 8-hour holdout against hundreds of chemicals, with proven holdout against Chemical Warfare Agents (CWA).
Zytron 500 is Kappler’s top-tier chemical protection fabric for hazmat work where there’s no margin for error. Now with an extensive chemicals-tested list numbering in the hundreds, responders around the world trust Z500 garments for ultra-demanding Level A and Level B applications.
Zytron 500 ASTM F1001 Chemical Test Battery*
| Chemical | Minutes |
|---|---|
| Acetone | >480 |
| Acetonitrile | >480 |
| Carbon Disulfide | >480 |
| Dichloromethane | >480 |
| Diethylamine | >480 |
| Dimethylformamide | >480 |
| Ethyl Acetate | >480 |
| n - Hexane | >480 |
| Methyl Alcohol | >480 |
| Nitrobenzene | >480 |
| Sodium Hydroxide | >480 |
| Sulfuric Acid | >480 |
| Tetrachloroethylene | >480 |
| Tetrahydrofuran | >480 |
| Toluene | >480 |
| Gases | |
| Ammonia Gas | >480 |
| 1,3 Butadiene Gas | >480 |
| Chlorine Gas | >480 |
| Ethylene Oxide Gas | >480 |
| Hydrogen Chloride Gas | >480 |
| Methyl Chloride Gas | >480 |
* Industrial chemical testing was conducted in accordance with ASTM F739 with normalized breakthrough times reported in minutes.
Chemical Warfare Agent Data**
| Chemical Agent | Minutes | Criteria |
|---|---|---|
| Bis (2-chloroethyl) sulfide (Mustard:HD) | >480 | 4.0 ug/cm2 |
| Isopropyl methylfluorophosphonate (Sarin:GB) | >480 | 1.25 ug/cm2 |
| Chlorovinyl arsinedichloride (Lewisite:L) | >480 | 4.0 ug/cm2 |
| O-ethyl S-(2-diisopropylaminoethyl) methylphosphonothiolate (Nerve:VX) | >480 | 1.25 ug/cm2 |
** Chemical Warfare Agent testing was conducted in accordance with MIL-STD-282 and/or NFPA 1990 (1994) with breakthrough times reported based on total cumulative permeation.
Note: These tests were performed in accordance with ASTM or other appropriate testing methods by independent laboratories. This data is derived from tests performed on material samples only, not finished garments.
Ask us about Zytron 500 chemical data. Email sales@farrwest.com or call 210.566.1857.
NFPA 1992 and NFPA 1994 are now consolidated under NFPA 1990. Three Zytron 500 styles carry certification: one splash suit to NFPA 1990 (1992) and two vapor suits to NFPA 1990 (1994) Class 2. Here is what each standard asks of a certified ensemble.
Hazardous Materials and CBRN Operations Liquid Splash
Hazardous Materials and CBRN Operations Vapor and Liquid
Check the suffix. Certification belongs to the style: Z5H582 and Z5H583 without the -94C2RPBC suffix are Hazmat Model vapor suits and are not NFPA certified. Certified Class 2 ensembles must be used with NIOSH CBRN approved self-contained breathing apparatus (SCBA).
Never wear garments that have not been fully inspected and pressure tested prior to use. Kappler’s procedure mirrors ASTM F1052 “Standard Test Method for Pressure Testing Vapor Protective Ensembles”.
AntiFog visor. Kappler’s AntiFog Expanded-View Visor is standard on all gas-tight suits including NFPA-certified styles. The permanently attached layer inside the PVC visor reduces condensation (fogging); the anti-fog treatment is permanent and is not designed to be replenished or replaced.
The testing device named for the certified Class 2 ensemble: Kappler Pressure Test Kit Model AKMOC.
View product MarkingEnsembles may be marked with Kappler ChemTape.
View product Exhaust valvePirelli exhaust valves are used on the certified Zytron 500 ensembles.
View product Gloves2N1® Glove System on Hazmat styles.
View product GlovesGuardian Butyl, Model CP-25: the middle layer of the glove assembly on the certified Class 2 styles.
View productFabric and construction across the line, the two certified ensembles, and sizing and storage.
| Fabric | |
|---|---|
| Material | Zytron® 500 chemical barrier fabric |
| Chemical holdout | Greater than 8-hour holdout against hundreds of chemicals, with proven holdout against Chemical Warfare Agents (CWA). |
| Total chemicals tested | 264 |
| Colors | Hi-vis orange and charcoal gray (by style) |
| Comfort | Softer pliable fabric enhances comfort for extended wear applications. |
| PFAS | Zytron 500 fabric does not contain PFAS chemistry. PFAS are present in the FEP outer layer of the gas-tight visor system; that layer contains no PFOA or PFOS. |
| Construction | |
| Garment types | Coveralls, splash and vapor total encapsulating suits, training suits and an overhood |
| Seams | Hazmat styles include seams that are sewn then double heat sealed/taped. Heat Sealed / Taped on all styles except training suits (Serged). |
| Visor | AntiFog Expanded-View Visor System is standard on gas-tight styles. |
| Gloves |
|
| Label | Kappler’s SMART™ label makes sizing easy to see, and a quick QR code scan provides complete chemical data plus extensive suit details. |
| Use | |
| Service life | Kappler Zytron® 500 garments are designed for multiple use, single exposure. |
| Applications | Hazmat response, chemical handling, refueling operations, petrochemical operations, hazardous material clean-up and remediation, CWA incineration, remediation and disposal. |
| Z5H582-94C2RPBC · Z5H583-94C2RPBC | |||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Certification | NFPA 1990 (1994) Class 2 Certified Vapor Total Encapsulating Suit | ||||||||||||||||||||||||
| Compliance | Berry Compliant | ||||||||||||||||||||||||
| Garment material | The primary garment material is Kappler Zytron® 500 chemical barrier fabric. | ||||||||||||||||||||||||
| Visor | 5 mil FEP film over a 40 mil pressed/polished FR PVC and anti-fog layer. There are no detachable covers or films. | ||||||||||||||||||||||||
| Gloves | Field Replaceable 2N1® Glove System with Removable Overglove; connected to the sleeve via a steel clamp/PVC ring via mechanical screw compression. | ||||||||||||||||||||||||
| Closure | 44-48” long zipper with molded nylon teeth; aluminum bronze slider components; mounted on polyurethane tape. Protected by a flap of garment material, fastened by a hook/loop system. | ||||||||||||||||||||||||
| Seams | Single needle lock stitch seam, nylon thread; inner and outer tapes of a chemical barrier film heat-sealed over the seam. | ||||||||||||||||||||||||
| Exhaust valves | Two Pirelli valves per ensemble: impact resistant plastic body, natural rubber flapper diaphragm, covered with splash resistant flaps made of the primary garment material. | ||||||||||||||||||||||||
| Footwear | Integrated sock bootie in the primary garment material. The user must wear separate outer safety boots. | ||||||||||||||||||||||||
| Other features | Knee Reinforcements, Radio Pocket | ||||||||||||||||||||||||
| Respiratory & head | |||||||||||||||||||||||||
| Respiratory | Ensembles must be used with NIOSH CBRN approved self-contained breathing apparatus (SCBA). | ||||||||||||||||||||||||
| Helmet | The Zytron® 500 ensemble will accommodate Type 1 Class G helmets of ANSI Z89.1. | ||||||||||||||||||||||||
| Testing device | Kappler Pressure Test Kit Model AKMOC | ||||||||||||||||||||||||
| Glove sizing | |||||||||||||||||||||||||
| Glove size chart |
| ||||||||||||||||||||||||
| Z5H577-92 | |
|---|---|
| Certification | NFPA 1990 (1992) Certified Splash Protective Total Encapsulating Suit |
| Garment material | Zytron® 500 fabric |
| Visor | Expanded View AntiFog Visor System; the interface material is butyl. |
| Gloves | Single layer neoprene glove assembly. These gloves are not field replaceable. These gloves have 100% cotton flock lining and have no surface treatments applied. |
| Closure | Plastic chain, metal slide and pull, urethane coated polyester cloth tape. Located on the front of the garment, oriented diagonally, with a 48" length for all sizes. |
| Exhaust valves | Pirelli valve; two valves incorporated into each ensemble. |
| Footwear | Attached Sock Booties with Splash Guards. The sock booties are designed to be worn inside outer boots; they do not have sufficient durability or slip resistance to be worn as outer boots. |
| Back | Expanded Back |
| Sizing | |
|---|---|
| Sizes | SM/MD, LG/XL, 2X/3X, 4XL (suits, coveralls and training suits) · Z5H750 overhood: one size |
| Combo-sizing | Typically worn over other clothing, Kappler’s garments are designed so that “combination sizes” comfortably fit the vast majority of users. |
| Shelf life & storage | |
| Storage life | Kappler’s Zytron® 500 garments have a predicted storage life of 10 years from the date of manufacture when stored properly, based on accelerated aging studies. |
| Storage conditions |
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Fabric features, typical garment types, the ASTM F1001 test battery and chemical warfare agent data.
ReferenceA concise reference guide to NFPA apparel standards, including the NFPA 1990 consolidated standard.
Technical servicesPFAS and PPE: what it means to the end user.
Tell us which styles, sizes and colors you need, or describe the job and we’ll help you choose between coveralls, splash suits, vapor suits and the certified styles.
