Miller BreatheAir 275961, BreatheAir 275970, BreatheAir 275963, BreatheAir 275981, BreatheAir Owner's Manual
OM-255447 Rev. A 2018−06
Description
Air Filtration Panel
BreatheAirtFiltration Panel
For product information,
Owner’s Manual translations,
and more, visit
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File: Accessory
From Miller to You
Thank you and congratulations on choosing Miller. Now you can
get the job done and get it done right. We know you don’t have
time to do it any other way.
That’s why when Niels Miller first started building arc welders in
1929, he made sure his products offered long-lasting value and
superior quality. Like you, his customers couldn’t afford anything
less. Miller products had to be more than the best they could be.
They had to be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and
service that meets the high standards of quality and value
established in 1929.
This Owner’s Manual is designed to help you get the most out of
your Miller products. Please take time to read the Safety
precautions. They will help you protect yourself against potential
hazards on the worksite. We’ve made installation and operation
quick and easy. With Miller you can count on years of reliable
service with proper maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting section that will help you
figure out what the problem is. The parts list will then help you to
decide the exact part you may need to fix the problem. Warranty
and service information for your particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Mil_Thank2 2017−07
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Breathing Air Hazards 1.................................................................
1-3. Proposition 65 Warnings 2...............................................................
1-4. Principal Safety Standards 2.............................................................
SECTION 2 − SPECIFICATIONS 3..............................................................
2-1. Breathing Air Quality 3..................................................................
2-2. Respirator Air Supply Specifications (Also See Section 2-5) 3.................................
2-3. Filtration Efficiency 3...................................................................
2-4. Equipment Required 4..................................................................
2-5. General Specifications 4................................................................
2-6. CO (Carbon Monoxide) Monitor Specifications 4............................................
SECTION 3 − OPERATION 5...................................................................
3-1. Filtration System Components 5..........................................................
3-2. Connecting And Operating Filtration System 6..............................................
3-3. Wiring Diagram For Remote Alarm Receptacle 8............................................
3-4. Checking The Filtration System Before Use 8...............................................
3-5. Shutting Down The Filtration System 9....................................................
SECTION 4 − MAINTENANCE 10................................................................
4-1. Routine Maintenance 10.................................................................
4-2. Filter And CO Monitor Maintenance 11.....................................................
4-3. Replacing Batteries In CO Monitor 12......................................................
4-4. Replacing CO Sensor In CO Monitor 13....................................................
4-5. Calibrating CO Monitor 14................................................................
4-6. Filtration System Troubleshooting 16.......................................................
SECTION 5 − PARTS LIST 18...................................................................
SECTION 6 − WARRANTY 21...................................................................
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
AIR FILTER 2018-06
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
1-2. Breathing Air Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Principal Safety Standards listed in Section 1-4.
Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
BREATHING UNFILTERED AIR can be
hazardous.
Welding produces fumes and gases. Misuse of the air
filtration system may expose you to fumes and gases
hazardous to your health.
D Read and follow these instructions and the safety labels carefully.
The air filtration system helps protect the user from specific airborne contaminants but must be used correctly to be fully effective.
Have an industrial hygienist test the air in your facility to ensure the
air filtration system provides adequate protection from contaminants in your environment. If you have questions about the air
filtration system, see equipment NIOSH label and consult your
Safety Director and a certified Industrial Hygienist. For occupational use applications, employers must implement a written
respiratory protection program meeting the requirements of OSHA
29 CFR 1910.134 (USA) or CSA Z94.4 (Canada), and other substance specific requirements as applicable.
D Do not use the air filtration system until you have been trained in its
proper operation by a qualified person.
D Follow all applicable ANSI, OSHA, CSA, CGA, and other regulato-
ry guidelines pertaining to the use of air filtration systems.
D Do not use the air filtration system where there is danger of fire or
explosion.
D Do not use the air filtration system in applications immediately dan-
gerous to life or health (IDLH).
D Do not enter a hazardous area until you are sure the air filtration
system is assembled correctly, and working properly.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid
these hazards.
D Dangerous contaminants may not smell or be visible. Leave the
area immediately if you notice any of the following:
Breathing becomes difficult....
You experience dizziness, impaired vision, or eye, nose, or ...
mouth irritation.
The air supply smells or tastes unusual....
The air supply equipment alarm sounds....
The equipment is damaged....
Air flow decreases or stops....
If you think the equipment is not supplying adequate protection....
Do not remove the equipment until you are in a safe area.
D Before each use, inspect air filtration system for damage and verify it
operates properly. Before using the air filtration system, test the air
flow to verify the system is receiving an adequate volume of air. Clean
and maintain the air filtration system according to the manufacturer’s
instructions.
D Do not use the air filtration system without all components or with
the air supply turned off because hazardous levels of oxygen and
carbon dioxide can accumulate in the helmet.
D Do not repair, modify, or disassemble the air filtration system or use
with parts or accessories not supplied by the manufacturer. Use only
those components that are part of the NIOSH-approved assembly.
D Breathable air must meet the requirements of Grade D breathing
air as described in Compressed Gas Association Commodity
Specification G.7.1 (United States) or CSA Standard Z180.1
(Canada). Use appropriate filters and carbon monoxide alarms to
ensure breathable air is supplied.
D Have a qualified person test the breathing air to ensure it meets
Grade D requirements. Breathing air testing shall be done in accordance with a written respirator protection program (prepared by a
qualified person) specific to the workplace.
D Locate the compressed air source in a clean environment that is free
from toxic fumes and gases and away from other sources of contamination, such as building exhaust vents and engine-powered vehicles
and equipment (including generators). Be sure inlet on compressed
air source is properly filtered to remove contaminants.
D Use only air line couplings designed for the supplied air system; air
couplings must be incompatible with outlets for other gas systems.
D Operate air filtration system within specified air pressures and air
hose lengths. The air supply system (air supply lines, fittings, filters, couplings, air pump/tanks) must be able to deliver sufficient
air volume within safe limits, 125 psig (862 kPa) maximum. If correct pressure is not maintained, negative air pressure can develop
in the helmet and create a risk of contaminants being inhaled. Also,
unless removed by filters, oil, water, and other contaminants could
flow downstream from the compressed air supply and adversely
affect the supplied air respirator’s performance. While air is flowing, use a reliable pressure gauge to continually monitor air
pressure at the air source connection point.
D To ensure adequate cooling of supply air, follow air compressor manu-
facturer’s recommendations when selecting air hose length. Do not
use an air compressor that supplies air warmer than 160F (71C);
supply air exceeding this temperature will degrade the air hose, which
could adversely affect the supplied air respirator’s performance.
OM-255447 Page 1
D Operate air filtration system only with filters in vertical/upright posi-
tion. Filters must be kept vertical/upright during operation or the
following events may occur:
Auto drains will not function properly, which may result in con-...
tamination of the CO monitor and cause water to pass through
the air supply hose and into the supplied air respirator.
Auto drains may become clogged, requiring that they be ...
cleaned or replaced. See instructions for cleaning or replacing
auto drains.
Moisture and/or contaminants may accumulate in filters. See ...
instructions for filter replacement.
D The air filtration system does not remove toxic fumes and gases, in-
cluding Carbon Monoxide (CO), Carbon Dioxide (CO2), and Nitrogen.
The air filtration system does not increase the oxygen content of the
air supply, and the system should not be used if the air entering the
system is oxygen deficient.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
D Release air pressure from air filtration system
before servicing
COMPRESSED AIR can injure or kill.
D Before working on compressed air system,
turn off unit, release pressure, and be sure air
pressure cannot be accidentally applied.
D Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
D Do not direct air stream toward self or others.
D Wear protective equipment such as safety
glasses, hearing protection, leather gloves,
heavy shirt and trousers, high shoes, and a cap when working on
compressed air system.
D Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
D If ANY air is injected into the skin or body seek medical help im-
mediately.
1-3. Proposition 65 Warnings
WARNING: Cancer and Reproductive Harm − www.P65Warnings.ca.gov
1-4. Principal Safety Standards
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and machine
internal circuits are live when power is on.
D Do not touch live electrical parts.
D Do not use equipment in damp, wet, or confined spaces, or if there
is a danger of falling.
D Disconnect input power before installing or servicing this
equipment.
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly grounded receptacle outlet.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use. Do not leave equipment un-
til it has completely stopped.
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
NIOSH Approval of Respiratory Devices, CFR Title 42 − Public Health,
Part 84, is available from the Centers for Disease Control, 1600 Clifton
Rd. Atlanta, GA 30329−4027 (phone: 800−232−4636) or as a free
download at www.cdc.gov/niosh.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
OM-255447 Page 2
American National Standard for Respiratory Protection, ANSI /ASSE
Standard Z88.2−2015, from American National Standards Institute, 25
West 43rd Street, New York, NY 10036 (phone: 212-642-4900,
website: www.ansi.org).
Selection, Use, and Care of Respirators, CAN/CSA Standard Z94.4,
from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csagroup.org).
Commodity Specification for Air, CGA Pamphlet G-7.1, from
Compressed Gas Association, 14501 George Carter Way, Suite 103,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Compressed Breathing Air and Systems, CSA Standard Z180.1, from
Canadian Standards Association, Standards Sales, 5060 Spectrum
Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csagroup.org).
SECTION 2 − SPECIFICATIONS
This equipment helps protect the user from certain contaminants. All users must read and understand these instructions and be
trained in the proper use of this equipment before using. Use this equipment according to all applicable health and safety standards.
If you have questions about the type of respiratory equipment required, consult your safety director and an Industrial Hygienist.
Do not enter a hazardous area until you are sure the supplied air respirator and air filtration system are assembled correctly, working
properly, and the respirator is worn properly.
Operate filtration system only with filters in vertical/upright position. Filters must be kept vertical/upright or auto drains may not function properly. Malfunctioning auto drains may allow contamination of the CO (carbon monoxide) monitor or moisture/contaminants
to accumulate in filters.
. See Owner’s Manual 269676 for information on the supplied air respirator (SAR).
2-1. Breathing Air Quality
The responsibility for the quality of breathing air rests with the user. Compliance with federal, state, or local regulations is the responsibility of the
user and this recommendation does not supersede any existing rules, regulations, or laws which may apply. Miller filtration systems meet or
exceed CGA Grade−D specifications for air quality as adopted by Federal OSHA. When the components are used in accordance with the
manufacturer’s instructions and recommendations, Miller filtration systems meet or exceeds federal regulations presently in force. It is incumbent
upon the user to comply with any changes in the regulations or law which may occur in future situations.
The air supply compressor should be located in a safe, clean ambient air environment. This safe location should be tested periodically using proper
instruments to ensure clean ambient air quality on a consistent basis. Total system Grade−D air quality should be tested at the time of initial setup.
If the compressor is moved, retesting air quality is recommended. Should the location or environment significantly change, the air quality should be
retested.
This series of filtration system products should be used according to the recommendations specified in the manual. The standard filtration system
package is not explosion-proof and should be located in a non-explosive environment. The CO (carbon monoxide) monitor should be calibrated monthly or if the accuracy of the CO monitor is in question. System air quality should be tested for, but not limited to, the following Grade−D air components:
CO − Carbon Monoxide
O2 − Oxygen
CO2 − Carbon Dioxide
H2O − Water (Moisture Content)
Hydrocarbons (Oil Mist)
Total Particulates
Miller filtration systems meet all of the following federal specifications for Grade-D air when used and serviced in accordance with these instructions:
Compressed Gas Association
CGA G.7.1 Commodity Specification for Air
Army Corps of Engineers EM385−1−1,
paragraph 07b−11−4,
Compressed Breathing Air
2-2. Respirator Air Supply Specifications (Also See Section 2-5)
Breathable air must be supplied to the supplied air respirator and meet the requirements of Grade D breathing air as described in Compressed Gas
Association Commodity Specification G.7.1 (United States) or CSA Standard Z180.1 (Canada). The air supply must be able to deliver 6−15 SCFM
(170−425 lpm) to operate the air regulator at the recommended pressures.
2-3. Filtration Efficiency
Stage Filtration Type Filter Drain / Indicator Efficiency
First Particulate/Bulk Liquid Separation Auto Drain And Filter Change Indicator Removes
Second Oil Coalescing And
Ultra Fine Particulate
Third Activated Charcoal Manual Drain And
95% Bulk Particulate And
Liquids At 5 Microns
Auto Drain And Filter Change Indicator Removes Oil And Particulate To
Filter Change Indicator
99.9998% At 0.01 Microns
Removes Organic Vapors, Odors,
And Tastes. Less Than 0.003
Pp/Wt Remaining Oil Content
OM-255447 Page 3
2-4. Equipment Required
The filtration system is designed for use with the Miller Type C supplied air respirator (SAR) for respiratory protection during entry into and escape
from atmospheres not immediately dangerous to life or health. When used with the equipment intended for use with this product, the respirator system
generates a positive air pressure to help prevent contaminants from entering the hood. The filtration system must be connected to a source of respirable
breathing air and be used with the equipment listed below:
D Helmet assembly
D C50 Air regulator and adapter
D Breathing tube assembly
D Belt assembly
D Airline hose
D Detachable couplings
2-5. General Specifications
Stock Number 275961 275963 275970 275981
Type
Dimensions
(L x W x H)
Weight
Inlet Size
Number of Outlets
Maximum Air Flow
Remote Alarm Signal
Maximum Inlet Pressure
Relief Valve
Monitoring Capability
CO Monitor Alarm Setting
Input Power
Operating Temp. Range
Storage Temp. Range
Two Person Two Person Four Person Four Person
32 x 27 x 15 in.
(813 x 686 x 381 mm)
45 lb (20.4 kg) 45 lb (20.4 kg) 47 lb (21.3 kg) 47 lb (21.3 kg)
2 2 4 4
49 CFM At 110 psi
1388 lpm At 758 kPa
Yes Yes Yes Yes
10 ppm 5 ppm 10 ppm 5 ppm
32 x 27 x 15 in.
(813 x 686 x 381 mm)
1/2 in. Industrial Interchange
49 CFM At 110 psi
1388 lpm At 758 kPa
150 psi (034 kPa)
125 psi (862 kPa)
Inline Continuous Monitoring Of Carbon Monoxide (CO)
9–16 VDC Or 115 VAC 50/60 Hz
32 to 125F (0 to 51C)
32 to 125F (0 to 51C)
32 x 27 x 15 in.
(813 x 686 x 381 mm)
123 CFM At 110 psi
3483 lpm At 758 kPa
32 x 27 x 15 in.
(813 x 686 x 381 mm)
123 CFM At 110 psi
3483 lpm At 758 kPa
2-6. CO (Carbon Monoxide) Monitor Specifications
The carbon monoxide monitor continuously analyzes air samples and displays the CO concentration in parts per million (ppm). If the CO level is
within acceptable limits (below 10 ppm U.S. or 5 ppm Canada) the system’s green (Normal) light goes on and the red (High CO) light flickers
once per second. If the CO concentration level exceeds the alarm set point, the green (Normal) light goes out, the red (High CO) light goes on,
the audible alarm sounds, and the remote alarm connections energize. After the CO concentration levels drop below the alarm set point, all alarm
indicators deactivate and the unit returns to normal operation.
Dimensions
(L x W x H)
Weight
Case Material
Input Voltage
Shielding
Circuit
Protection
Operating
Temperature
Humidity Range
Flow
Requirements
Display
7.25 x 5.25 x 7.25 in.
(184 x 133 x 184 mm)
2.2 lb (1 kg)
Extruded Aluminum − Anodized Black
115 VAC and/or 9–16 VDC
Internal RFI/EMI Filters
1 Amp / 250 VAC
Fast Acting Fuse
4–113F
(−15.5 − 45C)
10–90% Relative Humidity
50–100 cc/min
3-Digit LCD Indicates
Carbon Monoxide (CO) Concentration
Test Circuit
Sensor Type
Accuracy
Response Time
Detectable Range
Calibration
Alarm Setting
Warning Signals
Warranty
Manual CO Zero And Span Adjustments
10 ppm Carbon Monoxide (CO) U.S.
High CO − Red Light And Audible Alarm
Manually Activated
Sealed Electrochemical sensor for
Carbon Monoxide (CO)
+/− 1% Full Scale
90% In 10–15 Seconds
0–200 ppm Carbon Monoxide (CO)
(5 ppm CO Canada)
Normal Operation − Green Light
Low Battery − Amber Light
Two Years From Original Date Of
Purchase (See Section 6)
OM-255447 Page 4
SECTION 3 − OPERATION
3-1. Filtration System Components
Two-Person Units
1
20
19
18
Four-Person Units
1
20
23467 8
23467 8
5
14151617
5
13
10
! Operate filtration system only
with filters in vertical/upright posi-
9
10
tion. Filters must be kept vertical/
upright or auto drains may not
function properly. Malfunctioning
auto drains may allow contamination of the CO monitor or moisture/contaminants to accumulate
in filters.
. A four-person unit is shown through-
out this manual.
1 CO Monitor
11
2 CO Monitor Low Battery Light (See
Section 4-3)
3 High CO Light (Red)
4 Normal Operation Light (Green)
5 Air Sample Inlet
6 CO Monitor 115 VAC Power
12
7 Remote Signal Connector
8 Flowmeter
9 115 VAC Gang Box
10 Air Pressure Gauge
11 Air Outlet Fitting /Dust Cap
12 Relief Valve (Located Behind Air
Outlet Block)
13 115 VAC Power Cord
14 Air Pressure Regulator
15 Third Stage Filter Assembly
16 Second Stage Filter Assembly
17 First Stage Filter Assembly
18 Air Inlet Fitting
9
19 High CO Audible Alarm
20 Remote Alarm Receptacle
19
18
11
12
13
14151617
OM-255447 Page 5
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