Miller BreatheAir 275961 User manual

Description
Air Filtration Panel
OM-255447 Rev. A 2018−06
File: Accessory
BreatheAirtFiltration Panel
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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.
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.
Working as hard as you do
−every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
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...................................................................

OM-255447 Page 1
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 ex-
plained in the text.
NOTICE −Indicates statements not related to personal injury.
.Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid
these hazards.
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
professionalstanding, or who by extensive knowledge, train-
ing 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 train-
ing 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
filtrationsystem may expose you to fumes and gases
hazardous to your health.
DRead and follow these instructions and the safety labels carefully.
The air filtration system helps protect the user from specific air-
borne 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 contami-
nants 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 occupa-
tional 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 sub-
stance specific requirements as applicable.
DDo not use the air filtration system until you have been trained in its
proper operation by a qualified person.
DFollow all applicable ANSI, OSHA, CSA, CGA, and other regulato-
ry guidelines pertaining to the use of air filtration systems.
DDo not use the air filtration system where there is danger of fire or
explosion.
DDo not use the air filtration system in applications immediately dan-
gerous to life or health (IDLH).
DDo not enter a hazardous area until you are sure the air filtration
system is assembled correctly, and working properly.
DDangerous 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.
DBefore 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.
DDo 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.
DDo 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.
DBreathable 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.
DHave a qualified person test the breathing air to ensure it meets
Grade D requirements. Breathing air testing shall be done in accor-
dance with a written respirator protection program (prepared by a
qualified person) specific to the workplace.
DLocate the compressed air source in a clean environment that is free
from toxic fumes and gases and away from other sources of contami-
nation, 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.
DUse only air line couplings designed for the supplied air system; air
couplings must be incompatible with outlets for other gas systems.
DOperate air filtration system within specified air pressures and air
hose lengths. The air supply system (air supply lines, fittings, fil-
ters, couplings, air pump/tanks) must be able to deliver sufficient
air volume within safe limits, 125 psig (862 kPa) maximum. If cor-
rect 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 flow-
ing, use a reliable pressure gauge to continually monitor air
pressure at the air source connection point.
DTo 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 160F (71C);
supply air exceeding this temperature will degrade the air hose, which
could adversely affect the supplied air respirator’s performance.

OM-255447 Page 2
DOperate 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-...
taminationof 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.
DThe 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.
COMPRESSED AIR can injure or kill.
DBefore working on compressed air system,
turn off unit, release pressure, and be sure air
pressure cannot be accidentally applied.
DCheck compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
DDo not direct air stream toward self or others.
DWear 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.
DUse soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
DReinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
DIf ANY air is injected into the skin or body seek medical help im-
mediately.
READ INSTRUCTIONS.
DRead 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.
DUse only genuine replacement parts from the manufacturer.
DPerform 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.
DRelease air pressure from air filtration system
before servicing
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.
DDo not touch live electrical parts.
DDo not use equipment in damp, wet, or confined spaces, or if there
is a danger of falling.
DDisconnect input power before installing or servicing this
equipment.
DProperly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
DAlways 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 ground-
ed receptacle outlet.
DKeep cords dry, free of oil and grease, and protected from hot metal
and sparks.
DFrequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
DTurn off all equipment when not in use. Do not leave equipment un-
til it has completely stopped.
1-3. Proposition 65 Warnings
WARNING: Cancer and Reproductive Harm −www.P65Warnings.ca.gov
1-4. Principal Safety Standards
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: [phone], website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], web-
site: 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 Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Govern-
ment Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh,PA 15250-7954 (phone: [phone]) (there are 10 OS-
HA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
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: [phone],
website: www.ansi.org).
Selection, Use, and Care of Respirators, CAN/CSA Standard Z94.4,
from Canadian Standards Association, Standards Sales, 5060 Spec-
trum 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: [phone], 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).

OM-255447 Page 3
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 func-
tion 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 month-
ly 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)
Breathableair 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/BulkLiquid Separation Auto Drain And Filter Change Indicator Removes
95% Bulk Particulate And
Liquids At 5 Microns
Second Oil Coalescing And
Ultra Fine Particulate Auto Drain And Filter Change Indicator Removes Oil And Particulate To 99.9998% At 0.01 Microns
Third Activated Charcoal Manual Drain And
Filter Change Indicator Removes Organic Vapors, Odors, And Tastes. Less Than 0.003
Pp/Wt Remaining Oil Content

OM-255447 Page 4
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
breathingair and be used with the equipment listed below:
DHelmet assembly
DC50 Air regulator and adapter
DBreathing tube assembly
DBelt assembly
DAirline hose
DDetachable couplings
2-5. General Specifications
Stock Number 275961 275963 275970 275981
Type Two Person Two Person Four Person Four Person
Dimensions
(L x W x H) 32 x 27 x 15 in.
(813 x 686 x 381 mm) 32 x 27 x 15 in. (813 x 686 x 381 mm) 32 x 27 x 15 in. (813 x 686 x 381 mm) 32 x 27 x 15 in. (813 x 686 x 381 mm)
Weight 45 lb (20.4 kg) 45 lb (20.4 kg) 47 lb (21.3 kg) 47 lb (21.3 kg)
Inlet Size 1/2 in. Industrial Interchange
Number of Outlets 2244
Maximum Air Flow 49 CFM At 110 psi
1388 lpm At 758 kPa 49 CFM At 110 psi 1388 lpm At 758 kPa 123 CFM At 110 psi 3483 lpm At 758 kPa 123 CFM At 110 psi 3483 lpm At 758 kPa
Remote Alarm Signal Yes Yes Yes Yes
Maximum Inlet Pressure 150 psi (034 kPa)
Relief Valve 125 psi (862 kPa)
Monitoring Capability Inline Continuous Monitoring Of Carbon Monoxide (CO)
CO Monitor Alarm Setting 10 ppm 5 ppm 10 ppm 5 ppm
Input Power 9–16 VDC Or 115 VAC 50/60 Hz
Operating Temp. Range 32 to 125F (0 to 51C)
Storage Temp. Range 32 to 125F (0 to 51C)
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)
7.25 x 5.25 x 7.25 in.
(184 x 133 x 184 mm) Test Circuit Manually Activated
Weight 2.2 lb (1 kg) Sensor Type Sealed Electrochemical sensor for
Carbon Monoxide (CO)
Case Material Extruded Aluminum −Anodized Black Accuracy +/−1% Full Scale
Input Voltage 115 VAC and/or 9–16 VDC Response Time 90% In 10–15 Seconds
Shielding Internal RFI/EMI Filters Detectable Range 0–200 ppm Carbon Monoxide (CO)
Circuit
Protection
1 Amp / 250 VAC
Fast Acting Fuse Calibration Manual CO Zero And Span Adjustments
Operating
Temperature
4–113F
(−15.5 −45C) Alarm Setting 10 ppm Carbon Monoxide (CO) U.S. (5 ppm CO Canada)
Humidity Range 10–90% Relative Humidity Warning Signals Normal Operation −Green Light
High CO −Red Light And Audible Alarm
Low Battery −Amber Light
Flow
Requirements
50–100 cc/min Warranty Two Years From Original Date Of
Purchase (See Section 6)
Display 3-Digit LCD Indicates
Carbon Monoxide (CO) Concentration

OM-255447 Page 5
SECTION 3 −OPERATION
3-1. Filtration System Components
!Operate filtration system only
with filters in vertical/upright posi-
tion. Filters must be kept vertical/
upright or auto drains may not
function properly. Malfunctioning
auto drains may allow contamina-
tion of the CO monitor or mois-
ture/contaminants to accumulate
in filters.
.A four-person unit is shown through-
out this manual.
1 CO Monitor
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
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
19 High CO Audible Alarm
20 Remote Alarm Receptacle
12
5
1
Two-Person Units
Four-Person Units
23467 8 9
10
11
13
14151617
18
19
20
12
5
1
23467 8
9
10
11
13
14151617
18
19
20

OM-255447 Page 6
!Operate filtration system only with
filters in vertical/upright position.
Filters must be kept vertical/up-
right or auto drains may not func-
tion properly. Malfunctioning auto
drains may allow contamination of
the CO monitor or moisture/con-
taminants to accumulate in filters.
!Do not enter a hazardous area until
you are sure the supplied air respi-
rator and air filtration system are
assembled correctly, working
properly, and the respirator is worn
properly.
!Leave the contaminated area im-
mediatelyif the High CO light goes
on or the alarm sounds. Do not re-
move the respirator until you are in
a safe area.
!Keep synthetic oils, solvents,
paints, and fumes away from filters
as these substances may cause fil-
ter bowl failure.
Locate source of breathable air that meets
the requirements of Grade D breathing air
as described in Compressed Gas Associ-
ation Commodity Specification G.7.1
(United States) or CSA Standard Z180.1
(Canada).
Air supply must also be of sufficient flow
and pressure as specified in Section 2-5.
.The flow rate and pressure is impact-
ed by the number and type of respira-
tors being used.
1 Filter Change Indicator
Check filter change indicators daily.
Change filters when filter indicators
change from green to orange (see Section
4-2).
2 CO (Carbon Monoxide) Monitor
Install new 9 volt batteries in the CO moni-
tor (see Section 4-3).
3 On/Off/Test Switch
4 Remote Signal Cable
5 115 VAC Plug
6 Air Sample Hose
Connect the remote signal cable, 115 VAC
plug, and air sample hose to the CO moni-
tor. Place the On/Off/Test switch in the On
position and wait 30 seconds for the read-
out to stabilize. If a reading other than 00
is displayed it may be necessary to recali-
brate the CO monitor (see Section 4-5).
7 115 Volt AC Power Plug
Connect power plug to 115 VAC 15 amp
grounded receptacle.
8 Remote Alarm Receptacle
Connect optional remote alarm (DC only)
to remote alarm receptacle (see Section
3-3).
9 Flowmeter
Close Flowmeter by turning control knob
fully clockwise. Do not overtighten knob.
(Continued)
3-2. Connecting And Operating Filtration System
2
3
45
6
8
9
7
1