Miller BREATHEAIR FILTRATION BOX Owner's manual

Brand: Miller

Model: BREATHEAIR FILTRATION BOX

Type: Owner's manual

This manual is also suitable for

MJ000000

Description

Air Filtration Box

OM-254859 Rev. A 2018−06

File: Accessory

BreatheAirtFiltration Box

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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-254859 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

professional standing, 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

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 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.

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.

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 accor-

dance 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 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.

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, 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.

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 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-254859 Page 2

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.

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.

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

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 ground-

ed 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.

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: 1-877-413-5184, 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: 212-642-4900, 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: 1-866-512-1800) (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: 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 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: 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).

OM-254859 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)

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

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-254859 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

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 275983 275984 275985 275986

Type

Two Person Two Person Four Person Four Person

Dimensions

(L x W x H)

18.75 x 13 x 7 in.

(476 x 330 x 178 mm)

18.75 x 13 x 7 in.

(476 x 330 x 178 mm)

20 x 17 x 8 in.

(508 x 432 x 203 mm)

20 x 17 x 8 in.

(508 x 432 x 203 mm)

Weight

21 lb (9.5 kg) 21 lb (9.5 kg) 30 lb (13.6 kg) 30 lb (13.6 kg)

Inlet Size

1/2 in. Industrial Interchange

Number of Outlets

2 2 4 4

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-254859 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.

1 High CO Audible Alarm

2 High CO Light (Red)

3 Remote Alarm Receptacle

4 Normal Operation Light (Green)

5 Air Inlet Fitting

6 Relief Valve

7 Air Outlet Fitting /Dust Cap

8 Flowmeter

9 Air Pressure Regulator

10 CO Monitor Low Battery Light

(See Section 4-3)

11 CO (Carbon Monoxide) Monitor

12 115 VAC Recessed Plug

13 First Stage Filter Assembly

14 Second Stage Filter Assembly

15 Third Stage Filter Assembly

16 Air Pressure Gauge

13 14 15 16

Two-Person Units

Four-Person Units

13 14 15 16

OM-254859 Page 6

! Operate filtration system only with fil-

ters in vertical/upright position. Fil-

ters 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 accumu-

late in filters.

! Do not enter a hazardous area until

you are sure the supplied air respira-

tor and air filtration system are assem-

bled correctly, working properly, and

the respirator is worn properly.

! Leave the contaminated area immedi-

ately if the High CO light goes on or

the alarm sounds. Do not remove the

respirator until you are in a safe area.

! Keep synthetic oils, solvents, paints,

and fumes away from filters as these

substances may cause filter bowl

failure.

Locate source of breathable air that meets the

requirements of Grade D breathing air as de-

scribed in Compressed Gas Association

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 impacted

by the number and type of respirators be-

ing 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 monitor

(see Section 4-3).

3 On/Off/Test Switch

4 Remote Signal Cable

5 115 V AC Plug

6 Air Sample Hose

Connect the remote signal cable, 115 VAC

plug, and air sample hose to the CO monitor.

Place the On/Off/Test switch in the On posi-

tion and wait 30 seconds for the readout to

stabilize. If a reading other than 00 is dis-

played it may be necessary to recalibrate the

CO monitor (see Section 4-5).

7 115 Volt AC Receptacle

Connect customer-supplied grounded exten-

sion cord to 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

OM-254859 Page 7

10 Air Inlet Fitting

. Maximum inlet pressure is 150 psi

(1034 kPa).

Connect compressed air supply to fit-

ting. Air hose and inlet fitting specifica-

tions are as follows:

Minimum Hose ID: 1/2 in.

Air Inlet:1/2 in. Industrial Interchange

11 On/Off/Test Switch

Hold the On/Off/Test switch in the Test

position. All local and remote audible and

visual indicators should activate. If indi-

cators do not activate, check all connec-

tions. If problem continues, contact a

Factory Authorized Service Agent.

. Alarms can be tested at any time by

holding the switch in the Test

position.

12 Air Outlet Fitting

Remove dust caps and connect respira-

tor hoses to air outlet fittings.

13 Air Pressure Regulator

Adjust outlet pressure to setting recom-

mended by the respirator manufacturer.

Turn knob clockwise to increase pres-

sure, counterclockwise to decrease

pressure.

14 Flowmeter

Adjust CO monitor air sample flow rate

by turning the flowmeter control knob

counterclockwise until the ball hovers

between 50 and 100 cc/min. The filtra-

tion system is now ready to be used.

CO Monitor Operation

The CO monitor analyzes the air sample

and displays the CO concentration in

parts per million (ppm). The filtration sys-

tem green (Normal Operation) light goes

on and the red (High CO) light flickers

faintly (about once per second) when the

CO level is below 10 ppm (5 ppm

Canada).

When the CO concentration level ex-

ceeds the alarm setpoint, the green

(Normal) light goes out, the red (High

CO) light goes on, the audible alarm

sounds, and the remote alarm connec-

tions energize. When the CO concentra-

tion levels drop below the alarm set

point, all alarm indicators deactivate and

the unit returns to normal operation.

3-2. Connecting And Operating Filtration System (Continued)

OM-254859 Page 8

3-3. Wiring Diagram For Remote Alarm Receptacle

3-4. Checking The Filtration System Before Use

! Operate filtration system only with filters

in vertical/upright position. Filters must

be kept vertical/upright or auto drains

may not function properly. Malfunction-

ing auto drains may allow contamination

of the CO monitor or moisture/contami-

nants to accumulate in filters.

! Do not enter a hazardous area until you

are sure the supplied air respirator and

air filtration system are assembled cor-

rectly, working properly, and the respira-

tor is worn properly.

! Leave the contaminated area immediate-

ly if the High CO light goes on or the

alarm sounds. Do not remove the respi-

rator until you are in a safe area.

1 Filter Change Indicator

Check indicators, and replace filters if necessary

(see Section 4-2).

2 Air Outlet Fitting

Install respirators and hoses according to manu-

facturer’s specifications (see Section 4-2).

3 CO Monitor On/Off/Test Switch

Turn on CO monitor. Check for 00 reading on

monitor. Recalibrate CO monitor if necessary

(see Section 4-5).

4 Air Inlet Fitting

Connect compressed air supply to air inlet fitting.

Maximum inlet pressure is 150 psi (1034 kPa)

(see Section 3-2).

5 CO Monitor Readout

Check CO monitor readout. Test alarm by hold-

ing On/Off/Test switch in Test position (see Sec-

tion 3-2).

6 Air Pressure Regulator

Adjust outgoing air pressure to respirator manu-

facturer’s specifications (see Section 3-2).

OM-254859 Page 9

3-5. Shutting Down The Filtration System

Verify all personnel have left the work

area.

Shut off compressed air supply to the

filtration system.

1 Relief Valve Ring

Release filtration system air pressure

by pulling ring on relief valve.

2 Test/On/Off Switch

Turn off CO monitor by placing Test/

On/Off switch in Off position.

. Do not remove the 9 volt batteries

from the CO monitor. The batter-

ies are needed to maintain a bias

voltage to the CO sensor which

keeps the sensor ready for use.

Disconnect respirator hoses from air

outlet fittings.

3 Dust Cover

Install dust covers in air outlet fittings.

NOTICE − Store unit in an upright po-

sition to prevent water from damaging

filters.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-254859 Page 10

SECTION 4 − MAINTENANCE

4-1. Routine Maintenance

. Service unit more often if used in severe conditions.

n = Check Z = Calibrate ~ = Clean l = Replace

* To be done by Factory Authorized Service Agent

Reference

Daily

Section 3-2

n Filter Change Indicators

. Also clean filter bowls,

auto drains, and drain

hoses whenever a filter

is replaced.

Monthly

Section 4-5

Z CO Monitor

. Also clean filter bowls,

auto drains, and drain

hoses whenever CO

monitor is calibrated.

Every

6 Months

Section 5

l Unreadable Labels

Yearly

Section 4-2

~ Filter Bowls, Auto

Drains, Drain Hoses

. Also clean filter bowls,

auto drains, and drain

hoses whenever CO

monitor is calibrated or

a filter is replaced.

~ Inside Unit

OM-254859 Page 11

4-2. Filter And CO Monitor Maintenance

! Release pressure from system

before performing service. Re-

lease air pressure by pulling

ring on relief valve.

! Keep synthetic oils, solvents,

paints, and fumes away from

filters as these substances

may cause filter bowl failure.

1 Filter Bowl

2 Auto Drain

3 Drain Hose

Remove the filter bowls and inspect

for damage. Clean the bowls, auto

drains, and drain tubes with a mild

soapy solution. Dry bowls and auto

drains, and reinstall in the filter hous-

ings. Remove filter bowl by rotating

bowl counterclockwise 45 and then

pulling bowl down.

4 Filter Change Indicator

5 Filter

6 Filter Nut

Change filters when filter indicators

change from green to orange. Rotate

filter nut counterclockwise to remove

filter.

Air must be flowing though the filters

for the filter change indicators to func-

tion. With system pressurized, close

inlet and outlet ball valves. Release

the filter trio pressure by pressing the

manual drain assembly to the side.

7 CO Monitor

Calibration of the CO monitor is nec-

essary to ensure CO sensor accura-

cy (see Section 4-5). If an accurate

calibration cannot be obtained, sen-

sor replacement may be necessary.

Contact a Miller factory authorized

service agent before ordering re-

placement CO sensor.

Calibrate CO monitor monthly or

sooner if the CO reading is question-

able. After calibration, apply calibra-

tion date label to CO monitor for future

reference. To ensure accurate cali-

bration, it is recommended that only

Miller calibration kits be used.

. See the Parts List in Section 5 for

calibration kit part numbers.

Rotate housing

counterclockwise

and pull down.

161-090 / 161-091

OM-254859 Page 12

4-3. Replacing Batteries In CO Monitor

! Release pressure from sys-

tem before performing ser-

vice. Release air pressure

by pulling ring on relief

valve.

The batteries provide the continu-

ous bias voltage to the CO sensor

and also power the CO monitor if

AC input power is not present.

. If AC and DC power are not

supplied to the CO monitor for

more than two hours, a one

hour restabilization period is

required or erratic readings

may occur.

1 Low Battery Light

2 Battery Trays

Replace the batteries when the

Low Battery light goes on. If the fil-

tration system is not used for 90

days, check the batteries and re-

place if necessary. To replace the

batteries, slide the battery holding

trays out and remove the old bat-

teries. Replace with 9 volt batter-

ies (two required).

. Install batteries in trays as

shown.

3 On/Off/Test Switch

To test batteries, hold the On/Off

/Test switch in the Test position. If

batteries are okay, the audible

alarm sounds, the Normal Opera-

tion light (green) flashes, and the

Low Battery and High CO (red)

lights go on.

161-089

OM-254859 Page 13

4-4. Replacing CO Sensor In CO Monitor

! Release pressure from sys-

tem before performing ser-

vice. Release air pressure by

pulling ring on relief valve.

! Turn off unit, and disconnect

input power.

. Replacement sensors are

shipped with a metal spring be-

tween the electrodes. Do not

remove the springs until the

sensor is about to be installed

in the CO monitor.

1 CO Monitor

Disconnect remote signal cable,

115 VAC plug, and air sample hose

from CO monitor. Remove CO

monitor from unit.

Remove four screws securing CO

monitor side cover. Remove side

cover.

2 CO Sensor

Remove sensor from sensor cup

and disconnect leads.

Remove spring from from sensor

terminals.

Reconnect leads to correct termi-

nals on new sensor. Install sensor

in sensor cup.

Reassemble CO monitor and rein-

stall in filtration system. Reconnect

signal cable, 115 VAC plug, and air

sample hose.

. Allow 30–60 minutes for CO

monitor to stabilize before re-

calibrating (see Section 4-5 ).

NOT USED

REFERENCE

(BLUE)

CONTROL

(BLACK)

SENSING

(RED)

OM-254859 Page 14

4-5. Calibrating CO Monitor

A. CO Monitor Zero Adjustment

! Release pressure from sys-

tem before performing ser-

vice. Release air pressure by

pulling ring on relief valve.

NOTICE − Do not use inert gases to

zero the CO monitor. Using inert

gases will cause premature failure of

the CO monitor.

Use zero calibration gas to properly

“zero” the CO monitor and assure

that a valid calibration is achieved. If

zero adjustment cannot be done as

indicated, it may be necessary to re-

place the CO sensor (see Section

4-4).

Allow time for changes to stabilize

after each adjustment to the CO

monitor.

Place On/Off/Test switch

in the On position.

Allow 30 seconds for

readout to stabilize.

30 S

The Normal Operation

(green) light goes on.

Hold the On/Off/Test switch in the

Test position.

The audible alarm sounds, the Normal Operation light

(green) flashes, and the Low Battery and High CO

(red) lights go on. This test ensures the CO monitor

circuitry is functioning normally and there is continuity

to the CO sensor. Release switch.

LOW

BATTERY

Disconnect the air sample inlet

tube from the CO monitor.

Install regulator on the zero calibration

gas cylinder. Rotate regulator knob coun-

terclockwise to allow gas to flow through

the hose. Verify gas is flowing.

Attach clear tubing male plug to

air sample inlet on CO monitor.

Allow digital readout to sta-

bilize for 15 − 30 seconds.

Use supplied tool to rotate the zero adjustment screw (clockwise to increase

or counterclockwise to decrease) until a reading of 00 is displayed.

Close regulator and remove regulator from cylinder.

Reconnect air sample inlet hose to CO monitor.

15 − 30 S

TEST

OFF

TEST

OFF

OM-254859 Page 15

B. CO Monitor Span Adjustment

! Release pressure from sys-

tem before performing ser-

vice. Release air pressure by

pulling ring on relief valve.

! Use only 10 − 20 ppm CO gas

for calibration (10 ppm Cana-

da). Using a higher concen-

tration of CO gas may de-

crease the accuracy of the CO

monitor at lower level

readings.

To satisfy Canadian calibra-

tion requirements, 10 ppm

CO gas must be used. See

Parts List for Canadian cali-

bration kit.

Install regulator on the CO gas cylinder.

Rotate regulator knob counterclockwise

to allow gas to flow through the hose.

Verify gas is flowing.

Attach male plug on CO gas hose

to air sample inlet on CO monitor.

Disconnect the air sample inlet

tube from the CO monitor.

Allow digital readout to

stabilize for 15 − 30

seconds.

15 − 30 S

Use supplied tool to rotate the Span adjust-

ment screw (clockwise to increase or coun-

terclockwise to decrease) until the digital

readout is the same as the ppm concentra-

tion shown on the calibration gas cylinder

Close gas regulator and repeat the zero adjust-

ment procedure (see Section 4-5A). The digital

readout should return to a 00 reading.

Reconnect air sample inlet hose to CO monitor.

The CO monitor is now calibrated. Recalibrate

CO monitor monthly or if accuracy of monitor is

questionable. Check local requirements and re-

calibrate as required.

20 PPM

CARBON

MONOXIDE

20 PPM

CARBON

MONOXIDE

20 PPM

CARBON

MONOXIDE

OM-254859 Page 16

4-6. Filtration System Troubleshooting

Trouble Remedy

Unit does not turn on. Check batteries, and replace if necessary (see Section 4-3). Verify batteries are properly installed.

Unit does not supply air. Verify filtration system air supply is turned on and is of adequate pressure.

Check that hoses are properly connected to filtration system inlet and outlets (see Section 3-2).

Remove blockage in air inlet and outlets.

High CO light (red) is on and alarm

sounds.

Continue wearing the respirator and leave the contaminated area immediately:

Check contamination level of filters, and replace filters if necessary (see Section 4-2).

Check batteries, and replace if necessary (see Section 4-3). Verify batteries are properly

installed.

Verify compressor air inlet is located in a clean environment and away from sources of

contamination (such as vehicles and building exhaust vents). Be sure inlet on compressed air

source is properly filtered.

Calibrate CO monitor (see Section 4-5).

Have Safety Director and Industrial Hygienist determine if you are using the proper equipment for

the work environment.

Air supplied to respirator smells and

tastes unusual; eyes and throat irritation.

Continue wearing the respirator and leave the contaminated area immediately.

Check contamination level of filters, and replace filters if necessary (see Section 4-2).

Check that hoses are properly connected to filtration system inlet and outlets.

Have Safety Director and Industrial Hygienist determine if you are using the proper equipment for

the work environment.

Air supplied to respirator is insufficient.

Check that hoses are properly connected to filtration system inlet and outlets.

Remove blockage in air inlet and outlets.

Check contamination level of filters, and replace filters if necessary (see Section 4-2).

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