National Institute for Occupational Safety and Health

National Personal Protective Technology Laboratory 

626 Cochrans Mill Road 

Pittsburgh, PA 15236

Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 05 January 2022

DETERMINATION OF PERFORMANCE OF AS-RECEIVED AND ENVIRONMENTALLY

TREATED CLOSED-CIRCUIT ESCAPE RESPIRATORS (CCER)

1. PURPOSE

This procedure establishes the test for ensuring that Closed-Circuit Escape Respirators (CCER) 

submitted for Approval, Extension of Approval, or examined during Certified Product Audits, meet

the certification standards as set forth in Section 84.305 (a) (1) and (2), of Subpart O−Closed Circuit 

Escape Respirators updated requirements to 42 CFR Part 84. 

2. GENERAL

This Standard Testing Procedure (STP) describes the CCER performance test, equipment, 

instruments, materials, and minimum performance criteria in sufficient detail such that a person 

knowledgeable in the appropriate technical field can select the equipment with the necessary 

resolution, conduct the test, and determine whether or not the respirator passes the test. 

3. EQUIPMENT / MATERIALS

3.1. The ABMS instrument and equipment schematic (Figure 1 in the Attachments), includes 

using a LabVIEW digital display, control, and data recording software. 

3.2. The following instruments performing stressor measurements should be capable of breathby-breath responses and have the following measurement ranges: 

3.2.1. Carbon dioxide (CO2) gas analyzer capable of detecting CO2 from 0.00 to 15.00 

volume %, accurate to within ±0.02% CO2, with a response time of 

approximately 100 milliseconds and possessing a digital display readout 

(resolution) ±0.01% (such as AEI Technologies Carbon Dioxide analyzer Model 

CD-3A or equivalent)

3.2.2. Oxygen (O2) gas analyzer capable of detecting O2 from 0.00 to 100.00 volume 

%, accurate to within ± 0.01% O2, with a response time of approximately 100 

milliseconds and possessing digital display readout (resolution) ±0.01% (such as 

AEI Technologies Oxygen analyzer Model S3-A/I or equivalent gas analyzer)

3.2.3. Thermocouple modified to induce evaporative cooling from its tip (thermocouple 

wire junction point) and capable of measuring a breathing circuit wet bulb 

temperature ranging from 0 to 100 oC (such as an Omega P/N 5SRTC-TT-T-36-

36 Type ‘T’, 0.005-inch outer diameter thermocouple with appropriate junction 

point covering) 
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 2 of 12

3.2.4. Pressure transducer capable of measuring breathing circuit breathing resistance 

from -562.5 to +562.5 mm water (such as a Validyne Model P55D-1-N-2-28-S-4-

A or equivalent pressure transducer).

3.3. Support/control instruments and equipment include the following:

3.3.1. Thermocouple capable of breath-by-breath response and measuring a breathing 

circuit dry bulb temperature ranging from 0 to 100o

C (such as an Omega P/N 

5SRTC-TT-T-36-36 Type ‘T’, 0.005-inch outer diameter thermocouple, or 

equivalent)

3.3.2. Gas sample system electronic moisture removal device, electronic gas chiller 

capable of lowering the automated breathing and metabolic simulator (ABMS)

gas sample system dew point to 3.5 o

C, (such as the DEEC Instadryer or 

equivalent)

3.3.3. CO2 Mass Flow Controller (MFC) capable of measuring 0-5 LPM (such as the 

Brooks SLA5850S CO2, or equivalent) 

3.3.4. N2 MFC capable of measuring 0-1.7 LPM (such as a Brooks SLA5850S or 

equivalent)

3.3.4.1. Activated when N2 flow rates decrease below 1.6 LPM; deactivated 

when N2 flow rates increase above 1.7 LPM

3.3.5. N2 MFC capable of measuring 0-20 LPM (such as a Brooks SLA5850S or 

equivalent)

3.3.5.1. Activated when N2 flow rates increase above 1.7 LOM; deactivated when 

N2 flow rates decrease below 1.6 LPM

3.3.6. Weigh scale with a 0 to 35,000 mg range with 1 mg scale resolution (such as the 

Ohaus Ranger R71MHD35 weigh scale or equivalent)

3.3.7. Gas spirometer (such as the Collins P-1700-120 Liter scale gas spirometer or 

equivalent)

3.3.8. Timer (accurate to 0.01 percent)

3.3.9. Physitemp Thermalert Model TH-8 temperature indicator, or equivalent, with 

calibrated ‘T’ type thermocouple

3.3.10. Electronic barometric pressure transducer (such as the Vaisala PTU300 

electronic barometric pressure transmitter or equivalent)

3.4. Materials required include the following:

3.4.1. Nitrogen (N2) Cylinder – at minimum, High Purity grade containing >99.99% N2

3.4.2. Carbon dioxide cylinder – at minimum, Coleman/Instrument grade containing 

>99.99% CO2
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 3 of 12

3.4.3. Calibration gas traceable to recognized international standards containing 80.0% 

oxygen, 12.0% nitrogen, and 8.0% carbon dioxide

3.4.4. Phenolphthalein

3.4.5. Deionized water for the ABMS recirculating water system

4. TESTING REQUIREMENTS AND CONDITIONS

4.1. Prior to beginning any test, confirm that all measuring equipment and instruments

employed have been calibrated in accordance with the testing laboratory’s 

calibration procedure and schedule. All measuring equipment and instruments 

utilized must have been calibrated using a method traceable to recognized 

international standards when available.

4.2. Tests will be conducted at the following ambient conditions.

4.2.1. Ambient temperatures of 23oC ± 3oC; and

4.2.2. Atmospheric pressures of 735 mm Hg ± 15 mm Hg

4.3. Prior to beginning the Performance Test Procedure, the CCER will be inspected using the 

manufacturer’s and NIOSH inspection criteria. The manufacturer’s inspection will be 

specific to their respirator unit and are defined in the User Instructions (UI). NIOSH 

inspections will include:

4.3.1. Applying a -300mm H2O vacuum to assess the integrity of the breathing tube and 

associated parts. 

4.3.2. Using a phenolphthalein swab to detect alkaline chemicals present in the CCER 

unit user interface.

4.4. Performance Test Requirements and Conditions

4.4.1. Performance tests will continuously monitor the stressors listed in Table 1. The 

stressors will be measured at the interface between the CCER and the ABMS 

“mouth” by instruments capable of breath-by-breath measurement. Stressor 

measurements will be evaluated as one-minute averages. The operating (overall) 

averages of each stressor will be calculated upon the completion of each test as the 

average of the one-minute measurements of the stressor recorded during the test.

4.4.2. Performance testing of a CCER will conclude when the stored breathing gas supply 

has been fully expended or any one-minute average stressor measurement is 

outside the acceptable excursion range.

4.4.3. The performance test is performed on at least five units submitted for approval

(refer to Table 3), as follows:
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 4 of 12

4.4.3.1. Three units will be tested in the condition in which they are received from 

the applicant.

4.4.3.2. Two units will be tested after being subjected to the environmental 

treatments according to standard procedure for environmental treatments 

of CCERs.

4.4.4. Each unit will be tested by application of a repeating cycle of work rates, according 

to the sequence and requirements in Table 2. 

4.4.5. The performance test will begin with two exhalations into the unit at the specified 

ventilation rate to determine the design’s susceptibility to hypoxia.

4.4.6. Performance testing of CCERs with less than 50 liters of oxygen capacity will 

require the submission of additional test units to fully apply the work-rate test 

sequence and requirements specified in Table 3. The testing of each individual unit 

will complete the cycle specified in Table 3 until the breathing supply of the initial 

test unit is exhausted. This initial test unit will then be replaced by a second unit, 

which will continue the test cycle, commencing at the point in the work rate cycle

where the previous unit ended (overlap to previous cycle point may be no more 

than 2 minutes). 

5. PROCEDURE

5.1. Initial Startup

5.1.1. Verify all equipment is on and all test system operating parameters are in the 

appropriate range for valid testing.

5.1.2. Calibrate the O2 and CO2 exhaust flows analyzers.

5.1.3. Perform ABMS gas analyzer calibration for O2 and CO2.

5.1.3.1. Confirm the response times for each gas analyzer are within acceptable 

ranges as established by the manufacturer.

5.1.4. Verify correct waveforms for the specific performance test work rate cycle.

5.1.4.1. For the peak work rate portion of the performance test work rate cycles , 

set the VO2 to 3.00 L/min; see Figure 2.

5.1.4.2. For the high work rate portion of the performance test work rate cycle, 

set the VO2 to 2.00 L/min; see Figure 3.

5.1.4.3. For the low work rate portion of the performance test work rate cycle, set 

the VO2 to 0.50 L/min; see Figure 4.

5.1.5. Mount the CCER unit on the ABMS trachea and perform a leak check for the 

ABMS. Ensure all orifices are properly sealed and that the system is leak tight.
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 5 of 12

5.1.6. Select the Performance Test protocol just prior to beginning the simulation 

operation.

5.2. Perform the performance test by selecting the appropriate test protocol to set the 

corresponding VO2, VCO2, ventilation rate, and respiratory frequency operating 

conditions just prior to beginning the simulation.

5.2.1. The manufacturer’s recommended start-up procedure for the CCER being tested 

must be simulated on the ABMS as closely as possible, as described in the 

manufacturer’s UI.

5.2.2. Monitor the values in Table 1 throughout the test.

5.2.3. Determine the completion time as the time elapsed from test start to when the gas 

supply is fully expended. Expended gas supply is usually indicated when either 

the breathing bag is empty, or (if present) the O2 cylinder is empty, and (as a 

result) peak inhalation pressure begins to spike below -300 mmH2O. The test is 

also stopped if the peak breathing resistance exceeds +200 mmH2O.

5.2.4. The Peak, High, and Low work rates will be cycled through as the corresponding 

VO2, VCO2, ventilation rate, and respiratory frequency levels are varied as per the 

settings and time sequences in Table 3.

5.2.4.1. Start-up for a performance test must include two complete exhalations 

prior to beginning the simulation operation. If the manufacturer requires

that an exhaled breath be imparted prior to start-up, this exhaled breath 

will be considered as one of the two complete exhalations required for 

performance testing.

5.2.5. For CCER undergoing performance approval testing that contain less than 50 

Liters of capacity, the simulation operation shall be paused immediately prior to 

the capacity being depleted and the breathing bag collapsing. After replacing the 

expended CCER with a new CCER, simulation operation must restart immediately

thereafter. At least one full work rate cycle (peak, high, and low) must be 

completed for testing of CCERs with less than 50 Liters capacity.

5.3. Data analysis

5.3.1. Determine the completion time as the time elapsed from test start to when the 

breathing gas supply is fully expended. Expended breathing gas supply is usually 

indicated when either the breathing bag is empty, or (if present) the O2 cylinder is 

empty, and (as a result) peak inhalation pressure begins to spike below -300 mm 

H2O.

5.3.2. Calculate the overall average for each of the stressor measurements using the oneminute average values from the test start to when the breathing gas supply is fully 

expended.
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 6 of 12

6. PASS/FAIL CRITERIA

6.1. The apparatus fails this test and approval if:

6.1.1. Any average stressor measurement (as the overall average stressor from test start 

to when the breathing gas supply is fully expended) is outside the acceptable 

operating average range shown in Table 1 (middle column).

6.1.2. If from the test start up to when the breathing gas supply is fully expended any 

one-minute average stressor measurement is outside the acceptable excursion 

range shown in Table 1 (last column).

Table 1: Monitored stressors and their acceptable ranges

Stressor Acceptable Range

Operating Average

Acceptable Range

Excursion

Average inhaled CO2 <1.5% ≤4%

Average inhaled O2 >19.5% ≥15%

Peak Breathing

Resistances

∆P ≤ 200 mm H2O -300 ≤ ∆P ≤ 200 mm H2O

Wet-bulb temperature <43 ̊C ≤50 ̊C

6.1.3 The apparatus fails approval if the achieved capacity is below the minimum capacity 

as indicated in Table 2.

Table 2: Performance test requirements for a cycle (all volumes are given at standard temperature 

(0°C) and pressure (760 mm Hg), dry)

Work-Rate

Test Sequence

Duration

per cycle

VO2

(L/min)

VCO2

(L/min)

Ve

(L/min)

RF

(breaths/min)

1. Peak 5 min. 3.00 3.20 65.0 25

2. High 15 min. 2.00 1.80 44.0 20

3. Low 10 min. 0.50 0.40 20.0 12

VO2 = volume of oxygen consumed/min; VCO2 = volume of carbon dioxide produced/min

Ve = ventilation rate; RF = respiratory frequency

7. RECORDS / TEST SHEETS

7.1. Data shall be recorded and stored as an attached data sheet to include the following 

information in the TEST DATA SHEET (INCLUDING PRE-TEST CHECK DATA) FOR 

DETERMINATION OF CCER PERFORMANCE, STP 0603.
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 7 of 12

TEST DATA SHEET (INCLUDING PRE-TEST CHECK DATA) FOR DETERMINATION OF CCER 

PERFORMANCE, STP 0603

Date Barometric 

Pressure 

(mm Hg)

S/N # Manufacturer 

Date

Expiration 

Date

Phenolphthalein 

(Pass or Fail)

Oxygen 

Flow Rate 

(LPM)

CCER Leak Flow 

Rate (mL/min)

Case 

Integrity

Case Seal Secure 

Tape or 

Latch

Oxygen 

Indicator 

(psig)

Oxygen 

Starter

Temperature 

Indicator

Moisture 

Indicator

Waveform/Protocol

Oxygen 

Response 

(ms)

Carbon 

Dioxide 

Response 

(ms)

Oxygen 

Criteria 

Time 

(ms)

Carbon 

Dioxide 

Criteria Time 

(ms)

ABMS 

Leak Rate 

(mL/min)

ABMS Leak 

Rate with CCER 

(mL/min)

Technician 

Initials

Comments
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 8 of 12

Table 3: Example Test Summary Data for all CCER Units Submitted for NIOSH Approval

Device 

ID

Test Test 

date

Completion 

time

Calculated 

Capacity

Indicate 

Minimum 

Capacity

Comments

As-received

As-received

As-received

Environmental 

treatments

Environmental 

treatments
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 9 of 12

8. ATTACHMENTS

8.1. Figure 1: Schematic of the ABMS

8.2. Figure 2: Graph for the Peak Work-Rate Test

8.3. Figure 3: Graph for the High Work-Rate Test

8.4. Figure 4: Graph for the Low Work-Rate Test

Figure 1: Schematic of the ABMS
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 10 of 12

Figure 2: Example graph for Peak Work Rate, showing breathing gas volumetric flow rate (y-axis) vs.

time (x-axis).

Figure 3: Example graph for High Work Rate, showing breathing gas volumetric flow rate (y-axis) vs.

time (x-axis).
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 11 of 12

Figure 4: Example graph for Low Work Rate, showing breathing gas volumetric flow rate (y-axis) vs.

time (x-axis).
Procedure No. TEB-CCER-STP-0603 Revision: 1.0 Date: 5 January 2022 Page 12 of 12

Revision History

Revision Date Reason for Revision

0 14 October 2009 Initial Record

1.0 02 August 2011 Final Review

1.0 22 November 2011 Administrative changes – Document number changed

2.0 3 April 2012 Administrative changes were made to include information from the 

release of the proposed rule.

Former document number - STP-00001-PSDB-0007

0.0 25 March 2014 New document number to reflect numbering in the approval library, 

normalization of format. The only change made in the procedure is in 

section 4.6.6. The restart of subsequent units was changed from 

commencing the next work rate from where the previous unit ended, to 

the point at which the previous unit ended with no more than a 2 

minute overlap. No other changes to procedure from historical 

document.

1.0 05 January 2022 Changes were made to the equipment, materials, and the procedure. 

Examples waveforms were added as Figures.