Approvals: First Level Second Level Third Level Fourth Level

National Institute for Occupational Safety and Health

National Personal Protective Technology Laboratory

P.O. Box 18070

Pittsburgh, PA 15236

Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014

STANDARD TESTING PROCEDURE (STP) TO CONDUCT MAN TEST 4 FOR CLOSED-CIRCUIT 

ESCAPE RESPIRATORS (CCERs) TO BE USED IN UNDERGROUND COAL MINES

1. PURPOSE

This test establishes the procedures for ensuring that the level of protection provided by the Man 

Test 4 requirements on Closed-Circuit Escape Respirators (CCER) submitted for Approval, 

Extension of Approval, or examined during Certified Product Audits, meet the minimum 

certification standards set forth in Section 84.304(a) (5) of Subpart O−Closed Circuit Escape 

Respirators updated requirements to 42 CFR, Part 84, Volume 60, Number 110, June 8, 1995 as 

published in Federal Register / Vol. 77, No. 46 / Thursday, March 8, 2012 / Rules and 

Regulations pp. 14168-14197.

2. GENERAL

This STP describes the Man Test 4 for Closed-Circuit Escape Respirator test in sufficient detail 

that a person knowledgeable in the appropriate technical field can assemble the appropriate 

equipment, conduct the test, and determine whether or not the product passes the test.

3. EQUIPMENT/MATERIALS

3.1. The list of necessary test equipment and materials follows:

3.1.1. One B-D Yale (2317 100YL) 100cc (Becton, Dickson and Co.) syringe "LuerLok", Becton Dickson & Company, Rutherford, NJ, or equivalent

3.1.2. Doric Series 400A Digital Trendicator, Doric Scientific Division, Emerson 

Electric Company, 3883 Ruffin Road, San Diego, CA 92123 or equivalent

3.1.3. Gould Stratham Transducer Readout, Model SC1012, Gould, Inc., 2230 Stratham 

Blvd., Oxnard, CA 93030 or equivalent

3.1.4. Temperature Compensated Strain Sensitive Resistance wire-type transducer 

(Stratham Instruments) Pressure range +0.5 psig or equivalent

3.1.5. Electric timer, calibrated to l00ths of a minute (Precision Scientific Co.) or 

equivalent

3.1.6. Digital timer/stopwatch calibrated to 100ths (0.01) of a minute to or equivalent
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 2 of 18

3.1.7. Applied Electrochemistry CO2 Analyzer - Model CD-3A or equivalent

3.1.8. Applied Electrochemistry Oxygen Analyzer - Model S-3A/I or equivalent

3.1.9. Certified calibration gas with O2 at 80.0 % and CO2 at 8.0% and N2 at 12%. 

3.1.10. Fifty-pound sack or equivalent

3.1.11. Forty-five pound pipe weight or equivalent

3.1.12. Forty-five pound weight pulling machine (U.S. BOM) or equivalent

3.1.13. Knee pads or equivalent

3.1.14. Model 18-49B Horizontal Treadmill, 0-6 MPH, Quinton Instruments or 

equivalent

3.1.15. Model 24-90 Ladderwalk 0-130 feet/minute, Quinton Instruments, or equivalent

3.1.16. An automated external defibrillator (AED) at the test scene

4. TESTING REQUIREMENTS AND CONDITIONS

4.1. Two test subjects meeting requirements of the NIOSH Human Subject Review Board 

(HSRB) approved Protocol. Refer to “Protocol for tests with human subjects of closedcircuit breathing apparatus in certification, quality assurance, and development” HSRB 

12-NPPTL-04 for the proper consent form and complete details on the use of human test 

subjects in respirator certification testing.

4.2. Prior to beginning any testing, all measuring equipment to be used must have been 

calibrated in accordance with the manufacturer's calibration procedure and schedule. At 

a minimum, all measuring equipment utilized for this testing must have been calibrated 

within the preceding 12 months using a method traceable to the National Institute of 

Standards and Technology (NIST).

4.3. Any laboratory using this procedure to supply certification test data to NPPTL will be 

subject to the provisions of the NPPTL Supplier Qualification Program (SQP). This 

program is based on the tenets of ISO/IEC 17025, the NIOSH Manual of Analytical 

Methods and other NIOSH guidelines. An initial complete quality system audit and 

follow on audits are requirements of the Program. Additional details of the Program and 

its requirements can be obtained directly from NPPTL.

4.4. Normal laboratory safety practices must be observed. These include safety precautions 

given in the current NIOSH-Pittsburgh Health and Safety Manual, Job Hazard Analysis 

(JHA), work instruction documents and test equipment manufacturer recommended 

practices.

4.5. Refer to HSRB 12-NPPTL-04, “Protocol for tests with human subjects of closed-circuit 

breathing apparatus in certification, quality assurance, and development” for the proper 

consent form and complete details on the use of human test subjects in closed-circuit 

escape respirator certification testing.
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 3 of 18

5. PROCEDURE

Note: Reference Section 3 for equipment, model numbers and manufacturers. For calibration 

purposes use those described in the manufacturer's operation and maintenance manuals.

5.1. Use the test operating procedure as follows:

5.1.1. The man tests are conducted in duplicate in accordance with the specific duration 

test schedule corresponding to the service time approval requested by the 

manufacturer.

5.1.2. During the sampling periods the following parameters are monitored:

Closed Circuit

a) breathing resistance

b) gauge pressure

c) subject pulse rate

d) subject respiration rate

e) oxygen in inhalation tube

f) carbon dioxide in inhalation tube

g) temperature (mask and ambient)

5.1.3. Prior to tests the oxygen and carbon dioxide analyzers must be calibrated with 

the proper calibration gas (see 3.1.10).

5.1.4. All tests require the services of a physician, the presence of two persons currently 

certified in CPR/AED use and an automated external defibrillator (AED) located 

adjacent to the test area.

5.1.5. Test subjects are used for evaluation of a CCER for use in coal mines. Refer to 

HSRB 12-NPPTL-04 “Protocol for tests with human subjects of closed-circuit 

breathing apparatus in certification, quality assurance, and development”.

5.2. Data Analysis

5.2.1. All sample values must be within the regulations requirements. Other factors are 

also evaluated during the tests, such as; strap length, position and adjustments; 

comfort; weight; profile; total performance. Expert test subjects give test 

feedback and opinions for the SCBA evaluated and are geared towards:

5.2.1.1 General comments 

5.2.1.2. Specific comments per intended application.
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 4 of 18

Note: This test will be done on a minimum of two respirators, or more 

if additional testing is required (42 CFR, Part 84, Sections 84.12, 

84.30, and 84.60.)

6. PASS/FAIL CRITERIA

6.1. The criterion for passing this test is set forth in 42 CFR, Part 84, Subpart G, Section 

84.63(a)(c)(d), and Subpart H, Section 84.70, 84.79(a), 84.97, 84.99, 84.100, 84.103, 

Volume 60, Number 110, June 8, 1995.

6.2. This test establishes the standard procedure for ensuring that:

84.63 Test requirements; general.

(a)Each respirator and respirator component shall when tested by the applicant 

and by the Institute, meet the applicable requirements set forth in subparts H 

through L of this part.

(c)In addition to the minimum requirements set forth in subparts H through L of 

this part, the Institute reserves the right to require, as a further condition of 

approval, any additional requirements deemed necessary to establish the quality, 

effectiveness, and safety of any respirator used as protection against hazardous 

atmospheres.

(d)Where it is determined after receipt of an application that additional 

requirements will be required for approval, the Institute will notify the applicant 

in writing of these additional requirements, and necessary examinations, 

inspections, or tests, stating generally the reasons for such requirements, 

examinations, inspections, or tests.

84.79 Breathing gas; minimum requirements

(a)-1 Breathing gas used to supply apparatus shall be respirable and contain no 

less than 19.5 (dry atmosphere) volume percent of oxygen.

84.97 Test for carbon dioxide in inspired gas; closed-circuit apparatus; maximum 

allowable limits.

(c) During the testing required by paragraphs (a) and (b) of this section, the 

concentration of carbon dioxide in inspired gas at the mouth will be continuously 

recorded, and the maximum average concentration during the inhalation portion 

of the breathing cycle shall not exceed the following limits:
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 5 of 18

Where the service time is Maximum allowable average 

concentration of carbon dioxide 

in inspired air percent by volume

Not more than 30 minutes 2.5

1 hour....................... 2.0

2 hour....................... 1.5

3 hour....................... 1.0

4 hour....................... 1.0

84.99 Man tests; testing conditions; general requirements.

(a) The man tests described in Table 4 represent the workload performed in the 

mining, mineral, or allied industries by a person wearing the apparatus tested.

(b) The apparatus tested will be worn by personnel trained in the use of selfcontained breathing apparatus, and the wearer will, before participating in these 

tests, pass a physical examination conducted by a qualified physician.

(c) All man tests will be conducted by the Institute.

(d) The apparatus will be examined before each man test to ensure that it is in 

proper working order.

(e) Breathing resistance will be measured within the facepiece or mouthpiece and 

the wearer's pulse and respiration rate will be recorded during each 2-minute 

sample period prescribed in tests 1, 2, 3, and 4.

(f) Man tests 4 will be conducted in duplicate.

(g) If man tests are not completed through no fault of the apparatus, the test will 

be repeated.

84.100 Man test 4; requirements.

Man test 4, set forth in Table 4 respectively, prescribe the duration and sequence 

of specific activities. These tests will be conducted to:

(a) Familiarize the wearer with the apparatus during use; 

(b) Provide for a gradual increase in activity;

(c) Evaluate the apparatus under different types of work and physical orientation; 

and

(d) Provide information on the operating and breathing characteristics of the 

apparatus during actual use.
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 6 of 18

84.103 Man tests; performance requirements.

(a) The apparatus shall satisfy the respiratory requirements of the wearer for the 

classified capacity (Cap 3 for one hour test duration).

(b) Fogging of the eyepiece shall not obscure the wearer's vision, and the wearer 

shall not experience undue discomfort because of fit or other characteristics of 

the apparatus.

(c) When the ambient temperature during testing is 24 degrees + 6 degrees C. (75 

degrees + 10 degrees F.), the maximum temperature of inspired air recorded 

during man tests shall not exceed the following, after correction for deviation 

from 24 degrees C. (75 degrees F.):

Where service life of 

apparatus is--

Where percent 

relative humidity of 

inspired air is--

Maximum permissible temperature of 

inspired air shall not exceed--

1/4 hour or less 0-100 135 57

1/2 hour to 3/4 hour 0-50

50-100

125

1101

52

431

1 to 2 hours 0-50

50-100

115

1051

46

411

3 hours 0-50

50-100

110

1001

43

381

4 hours 0-50

50-100

105

951

41

351

1Where percent relative humidity is 50-100 and apparatus is designed for escape only, these 

maximum permissible temperatures will be increased by 5°C (10°F).
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 7 of 18

Tables to Subpart H of Part 84

Table 4-Duration and Sequence of Specific Activities for Test 4, in Minutes [42 CFR part 84, subpart H]

Activity Service time3 

minutes

5 

minutes

10 

minutes

15 

minutes

30 

minutes

45 

minutes

1 hour 2 

hours

3 

hours

4 hours

Sampling and 

readings

2 2 2 2 (

2

) (

3

) (

4

)

Walks at 4.8 km. 

(3 miles) per hour

1 2 2 2

Climbs vertical 

treadmill 1 (or 

equivalent)

1 1 1 1 1 1 1

Walks at 4.8 km. 

(3 miles) per hour

1 1 1 2 2 2

Pulls 20 kg. (45 

pound) weight to 

5 feet

30 times 

in 2 

minutes

30 times 

in 2 

minutes

30 times 

in 2 

minutes

60 times 

in 5 

minutes

60 times 

in 5 

minutes

60 times in 

5 minutes

Walks at 4.8 km. 

(3 miles) per hour

1 1 1 2 3

Carries 23 kg. (50 

pound) weight 

over overcast

1 time in 

1 minute

1 time in 

1 minute

2 times 

in 3 

minutes

4 times in 

8 minutes

Sampling and 

readings

2 2 2 2

Walks at 4.8 km. 

(3 miles) per hour

1 3 3 4

Runs at 9.7 km. 

(6 miles) per hour

1 1 1 1 1 1

Carries 23 kg. (50 

pound) weight 

over overcast

1 time in 

1 minute

1 time in 

1 minute

2 times 

in 3 

minutes

4 times 

in 6 

minutes

6 times in 

9 minutes

Pulls 20 kg (45 

pound) weight to 

5 feet

15 times 

in 1 

minute

15 times 

in 1 

minute

60 times 

in 5 

minutes

30 times 

in 2 

minutes

36 times in 

3 minutes

Sampling and 

readings

2 2 2 2

Walks at 4.8 km. 

(3 miles) per hour

1 1 2 6

Pulls 20 kg. (45 

pound) weight to 

5 feet

60 times 

in 5 

minutes

60 times in 

5 minutes

Carries 20 kg. (45 

pound) weight 

and walks at 4.8 

km. (3 miles) per 

hour

3 3

Sampling and 

readings

2 2

1Treadmill shall be inclined 15° from vertical and operated at a speed of 30 cm. (1 foot) per second.

2

Perform test No. 1 for 30-minute apparatus; then perform test No. 4 for 1-hour apparatus; then perform test No. 1 

for 30-minute apparatus.

3

Perform test No. 1 for 1-hour apparatus; then perform test No. 4 for 1-hour apparatus; then perform test No. 1 for 1-

hour apparatus.

4

Perform test No. 1 for 1-hour apparatus; then perform test No. 4 for 1-hour apparatus; then perform test No. 1 for 1-

hour apparatus twice (i.e., two one-hour tests).
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 8 of 18

7. RECORDS\TEST SHEETS

7.1. All test data will be recorded on the MAN TESTS, SELF-CONTAINED BREATHING 

APPARATUS test data sheet.

7.2. All videotapes and photographs of the actual test being performed, or of the tested 

equipment shall be maintained in the task file as part of the permanent record.

7.3. All equipment failing any portion of this test will be handled as follows:

7.3.1. If the failure occurs on a new certification application, or extension of approval 

application, send a test report to the Team Leader and prepare the hardware for 

return to the manufacturer.

7.3.2. If the failure occurs on hardware examined under an Off-the-Shelf Audit the 

hardware will be examined by a technician and the Team Leader for cause. All 

equipment failing any portion of this test may be sent to the manufacturer for 

examination and then returned to NIOSH. However, the hardware tested shall be 

held at the testing laboratory until authorized for release by the Team Leader, or 

his designee, following the standard operating procedures outlined in Procedure 

for Scheduling, and Processing Post-Certification Product Audits, RB-SOP0005-00.
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 9 of 18

MAN TESTS, SELF-CONTAINED BREATHING APPARATUS #4 - 4 HOUR

PROJECT NO: DATE : __________ 

Subject: Age : __________ 

Subject weight: Initial - Final - _______________ 

RESPIRATOR TYPE: 4 hour 

Unit weight: Initial - Final - _______________ 

Observers: ________________________________________________________________________ 

Sampling Schedule

Time/Min. Gas Percent Pulse Resp. Resistance Temperature Press

 CO2 02 bpm rpm inh. exh. unit amb. gauge

 0-2 _____________________________________________________________________________ 

 20-22 ____________________________________________________________________________ 

 40-42 ____________________________________________________________________________ 

 58-62 ____________________________________________________________________________ 

 83-85 ____________________________________________________________________________ 

102-104 ___________________________________________________________________________ 

118-122 ___________________________________________________________________________ 

140-142 ___________________________________________________________________________ 

160-162 ___________________________________________________________________________ 

178-182 ___________________________________________________________________________ 

200-202 ___________________________________________________________________________ 

220-222 ___________________________________________________________________________ 

238-240 ___________________________________________________________________________ 

Alarm - __________ min. at _________ psig.
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 10 of 18

Work Schedule

Time/Min. Exercise

0-2 sample

2-20 walk - 3mph

20-22 sample

22-40 walk - 3mph

40-42 sample

42-58 walk - 3mph

58-62 sample

62-64 walk - 3mph

64-65 vertical

65-67 walk - 3mph

67-72 rope pull - 60x5min

72-75 walk - 3mph

75-83 overcast - 4x8min

83-85 sample

85-89 walk - 3mph

89-90 run - 6mph

90-99 overcast - 6x9min

99-102 rope pull - 36x3min

102-104 sample

104-110 walk - 3mph

110-115 rope pull - 60x6min

115-118 carry 45lb weight & walk 3mph
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 11 of 18

Work Schedule (cont)

Time/Min. Exercise

118-122 sample

122-140 walk - 3mph

140-142 sample

142-160 walk - 3mph

160-162 sample

162-178 walk - 3mph

178-182 sample

182-200 walk - 3mph

200-202 sample

202-220 walk - 3mph

220-222 sample

222-238 walk - 3mph

238-240 sample

Comments : 

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

_____________________________________________________________________________________

___________________________________________

Test Engineer: PASS FAIL________ 
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 12 of 18

8. ATTACHMENTS

TEST SUBJECTS CHECK LIST

Test Subject MSHA Personnel

 1-week Notice 2-week Notice

1. ______Arrange Test Dates 1. ______ Arrange Test Dates

2. ______Confirm with Letter

(A) Confirm M.D. Availability

1.______ on planned test dates

2. ______ call Manufacturer (test dates)

3. ______Test Prep. Sheet and Man Test Sheet

(B) Subject Arrival

1. ______Orientation (Protocol Activity Sheets)

2. ______ Subject Reads Protocol

3. ______ Subject Signs NIOSH IRB protocol Consent Form 

4. ______ Orientation on Exercise Equipment

5. ______ Explain Respirator Operation and Donning

(C) ______ Conduct Tests

(D) ______ Meet and Review Comments

(E) ______ Pay Participants

(F) ______ Write Letter of Appreciation
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 13 of 18

OUTLINE (TEST SUBJECT SAFEGUARDS)

I. Presubmission - Manufacturer performs tests, as required by Part 84, on their apparatus to 

demonstrate conformance to regulations.

II. Apparatus Testing

(A) Laboratory tests performed

1. Must meet all applicable performance requirements

2. Must be of safe design

(B) Modifications must be made by manufacturer and apparatus retested for performance

III. Pre-subject preparation

(A.) All testing personnel have current CPR (including AED) training and certificates

(B.) Notices of subject tests are sent to appropriate NIOSH personnel including:

1. Staff involved in testing

2. Physician

3. Front desk guard

4. Administrative Officer

IV. Pre-test preparation

(A.) Physician and Team Leader have pagers for immediate notification of:

1. Emergency

2. Problems

(B.) Test subject receives a physical examination by Physician

1. Must meet all physical requirements

2. Must be referred by Physician as satisfactory

(C.) Test subject orientation

2. If new, tries out work exercise equipment

3. Is given information regarding test apparatus

4. Reads and signs HSRB document to safeguard subject

5. Reads protocol (test)

6. Given opportunity to ask questions

7. Is told that he is permitted to stop test anytime for any reason he feels justified

8. Asked if he is prepared to begin test

V. Testing

A. Two personnel present during tests
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 14 of 18

B. Crash cart present with current drugs and calibrated defibrillator

C. Subject monitored for oxygen concentration. CO2 levels, resistance, temperatures, respirations, 

pulse rate (test stopped if regulations levels are exceeded), and blood oxygen saturation (pulse 

oximetry).
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 15 of 18

BEFORE-EACH-MAN-TEST CHECK LIST

1. Suction Machine

2. Batteries and Bulbs in Laryngoscope

3. Batteries and Bulbs in Flashlight

4. Dates on Medication

5. Check O2 Cylinder

6. Unlock Crash Cart

Date Checked Signature Task Number Unit Man Test No.

 ___________ 

 ___________ 

 ___________
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 16 of 18
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 17 of 18
Procedure No. TEB-CCER-STP-0615 Revision: 0.0 Date: 7 April 2014 Page 18 of 18

Revision History

Revision Date Reason for Revision

00 07 October 2009 Initial Record

1.0 16 November 2011 Administrative change – Document number changed

2.0 20 February 2012 Man Test 4 for CAP-3 Closed-circuit Escape Respirators (CCER) 

Standard Testing Procedure (STP)

3.0 28 March 2012 Administrative changes were made to include information from the 

release of the proposed rule.

Former document number - STP-00001-PSDB-0004

0.0 7 April 2014 New document number to reflect numbering in the approval library, 

normalization of format. Various figures are moved into the 

attachments section from the body of the document for the sake of 

clarity. No changes to procedure from historical document.