BreatheSafe Parts and Service Manual

Product Overview

This document provides comprehensive parts and service information for the BreatheSafe air pressurisation system fitted to the Hitachi ZX170W Excavator. It details installation, operation, maintenance, troubleshooting, and warranty procedures for the HEPA H14 Variable Speed Pressuriser, INPRESS TS Cabin Display with CO2 Sensor, and HEPA Return Air Filter.

Contents

• Installation
• Safety
• Critical Parts & Maintenance Schedule
• Operator Guide
• Specifications - Pressuriser
• Parts List
• Technical Details
• Smoke Emitter Cabin Pressure Leak Test
• Cabin Sealing Test Procedure
• Commissioning Procedures
• Troubleshooting Guide
• User Settings Instructions
• Data Download
• Warranty

Installation Overview

Manufacturer: Hitachi

Type: Excavator

Model: ZX170W

Cabin Pressure Max: [Value not specified in overview]

Set Auto Cabin Pressure: [Procedure described later in manual]

The system includes the HEPA H14 Variable Speed Pressuriser, INPRESS TS Cabin Display with Data Recorder, and HEPA Return Air Filter.

Safety Information

WARNING

The pressurisation system involves areas that can be dangerous if not handled with extreme care. Qualified staff must wear appropriate Personal Protective Equipment (PPE) due to dust and fibres that may be captured by the air filtration stages during operation.

The electrical power system operates on 12V DC or 24V DC. All work on the pressuriser system must follow correct safe work procedures, including electrical safety measures and isolating relevant circuit breakers.

The air filtration system may contain high-speed rotating equipment with sharp edges. Ensure all safety guards are in place while the system is running.

HEPA filters cannot be cleaned and must be replaced at the end of their lifecycle or if the filter media is damaged.

Particulate Behaviour

This section describes the time it takes for particles of various sizes to drop from a height of 1.5m in still air:

• 20μm: 3.6 mins
• 10μm: 8.3 mins
• 5μm: 35.7 mins
• 2μm: 2.8 hrs
• 1μm: 12 hrs
• 0.5μm: 41.7 hrs

In warehouses and workshops, airborne particulates may remain suspended longer, increasing the risk of inhalation. Ensure PPE is worn during installation.

Personal Protective Equipment (PPE)

Critical Parts & Maintenance Schedule

The following tables outline the suggested maintenance schedule. Site conditions may affect these intervals. Excludes high corrosion environments.

Data download is required to claim the 3-year warranty on the Brushless Blower Motor.

Inspect every 500 Hours and replace when filter is full*

15,000 Hours / 36 months*

Critical Parts

*Filter service hours are subject to cab sealing efficiency, site conditions and correct system use.

Suggested Schedule Servicing:

Fan Capacity Indicator: The filter is serviceable if the motor capacity is between 10% & 80%. It is recommended that the filter is changed if the capacity is over 80%. *Site dependent.

Operator Guide

Operators Checklist - Pre-Start

1. Visually inspect the BreatheSafe system for any damage.
2. Visually inspect the cabin for any damage to doors, windows, seals.
3. Please remove dust & debris from shoes and clothes before entering the cabin.
4. Ensure door(s) and windows are closed correctly.
5. Start engine and turn HVAC on to speed 2 (medium speed).
6. After fixed speed delay, the BreatheSafe display will show 50 Pascals or pre-set value. The system is working correctly when the pascal value is green.

>> There is no further action required <<

Normal Operating Condition - Cab Air Conditioning

BreatheSafe recommends the OEM air conditioning fan is set at mid speed or greater to circulate air around the breathing zone and minimise CO2. An acceptable operating range for the BreatheSafe fan is 10-80%; readings over 80% recommend maintenance.

Alerts

• Fixed Fan Start Delay: Allows the operator to carry out pre-start checks, limiting fan speed to 30%. Press the red text to disable.
• CO2 Level Alert (if equipped): Ensure the air conditioning fan is set at mid speed or greater to circulate air and minimise CO2.
• Low Pressure Alarm: Indicates the cabin is not maintaining positive pressure. Check doors and windows are closed correctly. Refer to the maintenance department to check filters and cabin sealing. Ensure filters are serviceable.
• Check Filter: Reminder to inspect or replace the filter. The service hour meter requires re-setting. Refer to the maintenance department.

Specifications High-Capacity HEPA Pressuriser

Blower: Brushless Blower P/N 200002.

Protection: Locked Rotor Protection (Sub Zero Environments) Under Voltage, Under/Over Current & Over Temperature.

Voltage: 24VDC.

Current Draw: 11 amps (peak). *Note: Motor has slow start to stop excessive in-rush current.

Air Flow: Up to 30-300 m³/h or 50-215 CFM.

Pre-cleaner: Integrated VLR (Very Low Restriction). Turbo Pre-Cleaner.

Filter Element: BreatheSafe HEPA Primary Filter (H14=99.99% MPPS) TESTED AS PER EN1822 – P/N 500000.

Plugs & Fittings: Mining Spec. Deutsch electrical plugs as standard.

Construction: High strength composite construction.

Serviceability: Easy access HEPA filter with twist-lock (TL) dust cap single assembly.

Mounting: Heavy Duty adjustable mounting brackets.

Design: Fully designed in SolidWorks 3D CAD & Ansys Engineering Simulation Software.

FEA Testing: Critical components FEA (Finite Element Analyst) tested in Solid Works Simulation.

CFD Testing: CFD (Computational Fluid Dynamics) simulations in Flow Works to ensure optimum air flow through the system.

List of Abbreviations

Parts List - TL4 24V DC Pressuriser Unit

Pressuriser Assembly No: 200000

Diagram Description: The diagram shows an exploded view of the TL4 24V DC Pressuriser Unit, illustrating components such as the pre-cleaner assembly (Items 1-6), the brushless motor (Item 7), O-ring kit (Item 8), wiring sleeve (Item 10), HEPA H14 Filter (Item 11), and various nuts and bolts (Items 12-17).

Parts List GA

Complete Assembly No: 700---

Diagram Description: The diagram shows a general assembly view of the system, illustrating the mounting brackets (Items 1, 2, 3), fresh air inlet (Item 4), monitor module (Item 5), tube mount rail (Item 6), lower pipework assembly (Item 7), F/A/Tube arrangement (Item 8), R.A.F. Assy (Item 9), HPAFU unit (Item 10), spacers (Item 11), and pipework components (Items 13, 14, 15).

Parts List – Fresh Air Module

Diagram Description: The diagram shows the Fresh Air Module, consisting of a Fresh Air Panel (Item 1) and a 76 SS Tube (Item 2).

Parts List - Return Air Module

Diagram Description: The diagram illustrates the Return Air Module, showing clamp assemblies (Items 1, 2, 3), a filter frame (Item 4), a HEPA filter (Item 5), and M6 knobs (Item 6).

Parts List - Pipework Module

Diagram Description: The diagram shows various pipework components including stainless steel tubes (Items 1, 8), clamps (Items 2, 9, 10), spacers (Item 3), and pipe bends (Items 6, 7).

Parts List - Monitor Module

Diagram Description: The diagram illustrates the Monitor Module, showing a monitor bracket (Item 1), a small monitor box (Item 2), and a universal CO2 bracket (Item 3).

Technical Details

Display Key Features

• Digital cabin pressure monitoring system
• Automatic cabin pressure control
• Intelligent fan speed output
• Data logger
• Alarm for low-pressure (RS20)
• Light sensor for automatic dimming of the screen

Diagram Description: The display unit is shown with dimensions (184.5mm x 61.8mm x 54.6mm) and examples of its main screen showing Cabin Pressure, CO2 Concentration, Temperature, and Data Recorder status, along with buttons for Settings, Alarm Mute, and a Light Sensor.

CO2 Sensor

• CO2 Sensor Type is NDIR (Non-Dispersive Infrared)
• Sample Rate is every 2 seconds
• 12-30V DC Operating Voltage
• Automatic Altitude Compensation
• Alarm Set points are adjustable
• No setup required

Diagram Description: The CO2 sensor is depicted with dimensions (65mm x 120mm x 27mm).

Connections and Wiring Diagram

Connections: 200027

• Item 1: PIPE A - AMBIENT PRESSURE - OUTSIDE
• Item 2: PIPE B - POSITIVE PRESSURE - INSIDE
• Item 3: RJ45 CONNECTOR - CO2 SENSOR
• Item 4: OVERRIDE TOGGLE SW = MAX SPEED

Wiring Diagram

Diagram Description: The wiring diagram shows the INPRESS User Interface (UI) connected to the TL4 Pressuriser, CO2 Sensor, and Power Supply (24 VDC, 20A). Connections include RJ45 for peripheral connections and a Deutsch Plug. It details power supply, CAN options, serial transmit/receive, motor control, alarm output, temperature sensor, and door/window inputs.

Smoke Emitter Cabin Pressure Leak Test

Link to MSDS: SMOKE GENERATOR TQ7621AT30S.pdf

WARNING

For Professional Use Only. Keep out of reach of children. Do not ignite near or around flammable materials. Use only in well-ventilated areas, outdoors, and/or with proper respiratory protection. Persons with respiratory sensitivity should avoid exposure to any smoke. Concentrated smoke may cause severe burns to the skin, eyes, or respiratory system. Improper use may result in sufficient inhalation of smoke to cause respiratory tract irritation and lung damage. Harmful if swallowed.

Personal Protective Equipment (PPE)

• Safety glasses must be worn at all times.
• Sturdy footwear with rubber soles must be worn.
• Respiratory protection devices may be required.
• Gloves may be worn.

Pre-operational Safety Checks

• Locate and ensure familiarity with all machine operations and controls.
• Check work area and walkways for slip/trip hazards.
• Ensure the work area is clean and clear of flammable material; ensure a fire extinguisher is present.

Operational Safety Checks

• Ensure the machine is correctly isolated/immobilized.
• Ensure other persons do not inhale smoke haze.
• Take care not to place a lit emitter close to a flammable surface.

Ending Operations and Cleaning Up

• Leave the work area in a safe, clean, and tidy state.

Smoke Emitter Cabin Pressure Leak Test Procedure

1. The pressuriser system is switched on (TEST MODE).
2. Hold the smoke emitter angled down.
3. Ignite emitter using site-approved ignitor (e.g., solder torch or 'lighter').
4. When the product ignites, remove the lighter.
5. If the product flames up, blow out the flame.
6. Place the emitter in a non-flammable container inside the cabin at floor level and close the door/windows.
7. Observe smoke leaks to indicate worn-out or broken seal locations. Check leakage points outside the cabin.
8. Do not come into contact with or inhale smoke haze.
9. Wait until the smoke haze completely disperses before re-entering the cabin. Open door to allow sufficient ventilation of smoke prior to entering cabin.

Potential Hazards

• Falls: [No specific details provided]
• Fumes: May cause cancer. Exposure is highly unlikely when used as directed.
• Fire: [No specific details provided]

Don't

• Do not use if an open flame is forbidden.
• Never leave the emitter [cabin test] unattended.

*This SWP does not necessarily cover all possible hazards associated with this equipment and should be used in conjunction with other references. It is designed as a guide to compliment training and as a reminder to users prior to equipment use.

Cabin Sealing Test Procedure

Cabin Sealing Efficiency Test Procedure

1. Start Engine - Pressuriser System is ON.
2. Ensure all windows & door(s) are CLOSED correctly (no cabin pressure leaks). NOTE: For a new cabin with effective seals, you may need to open a window slightly before closing the door to bleed the static cabin air pressure outwards. Once the door is fully closed, then close windows to begin testing.
3. Enter the Settings menu via the touch screen button.
4. Select and press the System Check button to go to System Test – Max Fan.
5. Record / photograph the maximum cabin pressure achieved.

Screenshot Descriptions:

• Press Settings. (Shows a screen with 'BACK', 'Settings', 'SYSTEM CHECK', 'VIEW GRAPH', 'EVENT LOG', 'SITE ACCESS MENU' options)
• Press "System Check – Set Max" box. (Shows a screen with 'SYSTEM CHECK', 'SET MAX' highlighted)
• Record / Photograph the cabin pressure result (Max Fan Speed). (Shows a screen with 'System Test - Max Fan' and 'Cabin Pressure 425 Pascals')

Commissioning Procedures

Commissioning Procedures – Cabin Pressuriser

Follow each step of the installation guide supplied with the BreatheSafe kit. Cabin sealing is integral to RS20 & ISO 23875 compliance for maintaining positive pressure. Ensure cabin seals are adequate. The end-user must have correct procedures for servicing operator enclosure seals proactively.

Door and window seals must be in good working order or new seals fitted before installation.

Touch-screen cabin pressure display/controller Part# 200027:

*System Check Function: Enter the Settings menu, select "System Check - Set Max." The minimum BreatheSafe requirement for cabin sealing efficiency is 250 pascals. If this result is not met, re-examine and address pressure leaks and apply new sealing measures.

Submission for commissioning procedure:

Diagram Flow: Kit Installed → Cabin Display Enter: "System Check" → Does enclosure exceed 250? (Yes/No) → Yes: Record & photograph results. → No: Further enclosure sealing required.

Online Commissioning: Proceed to online commissioning at breathe-safe.com.au.

Commissioning Images Required:

• ID plate / Machine Serial Number / Asset Number or Call Sign
• INPRESS TL Pressuriser location
• HEPA Return Air Filter Location Option: Powered Return Air Filter
• Cabin Pressure Display Location - Including the "System Check" maximum cabin pressure result with motor output capacity %.

BreatheSafe Service Tag Details:

• Machine Serial Number and Installers details
• Date installed and System Check result (max cabin pressure)
• The set cabin pressure with actual pressure and motor percentage output
• Verify the 250-pascal threshold was achieved = pass OR not achieved = fail.

Upload machine and installation details with required images. A Commissioning Certificate will be sent via email. **Extended warranty for (RS20 & ISO 23875) BreatheSafe Systems is only applicable to operator enclosures meeting this requirement.

Diagram Description: The diagram shows a Commissioning Certificate template with fields for customer details, machine details, commissioning and calibration results, and a warranty service tag with fields for machine SN, date installed, controller SN, auto pre-set pressure, max cabin pressure, and notes.

Troubleshooting Guide

Breathesafe System Troubleshooting Guide *Touch Control

Access Codes: Site Access: 7597 | Factory Setup: 6759

User Settings Instructions

Enter Set Up Mode

Navigation: Start-Up Screen > Main Screen > Settings Button > Settings Screen > Site Access Button > Insert Pin > Site Menu.

To enter Setup mode, press the SETTING button, then enter the SITE ACCESS MENU. Type the 4-number pin (7597) and press ENTER.

Setup Parameters: The BreatheSafe 200027 unit allows adjustment of the following parameters:

• Time (hours/minutes/seconds)
• Date (day/month/year)
• Pressure alarm setpoint
• Preferred cabin pressure
• Alarm delay/intervals of alarm
• Calibration and system settings
• Resetting of the data logging
• Service reminders interval gap
• Reset current runtime between services
• CO2 settings and alarms

Pressure Setpoint

This function changes the pressure that the cabin will be maintained at. INPRESS TS maintains the pre-set pressure within the cabin compared to outside. Enter Setup mode and select ADJUST SETPOINT button. Use the onscreen UP and DOWN buttons to change fields.

Pressure Alarm Setting

The mining industry benchmark for cabin pressure is 50 pascals, with a low-pressure setpoint of 20 pascals. After a delay, an alarm will activate if cabin pressure remains below the pre-set value. Enter Setup mode and select ADJUST SETPOINT button. Use the onscreen UP and DOWN buttons to change fields.

Example Settings:

• Pressure Set Point: 50 Pascals
• Pressure Alarm Delay: 5 mins

Service Interval

Use the onscreen UP and DOWN buttons to change the service interval setpoint. To reset the current runtime to zero, press the RESET CURRENT RUNTIME button and enter the site access pin.

Date & Time Settings

Change the recorded date displayed and measured by the INPRESS TS.

Pressure Alarm Buzzer Setting

To disable the buzzer, toggle through to the ENABLED and DISABLED buttons.

Calibrate Zero Sensor

Over long runtime, the 200027 may need recalibration. This screen allows sensor recalibration if it is more than 5 Pascals out. To recalibrate, open windows and doors, turn off air conditioning, and any other device that may alter cabin pressure. Then, press the AUTO ZERO SENSOR button and leave the cabin while measuring. This process will reset the Zero Pressure.

CO2 Module Enable/Disable

Enable or disable the CO2 module used for measuring CO2 levels within the cabin.

CO2 Primary Alarm Point

The first alarm will sound when CO2 levels inside the enclosure reach this point.

CO2 Alarm Delay

After CO2 (concentration in ppm) reaches the 1000 ppm setpoint, the alarm will sound after a designated time. The Alarm Delay adjusts the time between the INPRESS TS measuring CO2 concentration and sounding the alarm. Use ADJUST buttons to toggle through Disabled / 1 - 10 minutes.

CO2 Critical Alarm Mute Reset

The critical alarm is set at 2500 PPM and cannot be changed. The mute delay, however, can be configured.

Data Download

Setting up RS232 Connection

1. Plug the RS232/USB adaptor into a free USB port on your computer.
2. Open TeraTerm software (an open-source tool easily accessible via online search).
3. In TeraTerm, go to Serial port settings and choose the correct port connection. Hint: Click on the COMxx Port with the "USB serial Port" connection from the drop-down menu. Example: COM 21. This connection may differ on your computer.
4. Click OK once the correct communication port is identified.
5. Go to SETUP and click on Serial Port.
6. Configure COM ports: Baud Rate: 57600, Data: 8 bit, Parity: EVEN, Stop: 2 bit, Flow Control: NONE.
7. If required, save the COM port settings via Settings > Save Setup. Name and save the file.
8. The next time a download is required, restore the setup to load the COM PORT settings.
9. From the drop-down menu, click on Save setup.
10. Click Restore setup.
11. Choose the file name you have already saved.
12. From the drop-down menu, click on the Edit menu function.
13. Press "Select All".
14. Select "Copy table".

Excel Data Instructions - Unformatted

1. Open an Excel sheet, select cell A-1. Press and hold CTRL, then press V to paste the copied data.
2. Once data is pasted, click 'DATA' on the pull-down menu, then 'Text to Columns'. Select 'Delimited' and click Next.
3. Select the 'Comma' button and click 'Finish'. Excel fields will update to place data in correct columns.

The data is now ready for archiving.

Data Logging Formats

BU No: xxxxxx (unique device number, format = 000000)

Time: [09:25]

Date: [25/07/12]

Pressure: 32 (Pascals) as an example.

Fields include: Date, time, motor (volts) output, cabin pressure (Pa), cabin pressure pre-set (Pa), low cabin pressure alarm (Pa).

Alarm Type:

• 0 = No alarm
• 1 = Low-pressure alarm
• 2 = Window open
• 3 = Door open

Warranty Information

Express Warranty

All BreatheSafe products carry a warranty against defects in materials or workmanship, provided defects are not due to factors outside BreatheSafe's control (neglect, lack of maintenance, improper installation/operation, unauthorized repair). BreatheSafe will replace defective goods at their Queensland factory or designated branch. All failed parts must be returned for evaluation unless otherwise stated.

Note: Systems must be installed and commissioned per BreatheSafe instructions. Online commissioning sheet completion extends warranty. Systems must be serviced and maintained correctly by trained personnel.

Warranty Period - Standard

• 1 year or 10,000 hours (whichever occurs first).
• Controllers: 1 year (no extended warranty option).
• Warranty Period Extension: Available when commissioning documents are registered online within 28 days of installation.
• Extended warranty: Offered if commissioning maximum pressure test reaches at least 250Pa.
• Brushless motor (fixed speed): 2 years or 10,000 hours (whichever occurs first).
• Variable speed brushless motor: 15,000 hours or 3 years (whichever occurs first).

Data download is required for the 3-year warranty option. Link to online Commissioning and Extended Warranty Registration form: https://www.breathe-safe.com.au/commission/

What is not covered under Express Warranty?

• Failures due to incorrect application.
• Damage from neglect, misuse, lack of maintenance, improper installation/operation, inappropriate or abnormal use, accidental or unauthorized servicing repair.
• Failures due to parts not sold or approved by BreatheSafe.
• Failures not directly related to a defect in material or workmanship.

This Express Warranty is VOID if the product is altered, modified, used in a manner not designed for, or includes unauthorized repairs or non-BreatheSafe parts.

BreatheSafe Responsibilities

If a defect occurs not caused by excluded failures, BreatheSafe will replace defective goods at their Queensland factory or designated branch, or provide new replacement parts, approved repair parts, or assembled components. BreatheSafe may elect to provide a refund instead of replacement or repair. Replacement/repaired products are sent freight prepaid or made available for pick-up.

Users Responsibilities

Customers must ensure systems are maintained according to BreatheSafe service requirements using only authorized parts. For warranty claims, contact BreatheSafe first for diagnosis and repair arrangements. Claims should be made within one week of repair.

Customers may be required to deliver parts to BreatheSafe's Queensland factory or designated branch. Link to online Warranty claim form: https://www.breathe-safe.com.au/warranty/

Exclusion and Limitations on Damages and Remedies

This warranty is in lieu of all other warranties. BreatheSafe disclaims implied warranties of fitness for a particular purpose. Maximum liability does not exceed the original purchase price. Interference, abuse, operating outside specified ambient temperatures or electrical power characteristics, and consequential damages are excluded.

Costs incurred for service outside BreatheSafe's factory or designated branch (traveling time, waiting time, transport, mechanical/overtime payments) are excluded from express warranty.

As per Australian Consumer Law, customers are entitled to a refund or replacement for major failures. For non-major failures, rectification is required within a reasonable time, or a refund is due. Compensation for other foreseeable loss or damage is also applicable.

*This express warranty grants specific legal rights, and customers may have other rights varying by country.