BreatheSafe Parts and Service Manual

Contents

Installation: 1

Safety: 2

Critical Parts & Maintenance Schedule: 3

Operator Guide: 4

Specifications - Pressuriser: 5

Parts List: 6-12

Technical Details: 13-14

Smoke Emitter Cabin Pressure Leak Test: 15

Cabin Sealing Test Pressure: 16

Commissioning Procedures: 17

Troubleshooting Guide: 18

User Settings Instructions: 19-24

Data Download: 25-27

Warranty: 28

Installation Overview

Manufacturer: Kobelco

Type: Excavator

Model: SK210 LC

Cabin Pressure Max: [Value not specified in overview]

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

System Components:

• HEPA H14 Variable Speed Pressuriser: A cylindrical unit designed to filter and pressurise air for the cabin.
• INPRESS TS Cabin Display with Data Recorder: A control unit with a screen displaying cabin pressure, CO2 levels, and other data, also capable of recording information.
• HEPA Return Air Filter: A filter component for the cabin's air circulation system.

Safety

WARNING

The pressurisation system described in this manual has areas that may be dangerous if not treated with great care.

Qualified staff must wear correct Personal Protective Equipment (PPE) when cleaning and servicing this unit due to dust and fibres that may be caught by the air filtration stages during normal operation.

The electrical power system is supplied by 12V DC or 24V DC. No work should be carried out on the pressuriser system without correct safe work procedures and electrical safety measures being taken, and all relevant circuit breakers opened to isolate the circuit.

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

Please be aware that HEPA filters cannot be cleaned and must be replaced at the end of their lifecycle or if filter media has been 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 minutes
• 10µm: 8.3 minutes
• 5µm: 35.7 minutes
• 2µm: 2.8 hours
• 1µm: 12 hours
• 0.5µm: 41.7 hours

Warehouses and workshops do not have still air, so hazardous airborne particulates may remain in the air for longer, increasing the chance for workers to breathe in dust. Ensure PPE is worn when installing this system.

Personal Protective Equipment (PPE)

Required PPE:

• Hard Hat ?
• Eye Protection ?
• Dust Mask ?
• Ear Protection ?
• Protective Clothing ?

Critical Parts & Maintenance Schedule

The following tables provide a suggested maintenance schedule. Site conditions may alter this. 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%. Operation above 80% recommends 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 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 SolidWorks 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: An exploded view of the TL4 24V DC Pressuriser Unit, showing all individual components with corresponding item numbers.

Parts List GA

Complete Assembly No: 700314

Diagram Description: An assembly diagram showing the main modules of the BreatheSafe system, including the TS Controller, Pipework, High Pressure Unit, Monitor Bracket, Fresh Air Module, and Return Air Module, interconnected.

Parts List - Pressuriser Module

Diagram Description: An exploded view of the Pressuriser Module, showing the lower mount brace, low profile mount, the TL4 24V DC unit, and a rain cover/guard.

Parts List - Pipework Module

Diagram Description: A diagram illustrating the pipework assembly for the BreatheSafe system, showing various pipe sections, elbows, hoses, and clamps with item numbers.

Parts List - Monitor Module

Diagram Description: A diagram showing the monitor bracket and a small controller box for the BreatheSafe system.

Parts List - Fresh Air Module

Diagram Description: A diagram of the Fresh Air Module, showing a spigot plate and a clamp.

Parts List - Return Air Module

Diagram Description: An illustration of the Return Air Module, detailing its main assembly, inlet, filter frame, clamps, blanking plates, and fasteners.

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: A representation of the BreatheSafe display unit, showing its dimensions (184.5mm x 61.8mm x 54.6mm) and examples of its main screen interface, including cabin pressure, CO2 concentration, temperature, motor capacity, and control buttons (Settings, Alarm Mute).

CO2 Sensor

• CO2 Sensor Type: NDIR (Non-Dispersive Infrared)
• Sample Rate: Every 2 seconds
• Operating Voltage: 12-30V DC
• Features: Automatic Altitude Compensation, Adjustable Alarm Set points
• Setup: No setup required

Diagram Description: A diagram of the CO2 sensor, showing its dimensions (65 mm x 120 mm x 27 mm).

Connections and Wiring Diagram

Connections: 200027

Wiring Diagram Components

Diagram Description: A wiring diagram illustrating the connections for the BreatheSafe system, showing the INPRESS User Interface, CO2 Sensor, TL4 Pressuriser, and power supply, with labelled components and connection points. It also details the pin assignments for various functions.

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.

Directions: (Smoke Bomb)

1. Ensure other workers in close proximity are informed of use. Place on a non-combustible container, away from flammable materials.
2. Place at Blower intake, or upwind of target area, or near centre of space.
3. Orient "Smoke Issues Here" toward air stream, away from surfaces. Place candle on a flame / heat resistance plate - if not it will melt into the plastic surface.
4. Ensure smoke will not create any hazard where it is anticipated to go.
5. Ignite emitter inside the cabin using site approved device (e.g., solder torch or 'lighter') and conduct smoke test.
6. Do not touch or hold smoke generator after ignition - item becomes very hot & remains hot after use.

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 and place it 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: Not applicable to this procedure.
• Fumes: May cause cancer. Exposure is highly unlikely when the product is used as directed. Direct contact with the product does not occur.
• Fire: Not applicable to this procedure.

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 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.

Screenshots depict the INPRESS TS display showing 'Settings' and 'System Test - Max Fan' screens, with cabin pressure readings.

Commissioning Procedures

Follow each step of the installation guide supplied with the BreatheSafe kit. Cabin sealing is integral to RS20 & ISO 23875; ensure cabin seals are adequate for maintaining positive pressure. The site (end-user) must have correct procedures for servicing OPERATOR enclosure seals proactively rather than reactively. Door and window seals must be in good working order or new seals fitted before BreatheSafe system installation.

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

• System Check Function: Enter the Settings menu and select "System Check - Set Max." The minimum BreatheSafe requirement for cabin sealing efficiency is 250 pascals; if this result is not met, it is essential to re-examine and find pressure leaks of the enclosure and apply new sealing measures.

Submission for commissioning procedure:

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

Proceed to online commissioning: Commissioning - BreatheSafe

The commissioning images required are:

• 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 %

Fill in the BreatheSafe Service Tag with the following details:

• Machine Serial Number and Installer's 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**

Please upload machine and installation details in conjunction with the required images. A Commissioning Certificate will be sent to the email address you nominate. **Extended warranty for (RS20 & ISO 23875) BreatheSafe Systems is only applicable to operator enclosures meeting this requirement.

Troubleshooting Guide

BREATHESAFE SYSTEM TROUBLE SHOOTING GUIDE *TOUCH CONTROL

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

User Settings Instructions

Enter Set Up Mode

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

To enter the Setup mode, press the SETTING button. Then enter SITE ACCESS MENU. Type in 4-number pin and press ENTER.

Insert Pin = 7597

Set Up Parameters

Placing the BreatheSafe 200027 unit into Setup mode allows the 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

Screenshots show the INPRESS TS interface for entering the PIN and navigating through settings pages.

Pressure Setpoint & Pressure Alarm Setting

Pressure Setpoint

The pressure setpoint changes the pressure that the cabin will be maintained. INPRESS TS maintains the pre-set pressure within the cabin compared to outside. Enter Setup mode and select ADJUST SETPOINT button. Then, use the onscreen UP and DOWN buttons to change the corresponding fields.

Pressure Alarm Setting

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

Screenshots illustrate the process of setting pressure and alarm parameters via the INPRESS TS interface.

Service Interval & Date & Time Settings

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.

Screenshots show the INPRESS TS interface for setting service intervals and adjusting date/time parameters.

Pressure Alarm Buzzer Setting & Calibrate Zero Sensor

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 the sensor to be recalibrated if more than 5 Pascals are 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.

Screenshots illustrate the INPRESS TS interface for adjusting alarm buzzer settings and calibrating the zero sensor.

CO2 Module Enable/Disable & CO2 Primary Alarm Point

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.

Screenshots show the INPRESS TS interface for enabling/disabling the CO2 module and setting the primary CO2 alarm point.

CO2 Alarm Delay & CO2 Critical Alarm Mute Reset

CO2 Alarm Delay

After CO2 (concentration in ppm) within the cabin reaches the 1000 ppm setpoint, the alarm will sound after this designated amount of time. The Alarm Delay adjusts the time between the INPRESS TS measuring CO2 concentration and sounding the alarm. Use the onscreen ADJUST buttons to change the corresponding fields. For example, press 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.

Screenshots show the INPRESS TS interface for setting the CO2 alarm delay and configuring the critical alarm mute timeout.

Data Download – Setting up RS232 Connection

1. Plug the RS232/USB adaptor into a free USB port on your computer ?.
2. Open up TeraTerm software. (TeraTerm is an open-source software tool and easily accessible via online search).
3. Use the following settings in TeraTerm: Serial 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 be different on your computer.
4. Click OK once the correct communication port has been identified.
5. Go to SETUP and click on Serial Port.
6. Change the COM ports to the following configuration:
   Baud Rate: 57600
   Data: 8 bit
   Parity: EVEN
   Stop: 2 bit
   Flow Control: NONE

Screenshots show the TeraTerm software interface for establishing a serial connection and configuring port settings.

Express Warranty

All BreatheSafe products carry a warranty against defects in materials or workmanship, provided the defects are not from factors outside of BreatheSafe's control (including neglect, lack of maintenance, improper installation or operation, unauthorized servicing repair, etc.). BreatheSafe will replace goods defected in material or workmanship at our Queensland factory or designated branch*. All parts deemed as failed or faulty must be returned to BreatheSafe for evaluation unless otherwise stated in writing.

Note: Systems must be installed and commissioned as per BreatheSafe installation and commissioning instructions. Once commissioned, the online commissioning sheet must be filled in, extending the components warranty as below. In addition, the system must be serviced and maintained correctly and by trained and qualified personnel. This requisite includes BreatheSafe technicians, qualified automotive air-conditioning technicians, or qualified auto electricians.

Warranty Period - Standard

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

Must be supplied with a variable speed pressure controller; data download required for 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 are due to incorrect application.
• Damage resulting from neglect, misuse, lack of maintenance, improper installation, or operation, inappropriate or abnormal use, accidental or unauthorized servicing repair.
• Failures are due to parts not being sold or approved by BreatheSafe.
• Failures arising from any other cause that is not directly related to a defect in material or workmanship.

This Express Warranty is VOID if the product is altered, modified, or used in the manner it was not designed for, also including unauthorized repairs, or using maintenance and repair parts other than those supplied by BreatheSafe.

BreatheSafe Responsibilities

If there is a defect in material or workmanship not caused by the excluded failures during the warranty period, BreatheSafe will either replace the defective goods at our Queensland factory, or designated branch*. Alternatively, BreatheSafe may elect to provide new replacement parts, BreatheSafe approved repair parts or assembled components needed to repair the defect. BreatheSafe reserves the right to provide a refund of the purchase price in lieu of replacement or repair at BreatheSafe's discretion. The replacement or repaired product will be sent to you freight prepaid by the customer or made available for pick-up on site.

Users Responsibilities

The customer should ensure that the system is maintained according to BreatheSafe service requirements and only authorized parts must be used to service and maintain BreatheSafe systems. In the event of a suspected warranty claim, BreatheSafe should be contacted in the first instance to arrange the repair or to assist with diagnosis. Claims should be made within one week of the repair.

After contacting BreatheSafe, you may be required to deliver or send the 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 provided in lieu of all other warranties, written or oral, whether expressed by affirmation, promise, description, drawing, model, or sample. To the extent allowed by law, all warranties other than this warranty, whether express or implied, including implied warranties of fitness for a particular purpose, are disclaimed. The maximum liability of BreatheSafe under this warranty shall not exceed the original purchase price of the product. Interference with the equipment by or abuse, or by operating the equipment at ambient temperatures or with electrical power characteristics outside the ranges indicated in our specification shall be excluded from this warranty, as shall consequential damages.

Excluded from any express warranty are costs incurred in relation to service outside our factory or our designated service branch, including traveling time, waiting time, transport costs, mechanical and overtime payments required.

As per Australian Consumer Law: You are entitled to choose a refund or replacement for major failures with goods. If a failure with the goods or service does not amount to a major failure, you are entitled to have the failure rectified in a reasonable time. If this is not done, you are entitled to a refund for the goods and to cancel the contract for the service and obtain a refund of any unused portion. You are also entitled to be compensated for any other reasonably foreseeable loss or damage from a failure in the goods or service.

*This express warranty gives you specific legal rights, and you may also have other rights that vary from country to country.