BreatheSafe Parts and Service Manual

CONTENTS

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

INSTALLATION

INSTALLATION OVERVIEW

Manufacturer: HITACHI

Type: Excavator

Model: EX3600-7

Cabin Pressure Max: -

Set Auto Cabin Pressure: -

Image of the Hitachi EX3600-7 Excavator with BreatheSafe components installed, alongside images of the HEPA H14 Variable Speed Pressuriser, INPRESS TS Cabin Display with Data Recorder, and HEPA Return Air Filter.

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) due to dust and fibres. The electrical power system (12V DC or 24V DC) requires correct safe work procedures and electrical safety measures, including circuit breaker isolation. The air filtration system may contain high-speed rotating equipment with sharp edges; ensure all safety guards are in place. HEPA filters cannot be cleaned and must be replaced at the end of their lifecycle or if filter media is damaged.

Particulate Behaviour

Diagram illustrating particle drop times from a height of 1.5m in still air for various particle sizes (e.g., 20µm takes 3.6 mins, 0.5µm takes 41.7 mins). Text explains that in non-still environments like warehouses, hazardous particles remain airborne longer, increasing exposure risk. Recommends wearing PPE.

Icons representing Personal Protective Equipment: Hard Hat, Eye Protection, Dust Mask, Ear Protection, Protective Clothing.

Maintenance Schedule

The following tables show the suggested maintenance schedule. Site conditions may alter this. Excludes high corrosion environments. Data download is required for 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 & MAINTENANCE SCHEDULE

*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%. Recommended to change if 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 OEM air conditioning fan is set at mid speed or greater to circulate air around the breathing zone and minimise CO₂. Acceptable operating range for BreatheSafe fan is 10-80%. >80% recommends maintenance.

ALERTS

• Fixed Fan Start Delay: Allows the operator to carry out pre-start checks – limiting at 30% fan speed, 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: Cabin is not maintaining positive pressure – check doors and windows are closed correctly. Refer to maintenance department to check filters and cabin sealing. Ensure filters are serviceable.
• Check Filter: Reminder to inspect or replace filter. Service hour meter requires re-set. Refer to maintenance department.

Screenshots of the BreatheSafe INPRESS TS display showing different statuses: Pre-start check, normal operation with cabin pressure and CO2 levels, and alert conditions.

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

PARTS LIST – TL4 24V DC PRESSURISER UNIT

PRESSURISER ASSEMBLY No: 200000

Exploded view diagram of the TL4 24V DC Pressuriser Unit, showing components labeled with numbers corresponding to the parts list.

PARTS LIST GA - COMPLETE ASSEMBLY No: 700392

Kit Part Number: 700392

Diagram of the complete BreatheSafe assembly for the EX3600-7 Excavator, showing various modules and pipework.

PARTS LIST – PRESSURISER MODULE

Diagram of a pressuriser module component, showing parts labeled with numbers corresponding to the parts list.

PARTS LIST – PRESSURISER MODULE

Diagram of a pressuriser module component, showing parts labeled with numbers corresponding to the parts list.

PARTS LIST – PRESSURISER MODULE

Diagram of a pressuriser module component, showing parts labeled with numbers corresponding to the parts list.

PARTS LIST – FRESH AIR MODULE

Diagram of the Fresh Air Module, showing the inlet component labeled with number 1.

PARTS LIST – MONITOR MODULE

Diagram of the Monitor Module, showing the mount plate (1) and monitor box (2).

PARTS LIST – PIPEWORK MODULE

Diagram of the Pipework Module, showing various pipe sections and connectors labeled with numbers corresponding to the parts list.

PARTS LIST – RETURN AIR MODULE

Diagram of the Return Air Module, showing the filter base housing (1), clamp bar (2), filter cover (3), knob (4), and HEPA filter (5).

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

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 of the INPRESS TS display unit with dimensions, and a diagram of the CO2 Sensor with dimensions.

TECHNICAL DETAILS

Connections: 200027

Wiring Diagram

Wiring diagram showing connections for the INPRESS User Interface (UI), CO2 Sensor, and TL4 Pressuriser, including power supply and Deutsch plug connections.

Safety Information

General Precautions: Do not handle until MSDS & all safety precautions have been read and understood. Use personal protective equipment as required. Before use, carefully read the product label. Safe work practices are advised to avoid eye or skin contact and inhalation. Observe good personal hygiene, including washing hands before eating. Prohibit eating, drinking, and smoking in contaminated areas. Avoid inhalation. Mechanical extraction ventilation is recommended when the removal of atmospheric contaminants is required. Maintain dust / fume levels below the recommended exposure standard. For small amounts, absorb with sand, vermiculite or similar and dispose of at an approved landfill site.

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.

DANGER

Use only as directed. Do not handle until all safety precautions, including Safety Data Sheet, have been read and understood. The product contains hexachloroethane. Wear protective clothing. If exposed or concerned, get medical advice. Store in a cool, dry, secure location. KEEP OUT OF REACH OF CHILDREN. Dispose of contents/container per location regulations. When used as directed, exposure should be limited and usually poses no hazard as hexachloroethane is consumed.

Smoke Emitter Cabin Pressure Leak Test (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 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 i.e., 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.

Pre-operational Safety Checks

• Locate and ensure you are familiar with all machine operations and controls.
• Check work area and walkways to ensure no slip/trip hazards are present.
• Ensure the work area is clean and clear of any flammable material & fire extinguish device is present.

Operational Safety Checks

• Ensure the machine is correctly isolated / immobilized.
• Ensure other persons do not inhale smoke haze.
• Take care and do not 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 i.e., 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
• Fumes
• Fire
• May cause cancer (Exposure is highly unlikely when the product is used as directed. Direct contact with the product does not occur.)

Don’ts

• 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 be used to compliment training and as a reminder to users prior to equipment use.

Cabin Sealing Efficiency Test Procedure

CABIN SEALING 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 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 of BreatheSafe display showing initial status (Cabin Pressure 50 Pa, CO2 Concentration 561 ppm), Settings menu with 'System Check' and 'Set Max' options, and System Test results (Cabin Pressure 425 Pascals).

Press Settings. Press “System Check – Set Max” box. Record / Photograph the cabin pressure result (Max Fan Speed).

Commissioning Procedures

COMMISSIONING PROCEDURES – CABIN PRESSURISER

Follow each step of the installation guide that was supplied with the BreatheSafe kit. Cabin sealing is an integral part of 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. 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 Settings menu > System Check – Set Max. The minimum BreatheSafe requirement for cabin sealing efficiency is 250 pascals; if not met, re-examine for pressure leaks and apply new sealing measures.

Submission for commissioning procedure as per the diagram below:

Diagram illustrating the submission process for commissioning, including required images and online submission.

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 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**

Please upload machine and installation details 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.

Proceed to online commissioning: Commissioning - BreatheSafe (breathe-safe.com.au)

Troubleshooting Guide

BREATHESAFE SYSTEM TROUBLE SHOOTING GUIDE *TOUCH CONTROL

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

User Settings Instructions

ENTER SET UP MODE

Sequence: 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 SITE ACCESS MENU. Type in 4-number pin and press ENTER.

Screenshots of BreatheSafe display showing initial screen and Enter Pin prompt, Settings menu options, and Settings Page 1 with various setting categories.

SET UP PARAMETERS

Placing the BreatheSafe 200027 unit into Setup mode 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

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. Alarm activates if cabin pressure remains below pre-set value after a delay. Enter Setup mode and select ADJUST SETPOINT button. Then, use the onscreen UP and DOWN buttons to change the corresponding fields.

Screenshots of BreatheSafe display showing Pressure Setpoint and Pressure Alarm Setting interfaces, including navigation through menus and adjustment screens. Also shows the Pressure Settings menu with options for Pressure Units, Alarm Set Point, Pressure Set Point, and Pressure Alarm Delay.

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 of BreatheSafe display showing Service Interval and Date/Time Settings interfaces, including navigation and adjustment screens.

PRESSURE ALARM BUZZER SETTING

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

CALIBRATE ZERO SENSOR

Recalibration may be needed if the sensor 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.

ALARM BUZZER SETTINGS

Options for Pressure Buzzer, CO2 Primary Buzzer, Temperature Buzzer, Window Buzzer, Door Buzzer.

Screenshots of BreatheSafe display showing Pressure Alarm Buzzer Setting, Calibrate Zero Sensor, and Alarm Buzzer Settings interfaces.

CO2 Settings

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) 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 of BreatheSafe display showing CO2 Module Enable/Disable, CO2 Primary Alarm Point, CO2 Settings, CO2 Alarm Delay, and CO2 Critical Alarm Mute Reset interfaces.

Data Download

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. Use the following settings in TeraTerm: Serial, choose the correct port connection (Hint: COMxx Port with “USB serial Port” from the drop-down menu. Example: COM 21, 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 COM port settings (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 the 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”.
15. Open a blank Excel document, click on the page, then right-click to paste the copied table.
16. Fields are: Date, time, motor (volts) output, cabin pressure (Pa), cabin pressure pre-set (Pa), low cabin pressure alarm (Pa).

Excel Data Instructions – Unformatted

Open an Excel sheet, select the first cell A-1. Press and hold CTRL, then press V. This pastes the data. On the Excel sheet, go to DATA > Text to Columns > Delimited. Select the ‘Comma’ button, then click ‘Finish’. Fields will update.

Data Logging Formats

• BU No: xxxxxx (device number, format 000000)
• Time: [09:25]
• Date: [25/07/12]
• Pressure: 32 (Pascals) as an example.
• Alarm Type: 0 = No alarm, 1 = Low-pressure alarm, 2 = Window open, 3 = Door open.

Warranty

Express Warranty

All BreatheSafe products carry a warranty against defects in materials or workmanship, excluding factors outside BreatheSafe's control (neglect, lack of maintenance, improper installation/operation, unauthorized servicing). BreatheSafe will replace defective goods at their Queensland factory or designated branch. Failed/faulty parts must be returned for evaluation unless otherwise stated. Systems must be installed and commissioned per instructions, with online registration for extended warranty. Servicing must be by trained/qualified personnel.

Warranty Period – Standard

• Controllers: 1 year (no extended option).
• General: 1 year or 10,000 hours (whichever occurs first).
• Warranty Period Extension (online registration within 28 days): Extended warranty offered if commissioning max 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**. Requires variable speed controller, data download for 3-year option.

Link to online Commissioning and Extended Warranty Registration: 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.
• Failures due to parts not sold or approved by BreatheSafe.
• Failures arising from any other cause not directly related to a defect in material or workmanship.

This Express Warranty is VOID if the product is altered, modified, used as not designed, has unauthorized repairs, or uses non-BreatheSafe maintenance/repair parts.

BreatheSafe responsibilities

If a defect exists not caused by excluded failures during the warranty period, BreatheSafe will replace defective goods or provide replacement parts/components. BreatheSafe may elect to provide a refund of the purchase price. Replacement/repaired product freight is prepaid by the customer or available for on-site pick-up.

Users Responsibilities

Ensure system maintenance according to BreatheSafe service requirements and use only authorized parts. For warranty claims, contact BreatheSafe first to arrange repair/diagnosis. Claims should be made within one week of repair. Parts may need to be delivered/sent to BreatheSafe's factory or 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. Implied warranties of fitness for a particular purpose are disclaimed. Maximum liability shall not exceed the original purchase price. Excluded: Interference, abuse, operation outside specified ranges, consequential damages. Excluded costs: Service outside factory/branch (travel, waiting, transport, mechanical, overtime).

As per Australian Consumer Law: Entitled to refund/replacement for major failures. Rectification for minor failures. Compensation for reasonably foreseeable loss or damage.