BreatheSafe Parts and Service Manual

VOLVO L180H / L250H WHEEL LOADER

Kit Part Number: 700400

Contact Information:

• Phone: +61 7 3276 7833
• Website: www.breathe-safe.com.au
• Email: sales@breathe-safe.com
• Address: 62 Mica Street, Carole Park, 4300, QLD

Controlled Document: M0134

Issue Date: 07/09/23

Revision: 1

System Components: HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter

Contents

The following sections detail the installation, operation, maintenance, and service of the BreatheSafe system for VOLVO L180H / L250H Wheel Loaders.

• 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

The system includes the following key components:

• HEPA H14 Variable Speed Pressuriser
• INPRESS TS Cabin Display with Data Recorder
• HEPA Return Air Filter

(Diagrams of these components are present in the original document, showing their physical appearance and integration.)

Safety

WARNING

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

• Qualified staff must wear the correct personal protective equipment (PPE) when cleaning and servicing this unit due to dust and fibres which may be caught by the stages of air filtration during normal unit 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 have several types of high-speed rotating equipment installed 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 is the length of time it takes for a particle 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

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

(Diagrams illustrating particulate fall times and components of the air filtration system are included in the original document.)

Personal Protective Equipment (PPE) Requirements:

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

Critical Parts & Maintenance Schedule

The following tables show the suggested maintenance schedule for all units. 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*

(Diagram showing Fan Capacity Indicator and example readings is present in the original document.)

Fan Capacity Indicator: The filter is serviceable if the motor capacity is between 10% & 80%. We recommend 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 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% recommend 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 INPRESS TS display showing system status and alerts are present in the original document.)

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

Pressuriser Assembly No: 200000 (TL4 24V DC Pressuriser Unit)

(Diagram of the Pressuriser Assembly No: 200000 with numbered parts is present in the original document.)

Parts List GA (General Assembly)

Kit Part Number: 700400

(Diagram of the General Assembly with numbered parts is present in the original document.)

Parts List - Pressuriser Module

(Diagram of the Pressuriser Module with numbered parts is present in the original document.)

Parts List - Pipework Module

(Diagram of the Pipework Module with numbered parts is present in the original document. Note: 4m length supplied to be cut to size.)

Parts List - Return Air Module

(Diagram of the Return Air Module with numbered parts is present in the original document.)

Parts List - Monitor Module

(Diagram of the Monitor Module with numbered parts is present in the original document.)

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

(Image of the INPRESS TS display unit with dimensions and screen examples is present in the original document.)

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

(Image of the CO2 Sensor with dimensions is present in the original document.)

Connections: 200027

Wiring Diagram

(A detailed wiring diagram illustrating connections between the INPRESS User Interface (UI), CO2 Sensor, TL4 Pressuriser, and Power Supply is present in the original document.)

Component Connections:

Smoke Emitter Cabin Pressure Leak Test

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

(Link to MSDS: SMOKE GENERATOR TQ7621AT30S.pdf is provided in the original document.)

Cabin Sealing Test Procedure

Follow these steps to test cabin sealing efficiency:

1. Start Engine - Pressuriser System is ON.
2. Ensure all windows & door(s) are CLOSED correctly (no cabin pressure leaks).
3. 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.
4. Enter the Settings menu via the touch screen button.
5. Select and press the System Check button to go to System Test – Max Fan.
6. Record / photograph the maximum cabin pressure achieved.

(Screenshots of the INPRESS TS display showing the test progression are present in the original document.)

Commissioning Procedures

Follow each step of the installation guide that was supplied with the BreatheSafe kit.

Cabin sealing is an integral part of RS20 & ISO 23875; you must ensure that cabin seals are adequate for maintaining positive pressure. Items such as door and window seals must be in good working order or new seals FITTED before the BreatheSafe system installation.

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

• System Check Function: Enter the Settings menu option 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:

(A flowchart diagram illustrating the commissioning process is present in the original document.)

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 %.

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.

(Images related to commissioning and warranty are present in the original document.)

Proceed to online commissioning: Commissioning - BreatheSafe

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.

(Screenshots of the INPRESS TS interface for entering setup mode are present in the original document.)

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

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 of the INPRESS TS interface for setting pressure and alarm parameters are present in the original document.)

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 the INPRESS TS interface for setting service interval and date/time are present in the original document.)

Alarm Buzzer Settings

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 of the INPRESS TS interface for alarm buzzer settings and zero sensor calibration are present in the original document.)

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 the INPRESS TS interface for CO2 settings are present in the original document.)

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.
4. 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.
5. Click OK once the correct communication port has been identified.
6. Go to SETUP and click on Serial Port.
7. Change the COM ports to the following configuration: Baud Rate: 57600 Data: 8 bit Parity: EVEN Stop: 2 bit Flow Control: NONE.
8. If required, you may choose to save the COM port settings. Go to Settings and click Save Setup. Name the file and save it.
9. The next time a download is required, you may restore the setup, and the required COM PORT settings will be loaded, ready to download the data file from the 200027 unit.

(Screenshots illustrating the RS232 connection setup and Tera Term interface are present in the original document.)

Excel Data Instructions - Unformatted

Open an Excel sheet and select the first cell A-1. Next, press and hold down the CTRL button on your keyboard and then press the letter V on the keyboard.

This procedure will paste the copied data onto that Excel sheet. Once that data has been pasted onto the Excel sheet, click on ‘DATA' on the pull-down menu, followed by ‘Text to Columns'. Next, select ‘Delimited' on the newly opened window and click on Next.

Only select the 'Comma' button in the next window and then click 'Finish'. Then, the Excel fields will update such that each piece of data is placed in the correct columns.

The data is now ready for archiving.

Data Logging Formats

• BU No: xxxxxx (the device number unique to each unit and used for identification – format = 000000)
• Time: [09:25]
• Date: [25/07/12]
• Pressure: 32 (Pascals) as an example.

Alarm Type:

(Screenshots of the Tera Term interface and Excel data are present in the original document.)

Warranty

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.

(Links to online Warranty claim form and Commissioning and Extended Warranty Registration form are provided in the original document.)

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.

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.