Parts and Service Manual

Introduction

This manual provides comprehensive information for the installation, operation, maintenance, troubleshooting, and servicing of the BreatheSafe cabin pressurisation system fitted to the Komatsu HD 1500-8 Dump Truck. It covers critical parts, technical details, user settings, data download procedures, and warranty information.

Installation Overview

Installation

Refer to the installation guide supplied with the BreatheSafe kit for detailed installation steps.

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 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 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.

DANGER

Use only as directed. Do not handle until all safety precautions, including the 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 because the hexachloroethane is consumed inside the tube as smoke is produced.

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 a site-approved device (e.g., solder torch or lighter) and conduct smoke test.
6. Do not touch or hold the smoke generator after ignition; the item becomes very hot and remains hot after use.

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.

Personal Protective Equipment (PPE)

• 👔 Hard Hat
• 🕵️ Eye Protection
• 💧 Dust Mask
• 🎧 Ear Protection
• 👟 Protective Clothing

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 extinguisher 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.

Potential Hazards

• Falls: May cause cancer
• Fumes: Exposure is highly unlikely when the product is used as directed. Direct contact with the product does not occur.
• Fire

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.

Critical Parts & Maintenance Schedule

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*

INPRESS TL TS Overview

The BreatheSafe system fitted is fully automatic. Always keep doors and windows closed even when not in service to prevent airborne dust entering the cabin – always during maintenance. A 10-minute "Pre-Start" program setting will ensure the pressuriser speed remains at 30% motor capacity (user resettable 1-10 min or disabled).

During the walk around / Pre-start:

• Visually inspect the cabin for any damage to doors, windows, seals.

Before and after entering the cabin:

1. Please remove debris from shoes and clothes before entering the cabin.
2. Ensure doors are fully closed, and windows are fully shut.
3. [Start the engine] & turn HVAC on speed 2 (Medium speed).
4. The BreatheSafe display shows 50 Pascals or above.

>> There is no further action required <<

Please clean the cabin regularly – Use a HEPA-type vacuum and do not use a brush or compressed air.

Troubleshooting – If the display indicates below 50 pascals (customer specified) or low-pressure alarm is activated, please check the following:

1. Double-check door(s) are fully closed.
2. Double-check window(s) are fully closed.
3. Double-check for any signs of damage: door, windows, seals, or missing panels.

If the display is below 50 pascals (customer specified), please check the following:

1. Monitor the % (volts) output to BreatheSafe cabin pressure display (i.e., 100% means the fresh air filter is completely dust loaded or a significant cabin pressure leak that the pressuriser cannot overcome).

Please note: Positive pressure above 20 pascals (ISO 23875 minimum) is adequate until the next available service.

Specifications High-Capacity HEPA Pressuriser

• Blower: Brushless Blower P/N 200002
• Protection: Locked Rota (Sub Zero Environments) Under Voltage, Under/Over Current & Over Temperature
• Voltage: 24v
• Current Draw: 11 amps (peak). *Note Brushless Motors on excessive in rush current on start up.
• 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.
• Finish: Satin Powder Coated throughout (Ducting).
• 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.
• CDF 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

Parts List GA

Complete Assembly No: 700045

Parts List - Pressuriser Mount

Pressuriser Assembly No: 100011A01

Parts List - Fresh Air Inlet

Fresh Air Module No: 100011F01

Parts List - Piping / Ducting

Pipework Assembly No: 100011P01

Parts List - Monitor Mount

Monitor Assembly No: 100011M01

NOTE: Items 4 -13 not shown in diagram.

The INPRESS Cabin Pressure Monitor can be installed independently to display and record cabin pressure. This is a cost-effective method for fitting a cabin pressure display including capability to record & download data.

Please note that positive AIR pressure inside the cabin does not mean overall safety without SUBMICRON or high-efficiency particulate air (HEPA) filtration pressurisation.

Parts List - Return Air Filtration

Return Air Filter No: 100011R01

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

Smoke Emitter Cabin Pressure Leak Test

Link to MSDS: SMOKE GENERATOR TQ7621AT30S.pdf

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 a 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.

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).
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.

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; you must ensure that cabin seals are adequate for maintaining positive pressure. In addition, the site (end-user) must have the correct procedure(s) for servicing OPERATOR enclosure seals in a proactive manner rather than reactive. 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:

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.

Proceed to online commissioning: Commissioning - BreatheSafe

Troubleshooting Guide

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.

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.

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.

Alarm Buzzer Settings

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.

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.

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
7. If required, you may choose to save the COM port settings. Go to Settings and click Save Setup. Name the file and save it.
8. 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.
9. From the drop-down menu, click on the Save setup.
10. Click Restore setup.
11. Choose the file name you have already saved.

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.

1. Open a blank excel document and click on the page. Then, right-click to paste the copied table.
2. Fields are: Date, time, motor (volts) output, cabin pressure (Pa), cabin pressure pre-set (Pa), low cabin pressure alarm (Pa).

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

Inpress TL 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. 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.

**Extended warranty for (RS20 & ISO 23875) BreatheSafe Variable Speed Systems is only applicable to operator enclosures meeting this requirement.