CATERPILLAR 432 Loader HEPA Return Air Filter Owner’s Manual

: June 1, 2024
: CATERPILLAR

Table of Contents

432 Loader HEPA Return Air Filter
Product Information
Specifications
Product Usage Instructions
Installation Overview
Installation Steps:
Safety Instructions
Maintenance Schedule
- FAQ
Q: How often should the HEPA filters be replaced?
Q: What is the warranty period for the Brushless Blower

432 Loader HEPA Return Air Filter

“`html

Product Information

Specifications

Kit Part Number: 700381
Contact: +61 7 3276 7833 | www.breathe-safe.com.au |
sales@breathe-safe.com | 62 Mica Street, Carole Park, 4300,
QLD
Manufacturer: CATERPILLAR
Model: 432 Loader
Features: HEPA H14 Variable Speed Pressuriser, INPRESS TS Cabin
Display with CO2 Sensor, HEPA Return Air Filter
Controlled Document: M0099 | Issue Date: 04/09/23 | Revision:
1

Product Usage Instructions

Installation Overview

CATERPILLAR Loader 432

Installation Steps:

Install HEPA H14 Variable Speed Pressuriser
Mount INPRESS TS Cabin Display with Data Recorder
Attach HEPA Return Air Filter

Safety Instructions

Qualified staff must wear proper PPE during cleaning and
servicing.
Electrical power system operates on 12V DC or 24V DC; follow
safe work procedures and electrical safety measures.
Ensure safety guards are in place during operation.
HEPA filters cannot be cleaned and must be replaced when
necessary.

Maintenance Schedule

Suggested maintenance schedule:

Component / System	Action Required
Turbo Pre-cleaner Pressuriser Blower	Check operation of Turbo PreCleaner and

blower
HEPA Primary Filter p/n: 500000 & HEPA Return Air Filter
P/N: 500016| Inspect filter capacity indicator, replace filters as
needed
Filter Frame Assembly, Mounts, Seals and Filter Housing| Check seals, bolts, mounts, and fittings for security; replace
if necessary

FAQ

Q: How often should the HEPA filters be replaced?

A: HEPA filters should be replaced at the end of their lifecycle
or if the filter media has been damaged.

Q: What is the warranty period for the Brushless Blower

Motor?

A: The warranty period for the Brushless Blower Motor is 3 years
with data download required.

“`

Kit Part Number: 700381

+61 7 3276 7833 www.breathe-safe.com.au sales@breathe-safe.com 62 Mica Street, Carole Park, 4300, QLD

Parts and Service Manual
CATERPILLAR 432 LOADER
HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter
Controlled Document: M0099 Issue Date: 04/09/23 Revision: 1

CATERPILLAR
432 Loader

CONTENTS
Installation ……………………………… 1 Safety…………………………………….. 2 Critical Parts & Maintenance Schedule ………………………………… 3 Operator Guide ……………………….. 4 Specifications – Pressuriser…………. 5 Parts List ………………………………6-9 Technical Details………………… 10-11 Smoke Emitter Cabin Pressure Leak Test……………………………………… 12 Cabin Sealing Test Pressure………. 13 Commissioning Procedures ………. 14 Troubleshooting Guide ……………. 15 User Settings Instructions ……. 16-21 Data Download………………….. 22-24 Warranty………………………………. 25

Manufacturer Type Model Cabin Pressure Max Set Auto Cabin Pressure

INSTALLATION OVERVIEW CATERPILLAR Loader 432

INSTALLATION

HEPA H14 Variable Speed Pressuriser INPRESS TS Cabin Display with Data Recorder

HEPA Return Air Filter 1

CATERPILLAR
432 Loader
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 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 AND NO WORK SHOULD BE CARRIED OUT ON THE PRESSURISER SYSTEM WITHOUT THE CORRECT SAFE WORK PROCEDURES AND ELECTRICAL
SAFETY MEASURES BEING TAKEN, AND ALL RELEVANT CIRCUIT BREAKER 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 GUARD 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.

SAFETY
Particulate Behaviour
This is the length of time it takes for a particle to drop from a height of 1.5m in STILL air.
Warehouses and workshops do not have still air, so hazardous airborne particulates may remain in air for longer, increasing chance for workers to breathe in dust. Ensure PPE is worn when installing this system.

Hard Hat

Eye Protection Dust Mask

Ear Protection

Protective Clothing

2

CATERPILLAR
432 Loader

Maintenance Schedule

The following tables show our suggested maintenance schedule for all units. Please note that site conditions may alter this. Excludes high corrosion environments.

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

Inspect every 500 Hours and replace when filter is full*

Component / System

Action Required

Turbo Pre-cleaner Pressuriser Blower

Check operation of the Turbo PreCleaner. Ensure blower is operational.

HEPA Primary Filter p/n: 500000
HEPA Return Air Filter P/N: 500016

Inspect filter capacity indicator. Replace HEPA filter when 80% or greater. Vacuum out housing before replacing the filter elements. Vacuum inside cabin floor before replacing filter.

Filter Frame Assembly, Mounts, Seals and Filter Housing

Check door seals, all bolts, screws, and all mounts are secure. Check the filter canister & ensure it is correctly fitted. Check latches are operational and in good order. Replace / Re-tension fixtures and fittings required.

15,000 Hours / 36 months*

Component / System

Action Required

500 Hour Inspection

All 500-hour inspection actions.

Pressuriser’s Blower 200002

Replace BRUSHLESS Pressuriser blower.

CRITICAL PARTS & MAINTENANCE SCHEDULE

Item Part Number

1

500000

2

500016

3

200002

4

200027

Critical Parts Qty. Description

1 Fresh Air HEPA H14 Filter (Tested as per EN1822)
1 HEPA Return Air Filter

1

Brushless Blower Motor 24V

1

BreatheSafe Digital Display Data

Recorder (INPRESS TS)

Service Interval
1000 Hours (>80% fan capacity) 500 Hours
15,000 Hours

*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%. We recommend that the filter is changed if the capacity is over 80%.
*Site dependent

3

CATERPILLAR
432 Loader

OPERATORS CHECKLIST

PRE-START

Visually inspect the BreatheSafe system for any damage.

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

Please remove dust & debris from shoes and clothes before entering the cabin.

Ensure door(s) and windows are closed correctly.

Start engine and turn HVAC on to speed 2 (medium speed).

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 CO. Acceptable operating range for BreatheSafe fan 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.
CO Level Alert (if equipped) · Ensure air conditioning fan is set at mid speed or greater to circulate air and minimise CO.
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.

OPERATOR GUIDE

4

CATERPILLAR
432 Loader

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 Air Flow

: 11 amps (peak). *Note: Motor has slow start to stop excessive in-rush current.
: Up to 30-300 m3/h or 50-215 CFM.

Pre-cleaner

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

Filter Element Plugs & Fittings

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

SPECIFICATIONS HIGH-CAPACITY HEPA PRESSURISER

DH DHPR DHAC DHACPR CPM CPU DB DPM GAS HEPA HPAFU HRAF HVAC MAF OEM PM RH TEMP TS UI VMS VS OGSP CO2s

List of Abbreviations Dual HEPA Dual HEPA Powered Recirculation Dual HEPA Activated Carbon Dual HEPA Activated Carbon Powered Recirculation Cabin Pressure Monitor Central Processing Unit Decibel Sensor Diesel Particulate Matter Gas Sensor High-Efficiency Particulate Air Filter High Pressure Air Filtration Unit HEPA Return Air Filter Heating Ventilation and Air Conditioning Mass Air Flow Original Equipment Manufacturer Particulate Mass Relative Humidity Temperature Touch screen User Interface Vehicle Monitoring System Vibration Sensor OnGuard Sensor Pod CO2 Sensor INPRESS TS

5

CATERPILLAR
432 Loader

Item No. Qty.

1

2

4

3

1

4

1

5

1

6

1

7

1

8

1

9

1

10

1

11

1

12

3

13

3

14

4

15

8

16

4

17

5

Description Pre-cleaner Hood & Rotor Assy
Pre-cleaner Injector Ring TL Fan Blade (inc. in #7)
TL Nose Cone / Pre-cleaner TL Motor Housing TL Filter Housing 24v DC Brushless VSD Motor & TL Fan Blade O Ring Seal Kit 2 Parts Included in 8 Wiring Sleeve HEPA H14 Filter M6 Nyloc Nut M6 x 55mm Hex Bolt M8 x 190 Hex Bolt M8 x 22mm O/D HD Washer M8 Nyloc Nut M4 x 75mm Pan Head Phillips Screw

Part No. 200004
200005 200006
200007 200008 200009 200002 200010 200011 200012 500000 300218 (M6NYL) 300982 (M655B) 301136 (M8190B) 300230 (M8222HTW) 300249 (M8NYL) 300162 (M475PBH)

4

2 1

PARTS LIST TL4 24V DC PRESSURISER UNIT
PRESSURISER ASSEMBLY No: 200000

12 5
13 7

11 6

9

16

15

8

14

10

17

6

CATERPILLAR
432 Loader

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Part No. 13453 13454 13455 13461 13464 13460 17098 08007 300388-0300 300388-0200 300388-0150 300388-0070 200306 200308 300481 300483 300480 300848 200272-0600 300850 300852 13472 200001 250044 250100 250106

Rev Description

Qty Colour

1 TL Mount Assy

1 New Cat Yellow 98489749

0 Locting Plate Assy

1 Caterpillar Yellow

0 R.A.F. Main Assy

1 Black Satin 27219268

0 Mounting Plate

1 Caterpillar Yellow

0 Stauff Clamp Brkt.

1 Caterpillar Yellow

0 Stauff Clamp Spacer

1 Black Satin 27219268

0 Monitor Box Mounting Bracket 1 Black Satin 27219268

1 Fresh Air Thru-Wall Spigot Assy 1 Black Satin 27219268

– 76 SS Tube @300L

1 (As Req’d)

– 76 SS Tube @200L

1 (As Req’d)

– 76 SS Tube @150L

2 (As Req’d)

– 76 SS Tube @70L

1 (As Req’d)

– Ø76.2 x 45SD Elb

1 –

– Ø76.2 x 90SD Elb

3 –

– Stauff GR7 Cover Plate

1 (As Req’d)

– Stauff GR7 Weld Plate

1 (As Req’d)

– Stauff Shell GR7 76.1 Black

4 –

– Ø76.2 Cobra Neck

1 –

– 76 ID Silicone Flexi Hose @600L 1 –

– 76 ID Silicone Hose @110L

1 –

– 76 ID Silicone Hose @58L

1 –

0 TL Bracket

1 Black Satin 27219268

[*] HEPAFU 12VDC VSD TL2

1 –

[*] TL Water Cannon Guard

1 (As Req’d)

[*] Monitor Box Small

1 (As Req’d)

[*] CO2 Brket Universal

1 (As Req’d)

Kit Part Number: 700381

Category Weld Assy Weld Assy R.A.F. Frame Part Part Part Part Weld Assy Pipework Pipework Pipework Pipework Pipework Pipework Pipework Pipework Pipework Pipework Pipework Pipework Pipework Part Stock Item Stock Item Stock Item Stock Item

PARTS LIST GA COMPLETE ASSEMBLY No: 700381

7

CATERPILLAR
432 Loader

Item No. 1 2 3 4 5 6

Part No. 13456 13457 13470 13471 500016 300814

Rev Description 0 R.A.F. Base Assy 0 Black Clamp Assy 0 Filter Frame 0 R.A.F. Front Clamp 0 HEPA Filter 285x165x31 0 M6 x 20 Male Scallop K

Qty Material 1 (Prt Dwgs) 2 (Prt Dwgs) 1 Zan 2 Zan 1 2 –

Thickness (Prt Dwgs) (Prt Dwgs) 1.6mm 1.5 1.6 –

Colour Satin Black MX88-124 Satin Black MX88-124 (Per Assy) Satin Black MX88-124 N/A –

PARTS LIST RETURN AIR MODULE

8

CATERPILLAR
432 Loader

Item No. 1 2 3

Part No. 250101 200027 200031

Rev Description

[*]

STD Large Monitor Box

N/A

INPRESS TS Controller CO2 Sensor

N/A

CO2 Sensor Suit 200027

Qty Colour Category

1

–

Stock Item

1

–

Stock Item

1

–

Stock Item

PARTS LIST MONITOR MOUNT

9

CATERPILLAR
432 Loader
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

TECHNICAL DETAILS

· 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

10

CATERPILLAR
432 Loader
Connections: 200027

Item 1 2 3 4

Destination
PIPE A AMBIENT PRESSURE OUTSIDE PIPE B POSITIVE PRESSURE INSIDE RJ45 CONNECTOR CO2 SENSOR OVERRIDE TOGGLE SW = MAX SPEED

Item 1 2 3 4 5 6 7 8 9 10 11 12

Destination 12/24 VOLT POSITIVE SUPPLY CAN H OPTION CAN L OPTION SERIAL TRANSMIT RS232 MOTOR CONTROL VOLTS OUT ALARM + OUTPUT TEMP SENSOR NO CONNECTION SERIAL RECEIVE RS232 DOOR INPUT (+) WINDOW INPUT (+) 0V NEGATIVE GROUND

Wiring Diagram

TECHNICAL DETAILS

v

11

CATERPILLAR
432 Loader

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.

SMOKE EMITTER CABIN PRESSURE LEAK TEST
Link to MSDS: SMOKE GENERATOR TQ7621AT30S.pdf

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

Personal Protective Equipment (PPE)
Safety glasses must be worn at all times. Sturdy footwear with rubber soles must be worn. Respiratory protection devices may be required. Gloves may be worn.

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 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 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
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.

Falls Fumes Fire

Potential Hazards

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.

12

CATERPILLAR
432 Loader

CABIN SEALING TEST PROCEDURE

1

Start Engine Pressuriser System is ON

Cabin Sealing Efficiency Test Procedure

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.

12:18

12/04/2022

25%

Cabin Pressure

50 Pa

CO2 Concentration 561 ppm

BACK

Settings

SYSTEM CHECK SET MAX

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

Press Settings.

Press “System Check Set Max” box.

12:18

12/04/2022

100%

System Test Max Fan

Cabin Pressure

425 Pascals

Record / Photograph the cabin pressure result (Max Fan Speed).

13

CATERPILLAR
432 Loader

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; 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 as per the diagram below:

“System Check”

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

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 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.

14

CATERPILLAR
432 Loader

BREATHESAFE SYSTEM TROUBLE SHOOTING GUIDE *TOUCH CONTROL

FAULT

POSSIBLE CAUSE

SOLUTION

*ERR error code

Poor sensor connection

Remove & refit pod connection cable

Corrupted coding

Access factory setup – default reset – pin 6759

*Check filter alarm

Service hour timeout

Access Check Runtime menu – reset hours via 7597 code

Temperature / CO2 error

Sensor not connected

Fit sensor or disable via site access CO2 & or temperature menu

Pressuriser running at full speed/noisy

Filter blocked

Service filter

Door or window open

Ensure doors & windows securely shut

Cabin sealing capacity not adequate

Perform pressure test procedure & seal leak points as required

Sense pipe blocked

Ensure clear & not bent

Internal sensor damaged

Replace controller

**No need to change setpoint

Filter blocking quickly

Defective cabin sealing

Perform pressure test procedure & seal leak points as required

Pre-cleaner failed

Check operation & replace if necessary

Display blank

Poor power supply

Check mains supply fuse & correct voltage

Check voltage & 20AMP supply/connections at pin 1 @ monitor

Check earth continuity at controller pin 12

Failed controller

Replace monitor

Controller showing 0.0 pressure

Fresh air filter blocked

Check filter condition & replace if required.

Low pressure alarm

Door or window open

Ensure doors & windows securely shut

Cabin sealing capacity not adequate

Perform pressure test procedure & rectify cab sealing

Pressuriser not operating

Ensure correct voltage 12v or 24v to pressuriser motor pin A

Check 1.6V – 10V present at motor Pin C

Check 20A Supply fuse

Check earth continuity Pin B

Pressure sense tube blocked

Unplug at monitor & ensure clear flow to external of cabin

Ensure pressure tube fitted correct port A

**No need to change setpoint

Pressuriser not working

Poor power supply

Check 20A mains fuse & correct voltage

Ensure adequate wire size & no voltage drop

Ensure correct voltage 12v or 24v to pressuriser motor pin A

Check 1.6V – 10V present at motor Pin C

Poor earth

Check earth continuity @ motor pin B

Motor faulty

Replace TL4M

Access Codes:

Site Access: 7597

Factory Setup: 6759

15

CATERPILLAR
432 Loader

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.

BACK

SET UP PARAMETERS

Insert Pin = 7597

7597

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

Enter Pin

12 3

45 6

78 9

CLEAR

0

ENTER

USER SETTINGS INSTRUCTIONS
16

CATERPILLAR
432 Loader

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.

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1 Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

1 2 3

3

4 5 6

4

7597

7 8 9

CLEAR

0

ENTER

BACK

Settings Page 1

DOOR WINDOW SETTING

PRESSURE SETPOINT

CHECK RUNTIME

DATE / TIME

CO2 SETTING

BACK Pressure Settings

PRESSURE UNITS =

Pascals

Alarm Set

Pressure Set

Pressure

5

Point 20

Point 50

Alarm Delay 5 mins

PRESSURE ALARM SETTING

USER SETTINGS INSTRUCTIONS

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.

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1

Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

BACK

Settings Page 1

STARTUP OPTIONS

DOOR WINDOW SETTING

PRESSURE SETPOINT

4 5 6

3

4

7597

7 8 9

CHECK

DATE /

CO2

RUNTIME

TIME

SETTING

CLEAR

0

ENTER

BACK Pressure Settings

PRESSURE UNITS =

Pascals

Alarm Set

Pressure Set

Pressure

5

Point

Alarm Delay

20

50

5 mins

17

CATERPILLAR
432 Loader
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.

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1 Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

1 2 3

3

4 5 6

4

7597

7 8 9

CLEAR

0

ENTER

BACK

Settings Page 1

DOOR WINDOW SETTING

PRESSURE SETPOINT

CHECK RUNTIME

DATE / TIME

CO2 SETTING

BACK Pressure Settings

PRESSURE UNITS =

Pascals

CURRENT

SET SERVICE

5

RUNTIME 700

INTERVAL 1000

DATE & TIME SETTINGS

USER SETTINGS INSTRUCTIONS

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

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1

Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

BACK

Settings Page 1

STARTUP OPTIONS

DOOR WINDOW SETTING

PRESSURE SETPOINT

4 5 6

3

4

7597

7 8 9

CHECK

DATE /

CO2

RUNTIME

TIME

SETTING

CLEAR

0

ENTER

BACK Date/Time Settings NEXT

PRESSURE UNITS =

Pascals

5

HOUR MIN

DAY MON YEAR

4 : 10

22 / 04 / 2023

18

CATERPILLAR
432 Loader
PRESSURE ALARM BUZZER SETTING
To disable the buzzer, toggle through to the ENABLED and DISABLED buttons.

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1 Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

1 2 3

3

4 5 6

4

7597

7 8 9

CLEAR

0

ENTER

BACK

Settings Page 1

DOOR WINDOW SETTING

PRESSURE SETPOINT

CHECK RUNTIME

DATE / TIME

CO2 SETTING

BACK

Settings Page 2

BACK Alarm Buzzer Settings

ALARM MUTE RESET

ZERO SENSOR

TEMP SETTING

5

BUZZER

LOG

FACTORY

6

SETTINGS

SETUP

ENABLED
PRESSURE BUZZER
ENABLED
WINDOW BUZZER

ENABLED
CO2 PRIMARY BUZZER
DISABLED

DISABLED
TEMPERATURE BUZZER

DOOR BUZZER

CALIBRATE ZERO SENSOR

ALARM BUZZER SETTINGS

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.

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1

Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

BACK

Settings Page 1

STARTUP OPTIONS

DOOR WINDOW SETTING

PRESSURE SETPOINT

4 5 6

3

4

7597

7 8 9

CHECK

DATE /

CO2

RUNTIME

TIME

SETTING

CLEAR

0

ENTER

BACK

Settings Page 2

BACK

Zero Sensor Adjustment

ALARM MUTE RESET

ZERO SENSOR

TEMP SETTING

5

BUZZER

LOG

FACTORY

6

SETTINGS

SETUP

AUTO ZERO SENSOR

Zero Pressure Adjust
Pa

19

CATERPILLAR
432 Loader
CO2 MODULE ENABLE/DISABLE
Enable or disable to CO2 module used for measuring CO2 levels within the cabin.

CO2 PRIMARY ALARM POINT

CO2 SETTINGS

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

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1 Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

1 2 3

3

4 5 6

4

7597

7 8 9

CLEAR

0

ENTER

BACK

Settings Page 1

DOOR WINDOW SETTING

PRESSURE SETPOINT

CHECK RUNTIME

DATE / TIME

CO2 SETTING

BACK

CO2 Sensor Alarm Setting

DISABLE CO2
SENSOR

CO2 ALARM CO2 PRIMARY

CO2 CRITICAL

DELAY

ALARM

SETTING

SETPOINT

5

2 Min

1000 PPM

2500 PPM

ALARM MUTE DELAY

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1

Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

BACK

Settings Page 1

STARTUP OPTIONS

DOOR WINDOW SETTING

PRESSURE SETPOINT

4 5 6

3

4

7597

7 8 9

CHECK

DATE /

CO2

RUNTIME

TIME

SETTING

CLEAR

0

ENTER

BACK

CO2 Sensor Alarm Setting

DISABLE CO2
SENSOR

CO2 ALARM CO2 PRIMARY

CO2 CRITICAL

DELAY

ALARM

SETTING

SETPOINT

5

2 Min

1000 PPM

2500 PPM

ALARM MUTE DELAY

20

CATERPILLAR
432 Loader

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.

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1 Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

CO2 CRITICAL ALARM MUTE RESET

CO2 SETTINGS

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

8:30

22/04/23

25%

Cabin Pressure

50Pa

CO2 Level

200 PPM

1

Temperature

20°C

2

BACK

Settings

SYSTEM CHECK

VIEW GRAPH

EVENT LOG

SITE ACCESS MENU

BACK

Enter Pin

1 2 3

3

4 5 6

4

7597

7 8 9

CLEAR

0

ENTER

BACK

Settings Page 1

DOOR WINDOW SETTING

PRESSURE SETPOINT

CHECK RUNTIME

DATE / TIME

CO2 SETTING

BACK

CO2 Sensor Alarm Setting

DISABLE CO2
SENSOR

CO2 ALARM CO2 PRIMARY

CO2 CRITICAL

DELAY

ALARM

SETTING

SETPOINT

5

2 Min

1000 PPM

2500 PPM

ALARM MUTE DELAY

BACK

Enter Pin

BACK

Settings Page 1

STARTUP OPTIONS

DOOR WINDOW SETTING

PRESSURE SETPOINT

4 5 6

3

4

7597

7 8 9

CHECK

DATE /

CO2

RUNTIME

TIME

SETTING

CLEAR

0

ENTER

BACK

CO2 Sensor Alarm Setting

DISABLE CO2
SENSOR

BACK

Critical Alarm Mute Timeout Adjustment
DISABLE CO2 SENSOR

CO2 ALARM CO2 PRIMARY

CO2 CRITICAL

DELAY

ALARM

SETTING

SETPOINT

5

2 Min

1000 PPM

2500 PPM

6

SET MUTE TIMEOUT MINUTES
10 Mins

ALARM MUTE DELAY

21

CATERPILLAR
432 Loader
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 dropdown menu.
Example: COM 21 This connection may be different on your computer.

DATA DOWNLOAD
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
22

CATERPILLAR
432 Loader
Data Download Setting up RS232 Connection
7 If required, you may choose to save the COM port settings. Go to Settings and clock save the setup.
Hint: From the drop-down menu, click on the 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.

DATA DOWNLOAD
9 From the drop-down menu, click on the Save setup.
10 Click Restore setup. 11 Choose the file name you
have already saved.
23

CATERPILLAR
432 Loader

Data Download Setting up RS232 Connection
12 From the drop-down menu, click on the Edit menu function.
13 Press “Select All”.
14 Select “Copy table”.

Excel Data Instructions Unformatted

DATA DOWNLOAD

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 byText 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 clickFinish’. 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.

15 Open a blank excel document and 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).

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

24

CATERPILLAR
432 Loader

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

INPRESS TL WARRANTY

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 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.
25