Breathe-Safe ZW100-5B Wheel Loader Instruction Manual
- June 1, 2024
- Breathe-Safe
Table of Contents
- Breathe-Safe ZW100-5B Wheel Loader
- Product Information
- Product Usage Instructions
- INSTALLATION
- SAFETY
- CRITICAL PARTS & MAINTENANCE SCHEDULE
- OPERATOR GUIDE
- SPECIFICATIONS
- PARTS LIST
- TECHNICAL DETAILS
- SMOKE EMITTER CABIN PRESSURE LEAK TEST
- CABIN SEALING TEST PROCEDURE
- COMMISSIONING PROCEDURES
- TROUBLESHOOTING GUIDE
- USER SETTINGS INSTRUCTIONS
- DATA DOWNLOAD
- WARRANTY
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
Breathe-Safe ZW100-5B Wheel Loader
Product Information
Product Specifications
- Manufacturer: HITACHI
- Type: ZW100-5B Wheel Loader
- Part Number: 700423
- Address: 62 Mica Street, Carole Park, 4300, QLD
- Contact: +61 7 3276 7833, sales@breathe-safe.com.au.
Product Usage Instructions
Installation Overview
Hitachi Wheel Loader ZW100-5B includes HEPA H14 Variable Speed Pressuriser,
INPRESS TS Cabin Display with CO2 Sensor, and HEPA Return Air Filter +
Activated Carbon.
Installation Steps
- Follow the manufacturer’s guidelines for installing the pressurisation system components.
- Ensure qualified staff wear appropriate personal protective equipment when cleaning and servicing the unit.
- Take necessary electrical safety measures when working on the pressuriser system.
- Ensure all safety guards are in place while the system is running.
Maintenance Schedule
Follow the maintenance schedule below:
Action Required | Component / System |
---|
Check the operation of Turbo PreCleaner. Ensure blower is
operational.| Turbo Pre-cleaner Pressuriser Blower
Inspect and replace HEPA filters when needed.| HEPA Primary Filter p/n:
500000, HEPA Return Air Filter P/N:
500004
Check seals, mounts, and filter housing. Replace/tighten
fixtures as necessary.| Filter Frame Assembly, Mounts, Seals, and Filter
Housing
Frequently Asked Questions (FAQ)
-
Can HEPA filters be cleaned?
No, HEPA filters cannot be cleaned. They must be replaced at the end of their lifecycle or if the filter media has been damaged. -
How often should the pressuriser blower be replaced?
The pressuriser blower should be replaced every 200002 hours or during the 500-hour inspection, as per the maintenance schedule.
INSTALLATION
INSTALLATION OVERVIEW
Manufacturer| Hitachi
Type| Wheel Loader
Model| ZW100-5B
Cabin Pressure Max|
Set Auto Cabin Pressure|
SAFETY
WARNING
- THE PRESSURISATION SYSTEM DESCRIBED IN THIS MANUAL HAS THE FOLLOWING AREAS THAT 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 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 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.
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 the air for longer, increasing the chance for workers to breathe in dust. Ensure PPE is worn when installing this system.
CRITICAL PARTS & MAINTENANCE SCHEDULE
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 the filter is full***
Component / System | Action Required |
---|---|
Turbo Pre-cleaner | Check the operation of the Turbo Pre– |
Cleaner.
Pressuriser Blower| Ensure the blower is operational.
HEPA Primary Filter p/n: 500000| Inspect filter capacity indicator.
Replace the HEPA filter when 80% or greater. Vacuum out the housing before
replacing the filter
elements.
HEPA Return Air Filter P/N:
500004
| Vacuum inside the cabin floor before replacing the 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***
**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
Item| Part Number| Qty.| Description| Service
Interval
1| 500000| 1| Fresh Air HEPA H14 Filter (Tested as per
EN1822)
| 1000* Hours (>80%
fan capacity)
2| 500004| 1| HEPA Return Air Filter| 500* Hours
3| 200002| 1| Brushless Blower Motor – 24V| 15,000 Hours
4| 200027| 1| BreatheSafe Digital Display – Data
Recorder (INPRESS TS)
|
5| 500069| 1| Filter Activated Carbon|
Filter service hours are subject to cab sealing efficiency, site conditions and correct system use.
Suggested Schedule Servicing
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, or
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 the engine and turn the HVAC on to speed 2 (medium speed).
6.| After a fixed speed delay, the BreatheSafe display will show 50
Pascals or a 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 be set at mid-speed or greater to circulate air around the breathing zone and minimise CO₂.
The acceptable operating range for a 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 the 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 the maintenance department to check filters and cabin sealing. Ensure filters are serviceable.
Check Filter
· Reminder to inspect or replace the filter. The service hour meter requires re-set.
· Refer to the maintenance department.
SPECIFICATIONS
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: The motor has a slow start to stop the 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 airflow through the system.
List of Abbreviations
DH| Dual HEPA
DHPR| Dual HEPA Powered Recirculation
DHAC| Dual HEPA Activated Carbon
DHACPR| Dual HEPA Activated Carbon Powered Recirculation
CPM| Cabin Pressure Monitor
CPU| Central Processing Unit
DB| Decibel Sensor
DPM| Diesel Particulate Matter
GAS| Gas Sensor
HEPA| High-Efficiency Particulate Air Filter
HPAFU| High-Pressure Air Filtration Unit
HRAF| HEPA Return Air Filter
HVAC| Heating Ventilation and Air Conditioning
MAF| Mass Air Flow
OEM| Original Equipment Manufacturer
PM| Particulate Mass
RH| Relative Humidity
TEMP| Temperature
TS| Touch screen
UI| User Interface
VMS| Vehicle Monitoring System
VS| Vibration Sensor
OGSP| OnGuard Sensor Pod
CO2s| CO2 Sensor INPRESS TS
PARTS LIST
TL4 24V DC PRESSURISER UNIT
- PRESSURISER ASSEMBLY No: 200000
Item No. | Qty. | Description | Part No. |
---|---|---|---|
1 | 1 | Pre-cleaner Hood & Rotor Assy | 200004 |
2 | 4 | Pre-cleaner Injector Ring | 200005 |
3 | 1 | TL Fan Blade (inc. in #7) | 200006 |
4 | 1 | TL Nose Cone / Pre-cleaner | 200007 |
5 | 1 | TL Motor Housing | 200008 |
6 | 1 | TL Filter Housing | 200009 |
7 | 1 | 24v DC Brushless VSD Motor & TL Fan Blade | 200002 |
8 | 1 | O Ring Seal Kit 2 Parts | 200010 |
9 | 1 | Included in 8 | 200011 |
10 | 1 | Wiring Sleeve | 200012 |
11 | 1 | HEPA H14 Filter | 500000 |
12 | 3 | M6 Nyloc Nut | 300218 (M6NYL) |
13 | 3 | M6 x 55mm Hex Bolt | 300982 (M655B) |
14 | 4 | M8 x 190 Hex Bolt | 301136 (M8190B) |
15 | 8 | M8 x 22mm O/D HD Washer | 300230 (M8222HTW) |
16 | 4 | M8 Nyloc Nut | 300249 (M8NYL) |
17 | 5 | M4 x 75mm Pan Head Phillips Screw | 300162 (M475PBH) |
PARTS LIST GA
- COMPLETE ASSEMBLY No: 700423
Item No.| Part No.| Rev| Description| Qty|
Colour| Group
---|---|---|---|---|---|---
1| 250502| []| Canister MK3 316SS| 1| –| Stock Item
2| 200000| []| HPAFU 24VDC VSD TL4| 1| –| Stock Item
3| 250505| []| MK3 Rain Cover Unvsl Cap SS| 1| –| Stock Item
4| 250001| []| TL-MK3 Mount SS| 1| –| –
5| 100440F01| 0| Fresh Air Module| 1| Charcoal Grey MX83-682| Module
6| 100440R01| 0| Return Air Module| 1| Charcoal Grey MX83-682| Module
7| 250101| []| Monitor Box, Large| 1| (As Req)| Stock Item
8| 250049| []| TL Side Mount WC Cover| 1| (As Req)| Stock Item
9| 250508| []| Duct Outlet MK3 Adj SS| 1| –| Stock Item
10| 300388-1200| –| 76 SS Tube @1200L| 2| (As Req)| Pipework
11| 200307| –| Ø76.2x90LD Elb| 3| –| Pipework
12| 200306| –| Ø76.2x45SD Elb| 3| –| Pipework
13| 300848| –| Ø76.2 Cobra Neck| 1| –| Pipework
14| 300480| –| Stauff Shell GR7 76.1 Black| 6| –| Pipework
15| 300481| –| Stauff GR7 Cover Plate| 3| (As Req)| Pipework
16| 300001| –| Clamp Hose W 65-89 SS| 12| –| Pipework
17| 200201| []| TS-CO2 Controller Assembly| 1| –| Stock Item
Kit Part Number: 700423
FRESH AIR MODULE
Item No.| Part No.| Rev| Description| Qty|
Material| Thickness| Colour| Category
---|---|---|---|---|---|---|---|---
1| 100440-F918| 0| Spigot Plate| 1| Mild Steel| 3| –| Part
2| 100440-F919| 0| Locating Flange| 1| Zan| 1.6| –| Part
3| 100440-F920| 0| Spacer| 1| Mild Steel| 5| –| Part
4| 300388-0080| –| 76 SS Tube @80L| 1| Stainless Steel Tube| 1.6| (As
Req)| Pipework
RETURN AIR MODULE
Item| Part No.| Rev| Description| Qty| Material|
Thickness| Colour| Category
---|---|---|---|---|---|---|---|---
1| 100440R02| 0| Return Air Base| 1| –| –| Charcoal Grey MX83-682| Weld
Assy
2| 100440-R917| 0| R.A.F. Frame| 1| Zan| 1.5| Charcoal Grey MX83-682|
Part
3| 500004| [*]| HEPA Filter 200x200x50| 1| N/A| –| –| HEPA Filter
4| 300814| –| M6x20 Scallop Knob Male| 2| –| –| –| Hardware
PARTS GA
Carbon Filter Carrier Removal
- Ensure all relevant circuit breakers are open and the electrical circuit is isolated.
- Unlock & open the door (Fig 1)
- Uncouple both filter latches (Fig 2)
- Pull the filter in the opposite direction of the airflow arrows, until clear (Fig 3)
- Full the filter towards you and remove (Fig 3)
- Clean the filter housing of all debris.
- To replace the filter, assemble the components in reverse order.
Carbon Filter Service Kit
- Please follow the steps shown for the Filter Media Carrier Removal, to remove the carrier from the case.
- Unscrew & remove the 4-off M5 screws (Fig 1)
- Lift out the solid Media Filter (Fig 2)
- Lift out the Secondary HEPA Filter (Fig 2)
- Clean the filter housing of all debris.
- To refit, assemble the components in reverse order.
TECHNICAL DETAILS
Connections: 200027
Item | Destination |
---|---|
1 | PIPE A – AMBIENT PRESSURE – OUTSIDE |
2 | PIPE B – POSITIVE PRESSURE – INSIDE |
3 | RJ45 CONNECTOR – CO2 SENSOR |
4 | OVERRIDE TOGGLE SW = MAX SPEED |
Item | Destination |
---|---|
1 | 12/24 VOLT POSITIVE SUPPLY |
2 | CAN H OPTION |
3 | CAN L OPTION |
4 | SERIAL TRANSMIT RS232 |
5 | MOTOR CONTROL VOLTS OUT |
6 | ALARM + OUTPUT |
7 | TEMP SENSOR |
8 | NO CONNECTION |
9 | SERIAL RECEIVE RS232 |
10 | DOOR INPUT (+) |
11 | WINDOW INPUT (+) |
12 | 0V NEGATIVE GROUND |
Wiring Diagram
GENERAL GUIDE
General Guide to Cabin Sealing, Testing, and Commissioning of BreatheSafe Variable Speed Pressurisation Units
(Clean Cabin with HEPA vacuum)
1| Inspect the cabin and ensure all cover panels are in place and any
cabin pressure leaks are sealed with grommets, sealer, fit new door seals for
used equipment, etc
2| Sitting inside the cabin with the door open, turn on the ignition to
power up the unit.
3| The pressuriser fan should power up to full speed, and the monitor
should indicate 0 Pa pressure (Allow ± 2 pascals wind gusts).
4| With the ignition on, close all doors and windows. If the cabin is
adequately sealed, the monitor should indicate 50 Pa (Pascals), set pressure
or whichever pre-set has been chosen. (If not achieved, check for cabin
pressure leaks).
5| Once a cabin pressure of 50 Pa is confirmed. Go to the settings menu,
and select “System Check.” The display will indicate “System Test – Max Fan”
on the screen while
showing the maximum cabin pressure.
6| The MAX cabin pressure should be above 250 Pascals related to the
efficiency of cabin seals (Please note the minimum result for warranty
compliance is 250 Pascals tested with a new 500000 HEPA filter). Therefore, a
cabin pressure result of 300 to 500 pascals is the ideal result.
7| If the above pressure is not achieved, leave the unit at full speed
and investigate external leaks outside the cabin: e.g., A/C outlets, drains,
window & door seals,
locks & hinges, etc.
8| If necessary, with the ignition on, controller on ‘MAX FAN SPEED,’
A/C blower OFF & all doors & windows closed, set off a smoke emitter inside
the cabin (SWP attached).
9| Locate any air leaks around the cabin and re-test. If silicone
sealant or similar is used, allow it to dry before re-testing, as even
slamming the door could push the
seal back out.
10| Continue the sealing and testing procedure as above until a satisfactory outcome is achieved. Fill out the record below and attach photo evidence of the maximum pressure result and NANOZEN Real-time Dust Monitoring result to register for warranty
SMOKE EMITTER CABIN PRESSURE LEAK TEST
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.
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.
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 nearby are informed of use. Place on a non-
combustible container, away from flammable materials.
2.| Place at Blower intake, upwind of the target area, or near the centre of
space.
3.| Orient “Smoke Issues Here” toward the air stream, away from surfaces.
Place the 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 the emitter inside the cabin using site approved device i.e.,
solder torch or ‘lighter’ and conduct the smoke test.
6.| Do not touch or hold the smoke generator after ignition – the item becomes
very hot & remains hot after use.
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 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 the door to allow sufficient ventilation of smoke before entering
the cabin.
Link to MSDS: SMOKE GENERATOR TQ7621AT30S.pdf.
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 complement training and as a reminder to users before equipment use.
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)
NOTE: for a new cabin with effective seals, you may need to open a window slightly before closing the door to bleed the static cabin air pressure outwards. Once the door is fully closed then close windows to begin testing.
3| Enter the Settings menu via the touchscreen button.
4| Select and press the System Check button to go to System Test – Max-Fan.
5| Record/photograph the maximum cabin pressure achieved.
COMMISSIONING PROCEDURES
COMMISSIONING PROCEDURES CABIN PRESSURE
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
proactively servicing OPERATOR enclosure seals rather than a reactive one.
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 in the enclosure and apply new sealing measures.
Submission for commissioning procedure as per the diagram below:
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.
TROUBLESHOOTING GUIDE
*BREATHE SAFE SYSTEM TROUBLESHOOTING 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 are 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 the 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
The controller shows a 0.0 pressure| Fresh air filter blocked| Check
filter condition & replace if required.
Low-pressure alarm| Door or window open| Ensure doors & windows are
securely shut
Cabin sealing capacity not adequate| Perform pressure test procedure & rectify
cab sealing
Pressuriser not operating| Ensure the correct voltage of 12v or 24v to
pressuriser motor pin A
Check 1.6V – 10V present at motor Pin C
Check the 20A Supply fuse
Check earth continuity Pin B
Pressure sense tube blocked| Unplug at monitor & ensure clear flow to the
external of the cabin
Ensure the pressure tube is fitted correct port A
**No need to change setpoint
Pressuriser not working| Poor power supply| Check the 20A mains fuse &
correct voltage
Ensure adequate wire size & no voltage drop
Ensure the correct voltage of 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**
USER SETTINGS INSTRUCTIONS
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 a 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 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 the 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 the 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.
PRESSURE ALARM BUZZER SETTING
To disable the buzzer, toggle through to the ENABLED and DISABLED buttons.
CALIBRATE ZERO SENSOR
Over a 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 MODULE ENABLE/DISABLE
Enable or disable to 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
Data Download – Setting up RS232 Connection
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
0| = No alarm
1| = Low-pressure alarm
2| = Window open
3| = Door open
WARRANTY
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 defective 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 arise 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 instead 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 instead 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 about service outside our factory our designated service branch, including travelling time, waiting time, transport costs, and 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 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.
Contact Information
- +61 7 3276 7833
- www.breathe-safe.com.au
- sales@breathe-safe.com
- 62 Mica Street, Carole Park, 4300, QLD.
References
- BreatheSafe - Intelligent HEPA H14 Cabin Air Filtration
- Home - Safe Software
- BreatheSafe - Intelligent HEPA H14 Cabin Air Filtration
- Commissioning - BreatheSafe
- Commissioning - BreatheSafe
Read User Manual Online (PDF format)
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