INPRESS TL AFFINITY PUBLISHER...B R E A T H E S A F E 2 0 1 9 Page3 830E 2-4 930E 2-4 HD1500 830E5...

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INSTALLATION OVERVIEWManufacturer KOMATSU

Type MINING HAUL TRUCKModel 830E 2-4 / 930E 2-4 / HD1500 / 830E 5 / 930E 5

Site TBASerial Number TBA

Cabin Pressure Max TBASet Auto Cabin Pressure 50

Key Modules High Capacity HEPA Cabin PressuriserINPRESS Cabin Pressure Monitoring & DisplayReturn Air filter HEPA

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WARNINGThe pressurisation system described in this manual has thefollowing areas which may be dangerous if not treated withgreat care.

Qualified staff must wear the correct personal protectiveequipment when cleaning and servicing this unit due tohazardous dust and fibres which may be caught by thestages of air filtration during normal unit operation.

The electrical power system is supplied by 12V DC or 24VDC and no work should be carried out on the pressurisersystem without the correct safe work procedures andelectrical safety measures being taken, and all relevantcircuit breakers opened to isolate the circuit.

The air filtration system may have several types of high-speed rotating equipment installed with very sharp edges.Ensure all safety guards are in place while the system isrunning.

Please be aware that HEPA filters cannot be cleanedand must be replaced at the end of their lifecycle or iffilter media has been damaged.

SAFETY FIRSTALWAYS!

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5

DUST-FREEPRESSURISEDAIR TO HVAC

1. Dirty, hazardous air enters the filter assemblythrough angled veins.

2. The veins cause the air flow to spin and move.

3. The spinning air flow is accelerated further by theintegrated pre-cleaner rotor. Centrifugal force throwsthe heavier than air dirt and dust particles to theoutside walls ejector ports.

4. 90% + of the coarse dust and hazardous debris isejected safely away as this process extends thelifecycle of the filter media.

5. An inner vortex is formed and only precleaned airis drawn down into the filter chamber.

6. The pre-cleaned air is pushed through the easilyserviceable filter media rated for submicron dustparticle filtration. HEPA (High-efficiency ParticulateAir) media complies with OH&S guidance forrespirable silica, coal dust and mineral fibres down to0.3-micron particles.

7. A variable speed centrifugal air pump generatespowerful pressurised air.

8. Clean, hazard free, pressurised air is delivered tothe operator’s cabin.

9. The pressurised air is mixed with the HVACsystems return air.

HEPA Return Air Filter isolates HVAC systemthus provides highest protection factor for theoperator.

In essence, this system controls dust from shoesand clothes.

10. The air passes through the HVAC system and intothe cab.

11. Positive cabin pressure ensures a safe workenvironment. Positive internal pressure repelsharmful, hazardous dust.

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HEPARETURNAIRFILTER

SAFEBREATHINGZONE

OPTION:HEPA AIRSCRUBBER

PRE-CLEANER

HEPAFILTRATION

SYSTEM OVERVIEW

12. The Breathesafe INPRESS unit monitors thecabin pressure as measured through its built-inpressure transducer and calculates the error based onthe pressure set-point. This value is applied to analgorithm and the controller calculates a proportionaloutput which adjusts the speed of the pressurisermotor.

. If the cabin pressure drops below the set point avisual and if fitted, an audible alarm is activated.

14. A backlit LCD, displays actual cabin pressure inpascals on the top line and the time and date or anyalarms present, on the bottom line.

15. The digital interface allows the operator to easilyadjust the pressure set point and access additionalfeatures.

CabinPressureDataLog

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CabinPressureDataLog

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16. Typically the processor can save up to 3.5 monthsof data including date, time, pressure readings andalarm instances. Data logs are easily downloadablevia a standard RS232 cable.

17. If required, remote data log access, reportanalysis and management are available using the4G network and customer support.

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PRESSURISEDAIR

50 pascals

8

CRITICAL PARTS

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TQ4706410H2

INPRESS TL PRESSURISERItem Part Number Qty. Descrip�on Service Interval1 TLF700EN 1

1Fresh Air HEPA H13 Filter TESTED AS PER EN1822HEPA RETURN AIR FILTER

500 - 1000 Hours500 - 1000 Hours

3 TL4M 1 Brushless Blower motor - INPRESS TL 7500 Hours

4 TQUCPM INP 1 BREATHE SAFE DIGITAL DISPLAY - DATA RECORDER 10000 Hours

INPRESS TL ACTIVATED CARBON PHASE (OPTION)Item Part Number Qty. Descrip�on Service Interval1 TQ470555400SCSO2 1 MK2 &MK3 FILTER MODULE: ACTIVATED CARBON 500 - 1000 HOURS

Includes: 1 x HEPA final filter1 x Solid Core Ac�vated Carbon Module

2 TQTRAP2461RASS 1 MK3 CASE STAINLESS STEEL 10000 HOURS

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SPECIFICATIONSHIGH CAPACITY HEPA PRESSURISER

Blower

Voltage

Current draw

Air Flow

Pre-cleaner

Filter Element

Plugs & Fittings

Construction

Serviceability

Finish

Mounting

Design

FEA Testing

CDF Testing

: Brushless Blower P/N TL4M

: 24v

: 11 amps (peek)

: Upto 180 m3/h.

: Integrated VLR (Very Low Restriction).

: Breathe Safe HEPA Primary Filter (H13=99.97% MPPS) TESTED AS PER EN1822 - P/N TLF700EN

: Mining Spec. Deutsch electrical plugs as standard.

: High strength composite construction.

: Easy access HEPA filter with twist-lock dust cap single assembly.

: Satin Powder Coated throughout (Ducting).

: Heavy Duty adjustable mounting brackets.

: Fully designed in SolidWorks 3D CAD.

: Critical components FEA (Finite Element Analyst) tested in Solid Works Simulation.

: CFD (Computational Fluid Dynamics) simulations in FlowWorks to ensure optimum air flowthrough the system.

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PRESSURISER PARTS

Proprietary & ConfidentialThe information containedin this drawing is the soleproperty of TRACS QLD Ltd.Any reproduction in partor as a whole without thewritten permission of

TRACS Ltd. is prohibited.

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ItemNo. Qty. DESCRIPTION PartNo1 1 Cover & Rotor Assy TQP99999HOOD2 4 Injector Ring TQP99999RINGS3 1 INPRESS Fan Blade TL4M4 1 INPRESS TL Filter Inlet Cone TLCASE5 1 INPRESS TL Motor Housing TLCASE6 1 INPRESS TL Filter Housing TLCASE

7 1 (24V motor TQ370407-4) TL4M

8 1 Motor/Filter Gasket TLO19 1 Filter Gasket TLG110 1 Wiring sleeve / grommet TL4M TLWSLEEVE

11 1 Filter Seal (HEPA Filter Ø161 x 250L) TLF700EN12 3 M6 Nyloc Nut13 3 M6 x 55 Hex Bolt14 4 M8 x 200 Hex Bolt15 8 M8 x 22 O/D HD Washer16 4 M8 Nyloc Nut17 5 M4 x 75 Pan Head Phillips Screw

REVISIONSREV. DESCRIPTION DATE APP'D

1 HARDWARE & PART NO'S UPDATED 03/01/2019 B.D.

Manufacturer: Breathe SafeModel: INPRESS TL Weight : N/A Kg

TITLE: 24V DC TL UNIT (inc HEPA Filter & Cap)

Drawn: B.D. Drawn Date: 06/10/2016

Dwg No: 07364 EXPLODED BOMPart No: TL4

TOLERANCES:LINEAR:

XX. = 1.50mmXX.X = 0.75mmXX.XX = 0.25mm

ANGULAR: = 0 50'

Unless Stated On Dwg Rev: 9

Remove ALL weld spatter, burrs / sharp edges. ALL edges to be rounded R1mm prior to powdercoating . Dress welds for good appearance.

Material: N/A mm - N/A

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830E 2-4930E 2-4HD1500

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REVISIONS

REV. DESCRIPTION DATE APP'D

ItemNo. Description Qty. PartNo

1 INPRESS TL Door Assembly 1 TLKKOMe-2/4TL2 TL Mount plate 1 DP071043 HEPA Kit INPRESS Blower Mount Assy 1 DP 070144 Pinch Weld 66-022 1 66-0225 N/Lock Latch 2 TQ4702C5-116 HEPA H13 Fresh Air Filter (Inc TL Cap) 1 TLF700EN7 24V DC TL UNIT 1 TL48 M8 x 40 Knurled screw 1 TQ4801683611bolt9 Flexi pipe (small) 1 TQ420363150 -EA10 Offset Hinge Assy 3 TQ703EH-6C11 Hose Clamp 65-89mm 2 TQ138048

Manufacturer: KomatsuModel: 830E 2-4 / 930E 2-4 / HD1500 (Haul Truck) Weight :N/A Kg

TITLE: TL Kit inc HRAFDrawn: B.D. Drawn Date: 12/12/2018

Dwg No: 07097 BOMPart No: TLKKOMeTL-2/4TL

TOLERANCES:LINEAR:


ANGULAR: = 0 50'



Material: mm - N/A

MACHINE KIT 830 & 930E 2-4 / HD1500

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Third Angle Projection



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REVISIONS


ItemNo. Qty. DESCRIPTION PartNo1 1 INPRESS TL4 Mount Assy (Vertical) TLKKOMe-5TL2 1 24V DC TL UNIT TL43 1 HEPA H13 Fresh Air Filter (inc TL Cap) TLF700EN

Manufacturer: Komatsu

A.C.N. 109 689 803 / A.B.N. 42 109 689 803All dimensions in mm U.N.O.

Model:830E-5 /930E-5 (Haul Truck) Weight :23.7 Kg

TITLE: INPRESS TL4 Mount Assy (Vertical)Drawn: B.D. Drawn Date: 07/03/2019

Dwg No: 08971 BOMPart No: TLKKOMe-5TL

Breathe Safe Pty Ltd., 290 Beatty Road Archerfield, Brisbane, Qld 4108 Tel: 07 3276 7833, Fax: 07 3276 8960, E-Mail: [email protected]

TOLERANCES:LINEAR:


ANGULAR: = 0 50'




MACHINE KIT 830 & 930E-5

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REVISIONS


ItemNo. Qty. DESCRIPTION PartNo1 1 Return Air Filter Assembly TQMDP089792 1 407 x 177 x 49 HEPA Filter Assy TQ4706410H

Manufacturer: Komatsu

A.C.N. 109 689 803 / A.B.N. 42 109 689 803All dimensions in mm U.N.O.

Model:830E-5 /930E-5 (Haul Truck) Weight :3.7 Kg

TITLE: Return Air Filter AssemblyDrawn: B.D. Drawn Date: 07/03/2019

Dwg No: 08979 BOMPart No: TQMDP08979 BOM

Breathe Safe Pty Ltd., 290 Beatty Road Archerfield, Brisbane, Qld 4108 Tel: 07 3276 7833, Fax: 07 3276 8960, E-Mail: [email protected]

TOLERANCES:LINEAR:


ANGULAR: = 0 50'




All Trucks HEPA Return Air Filter

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NOTE:

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.

PARTSLISTDigitalDisplay INPRESSTLINPRESS Cabin Pressure Monitor

INPRESSCabinPressureMonitor - TQUCPM INPRESS

PARTNUMBER DESCRIPTIONTQUCPM INPRESS INPRESSCabinPressureMonitor

TQ657005TQ657020 20 Amp Fuse - Motor

5 Amp Fuse - Controller

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TECHNICALDETAILS

PRESSURISERWIRING SCHEMATIC

INPRESS TL CABINAUTO PRESSUREMONITOR & 24V DC BRUSHLESS BLOWER MOTOR

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7500 Hours / 12 months*

Component / System Action Required

500 Hour Inspection All 500 hour inspection actions.

Pressurisers Blower TL4M Replace BRUSHLESS Pressuriser blower.

* unless extreme conditions or cabin pressure drops below 25 Pa

MAINTENANCE SCHEDULE

www.breathe-safe.comP: 1300 667 597

This Cabin is Fitted with Breathe SafeHEPA Grade Air Filtration & PressurisationSystem That ExceedsEN15695 To MinimiseYour Exposure to Harmful Airborne Dust

ProtectYOUR Lungs:Keep Door and WindowsClosed at All Times

ATTENTION!

Maintenance:•REPLACE FILTERS AFTER 500 HOURS ORWHEN CHECK LIGHT STAYS ON•WEAR RPE/PPE WHEN HANDLING OLD FILTERS•HEPA FILTERS CANNOT BE CLEANED

As above: replace filter and vacuum surrounds.HEPA ReturnAirFilterp/n TQ4701285165H

The following tables show are our suggested maintenance schedule

for all units. Please note that site conditions may alter this.

500 Hours*

Component / System Action Required

Turbo Pre-cleaner Check operation of the Turbo Pre-cleaner

Pressuriser Blower Ensure blower Is operational.

Replace HEPA filter elementVacuum out housing before replacing the filterelements.

Filter Frame Assembly, Mounts,Seals & Filter Housing.

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

HEPA Primary Filterp/n: TLF700EN

Activated carbon filter module and service kit.(When fitted - OPTION)

TQ47055400SCSO2(TQ470933 SERVICE KIT)

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Cabin PressuriserCOMMISSIONING PROCEDURES

WARNING: Qualified staff must wear the correct personalprotective equipment when cleaning and servicing this unitdue to hazardous dust and fibres which may be caught bythe stages of air filtration during normal unit operation.

The electrical power system is supplied by 12V DC or 24VDC and no work should be carried out on the pressurisersystem without the correct safe work procedures andelectrical safety measures being taken, and all relevantcircuit breakers opened to isolate the circuit.

The air filtration system may have several types of high-speed rotating equipment installed with very sharp edges.Ensure all safety guards are in place while the system isrunning.

Commissioning Steps

STEP 1.

Power up the pressuriser and ensure the fan or fans areoperating correctly.

STEP 2

Make sure the pressuriser switches on and off with theignition.

STEP 3

Using a manometer test the internal cabin pressure.

NOTE: The effectiveness of the Pressuriser isdependent on how well the cabin is sealed.

Effective cabin pressurisation is achieved with aminimum of 25Pa above ambient pressure. Werecommend 300 Pa from new.

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FAULT DIAGNOSISCabin Pressuriser

NOTE: This section is written on the assumption that thetradesperson is qualified in heavy-duty HVAC systems & has agood understanding of cabin fresh air filtration & cabinpressurisation.

They must have a good understanding of the operation of thesystem prior to fault diagnosis and repairs (If in doubt pleaseask).

Fault Pressuriser blower is not running

1. Check main circuit breaker or fused power supply. Make surethe motor is receiving the correct power supply with the ignitionon & engine running. - 24volts across the red & black wires(Turn on the HVAC fan to speed one)

2. Check that the In-cabin control unit is also receiving 24vacross pins 1 & pin 12 at the back of the control unit.

3. With the machine running open one of the doors or windows.Check the voltage on the yellow wire to the fan motor youshould have 10v (max speed) if it is not running then test theblower.

Testing of the brushless blower

1. To test the brushless blower - Disconnect it from the maincontrol loom (can only be tested when isolated).

2. Supply 24v DC to both the Red & Yellow wires on the motor.Connect the black wire to earth. The motor will now increasespeed to full RPM. If it does not increase speed to full RPM thenit is faulty.

Dust in the cabin - TESTING CABIN SEALING

1. Check filters are they serviceable - if in doubt removethem while testing.

2. Press & hold the down key on the controller for 10Seconds this will put the unit into test mode (10 volts willbe applied to the yellow wire forcing it onto high speed -maximum output)

3. Using a smoke bomb or a smoke machine inspect thecabin for leaks as you find & seal each leak check thepressure we recommend at least 100Pa of cabin pressurewith all the filters in place. Allow cabin sealants to cure ifthere are large leakages as overpressure will push throughthese. Test again and once you have achievedrecommended cabin air pressure you can reset thecontroller by pressing the speaker symbol for 2 seconds.

Note - Ensure all boot, bolts, hoses, cover panels &gaskets have been refitted after the last service/repair.

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- Please Do Not Scale -

BreatheSafe,290BeaČ

yRo

adArcherfield,Brisbane,Q

ld4108

Tel:07

3276

7833,Fax:

073276

8960

Rev:

Part No:

Dwg No:

1 of 1Date:

Title:

Weight:

BreatheSafe INPRESS General Arrangement

-

29/05/2014

0.96

03690-

Steve Johnstone

-

kgSheet No:

Date Printed / Copied:15 July 2014 All dimensions in mm

PROPRIETARY & CONFIDENTIALManufacture:BreatheSafe

E-Mail:[email protected]

TOLERANCESLINEAR : XX. = 1.50mm

XX.X = 0.75mmXX.XX = 0.25mm

ANGULAR : = 0 30'

(Unless Staded on Drawing)

The informaNon contained in this drawingis the sole property of Breathesafe Pty Ltd.Any reproducNon in part or as a whole is

prohibited without wriČen fromBreathesafe Pty Ltd.

Material:

Model

Drawn By:

INPRESS

©BR

EATH

ESAFE2014

INPRESS CONTROLLERSERVICE TEST MODE

SERVICETESTMODEHold down for 10seconds

CABIN SEALING TESTPROCEDURE1- Start Engine - Pressuriser is ON.2- Ensure all windows & doors are CLOSED correctly.3- Hold down button on INPRESS controller down for 10 seconds*This will force the blower motor onto MAX speed & still display the cabin Pressure.4- Photograph maximum cabin pressure and include it in the commissioning sheet report.

Notes: new cabin or a cabin with new seals:Open a window slightly before closing entrance door to vent static air pressure inside thecabin. When entrance door is fully closed then close the window to begin test.

** To exit ServiceTestMode presstheMute button for 2seconds

MUTEkey

SERVICE TEST MODE

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Users Guide

The Breathesafe INPRESS unit is a rugged industrial controller,specifically designed to monitor, record and intelligently controlthe cabin pressure inside a vehicle’s cab.

Efficient cabin air filtration and pressure management ensureharmful clouds of dust and toxic fumes, cannot ingress into thecab and be inhaled by the operators.

The controller has a built-in 14-bit digital pressure sensor thatcan accurately measure pressures between –250.0 and +250.0Pascals with repeatable accuracy.

An alarm setpoint can be set via the user keypad between therange of 0.0 and 100.0 Pascals. This feature can be accessed byentering the settings menu.

A red L.E.D. alarm, bright even in strong sunlight, is activated ifthe monitored pressure falls below a user adjustable set point.

Appropriate alarm descriptions are displayed on the backlit LCD,allowing effective system diagnostics.

Key Features

•Digital Cabin Pressure Monitoring System

•Data Logger with DAC Technology

•Intelligent Fan Speed Output

•Automatic Cabin Pressurisation

OPERATINGINSTRUCTIONSBreathesafe INPRESS

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Controller Appearance

REAR CONNECTIONS

This instrument has rear connectionsfor Power, Window Open, Door Open,Normally Open or Normally Closed VoltFree contacts for remote alarm monitoringand RS232 data logger download port.

ALARM MUTE BUTTONWhen an alarm is present, press thisbutton to mute the alarm. The redcheck LED will remain on whilst thealarm is present.

16X2 ALPHANUMERIC LCD DISPLAY L.E.D.BACK LIT

Displays actual cabin pressure in Pascals on the top lineand time and date or any alarms present on the bottomline.

BRIGHT L.E.D. ALARM

Illuminates when the cabin pressuredrops below the pre-set set point.Also if a door opens or a windowopens for more than a pre-set timeperiod.

UP BUTTON

This button is only used whensetting up the Breathesafe unit.When pressed it incrementsvalues.

DOWN BUTTON

This button is only usedwhen setting up theBreathesafe unit. Whenpressed it decrements avalue or exits a function.

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Low Pressure Alarm

If the cabin pressure falls below the pressure Set-point, thebright red alarm L.E.D. will illuminate. A description ofthe alarm trigger will be displayed on the LCD display tohelp with diagnostics.

An audible alarm (where fitted) further enhances this safetyfeature. The audible alarm may be muted at any time bypressing and holding the Mute button for 2 seconds.

The Mute button will become valid once all alarms havecleared and a new alarm is triggered.

Set-up Parameters

Placing the Breathesafe INPRESS unit into set-up modeallows the adjustment of the following parameters -

•Time (hours, minutes and seconds)

•Date (day, month, year)

•Pressure Alarm set-point

•Resetting of the data logging

•Calibration and system settings

Enter Set-up Mode

To enter the set-up mode, press and hold the Upand Down buttons simultaneously for approximately5 seconds.

Change Time & Date

Enter the Set-up mode. Use the Up and Down buttons tocycle to where the display asks - Change time? Yes orNo.

Press the Up button for Yes.


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The display will show the time on the top line and the dateon the bottom line. Press the Up button to increase thetime variable and press the Down button to skip to thenext time or date variable. Press the Mute button at anytime to exit this screen and enter the next function.

Change Set-point

Enter the Set-up mode. Use the Up and Down buttons tocycle to where the display asks - Change Set-point? Yes orNo.

Press the Up button for Yes.

The display will show the current pressure Alarm Set-point.Use the Up or Down keys to increase the pressurealarm value from 0.0 to 100.0 pascals.

Press the Mute button at any time to exit this screen andenter the next function.

Reset Data Log

Enter the Set-up mode. Use the Up and Down buttons tocycle to where the display asks - Reset Data Log? Yes orNo.

Press the Up button to reset the internal pointer back tothe beginning of the memory data area. The Breathesafe

INPRESS unit will start to data log from the firstmemory location once again.

Please note that this feature does not delete thepreviously recorded data but simply over-writes it. Pressthe Mute button at any time to exit this screen andenter the next function.

There are other parameters that can be adjusted but theseare password protected as they contain system settingsthat affect the calibration and system performance,therefore, they are not generally available to the end user.

Typical Breathesafe INPRESS installation


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Specification

Input voltage dc : 12.5 to 36V continuous operation (Regulator is automotive grade - protectedagainst 60V Load Dumps & -50V Reverse Power).

Protection : Protected against reverse power for an indefinite period of time. No fuses orcircuit breakers to replace or reset.

Current at 24Vdc : Normal operation no alarms = 0.04Amps - With alarms present = 0.08Amps

Display Resolution : 0.1 Pascal.

Operating Pressure : -250.0 to +250.0 Pascals linear.

Temperature range : 0 to 60 °C

Alarm Set point : 0.0 to 100.0 Pascals - Settable via the user keypad.

Input Pressure : 14 bits digital pressure sensor (Alarm 30 secs. on delay - 5 secs. of f delay).

Window Monitor : 12/24Vdc = Window closed - 0Vdc = Window open (Alarm 10 secs. delay - 5secs. off delay).

Door Monitor : 12/24Vdc = Door Closed - 0Vdc = Door open (Alarm 10 secs. on delay - 5secs. off delay).

Volt Free Output : N/O & N/C output relay - 125Vac/60Vdc 2A - Isolation between coil andcontacts 1000Vac.

Connections : Via 12 way Deutsch connector.

Dimensions : Fascia 187.5 x 58mm x 3.5mm thick machined aluminium - Depthapproximately 60mm without the connector.

Weight : 480 grams (16.9 ounces)

TECHNICALDETAILSBreathesafe INPRESS

Specifications

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1 2 3 4 5 6

12 11 10 8 7

- Please Do Not Scale -

BreatheSafe,290Bea�

yRo

adArcherfield,Brisbane,Q

ld4108

Tel:07

3276

7833,Fax:

073276

8960

Rev:

Part No:

Dwg No:

1 of 1Date:

Title:

Weight:

BreatheSafe INPRESS General Arrangement

- 0.96

03690-

-

kgSheet No:

03 June 2014Date Printed / Copied:

All dimensions in mm

PROPRIETARY & CONFIDENTIALManufacture:BreatheSafe

E-Mail:[email protected]

TOLERANCESLINEAR : XX. = 1.50mm

XX.X = 0.75mmXX.XX = 0.25mm

ANGULAR : = 0 30'

(Unless Staded on Drawing)

The informa�on contained in this drawing isthe sole property of Breathesafe Pty Ltd.Any reproduc�on in part or as a whole is

prohibited without wri�en fromBreathesafe Pty Ltd.

Material:

Model

Drawn By:

INPRESS

©BR

EATH

ESAFE2014

ITEM PIN DESIGNATION

1 Pin 1 12-24Vdc supply.

2 Pin 2

3 Pin 3

4 Pin 4

5 Pin 5 DAC output for fan speed control

6 Pin 6 Relay Common

7 Pin 7 Relay N/O

8 Pin 8 Relay N/C

10 Pin 10 DOOR +ve input

11 Pin 11 WINDOW +ve input

12 Pin 12 0Vdc supply


Connector Pin-Out Details

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Data Logging

By default, the Breathesafe INPRESS unit starts datalogging as soon as power is applied. This feature cannot bestopped or disabled.

Data logging records time, date, pressure reading, and anyalarms activated during operation.

Data Formats

BU No: xxxxxx (the device number unique to each unit andused for identification - format = 000000

Time [09:25]

Date [25/07/12]

Pressure 32.8 (Pascals) as an example.

Alarm type:

0 = no alarm

1 = low pressure alarm

2 = window open

3 = Door Open

Data Downloading

Stored data can only be downloaded using an RS232 portset to 57600 baud, 8-bit, Parity none, 1 stop bit and noflow control

The downloaded data is comma delimited and you canuse Excel for further processing. In Excel go to Data,Text to columns, selected Delimited, deselect all optionsapart from Comma and then select finish and the datawill automatically be placed into separate columns inExcel ready for use.

The data logging information can only be downloadedvia a terminal program like Tera Term for instance. Thisprogram is freeware and can be easily downloaded usingGoogle search. Download the program and run it on astandard computer.

Select serial for the communication and for the correctconnection parameters please see the previous pageunder DATA LOGGING. Go to the Setup menu andselect Window. In this section modify Scroll Buffer toshow 11000 lines and press Ok. You are now ready tostart downloading the logged data.

Ensure that a standard RS232 cable is connected to theRS232 port on the Breathesafe controller and enter thecapital letter ‘T’ on Tera Term and the download shouldautomatically start within two to


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three seconds.

The download will take approximately 1 minute and at theend, it will display ‘Done’ on the Breathesafe controller and‘End’ on the computer screen. Simply select all data andpaste on a standard Excel page and follow the settings asexplained above.

The downloaded data is not deleted. Data logging simplypauses during the download and resumes once thedownload has finished Saved data logs are not affected

When the internal memory is full the controller simplywraps around and over-writes the older logged information.

Fan Speed Control Output

The Breathesafe INPRESS unit has a 12-bit DAC (Digitalto Analogue Converter) output to automatically control thefan speeds to maintain a pre-set cabin pressure based on theBreathesafe unit’s alarm set-point.

In essence, the Breathesafe INPRESS unit monitors thecabin pressure as measured through its built-in pressuretransducer and calculates the error based on the pressureset-point. This value is applied to an algorithm and thecontroller calculates a proportional output which adjusts

the speed of the pressuriser motors.

The controller automatically adds an offset of 2.0Pascal’s to the alarm set-point and uses that value as thepressure set-point for fan speed control. If the alarm set-point is 25.0 Pascal’s, the unit will, in fact, try tomaintain 27.0 Pascal’s during normal running.

Remote Access

The controller can be accessed remotely for datadownloads using the 3G network. This feature requiresan on-going service provision with a network providerand is an additional cost.

With remote access, the logged data can be remotelydownloaded at any time so long as the BreathesafeINPRESS unit is powered up and within networkcoverage range.

Using a program such as Tera Term, describedpreviously, make the remote connection as TCP/IP andenter the IP address of the device including the pre-programmed TCP port number. Once connected to theremote device, enter the letter ‘T’ followed by the<Enter> key and the download will start within threeseconds.

To find out if you are connected to the BreathesafeINPRESS unit


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check the Tera Term taskbar for Connected or Disconnectedstatus.

We are able to provide at a cost, a remote access service forour Breathesafe INPRESS units which includes periodicdata downloads, data processing and analysis and provisionof the downloaded data in pdf format for future reference.

For further details on this feature please contact us.

Mounting Details

The unit is designed to be dashboard-mounted and utilizes aproprietary housing to secure the unit.

Mounting can be in any orientation, preferably internallyand positioned such that the operator can monitor the cabinpressure, ensuring his working environment is safe.

External Volt-Free Alarm Details

The Breathesafe INPRESS unit’s volt-free relay can be usedto connect back to an automated alarm system for remotemonitoring.

Alternatively, it can directly control a siren to warn thedriver of the low pressure or door/window open.

The alarm can be muted by pressing and holding theMute button for approximately 3 seconds. The Mutebutton will become valid once all alarms have clearedand a new alarm is triggered.

Supply Power

The Breathesafe INPRESS unit is designed to operate viathe vehicle’s ignition key-switch. The unit becomes fullyoperational approximately 5 seconds after turning theignition on.

Although fusing is not a requirement, it is advisable to fitan inline fuse rated at 5Amaximum for added protectionup to the unit’s connector. The unit is fully protectedagainst reverse power for an indefinite period of time

The operating voltage is in the range of 12.5 to 36Vdcand the power supply is designed specifically to operatein the harsh vehicle environments, which may includebattery jump starts and battery chargers.

The door and window digital inputs operate in the rangeof 12 to 24Vdc commensurate with the vehicle’s powersupply.


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Calibration

The Breathesafe INPRESS controller is fully digital andshould not require further calibration or set up. The unitbecomes fully operational approximately 5 seconds afterbeing switched on.

For added peace of mind, if you suspect that your unit hassuffered a severe physical shock, please return it back to fora full inspection and calibration check

Please do not attempt to open this unit and tamper with it asthere are no user serviceable parts inside and you may causeit irreparable damage in the process.

Data Logging Schedule

The Breathesafe INPRESS controller is designed to startData Logging as soon as it is powered up. Data samples aretaken and recorded every 15 minutes with time, date andcurrent pressure readings. This is additional to normal alarmlogging which occurs at every alarm instance.

The unit is designed to log over 10500 instances in itsinternal memory. The memory is not battery dependent andcan retain data for up to 10 years. Under normal operation,the controller logs four

samples every hour. Based on a 24-hour operation andwith no alarms the controller can record over 3.5 months’worth of data.

This period is shortened if the Breathesafe Ultra unitexperiences many alarms throughout each day. Based onan additional 10 alarms per day, the Breathesafe Ultracontroller can still, log over 3.4 months’ worth of data.

When the data logger’s memory is full it returns to thebeginning and over-writes previously recorded data in anendless loop. It is therefore very important that the data isdownloaded every two months as required *, to ensurethat there is no loss of important information.

Breathesafe can offer this service and peace of mind at avery affordable monthly charge **.

Please contact us for more information.

* The two months is an estimation only based on averageusage to ensure data is not over-written.

** This service can only be provided where there is3G/4G mobile data network coverage and the Breathesafeunit is powered up.

Vehicle Management Systems (VMS) integration can bedeveloped to report alarms and cabin pressure.


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WARRANTY

Breathesafe Product Range WarrantyWe warrant all goods to be of good material and workmanship and will replace at our Queensland factory ordesignated service branch*, any part proved to be defective in workmanship or material within a period of twelve(I2) months from the date of commissioning or thirteen (13) months from the date of despatched from the factorywhichever occurs first.

*Note - Systems must be maintained by trained & qualified personnel.

The customer should ensure that the system is maintained according to TRACS Qld service requirements and onlyGenuine parts must be used to service & maintain these systems.

Excluded from any express warranty are costs incurred in relation to service outside our factory or designatedservice branch including traveling time, waiting time, transport costs, mechanical, and overtime payments required.

This warranty does not cover damage caused by or through the fusion of the electric motors caused by the failureof electric overload protection devices, even where such motors or devices form part of the equipment supplied byus.

Interference with the equipment by or abuse, or by operating the equipment at ambient temperatures or withelectrical power characteristics outside the ranges indicated in our specification shall be excluded from thiswarranty, as shall consequential damages.

In the event of a suspected warranty claim, TRACS Qld should be contacted in the first instance to arrange therepair or to assist with diagnosis. Claims should be made within one month of the repair.

All parts deemed as failed or faulty must be returned to TRACS for evaluation unless otherwise stated in writing.

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CONTACTUS

Phone:+61 7 3276 7833

Fax:+61 7 3276 8960

290 Beatty Road,Archerfield QLD4108

169 ChisholmCrescent,

Kewdale WA 6105

Breathe Safe HQ

From within Australia call:1300 667 597

email:[email protected]

Breathe-Safe is an Australian owned and operated company promoting Australian products.

Breathe Safe WA

NORTHAMERICADISTRIBUTOR:INTERNATIONAL SERVICE & SUPPLY

10740 181 STREET NWEDMONTONALBERTAwww.issminesafety.com

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