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Product Trials

Real Trials. Real Results. Real Improvements.

Komatsu 830E HV Cabinet

Eliminating Dust Exposure & Reducing HV Cabinet Maintenance

HV cabinets on the Komatsu 830E use unfiltered alternator fan air to cool inverters, allowing mine dust to build up inside. This required frequent cleaning—typically every 500 hours—which exposed maintenance staff to respirable dust like crystalline silica and increased the risk of electrical faults.

To address this, BreatheSafe partnered with a customer to develop a sealed, pressurised filtration solution that eliminates the need for cabinet cleaning and reduces dust exposure to zero.

Identified Problems

  • Risk of silicosis and other lung diseases from respirable dust exposure

  • Dust entering via unsealed duct seams and degraded gaskets

  • Use of unfiltered air from alternator fan to cool inverters

  • Manual cleaning required every 500 hours

  • High risk to worker health and system reliability

Designed Solution

  • Pre-cleaned cabinets prior to installation

  • Installed 3 x High Pressure TL units on the Main HV cabinet

  • 1 x High Pressure TL unit fitted to the Arc Shoe cabinet

  • Integrated HEPA H14 filters with variable-speed pressurisation

  • Max static pressure (engine off): 1200 Pa

  • Auto setpoint: Maintains 400 Pa above OEM fan output

  • TL units create positive pressure to prevent dust ingress

  • Seamlessly integrated into HV cabinets—no structural modification required

Achievements and Outcomes

  • No cleaning required since installation—zero compressed air use

  • Cabinet dust load remains significantly reduced

  • Internal temps stable and aligned with ambient conditions

  • Components and wiring remain clean and clearly visible

  • Extended component life due to minimised static dust

  • Reduced downtime and maintenance costs

  • System inspected at 1,000 / 1,500 / 2,230 / 2,800 hours—still using original filters

  • After 3,715 hours, system runs at 57% fan load with no loss in sealing efficiency

  • Max pressure dropped 390 Pa, maintaining 810 Pa—well within spec based on door seals and voltage

Caterpillar 793F Autonomous Cabinet

Dust, Heat & Moisture Control in Electrical Cabinets

In 2018, BHP approached BreatheSafe to address airborne mine dust and heat issues inside the electrical cabinets of their Caterpillar 793F Autonomous Trucks. The dust was corroding electrical components, raising safety and performance concerns. The objective was to develop a sealed cabinet enclosure that would protect internal components from dust, water ingress, and temperature spikes, ensuring long-term reliability and reduced maintenance.

Identified Problems

  • Dust ingress caused by airborne particulates led to build-up inside electrical cabinets, increasing the risk of corrosion and system faults.

  • Abrasive particles inside the cabinet degrade seals, cables, and surfaces made of various materials.

  • Enclosure heat retention caused internal cabinet temperatures to exceed 40–50°C, negatively impacting the lifespan of components.

  • OEM cabinet design featured a small access door, making maintenance difficult and increasing technician exposure to hazards.

Designed Solution

BreatheSafe developed a custom-designed insulated cabinet enclosure, equipped with:

  • HEPA-filtered pressurisation

  • Temperature monitoring sensors

  • Active cooling system

  • Large easy-access service door

Key Features:

  • Maintains dust-free cabinet environment

  • Reduces component wear and electrical failure risk

  • Maintains internal temp below 50°C with active cooling

  • Automatic Pressure Control ensures constant positive pressure

  • Live remote monitoring of pressure and temperature

  • Brushless electrical fan motor for long-term performance

  • No tools required for filter changes or servicing

  • Fully sealed and insulated with OEM system compatibility

Achievements & Outcomes

  • Effective control of airborne dust and heat inside cabinets

  • Pressuriser activates as soon as temp exceeds 45°C, maintaining internal air cleanliness and temperature

  • Remote monitoring has helped optimize maintenance scheduling

  • Positive pressure is consistently maintained—even as vehicle speed changes or engine airflow varies

  • Extended HEPA filter life despite high-dust operating conditions

  • Improved accessibility and safety during servicing

  • Based on trial success, BHP has placed additional orders to convert more autonomous truck fleets to BreatheSafe systems

Hi, Phil Atley from Komatsu Australia, my role with the company is National Construction Grader Product Manager & National Government Business Manager. In this role I have requested the Breathesafe (formerly Tracs) team to work with me over a long period of time to provide air conditioning solutions for machines working in the most severe of applications, all around Australia & New Zealand. In my experience Nick & the team listen to what you are telling them what is the issue, promptly come back with a suggested solution, we negotiate specification, quoted price is supplied, the work and equipment supplied is cost effective and of a very high standard. We are receiving very positive feedback from our customers & end users about the BreatheSafe equipment fitted.

I recommend Nick and the team as mobile air-conditioning engineering solution company.

Phil Atley

National Government Business Manager., Komatsu

G’day, Peter Vansittart from Komatsu Australia. I have been involved in the mobile plant/ construction equipment business all my working life and at 62 years old that’s a while. With Komatsu Australia I am a National Product Manager responsible for construction bulldozers and special applications. I find solutions for many customer applications inside and outside main stream and maintain Komatsu engineering compliance.

While I have been working in this field for many years and with different air system suppliers I find that Nick and the team at BreatheSafe give great support and dedication. This leads to safe/compliant/efficient/cost effective products that are well backed up leading to satisfied customers. This is the acid test.

I have no hesitation in recommending the BreatheSafe organisation to assist with your mobile air system solution. 

Peter Vansittart

National Product Manager, Komatsu

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