High Pressure Filtration Systems
We design high-pressure cabin air filtration systems that provide machine operators, maintenance staff, and machines optimal protection. Our systems exceed air quality requirements for machines working in the harshest of environments. Our products are proven to reduce maintenance costs through efficient design and are reliable and effective, and are trusted by customers worldwide such as BHP, Rio Tinto, Glencore, Yancoal, Boral, and more.
Our customisation means it lasts longer, works more efficiently and increases the machine’s lifespan.
Every BreatheSafe High Pressure Air Filtration System includes 6 components to create the cleanest, dust-free environment
Cat High Voltage Electrical Enclosure Cabinet INPRESS
BreatheSafe system on cleanroom
Caterpillar 305E Excavator BreatheSafe
BreatheSafe TL High Pressure Pressuriser Unit
Minimise Maintenence Costs
The BreatheSafe system will extend the lifespan of the machine installed by minimising electronic exposure to dust.
It will also minimise the stand-down time for cleaning.
Maximise Air Filtration Efficiency
The TL achieves maximum air filtration efficiency by minimising the volume of air through the filter through its variable speed brushless motor (NASA, 2016).
It can keep the lowest blower speed and volume passing through the filter while maintaining cabin pressure due to the INPRESS monitor controller.
Cleanest Air with HEPA H14 Filters
The TL system targets all dust, both inhalable and respirable, which is below 1 micron in size. To remove these, we use long-life and durable HEPA H14 filters tested individually and serial numbered after manufacture (as per EN1822) at a minimum efficiency of 99.97% of particles in the 0.3-micron range.
EN1822 is the European Standard for air filters used in cleanrooms for pharma and electronics manufacturing.
Also available U15 and U16.
Safe and easy filter change with Twist Lock (TL)
BreatheSafe HEPA filters are easily replaced when full through the BreatheSafe Twist Lock system; no tools required. Twist the filter compartment on the TL unit and carefully pull it directly out. Replace with entire new compartment and dispose of dirty filter appropriately.
While the Twist Lock mechanism is designed to increase safety when changing filters easily, our philosophy at BreatheSafe is to take all measures to remain safe.
Wear PPE when changing filters for complete protection.
Zero exposure is the only way to guarantee zero harm.
Because the TL can run at a low blower speed due to the brushless motor, it runs at a much lower noise level than other units in the market.
Enginaire TURBO Precleaner
The integrated Enginaire Precleaner functions to remove up to 90% of larger airborne particles from the system's incoming air.
Activated Carbon Filter
Optional ancillary solid core type activated carbon filters remove particulates, harmful gases, and odours from the air stream. To remove these gases and odours, we use an extra filtration stage containing Activated Carbon.
Activated carbon is charcoal impregnated with various chemicals. When gas goes through it, gas particles react with the carbon-impregnated chemicals and form a stable harmless salt.
Another HEPA filter is placed at the air's exit from the activated carbon filter to prevent salts or carbon molecules from entering the clean air area
The TL has long-life brushless motors with variable blower speed functions. This prevents the unit from running at unnecessarily high speeds, extending the lifespan of the motor. The brushless motor is designed for extreme environments from -50°C to +75°C temperatures.
INPRESS Auto Pressure Control
The INPRESS is the monitor controller of the BreatheSafe system.
Automated control of the pressure inside the clean air area through the INPRESS integrated cabin pressure monitor. Pressure is controlled by DAC feed to TL brushless motor, allowing the system to maintain a preset cabin pressure while extending the lifespan of both motor and filter.
Automatic Pressure Monitor
The BreatheSafe INPRESS automatically controls the blower speeds to maintain preset cabin pressure. It does this by monitoring the pressure through its built-in pressure transducer.
Industry minimum standard is between 20 and 50 Pa from new. Our systems are preset to remain at 20 Pa but can be changed through system settings.
The INPRESS measures the pressure inside and outside the clean air compartment and calculates the error based on the pressure setpoint. An algorithm applies these values, and the controller calculates a proportional output that adjusts the speed of the pressuriser motors.
The controller automatically adds an offset of 2.0 Pa to the alarm setpoint and uses that value as the pressure setpoint for fan speed control. If the alarm setpoint is 25.0 Pa, the unit will maintain 27.0 Pa during regular running.
The BreatheSafe INPRESS automatically sounds alarms at pressure drops, alerting the operator to the potential of hazardous air.
Optionally, the unit can distinguish if a door or window is not sealed correctly and alert the operator. At the same time as this alert is sounding, the blower power will increase to keep the operator as safe as possible.
Automatic Data Logging
The BreatheSafe INPRESS automatically records and stores up to 10 – 12 months worth of data, depending on sampling requirements.
The controller is designed to start data logging as soon as it is powered up. Data samples are taken and recorded every 60 minutes with time, date and current pressure readings. This is additional to standard alarm logging, which occurs at every alarm instance.
Service Test Mode
Service test mode to assist with cabin sealing effectiveness and filter capacity tests.
HEPA Return Air Filter (HRAF)
NIOSH (2012) reported a greater than 10-fold protection factor increase when using a high efficiency return air filter. This is now essential for meeting the decay time requirements for ISO23875.
The intake is situated close to operators feet to generate a low pressure area drawing the airborne particulate that has been dislogged from clothes and boots. It continually refilters the air, blending with fresh air before passing through the HVAC system and into the breathing zone. Our powered automated system ensures effective reduction in decay time.
See example: Hitachi EX5600-7 with three HRAF installed in back of cabin behind operators.
According to NIOSH, effectively sealing an enclosure has a significant positive impact on reaching pressurisation and achieving dust decay time requirements. This will increase HEPA filter service life and optimise pressurisation efficiency by reducing cabin leaks.
Customised sealing kits for each machine are provided to be installed by experienced service personnel. Use the INPRESS controller service test mode to force the system into maximum pressure mode. The higher the pressure achievable during this test will indicate cabin sealing effectiveness.
The common areas to restore/upgrade are door seals, floor gaps, window seals, frames, and any other places where the HVAC system leaks.
See example: Caterpillar 793D Haul Truck with customised nose cone for effective sealing of cabin.
When mounting a High Pressure Air Filtration system, it is vital to maintain the machine's integrity. Therefore BreatheSafe recommends avoiding cutting or bolting into the machine. We aim to use the pre-existing lifting points available.
However, each machine is different, and our experts can find solutions around additional mounting requirements or other auxiliary equipment. Our experienced metalworkers create custom high-quality metal mounting systems made from mild steel. Each piece is primed and top coated in powder coating for protection.
As standard, we use 3-inch diameter ducting for the most efficient airflow. The more effective an enclosure is sealed, the smaller this can be. We design for the requirements of each vehicle and can work around tricky areas required for ducting.
Something new is always on the horizon at BreatheSafe
We are dedicated to innovation in technology to
protect workers and machinery.
Our systems can be customised for any machine and any environment
Nanozen dust monitors