Komatsu Breathesafe WA900-3EO Installation Overview
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Komatsu Breathesafe WA900-3EO Installation Overview

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Controlled document
:
Revision:
Issue date
:
WA900
Page
1
Manufacturer KOMATSU
Serial Number 60348
Cabin Pressure Max 253Pa
Set Auto Cabin Pressure 50
Key Modules High Capacity Pressuriser - HEPA H13 FRESH AIR INTAKE
www.breathe-safe.com.au
INSTALLATION OVERVIEW
Type W H E E L L O A D E R
Model WA900-3EO
Site ROBE RIVER IRON ASSOCIATES
INPRESS Cabin Pressure Monitoring & Display
HEPA Return Air filter - RECIRCULATION AIR INTAKE
HVAC SYSTEM UPGRADE

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  • Page 1 Controlled document Revision: WA900 Issue date INSTALLATION OVERVIEW Manufacturer KOMATSU Type W H E E L L O A D E R Model WA900-3EO Site ROBE RIVER IRON ASSOCIATES Serial Number 60348 Cabin Pressure Max 253Pa Set Auto Cabin Pressure 50 Key Modules High Capacity Pressuriser - HEPA H13 FRESH AIR INTAKE INPRESS Cabin Pressure Monitoring &...

  • Page 2: Safety First

    Controlled document Revision: WA900-3EO Issue date SAFETY FIRST Warning, Safety First! The air conditioning system described in this manual has the following areas, which may be dangerous if not treated with great care. Wear correct personal protective equipment when cleaning and servicing this unit due to hazardous fibres which may be caught by all stages of filtration during regular unit operation.
  • Page 3 Controlled document Revision: WA900-3EO Issue date OVERVIEW 1. Dirty, hazardous air enters the filter assembly 7. A variable speed centrifugal air pump generates 12. The Breathesafe INPRESS unit monitors the 16. Typically the processor can save up to 3.5 months through angled veins.
  • Page 4 Controlled document Revision: WA900-3EO Issue date PRESSURISER CRITICAL PARTS INPRESS TL PRESSURISER 24V Item Part Number Qty. Descrip�on Service Interval 500 - 1000 Hours TLF700EN Fresh Air HEPA H13 Filter TESTED AS PER EN1822 Cabin HEPA RETURN AIR FILTER 500 - 1000 Hours TQ47010320H TL4M Brushless Blower motor - INPRESS TL...

  • Page 5: Automatic Controls

    Controlled document Revision: WA900-3EO Issue date AIR CONDITIONING SYSTEM CONSTRUCTION Cases are fabricated from COILS heavy gauge zinc plated steel. 100% Powder coat finish as standard. Heat exchangers are of heavy gauge copper o r All wetted surfaces a l u m i n i u m t u b e ar e lin ed w ith a combin ation s ound deadening and a n d a l u m i n i u m f i n condensate preventative compound.

  • Page 6: Performance Specifications

    Controlled document Revision: WA900-3EO Issue date AIR CONDITIONING TECHNICAL DATA PERFORMANCE SPECIFICATIONS Cooling Capacity 7.0 kW Evaporator Air On Temperature C DB / 19 C WB Suction Temperature Ambient Temperature Refrigerant R134a Total Refrigerant Charge 2.2kgs THERMOSTAT The electronic thermostat controls return air temperature and coil te m p e ra tu re .
  • Page 7 Controlled document Revision: WA900-3EO Issue date OVERVIEW PRINCIPALS OF AIR CONDITIONING An air conditioning unit operates on a num- kind of latent heat is known as the la- tent heat same principle applies to all vapours. ber of different principles. Following is a brief of fusion (which means melting).

  • Page 8: Air Circuit

    Controlled document Revision: WA900-3EO Issue date OVERVIEW PRINCIPALS OF AIR CONDITIONING The components, which combine to make up and drawn through the top of the condenser and then flows to the receiver drier. the air conditioning system, are in four different discharged over the condenser coil.

  • Page 9: Heating Circuit

    Controlled document Revision: WA900-3EO Issue date OVERVIEW PRINCIPALS OF AIR CONDITIONING 4. Evaporator Coil refrigerant flow is not desired or when a from the rest of the system is desired. malfunction develops within the system. Operation of the compressor with the The evaporator coil is constructed from valve in this position will result in severe copper tubing, through which passes...
  • Page 10 Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS BREATHESAFE AIR CONDITIONING CONTROL - TQ6301-4 1. Controller Appearance Item Description Power switch Power indicator Fan motor indicator Cooling indicator PET cover Fan speed regulation Temp setting regulation IMPORTANT The air conditioning system must be run for a minimum of five minutes each week regardless of the season to lubricate the system and prevent damage to the seals.
  • Page 11 Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS 2. Plugging & Unplugging 3. Wiring IMPORTANT The electrical power system is supplied by 12v Connector A dc or 24v dc. No work should be carried out on the system 1.
  • Page 12 Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS 4. Technical Specification NOTES Rated Voltage : DC24V (DC19V~ DC32V) These outputs are effective at high level (positive). Ambient temperature : - 30 C / +80 : 5% / 95%RH non-condensing Setting temp.

  • Page 13: Power Switch

    Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS 5. Operation Instruction AIR VOLUME REGULATION POWER SWITCH Turning knob MIN, Pressing the switch to “ON”, decreases the air volume to turns the controller and system 15%. The voltage output is 1.6V and the fan motor runs at 600RPM, Pressing the switch to “OFF”,...
  • Page 14 Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS 6. Start up Procedure 8. Defrost Function With the engine running, pressing the Power Switch (1) to the “ON” The Controllers defrost sensor value operates as follows - position starts the Air Conditioning System. If the Defrost sensor temperature measures ≤...

  • Page 15: Service Intervals

    Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS SERVICE INTERVALS MAINTENANCE SCHEDULE DAILY INSPECTION Air conditioning Component / System Inspection Required Return air filters Check for cleanliness and deterioration. IMPORTANT Refrigeration hoses. Check for damage or deterioration. The air conditioning system must be run for a minimum of Fresh air filtration.
  • Page 16 Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS SERVICE INTERVALS THREE MONTHLY INSPECTION TWELVE MONTHLY OR 2000 HOURS INSPECTION Component / System Inspection Required Component / System Inspection Required Condenser coil. Check refrigeration connections against leakage. Compressor Check compressor belts for wear, tightness and align- Check coil support bolts.
  • Page 17 Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS SERVICE INTERVALS MAINTENANCE SCHEDULE - Pressuriser DAILY INSPECTION Component / System Inspection Required Pre-cleaner - Dust Bowl If fitted with a Dust Bowl Pre-cleaner, remove from the pressuriser unit, clean and refit. MONTHLY INSPECTION Component / System Inspection Required...

  • Page 18: Component Maintenance

    Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS COMPONENT MAINTENANCE 1. REPLENISHING REFRIGERANT and discharge pressure. Add more refrigerant should flashing occur. “Flashing” in the liquid line sight glass of a previously charged 8. On completion of the replenishment, tightly backseat the suction system indicates an inadequate charge of refrigerant and service valve and remove the charging line.

  • Page 19: Fan Blades

    Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS COMPONENT MAINTENANCE 4. FAN BLADES 6. RECEIVER DRIER / INLINE DRIER Check the fan blades for wear or damage. Check that blades are This is a fully sealed, non-serviceable component which should be tight on motor shaft.

  • Page 20: Thermal Expansion Valve

    Controlled document Revision: WA900-3EO Issue date OPERATING INSTRUCTIONS COMPONENT MAINTENANCE 9. THERMAL EXPANSION VALVE 10. COMPRESSOR This valve is factory set to provide the correct balance of pressure For compressor service refer to relevant manufactures service and temperature at the evaporator. manuals.

  • Page 21: Technical Details

    Controlled document Revision: WA900-3EO Issue date TECHNICAL DETAILS Coil Aluminium Fin, Copper Tube Condenser Coil complete with anti-corrosive powder coat finish. Capacity Fans 2 x Brushless EBM Axil Fan Motors. Voltage Current draw 5 amps (peek) per fan, 10 amps (peek) total Air Flow 1920 m3/h (per fan).
  • Page 22 Controlled document Revision: WA900-3EO Issue date TECHNICAL DETAILS - Please Do Not Scale - Date Printed / Copied: 08 September 2014 All dimensions in mm Item Description Part No. Heavy Duty Cam Latch TQ702002 04606 Door Assembly DP04606 Axial Fan - Brushless TQ370499 03048 Fan Mounting Assembly DP03048...
  • Page 23 Controlled document Revision: WA900-3EO Issue date TECHNICAL DETAILS - Please Do Not Scale - Date Printed / Copied: 08 September 2014 All dimensions in mm 1180 110° 1180 Dwg No: Rev: TOLERANCES Title: Third Angle Projection PROPRIETARY & CONFIDENTIAL 04600 Mk2 8Kw Deck Mounted Condenser Kit - Brushless The informa�on contained in this drawing is LINEAR :...
  • Page 24 TX Valve UE016 De-Ice Thermostat SM04754 Drain Pan Assembly Title: Evaporator Parts List Dwg No: Rev: Third Angle Projection 04750 KOMATSU WA900 Evaporator Kit SM04760 Blower Box - LH Model: Manufacture: Part No: Proprietary & WA900 KOMATSU Confiden�al Material: Weight: Sheet No: The informa�on contained...
  • Page 25 Controlled document Revision: WA900-3EO Issue date TECHNICAL DETAILS Remove ALL weld spatter, burrs / sharp edges. ALL edges to be rounded R1mm prior to powdercoating . Dress welds for good appearance. Item PartNo Qty. DESCRIPTION Cover & Rotor Assy TQP99999HOOD Injector Ring TQP99999RINGS INPRESS Fan Blade...
  • Page 26 Third Angle Projection Title: Dwg No: Rev: Pressuriser & Filter Parts Lis�ng Part No: Model: Manufacture: Proprietary & PC 4000 KOMATSU Confiden�al Material: Weight: Sheet No: The informa�on contained in this drawing is the sole 24.68 1 of 1 As Detailed property of TRACS QLD Ltd.
  • Page 27 Controlled document Revision: WA900-3EO Issue date COMMISSIONING COMMISSIONING System Evacuation for further details). using sheet metal or cardboard to raise discharge pressure to nominal 820 kPa (120 STEP 3 Psi). Turn the thermostat to its coldest setting: run STEP 8 the engine at fast idling speed and charge To provide adequate compressor cooling the system;...
  • Page 28 Controlled document Revision: WA900-3EO Issue date COMMISSIONING COMMISSIONING NITROGEN LEAK TESTING 2. Set the cylinder reducing valve to 1035 kPa (150 psig) General Instructions 3. Open the nitrogen cylinder shut-off valve and charge the plant up to a test pressure of 1035 kPa (150 psig). 4.

  • Page 29: System Evacuation

    Controlled document Revision: WA900-3EO Issue date COMMISSIONING COMMISSIONING SYSTEM EVACUATION - Overview A moisture free refrigerant system is essential for the correct functioning of the unit. Moisture can cause freezing and blockage at control points, etc, or the formation of hydrochloric acid when in contact with refrigerant, with detrimental effects upon valves, bearings, seals, etc.
  • Page 30 Controlled document Revision: WA900-3EO Issue date COMMISSIONING COMMISSIONING SYSTEM EVACUATION - General Instructions To correctly evacuate the system proceed as follows:- 1. Check the compressor suction and discharge service valves are both open, ie. midway between being fully front-seated or fully back-seated. 2.
  • Page 31 Controlled document Revision: WA900-3EO Issue date COMMISSIONING COMMISSIONING SYSTEM CHARGING - Overview To correctly charge the system refer to diagram below and proceed as detailed in the Systems Charging section. The charging operation should be performed at air temperatures of C and above.
  • Page 32 Controlled document Revision: WA900-3EO Issue date COMMISSIONING COMMISSIONING SYSTEM CHARGING - General Instructions engine. 10. Test the complete system for leaks, especially around hose con- 1. Install gauge set and purge hose if a partial charge is to be nections. added.
  • Page 33 Controlled document Revision: WA900-3EO Issue date COMMISSIONING COMMISSIONING PRESSURISER COMMISSIONING STEPS WARNING: Wear correct personal protective equipment when cleaning and servicing this unit due to hazardous fibres which may be caught by all stages of filtration during normal unit operation. The electrical power system is supplied by 12v dc or 24v dc.
  • Page 34 Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS FAULT DIAGNOSIS OVERVIEW FAULT DIAGNOSIS DISCHARGE - SUCTION TABLE SIGHT GLASS INDICATOR TABLE Our flowcharts are included as an aid in Indicates that the system COMPRESSOR trouble shooting the air conditioning system has correct refrigerant should it develop a fault.

  • Page 35: Fault Diagnosis

    Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS Symptoms Causes Solutions System Produces System too low on Locate leak & repair. No Cooling Bubbles in the sight glass. refrigerant due to slow Evacuate & charge system. leak. TX Valve jammed shut. Replace TX Valve.
  • Page 36 Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS Symptoms Causes Solutions System Only Partially Cools Faulty Condenser fan. Investigate & rectify cause. Blocked Condenser coil. Clean as necessary. Sluggish or faulty Remove fan for service or Evaporator fan motor. replacement. Suction gauge high.
  • Page 37 Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS Symptoms Causes Solutions System Cools Intermittently Electrical components Defective circuit breaker, Remove defective part for operate intermittently. fan switch or motor. service or replacement. Clutch disengages Improper ground, loose Check connections or prematurely during connection in clutch coil.
  • Page 38 Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS Symptoms Causes Solutions System Is Excessively Noisy Idler pulley whines or growls. Pulley has rough Worn bearings. Replace pulley bearing spots when rotated by hand. Defective coil winding. Repair or replace as Clutch vibrates –...
  • Page 39 Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS FAULT ANALYSIS CHART NOTES 1. CLOGGED STRAINER OR FILTER 4. POWER ELEMENT 6. THERMAL EXPANSION VALVE TOO LARGE Occasionally the strainer or filter in the liquid The power element of an expansion valve line may become clogged with foreign mate- consists of the thermal bulb, capillary tube If a replacement thermal expansion valve has...
  • Page 40 Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS FAULT ANALYSIS CHART NOTES 7. THERMAL EXPANSION VALVE TOO 9. SHORTAGE OF REFRIGERANT ture at which the vapour is condensing. SMALL A shortage of refrigerant will be initially indi- In extreme cases, the pressure may rise to a If the replacement thermal expansion valve is cated by bubbles in the sight glass.
  • Page 41 Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS FAULT ANALYSIS CHART NOTES 13. FAULT DIAGNOSIS FOR ELECTRONIC THERMOSTAT 15. ELECTRONIC THERMOSTAT FAULT FINDING Refer to the Electrical Schematic Drawing for the controller. COMPLAINT POSSIBLE CAUSE REMEDY As this is a fully sealed item it cannot be field checked for correct Continuously operates in Potentiometer control Repair lead.

  • Page 42: System Electrical Schematic

    LINEAR : = 1.50mm Model Manufacture: Part No: the sole property of Breathesafe Pty Ltd. XX.X = 0.75mm WA900 KOMATSU XX.XX = 0.25mm Material: Weight: Sheet No: Any reproduc�on in part or as a whole is 0.00 1 of 1...

  • Page 43: Poor Performance

    Controlled document Revision: WA900-3EO Issue date FAULT DIAGNOSIS FAULT DIAGNOSIS - PRESSURISER FAULT DIAGNOSIS - PRESSURISER DUST IN CABIN 1. Check all cabin seals and test to ensure positive cabin pressuri- NOTE: This section is written on the assumption sation is been achieved, and maintained at a minimum of 25Pa that the service mechanic is a qualified trades above ambient pressure.

  • Page 44: Warranty

    Controlled document Revision: WA900-3EO Issue date WARRANTY Breathesafe Product Range Warranty We warrant all goods to be of good material and workmanship and will replace at our Queensland factory or designated 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 factory whichever occurs first.
  • Page 45 Controlled document Revision: WA900-3EO Issue date CONTACT US Breathe Safe HQ 37 Argon Street Carole Park Qld 4300 Breathe Safe WA 169 Chisholm Crescent, Kewdale WA 6105 Phone: +61 7 3276 7833 Fax: +61 7 3276 8960 From within Australia call: 1300 667 597 email: sales@breathe-safe.com...

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