BreatheSafe HYUNDAI 757-7 Parts And Service Manual

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Kit Part Number: 700255

+61 7 3276 7833

www.breathe-safe.com.au

sales@breathe-safe.com

62 Mica Street, Carole Park, 4300, QLD

Parts and Service Manual

HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter

HYUNDAI

757-7 LOADER

Controlled Document: M0201

Issue Date: 11/10/23

Revision: 1

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Summary of Contents for BreatheSafe HYUNDAI 757-7

Page 1 Kit Part Number: 700255 Parts and Service Manual HYUNDAI 757-7 LOADER HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter +61 7 3276 7833 www.breathe-safe.com.au Controlled Document: M0201 sales@breathe-safe.com Issue Date: 11/10/23 62 Mica Street, Carole Park, 4300, QLD Revision: 1...
Page 2: Table Of Contents
HYUNDAI 757-7 Loader INSTALLATION INSTALLATION OVERVIEW Manufacturer Hyundai CONTENTS Type Loader Model 757-7 Installation ........1 Cabin Pressure Max Safety ........... 2 Set Auto Cabin Pressure Critical Parts & Maintenance Schedule ........3 Operator Guide ......4 Specifications - Pressuriser .... 5 Parts List ........
Page 3: Safety
HYUNDAI 757-7 Loader SAFETY WARNING Particulate Behaviour THE PRESSURISATION SYSTEM DESCRIBED IN THIS MANUAL HAS THE FOLLOWING AREAS WHICH MAY BE DANGEROUS IF NOT TREATED WITH This is the length of time it takes for a particle to drop from a height GREAT CARE.
Page 4: Critical Parts & Maintenance Schedule
Brushless Blower Motor – 24V 500 Hours 200002 15,000 Hours Inspect every and replace when filter is full* BreatheSafe Digital Display – Data Component / System Action Required 200027 Recorder (INPRESS TS) Turbo Pre-cleaner Check operation of the Turbo Pre- Cleaner.
Page 5: Operator Guide
>> There is no further action required << NORMAL OPERATING CONDITION Cab Air Conditioning BreatheSafe recommends OEM air conditioning fan is set at mid speed or greater to circulate air around the breathing zone and minimise CO₂. Acceptable operating range for BreatheSafe fan 10-80%. >80% recommend maintenance.
Page 6: Specifications - Pressuriser
Pre-cleaner : Integrated VLR (Very Low Restriction). Turbo Pre-Cleaner. HEPA Return Air Filter HRAF Filter Element : BreatheSafe HEPA Primary Filter (H14=99.99% MPPS) TESTED AS HVAC Heating Ventilation and Air Conditioning PER EN1822 – P/N 500000. Mass Air Flow Original Equipment Manufacturer Plugs &...
Page 7 HYUNDAI 757-7 Loader Item No. Qty. Description Part No. PARTS LIST – TL4 24V DC PRESSURISER UNIT Pre-cleaner Hood & Rotor Assy 200004 Pre-cleaner Injector Ring 200005 200000 PRESSURISER ASSEMBLY No: TL Fan Blade (inc. in #7) 200006 TL Nose Cone / Pre-cleaner 200007 TL Motor Housing 200008...
Page 8: Parts List
HYUNDAI 757-7 Loader Item No. Part No. Rev Description Colour Category PARTS LIST GA 100261F01 Fresh Air Module Module 100261P01 Pipework Module Module COMPLETE ASSEMBLY No: 700255 100261A01 Pressuriser Module Module 100261M01 Monitor Mount Module Module 200202 TS Controller Assembly Stock Item Kit Part Number: 700255...
Page 9 HYUNDAI 757-7 Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – PRESSURISER MODULE 14671 TL Support Assy (Prt Dwgs) (Prt Dwgs) Weld Assy TQM DP12503 STD TL Mount with M8 Nuts Outer Holes (Prt Dwgs) 200000 TL4 24V DC Unit...
Page 10 HYUNDAI 757-7 Loader Item No. Part No. Rev Description Qty Material Thickness Colour Category PARTS LIST – FRESH AIR MODULE 100261F02 F/A Door Plate (Prt Dwgs) (Prt Dwgs) Weld Assy 100261F03 Spigot Plate (Prt Dwgs) (Prt Dwgs) Weld Assy 100261F04 Clamp (Prt Dwgs) (Prt Dwgs)
Page 11 HYUNDAI 757-7 Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – PIPEWORK MODULE 300388-0150 76.3 x 1.6 @150mm Stainless Steel Ø3.0”ODx1.6W/T Pipework 300388-0300 76.3 x 1.6 @300mm Stainless Steel Ø3.0”ODx1.6W/T Pipework 100261-P576 Door Catch Extension Mild Steel Part 100261-P577...
Page 12 HYUNDAI 757-7 Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – MONITOR MODULE 100261M02 Monitor Plate (Prt Dwgs) (Prt Dwgs) Weld Assy 250101 Controller LRG STD Box (Prt Dwgs) Stock Item...
Page 13: Technical Details
HYUNDAI 757-7 Loader TECHNICAL DETAILS CO2 Sensor Display Key Features • • CO2 Sensor Type is NDIR (Non-Dispersive Infrared) Digital cabin pressure monitoring system • • Sample Rate is every 2 seconds Automatic cabin pressure control • • 12-30V DC Operating Voltage Intelligent fan speed output •...
Page 14 HYUNDAI 757-7 Loader TECHNICAL DETAILS Connections: 200027 Wiring Diagram Item Destination PIPE A – AMBIENT PRESSURE – OUTSIDE PIPE B – POSITIVE PRESSURE – INSIDE RJ45 CONNECTOR – CO2 SENSOR OVERRIDE TOGGLE SW = MAX SPEED Item Destination 12/24 VOLT POSITIVE SUPPLY CAN H OPTION CAN L OPTION SERIAL TRANSMIT RS232...
Page 15: Smoke Emitter Cabin Pressure Leak Test
HYUNDAI 757-7 Loader * Do not handle until MSDS & all safety precautions have been read and understood. Use personal protective equipment as required. SMOKE EMITTER CABIN PRESSURE LEAK TEST 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.
Page 16: Cabin Sealing Test Pressure
HYUNDAI 757-7 Loader CABIN SEALING TEST PROCEDURE Cabin Sealing Efficiency Test Procedure Start Engine – Pressuriser System is ON 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 door is fully closed then close windows to begin testing.
Page 17: Commissioning Procedures
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 of the enclosure and apply new sealing measures.
Page 18: Troubleshooting Guide
HYUNDAI 757-7 Loader BREATHESAFE SYSTEM TROUBLE SHOOTING 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...
Page 19: User Settings Instructions
Then enter SITE ACCESS MENU. Type in 4-number pin and press ENTER. CLEAR ENTER Insert Pin = 7597 7597 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) •...
Page 20 HYUNDAI 757-7 Loader PRESSURE ALARM SETTING USER SETTINGS INSTRUCTIONS PRESSURE SETPOINT The mining industry benchmark for cabin pressure is 50 pascals and low-pressure is The pressure setpoint changes the pressure that the cabin will be maintained. set at 20 pascals. INPRESS TS maintains the pre-set pressure within the cabin compared to outside.
Page 21 HYUNDAI 757-7 Loader SERVICE INTERVAL DATE & TIME SETTINGS USER SETTINGS INSTRUCTIONS Use the onscreen UP and DOWN buttons to change the service interval setpoint. Change the recorded date displayed and measured by the INPRESS TS. To reset the current runtime to zero, press the RESET CURRENT RUNTIME button and enter the site access pin.
Page 22 HYUNDAI 757-7 Loader ALARM BUZZER SETTINGS PRESSURE ALARM BUZZER SETTING CALIBRATE ZERO SENSOR To disable the buzzer, toggle through to the ENABLED and DISABLED buttons. Over 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.
Page 23 HYUNDAI 757-7 Loader CO2 SETTINGS CO2 MODULE ENABLE/DISABLE CO2 PRIMARY ALARM POINT Enable or disable to CO2 module used for measuring CO2 levels within the cabin. The first alarm will sound when CO2 levels inside the enclosure reach this point. BACK Settings Settings...
Page 24 HYUNDAI 757-7 Loader CO2 SETTINGS CO2 ALARM DELAY CO2 CRITICAL ALARM MUTE RESET After CO2 (concentration in ppm) within the cabin reaches the 1000 ppm setpoint, the The critical alarm is set at 2500 PPM and cannot be changed. The mute delay, alarm will sound after this designated amount of time.
Page 25: Data Download
HYUNDAI 757-7 Loader Data Download – Setting up RS232 Connection DATA DOWNLOAD Click OK once the correct Plug the RS232/USB adaptor communication port has into a free USB port on your been identified. computer Go to SETUP and click on Open up TeraTerm software.
Page 26 HYUNDAI 757-7 Loader DATA DOWNLOAD Data Download – Setting up RS232 Connection From the drop-down menu, If required, you may choose click on the Save setup. to save the COM port settings. Go to Settings and clock save the setup. Hint: From the drop-down menu, click on the Save Setup.
Page 27 HYUNDAI 757-7 Loader Data Download – Setting up RS232 Connection Excel Data Instructions – Unformatted DATA DOWNLOAD From the drop-down menu, Open an Excel sheet and select the first cell A-1. Next, press and hold down click on the Edit menu the CTRL button on your keyboard and then press the letter V on the function.
Page 28: Warranty
BreatheSafe systems. In the event of a suspected warranty claim, Warranty period – Standard 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.