Hyundai R480-9 Quick start guide

Parts and Service Manual
HYUNDAI
Controlled Document: M0200
Issue Date: 11/10/23
Revision: 1
Kit Part Number: 700500
R480-9 EXCAVATOR
[phone]
www.breathe-safe.com.au
[email protected]
62 Mica Street, Carole Park, 4300, QLD
HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter
He

1
HYUNDAI
R480-9 Excavator
INSTALLATION
INSTALLATION OVERVIEW
Manufacturer
Hyundai
Type
Excavator
Model
R480-9
Cabin Pressure Max
Set Auto Cabin Pressure
HEPA H14 Variable Speed Pressuriser
INPRESS TS Cabin Display with Data Recorder
HEPA Return Air Filter
CONTENTS
Installation.................................... 1
Safety ........................................... 2
Critical Parts & Maintenance
Schedule....................................... 3
Operator Guide............................. 4
Specifications - Pressuriser ............ 5
Parts List.................................. 6-12
Technical Details .................... 13-14
Smoke Emitter Cabin Pressure Leak
Test ............................................ 15
Cabin Sealing Test Pressure ......... 16
Commissioning Procedures ......... 17
Troubleshooting Guide................ 18
User Settings Instructions....... 19-24
Data Download ...................... 25-27
Warranty .................................... 28

2
HYUNDAI
R480-9 Excavator
WARNING
THE PRESSURISATION SYSTEM DESCRIBED IN THIS MANUAL HAS THE
FOLLOWING AREAS WHICH MAY BE DANGEROUS IF NOT TREATED WITH
GREAT CARE.
QUALIFIED STAFF MUST WEAR THE CORRECT PERSONAL PROTECTIVE
EQUIPMENT WHEN CLEANING AND SERVICING THIS UNIT DUE TO DUST
AND FIBRES WHICH MAY BE CAUGHT BY THE STAGES OF AIR FILTRATION
DURING NORMAL UNIT OPERATION.
THE ELECTRICAL POWER SYSTEM IS SUPPLIED BY 12V DC OR 24V DC AND
NO WORK SHOULD BE CARRIED OUT ON THE PRESSURISER SYSTEM
WITHOUT THE CORRECT SAFE WORK PROCEDURES AND ELECTRICAL
SAFETY MEASURES BEING TAKEN, AND ALL RELEVANT CIRCUIT BREAKER
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 GUARD ARE IN PLACE WHILE THE SYSTEM IS RUNNING.
Please be aware that HEPA filters cannot be cleaned and must be
replaced at the end of their lifecycle or if filter media has been damaged.
SAFETY
Particulate Behaviour
This is the length of time it takes for a particle to drop from a height
of 1.5m in STILL air.
Warehouses and workshops do not have still air, so hazardous
airborne particulates may remain in air for longer, increasing chance
for workers to breathe in dust. Ensure PPE is worn when installing
this system.
Hard Hat
Eye Protection
Dust Mask
Ear Protection
Protective
Clothing

3
HYUNDAI
R480-9 Excavator
Maintenance Schedule
Inspect every 500 Hours and replace when filter is full*
Component / System
Action Required
Turbo Pre-cleaner
Check operation of the Turbo Pre-
Cleaner.
Pressuriser Blower
Ensure blower is operational.
HEPA Primary Filter p/n: 500000
Inspect filter capacity indicator.
Replace HEPA filter when 80% or
greater. Vacuum out housing
before replacing the filter
elements.
HEPA Return Air Filter P/N: 5000
Vacuum inside cabin floor before
replacing filter.
Filter Frame Assembly, Mounts,
Seals and Filter Housing
Check door seals, all bolts, screws,
and all mounts are secure.
Check the filter canister & ensure it
is correctly fitted.
Check latches are operational and
in good order.
Replace / Re-tension fixtures and
fittings required.
15,000 Hours / 36 months*
Component / System
Action Required
500 Hour Inspection
All 500-hour inspection actions.
Pressuriser’s Blower 200002
Replace BRUSHLESS Pressuriser
blower.
CRITICAL PARTS & MAINTENANCE SCHEDULE
Critical Parts
Item
Part Number
Qty.
Description
Service Interval
1
500000
1
Fresh Air HEPA H14 Filter (Tested as per
EN1822)
1000* Hours (>80%
fan capacity)
2
5000
1
HEPA Return Air Filter
500* Hours
3
200002
1
Brushless Blower Motor –24V
15,000 Hours
4
200027
1
BreatheSafe Digital Display –Data
Recorder (INPRESS TS)
The following tables show our suggested maintenance schedule
for all units. Please note that site conditions may alter this.
Excludes high corrosion environments.
Data download is required to claim the 3-year warranty on
Brushless Blower Motor.
*Filter service hours are subject to cab sealing efficiency, site conditions and correct system
use.
Suggested Schedule Servicing*
Fan Capacity Indicator
The filter is serviceable if the motor capacity is
between 10% & 80%. We recommend that the filter is
changed if the capacity is over 80%.
*Site dependent

4
HYUNDAI
R480-9 Excavator
OPERATOR GUIDE
OPERATORS CHECKLIST
PRE-START
1.
Visually inspect the BreatheSafe system for any damage.
2.
Visually inspect the cabin for any damage to doors, windows, seals.
3.
Please remove dust & debris from shoes and clothes before entering the cabin.
4.
Ensure door(s) and windows are closed correctly.
5.
Start engine and turn HVAC on to speed 2 (medium speed).
6.
After fixed speed delay, the BreatheSafe display will show 50 Pascals or pre-set value.
The system is working correctly when the pascal value is green.
>> 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.
ALERTS
Fixed Fan Start Delay
•Allows the operator to carry out pre-start checks –limiting at 30% fan speed, press the red text to disable.
CO₂Level Alert (if equipped)
•Ensure air conditioning fan is set at mid speed or greater to circulate air and minimise CO₂.
Low Pressure Alarm
•Cabin is not maintaining positive pressure –check doors and windows are closed correctly.
•Refer to maintenance department to check filters and cabin sealing. Ensure filters are serviceable.
Check Filter
•Reminder to inspect or replace filter. Service hour meter requires re-set.
•Refer to maintenance department.

5
HYUNDAI
R480-9 Excavator
Blower : Brushless Blower P/N 200002.
Protection : Locked Rotor Protection (Sub Zero Environments) Under
Voltage, Under/Over Current & Over Temperature.
Voltage : 24VDC.
Current Draw : 11 amps (peak). *Note: Motor has slow start to stop excessive
in-rush current.
Air Flow : Up to 30-300 m3/h or 50-215 CFM.
Pre-cleaner : Integrated VLR (Very Low Restriction). Turbo Pre-Cleaner.
Filter Element : BreatheSafe HEPA Primary Filter (H14=99.99% MPPS) TESTED AS
PER EN1822 –P/N 500000.
Plugs & Fittings : Mining Spec. Deutsch electrical plugs as standard.
Construction : High strength composite construction.
Serviceability : Easy access HEPA filter with twist-lock (TL) dust cap single
assembly.
Mounting : Heavy Duty adjustable mounting brackets.
Design : Fully designed in SolidWorks 3D CAD & Ansys Engineering
Simulation Software.
FEA Testing : Critical components FEA (Finite Element Analyst) tested in Solid
Works Simulation.
CFD Testing : CFD (Computational Fluid Dynamics) simulations in Flow Works
to ensure optimum air flow through the system.
SPECIFICATIONS HIGH-CAPACITY HEPA PRESSURISER
Specifications High-Capacity HEPA Pressuriser
List of Abbreviations
DH
Dual HEPA
DHPR
Dual HEPA Powered Recirculation
DHAC
Dual HEPA Activated Carbon
DHACPR
Dual HEPA Activated Carbon Powered Recirculation
CPM
Cabin Pressure Monitor
CPU
Central Processing Unit
DB
Decibel Sensor
DPM
Diesel Particulate Matter
GAS
Gas Sensor
HEPA
High-Efficiency Particulate Air Filter
HPAFU
High Pressure Air Filtration Unit
HRAF
HEPA Return Air Filter
HVAC
Heating Ventilation and Air Conditioning
MAF
Mass Air Flow
OEM
Original Equipment Manufacturer
PM
Particulate Mass
RH
Relative Humidity
TEMP
Temperature
TS
Touch screen
UI
User Interface
VMS
Vehicle Monitoring System
VS
Vibration Sensor
OGSP
OnGuard Sensor Pod
CO2s
CO2 Sensor INPRESS TS

6
HYUNDAI
R480-9 Excavator
PARTS LIST –TL4 24V DC PRESSURISER UNIT
Item No.
Qty.
Description
Part No.
1
1
Pre-cleaner Hood & Rotor Assy
200004
2
4
Pre-cleaner Injector Ring
200005
3
1
TL Fan Blade (inc. in #7)
200006
4
1
TL Nose Cone / Pre-cleaner
200007
5
1
TL Motor Housing
200008
6
1
TL Filter Housing
200009
7
1
24v DC Brushless VSD Motor & TL Fan Blade
200002
8
1
O Ring Seal Kit 2 Parts
200010
9
1
Included in 8
200011
10
1
Wiring Sleeve
200012
11
1
HEPA H14 Filter
500000
12
3
M6 Nyloc Nut
300218 (M6NYL)
13
3
M6 x 55mm Hex Bolt
300982 (M655B)
14
4
M8 x 190 Hex Bolt
301136 (M8190B)
15
8
M8 x 22mm O/D HD Washer
300230 (M8222HTW)
16
4
M8 Nyloc Nut
300249 (M8NYL)
17
5
M4 x 75mm Pan Head Phillips Screw
300162 (M475PBH)
PRESSURISER ASSEMBLY No: 200000
1
2
4
7
13
17
8
10
14
15
16
9
5
12
6
11

7
HYUNDAI
R480-9 Excavator
PARTS LIST GA
COMPLETE ASSEMBLY No: 700500
Item No.
Part No.
Rev
Description
Qty
Colour
Category
1
100556A01
0
High Pressure Unit Module
1
Black Satin 27219268
Module
2
100531F01
0
Fresh Air Module
1
Black Satin 27219268
Module
3
100531M01
0
Monitor Mount Module
1
Charcoal Satin 27288351
Module
4
100556P01
0
Pipework Module
1
(As Req’d)
Module
5
07732
1
Return Air Module
1
(As Req’d)
Module
Kit Part Number: 700500

8
HYUNDAI
R480-9 Excavator
PARTS LIST –PRESSURISER MODULE
Item No.
Part No.
Rev
Description
Qty
Material
Thickness
Colour
Category
1
100531A02
0
Roof/Condenser Mount
Panel Assy
1
-
-
Black Satin 27219268
Weld Assy
2
08019
1
FOPS Mounting Brkt Assy
2
-
-
Satin Black MX88-124
Weld Assy
3
08308
3
Blank Plate
1
Zan
1.95
Satin Black MX88-124
Part
4
08624
0
Machined Spacer 30 O/D x
14.5 I/D x 63.5L
2
Mild Steel
Ø30 O/D x 63.5L
Satin Black MX88-124
Part
5
200000
[*]
HPAFU 24VDC VSD TL4
1
N/A
-
-
Stock Item
6
250007
[*]
TL Mount Brkt. 56.5mm
1
Mild Steel
3
(As Req’d)
Stock Item

9
HYUNDAI
R480-9 Excavator
PARTS LIST –FRESH AIR MODULE
Item No.
Part No.
Rev
Description
Qty
Material
Thickness
Colour
Category
1
08004
1
Fresh Air Adaptor Assy
1
-
-
Satin Black MX88-124
Weld Assy
2
07743
0
Fresh Air Adaptor Tab Assy
4
-
-
Satin Black MX88-124
Assembly
3
07999
0
Engine Bay Access Panel
1
Zan
1.6
Satin Black MX88-124
Part