INSTALLATION MANUAL

MAS SERIES 1000+

________________________________________________________________

MODULAR

SERIES MAS - 1000+

WITH MINE LOGIC SELF DIAGNOSTIC CONTROLLER

INSTALLATION MANUAL

SERIES MAS 1000 UNIT

PRESSURIZER ON CAB ROOF

ROOF PLATE

PLENUM MOUNTING RING

RETURN/ SUPPLY DUCTS

(DUCT PLATE)

SUMMER/ WINTER
PLENUM

IM1000+, REV 1 1
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

INDEX

PACKING LIST

INTRODUCTION

SERIES MAS-1000+ GENERAL DESCRIPTION AND OVERVIEW

PURE-PAK PR-PK-250 GENERAL DESCRIPTION AND OVERVIEW

INSTALLATION

A. GETTING YOUR ROOFMOUNT KIT INSTALLED

B. ELECTRICAL
C. CRANE OR HOIST
D. INSTALLING THE PRESSURIZER
E. CONTROLS

START UP

IM1000+, REV 1 2
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

PACKING LIST - (TYPICAL PACKAGE-ITEMS MAY VARY BASED ON

OPTIONS SELECTED)

1 MAS-1000+ UNIT
1 ROOF PLATE
1 18 INCH DUCT PLATE OR 12 INCH DUCT PLATE (depends on roof thickness)
1 PLENUM MOUNTING RING
1 PLENUM (SEE OPTIONS @ BACK OF THIS MANUAL)
1 POWER CORD COMPLETE WITH CANNON CONNECTOR
1 CONTROL CABLE (30 ft & 5 ft LENGTHS, WITH JUNCTION BLOCK)
1 PURE-PAK PR-PK-250 PRESSURIZER AND 4” FLEX HOSE
4 WELD BUTTONS
2 CONDENSATE DRAIN TRAP ASSEMBLIES
1 MINE LOGIC IN-CAB CONTROLLER
1 INSTALLATION MANUAL
1 OPERATING MANUAL

4” FLEX HOSE FOR PRESSURIZER CONNECTION

4” CLAMPS
NEOPRENE CAULKING
-SILENCER FOR PRESSURIZER

IM1000+, REV 1 3
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

INTRODUCTION

SERIES MAS-1000+ GENERAL DESCRIPTION

The Mine Air Systems SERIES MAS-1000+ units are specifically designed and
constructed to withstand the Heavy Duty Mining Environment.

The units are primarily stainless steel construction, and are designed for rooftop
or side wall mounting (see detailed installation instructions).

The key to the successful design of the units is the quick change-out feature,
called “Modular Engineering”. This feature allows for complete replacement of
the rooftop or side wall module in less than THIRTY minutes, by anyone with
basic mechanical skills. Similarly, complete replacement of the indoor control
module can be accomplished in the same time period. There is no electrical or
refrigeration work involved with removal or installation of either module!! The
only electrical work is the disconnection of 2 - mil spec cables.

Mine Air Systems units are the best designed, best built, best backed units in the
industry, but even “the best” have occasional component failures and require
regular maintenance. Our unique “Modular Engineering” ensures a turn-around
time, and level of satisfaction, unsurpassed in the industry!

NOTE: Due to our unique modular engineering design, it is

imperative that repairs are accomplished in keeping with the
original design, and that wiring, components and circuitry are
kept in “original format”.

IM1000+, REV 1 4
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

SERIES MAS-1000+ OVERVIEW

The system consists of a roof plate which welds to the cab roof, a unit (or units)
that bolt to the roof plate, ducting, and a “plenum” or air distribution box which
mounts inside.

The roof plate is common to both the 500 and 1000+ Series. The holes are at
the end where the penetrations through the roof and the plenum will go.

The weather seal is accomplished by welding and sealing the roof plate to the
roof. The relationship between the square flanges and the position of the 1/2”
mounting studs is important, so do not change or alter anything here.

There are several different plenums to suit different applications, so if you cannot
figure it out, or think you have the wrong one for your application, call MinePro!
They will discuss your options.

The separate pressurizer filters and forces air into the re-circulated air stream to
keep the dust out by keeping the cab in a positive pressure.

Lastly, there is the operator interface (controls) which allows the operator to
control his environment within the cab. For the 1000+ Series, it is mounted in the
cab, on a bracket which extends the mounting box into the space, within easy
reach from the seat.

Do not mount the CONTROLLER on an outside wall. Use the bracket supplied
or fabricate a bracket as shown.

FIELD FAB BRACKET APPROX. 3" IN DEPTH

EXAMPLES
WALL
WALL

MINE LOGIC
CONTROLLER

IM1000+, REV 1 5
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

PURE-PAK PR-PK-250 GENERAL DESCRIPTION

The Mine Air Systems PURE-PAK PR-PK-250 Air Filtration units are specifically
designed and constructed to withstand the Heavy Duty Mining Environment.

The units are constructed of stainless steel and corrosion resistant materials.
They can be used with any rooftop or side wall mounting heating air conditioning
and ventilating units (see detailed installation instructions).

The PURE-PAK PR-PK-250 is designed as part of a Mine Air Systems package

whose key to success is the quick change-out feature, called “Modular
Engineering”. This feature allows for complete replacement of this module, in
less than ten minutes. Similarly, complete replacement of the other modules can
be accomplished in the same time period. There is no electrical or refrigeration
work involved with removal or installation of either module.

The PURE-PAK PR-PK-250 design delivers enough clean filtered air under
pressure to keep unfiltered air out of a closed work space. The centrifical
PRECLEANER takes out the large heavy dirt while the filter cartridge removes
the really fine dirt.

The PURE-PAK PR-PK-250 can be located remotely from the work area and
connected via a flexible weather proof hose, lowering transmission of mechanical
noise.

Although the PURE-PAK PR-PK-250 is designed for use with the Mine Air 1000+
or 1020, it can be used wherever a source of clean pressurized air is required
and 480/3/60 or 380/3/50 is available.

Note: Due to our unique modular engineering design, it is imperative that

repairs are accomplished in keeping with the original design, and
that wiring, components and circuitry are kept in “original format”.

IM1000+, REV 1 6
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

PURE-PAK PR-PK-250 PRESSURIZER OVERVIEW

The PURE-PAK PR-PK-250 consists of three major components, a

PRECLEANER, a filter and a pressurizing fan all mounted to a common base
plate.

The pre-cleaner is self cleaning. It is stainless steel with an metal impeller. This
unit uses the speed of the air to separate the heaviest dirt from the air before it
enters the filter. Keeping this pre-cleaner in good operating condition is very
important to the proper functioning of PURE-PAK PR-PK-250 System. Heavy dirt
that passes a full or non functioning PRECLEANER can quickly damage the filter
media, allowing dirt to enter the work space.

The main filter media is designed to clean the fine dirt from the air and is located
in the black canister. This canister allows for quick and easy replacement of the
media during Preventative Maintenance. The canister lid has a Vac Valve
located on it. Its rubber should be soft allowing it to close under vacuum and let
out any water when not in operation. It should be on at all times and be located
at the bottom.

The stainless steel fan and motor housing are fixed securely to one end of the
common base plate. The fan shroud and outlet position can be relocated by
means of the bolts securing it.

Four threaded bushings (weld buttons) have been provided to permit the unit to
be bolted down to the selected area. This should be a reasonable distance from
the operator’s work area being supplied (controls and power supply).

A NOTE OF CAUTION!

The success of your Mine Air System depends on the consistency of

installation and on-going service and maintenance. Do not alter
(change/adjust/improve/rework/bend or fold) any aspect of the system without
calling us MinePro first! If you do any of these things, you will be creating a
special, individual unit, that may lose its modular change-out ability.

IM1000+, REV 1 7
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

INSTALLATION

Here is an exploded view of all the pieces.

SERIES MAS 1000 UNIT

PRESSURIZER ON CAB ROOF

ROOF PLATE

PLENUM MOUNTING RING

RETURN/ SUPPLY DUCTS

(DUCT PLATE)

SUMMER/ WINTER
PLENUM

FILTERS

IM1000+, REV 1 8
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

A. GETTING YOUR ROOFMOUNT KIT INSTALLED

Step 1

Remove the head-liner or insulation foam, around the area where you
want your plenum. Check on the roof to make sure that you will have
clearance. If the insulation is sandwiched between the roof plate and the
ceiling plate, you will want to consult the fabricator’s structural drawings
for structural member locations.

Here is an aerial view of how things look from above

CAB ROOF CAB FLOOR

CAB FLOOR
ROOFPLATE

PLENUM MOUNTING RING

Notice the slight offset of the centre line between the roof plate and the
plenum. This is to make absolutely sure that you are paying attention!

The pieces of the roofmount kit allow for the uneven surface created by
braces, beams, conduits, etc. on the inside.

The outside surface needs to be perfectly flat for correct mounting of the
roof plate. More on this later.

Once you are sure that you have got things planned where you want
them, proceed to Step 2.

IM1000+, REV 1 9
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

Step 2

Check to make sure things are straight, the holes will clear any obstacles,
and the plenum will wind up where you want it.

Mark the location of the 2 rectangular holes in the roof plate onto the
outside skin of the roof.

Corner drill and jigsaw (Sawzall) these openings 1/4” larger than your
marks on all four sides.

Note: As you have carefully located everything to avoid major

structural members, conduits, braces, etc., go-ahead and cut
through minor structural supports, as your new roof plate will
actually add strength to the roof when completed.

Step 3

Loosely assemble the duct plate to the plenum mounting ring as shown,
with 1/4” nuts and FLAT WASHERS. Note that the ring passes over the
two ducts, and the studs point away from the ducts.

Replace the roof plate over your holes.

Pass the duct plate/ring assembly up through the roof from the inside and
level across any high spots or supports as shown below.

ROOFPLATE

RETURN SUPPLY
CAB ROOF AIR AIR
DUCT DUCT

PLENUM MOUNTING RING TACK WELDS

ROOF

WELD

WELD RING

DUCT
PLATE

IM1000+, REV 1 10
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

Fabricate any spacers required to allow ring to span existing conduits or

ribs, and tack weld RING ONLY to inside of roof or wherever it contacts
braces.

Mark ducts at top of roof plate flanges (the extra will be cut off later).

RETURN AIR ROOF SUPPLY AIR

WELD
SPACER

FIELD FABRICATED
SPACERS
CONDUIT SUPPORT RIB

Remove nuts and washers from ring studs, and remove duct plates.

Weld ring (and spacers) securely to ceiling.

Cut ducts 1/2” shorter than your marks in preparation for step 4.

Step 4

Re-mount duct plate on ring studs as before.

Position and final align roof plate, and square to roof line.

***IMPORTANT STEP***

Step 5

Ensure that the roof plate is absolutely flat!!!

Do not pull the roof plate down to meet the roof. Shim the roof if
necessary to keep the roof plate perfectly flat.

If the roof plate is not flat, the Mine Air Unit will become torqued during the
mounting procedure and could become sufficiently stressed to cause
structural problems!

Once you are satisfied that the roof plate is flat, tack weld, then alternate
stitch weld, until roof plate is continuously welded to roof.

IM1000+, REV 1 11
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

Step 6

Stitch weld the ducts into the roof plate collars at each corner and centre.

Using a good quality urethane sealant (silicone is okay, but urethane is

superior), seal the edges of the ducts all the way around collar.

Step 7

Remove the nuts and flat washers from the plenum ring studs (the duct
plate should stay up there now!) The stainless steel plenum can now be
mounted, if the power is coming from outside the cab. If the power is
coming from inside the cab you should wait until the electrical part B is
complete before proceeding to Step 8.

Step 8

Remove the filter and mounting hole access covers from the plenum.
Mount the plenum so the louver openings are under the supply duct.
Make sure the control sensor, cable and connector are located freely
under the return duct and will not be pinched. Tighten nuts on studs and
replace access covers.

Note: It is important to use NYLOCK nuts and flat washers when

mounting the plenum.

Step 9

Clean the edge of the roof plate where it has been welded, and inspect for
any potential water leak areas. Seal with a good paintable sealant as
necessary, and then apply a good coat of paint to the entire roof plate and
adjacent roof area to stop rusting.

Note: Do not mount the unit to the roof plate yet, as you need to
look after the electrical part first!

IM1000+, REV 1 12
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

B. ELECTRICAL

You will need to provide a 30 amp 480/3/60 VAC or 380/3/50 VAC service for the
unit. A circuit breaker must be used, not fuses, due to high inrush current.

You will also need a main AC unit connector cable, Mine Air Part #40-06-025
which has the MILSPEC connector installed on one end to match the unit, and is
30’ long.

Note that the power connector for the unit is located on the electrical enclosure,
in the Return Air Section of the unit. This means that the power has to enter the
Return Air space either through the rear of the Roof plate duct collar from outside
(see below)...

TO E-BOX
POWER IN

RETURN AIR
COLLAR

ROOFPLATE

Or it will enter through the Return Air duct or Plenum inside the cab, as shown
below...

TO E-BOX
ROOFPLATE

CAB ROOF
The choice is yours, and will
vary with each installation.
PLENUM MOUNTING RING

RETURN/SUPPLY DUCTS
Look for 1/2” knockout filler
on side of plenum.
SLIMLINE PLENUM

POWER IN

IM1000+, REV 1 13
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

Note: If you enter the Return Air collar on the roof, be careful not to damage
the 1/2” top flange of the collar, and keep the connector you use at
least 1/4” from the top surface of the flange, as shown.

TO E-BOX
POWER IN

RETURN AIR
COLLAR

ROOFPLATE

3/4” LIQUID TITE STRAIGHT

CONNECTOR WORKS BEST

Be sure to use plenty of sealant around connector to prevent water leaks.

Once you have your connector and grommet in place, thread the bare end of the
power connector cable through from the roof, leaving the connector and 24” of
cable above the top of the collar flange for connection to the unit.
Thread the cable through to the vehicle electrical junction box location, where the
connections are made. See unit electrical diagram for full details.
Note:
In order to retain the modular nature of the system, the switched 3
phase
power for the Pure Pak Pressurizer (if used) comes from the unit to the
disconnect, where it passes through and out to the Pressurizer
motor.

PRESSURIZER PRESSURIZER

46 0/3/60 (RED) 460 /3/60 (RED)

AND SWITCHED POWER AND SWITCHED POWER
(BLUE BLACK AND GREY) (BLUE BLACK AND GREY)
TO PURE PAK MAS TO PURE PAK MAS
SERIES 1000 S ERIES 1000
UNIT UNIT

460 /3/60 TO PRPK250 FROM

4 60/3 /60 TO PRPK2 50 FROM
BLUE BLACK AND GREY WIRES
OR CABLE IN UNIT

3 PHASE DISCONNECT IN DISCONNECT 3 PHASE DISCONNECT

(WITHIN SIGHT AND 3 m (WITHIN SIGHT AND 3m
OR LESS FROM UNIT) OR LESS FROM UNIT)

MINE MINE
EQUIPMENT EQUIPMENT
CAB CAB
4 60/3/60 SERVICE 460 /3/60 SERVICE

IM1000+, REV 1 14
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

C. CRANE OR HOIST

A spreader bar with lifting straps and clevis is easier on the unit than chains.

Hoist unit down onto guide posts on the roof plate and secure unit with nuts and
lock washers.

Once the nuts are tightened to 45 ft. lbs., don’t forget to install the condensate
drain trap assemblies on to the unit.

D. PRESSURIZER

This is the optional component section. If you bought one, read on. Otherwise
skip to part E.

GETTING YOUR PURE-PAK PR-PK-250

INSTALLED

Step 1

Select a suitable location that is remote from the work area but easily accessible
for cleaning at the beginning of each shift or during Preventative Maintenance.
Depending on which PRECLEANER is installed and clearances available, these
units may be installed on either a horizontal or sloped surface as long as the
motor shaft is horizontal. If not installed on a horizontal surface adjust the pre
cleaner to an upright position using the canister clamps.

IM1000+, REV 1 15
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

Here is a view of how things may look.

FLEX HOSE

PRECLEANER

PRESSURIZER

CAB ROOF

Weld 1/2” studs or weld buttons centered on the mounting holes located
on the base plate. You will want to clean and paint this area before the unit is
secured in position.

Step 2

Make the electrical connections. Verification of the fan blade rotation will be
done during start up. It should when tested, turn toward the outlet.

Step 3

Connect a flexible weather proof 4” Diameter hose of adequate length from the
discharge of the fan to the inlet on the side of the Mine Air System 1000+.

Step 4

Secure wire and hose in a manner appropriate for the location and application.

IM1000+, REV 1 16
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

CONTROLS

Now that you have completed the electrical portion of the installation, you will
need to install the mine logic controller.

This component provides the direct digital interface with the relay box in the roof
top unit, and also contains the connection port for the PC interface.

Locate the controller where it is conveniently reached by the operator while

seated. We recommend a bracket mounted to the control stick tower or armrest,
and angled toward the operator’s line of sight. Vertical location is best between
waist and shoulder height.

Use electrical conduit to connect the controller to one of the 7/8” holes on either
side of the plenum box. The voltage is < 24 VDC and nominal current and
mechanical protection is advised with either flexible or rigid conduit used.

You will require the main control cable, Mine Air Part #40-17-000, which has the
MILSPEC connector installed on one end to match this unit, and is 30’ long.

Starting at the unit, feed the bare ends, (pinned end), of the cable (#40-17-002)
down through the return air opening, through the plenum, through the conduit,
and into the cab.

Leave sufficient cable within the unit to allow an easy loop in the return air space,
and cut at the controller end to leave 18” of spare cable.

Connect Milspec connector, 5ft cable (#40-17-001), to controller. To connect the

30 ft and 5 ft cables together use the junction block. This connector must first be
pinned in. Also, fabricate a junction box to enclose the connection using seal
tights on cables.

When all connections are complete, you are ready to connect the MILSPEC
connector to the unit receptacle, beside the main power receptacle and cable.

IM1000+, REV 1 17
11-July-01
11-July-01
IM1000+, REV 1
ItemNo.01 Procon Part #
52-23-002 PN/&AH Part No. Descri
Relay Board
ption Assy inside E-Box (c/w relays) Qty.1
0203 40-17-000
40-17-002 R37145D11 Cabl 40-17-000) 11
0405 40-17-001
50-12-000 AA
N/N/R38406D( Cableee Assembl
Cabl
MLC,
Assy 530fitefst(Cab(Unitot toPLC)Cab)(p/(po/o40-17-000)
Assy c Controller) 11
0607 52-23-002-01
50-12-000E A 2,3,4)
N/R38406D2 52-23-002)
RelMLC,ays,((MM(ipinn/eeo Logi
Logi ENGLISH 11
0809 50-12-000S
50-12-000F R38406D3
R38406D4 MLC, (
MLC, (MMiinnee Logi
c Controllleer)r),, SPANI
Logicc Control
Controller), FRENCHSH 11
01
06
Mine Logic Controller Setup

THROUGH 02 05 07 08 09
AND UP INSIR/DAEDUCT
UNIT

03 04
1-2- BLACK
BLUE 1-2- BLACK
BLUE
3-4- BROWN
LTBLUEBLUE/ WHITE STRIPE 3-4- BROWN
LT BLUE/ WHITE STRIPE
5-6- LT GREEN 5-6- BLUE
LT GREEN
7-8- GREEN
GRAY 7-8- GREEN
GRAY
10- 9- ORANGE
PINK SEAL TIGHTS 10- 9- ORANGE
PINK
11-
12- PURPLE
RED JUNCTION BOX 11-
12- PURPLE
RED
13-
14- RED / WHITE STIPE
TAN 13-
14- RED
TAN / WHITE STIPE
15-
16- WHITE
YELLOW 15-
16- WHITE
YELLOW
15-
16- WHITE
YELLOW 15-
16- WHITE
YELLOW
________________________________________________________________
INSTALLATION MANUAL
MAS SERIES 1000+

18
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

SERIES MAS 1000 UNIT

ROOF PLATE

CAB ROOF

PLENUM MOUNTING RING

DUCT PLATE

SUMMER/ WINTER PLENUM

MLC CABLE

You are now ready to start-up the unit! We recommend that you review all
steps at this point, making sure all electrical connections are tight and
secure, and nothing was missed.

IM1000+, REV 1 19
11-July-01
 INSTALLATION MANUAL
MAS SERIES 1000+
________________________________________________________________

THE START-UP
The unit was run-tested for 24 hours at the factory so problems on start-up are
rare.

A) ELECTRICAL

Close the 480 VAC or 380 VAC breaker feeding the roof mounted disconnect,
and check to be sure that voltage is between 460 and 500 volts (360 and 400
volts), and balanced to within 3% between all 3 legs.

B) MOTOR ROTATIONS - THESE PROCEDURES ARE

CRITICAL

1) MAS-1000+ UNIT
It is impossible to see if the compressor is turning correctly without special
instrumentation. All other fan motors have rotational arrows on them. The
compressor and all motors have been phase aligned at the factory prior to the 48
hours test, so if one visible motor is running backwards they are all running
backwards. MAKE THE PHASE CHANGE AT THE DISCONNECT NOT
WITHIN THE UNIT.

IMPORTANT
Never change rotation inside E-Box! If installing a new motor, adjust
rotation at the motor ONLY. When installing a new unit, change rotation outside
Mine Air unit ONLY.

2) PURE-PAK PR-PK- 250

Checking the pressurizer should only be done after the MAS-1000+ has been
checked. This is because the pressurizer is powered from a switched source in
the MAS-1000+. So if after step (a) the pressurizer rotation is wrong, MAKE
THE PHASE CHANGE AT THE PRESSURIZER MOTOR ONLY!

IM1000+, REV 1 20
11-July-01