Gast 0740 User Manual

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Page 1

WARNING

PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING

THIS MOTOR. SAVE THIS MANUAL FOR FUTURE REFERENCE AND

KEEP IN THE VICINITY OF THE MOTOR.

VACUUM PUMPS & COMPRESSORS

www.gastmfg.com

ISO 9001 & 14001 CERTIFIED

0440 Oilless

Thank you for purchasing this Gast product. It is manufactured to the highest standards

PART NO. 70 - 480 G405PL (REV-E)

OIL-LESS ROTARY VANE

OPERATION & MAINTENANCE MANUAL

3040 Oilless

using quality materials. Please follow all recommended maintenance, operational

and safety instructions and you will receive years of trouble free service.

General information

• Model numbers ending in “X” have automatic thermal protectors which protect the motor by shutting the motor off if it overheats. The motor will automatically restart once the motor has cooled.

Product Use Criteria:

• Pump only clean, dry air.

• Operate at 32ºF - 104ºF (0ºC - 40ºC).

• Protect unit from dirt & moisture.

• Do not pump flammable or explosive gases or

use in an atmosphere that contains such gases.

• Protect all surrounding items from exhaust air. This

exhaust air can become very hot.

• Corrosive gases and particulate material will

damage unit. Water vapor, oil-based contaminants or other liquids must be filtered out.

• Consult your Gast Distributor before using at high altitudes.

• Oil-Less rotary-vanes require NO lubrication.

• Sealed bearings are grease packed.

• Use of petroleum or hydrocarbon products will reduce carbon-vane service life.

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INSTALLATION

WARNING

DANGER

Your safety and the safety of others

is extremely important.

We have provided many important safety messages in this manual and on your product. Always read and obey all safety messages.

This is the safety alert symbol. This symbol alerts you to hazards that can kill or hurt you and others. The safety alert symbol and the words “DANGER” and “WARNING” will precede all safety messages. These words mean:

You will

be killed or seriously injured if you don’t

follow instructions.

You can

be killed or seriously injured if you don’t

follow instructions.

All safety messages will identify the hazard, tell you how to reduce the chance of injury, and tell you what can happen if the safety instructions are not followed.

Plumbing

Remove plugs from the IN and OUT ports. Connect with pipe and fittings that are the same size or larger than the product’s threaded ports.

Accessories

The product’s internal intake and exhaust filters will provide adequate filtration in most applications. Check filters periodically and replace when necessary. All have an intake and exhaust filter to prevent contaminants from entering the pump or the pneumatic system. Please consult your Gast Distributor/Representative for additional filter recommendations.

Install relief valves and gauges at inlet or outlet, or both, to monitor performance. Check valves may be required to prevent back streaming through the pump.

Motor Control It is your responsibility to contact a qualified electrician to assure that the electrical installation is adequate and in conformance with all national and local codes and ordinances.

Determine the correct overload setting required to protect the motor (see motor starter manufacturer’s recommendations). Select fuses, motor protective switches or thermal protective switches to provide protection. Fuses act as short circuit protection for the motor, not as protection against overload. Incoming line fuses help to withstand the motor’s starting current. Motor starters with thermal magnetic overload or circuit breakers protect motor from overload or reduced voltage conditions.

units should

Correct installation is your responsibility. Make sure you have the proper installation conditions and that installation clearances do not block air flow. Proper guards should be installed to prevent contact with moveable parts of this pump. Do Not lift the unit by the fan shroud.

Blocking air flow over the product in any way can cause the product to overheat.

Mounting This product can be installed in any orientation. Mounting the product to a stable, rigid operating surface and using shock mounts will reduce noise and vibration.

The wiring diagram supplied with the product provides required electrical information. Check that power source is correct to properly operate the dual-voltage motors.

Electrical Connection

Model with a power supply cord:

This product must be grounded. For either 120-volt or 220/240-volt circuits connect power supply cord grounding plug to a matching grounded outlet. Do not use an adapter. (See DIAGRAM A)

In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product may be equipped with a power supply cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

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Check with a qualified electrician or serviceman if the grounding instructions are not completely understood, or if you are not sure whether the product is properly grounded. Do not modify the plug provided. If it will not fit the outlet, have the proper outlet installed by a qualified electrician.

Model that is permanently wired: This product must be connected to a grounded, metallic, permanent wiring system, or an equipment grounding terminal or lead on the product.

Power supply wiring must conform to all required safety codes and be installed by a qualified person. Check that supply voltage agrees with that listed on product nameplate.

Be sure the 3-phase motor turns in the proper direction of rotation after installation. Turning in the wrong direction will drastically reduce vane life.

Extension cords: Use only a 3-wire extension cord that has a 3-blade grounding plug. Connect extension cord plug to a matching 3-slot receptacle. Do not use an adapter. Make sure your extension cord is in good condition. Check that the gage wire of the extension cord is the correct size wire to carry the current this product will draw.

OPERATION

Minimum gage for extension cords

Amps Volts Length of cord in feet

120v 25 50 100 150 200 250 300 400 500 240v 50 100 200 300 400 500 600 800 1000

0-2 18 18 18 16 16 14 14 12 12 2-3 18 18 16 14 14 12 12 10 10 3-4 18 18 16 14 12 12 10 10 8 4-5 18 18 14 12 12 10 10 88 5-6 18 16 14 12 10 10 888 6-8 18 16 12 10 10 8666 8-10 18 14 12 10 88664 10-12 16 14 10 886644 12-14 16 12 10 866642 14-16 16 12 10 866442 16-18 14 12 8864422 18-20 14 12 8664422

It is your responsibility to operate this product at recommended pressures or vacuum duties and room ambient temperatures. Do Not start against a vacuum or pressure load.

Start Up

If motor fails to start or slows down significantly under load, shut off and disconnect from power supply. Check that the voltage is correct for motor and that motor is turning in the proper direction. Vane life will be drastically reduced if motor is not operating properly. Vanes can break or be damaged if motor/pump runs in the wrong direction.

MAINTENANCE

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It is your responsibility to:

• Regularly inspect and make necessary repairs to product in order to maintain proper operation.

• Make sure that pressure and vacuum is released from product before starting maintenance.

Check intake and exhaust filters after first 500 hours of operation. Clean filters and determine how frequently filters should be checked during future operation. This one procedure will help to assure the product’s performance and service life.

Clean filters when necessary by removing and washing in a solvent or soap and water. After cleaning, dry with compressed air to make sure all moisture is removed before replacing filters.

Check that all external accessories such as relief valves and gauges are attached to cover and are not damaged before re-operating product.

SHUTDOWN PROCEDURES

It is your responsibility to follow proper shutdown procedures to prevent product damage. NEVER ADD OIL TO THIS OIL-LESS PUMP.

Proper shutdown procedures must be followed to prevent pump damage. Failure to do so may result in premature pump failure. The Gast Manufacturing Rotary Vane Oil-Less Vacuum Pumps and Compressors are constructed of ferrous metals or aluminum which are subject to rust and corrosion when pumping condensable vapors such as water. Follow the steps below to assure correct storage and shutdown between operating periods

1. Disconnect plumbing.

2. Operate product for at least 5 minutes without plumbing.

3. Run at maximum vacuum for 10-15 minutes.

4. Repeat step 2.

5. Disconnect power supply.

6. Plug open ports to prevent dirt or other contaminants from entering product.

SERVI CE KIT INSTALLATION

Flushing

Flushing this product to remove excessive dirt, foreign particles, moisture or oil that occurs in the operating environment will help to maintain proper vane performance. If your pump is not getting the vacuum or pressure level expected, flushing is required. Vanes will stick when dirty and may cause pump to be noisy or inefficient.

Use only Gast recommended Solvent or other nonpetroleum based flushing solvent. Do Not use kerosene or ANY other combustible solvent to flush product.

1. Disconnect electrical power supply.

2. Release all pressure and vacuum from pump.

3. Remove all accessories at the inlet and exhaust ports.

4. Remove filter.

5. Start product. Place towel over exhaust port to clean up solvent. If using liquid solvent, pour

several tablespoons directly into inlet port. If using Gast recommended Flushing Solvent, spray solvent for 5-10 seconds into inlet port.

6. Block the inlet port and draw a deep vacuum for

15-20 seconds. Release the vacuum.

7. Listen for changes in the sound of the motor. If

motor sounds smooth, go to next step. If motor does not sound like it is running smoothly, repeat steps 5 and 6 until you can hear a difference in the operating sound of the pump.

8. Start the pump and let it run for 1 minute, then turn

pump off.

9. Replace all accessories at the inlet and exhaust

ports.

10. Replace filter before resuming operation.

Gast will NOT guarantee field-rebuilt product performance. For performance guarantee, the product must be returned to a Gast Authorized Service Facility.

Service Kit contents vary. Most contain vanes, gaskets and filter parts.

Do Not attempt to remove the rotor. It is held in place by Loctite and can only be serviced by a Gast Authorized Service Facility.

Do Not loosen or adjust motor thru-bolts to prevent misalignment and damage to the pump.

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Disassembly

1. Remove the shroud and fan.

2. Use a wheel puller to remove the dead-end plate and bearing from the pump body. Note the direction of the bevel edge on the vane. Do not damage the dowel pins between the end plate and the body. Save the bearing spacer on the deadend of the shaft for reassembly. Remove the snap ring from the end plate. Save the snap ring, belleville springs and washer for reassembly.

3. Remove the bearing from the dead-end plate.

4. Check the exposed surfaces of the rotor, body, and end plate for scoring. If you find no scoring, you can perform a Minor Rebuild to replace only the vanes and the dead-end bearing. If you find severe damage, perform the Major Rebuild.

Minor Rebuild

5. Install the new vanes supplied with the kit. Be careful to face the vane bevels in the proper direction (as noted in step 2).

6. Place end plate over the shaft with dowel pins aligned. Place bearing spacer on dead end of shaft. Place the new bearing in its bore in the dead end plate. Be careful to press only on the inner bearing race.

7. Install and tighten the pump body bolts, install the belleville springs with the washer between them and the snap ring.

Major Rebuild

5. Remove the drive end cap. Use a wheel puller to remove the drive-end plate and bearing from the body. Do not remove or damage the dowel pins in the body. Save the bearing spacer and end plate gasket for reassembly.

6. Place one shoulder ring in its seat in the drive-end plate, then place one of the new bearings in the seat. Using an arbor press, press the bearing onto the shaft. Be careful to press only on the inner bearing race. Tighten the pump body bolts.

7. Install the new vanes supplied with the kit. Be careful to face the vane bevels in the proper direction (as noted in step 2).

8. Perform step #6 from Minor Rebuild.

9. Install the belleville springs with the washer between them and the snap ring. Install and tighten the pump body bolts.

10. Apply a thread-lock adhesive and start the driveend cap into its thread in the drive-end plate, but do not tighten it.

11. Place a dial indicator against the dead-end of the shaft to measure axial movement.Tighten the driveend cap until the indicator shows: 001” (for models 0240, 0440, 0740) and .002” (for models 1550, 3040) of shaft movement against the belleville springs.

12. Clean and reinstall filter(s).

We have Gast Authorized Repair Facilities throughout the world. For the most up-to-date listing, contact one of our sales offices below:

Gast Manufacturing, Inc.

2300 S. Highway M139 Benton Harbor, MI, 49022 Ph: 269/926-6171 FAX: 269/925-8288 www.gastmfg.com

Gast Hong Kong

Unit 12, 21/F, Block B New Trade Plaza 6, On Ping Street, Shatin N. T. Hong Kong Ph: (852) 2690 1066 Fax: (852) 2690 1012 www.gasthk.com

Gast Group Limited, United Kingdom

Unit 11, The I O Centre Nash Road Redditch, B98 7AS United Kingdom ph: +44 (0) 1527 504040 Fax: +44 (0) 1527 525262 www.gastmfg.com

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EXPLODED VIEW AND PARTS ORDERING INFORM ATION

REF DESCRIPTION QTY 1550-V136B 1550-P139B 3040-V115A 3040-P118B NO. VACUUM COMPRESSOR VACUUM COMPRESSOR 1 BODY 1 AB111J AB111J AB955 AB955 2 DRIVE END PLATE 1 AC314 AC314 AB986 AB986 3 DEAD END PLATE 1 AC315 AC315 AB987 AB987 4 ROTOR ASSEMBLY 1 AD238 AD238 AB794 AB794 5 ∆ VANE 4 AB125B AB125B AB934A AB934A 6 BEARING SHIM (SHDR RING) 2 AD255 AD255 AB926T AB926T 7 ∆ BEARING 2 AC894 AC894 AB964J AB964J 8 BELLEVILLE SPRING 2 AB337 AB337 AB791 AB791 9 SHIM WASHER 2 AB338 AB338 AB792 AB792 10 RETAINING RING 1 AB335 AB335 AB793 AB793 11 FAN 1 AC326C AC326C AD236 AD236 12 END CAP 1 AB339 AB339 AB790 AB790 13 FAN PULLEY 1 AB140 AB140 AC374B AC374B 14 INTAKE FILTER ELEMENT ASSY 1 AC433 AD750 15 ∆ CARTRIDGE OR FELT 1 or 2 AC393 AC393 AC393 AD752 16 INTAKE FILTER ASSEMBLY 1 AB600F AA900D 17 ∆ COVER GASKET 2 AA405 AA405 18 JAR 1 AA805 AA401 19 FILTER ELEMENT ASSEMBLY 1 AC433-1 20 EXHAUST MUFFLER ASSEMBLY 1 AB600J AA900F 21 FILTER ELEMENT ASSEMBLY 1 AC434-1 AC436-1

*** SERVICE KIT 1 K231A K231A K233A K233A

∆ Denotes parts in the service kit.

Parts listed are for stock models. For specific OEM models, contact the factory. When corresponding or ordering parts, please give complete model number and

serial number.

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EXPLODED VIEW AND PARTS ORDERING INFORM ATION

REF DESCRIPTION QTY 0240-V105A 0440-V105A 0440-P103A 0740-V104A 0740-P106A NO. VACUUM VACUUM COMPRESSOR VACUUM COMPRESSOR 1 BODY 1 B2321 B1321 B1321 B1321B B1321B 2 DRIVE END PLATE 1 AC638 AC638 AC638 AC636 AC636 3 DEAD END PLATE 1 AC637 AC637 AC637 AC635 AC635 4 ROTOR ASSEMBLY 1 AC645 AC646 AC646 AC647 AC647 5 ∆ VANE (CARBON) 4 AD286 AD372 AD372 AA510A AA510A 6 ∆ DEFLECTOR 2 AC649 AC649 AC649 AC649 AC649 7 ∆ BEARING 2 AC416 AC416 AC416 AC416 AC416 8 BELLEVILLE SPRING 2 AC657 AC657 AC657 AC657 AC657 9 RETAINING RING 1 AC658 AC658 AC658 AC658 AC658 10 WASHER 1 AC659 AC659 AC659 AC659 AC659 11 END CAP 1 AC639 AC639 AC639 AC639 AC639 12 BODY SPACER 1 B330F B330F B330F B330F B330F 13 COOLING FAN 2 B340C B340C B340C B340C B340C 14 INTAKE FILTER ELEMENT ASSY 1 V400C V400C V500D 15 ∆ COVER GASKET 2 B62A B62A B62A 16 JAR 1 AA125 AA125 AA125 17 FILTER ELEMENT ASSEMBLY 1 B343B B343B B343B B343B B343B 18 ∆ FILTER FELT 4 B344A B344A B344A B344A B344A 19 EXHAUST MUFFLER ASSEMBLY 1 V425A V425A V525A

*** SERVICE KIT 1 K225A K227A K227A K229A K229A

∆ Denotes parts in the service kit.

Parts listed are for stock models. For specific OEM models, contact the factory. When corresponding or ordering parts, please give complete model number and serial number.

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Gast finished products, when properly installed and operated under normal conditions of use, are warranted by Gast to be free from defects in material and workmanship for a period of twelve (12) months from the date of purchase from Gast or an authorized Gast Representative or Distributor. In order to obtain performance under this warranty, the buyer must promptly (in no event later than thirty (30) days after discovery of the defect) give written notice of the defect to Gast Manufacturing Incorporated, PO Box 97, Benton Harbor Michigan USA 49023-0097 or an authorized Service Center (unless specifically agreed upon in writing signed by both parties or specified in writing as part of a Gast OEM Quotation). Buyer is responsible for freight charges both to and from Gast in all cases.

This warranty does not apply to electric motors, electrical controls, and gasoline engines not supplied by Gast. Gast’s warranties also do not extend to any goods or parts which have been subjected to misuse, lack of maintenance, neglect, damage by accident or transit damage.

THIS EXPRESS WARRANTY EXCLUDES ALL OTHER WARRANTIES OR REPRESENTATIONS EXPRESSED OR IMPLIED BY ANY LITERATURE, DATA, OR PERSON. GAST’S MAXIMUM LIABILITY UNDER THIS EXCLUSIVE REMEDY SHALL NEVER EXCEED THE COST OF THE SUBJECT PRODUCT AND GAST RESERVES THE RIGHT, AT ITS SOLE DISCRETION, TO REFUND THE PURCHASE PRICE IN LIEU OF REPAIR OR REPLACEMENT.

GAST WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND, however arising, including but not limited to those for use of any products, loss of time, inconvenience, lost profit, labor charges, or other incidental or consequential damages with respect to persons, business, or property, whether as a result of breach of warranty, negligence or otherwise. Notwithstanding any other provision of this warranty, BUYER’S REMEDY AGAINST GAST FOR GOODS SUPPLIED OR FOR NON-DELIVERED GOODS OR FAILURE TO FURNISH GOODS, WHETHER OR NOT BASED ON NEGLIGENCE, STRICT LIABILITY OR BREACH OF EXPRESS OR IMPLIED WARRANTY IS LIMITED SOLELY, AT GAST’S OPTION, TO REPLACEMENT OF OR CURE OF SUCH NONCONFORMING OR NON-DELIVERED GOODS OR RETURN OF THE PURCHASE PRICE FOR SUCH GOODS AND IN NO EVENT SHALL EXCEED THE PRICE OR CHARGE FOR SUCH GOODS. GAST EXPRESSLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE WITH RESPECT TO THE GOODS SOLD. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTIONS SET FORTH IN THIS WARRANTY, notwithstanding any knowledge of Gast regarding the use or uses intended to be made of goods, proposed changes or additions to goods, or any assistance or suggestions that may have been made by Gast personnel.

Unauthorized extensions of warranties by the customer shall remain the customer’s responsibility.

CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY OF GAST PRODUCTS FOR CUSTOMER’S USE OR RESALE, OR FOR INCORPORATING THEM INTO OBJECTS OR APPLICATIONS WHICH CUSTOMER DESIGNS, ASSEMBLES, CONSTRUCTS OR MANUFACTURES.

This warranty can be modified only by authorized Gast personnel by signing a specific, written description of any modifications.

www.gastmfg.com

ISO 9001 & 14001 CERTIFIED

WARRANTY

TROUBLESHOOTING CHART

Low High Pump Motor Reason and remedy

Vacuum Pressure Vacuum Pressure Overheat Overload for problem.

• • At pump ••Filter dirty.

• At pump ••Muffler dirty.

• At pump ••Vacuum line collapsed.

••••Relief valve set too high.

•• Relief valve set too low.

••At pump At pump • • Plugged vacuum/pressure line.

•• Vanes sticking.

•• Vanes worn.

•• Shaft seal worn.

•• ••Dust or offset powder in pump.

•• • Motor not wired correctly.

• • • • Running at too high an RPM.

Clean or replace.

Repair or replace.

Inspect and adjust.

Inspect and repair.

Clean or replace.

Replace.

Inspect and clean.

Check wiring diagram and line voltage.