Gast AT05 User Manual

PART NO. 70-299 G379 (REV-C)

WARNING

PLEASE READTHIS MANUAL COMPLETELY BEFORE INSTALLING AND USING

THIS PRODUCT. SAVETHIS MANUAL FOR FUTURE REFERENCE AND

KEEP INTHE VICINITY OF THE PRODUCT.

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AT03-AT05 SERIES OILLESS

COMPRESSORS

OPERATION & MAINTENANCE MANUAL

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

using quality materials. Please follow all recommended maintenance, operational

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

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 manufacturer 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.

Your safety and the safety of others

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Disconnect electrical power at the circuit breaker
or fuse box before installing this product.

Install this product where it will not come into
contact with water or other liquids.

Install this product where it will be weather
protected.

Electrically ground this product.

Failure to follow these instructions can result in
death, fire or electrical shock.

WARNING

Electrical Shock Hazard

Air stream from product may contain solid or liquid
material that can result in eye or skin damage, wear
proper eye protection.

Do not pump flammable or explosive gases or use
in atmospheres that contain such gases.

Failure to follow these instructions can result in
fire, burns, eye injury or other serious injury.

WARNING

Injury

Hazar

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Product surfaces become very hot during operation,
allow product surfaces to cool before handling.

is extremely important.

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

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

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:

DANGER

You will
instructions.

be killed or seriously injured if you don’t follow

WARNING

You can
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.

INSTALLATI ON

be killed or seriously injured if you don’t follow

Motor Control

It is your responsibility to contact a qualified
electrician and 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.

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

OPERATION

Correct installation is your responsibility. Make sure you

have the proper installation conditions and that
installation clearances do not block air flow.

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.

It is your responsibility to operate this product at
recommended pressures or vacuum duties and room
ambient temperatures.

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.

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.

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MAINTENANCE

c

Disconnect electrical power supply cord before
performing maintenance on this product.

If product is hard wired into system, disconnect
electrical power at the circuit breaker or fuse box
before performing maintenance on this product.

Failure to follow these instructions can result in
death, fire or electrical shock.

Electrical Shock Hazard

WARNING

Air stream from product may contain solid or liquid
material that can result in eye or skin damage.

Flush this product in a well ventilated area.
Do Not use kerosene or other combustible solvents

to flush this product.

WARNING

Injury Hazard

Wear eye protection when flushing this product.

Failure to follow these instructions can result in
eye injury or other serious injury.

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. There are 2 options for this operation.
If Option 1 does not remedy your problem, go on to
Option 2.

Use only Gast Flushing Solvent or other non-petroleum
based flushing solvent. Do Not use kerosene or ANY
other combustible solvents to flush product.

Option 1

You will need 2 pipe nipples at least 4 inches long with
appropriate thread size for the unit involved. No nipples
are needed if the unit does not have a muffler box.

1. Remove filter and muffler cap (#9).

2. Remove 5 bolts. Use a small hammer to tap on
muffler box to remove it. Attach pipe nipples
where muffler caps were removed.

3. Start product and add flushing solvent to the inlet
port. If using liquid solvent, pour several
tablespoons directly into the inlet port. If using Gast
spray solvent, spray for 5-10 seconds into inlet
port. Place towel over exhaust port to clean up
solvent.

4. Plug inlet port for 20-30 seconds. Listen for
changes in the sound of the pump. If pump sounds
smooth, go to next step. If pump does not sound
like it is running smoothly, installing a Service Kit will

be required (See Service).

5. Release vacuum.

6. Repeat steps 3-5 three or four times.

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.

General Maintenance

1. Remove end cap and filters. Inspect filters for

rips,tears, cuts, brittleness and excessive foreign
material.

2. Clean filters if in good condition with
compressed air. Re-inspect for wear conditions.
Set filters aside.

3. Check both internal and external filter felts (#8 and

#11 on exploded view) for foreign material. If felts
are dirty or worn, replace with new felts.

4. Check condition of O-ring on internal filter. It should
be soft and flexible. Replace if it is not.

5. Remove and inspect muffler box. Clean box. Set
box aside. (Not all models have a muffler box.)

6. Check gasket for cracks or tears. Install new gasket
if any cracks or tears appear. Replace gasket.

7. Reinstall muffler box. Torque bolts to 90-120 in. lb.

8. Reinstall filters or install new filters if required.
Reinstall end cap finger tight.

If Option 1 is not successful, remove the end plate and
examine.

Option 2

1. Remove six end plate bolts. (See exploded view.)

2. Use a small hammer to carefully tap on end plate to
remove. Do not use a screwdriver to pry off.

3. Check that vanes are moving freely in and out of
vane slots. Replace vanes if more than 50% of the
vane extends past the vane slot.

4. Remove vanes and clean both sides with fine emery
cloth. Clean end-plate with fine emery cloth.

5. Flush vanes with solvent and remove all
solvent from vanes.

6. Flush body, rotor and end plate with solvent, then
remove all solvent from each part.

7. Check body, rotor and end plate for scoring. If each
part is clean and shows no signs of scoring,
re-install parts. If scoring appears,
send unit to factory or replace with new part(s).

8. Insert vanes, checking that the bevel edges are in

the correct direction.

9. Replace end plate. Torque bolts to 90-120 in. lb.

10. Check gasket for damage.

11. Reinstall muffler box. Torque bolts to 90-120 in. lb.

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

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