Gast NL52 User Manual

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ISO 9001 & 14001 CERTIFIED

®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright © 2003 Gast Manufacturing Inc. All Rights Reserved.

ART NO. 45-115 D150B (Rev. N)

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NL SERIES NON-LUBRICATED AIR MOTORS

OPERATION & MAINTENANCE MANUAL

Model NL22 Shown

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

using quality materials. This manual includes general safety instructions for operation under normal
conditions and for operation in hazardous conditions. Please follow all recommended maintenance,

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

Model NL32 Shown

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.

General information:

Operating Pressure: 80 psi or below (7 bar)

Product Use Criteria:

•Normal conditions: Operate at temperatures up to
250ºF (121ºC).

•Hazardous conditions: Operate at temperatures up to
104ºF (40ºC).

• Protect unit from dirt and moisture.

•Use ONLY compressed air to drive motor.

•Air lines connected to motor should be the same size or

the next size larger than the inlet port for efficient
output and speed control.

•Protect all surrounding items from exhaust air.

•Bearings are grease packed.

• Motors are to be used in commercial installations only

• This symbol appears on labels of air motors

that are designed for use in hazardous
atmospheres. These air motors comply with the
applicable standards and specifications and meet
the requirements of the guidelines of the EC
directive 94/9EC (ATEX 100a). They are intended to

be used in zones 1 and 2 where explosive
atmospheres are likely to occur.

• Air supply, directional control valve and pressure
regulator

should be selected based upon the air consumption
of the motor.

1

Your safety and the safety of others

is extremely important.

e have provided many important safety messages in

W
this manual and on your product. Always read and
obey all safety messages.

his is the safety alert symbol. This symbol

T
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

essages. These words mean:

m

DANGER

e killed or seriously injured if you don’t follow

b

ou will

Y
instructions.

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.

be killed or seriously injured if you don’t follow

Complete the following checklist prior to

starting installation in a hazardous area. All
actions must be completed in accordance with ATEX
100a.

Checklist for installation in hazardous areas:

Read air motor label to check that
motor has been designed for use
in a hazardous application:

• Hazardous zone

• Hazardous category

• Equipment group

• Temperature class

• Maximum surface temperatures

Example:
Model designation: 1UP-NRV-10
Year manufactured: 2003

Gast Mfg. Corp.
II 2GD c +1Cº Ta +40Cº
Benton Harbor, MI USA
Telephone: [phone]

* Legend:
II Equipment group II
2 Equipment category 2
G Gas atmospheres
D Dust atmospheres
c Constructional safety
+1CTa +40C* Max. surface temp. 275ºF/135ºC

Ambient range +1Cº to +40ºC (34ºF/104ºF)
Check the site environment for potentially
explosive oils, acids, gases, vapors or radiation

Check the ambient temperature of the site and
the ability to maintain proper ambient
temperature.
Ambient range:
Normal conditions: 34ºF/1ºC to 250ºF/121ºC
Hazardous conditions: 34ºF/1ºC to 104ºF/40ºC

Check the site to make sure that the air motor
will be adequately ventilated and that there is no
external heat input (e.g. couplings). The cooling
air may not exceed 104ºF/40ºC.

Check that products to be driven by the air
motor meet ATEX approval.

Check that the air motor is not damaged.

Improper environment, installation and operation can
result in severe personal injury and/or damage to
property.

Qualified personnel must perform all work to assemble,
install, operate, maintain and repair air motor.

Qualified personnel must follow:

• These instructions and the warning and information
labels on the motor.

• All other drive configuration documents, startup
instructions and circuit diagrams.

• The system specific legal regulations and
requirements.

• The current applicable national and regional
specifications regarding explosion protection,
safety and accident prevention.

2

INSTALLATION

Correct installation is your responsibility. Make sure you

have the proper installation conditions.

Injury Hazard

Install proper guards around output shaft as needed.

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

Wear proper eye protection when installing this product.

Failure to follow these instructions can result in
serious injury or property damage.

Mounting

This product can be installed in any orientation. Mount
the motor to a solid metal base plate that is mounted to

stable, rigid operating surface. Use shock mounts to

a
reduce noise and vibration. Install a pressure regulator
or simple shut-off valve to control motor.

Accessories

A muffler is shipped with the air motor (except 16AM)
but is not installed. Consult your Gast
Distributor/Representative for additional filter
recommendations. Install a moisture trap and 5 micron
filter in the air line ahead of motor.

Connection

Check the direction of the motor airflow. A single
rotation motor will operate properly only in one
direction.
Single rotation motors require a sound absorber to be
connected to the exhaust air port. Remove the plastic
shipping plugs from the ports. Save plugs for future
use during shutdown.

Install a 5-micron filter in the air line before the
connection to the motor. Next install an air pressure
regulator to control motor speed and torque.

Clean the compressed air connection with low pressure
air to remove any dirt from the line before connecting to
the ports.

Use the proper sized fasteners. For the most efficient
output and control of speed, use air lines that are the
same size as the motor inlet port if the connection is
less than 7 feet (2 meters). For longer connections, use
the next pipe size larger than the motor intake port.
Connect lines to motor in the proper direction.

Air consumption data at various speeds and pressures
are available from your Gast Distributor/Representative

r the factory.

o

OPERATION

Injury Hazard

Air stream from product may contain solid or liquid
material that can result in eye or skin damage.
DO NOT use combustible gases to drive this motor.

Wear hearing protection. Sound level from motor
may exceed 85 db(A).

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

Check all connections before starting motor. It is your
responsibility to operate this product at recommended
speeds, loads and room ambient temperatures. Do not
run the motor at high speeds with no load. This will
result in excessive internal heat that may cause motor
damage.

The starting torque is less than the running torque. The
starting torque will vary depending upon the position of
the vanes when stopped in relation to the air intake
port.

Connect the sound absorber on the exhaust air port or
valve connection.

Do not add any thrust to the end or side of the shaft
when making connections.

Do not use a hammer on the shaft or
connections.

Lubricating the drive shaft will make assembly
easier. Use a puller for removal of pulleys,
couplings and pinions on the motor shaft.

Check that the tension on the belt pulley
matches the manufacturer’s specifications. Do not
exceed the maximum radial and axial forces on the
shaft. If the motor shaft is connected to the part to be
driven without a coupling, check that the radial offset
and axial force effect will not cause problems.

Use only belts with < 109electrical leakage
resistance to prevent static electrical problems.
Ground the motor.

Use a pressure regulator and/or simple shut-off valve to
regulate the motor’s speed and torque. This will
provide the required power and will conserve air. Open
the air supply valve to the motor. Set the pressure or
flow rate to the required speed or torque.

Operate the motor for approximately 2 hours at
the maximum desired load. Measure the

surface temperature of the motor on the casting
opposite the pipe ports. The maximum surface
temperature listed on the motor is for normal
environmental and installation conditions. For most air
motors, the maximum surface temperature should not
exceed 266ºF /130ºC. Do not continue to operate the
motor if the measured surface temperature exceeds
temperature listed on the motor. If your measured
temperature does exceed listed value, consult with your
Gast Distributor/Representative for a recommendation.

3

MAINTENANCE

Injury Hazard

isconnect air supply and vent all air lines.

D

ear eye protection when flushing this product.

W

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.

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

It is your responsibility to regularly inspect and make
necessary repairs to this product in order to maintain
proper operation.

4. Check the air compressor.

5. Listen for changes in the sound of the motor.
If motor sounds smooth, you are finished.
If motor does not sound like it running smoothly,
installing a service kit will be required
(See “Service Kit Installation”).

Shutdown

It is your responsibility to follow proper shutdown
procedures to prevent product damage.

1. Turn off air intake supply.

2. Disconnect air supply and vent all air lines.

3. Disconnect air lines.

. Remove air motor from connecting machinery.

4

5. Remove the muffler.

6. Wear eye protection. Keep away

from air stream. Use clean, dry air

to remove condensation from the inlet port of

the motor.

7. Plug or cap each port.

8. Coat output shaft with oil or grease.

9. Store motor in a dry environment.

SERVICE KIT INSTALLATION

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 assure the motor’s performance
and service life.

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. Flush the motor if it is operating slowly
or inefficiently.

Use only Gast recommended Flushing Solvent.
DO NOT use kerosene or ANY other combustible
solvents to flush this product.

1. Disconnect air line and muffler.

2. Add flushing solvent directly into motor. If using
liquid solvent, pour several tablespoons directly
into the intake port. If using spray solvent,
spray for 5-10 seconds into intake port.

3. Rotate the shaft by hand in both directions for a
few minutes.

4. You must wear eye protection for this step.
Cover exhaust with a cloth and reconnect the air
line.

5. Restart the motor at a low pressure of
approximately 10 PSI/ 0.7 bar until there is no
trace of solvent in the exhaust air.

6. Listen for changes in the sound of the motor.
If motor sounds smooth, you are finished.
If motor does not sound like it is running smoothly,
installing a service kit will be required
(See “Service Kit Installation”).

Check that all external accessories such as relief valves
or gauges are attached and are not damaged before
operating product.

Cleaning sound absorber

1. Remove the sound absorber.

2. Clean the felt filter.

3. You must wear eye protection for this step.

4

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, end cap
gasket, body gasket, bearings and a muffler element or
felt.

Major and Minor Rebuilds Tool kits which include a
more in-depth rebuild manual are available through your
Gast Distributor/Representative. These kits include the

tools required to remove and reassemble end plates,
bearings and shaft seals, and to set the proper end
clearance. The rebuild manual also includes step by
step instructions, including illustrations, to help achieve
a successful rebuild. Gast Manufacturing, Inc. highly
recommends using the air motor rebuild manual and
tool kit when attempting a minor or major rebuild to
your Gast air motor.

Minor Rebuild:

1. Remove the end cap.

2. Remove dead end plate bolts.

3. Remove dead end plate. (Use factory issued tool,
do not use screwdriver to remove the end plate.)

4. Remove the dowel pins from the body and push
back into end plate until flush or just below the
machined surface of the end plate.

5. Remove vanes.

6. Clean parts. Check for scoring on the end plate
and rotor assembly. If scoring exists, send unit to
a Gast authorized service facility.

7. Install vanes. Angle cuts on vanes face to
center of rotor.

8. Place the proper end plate gasket on the end
plate. If the original is damaged, replace with a
new one supplied in the Service Kit.

9. Place the dead end plate on the body.

10. Press the bearing onto the shaft using a factory
supplied bearing pusher.