Gast 23 Series - User Manual

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Summary

Installation Procedures

Electrical Shock Hazard

Disconnect power before installing product to prevent shock.

Mounting

Install product on a stable surface using shock mounts for reduced noise.

Operation

Injury Hazard

Avoid touching hot surfaces and wear eye protection from air stream.

Start Up

Ensure correct voltage and motor direction for proper start-up.

Maintenance

Electrical Shock Hazard

Disconnect electrical power before performing maintenance.

Injury Hazard

Allow product to cool; wear eye protection from hot air stream.

General Maintenance

Inspect and clean filters, check O-rings, gaskets, and muffler.

Flushing

Clean pump internally using approved solvent for optimal performance.

Service Kit Installation

Electrical Shock Hazard

Disconnect electrical power supply before installing service kit.

This document is an operation and maintenance manual for the Gast 23 Series Oil-Less Vacuum Pumps & Compressors, identified by Part No. 70-290 G375PL (REV-G). The manual provides essential information for the safe and effective use and upkeep of these devices.

Function Description

The Gast 23 Series comprises oil-less vacuum pumps and compressors designed for various applications. These devices are engineered to move clean, dry air, generating either vacuum or pressure. The "oil-less" design signifies that they do not require lubrication, simplifying maintenance and ensuring that the air stream remains free of oil contamination. The manual illustrates three models: #0523-101, #1023-V103, and #1023-101Q, indicating a range of configurations within the series.

Important Technical Specifications

The manual highlights several critical technical specifications and operating parameters:

Clearances: Top clearance is specified at 0.002 inches, while end clearances range from 0.0015 to 0.005 inches. These precise measurements are crucial for optimal performance and to prevent premature wear.
Vane Life: The expected vane life is between 5,000 and 15,000 hours, depending on the specific application. This indicates the durability of the internal components and provides a guideline for replacement schedules.
Operating Temperature: The pumps and compressors are designed to operate within a temperature range of 32°F to 104°F (0°C to 40°C). Operating outside this range can affect performance and longevity.
Motor Protection: Model numbers ending in "X" are equipped with automatic thermal protectors. These protectors safeguard the motor by shutting it off if it overheats and automatically restart it once it has cooled, preventing damage from excessive temperatures.
Lubrication: As "oil-less" units, they require no lubrication. The sealed bearings are grease-packed, further reducing maintenance needs. The use of petroleum or hydrocarbon products is explicitly warned against, as it will reduce the service life of the carbon vanes.
Materials: The internal components, particularly the vanes, are made of carbon, which is a key aspect of their oil-less operation.

Usage Features

The manual outlines specific criteria and warnings for the proper use of the 23 Series devices:

Air Quality: The pumps are strictly designed to handle only clean, dry air. Pumping corrosive gases, particulate material, water vapor, oil-based contaminants, or other liquids will damage the unit and is explicitly prohibited. Filters are recommended to ensure air quality.
Atmosphere: The devices must not be used to pump flammable or explosive gases, nor should they be operated in atmospheres containing such gases.
Exhaust Air: Exhaust air can become very hot, necessitating protection for surrounding items.
Altitude: For high-altitude applications, users are advised to consult their Gast Distributor, indicating that performance may vary with atmospheric pressure.
Installation: The product can be installed in any orientation. Mounting to a stable, rigid surface with shock mounts is recommended to reduce noise and vibration. Proper installation clearances are essential to prevent blocking airflow, which could lead to overheating.
Plumbing: Plugs must be removed from IN and OUT ports, and connections should use pipes and fittings of the same size or larger than the product's threaded ports. Check valves are required to prevent back-streaming.
Motor Control: Users are responsible for ensuring adequate electrical installation, conforming to national and local codes. This includes determining correct overload settings, selecting appropriate fuses, motor protective switches, or thermal protective switches. The wiring diagram attached to the product provides necessary electrical information, and the power source must be correct for dual-voltage motors.
Start-Up: If the motor fails to start or slows significantly under load, it should be shut off and disconnected from the power supply. Voltage correctness and proper motor direction are crucial, as incorrect operation can drastically reduce vane life or cause damage.
Safety: The manual emphasizes safety with "DANGER" and "WARNING" alerts. Key safety instructions include disconnecting electrical power before installation or maintenance, avoiding contact with water or other liquids, ensuring weather protection, and proper electrical grounding to prevent shock, fire, or serious injury. Product surfaces can become very hot during operation, requiring cooling before handling. Air stream from the product may contain solid or liquid material, necessitating eye and skin protection.

Maintenance Features

The manual provides detailed instructions for both general maintenance and specific flushing procedures:

Regular Inspection: Users are responsible for regularly inspecting and repairing the product to maintain proper operation. Pressure and vacuum must be released before starting maintenance.
Filter Maintenance: Intake and exhaust filters should be checked after the first 500 hours of operation, then regularly thereafter. Filters should be cleaned with compressed air if in good condition or replaced if ripped, torn, brittle, or excessively dirty. Muffler filters should be replaced if compacted with debris.
O-Ring and Gasket Inspection: O-rings should be soft and flexible; if not, they should be replaced. Gaskets should be checked for cracks or tears and replaced if damaged.
Muffler Box: The muffler box should be removed, cleaned, and reinstalled.
Flushing: Two options are provided for flushing the product to remove dirt, foreign particles, moisture, or oil.
- Option 1 (In-situ flushing): Involves attaching pipe nipples, starting the product, and adding Gast AH255B Flushing Solvent (or other non-petroleum based solvent) to the inlet port. The inlet port is then plugged for 20-30 seconds, and the process is repeated. Kerosene or other combustible solvents are strictly prohibited.
- Option 2 (Disassembly and cleaning): If Option 1 is unsuccessful, the end plate is removed. Vanes are checked for free movement and replaced if more than 50% extends past the slot. Vanes and end plates are cleaned with fine emery cloth. The body, rotor, and end plate are flushed with AH255B solvent. All parts are checked for scoring; if scoring is present, the unit should be sent to the factory or replaced.
Service Kit Installation: The manual details the steps for installing a service kit, which typically includes vanes, gaskets, and filter parts. This process also requires disconnecting power and venting air lines. It is noted that Gast does not guarantee field-rebuilt product performance; for a performance guarantee, the product must be returned to a Gast-authorized facility.
Troubleshooting Chart: A comprehensive chart helps diagnose common issues based on symptoms like low/high vacuum or pressure, pump/motor overheat, and provides corresponding remedies such as cleaning/replacing filters, repairing vacuum lines, adjusting relief valves, or checking wiring.
Shutdown Procedures: Proper shutdown involves disconnecting plumbing, operating the product without plumbing for at least five minutes, running at maximum vacuum for 10-15 minutes, repeating the unplumbed operation, disconnecting power, and plugging open ports to prevent contamination.
Warranty: Gast warrants finished products to be free from defects in material and workmanship for twelve months from the purchase date from Gast or an authorized representative. The warranty excludes electric motors, electrical controls, gasoline engines not supplied by Gast, and damage due to misuse, lack of maintenance, neglect, accident, or transit. Gast's liability is limited to the cost of the product or a refund, and it is not responsible for indirect or consequential damages. The warranty explicitly disclaims merchantability or fitness for a particular purpose.