Idex Gast DOA Series - User Manual

LABORATORY OIL-LESS DIAPHRAGM
VACUUM PUMP & COMPRESSOR
OPERATION & MAINTENANCE MANUAL
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/Representative
before using at high altitudes.
• This pump is oil-less and requires NO lubrication.
• Laboratory units may be used for both pressure and vacuum.
IMPORTANT: PLEASE READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE.
Thank you for purchasing this Gast 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.
www.gastmfg.com
ISO 9001 & 14001 CERTIFIED
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright ©2002 Gast Manufacturing Inc. All Rights Reserved.
PART NO. 70 - 5105 G471PL (Rev A)
Model DOA-P704 Shown
1

Summary

INSTALLATION

Mounting

Guidance on securing the pump for stable operation, reducing noise and vibration.

Plumbing

Instructions for connecting intake and exhaust ports, noting port limitations.

Accessories

Information on filters, mufflers, and optional liquid traps for enhanced operation.

Motor Control

Ensuring adequate electrical installation and protection for the motor.

Electrical Connections

Details on grounding, wiring, and using appropriate power sources for safety.

OPERATION

Start-Up Procedure

Procedure for initial operation, including checks for motor function and voltage.

MAINTENANCE

Solvent Cleaning Procedures

Steps for cleaning filters and components using specific solvents for maintenance.

SHUTDOWN PROCEDURES

SERVICE KIT INSTALLATION

Disassembly

Systematic steps for taking the unit apart for maintenance or repair.

Replacing Diaphragm

Instructions for replacing the diaphragm, including torque specifications.

Replacing Leaf Valves

Procedure for replacing leaf valves, ensuring correct orientation and tightening.

Reassembly

Steps for putting the pump back together after maintenance, including alignment.

WARRANTY

PARTS & ORDERING INFORMATION

TROUBLESHOOTING CHART

AUTHORIZED SERVICE FACILITIES

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features
5. Safety Information

The document describes the Gast Laboratory Oil-Less Diaphragm Vacuum Pump & Compressor, Model DOA-P704 (and DOA-P504-BN), an oil-less diaphragm pump designed for both vacuum and pressure applications in laboratory settings. This manual, Part No. 70 - 5105 G471PL (Rev A), provides comprehensive operation and maintenance instructions, emphasizing safety and proper usage for long-term, trouble-free service.

Function Description

The Gast DOA-P704 is a versatile, oil-less diaphragm pump capable of generating both vacuum and pressure. Its oil-less design eliminates the need for lubrication, simplifying maintenance and ensuring that the air stream remains free of oil contaminants, which is crucial for laboratory applications. The pump is designed to handle clean, dry air and can be used for various tasks requiring either a vacuum source or a pressure source.

Important Technical Specifications

While specific performance metrics like maximum vacuum, pressure, and flow rates are not explicitly detailed in the provided pages, the manual highlights several critical operating conditions and design features:

• Oil-Less Operation: The pump is explicitly stated as "oil-less" and requires "NO lubrication," which is a key characteristic for maintaining a clean air stream.
• Operating Temperature Range: Designed to operate within a temperature range of 32°F - 104°F (0°C - 40°C).
• Air Quality Requirement: Must only pump "clean, dry air."
• Material Construction: Constructed of ferrous metals or aluminum, which are susceptible to rust and corrosion when pumping condensable vapors like water, necessitating proper shutdown procedures.
• Electrical Connection: Available in 120-volt and 220/240-volt configurations, requiring proper grounding and adherence to national and local electrical codes. The manual includes a detailed table for minimum wire gage for extension cords based on amperage, voltage, and cord length.
• Motor Control: Emphasizes the importance of selecting appropriate fuses, motor protective switches, or thermal protective switches for motor protection against short circuits and overloads.
• Dual-Voltage Motors: Notes that the power source must be correct for proper operation of dual-voltage motors.
• Sound Level: The sound level from the motor can exceed 70 dBA, indicating a need for hearing protection during operation.

Usage Features

The DOA-P704 is designed for straightforward installation and operation, with several features enhancing its usability:

• Versatile Mounting: The product can be installed in "any orientation," offering flexibility in laboratory setups. Mounting to a stable, rigid surface with shock mounts is recommended to reduce noise and vibration.
• Accessories: Some models are supplied with filters and mufflers. An optional liquid trap is recommended for wet applications. These accessories contribute to the pump's performance and longevity.
• Pressure and Vacuum Regulation: The exploded view and parts list indicate the presence of a pressure gauge (AA806), pressure regulator/relief valve (AF887/AH707), vacuum gauge (AE136), and vacuum regulator/relief valve (AA550C-V), allowing for precise control of output.
• Port Connections: Features IN and OUT ports for plumbing connections, with a caution that ports will not support the weight of the plumbing.
• Laboratory Use: Specifically designed for laboratory units, capable of both pressure and vacuum applications.

Maintenance Features

Maintenance is crucial for the longevity and performance of the DOA-P704, and the manual outlines several key procedures:

• Regular Inspections: Users are responsible for regularly inspecting and repairing the product to maintain proper operation.
• Filter Maintenance: Intake and exhaust filters should be checked after the first 500 hours of operation and cleaned/replaced as necessary. This is a critical step for assuring performance and service life.
• Solvent Cleaning: Recommends using Gast AH255B Solvent or other non-petroleum-based solvents for cleaning. Explicitly warns against using kerosene or any other combustible solvent. The cleaning process involves removing the top plate, filters, and inspecting the head and O-ring for damage.
• Diaphragm Replacement: Detailed instructions are provided for replacing the diaphragm, including the use of Loctite® 222MS thread locker and specific torque values (30 in-lbs) for the retainer plate screws. The diaphragm should be installed with the pattern side up.
• Leaf Valve Replacement: Comprehensive steps for replacing leaf valves are included, emphasizing careful handling of components, proper orientation of the leaf valve (inner curve facing down), and specific torque values (12 to 13 in-lbs) for the valve screw.
• Reassembly Instructions: Clear guidelines for reassembling the pump head and valve assembly, including proper placement of the O-ring, filter elements, and shims. Fasteners for the handle and head assembly should be hand-tightened initially, then torqued to 100 in-lbs in a criss-cross pattern.
• Shutdown Procedures: Crucial for preventing pump damage, especially when pumping condensable vapors. Steps include disconnecting plumbing, operating the product without plumbing for 5 minutes, running at maximum vacuum for 10-15 minutes, repeating the unplumbed operation, disconnecting power, and plugging open ports to prevent contamination.
• Service Kits: Service kits (K294J/K294K) are available and typically contain gaskets, valves, and filter parts, facilitating common maintenance tasks.
• Professional Service: Gast will not guarantee field-rebuilt product performance; for performance guarantee, the product must be returned to a Gast Authorized Service Facility. This highlights the complexity of certain repairs and the importance of professional expertise.

Safety Information

The manual places a strong emphasis on safety, using "DANGER" and "WARNING" alerts throughout:

• Electrical Shock Hazard: Repeated warnings to disconnect electrical power before installation or maintenance. Proper grounding is mandatory.
• Injury Hazard: Warnings about hot product surfaces during operation, the need for proper eye and hearing protection due to potential for solid/liquid material in the air stream and noise levels exceeding 70 dBA, and keeping fingers away from rotating parts.
• Environmental Hazards: Strict warnings against pumping flammable or explosive gases, or using the pump in such atmospheres. Also, cautions against corrosive gases, particulate material, water vapor, oil-based contaminants, or other liquids damaging the unit.
• Overheating Prevention: Emphasizes that blocking airflow can cause the product to overheat.
• Extension Cord Safety: Provides a detailed table for selecting the correct wire gage for extension cords to prevent overheating and potential fire hazards.

Overall, the Gast DOA-P704 is presented as a reliable and versatile oil-less diaphragm pump for laboratory use, with a strong focus on proper installation, operation, and maintenance to ensure safety and extend product life.

Idex Gast DOA Series Specifications