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FSB-C-804Air Compressor
MADE IN
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User’s Guide
Servicing North America:U.S.A.: Omega Engineering, Inc., One Omega Drive, P.O. Box 4047ISO 9001 Certified Stamford, CT 06907-0047 USA
Toll Free: 1-800-826-6342 TEL: (203) 359-1660FAX: (203) 359-7700 e-mail: [email protected]
Canada: 976 BergarLaval (Quebec), H7L 5A1 CanadaToll-Free: 1-800-826-6342 TEL: (514) 856-6928FAX: (514) 856-6886 e-mail: [email protected]
For immediate technical or application assistance:U.S.A. and Canada: Sales Service: 1-800-826-6342/1-800-TC-OMEGA®
Customer Service: 1-800-622-2378/1-800-622-BEST®
Engineering Service: 1-800-872-9436/1-800-USA-WHEN®
Mexico/ En Español: 001 (203) 359-7803 FAX: 001 (203) 359-7807Latin America: [email protected] e-mail: [email protected]
Servicing Europe:Benelux: Managed by the United Kingdom Office
Toll-Free: 0800 099 3344 TEL: +31 20 347 21 21FAX: +31 20 643 46 43 e-mail: [email protected]
Czech Republic: Frystatska 184733 01 Karviná, Czech RepublicToll-Free: 0800-1-66342 TEL: +420-59-6311899FAX: +420-59-6311114 e-mail: [email protected]
France: Managed by the United Kingdom OfficeToll-Free: 0800 466 342 TEL: +33 (0) 161 37 29 00FAX: +33 (0) 130 57 54 27 e-mail: [email protected]
Germany/ Austria: Daimlerstrasse 26D-75392 Deckenpfronn, GermanyToll-Free: 0800 6397678 TEL: +49 (0) 7056 9398-0FAX: +49 (0) 7056 9398-29 e-mail: [email protected]
United Kingdom: OMEGA Engineering Ltd.ISO 9001 Certified One Omega Drive, River Bend Technology Centre, Northbank
Irlam, Manchester M44 5BD United KingdomToll-Free: 0800-488-488 TEL: +44 (0) 161 777-6611FAX: +44 (0) 161 777-6622 e-mail: [email protected]
OMEGAnet® Online Service Internet e-mailomega.com [email protected]
It is the policy of OMEGA Engineering, Inc. to comply with all worldwide safety and EMC/EMIregulations that apply. OMEGA is constantly pursuing certification of its products to the European NewApproach Directives. OMEGA will add the CE mark to every appropriate device upon certification.The information contained in this document is believed to be correct, but OMEGA accepts no liability for anyerrors it contains, and reserves the right to alter specifications without notice.WARNING: These products are not designed for use in, and should not be used for, human applications.
23 SERIES OIL-LESSVACUUM PUMPS & COMPRESSORS
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 contaminantsor other liquids must be filtered out.
• Consult your Gast Distributor before using at highaltitudes.
• Oil-Less rotary-vanes require NO lubrication.• Sealed bearings are grease packed.• Use of petroleum or hydrocarbon products will
reduce carbon-vane service life.
Thank you for purchasing this Gast product. It is manufactured to the highest standardsusing quality materials. Please follow all recommended maintenance, operational
and safety instructions and you will receive years of trouble free service.
General information
• Clearances: Model 0323/0523Top: .0015”End: .0015”Model 0823/1023Tops .003”End : .002”
• Vane Life: 5,000-15,000 hours dependingupon application
• Model numbers ending in “X” have automatic thermalprotectors which protect the motor by shutting the motoroff if it overheats. The motor will automatically restartonce the motor has cooled.
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING
THIS PRODUCT. SAVE THIS MANUAL FOR FUTURE REFERENCE AND
KEEP IN THE VICINITY OF THE PRODUCT.
Your safety and the safety of othersis extremely important.
We have provided many important safety messagesin this manual and on your product. Always readand obey all safety messages.
This is the safety alert symbol. This symbolalerts you to hazards that can kill or hurt you andothers. The safety alert symbol and the words“DANGER” and “WARNING” will precede all safetymessages. These words mean:
You will be killed or seriously injured if you don’tfollow instructions.
You can be killed or seriously injured if you don’tfollow instructions.
All safety messages will identify the hazard, tell youhow to reduce the chance of injury, and tell youwhat can happen if the safety instructions are notfollowed.
Correct installation is your responsibility. Make sureyou have the proper installation conditions and thatinstallation clearances do not block air flow.
Blocking air flow over the product in any way cancause the product to overheat.
MountingThis product can be installed in any orientation.Mounting the product to a stable, rigid operating surfaceand using shock mounts will reduce noise and vibration.
INSTALLATION
Motor ControlIt is your responsibility to contact a qualifiedelectrician and assure that the electrical installation isadequate and in conformance with all national and localcodes and ordinances.
Determine the correct overload setting required toprotect the motor (see motor starter manufacturer’srecommendations). Select fuses, motor protectiveswitches or thermal protective switches to provideprotection. Fuses act as short circuit protection for themotor, not as protection against overload. Incoming linefuses help to withstand the motor’s starting current.Motor starters with thermal magnetic overload or circuitbreakers protect motor from overload or reducedvoltage conditions.
The wiring diagram attached to the product providesrequired electrical information. Check that powersource is correct to properly operate the dual-voltagemotor.
AccessoriesThe product’s intake and exhaust filters will provideadequate filtration in most applications. Consult yourGast representative for additional filterrecommendations. Install relief valves and gauges atinlet or outlet, or both, to monitor performance. Checkvalves are required to prevent back streaming throughthe pump.
OPERATION
WARNING
DANGER PlumbingRemove plugs from the IN and OUT ports. Connectwith pipe and fittings that are the same size or largerthan the product’s threaded ports.
Electrical Shock Hazard
Disconnect electrical power at the circuitbreaker or fuse box before installing thisproduct.Install this product where it will not come intocontact with water or other liquids.
Install this product where it will be weatherprotected.Electrically ground this product.Failure to follow these instructions can resultin death, fire or electrical shock. Injury Hazard
Product surfaces become very hot duringoperation,allow product surfaces to cool before handling.Air stream from product may contain solid or liquidmaterial that can result in eye or skin damage,wear proper eye protection.Failure to follow these instructions can result inburns, eye injury or other serious injury.
2
FlushingFlushing this product to remove excessive dirt, foreignparticles, moisture or oil that occurs in the operatingenvironment will help to maintain proper vaneperformance. There are 2 options for this operation.If Option 1 does not remedy your problem, go on toOption 2.
Use only Gast recommended flushing solvent orother non-petroleum based flushing solvent. DoNot use kerosene or ANY other combustiblesolvents to flush product.
Option 1You will need 2 pipe nipples at least 4 inches long with1/4” NPT for 0323 and 0523 products, or 3/8” NPT onone end for 0823 and 1023 products. No nipples areneeded 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 nippleswhere muffler caps were removed.
3. Start product and add flushing solvent to the inletport. If using liquid solvent, pour severaltablespoons directly into the inlet port. If using Gastrecommended spray solvent, spray for 5-10seconds into inlet port. Place towel over exhaustto clean up solvent.
4. Plug inlet port for 20-30 seconds. Listen forchanges in the sound of the pump. If pump soundssmooth, go to next step. If pump does not soundike it is running smoothly, installing a Service Kitwill be required (See Service).
5. Release vacuum.6. Repeat steps 3-5 three or four times.
If Option 1 is not successful, remove the end plateand examine.
MAINTENANCE
Electrical Shock Hazard
Disconnect electrical power supply cord beforeperforming maintenance on this product.If product is hard wired into system, disconnectelectrical power at the circuit breaker or fuseboxbefore performing maintenance on this product.
Failure to follow these instructions can result indeath, fire or electrical shock.
Injury HazardProduct surfaces become very hot duringoperation,allow product surfaces to cool before handling.Air stream from product may contain solid orliquidmaterial that can result in eye or skin damage,wear proper eye protection.Flush this product in a well ventilated area.
Failure to follow these instructions can result inburns, eye injury or other serious injury.
General Maintenance1. Remove end cap and filters. Inspect filters for
rips,tears, cuts, brittleness and excessive foreignmaterial.
2. Clean filters if in good condition withcompressed air. Re-inspect for wear conditions.Set filters aside.
3. Check filter/muffler (#11) for compacted debris. Ifdebris is present, replace filter/muffler.
4. Check condition of O-ring. It should be soft andflexible. Replace if it is not.
5. Remove and inspect muffler box. Clean box. Setbox aside. (Not all models have a muffler box.)
6. Check gasket for cracks or tears. Install newgasketif any cracks or tears appear. Replace gasket.
7. Replace muffler box.8. Reinstall filters or install new filters if required.
Reinstall end cap.
It is your responsibility to operate this product atrecommended pressures or vacuum duties androom ambient temperatures.
Start UpIf motor fails to start or slows down significantly underload, shut off and disconnect from power supply. Checkthat the voltage is correct for motor and that motor isturning in the proper direction. Vane life will bedrastically reduced if motor is not operating properly.Vanes can break or be damaged if motor/pump runs inthe wrong direction.
Model numbers ending in “X” have automaticthermal protectors which protect the motor byshutting the motor off if it overheats. The motor willautomatically restart once the motor has cooled.
3
SERVICE KIT INSTALLATION
SHUTDOWN PROCEDURES
It is your responsibility to follow proper shutdownprocedures to prevent product damage.NEVER ADD OIL TO THIS OIL-LESS PUMP.
1. Disconnect plumbing.2. Operate product for at least five 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.
Gast will NOT guarantee field-rebuilt productperformance. For performance guarantee, theproduct must be returned to a Gast-authorizedfacility.
Service Kit contents vary. Most contain vanes, gasketsand filter parts.
1. Remove filter/muffler parts from front of muffler box.2. Remove the 5 muffler box bolts.3. Use a small hammer to tap on box to remove. Do
not use a screwdriver.4. Remove the 6 end plate bolts.5. Remove end plate. Check direction of bevel edges
of vanes then remove vanes.6. Clean body and rotor slots.7. Check end plate, rotor and body for scoring.
Severe scoring or worn bearings will requireservice at a Gast-authorized facility.
DO NOT remove rotor or motor bolts.
8. Insert vanes, checking that the bevel edges are inthe 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 reliefvalves and gauges are attached and are not damagedbefore re-operating product.
Electrical Shock HazardDisconnect electrical power supply cord beforeinstalling service kit.
If product is hard wired into system, disconnectelectrical power at the circuit breaker or fusebox before installing service kit.Vent all air lines to release pressure or vacuum.
Failure to follow these instructions can result indeath, fire or electrical shock.
Option 21. 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 thevane extends past the vane slot.
4. Remove vanes and clean both sides with fine emerycloth. Clean end-plate with fine emery cloth.
5. Flush vanes with Gast recommended solvent andremove all solvent from vanes.
6. Flush body, rotor and end plate with Gastrecommended solvent, then remove all solvent fromeach part.
7. Check body, rotor and end plate for scoring. Ifeach part is clean and shows no signs of scoring,re-install parts. If scoring appears, send unit tofactory or replace with new part(s).
Check that all external accessories such as reliefvalves and gauges are attached to cover and arenot damaged before re-operating product.
4
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REF
DESCRIPTION
QTY
0323-101
0323-101Q
0523-101
0523-101Q
0523-V103
1BODY
1AK503
AK503
AK505
AK505
AK505
2*
VANE
4AH850A
AH850A
AH850A
AH850A
AH850A
3SHROUD
1AK502
AK502
AK502
AK502
AK502
4ENDPLATE
1AK516A
AK501
AK516A
AK501
AK516A
5*
GASKET
1AK521
AK521
6MUFFLERBOX
1AK519
AK519
7*
O-RING
2AK473
AK473
8*
FELT
2AK524
AK524
9ENDCAP
2AK510
AK510
10ENDCAPASSEMBLY
2AK526
AK526
11FILTER/MUFFLER
1AK840A
AK840A
12FOOTSUPPORT
1AC136
AC136
13ELBOW***
2AD997
14MUFFLERASSEMBLY
1V425L
15JAR
2AA125A
16COVER
1AV427APC
17FELTFILTER
4B344A
18SUPPORT
1B345A
19COVERGASKET
2B62A
20FILTERASSEMBLY
1V400G
21COVER
1AV402CPC
22FILTERASSEMBLY
1B343B
23SCREENCAP
1AJ571
24FELTSUPPORT
1B347
SERVICEKIT
1K478A
K478
K478A
K478
K559
Muf
fler
Asse
mbl
y
Vacu
umIn
take
Filte
rAss
embl
y
EXPLODEDPRODUCTVIEW,PARTS&ORDERINGINFORMATION
5
REF
DESCRIPTION
QTY0823-1010823-101Q1023-1011023-101Q1023-V1031423-101Q
1BODY
1AK517
AK517
AK518
AK518
AK518
AL283
2*
VANE
4AK513
AK513
AK513
AK513
AK513
AL284
3SHROUD
1AK511
AK511
AK511
AK511
AK511
AL281
4ENDPLATE
1AK515A
AK514
AK515A
AK514
AK515A
AK514
5*
GASKET
1AK522
AK522
AK522
6MUFFLERBOX
1AK520
AK520
AK520
7*
O-RING
2AK473
AK473
AK473
8*
FELT
2AK524
AK524
AK524
9ENDCAP
2AK510
AK510
AK510
10ENDCAPASSEMBLY
2AK526
AK526
AK526
11FILTER/MUFFLER
1AK840
AK840
AC432
12ELBOW
1BA206
12ELBOW***
2AF272
13MUFFLERASSEMBLY
1AB599B
13a
NIPPLE
2BA714
14JAR
2AA805
15COVERGASKET
2AA405
16COVERASSEMBLY
1AV805BPC
17MUFFLERASSEMBLY
1AC434-1
18COUPLING
2AC391
19CARTRIDGE
2AC393
20ENDCAPASSEMBLY
2AC394
21MUFFLERPLATE
1AC395
22STUD
2AC396
23FILTERASSEMBLY
1AB599
24COVERASSEMBLY
1AV805APC
25FILTERASSEMBLY
1AC433-1
SERVICEKIT
1K479A
K479
K479A
K479
K479A
K575A
For1
423
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els
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EXPLODEDPRODUCTVIEW,PARTS&ORDERINGINFORMATION
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6
MAINTENANCE RECORD
DATE PROCEDURE PERFORMED
7
TROUBLESHOOTING CHART
Low High Pump Motor Reason and remedyVacuum Pressure Vacuum Pressure Overheat Overload for problem.
• • At pump • • Filter dirty.Clean or replace.
• At pump • • Muffler dirty.Clean or replace.
• At pump • • Vacuum line collapsed.Repair or replace.
• • • Relief valve set too high.Inspect and adjust.
• • Relief valve set too low.Inspect and adjust.
• • At pump At pump • • Plugged vacuum/pressure line.Inspect and repair.
• • Vanes sticking.Clean or replace.
• • Vanes worn.Replace.
• • Shaft seal worn.Replace.
• • • • Dust or offset powder in pump.Inspect and clean.
• • • • Motor not wired correctly.Check wiring diagram and line voltage.
WARRANTY/DISCLAIMEROMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for aperiod of 13 months from date of purchase. OMEGA’s WARRANTY adds an additional one (1) monthgrace period to the normal one (1) year product warranty to cover handling and shipping time. Thisensures that OMEGA’s customers receive maximum coverage on each product. If the unit malfunctions, it must be returned to the factory for evaluation. OMEGA’s Customer ServiceDepartment will issue an Authorized Return (AR) number immediately upon phone or written request.Upon examination by OMEGA, if the unit is found to be defective, it will be repaired or replaced at nocharge. OMEGA’s WARRANTY does not apply to defects resulting from any action of the purchaser,including but not limited to mishandling, improper interfacing, operation outside of design limits, improper repair, or unauthorized modification. This WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence of having been damaged as a result of excessive corrosion;or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operatingconditions outside of OMEGA’s control. Components in which wear is not warranted, include but are not limited to contact points, fuses, and triacs.OMEGA is pleased to offer suggestions on the use of its various products. However, OMEGA neither assumes responsibility for any omissions or errors nor assumes liability for anydamages that result from the use of its products in accordance with information provided byOMEGA, either verbal or written. OMEGA warrants only that the parts manufactured by thecompany will be as specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OFTITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. LIMITATION OF LIABILITY: The remedies of purchaser set forth herein are exclusive, and the total liability of OMEGA with respect to this order, whether based on contract, warranty, negligence, indemnification, strict liability or otherwise, shall not exceed the purchase price of the component upon which liability is based. In no event shall OMEGA be liable for consequential, incidental or special damages.CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as a “BasicComponent” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medicalapplications or used on humans. Should any Product(s) be used in or with any nuclear installation oractivity, medical application, used on humans, or misused in any way, OMEGA assumes no responsibilityas set forth in our basic WARRANTY/DISCLAIMER language, and, additionally, purchaser will indemnifyOMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of theProduct(s) in such a manner.
RETURN REQUESTS/INQUIRIESDirect all warranty and repair requests/inquiries to the OMEGA Customer Service Department. BEFORERETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN(AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOIDPROCESSING DELAYS). The assigned AR number should then be marked on the outside of the returnpackage and on any correspondence.The purchaser is responsible for shipping charges, freight, insurance and proper packaging to preventbreakage in transit.
FOR WARRANTY RETURNS, please have the following information available BEFORE contacting OMEGA:1. Purchase Order number under which the product
was PURCHASED,2. Model and serial number of the product under
warranty, and3. Repair instructions and/or specific problems
relative to the product.
FOR NON-WARRANTY REPAIRS, consult OMEGAfor current repair charges. Have the followinginformation available BEFORE contacting OMEGA:1. Purchase Order number to cover the COST
of the repair,2. Model and serial number of the product, and3. Repair instructions and/or specific problems
relative to the product.
OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible. This affordsour customers the latest in technology and engineering.OMEGA is a registered trademark of OMEGA ENGINEERING, INC.© Copyright 2012 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied, photocopied,reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without theprior written consent of OMEGA ENGINEERING, INC.
M5158/0612
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