FSB-C-804

FSB-C-804
MADE IN
User’s Guide
Shop online at
omega.com ®
e-mail: [email protected]
For latest product manuals:
omegamanual.info
FSB-C-804
Air Compressor
OMEGAnet ® Online Service
omega.com
Internet e-mail
[email protected]
Servicing North America:
U.S.A.:
ISO 9001 Certified
Canada:
Omega Engineering, Inc., One Omega Drive, P.O. Box 4047
Stamford, CT 06907-0047 USA
Toll Free: 1-800-826-6342
TEL: (203) 359-1660
FAX: (203) 359-7700
e-mail: [email protected]
976 Bergar
Laval (Quebec), H7L 5A1 Canada
Toll-Free: 1-800-826-6342
FAX: (514) 856-6886
TEL: (514) 856-6928
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/
Latin America:
En Español: 001 (203) 359-7803
[email protected]
FAX: 001 (203) 359-7807
e-mail: [email protected]
Servicing Europe:
Benelux:
Managed by the United Kingdom Office
Toll-Free: 0800 099 3344
TEL: +31 20 347 21 21
FAX: +31 20 643 46 43
e-mail: [email protected]
Czech Republic:
Frystatska 184
733 01 Karviná, Czech Republic
Toll-Free: 0800-1-66342
FAX: +420-59-6311114
France:
TEL: +420-59-6311899
e-mail: [email protected]
Managed by the United Kingdom Office
Toll-Free: 0800 466 342
TEL: +33 (0) 161 37 29 00
FAX: +33 (0) 130 57 54 27
e-mail: [email protected]
Germany/ Austria: Daimlerstrasse 26
D-75392 Deckenpfronn, Germany
Toll-Free: 0800 6397678
FAX: +49 (0) 7056 9398-29
United Kingdom:
ISO 9001 Certified
TEL: +49 (0) 7056 9398-0
e-mail: [email protected]
OMEGA Engineering Ltd.
One Omega Drive, River Bend Technology Centre, Northbank
Irlam, Manchester M44 5BD United Kingdom
Toll-Free: 0800-488-488
TEL: +44 (0) 161 777-6611
FAX: +44 (0) 161 777-6622
e-mail: [email protected]
It is the policy of OMEGA Engineering, Inc. to comply with all worldwide safety and EMC/EMI
regulations that apply. OMEGA is constantly pursuing certification of its products to the European New
Approach 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 any
errors 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-LESS
VACUUM PUMPS & COMPRESSORS
OPERATION & MAINTENANCE MANUAL
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.
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.
General information
• Clearances:
Model 0323/0523
Top:
.0015”
End:
.0015”
Model 0823/1023
Tops
.003”
End :
.002”
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 before using at high
altitudes.
• Vane Life:
5,000-15,000 hours depending
upon application
• 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.
• 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
is extremely important.
We have provided many important safety messages
in this manual and on your product. Always read
and obey all safety messages.
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 be killed or seriously injured if you don’t
follow instructions.
WARNING
You can be killed or seriously injured if you don’t
follow 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.
INSTALLATION
Electrical Shock Hazard
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.
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.
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.
Accessories
The product’s intake and exhaust filters will provide
adequate filtration in most applications. Consult your
Gast representative for additional filter
recommendations. 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.
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
Injury Hazard
Product surfaces become very hot during
operation,
allow product surfaces to cool before handling.
Air stream from product may contain solid or liquid
material that can result in eye or skin damage,
wear proper eye protection.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.
2
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.
General Maintenance
1. Remove end cap and filters. Inspect filters for
2.
3.
4.
5.
6.
7.
8.
rips,tears, cuts, brittleness and excessive foreign
material.
Clean filters if in good condition with
compressed air. Re-inspect for wear conditions.
Set filters aside.
Check filter/muffler (#11) for compacted debris. If
debris is present, replace filter/muffler.
Check condition of O-ring. It should be soft and
flexible. Replace if it is not.
Remove and inspect muffler box. Clean box. Set
box aside. (Not all models have a muffler box.)
Check gasket for cracks or tears. Install new
gasket
if any cracks or tears appear. Replace gasket.
Replace muffler box.
Reinstall filters or install new filters if required.
Reinstall end cap.
MAINTENANCE
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.
Flushing
Electrical Shock Hazard
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.
Injury Hazard
Product surfaces become very hot during
operation,
allow product surfaces to cool before handling.
Air stream from product may contain solid or
liquid
material 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 in
burns, eye injury or other serious injury.
3
Use only Gast recommended 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
1/4” NPT for 0323 and 0523 products, or 3/8” NPT on
one end for 0823 and 1023 products. 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
recommended spray solvent, spray for 5-10
seconds into inlet port. Place towel over exhaust
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
ike 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.
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 Gast recommended solvent and
remove all solvent from vanes.
6. Flush body, rotor and end plate with Gast
recommended 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).
SERVICE KIT INSTALLATION
Check that all external accessories such as relief
valves and gauges are attached to cover and are
not damaged before re-operating product.
Failure to follow these instructions can result in
death, fire or electrical shock.
Electrical Shock Hazard
Disconnect electrical power supply cord before
installing service kit.
If product is hard wired into system, disconnect
electrical power at the circuit breaker or fuse
box before installing service kit.
Vent all air lines to release pressure or vacuum.
Gast will NOT guarantee field-rebuilt product
performance. For performance guarantee, the
product must be returned to a Gast-authorized
facility.
SHUTDOWN PROCEDURES
It is your responsibility to follow proper shutdown
procedures 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.
Service Kit contents vary. Most contain vanes, gaskets
and filter parts.
1.
2.
3.
4.
5.
6.
7.
Remove filter/muffler parts from front of muffler box.
Remove the 5 muffler box bolts.
Use a small hammer to tap on box to remove. Do
not use a screwdriver.
Remove the 6 end plate bolts.
Remove end plate. Check direction of bevel edges
of vanes then remove vanes.
Clean body and rotor slots.
Check end plate, rotor and body for scoring.
Severe scoring or worn bearings will require
service at a Gast-authorized facility.
DO NOT remove rotor or motor bolts.
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 and are not damaged
before re-operating product.
4
END CAP ASSEMBLY
FILTER / MUFFLER
FOOT SUPPORT
10
11
12
1
1
SUPPORT
COVER GASKET
FILTER ASSEMBLY
COVER
FILTER ASSEMBLY
SCREEN CAP
FELT SUPPORT
SERVICE KIT
18
19
20
21
22
23
24
K478A
AK516A
AK502
AH850A
AK503
0323-101
K478
AC136
AK840A
AK526
AK510
AK524
AK473
AK519
AK521
AK501
AK502
AH850A
AK503
0323-101Q
K478A
AK516A
AK502
AH850A
AK505
0523-101
K478
AC136
AK840A
AK526
AK510
AK524
AK473
AK519
AK521
AK501
AK502
AH850A
AK505
0523-101Q
K559
B347
AJ571
B343B
AV402CPC
V400G
B62A
B345A
B344A
AV427APC
AA125A
V425L
AD997
AK516A
AK502
AH850A
AK505
0523-V103
* Denotes parts included in the Service Kit. Parts listed are for stock models.
** No Service Kit available, order parts separately. *** Not shown.
For specific OEM models, please consult the factory.
When corresponding or ordering parts, please give complete model and serial numbers.
1
1
1
1
2
1
4
1
COVER
2
FELT FILTER
JAR
15
1
17
MUFFLER ASSEMBLY
14
2
1
1
2
2
2
2
1
1
1
1
4
1
QTY
16
ELBOW
13
***
END CAP
FELT
*
8
9
O-RING
*
MUFFLER BOX
7
6
GASKET
END PLATE
*
4
5
SHROUD
VANE
3
*
BODY
1
2
DESCRIPTION
REF
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
5
Vacuum Intake
Filter Assembly
Muffler
Assembly
1
END PLATE
5*
2
2
O-RING
FELT
7*
8*
1
2
1
1
FILTER / MUFFLER
ELBOW
ELBOW ***
MUFFLER ASSEMBLY
NIPPLE
JAR
COVER GASKET
COVER ASSEMBLY
MUFFLER ASSEMBLY
COUPLING
CARTRIDGE
END CAP ASSEMBLY
MUFFLER PLATE
STUD
FILTER ASSEMBLY
COVER ASSEMBLY
FILTER ASSEMBLY
SERVICE KIT
11
12
12
13
13 a
14
15
16
17
18
19
20
21
22
23
24
25
K479A
K479
AK840
AK526
AK510
AK524
AK473
AK520
AK522
AK514
K479A
AK515A
AK511
K479
AK840
AK526
AK510
AK524
AK473
AK520
AK522
AK514
AK511
K479A
AC433-1
AV805APC
AB599
AC396
AC395
AC394
AC393
AC391
AC434-1
AV805BPC
AA405
AA805
AB599B
AF272
AK515A
AK511
AK513
K575A
BA714
BA206
AC432
AK526
AK510
AK524
AK473
AK520
AK522
AK514
AL281
AL284
For specific OEM models, please consult the factory. When corresponding or ordering parts, please give complete
model and serial numbers.
* Denotes parts included in the Service Kit. Parts listed are for stock models.
** No Service Kit available, order parts separately. *** Not shown.
1
1
2
1
2
2
2
1
1
2
2
2
1
1
2
END CAP
END CAP ASSEMBLY
9
10
2
1
1
GASKET
MUFFLER BOX
6
AK515A
AK511
AK513
AL283
4
AK511
AK513
AK518
1
AK513
AK518
SHROUD
3
AK513
AK518
4
VANE
2*
AK517
1
BODY
1
AK517
QTY 0823-101 0823-101Q 1023-101 1023-101Q 1023-V103 1423-101Q
DESCRIPTION
REF
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
6
Vacuum Intake
Filter Assembly
Muffler
Assembly
For 1423 Models only.
(Shipped unattached)
MAINTENANCE RECORD
DATE
7
PROCEDURE PERFORMED
TROUBLESHOOTING CHART
Low
Vacuum
•
Pressure
•
High
Vacuum
At pump
Pressure
At pump
•
At pump
•
•
Pump
Overheat
Motor
Overload
•
•
•
•
•
•
•
•
for problem.
Filter dirty.
Clean or replace.
Muffler dirty.
Clean or replace.
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
Reason and remedy
•
•
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/DISCLAIMER
OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a
period of 13 months from date of purchase. OMEGA’s WARRANTY adds an additional one (1) month
grace period to the normal one (1) year product warranty to cover handling and shipping time. This
ensures 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 Service
Department 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 no
charge. 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 operating
conditions 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 any
damages that result from the use of its products in accordance with information provided by
OMEGA, either verbal or written. OMEGA warrants only that the parts manufactured by the
company will be as specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR
REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF
TITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY
AND 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 “Basic
Component” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical
applications or used on humans. Should any Product(s) be used in or with any nuclear installation or
activity, medical application, used on humans, or misused in any way, OMEGA assumes no responsibility
as set forth in our basic WARRANTY/DISCLAIMER language, and, additionally, purchaser will indemnify
OMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of the
Product(s) in such a manner.
RETURN REQUESTS/INQUIRIES
Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department. BEFORE
RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN
(AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID
PROCESSING DELAYS). The assigned AR number should then be marked on the outside of the return
package and on any correspondence.
The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent
breakage 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, and
3. Repair instructions and/or specific problems
relative to the product.
FOR NON-WARRANTY REPAIRS, consult OMEGA
for current repair charges. Have the following
information available BEFORE contacting OMEGA:
1. Purchase Order number to cover the COST
of the repair,
2. Model and serial number of the product, and
3. 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 affords
our 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 the
prior written consent of OMEGA ENGINEERING, INC.
Where Do I Find Everything I Need for
Process Measurement and Control?
OMEGA…Of Course!
Shop online at omega.com SM
TEMPERATURE
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Thermocouple, RTD & Thermistor Probes, Connectors, Panels & Assemblies
Wire: Thermocouple, RTD & Thermistor
Calibrators & Ice Point References
Recorders, Controllers & Process Monitors
Infrared Pyrometers
PRESSURE, STRAIN AND FORCE
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Transducers & Strain Gages
Load Cells & Pressure Gages
Displacement Transducers
Instrumentation & Accessories
FLOW/LEVEL
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Rotameters, Gas Mass Flowmeters & Flow Computers
Air Velocity Indicators
Turbine/Paddlewheel Systems
Totalizers & Batch Controllers
pH/CONDUCTIVITY
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pH Electrodes, Testers & Accessories
Benchtop/Laboratory Meters
Controllers, Calibrators, Simulators & Pumps
Industrial pH & Conductivity Equipment
DATA ACQUISITION
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Data Acquisition & Engineering Software
Communications-Based Acquisition Systems
Plug-in Cards for Apple, IBM & Compatibles
Data Logging Systems
Recorders, Printers & Plotters
HEATERS
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Heating Cable
Cartridge & Strip Heaters
Immersion & Band Heaters
Flexible Heaters
Laboratory Heaters
ENVIRONMENTAL
MONITORING AND CONTROL
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Metering & Control Instrumentation
Refractometers
Pumps & Tubing
Air, Soil & Water Monitors
Industrial Water & Wastewater Treatment
pH, Conductivity & Dissolved Oxygen Instruments
M5158/0612
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