MRV-ALPHA SENTRY CAM SAMPLER - Hi

HI-Q
Environmental
Products Co.
7386 Trade Street
San Diego, California 92121-2422
Air Sampling Equipment, Systems & Accessories
Phone: (858) 549-2820
Fax: (858) 549-9657
Web: www.HI-Q.net
PSU-2-H
(MOBILE, AIR SAMPLING PUMP SYSTEM)
Revised: 09/20/12 MAH
TABLE OF CONTENTS
General Specifications
2
Operational Specifications
2
Power Requirements
3
Set-up Assembly Instructions
3
Start-Up Procedure
10
Collection of Sample
11
Flow Meter and Flow Rate Adjustment
13
Operation of the Flow Control Valve
13
Calibration of the Flow Meter
14
Maintenance and Trouble Shooting
Pump , Elapsed Time Meter
18
Recommended Spare Parts
19
Appendices
A.
B.
C.
D.
E.
F.
G.
Wiring Diagram
Complete PSU Assembly Diagram
Filter Box Detail Views
Motor/Pump Maintenance Manual
Flow meter Installation & Operation Instructions
Electronic Timer Manual
Calibration Certificate
1
GENERAL SPECIFICATIONS:
The PSU-2-H Mobile Pump with Control Valve System is designed for use as a constant flow Air
Sampler. It is normally used to pull air samples through various filters to collect dust particulate,
asbestos fiber particles or airborne pathogens for analysis. Each unit is calibrated with a user
specified filter material. See the Calibration Certificate at the back of this manual for calibration
details.
The PSU-2-H is equipped with the PSU-RHLB weather resistant, lockable inlet which is designed
to hold the PSU-FH filter holder. The PSU-RHLB and PSU-FH combination have been tested to
have the highest particle capture efficiency. The PSU-RHLB sample inlet is adjustable between
55 and 78 inches above the ground.
This PSU-2-H Mobile Air Sampling System has been custom designed to enclose and provide
“chain of custody” for the pump, flow controller, flow meter, filter holder and all electronics inside
two individual lockable, weather resistant enclosures. The system is designed around HI-Q's
standard MRV-0523CV, 1/4 HP mobile Cart air sampler which is depicted at www.HI-Q.net under
“continuous duty air samplers.”
OPERATIONAL SPECIFICATIONS:
The PSU-2-H utilizes a 1/4 Hp (0523 series) motor mounted, rotary carbon vane vacuum pump.
The carbon-graphite vanes are self lubricating. The pump runs at a constant speed and can
develop up to 26” Hg when used as a vacuum pump. The unregulated (open to flow), pump
capacity is 127 LPM. The pump has dual voltage capabilities of 115 and 230 VAC. This unit is
wired for 115 VAC. The pump is equipped with a thermotector and will automatically shut down
should the motor overheat.
Regulation of the air flow is achieved through HI-Q's, Mechanical Heavy Duty Automatic Control
Valve, model number MCV-260. This valve utilizes the opposing spring/diaphragm principle.
Once the flow is set by increasing or decreasing the master spring tension (wing nut), the flow will
remain constant up to the pump capacity. The normal flow rating range is 20 to 100 LPM with the
upper end dependent on barometric pressure and filter media.
The PSU-2-H features an integral venturi flow meter that has been calibrated at the factory with a
NIST traceable secondary master flow element.
The PSU-2-H has a digital elapsed timer that is wired to run when the pump is running. If the
pump stops for any reason, the timer will also stop.
2
POWER REQUIREMENTS
This unit is wired for operation on a 115 VAC GROUNDED circuit. It is highly recommended that
a ground fault circuit be used to prevent electrical shock hazards. If a ground fault circuit is not
available, a weather resistant shock prevention unit: GFCI-2 can be supplied by HI-Q.
INPUT POWER:
Voltage:
Current:
Power:
Fuse:
115 V~, 50/60 Hz
4.5 A
190 W
10 A, T, 250V (Slo-Blo)
Explanation of Electrical Symbols:
V~:
Volts Alternating Current (VAC)
W:
Watts
Hz:
Hertz
:
A:
Amps
:
Protective Earth Ground
Shock Hazard
SET-UP ASSEMBLY INSTRUCTIONS
The PSU-2-H is completely assembled with the exception of the PSU-RHLB inlet/upper
gooseneck assembly and security cable. Proceed as follows:
1. Remove plastic dust cover from the gooseneck/filter box & intake tube assembly
located on the side of the mobile box.
3
2. Connect the two components by inserting and screwing down the Union Coupling on
the bottom of the blue painted upper inlet tube to hand tight. Do not use a wrench!
There is a rubber gasket seal on the coupling which will make the coupling air tight.
4
3. Remove the knurled aluminum nut (Goosenut) and the tapered black polyurethane
Poly-Pack seal from the top of the inlet tube and slide on to the bottom of the 5/8”
diameter tube on the bottom of the PSU-RHLB inlet as shown below. Make sure that
the o-ring imbedded in the top of the Poly-Pack seal is on top.
4. Slide the 5/8” diameter stainless tube down inside the inlet tube and tighten the
Goosenut.
5
5. Remove PSU-RHLB Inlet (upper portion of the inlet) by holding the PSU-RHLB Handle
in one hand and rotating the PSU-RHLB Inlet counter clockwise.
6. Remove the PSU-FH filter holder from the base of the PSU-RHLB by pivoting the two
filter holder locks out of the way.
6
7. Open the PSU-FH by twisting the upper knurled silver piece counter clockwise 120°
while holding the lower dark grey piece steady.
8. Place the 47mm diameter filter media in the shallow counterbore above the honeycomb
filter support and center on the o-ring seal.
7
9. Reassemble the PSU-FH filter holder and place on the PSU-RHLB inlet base. Ensure
that the two filter holder locks are rotated clockwise until the hooks are in the locking
groove on the bottom of the PSU-FH filter holder.
10. Replace the upper portion of the PSU-RHLB, thereby enclosing the PSU-FH filter
holder by slipping over the top of the filter holder, aligning the slots with the pins on the
base and rotating 90° clockwise until the locking holes line up. The inlet may be locked
with a standard padlock (not provided).
8
11. Set the sample air intake level by loosening the knurled aluminum nut from the
threaded black nylon gooseneck screw (Goosescrew) and raising or lowering the inlet
so that the intake bug screen is at desired height above the ground. Before securing
the sampling set height, make sure that the tapered black polyurethane Poly-Pack seal
is seated snugly in the lower black nylon threaded screw (Goosescrew).
12. Place the security cable around the intake tube between the stand-offs, then to the
locking hasp. It will be looped through the lock. (Lock not provided.) The security cable
prevents vandals from removing the gooseneck/filter housing. Make sure that the
cable prevents the entire assembly from being lifted up and out of the PSU-2-H handle.
13. A “U”-Bolt is installed on the side of the unit, to allow a cable or chain to be used to
secure the unit to a telephone pole or other permanent post.
9
START-UP PROCEDURE
After assembly of the gooseneck to the pump system, make sure the intake bug screen inlet is at
the correct height. (Standard breathing level protocol is 59” from the ground). If the filter holder
and collection media is already in place skip the first step of the following procedures.
1. Remove PSU-RHLB Inlet (upper portion of the inlet) by holding the PSU-RHLB Handle
in one hand and rotating the PSU-RHLB Inlet counter clockwise. Check to ensure that
a PSU-FH filter holder is installed. Check to ensure that a filter is installed in the
PSU-FH. Replace the PSU-RHLB Inlet. See drawing “PSU-RHLB & FH ASSY”.
2. Open the lid on the PSU. Turn on pump system, (toggle switch).
10
3. Adjust the flow rate to the flow rate designated by the laboratory protocol by using the
flow control knob on the flow control valve.
4. Press the Red timer reset button to set the timer to zero. The timer reads in hours and
tenths of hours. One tenth of an hour is 6 minutes.
COLLECTION OF SAMPLE AFTER DESIGNATED RUN TIME
The laboratory will establish the specific filter replacement procedure, run time and other details
for this sampling sequence. Standard procedures basically call for the cabinet to be opened and:
1. Record the flow rate at the end of the sampling time.
2. Turn off the pump.
3. Record the elapsed time in hours and tenths.
11
4. Open the PSU-RHLB inlet. Place the transport cap on the PSU-FH. Remove the
PSU-FH filter holder assembly from the PSU-RHLB inlet. Place the un-opened filter
assembly into an airtight container plastic bag/container.
5. Mark the container with the location data, elapsed time, date, starting flow rate and end
of sampling time flow rate. (This data will give you the average flow rate.)
6. Send the sealed sample to the laboratory for analysis.
7. Replace the filter with a pre-loaded filter assembly (per the instruction above).
8. Reset the timer to zero.
9. Restart the pump.
10. Adjust the flow rate, close cover and secure.
12
FLOW METER AND FLOW RATE ADJUSTMENT:
The instantaneous air flow rate can be read directly from the rotometer device attached to the
control cabinet located inside of the enclosure lid. The rotometer is used with a venturi tube to
establish the air flow rate. The principle is that air flowing through an orifice will create a pressure
differential. A rotometer is placed between the high and low pressure developed by the venturi so
that air will flow through the rotometer. The rotometer ball will rise in the “V” tube in proportion to
the flow rate.
The venturi/ flow meter is calibrated at the factory with an NIST (National Institute of Standards
and Technology) traceable secondary flow element. NOTE: The flow meter will only read
correctly when the lid is in the fully open position, and the flow meter is in a vertical position.
When the cabinet lid is closed, the flow meter will be horizontal and the flow ball will go to the top
of the meter. On rare occasions the ball might stick at the top restrainer pin. A light tap on the
rotometer should loosen it. You can also pinch the plastic tubing leading to the center of the black
venturi tube.
OPERATION OF THE FLOW CONTROL VALVE
The intake air flow rate is increased or decreased by turning the flow control knob on the top of
the spring on the flow controller. Turn the wing-nut clockwise to decrease the flow rate, and
counter clockwise to increase the flow rate. The flow rate should be adjusted with the filter
holder and filter element (paper) in place. The flow rate will need to be readjusted every time
the pump is turned off and on due to slight hysteresis in the spring and diaphragm of the flow
control valve.
This unit is calibrated in the metric scale of 0-100 ALPM (actual liters per minute)
13
CALIBRATION OF THE FLOW METER UNIT
This unit is calibrated at the factory, and is ready to use. It is however recommended that a field
test calibration unit be used periodically to confirm the accuracy of the rotometer reading. If the
operating entity has multiple units in the field, more than one flow calibration unit may be
advisable. These calibration units must be re-certified by the factory every year to conform to
the air sampling protocol. HI-Q’s standard Re-certification takes approximately 2 weeks (this
includes expedited shipping to and from our factory).
CALIBRATION
The PSU-2-H is calibrated at the factory. The following procedure is for verifying the flow rate or
re-calibration.
Equipment Required:
In-Line Calibration Adapter:
Model PSU-FH-CALADAPT: Calibration adapter for PSU-FH filter holder. Adapter slips
onto top of PSU-FH filter holder and seals against the filter holder’s o-ring. Adapter has ½”
Swagelok male quick disconnect fitting on inlet.
Air Flow Calibrator: Suggested flow calibration units with custom ½” stainless steel quick
disconnect fittings (can be viewed and purchased on-line at www.HI-Q.net):
Model AFC-110L-5QD: Analog Air Flow Calibrator (no power requirements, operates by
pressure differential created by moving air). Unit includes a 7 foot flexible hose with ½”
stainless steel female quick disconnect coupling on downstream connection for connection
to the PSU-FH-CALADAPT.
Model AFC-DIG-110L-5QD: Digital Air Flow Calibrator (115 VAC line power required.
Unit measures flow by sensing pressure differential created by moving air). Unit includes a
7 foot flexible hose with ½” stainless steel female quick disconnect coupling on
downstream connection for connection to the PSU- FH-CALADAPT.
Model AFC-COMPLETE-110L-5QD: Digital battery powered Air Flow Calibrator. Unit
measures flow by sensing pressure differential created by moving air. Unit measures
Temperature, Barometric pressure, and is able to indicate flow in Metric or English units
with either Standard or Actual (Apparent) corrections factors. Unit includes a 7 foot flexible
hose with ½” stainless steel female quick disconnect coupling on downstream connection
for connection to the PSU- FH-CALADAPT.
Model D-AFC-110L-5QD: “All In One” Digital battery powered Air Flow Calibrator. Unit
features graphical LCD display, data logging and a variety of optional electronic outputs.
The unit measures flow by sensing pressure differential created by moving air. Unit
measures Temperature, Barometric pressure, and is able to indicate flow in Metric or
English units with either Standard or Actual (Apparent) corrections factors. Unit includes a
14
7 foot flexible hose with ½” stainless steel female quick disconnect coupling on
downstream connection for connection to the PSU- FH-CALADAPT.
HI-Q air flow calibrators are venturi flow meters. Venturi flow meters produce a low pressure drop
(ΔP). Note that some other air flow calibrators produce a larger ΔP and their use for calibration
could result in poor calibration accuracy.
Re-Calibration Procedure
The PSU-2-H series use a rotameter to sense the ΔP across the flow venturi. The rotameter and
venturi are calibrated as a pair. When the rotameter/venturi pair is calibrated at the factory, a
custom scale is put on the rotameter with multiple calibration points. It is only possible to perform
a single point calibration in the field. Typically the highest flow reading is calibrated and then the
lower flow readings are checked against the calibrator. The following steps are for field
calibration:
1. Remove the PSU-RHLB Inlet.
2. Put new filter media into the PSU-FH filter holder and install on the PSU-RHLB base. It is
essential that one recalibrate the PSU-2-H Series with the same filter media as that which
will be used for sampling in the field. Varying the maximum pressure drop (caused by the
filter paper) at calibration will affect the overall accuracy of the calibration.
3. Place the PSU-FH-CALADAPT on top of the PSU-FH and push down to seat the o-ring
seal.
15
4. Rotate the locking wings of the PSU-FH-CALADAPT clockwise (when viewed from above)
until the slots on the wings engage the 3/8” dowel pins on the PSU-RHLB receptacle.
16
5. Connect ½ inch female quick disconnect on flexible hose provided with the airflow
calibrator to the ½ inch male quick disconnect on the inlet of the PSU-FH-CALADAPT.
6. Turn on the pump and adjust the sample flow to the maximum flow or to the anticipated
sample flow rate.
7. Compare the readings on the rotameter and the airflow calibrator.
8. If the readings are different, remove the pressed in button cover above the rotameter on
the control panel. Use a small standard blade screwdriver to adjust the needle valve on the
back of the rotameter until the readings agree.
9. Adjust the sample flow to other readings on the rotameter to confirm the calibration.
17
MAINTENANCE AND TROUBLE SHOOTING:
PUMP:
PSU-2-H sampling unit is designed to be a continuous duty operational system and is equipped
with an oilless rotary vane vacuum pump. The carbon/graphite vanes have been known to
function continuously for more than one year. It is important that the vanes be replaced before
they completely wear out. If they wear down too far, the remnants will slip out of the slot holding
them and shatter inside the eccentric cavity. This will cause chips to wedge against the motor
shaft, bending the shaft. The motor will then have to be completely replaced. It is more
economically practical to replace the vanes every 10 to 12 months of operation with the MRV-006
service repair kit. The “K479” Service Kit Includes: 2-Felt Filters, 4 Carbon Vanes, 1 Motor
Gasket, 2-“O”Rings, & 5 Bolt Gaskets.
You will also notice that the flow rate capacity will decrease to an unacceptable level if the vanes
are worn or the cavity is scored.
Replacement and cleaning is accomplished by following the procedure recommended by the
pump manufacturer.
The motor bearings are permanently lubricated and require no
maintenance.
If a vane should break in operation, the pump motor will overload and stop. If turning the switch
off, then on does not restart the motor, the pump head will have to be disassembled and the
vanes replaced. If the pump restarts, the cut off was due to overheating. In that case, the
electronic re-settable elapsed timer would have stopped at the same time as the seizing of the
motor, even with the main switch on and power to the motor. This saves the sample so that it can
be analyzed with an accurate elapsed time.
The pump may be removed from the box by removing the four ¼-20 hex nuts from the aluminum
mounting plate using a 9/16” socket or wrench. Pull the pump out of the box and rest it on the lip
of the box while disconnecting electrical connection on the pump. When re-installing pump, check
the wiring diagram on the pump to ensure that the plugs are correctly connected.
ELAPSED TIME METER:
The timer is powered by an internal non-replaceable battery with an approximate life span of 5
years. Completion of an electrical circuit starts and stops the timer. The timer in this unit is read in
hours and tenths of hours. (One tenth hour is six minutes.)
CLEANING:
The CF-900 series sampler is an electrically powered instrument and care should be taken to not
let any liquids get inside the sampler. The exterior of the sampler may be cleaned with a damp
cloth.
18
Spare/Replacement Parts/Price List for HI-Q’s:
MRV-0523CV-PSU, PSU-2, & PSU-3 Series Samplers
(Prices Effective 2/29/12)
Common PSU Replacement/Retrofit Parts (All PSU’s):
PART #
PART DESCRIPTION
Replacement
Schedule
MRV-021
MRV-022-PSU
MRV-023
MRV-027
MRV-028
MRV-029
MRV-030
MRV-032
MRV-032A
MRV-037
MRV-048
MRV-PSU-001
MRV-PSU-002
MRV-PSU-006-SS
MRV-PSU-008
MRV-PSU-020
MRV-PSU-026
MRV-PSU-027
MRV-PSU-027BB
MRV-PSU-028
MRV-PSU-029
MRV-PSU-031
MRV-PSU-032
MRV-PSU-032-A
MRV-PSU-033
MRV-PSU-034
MRV-PSU-035
MRV-PSU-036
MRV-PSU-037
MRV-PSU-038
MRV-PSU-039
MRV-PSU-040
MRV-PSU-041
MRV-PSU-041-A
MRV-PSU-042
MRV-PSU-043
MRV-PSU-044
MRV-PSU-045
MRV-PSU-046
MRV-009
MRV-PSU-048
MRV-PSU-052
MRV-PSU-053
MRV-PSU-060
MCV-RK, rebuild kit for the MCV-260 (includes diaphragm and “o” ring).
Electronic, resettable hour/tenths timer.
Reset button assembly for timer (MRV-022-PSU).
Black nylon gooseneck fitting.
Aluminum knurled nut for above.
Polypack seal for gooseneck.
Fuse holder assembly.
SPST Toggle switch w/on/off plate (pre TUV Rheinland listed PSU’s, pre ~2010)
DPST Toggle switch w/on/off plate (TUV Rheinland listed PSU’s)
8" wheel -1/2" axle.
Control Valve Adjustment Star Knob.
20' long, 14/3 power cord,.
Gooseneck 5/8" OD, SS, 90° bend includes SS 5/8” Compression x ½” FNPT.
1/2" x 16" stainless steel axle.
Front support legs with bumper assembly.
MCV-260, heavy duty, automatic flow control valve for PSU.
Hand grip tape.
100 CFM axial cooling fan. Stock fan with sleave bearings.
100 CFM axial cooling fan. Upgraded fan with ball bearings
Rubber foot for front foot support (2 per foot assembly).
Rubber union gasket: 1-3/4”od x 1-3/16”id x 1/8” thick.
4” Rotometer (does not include needle valve or blank scale).
4” Blank scale for rotometer with adhesive back.
4” Scale marked 20 to 110 LPM (Standard Venturi). No certification included.
Needle valve assembly of rotometer (used to calibrate).
Power cord strain relief for PSU box.
1/8” ID clear tubing set. Two pieces: 14” & 21” sections, 1/8” ID.
3/8” ID braid reinforced clear inlet tubing. 21” long section.
3/8” ID high temperature exhaust tubing (blue). 5” section.
Axial fan power cord.
Axial fan finger guard.
¾” Galvanized union assembly used to connect/disconnect gooseneck.
Rubber fan louver hand grip/bumper.
Cooling Fan White Louver Kit for PSU box. Kit includes mounting hardware.
Rubber PSU box stacking bumpers. 4 mounted under each PSU. Sold Each.
1½” dust cap assembly with hanging chain.
Power cord hanging rack assembly set. Two power rack assemblies per set.
End cap for 0523 or 1023 series pump. Does not include o-ring or felt filter (2/pump)
O-ring for pump end cap assembly. 1 per end cap, 2 per pump.
Felt filter for 0523 pump inlet/outlet. Slides over motor end caps (2 required).
Latch assembly for pump housing box.
Venturi tube, 6” long, black anodized with 3/8” female NPT inlet/outlet
Single hose barb, 1/8”(x 10-32) brass. Barb threads into black venturi tube.
Complete analog instrument panel for all PSU’s. Panel includes rotometer w/
venturi connection tubing, timer, power switch, fuse holder, fuse, wire harness &
internal terminal block. User will need to perform a single point calibration.
PSU handlebar assembly consists of the complete galvanized ¾” female union, flat
gasket, 20 inch blue painted ¾” pipe, nylon ¾” telescopic retaining screw, polypack
seal and ¾” knurled retaining nut.
Lower handlebar assembly attached to PSU Box. Individual assembled
components Included: 2 x Rail Fittings, 2 each 0.75” x 8” painted pipes, 1 each
0.75” T fitting, 1 each 0.75” x 0.375” reducer and ¾” Hex Cap. **Does Not Included
¾ Galvanized Union (MRV-PSU-040)**
Spiral Bundling Wrap-Around Sleeving, OD: 3/8” Polyethylene.
Heavy Duty Motor Mount Plate with 4 Shock mount feet & mounting hardware.
12 Months
48 Months
As Needed
As Needed
As Needed
24 Months
As Needed
60 Months
60 Months
As Needed
As Needed
As Needed
As Needed
As Needed
As Needed
As Needed
As Needed
18 Months
36 Months
36 Months
12 Months
24 Months
As Needed
As Needed
24 Months
36 Months
24 Months
24 Months
24 Months
As Needed
As Needed
As Needed
As Needed
As Needed
36 Months
As Needed
As Needed
36 Months
24 Months
10-12 Months
As Needed
As Needed
As Needed
As Needed
Unit
Price in
$USD
$35.00
$95.00
$12.00
$41.90
$35.00
$14.75
$12.50
$27.50
$27.50
$30.00
$9.75
$45.00
$115.00
$45.00
$112.45
$345.00
$18.50
$45.00
$68.00
$11.50
$5.25
$46.00
$12.75
$75.00
$24.50
$12.75
$14.50
$8.90
$7.50
$8.50
$9.25
$46.00
$24.00
$135.00
$10.45
$18.50
$42.50
$4.20
$1.50
$2.50
$37.50
$110.00
$2.75
$365.00
As Needed
$210.00
AS Needed
$165.00
As Needed
As Needed
$1.65/ft
$75.00
MRV-PSU-061
MRV-PSU-062
MRV-PSU-063
MRV-PSU-064
1/4 HP Pump Replacement/Retrofit Parts (PSU-2 SERIES):
PART #
PART DESCRIPTION
Replacement
Schedule
PSU-0523KIT
¼ HP PSU-Pump Conversion Kit. Kit contains all the parts necessary to convert a
¾ HP PSU sampler to a ¼ HP system. Main components are: ¼ HP oilless rotary
vane vacuum pump with mounting hardware, wiring kit, preassembled mounting
hardware/plumbing & complete retrofit assembly instructions.
1/4 HP, 115VAC, replacement pump/motor
Service Repair Kit for the 0523-101Q-G582DX. “K478” Service Kit Includes: 2Felt
Filters, 4 Carbon Vanes, 1 Motor Gasket, 2-“O”Rings, & 5 Bolt Gaskets.
Sintered bronze muffler for the 0523 series pump
Single replacement vane for 0523 series pumps (4 required).
Motor gasket for 0523 series pump (1 required).
Single motor shock absorber (4 per motor): ¼-20" thread x 1/2" high sandwich
mount. For MRV-0523-PSU. (sold per each)
Single motor shock absorber (4 per motor): 5/16" thread x 3/4" high sandwich
mount. For PSU-2 & PSU-3. (Sold per each)
10 Amp Slo-Blo fuse for ¼ HP 0523 pump equipped samplers.
Wiring harness connects ¼ HP pump to control panel.
Complete lower MRV-0523CV-PSU assembly. Lower PSU assembly consists of all
items below and including the galvanized ¾” male union.
Complete upper MRV-0523CV-PSU assembly. Upper PSU assembly consists of all
items above and including the galvanized ¾” female union. Also includes flat gasket.
Complete ¼ HP pump assembly with control valve, venturi tube with hose barbs, and
quick connect wiring harness for PSU-2.
¼ HP Pump accessories kit – kit does NOT include pump. Kit includes everything
needed to attach to a pump to facilitate in the field pump replacement such as the
control valve and venturi tube with hose barbs.
Complete lower PSU-2 assembly below & including the aluminum knurled ¾” pipe
nut (P/N: MRV-028). Lower PSU assembly consists of all items below and including
the aluminum ¾” knurled retaining nut.
Complete upper PSU-2 assembly from, but not including, aluminum knurled ¾” pipe
nut (P/N: MRV-028). Upper PSU assembly consists of all the items attached to and
including the 5/8” OD stainless steel gooseneck assembly.
As Needed
MRV-001
K478
(MRV-005)
MRV-007
MRV-010
MRV-013
MRV-PSU-024A
MRV-PSU-024B
MRV-031
MRV-PSU-007
MRV-PSU-050
MRV-PSU-051
MRV-PSU-054
MRV-PSU-055
MRV-PSU-056
MRV-PSU-057
Unit Price
in $USD
$745.00
24 Months
10-12 Months
$558.96
$74.75
0-12 Months
10-12 Months
10-12 Months
$19.11
$19.62
$2.10
36 Months
$7.20
36 Months
$7.20
As Needed
As Needed
As Needed
$3.50
$38.00
$2575.00
As Needed
$550.00
As Needed
$995.00
As Needed
$645.00
As Needed
$2700.00
As Needed
$375.00
3/4 HP Pump Replacement/Retrofit Parts (PSU-3 SERIES):
PART #
PART DESCRIPTION
Replacement
Schedule
PSU-2-1023KIT
¾ HP PSU-Pump Conversion Kit. Kit contains all the parts necessary to convert
standard ¼ HP PSU sampler to a ¾ HP system. Main components are: Modified ¾
HP oilless rotary vane vacuum pump with mounting hardware, second (additional)
100 CFM axial cooling fan with fan louver mounting kit, wiring kit, preassembled
mounting hardware/plumbing & complete retrofit assembly instructions.
¾ HP replacement pump/motor for PSU-3 series samplers.
100 CFM Fan & Louver retrofit kit. This kit is most commonly used as an additional
(2nd) cooling fan for retrofit ¾ HP PSU’s. Kit includes: 100 CFM fan, finger guard, fan
cord w/ electrical connections, inlet air hole screen, external fan louver, all mounting
hardware & installation instructions.
20’ power cord for MRV-1023CV-PSU and PSU-3 series.
Wiring harness connects ¾ HP pump to control panel.
3/8” braid reinforced clear inlet tubing from inlet into box to venturi
3/8” high temperature exhaust tubing (blue) from pump outlet to muffler jar
Muffler jar assembly, this muffler is internal to the PSU box
Replacement felt muffler cartridge for PSU-1023-037 muffler jar assembly
Complete lower PSU-3A-H assembly. Lower PSU assembly consists of all items
below and including the galvanized ¾” male union.
1/8” ID clear tubing set. Two pieces to connect venturi to differential pressure sensor
on PSU with digital flow option
Sintered bronze muffler for the 1023 series pump
Service kit for ¾ HP oilless rotary vane vacuum pumps. Kit includes: 2 felt filters, 4
carbon vanes, 1 motor gasket, 2 o-rings, and 5 bolt gaskets.
15 amp Slo-Blo fuse ¾ HP 1023 pump equipped samplers.
Single motor shock absorber (4 per motor): 5/16" thread x 3/4" high sandwich
mount. For PSU-2 & PSU-3. (Sold per each)
Square inlet screen for bottom of PSU enclosure
As needed
Unit Price
in $USD
$1,150.00
As Needed
As Needed
$807.36
$215.00
As Needed
As Needed
24 Months
24 Months
24 Months
24 Months
As Needed
$45.00
$38.00
$8.90
$7.50
$67.20
$10.08
$3100.00
24 Months
$14.75
0-12 Months
10-12 Months
$15.00
$96.70
PSU-1023-PUMP
PSU-FAN-KIT
PSU-1023-001
PSU-1023-007
PSU-1023-036
PSU-1023-037
PSU-1023-038
AC393
PSU-1023-050
PSU-DIG-035
MRV-008
K479
MRV-039
MRV-PSU-024B
PSU-BOT-SCRN
As Needed
$3.50
36 Months
$7.20
As Needed
$9.50
Filter Holders, Rain Shields and Inlets for PSU-2 and PSU-3
PART #
PART DESCRIPTION
Replacement
Schedule
PSU-2-RAINHAT
Omni Directional Inlet/Rain Hat for PSU & PSU-2 style samplers. Includes ½”
Stainless Steel Female Quick Disconnect to match inlet of “L”-style filter holder.
L-Style in-line filter holder for use w/ PSU-2 and PSU-3(does not include cartridge)
As Needed
Unit Price
in $USD
$468.00
As Needed
$310.00
Replacement 2-033 O-ring seal. Two per filter holder. (sold per each)
As Needed
$1.75
Stainless steel 1/2" male (stem) quick disconnect x 1/2" male NPT.
1/2" NPT street elbow, nickel plated brass.
Stainless steel 1/2" female (body) quick disconnect fitting x 1/2" male NPT.
Stainless Steel ½” male NPT x ½” female quick disconnect.
Stainless Steel ½” male NPT x ½” male quick disconnect.
Stainless Steel 5/8” compression fitting x ½” female NPT.
Latch assembly (stainless steel) for filter holder box.
Upper aluminum filter holder box assembly (hinge & latch included)
As Needed
As Needed
As Needed
As Needed
As Needed
As Needed
As Needed
As Needed
$25.69
$12.75
$64.12
$56.06
$27.50
$40.00
$30.63
$165.00
PSU-2-ILFH
PSU-2-ILFHORING
PSU-2-ILFH-001
PSU-2-ILFH-002
PSU-2-ILFH-003
MRV-PSU-022
MRV-PSU-023
MRV-PSU-024
MRV-PSU-047
MRV-PSU-049
Filter Holders, Inlets for PSU-2-H and PSU-3-H & Air Flow Calibrator
PART #
PART DESCRIPTION
Replacement
Schedule
PSU-RHLB
Cylindrical Inlet for use on PSU-2-H and PSU-3A-H, includes one PSU-FH filter
holder.
PSU-RHLB Inlet Handle Retrofit Kit includes handle, handle socket, mounting stud
and drilling template.
1/8” thick x 2 ¾” OD x 2¼” ID (approx. dims) RHPB receptacle flat Gasket. The
PSU-FH filter holder sits on top of this gasket at the base of the RHLB.
Lower (bottom) assembly of the PSU-RHLB. Includes: Male CAM-Locking Base with
studs & O-ring, cable assembly, swing-locks to retain holder, and press-fit 5/8” SS
down-tube with handle bar.
CAM-Lock Style filter holder for use in PSU-RHLB. Includes one PSU-FH-CAP.
Protective transport cap for the PSU-FH
Replacement ¼” thick honeycomb filter support, 1.6” diameter
Replacement 2-030 o-ring seals filter media perimeter. One per filter holder.
Parylene coated 2-225 silicone o-ring. One per PSU-RHLB and two per PSU-FH.
Orange in color.
Stainless steel snap ring that holds inlet of PSU-FH filter holder together.
As Needed
Unit Price
in $USD
$1,105.00
As Needed
$65.00
As Needed
$5.75
As Needed
$285.00
As Needed
As Needed
As Needed
As Needed
As Needed
$325.00
$36.00
$9.75
$1.75
$1.75
As Needed
$22.00
Aluminum filter removal tool for use with PSU-FH. By pushing the base of the PSUFH down over this tool, the honeycomb filter support is elevated 1/8”, allowing the
filter paper to be easily removed.
Aluminum calibration adapter for use with the PSU-FH. Includes ½” Swagelok quick
disconnect fitting to allow connection of AFC-DIG-110L-5QD.
Digital style 20 to 110 LPM air flow calibrator. The AFC includes a 7 foot long ½”
diameter transport line with ½” Stainless Steel Female Quick Disconnect.
Analog style 20 to 110 LPM air flow calibrator. The AFC includes a 7 foot long ½”
diameter transport line with ½” Stainless Steel Female Quick Disconnect.
As Needed
$87.50
As Needed
$165.00
As Needed
$1,235.00
As Needed
$705.00
PSU-RHLB-IH
PSU-RHLBRGASKET
PSU-RHLBBOTTOM
PSU-FH
PSU-FH-CAP
PSU-FH-001
PSU-FH-002
PSU-FH-O225
PSU-FH-SR
PSU-FH-TOOL
PSU-FHCALADAPT
AFC-DIG-110L5QD
AFC-110L-5QD
Operating Manuals and Instrumentation
PART #
PART DESCRIPTION
Replacement
Schedule
PSU-2- Manual
Complete PSU-2 operations manual, applies to MRV-0523CV-PSU also.
Complete PSU-2-H operations manual.
Complete PSU-2-H-D operations manual.
Complete PSU-3 series operations manual includes all PSU-3 series samplers.
Complete PSU-3-H-D operations manual.
Vacuum leak check gauge. Device includes 1/2" SS female quick disconnect with
appropriate elbows to attach to PSU inlet in combination with PSU-2-ILFH or PSUFH-CALADAPT.
As Needed
As Needed
As Needed
As Needed
As Needed
As Needed
PSU-2-H Manual
PSU-2-H-D Manual
PSU-3-Manual
PSU-3-H-D Manual
PSU-VACGAUGE
Unit Price
in $USD
$25.00
$25.00
$25.00
$25.00
$25.00
$145.00
Spare parts & sampler systems
PART #
PART DESCRIPTION
Replacement
Schedule
375FXELBOW
375MNPTX
5388K16
PSU-2-H
3/8" NPT FEMALE ELBOW
3/8 MNPT PIPE NIPPLE X 3 INCHES LONG
HOSE CLAMP 7/16-25/32
¼ HP PSU-SERIES MOBILE CART OUTDOOR AIR SAMPLING SYSTEM WITH
FILTER HOLDER & RAIN HAT LOCK BOX (PSU-2-H INCLUDES ONE EACH P/N:
PSU-RHLB & PSU-FH).TUV RHEINLAND LISTED.
¾ HP PSU-SERIES MOBILE CART OUTDOOR AIR SAMPLING SYSTEM WITH
FILTER HOLDER & RAIN HAT LOCK BOX (PSU-3-H INCLUDES ONE EACH P/N:
PSU-RHLB & PSU-FH).TUV RHEINLAND LISTED.
As Needed
As Needed
As Needed
PSU-3-H
Contact:
HI-Q Environmental Products Company
7386 Trade Street
San Diego, CA 92121
Phone:
Fax:
Email:
Web:
Unit Price
in $USD
$6.75
$5.00
$2.79
$3,750.00
As Needed
$4,710.00
As Needed
858-549-2820
858-549-9657
[email protected]
www.HI-Q.net
A. Wiring Diagram
1
B. Complete PSU Assembly Diagram
2
Disconnect
Coupling
PSU-RHLB
Inlet
Flow Meter
Elapsed Timer
Power Switch
Fuse Holder
Flow Control
Valve
1/4 HP Rotary Vane
Vacuum Pump
Locking
Hasp
HI-Q ENVIRONMENTAL PRODUCTS COMPANY
7386 TRADE STREET, SAN DIEGO, CA 92121
TEL: 858 549-2820 FAX: 858 549-9657
www.HI-Q.net
PSU-2-H
ASSEMBLY
DO NOT SCALE DRAWING
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING
IS THE SOLE PROPERTY OF HI-Q ENVIRONMENTAL
PRODUCTS CO. ANY REPRODUCTION IN PART OR
AS A WHOLE WITHOUT THE WRITTEN PERMISSION
OF HI-Q ENVIRONMENTAL PRODUCTS CO. IS
PROHIBITED.
MATERIAL:
FINISH:
DRAWN BY:
N/A
N/A
SIZE DWG. NO.
DATE:
REV.
A PSU-2-H ASSY
S.A. OWEN 10/20/05 CAD FILE: PSU-2-H HI-Q DETAILS.SLDDRW
A
SHEET 1 OF 1
C. PSU-RHLB and PSU-FH Detail Views
3
Rain Hat Inlet
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
HI-Q ENVIRONMENTAL PRODUCTS CO. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
HI-Q ENVIRONMENTAL PRODUCTS CO.
IS PROHIBITED.
PSU-RHLB BASE/
FILTER HOLDER RECEPTACLE
PSU-FH
N/A
N/A
DATE:
DWG. NO.
REV.
A PSU-RHLB & FH Rev B ASM B
SIZE
PSU-RHLB and PSU-FH
ASSEMBLY
Rev B
7386 TRADE STREET, SAN DIEGO, CA 92121
TEL: 858 549-2818 FAX: 858 549-9657
HI-Q ENVIRONMENTAL PRODUCTS CO.
S.A. OWEN 11/13/06 CAD FILE: PSU-RHLB & FH Rev B ASSEMBLY.SLDDRWSHEET 1 OF 4
DRAWN BY:
FINISH:
MATERIAL:
DO NOT SCALE DRAWING
DIMENSIONS ARE IN INCHES
TOLERANCES:
ANGULAR 1 DEGREE
ONE PLACE DECIMAL
.050
.010
TWO PLACE DECIMAL
.005
THREE PLACE DECIMAL
User Supplied Lock
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
HI-Q ENVIRONMENTAL PRODUCTS CO. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
HI-Q ENVIRONMENTAL PRODUCTS CO.
IS PROHIBITED.
FILTER HOLDER
LATCHES CLOSED
N/A
N/A
DATE:
S.A. OWEN 11/4/05
DRAWN BY:
FINISH:
MATERIAL:
DO NOT SCALE DRAWING
DIMENSIONS ARE IN INCHES
TOLERANCES:
ANGULAR 1 DEGREE
ONE PLACE DECIMAL
.050
.010
TWO PLACE DECIMAL
THREE PLACE DECIMAL
.005
DWG. NO.
REV.
CAD FILE: PSU-RHLB & FH Rev B ASSEMBLY.SLDDRWSHEET 2 OF 4
A PSU-RHLB & FH Rev B ASM A
SIZE
PSU-RHLB and PSU-FH
Rev B ASSEMBLY
7386 TRADE STREET, SAN DIEGO, CA 92121
TEL: 858 549-2818 FAX: 858 549-9657
HI-Q ENVIRONMENTAL PRODUCTS CO.
FILTER HOLDER
LATCHES OPEN
Filter Holder
Base
2-226 O-ring
Filter Media
Inlet Collar
Inlet
Transport
Cap
F
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
HI-Q ENVIRONMENTAL PRODUCTS CO. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
HI-Q ENVIRONMENTAL PRODUCTS CO.
IS PROHIBITED.
DETAIL F
SCALE 2 : 1
Honeycomb
Filter Support
2-226 O-ring
N/A
N/A
DATE:
S.A. OWEN 11/4/05
DRAWN BY:
FINISH:
MATERIAL:
DO NOT SCALE DRAWING
DIMENSIONS ARE IN INCHES
TOLERANCES:
ANGULAR 1 DEGREE
ONE PLACE DECIMAL
.050
.010
TWO PLACE DECIMAL
THREE PLACE DECIMAL
.005
2-030 O-Ring
PSU-FH Rev B ASM
DWG. NO.
CAD FILE:PSU-RHLB & FH Rev B ASSEMBLY.SLDDRW SHEET 3 OF 4
A
SIZE
PSU-FH Rev B
ASSEMBLY
A
REV.
7386 TRADE STREET, SAN DIEGO, CA 92121
TEL: 858 549-2818 FAX: 858 549-9657
HI-Q ENVIRONMENTAL PRODUCTS CO.
Filter Removal Tool
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF
HI-Q ENVIRONMENTAL PRODUCTS CO. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
HI-Q ENVIRONMENTAL PRODUCTS CO.
IS PROHIBITED.
D
N/A
DATE:
S.A. OWEN 11/4/05
DRAWN BY:
FINISH:
N/A
DO NOT SCALE DRAWING
MATERIAL:
D
PSU-FH Rev B ASM
DWG. NO.
CAD FILE:PSU-RHLB & FH Rev B ASSEMBLY.SLDDRW SHEET 4 OF 4
A
SIZE
PSU-FH Rev B
ASSEMBLY
A
REV.
7386 TRADE STREET, SAN DIEGO, CA 92121
TEL: 858 549-2818 FAX: 858 549-9657
HI-Q ENVIRONMENTAL PRODUCTS CO.
SECTION D-D
SCALE 1 : 1.2
DIMENSIONS ARE IN INCHES
TOLERANCES:
ANGULAR 1 DEGREE
ONE PLACE DECIMAL
.050
.010
TWO PLACE DECIMAL
THREE PLACE DECIMAL
.005
1/8"
By pushing Filter Holder Base
down onto Filter Holder
Removal Tool, the Honeycomb
Filter support is pushed 1/8" up
and thereby raises the filter
media 1/8".
D. Motor/Pump Maintenance Manual
4
PART NO. 70 - 290 G375PL (REV-G)
23 SERIES OIL-LESS
VACUUM PUMPS & COMPRESSORS
OPERATION & MAINTENANCE MANUAL
Model #0523-101 Shown
Model #1023-V103 Shown
Model #1023-101Q Shown
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.
IMPORTANT: PLEASE READ THIS MANUAL AND SAVE FOR FUTURE REFERENCE.
General information
• Clearances:
• Vane Life:
Top:
.002”
Ends: .0015” - .005”
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.
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.
• Oil-Less rotary-vanes require NO lubrication.
• Sealed bearings are grease packed.
• Use of petroleum or hydrocarbon products will
reduce carbon-vane service life.
ISO 9001 & 14001 CERTIFIED
www.gastmfg.com
®Registered Trademark/™Trademark of Gast Manufacturing Inc., Copyright © 2001 Gast Manufacturing Inc. All Rights Reserved.
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
WARNING
Ꮨ
Electrical Shock Hazard
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
WARNING
Injury Hazard
Disconnect electrical power at the circuit breaker
or fuse box before installing this product.
Product surfaces become very hot during operation,
allow product surfaces to cool before handling.
Install this product where it will not come into
contact with water or other liquids.
Air stream from product may contain solid or liquid
material that can result in eye or skin damage,
wear proper eye protection.
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.
Failure to follow these instructions can result in
burns, eye injury or other serious injury.
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.
Flushing
MAINTENANCE
WARNING
Ꮨ
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.
WARNING
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.
It is your responsibility to:
• Regularly inspect and make necessary repairs to
product in order to maintain proper operation.
• Make sure that pressure and vacuum is released
from product before starting maintenance.
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 to assure the product’s
performance and service life.
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.
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.
Use only Gast AH255B 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
AH255B, spray solvent for 5-10 seconds into inlet
port. Place towel over exhaust port 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
like 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 AH255B solvent and remove all
solvent from vanes.
6. Flush body, rotor and end plate with AH255B
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).
Check that all external accessories such as relief
valves and gauges are attached to cover and are
not damaged before re-operating product.
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 INSTALLATION
WARNING
Ꮨ
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.
Failure to follow these instructions can result in
death, fire or electrical shock.
Gast will NOT guarantee field-rebuilt product
performance. For performance guarantee, the
product must be returned to a Gast-authorized
facility.
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.
END CAP ASSEMBLY
FILTER / MUFFLER
FOOT SUPPORT
10
11
12
1
1
MUFFLER ASSEMBLY
JAR
COVER
FELT FILTER
SUPPORT
COVER GASKET
FILTER ASSEMBLY
COVER
FILTER ASSEMBLY
SCREEN CAP
FELT SUPPORT
SERVICE KIT
14
15
16
17
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
**
B347
AJ571
B343B
AV402CPC
V400G
B62A
B345A
B344A
AV427
AA125A
V425L
AD997
AK516A
AK502
AH805A
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
2
1
ELBOW
2
1
1
2
2
2
2
1
1
1
1
4
1
QTY
13
***
END CAP
FELT
*
8
9
O-RING
*
MUFFLER BOX
GASKET
7
6
*
END PLATE
4
5
SHROUD
VANE
3
*
BODY
1
2
DESCRIPTION
REF
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
Vacuum Intake
Filter Assembly
Muffler
Assembly
1
2
1
1
O-RING
FELT
END CAP
END CAP ASSEMBLY
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
7*
8*
9
10
11
12
12
13
13 a
14
15
16
17
18
19
20
21
22
23
24
25
AK517
K479A
AK515A
AK511
AK513
AK517
K479
AK840
AK526
AK510
AK524
AK473
AK520
AK522
AK514
AK511
AK513
AK518
AK518
AK511
AK513
K479A
K479
AK840
AK526
AK510
AK524
AK473
AK520
AK522
AK515A AK514
AK511
AK513
AK518
**
AC433-1
AV805APC
AB599
AC396
AC395
AC394
AC393
AC391
AC434-1
AV805BPC
AA405
AA805
AB599B
AF272
AK515A
AK511
AK513
AL283
AL283
AL281
AL284
K575A
BA714
BA206
AD432
AK526
AK610
AK524
AK473
AK520
AK522
K575A
BA714
BA206
AC432
AK515A 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
2
2
2
1
1
1
GASKET
4
1
MUFFLER BOX
END PLATE
3
1
4
6
SHROUD
2*
QTY 0823-101 0823-101Q 1023-101 1023-101Q 1023-V103 1423-101 1423-101Q
5*
BODY
VANE
1
DESCRIPTION
REF
EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION
Vacuum Intake
Filter Assembly
Muffler
Assembly
For 1423 Models only.
(Shipped unattached)
WARRANTY
Gast finished products, when properly installed and operated under normal conditions of use, are warranted by Gast to
be free from defects in material and workmanship for a period of twelve (12) months from the date of purchase from
Gast or an authorized Gast Representative or Distributor. In order to obtain performance under this warranty, the buyer
must promptly (in no event later than thirty (30) days after discovery of the defect) give written notice of the defect to
Gast Manufacturing Incorporated, PO Box 97, Benton Harbor Michigan USA 49023-0097 or an authorized Service
Center (unless specifically agreed upon in writing signed by both parties or specified in writing as part of a Gast OEM
Quotation). Buyer is responsible for freight charges both to and from Gast in all cases.
This warranty does not apply to electric motors, electrical controls, and gasoline engines not supplied by Gast. Gast’s
warranties also do not extend to any goods or parts which have been subjected to misuse, lack of maintenance,
neglect, damage by accident or transit damage.
THIS EXPRESS WARRANTY EXCLUDES ALL OTHER WARRANTIES OR REPRESENTATIONS EXPRESSED OR
IMPLIED BY ANY LITERATURE, DATA, OR PERSON. GAST’S MAXIMUM LIABILITY UNDER THIS EXCLUSIVE
REMEDY SHALL NEVER EXCEED THE COST OF THE SUBJECT PRODUCT AND GAST RESERVES THE RIGHT,
AT ITS SOLE DISCRETION, TO REFUND THE PURCHASE PRICE IN LIEU OF REPAIR OR REPLACEMENT.
GAST WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND,
however arising, including but not limited to those for use of any products, loss of time, inconvenience, lost profit, labor
charges, or other incidental or consequential damages with respect to persons, business, or property, whether as a
result of breach of warranty, negligence or otherwise. Notwithstanding any other provision of this warranty, BUYER’S
REMEDY AGAINST GAST FOR GOODS SUPPLIED OR FOR NON-DELIVERED GOODS OR FAILURE TO FURNISH
GOODS, WHETHER OR NOT BASED ON NEGLIGENCE, STRICT LIABILITY OR BREACH OF EXPRESS OR
IMPLIED WARRANTY IS LIMITED SOLELY, AT GAST’S OPTION, TO REPLACEMENT OF OR CURE OF SUCH
NONCONFORMING OR NON-DELIVERED GOODS OR RETURN OF THE PURCHASE PRICE FOR SUCH GOODS
AND IN NO EVENT SHALL EXCEED THE PRICE OR CHARGE FOR SUCH GOODS. GAST EXPRESSLY
DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE WITH
RESPECT TO THE GOODS SOLD. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTIONS
SET FORTH IN THIS WARRANTY, notwithstanding any knowledge of Gast regarding the use or uses intended to be
made of goods, proposed changes or additions to goods, or any assistance or suggestions that may have been made
by Gast personnel.
Unauthorized extensions of warranties by the customer shall remain the customer’s responsibility.
CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY OF GAST PRODUCTS FOR CUSTOMER’S
USE OR RESALE, OR FOR INCORPORATING THEM INTO OBJECTS OR APPLICATIONS WHICH CUSTOMER
DESIGNS, ASSEMBLES, CONSTRUCTS OR MANUFACTURES.
This warranty can be modified only by authorized Gast personnel by signing a specific, written description of any
modifications.
MAINTENANCE RECORD
DATE
PROCEDURE PERFORMED
PART NO. 70 - 290 G375PL (REV-G)
TROUBLESHOOTING CHART
Low
High
Vacuum
Pressure
Vacuum
G
G
At pump
G
G
Pressure
At pump
At pump
G
Pump
Motor
Reason and remedy
Overheat
Overload
for problem.
G
G
Filter dirty.
Clean or replace.
G
G
Muffler dirty.
Clean or replace.
G
G
Vacuum line collapsed.
Repair or replace.
G
G
Relief valve set too high.
Inspect and adjust.
G
G
G
G
G
G
Vanes sticking.
Clean or replace.
G
G
Vanes worn.
Replace.
G
G
Shaft seal worn.
Replace.
G
G
G
G
Dust or offset powder in pump.
Inspect and clean.
G
G
G
G
Motor not wired correctly.
Check wiring diagram and line voltage.
Relief valve set too low.
Inspect and adjust.
At pump At pump
G
G
Plugged vacuum/pressure line.
Inspect and repair.
AUTHORIZED SERVICE FACILITIES
Gast Manufacturing Inc.
2550 Meadowbrook Road
Benton Harbor, MI 49022
TEL: 616-926-6171
FAX: 616-927-0808
www.gastmfg.com
Gast Manufacturing Inc.
505 Washington Ave
Carlstadt, NJ 07072
TEL: 201-933-8484
FAX: 201-933-5545
Brenner Fiedler & Assoc.
13824 Bentley Place
Cerritos, CA 90701
TEL: 800-843-5558
TEL: 310-404-2721
FAX: 310-404-7975
Gast Manufacturing Co., Ltd
Beech House, Knaves Beech
Business Centre, Loudwater
High Wycombe, Bucks HP 10 9SD
England
TEL: 44 628 532600
FAX: 44 628 532470
Wainbee Limited
215 Brunswick Blvd.
Pointe Claire, Quebec
Canada H9R 4R7
TEL: 514-697-8810
FAX: 514-697-3070
Wainbee Limited
5789 Coopers Avenue
Mississauga, Ontario
Canada L4Z 3S6
TEL: 905-568-1700
FAX: 905-568-0083
Japan Machinery Co., Ltd.
Central PO Box 1451
Tokyo, 100-91 Japan
TEL: 81-3-3573-5421
FAX: 81-3-3571-7865
or: 81-3-3571-7896
General Correspondence
should be sent to:
Gast Mfg. Inc./A Unit of IDEX Corporation
P O Box 97
Benton Harbor, MI 49023-0097
ISO 9001 & 14001 CERTIFIED
www.gastmfg.com
E. Flow meter Installation & Operation Instructions
5
Bulletin F-43
9/14/05
9:01 AM
Page 1
Bulletin F-43
®
Series RM Rate-Master Flowmeters
Specifications - Installation and Operating Instructions
Dimensions in Inches
(Centimeters)
Model RMA Model RMB Model RMC
A
B
A
4 -9/16 (11.59)
B
3 (7.62)
6-7/16 (16.35)
1/8 NPT CONN. 1/4 NPT CONN.
J
BACK WIDTH
F
K
C
E
8-1/2 (21.59)
15 -1/8 (38.42)
12 -1/4 (31.12)
1/2 NPT CONN.
C
1-5/8 (3.17)
10 - 32 Thds.
3-15/16 (8.56)
1/4 - 20 Thds.
8-3/4 (10.72)
10 - 32 Thds.
D
3/8 (.95)
5/8 (1.59)
1 (2.54)
E
1-1/16 (2.60)
1-7/8 (3.42)
2-3/4 (5.83)
F
1-3/16 (2.73)
1-3/4 (3.29)
2-1/4 (5.33)
G
3/4 (1.91)
1 (2.54)
1-7/16 (2.98)
H
1 (2.54)
1-7/16 (2.98)
1-31/32 (3.51)
I
(OPEN)
1-3/8 (3.49)
1-13/16 (4.60)
2-1/2 (6.35)
J
3/4 (1.91)
1-1/4 (3.18)
2 (5.08)
K
4-13/16 (12.22)
8-3/4 (22.23)
15-3/8 (39.05)
L
1 (2.54)
1-1/2 (3.81)
2-1/4 (5.72)
D
PANEL CUTOUT FOR FLUSH MOUNTING
I
FULL OPEN
G
H
Fig. 1
Fig. 2
L
HIGH
WIDE
Dwyer Series RM Rate-Master Flowmeters are furnished in three
models (see Fig. 2), each available in a broad array of flow ranges with
direct reading scales for air, gas or water. Installation, operation and maintenance are very simple. Only a few common-sense precautions must be
observed to assure long, trouble-free service.
CAUTION: Dwyer Rate-Master® Flowmeters are designed to provide satisfactory long-term service when used with air, water or other compatible
media. Refer to factory for information on questionable gases or liquids.
Avoid solutions of acids, bases or salts having a pH below 5.0 or above
8.5. Caustic solutions, antifreeze (ethylene glycol) and aromatic solvents
should definitely not be used.
Calibration
Each Rate-Master® Flowmeter is calibrated at the factory. If at any time
during the meter’s life, you wish to re-check its calibration, do so only with
devices of certified accuracy. DO NOT attempt to check a Rate-Master®
Flowmeter with a similar flowmeter, as seemingly unimportant variations in
piping and back pressure may cause noticeable differences in the indicated reading. If in doubt, return your Dwyer Rate-Master® Flowmeter to the
factory. Its calibration will be checked for you at no charge. Before proceeding with installation, check to be sure you have the Rate-Master
model and flow range you require.
LOCATION: Temperature, Pressure, Atmosphere and Vibration:
Dwyer Rate-Master® Flowmeters are exceptionally tough and strong. They
are designed for use at pressures up to 100 psi (6.89 bar) and temperatures up to 130°F (54°C).
DO NOT EXCEED THESE LIMITS! The installation should not be exposed
to strong chlorine atmospheres or solvents such as benzene, acetone,
carbon tetrachloride, etc. The mounting panel should be free of excessive
vibration, as it may prevent the unit from operating properly.
DWYER INSTRUMENTS, INC.
P.O. BOX 373 • MICHIGAN CITY, IN 46361, U.S.A.
8-9/16 (21.75)
15 -3/16 (38.58)
7/8 (2.22)
1-5/16 (3.33)
2-1/16 (5.24)
PANEL HOLE SIZES FOR SURFACE MOUNTING
5/8 (1.59)
15/16 (2.38)
7/16 (1.11)
PIPE
BOLT
®
4-5/8 (11.75)
1/4 (0.64)
9/32 (0.71)
13/32 (1.03)
Inlet Piping Run: It is good practice to approach the flowmeter inlet with
as few elbows and restrictions as possible. In every case, the inlet piping
should be at least as large as the connection to the flowmeter; i.e.,1/8″
Iron Pipe Size for RMA models 1/4″ IPS for RMB models,1/2″ IPS for RMC
models. Length of inlet piping makes little difference for normal pressurefed flowmeters.
For flowmeters on vacuum air service, the inlet piping should be as short
and open as possible. This will allow operation near atmospheric pressure
and thereby insure the accuracy of the device. (Note: for vacuum air service, the flow control valve, if any, should be on the discharge side of the
flowmeter. Either the TMV unit or a separate in-line valve may be applied.).
Discharge Piping: As on the inlet, discharge piping should be at least as
large as the flowmeter connection. Also, for pressure-fed flowmeters on
air or gas service, the discharge piping should be as short and open as
possible. This will allow operation of the flow tube at near atmospheric
pressure and insure the accuracy of the device. This is of less importance
on water or liquid flowmeters, as the flowing medium is generally incompressible and moderate back pressure will not affect the accuracy of the
instrument as calibrated.
POSITIONING AND MOUNTING
All Rate-Master® Flowmeters must be mounted in a vertical position with
inlet connection at the bottom rear and outlet at the top rear.
Bezel or Through-Panel Mounting: Make panel cutout using appropriate dimensions from Fig. 2. Flowmeter must fit into panel freely without
forcing or squeezing. Insert the flowmeter from the front of the panel and
install the mounting clamps from the rear. Insert and tighten the clamp
bolts in the locations shown in Fig. 3. Do not exceed 5 in./lbs. Make connections to inlet and outlet ports using small amount of RTV sealant or
Teflon® thread tape to avoid leakage. Avoid excess torque, which may
damage the flowmeter body.
Phone: 219/879-8000
Fax: 219/872-9057
www.dwyer-inst.com
e-mail: [email protected]
Bulletin F-43
9/14/05
9:01 AM
Page 2
Fig. 6
Fig. 5
MOUNTING
BRACKET
SCREW 4
REQUIRED
Fig. 3
Fig. 4
Fig. 5B
Surface Mounting: Drill appropriate holes in panel, using the dimensions
shown in Fig. 2. Hold the flowmeter in position in front of the panel and
install the clamp bolts from the rear. (The mounting clamps may be used
as washers, if desired, by installing them backwards or straightening them
out.) Pipe up inlet and discharge following the directions in the previous
sections.
Surface Mounting on Piping Only: An alternate method of surface
mounting, omitting the clamp bolts and supporting the flowmeter solely on
the connecting piping, is possible. For this method, extra-long or straight
pipe threads should be used so that nuts may be run onto the pipe and
later tightened against the back of the panel to retain the unit in proper
position. Use appropriate hole layout in formation from Fig. 2, but omit the
small holes.
Surface Mounting on Piping Only Without Panel: For a temporary or
laboratory type installation, the panel may be omitted altogether and the
flowmeter installed directly in rigid piping. Its light weight permits this without difficulty.
OPERATION
To start system, open valve slowly to avoid possible damage. Control
valves on BV and SSV models are turned clockwise to reduce flow,
counter-clockwise to increase flow. A nylon insert is provided in the threaded section of the valve stem to give a firm touch to valve and to prevent
change of setting due to vibration.
The performance of low range units used in air or gas applications may be
affected by static electricity. Excessive static charge may cause the ball
float to behave erratically or provide a false reading. To ensure the proper
function of the unit, the application should be designed to minimize or dispel static electricity.
The standard technique for reading a Variable Area Flowmeter is to locate
the highest point of greatest diameter on the float, and then align that with
the theoretical center of the scale graduation. In the event that the float is
not aligned with a grad, an extrapolation of the float location must be made
by the operator as to its location between the two closest grads. The following are some sample floats shown with reference to the proper location
to read the float.
Variable Area Flowmeters used for gases are typically labeled with the prefix “S” or “N”, which represents “Standard” for English units or “Normal” for
metric units. Use of this prefix designates that the flowmeter is calibrated
to operate at a specific set of conditions, and deviation from those standard conditions will require correction for the calibration to be valid. In practice, the reading taken from the flowmeter scale must be corrected back to
standard conditions to be used with the scale units. The correct location to
measure the actual pressure and temperature is at the exit of the flowmeter, except when using the Top Mounted Valve under vacuum applications,
where they should be measured at the flowmeter inlet. The equation to correct for nonstandard operating conditions is as follows:
Q2 = Q1 x
Where:
P1 x T2
P2 x T1
Q1 = Actual or Observed Flowmeter Reading
Q2 = Standard Flow Corrected for Pressure and
Temperature
Fig. 6B
Fig. 7
P1 = Actual Pressure (14.7 psia + Gage Pressure)
P2 = Standard Pressure (14.7 psia, which is 0 psig)
T1 = Actual Temperature (460 R + Temp °F)
T2 = Standard Temperature (530 R, which is 70°F)
Example: A flowmeter with a scale of 10-100 SCFH Air. The float is sitting
at the 60 grad on the flowmeter scale. Actual Pressure is measured at the
exit of the meter as 5 psig. Actual Temperature is measured at the exit of
the meter as 85°F.
Q2 = 60.0 x
(14.7 + 5) x 530
14.7 x (460 + 85)
Q2 = 68.5 SCFH Air
CAUTION: Do not completely unscrew valve stem unless the flowmeter is
unpressurized and drained of any liquid. Removal while in service will allow
gas or liquid to flow out the front of the valve body and could result in serious personal injury. For applications involving high pressure and/or toxic
gases or fluids, special non-removable valves are available on special
order. Please contact factory for details.
MAINTENANCE
The only maintenance normally required is occasional cleaning to assure
reliable operation and good float visibility.
Disassembly: The flowmeter can be disassembled for cleaning
simply as follows:
1. Remove valve knob from RMB or RMC -BV or -SSV units by pulling the
knob forward. It is retained by spring pressure on the stem half-shaft so
that a gentle pull will remove it. On RMA-BV or -SSV models, turn the valve
knob counter-clockwise until the threads are disengaged. Then withdraw
the stem from the valve by gently pulling on the knob.
2. Remove the four mounting bracket screws located in the sides of the
flowmeter. See Fig. 3. Pull the flowmeter body gently forward away from
the back plate to avoid undue strain on the body. Leave the piping connections intact. There is no need to disturb them. See Fig. 4.
3. Threaded body style flowmeters - Remove the slip cap with a push on
a screwdriver as shown in Fig. 5. Remove the plug ball stop as shown in
Fig. 6 using allen wrench sizes as follows: Model RMA - 1/4″, Model RMB
- 1/2″ and Model RMC - 3/4″ Threadless body style flowmeters - Release
the plastic retaining clip with a screw driver (Figure 5B), it will unclip from
the valve body (TMV Option) or the plug ball stop, slide the clip back until
the valve body or ball stop can be removed. The clip will remain in the body
for convenience. Using a screwdriver gently lift up on the plug in the groove
as shown in Figure 6B until the o-ring seal is released and remove the plug.
For the TMV option gently pull up on the valve knob to release the valve
body seals and remove the valve.
4. Take out the ball or float by inverting the body and allowing the float
to fall into your hand, as shown in Fig. 7. (Note: It is best to cover the discharge port to avoid losing the float through that
opening.)
Cleaning: The flow tube and flowmeter body can best be cleaned with a
little pure soap and water. Use of a bottle brush or other soft brush will aid
the cleaning. Avoid benzene, acetone, carbon tetrachloride, alkaline detergents, caustic soda, liquid soaps (which may contain chlorinated solvents),
etc. Also, avoid prolonged immersion, which may harm or loosen the
scale.
Reassembly: Simply reverse steps 1 through 4 and place the flowmeter
back in service. A little stopcock grease or petroleum jelly on the “O” rings
will help maintain a good seal as well as facilitate assembly. No other special care is required.
Teflon® is a registered Trademark of E.I. DuPont Company
©Copyright 2005 Dwyer Instruments, Inc.
Printed in U.S.A. 9/05
DWYER INSTRUMENTS, INC.
P.O. BOX 373 • MICHIGAN CITY, IN 46361, U.S.A.
Phone: 219/879-8000
Fax: 219/872-9057
FR# 56-440197-00 Rev. 16
www.dwyer-inst.com
e-mail: [email protected]
F. Electronic Timer Manual
6
Bulletin No. CUB3T3/4-A
Drawing No. LP0395
Revised 9/00
Tel +1 (717) 767-6511
Fax +1 (717) 764-6587
www.redlion-controls.com
MODEL CUB3T3 & CUB3T4 - GENERAL PURPOSE MINIATURE ELECTRONIC TIMERS
!
!
!
!
!
!
6-DIGIT TIMER ACCUMULATES TIME IN HOURS,
1/10 HOURS, 1/100 HOURS, OR 1/10 MINUTES
OPERATES FROM EITHER SWITCH CONTACT, OR
10 to 300 V (AC 50/60 Hz or DC) INPUTS
SELF-POWERED WITH INTERNAL LITHIUM BATTERY FOR UP
TO 7 YEARS OF CONTINUOUS OPERATION
AVAILABLE IN FRONT PANEL AND REMOTE RESET OR REMOTE
RESET ONLY MODELS
EASY SNAP-IN MOUNTING IN 1" X 2" (25 mm x 50 mm) PANEL
OPENING
IDEAL FOR PORTABLE, MOBILE, OR STATIONARY INDUSTRIAL
EQUIPMENT
DESCRIPTION
SPECIFICATIONS
The CUB3T’s are state-of-the-art products with Micro-Electronic
technology. They open up a wide variety of new timing application possibilities
that, until now, were economically impractical.
The CUB3T3 and CUB3T4 are designed to be used as hour, tenth hour,
hundredth hour or tenth minute timers. The timing function on both models can
be activated by either a contact closure or the application of 10 to 300 (AC
50/60 Hz or DC). Both models are equipped with a remote reset. The CUB3T4
has the additional feature of a front panel reset. Time is displayed on a 6 digit
LCD that will wrap around from a full display of “999999” to “000000” when
an overflow occurs. An indicator, located in the upper lefthand corner of the
display, will blink at 2 Hz whenever the timer is actuated. The front panel reset
feature of the CUB3T4 allows the user to periodically measure elapsed time.
The CUB3T3, on the other hand, is ideally suited for measuring total run time.
Application of the CUB3T is simplicity itself. Its rugged reinforced nylon
case snap-fits into a standard rectangular opening without screws or other
hardware. No external power source is required since the internal lithium
battery provides up to 7 years of uninterrupted service. In addition to these
advantages, the CUB3T offers integrated circuitry, embedded in a single
monolithic, silicon micro-chip.
1. DISPLAY: 6-Digit, LCD, 0.2" (5.1 mm) High.
2. POWER: 3 Volts supplied by a non-replaceable lithium battery. Nominal
battery life is 7 years. Battery life is dependent upon usage. Signal and reset
contacts that remain closed for long periods of time reduce battery life.
3. REMOTE RESET:
50 msec min. pulse width (active low) from 3.0 V bi-polar output, an open
collector transistor, or a switch contact to common.
VIH = 2.0 V min. (3 V max), VIL = 0.5 V max.
4. SIGNAL INPUT:
Contact Connections: Switch Contact or Solid-State Transistor Switch.
Contact burden 15 µamps max. A maintained closed switch will actuate
the timer.
10 to 300 V Connections: 10 V min. to 300 V max. (AC 50/60 Hz or DC).
Input current 0.5 mA max. Constant voltage applied to the inputs will
actuate the timer.
5. CERTIFICATIONS AND COMPLIANCES:
SAFETY
EN 61010-1, IEC 1010-1
Safety requirements for electrical equipment for measurement, control,
and laboratory use, Part I.
ELECTROMAGNETIC COMPATIBILITY
Immunity to EN 50082-2
Electrostatic discharge
EN 61000-4-2 Level 2; 4 Kv contact 1
Level 3; 8 Kv air
Electromagnetic RF fields
EN 61000-4-3 Level 3; 10 V/m
80 MHz - 1 GHz
Fast transients (burst)
EN 61000-4-4 Level 4; 2 Kv I/O 2
RF conducted interference
EN 61000-4-6 Level 3; 10 V/rms
150 KHz - 80 MHz
Emissions to EN 50081-1
RF interference
EN 55022
Enclosure class B
SAFETY SUMMARY
All safety related regulations, local codes and instructions that appear in this
bulletin or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.
CAUTION: Read complete instructions prior
to installation and operation of the unit.
CAUTION: Risk of electric shock.
Metal panel must be connected to protective earth ground.
DIMENSIONS “In inches (mm)” & INSTALLATION
PANEL CUT-OUT
1” x 2” or 25 mm x 50 mm
PANEL THICKNESS
.05” to .125”
Notes:
1. For operation without loss of performance:
In static environments above 4 KV, typical anti-static precautions should
be observed before touching the bezel.
2. For operation without loss of performance:
Install 1 ferrite core, RLC#FCOR0000 or equivalent, to cables at unit.
OR
Route I/O cables in metal conduit connected to earth ground.
Refer to the EMC Installation Guidelines for additional information.
6. ENVIRONMENTAL CONDITIONS:
Operating Temperature: -25 to +75°C
Storage Temperature: -30 to 75°C
Operating and Storage Humidity: 85% max. RH (non-condensing) from 25°C to +75°C.
Altitude: Up to 2000 meters
7. CONSTRUCTION: Installation Category II, Pollution Degree 2.
8. ACCURACY: 0.025%
9. WEIGHT: 2 oz (56.7 g)
EMC INSTALLATION GUIDELINES
ELECTRICAL CONNECTIONS & INPUTS
Although this unit is designed with a high degree of immunity to
ElectroMagnetic Interference (EMI), proper installation and wiring methods
must be followed to ensure compatibility in each application. The type of the
electrical noise, source or coupling method into the unit may be different for
various installations. Cable length, routing and shield termination are very
important and can mean the difference between a successful or a troublesome
installation. Listed below are some EMC guidelines for successful installation in
an industrial environment.
All conductors should meet voltage and current ratings for each terminal.
Also, cabling should conform to appropriate standards of good installation,
local codes and regulations. It is recommended that voltage connections to the
unit be protected by a fuse or circuit breaker.
The CUB3T’s can be supplied with input signals from mechanical switch
contacts or solid-state switches as shown in the diagrams below. Reed switches,
mercury-wetted contacts, snap-action limit switches, and silver alloy contacts
with wiping action are usually satisfactory choices for mechanical switch input.
Heavy “clapper-type” contacts such as used in contactors or large machine tool
relays, tungsten contacts, or brush type contacts are not recommended for the
low level switching used by the input to the timer.
To avoid injury to personnel or equipment, properly isolate all unused wires.
For example, wire nuts, closed end splices, or other types of wire terminators
should be used.
Warning: Connecting voltage to contact or reset inputs will cause damage to
the unit.
1. Use shielded (screened) cables for all Signal and Control inputs. The shield
(screen) pigtail connection should be made as short as possible. The
connection point for the shield depends somewhat upon the application.
Listed below are the recommended methods of connecting the shield, in order
of their effectiveness.
a. Connect the shield only at the panel where the unit is mounted to earth
ground (protective earth).
b. Connect the shield to earth ground at both ends of the cable, usually when
the noise source frequency is above 1 MHz.
2. Never run Signal or Control cables in the same conduit or raceway with AC
power lines, conductors feeding motors, solenoids, SCR controls, and
heaters, etc. The cables should be run in metal conduit that is properly
grounded. This is especially useful in applications where cable runs are long
and portable two-way radios are used in close proximity or if the installation
is near a commercial radio transmitter.
3. Signal or Control cables within an enclosure should be routed as far away as
possible from contactors, control relays, transformers, and other noisy
components.
4. In extremely high EMI environments, the use of external EMI suppression
devices, such as ferrite suppression cores, is effective. Install them on Signal
and Control cables as close to the unit as possible. Loop the cable through the
core several times or use multiple cores on each cable for additional
protection. The following EMI suppression devices (or equivalent) are
recommended:
Ferrite Suppression Cores for signal and control cables:
Fair-Rite # 0443167251 (RLC #FCOR0000)
TDK # ZCAT3035-1330A
Steward #28B2029-0A0
5. Long cable runs are more susceptible to EMI pickup than short cable runs.
Therefore, keep cable runs as short as possible.
10 to 300 V Voltage Connections
Warning: Any lead may be at hazardous live input potential.
External wiring and devices connected to the unit must be rated the
same as applied signal input voltage and be properly isolated from
Class 2 or SELV circuitry.
Contact Connections
Installation Environment
TYPICAL APPLICATIONS
An equipment rental company charges customers by the hour for the
rental of forktrucks or other heavy equipment. To help determine the
amount of actual run time, a CUB3T300 is connected to a spare set of
contacts on the ignition switch of the forktruck. When the switch is in the
“RUN” position, the “Orn/Wht” and “White” leads of the CUB3T3 are
connected, which cause it to accumulate time in hours on the display. The
rental company simply resets the CUB3T3 by momentarily closing the
connection between the “Orn/Wht” and “Blue” leads before each rental
period. The normally open “REMOTE RESET” push-button (installed by
the rental company) is protected to prevent tampering by the customer.
The unit should be installed in a location that does not exceed the maximum
operating temperature and provides good air circulation. Placing the unit near
devices that generate excessive heat should be avoided.
The bezel should be cleaned only with a neutral soap product applied to a
soft damp cloth. Do NOT use solvents.
Continuous exposure to direct sunlight may accelerate the aging process of
the display.
Do not use tools of any kind (screwdriver, pens, pencils, etc.) to operate the
reset button of this unit.
TROUBLESHOOTING
For further technical assistance, contact technical support at the appropriate
company numbers.
A machine shop manager charges customers for machine time by the
hour. He is also interested in tracking machine run time vs. down time. A
CUB3T310 connected across the 115 VAC spindle motor of a drill press
will serve both purposes. A reading taken before and after each job will
indicate the actual machine run time in tenth hour increments. A reading at
the beginning and end of each shift will indicate total run time, allowing the
manager to evaluate production efficiency and down time.
WARNING: Lithium battery may explode if incinerated. Input
voltage must not exceed 3.0 VDC on contact input or
maximum rated voltage on voltage input to prevent
damage to the unit.
ORDERING INFORMATION
MODEL
NO.
Timer,
Timer,
CUB3T3
Timer,
Timer,
Timer,
Timer,
CUB3T4
Timer,
Timer,
DESCRIPTION
1 hr.; Remote Reset Only
0.1 hr.; Remote Reset Only
0.01 hr.; Remote Reset Only
0.1 min.; Remote Reset Only
1 hr. w/Front Panel and Remote Reset
0.1 hr. w/Front Panel and Remote Reset
0.01 hr. w/Front Panel and Remote Reset
0.1 min. w/Front Panel and Remote Reset
PART
NUMBER
CUB3T300
CUB3T310
CUB3T320
CUB3T330
CUB3T400
CUB3T410
CUB3T420
CUB3T430