(MOBILE, AIR SAMPLING PUMP SYSTEM)

Transcription

1 HI-Q Environmental Products Co. Air Sampling Equipment, Systems & Accessories 7386 Trade Street San Diego, California Phone: (858) Fax: (858) Web: PSU-2-H (MOBILE, AIR SAMPLING PUMP SYSTEM) Revised: 09/20/12 MAH

2 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. Wiring Diagram B. Complete PSU Assembly Diagram C. Filter Box Detail Views D. Motor/Pump Maintenance Manual E. Flow meter Installation & Operation Instructions F. Electronic Timer Manual G. Calibration Certificate 1

3 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 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

4 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 : Protective Earth Ground A: Amps : 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

5 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

6 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

7 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

8 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 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

10 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

11 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

12 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

13 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

14 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 ALPM (actual liters per minute) 13

15 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 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

16 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

17 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

18 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

19 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

20 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 Unit Price in $USD MRV-021 MCV-RK, rebuild kit for the MCV-260 (includes diaphragm and o ring). 12 Months $35.00 MRV-022-PSU Electronic, resettable hour/tenths timer. 48 Months $95.00 MRV-023 Reset button assembly for timer (MRV-022-PSU). As Needed $12.00 MRV-027 Black nylon gooseneck fitting. As Needed $41.90 MRV-028 Aluminum knurled nut for above. As Needed $35.00 MRV-029 Polypack seal for gooseneck. 24 Months $14.75 MRV-030 Fuse holder assembly. As Needed $12.50 MRV-032 SPST Toggle switch w/on/off plate (pre TUV Rheinland listed PSU s, pre ~2010) 60 Months $27.50 MRV-032A DPST Toggle switch w/on/off plate (TUV Rheinland listed PSU s) 60 Months $27.50 MRV-037 8" wheel -1/2" axle. As Needed $30.00 MRV-048 Control Valve Adjustment Star Knob. As Needed $9.75 MRV-PSU ' long, 14/3 power cord,. As Needed $45.00 MRV-PSU-002 Gooseneck 5/8" OD, SS, 90 bend includes SS 5/8 Compression x ½ FNPT. As Needed $ MRV-PSU-006-SS 1/2" x 16" stainless steel axle. As Needed $45.00 MRV-PSU-008 Front support legs with bumper assembly. As Needed $ MRV-PSU-020 MCV-260, heavy duty, automatic flow control valve for PSU. As Needed $ MRV-PSU-026 Hand grip tape. As Needed $18.50 MRV-PSU CFM axial cooling fan. Stock fan with sleave bearings. 18 Months $45.00 MRV-PSU-027BB 100 CFM axial cooling fan. Upgraded fan with ball bearings 36 Months $68.00 MRV-PSU-028 Rubber foot for front foot support (2 per foot assembly). 36 Months $11.50 MRV-PSU-029 Rubber union gasket: 1-3/4 od x 1-3/16 id x 1/8 thick. 12 Months $5.25 MRV-PSU Rotometer (does not include needle valve or blank scale). 24 Months $46.00 MRV-PSU Blank scale for rotometer with adhesive back. As Needed $12.75 MRV-PSU-032-A 4 Scale marked 20 to 110 LPM (Standard Venturi). No certification included. As Needed $75.00 MRV-PSU-033 Needle valve assembly of rotometer (used to calibrate). 24 Months $24.50 MRV-PSU-034 Power cord strain relief for PSU box. 36 Months $12.75 MRV-PSU-035 1/8 ID clear tubing set. Two pieces: 14 & 21 sections, 1/8 ID. 24 Months $14.50 MRV-PSU-036 3/8 ID braid reinforced clear inlet tubing. 21 long section. 24 Months $8.90 MRV-PSU-037 3/8 ID high temperature exhaust tubing (blue). 5 section. 24 Months $7.50 MRV-PSU-038 Axial fan power cord. As Needed $8.50 MRV-PSU-039 Axial fan finger guard. As Needed $9.25 MRV-PSU-040 ¾ Galvanized union assembly used to connect/disconnect gooseneck. As Needed $46.00 MRV-PSU-041 Rubber fan louver hand grip/bumper. As Needed $24.00 MRV-PSU-041-A Cooling Fan White Louver Kit for PSU box. Kit includes mounting hardware. As Needed $ MRV-PSU-042 Rubber PSU box stacking bumpers. 4 mounted under each PSU. Sold Each. 36 Months $10.45 MRV-PSU-043 1½ dust cap assembly with hanging chain. As Needed $18.50 MRV-PSU-044 Power cord hanging rack assembly set. Two power rack assemblies per set. As Needed $42.50 MRV-PSU-045 End cap for 0523 or 1023 series pump. Does not include o-ring or felt filter (2/pump) 36 Months $4.20 MRV-PSU-046 O-ring for pump end cap assembly. 1 per end cap, 2 per pump. 24 Months $1.50 MRV-009 Felt filter for 0523 pump inlet/outlet. Slides over motor end caps (2 required) Months $2.50 MRV-PSU-048 Latch assembly for pump housing box. As Needed $37.50 MRV-PSU-052 Venturi tube, 6 long, black anodized with 3/8 female NPT inlet/outlet As Needed $ MRV-PSU-053 Single hose barb, 1/8 (x 10-32) brass. Barb threads into black venturi tube. As Needed $2.75 MRV-PSU-060 Complete analog instrument panel for all PSU s. Panel includes rotometer w/ As Needed $ venturi connection tubing, timer, power switch, fuse holder, fuse, wire harness & internal terminal block. User will need to perform a single point calibration. MRV-PSU-061 PSU handlebar assembly consists of the complete galvanized ¾ female union, flat As Needed $ gasket, 20 inch blue painted ¾ pipe, nylon ¾ telescopic retaining screw, polypack seal and ¾ knurled retaining nut. MRV-PSU-062 Lower handlebar assembly attached to PSU Box. Individual assembled AS Needed $ 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 reducer and ¾ Hex Cap. **Does Not Included ¾ Galvanized Union (MRV-PSU-040)** MRV-PSU-063 Spiral Bundling Wrap-Around Sleeving, OD: 3/8 Polyethylene. As Needed $1.65/ft MRV-PSU-064 Heavy Duty Motor Mount Plate with 4 Shock mount feet & mounting hardware. As Needed $75.00

21 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. Unit Price in $USD As Needed $ MRV-001 1/4 HP, 115VAC, replacement pump/motor 24 Months $ K478 Service Repair Kit for the Q-G582DX. K478 Service Kit Includes: 2Felt Months $74.75 (MRV-005) Filters, 4 Carbon Vanes, 1 Motor Gasket, 2- O Rings, & 5 Bolt Gaskets. MRV-007 Sintered bronze muffler for the 0523 series pump 0-12 Months $19.11 MRV-010 Single replacement vane for 0523 series pumps (4 required) Months $19.62 MRV-013 Motor gasket for 0523 series pump (1 required) Months $2.10 MRV-PSU-024A Single motor shock absorber (4 per motor): ¼-20" thread x 1/2" high sandwich mount. For MRV-0523-PSU. (sold per each) 36 Months $7.20 MRV-PSU-024B Single motor shock absorber (4 per motor): 5/16" thread x 3/4" high sandwich mount. For PSU-2 & PSU-3. (Sold per each) 36 Months $7.20 MRV Amp Slo-Blo fuse for ¼ HP 0523 pump equipped samplers. As Needed $3.50 MRV-PSU-007 Wiring harness connects ¼ HP pump to control panel. As Needed $38.00 MRV-PSU-050 Complete lower MRV-0523CV-PSU assembly. Lower PSU assembly consists of all As Needed $ items below and including the galvanized ¾ male union. MRV-PSU-051 Complete upper MRV-0523CV-PSU assembly. Upper PSU assembly consists of all As Needed $ items above and including the galvanized ¾ female union. Also includes flat gasket. MRV-PSU-054 Complete ¼ HP pump assembly with control valve, venturi tube with hose barbs, and As Needed $ quick connect wiring harness for PSU-2. MRV-PSU-055 ¼ HP Pump accessories kit kit does NOT include pump. Kit includes everything As Needed $ needed to attach to a pump to facilitate in the field pump replacement such as the control valve and venturi tube with hose barbs. MRV-PSU-056 Complete lower PSU-2 assembly below & including the aluminum knurled ¾ pipe As Needed $ nut (P/N: MRV-028). Lower PSU assembly consists of all items below and including the aluminum ¾ knurled retaining nut. MRV-PSU-057 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 $ /4 HP Pump Replacement/Retrofit Parts (PSU-3 SERIES): PART # PART DESCRIPTION Replacement Schedule PSU KIT 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. Unit Price in $USD As needed $1, PSU-1023-PUMP ¾ HP replacement pump/motor for PSU-3 series samplers. As Needed $ PSU-FAN-KIT 100 CFM Fan & Louver retrofit kit. This kit is most commonly used as an additional As Needed $ (2 nd ) 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. PSU power cord for MRV-1023CV-PSU and PSU-3 series. As Needed $45.00 PSU Wiring harness connects ¾ HP pump to control panel. As Needed $38.00 PSU /8 braid reinforced clear inlet tubing from inlet into box to venturi 24 Months $8.90 PSU /8 high temperature exhaust tubing (blue) from pump outlet to muffler jar 24 Months $7.50 PSU Muffler jar assembly, this muffler is internal to the PSU box 24 Months $67.20 AC393 Replacement felt muffler cartridge for PSU muffler jar assembly 24 Months $10.08 PSU Complete lower PSU-3A-H assembly. Lower PSU assembly consists of all items As Needed $ below and including the galvanized ¾ male union. PSU-DIG-035 1/8 ID clear tubing set. Two pieces to connect venturi to differential pressure sensor 24 Months $14.75 on PSU with digital flow option MRV-008 Sintered bronze muffler for the 1023 series pump 0-12 Months $15.00 K479 Service kit for ¾ HP oilless rotary vane vacuum pumps. Kit includes: 2 felt filters, Months $96.70 carbon vanes, 1 motor gasket, 2 o-rings, and 5 bolt gaskets. MRV amp Slo-Blo fuse ¾ HP 1023 pump equipped samplers. As Needed $3.50 MRV-PSU-024B Single motor shock absorber (4 per motor): 5/16" thread x 3/4" high sandwich mount. For PSU-2 & PSU-3. (Sold per each) 36 Months $7.20 PSU-BOT-SCRN Square inlet screen for bottom of PSU enclosure As Needed $9.50

22 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. Unit Price in $USD As Needed $ PSU-2-ILFH L-Style in-line filter holder for use w/ PSU-2 and PSU-3(does not include cartridge) As Needed $ Filter Holders, Inlets for PSU-2-H and PSU-3-H & Air Flow Calibrator PSU-2-ILFH- Replacement O-ring seal. Two per filter holder. (sold per each) As Needed $1.75 ORING PSU-2-ILFH-001 Stainless steel 1/2" male (stem) quick disconnect x 1/2" male NPT. As Needed $25.69 PSU-2-ILFH-002 1/2" NPT street elbow, nickel plated brass. As Needed $12.75 PSU-2-ILFH-003 Stainless steel 1/2" female (body) quick disconnect fitting x 1/2" male NPT. As Needed $64.12 MRV-PSU-022 Stainless Steel ½ male NPT x ½ female quick disconnect. As Needed $56.06 MRV-PSU-023 Stainless Steel ½ male NPT x ½ male quick disconnect. As Needed $27.50 MRV-PSU-024 Stainless Steel 5/8 compression fitting x ½ female NPT. As Needed $40.00 MRV-PSU-047 Latch assembly (stainless steel) for filter holder box. As Needed $30.63 MRV-PSU-049 Upper aluminum filter holder box assembly (hinge & latch included) As Needed $ PART # PART DESCRIPTION Replacement Schedule Unit Price in $USD PSU-RHLB Cylindrical Inlet for use on PSU-2-H and PSU-3A-H, includes one PSU-FH filter As Needed $1, holder. PSU-RHLB-IH PSU-RHLB Inlet Handle Retrofit Kit includes handle, handle socket, mounting stud As Needed $65.00 and drilling template. PSU-RHLB- 1/8 thick x 2 ¾ OD x 2¼ ID (approx. dims) RHPB receptacle flat Gasket. The As Needed $5.75 RGASKET PSU-FH filter holder sits on top of this gasket at the base of the RHLB. PSU-RHLB- Lower (bottom) assembly of the PSU-RHLB. Includes: Male CAM-Locking Base with As Needed $ BOTTOM studs & O-ring, cable assembly, swing-locks to retain holder, and press-fit 5/8 SS down-tube with handle bar. PSU-FH CAM-Lock Style filter holder for use in PSU-RHLB. Includes one PSU-FH-CAP. As Needed $ PSU-FH-CAP Protective transport cap for the PSU-FH As Needed $36.00 PSU-FH-001 Replacement ¼ thick honeycomb filter support, 1.6 diameter As Needed $9.75 PSU-FH-002 Replacement o-ring seals filter media perimeter. One per filter holder. As Needed $1.75 PSU-FH-O225 Parylene coated silicone o-ring. One per PSU-RHLB and two per PSU-FH. As Needed $1.75 Orange in color. PSU-FH-SR Stainless steel snap ring that holds inlet of PSU-FH filter holder together. As Needed $22.00 PSU-FH-TOOL Aluminum filter removal tool for use with PSU-FH. By pushing the base of the PSU- FH down over this tool, the honeycomb filter support is elevated 1/8, allowing the filter paper to be easily removed. PSU-FH- Aluminum calibration adapter for use with the PSU-FH. Includes ½ Swagelok quick CALADAPT disconnect fitting to allow connection of AFC-DIG-110L-5QD. AFC-DIG-110L- Digital style 20 to 110 LPM air flow calibrator. The AFC includes a 7 foot long ½ 5QD diameter transport line with ½ Stainless Steel Female Quick Disconnect. AFC-110L-5QD 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 $ As Needed $1, As Needed $ Operating Manuals and Instrumentation PART # PART DESCRIPTION Replacement Schedule Unit Price in $USD PSU-2- Manual Complete PSU-2 operations manual, applies to MRV-0523CV-PSU also. As Needed $25.00 PSU-2-H Manual Complete PSU-2-H operations manual. As Needed $25.00 PSU-2-H-D Manual Complete PSU-2-H-D operations manual. As Needed $25.00 PSU-3-Manual Complete PSU-3 series operations manual includes all PSU-3 series samplers. As Needed $25.00 PSU-3-H-D Manual Complete PSU-3-H-D operations manual. As Needed $25.00 PSU-VACGAUGE 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 PSU- FH-CALADAPT. As Needed $145.00

23 Spare parts & sampler systems PART # PART DESCRIPTION Replacement Schedule Unit Price in $USD 375FXELBOW 3/8" NPT FEMALE ELBOW As Needed $ MNPTX 3/8 MNPT PIPE NIPPLE X 3 INCHES LONG As Needed $ K16 HOSE CLAMP 7/16-25/32 As Needed $2.79 PSU-2-H ¼ HP PSU-SERIES MOBILE CART OUTDOOR AIR SAMPLING SYSTEM WITH $3, FILTER HOLDER & RAIN HAT LOCK BOX (PSU-2-H INCLUDES ONE EACH P/N: PSU-RHLB & PSU-FH).TUV RHEINLAND LISTED. As Needed PSU-3-H 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 $4, Contact: HI-Q Environmental Products Company Phone: Trade Street Fax: San Diego, CA sales@hi-q.net Web:

24 A. Wiring Diagram 1

25

26 B. Complete PSU Assembly Diagram 2

27 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 TEL: FAX: 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: DO NOT SCALE DRAWING N/A PSU-2-H ASSEMBLY N/A SIZE DWG. NO. DRAWN BY: DATE: A PSU-2-H ASSY S.A. OWEN 10/20/05 CAD FILE: PSU-2-H HI-Q DETAILS.SLDDRW SHEET 1 OF 1 REV. A

28 C. PSU-RHLB and PSU-FH Detail Views 3

29 Rain Hat Inlet PSU-FH PSU-RHLB BASE/ FILTER HOLDER RECEPTACLE 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. DIMENSIONS ARE IN INCHES TOLERANCES: ANGULAR 1 DEGREE ONE PLACE DECIMAL.050 TWO PLACE DECIMAL.010 THREE PLACE DECIMAL.005 DO NOT SCALE DRAWING MATERIAL: FINISH: N/A N/A DRAWN BY: S.A. OWEN DATE: 11/13/06 User Supplied Lock HI-Q ENVIRONMENTAL PRODUCTS CO TRADE STREET, SAN DIEGO, CA TEL: FAX: SIZE DWG. NO. A CAD FILE: PSU-RHLB and PSU-FH ASSEMBLY Rev B PSU-RHLB & FH Rev B ASM PSU-RHLB & FH Rev B ASSEMBLY.SLDDRWSHEET 1 OF 4 REV. B

30 FILTER HOLDER LATCHES CLOSED FILTER HOLDER LATCHES OPEN 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. DIMENSIONS ARE IN INCHES TOLERANCES: ANGULAR 1 DEGREE ONE PLACE DECIMAL.050 TWO PLACE DECIMAL.010 THREE PLACE DECIMAL.005 FINISH: N/A 7386 TRADE STREET, SAN DIEGO, CA TEL: FAX: PROPRIETARY AND CONFIDENTIAL DO NOT SCALE DRAWING PSU-RHLB and PSU-FH MATERIAL: N/A Rev B ASSEMBLY DRAWN BY: DATE: S.A. OWEN 11/4/05 HI-Q ENVIRONMENTAL PRODUCTS CO. SIZE DWG. NO. A CAD FILE: PSU-RHLB & FH Rev B ASM PSU-RHLB & FH Rev B ASSEMBLY.SLDDRWSHEET 2 OF 4 REV. A

31 Transport Cap Inlet Inlet Collar Filter Media O-ring Filter Holder Base F O-ring Honeycomb Filter Support O-Ring DETAIL F SCALE 2 : 1 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. DIMENSIONS ARE IN INCHES TOLERANCES: ANGULAR 1 DEGREE ONE PLACE DECIMAL.050 TWO PLACE DECIMAL.010 THREE PLACE DECIMAL.005 FINISH: N/A HI-Q ENVIRONMENTAL PRODUCTS CO TRADE STREET, SAN DIEGO, CA TEL: FAX: PROPRIETARY AND CONFIDENTIAL DO NOT SCALE DRAWING PSU-FH Rev B MATERIAL: N/A ASSEMBLY DRAWN BY: DATE: S.A. OWEN 11/4/05 SIZE DWG. NO. A CAD FILE: PSU-FH Rev B ASM PSU-RHLB & FH Rev B ASSEMBLY.SLDDRW SHEET 3 OF 4 REV. A

32 Filter Removal Tool 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 D 1/8" SECTION D-D SCALE 1 : 1.2 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. DIMENSIONS ARE IN INCHES TOLERANCES: ANGULAR 1 DEGREE ONE PLACE DECIMAL.050 TWO PLACE DECIMAL.010 THREE PLACE DECIMAL.005 FINISH: N/A HI-Q ENVIRONMENTAL PRODUCTS CO TRADE STREET, SAN DIEGO, CA TEL: FAX: PROPRIETARY AND CONFIDENTIAL DO NOT SCALE DRAWING PSU-FH Rev B MATERIAL: N/A ASSEMBLY DRAWN BY: DATE: S.A. OWEN 11/4/05 SIZE DWG. NO. A CAD FILE: PSU-FH Rev B ASM PSU-RHLB & FH Rev B ASSEMBLY.SLDDRW SHEET 4 OF 4 REV. A

33 D. Motor/Pump Maintenance Manual 4

34 PART NO G375PL (REV-G) 23 SERIES OIL-LESS VACUUM PUMPS & COMPRESSORS OPERATION & MAINTENANCE MANUAL Model # Shown Model #1023-V103 Shown Model # Q 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: Top:.002 Ends: 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. 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 & CERTIFIED Registered Trademark/ Trademark of Gast Manufacturing Inc., Copyright 2001 Gast Manufacturing Inc. All Rights Reserved.

35 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: You will be killed or seriously injured if you don t follow instructions. 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 DANGER WARNING WARNING 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 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. 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. 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.

36 MAINTENANCE WARNING 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 rips,tears, cuts, brittleness and excessive foreign material. 2. Clean filters if in good condition with compressed air. Re-inspect for wear conditions. Set filters aside. 3. Check filter/muffler (#11) for compacted debris. If debris is present, replace filter/muffler. 4. Check condition of O-ring. It should be soft and flexible. Replace if it is not. 5. Remove and inspect muffler box. Clean box. Set box aside. (Not all models have a muffler box.) 6. Check gasket for cracks or tears. Install new gasket if any cracks or tears appear. Replace gasket. 7. Replace muffler box. 8. Reinstall filters or install new filters if required. Reinstall end cap. Flushing 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 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.

37 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 minutes. 4. Repeat step Disconnect power supply. 6. Plug open ports to prevent dirt or other contaminants from entering product. 9. Replace end plate. Torque bolts to in. lb. 10. Check gasket for damage. 11. Reinstall muffler box. Torque bolts to in. lb. Check that all external accessories such as relief valves and gauges are attached and are not damaged before re-operating product. SERVICE KIT INSTALLATION WARNING 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. Remove filter/muffler parts from front of muffler box. 2. Remove the 5 muffler box bolts. 3. Use a small hammer to tap on box to remove. Do not use a screwdriver. 4. Remove the 6 end plate bolts. 5. Remove end plate. Check direction of bevel edges of vanes then remove vanes. 6. Clean body and rotor slots. 7. Check end plate, rotor and body for scoring. Severe scoring or worn bearings will 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.

38 EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION REF DESCRIPTION QTY Q Q 0523-V103 1 BODY 1 AK503 AK503 AK505 AK505 AK505 2 * VANE 4 AH850A AH850A AH850A AH850A AH805A 3 SHROUD 1 AK502 AK502 AK502 AK502 AK502 4 END PLATE 1 AK516A AK501 AK516A AK501 AK516A 5 * GASKET 1 AK521 AK521 6 MUFFLER BOX 1 AK519 AK519 7 * O-RING 2 AK473 AK473 8 * FELT 2 AK524 AK524 9 END CAP 2 AK510 AK END CAP ASSEMBLY 2 AK526 AK FILTER / MUFFLER 1 AK840A AK840A 12 FOOT SUPPORT 1 AC136 AC ELBOW *** 2 AD MUFFLER ASSEMBLY 1 V425L 15 JAR 2 AA125A 16 COVER 1 AV FELT FILTER 4 B344A 18 SUPPORT 1 B345A 19 COVER GASKET 2 B62A 20 FILTER ASSEMBLY 1 V400G 21 COVER 1 AV402CPC 22 FILTER ASSEMBLY 1 B343B 23 SCREEN CAP 1 AJ FELT SUPPORT 1 B347 SERVICE KIT 1 K478A K478 K478A K478 ** * 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. Vacuum Intake Filter Assembly Muffler Assembly

39 EXPLODED PRODUCT VIEW, PARTS & ORDERING INFORMATION REF DESCRIPTION QTY Q Q 1023-V Q 1 BODY 1 AK517 AK517 AK518 AK518 AK518 AL283 AL283 2 * VANE 4 AK513 AK513 AK513 AK513 AK513 AL284 AL284 3 SHROUD 1 AK511 AK511 AK511 AK511 AK511 AL281 AL281 4 END PLATE 1 AK515A AK514 AK515A AK514 AK515A AK515A AK514 5 * GASKET 1 AK522 AK522 AK522 6 MUFFLER BOX 1 AK520 AK520 AK520 7 * O-RING 2 AK473 AK473 AK473 8 * FELT 2 AK524 AK524 AK524 9 END CAP 2 AK510 AK510 AK END CAP ASSEMBLY 2 AK526 AK526 AK FILTER / MUFFLER 1 AK840 AK840 AD432 AC ELBOW 1 BA206 BA ELBOW *** 2 AF MUFFLER ASSEMBLY 1 AB599B 13 a NIPPLE 2 BA714 BA JAR 2 AA COVER GASKET 2 AA COVER ASSEMBLY 1 AV805BPC 17 MUFFLER ASSEMBLY 1 AC COUPLING 2 AC CARTRIDGE 2 AC END CAP ASSEMBLY 2 AC MUFFLER PLATE 1 AC STUD 2 AC FILTER ASSEMBLY 1 AB COVER ASSEMBLY 1 AV805APC 25 FILTER ASSEMBLY 1 AC433-1 SERVICE KIT 1 K479A K479 K479A K479 ** K575A K575A * 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. Vacuum Intake Filter Assembly For 1423 Models only. (Shipped unattached) Muffler Assembly

40 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 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

41 PART NO G375PL (REV-G) TROUBLESHOOTING CHART Low High Pump Motor Reason and remedy Vacuum Pressure Vacuum Pressure Overheat Overload for problem. At pump Filter dirty. Clean or replace. At pump Muffler dirty. Clean or replace. At pump Vacuum line collapsed. Repair or replace. Relief valve set too high. Inspect and adjust. Relief valve set too low. Inspect and adjust. At pump At pump Plugged vacuum/pressure line. Inspect and repair. Vanes sticking. Clean or replace. Vanes worn. Replace. Shaft seal worn. Replace. Dust or offset powder in pump. Inspect and clean. Motor not wired correctly. Check wiring diagram and line voltage. AUTHORIZED SERVICE FACILITIES Gast Manufacturing Inc. Gast Manufacturing Inc. Brenner Fiedler & Assoc. Gast Manufacturing Co., Ltd 2550 Meadowbrook Road 505 Washington Ave Bentley Place Beech House, Knaves Beech Benton Harbor, MI Carlstadt, NJ Cerritos, CA Business Centre, Loudwater TEL: TEL: TEL: High Wycombe, Bucks HP 10 9SD FAX: FAX: TEL: England FAX: TEL: FAX: Wainbee Limited Wainbee Limited Japan Machinery Co., Ltd. General Correspondence 215 Brunswick Blvd Coopers Avenue Central PO Box 1451 should be sent to: Pointe Claire, Quebec Mississauga, Ontario Tokyo, Japan Gast Mfg. Inc./A Unit of IDEX Corporation Canada H9R 4R7 Canada L4Z 3S6 TEL: P O Box 97 TEL: TEL: FAX: Benton Harbor, MI FAX: FAX: or: ISO 9001 & CERTIFIED

42 E. Flow meter Installation & Operation Instructions 5

43 Bulletin F-43 Series RM Rate-Master Flowmeters Specifications - Installation and Operating Instructions F J BACK WIDTH A B Dimensions in Inches (Centimeters) Model RMA Model RMB Model RMC 4-9/16 (11.59) 8-1/2 (21.59) 15-1/8 (38.42) 3 (7.62) 1/8 NPT CONN. 6-7/16 (16.35) 1/4 NPT CONN. 12-1/4 (31.12) 1/2 NPT CONN. C 1-5/8 (3.17) Thds. 3-15/16 (8.56) 1/4-20 Thds. 8-3/4 (10.72) 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) A B C K 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) E L 1 (2.54) 1-1/2 (3.81) 2-1/4 (5.72) D G H I FULL OPEN Fig. 1 Fig. 2 L HIGH WIDE PANEL CUTOUT FOR FLUSH MOUNTING 4-5/8 (11.75) 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 7/16 (1.11) 1/4 (0.64) 5/8 (1.59) 9/32 (0.71) 15/16 (2.38) 13/32 (1.03) PIPE BOLT 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. 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. DWYER INSTRUMENTS, INC. Phone: 219/ P.O. BOX 373 MICHIGAN CITY, IN 46361, U.S.A. Fax: 219/ info@dwyer-inst.com

44 Fig. 5 Fig. 6 MOUNTING BRACKET SCREW 4 REQUIRED Fig. 3 Fig. 4 Fig. 5B Fig. 6B Fig. 7 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 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 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 ( ) x x ( ) 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 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 FR# Rev. 16 DWYER INSTRUMENTS, INC. Phone: 219/ P.O. BOX 373 MICHIGAN CITY, IN 46361, U.S.A. Fax: 219/ info@dwyer-inst.com