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AST PCH GMP-025 Series Instruction Manual

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PCH GMP-025 SERIES
INSTRUCTIONAL MANUAL
I.
AST Warranty
II. General Description of System, with Diagrams
III. Unpacking, Set-up and Pre-Start Checks
IV. Daily Operation
V. Periodic Maintenance
1600 FREEWAY BLVD.
BROOKLYN CENTER, MN 55430
Phone
(763) 592-2060
Fax
(763) 592-2075
Web
www.ast-corp.net
E-Mail
ast@ast-corp.net
MODEL
PCH GMP-025-1616
RATIO
1:1
MANUFACTURED FOR
________________________________
SERIAL NUMBER
________________________________
OPERATING INSTRUCTIONS
VI.
Trouble Shooting
VII.
Shutdown Procedures
VIII. TEDs
IX.
Bills of Material/Drawings
#60005-02  REV: 07/18

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  • Page 1 PCH GMP-025 SERIES INSTRUCTIONAL MANUAL MODEL PCH GMP-025-1616 RATIO MANUFACTURED FOR ________________________________ SERIAL NUMBER ________________________________ OPERATING INSTRUCTIONS AST Warranty Trouble Shooting II. General Description of System, with Diagrams VII. Shutdown Procedures III. Unpacking, Set-up and Pre-Start Checks VIII. TEDs IV. Daily Operation Bills of Material/Drawings V.

  • Page 2: Table Of Contents

    CONTENTS INTRODUCTION TROUBLE SHOOTING WARRANTY INFORMATION TROUBLESHOOTING TECHNICAL VIDEOS RATIO CHECK PROCEDURE CUSTOMER SERVICE TROUBLESHOOTING GUIDE SHUT-DOWN PROCEDURES GENERAL DESCRIPTION OF SYSTEM PUMP CLEANING PROCEDURE INLET ASSEMBLY SHORT-TERM SHUT-DOWN PROCEDURE ELECTRICAL DRIVE MOTOR END OF SEASON SHUT-DOWN PROCEDURE GEAR METERING PUMPS & OUTLETS DELIVERY HOSES DISPENSE VALVE STATIC MIXER...

  • Page 3: Introduction

    Additional or under the original manufacturer's warranty. replacement videos can be purchased through AST  AST obligation under this warranty is limited to repairing or replacing at its distribution center any such product or part thereof which shall within (1)

  • Page 4: General Description Of System

    The block is connected by (4) 5-16”-18 x 2- system, or other problems, which is considered misuse 1/4” bolts. Removing these 4 bolts will allow the entire under AST warranty. inlet assembly to be removed from the machine. Each of the major sections is described below.
  • Page 5 The internal gear reducer is pre-lubed and sealed. 3. GEROTOR PUMPS & MATERIAL OUTLETS Each AST gear metering pump consists of a hardened drive shaft, lube chamber with dual shaft seals, metering gear, material inlet block with air bleed port and a material...

  • Page 6: Static Mixer

    4. DELIVERY HOSES “A” and “B” materials flow through their individual delivery hoses. The two material hoses plus control air lines join the main system to the dispensing applicator. The type of hose used will vary, and are specifically chosen for the application. Any replacement must be identical or of superior specifications in terms of pressure, dimensional rigidity under pressure, and porosity.

  • Page 7: Electrical & Pneumatic Controls

    7. CONTROLS ELECTRICAL CONTROLS Operation signals are given by a trigger switch. This signal will start pump operation and air signals will automatically open and close the dispense valve when desired. One control for the operator to set or adjust is the drive motor speed controller. Turning the speed control potentiometer clockwise will increase the speed of the motor &...

  • Page 8: Unpacking, Set-Up & Pre-Start Checks

    UNPACKING, SET-UP & PRE-START CHECKS and apply compatible lubricant to the tip and the treaded area SET-UP & PRE-START CHECKS to permit easy removal later.  Attach proper mixer to applicator tip and tighten mixer nut.  Check for shipping damage. File claims with the shipper ...

  • Page 9: Daily Operation

    DAILY OPERATION PERIODIC MAINTENANCE START-UP METERING PUMP MAINTENANCE  Open “A” and “B” container supply valves.  Remove and clean any material residue or film with  Check level of materials in containers, making sure level compatible solvent (damp pad only – do not pour is always over ¼...

  • Page 10: Ratio Check Procedure

    RATIO CHECK PROCEDURE The following is the list of items to check if the equipment is not dispensing the correct ratio. Please note that some items included in this procedure are not included with all supplied equipment. Please use all safety devices such as but not limited to gloves and eye protection.

  • Page 11: Troubleshooting Guide

    TROUBLESHOOTING GUIDE Problem Possible Causes/Areas to Check Remedy Unit Will Not Run Check Electrical Supply Verify that requirements are met (115/120v, 100’ extension) Check motor controller fuses Replace Motor / Gear box failure Replace (ALWAYS remove power Switch in dispense assembly handle Replace if unit runs when bypassed when servicing) Unit runs but no flow / low...

  • Page 12: Shut-Down Procedures

    SHUT-DOWN PROCEDURES recommended to lubricate all internal surfaces PUMP CLEANING PROCEDURE immediately before installation and may make re- assembly easier along with future servicing of pump. The following is the recommended procedure for removing,  Lubricate pumps using zerks supplied. Use only inspecting, cleaning and reinstalling GMP pumps.
  • Page 13 When working with performed in advance of any intended use. solvents do so in a well-ventilated area free of combustible  AST assumes previous shut-down procedure was items. Take every effort not to mar or damage any surfaces followed.
  • Page 14  Set motor speed to low (30%) and actuate trigger, performed in advance of any intended use.  AST assumes previous shut-down procedure was operating system until correct material comes out both followed. ports of dispense valve.

  • Page 15: Drive Assembly

    55615-01D 55472A DRYER ASSEMBLY, DESICCANT CARTRIDGE WITH BRACKET 14707 LABEL/ DECAL, B & W “AST 1-3/8 X 4-3/8 X 3.5 MILS, VINYL W/ POLYESTER OVERLAY 11447 RIVET, POP, 1/8 DIAMETER x 1/16-1/8 GRIP RANGE 11124 DECAL, LETTER, A, 3, BLACK...
  • Page 17 Created: Modified: 9/11/03 Anthony Walsh 9/11/03 Anthony Walsh AST Bill of Materials Orig Date # Of Items Engineer PRODUCT # PRODUCT NAME 55914-06 ASSEMBLY, HOLSTER, PCH EXTENSION, PNEUMATIC PANEL MOUNTED, 1/2 SPACERS Item Part No. Description 23912-01 HOLSTER, WELDMENT, PCH EXTENSION ASSEMBLY, 55615 / 55474 22937-04 SPACER, 1”...
  • Page 19 ORIG DATE # OF ITEMS ENGINEER PRODUCT # PRODUCT NAME: 55625-01C SCHEMATIC, ELECTRICAL, GMP-SP-025, 14644A MOTOR CONTROLLER Item Part # Description CONTROLLER, MOTOR, NEMA 4, 1 HP, 90/ 180 VDC- See 56422-XXA 14644A CORD, POWER, 3 PRONG, MOLDED PLUG, 120 V, 6FT LONG 14702 GROMMET, PLASTIC, 7/8 OD x 5/8 ID 12862-02...
  • Page 20 I S I I B I i n i...
  • Page 21 ORIG DATE # OF ITEMS ENGINEER 7/6/2017 D.J.S. PRODUCT # PRODUCT NAME: 55916-02J DRIVE ASSEMBLY, MAINFRAME, PCH GMP-025 Item Part # Description PLATE, MAINFRAME, PUMP MOUNTING, GMP, LOW MOUNT, NO FHCS 26191A GEAR MOTOR, 1/4 HP, 90 VDC, 30:1 PARALLEL SHAFT, (83 RPM) 12842 PUMP ASSEMBLY, GEROTOR, .594 CU IN / REV, LUBER, EXTENDED SHAFT 55477H...

  • Page 22: Outlet Assembly

    AST CORP. ANY REPRODUCTION IN SEE. B.O.M. PART OR AS A WHOLE WITHOUT THE USED ON NEXT ASSY SIZE DWG. NO. REV. WRITTEN PERMISSION OF AST CORP. IS 55617A PROHIBITED. FINISH APPLICATION SCALE:1:2 DO NOT SCALE DRAWING SHEET 1 OF 1...
  • Page 23 ORIG DATE # OF ITEMS ENGINEER 11/3/1999 PRODUCT # PRODUCT NAME: 55617A OUTLET ASSEMBLY, GMP-025, 3/8” Item Part # Description GAUGE, 0-1000 PSI, 2 1/2” FACE, 1/4” NPT 11083 BUSHING, 3/8 M NPT x 1/4 F NPT 11214 TEE, 3/8 NPT, 3 F 11663 ADAPTER, 3/8 M NPT x 6 M JIC 11322...
  • Page 24 REVISIONS REV. DESCRIPTION DATE ASSEMBLY NOTES: 1. ASSEMBLE PER AST MFG. STANDARDS. 2. INTERIOR SURFACES TO BE INSPECTED AND CLEANED OF DEBRIS AND RESIDUE AFTER ASSEMBLY. UNLESS OTHERWISE SPECIFIED: NAME DATE DIMENSIONS ARE IN INCHES DRAWN 02/16 TOLERANCES: TITLE: ANGULAR: MACH 1 BEND...

  • Page 25: Inlet Assembly

    ORIG DATE # OF ITEMS ENGINEER 2/11/2016 PRODUCT # PRODUCT NAME: 55913-16 INLET ASSEMBLY, GMP, 6 GALLON TANK W/ SCREEN Item Part # Description LID ASSEMBLY, SILICONE GROOVE GASKETED, 8 GALLON 55645-02 TANK, 6 GALLON, STAINLESS, CONED BOTTOM, 12 IN DIA., 12 IN HEIGHT, 2 OUTLET 22246-25A BUSHING, 2 M NPT x 1, BLACK MALEABLE, (E’...
  • Page 26 DRAWING IS THE SOLE PROPERTY OF SEE B.O.M. 55918-03A AST CORP. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE NEXT ASSY USED ON WRITTEN PERMISSION OF AST CORP. IS FINISH PROHIBITED. NONE SCALE: 1:12 DO NOT SCALE SHEET 1 OF 1...
  • Page 27 ORIG DATE # OF ITEMS ENGINEER 1/26/2010 PRODUCT # PRODUCT NAME: 55918-03A ASSEMBLY, WHEEL/HARDWARE, GMP-025, W/ WELDED AXLES Item Part # Description COLLAR, SHAFT, 5/8 ID, SET SCREW LOCKING 11198 WHEEL, 10 x 2.75, 5/8 BORE 11217 CASTER, 5 DIAMETER x 6-1/4 OAH, SWIVEL, GRAY, 1/2 THREADED STEM 13228A WASHER, 1/2 SAE FLAT, STEEL 11009...
  • Page 28 I S I I B I...
  • Page 29 ORIG DATE # OF ITEMS ENGINEER 4/14/2010 PRODUCT # PRODUCT NAME: DISPENSE, EXTENSION ASSEMBLY, MANIFOLD W/ BALL VALVES, INTERNAL CHECK, GMP 55615-01D Item Part # Description MANIFOLD ASS’Y, 7/8-9, INTERNAL BALL, .100 PORTS, No. 6 W/ BALL VALVE 55696-01C RIVNUT, 1/4-20, STEEL 11972 CRACK GUIDE, WELDMENT 26117...
  • Page 30 ASSEMBLE PER AST MFG. STANDARDS. 55696-01 AST CORP. ANY REPRODUCTION IN SEE B.O.M. PART OR AS A WHOLE WITHOUT THE REPAIR KIT IS PART NUMBER 55691-01. WRITTEN PERMISSION OF AST CORP. IS NEXT ASSY USED ON PROHIBITED. FINISH Finish SCALE: 1:1...
  • Page 31 SIZE DWG. NO. DRAWING IS THE SOLE PROPERTY OF AST CORP. ANY REPRODUCTION IN SEE B.O.M. 55696-01C PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF AST CORP. IS NEXT ASSY USED ON PROHIBITED. FINISH Finish SCALE: 1:2 DO NOT SCALE...
  • Page 32 ORIG DATE # OF ITEMS ENGINEER PRODUCT # PRODUCT NAME: 55696-01C MANIFOLD ASS’Y, 7/8-9, INTERNAL BALL, .100 PORTS, NO. 6 W/ BALL VALVE Item Part # Description MANIFOLD, DISPENSE, DUAL COMPONENT, INTERNAL CHECK, .10 PORTS 23836-01B SPRING, COMPRESSION, .300 DIA x 7/8 L X 0.032 C/S, GMP 13108 BALL, 3/8 DIAMETER, CHROME STEEL 12013...
  • Page 33 DWG. NO. DRAWING IS THE SOLE PROPERTY OF 55472 AST CORP. ANY REPRODUCTION IN SEE B.O.M. PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF AST CORP. IS NEXT ASSY USED ON PROHIBITED. FINISH SCALE: 1:2 DO NOT SCALE...
  • Page 34 ORIG DATE # OF ITEMS ENGINEER PRODUCT # PRODUCT NAME: 55472A DRYER ASSEMBLY, DESICCANT CARTRIDGE WITH BRACKET Item Part # Description COUPLING, PVC TO PIPE, 2 TO 1-1/2, W/ HOSE CLAMPS, (FOR DESICCANT) 12552 BRACKET WELDMENT, DRYER / DESICCANT MOUNT (FOR 12046) 23629A TUBE FITTING, 1/4 M NPT x 3/8 TUBE, “Y 12503...

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