Part No.

70-6858 (Rev A)

Operation and Maintenance Manual

120R Dry Pipe Sprinkler

Compressor

A UNIT OF IDEX CORPORATION www.gastmfg.com

® Registered Trademark™ Trademark of Gast Manufacturing Inc © Copyright 2021 Gast Manufacturing Inc. All Rights Reserved. ISO 9001 CERTIFIED
 Part No.70-6858 (Rev. A) Part No. 70-6858 (Rev. A)

Dear Customer: PRODUCT USE CRITERIA, AND PURPOSE INSTALLATION

• Pump only clean, dry air.
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
•
•
Operate at 39°F to 104°F (4°C to 40°C).
Protect unit from dirt and moisture.
WARNING
receive years of trouble free service. • 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
WARNING air can become very hot.
• Corrosive gases and particulate material will damage unit.
Water vapor, oil-based contaminants, or other liquids must Electrical Shock Hazard
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USING THIS PRODUCT . be filtered out. Disconnect electrical power at the circuit breaker or fuse
SAVE THIS MANUAL FOR FUTURE REFERENCE AND KEEP IN THE VICINITY OF THE PRODUCT . • Consult your Gast Distributor/Representative before using at box before installing this product.
high altitudes. Install this product where it will not come into contact with
water or other liquids.
• This pump is oil-less and requires NO lubrication.
Install this product where it will be weather protected.
Electrically ground this product.
Your safety and the safety of others is extremely important. Failure to follow these instructions can result in death, fire,
TABLE OF CONTENTS or electrical shock.
We have provided many important safety messages in this
manual and on your product. Always read and obey safety
Product Use and Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 messages. Correct installation is your responsibility. Make sure you have
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 the proper installation conditions and that installation clearances
This is the safety alert symbol. This symbol alerts
do not block air flow.
Mounting/Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 and 4 you to hazards that can kill or hurt you and others.
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 The safety alert symbol and the words “DANGER”
and “WARNING” will preceed all safety messages.
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
These words mean: WARNING
Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DANGER Blocking air flow over the product in any way can cause
You will be killed or seriously injured if you don’t follow in- the product to overheat.
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
structions.
Technical Data / Part Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WARNING
Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 You can be killed or seriously injured if you don’t follow MOUNTING/PLUMBING- RISER MOUNT
Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
instructions. (120R-200S)
All safety messages will identify the hazard, tell you how to
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 reduce the chance of injury, and tell you what can happen if
1. Remove and read all literature. Remove all accessories
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 (connecting hose and intake filter).
the safety instructions are not followed.
2. Find the top strut channel section in the packaging and
install using the proper sized clamps for the riser pipe
diameter. 4”, 6”, and 8” clamps are included with every unit.
Use appropriate socket & adjustable wrench to secure clamp
bolt & nut (9/16”).
3. Ensure there is enough space between the bolt head and
strut channel to allow the system frame to mount in-
between.
4. THIS STEP REQUIRES TWO PEOPLE. Grasping the system
by the hand cutouts, carefully hang the frame on the strut
channel. Ensure both tabs on the frame are secured between
the bolt heads and strut channel.
5. Using a 3/4” socket or wrench, tighten both bolts. Confirm
the frame is securely attached to the strut channel.

2 © 2021, Gast Manufacturing © 2021, Gast Manufacturing 3

We reserve the right to make any alterations which may be due to any technical improvements We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA Printed in the USA
 Part No.70-6858 (Rev. A) Part No. 70-6858 (Rev. A)

6. Slide the bottom pipe clamps into the strut channel already
attached to the system. Use appropriate socket & adjustable
the compressor’s starting current. Motor starters with thermal
magnetic overload or circuit breakers protect motor from
OPERATION MAINTENANCE
wrench to secure clamp bolt & nut. overload or reduced voltage conditions.
7. If using, attach the supplied connecting hose to the The wiring diagram supplied with the product provides required WARNING WARNING
3/4” threaded outlet. Secure flange nut on hose whip electrical information. Check that power source is correct to
using adjustable wrench. Remove the plastic plug from properly operate the motor. Injury Hazard
the compressor head and install the intake filter, hand Install proper safety guards as needed.
tightening.
WARNING Keep fingers and objects away from openings and
8. Complete the installation by having a certified electrician rotating parts.
make the electrical connections. This compressor system When provided, motor terminal covers must be in place
provides standard electrical conduit connection. for safe operation. Electrical Shock Hazard
Once finished, turn the system on and ensure it pressurizes Product surfaces become very hot during operation, Disconnect electrical power supply before performing
the system and turns off once pressure setting is reached. allow product surfaces to cool before handling. maintenance on this product.
If needed, the pressure switch can be adjusted using the Air stream from the product may contain solid or liquid If product is hard-wired into system, disconnect electrical
provided instructions. Electrical Shock Hazard material that can result in eye or skin damage, wear proper power at the circuit breaker or fuse box before
eye protection. performing maintenance on this product.
This product must be properly grounded.
Wear hearing protection. Sound level from motor may Failure to follow these instructions can result in death, fire,
Check the condition of the power supply wiring. or electrical shock.
exceed 70 dBA.
MOUNTING/PLUMBING- TANK MOUNTED Do not permanently connect this product to wiring that
is not in good condition or is inadequate for the requirements
Failure to follow these instructions can result in burns,
(120R-200T) of this product.
eye injury, or other serious injury.

Failure to follow these instructions can result in death, fire,

1. Remove and read all literature. Remove all accessories
(connecting hose and intake filter).
or electrical shock.
It is your responsibility to operate this product at recommended
pressures and room ambient temperatures. Do not start against a
WARNING
2. If using, attach the supplied connecting hose to the pressure load. Injury Hazard
3/4” threaded outlet. Secure flange nut on hose whip Product surfaces become very hot during operation,
using adjustable wrench. Remove the plastic plug from allow product surfaces to cool before handling.
Start Up
the compressor head and install the intake filter, hand
Air stream from the product may contain solid or liquid
tightening. material that can result in eye or skin damage, wear proper
GROUNDING
eye protection.
3. Complete the installation by having a certified electrician
make the electrical connections. This compressor system This product must be connected to a grounded, metallic, WARNING Clean this product in a well-ventilated area.
provides standard electrical conduit connection. permanent wiring system, or an equipment grounding terminal or
This motor is thermally protected and may restart Failure to follow these instructions can result in burns,
lead on the product. eye injury, or other serious injury.
4. If desired, reuse the packaging bracket to secure the tank to after cooling.
the floor. Power supply wiring must conform to all required safety codes
Once finished, turn the system on and ensure it pressurizes and be installed by a qualified person. Check that supply voltage It is your responsibility to:
the system and turns off once pressure setting is reached. agrees with that listed on product nameplate. If motor fails to start or slows down significantly under load, shut
• Regularly inspect and make necessary repairs to product
If needed, the pressure switch can be adjusted using the off and disconnect from power supply. Check that the voltage
in order to maintain proper operation.
provided instructions. is correct for motor and that motor is turning in the proper
direction. Check the switch for damage. If so equipped, the • Make sure that pressure is released from product before
thermal protection switch has tripped, the motor can restart after starting maintenance.
cooling. • On model 120R-200T (tank mount), open manual tank drain
valve regularly to avoid excessive water accumulation.

ELECTRICAL Check intake filter after six months of operation. Clean filter and
determine how frequently filter should be checked during future
It is your responsibility to contact a qualified electrician PRESSURE SWITCH operation. This one procedure will help to assure the product’s
and assure that the electrical installation is adequate and in
Factory settings performance and service life.
conformance with all national and local codes and ordinances.
1. Remove filter cover.
Determine the correct overload setting required to protect 120R-200S - Riser Mount 50 psi cut in / 125 psi cut out*
the compressor (see motor starter manufacturer’s 2. Check filter element. Replace element if it is covered with
recommendations). Select fuses, motor protective switches or 120R-200T - Tank Mount 75 psi cut in / 125 psi cut out* contamination or shows signs of increasing differential
thermal protective switches to provide protection. Fuses act as pressure.
*Airflow output of this 120R Compressor exceeds 5.5 cubic ft /
short circuit protection for the compressor, not as protection min. at 10 psi. Per NFPA-13 requirements an air maintenance 3. Reinstall filter element and filter cover.
against overload. Incoming line fuses must be able to withstand
device will be required for supervisory air pressure settings.

4 © 2021, Gast Manufacturing © 2021, Gast Manufacturing 5

We reserve the right to make any alterations which may be due to any technical improvements We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA Printed in the USA
ACCESSORIES / KITS Part No.70-6858 (Rev. A) Part No. 70-6858 (Rev. A)
Consult your Gast distributor/representative to purchase.

Technical Data and Specifications

120R-200S 120R-200T
Voltage VAC 208-240/208-230 208-240/208-230
Frequency HZ 60/50 (single phase) 60/50 (single phase)
System Capacity,
gallons 921/792 940/804
40 psi in 30 min
Current amps 10/8 10/8
Weight lbs 94 128
Noise Level dB(A) 83 83
Dimensions (LxWxH) in 20.2 x 13.2 x 23 19.4 x 17.6 x 44.9
Motor HP 2 2
Max Pressure psi 125 125
Tank Size gallons 2 20
Thermal Protection Yes Yes
Duty Cycle 100% 100%
Relative Humidity % 20 - 80% 20 - 80%

Item: Intake Filter* Ambient Temperature 4/40 C 4/40 C

PN: K1027
*Included with system. UNDERSTANDING YOUR PART NUMBER
Recommended annual replacement.

120R- 2 0 0 S X

Compressor Voltage Alpha- WiFi S - Riser Mount Alpha-

Series 2 - 230 Numerical 0 - No T - Tank Mount Numerical
Engineering 1 - Yes Engineering
Code Code

Item: Service Kit*

PN: K1028
Recommended replacement as
needed.

6 © 2021, Gast Manufacturing © 2021, Gast Manufacturing 7

We reserve the right to make any alterations which may be due to any technical improvements We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA Printed in the USA
 Part No.70-6858 (Rev. A) Part No. 70-6858 (Rev. A)

EXPLODED PRODUCT VIEW 120R-200S/120R-200T ELECTRICAL SCHEMATIC 120R-200S/120R-200T

Item: Intake Filter*

PN: FIL1500

Item: Intake Filter*

PN: FIL1500

8 © 2021, Gast Manufacturing © 2021, Gast Manufacturing 9

We reserve the right to make any alterations which may be due to any technical improvements We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA Printed in the USA
 Part No.70-6858 (Rev. A) Part No. 70-6858 (Rev. A)

PNEUMATIC SCHEMATIC 120R-200S/120R-200T TROUBLESHOOTING CHART

Problem Possible Cause(s) Possible Solution(s)
A. No/poor electrical connection/
A. Confirm proper electrical connection and voltage
voltage
B. System pressure not below cut in
B. Verify cut in (ON) pressure
(ON) pressure
C. Breaker tripped C. Confirm proper breaker size is used and not tripped
D. Check system voltage while it is runniing. Verify voltage is
D. Voltage is too low
above the minimum of 230 volts
1. System will not start E. Plugged inlet filter E. Remove filter and clean or replace as necessary
F. Verify the unloader is purging on start up. If not, replace
F. Start up unloader is not functioning
start up unloader
G. Unit is overheated G. Verify voltage. Relocate system installation
H. Check valve leaking H. Clean or replace the check valve
I. Loose wiring I. Verify all wiring is tight
J. Pressure Switch is in “Stand By” J. Press and hold the -OK- button for 3 seconds to take the
Mode unit out of “Stand By”
A. System pressure is below cut out
A. Verify the cut out (off) pressure is correct
(off) pressure
2. Unit will not shut off
B. Plugged inlet filter B. Remove filter and replace as necessary
C. Sprinkler system leaks C. Identify and repair any system leaks
A. Compressor cup worn A. Install a service kit on the compressor
3. Excessive noise B. Leaking hose connection B. Tighten hose connection. Verify no other leaks
C. Vibration C. Confirm the riser clamps are tight

SERVICE AND MAINTENANCE CHART

Date Problem Technician Notes

AIR OUTLET

10 © 2021, Gast Manufacturing © 2021, Gast Manufacturing 11

We reserve the right to make any alterations which may be due to any technical improvements We reserve the right to make any alterations which may be due to any technical improvements
Printed in the USA Printed in the USA
 Part No. 70-6858 (Rev. A)

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 specif-
ically 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 warran-
ty, 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 REPLACE-
MENT 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 DESCRIP-
TIONS 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.

Gast Manufacturing Gast Group Limited Gast Group Ltd.

2300 M-139 Highway c/o IDEX Trading (Shanghai) Co., LTD Unit 11, The I O Centre
Benton Harbor, MI 49022 Room 3502-3505 Nash Road
Ph: 269-926-6171 No. 1027 Chang Ning Road, Redditch, B98 7AS
Fax: 269-927-0808 Zhaofeng Plaza United Kingdom
www.gastmfg.com Shanghai, China 200050 Phone +44 (0)1527-504040
Phone +86-21-52415599 Fax +44 (0)1527-525262
Fax +86-21-52418339

A UNIT OF IDEX CORPORATION www.gastmfg.com

® Registered Trademark™ Trademark of Gast Manufacturing Inc © Copyright 2021 Gast Manufacturing Inc. All Rights Reserved. ISO 9001 CERTIFIED