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Table of Contents
1.
Pump Description
2.
Safety Instructions...
3.
Pump Rotation.
4.
Specifications...
5.
Installation.
6.
Maintenance.
7.
Repairs..
8.
Changing Lobes..
9.
11
14
16
17
18
19
23
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1. Pump Description
This manual contains general assembly, installation, operation, disassembly and repair instructions for the
GTech USAs, CFS series rotary lobe pumps.
GTech USAs CFS series rotary lobe pumps are engineered with non-contact rotors. The design is robust and dependable, with
maintenance in place features which allow replacement of wear components without removing the fluid connections. In addition to
centrifuge feed applications this pump is also suitable for transfer of fluids that are:
EXAMPLE
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2. Safety Instructions
Please read the instructions thoroughly and observe all safety notes before setting the pump into operation. Failure to do
so may result in injury and or loss of life. Warnings and information stickers provide safe operation and maintenance.
They may not be removed at any given time. See separate section for all other safety symbols and instructions.
Before any startup of operations, you should familiarize yourself with all facilities and operating procedures and options. Pump may
only be set in operation if the suction and pressure pipes are connected so that access to the pumping chamber is not possible.
Before pump is set in operation, always ensure that access to the rotating parts (the drive shaft) is not possible. The drive shaft
must be completely covered by a coupling guard. Before setting into operation, ensure that the discharge pipe is not completely
closed off, otherwise the pump shaft seals, the pump housing, or the pipelines may be damaged or destroyed by the resulting high
pressure.
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3. Pump Rotation
Principle of Operation
GTech USAs CFS series rotary lobe pumps are of the positive displacement rotary type with helically protruded rotors. The suction
side has an expanding cavity and the discharge side with decreasing cavity. The volume or cavity at the suction side of the pump
decreases in pressure when the rotors rotate and the pumped fluid is drawn into the pump. The fluid is then transported in the
spaces between the lobes and the periphery of the pump housing segments until it comes out at the discharge side of the pump.
Direction of Rotation
The pumps are bi-directional and the direction of flow is dictated by the rotation of the drive shaft adjacent to the housing segment.
Reversing the direction of the rotation will reverse the direction of the flow.
4. Specifications
Pump
Series
Gallons /
100 RPM
Max
Discharge
Pressure
Maximum
Recommended
RPM
Maximum
Recommended
Pump Rate
Maximum
RPM
Maximum
Pump Rate
CFS-34
100
440
32 GPM
600
48 GPM
CFS-75
16
100
470
64 GPM
600
96 GPM
CFS-150
34
100
445
150 GPM
600
204 GPM
CFS-200
50
100
400
200 GPM
600
300 GPM
CFS-280
68
100
445
300 GPM
600
408 GPM
CFS-400
100
100
400
400 GPM
600
600 GPM
CFS-500
133
100
375
500 GPM
600
1330 GPM
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5. Installation
Receiving and Unpacking
Check the contents and all wrapping when unpacking the pump. Carefully inspect and note for any damage that may have been
occurred during the shipment. Report immediately any damage to the carrier. Leave any protective caps or supports of the pump
shaft, inlet and outlet connections until you are ready to install the pump. It is recommended to inspect the pump and record any
defects or discrepancies after the shipment of the pump.
Solids and other Foreign Materials in Fluid
GTech USAs CFS series rotary lobe pumps can accommodate 1.5 inches of solids. Rocks, wood residues, incompressible solids,
etc., larger than the above mentioned sizes may cause increased wear of lobes, housing segments, and may cause the pump to
fail. Provide a reliable filter system for a specific application to keep unwanted objects or solids from the pump.
Thick and Viscous Fluids
When using the pump for viscous sludge or slurries, depending on the liquid / sludge being pumped, the pump speed must be
reduced according to the fluids viscosity in order to prevent cavitation from occurring. Also consider the temperature and pressure
of the fluid and its recommended allowable change or operating temperature and pressure range.
Winter Operation and Shutdown
If there is a risk of frost or freezing, the pump must be drained by dry running the pump in either direction, until all liquid is drained
out of pump. You may use the drain valves in the connectors, if supplied. To fully drain the pump, you must remove the pump end
cover. It is also recommended to wash or rinse the internals of the pump from any solids entrained especially when the pump is
intended to be shut down during the wintertime. Attention! Before start-up fill in liquid again, especially when the suction side of the
pump is not flooded.
Hot & High Humidity Operations
During hot weather, the fluid being pumped may form vapor inside the pump or pipe systems. Vapor formation in the system may
increase pressure. This may damage the pump or pumping systems. Make sure to open up, where possible, all valves and
ventilation taps in the piping system. Ensure that any of the installed pump and pump system controls are operational and reliable.
Make sure to conduct safety checks and precautions as mentioned in Section 2.
Removing from Service
It is recommended to drain pump by opening the cover and flush if necessary. For special or critical pumping applications, flush
the pump system until it is free of solids then drain pump. Make sure to conduct safety checks and precautions as mentioned in
section 2.
Wellpoint Application
Air and water mixture may be pumped in wellpointing application. Ensure that the suction line of the pump is sealed properly to
avoid losing vacuum pressure in the system. Losing suction pressure in the wellpoint system may cause the pump to overheat.
Ensure that low vacuum and high temperature shutdown, if fitted, is working properly.
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6. Maintenance
Drive Motor Non- Serviceable
Check and Changing of Gearbox Oil (Mobile SHC 630)
Check the gear oil every 500 operating hours.
Change the gear oil every 4500 operating hours
GTech USA recommends using Mobile SHC 630 gear oil for the gear chamber, quench chamber, and the auxiliary gear reducer.
Inspecting and changing the quenching fluid (Mobile SHC 630)
Check the quenching fluid for visible contamination:
1)
2)
Mechanical seal failure. This may be caused by: axial face seal failure itself or due to contaminants, defects, high
temperature, excessive vibration & improper seals alignment or assembly and not recommended application.
Secondary seal such as O-rings, out of seat, higher than normal temperature and pressure application, seals
alignment, incorrect seal material.
Gear Housing:
Gear housing contamination is mainly caused by the failure of the O-ring that seals the shaft and the cartridge
seal assembly. Other contaminations may be caused by any possible ingress of moisture in any of the plugs,
sight glasses or filling ports. Overfilling the gear housing may result to higher than normal pressure accumulation
inside the housing.
Make sure the gear oil level in the housing is followed and properly maintained under this section.
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7. Repairs
Opening the Cover Plate
Since repair of the GTech USAs CFS series rotary lobe pumps can be done on site, the procedure below covers basic repairs and
maintenance when the pump is decoupled or isolated from the drive.
2.
3.
Fig. 1
Fig. 2
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8. Changing Lobes
By using the lobe pullers as shown above, the rotors can be replaced or changed without removing the piping system or
disassembly of the pump. It is necessary to remove the rotors when replacing the mechanical seals.
1. When the cover plate is removed, remove the strain screws, the pressure disk assembly which consist of the spring
washer/s, pressure disk, O-ring and strain screws (Fig 1).
2. Position the pullers so that the tip of the puller locks in the groove inside the rotor bore. Loosen the holding screws to fit
the puller into the groove if necessary. When the puller is secured, tighten the holding screws of the puller. Rotate the
jacking bolt by using a wrench or an air gun until the lobe starts to loosen and slide on the shaft. Do the same procedure
for the other lobes on the other shaft.
3. For all CFS series pumps, perform the above procedure until the last or inner pair of rotors is removed.
4. Perform also the above procedures when replacing the mechanical seal cartridge assembly and axial wear plates.
5. When the old lobes are completely removed, inspect the housing segments for wear. The housing segments can be
repositioned and adjusted to compensate for the wear between the lobes tips and the housing segments.
6. After all the changing of the seal cartridges, wear plates or housing segments, assemble the new lobes in pairs,
simultaneously to the upper and lower shafts.
7. Check lobes physically and the machined surfaces for scratches and deformities.
8. Old lobes and housing segments may be reused.
9. Install the new lobes as a pair.
10. After the lobes are put back onto the shaft, insert the pressure disk assembly (Fig. 2) in the bore of the lobe.
11. Put a smear of oil or grease on the O-ring around the pressure disk and slowly position the whole pressure disk
assembly into the lobe.
12. Continue to turn the strain bolt until it the threads start to engage on the shaft tapped holes. Do the same procedure
with the other pressure disk assembly for the other shaft. Make sure that the O-ring is not scratched or damaged while
inserting the pressure disk assembly.
13. Make sure that the pressure disk outside face is parallel, not tilted with the face of the lobe.
Remove the pressure disk assembly if it is not flat or parallel against the lobe face. Perform this procedure until the
pressure disk is seated flat.
14. Set the torque wrench to 100 foot-pounds and tighten the strain screw.
15. Reassemble the pump end cover.
16. Tighten the four (4) lock nuts that hold the cover.
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Fig. 6
For all pumps that use a cartridge seal assembly, the tightening torque of the strain screw is 100 foot-pounds wet.
Prior to installing a new strain bolt, check the bolt for defects and possible deformities.
Wear Plates
The wear plates seal the pump axially inside the pump chamber. The rate of wear is very dependent on the Type of application and
speed of the pump. Always inspect the wear plates before installing in the pump.
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Fig. 7
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Fig. 8
Place the first O-ring (item 13) of the cartridge seal assembly on the quench chamber as
shown.
2.
Apply a thin layer of grease/gear oil on the O-ring to hold in place and for the cartridge
seal to slide easily.
3.
Put a thin layer of grease or gear oil around the new cartridge seal assembly. Ensure that
the middle O-ring around the cartridge seal is defect free, clean and seated properly in the
groove.
4.
Without item 10 and item 11, slowly insert the cartridge assembly onto the shaft. Use the
wear plate to push the cartridge assembly until it seats on the first O-ring as mentioned in
step 1. If a fixture to position the cartridge assembly is provided, use the fixture to push
the cartridge until the fixture is flushed on the face of the quench chamber. Do not push
the cartridge to seat on the first O-ring by pushing item 3 (small seal holder). When the
cartridge seal is seated; install the other seal assembly onto the other shaft
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The top surface of the bigger seal holder on the cartridge assembly (item 5) is flushed and even
with the face of the quench chamber. This is an indication that the cartridge assembly is seated
with the inner O-ring (item 13).
5.
After installing the cartridge seals, slide the shaft O-ring (item 10). Apply a thin layer of
grease or gear oil on the O-ring. Use the washer (item 11) to push and seat the O-ring into
the groove between the cartridge assembly items 2 & 3 with the shaft. Use the provided
fixture to perform this.
When sliding the shaft O-ring onto the shaft, ensure to slide it carefully to protect the O-ring from
cuts from the shaft keyway. When an assembly requires more than one (1) shaft O-ring, repeat
step 5 until the last O-ring is seated properly.
6.
Ensure that the O-ring/s is/are positioned evenly around the shaft. Do not attempt to
rotate the shafts as the O-rings may pop out, kink and cut.
7.
Clean the washer (item 11) and slide onto the shaft. The washer is used as a cover and
barrier between the lobes and the shaft O-rings. It also filters any solids from getting into
the O-rings. The shaft O-ring/s (item 10) seals the gear housing from the pumped fluid or
material.
8.
Do not attempt to rotate the shafts after as the O-rings may pop out, kink and cut.
9.
Apply a thin layer of grease or gear oil on the last (item 13) O-ring and make sure the O-ring
groove formed between the quench chamber face and the cartridge seal assembly is
free of dirt. Position the O-ring to the O-ring groove and gently push the fixture used in
step 4 until the O-ring is seated in the groove. Wipe off any excess grease or oil.
10. Replace or install a new wear plate. Position the wear plate and bolt it on the quench
chamber. Do not use an air gun to tighten the bolts. Use anti seize compounds if
necessary and tighten the bolts to 30 foot pounds.
11. Put the keys in the shaft keyways. It is recommended to use a new set of keys whenever
new shafts and new lobes are to be used.
12. The lobes should be mounted on the
shaft so that the side with a counter bore is towards the outside of the assembly. Slowly
push the lobes onto the shafts
Carefully push the lobes or pair of lobes onto the shafts so that the washers and the shaft O-rings
will not pop out from the grooves.
13. Prepare the pressure disk assembly as shown and discussed in Section 7 Fig.2. and
tighten the strain screw/bolt. See Figure 6 for correct position of the pressure disk assembly.
14. Reassemble the end wear plate, O-ring with the pump casting cover.
15. Tighten the four lock nuts to put back the pump cover.
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Empty the residual pumped material or fluid from the pump. Depressurize the piping system and isolate
the pump if necessary. For acidic or caustic pumped fluids, follow the safety instructions by the material
or fluid manufacturer. Failure to follow the safety instructions may result to personal injury or eventual
loss of lives.
1.
2.
3.
Unscrew the bolts that hold the top housing segment from the quench chamber and the
flange ring.
4.
Remove the roll pins from the initial four (4) bolt holes. See below. Remove the other four
(4) roll pins that are used to align the housing segments with the quench chamber.
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5.
Move the upper housing segment down so that the roll pins will be inserted in the next bolt holes marked as first just
above the original position.
6.
Move the lower housing segment and insert in the next lower bolt holes marked as first.
7.
Perform step 5 and 6 on the four (4) other roll pins used to align the housing segments and the quench chamber.
8.
For CFS series pumps with multiple or housing segments in series, perform the same instruction as in step 5, 6 and 7 and
all the roll pins that initially align the housing segments.
9.
The housing segments can be repositioned or re-adjusted for the second time in the event that the pump housings worn
out after the initial adjustment. Perform the same procedure but this time the roll pins will be repositioned or inserted to the
two (2) topmost bolt holes for the upper segment and the two (2) lower most bolt holes for the bottom pump housing.
10. Reassemble the pump cover, wear plate, O-rings. Put back all the bolts to tighten the housings with the quench chamber
and flange ring.
11. Replace the bolts and gaskets as needed.
12. Reconnect all piping, controls, gauges or instrumentations and perform testing as required and follow all safety
instructions as explained in Section 2 before setting the pump back in service.
Repositioning or readjusting the housing segments may increase the volumetric efficiency of the pump to
a certain extent after the initial wearing of the segments and lobes. When the gap is more than 2 mm after the second
readjustment, it is recommended to replace the rotors and the pump housings if your application requires a certain operating
pressure and capacity. Loss of volumetric efficiency due to slippage from the increased wear or gap between the segments and the
rotors can adversely affect the performance of the pump and the pump system. Please note that the wear rate between the rotor
tips and the housing segments is directly proportional to the percentage of solids, size of abrasive contents and the pump operating
speed.
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CFS-280
Construction Materials
Lobes:
O-Rings:
Case:
Wear Plates:
Base:
Viton
Viton
Cast Iron
AR400
Steel
77
23
30
1450 LBS
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General Layout
Parts List
Pump Manual: CFS-280-VFD-XPD1 rev4
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Parts List
CFS 280 Series
100791 CFS-280-VFD-XPD1
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
Part Number
104393
104406
104989
105016
105732
102141
102142
102494
104262
104261
104840
106633
106552
Part Description
CFS Frame
Pump
Enclosure
Gearbox
Motor
WrapFlex Hub- Pump
WrapFlex Hub-Gearbox
WrapFlex Element and Cover
Inlet Plate
Discharge Plate
Emergency Stop Switch
Local / 2 Position Remote Switch
Speed Control Potentiometer
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Parts List
CFS 280 Series
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Parts List
CFS 280 Series
100791 CFS-280-VFD-XPD1
Item
Qty
Part Number
Part Description
105582
Gear Housing
2
3
1
1
105583
105605
Quench Chamber
Pump Housings/Castings
4
5
1
1
105584
105585
Flange Ring
Pump Cover
105608
1
2
105611
105586
8
9
2
2
105587
105588
10
105589
11
12
2
2
105590
105591
13
14
2
1
102276
105592
15
105599
16
1
1
103891
103890
17
102275
18
19
2
2
105593
105594
20
21
2
2
103885
105595
Strain Bolts
Pressure Discs
22
103215
23
24
2
2
105596
104076
Spring Washers
O-ring Seal for Pressure Discs 4x64
25
105597
26
10
105598
27
12
105599
28
29
1
4
105600
105601
30
31
2
8
105602
105603
103380
O-ring 3x104
104077
O-ring 3 x 24
106562
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VFD
CIMR-VU4A0031JAA
CIMR-VU4A0038JAA