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P.O. Box 2787 Conroe, TX 77305 P.O. Box 29 Kaiapoi 7644 2511 N.
Frazier St. Conroe, TX 77303 21 Empire Rd. Kainga Tel:
(281)290-9229 Fax: (936) 494-0012 Christchurch 8083 New Zealand
Email: [email protected] Tel: +64 3 323 6151 Website:
www.gtech-hiltech.com Website: www.gtech-bellmor.com
Dedicated to Quality Products and the People Who Use Them
Model CFS-280 Series Rotary Lobe Centrifuge Feed System
Operation and Maintenance Manual
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Pump Manual: CFS-280-VFD-XPD1 rev4
Table of Contents
1. Pump Description 3
2. Safety Instructions... 4
3. Pump Rotation. 5
4. Specifications... 5
5. Installation. 6
6. Maintenance. 7
7. Repairs.. 8
8. Changing Lobes.. 9
9. Replacing Mechanical Seals. 11
10. Adjustment of the Pump Housing Segments.... 14
11. Technical Data Sheet.... 16
12. Vendor Data 17
13. General Layout 18
14. Parts List. 19
15. VFD Schematics 23
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Pump Manual: CFS-280-VFD-XPD1 rev4
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:
Fluids with high solids concentration
Viscous and high viscous fluids
Fluids with entrained gas
Shear stress sensitive fluids
Other free-flowing fluids***
GTech USAs Pump Identification GTech USAs CFS series rotary lobe
pumps are identified by a serial number and model number as
depicted below:
EXAMPLE
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Pump Manual: CFS-280-VFD-XPD1 rev4
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.
Do not operate the pump with safety devices or guards
removed.
Only qualified personnel should operate this pump.
Do not operate the pump until all personnel are clear.
Never attempt to carry out or start maintenance procedures while
the pump is in motion.
Do not run the pump with the end cover removed.
Before any work is started on the pump, the electrical power
source to the prime mover must be isolated, and locked out with
precautions.
Ensure that no internal pressure exists within the quench/buffer
chamber or piping systems before starting out any maintenance
work.
Use the dedicated eye bolt on the pump to lift the pump
only.
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Pump Manual: CFS-280-VFD-XPD1 rev4
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 8 100 440 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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Pump Manual: CFS-280-VFD-XPD1 rev4
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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Pump Manual: CFS-280-VFD-XPD1 rev4
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) After the first 20 operating hours 2) Every 200 operating
hours
Draining and Flushing the Buffer Chamber (Perform only when
replacing the mechanical cartridge seals)
Each time a mechanical seal is replaced; the buffer chamber must
be drained and flushed beforehand. In applications where the quench
chamber is pressurized, isolate the pressure source by closing off
valves or other fittings before draining or flushing. Then unscrew
all possible quench chamber connections and the lower screw plug to
allow the quenching oil to drain out of the quench or buffer
chamber. Drain the gear chamber oil first before draining the
quench chamber oil. In case of heavy contamination, clean the
quench chamber with water, preferably warm water to flush the
contaminated oil. Use the drain port at the bottom of the casting.
After thoroughly washing the chamber, inspect the casting for any
defects. Ensure to flush the chamber with the recommended oil. Fill
the quench chamber with the gear oil recommended and hold it for at
least 15 minutes. Then flush the oil and refill it at the desired
oil level. Make sure that there is no trace of water in the quench
chamber before putting the pump back in service. Check and Changing
of Gear Oil (Mobile SHC 630)
Check the gear oil every 500 operating hours. Change the gear
oil every 4500 operating hours Immediate causes of oil
contamination in the following chambers:
Quench Chamber:
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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Pump Manual: CFS-280-VFD-XPD1 rev4
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.
Please follow the safety notes and instructions specified in
Section 2
If repair requires disassembling the lobes, depressurize first
the bearing/gear housing and the quench chamber by loosening or
completely removing the plug on top of the bearing housing and the
adapter from the gear oil reservoir of the quench chamber.
1. Remove the nuts from the cover plate
2. Take off the cover plate and the O-ring. Pump End Cover
3. Remove lobes as explained in Section 8.
Fig. 1
Pressure Disk Assembly
Fig. 2
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Pump Manual: CFS-280-VFD-XPD1 rev4
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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Pump Manual: CFS-280-VFD-XPD1 rev4
Fig. 6
Tightening torque for mounting the pressure disk:
For all pumps that use a cartridge seal assembly, the tightening
torque of the strain screw is 100 foot-pounds wet.
Do not reuse a previously used strain bolt.
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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Pump Manual: CFS-280-VFD-XPD1 rev4
9. Replacing Mechanical Seals GTech USAs CFS series rotary lobe
pumps are installed with cartridge type mechanical seals. For ease
and convenience in changing or replacing mechanical seals, all CFS
series pumps are equipped with cartridge type seal assembly. When
the lobes are out and the seals need to be replaced, the following
procedure is to be followed.
1. Removed the keys from the shafts.
2. Unscrew the stainless steel screw to take off wear plate. 3.
Pull spacer washer and O-ring from the shaft with a small screw
driver. 4. Remove set screws from the seal holder and position seal
holder puller while putting two screws over the puller to the seal
set screw tap holes. 5. Gently tighten the puller screws to lift
the seal assembly.
6. Carefully slide out the seal assembly from the shaft.
7. Remove spacer washer, O-ring and second cartridge seal from
the other shaft.
8. Before installing the new cartridge seal, it is necessary to
clean all parts carefully. Only then is the optimum function of
mechanical seals assured. 9. Check O-rings in the seal cartridge
assembly for defects prior to installing the new cartridge.
Fig. 7
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Pump Manual: CFS-280-VFD-XPD1 rev4
Fig. 8
From above, perform the following instructions:
1. 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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Pump Manual: CFS-280-VFD-XPD1 rev4
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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Pump Manual: CFS-280-VFD-XPD1 rev4
10. Adjusting of Pump Housing Segments
The pump housing segments are designed so that they can be
re-adjusted radially in any event the gap between the lobes and the
housing segments is worn out. Before performing this process,
follow the safety instructions and notes stated in Section 2. When
all the required safety procedures are met, the following can be
done:
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. Remove the suction and discharge piping.
2. Remove the pump cover.
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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Pump Manual: CFS-280-VFD-XPD1 rev4
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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Pump Manual: CFS-280-VFD-XPD1 rev4
Technical Data Sheet
GTech USA Model CFS 280
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Pump Manual: CFS-280-VFD-XPD1 rev4
CFS-280
Construction Materials Lobes: Viton
O-Rings: Viton
Case: Cast Iron
Wear Plates: AR400
Base: Steel
Electrical Specification and Requirements
Classification: ATEX, Cat 2 & 3 (Gas & Dust), Zone 1
Supply: 380 volts, 50 hertz, 3 phase
Max Operating A: 21.6A
Startup A: 130A
Main Motor: 15hp (11KW)
Weight and Dimension
Length: 77 Width: 23 Height: 30 Shipping Weight: 1450 LBS
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Pump Manual: CFS-280-VFD-XPD1 rev4
General Layout
Parts List
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Pump Manual: CFS-280-VFD-XPD1 rev4
CFS 280 Series
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Pump Manual: CFS-280-VFD-XPD1 rev4
Parts List CFS 280 Series 100791 CFS-280-VFD-XPD1
Item Qty Part Number Part Description
1 1 104393 CFS Frame
2 1 104406 Pump
3 1 104989 Enclosure
4 1 105016 Gearbox
5 1 105732 Motor
6 1 102141 WrapFlex Hub- Pump
7 1 102142 WrapFlex Hub-Gearbox
8 1 102494 WrapFlex Element and Cover
9 1 104262 Inlet Plate
10 1 104261 Discharge Plate
11 1 104840 Emergency Stop Switch
12 1 106633 Local / 2 Position Remote Switch
13 1 106552 Speed Control Potentiometer
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Pump Manual: CFS-280-VFD-XPD1 rev4
Parts List
CFS 280 Series
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Pump Manual: CFS-280-VFD-XPD1 rev4
Parts List CFS 280 Series 100791 CFS-280-VFD-XPD1
Item Qty Part Number Part Description
1 1 105582 Gear Housing
2 1 105583 Quench Chamber
3 1 105605 Pump Housings/Castings
4 1 105584 Flange Ring
5 1 105585 Pump Cover
6 1 105608 Pump Drive Shaft
1 105611 Pump Driven Shaft
7 2 105586 Lip Seal
8 2 105587 Cylindrical Roller Bearing
9 2 105588 Spacer for Cylindrical Roller Bearing & Gear
10 2 105589 Pump Timing Spur Gears
11 2 105590 Spacer for Gear & Spherical Roller Bearing
12 2 105591 Spherical Roller Bearing
13 2 102276 Mechanical Cartridge Seals
14 1 105592 Wear Plate, Inner with Shaft Holes
15 1 105599 Hex Head Bolt for Inner Wear Plate
16 1 103891 Lobe, Left Hand
1 103890 Lobe, Right Hand
17 1 102275 Wear Plate, Outer with no Shaft Holes
18 2 105593 Gearbox & Quench Chamber Oil Sight Glass
19 2 105594 Retainer for Spherical Roller Bearing
20 2 103885 Strain Bolts
21 2 105595 Pressure Discs
22 1 103215 O-ring Seal for Pump Cover 6x280
23 2 105596 Spring Washers
24 2 104076 O-ring Seal for Pressure Discs 4x64
25 2 105597 Drain and Fill Plugs
26 10 105598 Socket Head Bolts for Gear Box
27 12 105599 Hex Head Bolts for Pump Housing/Quench Chamber
28 1 105600 O-ring Seal for Gearbox & Quench Chamber
29 4 105601 Flange Nuts for Pump Cover/Flange Ring
30 2 105602 Vegetable Fiber Gaskets for Pump
31 8 105603 Hex Head Bolts for Pump Cover
2 103380 O-ring 3x104
2 104077 O-ring 3 x 24
1 106562 Set of AGI-600 Austemepred Grey Iron Housing
Segments
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Pump Manual: CFS-280-VFD-XPD1 rev4
VFD General Schematic
VFD
CIMR-VU4A0031JAA
CIMR-VU4A0038JAA