G-Tech Rotary Lobe Pump OIM Manual

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: info@gtech-hiltech.com 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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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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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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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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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) 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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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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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

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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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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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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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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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.

P a g e | 15

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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Technical Data Sheet

GTech USA Model CFS 280

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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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General Layout

Parts List

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CFS 280 Series

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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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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
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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VFD General Schematic

VFD
CIMR-VU4A0031JAA
CIMR-VU4A0038JAA

G-Tech Rotary Lobe Pump OIM Manual

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P.O. Box 2787 Conroe, TX 77305 P.O.

Box 29 Kaiapoi 7644

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