Operation and Maintenance Manual

CG P8O-Series Concentrate
Pumps
 TABLE OF CONTENTS

Pre-lnstallation ........................................................................1
Installation ...............................................................................1
Precautionary Notes ................................................................2
Disassem bly for lnspection .....................................................2
Complete Disassem bly ............................................................2
Re-Assem bly ............................................................................3
Reversing Rotation of Pump ....................................................4
Special Seal Components ........................................................4
Maintenance Parts or Factory Repair ......................................4
General Information .................................................................4
Bearings and RotorlPinion Shaft ............................................- 5
Spares and Repairs ..................................................................6
Trou bleshooting .......................................................................7
Drawings ..................................................................................8
Choose a location that is easily accessible for pump servicing. Ensure adequate electrical
service is available.

Locate the pump for direct piping. Special attention should be given to the suction piping which
should be as large, or larger, than the pump intake port. For efficient operation, it is
essential the suction side of a gear pump not be restricted. Avoid tees, elbows,
valves, and other flow devices within 5 pipe diameters of the pump inlet, or use the next larger
size piping. Provide adequate support for the piping. The pump should not be used to support
piping.

Pumps are shipped with the suction port marked - IN; the discharge port marked - OUT. The
discharge port on pumps is always the port nearest the relief valve connection on top of the
PumP.

Pumps will operate in either direction. However, the relief valve will only function in one direction.
Relief valve components are symmetrical and can be installed to operate with either clockwise
or counter-clockwise shaft rotation, however other interna1changes must also be made.

Have an electrician connect the motor using sound practice. Provide adequate overload
protection. Note: When checking the direction of rotation, the pump should be
full of liquid, if possible. Pumps must not run dry for longer than 10 minutes
under any circumstances. Determine the direction of rotation by watching the motor fan
or coupling, which in standard rotation installations will turn clockwise when looking from the
motor toward the pump.

Assure motor selected meets the requirements of the specified operating conditions.
Changed conditions, for example, higher viscosity, higher specific gravity, or lower head losses,
can over- load the motor. When changing operating conditions, or whenever there is any
doubt, please contact your local distributor with the full details. All motors supplied are rated at
least 10% greater than power required at pressurelO% over the rated pump operating
conditions.

Installation
Provide a solid foundation free from excessive vibration

Shim to prevent distortion of the pump mount base. Securely anchor the pump and motor to
the foundation.

All pipe connections on the suction side of the pump must be air tight. An air leak on the
suction side of the pump will result in the loss of prime.

A suction strainer is required on the suction side of the pump to exclude solid particles from the
pump. Contact Chemguard for a recommendation.

Support the piping independent of the pump. Excessive strain on the pump casing can
interfere with gear alignment.

When the piping is complete, loosen the bracket set screws and allow the pump to align with
the piping. Tighten the bracket set screws and re-check the shaft alignment. Make cure there
is no metal to metal contact of the coupling halves. Do not over tighten the pipelpump
connections, as damage can result.

A compound or vacuum gauge must be installed in the suction piping between the suction
strainer and the inlet to the pump. A discharge pressure gauge should be installed in the piping
on the discharge side of the pump.

Check the shaft rotation to ensure it is correct. Normal rotation is clockwise as viewed from the
shaft side of the pump.

Precautionary Notes
Prior to performing any service on the pump or motor:
(a) Disconnect and lockout the power source to the motor (refer to OSHA 1910.147.)
(b) Shut off valves from concentrate supply, and flush out piping.

Drain the pump and piping of excess liquid. Caution: Handle and dispose of liquids in
accordance with the manufacturer's Material Safety Data Sheets.

Disassembly for Inspection Purposes Onlv

Remove the bolts from the drive plate.

Carefully separate the drive cover and housing. Rotate the pump shaft by hand. It
should turn freely. If resistance is present, check for built up residue.

Use a soft marker to mark the rotorlpinion location. Remove the rotor from the
housing.

lnspect the housing, shaftlpinion, rotor, and drive plate for signs of wear or damage.
Excessive wear will decrease pump performance.

lnspect the O-rings, gaskets, and bearings for chipping, splitting, or missing sections

lnspection of the pump seal requires complete removal of the pump from the motor and
bracket.

Complete Disassembly for Repair or Replacement

Complete precautionary steps 1 and 2

Remove the four (4) hex head cap screws that secure the rear pump bracket to the
pump base using care to preserve any alignment shims and mark them for location.

Remove the four (4) hex head cap screws securing the rear bracket to the pump, and
set the bracket aside.

Support the pump and remove the four (4) cap screws attaching the front bracket to the
pump base using care to preserve any alignment shims and mark them for location.

Rotate the pump shaft by hand. It should rotate freely

6. Remove the coupling and shaft key (Item 9). Inspect the end and keyway of shaft
(Item 16) for burrs or other damage.

7. Remove the four (4) hex head cap screws securing the front bracket to the pump,
and set the bracket aside.

8. Loosen the set screw in seal gland (Item 18) and remove the gland by rotating
counter clock-wise, using care to avoid damage to the lip seal.

9. Remove the six (6) socket head cap screws (Item 5) securing the front cover (Item 53) to the pump
case (Item 1).

10. Carefully separate the front cover (Item 53) from pump case (Item l ) , using care to
avoid damage to O-Ring (Item 7).

11. Use a soft marker to mark the rotorlpinion location. Remove the front rotor (Item 56)
from the case (Item 1).

12. Remove the pinion (Item 51) from the case (Item l),
being careful to retain the pinion
key (Item 58).

13. Loosen the set screw in solid gland (Item 55) and remove the gland by rotating counter
clock-wise.

14. Remove the six (6) socket head cap screws (Item 5) securiug rear cover (Item 2) to the
pump case (Item 1).

15. Carefully separate the rear cover (Item 2) from pump case (Item l ) , using care to avoid
damage to O-Ring (Item 7).

16. Use a soft marker to mark the rotorlpinion location. Remove the rear rotor (Item 10) from
case (Item 1).

17. Carefully slide rotorlshaft assembly (Items 11, 16, & 72) from case (Item 1) using care to
avoid damage to case bearings (Item 20).

18. Inspect, repair, or replace al1 damaged parts. Note: I f significant damage i s evident to
pump components, i t i s best to replace the pump. If possible, determine the cause of
the damage and correct the problem.

19. Bearings (Items 6, 20, and 52) and wear sleeves (Item 74) are not field replaceable,
and if damaged, the entire pump should be returned for factory rebuild.

Reassembly
1. Pump reassembly is the reverse of disassembly. However, care should be exercised in
three important areas:
(a) It is good practice to replace elastomer O-Rings and lip seal every time the pump
is reassembled. Gently stretch the O-Rings before placing them in the O-Ring
grooves.
(b) Place the rotors into position with your marks facing out.
(c) Use a cross bolt tightening pattern to re-assemble the case and covers.
 Periodically turn the pump shaft. Check for unusual noise. lmproper tightening
may cause the pump to bind.

2. The pump will function best if primed first. Return the pump to service and check for
leaking and loose connections. Air leaks on the suction side of the pump will reduce
pump performance.

Reversing Rotation of pumu

1. See precautionary notes

2. To change the relief valve plate for reverse rotation:

(a) Loosen the bolts holding the relief valve plate to the pump body.
(b) Remove the bolts and the cover using care to avoid damage to the O-rings.
(c) Rotate the cover 180' and place on pump body.
(dj Re-install and tighten the relief valve plate bolts.

3. To change the seal vents for reverse rotation:

(a) Carefully remove the seal gland (Item 18) from front cover (Item 53). (Note:
Set screw on seal gland must be loosened before removing seal gland.)
@) Carefully remove solid gland (Item 55) from rear cover (Item 2). (Note: Set
screw on seal gland must be loosened before removing seal gland.)
(c) Remove set screws (Item 59) and spring pin vent tubes (Item 15) from both
front and rear cover.
(d) Install set screws (Item 59) in holes on discharge side of pump, and install
spring pin vent tubes (Item 15) in holes on suction side of pump on both the
front and rear covers.
(e) Reinstall glands (Items 18 & 55) and tighten set screws.

Special Sea1 Components

Standard Model CGP80-Series pumps use a lip seal as the main shaft seal. The seal is of Buna-N
synthetic material.

Maintenance Parts or Factorv Repair

1. When ordering parts, locate the pump serial number stamped on the machined face of the
cover or body of the pump housing.

2. Chemguard maintains a repair service shop that will rebuild, test, and return pumps promptly.

3. Remove pipes, coupling, and mounting bracket before returning the pump to the factory.

4. Contact Chemguard for a Return Authorization number before sending the pump to the factory

General Information
The following is general information about Chemguard rotary gear pumps. Due to the variety of
options and configurations available, it is not possible to provide detailed information in this manual.
Drawings and a bill of materials are provided as part of this manual.
Never operate a pump with the discharge line closed or plugged. Severe damage to the pump
and/or system will result.

Chemguard does not accept responsíbílity or líabílity for damage or ínjury resulting from
improper application and/or operation of the pump and/or system.

Direction of Rotation. Chemguard pumps are designed to operate in either direction by simply
changing the shaft rotation, rotating the relief valve plate, and changing the interna1 seal vents.
Failure to reverse the relief valve plate will render the relief valve inoperable. The procedure for
reversing the flow direction of the relief valve is covered in the Assembly and Disassembly
instructions.

Pump Alisnment. Bedplate mounted pumps and motor combinations are aligned and tested at the
factory. Vibration during shipment andlor poor bedplate mounting conditions can cause premature
failure or unacceptable noise and vibration. Check shaft alignment prior to operation.

Simple alignment checks can be performed by placing a straight edge on the top and side of the
coupling. lmproper alignment is indicated by a separation between the coupling and straight
edge. Adjust the motor and pump location until any separation disappears in both planes.

B e d ~ l a t eMountins. Install nuts on the foundation bolts to provide location adjustment. Loosely place
the bedplate on the foundation bolts. Adjust the bedplate height and location to meet the inlet and
outlet piping. Ensure the bedplate is level and true. Fasten in place with lock washers or lock nuts.
Check coupling alignment.

P i ~ i n a .lmproper suction piping is the leading cause of poor pump performance, including cavitation,
noisy operation, inadequate performance, and premature pump failure. Particular care should be
taken to avoid long, restricted pipe runs, the use of elbows, tees, valves, or other flow devices within
five (5) pipe diameters of the pump inlet. lnlet piping should be at least equal to the pump inlet size.
In no case should the restriction on the suction of the pump exceed ClnchesIHg.

The discharge piping arrangement is somewhat less critica1 than the inlet side, however, good
engineering practice, as defined by the Hydraulic Institute, should be followed.

Pumps are not designed to be used as piping system support devices. Piping systems should have
adequate, independent hangers to provide support. Again, the Hydraulic lnstitute offers guidelines for
proper pipe support design.

Seals. Chemguard offers lip seals as standard seals. Operating characteristics of Lip Seals are:

(1) Available in Buna-N or Viton. (The standard seal material on Chemguard pumps is
Buna-N,)

(2) Lip seals are inexpensive, but have certain limitations including an expected
operating life of 2,000 -3,000 hours, should not be used with system pressures over
250 psig, and should not be used in vacuum applications over 10-InchesIHg.

Bearinns and RotorlPinion Shaft

CG (Carbon Graphite) Bearinus. Recommended for al1 foam concentrate applications.

Ni-Resist Rotor. Recommended for al1 foam concentrate applications.

Stainless Steel Shafi and Pinion. Manufactured with minimum open tolerances as standard for use
with AR-AFFF foam concentrates. Increased slip will slightly reduce efficiency with standard AFFF
foam concentrates.

Spares and Repairs

Chemguard operates a repair service for al1 pumps for which records exist. To ensure the correct
parts are supplied, the pump serial number is required. The serial number is stamped into the
metal of the pump body or cover, in a prominent position on the top area of the pump.

We advise customers whose pumps are custom fabricated to have spare pumps or parts on hand.
Custom fabricated pumps and parts generally have long delivery times for replacement.
Trou bleshooting
Problem
No liquid delivered.
Not enough liquid delivered.
Pump works for awhile: then
loses sucfion.
Pump takes too much power.
Noisy pump.
Gland leakage.
Probable Cause
Pump not primed
Suction lift too high; check with a gauge at the pump suction
Wrong direction of rotation
Pump not rotating (failure of drive from prime mover)
Air leaks in suction line or through stuffing box
Speed too low
Suction lift too high, or not enough suction head (for hot
liquids)
Foot valve too small or obstructed
Foot valve or end of suction pipe not immersed deeply
enough
Piping improperly installed, permitting air or gas to pocket in
PumP
Mechanical defects:
Pump damaged
Pump badly worn
Seal defective
Relief valve not sealing or jammed by foreign matter
Leaky suction lines
Suction lift too high
Air or gases in liquid
Plugged lines or strainer
Speed too high
Liquid heavier or more viscous than design condition
Suction or discharge line obstructed
Mechanical defects:
Shaft bent
Rotating element binds
Misalignment due to improper connection of pipe lines or driver
Check pressure is being measured at the pump and not
some
distance away from the pump, thus ignoring pressure
losses in piping, valves, etc.
Poor piping conditions
Speed too high
Suction lift or viscosity too high (piping diameter too small)
Wrong direction of rotation (recesses in the pump covers to
prevent hydraulic noise operate only in one direction)
Badly supported pipe or bedplates causing resonant
vibration
Relief valve chattering
Pressure too low; an increase in pressure can prevent gear
noise
in low pressure applications
Cavitation due to inlet or outlet conditions
Seal damaged andlor shaft scored
Pressure on pump too high or pressure relief
passage blocked
Shaft run out excessive
m r d ' m.u6TillllIIEW<ULnaCIWLE
DllIU
> u -TE um piN NOTES1
~ ~ ~ m > m i m a > ~ m i u ~ ~ ~ 1. FOR VENTED PUMPS, INSERT ONE ITEM (59) I N
ITEMS ( 5 3 b
(2) ALVAYS W OUTLET SIDE OF PUMP ACCORDING
TO THE C V OR CCV ROTATION OF PUW. FOR
NON-VENTED PUWPS, INSERT TVO ITEM (59) I N

INSTRUCTIONS AND DIMENSIONS.

5. ADHERE I T M (74) TO lTEM (1) USING LOCTITE.
SLOTS I N SLEEVES MUST LINE UP VITH SIDE
PORTING

mL DYn rraE
W T * U D 6 tE*L
 BlLL OF MATERIALS

Date m ECRI0002
Rev: m

BOM Number: Drawing Number:

Description
1- Rev:
Rav.

I 3
I~hemguardModel CGP80-60 Bronze pump assembly W 1 2 NPT & 250 LB ANSl Flanged inlet & outlet 1
 BlLL OF MATERIALS

Date mECR10002
Rev: m

BOM Number:

Description
m
Drawing Number:
Rev:
Rev.

I I
l ~ h e r n ~ u aModel
rd CGP80-80 Bronze purnp assernbly W12" NPT & 250 LB ANSl Flanged inlet & outlet 1