The first digits of the serial number indicate the year of production. SPX Flow Technology Belgium NV Evenbroekveld 2-6, BE-9420 Erpe-Mere www.johnson-pump.com / www.spxflow.com 1.2.2 Handling Check the mass (weight) of the pump unit. All parts weighing more than 20 kg must be lifted using lifting slings and suitable lifting devices, e.g.
Safety 1.3.1 General Important! The pump must not be used for other purposes than recommended and quoted for without consulting your local supplier. A pump must always be installed and used in accordance with existing national and local sanitary and safety regulations and laws. When ATEX pump/pump unit is supplied, the separate ATEX manual must be considered •...
1.3.2 Pump units 1.3.2.1 Pump unit handling Use an overhead crane, forklift or other suitable lifting device. Secure lifting slings around the If there are lifting rings on both Warning front part of the pump and the the pump and the motor the slings Never lift the pump unit with back part of the motor.
When changing the operating conditions of the pump please contact your supplier to ensure a safe and reliable working pump. This also applies to modifications on a larger scale, such as a change of motor or pump on an existing pump unit. SPX Flow Technology Belgium NV Evenbroekveld 2-6 BE-9420 Erpe-Mere www.johnson-pump.com / www.spxflow.com...
2.0 Pump description TopGear/GP pumps are rotary positive displacement pumps with internal gear. They are made of cast iron. TG GP pumps: heating/cooling jackets (steam), several sleeve bearings, gear and shaft materials and mounted relief valve and electrical heating. Type designation The pump properties are encoded in the following type indication, which is to be found on the name plate.
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Examples: TG GP 58-80 G 2 S S SG 2 B G2 TC 10 11 TG GP 15-50 FD G 3 O S UG 6 U G6 AW 10 11 7. Jacket options for pump cover Pump cover without jackets Pump cover with jacket and thread connection Electrical heating idler pin –...
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Examples: TG GP 58-80 G 2 S S SG 2 B G2 TC 10 11 TG GP 15-50 FD G 3 O S UG 6 U G6 AW 10 11 11. Bush on shaft materials Bush in hardened steel Bush in carbon Bush in ceramic Bush in hard metal Bush in bronze...
3.0 General technical information Pump standard parts Top cover Intermediate casing Pump shaft Bearing bracket Idler pin Rotor Pump cover Idler gear Pump casing Operating principle As the rotor and idler gear unmesh, an underpressure is created and the liquid enters the new created cavities. Liquid is transported in sealed pockets to the discharge side.
3.2.1 Self-priming operation TopGear pumps are self-priming when sufficient liquid is present in the pump to fill up the clearances and the dead spaces between the teeth. (For self-priming operation see also section 3.19.6.2 Piping). 3.2.2 Safety relief valve – Working principle The positive displacement principle requires the installation of a safety relief valve protecting the pump against overpressure.
Main characteristics The pump size is designated by the displacement volume of 100 revolutions expressed in litres (or dm ) but rounded followed by the nominal port diameter expressed in millimetres. ∆p Vs-100 n.max n.mot Q.th Q.th p.test TG GP pump size (mm) (mm) (mm)
Pressure Differential pressure or working pressure (p) is the pressure on which the pump normally operates. TopGear GP-line has the maximum differential pressure at 16 bar. The hydrostatic test pressure is 1.5 times the differential pressure i.e.: TopGear GP-line has the hydrostatic test pressure at 24 bar. Following figure gives a graphical presentation of the several kind of pressures.
Sound power level (L The sound power L is the power emitted by the pump as sound waves and is used to compare sound levels of machines. It is the sound pressure Lp that acts on a surrounding surface at distance of 1 meter.
Material options Maximum temperature Overall temperature of TopGear GP pumps is 300°C but: 1. Maximum temperature of size GP2-25, GP3-32 and GP6-40 is limited to 200°C due to ball bearing type 2RS. Minimum temperature is -20°C. 2. Temperature limits must be considered depending on the used materials for bearing bushes and shaft sealing.
3.11.2 Maximum temperature of internals For some material combinations the general temperature performances must be limited. The maximum allowable working temperature of internals depends on the combination of used materials and their thermal expansions and the interference fit to hold the bearing bush fixed. •...
3.11.4 Maximum torque of pump shaft and rotor material combination The maximum allowable torque is a constant independent from speed and may not be exceeded to avoid damaging the pump i.e. pump shaft, rotor/shaft fitting and rotor teeth. Mn (nominal torque) in Nm Md (starting torque in Nm N Rotor N Rotor...
The indicated numbers in the tables below are average values in microns (µm). Radial clearance on rotor, idler outside diameter – Axial clearance on pump cover C0 (µm) C1 (µm) C2 (µm) C3 (µm) Pump size axial clearance normal = 2.2 x C1 = 3 x C1 pumpcover set minimum Code rotor...
3.17 Shaft sealing 3.17.1 Packed gland (no lantern ring) 2-25 15-50 86-100 TG GP pump size 6-40 58-80 185-125 360-150 3-32 23-65 120-100 Shaft diameter Section width Number of rings Dimensions in mm 3.17.2 Packing ring materials Most universal solution. Woven shaft packing consisting of PTFE yarns with incorporated graphite and sliding matters (yarns GORE-GFO).
3.18.1 Pressure Safety relief valves are divided into 4 working pressure classes i.e. 4, 6, 10 and 16 indicating the maximum working pressure for that valve. Each class has a standard set pressure at 1 bar above the indicated maximum working pressure. The set pressure can be set lower on request never higher. Working pressure class Standard set pressure (bar) Working pressure range (bar)
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Spring ratio – Safety relief valve Spring dimensions TG GP pump size ∆H [mm] in order Pressure class bar/mm to adjust by 1 bar 25.5 0.26 3.85 2-25 25.5 0.43 2.33 3-32 25.5 1.72 0.58 6-40 25.5 1.72 0.58 37.0 0.21 4.76 37.0...
3.19 Installation 3.19.1 General This manual gives basic instructions which are to be observed during installation of the pump. It is therefore important that this manual is read by the responsible personnel prior to assembly and afterward to be kept available at the installation site. The instructions contain useful and important information allowing the pump/pump unit to be properly installed.
3.19.2.4 Indoor installation Locate the pump so that the motor can be vented properly. Prepare the motor for operation according to instructions provided by the motor manufacturer. When flammable or explosive products are pumped, a proper earthing should be provided. The components of the unit should be connected with earthing bridges to reduce the danger arising from static electricity.
3.19.3.2 Radial load on shaft end The shaft end of the pump shaft may be loaded in radial sense with the maximum radial force (Fr). See table. TG GP pump size Fr (N) - max 2-25/3-32 6-40 15-50/23-65 1000 58-80/86-100/120-100 2000 185-125 3000...
3.19.5 Shaft rotation for pump with safety relief valve The shaft rotation determines which port of the pump is suction and which is discharge. The relation between the shaft rotation and the suction/discharge side is indicated by the rotation arrow plate attached at the valve casing of the safety relief valve. TG 2-25 TG 23-65 TG 58-80...
3.19.6 Suction and discharge pipes 3.19.6.1 Forces and moments Note! Excessive forces and moments on the nozzle flanges derived from piping can cause mechanical damage to pump or pump unit. Pipes should therefore be connected in line, limiting the forces on the pump connections. Support the pipes and make sure they remain stress-free during operation of the pump.
Self-priming operation At the start sufficient liquid must be available in the pump filling up the internal clearance volume and the dead spaces, allowing the pump to build up a pressure difference. Therefore, for pumping low viscosity fluids, a foot valve with the same or larger diameter than the suction pipe must be installed or the pump can be installed without foot-valve but in U-line.
3.19.7.2 Heating jackets 1. S-type jackets The S-jackets are designed for use with saturated steam (max 10 bar ⇒ 180°C) or with non- dangerous media (max 10 bar - max 200°C). They are provided with threaded connections Bl (see chapter 6.0 for the dimensions). The connection can be done by threaded pipes or pipe connections with sealing in the thread (conical thread applying ISO 7/1) or sealed outside the thread by means of flat gaskets (cylindrical thread applying ISO 228/1).
3.19.8 Guidelines for assembly When a bare shaft pump is delivered, the assembly with drive is the responsibility of the user. The user also must provide all necessary devices and equipment allowing a safe installation and commissioning of the pump. 3.19.8.1 Transport of pump unit •...
Electrical equipment, terminals and components of control systems may still carry live current when at rest. Contact with these may be fatal, resulting in serious injury or cause irreparable material damage. Line Motor U (volt) 230/400 V 400 V U 1 V 1 W 1 U 1 V 1 W 1 delta star...
Repeat this check at operating temperature and spend time achieving minimum alignment deviation. Fit the protecting guard. See the figure below and the corresponding table for the maximum allowed tolerances for aligning the coupling halves. Alignment tolerances - Va External diameter of coupling [mm] [mm] [mm]...
3.20 Instructions for start-up 3.20.1 General The pump can be put into service when all arrangements described in chapter 3.19 Installation have been made. • Prior to commissioning, responsible operators have to be fully informed on proper operation of the pump/pump unit and the safety instructions. This instruction manual must at all times be available to the personnel.
3.20.4 Checklist – Initial start-up After thorough servicing or when the pump is to be put into service for the first time (initial start-up) the following checklist must be observed: Supply and discharge line c Suction and discharge pipes are cleaned. c Suction and discharge pipes are checked for leaks.
3.20.5 Start-up When the pump is to be put into service the following checklist and procedure must be observed: c Pump is filled with liquid. c Pump is sufficiently preheated. c Suction and discharge valves are fully open. c Start the pump for a short while and check the direction of rotation of the motor. c Start the pump and check suction of liquid (suction pressure).
3.21 Trouble shooting Symptom Cause Remedy No flow Suction lift too high • Reduce difference between Pump not priming pump and suction tank level. • Increase suction pipe diameter. • Reduce length and simplify suction pipe (use as few elbows and other fittings as possible). Also see section 3.19 Installation.
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Symptom Cause Remedy Not enough capacity Viscosity too low 17 • Increase pump speed. Attention! Do not exceed maximum speed and check NPSHr. • If necessary, install a larger pump. • If pump is heated by means of heating jackets or electrical heating, reduce the heating input.
3.21.1 Instructions for re-using and disposal 3.21.1.1 Re-use Re-use or putting the pump out of service should only be undertaken after complete draining and cleaning of the internal parts. Note! When doing so, observe adequate safety regulations and take environmental protection measures.
3.22 Maintenance instructions 3.22.1 General This chapter only describes operations that can be performed on-site for normal maintenance. For maintenance and repair requiring a workshop contact your local supplier. • Insufficient, wrong and/or irregular maintenance can lead to malfunctions in the pump, high repair costs and long-term inoperability.
3.22.2.6 External cleaning • Keep the surface of the pump as clean as possible. This simplifies inspection, the attached markings remain visible and grease nipples are not forgotten. • Make sure cleaning products do not enter the ball bearing space. Cover all parts that must not come into contact with fluids.
3.22.3 Specific components 3.22.3.1 Nuts and bolts Nuts and bolts showing damage or parts with defective threading must be removed and replaced with parts belonging to the same fixation class as soon as possible. • Preferably use a torque wrench for tightening. •...
The standard “multi-purpose” grease (consistent class NLGI-2) is suitable for temperatures up to 120°C. For higher temperatures the standard grease should be replaced by a high temperature grease (consistent class NLGI-3). This grease is, depending on the make, suitable for temperatures up to 150°C or 180°C.
3.22.3.7 Shaft seal Gland packing PO • For pumps with gland packing, regularly check the packing for leaks. A slight leakage is normal. • Regularly check connections on the lantern ring (if applicable). • If the gland packing leaks excessively or when the pump needs serve, the old packing rings must be replaced.
3.22.4 Front pull-out The TG-pumps also have a front pull-out system. To remove liquid residues or to check the idler bearing for wear, the pump cover can be pulled out from the pump housing without disconnecting suction and discharge pipes. See chapters 4.0 Disassembly/Assembly and section 6.6 Weights.
3.22.7 Designation of threaded connections. To make clear what sealing type of threaded connection is provided we denominate them according to standards ISO 7/1 and ISO 228/1 as follows. 3.22.7.1 Threaded connection Rp (example Rp 1/2) If no flattened sealing face is provided we call the connection Rp accordingly ISO 7/1. This connection has to be sealed in the thread.
4.0 Instructions for assembly and disassembly General Insufficient or wrong assembly and disassembly can lead to the pump malfunctioning, high repair costs and long-term inoperability. Contact your local supplier for information. Disassembly and assembly may only be carried out by trained personnel. Such personnel should be familiar with the pump and follow the instructions below.
Anti-friction bearings 4.5.1 General • Never re-use a disassembled bearing or a disassembled lock plate! • For disassembly and assembly of the bearing (and coupling), use correct tools in order to inspect the pump without any shock loads. Shocks can damage the crisp material of bush bearings and mechanical seal.
4.5.4 TG GP15-50 to TG GP360-150 disassembly 1. First disassemble the flexible coupling half with the aid of a coupling extractor. 2. Remove key (1570), set screws (1480), tap bolts (1540) and long screws (1530). 3. Remove the outer bearing cover (1470) and the V-seal (1490). 4.
Relief valve • The relief valve may not be disassembled before the spring has been released completely • Before releasing the spring, measure the position of the adjusting bolt, so that the spring afterwards can be adjusted to its original opening pressure 4.6.1 Disassembly •...
Electrical heating 4.7.1 General When replacing a cartridge heater, make sure that the same type of cartridge heater (dimensions, voltage, power, …) is used. 4.7.2 Electrical heating on the pump cover (in the idler pin) 4.7.2.1 Disassembly • Disconnect the leads of the cartridge heater (0800) from the electronic or electrical power control device.
4.7.3 Electrical heating around shaft seal (in the intermediate casing) 4.7.3.1 Disassembly • Disconnect the leads of the cartridge heater (0800) from the electronic or electrical power control device. • Disconnect the flexible conduit (0830) from the electronic or electrical power control device. •...
5.0 Sectional drawings and part lists How to order spares When ordering spare parts, please state: 1. Pump type and serial number (see name plate) 2. Position number, quantity and description Example: 1. Pump type: TG GP58-80 G2 SS SG2 BG2 TC Serial number: 2000-101505 2.
6.0 Dimensional drawings Standard pump 6.1.1 TG GP2-25 to TG GP6-40 ma ze 4xøvd ISO/R775 TG GP2-25 TG GP3-32 TG GP6-40 G 1 1/4 G 1 1/2 G 1/4 G 1/4 G 1/4 G 1/4 Rp 3/8 Rp 3/8 5 h9 6 h9 21.5 16 j6...
6.1.2 TG GP15-50 to TG GP360-150 ma ze 4xØvd ISO / R775 TG GP15-50 TG GP23-65 TG GP58-80 TG GP86-100 TG GP120-100 TG GP185-125 TG GP 360-150 G 1/4 G 1/4 G 1/2 G 1/2 G 1/2 G 1/2 G 3/4 G 1/2 G 1/2 G 1/4...
Flange connections 6.2.1 TG GP2-25 to TG GP6-40 øak TG GP2-25 TG GP3-32 TG GP6-40 ac PN16 ac PN20 79.5 98.5 ad PN16 ad PN20 ak PN16 4xd14 4xd18 4xd18 ak PN20 4xd16 4xd16 4xd16 am PN16 am PN20 6.2.2 TG GP15-50 to TG GP360-150 TG GP58-80/ TG GP15-50/...
Jackets – Electrical heating 6.3.1 Jackets TG GP2-25 to TG GP6-40 Jackets (SS) with thread connections on pump cover and around shaft seal 2xBl 2xBl 2xBf 2xBf Single jacket (SO) with thread Single jacket (OS) with thread connection on pump cover connection around shaft seal TG GP2-25 TG GP3-32...
6.3.2 Jackets TG GP15-50 to TG GP360-150 2xBf 2xBl Jackets (SS) with thread connections on pump cover and around shaft seal 2xBf 2xBl Single jacket (SO) with thread Single jacket (OS) with thread connection on pump cover connection around shaft seal TG GP15-50 TG GP23-65 TG GP58-80...
6.3.3 Electrical heating Electrical heating on the pump cover (in the idler pin) and around the shaft seal (in the intermediate casing) = E..E.. Electrical heating on the pump cover Electrical heating around the shaft seal (in the idler pin) = E..O (in the intermediate casing) = OE..
Declaration of Compliance for food contact materials Manufacturer SPX Flow Technology Belgium NV Evenbroekveld 2-6 BE-9420 Erpe-Mere Belgium We hereby certify the compliance of the materials coming into contact with food during the intended use with the general requirements as of the date of this Declaration of Regulation (EC) No 1935/2004 of 27 October 2004 on materials and articles intended to come into contact with food and repealing Directives 80/590/EEC and 89/109/EEC.
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NOTES A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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NOTES A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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TopGear GP I N T E R N A L G E A R P U M P S S PX F LOW T E C H N O LO GY B E LG I U M N V Evenbroekveld 2-6 BE-9420 Erpe-Mere, Belgium P: +32 (0)53 60 27 15 F: +32 (0)53 60 27 01...
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