1.0 Introduction General This instruction manual contains necessary information on the TopGear pumps and must be read carefully before installation, service and maintenance. The manual must be kept easily accessible to the operator. Important! The pump must not be used for other purposes than recommended and quoted for without consulting your local supplier.
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.
1.3.2.3 Before commissioning the pump unit Read the pump’s operating and safety manual. Make sure that the installation has been correctly carried out according to the relevant pump’s manual. Check the alignment of the pump and motor shafts. The alignment may have been altered during transport, lifting and mounting of the pump unit.
2.0 Pump description TopGear/GS pumps are rotary positive displacement pumps with internal gear. They are made of cast iron. TG GS pumps: heating / cooling jackets (steam), several sleeve bearings, gear and shaft materials and mounted relief valve. Type designation The pump properties are encoded in the following type indication, which is to be found on the nameplate.
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Example 58-80 7. Idler bush and idler materials Idler bush in hardened steel with idler in iron CG Idler bush in carbon with idler in iron Idler bush in bronze with idler in iron HG Idler bush in ceramic with idler in iron Idler bush in hardened steel with idler in steel Idler bush in carbon with idler in steel Idler bush in bronze with idler in steel...
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 3.18.6.2 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 GS pump size (mm) (mm) (mm)
Pressure Differential pressure or working pressure (p) is the pressure on which the pump normally operates. TopGear GS-line has the maximum differential pressure at 10 bar. TopGear GS-range The hydrostatic test pressure is 1.5 times the differential pressure i.e.: TopGear GS-line has the hydrostatic test pressure at 15 bar. Following figure gives a graphical presentation of the several kinds of pressures.
3.7.2 The sound level of the pump unit The sound level of the drive (motor, transmission, . . .) must be added to the sound level of the pump itself to determine the total sound level of the pump unit. The sum of several sound levels must be calculated logarithmically.
3.10 Internals 3.10.1 Bush materials Overview of bush materials and application field Material Code Material Steel Carbon Bronze Ceramic Hard metal if yes to maximum working pressure = 16 bar Hydrodynamical lubrication if no 6 bar (*) 10 bar (*) 6 bar (*) 6 bar (*) 10 bar (*)
3.10.4 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...
3.17.1 Pressure Safety relief valves are divided into 3 working pressure classes i.e. 4, 6 and 10 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)
3.18 Installation 3.18.1 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.
3.18.2.4 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.
3.18.3.2 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 GS pump size Fr (N) - max 2-25/3-32 6-40 15-50/23-65 1000 58-80/86-100 2000 185-125 3000...
3.18.5 Double safety relief valve When a double safety relief valve is installed three arrow plates are attached – one on each valve (A and B) indicating the liquid flow direction of each valve (small arrows 2 and 3) and one on the Y-casing (C) indicating the most favourable direction of rotation of the pump (arrow 1).
3.18.6.2 Piping • Use piping with an equal diameter than the connection ports of the pump and shortest possible. • The pipe diameter has to be calculated in function of the liquid parameters and the installation parameters. If necessary use larger diameters to limit pressure losses. • If the fluid to be pumped is viscous, pressure losses in the suction and discharge lines may increase considerably. Other piping components like valves, elbows, strainers, filters and foot valve also cause pressure losses.
3.18.6.3 Isolating valves To allow proper maintenance it is necessary to be able to isolate the pump. Isolation can be done by installing valves in suction and discharge lines. Discharge • These valves must have a cylindrical passage of the same diameter of the piping (full bore). (Gate or ball valves are preferable).
3.18.7.2 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. 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).
3.18.9 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. 3.18.9.1 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 1 V 1 W 1 U 1 V 1 W 1 U (volt) 230/400 V 400 V...
3.19 Instructions for start-up 3.19.1 General The pump can be put into service when all arrangements described in chapter 3.18 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.
3.19.4 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.
3.19.5 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 Quench media is present. Can it circulate freely? 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.
3.20 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 3.18 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.
Symptom Cause Remedy Rapid wear of the Viscosity too high 36 • Heat the pump. mechanical seal Bad de-aerating/ dry running 37 • Fill pump with liquid • Check position of relief valve or top cover. Temperature too high 38 • Reduce temperature. •...
3.21 Maintenance instructions 3.21.1 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. Therefore, you should carefully follow the guidelines given in this chapter.
3.21.2.6 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. In case of sealed bearings, cleaning products must not attack rubber gaskets. Never spray the hot parts of a pump with water, as certain components may crack due to the sudden cooling and the fluid being pumped may spray into the environment.
Clogged filter in the discharge line may result in higher discharge pressure. 3.21.3.5 Anti-friction bearings TG GS2-25, TG GS3-32 and TG GS6-40 pumps are equipped with 2RS ball bearings which are grease packed for life. They do not require periodically greasing.
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.
3.21.4 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.
3.21.7 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. 3.21.7.1 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.
Note! Add a correct grade and the appropriate type of grease. Do not overfill. 4.5.2 TG GS2-25, TG GS3-32 and TG GS6-40 disassembly 1. First disassemble the flexible coupling half using a coupling extractor. 2. Remove key (1570), set screws (1480) and tap bolts (1540).
4.5.4 TG GS15-50 to TG GS185-125 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. Detach bearing bracket (1400) by loosening the screws (1410). 5.
Mechanical seal Guidelines for assembly and adjustment of the mechanical seal – pump types GS. 4.6.1 General • All personnel responsible for maintenance, inspection and assembly must be adequately qualified. • Use specific instructions coming with the mechanical seal which is to be assembled/adjusted. • The assembling and adjusting of mechanical seals must be performed in a clean workshop. • Use technically appropriate tools that are in good condition. Handle them correctly. 4.6.2 Preparation Check if the mechanical seal to be mounted has the appropriate size and construction and verify if it can be assembled.
• Always replace damaged parts with original parts. • At every disassembly new graphite gaskets must be used. Never re-use gaskets. 4.7.2 TG GS2-25/TG GS3-32/TG GS6-40 Disassembly 1. Remove ball bearing (1440) and bearing bracket (1400) as described in bearing disassembly, section 4.5.2. 2. Remove pump cover (4000) and idler (0600). 3. Remove outer circlips (2230) from the shaft.
4.7.4 TG GS58-80/ TG GS86-100/ TG GS 185-125 Disassembly 1. Remove ball bearing (1440) and bearing bracket (1400) as described in bearing disassembly, section 4.5.4. 2. Remove pump cover (4000) and idler (0600). 3. Detach bearing cover (2200) by loosening screws (2220) and remove them together with the washers (2290).
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 4.8.1 Disassembly • Undo the screws (7310) and the cover (7050). • Measure and record the exact position of the adjusting bolt (7320). (See dimension H). • Loosen nut (7330) and adjusting screw (7320) until the spring (7150) has been completely released. • Remove spring casing (7040) by loosening the screws (7300). •...
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 GS58-80G2SSG2G1AV Serial number: 2000-101505 2. Pos 0600, 1, Idler + Bush complete TG GS2-25 to 1080 TG GS6-40 0100 1090 1050...
6.0 Dimensional drawings Standard pump 6.1.1 TG GS2-25 to TG GS6-40 ma ze 4xøvd ISO/R775 TG GS2-25 TG GS3-32 TG GS6-40 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...
6.1.2 TG GS15-50 to TG GS185-125 ma ze 4xøvd ISO/R775 TG GS15-50 TG GS23-65 TG GS58-80 TG GS86-100 TG GS185-125 G 1/4 G 1/4 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/4 G 1/4 G 1/4...
Flange connections 6.2.1 TG GS2-25 to TG GS6-40 øak TG GS2-25 TG GS3-32 TG GS6-40 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...
Bracket support 2xvt TG GS2-25 TG GS3-32 TG GS6-40 TG GS15-50 TG GS23-65 TG GS58-80 TG GS86-100 TG GS185-125 Mass Weight TG GS2-25 TG GS3-32 TG GS6-40 Pump (without jackets) Front-Pull out (pump cover+idler) Back-Pull Out (shaft+interm. casing+bracket) Screw on flanges...
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TopGear GS 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...