Summary of Contents for Johnson Pump SPX TopGear GS
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All manuals and user guides at all-guides.com I N S T R U CT I O N M A N UA L TopGear GS I N T E R N A L G E A R P U M P S O R I G I N A L I N S T R U CT I O N S A .
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All manuals and user guides at all-guides.com EC-Declaration of conformity Machinery Directive 2006/42/EC, Annex IIA Manufacturer SPX Flow Technology Belgium NV Evenbroekveld 2-6 BE-9420 Erpe-Mere Belgium Herewith we declare that TopGear GS-range Gear Pumps Types: TG GS2-25 TG GS3-32 TG GS6-40 TG GS15-50 TG GS23-65 TG GS58-80...
All manuals and user guides at all-guides.com Contents Introduction ......................7 1.1 General ........................7 1.2 Reception, handling and storage ..............7 1.2.1 Reception ......................7 1.2.2 Handling ......................7 1.2.3 Storage ....................... 7 1.3 Safety ........................8 1.3.1 General ....................... 8 1.3.2 Pump units ......................
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All manuals and user guides at all-guides.com 3.17 Safety relief valve ..................... 23 3.17.1 Pressure ......................24 3.17.2 Heating ......................24 3.17.3 Safety relief valve – Relative adjustment ...........24 3.17.4 Sectional drawings and part lists ..............26 3.17.4.1 Single safety relief valve ................26 3.17.4.2 Heated spring casing ................
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All manuals and user guides at all-guides.com 3.21 Maintenance instructions ................43 3.21.1 General ......................43 3.21.2 Preparation .......................43 3.21.2.1 Surroundings (on site) ................43 3.21.2.2 Tools ......................43 3.21.2.3 Shut-down ....................43 3.21.2.4 Motor safety ....................43 3.21.2.5 Conservation ....................43 3.21.2.6 External cleaning ..................
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All manuals and user guides at all-guides.com Sectional drawings and part lists ..............57 5.1 TG GS2-25 to TG GS6-40 ................57 5.1.1 Hydraulic part ....................58 5.1.2 Bearing bracket ....................58 5.1.3 Flange connection options ................58 5.1.4 Jacket .........................59 5.1.5 Single Mechanical seal ..................59 5.2 TG GS15-50 to TG GS185-125 ...............
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com Technical conventions Quantity Symbol Unit Dynamic µ mPa.s = cP (Centipoise) viscosity ρ = density Kinematic ν = µ [kg] ρ dm viscosity ν = kinematic viscosity [ mm ] = cSt (Centistokes) Note! In this manual only dynamic viscosity is used. Pressure [bar] ∆p...
All manuals and user guides at all-guides.com 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.
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All manuals and user guides at all-guides.com 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...
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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).
All manuals and user guides at all-guides.com 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...
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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 (*)
All manuals and user guides at all-guides.com 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...
All manuals and user guides at all-guides.com 3.13 Extra clearances To handle extra clearances following clearance classes are defined: C0 = Pump cover axial clearance set at minimum C1 = Standard clearance (not indicated because standard) C2 = ~2 x standard clearance C3 = 3 x standard clearance To indicate required clearances a code of 4 digits, xxxx, is given on the order.
All manuals and user guides at all-guides.com 3.14 Play between gear teeth TG GS 2-25 3-32 6-40 15-50 23-65 58-80 86-100 185-125 Minimum (µm) Maximum (µm) Play between gear teeth 3.15 Maximum size of solid particles TG GS 2-25 3-32 6-40 15-50 23-65...
All manuals and user guides at all-guides.com 3.17 Safety relief valve Example V 35 - G 10 H 1. Safety relief valve = V 2. Type indicating = inlet diameter (in mm) Safety relief valve size for TG GS2-25, TG GS3-32, TG GS6-40 Safety relief valve size for TG GS15-50, TG GS23-65 Safety relief valve size for...
All manuals and user guides at all-guides.com 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.
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All manuals and user guides at all-guides.com Spring ratio – Safety relief valve Spring dimensions TG GS pump size Pressure class bar/mm 25.5 0.26 2-25 3-32 25.5 0.43 6-40 25.5 1.72 37.0 0.21 15-50 37.0 0.21 23-65 36.5 0.81 49.0 0.32 58-80 49.0...
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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...
All manuals and user guides at all-guides.com 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).
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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).
All manuals and user guides at all-guides.com 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).
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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)
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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).
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All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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 •...
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 3.21.3 Specific components 3.21.3.1 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. •...
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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. •...
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 4.6.6 Assembly of the stationary seat • Fit the stationary seat(s) into the casing. • Use appropriate tools to push the seat perpendiculaly in its housing. • Protect the seat face with a piece of paper or hardboard and lubricate the rubber sealing elements with a lubricant. This will facilitate the assembly. Attention! Do not use mineral oil for EP rubber. • Check the perpendicularity of the seat face to the shaft rotating axis afte assembling. Pumps 4.7.1 General Note! To avoid damaging of carbon or ceramic shaft sealing parts the rotor with shaft must...
All manuals and user guides at all-guides.com 4.7.3 TG GS15-50/TG GS23-65 Dissasembly 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. Remove bearing cover (2200), outer circlips (2240) from the shaft. 4.
All manuals and user guides at all-guides.com 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.
All manuals and user guides at all-guides.com 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). •...
All manuals and user guides at all-guides.com 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 GS58-80G2SSG2G1AV Serial number: 2000-101505 2.
All manuals and user guides at all-guides.com 5.1.4 Jacket 0220 0200 0230 0210 Pos. Description GS2-25 GS3-32 GS6-40 preventive overhaul 0200 jacket cover 0210 tap bolt 0220 gasket 0230 cap head screw 5.1.5 Single Mechanical seal 3010 2240 2230 2210 2250 Pos.
All manuals and user guides at all-guides.com 5.2.3 Jacket 0220 0200 0240 0250 0210 0230 Pos. Description GS15-50 GS23-65 GS58-80 GS86-100 GS185-125 preventive overhaul 0200 jacket cover 0210 tap bolt 0220 gasket 0230 cap head screw 0240 plug 0250 sealing ring 5.2.4 Single mechanical seal 2280...
All manuals and user guides at all-guides.com 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...
All manuals and user guides at all-guides.com 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...
All manuals and user guides at all-guides.com 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...
All manuals and user guides at all-guides.com Jackets (S) on pump cover and thread connection 6.3.1 TG GS2-25 to TG GS6-40 2xBl TG GS2-25 TG GS3-32 TG GS6-40 G 1/2 G 3/4 6.3.2 TG GS 15-50 to TG GS185-125 2xBl TG GS15-50 TG GS23-65 TG GS58-80...
All manuals and user guides at all-guides.com 6.4.3 Heated safety relief valve TG GS15-50 TG GS23-65 TG GS58-80 TG GS86-100 TG GS185-125 TG GS15-50 TG GS23-65 TG GS58-80 TG GS86-100 TG GS185-125 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 –...
All manuals and user guides at all-guides.com 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.
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All manuals and user guides at all-guides.com 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...
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