Page 2 - EC-Declaration of conformity; Producer; SPX Process Equipment BE NV; TopGear MAG Magnetic Drive Gear Pumps; Manufacturer Declaration; The product must not be put into service until the machinery into
EC-Declaration of conformity (as per EC's Machinery Directive 98/37/EC, Annex IIA) Producer SPX Process Equipment BE NV Evenbroekveld 2-6 BE-9420 Erpe-MereBelgium We hereby guarantee that TopGear MAG Magnetic Drive Gear Pumps Types: TG MAG15-50 TG MAG23-65 TG MAG58-80 TG MAG86-100 TG MAG185-125 are ...
Page 3 - Contents
3 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) Contents 1.0 Introduction ........................................................................................................ 7 1.1 General ...................................................................................................................
Page 7 - TopGear
7 TopGear Serial No: Model: TG SPX Process Equipment BE NV Evenbroekveld 2-4 BE-9420 Erpe-Mere www.johnson-pump.com and spxpe.com A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 1.0 Introduction 1.1 General This instruction manual contains necessary information on the TopGear pumps and must be read careful...
Page 9 - Use an overhead crane, forklift or other suitable lifting device.; Warning
9 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 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 front part of the pump and the back part of the motor. Make sure that the load is balanced before attempting the l...
Page 11 - Technical conventions; Quantity; In this manual only dynamic viscosity is used.
11 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 1.4 Technical conventions Quantity Symbol Unit Dynamic viscosity µ mPa.s = cP (Centipoise) Kinematic viscosity ν = µ ρ ρ = density [ ] kg — dm 3 ν = kinematic viscosity [ ] mm 2 — s = cSt (Centistokes) Note! In this manual only dynamic viscosity is used. P...
Page 12 - Pump description; Type designation; Pump material and Port connection type
12 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 2.0 Pump description TopGear MAG pumps are rotary positive displacement pumps with internal gear. They are made of cast iron or stainless steel. TG MAG pumps are assembled from modular elements, which allows a variety of constructions. Different magnet cou...
Page 14 - Operating principle; General information and technical data; Pump standard parts; The pump is assembled to be used for flow in one direction.
14 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.2 Operating principle 3.0 General information and technical data 3.1 Pump standard parts Top cover Intermediate cover Pump shaft Bearing bracket Rotor shaft Pump casing Idler gear Pump cover Idler pin As the rotor and idler gear unmesh, an underpressure ...
Page 15 - Safety relief valve – Working principle; not the maximum pressure within the installation.; General performance
15 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 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 3.18.5.2 Piping). 3.2.2 Safety relief va...
Page 16 - Main characteristics; Legend; Maximum viscosity; Differential pressure or working pressure; Sound level of a pump without drive; Sound pressure level (L
16 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.5 Main characteristics The pump size is designated by the displacement volume of 100 revolutions expressed in litres (or dm 3 ) but rounded followed by the nominal port diameter expressed in millimetres. Legend d : port diameter (inlet and outlet port) B...
Page 18 - Maximum and minimum allowable temperature; Maximum pressure at 260°C: 12 bar; Overview of bush materials and application field
18 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.7.3 Influences The real sound level of the pump unit can for several reasons deviate from the values listed in the tables above. • Noise production decreases when pumping high viscosity liquids due to better lubricating and damping properties. Moreover t...
Page 19 - The maximum torque
19 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) TG MAG pump size K.hyd 15-50 6250 23-65 4000 58-80 3750 86-100 3600 185-125 2500 3.10.3 Operation under hydrodynamic lubrication conditions Hydrodynamic lubrication could be important criteria for bush material selection. If the bush bearings are running u...
Page 20 - The indicated numbers in the tables below are average
20 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.11 Mass moment of inertia TG MAG pump size 15-50 23-65 58-80 86-100 185-125 J (10-3 x kgm²) 3.5 6.8 32 54 200 Inner parts: IdlerRotor shaftAxial rotor bearingsShaft sleeveInner magnetic rotor Outer parts: Pump shaftOuter magnetic rotor Mass moment of ine...
Page 21 - Diametral clearance on pin / idler bearing
21 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) Radial clearance on rotor, idler outside diameter – Axial clearance on pump cover Pump size CO (µm) axial clear. set minimum C1 (µm) normal C1 (µm) normal C2 (µm) C3 (µm) Code Rotor 1xxx 2xxx 3xxx Code Idler x1xx x2xx x3xx Code pump cover assembly xxx0 xxx...
Page 22 - Components of the magnetic drive; • Drop in flow output
22 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.16 Components of the magnetic drive 3.16.1 Magnetic coupling The magnetic coupling is transmitting the torque of the drive motor to the rotor shaft. The magnetic coupling arrangement replaces a dynamic shaft seal and makes the pump 100 % leakfree.The mag...
Page 23 - Maximum allowable temperature and nominal torque; Material magnetic coupling parts; Inner magnetic rotor:
23 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) During normal operation heat is generated inside the magnetic coupling due to hydraulic friction and eddy currents in the wall of the separation can by the moving magnetic fields. Cooling of the cou-pling see chapter 3.16.3 Circulation pump. Maximum allowa...
Page 25 - Safety relief valve; Example; Working pressure class
25 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.17 Safety relief valve Example V 35 - G 10 H 1 2 3 4 5 1. Safety relief valve = V 2. Type indication = inlet diameter (in mm) 27 Safety relief valve size for TG MAG 15-50, TG MAG 23-65 35 Safety relief valve size for TG MAG 58-80 50 Safety relief valve s...
Page 26 - Heating
26 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.17.1 Definition and working principle The safety relief valve built on top of TopGear pumps is designed to protect the pump against over-pressure. It limits the differential pressure (or working pressure) of the pump. It is a spring-loaded pressure relie...
Page 27 - Du; Safety relief valve – Relative adjustment; exceeds the set pressure of the valve + 2 bar.; Lo
27 H 7050 73207310 d Du A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.17.5 Safety relief valve – Relative adjustment Adjustment of the standard setting pressure is performed at the factory. Note! When testing the safety relief valve mounted on the pump, make sure the pressure never exceeds the set pres...
Page 28 - Sectional drawings and part lists
28 7400 7360 7030 7170 7110 7010 7100 7150 7100 7040 7240 7400 7300 7330 7320 7180 7050 7310 7030 7400 7360 7420 7170 7110 7010 7100 7150 7100 7400 7240 7040 7300 7330 7320 7180 7050 7310 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.17.6 Sectional drawings and part lists 3.17.6.1 Single safety relief ...
Page 30 - • For loosening pump cover refer to; ma; • To adjust pressure of safety relief valve refer to; mc; Protect the user against leakages and possible liquid streams.
30 ma mb mc mc A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.18.2 Location 3.18.2.1 Short suction line Locate the pump/pump unit as close as possible to the liquid source and if possible below the liquid supply level. The better the suction conditions, the better the performance of the pump. See also s...
Page 31 - • The starting torque of internal gear pumps is almost identical t; when pump and drive are well aligned.
31 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.18.2.5 Stability Foundation The pump unit must be installed on a base plate or on a frame placed exactly level on the founda-tion. The foundation must be hard, level, flat and vibration free to guarantee correct alignment of the pump/drive while operatin...
Page 33 - • Check the tightness of the pipes after connection.; Suction piping; hould; Self-priming operation; A foot valve is not recommended when pumping high viscous liquids.
33 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.18.5.2 Piping • Use piping with a diameter equal to or greater than the connection ports of the pump and with the shortest possible lengths. • The pipe diameter has to be calculated in function of the liquid parameters and the installation parameters. If...
Page 34 - strainer if necessary to reduce viscosity and pressure drop.; For pipe dimensions of Cf see chapter 6.0.
34 2xBl ma zg Bh dh dg zh Bg dk dk 2xBf dl 2x Be Bb Ba A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 3.18.5.4 Strainer Foreign particles can seriously damage the pump. Avoid the entry of these particles by installing a strainer. • When selecting the strainer attention should be given to the size of the o...
Page 35 - T-jacket on pump cover; Jacket on pump cover; • Prior to lifting and transpor
35 Bh dh dg 2xCf ma zk 2xCf zh Bg zm dk dk Bo Bo A.0500.551 – IM-TGMAG/02.00 EN (02/2008) T-jacket on pump cover 3. Jacket on pump cover In case of steam supply, connect the supply line at the highest position and the return line to the lowest position so that condensed water will be drained via the...
Page 36 - Circuit breaker; Fit –; without impact tool; – both halves of the coupling to the pump shaft and the motor shaft; Alignment
36 U U delta star delta star L1 L1 L2 L2 L3 L3 N N U1 V1 W1 U1 V1 W1 W2 U2 V2 W2 U2 V2 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) Circuit breaker For safety work on a pump unit, install a circuit breaker as close as possible to the machine. It also is advisable to place an earth fault circuit breaker....
Page 37 - Alignment tolerances; Belt drive
37 40 31 25 X PT100 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 1 Place a ruler (A) on the coupling. Remove or add as many shims as is necessary to bring the electric motor to the correct height so that the straight edge touches both coupling halves over the entire length, see figure. 2 Repeat the same...
Page 38 - Do not use the TG MAG pump for flushing the system; , because it is not meant to
38 2x Be Bb Ba A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 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 oper...
Page 41 - Trouble shooting
41 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) Symptom Cause Remedy No flowPump not priming Suction lift too high 1 • Reduce difference betweenpump and suction tank level. • Increase suction pipe diameter. • Reduce length and simplify suction pipe (use as few elbows and other fittings as possible).Also...
Page 43 - Maintenance instructions; compliance with the guidelines.
43 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) Symptom Cause Remedy Pump leak O-rings, sealing rings or gasket damaged or not correctly assembled 41 • Check condition of O-rings and assemble them correctly or replace them • Check condition and clean/repair sealing faces • Replace gasket under top cover...
Page 45 - fluid may spray out of the pump.
45 2x Be Bb Ba A.0500.551 – IM-TGMAG/02.00 EN (02/2008) • For fluids that solidify or become very viscous at ambient temperature, it is best to empty the pump immediately after shutting down by separating it from the piping. Always wear safety goggles and gloves. • Protect yourself with a protective...
Page 49 - Instructions for assembly and disassembly
49 0040 0040 4000 0040 0600 8120 8110 8100 4000 0701 0010 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 4.0 Instructions for assembly and disassembly 4.1 General Insufficient or wrong assembly and disassembly can lead to the pump malfunctioning, high repair costs and long-term inoperability. Contact your...
Page 50 - Removal of bearing bracket; bolt in the shaft end.
50 F A B C E 2 0.5 x 45° D 0/-0.1 ∅ G 1080 0100 1090 0010 1700 1410 TG MAG A B C D E F G TG MAG 15-50 M 10 12 160 10,5 10 8 7,8 TG MAG 23-65 TG MAG 58-80 M 12 15 205 13,5 10 10 9,4 TG MAG 86-100 TG MAG 185-125 M 16 20 240 17 10 13 13 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 4.2.2 Disassembly of top ...
Page 51 - Use threaded holes in the flange of the pump shaft; Removal of ball bearings; the shaft using a ball-bearing extractor.
51 8640 0702 8320 1540 8320 0702 1430 1440 1460 1450 8620 8620 1400 1440 1490 1570 8610 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 4.2.4 Disassembly of pump shaft complete 1. Remove key (1570) from the pump shaft. 2. Remove sealing segment (1490) from the bearing bracket (see picture). 3. Remove circl...
Page 52 - Bearing set
52 8490 8310 8200 8210 8330 8210 8130 8440 8450 8460 0010 8350 A B C D A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 4.2.6 Disassembly of separation can 1. Un-tighten cap head screws (8210) crosswise and remove them. 2. Use two cap head screws (8210) in the threaded holes of the flange to remove the can ...
Page 56 - circulation pump; There are two different inserts according to
56 R L X 8480 8350-C 8450 8430 8430 8450 8350-C 8350-A 8480 8470 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 4.3.2 Pre-assembly of the back-pull-out 4.3.2.1 Adjustment of the axial clearance of the circulation pump 1. Place pump insert (8430) and radial bearing holder (8350-C) in the intermediate cover...
Page 58 - Mount the inner magnetic rotor (8310) on the hub of the
58 8490 8310 8520 8510 8500 8350-D 8400 0701 8350-B A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 6. Fit the keys (8400) into the rotor shaft (0701). Be care- ful that the keys (8400) are not hitting the shaft sleeve (8350-B) during assembly. 7. Fit rear axial bearing holder (8350-D) on the rotor shaft (...
Page 60 - Place the pump vertically on the workbench with the
60 0040 0600 8120 8110 8100 4000 1410 1700 A S B 0702 1400 Tool 8330 8450 0701 0010 A.0500.551 – IM-TGMAG/02.00 EN (02/2008) TG MAG Axial clearance C [mm] 15-50 0.120 – 0.200 23-65 0.125 – 0.215 58-80 0.150 – 0.250 86-100 0.165 – 0.275 185-125 0.190 – 0.320 4.3.5 Assembly of the bearing bracket 1. P...
Page 62 - Sectional drawings and part lists; How to order spares; Position number, quantity and description
62 1020 1010 1000 0040 4000 8100 8110 8120 0600 1060 1050 1090 0100 1080 8130 0010 1040 1030 8520 8510 8500 8490 8310 8480 8350 8470 1210 1220 8440 8410 8400 0701 8420 8430 8450 8460 8210 8330 8200 8320 8600 0702 1570 8610 1540 1440 1450 1430 1460 8620 8630 1230 1550 1560 1440 1490 1410 8640 8620 14...
Page 66 - Dimensional drawings
66 sp ve vh da df Bb ma ze zc mb ea db Ba va vb vc zb zb Be Be aa za dc 4 x Ø vd vf ec eb ed ef ISO/R775 Bu A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 6.0 Dimensional drawings 6.1 TG MAG15-50 to 185-125 pumps TG MAG 15-50 23-65 58-80 86-100 185-125 aa 50 65 80 100 125 Ba G 1/4 G 1/4 G 1/2 G 1/2 G 1/2 ...
Page 67 - Flange connections
67 zb zb am ad ac ab aa Ø ak zb zb am aa ab ac aa Ø ak A.0500.551 – IM-TGMAG/02.00 EN (02/2008) 6.2 Flange connections 6.2.1 Cast iron 6.2.2 Stainless steel TG MAG 15-50 23-65 58-80 86-100 185-125 aa 50 65 80 100 125 ab 100 118 135 153 180 ac PN16 125 145 160 180 210 ac PN20 120.5 139.5 152.5 190.5 ...
Page 69 - Safety relief valves; Jackets dimensions
69 dv mc tg mc dv TG MAG58-80 TG MAG86-100 TG MAG185-125 TG MAG15-50 TG MAG23-65 TG MAG Mat. 15-50 23-65 58-80 86-100 185-125 Bf G / R G 1/4 G 1/4 G 3/8 G 3/8 G 3/8 Bg G / R G 1/8 G 1/8 G 1/8 G 1/8 G 1/8 Bh G / R G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 Bl G G 1/2 G 1/2 G 1 G 1 G 1 R G 3/4 G 3/4 G 3/4 Cf G / R...
Page 72 - Copyright © 2008 SPX Corporate
SPX Process Equipment BE NVEvenbroekveld 2-6BE-9420 Erpe-Mere, BelgiumPhone: +32 (0)53 60 27 15 Fax: +32 (0)53 60 27 01E-mail: [email protected] For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.johnson-pu...
