Gespasa AG-90 User manual

Partida Horta d’Amunt s/n · Apdo. de Correos nº 149
25600 BALAGUER (Lleida) · SPAIN
++34 (9)73 451 072
++34 (9)73 448 400
[email protected] · http://www.gespasa.es
INSTRUCTION MANUAL
WARRANTY AND CONFORMITY DECLARATION
AG-90 0.37 kW 12 or 24 VDC
12 VDC code 00040 12 VDC with switch code 00042
24 VDC code 00050 24 VDC with switch code 00052
9073 120
112
6,90
350
165
h: 175
M-13
CONNECTION: 1" · SUCTION: 2.7 m 1 1/2" · DELIVERY: 4 m 1 1/4"
AG-90 12 VDC
SAG-90 12 VDC
AG-90 24 VDC
SAG-90 24 VDC
PA-80PSF-040FREE PA-120
90 l/min 75 l/min 70 l/min 76 l/min
65 l/min 58 l/min 56 l/min 60 l/min
92 l/min
78 l/min
72 l/min
80 l/min
68 l/min 60 l/min 57 l/min 62 l/min
38 A 42 A 44 A 42 A
45 A 48 A 48 A 46 A
30 A 32 A 33 A 31 A
34 A 35 A 36 A 35 A
No. DESCRIPTION CODE
1 12 VDC MOTOR 000604000
1 24 VDC MOTOR 000704000
1 12 VDC MOTOR + SWITCH 000604001
1 24 VDC MOTOR + SWITCH 000704001
2 MECHANICAL SEAL 804601003
4 6-BLADE SET 000302009
5 PUMP BODY 000302101
6 M-6x55 mm DIN.912 ZINC-PLATED SCREW 805400001
7 BYPASS PLUG 000302008
8 30x3 mm NBR BYPASS JOINT 803100019
9 BYPASS SPRING 000302205
10 BYPASS VALVE 805606101
11 85x4 mm JOINT 803100020
12 D.16 mm ROLLER 000302014
13 5x5x20 mm COTTER PIN 000302002
14 BIG RED CLAMP CASE 804350005
15 BIG BLACK CLAMP CASE 804350004
16 BIG METAL CLAMPS 804300004
1
13
14
16
15
2
4
12
11
5
6
7
8
9
10
clockwise turn sense
sentido giro horario

Read this manual before installing or handling this kit.
INSTALLATION WITH OWN EQUIPMENT
- Before connecting the pump to the battery, check the supply is the same as that is described in the technical plate of the pump motor.
- If possible, connect the pipe to the pump through flanges (code 800003022 · F1" aluminium flange kit). This system is better than those connected through threads as the pump
does not suffer any tension.
- If the installation has a rigid pipe, install a section of, at least, 20 cm of flexible pipe before and after the pump.
- If the pump is connected through threads, avoid to force the pump body. Any little displacement between the body and the motor can cause damages.
1. TECHNICAL SPECIFICATIONS
It is not suitable for the transfer of liquids of Class A and B with a flash point lower than 55 ºC.
2. WARNINGS
Please read these instructions carefully before using this product. The people who do not know the instructions must not use it.
This manual describes how to use the pump according to the project hypothesis, the technical specifications, the installation type, the use, the maintenance and the training relating
to the possible dangers.
The instruction manual must be considered as a part of the pump and keep it for future inquiries during all its working life. We suggest keeping it in a dry and protected place.
The manual reflects the technical situation when selling the pump and cannot be considered inadequate for the reason of being updated according to the new experiences. The
manufacturer reserves the right to update the production and the manuals without being forced to update the old ones.
3. SECURITY INSTRUCTIONS
3.1. Make the electric connection only with the qualified personnel following the applicable electric regulations.
3.2. Connect adequately to the earth. Use approved cables and electric equipment.
3.3. The broken down motors must be fixed in an authorized workshop or in our factory.
3.4. Check the packaging in the receipt of the goods and store it in a dry place.
3.5. Check the kit does not have any damage during their transportation or storage.
3.7. IMPORTANT
It is forbidden to use the pump in environments where there is the risk of suffering an explosion or a fire (defined according to law). In particular the pump must
not be used to pump liquids that, according to law, need explosionproof motors, i.e. not allowed uses with petrol, acetone, solvent... (Regulation references: IEC
79-10 International Regulation). Do not smoke near the pump or use it near a flame. This could cause an explosion and even the death.
3.8. ATTENTION: If the pump, the hose and the nozzle are outdoors in summer weather or hot countries, after the refuelling (once the pump is stopped), it is advisable to open the
nozzle in order to discharge the accumulated pressure of the hose.
Otherwise, the high sun temperature makes possible to create an overpressure because of the expansion due to the diesel dilation the pipes have, being able to cause a retainer or
mechanical element breaking of the pump and/or the meter.
If the pump was without operating in a place exposed to bitterly cold weather or ice, it would be necessary to empty the hoses and the pump body.
It would be also advisable to make this operation if the pump or the supply kit was without operating during a long time even though the temperature was normal.
3.9. If the hose connections are made with clamps, ensure they are well-tightened in order to avoid any air intake.
3.10. Please avoid spilling any type of liquid on the motor.
3.11. ATTENTION
The installer will be responsible of using the pipes with the adequate features. The inadequate use of the pipes could cause the contamination and damages
to the pump or people.
Check all the connections after the first installation and daily control they are not loosened. If necessary, tighten them. The connection loosening could cause
serious ecological and security problems.
3.12. ATTENTION
The pump must not be switched on before finishing its installation. It is completely forbidden to put the fingers or other parts of the body into the holes: the
pump has parts in motion. Before starting the pump disassemble or assembly, always switch it off and disconnect it from the power supply in order to avoid
accidental ignitions with the unprotected parts in motion.
- AG-90 12 or 24 VDC self-suction pump of grey foundry
- Eccentric of self-adjusting blades
- With recirculation bypass system
- *Flow with free outlet: 70-80 l/min
- Motor: 0.37 kW 12 or 24 VDC · self-ventilated · dust protected · tropicalised
- Noise level: LEQA < 85 dBA (1 m)
- Continuous duty · IP-55 protection
- Consumption: 35-53 A (12 VDC) · 24-32 A (24 VDC)
- 1,500 rpm
- Bypass pressure: 1.4-1.6 bar
- Connection through F1" (BSP) threads and flanges
- With clamps for the connection to the battery 12 or 24 VDC and ON/OFF switch
- It has built in an steel filter in the suction of 350 µm (micron).
Dim. (approx.): 350x165x175 mm (length x width x height)
Weight (approx.): 15.50 kg
*NOTE: When using an automatic nozzle or any other accessory (like meter, filter...), the flow will be reduced (see the table in the front page).
FLUID COMPATIBILITY
The AG-90 12 or 24 VDC pumps are especially for the diesel transfer. They must not be used to transfer other liquids.
They are suitable for the agriculture, building, public works and industry use.
3.13. IT IS OBLIGATORY THE INSTALLATION OF A FUSE SUITABLE FOR THE PUMP CONSUMPTION FOR THE KIT WARRANTY.
4. INSTALLATION
12 VDC
24 VDC
Pressure (bar) · NPSH (bar)
Flow (l/min)
FLOW CURVES
2.5
2
1.5
1
0.5
0
0 20 40 60 80 100 120
3.6. ATTENTION
The electric connections must be done according to the EN 60204-1:2007 CORR:2010 Regulation. In their series version the electric motor is not equipped
with the protection against electric overloads. The user will take charge of Its assembly.
Connect the cable to the supply system after checking it has the same values as those written in the motor plate (it admits a tension tolerance of 10 %). The
box-switch of the motor has electric parts whose assembly must be done by specialized personnel complying with the security rules.

- The elbows can cause a flow leak. Install the minimum ones the installation requires in order to avoid a charge loss.
- The elbows, unions and connections must have an inner diameter equal or higher to the diameter of the installed pipe. Reducing the diameter diminishes the flow and can cause a
breakdown in the motor.
- Fitting a microfilter in the pump suction will avoid many breakdowns because of the impurities and the long-term of your pump. You will also avoid problems in your vehicle or
machinery injectors when installing an FG-100 microfilter.
Refer to:
Check valve + York Base filter
FUP-1 filter · code 66030
FG-100 microfilter · code 39023
- Using the «silent blocks» pump installation, the vibration noise will be reduced.
- The AG-90 12 or 24 VDC pump can use manual and automatic nozzles. WHEN USING NOZZLES, THE FLOW WILL BE REDUCED BETWEEN 7 and 14 %.
- In case that the pump does not suction during its installation:
Immediately stop the pump.
Check the suction tube is well-sealed (there is not any air inlet).
Check the recommended height or length of the suction tube are not exceeded.
If you are using an automatic nozzle, it is possible there is an air chamber in the delivery line. The air evacuation can be difficult because of the automatic stop device that holds
close the valve when the pressure is too low. If so, disassemble the nozzle, start the pump until the liquid flows. Then, assemble again the nozzle.
Refer to the next section "PROBLEM GUIDE".
- Seal the hose connections of the hoses or pipes with Teflon or compatible seal liquid. Any air inlet through the suction tube will cause the pump does not suction. Make sure the
leak absence.
ATTENTION
Clean carefully the suction and discharge holes, removing the dust or original packaging material.
Check the sealing liquids or Teflon go into the pumps. Otherwise the pump or the bypass can be blocked.
2,7 m
5 m
10 m
P: 2,2 bar
4 m
ATTENTION
Never use hydraulic pressure adapters for the connections. These adapters are too narrow, decreasing the flow and the pump life.
The installer is the responsible of using the required accessories for the good operation of the kit. The inadequate use of accessories can contaminate or
damage the pump or people.
5.1. When switching on the pump, the pump motor starts working, self-suctioning the liquid and when opening the nozzle, the diesel transfer will start.
5.2. When the refuelling is finished, turn off the pump switch.
5.4. IMPORTANT
As the pump has worked with the nozzle closed, there is an overpressure in the hose. WHEN STOPPED THE MOTOR, IT IS ADVISABLE TO OPEN THE NOZZLE in
order to allow the discharge of the pressure accumulated in the hose
5.5. The pump use under extreme conditions can cause an increase of the motor temperature, causing its stop because of the thermal motor protection.
Turn the pump off and wait until it gets cold. Then, the thermal protection will be deactivated.
6.3. Check the hose and the nozzle in order to see whether these are worn or broken. The damaged hoses or nozzles can be a potential risk and/or attempt
against the environment.
7. REPAIR
- Use compatible hoses. Respect the diameters described in this manual. Using a too soft hose can cause the obstruction of the suction power.
- Suction: minimum diameter 1" · best diameter 1 1/2"
- Delivery: minimum diameter 1" · best diameter 1 1/4"
- Fit a diesel filter in the suction hose.
- CHECK VALVE: For suctions of more than 2.7 m in depth, with or without meter, it is required a check
valve. It is always advisable to install a check valve according to the pipe diameter.
Equivalent height of the maximum suction: 4 m for diesel. (This equivalence is the vertical distance
from the bottom of the suction tube to the pump inlet tube plus the wastages due to the friction in the
vertical and horizontal route of the tube, the elbows etc.). The top depression levels will affect the flow,
cause the accelerated fatigue of the pump and the possibility of cavitation will drastically increase.
- For a suction height higher than 2.7 m or for a horizontal suction length of 10 m, it is necessary a
suction tube higher than the pump admission hole, i.e. 1 1/2".
- RECOMMENDATION: If the delivery hose has a length higher than 5 m in a supply kit, it is advisable
to install a non-return valve in the pump outlet or the meter in order to avoid any overpressure in the
pump retainer or the meter. Make sure the valve is installed in the correct way.
- When lengthening the electricity cable, its cross-sectional area must be increased. Otherwise, the motor can be damaged. Do not make "connections" in the electricity cable.
We have got customized ACCESSORIES for each type of pump allowing the rapidity and neatness of the installation both in the suction and in the delivery.
- The suction reels have special injected self-screwing sealing joints, assuring a total sealing.
- The delivery hoses clamped with brass adapters have injected self-screwing joints of its total sealing, not being necessary sealing liquids or other elements.
- The PP telescopic tubes with built-in filter do not have impurities in their inner, allowing getting the recipient bottom. (To specify sizes).
5. CORRECT PUMP USE
5.3. IMPORTANT
DO NOT FORGET TO STOP THE PUMP THROUGH THE SWITCH OR DISCONNECTING THE CLAMPS, once the refilling is completed. In the event of closing the liquid
way through the nozzle, the liquid freely runs through the bypass of the pump inner. The kit can be damaged.
The pump cannot work in bypass (closed nozzle) during a period higher than 3 minutes because, otherwise, the pump will be seriously damaged. Do not start
the pump without liquid in its inner.
6. MAINTENANCE
Periodically follow the below steps so that the pump remains in its best state:
6.1. The AG-90 12 or 24 VDC pumps have an extractable filter on the suction in order to avoid the solid impurities input into the pump and/or the meter. The absence of these impurities
means the long life of the pump.
6.2. Check the filter in order to see whether there are any stored waste.
The authorized repair workshops are the only ones that can repair the damaged motors. Clean and drain the pumps before sending them.
If a pump is used, by mistake, with fluids not derived from diesel, this must be rinsed as many times as necessary, enclosing a note where it is stated which fluids have been pumped.
The pumps, which do not have this specifications, will be admitted neither in the workshop nor in the factory.
When ordering spare parts, make sure of giving the spare part code, its description and its serial number. This will guarantee the correct supply of the required part.

8. PROBLEM GUIDE
9. WARRANTY
1. All the products manufactured by TOT COMERCIAL SA have a WARRANTY of 12 (twelve) months or 500,000 litres from their purchase, against any manufacturing
defect.
2. TOT COMERCIAL SA guarantees, in the warranty period, the change, the devolution of the defective part or product. This material must be sent with prepaid
freight to our factory or any appointed technical service. After our technical inspection, it will be determined whether the responsibility is from the manufacturer,
the user, the installer or the transport.
3. The warranty does not cover: the inadequate use, the negligence, the abuse, the corrosion, the manipulation or the wrong installation of the products, the use
of non-original spare parts or not corresponding to the specific model. All the manufactured and/or commercialized equipment must be installed according to the
manufacturer's instructions.
4. The accessories and the products not manufactured by TOT COMERCIAL SA are liable for their original manufacturer's warranty.
5. Because of the constant innovations and development, TOT COMERCIAL SA reserves the right to modify the specifications of its products and publicity, without
prior notification.
BREAKDOWN POSSIBLE CAUSE SOLUTION
The tank is full. The pump is
working, but the liquid does not go
out through the automatic nozzle.
- There is an air chamber in the delivery line,
and the automatic nozzle cannot be opened.
- Remove the automatic nozzle. Start the pump until it is primed, and the liquid is automatically
going out. Then install again the automatic nozzle.
The pump is working, but no fluid
comes out.
- problem in the suction line
- The bypass valve is opened
- retainer leak
- blocked outlet tube, nozzle or filter
- motor breakdown. The rotor must turn
clockwise, looking at the pump from its heading;
if not, return it for repairing.
- blade friction
- Check whether there are leaks in the suction line.
- Remove and check the valve.
- Tighten the cover or change the retainer.
- Check whether the outlet tube of the pump, the hose, the nozzle and the filter are blocked.
- Check the connection polarity.
- Check whether the blades and the grooves are worn out.
The pump makes noise, but it does
not work.
- dirt inside the pump, blade friction
- motor breakdown
- Clean the pump interior.
- Return it for repairing.
Low flow - filthy filter
- problem in the suction or delivery line
- The bypass is blocked.
- blade friction
- roller or blade wear
- dirt in the red adapter
- Disassemble and clean the filter.
- Check the suction line in order to see whether there is any leak or restriction; it can be too
narrow, too long or no hermetic
- Remove and check the bypass valve. Clean it.
- Check the blades and the slots in order to see whether these are worn out or not.
- Check whether the roller and the blades are worn out or not; replace them.
- Clean the inner sieve.
The pump runs slowly making
strange noise.
- wrong voltage
- motor breakdown
- Check the inlet voltage.
- Return it for repairing.
The motor is stopped or burns. - low voltage
- solid impurities in the pump inner
- Check the inlet voltage.
- Disassemble and clean the pump.
The motor heats up excessively. - high viscosity fluid pumping
- blocked filter
- narrow suction or delivery tube
- motor breakdown
- These fluids only can be pumped during a short period.
- Remove and clean the filter
- Replace it with an adequate tube
- Return it for repairing.
The motor does not start. - There is no supply system.
- motor breakdown
- not lined up / connected switch connection
- Check the battery state.
- Return it for repairing.
- Fit the switch connection / Connect it.
Liquid leak - connection joint in bad state
- mechanical seal in bad state
- Check all the connection joints.
- Replace the mechanical seal.
10. EU CONFORMITY DECLARATION
Manufacturer: TOT COMERCIAL SA - Partida Horta d'Amunt s/n - Apartado Correos nº 149 - 25600 BALAGUER (Lleida) SPAIN
STATES under its own responsibility the supplied product: SELF-SUCTION FUEL PUMP · Make: GESPASA
Model: AG-90 12 or 24 VDC
is in accordance with the following legislative and/or normative documents
- This Declaration will lose its validity in case that any modification is made without the explicit manufacturer's consent.
Balaguer, November 2017
Andreu Pané
DIRECTIVES Nr. and issued rules date
2006/42/UE: Safety of machinery EN 809:1999+A1:2010/AC:2010
EN-ISO 12100:2012