Johnson Pump SPX FLOW TopGear GS User manual

INSTRUCTION MANUAL
ORIGINAL INSTRUCTIONS
READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
TopGear GS, GP, GM, H, MAG, SRT
EXPLOSION PROTECTION ACCORDING TO 2014/34/EU (ATEX 114)
A.0500.601 – Atex IM-TG G/ H/ MAG/ SRT/ 08.00
EN (01/2021)

Declaration of conformity
according to EU directive 2014/34/EU (Atex 114)
This declaration of conformity is issued under the sole responsibility of the
manufacturer.
Manufacturer
SPX Flow Europe Limited - Belgium
Evenbroekveld 2-6
9420 Erpe-Mere
Belgium
Declares hereby that
the following product families, if ordered as Atex pump or Atex pump unit, are
meeting the requirements set forth in EU directive 2014/34/EU.
If the product is modified without our written permission, or if the safety
instructions in the instruction manuals are not being followed, this declaration
becomes invalid.
• Product families: TopGear GS, GP, GM, H, MAG and SRT
• Notified body: DEKRA Certification B.V.
Meander 1051
6825 MJ - Arnhem
The Netherlands
The notified body holds a copy of the technical construction files
• Standards: Applicable harmonised standards
EN ISO 80079-36:2016
EN ISO 80079-37:2016
• Marking: II 2 G Ex h IIC T1 … T5 Gb
II 2 D Ex h IIIC T450 °C … T100 °C Db
Erpe-Mere, 3 October 2019
Gerard Santema
General Manager

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Contents
Disclaimer .............................................................................................................4
1.0 General.........................................................................................................5
1.1 Symbol ................................................................................................................................5
1.2 Safety Information.............................................................................................................5
1.3 Responsibility for ATEX 114 certification – extend of delivery ..............................5
1.4 Marking................................................................................................................................6
1.5 Atex type designation examples....................................................................................7
1.6 Temperature classes and allowable temperatures....................................................7
1.6.1 II 2G allowable temperature TG GS, GP, GM, H and SRT................................. 7
1.6.2 II 2G allowable temperature TG MAG...................................................................... 8
1.6.3 II 2(G)D allowable temperature TG GS, GP, GM, H and SRT ............................ 8
1.6.4 II 2(G)D allowable temperature TG MAG ................................................................. 9
1.7 Responsibility.....................................................................................................................9
1.8 Operation............................................................................................................................9
1.9 Monitoring .......................................................................................................................10
1.9.1 Monitoring TG GS, GP, GM, H and SRT................................................................ 10
1.9.2 Monitoring TG MAG.....................................................................................................11
1.10 Residual risks.................................................................................................................. 12
1.10.1 List of residual risks for TG GS, GP, GM, H and SRT.........................................12
1.10.2 List of residual risks for TG MAG ..............................................................................13
2.0 Performance ............................................................................................. 14
3.0 Installation................................................................................................. 15
3.1 Checks ............................................................................................................................. 15
3.2 ATEX 114 certification.................................................................................................. 15
3.3 Working environment.................................................................................................... 15
3.4 Base plate ...................................................................................................................... 15
3.5 Drive, shaft coupling and protection guard ............................................................. 15
3.6 Direction of rotation....................................................................................................... 16
3.7 Piping................................................................................................................................ 16
3.8 Shaft sealing auxiliary connections............................................................................ 16
3.9 Check alignment ............................................................................................................ 16
4.0 Commissioning........................................................................................ 18
4.1 General ............................................................................................................................ 18
4.2 Precautions ..................................................................................................................... 18
5.0 Maintenance............................................................................................. 19
5.1 General ............................................................................................................................ 19
5.2 Ball bearing ..................................................................................................................... 19
5.3 Shaft seal......................................................................................................................... 19
5.4 Magnetic coupling......................................................................................................... 20

4A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
TopGear GS, GP, GM, H, MAG and SRT
Operating instructions concerning explosion
protection
Disclaimer
Considerable effort has been made to ensure that this manual is free of inaccuracies
and omissions. However, even though the manual contains up to date data at time of
going to press, due to constant improvements some of the data contained herein may
not exactly reflect the current model of the particular product described in this manual.
SPX reserves the right to change the construction and design of the products at any time
without being obliged to change previous models accordingly.
These instructions contain important and useful information on explosion
protection in accordance with EC directive 2014/34/EU (ATEX 114).
All relevant instructions about installation, operation and maintenance of the
pump and the pump unit can be found in the separate pump’s “Instruction
Manual”. These instructions should be adhered to at all times!
SPX Flow Europe Limited - Belgium
Evenbroekveld 2-6
9420 Erpe-Mere
Belgium
Tel. [phone]

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A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
1.0 General
1.1 Symbol
The following symbol is used to indicate special instructions concerning explosion
protection:
1.2 Safety Information
This manual covers the main issues concerning explosion protection and must be used
together with the general Instruction Manual for TopGear pumps, called hereafter ‘IM’ and
the manuals of other equipment such as gear and motor drives. For explosion protection
safety it is imperative that the pump set must be protected from all unauthorised operation
and unnecessary wear.
Explosive gas mixtures or concentrations of dust, in conjunction with hot, live and moving
parts on pump, gear and motor unit, can lead to severe or fatal personal injuries.
Installation, connection, start-up, maintenance and repair work may only be performed by
qualified personnel while taking in account:
• these specific instructions, together with all other instructions for the installed
equipment and installation;
• warning and information signs on the equipment;
• the specific regulations and requirements for the system in which the pump unit
will operate (current valid national and regional regulations).
1.3 Responsibility for ATEX 114 certification – extent of delivery
SPX will be held responsibile only for delivered materials and equipment selected
according to the operating conditions data, based on information supplied by the customer
or the end user and stated in the order confirmation. When in doubt contact your supplier.
In the event SPX delivers a pump with bare shaft, the explosion protection certification
marking on the pump nameplate refers exclusively to the pump part. All other assembled
equipment should have a minimum level of protection as required by the area classification
(zone) in which the equipment is installed. The complete unit must be certified separately
by the manufacturer and must have a separate nameplate supplied by the manufacturer.
In the event SPX delivers a complete unit, the explosion protection certification, and
marking on the nameplate attached to the base plate or to the pump frame, will refer to that
specific unit.

6A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
1.4 Marking
Name plate on the pump
1 Pump type: example: TG GP 23-65
2 Pump internals: example: G2 OO BG2 BG2 TC
3 Serial number: example: NNNN-xxxxxxx
(NNNN indicates the year of production)
4 Ex marking: Ex-symbol followed by Atex type designation – (see examples)
5 Certificate number: DEKRA 19ATEX0103
6 Environment temp.: To be specified if beyond the standard ATEX range -20°C / 40°C
Name plate on the unit (in case of delivery of complete unit from SPX)
1 Type: example: TG H 185-125
2 Code: example: 6.TG68A6-6786946
3 Serial number: example: NNNN-xxxxxxx
(NNNN indicates the year of production)
4 Ex marking: Ex-symbol followed by Atex type designation – (see examples)
5 Certificate number: DEKRA 19ATEX0103
6 Environment temp.: To be specified if beyond the standard ATEX range -20°C / +40°C

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1.5 Atex type designation examples
Example 1: II 2G Ex h IIC T3-T4 Gb
II 2G Marking according to Group II, Category 2, Gas (G) protection
Ex h Marking for non electrical Ex equipment. Type of protection „c”
(constructional safety)
IIC Gas group
T3-T4 Temperature class T3 to T4
Gb Equipment protection level
Example 2: II 2G Ex h IIC 240°C (T2) Gb
II 2G Marking according to Group II, Category 2, Gas (G) protection
Ex h Marking for non electrical Ex equipment. Type of protection „c”
(constructional safety)
IIC Gas group
240°C (T2) Maximum surface temperature of 240 degrees Celsius
Gb Equipment protection level
Example 3: II 2D Ex h IIIC T240°C Db
II 2D Marking according to Group II, Category 2, Dust (D) protection
Ex h Marking for non electrical Ex equipment. Type of protection „c”
(constructional safety)
IIIC Dust group
T240°C Maximum surface temperature of 240 degrees Celsius
Db Equipment protection level
Environment temperature should be between -20°C and +40°C, if not, the corresponding
environment temperature will be indicated on the nameplate.
1.6 Temperature classes and allowable temperatures
In normal operation the highest temperature on the surfaces of the pump should
correspond to the highest temperature of the pumped product, or the heating medium
in case the pump is heated by jackets. The maximum permissible temperature depends
on the temperature class (T4 to T1) or on Tmax to be complied with. The bearing bracket
surfaces must be freely exposed to the atmosphere to allow cooling.
1.6.1 II 2G allowable temperature TG GS, GP, GM, H and SRT
ISO EN 80076-36
Temperature class
Tmax
Pumped medium
temperature TA
Heating medium TA (if any) Bearing bracket
temperature (L3)
S-jacket T-jacket
T4 - 135°C ≤ 120°C ≤ 120°C ≤ 120°C ≤ 100°C
T3 - 200°C ≤ 180°C ≤ 180°C ≤ 180°C ≤ 120°C
T2 - 300°C ≤ 270°C *) – ≤ 270°C *) ≤ 160°C
T1 - 450°C ≤ 300°C *) – ≤ 300°C *) ≤ 180°C
(*) temperature to decrease according to material limits (see IM).
• When the temperature limits are reduced because of internal materials selection, the
maximum allowable surface temperature Tmax will be supplied instead of the temperature
class, the same way as in case of D, dust protection.
• For T5 (100°C) and T6 (85°C) classes contact your distributor.
• TG GS, GP, GM, can be used in a temperature range between -20ºC and +40ºC.
• TG H in stainless steel execution can be used in a temperature range between -40ºC
and +40ºC; materials other than stainless steel can be used in the temperature range
between -20ºC and +40ºC.

8A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
1.6.2 II 2G allowable temperature TG MAG
ISO EN 80076-36
Temperature class
Tmax
Pumped medium
temperature TA
Heating medium TA (if any) Separation can
temperature (L2)
Bearing bracket
temperature (L3)
S-jacket T-jacket
T4 - 135°C ≤ 100°C ≤ 100°C ≤ 100°C ≤ 120°C ≤ 100°C
T3 - 200°C ≤ 160°C ≤ 160°C ≤ 160°C ≤ 180°C ≤ 100°C
T2 - 300°C ≤ 250°C *) – ≤ 250°C *) ≤ 270°C ≤ 160°C **)
T1 - 450°C ≤ 260°C *) – ≤ 260°C *) ≤ 280°C ≤ 160°C **)
(*) temperature to decrease according to material limits (see IM).
(**) special bearing construction required, please contact SPX or your local distributor
• When the temperature limits are reduced because of internal materials selection, the
maximum allowable surface temperature Tmax will be supplied instead of the
temperature class, the same way as in case of D, dust protection.
• For T5 (100°C) and T6 (85°C) classes and if ambient temperature exceeds the range
-20°C / +40°C contact your distributor.
1.6.3 II 2(G)D allowable temperature TG GS, GP, GM, H and SRT
The maximum surface temperature (Tmax) is indicated on the name plate.
Tmax is determined as the lowest temperature derived from following equations:
• Tmax = temperature limits of selected internal materials (i.e. pump selection).
• Tmax = T5mm - 75°C (T5mm “ignition temperature of a dust layer of 5 mm thickness”)
• Tmax = 2/3 x T.CI (TCI “ignition temperature of a dust cloud”).
Remark:
T5mm and TCI are to be determined by the customer/user in case of dust (D) protection.
In case the ambient temperature exceeds the range of -20°C / +40°C contact your
distributor.
Maximum surface
temperature Pumped medium
temperature TA
Heating medium TA(if any) Bearing bracket
temperature (L3)
Tmax T.class *) S-jacket T-jacket
135°C (T4) ≤ 120°C ≤ 120°C ≤ 120°C ≤ 100°C
170°C (T3) ≤ 150°C ≤ 150°C ≤ 150°C ≤ 120°C
200°C (T3) ≤ 180°C ≤ 180°C ≤ 180°C ≤ 120°C
220°C (T2) ≤ 200°C – ≤ 200°C ≤ 160°C
240°C (T2) ≤ 220°C – ≤ 220°C ≤ 160°C
260°C (T2) ≤ 235°C – ≤ 235°C ≤ 160°C
280°C (T2) ≤ 250°C – ≤ 250°C ≤ 160°C
300°C (T2) ≤ 270°C – ≤ 270°C ≤ 180°C
330°C (T1) ≤ 300°C – ≤ 300°C ≤ 180°C
*) corresponding temperature class of Gas protection indicated on the nameplate between brackets
• TG GS, GP, GM, can be used in a temperature range between -20ºC and +40ºC.
• TG H in stainless steel execution can be used in a temperature range between -40ºC
and +40ºC; materials other than stainless steel can be used in the temperature range
between -20ºC and +40ºC.

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A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
1.6.4 II 2(G)D allowable temperature TG MAG
The maximum surface temperature (Tmax) is indicated on the name plate.
Tmax is determined as the lowest temperature derived from following equations:
• Tmax = temperature limits of selected internal materials (i.e. pump selection).
• Tmax = T5mm - 75°C (T5mm “ignition temperature of a dust layer of 5 mm thickness”)
• Tmax = 2/3 x T.CI (TCI “ignition temperature of a dust cloud”).
Remark:
T5mm and TCI are to be determined by the customer/user in case of dust (D) protection.
In case the ambient temperature exceeds the range of -20°C / +40°C contact your
distributor.
Maximum surface
temperature Pumped medium
temperature TA
Heating medium TA(if any) Separation can
temperature (L2)
Bearing bracket
temperature (L3)
Tmax T.class *) S-jacket T-jacket
135°C (T4) ≤ 100°C ≤ 100°C ≤ 100°C ≤ 120°C ≤ 100°C
170°C (T3) ≤ 130°C ≤ 130°C ≤ 130°C ≤ 150°C ≤ 100°C
200°C (T3) ≤ 160°C ≤ 160°C ≤ 160°C ≤ 180°C ≤ 100°C
220°C (T2) ≤ 180°C ≤ 180°C ≤ 180°C ≤ 200°C ≤ 100°C
240°C (T2) ≤ 200°C – ≤ 200°C ≤ 220°C ≤ 160°C **)
260°C (T2) ≤ 215°C – ≤ 215°C ≤ 235°C ≤ 160°C **)
280°C (T2) ≤ 230°C – ≤ 230°C ≤ 250°C ≤ 160°C **)
300°C (T2) ≤ 250°C – ≤ 250°C ≤ 270°C ≤ 160°C **)
330°C (T1) ≤ 260°C – ≤ 260°C ≤ 280°C ≤ 160°C **)
*) corresponding temperature class of Gas protection indicated on the nameplate between brackets
**) special bearing construction required, please contact SPX or your local distributor
1.7 Responsibility
It is the responsibility of the operator to ensure specified product temperatures are not
exceeded and to ensure regular inspections and maintenance for good operation of the
shaft seal, the bearings and the internal pump parts. If this cannot be ensured by the
operator, suitable monitoring facilities must be provided, see paragraph 1.9.
1.8 Operation
• For explosion protection it is imperative that the gear pump will not run dry. The pump
internal, including shaft seal chamber or magnetic coupling and auxiliary systems, must
be filled completely with, and lubricated by the product to be handled during operation
(including start-up, priming and shut-off).
• In case of self priming the pump must be filled with liquid and the appropriate shaft
sealing (quenched shaft seal) must be selected and controlled with regard to the
quench liquid.
• The pump must never be operated continuously with the safety relief valve opened. The
relief valve is designed as a safety device in case of over-pressure and may not be used
for flow control.
• When flow control is performed by by-passing the return liquid, the liquid must return
to the suction tank and not directly to the suction port of the pump, in which case heat
accumulation in the pump could create a dangerous situation.
• The pump must never be operated with the shutoff valves in the suction or discharge
lines closed.

10 A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
1.9 Monitoring
If the good functioning and maximum allowable surface temperatures cannot be ensured
by regular inspection by the operator, suitable monitoring devices must be provided.
1.9.1 Monitoring TG GS, GP, GM, H and SRT
Surface temperature monitoring is always of extreme importance in the following areas,
see figure 1:
• Surface temperature of the pump casing at the front cover (L1).
• Surface temperature at the gland end, gland packing or mechanical seal (L2). In case
of a quenched or double mechanical seal, monitoring can be done by checking the
quench fluid, see paragraph 5.3. Use of a quenched single mechanical seal or a double
mechanical seal is recommended when there is a risk of dry running or lubrication failure
of the mechanical seal such as in case of self priming.
• Surface temperature at the ball bearing area of the bearing bracket (L3).
The maximum allowable surface temperature of L1 and L2 refers to TA.
The maximum allowable surface temperature of L3 refers to the maximum temperature of
the bearing bracket.
Additional vibration monitoring can be useful to detect excessive vibrations, indicating
premature failure of ball bearing or internal wear in the following areas:
• internal areas at the pump front (V1).
• ball bearing at bearing bracket (V2).
Fig 1 – Indication of monitoring possibilities and advised locations (optionally)

11
L2
V1
V2
L1
L3
A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
1.9.2 Monitoring TG MAG
Surface temperature monitoring is always of extreme importance in the following areas, see
figure 2:
When operating TG MAG pumps in potentially explosive areas the temperature
on the separation can (L2) must be monitored permanently (see IM “Check
temperature censor on can”)
Furthermore we recommend to monitore the surface temperatures on the bearing bracket
(L3) and on the front cover (L1) if the good functioning and maximum allowable surface
temperatures cannot be ensured by regular inspection by the operator.
The temperature monitoring equipment must fulfill the requirements of ATEX 114.
Fig 2 – Indication of monitoring possibilities and advised locations
L1 – Surface temperature of the pump casing at the front cover
L2 – Surface temperature on the separation can
L3 – Surface temperature at the ball bearing area of the bearing bracket
The maximum allowable surface temperature of L1 and L2 refers to TA.
The maximum allowable surface temperature of L3 refers to the maxium temperature
of the bearing bracket.
Additional vibration monitoring can be useful to detect exessive vibrations, indicating
premature failure of the ball bearings or internal wear in follwing areas:
V1 – internal areas at the pump front
V2 – ball bearings at the bearing bracket
Furthermore we recommend to monitor the power consumption of the drive motor to
detect slipping of the magnetic coupling in case of failure of the pump or if the break-away
torque of the magnetic coupling is exceeded due to changing operating parameters.

12 A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
1.10 Residual risks
List of residual risks (after risk analysis according to EN ISO 80079-36).
1.10.1 List of residual risks for TG GS, GP, GM, H and SRT
Potential ignition source Measures applied to prevent the source
becoming effective
Ignition
protection used
Normal
operation
Expected
malfunction
Rare
malfunction
Exposed to
hot surfaces
of pump
casing
The customer has to ensure that the
temperature of the pump liquid does not
exceed the permissible temperature.
EN ISO 80079-36
§6.2
Additionally, the operator has to ensure
the operating limits for speed, flow and
pressure are not exceeded.
User Instructions
Excessive heat
accumulation
The customer has to ensure a minimum
flow through the pump to evacuate
generated heat or has to monitor the pump
casing temperature.
EN ISO 80079-36
§6.2
User Instructions
Exposed to
hot surface
of bearing
bracket
The bearing bracket must be freely
exposed to the atmosphere to allow
cooling of the surfaces. The operator
must regularly check the tmperature for
good operation and the temperature of
the bearing externals. The grease selected
must be suitable for the ambient and
working conditions.
EN ISO 80079-36
§6.2
EN ISO 80079-37
§5.7
User Instructions
Internal high
temperatures
and/or sparks
Dry running is excluded from normal
operation.
EN ISO 80079-37
§5.6 & §5.7
The operator has to ensure that the pump
runs with the shaft sealing chamber filled
with the pumped liquid during start, normal
operation and shut-off.
User Instructions
Excessive
heat at
shaft sealing
-packed gland type
-triple lip-seal
The operator has to ensure good
lubrication of the packing rings and must
regularly inspect the surface temperature
and function. Lip-seal running surfaces
must be greased in order to prevent any
dry-run. The temperature of the shaft bush
must be monitored.
EN ISO 80079-37
§5.3
User Instructions
Excessive
heat at
shaft sealing,
mechanical
seal type
The customer has to follow the specific
instructions for the mechanical seal type
in the instruction manual or/and separate
certificate instructions if present.
Single and double mechanical seals with
quench are to be protected by controlling
the quench liquid.
EN ISO 80079-37
§5.3
User Instructions
Mechanical
sparks caused by
contact between
rotating shaft
and stationary
seal gland
Shaft gland materials are made from
stainless steel to minImize spark risks
(cold sparks).
EN ISO 80079-36
Pump may not run dry. Excessive wear of
shaft bearings and internals must be
prevented through adequate maintenance.
User Instructions
Electrostatic
discharges
Customer should provide earth
connections or equipotential bridges in
case of indirect risks.
EN ISO 80079-36
User Instructions
Remarks:
• For category 2, the risks at “normal operation” and those at “expected malfunction” have
to be controlled.
• For category 3, the risks at “normal operation” have to be controlled.

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1.10.2 List of residual risks for TG MAG
Potential ignition source Measures applied to prevent the source
becoming effective
Ignition
protection used
Normal
operation
Expected
malfunction
Rare
malfunction
Exposed to
hot surfaces
of pump
casing
and jackets
Customer has to ensure that the
temperature of the pump and heating liquid
do not exceed the allowable lImits.
EN ISO 80079-36
§6.2
Additionally, the operator has to ensure
the operating limits for speed, flow and
pressure are not exceeded.
User Instructions (IM)
Exposed to
hot surfaces
at the outside
surface of the
can (i.e. inside
the bearing
backet)
Customer has to ensure that the pump is
properly filled to ensure good circulation
over the internals of the mag-drive (i.e.
forced circulation by means of the built-in
auxiliary pump). The temperature of the can
must be monitored.
EN ISO 80079-36
§6.2
User Instructions
Excessive heat
accumulation
Customer has to ensure a minimum flow
through the pump.
EN ISO 80079-36
§6.2
User Instructions
Exposed to
hot surface
temperature
of bearing
bracket
Bearing bracket must be freely exposed
to the atmosphere to allow cooling of the
surfaces. Operator must regularly check
temperature and good operation of external
bearing.
EN ISO 80079-36
§6.2
EN ISO 80079-37
§5.6 & §5.7
User Instructions
Internal high
temperatures
and/or sparks
Dry running and self-priming is excluded
from normal operation.
EN ISO 80079-37
§5.6 & §5.7
Operator has to ensure to run the pump
and magnetic coupling chamber
completely filled with the pumped liquid
during start, normal operation and shut-off.
User Instructions
Mechanical sparks
by rubbing contact
of rotating shaft
with stationary
pump and bracket
components
In the event of failure of the bracket ball
bearings, a safety device made of brass
(an incendive material) is provided to avoid
sparkings at the inside of the bracket.
Pump may not run dry. Excessive wear
of shaft bearings and internals must be
prevented by adequate maintenance
procedures.
EN ISO 80079-37
§5.6 & §5.7
User Instructions
Electro-static
discharges
Customer should provide earth
connections or equipotential bridges in
case of indirect risks
EN ISO 80079-36
User Instructions
Remarks:
• For category 2, the risks at “normal operation” and those at “expected malfunction” have
to be controlled.
• For category 3, the risks at “normal operation” have to be controlled.

14 A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
2.0 Performance
• Operation of the pump outside its specified operating range and unauthorised modes
of operation may result in the specified temperature limits being exceeded. See IM for
temperature limits.
• In order to remove the heat generated by hydraulic and mechanical friction inside the
pump, it must be assured that there is always a sufficient minimum flow through the
pump. If this cannot be ensured under all possible operating conditions or because
the conditions might change over time due to wear, we advise to foresee a suitable
temperature monitoring device. (See chapter 1.9)
Note: Internally produced friction heat depends of pump speed and of the properties of
the pumped media: viscosity, specific heat, lubricating properties etc.
It is the responsibility of the operator to ensure the pump operates below the allowable
temperature limits as indicated above.
Dangerous situations can occur in the following events and should be
prevented and/or excluded from normal operation and expected operation
(group II-category 2) by adequate operation, supervising and maintenance:
• Running the pump without liquid will produce extra heat in the sleeve bearings and on
other friction sensitive parts. Temperature can rise above allowable limits as a result
of insufficient lubrication and/or lack of heat expulsion through liquid flow. Insufficient
lubrication can cause preliminary pump wear and failure.
• Heat accumulation can be caused by direct return of liquid from discharge side to
suction side of the pump.
The pump temperature could increase above allowable limit when the pump is operating
with the relief valve opened for a length of time or during flow control when by-passing
the medium to the suction side of the pump.
• Increase of internal slip by internal wear in such a way that the output flow rate will
become insufficient to evacuate the internal friction heat. Temperature could increase
above allowable limit.
• Monitoring of the surface temperatures of the pump casing at indicated areas (see fig.
1 and 2) and controlling or monitoring the quench medium in case of a quenched shaft
seal ensures sufficient protection against potentially dangerous situations.

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A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
3.0 Installation
3.1 Checks
Before installation, the equipment must be checked.
• Ensure the equipment data (as indicated on nameplate, documentation etc.) corres-
ponds to the explosive atmosphere zone, category and system requirements.
• Possible damage: the installed equipment must be undamaged and must have been
properly stored before installation (for maximum 3 years). In case of any doubt or any
damage found contact your supplier.
• Ensure that heated air from other units will not affect the environment of the pump unit;
environment air should not exceed a temperature of 40°C.
3.2 ATEX 114 certification
All additional equipment such as shaft couplings, guards, drive, motor, auxiliary equipment
etc. must be part of the ATEX 114 certification or must be certified separately for the
appropriate temperature category. The assembled pump unit must have a separate
certification and a separate nameplate supplied by the pump unit manufacturer.
3.3 Working environment
• The pump and unit must be accessible for maintenance and inspection during operation,
see IM.
• Unobstructed air supply to the pump, drive and motor should be ensured.
• An electric motor should have a free inlet for cooling air of at least 1/4 of its motor
diameter.
• The pump should be mounted horizontally, bearing entirely and squarely on the pump
feet. Deviation from the prescribed installation will influence draining, filling, venting and
good functioning of the shaft seal.
• The bearing bracket must be exposed to the atmosphere to allow cooling and to
ensure good functioning and lubrication of the grease lubricated ball bearing.
Insufficient cooling could lead to unacceptable surface temperatures of the bearing
bracket, to insufficient lubrication and to premature ball bearing failure. If proper cooling
cannot be maintained at all times, monitoring of the surface temperature of the bearing
bracket should be ensured.
• Proper separate earthing facilities should be provided close to the pump unit baseplate.
• In hazardous areas the electrical connection has to be EN 60079-14 compliant.
• The execution of the temperature monitoring equipment must fulfill the requirements
of ATEX 114.
3.4 Base plate
• The baseplate always must be provided with an earthing boss.
• Ensure the earth circuit is properly connected to the baseplate.
3.5 Drive, shaft coupling and protection guard
• The starting torque of an internal gear pump is almost identical to the nominal torque
during operation. The starting torque of the motor must be sufficiently high: the motor
power is selected 20% to 25% higher than the absorbed power of the pump.
If the starting torque is too low it will take longer to start the pump and the motor
temperature could increase to an unacceptable level. When using a variable speed
motor the cooling device of the motor must operate independently from the motor speed
or must be guaranteed to be sufficient at its lowest speed.

16 A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
• Follow the separate instructions for gear and motor drive and for explosion protected
shaft couplings.
• When using a belt drive, ensure the belts have sufficient electrical conductivity to avoid
electrostatic loads. Use only belts with electrical leakage resistance lower than 109Ohm
and avoid using aluminium or light metal pulleys containing more than 7.5% magnesium.
• Certification of the protection guard must be included in the explosion protection
certificate of the drive or pump unit or should be certified separately by the manufacturer
or supplier of the guard. The coupling guard must be made of non-sparking materials.
Never use light metals containing more than 7.5% magnesium! In case of
aluminium coupling parts or belt-pulleys, the coupling guard must be made of brass.
• For magnetically driven pumps, the size of the magnetic coupling (break-away torque)
must be selected in function of the start-up torque of the electric motor to avoid that the
magnetic coupling slips during start-up. This could lead to unacceptable high surface
temperatures and/or failure of the magnetic coupling and/or bearings.
3.6 Direction of rotation
• Gear pumps can run in both rotation directions: ensure that the relief valve or top cover
is set to the right direction of rotation, see IM.
• The pump units’ direction of rotation should be tested with the pump filled only, to avoid
dry running.
• If necessary the direction of rotation of the motor should be tested independently from
the pump i.e. not coupled to the pump. Remember to secure or remove the shaft key in
case of separate testing.
Always align the coupling after having disassembled it and refit the coupling
guard!
• TG MAG pumps are assembled for only one specific direction of rotation, due to the
internal cooling system of the magnetic coupling. The direction of rotation is indicated
on the name plate and with an arrow-plate on the top cover or the safey relief valve.
The last digit of the pump type description on the nameplate, (2) pump internals, is
indicating the direction of rotation:
R = clockwise seen from the shaft end
L = counter-clockwise seen from the shaft end
3.7 Piping
The suction and discharge lines should be designed properly for the required per-
formance conditions and should be executed accordingly (see IM). Non compliance to the
working conditions of the pump unit can cause severe problems such as NPSH-problems,
vapour lock, excessive vibrations and premature pump failure. Lines should be checked on
dimensions and tightness under pressure and should be internally cleaned and be free of
welding and foreign particles before they are connected to the pump.
3.8 Shaft sealing auxiliary connections
The gear pumps allow the application of several types of shaft seals. In order to ensure
proper functioning, venting and lubrication of the shaft seal a number of connections are
available which will enable liquid circulation or flushing. See IM for more information on the
possibilities and connections.
3.9 Check alignment
After installation the alignment of the pump shaft and drive shaft must be checked,
preferably with the pump and the pipes completely filled with liquid, and must be
corrected if necessary.

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18 A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
4.0 Commissioning
4.1 General
Take note that the TopGear pump is a Positive Displacement pump and procedures
may often differ from procedures commonly used for centrifugal pumps. Follow the
instructions and checklist given in the IM and the separate instructions for gear and motor
drives.
Ensure that all the shut-off valves are fully opened and the strainers are
unclogged before starting up the pump.
4.2 Precautions
For explosion protection the following precautions are of importance:
• Ensure that the area around the pump and the pump unit is clean.
• Ensure that the suction line si fitted securely and tight and is clean. Welding particles
should be removed in advance.
• The pump, the shaft sealing area or magnetic coupling and the auxiliary equipment must
be vented and filled with the product to be pumped before any operation.
• In case of self priming dry running of the pump must be avoided and an appropriate
quenched shaft seal must be provided to prevent dry running of the shaft seal.
• Determine the direction of rotation with the motor disconnected from the pump or
ensure that the pump is filled up and vented before start-up.
• Ensure the shutoff valves in the suction and discharge lines are opened at start-up.
• In case the pumped liquid needs to be heated, ensure the pump, shaft sealing area and
the product to be pumped are sufficiently preheated before start-up.
• Shut down the pump immediately in the event of irregular operating modes or mal-
function.
• Shut down the pump in case the flow drops or the pump pressure changes ab-
normally (i.e. lower or higher pressure). A flow decrease or pressure change is often
a sign of malfunction, a clogged strainer or internal wear. The cause must be found and
repaired before the pump should be started again, see Trouble Shooting list in the IM.

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5.0 Maintenance
5.1 General
• Pumps certified for ‘Explosion protection’ need maintenance and precaution to
prevent risks of ignition due to malfunction and unacceptable wear.
• Follow the Maintenance Instructions given in the Instruction Manual (IM). Follow the
separate instructions for gear and motor drive as well.
• A decrease of flow rate (or in case the pump does not supply the required pressure)
is an indication of a possible malfunction or a sign of internal pump wear and requires
maintenance or repairs. Other indications of internal pump wear is excessive noise
during operating, vibrations or shaft seal leakage.
• Use anti-sparkling tools when working on the pump or pump unit in an potentially
explosive atmosphere.
!Only use a damp cloth for cleaning all surfaces.
5.2 Ball bearing
• The bearing bracket and external bearing assembly must be checked regularly for
correct functioning.
• Excessive noise, vibrations and heat build-up are an indication of malfunction and
premature failure of a ball bearing or its lubrication.
• It is recommended to check the bearing(s) on vibrations by monitoring it.
TG GS, GP, GM, H and SRT
• Relubrication of the ball bearing(s): see IM.
• The axial clearance of the running internals is achieved by adjustment of the bearing
assembly. For information about axial clearance adjustment, see IM.
TG MAG
• The ball bearings in the bearing bracket are sealed and filled with grease for life-time.
and do not require re-lubrication.
• Ball bearings must be lubricated with heat-resistant grease when pumping liquids over
180°C.
5.3 Shaft seal
• The correct function and lubrication of the shaft seal must be checked regularly and dry
running must be prevented. Gland packing must have a small, visible leakage.
• Several types of connections can be made to ensure proper liquid circulation, venting
and lubrication. For more information see IM.
• For single shaft seals, such as gland packing and single mechanical seal, the operator
must ensure that the temperature of the seal area surfaces will not exceed the allowable
temperature. If this cannot be ensured by the operator, monitoring devices should be
installed.
• Quenched mechanical seals (single or double) have to be protected by controlling the
quench liquid.

20 A.0500.601 – Atex IM -TG G/H/MAG/SRT/08.00 EN (01/2021)
For a non-pressurised quench:
• Check the level in the supply reservoir;
• Check the temperature of the quench liquid;
• Check the condition of the quench liquid by inspection: change the quench liquid in
case it is heavily contaminated with leaking fluid.
Note: Frequent contamination is an indication of an unacceptable shaft seal leakage,
which should be repaired.
For a pressurised quench:
• Check the level in the supply reservoir;
• Check the temperature of the quench liquid;
• Check the pressure.
Take note: the quench liquid should always be pressurised while the pump is
running, including at start and at shut-off period.
• Check the condition of the quench liquid: change the quench liquid in case it is
contaminated with leaking fluid.
Note: Contamination of the liquid is an indication of irregular or faulty operation and
should be inspected. E.g. the mechanical seal at medium side may be leaking or may be
opened due to insufficient counter pressure of the quench liquid.
5.4 Magnetic coupling
• TG MAG pumps used in explosive environment must be equipped with a temperature
sensor on the separation can. (Position L2 see fig. 2).
• The temperature sensor must be connected and pre-set before the pump is started after
maintenance. Temperature settings of the sensor see under 1.6.2 and 1.6.4.
• Apply heat-conducting paste to the tip of the sensor in order to secure good heat
transmission