Johnson Pump TG GS2-25 User manual

A.0500.501 – IM-TG GS/05.01 EN (03/2013)
TopGear GS
INTERNAL GEAR PUMPS
ORIGINAL INSTRUCTIONS
READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
INSTRUCTION MANUAL

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
TG GS86-100
TG GS185-125
whether delivered without drive or delivered as an assembly with drive,
are in conformity with the relevant provisions of the Machinery Directive
2006/42/EC, Annex I.
Manufacturer Declaration
Machinery Directive 2006/42/EC, Annex IIB
The partly completed pump (Back-Pull-Out unit), member of the product
family TopGear GS-range gear pumps, is meant to be incorporated
into the specified pump (unit) and may only be put into use after the
complete machine, of which the pump under consideration forms part,
has been declared to comply with the provisions of the Directive.
Erpe-Mere, 29 December 2009
Frédéric Mus
General Manager

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A.0500.501 – IM-TGGS/05.01 EN (03/2013)
Contents
1.0 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 ......................................................................................................... 9
1.3.2.1 Pump unit handling.......................................................................................9
1.3.2.2 Installation.......................................................................................................9
1.3.2.3 Before commissioning the pump unit....................................................10
1.3.2.4 Disassembly/assembly of the coupling guard..................................... 10
1.3.2.5 Name plate – CE Declaration of Conformity....................................... 10
1.4 Technical conventions..................................................................................... 11
2.0 Pump description ...........................................................................................12
2.1 Type designation .............................................................................................. 12
3.0 General technical information......................................................................14
3.1 Pump standard parts.......................................................................................14
3.2 Operating principle.......................................................................................... 14
3.2.1 Self-priming operation...................................................................................15
3.2.2 Safety relief valve – Working principle ......................................................15
3.3 Sound .................................................................................................................15
3.4 General performance ......................................................................................15
3.5 Main characteristics .......................................................................................16
3.6 Pressure .............................................................................................................17
3.7 Sound level ....................................................................................................... 17
3.7.1 Sound level of a pump without drive..........................................................17
3.7.2 The sound level of the pump unit................................................................18
3.7.3 Influences .........................................................................................................18
3.8 Maximum temperature.....................................................................................18
3.9 Jacket options ...................................................................................................18
3.10 Internals.............................................................................................................. 19
3.10.1 Bush materials.................................................................................................19
3.10.2 Maximum temperature of internals..............................................................19
3.10.3 Operation under hydrodynamic lubrication conditions..........................19
3.10.4 Maximum torque of pump shaft and rotor material combination..........20
3.11 Mass moment of inertia...................................................................................20
3.12 Axial and radial clearances.............................................................................20
3.13 Extra clearances ...............................................................................................21
3.14 Play between gear teeth.................................................................................22
3.15 Maximum size of solid particles ....................................................................22
3.16 Shaft sealing ....................................................................................................22

4A.0500.501 – IM-TGGS/05.01 EN (03/2013)
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................................................................................ 27
3.17.4.3 Double safety relief valve.......................................................................... 27
3.18 Installation.......................................................................................................... 28
3.18.1 General .............................................................................................................28
3.18.2 Location ............................................................................................................28
3.18.2.1 Short suction line ....................................................................................... 28
3.18.2.2 Accessibility ................................................................................................28
3.18.2.3 Outdoor installation ................................................................................... 28
3.18.2.4 Indoor installation.......................................................................................29
3.18.2.5 Stability......................................................................................................... 29
3.18.3 Drives.................................................................................................................29
3.18.3.1 Starting torque............................................................................................29
3.18.3.2 Radial load on shaft end...........................................................................30
3.18.4 Shaft rotation ...................................................................................................30
3.18.5 Double safety relief valve ..............................................................................31
3.18.6 Suction and discharge pipes .......................................................................31
3.18.6.1 Forces and moments.................................................................................31
3.18.6.2 Piping............................................................................................................ 32
3.18.6.3 Isolating valves............................................................................................ 33
3.18.6.4 Strainer.........................................................................................................33
3.18.7 Secondary piping............................................................................................33
3.18.7.1 Drain lines .................................................................................................... 33
3.18.7.2 Heating jackets.......................................................................................... 34
3.18.8 Flush/quench media.......................................................................................34
3.18.9 Guidelines for assembly................................................................................35
3.18.9.1 Transport of pump unit.............................................................................. 35
3.18.9.2 Foundation pump unit ............................................................................... 35
3.18.9.3 Variators, Gear box, Gear motors, Motors............................................35
3.18.9.4 Electric motor drive.................................................................................... 35
3.18.9.5 Combustion engines ................................................................................. 36
3.18.9.6 Shaft coupling............................................................................................. 36
3.18.9.7 Guarding of moving parts ........................................................................ 36
3.19 Instructions for start-up ..................................................................................37
3.19.1 General .............................................................................................................37
3.19.2 Cleaning the pump.........................................................................................37
3.19.2.1 Cleaning suction line................................................................................. 37
3.19.3 Venting and filling............................................................................................37
3.19.4 Checklist – Initial start-up ............................................................................38
3.19.5 Start-up.............................................................................................................39
3.19.6 Shut-down........................................................................................................39
3.19.7 Abnormal operation........................................................................................39
3.20 Trouble shooting............................................................................................... 40
3.20.1 Instructions for re-using and disposal .......................................................42
3.20.1.1 Re-use ..........................................................................................................42
3.20.1.2 Disposal ....................................................................................................... 42

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A.0500.501 – IM-TGGS/05.01 EN (03/2013)
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 ........................................................................................ 44
3.21.2.7 Electrical installation.................................................................................. 44
3.21.2.8 Draining of fluid ......................................................................................... 44
3.21.2.9 Fluid circuits ................................................................................................ 44
3.21.3 Specific components.....................................................................................45
3.21.3.1 Nuts and bolts ............................................................................................45
3.21.3.2 Plastic or rubber components.................................................................45
3.21.3.3 Flat gaskets ................................................................................................. 45
3.21.3.4 Filter or suction strainer............................................................................ 45
3.21.3.5 Anti-friction bearings................................................................................. 45
3.21.3.6 Sleeve bearings.......................................................................................... 46
3.21.3.7 Shaft seal – Mechanical seal .................................................................. 46
3.21.4 Front pull-out ...................................................................................................47
3.21.5 Back pull-out....................................................................................................47
3.21.6 Clearance adjustment ..................................................................................47
3.21.7 Designation of threaded connections........................................................48
3.21.7.1 Threaded connection Rp (example Rp 1/2) ........................................ 48
3.21.7.2 Threaded connection G (example G 1/2)............................................ 48
4.0 Instructions for assembly and disassembly..............................................49
4.1 General...............................................................................................................49
4.2 Tools.................................................................................................................... 49
4.3 Preparation ........................................................................................................49
4.4 After disassembly.............................................................................................49
4.5 Anti-friction bearings....................................................................................... 50
4.5.1 General .............................................................................................................50
4.5.2 TG GS2-25, TG GS3-32 and TG GS6-40 disassembly.....................50
4.5.3 TG GS2-25, TG GS3-32 and TG GS6-40 assembly ..........................50
4.5.4 TG GS15-50 to TG GS185-125 disassembly.......................................51
4.5.5 TG GS15-50 to TG GS185-125 assembly ............................................51
4.6 Mechanical seal................................................................................................ 52
4.6.1 General .............................................................................................................52
4.6.2 Preparation.......................................................................................................52
4.6.3 Special tools ....................................................................................................52
4.6.4 General instructions during assembly .....................................................52
4.6.5 Assembly of the rotating part ......................................................................52
4.6.6 Assembly of the stationary seat .................................................................53
4.7 Pumps.................................................................................................................53
4.7.1 General .............................................................................................................53
4.7.2 TG GS2-25/TG GS3-32/TG GS6-40 ....................................................53
4.7.3 TG GS15-50/TG GS23-65 .......................................................................54
4.7.4 TG GS58-80/ TG GS86-100/ TG GS 185-125 ..................................55
4.8 Relief valve.........................................................................................................56
4.8.1 Disassembly ....................................................................................................56
4.8.2 Assembly .........................................................................................................56

6A.0500.501 – IM-TGGS/05.01 EN (03/2013)
5.0 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 ...............................................................60
5.2.1 Hydraulic part..............................................................................................................61
5.2.2 Bearing bracket..........................................................................................................61
5.2.3 Jacket..............................................................................................................................62
5.2.4 Single mechanical seal ...........................................................................................62
6.0 Dimensional drawings ...................................................................................63
6.1 Standard pump.................................................................................................63
6.1.1 TG GS2-25 to TG GS6-40 ..................................................................... 63
6.1.2 TG GS15-50 to TG GS185-125..................................................................64
6.2 Flange connections .........................................................................................65
6.2.1 TG GS2-25 to TG GS6-40.........................................................................65
6.2.2 TG GS15-50 to TG GS185-125 .............................................................65
6.3 Jackets (S) on pump cover and thread connection ................................. 66
6.3.1 TG GS2-25 to TG GS6-40.........................................................................66
6.3.2 TG GS 15-50 to TG GS185-125 .............................................................66
6.4 Safety relief valves................................................................................................................. 67
6.4.1 Single safety relief valve................................................................................67
6.4.2 Double safety relief valve ..............................................................................67
6.4.3 Heated safety relief valve..............................................................................68
6.5 Bracket support................................................................................................69
6.6 Weights – Mass ...............................................................................................69

7
SPX Flow Technology Belgium NV
Evenbroekveld 2-6, BE-9420 Erpe-Mere
www.johnson-pump.com / www.spx.com
A.0500.501 – IM-TGGS/05.01 EN (03/2013)
1.0 Introduction
1.1 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.
Liquids not suitable for the pump can cause damages to the pump unit, with a risk of personal injury.
1.2 Reception, handling and storage
1.2.1 Reception
Remove all packing materials immediately after delivery. Check the consignment for damage
immediately on arrival and make sure that the name plate/type designation is in accordance with the
packing slip and your order.
In case of damage and/or missing parts, a report
should be drawn up and presented to
the carrier at once. Notify your local supplier.
All pumps have the serial number stamped
on a nameplate.
This number should be stated in all correspondence
with your local supplier.
The first digits of the serialnumber indicate
the year of production.
1.2.2 Handling
Check the mass (weight) of the pump unit. All parts weighing more than 20 kg must be lifted using
lifting slings and suitable lifting devices, e.g. overhead crane or industrial truck. See section 6.6
Weights – Mass.
Never lift the pump unit with only two fastening
points. Incorrect lift can cause personal injury
and/or damage to the pump unit.
Always use two or more lifting slings. Make sure
they are secured in such a way as to prevent
them from slipping. The pump unit should be in a
straight fashion.
1.2.3 Storage
If the pump is not commissioned immediately, the shaft should be turned a full turn once every week.
This ensures a proper distribution of the conservating oil.

8A.0500.501 – IM-TGGS/05.01 EN (03/2013)
1.3 Safety
1.3.1 General
Important!
The pump must not be used for other purposes than recommended and quoted for without
consulting your local supplier.
A pump must always be installed and used in accordance with existing national and local sanitary
and safety regulations and laws.
When ATEX pump/pump unit is supplied, the separate ATEX manual must be considered
• Alwayswearsuitablesafetyclothingwhenhandlingthepump.
• Anchorthepumpproperlybeforestart-uptoavoidpersonalinjuryand/ordamagetothepump
unit.
• Installshut-offvalvesonbothsidesofthepumptobeabletoshutofftheinletandoutletbefore
service and maintenance. Check to see that the pump can be drained without injuring anyone
and without contaminating the environment or nearby equipment.
• Makesurethatallmovablepartsareproperlycoveredtoavoidpersonalinjury.
• Allelectricalinstallationworkmustbecarriedoutbyauthorizedpersonnelinaccordancewith
EN60204-1 and/or local regulations. Install a lockable circuit breaker to avoid inadvertent
starting. Protect the motor and other electrical equipment from overloads with suitable
equipment. The electric motors must be supplied with ample cooling air.
In environments where there is risk of explosion, motors classified as explosion-safe must be
used, along with special safety devices. Check with the governmental agency responsible for
such precautions.
• Improperinstallationcancausefatalinjuries.
• Dust,liquidsandgasesthatcancauseoverheating,shortcircuits,corrosiondamageandre
must be kept away from motors and other exposed equipment.
• Ifthepumphandlesliquidshazardousforpersonorenvironment,somesortofcontainermust
be installed into which leakage can be led. All (possible) leakage should be collected to avoid
contamination of the environment.
• Keeparrowsandothersignsvisibleonthepump.
• Ifthesurfacetemperatureofthesystemorpartsofthesystemexceeds60°C,theseareasmust
be marked with warning text reading ”Hot surface” to avoid burns.
• Thepumpunitmustnotbeexposedtorapidtemperaturechangesoftheliquidwithoutprior
pre-heating/pre-cooling. Big temperature changes can cause crack formation or explosion,
which in turn can entail severe personal injuries.
• Thepumpmustnotoperateabovestatedperformance.Seesection3.5Maincharacteristics.
• Beforeinterveninginthepump/system,thepowermustbeshutoffandthestartingdevicebe
locked. When intervening in the pump unit, follow the instructions for disassembly/assembly,
chapter 4.0. If the instructions are not followed, the pump or parts of the pump can be damaged.
It will also invalidate the warranty.
• Gearpumpsmayneverruncompletelydry.Dryrunningproducesheatandcancausedamageto
internal parts such as bush bearings and shaft seal. When dry running is required, the pump has
e.g. to be run a short time with liquid supply.
Note! A small quantity of liquid should remain in the pump to ensure lubrication of internal parts.
If there is a risk for dry running for a longer period, install a suitable dry running protection.
Consult your local supplier.
• Ifthepumpdoesnotfunctionsatisfactorily,contactyourlocalsupplier.

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A.0500.501 – IM-TGGS/05.01 EN (03/2013)
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 lift.
NB! Always use two lifting slings.
If there are lifting rings on both
the pump and the motor the slings
may be fastened to these.
NB! Always use two lifting slings.
Warning
Never lift the pump unit with
only one fastening point.
Incorrect lifts can result in
personal injury and/or damage
to the unit.
1.3.2.2 Installation
All pump units should be equipped with a locking safety switch to prevent accidental start during
installation, maintenance or other work on the unit.
Warning
The safety switch must be turned to off and locked before any work is carried out on the pump unit.
Accidental start can cause serious personal injury.
The pump unit must be mounted on a level surface and either be bolted to the foundation or be fitted
with rubber-clad feet.
The pipe connections to the pump must be stress-free mounted, securely fastened to the pump and
well supported. Incorrectly fitted pipe can damage the pump and the system.
Warning
Electric motors must be installed by authorized personnel in accordance with EN60204-1. Faulty
electrical installation can cause the pump unit and system to be electrified, which can lead to fatal
injuries.
Electric motors must be supplied with adequate cooling ventilation. Electric motors must not be
enclosed in airtight cabinets, hoods etc.
Dust, liquids and gases which can cause overheating and fire must be diverted away from the
motor.
Warning
Pump units to be installed in potentially explosive environments must be fitted with an Ex-class
(explosion safe) motor. Sparks caused by static electricity can give shocks and ignite explosions.
Make sure that the pump and system are properly grounded. Check with the proper authorities
for the existing regulations. A faulty installation can lead to fatal injuries.

10
SPX Flow Technology
Belgium NV
Evenbroekveld 2-6
BE-9420 Erpe-Mere
www.johnson-pump.com / www.spx.com
A.0500.501 – IM-TGGS/05.01 EN (03/2013)
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. For safe disassembly of the coupling guard see
below: Disassembly/assembly of the coupling guard.
Warning
The pump unit must not be used with other liquids than those for which it was recommended and
sold. If there are any uncertainties contact your sales representative. Liquids, for which the pump is
not appropriate, can damage the pump and other parts of the unit as well as cause personal injury.
1.3.2.4 Disassembly/assembly of the coupling guard
The coupling guard is a fixed guard to protect the users and operator from fastening and injuring
themselves on the rotating shaft/shaft coupling. The pump unit is supplied with factory mounted
guards with certified maximum gaps in accordance with standard DIN EN ISO 13857.
Warning
The coupling guard must never be removed during operation. The locking safety switch must
be turned to off and locked. The coupling guard must always be reassembled after it has been
removed. Make sure to also reassemble any extra protective covers. There is a risk of personal injury
if the coupling guard is incorrectly mounted.
a) Turn off and lock the power switch.
b) Disassemble the coupling guard.
c) Complete the work.
d) Reassemble the coupling guard and any other protective covers. Make sure that the screws are
properly tightened.
1.3.2.5 Name plate – CE Declaration of Conformity
Always quote the serial number on the name plate together with questions concerning the pump unit,
installation, maintenance etc.
When changing the operating conditions of the pump please contact your supplier to ensure a safe
and reliable working pump.
This also applies to modifications on a larger scale, such as a change of motor or pump on an
existing pump unit.

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A.0500.501 – IM-TGGS/05.01 EN (03/2013)
Quantity Symbol Unit
Dynamic µ mPa.s = cP (Centipoise)
viscosity
Kinematic ν= µ ρ= density [kg]
viscosity ρ   dm3
ν= kinematic viscosity [ mm2] = cSt (Centistokes)
s
Note! In this manual only dynamic viscosity is used.
Pressure p [bar]
∆p Differential pressure = [bar]
pmMaximum pressure at discharge flange (design pressure) = [bar]
Note! In this manual, unless otherwise specified - pressure is relative pressure [bar].
Net Positive
Suction Head NPSHa Net Positive Suction Head is the toal absolute inlet pressure at
the pump suction connection, minus the vapour pressure of the
pumped liquid.
NPSHa is expressed in meter liquid column.
It is the responsibility of the user to determine the NPSHa value.
NPSHr Net Positive Suction Head Required is the NPSH determined,
after testing and calculation, by the pump manufacturer to avoid
performance impairement due to cavitation within the pump at
rate capacity.
The NPSHr is measured at the suction flange, at the point where
the capacity drop results in a pressure loss of at least 4%.
Note! In this manual, unless otherwise specified, NPSH = NPSHr
When selecting a pump, ensure that NPSHa is at least 1 m higher than the NPSHr.
1.4 Technical conventions

12 A.0500.501 – IM-TGGS/05.01 EN (03/2013)
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.
2.1 Type designation
The pump properties are encoded in the following type indication, which is to be found on the
nameplate.
Example:
1. Pump family name
TG = TopGear
2. Pump range name
G = General purpose
S = Single mechanical seal - shaft bearings outside the liquid
3. Hydraulics indicated with displacement volume per 100 revolution (in dm3) and
nominal port diameter (in mm)
TG GS2-25
TG GS3-32
TG GS6-40
TG GS15-50
TG GS23-65
TG GS58-80
TG GS86-100
TG GS185-125
4. Pump material
G Pump in cast iron
5. Port connection type
1 Thread connections
2 PN16 flanges to DIN2533
3 PN20 flanges to ANSI 150 lbs
6. Jacket options for pump cover
O Pump cover without jackets
S Pump cover with jacket and thread connection
TG GS 58-80 G 2 S SG 2 G1 AV
123456 78910

13
A.0500.501 – IM-TGGS/05.01 EN (03/2013)
Example:
7. Idler bush and idler materials
SG Idler bush in hardened steel with idler in iron
CG Idler bush in carbon with idler in iron
BG Idler bush in bronze with idler in iron
HG Idler bush in ceramic with idler in iron
SS Idler bush in hardened steel with idler in steel
CS Idler bush in carbon with idler in steel
BS Idler bush in bronze with idler in steel
HS Idler bush in ceramic with idler in steel
US Idler bush in hard metal with idler in steel
BR Idler bush in bronze with idler in stainless steel
CR Idler bush in carbon with idler in stainless steel
HR Idler bush in ceramic with idler in stainless steel
UR Idler bush in hard metal with idler in stainless steel
8. Idler pin materials
2 Idler pin in hardened steel
5 Idler pin in nitrided stainless steel
6 Idler pin in hard coated stainless steel
9. Rotor and shaft materials
G1 Rotor in iron and shaft in steel
N1 Rotor in nitrided nodular iron and shaft in steel
R1 Rotor in stainless steel and shaft in steel
10. Shaft seal arrangement
Single mechanical seal Burgmann type MG12
AV Single mech. seal Burgmann MG12 Carbon/SiC/FPM (Fluorocarbon)
WV Single mech. seal Burgmann MG12 SiC/SiC/FPM (Fluorocarbon)
Single mechanical seal Burgmann type M7N
HV Single mech. seal Burgmann M7N SiC/Carbon/FPM (Fluorocarbon)
HT Single mech. seal Burgmann M7N SiC/Carbon/PTFE-wrapped
WV Single mech. seal Burgmann M7N SiC/SiC/FPM (Fluorocarbon)
 WT Singlemech.sealBurgmannM7NSiC/SiC/PTFE-FFKM
Remark: EPDM and FFKM (Chemraz®) O-ring sets available on request
Single mechanical seal option without mechanical seal
XX Single seal parts – seal on request
TG GS 58-80 G 2 S SG 2 G1 AV
123456 78910

14 A.0500.501 – IM-TGGS/05.01 EN (03/2013)
3.2 Operating principle
3.0 General technical information
3.1 Pump standard parts
Top cover Intermediate casing
Pump shaft
Bearing bracket
Rotor
Pump casing
Idler gear
Pump cover
Idler pin
As the rotor and idler gear unmesh, an underpressure
is created and the liquid enters the new created cavities.
Liquid is transported in sealed pockets to the discharge side.
The walls of the pump casing and the crescent are creating
a seal and separate suction from discharge side.
The rotor and idler gear mesh and liquid are being pushed
into the discharge line.
Reversing the shaft rotation will reverse the flow through the pump as well.

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A.0500.501 – IM-TGGS/05.01 EN (03/2013)
3.2.1 Self-priming operation
TopGear pumps are self-priming when sufficient liquid is present in the pump to fill up the
clearances and the dead spaces between the teeth. (For self-priming operation see also section
3.18.6.2 Piping).
3.2.2 Safety relief valve – Working principle
The positive displacement principle requires the installation of a safety relief valve
protecting the pump against overpressure. It can be installed on the pump or in the installation.
This safety relief valve limits the differential pressure (∆p) between suction and discharge, not the
maximum pressure within the installation.
For example, as media cannot escape when
the discharge side of the pump is obstructed,
an over-pressure may cause severe damage to
the pump.
The safety relief valve provides an escape
path, rerouting the media back to the suction
side when reaching a specified pressure level.
• Thesafetyreliefvalveprotectsthepumpagainstover-pressureonlyinoneowdirection.
The safety relief valve will not provide protection against over-pressure when the pump rotates
in the opposite direction. When the pump is used in both directions, a double safety relief valve
is required.
• Anopensafetyreliefvalveindicatesthattheinstallationisnotfunctioningproperly.Thepump
must be shut down at once. Find and solve the problem before restarting the pump.
• Whenthesafetyreliefvalveisnotinstalledonthepump,otherprotectionsagainstover-
pressure have to be provided.
• Note! Do not use the safety relief valve as a flow regulator. The liquid will circulate only through
the pump and will heat up quickly.
Contact your local supplier if a flow regulator is required.
3.3 Sound
TopGear pumps are rotary displacement pumps. Because of the contact between internal parts
(rotor/idler), pressure variations etc. they produce more noise than for example centrifugal pumps.
Also the sound coming from drive and installation must be taken into consideration.
As the sound level at the operating area may exceed 85 dB(A), ear protection must be worn.
See also section 3.7 Sound level.
3.4 General performance
Important!
The pump is calculated for the liquid transport as described in the quotation. Contact your local
supplier if one or several application parameters change.
Liquids not suitable for the pump can cause damages to the pump unit and imply risk of personal
injury.
Correct application requires that consideration be given to all of the following:
Product name, concentration and density. Product viscosity, product particles (size, hardness,
concentration, shape), product purity, product temperature, inlet and outlet pressure, RPM, etc.

16 A.0500.501 – IM-TGGS/05.01 EN (03/2013)
3.5 Main characteristics
The pump size is designated by the displacement volume of 100 revolutions expressed
in litres (or dm3) but rounded followed by the nominal port diameter expressed in
millimetres.
TG GS pump size d
(mm)
B
(mm)
D
(mm)
Vs-100
(dm3)
n.max
(min-1)
n.mot
(min-1)
Q.th
(l/s)
Q.th
(m3/h)
v.u
(m/s)
v.i
(m/s)
∆p
(bar)
p.test
(bar)
2-25 25 13.5 65 1.83 1800 0.5 2.0 6.1 0.7 10 15
1450 0.4 1.6 4.9 0,5
3-32 32 22 65 2.99 1800 0.9 3.2 6.1 1.1 10 15
1450 0.7 2.6 4.9 0.9
6-40 40 28 80 5.8 1800 1.7 6.3 7.5 1.4 10 15
1450 1.4 5.0 6.1 1.1
15-50 50 40 100 14.5 1500 3.6 13.1 7.9 1.8 10 15
1450 3.5 12.6 7.6 1.8
23-65 65 47 115 22.7 1500 5.7 20.4 9.0 1.7 10 15
1450 5.5 19.7 8.7 1.7
58-80 80 60 160 57.6 1050 10.1 36.3 8.8 2.0 10 15
960 9.2 33.2 8.0 1.8
86-100 100 75 175 85.8 960 960 13.7 49.4 8.8 1.7 10 15
185-125 125 100 224 185 750 23 83 8.8 1.9 10 15
725 22 80 8.5 1.8
Legend
d : port diameter (inlet and outlet port)
B : width of idler gear and length of rotor teeth
D : peripheral diameter of rotor (outside diameter)
Vs-100 : displaced volume pro 100 revolutions
n.max : maximum allowable shaft speed in rpm
n.mot : normal speed of direct drive electric motor (at 50Hz frequency)
Q.th : theoretical capacity without slip at differential pressure = 0 bar
v.u : peripheral velocity of rotor
v.i : velocity of liquid in the ports at Qth (inlet and outlet port)
∆p : maximum working pressure = differential pressure
p.test : hydrostatic test pressure
Maximum viscosity
Shaft sealing type
Maximum viscosity
(mPa.s) *)
GS
Single mechanical seal
GS with Burgmann MG12 3 000
GS with Burgmann M7N 5 000
*) Remark:
Figures are for Newtonian liquids at operating temperature. The maximum allowable
viscosity between the sliding faces of the mechanical seal depends on nature of liquid
(Newtonian, plastic etc.), the sliding speed of the seal faces and the mechanical seal
construction.

17
TopGear GS-range
15 bar
10 bar
A.0500.501 – IM-TGGS/05.01 EN (03/2013)
3.6 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.
The hydrostatic test pressure is 1.5 times the differential pressure i.e.:
TopGear GS-line has the hydrostatic test pressure at 15 bar.
Following figure gives a graphical presentation of the several kinds of pressures.
3.7 Sound level
3.7.1 Sound level of a pump without drive
Sound pressure level (LpA)
The following table gives an overview of the A-weightened sound pressure level, LpA emitted by
a pump without drive, measured according to ISO3744 and expressed in decibels dB(A).
The reference sound pressure is 20µPa.
The values depend on the position from where one measures and were therefore measured at the
front of the pump, at distance of 1 meter from the pump cover and were corrected for background
noise and reflections.
The values listed are the highest measured values under following operating conditions.
 •workingpressure:upto10bar.
 •pumpedmedium:water,viscosity=1mPa.s
 •—%nmax=—%maximumshaftspeed
TG GS Pump size nmax(min-1)
Lpa (dB(A))
Ls (dB(A))
25% nmax 50%nmax 75%nmax 100%nmax
2-25 1800 51 62 68 72 9
3-32 1800 53 65 72 76 9
6-40 1800 57 68 76 80 9
15-50 1500 61 72 79 83 9
23-65 1500 63 75 81 85 10
58-80 1050 67 79 85 89 10
86-100 960 69 80 86 90 11
185-125 750 71 82 87 91 11
Sound power level (LWA)
The sound power LW is the power emitted by the pump as sound waves and is used to compare
sound levels of machines. It is the sound pressure Lp that acts on a surrounding surface at distance
of 1 meter.
LWA = LpA + Ls
The A-weightened sound power level LWA is also expressed in decibels dB(A).
The reference sound power is 1 pW (= 10-12 W). LSis the logarithm of the surrounding surface at
distance of 1 metre from the pump, expressed in dB(A) and is listed in the last column of above
table.
Hydrostatic test pressure
Differential and working pressure

18 A.0500.501 – IM-TGGS/05.01 EN (03/2013)
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.
For a quick determination of the total sound level the following table can be used:
L1–L20 1 2 3 4 5 6
L[f(L1–L2)] 3.0 2.5 2.0 1.7 1.4 1.2 1.0
Ltotal = L1+ L corrected
whereLtotal : the total sound level of the pump unit
L1: the highest sound level
L2: the lowest sound level
Lcorrected : term, depending on the difference between both sound levels
For more than two values this method can be repeated.
Example: Drive unit : L1= 79 dB(A)
Pump : L2= 75 dB(A)
Correction : L1- L2= 4 dB(A)
According to the table : Lcorrected = 1.4 dB(A)
Ltotal = 79 + 1.4 = 80.4 dB(A)
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 the resistance torque of the idler is increasing due to higher liquid
friction which results in lower vibration amplitude.
• Noiseproductionincreaseswhenpumpinglowviscosityliquidscombinedwithlowworking
pressure because the idler can move freely (lower charge, lower liquid friction) and the liquid
does not damp much.
• Vibrationsinpiping,vibratingofthebaseplateetc.willmaketheinstallationproducemorenoise.
3.8 Maximum temperature
Overall temperature of TopGear GS pumps is 200°C. The temperature is limited because of the
position of the roller bearing close to the pump. Higher temperature could be a problem for grease
lubrication and life time of these bearing.
3.9 Jacket options
S-jackets are designed for use with saturated steam or with non-dangerous media. They are
provided with cylindrical threaded connections according to ISO 228-I.
Maximum temperature: 200°C
Maximum pressure: 10 bar
Material: Cast iron GG25

19
A.0500.501 – IM-TGGS/05.01 EN (03/2013)
3.10 Internals
3.10.1 Bush materials
Overview of bush materials and application field
Material Code S C B H U
Material Steel Carbon Bronze Ceramic Hard metal
Hydrodynamical
lubrication
if yes to maximum working pressure = 16 bar
if no 6 bar (*) 10 bar (*) 6 bar (*) 6 bar (*) 10 bar (*)
Corrosive resistance Fair Good Fair Excellent Good
Abrasive resistance Slight None None Good Good
Dry running allowed No Ye s Moderate No No
Sensitive to thermal choc No No No Yes dT<90°C No
Sensitive to blistering in oil No > 180°C No No No
Oil aging No No > 150°C No No
Food processing allowed Ye s No (antimony) No (lead) Ye s Ye s
(*) These are not absolute figures. Higher or lower values possible in function of the application,
expected lifetime etc.
3.10.2 Maximum temperature of internals
Because the overall temperature of TopGear GS pumps is limited to 200°C, there are no extra
temperature restrictions for internals.
3.10.3 Operation under hydrodynamic lubrication conditions
Hydrodynamic lubrication could be important criteria for bush material selection.
If the bush bearings are running under the condition of hydrodynamic lubrication there is no more
material contact between bush and pin or shaft and the lifetime cycle is increased importantly.
If there is no condition for hydrodynamic lubrication, the bush bearings make material contact with
pin or shaft and the wear of these parts is to be considered.
The condition of hydrodynamic lubrication is fulfilled
with the following equation:
Viscosity * shaft speed / diff.pressure ≥K.hyd
with: viscosity [mPa.s]
shaft speed [rpm]
diff.pressure [bar]
K.hyd = design constant for each pump size.
TG GS pump size K.hyd
2-25 6000
3-32 7500
6-40 5500
15-50 6250
23-65 4000
58-80 3750
86-100 3600
185-125 2500

20 A.0500.501 – IM-TGGS/05.01 EN (03/2013)
3.11 Mass moment of inertia
TG GS 2-25 3-32 6-40 15-50 23-65 58-80 86-100 185-125
J (10-3 x kgm2) 0.25 0.30 0.75 3.5 6.8 32 54 200
3.12 Axial and radial clearances
TG GS 2-25 3-32 6-40 15-50 23-65 58-80 86-100 185-125
Minimum (µm) 80 80 90 120 125 150 165 190
Maximum (µm) 134 134 160 200 215 250 275 320
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.
TG GS pump size
Mn (nominal torque) in Nm Md (starting torque in Nm
G Rotor
Iron
N Rotor
Nitrided
nodular
iron
R Rotor
Stainless
steel
G Rotor
Iron
N Rotor
Nitrided
nodular
iron
R Rotor
Stainless
steel
2-25 21 – 31 29 – 43
3-32 21 – 31 29 – 43
6-40 67 67 67 94 94 94
15-50 255 255 255 360 360 360
23-65 255 255 255 360 360 360
58-80 390 390 390 550 550 550
86-100 600 600 600 840 840 840
185-125 1300 1300 1300 1820 1820 1820
The nominal torque (Mn) has to be checked for the normal working conditions and the installed
nominal motor torque (M n.motor) but converted to the pump shaft speed.
The starting torque (Md) may not be exceeded during start up. Use this value for the maximum torque
set of a torque limiter if installed on the pump shaft.