SPX FLOW TopGear BLOC Series User manual

A.0500.751 – IM-TG BLOC/01.01 EN (11/2021)
TopGear BLOC
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 Europe Limited Belgium
Evenbroekveld 2-6
BE-9420 Erpe-Mere
Belgium
Herewith we declare that
TopGear BLOC range Gear Pumps
Types: TG BLOC15-50
TG BLOC23-65
TG BLOC58-80
TG BLOC86-100
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 BLOC range gear pumps, is meant to be incorporated
into the specied 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, 01 January 2021
Frank Vander Beken
Branch Manager

3
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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 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 Inuences ....................................................................................................................18
3.8 Material options.......................................................................................................... 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.....................19
3.11 Mass moment of inertia.............................................................................................20
3.12 Radial clearances....................................................................................................... 20
3.13 Play between gear teeth........................................................................................... 20
3.14 Maximum size of solid particles .............................................................................. 20
3.15 Shaft sealing................................................................................................................ 20
3.16 Safety relief valve ....................................................................................................... 21
3.16.1 Pressure.......................................................................................................................22
3.16.2 Heating.........................................................................................................................22
3.16.3 Safety relief valve – Relative adjustment..............................................................22

4A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
3.16.4 Sectional drawings and part lists...........................................................................24
3.16.4.1 Single safety relief valve ....................................................................................... 24
3.16.4.2 Heated spring casing............................................................................................ 25
3.16.4.3 Double safety relief valve...................................................................................... 25
3.17 Installation.................................................................................................................... 26
3.17.1 General ........................................................................................................................26
3.17.2 Location .......................................................................................................................26
3.17.2.1 Short suction line ................................................................................................... 26
3.17.2.2 Accessibility ............................................................................................................ 26
3.17.2.3 Outdoor installation ............................................................................................... 26
3.17.2.4 Indoor installation................................................................................................... 27
3.17.2.5 Stability..................................................................................................................... 27
3.17.3 Drives............................................................................................................................27
3.17.3.1 Starting torque........................................................................................................ 27
3.17.4 Shaft rotation for pump without safety relief valve.............................................28
3.17.5 Shaft rotation for pump with safety relief valve...................................................29
3.17.6 Suction and discharge pipes..................................................................................30
3.17.6.1 Forces and moments............................................................................................. 30
3.17.6.2 Piping........................................................................................................................ 30
3.17.6.3 Isolating valves........................................................................................................ 31
3.17.6.4 Strainer..................................................................................................................... 31
3.17.7 Secondary piping.......................................................................................................31
3.17.7.1 Drain lines ................................................................................................................ 31
3.17.7.2 Heating jackets....................................................................................................... 32
3.17.8 Flush media.................................................................................................................32
3.17.9 Guidelines for assembly...........................................................................................33
3.17.9.1 Transport of pump unit.......................................................................................... 33
3.17.9.2 Foundation pump unit ........................................................................................... 33
3.17.9.3 Variators, Motors .................................................................................................... 33
3.17.9.4 Electric motor drive................................................................................................ 33
3.18 Instructions for start-up ............................................................................................ 35
3.18.1 General ........................................................................................................................35
3.18.2 Cleaning the pump....................................................................................................35
3.18.2.1 Cleaning suction line............................................................................................. 35
3.18.3 Venting and lling.......................................................................................................35
3.18.4 Checklist – Initial start-up .......................................................................................36
3.18.5 Start-up........................................................................................................................37
3.18.6 Shut-down...................................................................................................................37
3.18.7 Abnormal operation................................................................................................... 37
3.19 Trouble shooting.........................................................................................................38
3.19.1 Instructions for re-using and disposal ..................................................................40
3.19.1.1 Re-use ...................................................................................................................... 40
3.19.1.2 Disposal ................................................................................................................... 40
3.20 Maintenance instructions ......................................................................................... 41
3.20.1 General ........................................................................................................................41
3.20.2 Preparation..................................................................................................................41
3.20.2.1 Surroundings (on site) .......................................................................................... 41
3.20.2.2 Tools.......................................................................................................................... 41
3.20.2.3 Shut-down............................................................................................................... 41
3.20.2.4 Motor safety ............................................................................................................ 41
3.20.2.5 Conservation........................................................................................................... 41
3.20.2.6 External cleaning .................................................................................................... 42
3.20.2.7 Electrical installation.............................................................................................. 42
3.20.2.8 Draining of uid ..................................................................................................... 42

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A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
3.20.2.9 Fluid circuits ............................................................................................................ 42
3.20.3 Specic components................................................................................................43
3.20.3.1 Nuts and bolts ........................................................................................................ 43
3.20.3.2 Plastic or rubber components............................................................................. 43
3.20.3.3 Flat gaskets ............................................................................................................. 43
3.20.3.4 Filter or suction strainer........................................................................................ 43
3.20.3.5 Anti-friction bearings............................................................................................. 43
3.20.3.6 Sleeve bearings...................................................................................................... 43
3.20.3.7 Shaft seal – Mechanical seal .............................................................................. 43
3.20.4 Front pull-out ..............................................................................................................44
3.20.5 Back pull-out...............................................................................................................44
3.20.6 Clearance adjustment .............................................................................................44
3.20.7 Designation of threaded connections...................................................................45
3.20.7.1 Threaded connection Rp (example Rp 1/2) .................................................... 45
3.20.7.2 Threaded connection G (example G 1/2)........................................................ 45
4.0 Instructions for assembly and disassembly....................................................... 46
4.1 General.........................................................................................................................46
4.2 Tools..............................................................................................................................46
4.3 Preparation ..................................................................................................................46
4.4 After disassembly.......................................................................................................46
4.5 Couplling bush ........................................................................................................... 47
4.5.1 General ........................................................................................................................47
4.5.2 TG BLOC15-50 to TG BLOC86-100 coupling bush assembly ...................47
4.6 Anti-friction bearings................................................................................................. 47
4.6.1 General ........................................................................................................................47
4.6.2 TG BLOC15-50 to TG BLOC86-100 disassembly ......................................... 47
4.6.3 TG BLOC15-50 to TG BLOC86-100 assembly...............................................48
4.7 Mechanical seal..........................................................................................................49
4.7.1 General ........................................................................................................................49
4.7.2 Preparation..................................................................................................................49
4.7.3 Special tools ...............................................................................................................49
4.7.4 General instructions during assembly ................................................................49
4.7.5 Assembly of the rotating part .................................................................................49
4.7.6 Assembly of the stationary seat ............................................................................50
4.8 Pumps........................................................................................................................... 50
4.8.1 General ........................................................................................................................50
4.8.2 TG BLOC15-50 to TG BLOC86-100 .................................................................50
4.9 Relief valve................................................................................................................... 51
4.9.1 Disassembly ...............................................................................................................51
4.9.2 Assembly ....................................................................................................................51
5.0 Sectional drawings and part lists......................................................................... 52
5.1 TG BLOC15-50 to TG BLOC86-100.................................................................. 52
5.2.1 Hydraulic part .............................................................................................................53
5.2.2 Bearing lantern...........................................................................................................53
5.2.3 Jacket............................................................................................................................54
5.2.4 Single mechanical seal.............................................................................................54
6.0 Dimensional drawings ............................................................................................ 55
6.1 Standard pump........................................................................................................... 55
6.1.1 TG BLOC15-50 to 86-100 ....................................................................................55
6.2 Flange connections ...................................................................................................56

6A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
6.2.1 TG BLOC15-50 to 86-100 ....................................................................................56
6.2.1.1 Cast iron................................................................................................................... 56
6.2.1.2 Stainless steel..........................................................................................................57
6.3 Jackets (S) on pump cover and thread connection ........................................... 57
6.3.1 TG BLOC15-50 to 86-100 .................................................................................... 57
6.4 Safety relief valves .....................................................................................................58
6.4.1 Single safety relief valve...........................................................................................58
6.4.2 Double safety relief valve .........................................................................................58
6.4.3 Heated safety relief valve.........................................................................................59
6.4.4 Heated double safety relief valve ...........................................................................59
6.5 Weights – Mass .........................................................................................................60

7
SPX Flow Europe Limited - Belgium
Evenbroekveld 2-6, 9420 Erpe-Mere
www.johnson-pump.com / www.spxflow.com
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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 name plate.
This number should be stated in all correspondence
with your local supplier.
The rst digits of the serial number 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.
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.
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.

8A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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 classied 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.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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(If there are lifting rings on
the motor the slings may be fastened
to these). Make sure that the load is
balanced before attempting the lift.
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 tted
with rubber-clad feet.
The pipe connections to the pump must be stress-free mounted, securely fastened to the pump and
well supported. Incorrectly tted 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 electried, 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 re must be diverted away from the
motor.
Warning
Pump units to be installed in potentially explosive environments must be tted 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 Europe Limited - Belgium
Evenbroekveld 2-6
9420 Erpe-Mere
www.johnson-pump.com / www.spxflow.com
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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.
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 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 modications on a larger scale, such as a change of motor or pump on an
existing pump unit.

11
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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]
pm Maximum pressure at discharge ange (design pressure) = [bar]
Note! In this manual, unless otherwise specied - 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 ange, at the point where
the capacity drop results in a pressure loss of at least 4%.
Note! In this manual, unless otherwise specied, NPSH = NPSHr
When selecting a pump, ensure that NPSHa is at least 1 m higher than the NPSHr.
1.4 Technical conventions

12 A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
2.0 Pump description
TopGear BLOC pumps are rotary positive displacement pumps with internal gear. They are made of
cast iron or stainless steel. TG BLOC pumps are assembled from modular elements, which allows
a variety of constructions: 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 name
plate.
Example:
TG BLOC 58-80 G2 S SG 2 G1 AV
1 2 3 4 5 6 7 8 9 10
1. Pump family name
TG = TopGear
2. Pump range name
BLOC = Close-coupled pump with single mechanical seal
3. Hydraulics indicated with displacement volume per 100 revolution (in dm3) and
nominal port diameter (in mm)
TG BLOC15-50
TG BLOC23-65
TG BLOC58-80
TG BLOC86-100
4. Application
Non-food
FD Food
5. Pump material & port connection type
G2 Pump in cast iron with PN16 anges to DIN2533
G3 Pump in cast iron with PN20 anges to ANSI 150 lbs
R2 Pump in stainless steel with PN25/PN40
R3 Pump in stainless steel with PN20 anges to ANSI 150 lbs
R4 Pump in stainless steel with PN50 anges to ANSI 300 lbs
R5 Pump in stainless steel with PN16 anges to DIN2533
6. Jacket options for pump cover
O Pump cover without jackets
S Pump cover with jacket and thread connection
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
BR Idler bush in bronze with idler in stainless steel
CR Idler bush in carbon with idler in stainless steel
UR Idler bush in hard metal with idler in stainless steel

13
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
Example:
TG BLOC 58-80 G2 S SG 2 G1 AV
1 2 3 4 5 6 7 8 9 10
8. Idler pin materials
2 Idler pin in hardened steel
4 Idler pin in kolsterised stainless steel
5 Idler pin in nitrided stainless steel
9. Rotor and shaft materials
G1 Rotor in iron and shaft in steel
G5 Rotor in iron and shaft in nitrided stainless steel
R4 Rotor in stainless steel and shaft in stainless steel
R5 Rotor in stainless steel and shaft in nitrided stainless 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
Single mechanical seal Roplan type RTI 239
RV Single mech. seal Roplan RTI 239 SiC/Carbon/FPM (Fluorocarbon)
Single mechanical seal option without mechanical seal
GS XX Single seal parts – seal on request

14
Top cover
Idler pin
Pump cover Idler gear
Rotor
Pump casing
Intermediate
casing
Lantern
piece
Pump shaft
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
3.2 Operating principle
3.0 General technical information
3.1 Pump standard parts
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 ow through the pump as well.

15
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
3.2.1 Self-priming operation
TopGear pumps are self-priming when sufcient liquid is present in the pump to ll up the
clearances and the dead spaces between the teeth. (For self-priming operation see also section
3.17.6.2 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 specied 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 ow regulator. The liquid will circulate only through
the pump and will heat up quickly.
Contact your local supplier if a ow 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.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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 BLOC 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)
15-50 50 40 100 14.5 1500 3.6 13.1 7.9 1.8 16 24
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 16 24
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 16 24
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
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
*) 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.
Shaft sealing type
Maximum viscosity
(mPa·s) *)
GS
Single mechanical seal
GS with Burgmann MG12 3 000
GS with Burgmann M7N 5 000
GS with Roplan RTI 239 7 500

17
15 bar
24 bar
16 bar
10 bar
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
3.6 Pressure
Differential pressure or working pressure (p) is the pressure on which the pump normally
operates. TopGear BLOC-line has the maximum differential pressure at 16 bar. (86-100 10 bar)
The hydrostatic test pressure is 1.5 times the differential pressure i.e.:
TopGear BLOC-line has the hydrostatic test pressure at 24 bar (86-100 15 bar).
Following gure 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 reections.
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 BLOC Pump size nmax(min-1)
Lpa (dB(A))
Ls (dB(A))
25% nmax 50%nmax 75%nmax 100%nmax
15-50 1500 61 72 79 83 9
23-65 1500 63 75 81 85 10
58-80 105 0 67 79 85 89 10
86-100 960 69 80 86 90 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
Hydrostatic test pressure
Differential and working pressure
TG BLOC15-50,23-65,58-80 TG BLOC86-100

18 A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
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:
L
1
–L
2
0123456
L[f(L
1
–L
2
)] 3.0 2.5 2.0 1.7 1.4 1.2 1.0
Ltotal = L1+ L corrected
where Ltotal : 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 Inuences
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 Material options
The overall temperatures for selected casing materials are shown in below table.
Remarks:
1. Temperature limits must be considered depending on the used materials for bearing bushes and
shaft sealing.
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: 180°C
Maximum pressure: 10 bar
Material: Cast iron GG25
TG BLOC
pump size
Minimum allowable temperature (°C) Maximum allowable temperature (°C)
Casing materials Casing materials
Cast iron (C) Stainless steel (R) Cast iron (C) Stainless steel (R)
15-50
–10 –40 +300 +250
23-65
58-80
86-100

19
A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
3.10 Internals
3.10.1 Bush materials
Overview of bush materials and application eld
Material Code S C B
Material Steel Carbon Bronze
Hydrodynamic
lubrication
if yes to maximum working pressure = 16 bar
if no 6 bar (*) 10 bar (*) 6 bar (*)
Corrosive resistance Fair Good Fair
Abrasive resistance Slight None None
Dry running allowed No Yes Moderate
Sensitive to thermal choc No No No
Sensitive to blistering in oil No > 180°C No
Oil aging No No > 150°C
Food processing allowed Yes No (antimony) No (lead)
(*) These are not absolute gures. 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 BLOC pumps is limited to 180°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 fullled
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 BLOC pump size K.hyd
15-50 6250
23-65 4000
58-80 3750
86-100 3600
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 tting and rotor teeth.
TG BLOC pump size
Mn (nominal torque) in Nm Md (starting torque) in Nm
G Rotor
Iron
R Rotor
Stainless
steel
G Rotor
Iron
R Rotor
Stainless
steel
15-50 255 255 360 360
23-65 255 255 360 360
58-80 390 390 550 550
86-100 600 600 840 840
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.

20 A.0500.751 – IM-TGBLOC/01.01 EN (11/2021)
3.11 Mass moment of inertia
TG BLOC 15-50 23-65 58-80 86-100
J (10-3 x kg·m2) 3.5 6.8 32 54
3.12 Radial clearances
3.13 Play between gear teeth
3.14 Maximum size of solid particles
3.15 Shaft sealing
Mechanical seal according to EN12756 (DIN24960) – General information
In TopGear TG BLOC the short EN12756 (DIN24960) single mechanical seal can be built in.
The mechanical seal is set against the rotor shoulder.
TG BLOC pump size 15-50
23-65
58-80
86-100
Shaft diameter 40 45
Short EN12756 (DIN 24960) KU040 KU045
L1K (short KU) 45 45
Dimensions in mm
Performance
Maximum performance such as viscosity, temperature and working pressure depends on the make of
the mechanical seal and the used materials.
The following basic values can be taken into consideration:
Maximum temperatures of elastomers
Nitrile (P): 110°C
FPM (Fluorocarbon): 180°C
PTFE (solid or PTFE wrapped): 220°C
Chemraz: 230°C
Kalrez®*: 250°C
* Kalrez® is a registered trademark of DuPont Performance Elastomers
Maximum viscosity
3000 mPas: For single mechanical seals of light construction
5000 mPas: For single mechanical seals of medium torque construction
(consult manufacturer).
7500 mPas: For single mechanical seals of high torque construction
(consult manufacturer).
The maximum allowed viscosity between the sliding faces of the mechanical seal depends on the
nature of the liquid (Newtonian, plastic etc.), the sliding speed of the seal faces and the mechanical
construction.
Play between gear teeth
TG BLOC 15-50 23-65 58-80 86-100
Minimum (µm) 360 400 400 400
Maximum (µm) 720 800 800 800
TG BLOC 15-50 23-65 58-80 86-100
Minimum (µm) 70 75 100 115
Maximum (µm) 150 165 200 225
TG BLOC 15-50 23-65 58-80 86-100
Size (µm) 120 125 150 165