SPX FLOW TopGear GP Series User manual

INSTRUCTION MANUAL
ORIGINAL INSTRUCTIONS
READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
TopGear GP
INTERNAL GEAR PUMPS
A.0500.451 – IM-TG GP/07.02 EN (03/2016)

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 GP-range Gear Pumps
Types: TG GP2-25
TG GP3-32
TG GP6-40
TG GP15-50
TG GP23-65
TG GP58-80
TG GP86-100
TG GP120-100
TG GP185-125
TG GP360-150
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 GP-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, 1 April 2014
Gerard Santema
General Manager

3
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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 _______________________________ 15
3.1 Pump standard parts _______________________________________ 15
3.2 Operating principle ________________________________________ 15
3.2.1 Self-priming operation ______________________________________16
3.2.2 Safety relief valve – Working principle_________________________16
3.3 Sound ___________________________________________________ 16
3.4 General performance_______________________________________ 16
3.5 Main characteristics _______________________________________ 17
3.6 Pressure _________________________________________________ 18
3.7 Sound level ______________________________________________ 18
3.7.1 Sound level of a pump without drive __________________________18
3.7.2 The sound level of the pump unit _____________________________19
3.7.3 Influences ________________________________________________19
3.8 Material options ___________________________________________ 20
3.9 Jacket options_____________________________________________ 20
3.10 Electrical heating __________________________________________ 20
3.11 Internals _________________________________________________ 20
3.11.1 Bush materials ____________________________________________20
3.11.2 Maximum temperature of internals ____________________________21
3.11.3 Operation under hydrodynamic lubrication conditions____________21
3.11.4 Maximum torque of pump shaft and rotor material combination ____22
3.12 Mass moment of inertia _____________________________________ 22
3.13 Axial and radial clearances __________________________________ 22
3.14 Extra clearances___________________________________________ 22
3.15 Play between gear teeth ____________________________________ 23
3.16 Maximum size of solid particles ______________________________ 23

4A.0500.451 – IM-TGGP/07.02 EN (03/2016)
3.17 Shaft sealing _____________________________________________ 24
3.17.1 Packed gland (no lantern ring) _______________________________24
3.17.2 Packing ring materials ______________________________________24
3.18 Safety relief valve __________________________________________ 25
3.18.1 Pressure _________________________________________________26
3.18.2 Heating __________________________________________________26
3.18.3 Safety relief valve – Relative adjustment _______________________26
3.18.4 Sectional drawings and part lists _____________________________28
3.18.4.1 Single safety relief valve ________________________________ 28
3.18.4.2 Heated spring casing __________________________________ 29
3.18.4.3 Double safety relief valve _______________________________ 29
3.19 Installation________________________________________________ 30
3.19.1 General __________________________________________________30
3.19.2 Location _________________________________________________30
3.19.2.1 Short suction line______________________________________ 30
3.19.2.2 Accessibility __________________________________________ 30
3.19.2.3 Outdoor installation ____________________________________ 30
3.19.2.4 Indoor installation______________________________________ 31
3.19.2.5 Stability______________________________________________ 31
3.19.3 Drives ___________________________________________________31
3.19.3.1 Starting torque________________________________________ 31
3.19.3.2 Radial load on shaft end ________________________________ 32
3.19.4 Shaft rotation for pump without safety relief valve _______________32
3.19.5 Shaft rotation for pump with safety relief valve __________________33
3.19.6 Suction and discharge pipes ________________________________34
3.19.6.1 Forces and moments___________________________________ 34
3.19.6.2 Piping _______________________________________________ 34
3.19.6.3 Isolating valves________________________________________ 35
3.19.6.4 Strainer ______________________________________________ 35
3.19.7 Secondary piping__________________________________________35
3.19.7.1 Drain lines____________________________________________ 35
3.19.7.2 Heating jackets _______________________________________ 36
3.19.8 Guidelines for assembly ____________________________________37
3.19.8.1 Transport of pump unit _________________________________ 37
3.19.8.2 Foundation pump unit __________________________________ 37
3.19.8.3 Variators, Gear box, Gear motors, Motors__________________ 37
3.19.8.4 Electric motor drive ____________________________________ 37
3.19.8.5 Combustion engines ___________________________________ 38
3.19.8.6 Shaft coupling ________________________________________ 38
3.19.8.7 Guarding of moving parts _______________________________ 39
3.19.8.8 Electrical heating ______________________________________ 39
3.20 Instructions for start-up _____________________________________ 40
3.20.1 General __________________________________________________40
3.20.2 Cleaning the pump_________________________________________40
3.20.2.1 Cleaning suction line___________________________________ 40
3.20.3 Venting and filling__________________________________________40
3.20.4 Checklist – Initial start-up __________________________________41
3.20.5 Start-up__________________________________________________42
3.20.6 Shut-down _______________________________________________42
3.20.7 Abnormal operation ________________________________________42

5
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
3.21 Trouble shooting___________________________________________ 43
3.21.1 Instructions for re-using and disposal _________________________45
3.21.1.1 Re-use ______________________________________________ 45
3.21.1.2 Disposal _____________________________________________ 45
3.22 Maintenance instructions ___________________________________ 46
3.22.1 General __________________________________________________46
3.22.2 Preparation _______________________________________________46
3.22.2.1 Surroundings (on site)__________________________________ 46
3.22.2.2 Tools ________________________________________________ 46
3.22.2.3 Shut-down ___________________________________________ 46
3.22.2.4 Motor safety __________________________________________ 46
3.22.2.5 Conservation _________________________________________ 46
3.22.2.6 External cleaning ______________________________________ 47
3.22.2.7 Electrical installation ___________________________________ 47
3.22.2.8 Draining of fluid _______________________________________ 47
3.22.2.9 Fluid circuits__________________________________________ 47
3.22.2.10 Electrical heating _______________________________________ 47
3.22.3 Specific components_______________________________________48
3.22.3.1 Nuts and bolts ________________________________________ 48
3.22.3.2 Plastic or rubber components ___________________________ 48
3.22.3.3 Flat gaskets __________________________________________ 48
3.22.3.4 Filter or suction strainer_________________________________ 48
3.22.3.5 Anti-friction bearings ___________________________________ 48
3.22.3.6 Sleeve bearings _______________________________________ 49
3.22.3.7 Shaft seal ____________________________________________ 50
3.22.4 Front pull-out _____________________________________________51
3.22.5 Back pull-out _____________________________________________51
3.22.6 Clearance adjustment ______________________________________51
3.22.7 Designation of threaded connections. _________________________52
3.22.7.1 Threaded connection Rp (example Rp 1/2) ________________ 52
3.22.7.2 Threaded connection G (example G 1/2) __________________ 52
4.0 Instructions for assembly and disassembly ____________________ 53
4.1 General __________________________________________________ 53
4.2 Tools ____________________________________________________ 53
4.3 Preparation _______________________________________________ 53
4.4 After disassembly__________________________________________ 53
4.5 Anti-friction bearings _______________________________________ 54
4.5.1 General __________________________________________________54
4.5.2 TG GP2-25, TG GP3-32 and TG GP6-40 disassembly _________54
4.5.3 TG GP2-25, TG GP3-32 and TG GP6-40 assembly ____________54
4.5.4 TG GP15-50 to TG GP360-150 disassembly__________________55
4.5.5 TG GP15-50 to TG GP360-150 assembly ____________________55
4.6 Relief valve _______________________________________________ 56
4.6.1 Disassembly _____________________________________________56
4.6.2 Assembly ________________________________________________56

6A.0500.451 – IM-TGGP/07.02 EN (03/2016)
4.7 Electrical heating __________________________________________ 57
4.7.1 General __________________________________________________57
4.7.2 Electrical heating on the pump cover (in the idler pin) ____________57
4.7.2.1 Disassembly __________________________________________ 57
4.7.2.2 Assembly ____________________________________________ 57
4.7.3 Electrical heating around shaft seal (in the intermediate casing) ___58
4.7.3.1 Disassembly __________________________________________ 58
4.7.3.2 Assembly ____________________________________________ 58
5.0 Sectional drawings and part lists ____________________________ 59
5.1 TG GP2-25 to TG GP6-40 _________________________________ 59
5.1.1 Hydraulic part ____________________________________________60
5.1.2 Bearing bracket ___________________________________________60
5.1.3 Flange connection options __________________________________60
5.1.4 Jacket options ____________________________________________61
5.1.4.1 Jacket option on pump cover ____________________________ 61
5.1.4.2 Jacket option around shaft seal __________________________ 61
5.1.5 Seal option: Packing rings PO _______________________________62
5.2 TG GP15-50 to TG GP360-150_____________________________ 63
5.2.1 Hydraulic part ____________________________________________64
5.2.2 Bearing bracket ___________________________________________64
5.2.3 Jacket options and electrical heating __________________________65
5.2.3.1 Jacket on pump cover __________________________________ 65
5.2.3.2 Jacket around the shaft seal _____________________________ 65
5.2.3.3 Electrical heating on the pump cover (in the idler pin)________ 66
5.2.3.4 Electrical heating around shaft seal (in the intermediate casing) 67
5.2.4 Seal options: Packing rings PO ______________________________68
6.0 Dimensional drawings _____________________________________ 69
6.1 Standard pump ___________________________________________ 69
6.1.1 TG GP2-25 to TG GP6-40 _________________________________69
6.1.2 TG GP15-50 to TG GP360-150_____________________________70
6.2 Flange connections ________________________________________ 71
6.2.1 TG GP2-25 to TG GP6-40 _________________________________71
6.2.2 TG GP15-50 to TG GP360-150_____________________________71
6.3 Jackets – Electrical heating__________________________________ 72
6.3.1 Jackets TG GP2-25 to TG GP6-40 __________________________72
6.3.2 Jackets TG GP15-50 to TG GP360-150 ______________________73
6.3.3 Electrical heating __________________________________________74
6.4 Safety relief valves _________________________________________ 75
6.4.1 Single safety relief valve ____________________________________75
6.4.2 Double safety relief valve____________________________________75
6.4.3 Heated safety relief valve____________________________________76
6.5 Bracket support ___________________________________________ 77
6.6 Weights – Mass___________________________________________ 77

7
. . . .
. . . .
D 22/12/2015 S.P. S.P.
C 26/06/2015 S.P. S.P.
B 31/05/2012 D.S. D.S.
Rev. Date Drawn Approved
Datum: Naam:
Date: Name:
Datum: Rev.
Date:
4.0030.163 Nameplate 55x40 - TopGear Pump
SPX Flow Technology Belgium NV
Evenbroekveld 2-6
BE - 9420 Erpe-Mere
D
Davy Schandevyl
Davy Schandevyl
23/03/2012
31/05/2012
Copyright © restricted according to the law
This information is confidential and proprietary to SPX corporation and its worldwide subsidiaries and affiliates.
It may not be disclosed to anyone, other than SPX personnel, without written authorization from SPX corporation.
Revision description
Getekend door:
Drawn by:
Goedgekeurd door:
Approved by:
.
.
Changed: SPXFlow logo & website
EAC logo added
Remarks of Claire Cole
49
3
34
3
SPX Flow Technology Belgium NV
Evenbroekveld 2-6, BE-9420 Erpe-Mere
www.johnson-pump.com / www.spxflow.com
• Benaming / Description: Nameplate 55x40 - TopGear Pump
• Artikelnummer / Article number: 4.0030.163
• Afgeronde hoeken / Rounded edges: R4mm
• Øgaten / Ø holes: 2mm
• Afmeting SPX-logo / Dimensions SPX-logo: 20mm x 2,27mm
• Tekst firmagegevens / Text company data:
lettertype / font: Arial regular
lettergrootte / fontsize: 5pt
• Afmeting JP-logo / Dimensions JP-logo: 15mm x 1,73mm
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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 first 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.
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.0500.451 – IM-TGGP/07.02 EN (03/2016)
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 fire
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.

9
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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
. . . .
. . . .
. . . .
C 22/12/2015 S.P. S.P.
B 26/06/2015 S.P. S.P.
Rev. Date Drawn Approved
Datum: Naam:
Date: Name:
Datum: Rev.
Date:
4.0030.170 Nameplate 86x54 - Pump Unit
SPX Flow Technology Belgium NV
Evenbroekveld 2-6
BE - 9420 Erpe-Mere
C
Davy Schandevyl
.
26/03/2012
.
Copyright © restricted according to the law
This information is confidential and proprietary to SPX corporation and its worldwide subsidiaries and affiliates.
It may not be disclosed to anyone, other than SPX personnel, without written authorization from SPX corporation.
Revision description
Getekend door:
Drawn by:
Goedgekeurd door:
Approved by:
.
.
.
Changed: SPXFlow logo & website
EAC logo added
SPX Flow Technology
Belgium NV
Evenbroekveld 2-6
BE-9420 Erpe-Mere
www.johnson-pump.com / www.spxflow.com
80
3
48
3
• Benaming / Description: Nameplate 86x54 - Pump Unit
• Artikelnummer / Article number: 4.0030.170
• Afgeronde hoeken / Rounded edges: R4mm
• Øgaten / Ø holes: 2mm
• Afmeting SPX-logo / Dimensions SPX-logo: 32mm x 3,64mm
• Tekst firmagegevens / Text company data:
lettertype / font: Arial regular
lettergrootte / fontsize: 7pt
• Afmeting JP-logo / Dimensions JP-logo: 30mm x 3,47mm
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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.

11
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
1.4 Technical conventions
Quantity Symbol Unit
Dynamic viscosity µ mPa.s = cP (Centipoise)
Kinematic viscosity ν= µ
ρ
ρ= density [kg ]
dm³
ν= kinematic viscosity [mm² ]
s= cSt (Centistokes)
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 total 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 impairment 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.

12
TG GP 58-80 G 2 S S SG 2 B G2 TC
1 2 3 4 5 6 7 8 9 10 11 12 13
TG GP 15-50 FD G 3 O S UG 6 U G6 AW
1 2 3 4 5 6 7 8 9 10 11 12 13
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
2.0 Pump description
TopGear/GP pumps are rotary positive displacement pumps with internal gear. They are made of
cast iron. TG GP pumps: heating/cooling jackets (steam), several sleeve bearings, gear and shaft
materials and mounted relief valve and electrical heating.
2.1 Type designation
The pump properties are encoded in the following type indication, which is to be found on the name
plate.
Examples:
1. Pump family name
TG = TopGear
2. Pump range name
G = General purpose
P = Simpliest soft packing version
3. Hydraulics indicated with displacement volume per 100 revolution (in dm3) and
nominal port diameter (in mm)
TG GP2-25
TG GP3-32
TG GP6-40
TG GP15-50
TG GP23-65
TG GP58-80
TG GP86-100
TG GP120-100
TG GP185-125
TG GP360-150
4. Application
Non-food
FD Food
5. Pump material
G Pump in cast iron
6. Port connection type
1 Thread connections
2 PN16 flanges to DIN2533
3 PN20 flanges to ANSI 150 lbs

13
TG GP 58-80 G 2 S S SG 2 B G2 TC
1 2 3 4 5 6 7 8 9 10 11 12 13
TG GP 15-50 FD G 3 O S UG 6 U G6 AW
1 2 3 4 5 6 7 8 9 10 11 12 13
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
Examples:
7. Jacket options for pump cover
O Pump cover without jackets
S Pump cover with jacket and thread connection
E1 Electrical heating idler pin – loss factor 15 W/°C/m² (indoor installation) – 110V
E2 Electrical heating idler pin – loss factor 15 W/°C/m² (indoor installation) – 230V
E3 Electrical heating idler pin – loss factor 20 W/°C/m² (outside but protected) – 110V
E4 Electrical heating idler pin – loss factor 20 W/°C/m² (outside but protected) – 230V
E5 Electrical heating idler pin – loss factor 25 W/°C/m² (outside unprotected) – 110V
E6 Electrical heating idler pin – loss factor 25 W/°C/m² (outside unprotected) – 230V
8. Jacket options around shaft seal
O Shaft seal without jackets
S Shaft seal with jacket and thread connection
E1 Electrical heating interm. casing – loss factor 15 W/°C/m² (indoor installation) – 110V
E2 Electrical heating interm. casing – loss factor 15 W/°C/m² (indoor installation) – 230V
E3 Electrical heating interm. casing – loss factor 20 W/°C/m² (outside but protected) – 110V
E4 Electrical heating interm. casing – loss factor 20 W/°C/m² (outside but protected) – 230V
E5 Electrical heating interm. casing – loss factor 25 W/°C/m² (outside unprotected) – 110V
E6 Electrical heating interm. casing – loss factor 25 W/°C/m² (outside unprotected) – 230V
9. 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
10. Idler pin materials
2 Idler pin in hardened steel
5 Idler pin in nitrided stainless steel
6 Idler pin in hard coated stainless steel

14
TG GP 58-80 G 2 S S SG 2 B G2 TC
1 2 3 4 5 6 7 8 9 10 11 12 13
TG GP 15-50 FD G 3 O S UG 6 U G6 AW
1 2 3 4 5 6 7 8 9 10 11 12 13
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
Examples:
11. Bush on shaft materials
S Bush in hardened steel
C Bush in carbon
H Bush in ceramic
U Bush in hard metal
B Bush in bronze
12. Rotor and shaft materials
G2 Rotor in iron and shaft in hardened steel
G5 Rotor in iron and shaft in nitrited stainless steel
G6 Rotor in iron and shaft in hard coated stainless steel
N2 Rotor in nitrited nodular iron and shaft in hardened steel
N5 Rotor in nitrited nodular iron and shaft in nitrited stainless steel
N6 Rotor in nitrited nodular iron and shaft in hard coated stainless steel
R2 Rotor in stainless steel and shaft in hardened steel
R5 Rotor in stainless steel and shaft in nitrited stainless steel
R6 Rotor in stainless steel and shaft in hard coated stainless steel
13. Shaft seal arrangement
TC Packing rings PTFE graphite
AW Packing rings Aramide – white
CC Packing rings graphite fibre
XX Packing rings without packing rings – on request

15
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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 is being pushed
into the discharge line.
Reversing the shaft rotation will reverse the flow through the pump as well.

16 A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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
3.19.6.2 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 flow 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.

17
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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 GP 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 16 24
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 16 24
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 16 24
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 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 16 24
120-100
100 90 190 120 750 15.0 54.0 7.5 1.9 16 24
900 18.0 65.0 9.0 2.3
725 14.5 52.2 7.2 1.8
185-125 125 100 224 185 750 23 83 8.8 1.9 16 24
725 22 80 8.5 1.8
360-150 150 125 280 360 600 36 130 8.8 2.0 16 24
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)
Packed gland PO 80 000

18
Hydrostatic test pressure
Differential and Working pressure
16 bar
24 bar
TopGear GP-range and GM-range
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
3.6 Pressure
Differential pressure or working pressure (p) is the pressure on which the pump normally
operates. TopGear GP-line has the maximum differential pressure at 16 bar.
The hydrostatic test pressure is 1.5 times the differential pressure i.e.:
TopGear GP-line has the hydrostatic test pressure at 24 bar.
Following figure gives a graphical presentation of the several kind 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 GP 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
120-100 750 70 81 87 91 11
185-125 750 71 82 87 91 11
360-150 600 72 83 89 92 11

19
A.0500.451 – IM-TGGP/07.02 EN (03/2016)
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.
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.

20 A.0500.451 – IM-TGGP/07.02 EN (03/2016)
3.8 Material options
Maximum temperature
Overall temperature of TopGear GP pumps is 300°C but:
1. Maximum temperature of size GP2-25, GP3-32 and GP6-40 is limited to 200°C due to ball
bearing type 2RS.
Minimum temperature is -20°C.
2. 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: 200°C
Maximum pressure: 10 bar
Notice that the maximum pressure of 10 bar will be the limiting factor for use with saturated steam.
Saturated steam at 10 bar gives a temperature of 180°C.
Material: Cast iron GG25
3.10 Electrical heating
Electrical heating is especially designed for pumping bitumen, heating the pump up from ambient air
temperature to approximately 250°C. It can be used with an electric supply of 110V or 230V.
In case of other applications and/or lower or higher temperatures, please contact your local
supplier.
Electrical heating is available on the pumpcover (in the idler pin) and/or in the intermediate casing for
the following sizes and environments, see table.
Availability of electrical heating in the TopGear GP-line (- : not available / + : available)
TG GP pump
size
Loss factor 25 W/°C/m²
Outside unprotected
Loss factor 20 W/°C/m²
Outside but protected
from bad weather 1)
Loss factor 15 W/°C/m²
Indoor installation
Idler pin Intermediate
casing
Idler pin Intermediate
casing
Idler pin Intermediate
casing
15-50 - - - - + -
23-65 - - - - + -
58-80 + + + + + +
86-100 + + + + + +
120-100 + + + + + +
185-125 + + + + + +
1) meaning raining and wind can’t have free play to the pump because of roof or shadowed by other equipment
3.11 Internals
3.11.1 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 Yes 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 Yes No (antimony) No (lead) No (traceability) Yes
(*) These are not absolute figures. Higher or lower values possible in function of the application, expected life
time etc.