SPX TopGear H Series User manual

A.0500.351 – IM-TG H/07.02 EN (10/2015)
TopGear H
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 H-range Gear Pumps
Types: TG H2-32
TG H3-32
TG H6-40
TG H15-50
TG H23-65
TG H58-80
TG H86-100
TG H185-125
TG H360-150
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 H-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.0500.351 – IM-TGH/07.02 EN (10/2015)
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
Maximum viscosity_______________________________________________ 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 Internals _________________________________________________ 20
3.10.1 Bush materials ____________________________________________20
3.10.2 Maximum temperature of internals ___________________________21
3.10.3 Operation under hydrodynamic lubrication conditions____________21
3.10.4 Maximum torque of pump shaft and rotor material combination ____22
3.11 Mass moment of inertia _____________________________________ 22
3.12 Axial and radial clearances __________________________________ 22
3.13 Extra clearances___________________________________________ 23
3.14 Play between gear teeth ____________________________________ 24
3.15 Maximum size of solid particles ______________________________ 24
3.16 Shaft sealings ____________________________________________ 25
3.16.1 Packed gland _____________________________________________25
3.16.2 Packing ring materials ______________________________________25
3.16.3 Mechanical seals __________________________________________25
3.16.3.1 Mechanical seals according to EN12756 (DIN24960)
General information______________________________________________ 25
3.16.3.2 Cartridge mechanical seals _______________________________ 26
3.16.4 Reverted packing execution for e.g. chocolate application ________28
3.17.5 Triple PTFE lip-seal cartridge ________________________________29

4A.0500.351 – IM-TGH/07.02 EN (10/2015)
3.17 Safety relief valve __________________________________________ 30
3.17.1 Pressure _________________________________________________31
3.17.2 Heating __________________________________________________31
3.17.3 Safety relief valve – Relative adjustment _______________________32
3.17.4 Sectional drawings and part lists _____________________________33
3.17.4.1 Single safety relief valve __________________________________ 33
3.17.4.2 Heated spring casing ____________________________________ 34
3.17.4.3 Double safety relief valve _________________________________ 34
3.18 Installation________________________________________________ 35
3.18.1 General __________________________________________________35
3.18.2 Location _________________________________________________35
3.18.2.1 Short suction line _______________________________________ 35
3.18.2.2 Accessibility____________________________________________ 35
3.18.2.3 Outdoor installation______________________________________ 35
3.18.2.4 Indoor installation _______________________________________ 36
3.18.2.5 Stability _______________________________________________ 36
3.18.3 Drives ___________________________________________________36
3.18.3.1 Starting torque _________________________________________ 36
3.18.3.2 Radial load on shaft end __________________________________ 37
3.18.4 Shaft rotation for pump without safety relief valve _______________37
3.18.5 Shaft rotation for pump with safety relief valve __________________38
3.18.6 Suction and discharge pipes ________________________________39
3.18.6.1 Forces and moments ____________________________________ 39
3.18.6.2 Piping _________________________________________________ 39
3.18.6.3 Isolating valves _________________________________________ 40
3.18.6.4 Strainer________________________________________________ 40
3.18.7 Secondary piping__________________________________________40
3.18.7.1 Drain lines _____________________________________________ 40
3.18.7.2 Heating jackets_________________________________________ 41
3.18.8 Flush/quench media _______________________________________42
3.18.8.1 Packing________________________________________________ 42
3.18.8.2 Single Mechanical seal ___________________________________ 43
3.18.8.3 Double mechanical seal – Tandem arrangement ______________ 43
3.18.8.4 Double mechanical seal – Back-to-back arrangement _________ 44
3.18.8.5 Cartridge mechanical seal ________________________________ 44
3.18.8.6 Secondary connections __________________________________ 45
3.18.9 Guidelines for assembly ____________________________________47
3.18.9.1 Transport of pump unit ___________________________________ 47
3.18.9.2 Foundation pump unit ____________________________________ 47
3.18.9.3 Variators, Gear box, Gear motors, Motors ___________________ 47
3.18.9.4 Electric motor drive ______________________________________ 48
3.18.9.5 Combustion engines_____________________________________ 48
3.18.9.6 Shaft coupling __________________________________________ 49
3.18.9.7 Guarding of moving parts_________________________________ 49
3.19 Instructions for start-up _____________________________________ 50
3.19.1 General __________________________________________________50
3.19.2 Cleaning the pump ________________________________________50
3.19.2.1 Cleaning suction line_____________________________________ 50
3.19.3 Venting and filling__________________________________________50
3.19.4 Checklist – Initial start-up __________________________________51
3.19.5 Start-up__________________________________________________52
3.19.6 Shut-down _______________________________________________52
3.19.7 Abnormal operation ________________________________________52
3.20 Trouble shooting___________________________________________ 53
3.20.1 Instructions for re-using and disposal _________________________55
3.20.1.1 Re-use ________________________________________________ 55
3.20.1.2 Disposal _______________________________________________ 55

5
A.0500.351 – IM-TGH/07.02 EN (10/2015)
3.21 Maintenance instructions ___________________________________ 56
3.21.1 General __________________________________________________56
3.21.2 Preparation _______________________________________________56
3.21.2.1 Surroundings (on site) ___________________________________ 56
3.21.2.2 Tools __________________________________________________ 56
3.21.2.3 Shut-down _____________________________________________ 56
3.21.2.4 Motor safety____________________________________________ 56
3.21.2.5 Conservation ___________________________________________ 56
3.21.2.6 External cleaning ________________________________________ 57
3.21.2.7 Electrical installation _____________________________________ 57
3.21.2.8 Draining of fluid ________________________________________ 57
3.21.2.9 Fluid circuits____________________________________________ 58
3.21.3 Specific components_______________________________________58
3.21.3.1 Nuts and bolts __________________________________________ 58
3.21.3.2 Plastic or rubber components _____________________________ 58
3.21.3.3 Flat gaskets ____________________________________________ 58
3.21.3.4 Filter or suction strainer __________________________________ 58
3.21.3.5 Anti-friction bearings_____________________________________ 58
Recommended greases (Also consult supplier !)______________________ 58
3.21.3.6 Sleeve bearings_________________________________________ 59
3.21.3.7 Shaft seals _____________________________________________ 60
3.21.4 Front pull-out _____________________________________________62
3.21.5 Back pull-out _____________________________________________62
3.21.6 Clearance adjustment ______________________________________62
3.21.7 Designation of threaded connections _________________________63
3.21.7.1 Threaded connection Rp (example Rp 1/2) __________________ 63
3.21.7.2 Threaded connection G (example G 1/2)____________________ 63
4.0 Instructions for assembly and disassembly ____________________ 64
4.1 General __________________________________________________ 64
4.2 Tools ____________________________________________________ 64
4.3 Preparation _______________________________________________ 64
4.4 After disassembly__________________________________________ 64
4.5 Anti-friction bearings _______________________________________ 65
4.5.1 General __________________________________________________65
4.5.2 TG H2-32 and TG H3-32 disassembly________________________65
4.5.3 TG H2-32 and TG H3-32 assembly __________________________65
4.5.4 TG H6-40 to TG H360-150 disassembly______________________66
4.5.5 TG H6-40 to TG H360-150 assembly ________________________66
4.6 Relief valve _______________________________________________ 67
4.6.1 Disassembly _____________________________________________67
4.6.2 Assembly ________________________________________________67
4.7 Mechanical seal ___________________________________________ 68
4.7.1 General __________________________________________________68
4.7.2 Preparation _______________________________________________68
4.7.3 Special tools _____________________________________________68
4.7.4 General instructions during assembly _________________________69
4.7.5 Assembly of the stationary seat _____________________________ 69
4.7.6 Assembly of the rotating part ________________________________69
4.7.7 Adjustment of mechanical seal _______________________________70
4.7.7.1 GS – Single mechanical seal______________________________ 70
4.7.7.2 GG – Double mechanical seal tandem______________________ 74
4.7.7.3 GD – Double mechanical seal “Back-to-back” _______________ 74
4.7.7.4 GC – Mechanical seal cartridge ___________________________ 76

6A.0500.351 – IM-TGH/07.02 EN (10/2015)
5.0 Sectional drawings and part lists ____________________________ 79
5.1 TG H2-32 and TG H3-32 ________________________________________ 79
5.1.1 Hydraulic part _____________________________________________80
5.1.2 Bearing bracket ___________________________________________80
5.1.3 Flange connection options __________________________________80
5.1.4 S-jacket options ___________________________________________81
5.1.4.1 S-jacket on pump cover __________________________________ 81
5.1.4.2 S-jacket around shaft seal ________________________________ 81
5.1.5 Seal options ______________________________________________81
5.1.5.1 Packing rings – PQ______________________________________ 81
5.1.5.2 Single mechanical seal – GS______________________________ 82
5.1.5.3 Double mechanical seal tandem – GG______________________ 82
5.1.5.4 Double mechanical seal back-to-back – GD _________________ 82
5.2 TG H6-40 to TG H360-150 ________________________________ 83
5.2.1 Hydraulic part _________________________________________________ 84
5.2.2 Bearing bracket________________________________________________ 84
5.2.3 Flange connection options __________________________________85
5.2.4 Jacket options_____________________________________________86
5.2.4.1 S-jacket on pump cover __________________________________ 86
5.2.4.2 S-jacket around shaft seal ________________________________ 86
5.2.4.3 T-jackets with flange connections on pump cover ____________ 87
5.2.4.4 T-jackes with flange connections around shaft seal ___________ 88
5.2.5 Shaft seal options _________________________________________89
5.2.5.1 Packing rings PQ with lantern ring
______________________________________________________ 89
5.2.5.2 Packing rings PO without lantern ring_______________________ 89
5.2.5.3 Single mechanical seal – GS______________________________ 89
5.2.5.4 Cartridge mechanical seal – GC___________________________ 90
5.2.5.5 Double mechanical seal tandem – GG______________________ 90
5.2.5.6 Double mechanical seal back-to-back – GD _________________ 90
5.2.5.7 Cartridge mecanical seal - LCT TV (LCT XX)_________________ 91
5.2.5.7 Reverted packing – Chocolate version _____________________ 92
6.0 Dimensional drawings _____________________________________ 93
6.1 Standard pump ___________________________________________ 93
6.1.1 TG H2-32 to TG H3-32 ____________________________________93
6.1.2 TG H6-40 to TG H360-150_________________________________94
6.2 Flange connections ________________________________________ 95
6.2.1 TG H2-32 to TG H3-32 ____________________________________95
6.2.2 TG H6-40 to TG H360-150_________________________________95
6.3 Jackets __________________________________________________ 96
6.3.1 TG H2-32 and TG H3-32___________________________________96
6.3.2 TG H6-40 to TG H360-150_________________________________97
6.4 Safety relief valves___________________________________________________ 98
6.4.1 Single safety relief valve ____________________________________98
6.4.2 Double safety relief valve____________________________________99
6.4.3 Heated safety relief valve _________________________________ 100
6.5 Bracket support __________________________________________ 101
6.6 Weights – Mass__________________________________________ 101

7
. . . .
. . . .
. . . .
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
C
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:
.
.
.
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.spx.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: 17mm x 4,60mm
• Tekst firmagegevens / Text company data:
lettertype / font: Arial regular
lettergrootte / fontsize: 5pt
• Afmeting JP-logo / Dimensions JP-logo: 20mm x 2,31mm
A.0500.351 – IM-TGH/07.02 EN (10/2015)
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.
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.

8A.0500.351 – IM-TGH/07.02 EN (10/2015)
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.0500.351 – IM-TGH/07.02 EN (10/2015)
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
. . . .
. . . .
. . . .
. . . .
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
B
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:
.
.
.
.
EAC logo added
SPX Flow Technology
Belgium NV
Evenbroekveld 2-6
BE-9420 Erpe-Mere
www.johnson-pump.com / www.spx.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 8,63mm
• Tekst firmagegevens / Text company data:
lettertype / font: Arial regular
lettergrootte / fontsize: 7pt
• Afmeting JP-logo / Dimensions JP-logo: 45mm x 5,2mm
A.0500.351 – IM-TGH/07.02 EN (10/2015)
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.0500.351 – IM-TGH/07.02 EN (10/2015)
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 H 58-80 R 2 S S BR 5 B R5 PQTC
1 2 3 4 5 6 7 8 9 10 11 12 13
TG H 360-150 FD R 5 O O UR 6 U R8 GS WV
1 2 3 4 5 6 7 8 9 10 11 12 13
A.0500.351 – IM-TGH/07.02 EN (10/2015)
2.0 Pump description
TopGear H-pumps are rotary positive displacement pumps with internal gear. They are made of
stainless steel, nodular iron or cast steel. TGH-pumps are assembled from modular elements, which
allows a variety of constructions: different shaft sealings (packing and/or mechanical seal), heating/
cooling jackets (steam or thermal oil), 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
H = High demanding applications
3. Hydraulics indicated with displacement volume per 100 revolution (in dm3)
and nominal port diameter (in mm)
TG H2-32
TG H3-32
TG H6-40
TG H15-50
TG H23-65
TG H58-80
TG H86-100
TG H185-125
TG H360-150
4. Application
Non-food
FD Food
5. Pump material
R Pump in stainless steel
S Pump in carbon steel
N Pump in nodular iron
6. Port connection type
1 Thread connections
2 PN25 flanges
3 PN20 flanges to ANSI 150 lbs
4 PN50 flanges to ANSI 300 lbs
5 PN16 flanges to DIN 2533
7. Jacket options for pump cover
O Pump cover without jackets
S Pump cover with jacket and thread connection
T Pump cover with jacket and flange connection

13
A.0500.351 – IM-TGH/07.02 EN (10/2015)
8. Jacket options around shaft seal
O Shaft seal without jackets
S Shaft seal with jacket and thread connection
T Shaft seal with jacket and flange connection
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
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 for packing
G8 Rotor in iron and shaft in hard coated stainless steel for mechanical seal
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 for packing
N8 Rotor in nitrited nodular iron and shaft in hard coated stainless steel for mechanical seal
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 for packing
R8 Rotor in stainless steel and shaft in hard coated stainless steel for mechanical seal
13. Shaft seal arrangements
Packing version without lantern ring
PO TC PTFE graphited packing rings
PO AW Aramide-white packing rings
PO CC Graphite fibre packing rings
PO XX Packing version parts – rings on request

14
TG H 58-80 R 2 S S BR 5 B R5 PQTC
1 2 3 4 5 6 7 8 9 10 11 12 13
TG H 360-150 FD R 5 O O UR 6 U R8 GS WV
1 2 3 4 5 6 7 8 9 10 11 12 13
A.0500.351 – IM-TGH/07.02 EN (10/2015)
Example:
13. Shaft seal arrangements (cont’d)
Packing version with lantern ring
PQ TC PTFE graphited packing rings
PQ AW Aramide-white packing rings
PQ CC Graphite fibre packing rings
PQ XX Packing version parts – rings on request
Reverted packing version; chocolate execution
PR TC Packing rings PTFE graphited
PR AW Packing rings aramide-white
PR XX Packing version parts – rings on request
Single mechanical seal Burgmann type MG12 to be used with set ring
GS AV Single mechanical seal Burgmann MG12; Carbon/SiC/FPM (Fluorocarbon)
GS WV Single mechanical seal Burgmann MG12; SiC/SiC/FPM (Fluorocarbon)
Single mechanical seal Burgmann type M7N
GS HV Single mechanical seal Burgmann M7N; SiC/Carbon/FPM (Fluorocarbon)
GS HT Single mechanical seal Burgmann M7N; SiC/Carbon/PTFE-wrapped
GS WV Single mechanical seal Burgmann M7N; SiC/SiC/FPM (Fluorocarbon)
GS WT Single mechanical 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
GS XX Single seal parts – seal on request
Single mechanical seal cartridge
GCT WV Cartex TN3 (with throttle bush); SiC/SiC/FPM (Fluorocarbon)
GCT WT Cartex TN3 (with throttle bush); SiC/SiC/PTFE
GCQ WV Cartex QN3 (with lip ring); SiC/SiC/FPM (Fluorocarbon)
GCQ WT Cartex QN3 (with lip ring); SiC/SiC/PTFE
Remark: EPDM and FFKM (Chemraz®) O-ring sets available on request
Double mechanical seal cartridge
GCD WV BV Cartex DN3; SiC/SiC/FPM (Fluorocarbon)-SiC/Carbon/FPM (Fluorocarbon)
GCD WT BV Cartex DN3; SiC/SiC/PTFE-SiC/Carbon/FPM (Fluorocarbon)
Remark: EPDM and FFKM (Chemraz®) O-ring sets available on request
GCX XX XX Cartridge seal version without cartridge seal
(cartridge seal on request)
GG XX XX Double mechanical seal tandem version; without mechanical seals
(seals on request)
GD XX XX Double mechanical seal back-to-back version; without mechanical seals
(seals on request)
Triple PTFE lip-seal cartridge
LCT TV Cartridge triple lip seal; PTFE seals / FKM Viton (Fluoroelastomer) o-rings
LCT XX Cartridge triple lip seal; PTFE seals / no o-rings)

15
A.0500.351 – IM-TGH/07.02 EN (10/2015)
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.0500.351 – IM-TGH/07.02 EN (10/2015)
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 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.0500.351 – IM-TGH/07.02 EN (10/2015)
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 H 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.maw
(bar)
p.test
(bar)
2-32 32 13.5 65 1.83 1800 0.5 2.0 6.1 0.7 16 20 30
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 20 30
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 20 30
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 20 30
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 20 30
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 20 30
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 20 30
185-125 125 100 224 185 750 23 83 8.8 1.9 16 20 30
725 22 80 8.5 1.8
360-150 150 125 280 360 600 36 130 8.8 2.0 16 20 30
Maximum viscosity
*) 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) *)
Packed gland PO, PQ, PR 80 000
Double mechanical seal
Back-to-back – GD and GCD pressurized 80 000
Tandem – GG and GCD not pressurized 5 000
Single mechanical seal
GS with Burgmann MG12 3 000
GS with Burgmann M7N 5 000
GCQ and GCT cartridge 5 000
Triple PTFE lip-seal 80 000
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.maw : maximum allowable working pressure = design pressure
p.test : hydrostatic test pressure

18
Hydrostatic test pressure of casing
30 bar
20 bar
Allowable working pressure design pressure of casing
16 bar
Differential pressure working pressure
A.0500.351 – IM-TGH/07.02 EN (10/2015)
3.6 Pressure
For performance on pressure, three kinds of pressures must be considered:
Differential pressure or working pressure (p) is the pressure on which the pump normally
operates. The maximum differential pressure for all TopGear H-range pumps is 16 bar.
Maximum allowable working pressure (p.m) is the pressure on which the pump casing is
designed and that can been achieved occasionally when the operating pressure rises over the
normal operating pressure e.g. when the pump run with open relief valve.
In the TopGear H-range the design pressure is 20 bar i.e. 4 bar higher than the maximum
differential pressure. It ensures higher safety such as is required in API676 for rotary positive
displacement pumps.
The hydrostatic test pressure = 30 bar is the pressure on which the pump casing is tested.
The test pressure is 1.5 times the design pressure.
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 H pump size nmax(min-1)
Lpa (dB(A))
Ls (dB(A))
25% nmax 50%nmax 75%nmax 100%nmax
2-32 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
360-150 600 72 83 89 92 11

19
A.0500.351 – IM-TGH/07.02 EN (10/2015)
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 act 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–L2 0 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
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 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 base plate etc. will make the installation produce more noise.

20 A.0500.351 – IM-TGH/07.02 EN (10/2015)
3.8 Material options
Overall temperature
The TG H range is designed for high temperatures. The overall temperatures for selected casing
materials are shown in below table.
TG H
pump size
Minimum allowable temperature (°C) Maximum allowable temperature (°C)
Casing materials Casing materials
Stainless steel (R) Carbon steel (S) Nodular iron (N) Stainless steel (R) Carbon steel (S) Nodular iron (N)
2-32 –40 – – +200 – –
3-32
6-40
–40 –30
–
+250 +300
–
15-50
–25 +300
23-65
58-80
86-100
185-125
360-150
Remarks:
1. Maximum temperature of size TG H2-32 and TG H3-32 is limited to 200°C due to ball bearings
type 2RS.
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.
T-jackets are designed for use with thermal oil and apply to the DIN4754 safety standard for
thermal oil transfer. This DIN standard specifies flange connections for temperature from 50°C
upwards and jackets of ductile material for temperature from 200°C upwards. Both are provided in
the T-design.
T-jackets could also be used for over heated steam or more dangerous media.
The flanges have a special shape with welding neck based on PN16 dimensions.
Maximum temperature: 300°C
Maximum pressure at 300°C: 12 bar
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) No (traceability) Yes
(*) These are not absolute figures. Higher or lower values possible in function of the application,
expected lifetime etc