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SPX Cooling Technologies MAG185-125 User's Manual

1. Compliance with local safety regulations The exhaust of combustion gases must be screened to avoid contact The starter must be uncoupled automatically once the engine has started The pre set maximum number of engine revolutions may not be modified Before starting the engine the oil level must be checked Note Never run the engine in a closed area Never refuel the engine while it is still running Shaft coupling Internal gear pumps demand a relatively high starting torque During the operation shock loads occur due to pulsations inherent to the gear pump principle Therefore choose a coupling which is 1 5 times the torque recommended for normal constant load Fit without impact tool both halves of the coupling to the pump shaft and the motor shaft respectively Alignment The pump and motor shafts of complete units are accurately pre aligned in the factory After installation of the pump unit the pump and motor shaft alignment must be checked and re aligned if necessary Alignment of the coupling halves may only take place by moving the electric motor A 0500 551 IM TGMAG 02 00 EN 02 2008 1 Place a ruler A on the coupling Remove or add as many shims as is necessary to bring the electric motor to the correct height so that the straight edge touches both coupling halves over the entire length see figure 2 Repeat the same check on both sides of the coupling at
2. s Vertical safety relief valve Set pressure modification Spring ratio Safety relief valve Spring dimensions Pressure Du d Lo p f TG MAG pump size class mm mm mm bar min 4 37 0 4 5 93 0 21 5 isso 5 6 37 0 4 5 93 0 21 d 23 65 5 10 365 60 90 0 81 9 16 365 60 90 0 81 i 1 ll olg NE sd Je 4 4 9 7 0 124 0 32 L l c 3 6 49 0 7 0 124 0 66 58 80 10 48 6 8 0 124 0 66 r E 16 48 6 8 0 124 0 66 t Du g 4 49 0 7 0 124 0 16 m 86 100 6 48 6 8 0 124 0 33 185125 10 490 90 120 0 55 16 62 11 109 0 86 Note Spring ratio p f depends upon the dimensions of the spring It is recommended to check the dimensions prior to adjusting the pressure When the safety relief valve is not functioning properly the pump must immediately be taken out of service The safety relief valve must be checked by your distributor A 0500 551 IM TGMAG 02 00 EN 02 2008 27 28 3 17 6 Sectional drawings and part lists 3 17 6 1 Single safety relief valve 7100 7100 7320 7050 7170 7010 7150 Single safety relief valve horizontal Pos rei 3 antai vor ich Preventive Overhaul 7010 Valve complete 1 1 1 7030 Valve casing 1 1 1 7040 Spring casing 1 1 1 7050 Cover 1 1 1 7100 Spring plate 2 2 2 7110 Valve seat 1 1 1 7150 Spring 1 1 1 7170 Flat gasket 1 1 1 x x 7180 Flat gasket 1 1 1 x x 7240 Name plate 1 1 1 730
3. Check condition of O rings and assemble them or not correctly assembled correctly or replace them Check condition and clean repair sealing faces Replace gasket under top cover or safety relief valve and or sealing rings under plugs Note If symptoms persist the pump must be taken out of service immediately Contact your distributor 3 20 1 Instructions for re using and disposal 3 20 1 1 Re use Re use or putting the pump out of service should only be undertaken after complete draining and cleaning of the internal parts 4 Note When doing so observe adequate safety regulations and take environmental protection measures Liquids should be drained and following local safety regualtions the correct personal equipment should be used 3 20 1 2 Disposal Disposal of the pump should only be done after it has been completely drained Proceed according to local regulations Where applicable please disassemble the product and recycle the parts material 3 21 Maintenance instructions 3 21 1 General This chapter only describes operations that can be performed on site for normal maintenance For maintenance and repair requiring a workshop contact your distributor Insufficient wrong and or irregular maintenance can lead to malfunctions in the pump high repair costs and long term inoperability Therefore you should carefully follow the guidelines given in this chapter During maintenance ope
4. K hyd with the following equation 15 50 6250 23 65 4000 Viscosity shaft speed diff pressure K hyd 58 80 3750 with viscosity mPa s 86 100 3600 shaft speed rpm 185 125 2500 diff pressure bar K hyd design constant for each pump size Maximum torque of pump shaft and rotor material combination The maximum torque is limited by the maxium transmittable torque of the magnetic coupling This means the magnetic coupling will slip through before the rotor shaft or pump shaft reach their mechanical limitations A 0500 551 IM TGMAG 02 00 EN 02 2008 19 20 3 11 Mass moment of inertia TG MAG pump size 15 50 23 65 58 80 86 100 185 125 J 10 3 x kgm 3 5 6 8 32 54 200 Outer parts Inner parts l Inner parts Idler Rotor shaft Axial rotor bearings Shaft sleeve Inner magnetic rotor Outer parts Pump shaft Outer magnetic rotor Mass moment of inertia J 10 x kgm TG MAG outer parts per lenght of magnets inner parts per lenght of magnets type 40 60 80 100 120 40 60 80 100 120 15 50 22 26 7 E 8 9 23 65 22 26 7 10 12 58 80 66 80 93 46 52 58 86 100 72 85 99 65 70 76 5 185 125 248 3038 358 413 230 247 264 280 3 12 Axial and radial clearances TG MAG pump size 15 50 23 65 58 80 86 100 185 125 radial clearance max um 310 32
5. Shut down When the pump is to be put out of service the following procedure must be observed L Tum the motor off L Close the supply lines of the heating cooling circuit if applicable L If solidification of the liquid must be avoided clean the pump while the product is still in a fluid state Also see section 3 21 Maintenance instructions Note When the liquid flows back from the discharge pipe to the pump the pump may rotate in the opposite direction This can be prevented by closing the discharge valve after the motor has been switched off Abnormal operation Note In case of abnormal operation or when troubles occur the pump must be taken out of service immediately Inform all responsible personnel L Prior to restarting the pump determine the reason for the problem and solve the problem A 0500 551 IM TGMAG 02 00 EN 02 2008 3 20 Trouble shooting Symptom Cause Remedy No flow Pump not priming Suction lift too high 1 Reduce difference between pump and suction tank level Increase suction pipe diameter Reduce length and simplify suction pipe use as few elbows and other fittings as possible Also see section 3 18 Installation Air leak in suction line Repair leak Very low viscosity Increase pump speed and reduce axial clearance see section 3 21 Maintenance instructions Suction strainer or filter clogged Clear suction strainer or filter Pump casi
6. 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 L 0 1 2 3 4 5 6 L L L 3 0 2 5 20 1 7 1 4 1 2 1 0 Loa 7 L E L corrected where L the total sound level of the pump unit otal L the highest sound level L the lowest sound level Lid term depending on the difference between both sound levels For more than two values this method can be repeated Example Drive unit L 79 dB A Pump L 75 dB A Correction L L 4 dB A According to the table L 1 4 dB A L 79 1 4 80 4 dB A total A 0500 551 IM TGMAG 02 00 EN 02 2008 17 18 3 7 3 3 8 3 9 3 10 3 10 1 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
7. olf JOHNSON PUMP AN SPX BRAND Instruction Manual TooGear MAG Magnetic Drive Internal Gear pumps m Read and understand this manual prior to operating or servicing this product 254 A 0500 551 IM TG MAG 02 00 GB 02 2008 EC Declaration of conformity as per EC s Machinery Directive 98 37 EC Annex IIA Producer SPX Process Equipment BE NV Evenbroekveld 2 6 BE 9420 Erpe Mere Belgium We hereby guarantee that TopGear MAG Magnetic Drive Gear Pumps Types TG MAG15 50 TG MAG23 65 TG MAG58 80 TG MAG86 100 TG MAG185 125 are in conformity with EC s Machinery Directive 98 37 EC Annex l Manufacturer Declaration as per EC s Machinery Directive 98 37 EC Annex IIB The product must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive Erpe Mere 1 July 2007 Gerwin Schaafsma Operational Manager Europe Contents 1 0 IMrOGUSUO acuida DE 7 11e Generals l GO OO Ad O m 7 1 2 Reception handling and Storage asosatkaccr dod ione e nob brane di 7 1 2 1 ReGepllO l iet E cada i teet tede erectae d Marco E 7 1 2 2 Handling cerei tee A chests act coude acai stc tia 7 12 3 Storage cei pde bed ada a Maia 7 NS o Safet 8 1 89 1 General aaa a a 8 1 3 2 PUMP UNITS siioni oiaro w ZA A WE AA s ed 9 1 3 2 1 Pump uhit handling ect nes 9 1
8. 4 2 2 Disassembly of top cover 0100 or safety relief valve 1 Un tighten tap bolts 1080 crosswise and remove them 2 Take off top cover 0100 or safety relief valve 3 Remove gasket 1090 and clean the sealing faces on the pump casing 0010 and top cover 0100 or safety relief valve 4 2 3 Disassembly of bearing bracket Removal of bearing bracket 1 Place the pump in vertical position with the pump shaft pointing up on the work bench Remove bearing bracket support 1700 2 3 Un tighten cap head screws 1410 crosswise and remove them 4 Mount the 4 guiding bars tool into the holes of cap head screws 1410 and screw lifting eye bolt in the shaft end c B L E TG MAG A B c D E F G A H a F OG TG MAG 15 50 2 ID oko M1o 12 160 105 10 8 78 j TG MAG 23 65 Hf 0 5 x 48 Z TG MAG 58 80 I c Mil 15 205 135 10 10 94 F TG MAG 86 100 t TG MAG 185 125 M16 20 240 17 10 13 13 5 Lift the bearing bracket complete with pump shaft and outer magnet rotor off the pump Remark The guiding bars are necessary to prevent that the magnets in the outer rotor are damaged during disassembly of the bearing bracket Protect metal part with plastic tube 50 A 0500 551 IM TGMAG 02 00 EN 02 2008
9. 4 2 4 Disassembly of pump shaft complete 1 Remove key 1570 from the pump shaft 2 Remove sealing segment 1490 from the bearing bracket see picture _ 1570 Piercer 1490 Screw driver 3 Remove circlip 8640 from the rear end of the shaft 4 Un tighten countersunk screws 1540 from the front end and remove them Remark The pump shaft 0702 can be rotated to allow access to these screws Be care ful that the spanner does not damage the magnets in the outer magnectic rotor 8320 5 Drive out the complete pump shaft to the front by tapping with a plastic hammer on the pump shaft 0702 4 2 5 Disassembly of outer magnetic rotor 1 Un tighten cap head screws 8610 crosswise and remove them 2 Use threaded holes in the flange of the pump shaft to remove the outer magnetic rotor 8320 Removal of ball bearings 1 Remove circlips 1450 and support ring 1460 from the pump shaft 0702 2 Remove the bearing 1440 from the shaft using a ball bearing extractor 3 Remove the bearing cover 1430 from the pump shaft 0702 4 Remove both circlips 8620 from the bearing bracket 1400 to the front 5 Drive out ball bearing 1440 from the bearing bracket 1400 to the rear A 0500 551 IM TGMAG 02 00 EN 02 2008 51 4 2 6 Disassembly of separation can 1 Un tighten cap head screws 8210 crosswise and remove them 2 Use two cap head screws 8210 in the threaded holes of
10. seen 45 3 21 3 3 Plat gaskets ae a N 45 3 21 3 4 Filter or suction strainer sssssseseeeeeene teens 46 3 21 3 5 Anti friction bearings tentent ntes 46 3 21 3 6 Sleeve bearings perte a Aa 46 3 21 4 Front pull out u ieneeieo aem te rte iter eae erae 46 3 21 5 Backpullzout 5 hoe tei ae dete ei 46 3 21 6 Clearance adjustment sees 46 3 21 7 Designation of threaded connections sees 48 3 21 7 1 Threaded connection Rp example Rp 1 2 3 21 7 2 Threaded connection G example G 1 2 4 0 Instructions for assembly and disassembly 49 41 RESTA lr RN oo Pr 49 4 2 DISaSSemblV NAGO deseo Dieci D ast cen RU Du dn Eo 49 4 2 1 Disassembly of front pull out assembly sss 49 4 2 2 Disassembly of top cover 0100 or safety relief valve 50 4 2 3 Disassembly of bearing bracket seen 50 4 2 4 Disassembly of pump shaft complete sse 51 4 2 5 Disassembly of outer magnetic rotor usera 51 4 2 0 Disassembly of separation can seen 52 4 2 7 Disassembly of back pull out assembly sss 52 43 Assemblynsasuiudnisbestotismeteiiedot oai bul e CO S dna ael re ERR 54 4 3 1 Assembly of bearing bracket seen 54 4 3 2 Pre assembly of the back pull out seen 56 4 3 2 1 X Adjustment o
11. weighted sound pressure level L emitted by a pump without drive measured according to 503744 and expressed in decibels dB A The reference sound pressure is 20uPa A 0500 551 IM TGMAG 02 00 EN 02 2008 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 n maximum shaft speed Lpa dB A TG MAG pump size n min 1 25 n 50 n 75 n 100 n Ls dB A 15 50 1500 61 72 79 83 9 23 65 1500 63 75 81 85 10 58 80 1050 67 79 85 89 10 86 100 960 69 80 86 90 11 185 125 750 71 82 87 91 11 Sound power level L The sound power L 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 weighted sound power level L is also expressed in decibels dB A The reference sound power is 1 pW 10 W L is 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 the table above 3 7 2 The sound level of the pump unit
12. A clogged filter in the suction piping may result in insufficient suction pressure at the inlet Clogged filter in the discharge line may result in higher discharge pressure 3 21 3 5 Anti friction bearings TG MAG pumps are equipped with 2RS ball bearings which are grease packed for life They do not require periodical greasing The bearings should be replaced after 25 000 operating hours 3 21 3 6 Sleeve bearings 3 21 4 3 21 5 3 21 6 We recommend checking the pump regularly for wear on the gear wheels and sleeve bearings to avoid excessive wear of other parts A quick check can be done by using the front pull out and back pull out system See table for maximum allowable radial clearance of the sleeve bearings Forreplacement of the sleeve bearings contact your distributor TG MAG pump size De clearances 15 50 to 23 65 0 15 mm 58 80 to 86 100 0 25 mm 185 125 0 30 mm Front pull out The TG pumps have a front pull out system To remove liquid residues or to check the idler bearing for wear the pump cover can be pulled out from the pump housing without disconnecting suction and discharge pipes See chapters 4 0 Disassembly Assembly and section 6 6 Weights Back pull out To flush the pump or to check the rotor shaft bearing arrangement the bearing bracket with outer magnetic rotor and the rotor shaft bearing assembly can be pulled out backwards without disconnecting the suction and
13. MAG pump is put into service for the first time the suction line must be cleaned thoroughly Do not use the TG MAG pump for flushing the system because it is not meant to pump low viscous liquids which might contain particles Venting and filling To operate properly the pump should be vented and filled with liquid to be pumped before initial start up If the liquid level on the suction side is below the suction flange level of the pump the pump must be filled with liquid to make priming possible e Unscrew filing plugs Bb and Be Fill up the pump with liquid to be pumped via connections Be e Rotate the pump shaft by hand in the normal sense of rotation while filling the liquid into the pump e Tighten the filling plugs Be Screw in plug Bb but not tighten it e Start the pump and tighten plug Bb when all air has escaped and liquid starts flowing out of this connection If the liquid level at the suction side is above the suction flange level of the pump vent the pump as follows e Loosen filing plugs Bb and Be so that air can escape e Open the suction side valve to let the pumped liquid flow into the pump Rotate the pump shaft by hand in the proper sense of rotation during venting e Tighten the plugs Bb and Be when liquid starts flowing out of these connections When the TG MAG pump is brought into service for the first
14. also invalidate the warranty Gear pumps must never run completely dry Dry running produces heat and can cause damage to internal parts such as bush bearings 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 distributor fthe pump does not function satisfactorily contact your distributor A 0500 551 IM TGMAG 02 00 EN 02 2008 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 If there are lifting rings on both the Warning part of the pump and the back part of pump and the motor the slings may be Never lift the pump unit with only one the motor Make sure that the load is fastened to these fastening point Incorrect lifts can re balanced before attempting the lift NB Always use two lifting slings sult in personal injury and or damage NB Always use two lifting slings 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 Personnel who have a pacemaker should not be allowed to work with the magnetic coupling The ma
15. bar Net Positive NPSHa Net Positive Suction Head is the total absolute inlet pressure at SuctionHead 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 496 Note In this manual unless otherwise specified NHPH NPSHr When selecting a pump ensure that NPSHa is at least 1 m higher than the NPSHr A 0500 551 IM TGMAG 02 00 EN 02 2008 11 12 2 0 2 1 Pump description TopGear MAG pumps are rotary positive displacement pumps with internal gear They are made of cast iron or stainless steel TG MAG pumps are assembled from modular elements which allows a variety of constructions Different magnet coupling executions heating cooling options several sleeve bearings gear and shaft materials and mounted safety relief valve Type designation The pump properties are encoded in the following type indication which is to be found on the name plate Example TG MAG 58 80 G2 SOC BG2 Q S5 S10 V R TG MAG 58 80 G2 s oc BG 2 Q S5 S10 v R 1 2 3
16. clearance of the circulation pump 1 Place pump insert 8430 and radial bearing holder 8350 C in the intermediate cover 8450 Do not use any shim 8470 at this stage Remark There are two different inserts according to the sense of rotation of the pump shaft see sketch 2 Fit cap head screws 8480 and tighten them cross wise to fix the radial bearing holder B350 C and insert 8430 to the intermediate cover 8450 8430 Do not use any force and be careful not to damage 8350 A the bearing faces while pushing part 8350 4 in until the bearing faces are making contact 4 Measure the distance between front face of the axial bearing holder 8350 A front face gear tooth and ron the front face of the crescent of the pump insert 8430 shim 8470 S2 X C Axial clearance C see table below TG MAG Axial pei c 15 50 0 120 0 200 23 65 0 125 0 215 58 80 0 150 0 250 86 100 0 165 0 275 185 125 0 190 0 320 A 0500 551 IM TGMAG 02 00 EN 02 2008 6 Peel the required number of layers off the bearing shim 8470 to adjust the thickness of the shim S to the required value 7 Un tighten cap head screws 8480 and remove radial bearing holder 8350 C from the intermediate cover 8450 8 Assemble radial bearing holder B350 C again in the same way with the shim placed between holder and intermediate cover 8450 9 Place front axial bearin
17. cover 4000 and pump casing 0010 S A B C Axial clearance C between rotor shaft 0701 and pump cover 4000 see table below TG MAG Axial pex c 15 50 0 120 0 200 23 65 0 125 0 215 58 80 0 150 0 250 86 100 0 165 0 275 185 125 0 190 0 320 8 Adjust the thickness of shim 8100 by peeling off the required number of layers 9 Place shim 8100 support ring 8110 and O ring 8120 on the pump cover 4000 10 Place idler 0600 complete with bearing bush on the idler pin 11 Mount pump cover 4000 on the pump casing 0010 12 Screw in tap bolts 0040 and tighten them crosswise to fix the pump cover 4000 on the pump casing 0010 A 0500 551 IM TGMAG 02 00 EN 02 2008 47 48 3 21 7 3 21 7 1 3 21 7 2 Designation of threaded connections To make clear what sealing type of threaded connection is provided we denominate them according to standards ISO 7 1 and ISO 228 1 as follows Threaded connection Rp example Rp 1 2 If no flattened sealing face is provided we call the connection Rp according to ISO 7 1 This connection has to be sealed in the thread The plugs or pipe connections must be provided with conical thread according to ISO 7 1 external thread example ISO 7 1 R1 2 Conical plug Conical pipe end ISO 7 1 R 1 2 ISO 7 1 R 1 2 ISO 7 1 Type Symbol Example f GH Internal PZN LEJ
18. discharge pipes When a spacer coupling is used the driving mechanism need not be moved See chapters 4 0 Disassembly Assembly and section 6 6 Weights for the mass weight of the components Clearance adjustment The TG pumps are delivered with the correct axial clearance setting In some cases however the axial clearance needs to be adjusted e When uniform rotor and idler wear need to be compensated by re setting the axial clearance e When pumping low viscous liquids the slip can be reduced by decreasing the axial clearance e When the liquid is more viscous than expected the friction inside the pump can be reduced by increasing the axial clearance A 0500 551 IM TGMAG 02 00 EN 02 2008 Proceed as follows to set the axial clearance 1 Un tighten tap bolts 0040 crosswise and remove them 2 Use two tap bolts 0040 in the threaded holes in the pump cover 4000 to push off the pump cover 4000 3 Take idler 0600 complete with bearing bush off the idler pin Remove O ring 8120 support ring 8110 and shim 8100 from the pump cover 4000 5 Check that the contact faces and O ring chamber are not damaged and free of dirt Check the condition of O ring 8120 in case of doubt replace the O ring with a new one 6 Measure the distances as indicated on the sketch below 7 Calculate the required thickness of the shim 8100 between pump
19. in the hub for the inner magnetic rotor and the front axial bearing is actually part of the circulation pump supplying lubrication and cooling for the magnetic drive Materials rotor bearing assembly Metal parts 1 4460 duplex steel Shaft sleeve Silicon carbide Axial bearing faces Silicon carbide Radial bearing bushes Option O silicon carbide Option C carbon Circulation pump To ensure proper lubrication of the rotor bearings and cooling of the magnetic coupling a circulation pump is providing a controlled flow over the magnetic drive The liquid is flowing from the discharge side of the pump via holes and grooves in the bearing assembly and the magnetic drive back to the suction side of the pump This circulation pump is designed as an internal gear pump where the drive gear integrated in the front axial bearing is driving a disk rotor which is rotating in an insert situated between rotor and intermediate cover The insert and the complete rotor bearing assembly are mounted on the intermediate cover Shaft nut Rear axial bearing Hub inner rotor Intermediate cover Disk rotor Insert Front axial bearing Gear of circulation pump Material circulation pump parts Pump gear 1 4460 duplex steel Disk rotor PEEK Insert 1 4460 duplex steel Sealing rings and gaskets The magnetic drive replaces a dynamic shaft sealing so there are only static seals on TopGear MAG pumps The intermediate cover separatio
20. internals 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 essere nennen 20 3 12 Axial and radial clearances sse 20 3 13 Extra clearances eat des de d Dated 20 3 14 Play between gear Teetlssaideimadedikeirien iiec dg alode ddl data 21 3 15 Maximum size of solid particles see 21 A 0500 551 IM TGMAG 02 00 EN 02 2008 3 16 Components of the magnetic drive eee 22 3 165 Magneticcouplirig uie eap deque etes 22 3 16 2 Rotor bearing assembly eee 23 3 16 3 Circulation pump ete eee e dni eee ie es 24 3 16 4 Sealing rings and gaskets seen 24 3 17 Safety relief valve iei tht tente ere miel tre erbe 25 3 17 1 Definition and working principle eene 26 3 17 2 Materials rtt tee n pie teni eredi 26 3 17 3 CII e 26 3 17 4 Heating etti tte tte te de tn t tel ar nti 26 3 17 5 Safety relief valve Relative adjustment sss 27 3 17 6 Sectional drawings and part lists sse 28 3 17 6 1 Single safety relief valv28 3 17 6 2 Heated spring casing sessanta tentat 29 3 1 8 InstallatlQn a s pneter tei r i Pete eite Adi 3 18 1 General i ct cete abet eo edet 3 18 2 L
21. lower liquid friction and the liquid does not dampen much Vibrations in piping vibrating of the baseplate etc will make the installation produce more noise Maximum and minimum allowable temperature The maximum allowable temperature of the pumped medium is 260 C but the temperature limits must be considered depending on the material used for the idler bearing bush O ring material and material of the permanent magnets used in the magnetic coupling The minimum allowable tempera ture is 20 for cast iron and 40 C for stainless steel casing parts 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 l Maximum temperature 200 C Maximum pressure 10 bar 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 260 C Maximum pressure at 260 C 12 bar Internals Bush materials Overview of bush materials and application field Material Code s c B H u a Mat
22. other ductile material For pipe dimensions of Cf see chapter 6 0 A 0500 551 IM TGMAG 02 00 EN 02 2008 T jacket on pump cover dk _ dk ma zk zh 2xCf A T ER Fiat ay Act AL JOB puis gt GH an 3 Jacket on pump cover In case of steam supply connect the supply line at the highest position and the return line to the lowest position so that condensed water will be drained via the lowest line In case of liquid supply the positions are not important A drain plug Bh is provided and can be considered as a drain line 4 Jackets on safety relief valve around spring casing The jackets on the safety relief valve are designed for use with saturated steam max 10 bar 180 C or with non dangerous media They are provided with threaded connections Bo see chapter 6 0 for dimensions The connection can be done by threaded pipes or pipe connections with sealing in the thread conical thread applying ISO 7 1 Thread type see section 3 21 7 3 18 7 Guidelines for assembly When a bare shaft pump is delivered the assembly with drive is the responsibility of the user The user also must provide all necessary devices and equipment allowing a safe installation and comm
23. required length of the magnets must be selected according to the operating conditions and the maximum allowable temperature Please contact your disributor regarding the correct sizing of the magnetic coupling Material magnetic coupling parts Inner magnetic rotor stainless steel 1 4571 magnets and iron parts completely encapsulated Outer magnetic rotor carbon steel St52 3 equipped with SmCo or NdFeB magnets Separation can flange and bottom plate stainless steel 1 4571 thin walled pipe portion Hastelloy C4 3 16 2 Rotor bearing assembly The rotor bearings are designed to support the radial and axial load generated by the rotor and are lubricated by the pumped liquid The bearing assembly is supplied as a complete set consisting of two radial bearing bushes mounted in the bearing holder two separate axial bearing faces and a shaft sleeve The shaft sleeve is clamped between the two axial bearings via a shaft nut and is rotating with the shaft The front faces of the radial bearing bushes are acting as axial bearing faces The axial bearing clearance is determined by the length of the shaft sleeve so there is no adjustment required That means in case of wear or damage the complete bearing assembly must be exchanged Front axfal bearing Radial bearing holder Shaft sleeve Rear axial bearing Hub inner magnetic rotor A 0500 551 IM TGMAG 02 00 EN 02 2008 23 24 3 16 3 3 16 4 The rear axial bearing is mounted
24. special safety instructions which must be observed Personnel who carry a cardiac pacemaker should not be allowed to work on a pump equipped with magnetic coupling The magnetic field is sufficiently strong to affect the proper operation of a pace maker so keep a safe distance of at least 3 m Do not come close not less than 1 m to the magnetic coupling with objects equipped with magnetic data carriers such as cheque cards computer disks watches etc to avoid damage and or loss of information Preservation To prevent damage during transportation the rotor bearing is blocked on the drain hole of the pump casing with a protection plug Remove this protection plug and place the plug 1030 together with the sealing ring 1040 on the pump in plastic bag Check that the pump shaft can be rotated by hand Keep the protection plug for subsequent transport checks or repair work Protection plug 1040 1030 Do not subject the pump to any jolting loads This can cause damage to the magnets or the slide bearings of the rotor shaft on account of their brittleness A 0500 551 IM TGMAG 02 00 EN 02 2008 29 3 18 2 Location 3 18 2 1 Short suction line Locate the pump pump unit as close as possible to the liquid source and if possible below the liquid supply level The better the suction conditions the better the performance of the pump See also section 3 18 5 2 Piping 3 18 2 2 Accessibility Sufficient space should be left arou
25. the height of the shaft Move the electric motor so that the straight edge touches both coupling halves over the entire length 3 To be certain the check is also undertaken using external callipers B at 2 corresponding points on the sides of the coupling halves see figure 4 Repeat this check at operating temperature and spend time achieving minimum alignment deviation 5 Fit the protecting guard See the figure below and the corresponding table for the maximum allowed tolerances for aligning the coupling halves Alignment tolerances External diameter Va Vana Vanin VI of coupling mm min mm max anii mm mm 81 95 2 5 4 6 0 15 0 15 96 110 2 5 4 6 0 18 0 18 111 130 2 5 4 6 0 21 0 21 131 140 2 5 4 6 0 24 0 24 141 160 2 6 6 q 0 27 0 27 161 180 2 6 6 ri 0 30 0 30 181 200 2 6 6 7 0 34 0 34 201 225 2 6 6 7 0 38 0 38 Belt drive Belt drives also increase the loading on the shaft end and the bearings Therefore certain limitations must be imposed on the maximum load of the shaft viscosity pumping pressure and speed See section 3 18 3 2 Radial load on shaft end 3 18 7 7 Guarding of moving parts coupling with spacer Before commissioning the pump place a protective guard over the coupling or belt drive This guard must comply with the EN 953 design and construction standard For pumps operating at temperatures a
26. the flange to remove the can 8330 3 Take out O ring 8200 Take care not to damage the inner rotor magnet Removal of rotor and bearing assembly Pn RAA back pull out from the pump casing A 1 Un tighten cap head screws 8460 and remove them 2 Use two bolts in the threaded holes of the intermediate cover 8450 to remove the complete back pull out assembly from the pump casing 0010 3 Take out O rings 8130 and 8440 4 2 7 Disassembly of back pull out assembly 1 Place the back pull out assembly on the workbench in vertical position 2 Un tighten cap head screws 8490 of the inner magnetic rotor 8310 crosswise and remove them 3 Remove the inner magnetic rotor 8310 from the hub 8350 D Bearing set 8350 B C D duel ZZA JJ a gt A 0500 551 IM TGMAG 02 00 EN 02 2008 4 Un tighten and remove the two set screws 8520 from the locking nut 8510 5 Lock the rotor shaft 0701 against rotation by pushing a copper bar between the rotor teeth and un tighten and remove locking nut 8510 and disc spring 8500 6 Remove the hub 8350 D with the rear axial bearing from the rotor shaft 0701 7 Remove the two keys 8400 from rotor shaft 0701 using a key extractor Remark Do not use hammer and screwdriver to remove the keys since this could damage the bearings 8 Remo
27. the pump See table for maximum allowable forces F and moments M on the connecting flanges with pump on a solid foundation e g grouted base plate or solid frame When pumping hot liquids attention should be given to forces and moments caused by thermal expansion in which case expansion joints should be installed F TG MAG pump size F N M Nm y 15 50 2600 675 23 65 2900 800 58 80 3550 1375 86 100 4100 1750 185 125 5900 3750 Check after connecting whether the shaft can move freely A 0500 551 IM TGMAG 02 00 EN 02 2008 3 18 5 2 Piping Use piping with a diameter equal to or greater than the connection ports of the pump and with the shortest possible lengths The pipe diameter has to be calculated in function of the liquid parameters and the installation parameters If necessary use larger diameters to limit pressure losses fthe fluid to be pumped is viscous pressure losses in the suction and discharge lines may increase considerably Other piping components like valves elbows strainers filters and foot valve also cause pressure losses Diameters length of piping and other components should be selected in such a way that the pump will operate without causing mechanical damage to the pump pump unit taking into account the minimum required inlet pressure the maximum allowable working pressure and the installed motor power and torque Checkthe
28. vn 150 150 195 195 250 vo 17 17 20 20 20 vp 40 40 50 50 50 vr 30 30 50 50 50 vs M16 M16 M20 M20 M20 vt 12 12 14 14 14 vu 3 3 4 4 4 6 6 Weights Mass TG MAG Mat Version Mass Weight 15 50 23 65 58 80 86 100 185 125 Pump G kg daN 48 52 109 117 240 without jackets R kg daN 51 55 113 125 252 Front Pull out G kg daN 2 5 8 5 9 12 24 pump cover idler R kg daN 8 4 10 13 26 Back Pull out G kg daN 35 35 78 81 170 ET bearing R kg daN 35 35 78 81 170 soc kg daN 3 3 5 7 12 ssc kg daN 3 3 5 7 12 Jackets OSC kg daN 0 0 0 0 0 supplement TOC kg daN 8 5 8 5 5 5 8 18 TIC kg daN 4 4 6 5 9 14 OTC kg daN 0 5 0 5 1 1 1 Relief valve G kg daN 5 5 7 10 10 supplement R kg daN 5 5 8 11 11 A 0500 551 IM TGMAG 02 00 EN 02 2008 PROCESS EQUIPMENT Your local contact SPX Process Equipment BE NV Evenbroekveld 2 6 BE 9420 Erpe Mere Belgium Phone 32 0 53 60 27 15 Fax 32 0 53 60 27 01 E mail jp industry beQ processequipment spx com For more information about our worldwide locations approvals certifications and local representatives please visit www johnson pump com and www spxpe com SPX reserves the right to incorporate our latest design and material changes without notice or obligation Design features materials of construction and dimensional data as described in this bulletin are provided for your information onl
29. 0 Hexagonal screw 4 4 4 7310 Hexagonal screw 4 4 4 7320 Adjusting screw 1 1 1 7330 Hexagonal nut 1 1 1 7400 7240 7360 Arrow plate 1 1 1 7400 Rivet 4 4 4 7150 7420 Set screw 2 2 8 7420 Single safety relief valve vertical A 0500 551 IM TGMAG 02 00 EN 02 2008 3 17 6 2 Heated spring casing Pos Description Material V27 V35 V50 Preventive Overhaul 7041 Heated spring casing 1 1 1 3 18 3 18 1 gt gt Installation General This manual gives basic instructions which are to be observed during installation of the pump It is therefore important that this manual is read by the responsible personnel prior to assembly and after ward to be kept available at the installation site The instructions contain useful and important information allowing the pump pump unit to be properly installed They also contain important information to prevent possible accidents and serious damage prior to commissioning and during operation of the installation Non compliance with the safety instructions may produce a risk to the personnel as well as to the environment and the machine and result in a loss of any right to claim damages It is imperative that signs affixed to the machine e g arrow indicating the direction of rotation or symbols indicating fluid connections be observed and kept legible Because of the presence of strong magnetic fields there are
30. 0 185 125 preventive overhaul 0200 jacket cover 2 2 2 2 2 0210 tap bolt 6 6 8 8 8 0220 gasket 1 1 1 1 1 x x 0230 cap head screw 2 2 2 2 4 0240 plug 1 1 1 1 1 0250 sealing ring 1 1 1 1 1 x x 0300 welding neck flange 2 2 2 2 2 0310 gasket 2 2 2 2 2 x x 0320 cap head screw 8 8 8 8 8 5 1 4 2 T jackets on intermediate cover i i iz i ji DQ 0500 Os 1 ogio SS __ 0540 Sy d 0530 J A 5 a s _ 0420 8450 ST o N o 0490 E 0480 e wy 0490 Oz 0480 O 0440 0440 e 0430 8 0430 Pos Description 15 50 23 65 58 80 86 100 185 125 preventive overhaul 8450 intermediate cover 1 1 1 1 1 0420 sealing ring 2 2 2 2 2 x x 0430 plug 2 2 2 2 2 0440 sealing ring 2 2 2 2 2 x x 0480 plug 2 2 2 2 2 0490 sealing ring 2 2 2 2 2 x x 0500 welding neck flange 2 2 2 2 2 0510 gasket 2 2 2 2 2 x Xx 0520 cap head screw 8 8 8 8 8 0530 flange 2 2 2 2 2 0540 flange holder 2 2 2 2 2 A 0500 551 IM TGMAG 02 00 EN 02 2008 65 66 6 0 Dimensional drawings 6 1 TG MAG15 50 to 185 125 pumps ma ze zc ea mk A o G z Et 3 dc ANN SE z Bu u u va sp vf vb 4 x O vd ve Ba d
31. 0 370 380 420 min um 250 260 300 300 340 axial clearance max um 200 215 250 275 320 min um 120 125 150 165 190 3 13 Extra clearances To handle extra clearances following clearance classes are defined CO Pump cover axial clearance set at minimum C1 Standard clearance not indicated because standard C2 2 x standard clearance C3 3x standard clearance To indicate required clearances a code of 4 digits xxxx is given on the order The figure 1 stands always for normal and no special action is considered The indicated numbers in the tables below are average values in microns um A 0500 551 IM TGMAG 02 00 EN 02 2008 Radial clearance on rotor idler outside diameter Axial clearance on pump cover Pump size CO um C1 um C1 um C2 um C3 um axial clear normal normal set minimum Code Rotor 1xxx 2xxx 3xxx Code Idler x1xx x2xx x3xx Code pump xxxO xxx1 xx2 xx3 cover assembly TG MAG 15 50 52 280 160 350 480 TG MAG 23 65 56 290 170 375 510 TG MAG 58 80 66 325 200 440 600 TG MAG 86 100 72 340 220 480 660 TG MAG 185 125 85 380 255 560 765 Please note On TG MAG pumps the radial rotor clearance C1 is slightly larger than on other TopGear pump families while clearance class C2 and C3 are identical with the standard range Diametral clearance on pin idler bearing Pump size xum f
32. 00 top cover complete 1 1 1 1 1 0600 idler bush complete 1 1 1 1 1 x 0701 rotor shaft 1 1 1 1 1 x 1000 pin cover 1 1 1 1 1 1010 tap bolt 6 6 6 6 6 1020 gasket 1 1 1 1 1 x x 1030 plug 1 1 1 1 1 1040 sealing ring 1 1 1 1 1 x x 1050 plug 2 2 2 2 2 1060 sealing ring 2 2 2 2 2 x x 1080 tap bolt 8 8 8 8 8 1090 gasket 1 1 1 1 1 x x 1210 plug 1 1 1 1 1 1220 sealing ring 1 1 1 1 1 x x 1230 plug for connection PT100 1 1 1 1 1 1410 cap head screw 4 4 4 4 4 4000 pump cover idler pin complete 1 1 1 1 1 x 8100 shim 1 1 1 1 1 x 8110 support ring 1 1 1 1 1 8120 o ring 1 1 1 1 1 x x 8130 o ring 1 1 1 1 1 x x 8200 o ring 1 1 1 1 1 x x 8210 cap head screw 6 6 8 8 8 8310 inner magnetic rotor 1 1 1 1 1 x 8320 outer magnetic rotor 1 1 1 1 1 x 8330 separation can 1 1 1 1 1 8350 rotor bearing assembly 1 1 1 1 1 x 8400 key 2 2 2 2 2 8410 pin 1 1 1 1 1 8420 disc rotor 1 1 1 1 1 8430 insert 1 1 1 1 1 8440 o ring 1 1 1 1 1 x x 8450 intermediate cover 1 1 1 1 1 8460 cap head screw 2 2 2 2 2 8470 shim 1 1 1 1 1 x 8480 cap head screw 4 4 4 4 4 8490 cap head screw 4 4 4 4 4 8500 disc spring 1 1 1 1 1 x 8510 locking nut 1 1 1 1 1 8520 set screw 2 2 2 2 2 5 1 2 Bearing bracket Pos Description 15 50 23 65 58 80 86 100 185 125 preventive overhaul 0702 pump shaft 1 1 1 1 1 1400 bearing bracket 1 1 1 1 1 1430 bearing cover 1 1 1 1 1 1440 ball bearing metal cage 2 2 2 2
33. 2 x x 1450 circlip 1 1 1 1 1 x 1460 support ring 1 1 1 1 1 1490 sealing segment 1 1 1 1 1 x x 1540 countersunck screw 4 4 4 4 4 1550 nameplate 1 1 1 1 1 1560 rivet 4 4 4 4 4 1570 key 1 1 1 1 1 x 8600 pin 2 2 2 2 2 8610 cap head screw 4 4 4 4 4 8620 circlip 2 2 2 2 2 x 8630 protection ring 1 1 1 1 1 8640 circlip 1 1 1 1 1 x A 0500 551 IM TGMAG 02 00 EN 02 2008 63 5 1 3 S jacket options 5 1 3 1 S Jackets on pump cover Pos Description 15 50 23 65 58 80 86 100 185 125 preventive overhaul 0200 jacket cover 1 1 1 1 1 0210 tap bolt 6 6 8 8 8 0220 gasket 1 1 1 1 1 x x 0230 cap head screw 2 2 2 2 4 0240 plug 1 1 1 1 1 0250 sealing ring 1 1 1 1 1 X x 5 1 3 2 S Jackets on intermediate cover 0490 0480 8450 0490 0480 0440 _ 6 0440 0430 _ 0430 Pos Description 15 50 23 65 58 80 86 100 185 125 preventive overhaul 8450 intermediate cover 1 1 1 1 1 0430 plug 2 2 2 2 2 0440 sealing ring 2 2 2 2 2 x x 0480 plug 2 2 2 2 2 0490 sealing ring 2 2 g 2 2 x x 64 A 0500 551 IM TGMAG 02 00 EN 02 2008 5 1 4 T jacket options 5 1 4 1 T jackets on pump cover 0220 0230 0210 Pos Description 15 50 23 65 58 80 86 10
34. 243 crosswise with the specified torque to fix the magnetic rotor 8320 on the pump shaft 0702 See chapter 3 21 3 1 7 Mount both circlips 8620 into the bearing bracket 1400 8 Support the pump shaft 0702 complete with magnetic rotor 8320 and bearing in vertical position 9 Lower the bearing bracket 1400 over the pump shaft 0702 pushing the ball bearing 1440 into the seat in the bearing bracket until the bearing makes contact with circlip 8620 A 0500 551 IM TGMAG 02 00 EN 02 2008 10 Assembly the rear ball bearing 1440 on the pump shaft 0702 by driving it with a pipe and plastic hammer via the inner bearing ring until the bearing makes contact with circlip 8620 11 Fit circlip 8640 on the pump shaft 0702 12 Place the bearing bracket 1400 on the workbench in horizontal position 13 Screw countersunk screws 1540 and tighten them crosswise to lock the front bearing Take care not to damage the outer rotor magnet 14 Mount the sealing segment 1490 on the rear end according to sketch First part of Second part of sealing segment sealing segment EE NY NS A 0500 551 IM TGMAG 02 00 EN 02 2008 55 56 4 3 2 4 3 2 1 3 Mount axial bearing 8350 A into the insert 8430 5 Calculate the required thickness of the bearing Pre assembly of the back pull out Adjustment of the axial
35. 3 2 2 Installation 1 8 2 8 Before commissioning the pump unit 1 8 2 4 Disassembly assembly of the coupling guard 1 3 2 5 Name plate CE Declaration of Conformity cscs 1 4 Technical conventions sss nenne ananasa 11 2 0 mio ipie COSMO Pot rga r NC C 12 21 lTypedesigHatlOr node ad W a a b Facit ni be uad a ied 12 3 0 General information and technical data sss 14 3 1 Pump standard parts eter tette tenni 14 22 Operating principle i a caiioimneng tb O eoe dl ae R Bia 14 3 2 1 Self priming operation eese nnns 15 3 2 2 Safety relief valve Working principle sese 15 3 3 Sounds icit ave tee iin d ahead ee ert aded eee ases 15 3 4 General performance ues osse testabin pret ert ceo ade winds Gad 15 3 5 Main characteristics sse nenenenenenetnt 16 3 6 Pr ssUre zasne zza erede eee ir cete te Ente ne Ie Ee REKE 16 3 7 Sound level rejani gue C dali aed did denk ei de 16 3 7 1 Sound level of a pump without drive sssssseeeeer 16 3 7 2 The sound level of the pump unit sse 17 3 7 9 Influences item tdeo d eater daudi 18 3 8 Maximum and minimum allowable temperature 1111112111111111111111 18 3 9 Jacket OptlODS a ait tenente ene mere etr nr iini fece eri dA 3 10 Internals iiL eet eed a kok i a tei 3 10 14 Bush materials gd e ge e 3 10 2 Maximum temperature of
36. 4 5 6 7 8 9 10 11 12 13 1 Pump family code TG TopGear 2 Pump range name MAG magnetic driven pump 3 Hydraulics indicated with displacement volume per 100 revolutions in dm and nominal port diameter in mm TG MAG 15 50 TG MAG 23 65 TG MAG 58 80 TG MAG 86 100 TG MAG 185 125 4 Pump material and Port connection type G2 PN16 flanges to DIN 2533 G3 PN20 flanges to ANSI 150 Ibs R2 PN25 PN40 flanges R3 PN20 flanges to ANSI 150 Ibs R4 PN50 flanges to ANSI 300 Ibs R5 PN16 flanges to DIN 2533 5 Jacket options for pump cover 0 Pump cover without jackets S Pump cover with jacket and thread connection T Pump cover with jacket and flange connection 6 Jacket options for intermediate cover OC Intermediate cover without heating SC Intermediate cover with thread connection TC Intermediate cover with flange connection A 0500 551 IM TGMAG 02 00 EN 02 2008 TG MAG 58 80 G2 S oc BG 2 Q S5 S10 7 10 11 12 Idler bush and idler materials SG Idler bush in hardened steel with idler in cast iron CG Idler bush in carbon with idler in cast iron BG Idler bush in bronze with idler in cast iron HG Idler bush in ceramic with idler in cast 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 cera
37. Another possibility in case of long lines or when a non return valve is installed in the discharge line is to install a by pass with isolating valve close to the discharge side of the pump This valve will be opened in case of priming and allows air or gas evacuation at low backpressure The bypass should be lead back to the supply tank not to the suction port 3 18 5 3 Isolating valves To allow proper maintenance it is necessary to be able to isolate the pump Isolation can be done by installing valves in suction and discharge lines Byspass These valves must have a cylindrical passage of the same diameter of the piping full bore Gate or ball valves are preferable Suction When operating the pump the valves must be opened completely The output must never be regulated by means of closing valves in suction or discharge pipes It must be regulated by changing shaft speed or by re routing the media over a by pass back to the supply tank A 0500 551 IM TGMAG 02 00 EN 02 2008 33 34 3 18 5 4 3 18 6 3 18 6 1 3 18 6 2 Strainer Foreign particles can seriously damage the pump Avoid the entry of these particles by installing a strainer When selecting the strainer attention should be given to the size of the openings so that pres sure losses are minimised The cross sectional area of the strainer must be three times that of the suction pipe Install the strainer in such a way that maintenance an
38. HUN Cynlindrical parallel Rp ISO 7 1 Rp 1 2 External Always conical a a thread tapered R RENI ANA vA yy wA Wd Threaded connection G example G 1 2 If the threaded connection is provided of a flattened sealing face we call it G according to ISO 228 1 This connection can be sealed by a gasket The plugs or pipe connections must be provided with a sealing collar and cylindrical external thread according to ISO 228 1 Example ISO 228 1 G1 2 Plugs or pipe connections provided with conical thread according to ISO 7 1 external thread example ISO 7 1 R1 2 can also be used Plug with collar Conical pipe end ISO 228 1 Clearance class Symbol Example ISO 228 1 G 1 2 ISO 7 1 R 1 2 Internal Only one class G ISO 228 1 G 1 2 thread Class A 1 G ISO 228 1 G 1 2 External standard L thread Class B G B ISO 228 1 G 1 2 B extra clearance ISO 7 1 Type Symbol Example i f j f i External Always conical x Y 1 Y j 1 thread tapered R Sors ua MM 9 A 0500 551 IM TGMAG 02 00 EN 02 2008 4 0 Instructions for assembly and disassembly 4 1 General Insufficient or wrong assembly and disassembly can lead to the pump malfunctioning high repair costs and long term inoperability Contact your distributor for information Disassembly and assembly may only be carried out by trained personnel Such personnel s
39. MAG 02 00 EN 02 2008 TG MAG15 50 TG MAG23 65 TG MAG58 80 TG MAG86 100 TG MAG185 125 69 6 4 2 Heated safety relief valve dv dk Bo TG MAG15 50 Bo TG MAG23 65 TG MAG58 80 TG MAG86 100 TG MAG185 125 di 1 TG MAG Mat 15 50 23 65 58 80 86 100 185 125 Bo G R G 1 2 G 1 2 G 1 2 G 1 2 G 1 2 di G R 101 101 418 444 509 dj G R 119 119 458 484 549 dk G R 253 263 dm G R 62 59 5 98 5 103 5 103 5 dn G R 111 111 127 127 127 do G R 6 5 4 6 8 24 G 290 300 550 576 641 R 293 303 555 581 646 mc G R 50 50 70 70 70 tg G R 200 200 70 A 0500 551 IM TGMAG 02 00 EN 02 2008 6 5 Bracket support TG MAG 15 50 23 65 58 80 86 100 185 125 vm 120 120 160 160 200
40. Reduce pump speed If necessary install a larger pump Cavitation 23 Reduce difference between pump and suction tank level Increase suction pipe diameter Reduce length and simplify suction pipe use as few elbows and other fittings as possible Also see section 3 18 Installation Backpressure too high 24 Increase pipe diameter Reduce working pressure Check accessories filter heat exchanger etc Coupling misalignment 25 Check and correct alignment Also see section 3 18 Installation Vibration of base plate or pipings 26 Make base plate heavier and or affix baseplate pipework better Ball bearings damaged or worn 27 Replace ball bearings Un balance of the outer magnetic rotor 28 Check correct assembly of the outer magnetic rotor on the pump shaft Check correct tightening of bolts secure bolts against loosening Pump consumes too much power or becomes hot Pump speed too high 29 Reduce pump speed If necesary install a larger pump Coupling misalignment 30 Check and correct alignment Also see section 3 18 Installation Viscosity too high 31 Increase axial clearance See section 3 21 Maintenance instructions Heat pump Reduce pump speed Increase discharge pipe diameter Excessive friction losses inside rotor shaft bearing arrangement 32 Check correct axial clearance of circulati
41. bove 100 C ensure that bearing bracket and bearings are cooled sufficiently by the surrounding air 3 18 7 8 Check temperature censor on can In case the pump is provided with a PT100 element the electrical connections must be made by an approved electrician TG MAG X 15 50 75 23 65 75 58 80 80 86 100 80 185 125 100 A 0500 551 IM TGMAG 02 00 EN 02 2008 PT100 Connection for PT100 Pasta for better contact 37 38 3 19 3 19 1 3 19 2 3 19 2 1 3 19 3 Instructions for start up General The pump can be put into service when all arrangements described in chapter 3 18 Installation have been made Prior to commissioning responsible operators have to be fully informed on proper operation of the pump pump unit and the safety instructions This instruction manual must at all times be available to the personnel Prior to commissioning the pump pump unit must be checked for visible damage Damage or unexpected changes must be reported immediately to the plant operator Cleaning the pump There may be residual mineral oil inside the pump deriving from the pump testing and the initial lubri cation of the bearing bushes If these products are not acceptable for the pumped liquid the pump should be cleaned thoroughly Proceed as described in section 3 21 2 8 Draining of fluid Cleaning suction line Before the TG
42. d cleaning are possible Make sure that the pressure drop in the strainer is calculated with the right viscosity Heat the strainer if necessary to reduce viscosity and pressure drop For the maximum allowable particle size see section 3 15 Secondary piping For dimensions of connections and plugs see chapter 6 0 Drain lines The pump is provided with a drain plug Heating jackets 1 S type jackets The S jackets are designed for use with saturated steam max 10 bar 180 C or with non dangerous media They are provided with threaded connections Bl see chapter 6 0 for the dimensions The connection can be done by threaded pipes or pipe connections with sealing in the thread conical thread applying ISO 7 1 or sealed outside the thread by means of flat gaskets cylindrical thread applying ISO 228 1 Thread type see section 3 21 7 S jacket on the pump cover dk dk 2xBI 2xB ZAS OY MWS aw 4E Te gt ie A o INTO oY b LB cx i 3 RE d i NBg 2 T type jackets The T jackets are provided with special steel flanges delivered with the pump on which the pipes should be welded properly by qualified personnel The jackets are made of nodular iron or
43. d or if there is any dirt between the fitting faces A 0500 551 IM TGMAG 02 00 EN 02 2008 57 58 10 11 12 13 14 15 Fit the keys 8400 into the rotor shaft 0701 Be care ful that the keys 8400 are not hitting the shaft sleeve 8350 B during assembly Fit rear axial bearing holder 8350 D on the rotor shaft 0701 Place spring washer 8500 on the rotor shaft 0701 as indicated on the sketch and screw on locking nut 8510 Place the assembly vertically on the work bench and lock the rotor by pushing a copper bar through the rotor teeth Tighten locking nut 8510 until the shaft nut makes contact with the axial face of the rear axial bearing holder 8350 D Check the axial bearing clearance using a feeler gauge see table below TG MAG Axial clearance mm 15 50 0 11 0 138 23 65 58 80 0 13 0 15 86 100 185 125 0 15 0 18 Tighten set screws 8520 to secure the locking nut 8510 Mount the inner magnetic rotor 8310 on the hub of the rear axial bearing holder B350 D Make sure that the locking pins are falling into the holes of the inner magnetic rotor 8310 Screw in cap head screws 8490 and tighten them with Loctite 243 crosswise with the specified torque see Chapter 3 21 3 1 to fix the inner magnetic rotor 8310 on the hub Check if the rotor shaft 0701 can be turned by hand evenly and without re
44. e operated briefly once a week or alternatively the shaft must be turned a full turn once a week This ensures proper circulation of the protective oil 3 21 2 6 External cleaning Keep the surface of the pump as clean as possible This simplifies inspection and the attached markings remain visible Make sure cleaning products do not enter the ball bearing space Cover all parts that must not come into contact with fluids In case of sealed bearings cleaning products must not attack rubber gaskets Never spray the hot parts of a pump with water as certain components may crack due to the sudden cooling and the fluid being pumped may spray into the environment 3 21 2 7 Electrical installation Maintenance operations on the electric installation may be performed only by trained and quali fied personnel and after disconnecting the electric power supply Carefully follow the national safety regulations Respect the above mentioned regulations if performing work while the power supply is still connected Check if electrical devices to be cleaned have a sufficient degree of protection e g IP54 means protection against dust and splashing water but not against water jets See EN 60529 Choose an appropriate method for cleaning the electrical devices Replace defective fuses only with original fuses of the prescribed capacity After each maintenance session check the components of the electrical installation for visible damage and repair them
45. eaker The switching equipment must comply with prevailing regulations as stipulated by EN 60204 1 Motor overload protection To protect the motor against overloads and short circuits a thermal or thermo magnetic circuit breaker must be incorporated Adjust the switch for the nominal current absorbed by the motor Connection Do not use a star delta circuit with electric motors due to the required high starting torque For single phase alternating current use motors with a reinforced starting torque Ensure a sufficiently high starting torque for frequency controlled motors and adequate cooling of the motor at low speeds If necessary install a motor with forced ventilation Electrical equipment terminals and com U ponents of control systems may still carry Li L1 live current when at rest Contact with these may be fatal result in serious injury or cause irreparable material damage L3 L3 L2 L2 Line Motor U volt 230 400 V 400V 3x230V delta 3x400V star delta Combustion engines When using a combustion engine in the pump unit see the engine instruction manual included in the delivery Contact Uy vaw UD WI the pump supplier if the manual is not A 11 yd E included chc Moe Irrespective of this manual the following must be respected for all combustion engines
46. ed volume pro 100 revolutions n max maximum allowable shaft speed in rpm n mot normal speed of direct drive electric motor at 50Hz frequency O th theoretical capacity without slip at differential pressure O bar v u peripheral velocity of rotor v i velocity of liquid in the ports at Oth inlet and outlet port Ap maximum working pressure differential pressure p test hydrostatic test pressure Maximum viscosity Maximum viscosity 10 000 mPas Remark Figures are for Newtonian liquids at operating temperature Pressure For performance on pressure three kinds of pressures must be considered i e Differential pressure or working pressure p is the pressure on which the pump normally operates The maximum differential pressure of all TopGear MAG pumps is 16 bar Maximum allowable working pressure or design pressure p m is the pressure on which the pump casing is designed It represents the maximum allowable pressure difference between internal pressure in the pump casing and the atmosphere On TopGear MAG pumps the design is 16 bar for cast iron pump casings and 20 bar for stainless steel pump casings Hydrostatic test pressure is the pressure on which the pump casing including separation can of the magnetic coupling is tested For TopGear MAG pumps the hydrostatic test pressure is 24 bar Sound level Sound level of a pump without drive Sound pressure level L a The following table gives an overview of the A
47. erial Steel Carbon Bronze Ceramic Hard metal Silicon Carbide Hydrodynamical ifyes to maximum working pressure 16 bar lubrication if no 6 bar 10 bar 6 bar 6 bar 10 bar 10 bar Corrosive resistance Fair Good Fair Excellent Good Good Abrasive resistance Slight None None Good Good Good Dry running allowed No Yes Moderate No No No Sensitive to thermal shock No No No Yes dT lt 90 C No No Sensitive to blistering in oil No gt 180 C No No No No Oil aging No No gt 150 C No No No Food processing allowed Yes No antimony No lead Yes Yes Yes These are not absolute figures Higher or lower values possible in function of the application expected life time etc A 0500 551 IM TGMAG 02 00 EN 02 2008 3 10 2 Maximum temperature of internals 3 10 3 3 10 4 For some material combinations the general temperature performances must be limited The maximum allowable working temperature of internals depends on the combination of materials used and their thermal expansions and the interference fit to hold the bearing bush fixed Some bush bearings have an extra locking screw In this case the maximum allowable tempera ture is based on the most probable interference fit n case the bearing bush has no locking screw because material and construction do not allow concentrated stress the maximum allowable temperature is based on the minimum inter ference fit Maximum tem
48. es should be in line with the cap head screws 8460 Fit cylinder screws 8210 and tighten them crosswise to fix the separation can 8330 on the intermediate cover 8450 Remark The cap head screws 8210 are fixing both the intermediate cover 8450 and separation can 8330 tightly on the pump casing 0010 A 0500 551 IM TGMAG 02 00 EN 02 2008 59 60 4 3 5 4 3 6 Assembly of the bearing bracket 1 Assembly of the front pull out assembly 1 2 Place the pump vertically on the workbench with the separation can 8330 pointed upwards Screw the 4 guiding pins tool into the threaded holes of the cap head screws 1410 Screw a lifting eye bolt into the shaft end of pump shaft 0702 Use a crane to fit the bearing bracket 1400 over the guiding pins to the intermediate cover from the top see picture Remove the guiding pins and fit cap head screws 1410 Tighten cap head screws 1410 crosswise to fix the bearing bracket 1400 to the intermediate cover 8450 Mount bearing bracket support 1700 to the bearing bracket 1400 Check that the contact faces and O ring chamber are not damaged and free of dirt Check the condi tion of O ring 8120 in case of doubt replace the O ring with a new one Measure the distances as indicated on the sketch n Calculate the required thickness of the shim 8100 between pump cover 4000 and pu
49. f vc vh da ISO R775 eb TG MAG 15 50 23 65 58 80 86 100 185 125 aa 50 65 80 100 125 Ba G 1 4 G 1 4 G 1 2 G 1 2 G 1 2 Bb G 1 8 G 1 8 G 1 8 G 1 8 G 1 8 Be G 1 4 G 1 4 G 1 4 G 1 4 G 1 4 Bu G 1 4 G 1 4 G 1 4 G 1 4 G 1 4 da 389 400 493 526 633 db 112 112 160 160 200 dc 209 219 297 315 380 de M16 M16 M20 M20 M20 df 86 86 110 110 140 ea 60 60 80 80 110 eb 8 h9 8 h9 10 h9 10 h9 14 h9 ec 31 31 35 40 51 5 ed 28 je 28 j6 32 k6 37 k6 48 k6 ef M10 M10 M12 M12 M16 ma 75 80 105 195 155 mb 125 125 150 160 190 sp 15 26 22 5 32 30 5 va 70 80 100 100 120 vb 120 130 160 160 200 ve 150 160 200 200 260 vd 12 12 14 14 18 ve 60 60 90 90 125 vf 14 14 17 17 22 vh 90 90 125 125 170 za 125 125 180 185 230 zb 125 125 160 180 200 ze 359 359 453 476 580 ze 68 80 94 109 132 A 0500 551 IM TGMAG 02 00 EN 02 2008 6 2 Flange connections 6 2 1 Cast iron zb zb TG MAG58 80 to TG MAG185 125 TG MAG15 50 to TG MAG23 65 6 2 2 Stainless steel TG MAG 15 50 23 65 58 80 86 100 185 125 aa 50 65 80 100 125 ab 100 118 135 153 180 ac PN16 125 145 160 180 210 ac PN20 120 5 139 5 152 5 190 5 216 ad 125 145 200 220 250 ak PN16 4xd18 4xd18 8xd18 8xd18 8xd18 ak PN20 4xd18 4xd18 4xd18 8xd18 8xd22 am 21 21 24 25 28 zb 125 125 160 180 200 Sq
50. f TopGiear pumps is designed to protect the pump against over pressure It limits the differential pressure or working pressure of the pump It is a spring loaded pressure relief valve that opens rapidly by pop action when the working pressure increases to the set pressure on which the spring is set in advance The safety relief valve built on top of the TopGear pump may not be used permanently opened because the liquid will be heated up very fast by viscous friction losses All power input will go to the pumped liquid that circulates in the pump when the safety relief valve is opened and no discharge flow is given The single safety relief valve protects the pump only in one direction of flow Heating The spring casing of the safety relief valve can by provided by a welded jacket with thread connections to heat the area around the spring The valve body is heated together with the pump because it is mounted directly on the pump casing Materials The safety relief valve casing is made of grey cast iron G or stainless steel R The option heated spring casing is only available for cast iron pumps in this case the spring casing is made of steel The internals of the safety relief valve i e valve spring spring plates and adjusting bolt and nut is made of stainless steel Pressure Safety relief valves are divided into 4 working pressure classes i e 4 6 10 and 16 indicating the maximum working pressure for that valve Each class ha
51. f the axial clearance of the circulation pump 56 4 3 2 2 Assembly of rotor shaft 57 4 3 8 Assembly of the back pull out assembly to the pump casing 59 4 3 4 Assembly of the separation can sse 59 4 3 5 Assembly of the bearing bracket sse 60 4 3 6 Assembly of the front pull out assembly ses 60 4 3 7 Assembly of top cover 0100 or safety relief valve 61 A 0500 551 IM TGMAG 02 00 EN 02 2008 5 0 Sectional drawings and part lists trt titt 62 5 1 TGMAG15 50 to TG MAGI185 125 sess 62 5 1 1 Hydraulic part att nter tectae tec peti pati 63 5 1 2 Bearing bracket wee a yy A patre 63 5 1 3 S jacket options aaa O tite ph A O AAA 64 5 1 3 4 S Jackets on pump cover nennen 64 5 1 8 2 S Jackets on intermediate cover sse 64 5 1 4 T jacket options seen 5 1 4 1 T jackets on pump cover 5 1 4 2 T jackets on intermediate cover 6 0 Dimensional QrAWINGS zza dada ank nokta ka 66 6 1 TG MAG15 50 to 185 125 pUmps ossuiedea rodean etin 66 6 2 Flange CONNECTIONS acide acasen dii nani beds eire cual cra cete at gcn n in pea n 67 6 2 GCastlFonz sos estende eter AN AAA 67 6 22 Stainless steel e etie teet ee beiden 67 6 37 JACK Cts inin nna n 68 6 3 1 S jackets with thread connections on pump cover and intermediate cover SS s
52. g the coupling slips The slipping of the coupling is associated with excessive heat generation and strong vibrations which can damage the coupling permanently and destroy the bearings Therefore the drive motor must be switched off as soon as the coupling slips due to overload This situation can be detected by following means Drop in flow output Drop of discharge pressure Reduced power consumption of the drive motor The drive motor must be stopped in order to stop the slipping of the magnetic coupling A 0500 551 IM TGMAG 02 00 EN 02 2008 During normal operation heat is generated inside the magnetic coupling due to hydraulic friction and eddy currents in the wall of the separation can by the moving magnetic fields Cooling of the cou pling see chapter 3 16 3 Circulation pump Maximum allowable temperature and nominal torque Samarium Cobalt SmCo 280 C Neodymium Iron Boron NdFeB 120 C The type of the magnetic coupling is related to the selected pump type There are three types of magnetic couplings with different nominal diameters to cover the five pump sizes Each coupling type is available with magnets in different lengths and in both magnetic materials see table below Nominal Length of magnets mm diameter mm 40 60 80 100 120 TG MAG 15 50 23 65 110 x x x 2 z TG MAG 58 80 86 100 165 x x x x TG MAG 185 125 215 x x x x x The material of the magnets and the
53. g holder 8350 A into the pump insert 8430 until the axial bearing faces are making contact and check if the axial clearance C of the circulation pump is correct Dimension X should be within the range of dimen sion C See point 5 4 3 2 Assembly of rotor shaft 1 Place the shaft rotor on the workbench in vertical position put a thin layer of grease on all sliding faces of the bearings 2 Place the disk rotor 8420 into the chamber of the pump insert B430 3 Check that the axial contact faces of the axial bearing holder 8350 A and shaft sleeve 8350 B are undamaged and free of any dirt 4 Place the disk rotor 8420 the front axial bearing holder 8350 A and the bearing arrangement over the shaft rotor 0701 Make sure that the pin 8410 in the rear face of the rotor is fitting into the hole of the axial bearing holder 8350 A 5 Push shaft sleeve 8350 B carefully from the rear side into the radial bearing holder 8350 C Do not use any force or a hammer while fitting the rotor shaft 0701 into the bearings Remark Do not use any force while mounting the shaft sleeve 8350 B and no hammer to drive it in These parts are very sensitive and should be handled with utmost care in order not to damage them during assembly The parts should fit into each other smoothly and under light pressure by hand If it is not possible to fit these parts by hand disassemble the parts and check if the parts are not damage
54. g parts See also section 3 18 7 Guidelines for assembly 3 18 3 1 Starting torque The starting torque of internal gear pumps is almost identical to the nominal torque Take care that the motor has a sufficiently large starting torque Therefore choose a motor with a capacity 25 higher than the pump power consumption Note A mechanical variable speed drive requires checking of the available torque at low and high speed Frequency invertors may have limited the starting torques The selection of the size and performance of the magnetic coupling depends on the output torque of the drive motor during start up Please verify that the maximum allowable torque of the magnetic coupling is not exceeded 3 18 3 2 Radial load on shaft end The shaft end of the pump shaft may be loaded in radial sense with the maximum radial force Fr See table Fr TG MAG pump size Fr max N H 15 50 JU 1000 58 80 1800 86 100 Lp 185 125 2500 H i IN T This force is calculated for the maxium allowable torque at the shaft end and for a bearing life of 25 000 hours In case a direct drive with a flexible coupling is used the indicated force will not be exceeded when pump and drive are well aligned Starting with the TG MAG 15 50 V belt drive can be used In case of V belt drive The max
55. gnetic field is sufficiently strong to affect the operation of a pacemaker A safe distance is 3 metre Always keep electronic equipment with memory cheque cards with magnetic strips and similar items at least 1 metre away from the coupling ZA A 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 4 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 4 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 author
56. hould be familiar with the pump and follow the instructions below Non compliance with the instructions or neglecting warnings can harm the user or lead to severe A damage to pump and or pump unit SPX Process Equipment is not liable for accidents and damage resulting from such neglect Because of the presence of strong magnetic fields there are special safety instructions which must be observed Personnel who carry a cardiac pacemaker should not be allowed to work on a pump equipped with W magnetic coupling The magnetic field is sufficiently strong to affect the proper operation of a pace maker so keep a safe distance of at least 3 m data carrier such as cheque cards computer disks watches etc to avoid damage and or loss of A Do not come close not less than 1 m to the magnetic coupling with objects equippid with magnetic information Do not subject the pump to any jolting loads This can cause damage to the magnets or the slide bearings of the rotor shaft on account of their brittleness 4 2 Disassembly 4 2 1 Disassembly of front pull out assembly 1 Un tighten tap bolts 0040 crosswise and remove them 2 Use two tap bolts 0040 in the threaded holes in the pump cover 4000 to push off the cover 3 Take idler 0600 complete with bearing bush off the idler pin 4 Remove O ring 8120 support ring 8110 and shim 8100 from the pump cover 4000 8100 A 0500 551 IM TGMAG 02 00 EN 02 2008 49
57. if necessary 3 21 2 8 Draining of fluid Close off the pressure and suction lines as close as possible to the pump If the fluid being pumped does not solidify let the pump cool down to the ambient temperature before drainage A 0500 551 IM TGMAG 02 00 EN 02 2008 For fluids that solidify or become very viscous 2x Be Bb at ambient temperature it is best to empty the pump immediately after shutting down by separating it from the piping Always wear safety goggles and gloves Protect yourself with a protective cap The fluid may spray out of the pump Open the venting plugs Be and Bb f no drain line is provided take precautions so that the liquid is not contaminating the environment Open the drain plug Ba at the bottom of the pump housing Let drain the liquid by gravity e Purge pump spaces with flush media or cleaning liquid by connecting a purge system to the following inlet openings Ba Be plugs close to both flanges for purging the pump casing part Bb plug on top of the intermediate cover for purging the magnetic coupling 4 Note If toxic liquids were pumped special precautions regarding flushing cleaning of the pump and personal protection equipment must be taken before disassembling the pump Re assemble the plugs and close the valves if any 3 21 2 9 Fluid circuits Depressurize the jackets and the
58. if one or several application parameters change Liquids not suitable for the pump can cause damage 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 A 0500 551 IM TGMAG 02 00 EN 02 2008 15 16 3 5 3 6 3 7 3 7 1 Main characteristics The pump size is designated by the displacement volume of 100 revolutions expressed in litres or dm but rounded followed by the nominal port diameter expressed in millimetres Pump size d B D Vs 100 n max n mot Q th Q th v u v i Ap p test TG MAG mm mm mm dm min min 1 s m h m s m s bar 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 m 65 47 115 22 5 1500 5 6 20 3 9 0 1 7 16 24 1450 5 4 19 6 8 7 1 7 PURO 80 60 160 55 8 1050 9 8 35 2 8 8 2 0 16 24 960 8 9 32 1 8 0 1 8 86 100 100 75 175 84 2 960 960 13 5 48 5 8 8 1 7 16 24 125 100 224 183 7 750 28 82 7 8 8 1 9 16 24 185 125 725 22 2 79 9 8 5 1 8 Legend d port diameter inlet and outlet port B width of idler gear and length of rotor teeth D peripheral diameter of rotor outside diameter Vs 100 displac
59. imum allowable radial force Fr as indicated in the table may be chosen higher but must be calculated case by case in function of pressure torque and size of the pulley Consult your distributor for advice A 0500 551 IM TGMAG 02 00 EN 02 2008 31 3 18 4 Shaft rotation Shaft rotation determines which port of the pump is suction and which is discharge 1 Direction of rotation of pump shaft 2 Suction side Relation between shaft rotation and suction discharge side is indicated by the rotation arrow plate attached at the relief valve or the top cover The small arrows 2 and 3 indicate the flow direction of the pumped liquid Always make sure that the pump rotates in the direction indicated by the rotation arrow plate S Discharge side For the specified direction of rotation see the arrow plate on the pump cl ID Suction Discharge Suction Suction Discharge Suction Installation of safety relief valve 3 18 5 Suction and discharge pipes 3 18 5 1 Forces and moments Note Excessive forces and moments on the connecting flanges derived from piping can cause mechanical damage to pump or pump unit Pipes should therefore be connected in line limiting the forces on the pump connections Support the pipes and make sure they remain stress free during operation of
60. issioning of the pump 3 18 7 1 Transport of pump unit Prior to lifting and transporting a pump unit make sure that the packaging is of sturdy enough construction and will not be damaged during transport Use crane hooks in the baseplate or the frame See chapter 1 0 3 18 7 2 Foundation pump unit The pump unit must be installed on a base plate or on a frame placed exactly level on the foundation The foundation must be hard level flat and vibration free in order to guarantee the alignment of pump drive while operating See section 3 18 2 5 3 18 7 3 Variators Gear box Gear motors Motors Consult the suppliers s instruction manual included with the delivery Contact the pump supplier if the manual is not included 3 18 7 4 Electric motor drive Before connecting an electric motor to the mains check the prevailing local regulations of your electricity provider as well as the EN 60204 1 standard Leave the connecting of electric motors to qualified personnel Take the necessary measures to prevent damage to electrical connections and wiring A 0500 551 IM TGMAG 02 00 EN 02 2008 35 36 3 18 7 5 3 18 7 6 Circuit breaker For safety work on a pump unit install a circuit breaker as close as possible to the machine It also is advisable to place an earth fault circuit br
61. ities for the existing regulations A faulty installation can lead to fatal injuries A 0500 551 IM TGMAG 02 00 EN 02 2008 10 1 3 2 3 1 3 2 4 1 3 2 5 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 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 EN 294 1992 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 co
62. markable resistance A 0500 551 IM TGMAG 02 00 EN 02 2008 4 3 3 Assembly of the back pull out assembly to the pump casing 1 Check that the O ring grooves and axial support faces are not damaged and free of dirt Cover O ring 8130 slightly with grease and fit it into the groove in the pump casing 0010 Cover O ring 8440 slightly with grease and fit it into the groove in the intermediate casing 8450 Fit the complete back pull out assembly carefully into the pump casing 0010 Take care of the correct posi tion of the holes for the tightening bolts Fit cap head screws 8460 and tighten them to fix the intermediate cover 8450 to the pump casing 0010 Remark The pump insert 8430 is centering the assembly in the pump casing 0010 with a tight fitting Do not hit with a plastic hammer on the rotor shaft 0701 during assembly If the assembly cannot be fitted by hand use long bolts to pull the intermediate cover 8450 against the pump casing 0010 4 3 4 Assembly of the separation can 1 Check that the O ring groove and axial support faces are not damaged and free of dirt Cover O ring 8200 slightly with grease and fit it into the groove in the separation can 8310 Fit the separation can 8330 over the inner magnetic rotor 8310 Take care of the correct position of the holes for the tightening bolts and the threaded holes for disassembly The threaded hol
63. mic with idler in steel US Idler bush in hardmetal with idler in steel BR Idler bush in bronze with idler in stainless steel CR Idler bush in carbon with idler in stainless steel UR Idler bush in hardmetal with idler in stainless steel HR Idler bush in ceramic with idler in stainless steel Idler pin materials 2 ldler pin in hardened steel 5 Idler pin in nitrided stainless steel 6 Idler pin in hard coated stainless steel Bushes on shaft materials C Bushes in carbon Q Bushes in silicon carbide Rotor and shaft materials S5 Rotor and shaft in nitrided carbon steel R5 Rotor and shaft in nitrided stainless steel Permanent magnet material and length of magnets in cm S04 Samarium Cobalt magnets length 40 mm S06 Samarium Cobalt magnets length 60 mm S08 Samarium Cobalt magnets length 80 mm S10 Samarium Cobalt magnets length 100 mm S12 Samarium Cobalt magnets length 120 mm N04 Neodymium Iron Boron magnets length 40 mm NO6 Neodymium Iron Boron magnets length 60 mm NO8 Neodymium Iron Boron magnets length 80 mm N10 Neodymium Iron Boron magnets length 100 mm N12 Neodymium Iron Boron magnets length 120 mm Elastomer material V FPM Fluorcarbon X Elastomer on request 13 Sense of rotation R Clockwise seen from the shaft end of the pump L Counter clockwise seen from the shaft end of the pump A 0500 551 IM TGMAG 02 00 EN 02 2008 13 3 0 General information and technical data 3 1 Pump standard
64. mp casing 0010 S A B C Axial clearance C between rotor shaft 0701 and pump cover 4000 see table TG MAG Axial yo a c 15 50 0 120 0 200 23 65 0 125 0 215 58 80 0 150 0 250 86 100 0 165 0 275 185 125 0 190 0 320 A 0500 551 IM TGMAG 02 00 EN 02 2008 Adjust the thickness of shim 8100 by peeling of the required number of layers Place shim 8100 support ring 8110 and O ring 8120 on the pump cover 4000 Place idler 0600 complete with bearing bush on the idler pin Mount pump cover 4000 on the pump casing 0010 Qr c lt Q cond Screw in tap bolts 0040 and tighten them crosswise to fix the pump cover 4000 on the pump casing 0010 9 In case of a stainless steel pump cover 4000 check if the sealing faces around the idler pin and on pin cover 1000 are not damaged and free of dirt 10 Use a new gasket 1020 before fixing pin cover 4949 1000 on the pump cover 4000 with tap bolts 1010 Tighten tap bolts 1010 crosswise with DA the specified torque ZKZ 4 3 7 Assembly of top cover 0100 or safety relief valve 1 Check that the sealing faces of the pump casing 0010 and on the top cover 0100 or safety relief valve are not damaged and free of dirt 1080 _g lij 8 2 Place a new gasket 1090 on the pump casing 7 8 8 fi 3 Place top cover 0100 or safety relief valve on the Ng em N
65. n can and pump cover are sealed with O rings Standard O ring material is FPM but other O ring materials can be supplied on request The maximum allowable operating temperature and chemical resistance must be considered for selection of the O ring material Max allowable temperature for FPM Fluorcarbon 200 C The topcover safety relief valve is sealed with a graphite gasket and following sealing rings are used to seal plugs Cast iron pump casing parts Steel sealing rings with asbestos free filling Stainless steel casing parts PTFE sealing rings A 0500 551 IM TGMAG 02 00 EN 02 2008 3 17 Safety relief valve Example V35 G 10H 12 3 4 5 1 Safety relief valve V 2 Type indication inlet diameter in mm 27 Safety relief valve size for TG MAG 15 50 TG MAG 23 65 35 Safety relief valve size for TG MAG 58 80 50 Safety relief valve size for TG MAG 86 100 TG MAG 185 125 3 Materials G Safety relief valve in cast iron R Safety relief valve in stainless steel 4 Working pressure class 4 Working pressure 1 4 bar 6 Working pressure 3 6 bar 10 Working pressure 5 10 bar 16 Working pressure 9 16 bar 5 Heated spring casing H Safety relief valve heated spring casing Safety relief valve horizontal A 0500 551 IM TGMAG 02 00 EN 02 2008 Safety relief valve vertical 25 26 3 17 1 3 17 2 3 17 3 3 17 4 Definition and working principle The safety relief valve built on top o
66. nd the pump pump unit to allow proper inspection pump isolation and maintenance Sufficient space should be left in front of the pump to enable disassembly of the pump cover idler and idler pin Forloosening pump cover refer to ma For disassembling rotating parts rotor shaft and magnetic coupling refer to mb To adjust pressure of safety relief valve refer to mc For dimensions of ma mb mc see chapter 6 0 ma mb mc It is imperative that the operating device of pump and or pump unit is always accessible also during operation 3 18 2 3 Outdoor installation The TopGear pump may be installed in the open the ball bearings are sealed by rubber V joints protecting the pump against dripping water In very wet conditions we advice to install a roof 3 18 2 4 Indoor installation A A Locate the pump so that the motor can be vented properly Prepare the motor for operation according to instructions provided by the motor manufacturer When flammable or explosive products are pumped a proper earthing should be provided The components of the unit should be connected with earthing bridges to reduce the danger arising from static electricity Use explosion free or explosion proof motors according to local regulations Provide suitable coupling guards and suitable couplings Excessive tempera
67. ng incorrectly installed after repair Install pump casing correctly See section 3 18 Installation Wrong direction of rotation of motor For 3 phase drivers change 2 connections Change suction and discharge opening Attention Check the location of the safety relief valve and correct circulation pump insert Magnetic coupling is slipping Check correct assembly of rotor shaft and bear ings and magnetic coupling Check start up conditions for the magnetic cou pling in combination with applied electrical motor if necessary add fly wheel or apply soft start Check operating parameters against break away torque of the magnetic coupling Check if the pump is blocked remove blockage Irregular flow Liquid level in suction tank falls too low Correct liquid supply Provide a liquid level switch Output too high Reduce pump speed or install a smaller pump Install by pass line with check valve Air sucking 10 Repair leak in suction line Cavitation 11 Reduce difference between pump and suction tank level Increase suction pipe diameter Reduce length and simplify suction pipe use as few elbows and other fittings as possible Also see chapter 3 18 Installation Liquid vaporises in pump e g by heating up 12 Check temperature Check vapour pressure of liquid Reduce pump speed If necessary install a larger pump Not enough ca
68. nts of the magnetic coupling A 0500 551 IM TGMAG 02 00 EN 02 2008 43 44 3 21 2 2 Tools For maintenance and repairs use only technically appropriate tools that are in good condition A Handle them correctly For maintenance work on the magnetic drive use preferably tools made of non magnetic material Magnetic tools might be suddenly attracted by the magnetic rotors which can lead to damage of the components or personal injury 3 21 2 3 Shut down Before commencing the maintenance and inspection activities the pump must be taken out of service The pump pump unit must be fully depressurized If the pumped fluid permits let the pump cool down to the surrounding temperature 3 21 2 4 Motor safety Take appropriate steps to prevent the motor from starting while you are still working on the pump This is particularly important for electric motors that are started from a distance Follow the below described procedure Set the circuit breaker at the pump to off Turn the pump off at the control box Secure the control box or place a warning sign on the control box Remove the fuses and take them with you to the place of work Do not remove the protective guard around the coupling until the pump has come to a complete standstill 3 21 2 5 Conservation If the pump is not to be used for longer periods First drain the pump Then treat the internal parts with VG46 mineral oil or other preservering liquid The pump must b
69. nvironments 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 fthe 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 fthe 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 Large 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
70. ocation 3 18 2 1 Short suction line 3 18 2 2 Accessibility itae ttt d eee A AE 3 18 2 3 Outdoor installation eese nennen rnnt nnnnnn 30 3 18 2 4 Indoor installation esee nennen nnne nnne nnnnnn 30 3 18 2 5 Stability tid halo rb deeds dr tinet 31 OR ESECEENDIQ T E 31 3 18 94 Starting torque ege pe bee a AAA 31 3 18 3 2 Radial load on shaft ondi sisese 31 818 4 Shaftrotation coco eee Pelosi cedo 3 18 5 Suction and discharge pipes 3 18 5 1 Forces and moments 3 18 5 2 PIPIN secca te peer Ay AAA 3 18 5 3 Isolating vales etin e enc e ert ve oe 3918 54 Strallniel seo pdt cesa teta e penat rante Deed a e Re 3 18 6 Secondary PIPING sees tnnt aranz 3 18 6 1 Drain lines W o o PE Rn 3 18 6 2 Heating jackets ttd nem erp tet a 3 18 7 Guidelines for assembly sse 3 18 7 1 Transport of pump unit aia 35 3 18 7 2 Foundation pump unit sss 35 3 18 7 3 Variators Gear box Gear motors Motors sss 35 3 18 7 4 Electric motor drive tentent 3 18 7 5 Combustion engines eee neces eene ttes 3 18 7 6 Shaft coupling sss 3 18 7 7 Guarding of moving parts 111111111 3 18 7 8 Check temperature censor on can 3 19 Instructions for start up essent tnnt nenne 3 19 1 General oue con ia ok a Ad i A i ndk iat Aidi 3 19 2 Cleaning the PUMO nyrsio ie 3 19 2 1 Cleaning suc
71. on pump and rear face of the rotor Check axial clearance of the plain bearing ar rangement replace bearing if necessary Rapid wear Back pressure too high 33 Increase pipe diameter Reduce working pressure Check accessories filter heat exchanger etc Solid matter in liquid 34 Filter liquid Pump runs dry 35 Correct liquid supply Provide liquid level switch or dry running protec tion Heat up liquid Stop or reduce air sucking Corrosion 36 Change pump materials or application parameters Motor overloading Back pressure too high 37 Increase pipe diameter Reduce working pressure Check accessories filter heat exchanger etc Viscosity too high 38 Increase axial clearance See section 3 21 Maintenance instructions Heat pump Reduce pump speed Increase discharge pipe diameter Excessive friction losses inside rotor shaft bearing arrangement 39 Check correct axial clearance of circulation pump and rear face of the rotor Check axial axial clearance of the plain bearing arrangement replace bearing if necessary Rotor shaft runs against pump cover 40 Check axial axial clearance of the plain bearing arrangement replace bearing if necessary A 0500 551 IM TGMAG 02 00 EN 02 2008 Symptom Cause Remedy Pump leak O rings sealing rings or gasket damaged 41
72. ooter 82201 Code for adapted 6 material pin 2 or 3 xx1x xx2x xx3x Code for adapted bronze idler bush Y or Z xx1x xXYX XxZX TG MAG 15 50 150 300 450 TG MAG 23 65 160 320 480 TG MAG 58 80 240 480 720 TG MAG 86 100 275 550 825 TG MAG 185 125 325 650 975 The extra clearances are realised as follows Rotor and Idler By extra machining of outside diameter code 2 3 or standard 1 Pump cover By adjusting during assembly code 0 2 3 or standard 1 Idler pin bush bearing 2 cases are possible standard 1 case 1 by providing a special pin 6 material with adapted pin diameter code 2 or 3 case 2 by providing a special bronze bush with adapted inside bush diameter code Y or Z 3 14 Play between gear teeth Play between gear teeth TG MAG 15 50 23 65 58 80 86 100 185 125 gt Minimum um 360 400 400 400 440 CN Maximum um 720 800 800 800 880 B 3 15 Maximum size of solid particles TG MAG 15 50 23 65 58 80 86 100 185 125 Size um 80 120 150 If there are metal particles in the liquid customer must install a magnetic filter before the liquid reaches the pump If there are hard particles in the liquid consult your distributor A 0500 551 IM TGMAG 02 00 EN 02 2008 21 3 16 Components of the magnetic drive 3 16 1 Magnetic coupling The magnetic coupling is transmitting the torque of the drive motor to the
73. orrectly Flow direction of safety relief valve corresponds with suction and discharge lines The set pressure of the safety relief valve is checked see nameplate Jackets Jackets are installed Maximum pressure and temperature of the heating cooling media have been checked The appropriate heating media or coolant is installed and connected L The installation complies with the safety standards Drive Alignment of pump motor gearbox etc is checked Protection All guards and safety devices coupling rotating parts excessive temperature are in place and operative In case of pumps that may reach working temperatures of 60 C or more ensure sufficient safety guards against accidental contact re in place Monitoring system is operational Start up When the pump is to be put into service the following checklist and procedure must be observed Pump is filled with liquid Pump is sufficiently preheated Suction and discharge valves are fully open Start the pump for a short while and check the direction of rotation of the motor and that the magnetic coupling is not slipping Start the pump and check suction of liquid suction pressure RPM of the pump is checked Discharge pipe and seal are checked for leaks Proper operation of the pump is verified A 0500 551 IM TGMAG 02 00 EN 02 2008 39 40 3 19 6 3 19 7
74. over and without jackets on intermediate cover TOC 6 3 4 No jackets on pump cover but jackets on intermediate cover and thread connections OSC No jackets on pump cover but jackets on intermediate cover and flange connections OTC OTC OSC A 68 A 0500 551 IM TGMAG 02 00 EN 02 2008 Jackets dimensions TG MAG Mat 15 50 23 65 58 80 86 100 185 125 Bf G R G 1 4 G 1 4 G 3 8 G 3 8 G 3 8 Bg G R G 1 8 G 1 8 G 1 8 G 1 8 G 1 8 Bh G R G 1 4 G 1 4 G 1 4 G 1 4 G 1 4 BI 2 G 1 2 G 1 2 e S 23 R G3 4 G 3 4 G 3 4 Cf G R 21 3x2 21 3x2 26 9x 2 3 26 9 x 2 3 26 9 x 2 3 dg G R 87 84 121 115 135 dh G R 50 56 78 90 130 dk G R 56 56 75 75 100 dl G R 80 80 106 106 142 ma G R 75 80 105 125 155 zg G R 96 110 123 140 163 zh G R 65 65 86 86 126 zm G R 155 155 207 207 243 zk G R 134 148 165 182 205 6 4 Safety relief valves 6 4 1 Single safety relief valve tg E Mat 15 50 23 65 G 290 300 dv R 293 303 mc G R 50 50 tg G R 200 200 uc Mat 58 80 86 100 185 125 di G 550 576 641 R 555 581 646 mc G R 70 70 70 tg G R A 0500 551 IM TG
75. pacity Pump speed too low 13 Increase pump speed Attention Do not exceed maximum speed and check NPSHr Air sucking 14 Repair leak in suction line Cavitation 15 Reduce difference between pump and suction tank level Increase suction pipe diameter Reduce length and simplify suction pipe use as few elbows and other fittings as possible Also see section 3 18 Installation Back pressure too high 16 Check discharge pipe Increase pipe diameter Reduce working pressure Check accessories filter heat exchanger etc Safety relief valve set too low 17 Correct pressure setting Viscosity too low 18 Increase pump speed Attention Do not exceed maximum speed and check NPSHr If necessary install a larger pump Axial clearance 19 Check axial clearance and correct See section 3 21 Maintenance instructions Gases come free 20 Increase pump speed Attention Do not exceed maximum speed and check NPSHr Install a larger pump A 0500 551 IM TGMAG 02 00 EN 02 2008 41 42 Symptom Cause Remedy Not enough capacity Liquid leaking back to suction over the magnetic coupling 21 Check correct assembly of the circulation pump arrangement Check adjust axial clearance of the circulation pump and rear face of the rotor Pump too noisy Vibrations Pump speed too high 22
76. parts Outer magnetic rotor Intermediate cover Pump shaft Bearing bracket Inner magnetic rotor Rotor bearing assembly Idler pin cover Separation can Idler pin Rotor shaft Pump cover Pump casing Idler gear 3 2 Operating principle As the rotor and idler gear unmesh an underpressure is created and the liquid enters the newly 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 The pump is assembled to be used for flow in one direction 14 A 0500 551 IM TGMAG 02 00 EN 02 2008 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 5 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 See 3 19 4 Checklist Initial start up Safety relief valve This safety relief valve limits the differential pressure Ap between suction and discharge not the maximum pressure within the installation For e
77. perature C of idler bush bearing material and idler material combinations Bush and Idler materials C tae pump Cast iron idler G Steel idler S Stainless steel idler R SG CG BG HG SS CS BS HS US BR CR HR UR 15 50 300 280 240 240 300 250 300 200 240 300 250 200 240 23 65 300 300 250 240 300 280 300 200 240 300 280 200 240 58 80 300 300 250 240 300 280 300 200 240 300 280 200 240 86 100 300 300 250 280 300 280 300 240 240 300 280 240 240 185 125 300 300 250 300 300 280 300 260 240 300 280 260 240 Remark Hardness diminishment of steel bush S and hardened steel pin 2 above 260 C The maximum allowable temperature of the rotor shaft bearing assembly is 280 C 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 significantly If there is no condition for hydrodynamic lubrication the bush bearings make material contact with pin or shaft and the wear of these parts is to be considered The condition of hydrodynamic lubrication is fulfilled TG MAG pump size
78. pump casing 0010 1090 ez Remark The position of the top cover 0100 or safety relief valve depends on the sense of rotation The grooves in the contact face of the top cover 0100 or safety relief valve must connect the hole in the top face of the pump casing 0010 with the suction side of the pump The sense of rotation is indicated with an arrow on the top cover 0100 or safety relief valve 4 Screwin tap bolts 1080 and tighten them crosswise with the specified torque see Chapter 3 21 3 1 to fix the top cover 0100 or safety relief valve on the pump casing 0010 A 0500 551 IM TGMAG 02 00 EN 02 2008 62 5 0 Sectional drawings and part lists How to order spares When ordering spare parts please state 1 Pump type and serial number see name plate 2 Position number quantity and description Example 1 Pump type TG MAG58 80 G2 SOC BG2 Q S5 S10 V R Serial number 2007 479401 2 Pos 0600 1 Idler Bush complete 1080 Bs 5 1 TGMAG15 50 to EIL TG MAG185 125 8130 1410 1560 1490 e A 0500 551 IM TGMAG 02 00 EN 02 2008 5 1 1 Hydraulic part Pos Description 15 50 23 65 58 80 86 100 185 125 preventive overhaul 0010 pump casing 1 1 1 1 1 0040 tap bolt 6 6 8 8 8 01
79. rations on the pump due to inspections preventive maintenance or removal from the installation always follow the prescribed procedures Non compliance with these instructions or warnings may be dangerous for the user and or seriously damage the pump pump unit gt Maintenance operations should be performed by qualified personnel only Always wear the required safety clothing providing protection against high temperatures and harmful and or corrosive fluids Make sure that the personnel read the entire instruction manual and in particular indicate those sections concerning the work at hand SPX Process Equipment is not responsible for accidents and damage caused by non compliance with the guidelines Personnel who carry a cardiac pacemaker should not be allowed to work on a pump equipped with magnetic coupling The magnetic field is sufficiently strong to affect the proper operation of a pacemaker so keep a safe distance of at least 3 m Do not come close not less than 1 m to the magnetic coupling with subjects equippid with magnetic data carrier such as cheque cards computer disks watches etc to avoid damage and or loss of information Par 3 21 2 Preparation 3 21 2 1 Surroundings on site Because certain parts have very small tolerances and or are vulnerable a clean work environment 4 must be created during on site maintenance Particularly remove metallic chips or any dirt which could be attracted by the compone
80. retaining fluid circuits Uncouple the connections to the jackets f necessary clean the jackets and the circuits with compressed air Avoid any leakage of fluid or thermal oil into the environment 3 21 3 Specific components 3 21 3 1 Nuts and bolts Nuts and bolts showing damage or parts with defective threading must be removed and replaced with parts belonging to the same fixation class as soon as possible Preferably use a torque wrench for tightening For the tightening torques see table below Ma Nm Plug with 6 i Bolt edge and flat Ma Nm 8 8 A4 SA Tnm M6 10 G 1 8 10 I M8 25 G 1 4 20 i M10 51 G 1 2 50 I j M12 87 1 M16 215 i T 1 Plug with edge and elastic washer I i 3 21 3 2 Plastic or rubber components Do not expose components made of rubber or plastic cables hoses seals to the effects of oils solvents cleaning agents or other chemicals unless they are suitable These components must be replaced if they show signs of expansion shrinkage hardening or other damage 3 21 3 3 Flat gaskets Never re use flat gaskets Always replace the flat gaskets and elastic rings under the plugs with genuine spares A 0500 551 IM TGMAG 02 00 EN 02 2008 45 46 3 21 3 4 Filter or suction strainer Any filters or suction strainers at the bottom of the suction line must be cleaned regularly Note
81. rotor shaft The magnetic coupling arrangement replaces a dynamic shaft seal and makes the pump 100 leakfree The magnetic coupling consists of following components Outer magnetic rotor Separation can The outer magnetic rotor is assembled on the pump shaft which is driven by the motor The inner magnetic rotor is mounted on the rotorshaft inside the wet part of the pump The separation can is situated between the outer and inner magnetic rotor and is sealing the pump hermetically Permanent magnets are mounted on the inner and outer rotor of the magnetic coupling The magnets on the inner magnetic rotor are completely encapsulated in stainless steel to prevent contact with the pumped medium The magnets mounted on the outer rotor are open and protected against corrosion in contact with the atmosphere The torque is transmitted by magnetic fields between inner and outer magnets which are passing through the stationary separation can Inner and outer magnetic rotor are running synchronically without slip The separation can is a welded construction where the flange and bottom plate are welded to the thin walled pipe section The can is designed for system pressures up to 25 bar The section between the magnetic rotors is made of Hastelloy in order to minimize eddy current losses The separation can is sealed against the intermediate cover by an O ring When the torque of the pump exceeds the maximum allowable torque of the magnetic couplin
82. s a standard set pressure at 1 bar above the indicated maximum working pressure The set pressure can be set lower on request never higher Working pressure class 4 6 10 16 Standard set pressure bar 5 7 11 17 Working pressure range bar 1 4 3 6 5 10 9 16 Set pressure range bar 2 5 4 7 6 11 10 17 Heating The weld on spring casing is provided with 2 thread connections Flange connections are not available Maximum temperature 200 C Maximum pressure 10 bar A 0500 551 IM TGMAG 02 00 EN 02 2008 3 17 5 Safety relief valve Relative adjustment Adjustment of the standard setting pressure is performed at the factory Note When testing the safety relief valve mounted on the pump make sure the pressure never exceeds the set pressure of the valve 2 bar To adjust the standard opening pressure proceed as follows 1 Loosen the tap bolts 7310 2 Remove cover 7050 3 Take the measurement of dimensions of H 4 Read spring ratio in the below table and determine the distance over which the adjusting bolt 7320 must be loosened or tightened 31 CG H Lu A N 7 U Z A gt e LS au ze C HW
83. ss 68 6 3 2 T jackets with flange connections on pump cover and intermediate cover TT sss 68 6 3 8 Jackets with thread connections on pump cover and without jackets on intermediate cover SOC Jackets with flange connections on pump cover and without jackets on intermediate cover TOC 68 6 3 4 No jackets on pump cover but jackets on intermediate cover and thread connections OSC No jackets on pump cover but jackets on intermediate cover and flange connections OTC 68 6 4 Safety relief valves ent 69 6 4 1 Single safety relief valve sesenta 69 6 4 2 Heated safety relief valve seen 70 6 0 Bracket support dae etm eene d REESE AE 71 6 6 WEIGRIS MASS unterm den Dacianadina in nae ene iaa lintel orna Doris exe tita 71 A 0500 551 IM TGMAG 02 00 EN 02 2008 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 A The pump must not be used for other purposes than recommended and quoted for without consulting your distributor 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 deliver
84. t gt gt gt gt gt Safety General Personnel who have a pacemaker should not be allowed to work with the magnetic coupling The magnetic field is sufficiently strong to affect the operation of a pace maker A safe distance is 3 metre Important The pump must not be used for other purposes than recommended and quoted for without consult ing your distributor A pump must always be installed and used in accordance with existing national and local environ mental and safety regulations and laws When ATEX pump pump unit is supplied the separate ATEX manual must be followed 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 Allelectrical 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 start ing Protect the motor and other electrical equipment from overloads with suitable equipment The electric motors must be supplied with ample cooling air In e
85. tightness of the pipes after connection Suction piping Liquids should enter the pump from a level higher than the pump level the inclining pipe should rise upwards towards the pump without any air pockets A too small diameter or a too long suction pipe a too small or blocked strainer will increase pressure losses so that the NPSHa NPSH available becomes smaller than the NPSH NPSH required Cavitation will occur causing noise and vibrations Mechanical damage to pump and pump unit may occur When a suction strainer or filter is installed pressure losses in the suction line must be checked constantly Also check if the inlet pressure at the suction flange of the pump is still sufficiently high Self priming operation At the start sufficient liquid must be available in the pump filling up the internal clearance volume and the dead spaces allowing the pump to build up a pressure difference Therefore for pumping low viscosity fluids a foot valve with the same or larger diameter than the suction pipe must be installed or the pump can be installed without foot valve but in U line Note A foot valve is not recommended when pumping high viscous liquids Toremove air and gases from suction line and pump counter pressure at the discharge side must be reduced In case of self priming operation start up of the pump should be performed with open and empty discharge line allowing air or gases to escape at low backpressure
86. time or in case a new gasket for the top cover was mounted bolts that compress the gasket must be re tighened again after 3 4 days for tightening torques refer to section 3 21 3 1 Nuts and bolts A 0500 551 IM TGMAG 02 00 EN 02 2008 3 19 4 3 19 5 Checklist Initial start up After thorough servicing or when the pump is to be put into service for the first time initial start up the following checklist must be observed Supply and discharge line Suction and discharge pipes are cleaned _ Suction and discharge pipes are checked for leaks L Suction pipe is protected properly to prevent the ingress of foreign bodies Characteristics L The characteristics of the pump unit and safety relief valve to be checked pumptype see name plate RPM working pressure effective power working temperature direction of rotation NPSHr etc Electrical installation Electrical installation complies with local regulations Motor voltage corresponds with mains voltage Check terminal board Make sure that the starting torque is sufficiently high no star delta starting will be used Motor protection is adjusted properly Direction of motor rotation corresponds with direction of pump rotation Motor rotation detached from unit is checked Safety relief valve L Safety relief valve on pump or in piping is installed _ Safety relief valve is positioned c
87. tion line essent tnnt t aaa 3 19 3 Venting and filling seen tenente ttn ttn 3 19 4 Checklist Initial start up seeeeneneentn nnn 3 19 5 Start up usce ie mem A A A A A dee dee dee dei Dade 3 19 6 Shut dOWN ue ewa w z setae ddnde ie de d dead ede ede Dd 3 19 7 Abnormal operation eene tenente tentent tnter nennt A 0500 551 IM TGMAG 02 00 EN 02 2008 3 20 Trouble Shooting os di Gd pb pcs Ho dto d e bre E rene 41 3 20 1 Instructions for re using and disposal sees 43 tI AREE CIUS 43 3 20 1 2 Disposal ente tci n ab e A etta ia Ret xn 43 3 21 Maintenance instructions sacosse cedubdndstiltedeniq etched todo crbra id mfaido eot 43 3 21 4 Xen amp ralix usus tes iza A ui intet de epe tee 43 3 2 1 2 iPreparatiori andzia nee eee ree e n UTR ISO RR kt 43 3 21 2 1 Surroundings on site seen 43 3 21 2 2 NOOS 1 iret eet ta OX HL HH RI KA EB REL 3 21 2 8 Shut dOWLi su ire inte tide Ra E Gerd re DS m dea teta rae Feed 3 21 2 4 Motor safety 3 21 2 5 Conservation 3 21 2 6 External cleaning 3 21 2 7 Electrical installation 44 3 21 2 8 Draining Of fluid i a o a dE 44 3 21229 Fud CIRCUITS rtt ede aea Seen WKK 45 3 21 3 Specific components seen nente 45 3 21 334 Nuts and bolts iicet reete item item dcn 45 3 21 3 2 Plastic or rubber components
88. tures Depending on the fluid being pumped high temperatures may be reached inside and around the pump From 60 C onwards the safety representative must provide the necessary protective means and place Hot surfaces notices When insulating the pump unit ensure that adequate cooling is allowed for the bearing housing This is required for cooling of the bearings and grease of the bearing bracket see 3 18 7 7 Guarding of moving parts Protect the user against leakages and possible liquid streams A 0500 551 IM TGMAG 02 00 EN 02 2008 3 18 2 5 Stability Foundation The pump unit must be installed on a base plate or on a frame placed exactly level on the founda tion The foundation must be hard level flat and vibration free to guarantee correct alignment of the pump drive while operating See also section 3 18 7 Guidelines for assembly and section 3 18 7 6 Shaft coupling Horizontal mounting Pumps are to be mounted horizontally on the integral feet Other kinds of installation have an influence on draining and filling etc If the pump pump unit is installed differently contact your distributor Support The support under the bearing bracket is designed to absorb belt forces and vibrations while letting the pump shaft expand freely along its axis ia 3 18 3 Drives If a bare shaft pump is supplied the user is responsible for the drive and the assembling with the pump The user also must provide guarding of movin
89. uare flanges instead of rounded flanges TG MAG 15 50 23 65 58 80 86 100 185 125 aa 50 65 80 100 125 ab 98 120 133 160 186 ac PN16 125 145 160 180 210 ac PN20 120 5 139 5 152 5 190 5 216 ac PN25 125 145 160 190 220 ac PN40 125 145 160 190 220 ac PN50 127 149 5 168 200 235 ad 165 187 206 238 273 ak PN16 4xd18 4xd18 8xd18 8xd18 8xd18 ak PN20 4xd18 4xd18 4xd18 8xd18 8xd22 ak PN25 4xd18 8xd18 8xd18 8xd22 8xd26 ak PN40 4xd18 8xd18 8xd18 8xd22 8xd26 ak PN50 8xd18 8xd22 8xd22 8xd22 8xd22 am 21 21 24 25 28 zb 125 125 160 180 200 A 0500 551 IM TGMAG 02 00 EN 02 2008 67 6 3 Jackets 6 3 1 S jackets with thread connections on pump cover and intermediate cover SS zg zh 2xBf 6 3 2 KQ P H 89 t 6 3 3 Jackets with thread connections on pump cover and without jackets on intermediate cover SOC Jackets with flange connections on pump c
90. ve the shaft sleeve 8350 B Take care that shaft sleeve 8350 B and axial bearing 8350 A are not damaged 9 Remove the bearing arrangement over the rotor shaft 0701 front axial bearing 8350 A and disc rotor 8420 10 Un tighten cap head screws 8480 crosswise and remove them 11 Remove radial bearing holder B350 C and shim 8470 and insert 8430 from intermediate cover 8450 A 0500 551 IM TGMAG 02 00 EN 02 2008 53 4 3 Assembly 4 3 1 Assembly of bearing bracket 1 Place pump shaft 0702 in vertical position on the workbench 2 Place bearing cover 1430 over pump shaft 0702 The countersunk holes should point in the direction of the flange 3 Assemble ball bearing 1440 on the pump shaft Use a pipe and a plastic hammer and drive the bearing via the inner bearing ring carefully over the pump shaft 0702 until the inner bearing ring makes contact with the shaft shoulder 4 Place support ring 1460 over the pump shaft 0702 and secure the ball bearing 1440 with circlip 1450 on the shaft The circlip 1450 should be fitted under axial pre load into the groove in the pump shaft 0702 5 Mount the outer magnetic rotor 8320 on the flange of pump shaft 0702 Make sure that the locking pins 8600 are coinciding with the holes in the flange 6 Screw cap head screws 8610 into the magnetic rotor 8320 Tighten these cap head screws 8610 with Loctite
91. vers 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 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 distributor 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 o a SPX Process Equipment BE NV o B Evenbroekveld 2 4 BE 9420 Erpe Mere JOHNSON PUMP AN SPX BRAND www johnson pump com and spxpe com Pump type Article No Unit serial No Date A 0500 551 IM TGMAG 02 00 EN 02 2008 1 4 Technical convention S Quantity Symbol Unit Dynamic viscosity u mPa s cP Centipoise Kinematic viscosity v u kg p p density gms mm v kinematic viscosity uj cSt Centistokes Note In this manual only dynamic viscosity is used Pressure p bar Ap Differential pressure bar p Maximum pressure at discharge flange design pressure bar Note In this manual unless otherwise specified pressure is relative pressure
92. xample 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 C an escape path rerouting the media back to 2 the suction side when reaching a specified DZA pressure level The safety relief valve protects the pump against over pressure only in one flow direction 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 overpressure must be provided Note Do not use the safety relief valve as a flow regulator The liquid will ciculate only through the pump and will heat up quickly Contact your distributor if a flow regulator is required 3 3 Sound TopGear pumps are rotary displacement pumps Because of the contact between internal parts ro tor 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 distributor
93. y 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 distributor o All pumps have the serial number TopGear stamped on a nameplate Model TG This number should be stated in all correspondence with your distributor The first two digits of the serial number indicate the year of production Serial No SPX Process Equipment BE NV pfi on NSON PUMP Evenbroekveld 2 4 Om AN SPX BRAND BE 9420 Erpe Mere o www johnson pump com and spxpe com 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 Always use two or more lifting slings Make sure Never lift the pump unit with only two fastening they are secured in such a way as to prevent points Incorrect lift can cause personal injury them from slipping The pump unit should be and or damage to the pump unit lifted in a horizontal position 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 protective oil A 0500 551 IM TGMAG 02 00 EN 02 2008 gt gt g
94. y and should not be relied upon unless confirmed in writing Copyright 2008 SPX Corporate

SPX Cooling Technologies MAG185-125 User's Manual

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