Instruction Manual
TopGear MAG
Magnetic Drive Internal Gear pumps
Read and understand this manual prior to operating
or servicing this product.
A.0500.551 – IM-TG MAG/02.00 GB (02/2008)
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Contents
1.0
Introduction........................................................................................................ 7
1.1 General..................................................................................................................7
1.2 Reception, handling and storage ....................................................................7
1.2.1
1.2.2
1.2.3
Reception.......................................................................................................... 7
Handling............................................................................................................ 7
Storage.............................................................................................................. 7
1.3 Safety.....................................................................................................................8
1.3.1
General.............................................................................................................. 8
1.3.2
Pump units........................................................................................................ 9
1.3.2.1
1.3.2.2
1.3.2.3
1.3.2.4
1.3.2.5
Pump unit handling....................................................................................9
Installation....................................................................................................9
Before commissioning the pump unit.................................................10
Disassembly/assembly of the coupling guard..................................10
Name plate – CE Declaration of Conformity....................................10
1.4 Technical conventions.....................................................................................11
2.0
3.0
Pump description ...........................................................................................12
2.1 Type designation ..............................................................................................12
General information and technical data ....................................................14
3.1 Pump standard parts.......................................................................................14
3.2 Operating principle..........................................................................................14
3.2.1
Self-priming operation .................................................................................15
3.2.2
Safety relief valve – Working principle.....................................................15
3.3 Sound .................................................................................................................15
3.4 General performance ......................................................................................15
3.5 Main characteristics .......................................................................................16
3.6 Pressure.............................................................................................................16
3.7 Sound level .......................................................................................................16
3.7.1
3.7.2
3.7.3
Sound level of a pump without drive........................................................16
The sound level of the pump unit..............................................................17
Influences........................................................................................................18
3.8 Maximum and minimum allowable temperature ........................................18
3.9 Jacket options...................................................................................................18
3.10 Internals..............................................................................................................18
3.10.1 Bush materials...............................................................................................18
3.10.2 Maximum temperature of internals............................................................19
3.10.3 Operation under hydrodynamic lubrication conditions ........................19
3.10.4 Maximum torque of pump shaft and rotor material combination........19
3.11 Mass moment of inertia...................................................................................20
3.12 Axial and radial clearances.............................................................................20
3.13 Extra clearances...............................................................................................20
3.14 Play between gear teeth.................................................................................21
3.15 Maximum size of solid particles ....................................................................21
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3.16 Components of the magnetic drive..............................................................22
3.16.1 Magnetic coupling ........................................................................................22
3.16.2 Rotor bearing assembly...............................................................................23
3.16.3 Circulation pump...........................................................................................24
3.16.4 Sealing rings and gaskets...........................................................................24
3.17 Safety relief valve .............................................................................................25
3.17.1 Definition and working principle................................................................26
3.17.2 Materials..........................................................................................................26
3.17.3 Pressure..........................................................................................................26
3.17.4 Heating............................................................................................................26
3.17.5 Safety relief valve – Relative adjustment.................................................27
3.17.6 Sectional drawings and part lists..............................................................28
3.17.6.1 Single safety relief valv28
3.17.6.2 Heated spring casing.............................................................................29
3.18 Installation..........................................................................................................29
3.18.1 General............................................................................................................29
3.18.2 Location...........................................................................................................30
3.18.2.1 Short suction line ....................................................................................30
3.18.2.2 Accessibility..............................................................................................30
3.18.2.3 Outdoor installation................................................................................30
3.18.2.4 Indoor installation....................................................................................30
3.18.2.5 Stability......................................................................................................31
3.18.3 Drives...............................................................................................................31
3.18.3.1 Starting torque.........................................................................................31
3.18.3.2 Radial load on shaft end........................................................................31
3.18.4 Shaft rotation .................................................................................................32
3.18.5 Suction and discharge pipes .....................................................................32
3.18.5.1 Forces and moments..............................................................................32
3.18.5.2 Piping.........................................................................................................33
3.18.5.3 Isolating valves.........................................................................................33
3.18.5.4 Strainer......................................................................................................34
3.18.6 Secondary piping..........................................................................................34
3.18.6.1 Drain lines.................................................................................................34
3.18.6.2 Heating jackets.......................................................................................34
3.18.7 Guidelines for assembly..............................................................................35
3.18.7.1 Transport of pump unit...........................................................................35
3.18.7.2 Foundation pump unit ............................................................................35
3.18.7.3 Variators, Gear box, Gear motors, Motors.........................................35
3.18.7.4 Electric motor drive.................................................................................35
3.18.7.5 Combustion engines..............................................................................36
3.18.7.6 Shaft coupling..........................................................................................36
3.18.7.7 Guarding of moving parts .....................................................................37
3.18.7.8 Check temperature censor on can .....................................................37
3.19 Instructions for start-up ..................................................................................38
3.19.1 General............................................................................................................38
3.19.2 Cleaning the pump.......................................................................................38
3.19.2.1 Cleaning suction line..............................................................................38
3.19.3 Venting and filling..........................................................................................38
3.19.4 Checklist – Initial start-up ..........................................................................39
3.19.5 Start-up...........................................................................................................39
3.19.6 Shut-down......................................................................................................40
3.19.7 Abnormal operation......................................................................................40
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3.20 Trouble shooting...............................................................................................41
3.20.1 Instructions for re-using and disposal......................................................43
3.20.1.1 Re-use.......................................................................................................43
3.20.1.2 Disposal ....................................................................................................43
3.21 Maintenance instructions ...............................................................................43
3.21.1 General............................................................................................................43
3.21.2 Preparation.....................................................................................................43
3.21.2.1 Surroundings (on site) ...........................................................................43
3.21.2.2 Tools...........................................................................................................44
3.21.2.3 Shut-down................................................................................................44
3.21.2.4 Motor safety..............................................................................................44
3.21.2.5 Conservation............................................................................................44
3.21.2.6 External cleaning .....................................................................................44
3.21.2.7 Electrical installation...............................................................................44
3.21.2.8 Draining of fluid ......................................................................................44
3.21.2.9 Fluid circuits.............................................................................................45
3.21.3 Specific components...................................................................................45
3.21.3.1 Nuts and bolts..........................................................................................45
3.21.3.2 Plastic or rubber components..............................................................45
3.21.3.3 Flat gaskets ..............................................................................................45
3.21.3.4 Filter or suction strainer.........................................................................46
3.21.3.5 Anti-friction bearings..............................................................................46
3.21.3.6 Sleeve bearings.......................................................................................46
3.21.4 Front pull-out..................................................................................................46
3.21.5 Back pull-out..................................................................................................46
3.21.6 Clearance adjustment .................................................................................46
3.21.7 Designation of threaded connections......................................................48
3.21.7.1 Threaded connection Rp (example Rp 1/2) .....................................48
3.21.7.2 Threaded connection G (example G 1/2).........................................48
4.0
Instructions for assembly and disassembly..............................................49
4.1 General...............................................................................................................49
4.2 Disassembly......................................................................................................49
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
Disassembly of front-pull-out assembly...................................................49
Disassembly of top cover (0100) or safety relief valve........................50
Disassembly of bearing bracket ................................................................50
Disassembly of pump shaft complete......................................................51
Disassembly of outer magnetic rotor .......................................................51
Disassembly of separation can..................................................................52
Disassembly of back-pull-out assembly..................................................52
4.3 Assembly............................................................................................................54
4.3.1
Assembly of bearing bracket......................................................................54
4.3.2
Pre-assembly of the back-pull-out............................................................56
4.3.2.1
4.3.2.2
Adjustment of the axial clearance of the circulation pump ...........56
Assembly of rotor shaft..........................................................................57
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
Assembly of the back-pull-out assembly to the pump casing............59
Assembly of the separation can ................................................................59
Assembly of the bearing bracket...............................................................60
Assembly of the front-pull-out assembly.................................................60
Assembly of top cover (0100) or safety relief valve..............................61
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5.0
Sectional drawings and part lists................................................................62
5.1 TG MAG15-50 to TG MAG185-125 .........................................................62
5.1.1
5.1.2
5.1.3
Hydraulic part.................................................................................................63
Bearing bracket.............................................................................................63
S-jacket options ............................................................................................64
5.1.3.1
S-Jackets on pump cover......................................................................64
5.1.3.2
S-Jackets on intermediate cover .........................................................64
5.1.4
T-jacket options .............................................................................................65
5.1.4.1
T-jackets on pump cover .......................................................................65
5.1.4.2
T-jackets on intermediate cover...........................................................65
6.0
Dimensional drawings ...................................................................................66
6.1 TG MAG15-50 to 185-125 pumps ............................................................66
6.2 Flange connections .........................................................................................67
6.2.1
Cast iron..........................................................................................................67
6.2.2
Stainless steel................................................................................................67
6.3 Jackets................................................................................................................68
6.3.1
6.3.2
6.3.3
S-jackets with thread connections on
pump cover and intermediate cover (SS) ...............................................68
T-jackets with flange connections on
pump cover and intermediate cover (TT) ................................................68
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 ...........................................................................................69
6.4.1
Single safety relief valve..............................................................................69
6.4.2
Heated safety relief valve ............................................................................70
6.5 Bracket support................................................................................................71
6.6 Weights – Mass ...............................................................................................71
6
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1.0 Introduction
1.1 General
This instruction manual contains necessary information on the TopGear pumps and must be read
carefully before installation, service and maintenance. The manual must be kept easily accessible to
the operator.
Important!
The pump must not be used for other purposes than recommended and quoted for without
consulting your 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 delivery. Check the consignment for damage
immediately on arrival and make sure that the name plate/type designation is in accordance with the
packing slip and your order.
In case of damage and/or missing parts, a report should be drawn up and presented to the carrier at
once. Notify your distributor.
TopGear
All pumps have the serial number
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
Evenbroekveld 2-4
BE-9420 Erpe-Mere
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
they are secured in such a way as to prevent
them from slipping. The pump unit should be
lifted in a horizontal position.
Never lift the pump unit with only two fastening
points. Incorrect lift can cause personal injury
and/or damage to the pump unit.
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.
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1.3 Safety
1.3.1 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.
All electrical installation work must be carried out by authorized personnel in accordance with
EN60204-1 and/or local regulations. Install a lockable circuit breaker to avoid inadvertent 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 environments where there is risk of explosion, motors classified as explosion-safe must be
used, along with special safety devices. Check with the governmental agency responsible for
such precautions.
•
•
Improper installation can cause fatal injuries.
Dust, liquids and gases that can cause overheating, short circuits, corrosion damage and fire
must be kept away from motors and other exposed equipment.
•
If the pump handles liquids hazardous for person or environment, some sort of container must
be installed into which leakage can be led. All (possible) leakage should be collected to avoid
contamination of the environment.
•
•
Keep arrows and other signs visible on the pump.
If the surface temperature of the system or parts of the system exceeds 60°C, these areas must
be marked with warning text reading ”Hot surface” to avoid burns.
•
The pump unit must not be exposed to rapid temperature changes of the liquid without prior pre-
heating/pre-cooling. 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 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.
If the pump does not function satisfactorily, contact your distributor.
8
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1.3.2 Pump units
1.3.2.1 Pump unit handling
Use an overhead crane, forklift or other suitable lifting device.
Secure lifting slings around the front
part of the pump and the back part of
the motor. Make sure that the load is
balanced before attempting the lift.
NB! Always use two lifting slings.
If there are lifting rings on both the
pump and the motor the slings may be
fastened to these.
Warning
Never lift the pump unit with only one
fastening point. Incorrect lifts can re-
sult in personal injury and/or damage
to the unit.
NB! Always use two lifting slings.
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 magnetic 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!
Warning
The safety switch must be turned to off and locked before any work is carried out on the pump unit.
Accidental start can cause serious personal injury.
The pump unit must be mounted on a level surface and either be bolted to the foundation or be fitted
with rubber-clad feet.
The pipe connections to the pump must be stress-free mounted, securely fastened to the pump and
well supported. Incorrectly fitted pipe can damage the pump and the system.
Warning
Electric motors must be installed by authorized personnel in accordance with EN60204-1. Faulty
electrical installation can cause the pump unit and system to be electrified, which can lead to fatal
injuries.
Electric motors must be supplied with adequate cooling ventilation. Electric motors must not be
enclosed in airtight cabinets, hoods etc.
Dust, liquids and gases which can cause overheating and fire must be diverted away from the
motor.
Warning
Pump units to be installed in potentially explosive environments must be fitted with an Ex-class
(explosion safe) motor. Sparks caused by static electricity can give shocks and ignite explosions.
Make sure that the pump and system are properly grounded. Check with the proper authorities for
the existing regulations. A faulty installation can lead to fatal injuries.
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1.3.2.3 Before commissioning the pump unit
Read the pump’s operating and safety manual. Make sure that the installation has been correctly
carried out according to the relevant pump’s manual.
Check the alignment of the pump and motor shafts. The alignment may have been altered during
transport, lifting and mounting of the pump unit. For safe disassembly of the coupling guard see
below: Disassembly/assembly of the coupling guard.
Warning
The pump unit must not be used with other liquids than those for which it was recommended and
sold. If there are any uncertainties contact your sales representative. Liquids, for which the pump is
not appropriate, can damage the pump and other parts of the unit as well as cause personal injury.
1.3.2.4 Disassembly/assembly of the coupling guard
The coupling guard is a fixed guard to protect the users and operator from fastening and injuring
themselves on the rotating shaft/shaft coupling. The pump unit is supplied with factory mounted
guards with certified maximum gaps in accordance with standard 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 covers. There is a risk of personal injury if the
coupling guard is incorrectly mounted.
a) Turn off and lock the power switch.
b) Disassemble the coupling guard.
c) Complete the work.
d) Reassemble the coupling guard and any other protective covers. Make sure that the screws are
properly tightened.
1.3.2.5 Name plate – CE Declaration of Conformity
Always quote the serial number on the name plate together with questions concerning the pump unit,
installation, maintenance etc.
When changing the operating conditions of the pump please contact your 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.
SPX Process Equipment BE NV
Evenbroekveld 2-4
BE-9420 Erpe-Mere
Pump type:
Article No.:
Unit serial No.:
Date:
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1.4 Technical conventions
Quantity
Symbol
Unit
Dynamic viscosity
Kinematic viscosity
µ
mPa.s = cP (Centipoise)
ν = µ
kg
—
ρ = density
ρ
3
[dm]
mm2
—
[ s ] = cSt (Centistokes)
ν = kinematic viscosity
Note! In this manual only dynamic viscosity is used.
Pressure
p
[bar]
∆p
pm
Differential pressure = [bar]
Maximum pressure at discharge flange (design pressure) = [bar]
Note! In this manual, unless otherwise specified - pressure is relative pressure [bar].
Net Positive
SuctionHead
NPSHa
Net Positive Suction Head is the total absolute inlet pressure at
the pump suction connection, minus the vapour pressure of the
pumped liquid.
NPSHa is expressed in meter liquid column.
It is the responsibility of the user to determine the NPSHa value.
NPSHr
Net Positive Suction Head Required is the NPSH determined,
after testing and calculation, by the pump manufacturer to avoid
performance impairment due to cavitation within the pump at rate
capacity.
The NPSHr is measured at the suction flange, at the point where
the capacity drop results in a pressure loss of at least 4%.
Note! In this manual, unless otherwise specified, NHPH = NPSHr
When selecting a pump, ensure that NPSHa is at least 1 m higher than the NPSHr.
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2.0 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.
2.1 Type designation
The pump properties are encoded in the following type indication, which is to be found on the name-
plate:
Example:
TG MAG 58-80 G2-S0C-BG2-Q-S5-S10-V-R
TG MAG 58-80
G2
S
0C
BG
2
Q
S5
S10
V
R
1
2
3
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 dm3) 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 lbs
R2 PN25 / PN40 flanges
R3 PN20 flanges to ANSI 150 lbs
R4 PN50 flanges to ANSI 300 lbs
R5 PN16 flanges to DIN 2533
5. Jacket options for pump cover
0
S
T
Pump cover without jackets
Pump cover with jacket and thread connection
Pump cover with jacket and flange connection
6. Jacket options for intermediate cover
0C Intermediate cover without heating
SC Intermediate cover with thread connection
TC Intermediate cover with flange connection
12
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TG MAG 58-80
G2
S
0C
BG
2
Q
S5
S10
V
R
1
2
3
4
5
6
7
8
9
10
11
12
13
7. 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 ceramic 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
8. Idler pin materials
2
5
6
Idler pin in hardened steel
Idler pin in nitrided stainless steel
Idler pin in hard coated stainless steel
9. Bushes on shaft materials
C
Q
Bushes in carbon
Bushes in silicon carbide
10. Rotor and shaft materials
S5 Rotor and shaft in nitrided carbon steel
R5 Rotor and shaft in nitrided stainless steel
11. 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
N06 Neodymium Iron Boron magnets, length = 60 mm
N08 Neodymium Iron Boron magnets, length = 80 mm
N10 Neodymium Iron Boron magnets, length = 100 mm
N12 Neodymium Iron Boron magnets, length = 120 mm
12. Elastomer material
V
X
FPM (Fluorcarbon)
Elastomer on request
13. Sense of rotation
R
L
Clockwise seen from the shaft end of the pump
Counter-clockwise seen from the shaft end of the pump
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3.0 General information and technical data
3.1 Pump standard parts
Outer magnetic rotor
Intermediate cover
Top cover
Pump shaft
Bearing bracket
Inner magnetic rotor
Rotor bearing assembly
Idler pin cover
Idler pin
Separation can
Rotor shaft
Pump casing
Pump cover
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
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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 (∆p) between suction and discharge,
not the maximum pressure within the installation.
For example, as media cannot escape when
the discharge side of the pump is obstructed,
an over-pressure may cause severe damage
to the pump. The safety relief valve provides
an escape path, rerouting the media back to
the suction side when reaching a specified
pressure level.
•
•
The safety relief valve protects the pump against over-pressure only in one flow direction.
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
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.
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3.5 Main characteristics
The pump size is designated by the displacement volume of 100 revolutions expressed in litres
(or dm3) but rounded followed by the nominal port diameter expressed in millimetres.
Pump size
TG MAG
d
B
(mm)
D
(mm)
Vs-100
(dm3)
n.max
(min-1)
n.mot
Q.th
(l/s)
Q.th
v.u
(m/s)
v.i
(m/s)
∆p
(bar)
p.test
(bar)
(mm)
(min-1)
(m3/h)
50
65
80
40
47
60
100
115
160
14.5
22.5
55.8
1500
1500
1050
3.6
3.5
5.6
5.4
9.8
8.9
13.5
23
13.1
12.6
20.3
19.6
35.2
32.1
48.5
82.7
79.9
7.9
7.6
9.0
8.7
8.8
8.0
8.8
8.8
8.5
1.8
1.8
1.7
1.7
2.0
1.8
1.7
1.9
1.8
16
16
16
24
24
24
15-50
23-65
1450
1450
58-80
960
960
86-100
185-125
100
125
75
175
224
84.2
960
750
16
16
24
24
100
183.7
725
22.2
Legend
d
:
:
:
:
:
:
:
:
:
:
:
port diameter (inlet and outlet port)
B
width of idler gear and length of rotor teeth
peripheral diameter of rotor (outside diameter)
displaced volume pro 100 revolutions
maximum allowable shaft speed in rpm
D
Vs-100
n.max
n.mot
Q.th
v.u
normal speed of direct drive electric motor (at 50Hz frequency)
theoretical capacity without slip at differential pressure = 0 bar
peripheral velocity of rotor
v.i
velocity of liquid in the ports at Qth (inlet and outlet port)
maximum working pressure = differential pressure
hydrostatic test pressure
∆p
p test
Maximum viscosity
Maximum viscosity = 10 000 mPas
Remark:
Figures are for Newtonian liquids at operating temperature
3.6 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.
3.7 Sound level
3.7.1 Sound level of a pump without drive
Sound pressure level (LpA)
The following table gives an overview of the A-weighted sound pressure level, LpA emitted by
a pump without drive, measured according to ISO3744 and expressed in decibels dB(A). The
reference sound pressure is 20µPa.
16
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The values depend on the position from where one measures and were therefore
measured at the front of the pump, at distance of 1 meter from the pump cover and
were corrected for background noise and reflections.
The values listed are the highest measured values under following operating conditions.
• working pressure: up to 10 bar.
• pumped medium: water, viscosity = 1 mPa.s
• —% nmax = — % maximum shaft speed
Lpa (dB(A))
TG MAG pump size
nmax(min-1)
Ls (dB(A))
25% nmax
50%nmax
75%nmax
100%nmax
15-50
1500
1500
1050
960
61
63
67
69
71
72
75
79
80
82
79
81
85
86
87
83
85
89
90
91
9
23-65
10
10
11
11
58-80
86-100
185-125
750
Sound power level (LWA)
The sound power LW is the power emitted by the pump as sound waves and is used to compare
sound levels of machines. It is the sound pressure Lp that acts on a surrounding surface at distance
of 1 meter.
LWA = LpA + Ls
The A-weighted sound power level LWA is also expressed in decibels dB(A).
The reference sound power is 1 pW (= 10-12 W). LS 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
The sound level of the drive (motor, transmission,…) must be added to the sound level of the pump
itself to determine the total sound level of the pump unit. The sum of several sound levels must be
calculated logarithmically.
For a quick determination of the total sound level the following table can be used:
L1–L2
0
1
2
3
4
5
6
L[f(L1–L2)]
3.0 2.5 2.0 1.7 1.4 1.2 1.0
Ltotal = L1 + L corrected
where Ltotal
: the total sound level of the pump unit
: the highest sound level
L1
L2
: the lowest sound level
Lcorrected
: term, depending on the difference between both sound levels
For more than two values this method can be repeated.
Example:
Drive unit
Pump
: L1 = 79 dB(A)
: L2 = 75 dB(A)
: L1 - L2 = 4 dB(A)
Correction
According to the table : Lcorrected = 1.4 dB(A)
Ltotal = 79 + 1.4 = 80.4 dB(A)
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3.7.3 Influences
The real sound level of the pump unit can for several reasons deviate from the values listed in the
tables above.
•
•
•
Noise production decreases when pumping high viscosity liquids due to better lubricating and
damping properties. Moreover the resistance torque of the idler is increasing due to higher liquid
friction which results in lower vibration amplitude.
Noise production increases when pumping low viscosity liquids combined with low working
pressure because the idler can move freely (lower charge, lower liquid friction) and the liquid
does not dampen much.
Vibrations in piping, vibrating of the baseplate etc. will make the installation produce more noise.
3.8 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.
3.9 Jacket options
S-jackets are designed for use with saturated steam or with non-dangerous media. They are
provided with cylindrical threaded connections according to ISO 228-I.
Maximum temperature:
Maximum pressure:
200°C
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
3.10 Internals
3.10.1 Bush materials
Overview of bush materials and application field
Material Code
S
C
B
H
U
Q
Material
Steel
Carbon
Bronze
Ceramic
Hard metal Silicon Carbide
if yes
if no
to maximum working pressure = 16 bar
Hydrodynamical
lubrication
6 bar (*) 10 bar (*)
6 bar (*)
Fair
6 bar (*)
Excellent
Good
10 bar (*)
Good
Good
No
10 bar (*)
Good
Good
No
Corrosive resistance
Abrasive resistance
Dry running allowed
Sensitive to thermal shock
Sensitive to blistering in oil
Oil aging
Fair
Slight
No
Good
None
None
Yes
Moderate
No
No
No
No
Yes dT<90°C No
No
No
> 180°C
No
No
No
No
Yes
No
No
Yes
No
No
> 150°C
No (lead)
No
Food processing allowed
Yes
No (antimony)
Yes
(*) These are not absolute figures. Higher or lower values possible in function of the application, expected life-
time etc.
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3.10.2 Maximum temperature of internals
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.
•
In 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 temperature (°C) of idler bush bearing material and
idler material combinations
Bush and Idler materials (°C)
TG MAG pump
Cast iron idler G
Steel idler S
BS HS
Stainless steel idler R
BR CR HR UR
size
SG*)
CG
BG
HG
SS*) CS
US
15-50
300 280 240 240 300 250 300 200 240 300 250 200 240
300 300 250 240 300 280 300 200 240 300 280 200 240
300 300 250 240 300 280 300 200 240 300 280 200 240
300 300 250 280 300 280 300 240 240 300 280 240 240
300 300 250 300 300 280 300 260 240 300 280 260 240
23-65
58-80
86-100
185-125
*) 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.
3.10.3 Operation under hydrodynamic lubrication conditions
Hydrodynamic lubrication could be important criteria for bush material selection.
If the bush bearings are running under the condition of hydrodynamic lubrication there is no more
material contact between bush and pin or shaft and the lifetime cycle is increased 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
with the following equation:
TG MAG pump size
15-50
K.hyd
6250
4000
3750
3600
2500
23-65
Viscosity * shaft speed / diff.pressure ≥ K.hyd
58-80
with:
viscosity [mPa.s]
86-100
shaft speed [rpm]
185-125
diff.pressure [bar]
K.hyd = design constant for each pump size.
3.10.4 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.
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3.11 Mass moment of inertia
TG MAG pump size
15-50
23-65
58-80
86-100
185-125
J (10-3 x kgm²)
3.5
6.8
32
54
200
Outer parts
Inner parts
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 [ 10-3 x kgm2]
outer parts per lenght of magnets inner parts per lenght of magnets
TG MAG
type
40/60
22
80
26
100
-
120
40/60
8
80
9
100
-
120
15-50
-
-
23-65
22
26
-
-
-
10
12
52
70
247
-
-
-
58-80
66
80
93
99
358
46
58
76
264
86-100
185-125
72
85
-
65
-
248
303
413
230
280
3.12 Axial and radial clearances
TG MAG pump size
15-50
310
250
200
120
23-65
58-80
370
300
250
150
86-100
185-125
radial clearance
axial clearance
max (µm)
min (µm)
max (µm)
min (µm)
320
260
215
125
380
300
275
165
420
340
320
190
3.13 Extra clearances
To handle extra clearances following clearance classes are defined:
C0 = Pump cover axial clearance set at minimum
C1 = Standard clearance (not indicated because standard)
C2 = ~2 x standard clearance
C3 = 3 x 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 (µm).
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Radial clearance on rotor, idler outside diameter – Axial clearance on pump cover
Pump size
CO (µm)
axial clear.
set minimum
C1 (µm)
normal
C1 (µm)
normal
C2 (µm)
C3 (µm)
Code Rotor
Code Idler
1xxx
2xxx
x2xx
xxx2
3xxx
x3xx
xxx3
x1xx
xxx1
Code pump
xxx0
cover assembly
TG MAG 15-50
TG MAG 23-65
TG MAG 58-80
TG MAG 86-100
TG MAG 185-125
52
56
66
72
85
280
290
325
340
380
160
170
200
220
255
350
375
440
480
560
480
510
600
660
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
C1 (µm)
normal
C2 (µm)
= 2 x C1
C3 (µm)
= 3 x C1
Pump size
Code for adapted 6 material pin (2 or 3) *)
Code for adapted bronze idler bush (Y or Z ) **)
TG MAG 15-50
xx1x
xx1x
150
160
240
275
325
xx2x
xxYx
300
320
480
550
650
xx3x
xxZx
450
480
720
825
975
TG MAG 23-65
TG MAG 58-80
TG MAG 86-100
TG MAG 185-125
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
Minimum (µm)
Maximum (µm)
360
720
400
800
400
800
400
800
440
880
3.15 Maximum size of solid particles
TG MAG
15-50
23-65
58-80
86-100
185-125
Size (µm)
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.
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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 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
Inner magnetic rotor
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 coupling,
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.
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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):
Neodymium Iron Boron (NdFeB):
280°C
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
diameter
[mm]
Length of magnets [mm]
40
60
80
100
120
TG MAG 15-50 / 23-65
TG MAG 58-80 / 86-100
TG MAG 185-125
110
165
215
x
x
x
x
x
x
x
x
x
-
x
x
-
-
x
The material of the magnets and the 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 axial bearing
Radial bearing holder
Shaft sleeve
Rear axial bearing +
Hub inner magnetic rotor
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The rear axial bearing is mounted 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:
Shaft sleeve:
1.4460 / duplex steel
Silicon carbide
Axial bearing faces:
Radial bearing bushes:
Silicon carbide
Option (Q) silicon carbide
Option (C) carbon
3.16.3 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
Rotor shaft
Material circulation pump parts
Pump gear:
Disk rotor:
Insert:
1.4460 duplex steel
PEEK
1.4460 duplex steel
3.16.4 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, separation 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:
Stainless steel casing parts:
Steel sealing rings with asbestos-free filling
PTFE sealing rings
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3.17 Safety relief valve
Example
V 35 - G 10 H
1
2
3
4
5
1. Safety relief valve = V
2. Type indication = inlet diameter (in mm)
27
35
50
Safety relief valve size for
TG MAG 15-50, TG MAG 23-65
Safety relief valve size for
TG MAG 58-80
Safety relief valve size for
TG MAG 86-100, TG MAG 185-125
3. Materials
G
R
Safety relief valve in cast iron
Safety relief valve in stainless steel
4. Working pressure class
4
6
Working pressure 1-4 bar
Working pressure 3-6 bar
Working pressure 5-10 bar
Working pressure 9-16 bar
10
16
5. Heated spring casing
H
Safety relief valve heated spring casing
Safety relief valve – horizontal
Safety relief valve – vertical
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3.17.1 Definition and working principle
The safety relief valve built on top of TopGear 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.
3.17.2 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.
3.17.3 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 has 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
7
10
11
16
17
Standard set pressure (bar)
Working pressure range (bar)
Set pressure range (bar)
5
1 – 4
2 – 5
3 – 6 5 – 10 9 – 16
4 – 7 6 – 11 10 – 17
3.17.4 Heating
The weld on spring casing is provided with 2 thread connections. Flange connections are not
available.
Maximum temperature:
Maximum pressure:
200°C
10 bar
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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.
7050
7320
H
7310
Vertical safety relief valve
Set pressure modification
Spring ratio – Safety relief valve
Spring dimensions
Pressure
Du
d
Lo
p/f
class
mm
mm
mm
bar/min
TG MAG pump size
4
6
37.0
37.0
36.5
36.5
4.9
4.5
4.5
6.0
6.0
7.0
7.0
8.0
8.0
7.0
8.0
9.0
11
93
93
0.21
0.21
0.81
0.81
0.32
0.66
0.66
0.66
0.16
0.33
0.55
0.86
15-50
23-65
d
10
16
4
90
90
124
124
124
124
124
124
120
109
6
49.0
48.6
48.6
49.0
48.6
49.0
62
58-80
10
16
4
Du
6
86-100
185-125
10
16
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.
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3.17.6 Sectional drawings and part lists
3.17.6.1 Single safety relief valve
7400
7240
7300
7030
7330
7320
7040
7180
7100
7100
7110
7310
7050
7170
7010
7150
Single safety relief valve – horizontal
7360
7400
7310
7050
7180
7320
7330
7300
7040
V35
V50
Description –
Material
V27
(horizontal)
Pos.
(verti-
cal)
Preventive Overhaul
(vertical)
7010 Valve complete
7030 Valve casing
7040 Spring casing
7050 Cover
1
1
1
1
2
1
1
1
1
1
4
4
1
1
1
4
–
1
1
1
1
2
1
1
1
1
1
4
4
1
1
1
4
2
1
1
1
1
2
1
1
1
1
1
4
4
1
1
1
4
2
7100 Spring plate
7110 Valve seat
7150 Spring
7170 Flat gasket
7180 Flat gasket
7240 Name plate
7300 Hexagonal screw
7310 Hexagonal screw
7320 Adjusting screw
7330 Hexagonal nut
7360 Arrow plate
7400 Rivet
x
x
x
x
7100
7400 7240
7150
7420 Set screw
7100
7010
7110
7170
7360
7400
7030
7420
Single safety relief valve – vertical
28
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3.17.6.2 Heated spring casing
7041
Pos.
Description – Material
V27
V35
V50
Preventive Overhaul
7041 Heated spring casing
1
1
1
3.18 Installation
3.18.1 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 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.
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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 around 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.
•
•
•
For loosening 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
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 temperatures
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.
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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.
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 moving 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.
TG MAG pump size
15-50
Fr_max [N]
1000
23-65
58-80
1800
2500
86-100
185-125
•
•
•
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 maximum 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.
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3.18.4 Shaft rotation
Shaft rotation determines which port of
the pump is suction and which is discharge.
1
3
2
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.
3 Discharge side
For the specified direction of rotation, see the arrow plate on the pump.
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 the pump.
See table for maximum allowable forces (Fx, y, z) and moments (Mx, y, z) 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.
TG MAG pump size Fx, y, z (N)
Mx, y, z (Nm)
675
15-50
2600
2900
3550
4100
5900
23-65
800
58-80
1375
1750
3750
86-100
185-125
Check after connecting whether the shaft can move freely.
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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.
If the 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.
Check the 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.
•
•
•
To remove 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.
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
Discharge
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.
By-pass
•
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.
Piping
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3.18.5.4 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 and 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.
3.18.6 Secondary piping
For dimensions of connections and plugs see chapter 6.0.
3.18.6.1 Drain lines
The pump is provided with a drain plug.
2x Be
Bb
Ba
3.18.6.2 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
ma
zg
zh
dk
dk
2xBf
2xBl
Bh
Bg
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 other
ductile material. For pipe dimensions of Cf see chapter 6.0.
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T-jacket on pump cover
ma
zk
zh
2xCf
dk dk
2xCf
Bh
Bg
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
Bo
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.
Bo
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
commissioning 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.
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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 breaker. 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-
ponents of control systems may still carry
live current when at rest. Contact with these
may be fatal, result in serious injury or
cause irreparable material damage.
U
U
L1
L2
L3
N
L1
L2
L3
N
Line
Motor
U (volt)
3 x 230 V
3 x 400 V
230/400 V
400 V
–
delta
star
delta
3.18.7.5 Combustion engines
When using a combustion engine in the
pump unit, see the engine instruction
manual included in the delivery. Contact
the pump supplier if the manual is not
included.
U
V
W
U
U
V
W
U
1
1
1
1
1
1
delta
star
d
W
V
2
W
V
2
2
2
2
2
Irrespective of this manual the following
must be respected for all combustion
engines:
•
•
•
•
•
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
3.18.7.6 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!
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1
2
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.
Repeat the same check on both sides of the coupling at the
height of the shaft. Move the electric motor so that the straight
edge touches both coupling halves over the entire length.
3
4
5
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.
Repeat this check at operating temperature and spend time achieving minimum alignment
deviation.
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
of coupling [mm]
Va
Vamax - Vamin
[mm]
Vrmax
[mm]
min [mm] max [mm]
81-95
2
2
2
2
2
2
2
2
5*
5*
5*
5*
6*
6*
6*
6*
4
4
4
4
6
6
6
6
6*
6*
6*
6*
7*
7*
7*
7*
0.15
0.18
0.21
0.24
0.27
0.30
0.34
0.38
0.15
0.18
0.21
0.24
0.27
0.30
0.34
0.38
96-110
111-130
131-140
141-160
161-180
181-200
201-225
* = coupling with spacer
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
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 above 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.
PT100
Connection for PT100
25
Pasta for better contact
TG MAG
15-50
X
75
75
80
80
100
X
23-65
58-80
86-100
185-125
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3.19 Instructions for start-up
3.19.1 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.
3.19.2 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.
3.19.2.1 Cleaning suction line
Before the TG 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.
3.19.3 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.
•
•
Unscrew filling plugs Bb and Be. Fill up the pump with liquid to be pumped via connections Be.
Rotate the pump shaft by hand in the normal sense of rotation while filling the liquid into the
pump.
•
•
Tighten the filling plugs Be. Screw in plug Bb but not tighten it.
Start the pump and tighten plug Bb when all air has escaped and liquid starts flowing out of this
connection.
2x Be
Bb
Ba
If the liquid level at the suction side is above the suction flange level of the pump vent the pump as
follows:
•
•
Loosen filling plugs Bb and Be so that air can escape.
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.
•
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 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)
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3.19.4 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
c Suction and discharge pipes are cleaned.
c Suction and discharge pipes are checked for leaks.
c Suction pipe is protected properly to prevent the ingress of foreign bodies.
Characteristics
c 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
c Electrical installation complies with local regulations
c Motor voltage corresponds with mains voltage. Check terminal board.
c Make sure that the starting torque is sufficiently high (no star/delta starting will be used).
c Motor protection is adjusted properly.
c Direction of motor rotation corresponds with direction of pump rotation.
c Motor rotation (detached from unit) is checked.
Safety relief valve
c Safety relief valve (on pump or in piping) is installed
c Safety relief valve is positioned correctly. Flow direction of safety relief valve
corresponds with suction and discharge lines.
c The set pressure of the safety relief valve is checked (see nameplate).
Jackets
c Jackets are installed.
c Maximum pressure and temperature of the heating/cooling media have been checked.
c The appropriate heating media or coolant is installed and connected.
c The installation complies with the safety standards.
Drive
c Alignment of pump, motor, gearbox etc. is checked.
Protection
c All guards and safety devices (coupling, rotating parts, excessive temperature) are in place
and operative.
c In case of pumps that may reach working temperatures of 60°C or more, ensure sufficient safety
guards against accidental contact re in place.
c Monitoring system is operational.
3.19.5 Start-up
When the pump is to be put into service the following checklist and procedure must be observed:
c Pump is filled with liquid.
c Pump is sufficiently preheated.
c Suction and discharge valves are fully open.
c Start the pump for a short while and check the direction of rotation of the motor and that the
magnetic coupling is not slipping.
c Start the pump and check suction of liquid (suction pressure).
c RPM of the pump is checked.
c Discharge pipe and seal are checked for leaks.
c Proper operation of the pump is verified.
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3.19.6 Shut-down
When the pump is to be put out of service the following procedure must be observed:
c Turn the motor off.
c Close the supply lines of the heating/cooling circuit if applicable.
c 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.
3.19.7 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.
c Prior to restarting the pump, determine the reason for the problem and solve the problem.
40
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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
Very low viscosity
2
3
•
•
Repair leak.
Increase pump speed and reduce axial clearance
(see section 3.21 Maintenance instructions).
Suction strainer or filter clogged
4
5
•
•
Clear suction strainer or filter.
Pump casing incorrectly installed
after repair
Install pump casing correctly.
See section 3.18 Installation.
Wrong direction of rotation of motor
6
•
•
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
7
•
•
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.
Correct liquid supply
Irregular flow
Liquid level in suction tank falls too low
Output too high
8
9
Provide a liquid level switch
Reduce pump speed/or install a smaller pump.
Install by-pass line with check-valve.
Repair leak in suction line.
Air sucking
Cavitation
10
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
13
•
•
•
Check temperature.
Check vapour pressure of liquid.
Reduce pump speed. If necessary install a larger
pump.
Not enough capacity Pump speed too low
•
Increase pump speed. Attention! Do not exceed
maximum speed and check NPSHr.
Air sucking
Cavitation
14
15
•
•
Repair leak in suction line.
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.).
Correct pressure setting.
Safety relief valve set too low
Viscosity too low
17
18
Increase pump speed. Attention! Do not exceed
maximum speed and check NPSHr.
•
•
If necessary, install a larger pump.
Axial clearance
19
20
Check axial clearance and correct.
See section 3.21 Maintenance instructions.
Gases come free
•
•
Increase pump speed. Attention! Do not exceed
maximum speed and check NPSHr.
Install a larger pump
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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
Cavitation
22
23
Reduce pump speed.
If necessary, install a larger pump.
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
26
Check and correct alignment.
Also see section 3.18 Installation.
Vibration of base plate or pipings
•
Make base plate heavier and/or affix baseplate/
pipework better.
Ball bearings damaged or worn
27
28
•
•
Replace ball bearings.
Un-balance of the outer magnetic rotor
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
Coupling misalignment
Viscosity too high
29
30
31
Reduce pump speed.
If necesary, install a larger pump.
Check and correct alignment.
Also see section 3.18 Installation.
Increase axial clearance.
See section 3.21 Maintenance instructions.
•
•
•
•
Heat pump.
Reduce pump speed.
Increase discharge pipe diameter.
Excessive friction losses inside rotor shaft 32
/ bearing arrangement
Check/correct axial clearance of circulation 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.)
Filter liquid.
Solid matter in liquid
Pump runs dry
34
35
Correct liquid supply.
Provide liquid level switch or dry running protec-
tion.
•
•
•
Heat up liquid.
Stop or reduce air sucking.
Corrosion
36
37
Change pump materials or application
parameters.
Motor overloading
Back pressure too high
•
•
•
•
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 39
/ bearing arrangement
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
42
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Symptom
Cause
Remedy
Pump leak
O-rings, sealing rings or gasket damaged 41
or not correctly assembled
•
Check condition of O-rings and assemble them
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.
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 operations 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.
•
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.
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
must be created during on site maintenance. Particularly remove metallic chips or any dirt which
could be attracted by the components of the magnetic coupling.
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3.21.2.2 Tools
For maintenance and repairs use only technically appropriate tools that are in good condition.
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 be 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 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.
44
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2x Be
Bb
•
•
For fluids that solidify or become very viscous
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.
If no drain line is provided, take precautions
so that the liquid is not contaminating the
environment.
Ba
•
Open the drain plug Ba at the bottom of the pump housing.
Let drain the liquid by gravity.
•
•
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
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 retaining fluid circuits.
Uncouple the connections to the jackets.
If 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.
Plug with
Ma (Nm)
8.8 / A4
Bolt
edge and flat
seal
Ma (Nm)
M6
10
25
G 1/8
G 1/4
G 1/2
-
10
20
50
-
M8
M10
M12
M16
51
87
215
-
-
Plug with edge and elastic washer
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.
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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! 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
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.
•
For replacement of the sleeve bearings contact your distributor.
Maximum allowed
TG MAG pump size
radial clearances
15-50 to 23-65
58-80 to 86-100
185-125
0.15 mm
0.25 mm
0.30 mm
3.21.4 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.
3.21.5 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 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.
3.21.6 Clearance adjustment
The TG pumps are delivered with the correct axial clearance setting. In some cases, however, the
axial clearance needs to be adjusted:
•
•
•
When uniform rotor and idler wear need to be compensated by re-setting the axial clearance.
When pumping low viscous liquids the slip can be reduced by decreasing the axial clearance.
When the liquid is more viscous than expected, the friction inside the pump can be reduced by
increasing the axial clearance.
46
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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.
4. Remove O-ring (8120), support ring (8110) and shim (8100) from the pump cover (4000).
0600
8120
8110
8100
4000
0701
0040
0010
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
B
S
A
7. Calculate the required thickness of the shim (8100) between pump cover (4000) and pump
casing (0010).
S = A – B + C. Axial clearance C between rotor shaft (0701) and pump cover (4000) see table
below.
Axial clearance C
TG MAG
[mm]
15-50
0.120 – 0.200
0.125 – 0.215
0.150 – 0.250
0.165 – 0.275
0.190 - 0.320
23-65
58-80
86-100
185-125
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).
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3.21.7 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.
3.21.7.1 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 pipe end
ISO 7/1 - R 1/2
Conical plug
ISO 7/1 - R 1/2
ISO 7/1
Type
Symbol
Example
Internal
thread
Cynlindrical (parallel)
Rp
ISO 7/1 – Rp 1/2
External
thread
Always conical
(tapered)
R
ISO 7/1 – R 1/2
3.21.7.2 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
ISO 228/1 - G 1/2
Conical pipe end
ISO 7/1 - R 1/2
ISO 228/1
Clearance class
Symbol
Example
Internal
thread
Only one class
G
ISO 228/1 – G 1/2
Class A
(standard)
G
ISO 228/1 – G 1/2
External
thread
Class B
(extra clearance)
G...B
ISO 228/1 – G 1/2 B
ISO 7/1
Type
Symbol
Example
External
thread
Always conical
(tapered)
R
ISO 7/1 – R 1/2
48
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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 should 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
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
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 equippid with magnetic
data carrier such as cheque cards, computer disks, watches etc. to avoid damage and/or loss of
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.
4000
0040
0040
3. Take idler (0600) complete with bearing bush
off the idler pin.
0600
4. Remove O-ring (8120),
8120
support ring (8110)
and shim (8100)
from the
8110
8100
pump cover
(4000).
4000
0701
0040
0010
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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.
1080
3. Remove gasket (1090) and clean the
sealing faces on the pump casing (0010)
0100
and top cover (0100) or safety relief valve.
1090
0010
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.
2. Remove bearing bracket support (1700).
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
E
TG MAG
A
B
C
D
E
F
G
A
F
∅G
TG MAG 15-50
TG MAG 23-65
TG MAG 58-80
TG MAG 86-100
M 10 12 160 10,5 10
8
7,8
2
D 0/-0.1
0.5 x 45°
M 12 15 205 13,5 10 10 9,4
TG MAG 185-125 M 16 20 240
17
10 13 13
1410
Lifting eye bolt
5. Lift the bearing bracket complete with
pump shaft and outer magnet rotor off the pump.
1700
Tool
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.
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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
8640
0702
Piercer
1490
Screw driver
1540
8320
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).
8320
4.2.5 Disassembly of outer magnetic rotor
1. Un-tighten cap head screws (8610) crosswise
and remove them.
8610
2. Use threaded holes in the flange of the pump shaft
to remove the outer magnetic rotor (8320).
0702
Removal of ball bearings
1430
1. Remove circlips (1450) and support ring
(1460) from the pump shaft (0702).
1440
1460
1450
2. Remove the bearing (1440) from
the shaft using a ball-bearing extractor.
8620
3. Remove the bearing cover (1430) from the
pump shaft (0702).
8620
1400
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.
1440
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4.2.6 Disassembly of separation can
1. Un-tighten cap head screws (8210)
crosswise and remove them.
8200
2. Use two cap head screws (8210) in
the threaded holes of the flange
to remove the can (8330).
8210
8330
3. Take out O-ring (8200).
8210
Take care not to damage the inner rotor magnet.
Removal of rotor and bearing assembly
(back-pull-out) from the pump casing
1. Un-tighten cap head screws (8460)
and remove them.
8130
2. Use two bolts in the threaded holes of
the intermediate cover (8450) to
8440
8450
8460
remove the complete back-pull-out
assembly from the pump casing (0010).
3. Take out O-rings (8130) and (8440).
0010
4.2.7 Disassembly of back-pull-out assembly
8490
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.
8310
3. Remove the inner magnetic rotor (8310)
from the hub (8350-D)
Bearing set
8350
A
B
C
D
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4. Un-tighten and remove the two set screws
(8520) from the locking nut (8510).
8310
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).
8520
8510
6. Remove the hub (8350-D) with the rear
axial bearing from the rotor shaft (0701).
8500
7. Remove the two keys (8400) from rotor shaft
(0701) using a key extractor.
8350-D
8400
Remark: Do not use hammer and screwdriver to
remove the keys since this could damage the bearings.
0701
8. Remove the shaft sleeve (8350-B). Take care that
shaft sleeve (8350-B) and axial bearing
(8350-A) are not damaged.
8350-B
8350-C
8430
9. Remove the bearing arrangement over
the rotor shaft (0701), front axial
bearing (8350-A) and disc rotor (8420)
8350-A
8420
0701
8410
10. Un-tighten cap head screws (8480)
crosswise and remove them.
8480
11. Remove radial bearing holder (8350-C) and shim 8470
and insert (8430) from intermediate cover (8450).
8350-C
8450
8470
8430
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53
1450
1460
1440
4.3 Assembly
4.3.1 Assembly of bearing bracket
1. Place pump shaft (0702) in vertical position on the
workbench.
1430
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.
0702
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).
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.
8610
8600
8320
6. Screw cap head screws (8610) into the magnetic
rotor (8320). Tighten these cap head screws (8610)
with Loctite 243 crosswise with the specified torque
to fix the magnetic rotor (8320) on the pump shaft
(0702). (See chapter 3.21.3.1)
1400
8630
8620
8620
7. Mount both circlips (8620) into the bearing bracket
(1400).
8620
1400
8. Support the pump shaft (0702) complete with
magnetic rotor (8320) and bearing in vertical
position.
0702
8320
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).
54
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8640
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).
1440
0702
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.
0702
1400
1540
Take care not to damage the outer rotor magnet.
8320
14. Mount the sealing segment (1490) on the rear end
according to sketch.
First part of
sealing segment
Second part of
sealing segment
1490
Felt
1490
1490
1490
Felt
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4.3.2 Pre-assembly of the back-pull-out
4.3.2.1 Adjustment of the axial clearance of the
circulation pump
8480
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).
8350-C
8450
R
L
8470
8430
2. Fit cap head screws (8480) and tighten them cross-
wise to fix the radial bearing holder (8350-C) and
insert (8430) to the intermediate cover (8450).
8430
8450
8350-C
3. Mount axial bearing (8350-A) into the insert (8430).
Do not use any force and be careful not to damage
the bearing faces while pushing part (8350-A) in until
the bearing faces are making contact.
8350-A
4. Measure the distance between front face of the axial
bearing holder (8350-A)(front face gear tooth) and
the front face of the crescent of the pump insert
(8430).
5. Calculate the required thickness of the bearing
shim (8470): S = X – C.
X
Axial clearance C see table below.
8480
Axial clearance C
TG MAG
[mm]
15-50
0.120 – 0.200
0.125 – 0.215
0.150 – 0.250
0.165 – 0.275
0.190 – 0.320
23-65
58-80
86-100
185-125
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6. Peel the required number of layers off the bearing shim
(8470) to adjust the thickness of the shim S to the required
value.
8480
7. Un-tighten cap head screws (8480) and remove radial
bearing holder (8350-C) from the intermediate cover
(8450).
8. Assemble radial bearing holder (8350-C) again in the same
way with the shim placed between holder and intermediate
cover (8450).
8350-C
9. Place front axial bearing 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).
8470
8450
8430
4.3.2.2 Assembly of rotor shaft
8350-B
1. Place the shaft rotor on the workbench in vertical
position, put a thin layer of grease on all sliding faces of
the bearings.
8350-C
8430
2. Place the disk rotor (8420) into the chamber of the pump
insert (8430).
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).
8350-A
8420
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.
0701
8410
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 damaged or if there is any dirt between
the fitting faces.
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6. 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.
8490
8310
7. Fit rear axial bearing holder (8350-D) on the rotor shaft
(0701).
8. Place spring washer (8500) on the rotor shaft (0701) as
indicated on the sketch and screw on locking nut (8510).
9. Place the assembly vertically on the work bench and lock
the rotor by pushing a copper bar through the rotor teeth.
8520
8510
8500
10. Tighten locking nut (8510) until the shaft nut makes
contact with the axial face of the rear axial bearing holder
(8350-D).
11. Check the axial bearing clearance using a feeler gauge
(see table below).
8350-D
8400
Axial clearance
TG MAG
[mm]
8350-B
15-50
0.11 – 0.13
23-65
58-80
0.13 – 0.15
86-100
185-125
0.15 – 0.18
0701
12. Tighten set screws (8520) to secure the locking nut
(8510).
13. Mount the inner magnetic rotor (8310) on the hub of the
rear axial bearing holder (8350-D). Make sure that the
locking pins are falling into the holes of the inner magnetic
rotor (8310).
14. 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.
15. Check if the rotor shaft (0701) can be turned by hand
evenly and without remarkable resistance.
58
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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.
2. Cover O-ring (8130) slightly with
grease and fit it into the groove in the
pump casing (0010).
8130
8440
3. Cover O-ring (8440) slightly with
grease and fit it into the groove in the
intermediate casing (8450).
8450
8460
4. 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.
0010
0701
5. 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
8450
1. Check that the O-ring groove and axial
support faces are not damaged and free
of dirt
8460
8200
8330
2. Cover O-ring (8200) slightly with
grease and fit it into the groove in the
separation can (8310)
8310
8210
3. 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
holes should be in line with the cap
head screws (8460).
8460
4. 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).
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4.3.5 Assembly of the bearing bracket
1. Place the pump vertically on the workbench with the
separation can (8330) pointed upwards.
Lifting eye bolt
2. Screw the 4 guiding pins (tool) into the threaded holes of
the cap head screws (1410).
1410
0702
1400
3. Screw a lifting eye bolt into the shaft end of pump shaft
(0702).
1700
4. Use a crane to fit the bearing bracket (1400) over the
guiding pins to the intermediate cover from the top (see
picture).
Tool
5. 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).
8330
8450
6. Mount bearing bracket support (1700) to the bearing
bracket (1400).
4.3.6 Assembly of the front-pull-out assembly
1. 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.
0600
8120
8110
8100
4000
0040
0701
0010
2. Measure the distances as indicated
on the sketch.
S
B
A
Axial clearance C
TG MAG
3. Calculate the required thickness of the shim (8100)
between pump cover (4000) and pump casing (0010).
[mm]
15-50
0.120 – 0.200
0.125 – 0.215
0.150 – 0.250
0.165 – 0.275
0.190 – 0.320
23-65
S = A – B + C. Axial clearance C between rotor shaft
(0701) and pump cover (4000) – see table.
58-80
86-100
185-125
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4. Adjust the thickness of shim (8100) by peeling of the required number of layers.
5. Place shim (8100), support ring (8110) and O-ring (8120) on the pump cover (4000).
6. Place idler (0600) complete with bearing bush on the idler pin.
7. Mount pump cover (4000) on the pump casing (0010).
8. 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),
4000
check if the sealing faces around the idler pin and
on pin cover (1000) are not damaged and free of
dirt.
1020
1000
10. Use a new gasket (1020) before fixing pin cover
(1000) on the pump cover (4000) with tap bolts
(1010). Tighten tap bolts (1010) crosswise with
the specified torque.
1010
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
2. Place a new gasket (1090) on the pump casing
(0010).
0100
1090
3. Place top cover (0100) or safety relief valve on the
pump casing (0010).
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.
0010
4. Screw in 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).
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61
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-S0C-BG2-Q-S5-S10-V-R
Serial number: 2007-479401
2. Pos 0600, 1, Idler + Bush complete
1080
5.1 TG MAG15-50 to
0100
TG MAG185-125
1090
1050
1060
8130
0600
8120
8110
8100
0010
4000
0040
1040
1030
8520
1020
1010
8510
8500
8480
8490
8350
1210
1220
1000
8410
8310
8470
8440
8460
8450
8400
0701
1410
8640
8430
8420
8210
1490
1560
1550
1440
8330
8200
1230
8620
1400
1450
1440
1540
8630
1700
8610
8620
1460
1570
0702
1430
8600
8320
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5.1.1 Hydraulic part
Pos.
Description
15-50
1
6
1
1
1
1
6
1
1
1
2
2
8
1
1
1
1
4
1
1
1
1
1
1
6
1
1
1
1
2
1
1
1
1
1
2
1
4
4
1
1
2
23-65
1
6
1
1
1
1
6
1
1
1
2
2
8
1
1
1
1
4
1
1
1
1
1
1
6
1
1
1
1
2
1
1
1
1
1
2
1
4
4
1
1
2
58-80
1
8
1
1
1
1
6
1
1
1
2
2
8
1
1
1
1
4
1
1
1
1
1
1
8
1
1
1
1
2
1
1
1
1
1
2
1
4
4
1
1
2
86-100
1
8
1
1
1
1
6
1
1
1
2
2
8
1
1
1
1
4
1
1
1
1
1
1
8
1
1
1
1
2
1
1
1
1
1
2
1
4
4
1
1
2
185-125
1
preventive overhaul
0010 pump casing
0040 tap bolt
8
0100 top cover, complete
0600 idler + bush, complete
0701 rotor shaft
1000 pin cover
1
1
x
x
1
1
1010 tap bolt
6
1020 gasket
1
x
x
x
x
x
x
x
x
x
x
1030 plug
1
1040 sealing ring
1050 plug
1
2
1060 sealing ring
1080 tap bolt
2
8
1090 gasket
1
1210 plug
1
1220 sealing ring
1230 plug - for connection PT100
1410 cap head screw
4000 pump cover + idler pin, complete
8100 shim
1
1
4
1
x
x
1
8110 support ring
8120 o-ring
1
1
x
x
x
x
x
x
8130 o-ring
1
8200 o-ring
1
8210 cap head screw
8310 inner magnetic rotor
8320 outer magnetic rotor
8330 separation can
8350 rotor bearing assembly
8400 key
8
1
x
x
1
1
1
x
2
8410 pin
1
8420 disc rotor
1
8430 insert
1
8440 o-ring
1
x
x
x
x
8450 intermediate cover
8460 cap head screw
8470 shim
1
2
1
8480 cap head screw
8490 cap head screw
8500 disc spring
8510 locking nut
8520 set screw
4
4
1
1
2
5.1.2 Bearing bracket
Pos.
Description
15-50
1
23-65
1
58-80
1
86-100
185-125
preventive overhaul
0702 pump shaft
1400 bearing bracket
1430 bearing cover
1440 ball-bearing (metal cage)
1450 circlip
1
1
1
2
1
1
1
4
1
4
1
2
4
2
1
1
1
1
1
2
1
1
1
4
1
4
1
2
4
2
1
1
1
1
1
1
1
1
2
2
2
x
x
x
x
1
1
1
1460 support ring
1490 sealing segment
1540 countersunck screw
1550 nameplate
1560 rivet
1
1
1
1
1
1
x
4
4
4
1
1
1
4
4
4
1570 key
1
1
1
x
8600 pin
2
2
2
8610 cap head screw
8620 circlip
4
4
4
2
2
2
x
x
8630 protection ring
8640 circlip
1
1
1
1
1
1
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5.1.3 S-jacket options
5.1.3.1 S-Jackets on pump cover
0220
0200
0250
0240
0230
0210
Pos.
Description
15-50
23-65
58-80
86-100
185-125 preventive overhaul
0200 jacket cover
0210 tap bolt
1
6
1
2
1
1
1
6
1
2
1
1
1
8
1
2
1
1
1
8
1
2
1
1
1
8
0220 gasket
1
4
1
1
x
x
x
x
0230 cap head screw
0240 plug
0250 sealing ring
5.1.3.2 S-Jackets on intermediate cover
8450
0490
0480
0490
0480
0440
0430
0440
0430
Pos.
Description
15-50
23-65
58-80
86-100
185-125 preventive overhaul
8450 intermediate cover
0430 plug
1
2
2
2
2
1
2
2
2
2
1
2
2
2
2
1
2
2
2
2
1
2
0440 sealing ring
0480 plug
2
2
2
x
x
x
x
0490 sealing ring
64
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5.1.4 T-jacket options
5.1.4.1 T-jackets on pump cover
0220
0200
0250
0240
0310
0300
0320
0230
0210
Pos.
Description
15-50
23-65
58-80
86-100
185-125
preventive overhaul
0200 jacket cover
0210 tap bolt
2
6
1
2
1
1
2
2
8
2
6
1
2
1
1
2
2
8
2
8
1
2
1
1
2
2
8
2
8
1
2
1
1
2
2
8
2
8
1
4
1
1
2
2
8
0220 gasket
x
x
0230 cap head screw
0240 plug
0250 sealing ring
0300 welding neck flange
0310 gasket
x
x
x
x
0320 cap head screw
0520
0500
0510
5.1.4.2 T-jackets on intermediate cover
0540
0530
0420
8450
0490
0480
0490
0480
0440
0430
0440
0430
Pos.
Description
15-50
23-65
1
58-80
1
86-100
185-125
preventive overhaul
8450 intermediate cover
0420 sealing ring
0430 plug
1
2
2
2
2
2
2
2
8
2
2
1
2
2
2
2
2
2
2
8
2
2
1
2
2
2
2
2
2
2
8
2
2
2
2
x
x
x
x
x
x
x
x
2
2
0440 sealing ring
0480 plug
2
2
2
2
0490 sealing ring
0500 welding neck flange
0510 gasket
2
2
2
2
2
2
0520 cap head screw
0530 flange
8
8
2
2
0540 flange holder
2
2
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6.0 Dimensional drawings
6.1 TG MAG15-50 to 185-125 pumps
ma
mb
ze
zc
zb
zb
Be
Be
Bb
ea
dc
za
db
Bu
vf
va
vb
vc
sp
Ba
4 x Ø vd
df
ve
vh
da
ISO/R775
eb
ec
ef
ed
TG MAG
aa
15-50
23-65
65
58-80
80
86-100
185-125
125
50
G 1/4
G 1/8
G 1/4
G 1/4
389
112
209
M16
86
100
G 1/2
G 1/8
G 1/4
G 1/4
526
160
315
M20
110
80
Ba
Bb
Be
Bu
da
db
dc
de
df
G 1/4
G 1/8
G 1/4
G 1/4
400
112
219
M16
86
G 1/2
G 1/8
G 1/4
G 1/4
493
160
297
M20
110
80
G 1/2
G 1/8
G 1/4
G 1/4
633
200
380
M20
140
ea
eb
ec
ed
ef
60
60
110
8 h9
31
8 h9
31
10 h9
35
10 h9
40
14 h9
51.5
48 k6
M16
155
28 j6
M10
75
28 j6
M10
80
32 k6
M12
105
150
22.5
100
160
200
14
37 k6
M12
125
160
32
ma
mb
sp
va
125
15
125
26
190
30.5
120
70
80
100
160
200
14
vb
120
150
12
130
160
12
200
vc
260
vd
18
ve
60
60
90
90
125
vf
14
14
17
17
22
vh
90
90
125
180
160
453
94
125
185
180
476
109
170
za
125
125
359
68
125
125
359
80
230
zb
200
zc
580
ze
132
66
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6.2 Flange connections
6.2.1 Cast iron
TG MAG58-80 to
TG MAG185-125
TG MAG15-50 *) to
TG MAG23-65 *)
zb
zb
am
Ø
ak
TG MAG
aa
15-50
50
23-65
65
58-80
80
86-100
100
185-125
125
ab
100
118
135
153
180
ac PN16
ac PN20
ad
125
145
160
180
210
120.5
125 *)
4xd18
4xd18
21
139.5
145 *)
4xd18
4xd18
21
152.5
200
190.5
220
216
250
ak PN16
ak PN20
am
8xd18
4xd18
24
8xd18
8xd18
25
8xd18
8xd22
28
zb
125
125
160
180
200
*) Square flanges instead of rounded flanges
6.2.2 Stainless steel
zb
zb
am
Ø
ak
TG MAG
aa
15-50
23-65
65
58-80
86-100
185-125
50
98
80
133
100
160
125
186
ab
120
ac PN16
ac PN20
ac PN25
ac PN40
ac PN50
ad
125
145
160
180
210
120.5
125
139.5
145
152.5
160
190.5
190
216
220
125
145
160
190
220
127
149.5
187
168
200
235
165
206
238
273
ak PN16
ak PN20
ak PN25
ak PN40
ak PN50
am
4xd18
4xd18
4xd18
4xd18
8xd18
21
4xd18
4xd18
8xd18
8xd18
8xd22
21
8xd18
4xd18
8xd18
8xd18
8xd22
24
8xd18
8xd18
8xd22
8xd22
8xd22
25
8xd18
8xd22
8xd26
8xd26
8xd22
28
zb
125
125
160
180
200
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67
6.3 Jackets
6.3.1
S-jackets with thread connections on pump cover and intermediate cover (SS)
dk
dk
zg
zh
2xBf
ma
2xBl
Bh
Bg
6.3.2
T-jackets with flange connections on pump cover and intermediate cover (TT)
2xCf
dk
dk
ma
zk
zh
2xCf
Bh
Bg
6.3.3
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)
SOC
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
68
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Jackets dimensions
TG MAG
Bf
Mat.
G / R
G / R
G / R
G
15-50
G 1/4
G 1/8
G 1/4
23-65
G 1/4
G 1/8
G 1/4
58-80
G 3/8
G 1/8
G 1/4
G 1
86-100
G 3/8
G 1/8
G 1/4
G 1
185-125
G 3/8
G 1/8
G 1/4
G 1
Bg
Bh
Bl
G 1/2
G 1/2
R
G 3/4
G 3/4
26.9 x 2.3
115
G 3/4
26.9 x 2.3
135
Cf
dg
dh
dk
dl
G / R
G / R
G / R
G / R
G / R
G / R
G / R
G / R
G / R
G / R
21.3 x 2
87
21.3 x 2 26.9 x 2.3
84
56
121
78
50
90
130
56
56
75
75
100
80
80
106
105
123
86
106
142
ma
zg
zh
zm
zk
75
80
125
155
96
110
65
140
163
65
86
126
155
134
155
148
207
165
207
243
182
205
6.4 Safety relief valves
6.4.1 Single safety relief valve
mc
tg
TG MAG15-50
TG MAG23-65
TG
MAG
Mat.
15-50 23-65
G
R
G / R
290
293
50
300
303
50
dv
dv
mc
tg
G / R 200
200
mc
dv
TG MAG58-80
TG MAG86-100
TG MAG185-125
TG
MAG
Mat.
58-80 86-100 185-125
G
R
G / R
G / R
550
555
70
-
576
581
70
-
641
646
70
-
dv
mc
tg
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69
6.4.2 Heated safety relief valve
dj
di
dn
dm
do
mc
tg
TG MAG15-50
TG MAG23-65
Bo
Bo
dv
dk
dn
dm
do
Bo
Bo
TG MAG58-80
TG MAG86-100
TG MAG185-125
dv
dj
di
TG MAG
Bo
di
dj
dk
dm
dn
do
Mat.
15-50
23-65
58-80
G 1/2
418
458
-
98.5
127
6
86-100
185-125
G 1/2
509
549
-
103.5
127
24
G / R
G / R
G / R
G / R
G / R
G / R
G / R
G
G 1/2
101
119
253
62
111
6,5
290
293
50
G 1/2
101
119
263
59.5
111
4
300
303
50
G 1/2
444
484
-
103.5
127
8
576
581
70
550
555
70
641
646
70
dv
R
G / R
G / R
mc
tg
200
200
-
-
-
70
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6.5 Bracket support
2xvt
vo
vs
vm
vn
vp
TG MAG
vm
vn
15-50
120
150
17
23-65
120
150
17
58-80
160
195
20
86-100
160
195
20
185-125
200
250
20
vo
vp
40
40
50
50
50
vr
30
30
50
50
50
vs
vt
M16
12
M16
12
M20
14
M20
14
M20
14
vu
3
3
4
4
4
eights – Mass
6.6 W
TG MAG
Mat.
Version
Mass
kg
Weight
15-50
48
51
2.5
3
23-65
52
55
3.5
4
58-80
86-100
117
125
12
185-125
240
252
24
G
R
daN
daN
daN
daN
daN
daN
109
113
9
Pump
(without jackets)
kg
G
R
kg
Front-Pull out
(pump cover + idler)
kg
10
78
78
13
26
Back-Pull out
(rotor shaft/bearing +
bracket)
G
R
kg
35
35
35
35
81
170
170
kg
81
SOC
SSC
OSC
TOC
TTC
kg
kg
kg
kg
kg
kg
kg
kg
daN
daN
daN
daN
daN
daN
daN
daN
3
3
3
3
5
5
7
7
12
12
0
0
0
0
0
Jackets
(supplement)
3.5
4
3.5
4
5.5
6.5
1
8
13
14
1
9
OTC
0.5
5
0.5
5
1
G
R
7
10
11
10
11
Relief valve
(supplement)
5
5
8
A.0500.551 – IM-TGMAG/02.00 EN (02/2008)
71
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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: [email protected]
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 only and should not be relied upon unless
confirmed in writing.
Copyright © 2008 SPX Corporate
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