Instruction/ maintenance manual of the product TG MAG185-125 SPX Cooling Technologies
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Instruction Manual T opGear MA G Magnetic Drive Internal Gear pumps Read and understand this manual prior to operating or servicing this product. A.0500.
E C-Declaration of conformity (as per EC's Machinery Directive 98/37/ E C, Annex I IA) Producer SPX Process Equipment B E NV Evenbroekveld 2-6 B E-9420 Erpe-Mere Belgium W e hereby guarantee that.
3 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) Contents 1.0 Introduction ........................................................................................................ 7 1.1 General .........................................................
4 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.16 Components of the magnetic drive.............................................................. 22 3.16.1 Magnetic coupling ..........................................................................
5 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.20 T rouble shooting ............................................................................................... 41 3.20.1 Instructions for re-using and disposal ..................................
6 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 5.0 Sectional drawings and part lists ................................................................ 62 5.1 T G MAG15-50 to T G MAG185-125 ......................................................... 62 5.
7 T opGear Serial No: Model: TG SPX Process Equipment BE NV Evenbroekveld 2-4 BE-9420 Erpe-Mere www.johnson-pump.com and spxpe.com A.0500.551 – I M-T G MAG/02.
8 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 1.3 S afety 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 .
9 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 1.3.2 Pump units 1.3.2.1 Pump unit handling Use an overhead crane, forklift or other suitable lifting device. Secure lifting slings around the front part of the pump and the back part of the motor . Make sure that the load is balanced before attempting the lift.
10 Pump type: Article No.: Unit serial No.: Date: SPX Process Equipment BE NV Evenbroekveld 2-4 BE-9420 Erpe-Mere ww w. johnson-pump.com and spxpe.com A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 1.3.2.3 B efore commissioning the pump unit Read the pump’ s operating and safety manual.
11 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 1.4 T ec hnical conventions Quantity Symbol Unit Dynamic viscosity µ mPa.s = cP (Centipoise) Kinematicviscosity ν = µ ρ ρ = density [ ] kg — dm 3 ν = kinematic viscosity [ ] mm 2 — s = cSt (Centistokes) Note! In this manual only dynamic viscosity is used.
12 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 2.0 Pump description T opGear MAG pumps are rotary positive displacement pumps with internal gear. T hey are made of cast iron or stainless steel. TG MA G pumps are assembled from modular elements, which allows a variety of constructions.
13 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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 c.
14 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.2 Operating principle 3.0 General information and tec hnical dat a 3.1 Pump st andard parts T op co ver Intermediate cover Pump shaft Bearing bracke.
15 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.2.1 Self-priming operation T opGear 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.
16 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.5 Main c haracteristics The pump size is designated by the displacement volume of 100 revolutions expressed in litres (or dm 3 ) but rounded followed by the nominal port diameter expressed in millimetres.
17 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) The values depend on the position from where one measures and were therefore measured at the front of the pump, at distance of 1 meter from the pump cover and were corrected for background noise and reflections.
18 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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. • Noiseproductiondecreaseswhenpumpinghighviscosityliquidsduetobetterlubricatingand damping properties.
19 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) TG MAG pump size K.hyd 15-50 6250 23-65 4000 58-80 3750 86-100 3600 185-125 2500 3.10.3 Operation under hydrodynamic lubrication conditions Hydrodynamic lubrication could be important criteria for bush material selection.
20 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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.
21 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) Radial clearance on rotor , idler outside diameter – Axial clearance on pump cover Pump size CO (µm) axial clear.
22 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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. Themagneticcouplingarrangementreplacesadynamicshaftsealandmakesthepump100% leakfree.
23 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) During normal operation heat is generated inside the magnetic coupling due to hydraulic friction and eddy currents in the wall of the separation can by the moving magnetic fields. Cooling of the cou- pling see chapter 3.
24 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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.
25 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.17 Safety relief valve Example V 35 - G 10 H 1 2 3 4 5 1. Safety relief valve = V 2. T ype indication = inlet diameter (in mm) 27 Safety relief valv.
26 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.17.1 Definition and working principle The safety relief valve built on top of T opGear pumps is designed to protect the pump against over- pressure. It limits the differential pressure (or working pressure) of the pump.
27 H 7050 7320 7310 d Du A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.17.5 Safety relief valve – Relative adjustment Adjustment of the standard setting pressure is performed at the factory. Note! When testing the safety relief valve mounted on the pump, make sure the pressure never exceeds the set pressure of the valve + 2 bar .
28 7400 7360 7030 7170 7110 7010 7100 7150 7100 7040 7240 7400 7300 7330 7320 7180 7050 7310 7030 7400 7360 7420 7170 71 10 7010 7100 7150 7100 7400 7240 7040 7300 7330 7320 7180 7050 7310 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.17.6 Sectional drawings and part lists 3.
29 7041 1040 1030 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.17.6.2 Heated spring casing Pos. Description – Material V27 V35 V50 Preventive Overhaul 7041 Heated spring casing 1 1 1 3.18 Inst allation 3.18.1 General This manual gives basic instructions whic h are to be observed during installation of the pump.
30 ma mb mc mc A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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.
31 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.18.2.5 Stability Foundation The pump unit must be installed on a base plate or on a frame placed exactly level on the founda- tion. The foundation must be hard, level, flat and vibration free to guarantee correct alignment of the pump/drive while operating.
32 3 1 2 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.18.4 Shaft rotation Shaft rotation determines which port of the pump is suction and which is disc harge. Relation between shaft rotation and suction/discharge side is indicated by the rotation arrow plate att ached at the relief valve or the top cover .
33 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.18.5.2 Piping • Use piping with a diameter equal to or greater than the connection ports of the pump and with the shortest possible lengths. • Thepipediameterhastobecalculatedinfunctionoftheliquidparametersandtheinstallation parameters.
34 2xBl ma zg Bh dh dg zh Bg dk dk 2xBf dl 2x Be Bb Ba A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.18.5.4 Strainer Foreign particles can seriously damage the pump.
35 Bh dh dg 2xCf ma zk 2xCf zh Bg zm dk dk Bo Bo A.0500.551 – I M-T G MAG/02.00 E N (02/2008) T -jacket on pump cover 3. Jack et 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.
36 U U delta star delta star L1 L1 L2 L2 L3 L3 N N U 1 V 1 W 1 U 1 V 1 W 1 W 2 U 2 V 2 W 2 U 2 V 2 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) Circuit breaker For safety work on a pump unit, install a circuit breaker as close as possible to the machine.
37 4 03 1 25 X PT100 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 1 Place a ruler (A) on the coupling. Remove or add as many shims as is necessary to bring the electric motor to the correct height so that the straight edge touches both coupling halves over the entire length, see figure.
38 2x Be Bb Ba A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.19 Instructions for start-up 3.19.1 General The pump can be put into service when all arrangements described in c hapter 3.
39 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.19.4 Chec klist – Initial st art-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.
40 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.19.6 Shut-down W hen the pump is to be put out of service the following procedure must be observed: c T urn the motor off.
41 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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).
42 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) Symptom Cause Remedy Not enough capacity Liquid leaking back to suction over the magnetic coupling 21 • Check/correct assembly of the circulation pu.
43 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) Symptom Cause Remedy Pump leak O-rings, sealing rings or gasket damaged or not correctly assembled 41 • Check condition of O-rings and assemble them.
44 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.21.2.2 T ools For maintenance and repairs use only tec hnically 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.
45 2x Be Bb Ba A.0500.551 – I M-T G MAG/02.00 E N (02/2008) • Foruidsthatsolidifyorbecomeveryviscous at ambient temperature, it is best to empty the pump immediately after shutting down by separating it from the piping.
46 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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.
47 0040 4000 8100 8110 8120 0600 0701 0010 A S B A.0500.551 – I M-T G MAG/02.00 E N (02/2008) Proceed as follows to set the axial clearance: 1. Un-tighten t ap bolts (0040) crosswise and remove them. 2. Use two t ap bolts (0040) in the threaded holes in the pump cover (4000) to push off the pump cover (4000) 3.
48 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 3.21.7 Designation of threaded connections. T o make clear what sealing type of threaded connection is provided we denominate them according to standards I SO 7/1 and I SO 228/1 as follows.
49 0040 0040 4000 0040 0600 8120 8110 8100 4000 0701 0010 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 4.0 Instructions for assembly and dis assembly 4.1 General Insufficient or wrong assembly and disassembly can lead to the pump malfunctioning, high repair costs and long-term inoperability .
50 F A B C E 2 0.5 x 45° D 0/-0.1 ∅ G 1080 0100 1090 0010 1700 1410 TG MAG A B C D E F G T G MAG 15-50 M 10 12 160 10,5 10 8 7,8 T G MAG 23-65 T G MAG 58-80 M 12 15 205 13,5 10 10 9,4 T G MAG 86-100 T G MAG 185-125 M 16 20 240 17 10 13 13 A.0500.551 – I M-T G MAG/02.
51 8640 0702 8320 1540 8320 0702 1430 1440 1460 1450 8620 8620 1400 1440 1490 1570 8610 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 4.2.4 Dis assembly of pump shaft complete 1. Remove key (1570) from the pump shaft. 2. Remove sealing segment (1490) from the bearing bracket (see picture).
52 8490 8310 8200 8210 8330 8210 8130 8440 8450 8460 0010 8350 A B C D A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 4.2.6 Dis assembly of separation can 1. Un-tighten cap head screws (8210) crosswise and remove them. 2. Use two cap head screws (8210) in the threaded holes of the flange to remove the can (8330).
53 8520 8510 8500 8350-D 8400 0701 8310 8350-B 8350-A 8420 0701 8410 8350-C 8430 8480 8350-C 8450 8430 8470 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 4.
54 1450 1460 1440 1430 0702 0702 8610 8600 8320 1400 8620 1400 0702 8320 8620 8630 8620 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 4.3 Assembly 4.3.1 Assembly of bearing bracket 1. Place pump shaft (0702) in vertical position on the workbench. 2. Place bearing cover (1430) over pump shaft (0702).
55 8640 1440 0702 8620 1540 8320 0702 1490 1490 1400 1490 1490 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 10. Assembly the rear ball bearing (1440) on the pump shaft (0702) by driving it with a pipe and plastic hammer via the inner bearing ring until the bearing makes contact with circlip (8620).
56 R L X 8480 8350-C 8450 8430 8430 8450 8350-C 8350-A 8480 8470 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 4.3.2 Pre-assembly of the back-pull-out 4.3.2.1 Adjustment of the axial clearance of the circulation pump 1. Place pump insert (8430) and radial bearing holder (8350-C) in the intermediate cover (8450).
57 8480 8350-C 8450 8430 8470 8350-B 8350-C 8430 8350-A 8420 0701 8410 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 6. Peel the required number of layers off the bearing shim (8470) to adjust the thickness of the shim S to the required value.
58 8490 8310 8520 8510 8500 8350-D 8400 0701 8350-B A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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 . 7. Fit rear axial bearing holder (8350-D) on the rotor shaft (0701).
59 0010 8130 8440 8450 8460 0701 8450 8460 8200 8330 8310 8460 8210 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 4.3.3 Assembly of the back-pull-out assembly to the pump casing 1. Check that the O-ring grooves and axial support faces are not damaged and free of dirt.
60 0040 0600 8120 8110 8100 4000 1410 1700 A S B 0702 1400 T ool 8330 8450 0701 0010 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) TG MAG A xial clearance C [mm] 15-50 0.120 – 0.200 23-65 0.125 – 0.215 58-80 0.150 – 0.250 86-100 0.165 – 0.275 185-125 0.
61 4000 1020 1000 1010 1080 0100 1090 0010 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 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).
62 1020 1010 1000 0040 4000 8100 8110 8120 0600 1060 1050 1090 0100 1080 8130 0010 1040 1030 8520 8510 8500 8490 8310 8480 8350 8470 1210 1220 8440 8410 8400 0701 8420 8430 8450 8460 8210 8330 8200 8320 8600 0702 1570 8610 1540 1440 1450 1430 1460 8620 8630 1230 1550 1560 1440 1490 1410 8640 8620 1400 1700 A.
63 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 5.1.1 Hydraulic part 5.1.2 Bearing bracket Pos. Description 15-50 23-65 58-80 86-100 185-125 preventive overhaul 0010 pump casing 1 1 1 1 1 0040 t ap .
64 0210 0230 0240 0250 0200 0220 8450 0430 0440 0490 0490 0480 0480 0430 0440 A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 5.1.3 S-jacket options 5.1.
65 0230 0320 0300 0240 0250 0200 0220 0210 0310 0520 0500 0510 0540 0530 0420 8450 0490 0480 0490 0480 0440 0430 0440 0430 A.0500.551 – I M-T G MAG/02.
66 sp ve vh da df Bb ma ze zc mb ea db Ba va vb vc zb zb Be Be aa za dc 4 x Ø vd vf ec eb ed ef ISO/ R7 75 Bu A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 6.
67 zb zb am ad ac ab aa Ø ak zb zb am aa ab ac aa Ø ak A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 6.2 Flange connections 6.2.1 Cast iron 6.2.2 St ainless steel TG MAG 15-50 23-65 58-80 86-100 185-125 aa 50 65 80 100 125 ab 100 118 135 153 180 ac PN16 125 145 160 180 210 ac PN20 120.
68 dk dk 2xBl ma Bh Bg zg zh 2xBf dh dl dg dk dk dh zm dg 2xCf Bh ma zk zh 2xCf Bg SOC TOC OSC OTC A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 6.3 Jac kets 6.3.1 S-jackets with thread connections on pump cover and intermediate cover (SS) 6.3.2 T -jac kets with flange connections on pump cover and intermediate cover (TT) 6.
69 dv mc tg mc dv TG MAG58-80 TG MAG86-100 TG MAG185-125 TG MAG15-50 TG MAG23-65 TG MAG Mat. 15-50 23-65 58-80 86-100 185-125 Bf G / R G 1/4 G 1/4 G 3/8 G 3/8 G 3/8 Bg G / R G 1/8 G 1/8 G 1/8 G 1/8 G 1/8 Bh G / R G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 Bl G G 1/2 G 1/2 G 1 G 1 G 1 R G 3/4 G 3/4 G 3/4 Cf G / R 21.
70 dj dv di dm dn Bo Bo do mc tg mc dj di dk dv do dm dn Bo Bo TG MAG58-80 TG MAG86-100 TG MAG185-125 TG MAG15-50 TG MAG23-65 A.0500.551 – I M-T G MAG/02.
71 vs vr vm vn vp vo vu 2xvt A.0500.551 – I M-T G MAG/02.00 E N (02/2008) 6.6 W eights – Mass 6.5 Brac ket support TG MAG 15-50 23-65 58-80 86-100 185-125 vm 120 120 160 160 200 vn 150 150 195 195 250 vo 17 17 20 20 20 vp 40 40 50 50 50 vr 30 30 50 50 50 vs M16 M16 M20 M20 M20 vt 12 12 14 14 14 v u 33444 TG MAG Mat.
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An important point after buying a device SPX Cooling Technologies TG MAG185-125 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought SPX Cooling Technologies TG MAG185-125 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data SPX Cooling Technologies TG MAG185-125 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, SPX Cooling Technologies TG MAG185-125 you will learn all the available features of the product, as well as information on its operation. The information that you get SPX Cooling Technologies TG MAG185-125 will certainly help you make a decision on the purchase.
If you already are a holder of SPX Cooling Technologies TG MAG185-125, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime SPX Cooling Technologies TG MAG185-125.
However, one of the most important roles played by the user manual is to help in solving problems with SPX Cooling Technologies TG MAG185-125. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device SPX Cooling Technologies TG MAG185-125 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
