GE SS1000 User's Manual
Contents
1. d 805 606 1300N HLIM Q3HSINHA LON SI 1JMOV88 39uvHoS Q YY ESUJIJRI 11081 ONY SIH NI NI SNOLSNIWIG S 152703167011 7044 010 2907 Girt 61 90 161 tT6 88 el TOS dics LEFI 8E 217 T06 9 T6 VEI Ge FICS 8010 dl 0112 4 22 1 157217911 01 TSl G 531035 006 NO 9 Juv 58011238802 JJYYHISIG QNV LIMNI 157067061 20 85 ED Figure 8 8 500X Motor Adapter Pump 23 2 ONY 4 18 1 NOLLVTIWISNI NO NOLLVHUOJNI 011100 803 1589211 BIGHAN 580112081581 4 4 335 31034 34V 58011234802 3J98YH3SIQ NV 1311 V7 7580108 21419313 21981 ONY 21281 1d32OV TIIM 8114 0 80108 ONY V7 1691 05 9 5831381 11140 ONY S3H3MI Hi SNOISNINIQ 310N 91781 005 5 31281 00679 622 338 00 6D 338 1 ZH 09 Y 05 8 866 2H 09 05 X2SS 339 1 235 162 80 0676 576611 8279 SNOISN3HIQ jO 318Y1 TY 10511 JN 066 500 XB Motor Adapter Pumps 8 2 et 21730671 I 6 99 0 38 061 510 300072 Sti 61 90 FSi XJ NO1133NNO0 398YH2SIQ 1971011 jYvisnrv 00 16706 133 966 Figure 8 9 500 XB Motor Adapter Pump 24 AWO 328383338 ONY 440 403 3uV YOLOW 8034 SNOISNINIG 310V1 V7 6081 9081 POBI 1300W HLIM Q3QIA082. Adapter Pump 10 11 14 14 15 25 24 25 26 27 28 29 10 INTRODUCTION This manual contains information important to the installation operation and maintenance of your Tonkaflo multi stage centrifugal pump Your Tonkaflo pump has been designed for reliable service in many types of pumping applications Proper installation and normal main tenance will help ensure extended pump life and prevent costly downtime Before installing and operating your Tonkaflo pump read these instructions carefully and keep this manual handy for future reference This manual is intended for general mainte nance only Further information may be obtained by contacting your nearest Tonkaflo distributor or GE Infrastructure at GE Infrastructure Water amp Process Technologies 5951 Clearwater Drive Minnetonka MN 55343 8995 USA Phone 952 933 2277 Toll Free 800 848 1750 Fax 952 988 6060 This manual is not intended for repair or overhaul of the Tonkaflo pump liquid ends Only the factory and those certified by the Factory Service School are authorized to repair service or overhaul of Tonkaflo pump liquid ends Your new Tonkaflo multi stage centrifugal pump is designed for quiet smooth running and highly efficient operation The materials of construction make Tonkaflo pumps suitable for many chemical and pure water applications Tonkaflo pumps unique modular design allows the user to choose the number of stages which
3. Three Phase Motors The wiring diagram located on the motor nameplate electrical junction box junction box cover or wiring tag should be used to correctly wire the motor according to the line voltage available Be sure your pump is electrically grounded at the junction box on the motor CAUTION 500 1000X and 1800X motor adapter pumps have a threaded motor shaft Reverse operation can damage the motor shaft pump shaft or centrifugal stages Before Starting Three Phase Motors STEPS 1 Prime pump before applying power to avoid damage to the pump 2 Apply power for ONE SECOND MAXIMUM to check the direction of motor shaft rotation The motor shaft should turn in a clockwise direc tion as viewed from the motor end The direction of rotation for three phase motors may be reversed by interchanging any two 2 leads Figure 3 3 Changing Motor Rotation Three phase motors can run in either direction depending on how they are connected to the power supply When the three cable leads are first connected to the power supply there is a 50 chance that the motor will run in the proper direction To make sure the motor is running in the proper direction carefully follow the procedure below STEPS A Start the pump and note the pressure and flow rate developed at the pump discharge B Stop the pump and interchange any of the two leads Start the pump again and recheck the flow rate and pressure D Compare the result
4. most closely match the desired performance and thereby achieve the highest pump ing efficiency Unlike many other pump manufacturers Tonkaflo will produce pumps to fit your particular applications should a standard model pump not suit your requirements NOTE This manual along with all GE Infrastructure manuals is available at www ge water com 2 0 TONKAFLO SPECIFICATIONS The Tonkaflo pumps covered in this instruction manual are the lower capacity 55500 551000 551800 Series pumps These pumps cover a flow range of 1 5 18 0 34 4 1 m h with single unit pressure up to 700 psig 48 3 barg The capacity and discharge pressure can be increased by operating pumps in parallel or series respectively There is no maximum limit on capacity when operating Tonkaflo pumps in parallel When operating pumps in series the maximum rated discharge is 750 psig 51 7 barg with standard pumps and 1000 psig 69 barg with optional high pressure construction on the downstream pump With inlet pres sures greater than 200 psig 13 8 barg optional high pressure mechanical seals should be used 21 Capacities Table 2 1 Capacities 2900 rpm 3500 rpm 55 50 Hertz 60 Hertz Maximum Series Minimum Maximum Minimum Maximum Efficiency 1 6 gpm 1 5 7 gpm 0 23 1 4 m h 0 34 1 6 m h 1000 3 3 11 gpm 4 13 gpm 0 75 2 5 m h 0 91 30 m h 1800 4 17 5 gpm 5 21gpm 0 91 4 0 m h 1 14 4 8 m h NOTE Th
5. 1 On a used motor file the motor shaft smooth where the set screws were seated Coat the motor shaft with an anti seize compound Slide the shaft coupler onto the motor shaft until fully seated and tighten the two set screws Place the motor adapter onto the motor such that the one drain hole is locat ed down and the four side access ports are horizontal when the pump is rein stalled Coat the round end of the pump shaft and shaft key with an anti seize com pound Place the pump liquid end assembly with pump shaft and shaft key into the motor adapter with the key aligned with the coupler key way Install the four 4 5 16 18NC bolts and tighten Using a wood dowel place it against the pump shaft end located in the dis charge port Tap on the end of the wood dowel until the pump shaft is fullu seated in the shaft coupler and then tighten the cone point set screw Figure 4 6 Removal of Mechanical Seal Holder from Motor Adapter Reinstall the pump and pump piping connections Reinstall the motor wiring For pump start up see Section 3 0 Pump Installation Motor Removal X Motor Adapter Pumps STEPS 1 2 Disconnect the motor electrical power Remove the wiring to the motor Remove the piping from the pump Remove the pump mounting bolts and place the pump on a work bench Remove the four 4 5 16 18NC bolts that hold the pump liquid end to the motor adapter 18 5 5 6 Slide the liquid end assem
6. 3781 V SHOLOW 21812313 3NYJi 21981 NY 21281 14222 TIIM 8314 0 80108 QNV V 8831381 1118 ONY S3HONI NI JYY 550158381071 153108 6 891 217306 19520589061 510 0007 t 12 612 570611 921 Jm 99 H IS UFL 61 90 361 F record dal 902 17691 2 1191390 335 079 5 011238802 198 2510 IL 21981 0066 uz 2671621 D 319 150 0 005 31281 00677 205 1086 16221 339 00 52 61 el FES L Fa S TE pII 0r TOS P jm g E 11 igure 8 1800XB Motor Adapter Pump F 26 1801 dil 57017611 207351 JONYNGINEVA ONY 40 18 15 NOILVTYISNI 9039 05 NO NO11VWJO1N 1VNOILIQQY 1585211 SNOIIOQUISNI 335 10 T0002 7QUMWIDIA v 1 1 N01123NNOD 393YHOS Q ANY 13181 NJ 8010 21812313 157031796 21612 ONY 21612 14399 TIM uildVOY YOLON ONY dW d 57 S OFE yg 200611 SH3I3RLTIIN ONY SJH NI NI 38Y SNOISNINIG 71 QUEE 183108 0078 2 1130 335 l v S N011238N02 398 2510 080 641701 ual 00875 1 0076 005 0 31 55 5 UYL 2121 FRE 8 079921 jim 96010 86 00 00 66 510 000 ses i r ip 91729 9107 09971 191 761 I 0 l 01 5275 817 9861 1 0 F 529 SYJLINI NIN S3H3N1 4 532 14 2 1975511 SNOISN3HIQ 21 T10Y121A 8279 S 338 1 Liv 96 19
7. 91 9761 1 0 2 9681 1 36 p 91 9 er eati vors 96t 96 9 1 0 pl 1 1300N SNOISN3HiQ 10 318Y Figure 8 12 1800XC Motor Adapter Pump 27 1800XC Motor Adapter Pumps 8 5 CUTAWAY DRAWINGS 9 0 Motor Adapter Pum 9 1 NS mu SIN ZZ mae Figure 9 13 X Motor Adapter Pump 28 92 XB and XC Motor Adapter Pump Figure 9 14 XB and XC Motor Adapter Pump 29 100 STANDARD MODEL PARTS LIST 101 Spare Parts List Part Number Item Description Series 500 Series 1000 500XB Series 1800X 1800XB 1800XC B Liquid End Assembly Specify Model Model Model P os KE MM NN E EIS Model Model Model ESSET b Fb iG Mechanica iu sess mo EN Mechanical Seal 400 psig barg Kit 1120477 1120477 1120477 a Retaining Ring 1120054 1120054 1120054 Discharge Bracket 1120659 1120075 1125914 Ez Clamp Discharge 1112951 1112951 1112951 30 1 2 4 5 7 10 11 12 13a 13b 13c 14 15 16 Part Number Series 500 Series 1000X 500XB Series Item Description 1800X 1800XB 1800XC Bolt 5 16 18NC x 1 1113102 1113102 pese mo Lock washer 1 2 1113104 1113104 Accessories Part Number Series 500X Series 1000
8. FT COUPLER ZZ Ww E EN KURLED CUP POINT SET 2 Figure 4 6 Removal of Mechanical Seal Holder from Motor Adapter 14 MECHANICAL SEAL HOLDER STATIONARY SEAT PORTION OF MECHANICAL SEAL ROTARY SEAL PORT O OF MECHANICAL SEAL PUMP SHAFT STAIONARY SEAT ROTARY SEAL FACE WITH RUBBER AP WASHER RETAINING RING Figure 4 7 Removal of Mechanical Seal from Pump Shaft and Cavity of Mechanical Seal Holder 3 Remove the rotary portion spring washer and face assembly of the seal assembly from the pump shaft by rotating and pulling the rotary portion until it slides off the pump shaft Figure 4 6 Removal of Mechanical Seal Holder from Motor Adapter 4 Remove the mechanical seal holder from the motor adapter by sliding the holder off the pump shaft Two 2 flat blade screwdrivers may be needed to remove seal holder from the motor adapter Figure 4 6 5 Remove the stationary seat of the mechanical seal from the cavity of the mechanical seal holder Figure 4 7 Removal of Mechanical Seal from Pump Shaft and Cavity of Mechanical Seal Holder 6 Install the new stationary seat into the seal holder cavity Lubricate the rub ber boot on the outside of the stationary seal with petroleum or silicone grease before replacement Make sure the stationary seat is fully seated Lightly lubricate the ground surface of the stationary seat with grease 15 44 10 11 12 13 Examine the ru
9. OSMONICS TONKAFLO PUMPS SS SERIES INSTALLATION OPERATION AND MAINTENANCE MANUAL For 55500 551000 and 551800 Series Tonkaflo Centrifugal Pumps with X XB and XC Motor Adapters Without Bearing Frames GE Infrastructure Water amp Process Technologies 1 0 2 0 3 0 TABLE OF CONTENTS Page INTRODUCTION tt 1 POINTS A OS PEC TIC OI 2 21 SOOO ES nn 2 22 Maximum Developed Boost Pressure asset 3 2 5 Maximum Recommended Operating Temperature 3 2 4 Standard Materials of Construction aaa 3 25 Special Materials of Construction sca cra cca 3 26r 4 27 Speciol Liquids U UU ED D M ED E D 4 PUMPTNSTALPEATIONU Y 5 Mm 5 3 2 _ Pump Mounting and LOCATON c ess canal 5 33 Inlet and Discharge Piping and Connections 5 25 PUDDING o u uuu E 5 3 3 2 Discharge PIDInQ n 6 33 57 Pump PIPING CONNECUONS 7 3 3 4 Inlet Line Screen Filter nnn 7 3 3 5 Discharge Screen Strainer e e rectus 7 C MMC uidi 8 35 Protection Against RUNNIN 8 NEM ooo a E T 9 3 6 1 Single Phase MOTOTS n 9 362 hree PASE MOTO 9 3 6 5 Three Phase Power Imbalance 0 INSTALLATION OPERATION AND MAINTENANCE MANUAL FOR 55500 551000 AND 551800 SERIES TONKAFLO CENTRIFUGAL PUMPS WITH X XB XC FRAMES MOTOR ADAP
10. TERS WITHOUT BEARING FRAME 4 0 5 0 6 0 7 0 8 0 9 0 GENERAL TROUBLESHOOTING FOR ALL PUMPS 41 Troubleshooting Chart 42 Mechanical Seal Leakage 435 Mechanical Seal Replacement 55500 551000 SS1800 Series Pumps 44 High Pressure Mechanical Seal Replacement 55500 551000 and SS1800 Series 5 1 Motor Bearing Lubrication 5 2 Motor Removal XB and XC Motor Adapter Pump 5 3 Motor Installation XB and XC Motor Adapter Pump 5 4 Motor Removal X Motor Adapter Pump 5 5 Motor Installation X Motor Adapter Pump TONKAFLO PUMP RETURNED GOODS AUTHORIZATION RGA PROCEDURE 7 1 Motor Warranty 7 2 In of Warranty Pump Failure 7 3 Out of Warranty Pump Failure DIMENSIONAL DRAWINGS 8 1 500X Motor Adapter Pump 82 500 Motor Adapter Pump 8 3 1000X 1800X Motor Adapter Pump 8 4 1800 Motor Adapter Pump 85 1800XC Motor Adapter Pump CUTAWAY DRAWINGS 91 XMotor Adapter Pump 92 XBand XC Motor Adapter Pump 13 16 17 17 17 18 18 19 21 22 22 22 22 23 23 24 25 26 27 28 28 29 10 0 STANDARD MODEL PARTS LIST 11 0 12 0 10 1 10 2 10 3 Figure 3 1 3 2 3 3 3 4 4 5 4 6 Spare Parts List Accessories LIST OF FIGURES Title Removal of Mechanical Seal from Pump Shaft and Cavity of Mechanical Seal Holder 500 Motor Adapter aaa 500XB Motor Adapter Pump 1000X and 1800X Motor Adapter Pump 1800XB Motor Adapter Pump 1800XC Motor Adapter Pump X Motor
11. X 500XB Series Description 1800X 1800XB 1800XC Installation Operation and Maintenance 1125857 1125857 1125857 Manual Retaining Ring Pliers 1120108 1120108 1120108 Loctite 242 Standard Strength 0 5 cc tube 1120109 Loctite 271 High Strength 50 cc bottle 1113690 Anti Seize Thread Compound 1120110 1120110 1120110 31 10 3 Mechanical Seal Replacement Kit Part Number Series 500 Series 1000X 500XB Series Description 1800 1800 8 1800 Standard 200 psig 13 8 1121174 1121174 1121174 High Pressure 300 psig 20 7 1120312 1120312 1120312 High Pressure 400 psig 27 8 barg 1120477 1120477 1120477 Allen Wrench 3 16 inch 1113770 1113770 Victaulic Adapters 1 25 x 1 25 M NPT 316SS 1113653 1113653 1113653 Victaulic Adapters 1 25 x 1 F NPT 316SS 1120797 1120797 1120797 Victaulic Adapters 1 25 x 0 75 31655 1120229 1120229 Victaulic Coupling 1 25 1000 psig 69 barg 1110597 1110597 1110597 Pump Discharge Screen 1 25 1120264 1120264 1120264 32 11 0 ORDERING PARTS Order parts through your local distributor or directly from GE Infrastructure Water amp Process Technologies 5951 Clearwater Drive Minnetonka MN 55343 8995 USA Phone 952 933 2277 Fax 952 933 0141 Toll Free 800 848 1750 To order parts the following information is necessary 1 Pump model number 2 Pump serial number from nameplate 2 Other nameplate information such as operating tempera
12. asp the liquid end and insert the splined pump shaft into the liquid end by carefully rotating the liquid end clockwise and then counterclockwise while applying light pressure toward the motor adapter Be sure the splined shaft and splined bore of each impeller meshes properly until the inlet casting mates with the mechanical seal holder It may be necessary to lift the assem bly up slightly when rotating it then place it onto the splined shaft WARNING CARE MUST BE TAKEN NOT TO BEND THE PUMP SHAFT OR TO FORCE THE SHAFT INTO THE IMPELLER BORE Install the four 4 5 16 inch bolts and lock washers and tighten High Pressure Mechanical Seal Replacement 55500 551000 and 551800 Series Pumps High pressure mechanical seals have the same basic design as standard mechanical seals Replace them using the same procedure as denoted in Section 4 3 Mechanical Seal Replacement SS500 SS1000 and SS1800 Series Pumps Figure 4 6 Removal of Mechanical Seal Holder from Motor Adapter and Figure 4 7 Removal of Mechanical Seal from Pump Shaft and Cavity of Mechanical Seal Holder 16 5 0 TONKAFLO PUMP FIELD MAINTENANCE 5 1 5 2 Motor Bearing Lubrication Motors up to 3 Hp typically have sealed bearings Motors of 5 7 5 and 10 Hp may or may not have sealed bearings For these larger motors lubrication intervals vary between manufacturers but generally lubrication every 2000 hours is required Consult Your Local Motor Distributor For Lubricat
13. bber O ring on the mechanical seal holder and if the O ring is damaged replace it with a new one A new O ring is included with the facto ry supplied Mechanical Seal Replacement Kit Section 10 3 Be sure to lubri cate with grease before installing Place the mechanical seal holder containing the new stationary seat onto the pump shaft and slide it down the shaft until fully engaged with the motor adapter Care must be taken not to damage seal seat when sliding over the pump shaft Lubricate the round surface of the pump shaft with grease After lubrication replace the rotary portion of the mechanical seal by placing onto the pump shaft and carefully rotating and pushing it down the pump shaft until it is fully seated against the stationary portion of the mechanical seal WARNING USE CARE WHEN SLIDING THE ROTARY PORTION OF THE MECHANICAL SEAL OVER THE RETAINING RING GROOVE IN THE PUMP SHAFT THE RUBBER ON THE MECHANICAL SEAL CAN BE DAMAGED IF NOT LUBRICATED WITH GREASE Place the stainless steel retaining ring back onto the shaft to hold the rotary portion of the mechanical seal in place with the square edges of the retaining ring away from the seal spring A retaining ring is included in the factory sup plied mechanical seal replacement kit Use of retaining rings that are not Stainless steel or equivalent may cause the seal to fail in operation Be sure the retaining ring is properly seated in the groove on the pump shaft Firmly gr
14. bly off of the pump shaft taking care not to bend the pump shaft 7 Remove the retaining ring and remove The rotary head of the mechanical seal 8 Remove the seal holder along with the stationary seal seat 9 Remove the four 4 3 8 16NC bolts that hold the motor adapter to the motor and remove the motor adapter 10 Remove the pump shaft assembly where it is screwed to the threaded motor shaft by first heating the joint area to loosen the thread locking compound Secure the motor shaft using a vise grip and loosen the pump shaft assem bly An impeller may be used to grip the shaft taking proper care not to dam age the impeller Or use a vise grip and fabric rug to grip the splined shaft taking care not to damage the splines 11 motor now be serviced by a qualified service center or replaced Motor Installation X Motor Adapter Pumps STEPS 1 To re use repaired motor clean the threads on the shaft of any thread sealant residue 2 Reinstall the pump shaft onto the threaded motor shaft until fully seated Rotate the pump shaft to make sure it runs true Run out should be less than 0 03 inch 0 76 mm for every 10 inches of pump shaft length Loosen the pump shaft from the motor shaft apply thread sealant to the threads and tighten the shaft again until fully seated Use standard strength thread sealant on single phase motors and a high strength thread sealant on three phase motors 4 Install t
15. chorge Foot valve operating improperly Air leak in inlet piping Air leak in mechanical seal Wrong installation of belt drive Suction lift too high Reverse rotation of pump shaft Pump not primed adequately Inlet strainer filter plugged Pump throttling valve on discharge closed pump deadheaded A i be GENERAL TROUBLESHOOTING FOR ALL PUMPS MOTOR RUNS HOT OR STOPS 1 Motor surface temperature up to 104 F 40 C over ambient can occur The motor will feel hot to the touch Bad connection Motor exceeded rated amp draw Excessive ambient temperature Heater size to small in motor heater Binding rotation in the pump shaft Bearings not adequately lubricated Specific gravity or viscosity of liquid higher than design conditions Motor wired improperly MOTOR DOES NOT RUN LOW PRESSURE Blown fuse or tripped circuit breaker or overload heater Motor to hot allow to cool Motor voltage connection and line voltage different Bad connection Motor wired improperly Wrong ratio for belt drive Pump not adequately primed Air leak in inlet piping Excessive flow Clogged suction line filter or screen Reverse rotation of pump shaft Foot valve operating improperlu Wrong ratio for belt drive PUMP VIBRATION PUMP LEAKING Misalignment of flexible coupling Bent pump shaft Improper mounting Starved suction Worn bearings Motor out of balance Operating b
16. d LON LIMIWNG 39uvHOSIQ V 9312811118 ONY S3HONT NI SNOISN3WIQ 310N S2 071 01 i 144 010 90 Cr dAl 1015 et 2175067 078706 510700072 971317611 L6 02 941 020 000 Figure 8 10 1000X and 1800X Motor Adapter Pump 25 1000X and 1800X Motor Adapter Pumps 8 3 pet es 016 162 22211 i CLI EFG 99 Pes Tr p 21750065 es pel t s 192 v12 v 8tv 92711 X2191 8911 es rres 9 01 6 Irci sii e S s 6 17092 so 11 9081 HB HB 6701 77 175212926 vel 01 162 221 1 S 928 OSZE 1902 42 11 97011 resis ica 1722 WW 438 WA 439 1 ima 1300W SNOISN3HIQ 30 310 1 1800XB Motor Adapter Pumps 8 4 005 0 31425 2 11130 BE 00 00 66 510 000 SES iv 91720 910 F 0991 eL F vel 81758851 160 629 Su T S3HONI 512714 2 SNOISN3HIQ 2IT0V12IA 866 9506 6 51 0771 6861 1H06 gxarat p6 9S S SI O hI gxacgt ret est s si o ei teso oo ce v6t 99 6 51 0781 1146 512 99 5 628 98291 WH NI upuhr sq cons P 58015843810 30 318V1 JONVN3INIYN ONY 90 18 15 NOILYTIYISNI NO NOIIVWSOJNI 1VNO11100Y 1585211 580712081581 335 v 71 1 38V SNOILJJINNOJ 298 2510 ANY 1
17. embly from the pump shaft On Tonkaflo XB and XC frame pumps you can service the mechanical seal by either removing the complete liquid end assembly from the pump shaft or by loosening the cone point set screw which secures the pump shaft to the shaft coupler and removing the pump shaft with the liquid end assembly STEPS 18 Remove the four 4 5 16 inch bolts and lock washers from the inlet casting and firmly grasp the liquid end Figure 4 5 Removal of Pump Liquid End from Motor Adapter Pull the liquid end straight off the pump shaft being careful not to bend the pump shaft Two 2 flat blade screwdrivers may be needed to remove the seal holder from the liquid end assembly WARNING EXTREME CARE MUST BE TAKEN NOT TO BEND PUMP SHAFT 2 Remove the stainless steel retaining ring size 5160 62 from the pump shaft using the proper size retaining ring pliers Truarc L1520 or equivalent These pliers are available from the factory or can be purchased from a local source 13 PUMP LIOUID END ASSEMBLY 5 16 18NC X BOLTS AND LOCK WASKER 4 MOTOR ADAPTER Figure 4 5 Removal of Pump Liquid End from PUMP SHAFT RETAINING RIN MEAHANICAL SEAL SPRING WASHER AND SEAL FACE ASSEMBLY MECHANICAL WECHANICAL SEAL SEAL HOLDER STATIONARY SEAT RY 4 afe x FOR SET SCREW 2 CONE POINT SET SCREW t YA 5 SSS SSS N SHAFT WITH ANTISEIZE COMPOUND BEFORE ASSEMBLY LZ SHA
18. ere must be adequate flow at all times through the pump to prevent excessive heat build up 2 2 Maximum Developed Boost Pressure Table 2 2 Maximum Developed Boost Pressure Maximum Developed Pressure psig barg SS 630 43 4 700 48 3 Number of Centrifugal Stages 2 3 Maximum Recommended Operating Temperature The maximum recommended operating temperature range is 125 F 52 C The max imum operating temperature is dependent upon the operating pressure For high temperature applications consult the factory for special materials of construction The maximum recommended temperature is stated on the pump case The temper ature stated is for the design flow and pressure 24 Standard Materials of Construction SS Wetted castings and pump shaft are 316 stainless steel SS The pump casing is 316SS Impellers and diffusers are Noryl The mechanical seal has a carbon rotating face and a ceramic stationary face The secondary sealing element of the mechanical seal is Buna N The O rings and diffuser bearings are Buna N 2 5 Special Materials of Construction Optional ethylene propylene EPDM Viton and Teflon elastomers are available Contact the factory Viton and Teflon are trademarks of E l DuPont de Nemours and Company Inc 2 6 Pump Nomenclature Example Model SS505X Model SS1848XB 50 Materials of Construction Materials of Construction Series 500 Series 1800 Number of Stages Number of Stages M
19. eyond specified capacity range of the pump 12 Mechanical seal needs replacing O rings in pump casing damaged Oil seals need replacing Piping not sealed properly 4 2 4 3 Mechanical Seal Leakage WARNING POWER MUST BE DISCONNECTED BEFORE MAINTENANCE If liquid is leaking from the hole on the bottom or on either side of the motor adapter the mechanical seal may need to be replaced With new pumps pumps with new mechanical seals or pumps which have been dormant for long periods the seal faces may not be completely seated and a slight leakage will occur If this leakage contin ues for more than 60 seconds the first remedy is to remove the discharge piping and tap the pump shaft using a wooden dowel to seat the seal WARNING BE CAREFUL NOT TO DAMAGE THE SHAFT If this does not stop the leak then the liquid end assembly needs to be partially removed to gain access to the mechanical seal as shown in Figure 4 5 Removal of Pump Liquid End from Motor Adapter or Figure 4 6 Removal of Mechanical Seal from Motor Adapter The ceramic seal seat also needs to be wiped clean and then coated very lightly with oil or Vaseline Also the carbon wear ring needs to be wiped clean and coated light ly with petroleum grease Then reassemble the pump Mechanical Seal Replacement SS500 SS1000 and 551800 Series Pumps NOTE On Tonkaflo X frame pumps the mechanical seal must be replaced by removal of the complete liquid end ass
20. he motor adapter onto the motor and install and tighten the four bolts into the motor 5 Position the seal holder into the motor adapter using Vaseline or grease on the O ring as a lubricant Replace the O ring if damaged 6 Install a new mechanical seal stationary seat using Vaseline grease or water as a lubricant on the rubber portion 7 Install the rotary portion of the mechanical seal using a small amount of Vaseline lubricant on the round body of the shaft and also on the face of the ceramic seat face where the carbon wear ring contacts it 19 10 11 Install the retaining ring into the shaft groove with the sharp edges away from the motor Install the liquid end assembly onto the pump shaft Do not force it in Rotate and place the liquid end onto the mechanical seal holder until seated against motor adapter Install the four 4 5 16 inch lock washers and bolts to hold the liquid end onto the motor adapter and tighten Reinstall the pump Section 3 0 Pump Installation 20 6 0 LIQUID END TONKAFLO SERVICE POLICY Sections 4 0 General Troubleshooting for All Pumps and 5 0 Tonkaflo Pump Field Maintenance in the Tonkaflo Installation Operation and Maintenance Manual were written to assist our customers in performing minor maintenance in the field of Tonkaflo pumps Proper maintenance will ensure longer pump life and minimize downtime Tonkaflo pumps are manufactured to make field repairs on the mechanica
21. ion Advice or the motor information supplied with your pump Motor Removal XB and XC Motor Adapter Pumps STEPS 18 Disconnect the motor electrical power 2 Remove the wiring to the motor 3 Remove the piping from the pump 4 Remove the pump mounting bolts and place the pump on a work bench 5 Remove the cone point set screw from the shaft coupler which is located through either side port in the motor adapter adjacent to the inlet housing Do not remove the two knurled cup point set screws securing the shaft coupler to the motor shaft at this time 6 Remove the four 4 5 16 18NC bolts that hold the pump liquid end to the motor adapter 7 Slide the liquid end assembly away from the motor adapter 1 4 to 1 2 inch 6 13 mm 8 Use two 2 flat blade screwdrivers or small pry bars to remove the seal hold er from the motor adapter along with the pump shaft Figure 4 5 Removal of Pump Liquid End from Motor Adapter Remove the liquid end assembly including the pump shaft as a unit 9 Remove the four 4 1 2 12NC bolts that hold the motor adapter to the motor and remove the motor adapter 10 Loosen the two set screws that hold the shaft coupler to the motor shaft and remove the shaft coupler The motor may now be serviced by a qualified ven dor or replaced Figure 4 6 Removal of Mechanical Seal Holder from Motor Adapter 17 5 3 5 4 Motor Installation XB and XC Motor Adapter Pumps STEPS T 9 10 1
22. iping When pumping liquid from a tank the suction line must be submerged enough so air is not drawn into the suction line from a vortex Increasing the size of the inlet pipe to reduce the velocity will help to prevent the vortex from forming Hot liquids within the temperature range of the pump must have sufficient positive head to prevent vaporization at the impeller inlet The Net Positive Suction Head NPSH required data are included on the pump performance curves provided with this instruction manual The pump must never be throttled on the suction side After installation test the suction line with water with a range of 20 100 psig 1 4 6 9 bar pressure to detect any leaks Long Radius Elbow slopes upward Air pocket because line Eccentric does not slope upward and Reducer Control eccentric reducter not used if used EX Shutoff Valve Check Valve i f Check Valve Pump Pump Correct Incorrect Control Shutoff Valve should not be Foot Valve if used between check valve and pump Strainer 3 3 2 Figure 3 1 Inlet Piping Discharge Piping The discharge piping should be sized to properly handle the maximum flow and pressure developed by the pump 3 3 4 Size selected should result frictional line loss of 5 psi 100 ft 1 1 less for suction lines and 10 psi 100 ft 2 3 kPa M or less for discharge lines A larger pipe size will reduce
23. l seal a quick and easy process If repair at the factory is desired call the factory for a Return Goods Authorization RGA number Section 7 0 and follow the directions provided by a GE representative For motor problems such as worn out motor bearings it is recommended that maintenance be done at local motor repair shop WARNING FIELD SERVICE OF THE LIQUID END WITH THE EXCEPTION OF MECHANICAL SEAL REPLACEMENT IS NOT RECOMMENDED If a liquid end is damaged by running the pump dry inadequate flow deadheading cavita tion or other reasons return it with the motor to the factory for repair 21 7 0 TONKAFLO PUMP RETURN GOODS AUTHORIZATION RGA PROCEDURE If you wish to return goods for repair warranty evaluation and or credit please have your original sales order or invoice available when you call GE Call 800 848 1750 and ask to speak with Customer Service A GE Customer Service representative will provide instructions and a return authorization number which needs to be clearly written on the outside of the box used to ship your materials All equipment must be shipped to GE with the freight prepaid by the customer Call our Customer Service Center with any questions or issues concerning freight claims and a representative will discuss your situation All materials to be returned must be rendered into a non hazardous condition prior to ship ping There are two ways to handle a return 1 send in the pump for repair a
24. nd return or 2 pur chase a new pump and when desired send the defective pump to the factory for repair and return 7 1 Motor Warranty Motors must be sent to the nearest authorized motor service station center for repair replacement and warranty disposition 7 2 In Warranty Pump Failure STEPS 1 Return the defective pump to the foctoru for repoir on RGA within 15 dous from RGA issue dote GE obsorbs the cost of repoir The repoired pump will be returned and is under warranty for the remainder of the original warranty period or three months whichever is longer 2 GE will not restock or issue return credit against a new customer built pump purchase regardless of the warranty status of the failed pump The warranty Section 12 0 Tonkaflo Pump Warranty is 12 months from installation or 15 months from receipt whichever occurs first 7 3 Out of Warranty Pump Failure Return the pump on an RGA for repair The pump will be repaired and repair charges invoiced to the customer The warranty for repairs is three months 22 DIMENSIONAL DRAWINGS 8 0 ges oes 925 615 216 SNOISN3NIQ NJ 308383438 SNOISNIWIG won 500X Motor Adapter Pumps 8 1 1015 887 15 0 2 911 S2 O li 8 010 TEVE 020 F000 527059 6211 010 351877 05 1 CFI 91 21740579 cd 400 801 19 NMOHS SNOISNIWIG JiQv Y SdW
25. otor Adapter Motor Adapter No Bearing Frame No Bearing Frame 56J Motor 182 184TC Motor 50 Hertz Operation 2 7 Special Liquids For liquids other than water aqueous solutions or corrosive solutes consult the factory for compatibility 3 0 PUMP INSTALLATION 3 1 3 2 3 3 Inspection Your pump was inspected and tested at the factory prior to shipment to ensure it meets the requirements of your order It is suggested the pump be checked upon receipt for possible damage due to shipping Any damage should be immediately reported to the carrier Pump Mounting and Location The pump is supported by the motor base and on longer pumps a support at the dis charge end The X XB and XC motor adapter pumps may be mounted and operated in either a horizontal or vertical position The vertical position requires the motor to be up The inlet casting may be rotated to any of four positions by removing the four 4 bolts on the inlet casting turning the inlet casting to the desired position and replacing the 4 bolts When mounting the pump be sure the pump casing support and motor base are in line and on the same plane so that no stress results in the pump after fastening down CAUTION The inlet and discharge piping should be independently supported Inlet and Discharge Piping and Connections 3 3 1 Inlet Piping THE INLET PIPING AND PUMP MUST BE FILLED WITH LIQUID PRIMED BEFORE START UP A pressure vacuum ga
26. pumps located in the discharge piping will protect your process fluid should the pump be damaged The installation of the screen is shown in Figure 3 2 Installation of Discharge Screen 3 4 3 5 DISCHARGE SCREEN CLAMP VICTAULIC PUMP DISCHARGE CASTING Figure 3 2 Installation of Discharge Screen Pump Priming IMPORTANT THE INLET PIPING AND PUMP MUST BE FILLED WITH LIQUID i e PRIMED BEFORE START UP If the pump is above the liquid source fill the pump and supply line with liquid from an external source WARNING THE PUMP MUST BE SHUTOFF IMMEDIATELY IF PRIME IS LOST TO AVOID POSSIBLE DAMAGE TO THE INTERNALS OF THE LIQUID END WARNING NEVER RUN PUMP DRY The liquid end of your Tonkaflo pump is lubricated by the process fluid The pump must never be run dry to avoid damage to the liquid end Protection Against Running Dry It is suggested that controls to protect the pump from running dry be used These controls include pressure switches flow switches and temperature switches 3 6 Motor Wiring 3 6 1 3 6 2 Single Phase Motors When initially connecting to the power source be certain that the motor volt age connections and available line voltage are the same Connect electrical wires as shown on the motor wiring diagram located on the motor name plate electrical junction box junction box cover or wiring tag Be sure your pump 15 electrically grounded at the junction box on the motor
27. s observed The wire connection thot yield ed the highest pressure flow rate is the proper connection Interchange the two leads only if necessary Figure 3 3 Changing Motor Rotation Original 2 Switching 3 Final Configuration Two Leads Configuration lI O P TI Figure 3 3 Changing Motor Rotation 3 6 3 Three Phase Power Imbalance Current imbalance should not exceed 5 of the average three phase current The current imbalance can be calculated as follows STEPS iM Measure the current through each of the three legs 2 Average the three current measurements together 3 Determine the difference between the current in each leg and the average of all three legs 4 Take the difference with the largest value and divide it by the average current Multiply by 100 to obtain the current imbalance percentage 5 If the current imbalance is greater than 5 roll the leads and retest Figure 3 4 Rolling the Leads to Balance Current Rotation If rolling the leads does not correct the problem the source of imbalance must be located and corrected For more information on current imbal ance refer to the motor operation manual 10 Original Configuration 111 I 2 Rolling the Leads lii Figure 3 4 Rolling the Leads to Balance Current Draw 11 3 Final Configuration lii 4 0 4 1 Troubleshooting Chort LOW FLOW Restrictions in inlet or dis
28. the frictional line loss WARNING THE PUMP MUST NOT RUN WITH A CLOSED DISCHARGE OR IRREVERSIBLE DAMAGE TO THE WETTED INTERNAL PARTS OF THE PUMP WILL RESULT Pump Piping Connections The standard inlet and discharge connections for a Series 500 pump is a 3 4 inch NPT female pipe thread and for Series 1000 and 1800 pumps is 1 1 4 inch Victaulic couplings clamped unions with gasket Victaulic cou plings are available worldwide Contact the factory or your local industrial piping wholesaler Inlet Line Screen Filter This is a precision multi stage pump with close tolerances to provide maxi mum efficiency It is good practice to install a large area 30 mesh or finer screen or a cartridge filter in the pump inlet line to collect any foreign objects or large particles Size the screen or filter so as to induce a minimal pressure drop WARNING THE PUMP MUST NOT BE OPERATED WITH RESTRICTED SUC TION LINE INLET FLOW Positive gauge pressure must be maintained at the pump inlet downstream from the screen or filter A clogged screen or filter will result in a greater pressure drop than a clean screen or filter To prevent possible pump dam age from low inlet pressure a low pressure alarm or shut off switch should be located between the screen or filter and the pump A low flow shut off switch should also be located in the same area Discharge Screen Strainer A 30 mesh screen available as an accessory for 500 1000 and 1800 Series
29. tness for any particular purpose In no event shall GE be liable for consequential or incidental damages Pump Model Number Pump Serial Number P N 1125857 Rev B 34 For more information call 952 933 2277 or 800 848 1750 in the U S or visit www gewater com GE Infrastructure Water amp Process Technologies North American Sales Euro Africa Sales Asia Pacific Sales 5951 Clearwater Drive 230 rue Robert Schurman 1044 8 501 44 2 Minnetonka MN ZA des Uselles Sukhumvit Road Parkanog 55343 8995 77350 Le M e sur Seine Bangkok 10110 USA FRANCE THAILAND 952 933 2277 Phone 33 1 64 10 2000 Phone 66 2 38 14213 Phone 952 933 0141 Fax 33 164 10 3747 Fax 66 2 39 18183 Fax 2004 General Electric Company All rights reserved P N 1125857 Rev B
30. ture or material code and type of mechanical seal 4 Motor horsepower motor frame size and enclosure specifications 5 Part name 6 Part number 7 Quantity desired 8 Special materials of construction if any 35 12 0 WARRANTY TONKAFLO PUMP WARRANTY GE warrants its pumps to be free from defects in design material or workmanship for a peri od of 15 months from receipt or 12 months from installation of the product whichever occurs first when said products are operated in accordance with written instructions and are installed properly If Tonkaflo pumps are altered or repaired without prior approval of GE all warranties are void If any defects or malperformance occur during the warranty period GE s sole obligation shall be limited to alteration repair or replacement at GE s expense freight on board F O B factory of parts or equipment which upon return to GE and upon GE s exami nation prove to be defective Equipment and accessories not manufactured by GE are war ranted only to the extent of and by the original manufacturer s warranty GE shall not be liable for damage or wear to equipment caused by abnormal conditions excessive temper atures vibration failure to properly prime or to operate equipment without flow or caused by corrosives abrasives or foreign objects The foregoing warranty is exclusive and in lieu of all other warranties whether expressed or implied including any warranty of merchantabili ty or fi
31. uge installed in the inlet piping to measure positive or negative pressure is recommended Be sure the pump is not mounted above the liquid source and the inlet suction plumbing not restricted so adequate suction pressure is available The inlet piping should be at least as large as the pump inlet port The dis charge piping should be sized to properly handle the maximum flow and pres sure developed by the pump The recommended pipe size for most applications should result in frictional line loss of 5 psig 100 feet 0 34 barg 100 meters or less for suction lines and 10 psig 100 feet 0 7 barg 100 meters or less for discharge lines A larger pipe size will reduce the frictional line loss The pump inlet piping should be designed to avoid areas where air may be trapped and accumulate Keep the inlet pipe free of high points which could trap air and could disrupt pump priming and start up Pump inlet pipe size changes just ahead of the pump should be tapered Reducers should be eccentric to avoid air pockets Should your application require pump operation with a neg ative gauge pressure at the inlet consult the factory or your local Tonkaflo pump distributor When the pump operates with a suction lift the suction pipe should slope upward to the pump from the source of supply Provision must be made for priming the pump To maintain pump prime a foot valve can be used with an opening at least as large as the inlet p
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