TONKAFLO PUMPS SS SERIES INSTALLATION, OPERATION, AND MAINTENANCE MANUAL For SS500, SS1000, and SS1800 Series Tonkaflo Centrifugal Pumps with X, XB, and XC Motor Adapters Without Bearing Frames GE Water & Process Technologies
INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR SS500, SS1000 AND SS1800 SERIES TONKAFLO CENTRIFUGAL PUMPS WITH X-, XB- OR XC-FRAMES MOTOR ADAPTERS WITHOUT BEARING FRAME TABLE OF CONTENTS Page 1.0 INTRODUCTION 1 2.0 TONKAFLO SPECIFICATIONS 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2 3 3 3 3 4 4 3.0 Capacities Maximum Developed Boost Pressure Maximum Recommended Operating Temperature Standard Materials of Construction Special Materials of Construction Pump Nomenclature Special Liquids PUMP INSTALLATION 3.
Page 4.0 GENERAL TROUBLESHOOTING FOR ALL PUMPS 12 4.1 4.2 4.3 12 13 4.4 5.0 Troubleshooting Chart Mechanical Seal Leakage Mechanical Seal Replacement: SS500, SS1000 and SS1800 Series Pumps High-Pressure Mechanical Seal Replacement: SS500, SS1000 and SS1800 Series 13 16 TONKAFLO PUMP FIELD MAINTENANCE 17 5.1 5.2 5.3 5.4 5.
Page 10.0 STANDARD MODEL PARTS LIST 30 10.1 10.2 10.3 30 31 32 Spare Parts List Accessories Mechanical Seal Replacement Kit 11.0 ORDERING PARTS 33 12.0 TONKAFLO PUMP WARRANTY 34 LIST OF FIGURES Figure Title 3.1 3.2 3.3 3.4 4.5 4.
1.0 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 maintenance 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.
2.0 TONKAFLO SPECIFICATIONS The Tonkaflo pumps covered in this instruction manual are the lower capacity SS500, SS1000, and SS1800 Series pumps. These pumps cover a flow range of 1.5 - 18 gpm (0.34 - 4.1 m3/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.
2.2 Maximum Developed Boost Pressure Table 2.2 Maximum Developed Boost Pressure Maximum Developed Pressure psig (barg) 2.3 Number of Centrifugal Stages SS Series 50 Hertz 60 Hertz 50 Hertz 60 Hertz 500 630 (43.4) 700 (48.3) 76 58 1000 300 (20.7) 340 (23.4) N/A 28 1800 570 (39.3) 680 (46.9) 56 48 Maximum Recommended Operating Temperature The maximum recommended operating temperature range is 125°F (52°C). The maximum operating temperature is dependent upon the operating pressure.
2.6 Pump Nomenclature Example: Model S S 5 0 5 X SS 5 05 X = = = = Model S S 1 8 4 8 X B - 5 0 SS 18 48 XB Materials of Construction Series 500 Number of Stages Motor Adapter, No Bearing Frame, 56J Motor 50 2.7 = = = = Materials of Construction Series 1800 Number of Stages Motor Adapter, No Bearing Frame, 182/184TC Motor = 50 Hertz Operation Special Liquids For liquids other than water, aqueous solutions, or corrosive solutes, consult the factory for compatibility.
3.0 PUMP INSTALLATION 3.1 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. 3.2 Pump Mounting and Location The pump is supported by the motor base, and on longer pumps, a support at the discharge end.
IMPORTANT: Should your application require pump operation with a negative 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 piping.
Size selected should result in frictional line loss of 5 psi/100 ft (1.1 kPa/M) or less for suction lines and 10 psi/100 ft (2.3 kPa/M) or less for discharge lines. A larger pipe size will reduce the frictional line loss. WARNING: 3.3.
Figure 3.2 Installation of Discharge Screen 3.4 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.
3.6 Motor Wiring 3.6.1 Single-Phase Motors When initially connecting to the power source, be certain that the motor voltage connections and available line voltage are the same. Connect electrical wires as shown on the motor wiring diagram located on the motor nameplate, electrical junction box, junction box cover, or wiring tag. Be sure your pump is electrically grounded at the junction box on the motor. 3.6.
D. Compare the results observed. The wire connection that yielded the highest pressure and flow rate is the proper connection. Interchange the two leads only if necessary (Figure 3.3, Changing Motor Rotation). 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 1. Measure the current through each of the three legs. 2.
Figure 3.
4.0 GENERAL TROUBLESHOOTING FOR ALL PUMPS 4.1 Troubleshooting Chart LOW FLOW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. MOTOR RUNS HOT OR STOPS Restrictions in inlet or discharge 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) 1.
4.2 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.
Figure 4.5 Removal of Pump Liquid-End from Figure 4.
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.
7. Examine the rubber 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 factory-supplied Mechanical Seal Replacement Kit (Section 10.3). Be sure to lubricate with grease before installing. 8. 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.
5.0 TONKAFLO PUMP FIELD MAINTENANCE 5.1 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 Lubrication Advice, or the motor information supplied with your pump. 5.2 Motor Removal: XB and XC Motor Adapter Pumps STEPS 1.
5.3 Motor Installation: XB and XC Motor Adapter Pumps STEPS 5.4 1. On a used motor, file the motor shaft smooth where the set screws were seated. 2. Coat the motor shaft with an anti-seize compound. 3. Slide the shaft coupler onto the motor shaft until fully seated, and tighten the two set screws. 4. Place the motor adapter onto the motor, such that the one drain hole is located down and the four side access ports are horizontal when the pump is reinstalled. 5.
5.5 6. Slide the liquid end assembly 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.
8. Install the retaining ring into the shaft groove with the sharp edges away from the motor. 9. 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. 10. Install the four (4) 5/16-inch lock washers and bolts to hold the liquid end onto the motor adapter and tighten. 11. Reinstall the pump (Section 3.0, Pump Installation).
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 mechanical seal a quick and easy process.
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.
8.0 DIMENSIONAL DRAWINGS 8.1 500X Motor Adapter Pumps Figure 8.
8.2 500 XB Motor Adapter Pumps Figure 8.
8.3 1000X and 1800X Motor Adapter Pumps Figure 8.
8.4 1800XB Motor Adapter Pumps Figure 8.
8.5 1800XC Motor Adapter Pumps Figure 8.
9.0 CUTAWAY DRAWINGS 9.1 X Motor Adapter Pump Figure 9.
9.2 XB and XC Motor Adapter Pump Figure 9.
10.0 STANDARD MODEL PARTS LIST 10.
Part Number Item Description Series 500X 1000X 1800X Series 500XB 1800XB Series 1800XC 17a Bolt, 5/16-18NC x 1 1113102 1113102 1113102 18 Lock washer, 5/16 1112256 1112256 1112256 19a Bolt, 3/8-16NC x 1.25 Long 1110984 N/A N/A 19b Bolt, 1/2-13NC x 1.25 Long N/A 1113973 1113973 20a Lock washer, 3/8 1110012 N/A N/A 20b Lock washer, 1/2 N/A 1113104 1113104 10.
10.3 Mechanical Seal Replacement Kit Part Number Series 500X 1000X 1800X Series 500XB 1800XB Series 1800XC Standard, 200 psig (13.8 barg) 1121174 1121174 1121174 High-Pressure, 300 psig (20.7 barg) 1120312 1120312 1120312 High-Pressure, 400 psig (27.8 barg) 1120477 1120477 1120477 N/A 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.
11.0 ORDERING PARTS Order parts through your local distributor or directly from: GE Infrastructure Water & Process Technologies 5951 Clearwater Drive Minnetonka, MN 55343-8995 USA Phone Fax: Toll Free (952) 933-2277 (952) 933-0141 (800) 848-1750 To order parts, the following information is necessary: 1. Pump model number 2. Pump serial number (from nameplate) 3. Other nameplate information such as operating temperature or material code, and type of mechanical seal 4.
12.0 WARRANTY TONKAFLO PUMP WARRANTY GE warrants its pumps to be free from defects in design, material, or workmanship for a period 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.
For more information call 952-933-2277 or 800-848-1750 in the U.S., or visit www.gewater.com. GE Infrastructure Water & Process Technologies North American Sales 5951 Clearwater Drive Minnetonka, MN 55343-8995 USA (952) 933-2277 Phone (952) 933-0141 Fax Euro/Africa Sales 230 rue Robert Schurman ZA des Uselles 77350 Le Mée sur Seine FRANCE +33 1 64 10 2000 Phone +33 1 64 10 3747 Fax © 2004, General Electric Company. All rights reserved. P/N 1125857 Rev.