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Page

4.0

GENERAL TROUBLESHOOTING FOR ALL PUMPS

4.1

Troubleshooting Chart

4.2

Mechanical Seal Leakage

4.3

Mechanical Seal Replacement: SS500, SS1000 and
SS1800 Series Pumps

4.4

High-Pressure Mechanical Seal Replacement: SS500, SS1000
and SS1800 Series

5.0

TONKAFLO PUMP FIELD MAINTENANCE

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

6.0

LIQUID END, TONKAFLO SERVICE POLICY

7.0

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

8.0

DIMENSIONAL DRAWINGS

8.1

500X Motor Adapter Pump

8.2

500XB Motor Adapter Pump

8.3

1000X and 1800X Motor Adapter Pump

8.4

1800XB Motor Adapter Pump

8.5

1800XC Motor Adapter Pump

9.0

CUTAWAY DRAWINGS

9.1

X Motor Adapter Pump

9.2

XB and XC Motor Adapter Pump

Содержание OSMONICS TONKAFLO SS1000 SERIES

Страница 1: ...MPS 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 Infrastructure Water Process Technologies ...

Страница 2: ......

Страница 3: ...dard Materials of Construction 3 2 5 Special Materials of Construction 3 2 6 Pump Nomenclature 4 2 7 Special Liquids 4 3 0 PUMP INSTALLATION 5 3 1 Inspection 5 3 2 Pump Mounting and Location 5 3 3 Inlet and Discharge Piping and Connections 5 3 3 1 Inlet Piping 5 3 3 2 Discharge Piping 6 3 3 3 Pump Piping Connections 7 3 3 4 Inlet Line Screen Filter 7 3 3 5 Discharge Screen Strainer 7 3 4 Pump Prim...

Страница 4: ... XB and XC Motor Adapter Pump 18 5 4 Motor Removal X Motor Adapter Pump 18 5 5 Motor Installation X Motor Adapter Pump 19 6 0 LIQUID END TONKAFLO SERVICE POLICY 21 7 0 TONKAFLO PUMP RETURNED GOODS AUTHORIZATION RGA PROCEDURE 22 7 1 Motor Warranty 22 7 2 In of Warranty Pump Failure 22 7 3 Out of Warranty Pump Failure 22 8 0 DIMENSIONAL DRAWINGS 23 8 1 500X Motor Adapter Pump 23 8 2 500XB Motor Adap...

Страница 5: ...ent Draw 11 4 5 Removal of Pump Liquid End from Motor Adapter 14 4 6 Removal of Mechanical Seal Holder from Motor Adapter 14 4 7 Removal of Mechanical Seal from Pump Shaft and Cavity of Mechanical Seal Holder 15 8 8 500X Motor Adapter Pump 23 8 9 500XB Motor Adapter Pump 24 8 10 1000X and 1800X Motor Adapter Pump 25 8 11 1800XB Motor Adapter Pump 26 8 12 1800XC Motor Adapter Pump 27 9 13 X Motor A...

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Страница 7: ... 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 operat...

Страница 8: ...s 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 2 1 Capacities Table 2 1 Capacities NOTE There must be adequate flow at all times through the pump to prevent excessive heat build up...

Страница 9: ...ction 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 e...

Страница 10: ...t the factory for compatibility 4 M o d e l S S 5 0 5 X SS Materials of Construction 5 Series 500 05 Number of Stages X Motor Adapter No Bearing Frame 56J Motor M o d e l S S 1 8 4 8 X B 5 0 SS Materials of Construction 18 Series 1800 48 Number of Stages XB Motor Adapter No Bearing Frame 182 184TC Motor 50 50 Hertz Operation ...

Страница 11: ... supported 3 3 Inlet and Discharge Piping and Connections 3 3 1 Inlet Piping THE INLET PIPING AND PUMP MUST BE FILLED WITH LIQUID i e PRIMED BEFORE START UP A pressure vacuum gauge 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...

Страница 12: ... 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 T...

Страница 13: ...s 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 filte...

Страница 14: ...E 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 3 5 Protection Against Running Dry It is suggested that controls to protect the pump from running dry be used These controls...

Страница 15: ...amage 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 interc...

Страница 16: ...hrough 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 Roll...

Страница 17: ...Figure 3 4 Rolling the Leads to Balance Current Draw 11 ...

Страница 18: ...P LEAKING 1 Mechanical seal needs replacing 2 O rings in pump casing damaged 3 Oil seals need replacing 4 Piping not sealed properly LOW FLOW 1 Restrictions in inlet or discharge 2 Foot valve operating improperly 3 Air leak in inlet piping 4 Air leak in mechanical seal 5 Wrong installation of belt drive 6 Suction lift too high 7 Reverse rotation of pump shaft 8 Pump not primed adequately 9 Inlet s...

Страница 19: ...oated light ly with petroleum grease Then reassemble the pump 4 3 Mechanical Seal Replacement SS500 SS1000 and SS1800 Series Pumps NOTE On Tonkaflo X frame pumps the mechanical seal must be replaced by removal of the complete liquid end assembly 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 pum...

Страница 20: ...Figure 4 5 Removal of Pump Liquid End from Figure 4 6 Removal of Mechanical Seal Holder from Motor Adapter 14 ...

Страница 21: ...der 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...

Страница 22: ...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 11 Be sure the retaining ring is properly seated in the groove on the pump shaft 12 Firmly grasp the liquid end and insert the splined pump shaft into the liquid end by carefully rotating the ...

Страница 23: ...ide 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 re...

Страница 24: ...ith the key aligned with the coupler key way 7 Install the four 4 5 16 18NC bolts and tighten 8 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 fully seated in the shaft coupler and then tighten the cone point set screw Figure 4 6 Removal of Mechanical Seal Holder from Motor Adapter 9 Reinstall the pump ...

Страница 25: ... 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 3 Loosen the pump shaft from the motor shaft apply thread sealant to the threads and tighten the shaft again unt...

Страница 26: ...d 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 20 ...

Страница 27: ...irs on the mechanical seal a quick and easy process If a 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 a local motor repair shop WARNING FIELD SERVICE OF THE LIQUID END WITH THE EXCEPTI...

Страница 28: ...epair and 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 factory for repair on an RGA within 15 days from RGA issue date GE ...

Страница 29: ...8 0 DIMENSIONAL DRAWINGS 8 1 500X Motor Adapter Pumps Figure 8 8 500X Motor Adapter Pump 23 ...

Страница 30: ...8 2 500 XB Motor Adapter Pumps Figure 8 9 500 XB Motor Adapter Pump 24 ...

Страница 31: ...8 3 1000X and 1800X Motor Adapter Pumps Figure 8 10 1000X and 1800X Motor Adapter Pump 25 ...

Страница 32: ...8 4 1800XB Motor Adapter Pumps Figure 8 11 1800XB Motor Adapter Pump 26 ...

Страница 33: ...8 5 1800XC Motor Adapter Pumps Figure 8 12 1800XC Motor Adapter Pump 27 ...

Страница 34: ...9 0 CUTAWAY DRAWINGS 9 1 X Motor Adapter Pump Figure 9 13 X Motor Adapter Pump 28 ...

Страница 35: ...9 2 XB and XC Motor Adapter Pump Figure 9 14 XB and XC Motor Adapter Pump 29 ...

Страница 36: ... Kit Mechanical Seal 400 psig barg Kit a Retaining Ring Discharge Bracket Clamp Discharge Series 500XB 1800XB Specify Model 1125921 1125795 1125137 1113769 1120062 1123244 1120500 Specify Model 1122719 1122786 1121174 1120312 1120477 1120054 1120075 1112951 Series 500X 1000X 1800X Specify Model 1123229 N A N A 1113769 1120062 N A N A Specify Model 1122719 1122786 1121174 1120312 1120477 1120054 11...

Страница 37: ...113102 1112256 1110984 N A 1110012 N A Series 1800XC 1113102 1112256 N A 1113973 N A 1113104 Part Number Description Installation Operation and Maintenance Manual Retaining Ring Pliers Loctite 242 Standard Strength 0 5 cc tube Loctite 271 High Strength 50 cc bottle Anti Seize Thread Compound Series 500XB 1800XB 1125857 1120108 N A N A 1120110 Series 500X 1000X 1800X 1125857 1120108 1120109 1113690...

Страница 38: ...c Adapters 1 25 x 1 F NPT 316SS Victaulic Adapters 1 25 x 0 75 F NPT 316SS Victaulic Coupling 1 25 1000 psig 69 barg Pump Discharge Screen 1 25 Series 500XB 1800XB 1121174 1120312 1120477 1113770 1113653 1120797 1120229 1110597 1120264 Series 500X 1000X 1800X 1121174 1120312 1120477 N A 1113653 1120797 1120229 1110597 1120264 Series 1800XC 1121174 1120312 1120477 1113770 1113653 1120797 N A 111059...

Страница 39: ... 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 3 Other nameplate information such as operating temperature 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...

Страница 40: ...oard 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 opera...

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Страница 42: ... Euro Africa Sales Asia Pacific Sales 5951 Clearwater Drive 230 rue Robert Schurman 1044 8 SOI 44 2 Minnetonka MN ZA des Uselles Sukhumvit Road Parkanog 55343 8995 77350 Le Mée 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 1 64 10 3747 Fax 66 2 39 18183 Fax GE Infrastructure Water Process Technologies ...

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