OSMONICS
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 Infrastructure
Water & Process Technologies
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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
2.0
INTRODUCTION
TONKAFLO SPECIFICATIONS
1
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Capacities
2
3
3
3
3
4
4
Maximum Developed Boost Pressure
Maximum Recommended Operating Temperature
Standard Materials of Construction
Special Materials of Construction
Pump Nomenclature
Special Liquids
3.0
PUMP INSTALLATION
5
3.1
3.2
3.3
Inspection
5
5
5
Pump Mounting and Location
Inlet and Discharge Piping and Connections
3.3.1 Inlet Piping
5
3.3.2 Discharge Piping
6
3.3.3 Pump Piping Connections
3.3.4 Inlet Line Screen/Filter
3.3.5 Discharge Screen (Strainer)
Pump Priming
Protection Against Running Dry
Motor Wiring
7
7
7
8
8
9
3.4
3.5
3.6
3.6.1 Single-Phase Motors
3.6.2 Three-Phase Motors
3.6.3 Three-Phase Power Imbalance
9
9
10
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Page
12
4.0
GENERAL TROUBLESHOOTING FOR ALL PUMPS
4.1
4.2
4.3
Troubleshooting Chart
Mechanical Seal Leakage
Mechanical Seal Replacement: SS500, SS1000 and
SS1800 Series Pumps
High-Pressure Mechanical Seal Replacement: SS500, SS1000
and SS1800 Series
12
13
13
16
17
4.4
5.0
TONKAFLO PUMP FIELD MAINTENANCE
5.1
5.2
5.3
5.4
5.5
Motor Bearing Lubrication
17
17
18
18
19
Motor Removal: XB and XC Motor Adapter Pump
Motor Installation: XB and XC Motor Adapter Pump
Motor Removal: X Motor Adapter Pump
Motor Installation: X Motor Adapter Pump
6.0
7.0
LIQUID END, TONKAFLO SERVICE POLICY
21
22
TONKAFLO PUMP RETURNED GOODS AUTHORIZATION
(RGA) PROCEDURE
7.1
7.2
7.3
Motor Warranty
In-of-Warranty Pump Failure
Out-of-Warranty Pump Failure
22
22
22
8.0
9.0
DIMENSIONAL DRAWINGS
23
8.1
8.2
8.3
8.4
8.5
500X Motor Adapter Pump
500XB Motor Adapter Pump
1000X and 1800X Motor Adapter Pump
1800XB Motor Adapter Pump
1800XC Motor Adapter Pump
23
24
25
26
27
CUTAWAY DRAWINGS
28
9.1
9.2
X Motor Adapter Pump
XB and XC Motor Adapter Pump
28
29
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Page
30
10.0 STANDARD MODEL PARTS LIST
10.1 Spare Parts List
10.2 Accessories
10.3 Mechanical Seal Replacement Kit
30
31
32
11.0 ORDERING PARTS
33
34
12.0 TONKAFLO PUMP WARRANTY
LIST OF FIGURES
Figure
Title
3.1
3.2
3.3
3.4
4.5
4.6
Inlet Piping
Installation of Discharge Screen
Changing Motor Rotation
Rolling the Leads to Balance Current Draw
Removal of Pump Liquid-End from Motor Adapter
Removal of Mechanical Seal Holder from
Motor Adapter
6
8
10
11
14
14
4.7
Removal of Mechanical Seal from Pump Shaft
and Cavity of Mechanical Seal Holder
500X Motor Adapter Pump
15
23
24
25
26
27
28
29
8.8
8.9
500XB Motor Adapter Pump
1000X and 1800X Motor Adapter Pump
1800XB Motor Adapter Pump
1800XC Motor Adapter Pump
X Motor Adapter Pump
8.10
8.11
8.12
9.13
9.14
XB and XC Motor Adapter Pumps
LIST OF TABLES
Table
Title
2.1
2.2
Capacities
Maximum Developed Boost Pressure
2
3
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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 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 & Process Technologies
5951 Clearwater Drive
Minnetonka, MN 55343-8995 USA
Phone:
Toll Free: (800) 848 - 1750
Fax: (952) 988 - 6060
(952) 933 - 2277
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 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
1
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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. 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.
2.1
Capacities
Table 2.1
Capacities
2900 rpm
50 Hertz
Minimum - Maximum
3500 rpm
60 Hertz
Minimum - Maximum
SS
Series
Maximum
Efficiency
500
40%
49%
57%
1 - 6 gpm
1.5 - 7 gpm
(0.23 - 1.4 m3/h)
(0.34 - 1.6 m3/h)
1000
1800
3.3 - 11 gpm
4 - 13 gpm
(0.75 - 2.5 m3/h)
(0.91 - 30. m3/h)
4 - 17.5 gpm
5 - 21 gpm
(0.91 - 4.0 m3/h)
(1.14 - 4.8 m3/h)
NOTE: There must be adequate flow at all times through the pump to prevent excessive
heat build-up.
2
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2.2
Maximum Developed Boost Pressure
Table 2.2
Maximum Developed
Boost Pressure
Maximum Developed
Pressure
Number of Centrifugal
Stages
psig (barg)
SS
Series
50 Hertz
76
60 Hertz
50 Hertz
630 (43.4)
300 (20.7)
570 (39.3)
60 Hertz
700 (48.3)
340 (23.4)
680 (46.9)
58
28
48
500
1000
1800
N/A
56
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.
2.4
2.5
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.
Special Materials of Construction
Optional ethylene propylene (EPDM), Viton*, and Teflon* elastomers are available.
Contact the factory.
*
Viton and Teflon are trademarks of E.I. DuPont de Nemours and Company, Inc.
3
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2.6
Pump Nomenclature
Example:
M o d e l S S 1 8 4 8 X B - 5 0
M o d e l S S 5 0 5 X
SS
18
48
XB
=
=
=
=
Materials of Construction
Series 1800
Number of Stages
Motor Adapter,
No Bearing Frame,
182/184TC Motor
50 Hertz Operation
SS
5
05
X
=
=
=
=
Materials of Construction
Series 500
Number of Stages
Motor Adapter,
No Bearing Frame,
56J Motor
50
=
2.7
Special Liquids
For liquids other than water, aqueous solutions, or corrosive solutes, consult the
factory for compatibility.
4
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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 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.
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 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.
5
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IMPORTANT:
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 piping.
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.
Figure 3.1
Inlet Piping
3.3.2 Discharge Piping
The discharge piping should be sized to properly handle the maximum flow
and pressure developed by the pump.
6
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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:
THE PUMP MUST NOT RUN WITH A CLOSED DISCHARGE OR
IRREVERSIBLE DAMAGE TO THE WETTED INTERNAL PARTS
OF THE PUMP WILL RESULT!
3.3.3 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.
3.3.4 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.
3.3.5 Discharge Screen (Strainer)
A 30-mesh screen (available as an accessory for 500, 1000 and 1800 Series
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).
7
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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:
WARNING:
THE PUMP MUST BE SHUTOFF IMMEDIATELY IF PRIME IS LOST TO
AVOID POSSIBLE DAMAGE TO THE INTERNALS OF THE LIQUID END.
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 include: pressure switches, flow switches, and temperature switches.
8
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3.6
Motor Wiring
3.6.1 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 is electrically grounded at the junction box on the motor.
3.6.2 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:
The 500X, 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.
2.
Prime pump before applying power to avoid damage to the pump.
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.
C.
Stop the pump and interchange any of the two leads.
Start the pump again and recheck the flow rate and pressure.
9
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D.
Compare the results observed. The wire connection that yield-
ed 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.
2.
3.
Measure the current through each of the three legs.
Average the three current measurements together.
Determine the difference between the current in each leg and the
average of all three legs.
4.
5.
Take the difference with the largest value, and divide it by the average
current. Multiply by 100 to obtain the current imbalance percentage.
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
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Figure 3.4
“Rolling” the Leads
to Balance Current
Draw
11
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4.0
GENERAL TROUBLESHOOTING FOR ALL PUMPS
4.1
Troubleshooting Chart
LOW FLOW
MOTOR RUNS HOT OR STOPS
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 strainer/filter plugged.
10. Pump throttling valve on discharge
closed (pump deadheaded)
1. Motor surface temperature up to
104°F (40°C) over ambient can
occur. The motor will feel hot to the
touch.
2. Bad connection
3. Motor exceeded rated amp draw
4. Excessive ambient temperature
5. Heater size to small in motor heater
6. Binding rotation in the pump shaft
7. Bearings not adequately lubricated
8. Specific gravity or viscosity of liquid
higher than design conditions
9. Motor wired improperly
MOTOR DOES NOT RUN
LOW PRESSURE
1. Blown fuse or tripped circuit breaker or
overload heater
1. Pump not adequately primed
2. Air leak in inlet piping
2. Motor to hot - allow to cool
3. Motor voltage connection and line
voltage different
4. Bad connection
5. Motor wired improperly
6. Wrong ratio for belt drive
3. Excessive flow
4. Clogged suction line filter or screen
5. Reverse rotation of pump shaft
6. Foot valve operating improperly
7. Wrong ratio for belt drive
PUMP VIBRATION
PUMP LEAKING
1. Misalignment of flexible coupling
2. Bent pump shaft
3. Improper mounting
4. Starved suction
1. Mechanical seal needs replacing
2. O-rings in pump casing damaged
3. Oil seals need replacing
4. Piping not sealed properly
5. Worn bearings
6. Motor out of balance
7. Operating beyond specified capacity
range of the pump
12
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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. 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.
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 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
1.
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 5160-62H) 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
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Figure 4.5
Removal of Pump
Liquid-End from
Figure 4.6
Removal of Mechanical
Seal Holder from
Motor Adapter
14
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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.
6.
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).
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
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7.
8.
9.
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 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.
10.
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.
11.
12.
Be sure the retaining ring is properly seated in the groove on the pump shaft.
Firmly grasp 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.
13.
Install the four (4) 5/16-inch bolts and lock washers and tighten.
4.4
High-Pressure Mechanical Seal Replacement: SS500, SS1000 and SS1800 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
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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.
2.
3.
4.
5.
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 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.
7.
8.
Remove the four (4) 5/16-18NC bolts that hold the pump liquid end to the
motor adapter.
Slide the liquid end assembly away from the motor adapter 1/4- to 1/2-inch
(6 - 13 mm).
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
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5.3
Motor Installation: XB and XC Motor Adapter Pumps
STEPS
1.
On a used motor, file the motor shaft smooth where the set screws were
seated.
2.
3.
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.
4.
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.
5.
6.
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.
7.
8.
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 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 and pump piping connections.
Reinstall the motor wiring.
10.
11.
For pump start-up see Section 3.0 (Pump Installation).
5.4
Motor Removal: X Motor Adapter Pumps
STEPS
1.
2.
3.
4.
5.
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
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6.
7.
Slide the liquid end assembly off of the pump shaft, taking care not to bend
the pump shaft.
Remove the retaining ring and remove. The rotary head of the mechanical
seal.
8.
9.
Remove the seal holder along with the stationary seal seat.
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.
The motor can now be serviced by a qualified service center, or replaced.
5.5
Motor Installation: X Motor Adapter Pumps
STEPS
1.
2.
To re-use a repaired motor, clean the threads on the shaft of any thread-
sealant residue.
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 until fully seated. Use standard strength
thread sealant on single-phase motors, and a high-strength thread sealant on
three-phase motors.
4.
5.
6.
7.
Install the motor adapter onto the motor and install and tighten the four bolts
into the motor.
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.
Install a new mechanical seal stationary seat, using Vaseline, grease, or water
as a lubricant on the rubber portion.
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
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8.
9.
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.
10.
11.
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
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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. 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 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
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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 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 absorbs the cost of repair. The repaired 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
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8.0
DIMENSIONAL DRAWINGS
8.1 500X Motor Adapter Pumps
Figure 8.8
500X Motor
Adapter Pump
23
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8.2
500 XB Motor Adapter Pumps
Figure 8.9
500 XB Motor
Adapter Pump
24
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8.3
1000X and 1800X Motor Adapter Pumps
Figure 8.10
1000X and 1800X
Motor Adapter Pump
25
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8.4
1800XB Motor Adapter Pumps
Figure 8.11
1800XB Motor
Adapter Pump
26
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8.5
1800XC Motor Adapter Pumps
Figure 8.12
1800XC Motor
Adapter Pump
27
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9.0
CUTAWAY DRAWINGS
9.1 X Motor Adapter Pump
Figure 9.13
X Motor Adapter
Pump
28
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9.2
XB and XC Motor Adapter Pump
Figure 9.14
XB and XC
Motor Adapter
Pump
29
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10.0
STANDARD MODEL PARTS LIST
10.1
Spare Parts List
Part Number
Series
500X
1000X
1800X
Series
500XB
1800XB
Series
1800XC
Item
Description
Specify
Model
Specify
Model
Specify
Model
1
Liquid End Assembly
1123229
N/A
1125921
1125795
1125137
1113769
1120062
1123244
1120500
1125921
1125758
1125137
1113769
1120062
1123244
1120500
2
4
Motor Adapter
Shaft Coupler
N/A
5
Set Screw, Shaft Coupler
Set Screw, Cone-Point
Pump Shaft Key, 3/16 x 3/16 x 1-inch
Pump Shaft Extension & Sleeve
Spiral Pin
1113769
1120062
N/A
6
7
8
N/A
9
Specify
Model
Specify
Model
Specify
Model
10
Pump Shaft
1122719
1122786
1121174
1120312
1120477
1120054
1120659
1112951
1122719
1122786
1121174
1120312
1120477
1120054
1120075
1112951
1122719
1122786
1121174
1120312
1120477
1120054
1125914
1112951
11
12
Seal Holder, SS
O-ring, Buna-N
13a
13b
13c
14
Mechanical Seal, Standard Kit
Mechanical Seal, 300 psig (barg), Kit
Mechanical Seal, 400 psig (barg), Kit
(a) Retaining Ring
15
Discharge Bracket
16
Clamp, Discharge
30
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Part Number
Series
500X
1000X
1800X
Series
500XB
1800XB
Series
1800XC
Item
Description
17a
18
Bolt, 5/16-18NC x 1
1113102
1112256
1110984
N/A
1113102
1112256
N/A
1113102
1112256
N/A
Lock washer, 5/16
19a
19b
20a
20b
Bolt, 3/8-16NC x 1.25 Long
Bolt, 1/2-13NC x 1.25 Long
Lock washer, 3/8
1113973
N/A
1113973
N/A
1110012
N/A
Lock washer, 1/2
1113104
1113104
10.2
Accessories
Part Number
Series
500X
1000X
1800X
Series
500XB
1800XB
Series
1800XC
Description
1125857
1125857
1125857
Installation, Operation, and Maintenance
Manual
1120108
1120109
1113690
1120110
1120108
N/A
1120108
N/A
Retaining Ring Pliers
Loctite 242 Standard Strength, 0.5 cc tube
Loctite 271 High Strength, 50 cc bottle
Anti-Seize, Thread Compound
N/A
N/A
1120110
1120110
31
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10.3
Mechanical Seal Replacement Kit
Part Number
Series
500X
1000X
1800X
Series
500XB
1800XB
Series
1800XC
Description
1121174
1120312
1120477
N/A
1121174
1120312
1120477
1113770
1113653
1120797
1120229
1110597
1120264
1121174
1120312
1120477
1113770
1113653
1120797
N/A
Standard, 200 psig (13.8 barg)
High-Pressure, 300 psig (20.7 barg)
High-Pressure, 400 psig (27.8 barg)
Allen Wrench, 3/16-inch
1113653
1120797
1120229
1110597
1120264
Victaulic Adapters, 1.25 x 1.25, M-NPT, 316SS
Victaulic 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
1110597
1120264
32
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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.
2.
3.
Pump model number
Pump serial number (from nameplate)
Other nameplate information such as operating temperature or material code, and
type of mechanical seal
4.
5.
6.
7.
8.
Motor horsepower, motor frame size and enclosure specifications
Part name
Part number
Quantity desired
Special materials of construction, if any.
33
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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 fitness 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
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GE Infrastructure
Water & Process Technologies
North American Sales
5951 Clearwater Drive
Minnetonka, MN
55343-8995
Euro/Africa Sales
230 rue Robert Schurman
ZA des Uselles
77350 Le Mée sur Seine
FRANCE
Asia/Pacific Sales
1044/8 SOI 44/2
Sukhumvit Road Parkanog
Bangkok 10110
USA
THAILAND
(952) 933-2277 Phone
(952) 933-0141 Fax
+33 1 64 10 2000 Phone
+33 1 64 10 3747 Fax
+ 66 2 38 14213 Phone
+ 66 2 39 18183 Fax
© 2004, General Electric Company. All rights reserved.
P/N 1125857 Rev. B
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