GE SS500, SS1000, SS1800 User Manual

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

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

T

ABLE OF C

ONTENTS

Page

1.0 INTRODUCTION 1

2.0 TONKAFLO SPECIFICATIONS 2

2.1 Capacities 2

2.2 Maximum Developed Boost Pressure 3

2.3 Maximum Recommended Operating Temperature 3

2.4 Standard 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 Priming 8

3.5 Protection Against Running Dry 8

3.6 Motor Wiring 9

3.6.1 Single-Phase Motors 9

3.6.2 Three-Phase Motors 9

3.6.3 Three-Phase Power Imbalance 10

Page

4.0 GENERAL TROUBLESHOOTING FOR ALL PUMPS 12

4.1 Troubleshooting Chart 12

4.2 Mechanical Seal Leakage 13

4.3 Mechanical Seal Replacement: SS500, SS1000 and
SS1800 Series Pumps 13

4.4 High-Pressure Mechanical Seal Replacement: SS500, SS1000
and SS1800 Series 16

5.0 TONKAFLO PUMP FIELD MAINTENANCE 17

5.1 Motor Bearing Lubrication 17

5.2 Motor Removal: XB and XC Motor Adapter Pump 17

5.3 Motor Installation: 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 Adapter Pump 24

8.3 1000X and 1800X Motor Adapter Pump 25

8.4 1800XB Motor Adapter Pump 26

8.5 1800XC Motor Adapter Pump 27

9.0 CUTAWAY DRAWINGS 28

9.1 X Motor Adapter Pump 28

9.2 XB and XC Motor Adapter Pump 29

Page

10.0 STANDARD MODEL PARTS LIST 30

10.1 Spare Parts List 30

10.2 Accessories 31

10.3 Mechanical Seal Replacement Kit 32

11.0 ORDERING PARTS 33

12.0 TONKAFLO PUMP WARRANTY 34

LIST OF FIGURES

Figure Title

3.1 Inlet Piping 6

3.2 Installation of Discharge Screen 8

3.3 Changing Motor Rotation 10

3.4 Rolling the Leads to Balance Current 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 Adapter Pump 28

9.14 XB and XC Motor Adapter Pumps 29

LIST OF T

ABLES

T

able Title

2.1 Capacities 2

2.2 Maximum Developed Boost Pressure 3

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. This manual is intended for general mainte­nance 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: (952) 933 - 2277
Toll Free: (800) 848 - 1750
Fax: (952) 988 - 6060

This manual is not int

ended 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 pump­ing efficiency. Unlike many other pump manufacturers, Tonkaflo will produce pumps to fit
your particular applications should a standard model pump not suit your requirements.

NO

TE: This manual, along with all GE Infrastructure manuals, is available at

www.ge.water.com.

1

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 pres­sures greater than 200 psig (13.8 barg), optional high-pressure mechanical seals should be
used.

2.1 Capacities

Table 2.1

Capacities

NO

TE: There must be adequate flow at all times through the pump to prevent excessive

heat build-up.

2

SS

Series

500

1000

1800

2900 rpm

50 Hertz

Minimum - Maximum

1 - 6 gpm

(0.23 - 1.4 m3/h)

3.3 - 11 gpm

(0.75 - 2.5 m

3

/h)

4 - 17.5 gpm

(0.91 - 4.0 m

3

/h)

3500 rpm

60 Hertz

Minimum - Maximum

1.5 - 7 gpm

(0.34 - 1.6 m3/h)

4 - 13 gpm

(0.91 - 30. m

3

/h)

5 - 21 gpm

(1.14 - 4.8 m

3

/h)

Maximum
Efficiency

40%

49%

57%

2.2 Maximum Developed Boost Pressure

Table 2.2

Maximum Developed

Boost Pressure

2.3 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. For high
temperature applications, consult the factory for special materials of construction.

The maximum recommended temperature is stated on the pump case. The temper­ature stated is for the design flow and pressure.

2.4 S

tandard 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.

3

* Viton and Teflon are trademarks of E.I. DuPont de Nemours and Company, Inc.

SS

Series

500

1000

1800

60 Hertz

700 (48.3)

340 (23.4)

680 (46.9)

50 Hertz

630 (43.4)

300 (20.7)

570 (39.3)

60 Hertz

58

28

48

50 Hertz

76

N/A

56

Maximum Developed

Pressure

psig (barg)

Number of Centrifugal

Stages

2.6 Pump Nomenclature

Example:

2.7 Special

Liquids

For liquids other than water, aqueous solutions, or corrosive solutes, consult the
factory for compatibility.

4

Model SS505X

SS = Materials of Construction
5 = Series 500
05 = Number of Stages
X = Motor Adapter,

No Bearing Frame,
56J Motor

Model SS1848XB-50

SS = Materials of Construction
18 = Series 1800

48 = Number of Stages

XB = Motor Adapter,

No Bearing Frame,
182/184TC Motor

50 = 50 Hertz Operation

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. 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.

CA

UTION: 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 dis­charge piping should be sized to properly handle the maximum flow and pres­sure 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

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

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.

W

ARNING: 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 cou­plings 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 maxi­mum 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.

W

ARNING: 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 dam­age 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