GE OSMONICS TONKAFLO QS1800V Series, Installation, Operation And Maintenance Manual

Page 1: ... QSV SERIES INSTALLATION OPERATION AND MAINTENANCE MANUAL For QS1800V and QS2800V Series Tonkaflo Centrifugal Pumps with Quiet Stainless Steel Vertically Mounted Flow Cooled Motors GE Infrastructure Water Process Technologies ...

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Page 3: ...d Location 5 3 3 Operation Safeguards 6 3 4 Inlet and Discharge 6 3 4 1 Inlet Piping 6 3 4 2 Discharge Piping 7 3 4 3 Piping Connections 7 3 4 4 Inlet Line Screen Filter 7 3 4 5 Discharge Screen Strainer 8 3 5 Pump Priming 9 3 6 Motor Wiring 10 3 6 1 Single Phase Motors 10 3 6 2 Three Phase Motors 11 3 6 3 Three Phase Power Imbalance 12 3 6 4 Wire Sizing 12 3 7 Electrical Grounding 13 3 8 Motor Pr...

Page 4: ...N RGA PROCEDURE 23 7 1 Motor Warranty 23 7 2 In Warranty Pump Failures 23 7 3 Out of Warranty Pump Failures 23 7 4 Shipping Charges 23 7 4 1 In Warranty 23 7 4 2 Out of Warranty 23 8 0 DIMENSIONAL DRAWING 24 9 0 REPLACEMENT PARTS 25 9 1 Parts Schematic 25 9 2 Parts List Standard Models 26 9 3 Accessories and QS Series Tonkaflo Pumps 26 9 4 Ordering Parts 27 10 0 WARRANTY 28 ...

Page 5: ...wer to the Single Phase Controller 10 3 6 Changing Motor Rotation 11 3 7 Rolling the Leads to Balance Current Draw 12 6 8 Liquid End and Motor Module 20 6 9 Removing Liquid End 21 6 10 Liquid End Removed 21 6 11 Component Detail 22 6 12 Rejoining Liquid End to Motor Module 22 8 13 QS1800V and QS2800V Series 24 9 14 Parts Schematic 25 LIST OF TABLES Table Description 2 1 Pump Performance Summary 3 ...

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Page 7: ...r 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 Tonkaflo liquid ends Your new Tonkaflo multi stage centrifugal pump is designed for quiet efficient vertical oper ation in environments where noise from a fan cooled motor is acceptable A modular design permits the liquid end to be separated fr...

Page 8: ...junction box on the top side of the liquid end shell The motor label showing horsepower voltage Hz rated amp draw service factor and service factor amps S F A is located immediate ly upstream from the junction box on the top side of the motor module Figure 2 1 Pump Label and Motor Label shows these locations Figure 2 1 Pump and Motor Labels 2 Pump Label Liquid End Junction Box Motor Label Motor Mo...

Page 9: ...other pump in series ahead of the QSV pump Care must be taken however so that the inlet pressure to any QSV pump does not exceed the 100 psig 6 9 barg maximum inlet pressure rating There must be adequate flow through the pump at all times to prevent exces sive heat build up 3 Series QS1800V QS2800V Max Efficiency 56 64 Max Efficiency 57 51 Capacity gpm m3 h 5 21 0 25 1 1 10 40 2 3 9 1 Maximum Boos...

Page 10: ...e plated cast iron or Noryl plastic covered carbon steel stator ends bronze filter check valve nitrile and neoprene rubber seals Wire Insulation Neoprene chloroprene hypalon and or poly olefin epoxy potted Antifreeze 20 Propylene glycol non toxic 80 Water WARNING 90 F 32 C MAXIMUM OPERATING TEMPERATURE Special Liquids Tonkaflo pumps can handle a variety of liquids For liquids other than water aque...

Page 11: ... The QSV Series pumps are intended for vertical mounting with the right angle inlet of the pump down See Figure 2 for correct orientation The weight of the pump and motor must be supported by setting the flat end of the outer housing on a rubber pad supported by a plate or angle Attach the pump to the frame work of your system using ALL brackets included Refer to Section 8 0 Dimensional Drawing fo...

Page 12: ...ion Dry running Fluid temperature greater than 90 F 32 C Low voltage Imbalanced three phase power Safeguards include low pressure switches low flow shutdown switches tempera ture limit switches quick trip circuit breakers and properly sized motor starter heaters The three phase electrical power must exhibit amperage readings in each leg within 5 of the average for all three legs Section 3 6 3 Thre...

Page 13: ...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 maintai...

Page 14: ... in the dis charge piping will protect your process fluid should the pump be damaged The installation of the screen is shown in Figure 3 3 Discharge Screen Installation Figure 3 3 Discharge Screen Installation 8 Pump Victaulic Clamp Victaulic Gasket Discharge Screen Cup Must Point Towards Pump ...

Page 15: ...E AND PUMP LIQUID END MUST BE COMPLETELY FILLED WITH LIQUID PRIMED BEFORE START UP Figure 3 4 Priming Pump Level Figure 3 4 Priming Water Level WARNING THE PUMP MUST BE SHUT OFF IMMEDIATELY IF PRIME IS LOST TO AVOID POSSIBLE DAMAGE TO THE INTERNAL PARTS OF THE MOTOR AND LIQUID END 9 Discharge Inlet Water Level ...

Page 16: ... mounted in direct sunlight or high temperature locations as this will cause shortened capacitor life and unnecessary tripping of the overload protector The controller enclosure is designed for vertical upright mounting only Mounting in other positions will affect its operation The controller must be electrically wired to the motor using minimum 8 AWG for 5 horsepower motors and 10 AWG for 3 horse...

Page 17: ...motor will run in the proper direction To make sure the motor running in the proper direction carefully follow the next procedure Figure 3 6 Changing Motor Rotation 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 Figure 3 6 Changing Motor Rotation C Start the pump again and re check the flow rate and pr...

Page 18: ...e 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 re test Figure 3 7 Rolling the Leads to Balance Current Draw If rolling the leads does not correct the problem the source of the imbalance must be located and corrected For more information on current imbal ance refer to the motor operation manual F...

Page 19: ...ound following local electrical codes Grounding lugs are provided within the junction box for this purpose Check the continuity of your ground connection to the motor module using a volt ohm meter The motor module flange may also be directly connected to an earth ground 3 8 Motor Protection IMPORTANT Warranty on the flow cooled motor is void unless proper quick trip ambient compen sated protection...

Page 20: ...UTION Do not run pump dry or without sufficient heads The pump shall not be operated with an inlet pressure less than 20 psi 1 4 bar Do not deadhead pump The pump shall not be operated below the minimum or above the maximum capacity specified for your particular model Table 2 1 Pump Performance Summary Do not exceed 90 F 32 C operating fluid temperature The pump may be flushed with sanitizing wate...

Page 21: ...t should be piped to induce minimal pres sure drops through piping diameter changes elbows instrumentation etc QSV pumps should NEVER be throttled at the inlet Check discharge screen for obstructions Verify no debris is clogging screen or filter Make sure the discharge valve is open enough to keep the pump running on the per formance curve Fluid motion in your inlet pip ing may draw air into the p...

Page 22: ... by the pump per formance summary table or the performance curve included with the pump Verify no debris is clogging the inlet screen or filter Fluid motion in your inlet pip ing may draw air into the pump if the piping is not sealed properly Air bubbles will be visible in the discharge line Make sure the motor is spin ning in the proper direction Reverse two of the leads if necessary POSSIBLE CAU...

Page 23: ...t off circuitry to make sure the necessary circuit by passes are in place to start the motor Check single phase motor controller and verify that it is in working order See detailed label inside controller box Check the amp draw through each leg leading to the motor using an ammeter The read ings should not exceed the maximum amps S F A indi cated on the motor label POSSIBLE CAUSES Blown fuse tripp...

Page 24: ...e low voltage test indicates an open circuit Consult the motor installation and main tenance manual for accept able values With the circuit de energized check for continuity using an ohmmeter Confirm the circuit is wired for single phase or three phase power and the motor is grounded Make sure the three legs of your three phase power are balanced within 5 of each other POSSIBLE CAUSES Motor starte...

Page 25: ...w range specified by the performance summary table or the pump perform ance curve Seal threaded fittings with Teflon tape Make sure gas kets are properly seated in Victaulic or flanged fittings Replace the O ring if possible or return the pump to the factory for repair POSSIBLE CAUSES Improper mounting Starved suction line Operating off the performance curve Piping not properly sealed O rings in p...

Page 26: ...ion 6 2 Liquid End Removal and Installation for liquid end removal If a repair at the factory is desired call the factory for a Return Goods Authorization RGA number and follow the directions provided by a GE Customer Service represen tative See Section 7 0 Return Goods Authorization RGA Procedure for more details 6 2 Liquid End Removal and Installation WARNING DISCONNECT POWER SOURCE BEFORE ATTEM...

Page 27: ...use the following pro cedure Figures 6 9 and 6 10 detail the components and assembly STEPS 1 Lubricate the O ring with petroleum or silicone grease 2 Align the splines on the liquid end coupling to the splines on the motor and join together using the four cap screws and lock washers Do not over tighten 21 Figure 6 9 Removing Liquid End QS2825V Shown Figure 6 10 Liquid End Removal QS2825V Shown Pul...

Page 28: ... Figure 6 11 Component Detail QS2825V Shown Figure 6 12 Rejoining Liquid End to Motor Module QS2528V Shown Liquid End Coupling O Ring Motor Shaft Align Splines and Pull Together Replace Washers and Bolts ...

Page 29: ...ump to the factory for repair and return 7 1 Motor Warranty Motors must be sent to the nearest authorized motor service center for repair replacement and warranty disposition 7 2 In Warranty Pump Failure 7 2 1 Return the defective pump to the factory for repair on an RGA within fifteen 15 days GE absorbs the cost of repair The repaired pump will be returned and remains under warranty for the remai...

Page 30: ...24 8 0 DIMENSIONAL DRAWING Figure 8 13 QS1800V and QS2800V Series ...

Page 31: ...9 0 REPLACEMENT PARTS 9 1 Parts Schematic Figure 9 14 Parts Schematic 25 ...

Page 32: ...61 1125199 1149629 1123200 1149629 1156215 1125267 1112276 1111878 1125312 1158439 1125268 1125313 Item Number QS1800V QS2800V Part Number Part Description Part Number 1110597 1113653 1120797 1120229 1120264 1123394 Part Description Victaulic Coupling 1 25 inch 31 8 mm Style 77 Buna N Adapter 1 25 inch 318 mm Victaulic x 1 25 inch 31 8 mm FNPT 316SS Adapter 1 25 inch 318 mm Victaulic x 1 0 inch 25...

Page 33: ... 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...

Page 34: ... of parts or equipment which upon return to GE and upon GE s examination prove to be defective Equipment and accessories not manufactured by GE are warranted 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 temperatures vibration fail ure to properly prime or to operate equipment without...

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