Sulzer J 205 Workshop Manual
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Sulzer J 205 Workshop Manual

Submersible drainage pump
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Submersible Drainage Pump J 205 - J 405 - J 604
Workshop Manual
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www.sulzer.com

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Summary of Contents for Sulzer J 205

  • Page 1 Submersible Drainage Pump J 205 - J 405 - J 604 Workshop Manual www.sulzer.com...

  • Page 2: Table Of Contents

    Clearance measure ..........................9 Change of impeller / Check of diffuser and wear ring ..............10 Change of mechanical seal unit on J 205, J 405 / Mechanical seal on J 604 ......11 Complete pump overhaul / Dismantling ..................12 Electrical supply leads ........................12 Discharge connection .........................12...
  • Page 3 J 205 three phase Direct Start D.O.L. 230/460V 60Hz with contactor (12-leads stator) ....24 10.3 J 205 three phase Direct Start D.O.L. 230/460V 60Hz with terminal block (12-leads stator) ...24 10.4 J 205/J 405 three phase Direct Start D.O.L. with terminal block (6-leads stator) ......25 10.5...

  • Page 4: General

    - For electrical information and wiring diagrams see section 10. Submersible drainage pumps J 205 - J 604 are built for long periods of trouble free operation. The pumps can “run on snore” without any risk for the mechanical seals. They get sufficient cooling from the pumped media and sufficient lubrication and cooling from the oil in the housing between the seals.

  • Page 5: Complete Pump Overhaul

    For complete overhaul follow the workshop manual and dismantle the pump completely, replace damaged and worn parts. Use only Sulzer spare parts. Spare part lists are available in the download section of the Sulzer website at www.sulzer.com. Cleaning of pump before service Before overhaul or maintenance is started the pump should be cleaned.

  • Page 6: Electrical Check

    Remove strain relief clamp prior to unscrewing Figure 2: Pump with contactor/terminal block/SoftDrive cable gland body. Pull out cable, cable seal and wash- (J 205) ers. (Figure 2-4) Figure 3: Pump with contactor/terminal block (J 405) Figure 4: Pump with terminal block (J 604)

  • Page 7: Insulation Test

    Insulation test Disconnect all stator leads from the contactor/terminal Megohmeter block. Check that the contact points are not burned. Measure insulation resistance between the different phase windings, between windings and earth and be- tween windings and thermal contacts circuit. The insulation resistance should be measured with 500V megohmeter (megger) and the reading should be at least 1 MΩ.

  • Page 8: Oil / Motor Check

    Measure the insulation between the leakage-lead and Earth. The value should be larger than 100 kΩ, if it is not the oil should be checked. J 205 - J 405: Unscrew outer and inner oil plug (Figure 7) J 604: Unscrew oil plug...

  • Page 9: Impeller Clearance Check

    Impeller clearance check Dismantling base plate and strainer Loosen the bottom nuts that secures the base plate and remove the base plate and the strainer. (Figure Hint! Use an extension socket M16 (J 405), M20 (J 604) to dismantle base plate. Figure 8: Dismantling base plate and strainer Clearance measure Check the impeller for damage and that the impeller...

  • Page 10: Change Of Impeller / Check Of Diffuser And Wear Ring

    (Figure 10) Note! J 205 - J 405: Never run the motor without having the impeller mounted. This can cause damage to o-rings in Figure 10: Change of impeller / Check of diffuser and seal unit.

  • Page 11: Change Of Mechanical Seal Unit On J 205, J 405 / Mechanical Seal On J 604

    Change of mechanical seal unit on J 205, J 405 / Mechanical seals J 604 Dismantling Clean the shaft end. J 205 - J 405: Unscrew the screws holding the me- chanical seal unit. Use the same screws in the alterna- tive holes on the seal unit to carefully pull the seal unit out from the shaft.

  • Page 12: Complete Pump Overhaul / Dismantling

    Make sure all inspection plugs are removed from the cooling jacket prior to dismantling cooling jacket. J 205: Lift the pump up in the handle into a vertical position with a lifting device and secure it. Put the pump standing on the outer longer stud bolts. Place a dis- tance piece under the diffuser stud bolts (preferably a wooden frame at a diameter of the diffuser stud bolts).

  • Page 13: Motor Housing

    It is advisable to mount the oil plugs back on the oil cas- ing to avoid unnecessary spill of oil. J 205: Mount a lifting chain/wire with two screws on the upper part of the motor housing and keep it in an up- right position secured by the lifting crane.

  • Page 14: Wear Plate On J 205 And J 405

    Wear plate on J 205 and J 405 (Figure 20) J 205: Lye the oil casing/wear plate down and take out the stud bolts holding the wear plate. Remove the wear plate and check the condition if it must be replaced.

  • Page 15: Mounting Of New Stator

    Mounting of new stator J 205, J 405: (Figure 22, 23) Block up the new sta- tor and make sure that the motor housing can be fully pushed down onto the stator. Protect the stator insula- tion from damages and fold stator cables together in...

  • Page 16: Mounting Of Terminal Plate/Upper Bearing Bracket

    The mo- tor cable are usually two groups of 3 cables (except on J 205 there are 2 groups of 6 power cables for 230/460V 60Hz). The thermal control is most com- mon 6 cables and the leakage sensor a single cable and they are all thinner.

  • Page 17: Complete Pump Overhaul Assembly

    Terminal blocks & contactor Figure 29: Mounting of wear plate (J 205, J 405) J 205: Can be equipped with contactor unit or terminal block or SoftDrive. J 405: Can be equipped with terminal block...

  • Page 18: Motor Housing & Rotor Unit With Oil Casing

    LP-gas. Angular contact ball bear- ings should be mounted only by pressing on the inner ring. Top bearings on J 205-J 604 are type sealed and pre- filled with high temperature grease for life time perfor- mance.

  • Page 19: Mechanical Seals On J 205-J 604 And Upper/Lower Oil Casing On J 604

    Keep seals in original packing until they are assembled. J 205 - J 405: Lift the pump in the handle with a crane and lye the pump down in a horizontal position. Mount the mechanical seal unit carefully with new and well Figure 34: Mounting of mechanical seal unit (J 205, J 405) greased o-rings and tighten it firmly with screws.

  • Page 20: Impeller, Diffuser & Wear Ring

    Adjust the clearance with shims between impeller and shaft / shaft sleeve if necessary. Mount the diffuser and tighten the nuts to J 205= 45 Nm, J 405=140 Nm, J 604=273 Nm. No adjust- Figure 37: Mounting of impeller, diffuser and wear ring ments or distance has to be considered when diffuser is mounted.

  • Page 21: Cooling Jacket J 205 And J 405

    J 405 and J 604. Mount the handle on J 205 and J 405 and two eye bolts on J 604 if not done earlier. Lift the pump back to an upright position.

  • Page 22: Cable Gland, Cover And Discharge Connection

    Tighten it until the rubber offers resistance, and Figure 42: Pump with contactor/terminal block/SoftDrive thereafter, one more full rotation. (J 205) DANGER! The earth cable must be longer than the power cables so it pulls away last if cable is pulled out by mistake.

  • Page 23: Electrical Information And Wiring Diagrams

    Electrical information and wiring diagrams 10.1 J 205/J 405 three phase Direct Start D.O.L. with contactor (6-leads stator) The stators are wound for different voltages/frequencies and can be Delta- or Star-connected. For example stator 400/690V 50Hz is Delta-connected for 400V duty. The contactor is activated by the same voltage as the supply voltage.

  • Page 24: J 205 Three Phase Direct Start D.o.l. 230/460V 60Hz With Contactor (12-Leads Stator)

    10.2 J 205 three phase Direct Start D.O.L. 230/460V 60Hz with contactor (12-leads stator) The stators are wound for dual voltage and can be changed from one voltage to the other by changing the par- allel connection (e.g. 230V) to serial connection (e.g. 460V) The contactor is activated by the same voltage as the supply voltage.

  • Page 25: J 205/J 405 Three Phase Direct Start D.o.l. With Terminal Block (6-Leads Stator)

    10.4 J 205/J 405 three phase Direct Start D.O.L. with terminal block (6-leads stator) The stators are wound for different voltages/frequencies and can be Delta- or Star-connected. For example stator 400/690V 50Hz is Delta-connected for 400V duty and 578/1000V is Star-connected for 1000V duty.

  • Page 26: J 205 Three Phase Direct Start D.o.l. With Soft Start

    Figure 55 Direct Start D.O.L. with soft start 10.7 J 205/J 405 three phase Direkt Start D.O.L. 1000V 50Hz with ground check diode The stators are wound for 1000V 50Hz duty Star-connected and for thermal protection and ground check control with diode.

  • Page 27: J 604 Three Phase Star Delta Start With Terminal Block (6-Leads Stator)

    10.8 J 604 three phase Star Delta Start with terminal block (6-leads stator) The stators are wound for different voltages/frequencies For example stator 400/690V 50Hz is Delta connected for 400V duty. The Star delta starting is obtained by using a separate starter. (Figure 57) Star/Delta starting U1 V1 F1 DI D2 F3...

  • Page 28: J 604 Three Phase Direct Start D.o.l. With Terminal Block (6-Leads Stator) And With Power Cable And Separate 7-Core Control Cable

    10.10 J 604 three phase Direct Start D.O.L. with terminal block (6-leads stator) and with power cable and separate 7-core control cable. The stators are wound for different voltages/frequencies and can be Delta- or Star-connected. For example sta- tor 400/690V 50Hz is Delta-connected for 400V duty and 578/1000V is Star-connected for 1000V duty. (Figure 60, 61) Direct on line starting Direct on line starting...

  • Page 29: Fuses

    230V 400V 500V 690V 1000V current Pump 230V 380V 460V 575V current factor factor J 205 J 205 J 405 66.5A 53.2A J 405 136A J 604 184A 106A J 604 226A 113A 10.13 Winding resistance Correct readings should be:...

  • Page 30: Sectional Drawing / Tools

    Sectional drawing / Tools J 205...
  • Page 31 J 405...
  • Page 32 J 604...
  • Page 33 00831644: Tool for lower bearing J 205 155,5 42,58 37,42 116,68 133,32 00831650: Tool for lower bearing J 405 43,02 20,59 203,52 SECTION A-A...
  • Page 34 00831645: Tool for lower bearing J 604 45,67 58,33 228,5 00831649: Tool for upper bearing J 205-405 64,01 25,11 87,84 78,58 25,54 30,57 111,5...
  • Page 35 00831648: Tool for upper bearing J 604 38,32 104,5 00831647: Tool for primary seal J 604 163,5 147,5 136,4 (133,38 ) (121,52 ) SECTION A-A 118,5 12,2 O 3,5...
  • Page 36 00831646: Tool for secondary seal J 604 SECTION A-A 162,5 62,6 00831847 : Tool for lifting stator...
  • Page 38 Sulzer Pump Solutions Ireland Ltd., Clonard Road, Wexford, Ireland Tel. +353 53 91 63 200, www.sulzer.com Copyright © Sulzer Ltd 2020...

This manual is also suitable for:

J 405J 604

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