Sulzer XJ 25 Workshop Manual
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Sulzer XJ 25 Workshop Manual

Abs submersible drainage pump
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ABS submersible drainage pump XJ 25 - XJ 80, XJC 50 - XJC 80
ABS submersible sludge pump XJS 25 - XJS 80
EN
Workshop Manual
www.sulzer.com

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Summary of Contents for Sulzer XJ 25

  • Page 1 ABS submersible drainage pump XJ 25 - XJ 80, XJC 50 - XJC 80 ABS submersible sludge pump XJS 25 - XJS 80 Workshop Manual www.sulzer.com...
  • Page 2 Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 ABS submersible drainage pump XJ and XJC XJ 25 ND (50/60 Hz) XJ 25 HD (50/60 Hz) XJ 40 ND (50/60 Hz) XJ 40 HD (50/60 Hz)

  • Page 3: Table Of Contents

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Contents General ..............................5 Service intervals ..........................5 AquaTronic version ..........................5 Repair kits and o-ring kits ........................5 Tools ..............................5 Complete pump overhaul ........................5 Cleaning of pump before service ....................... 5 Recycling in case of scrapping the pumps ..................
  • Page 4 Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Complete pump overhaul / assembly ................... 22 General ............................22 Assembly of ball bearings ........................ 22 Assembly of stator ..........................22 Secondary seal ..........................23 Primary seal and upper diffuser ....................... 23 Impeller ............................23...

  • Page 5: General

    - For electrical information and wiring diagrams see chapter 10. ABS submersible drainage pumps XJ 25-80, XJC 50-80 and ABS submersible sludge pumps XJS 25-80 are built for long periods of trouble free operation. The pumps can “run on snore” without any risk for the mechanical seals. They get suf- ficient cooling from the pumped media and sufficient lubrication and cooling from the oil in the housing between the seals.

  • Page 6: Recycling In Case Of Scrapping The Pumps

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Recycling in case of scrapping the pumps Recycling of individual pump parts is beneficial to the environment. The pump can be fully dismantled for recycling. Alu- minium, stainless steel, ductile iron and high chrome cast iron can be recycled when a pump is scrapped.

  • Page 7: Service Inspection

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Service inspection Service Data Kit Contact Sulzer. Pump start and cable check Check the cable for damage and that there is no water or corrosion in the connecting plug.

  • Page 8: Insulation Test

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Insulation test Disconnect stator leads. Check that the contact points are not burned. Measure insulation resistance between the different phase windings, between windings and earth and between windings and thermal sensor circuit.

  • Page 9: Thermal Sensors

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Thermal sensors The circuit thermal sensors with the two built-in NTC thermistors, used when pumps are equipped with AquaTronic, should be checked for continuity, using an ohmmeter. At 25ºC = 47 kOhm. The circuit, used when pumps are equipped with DS contactor, with the two termo contacts (TC1+TC2) should be checked for continuity, using an ohmmeter or buzzer.

  • Page 10: Oil / Motor Check

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Oil / Motor check AquaTronic version See separate manual for Service Diagnostic Program. Standard version and AquaTronic version Unscrew the two oil plugs and drain off the oil in a clean can and inspect it. Oil should be clear and without impurity.

  • Page 11: Hydraulic Check

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Hydraulic check If the test run against shut of head shows that the pump is not close to expected head a hydraulic check is needed. Wear ring ND, HD 4.1.1...

  • Page 12: Diffuser Nd, Hd, Ld

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Diffuser ND, HD, LD 4.2.1 Dismantling of diffuser Remove the screws which hold the upper diffuser and bear- Check the diffuser for scratches. The rubber should have a ing house together.

  • Page 13: Impeller Nd, Hd, Ld

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Impeller ND, HD, LD 4.3.1 Dismantling of impeller Hold the impeller with a large screwdriver or similar, be- Pry the impeller loose with two screwdrivers under the im- tween the vanes and unscrew the impeller washer.

  • Page 14: Xj 80 Sd, Change Of Diffusers, Impellers And Guide Vane Plate

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 XJ 80 SD, change of diffusers, impellers and guide vane plate Dismantling Turn the pump upside down Loosen the bottom nuts and Loosen the dual nuts and washers that hold the lower dif- remove the base plate and the rubber sleeves.

  • Page 15: Assembly

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Remove the distance sleeve between the impellers and Pull out the upper diffuser. Turn the impeller so the three pull out the guide vane plate. Note the number of 0.5 shims...
  • Page 16 Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Mount the lower diffuser on the stud bolts and screw two Grease and mount o-ring on the oil casing. Put the strainer screws onto each stud bolt. Check that the distances are in place and then the rubber sleeves and the base plate.

  • Page 17: Primary Seal And Upper Diffuser

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Primary seal and upper diffuser Dismantling of primary seal and upper diffuser Remove the circlip and pull out the rotating part of the pri- Withdraw the upper diffuser by using two screwdrivers.
  • Page 18 Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Place the rubber foam in the bearing house. Grease and Grease and mount a new primary seal o-ring on the shaft. mount o-ring on the bearing house, and mount upper dif- Oil the sealing surfaces of the mechanical seal and push fuser with screws.

  • Page 19: Complete Pump Overhaul / Dismantling

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Complete pump overhaul / dismantling Perform all dismantling operation in chapter 2 then continue with:. Electronics 7.1.2 Standard version 7.1.1 AquaTronic version Turn the pump and remove AquaTronic Turn the pump and remove the contactor from the omega rail.

  • Page 20: Rotor Unit

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Rotor unit 7.4.1 Dismantling of rotor unit. 11 (2x) Lifiting tool for XJ 50 - 80. Remove the jacket (for easy dismantling of jacket use lifting Remove the jacket on XJC.

  • Page 21: Dismantling Of Ball Bearings

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Dismantling of ball bearings Remove upper bearing with a ball bearing puller tool. Remove the circlip and press out the bearing. Make sure to support the bearing house properly.

  • Page 22: Complete Pump Overhaul / Assembly

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Complete pump overhaul / assembly General Clean all parts carefully, especially o-ring groves and mating surfaces. Grease or oil o-rings to eliminate damage during assembly. Grease or oil screw threads to simplify disassembly during future overhaul.

  • Page 23: Secondary Seal

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Sensor cables Motor cables When the housing has been mounted it may be cooled by Press rotor with shaft in place in the bearing house (with compressed air.

  • Page 24: Refilling Of Oil

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Refilling of oil Fill all the way up to entrance of oil inspection hole. Make sure to fill in oil chamber marked with an oil drop. Tighten the oil plug with a new o-ring Use Paraffin oil (white oil) with viscosity 10-15 cSt, e.g.

  • Page 25: Assemble The Top Cover

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 8.11 Assemble the top cover Grease and mount the o-ring on the cover. Mount the cover on the jacket and arrange the leads so that they may not be jammed or block the funtioning of the contactor.

  • Page 26: Electrical Information And Wiring Diagrams

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Electrical information and wiring diagrams 10.1 Three phase Direct Start D.O.L. with contactor The stators are wound for different voltages and can be internally Delta- or Star-connected.

  • Page 27: Three Phase Direct Start D.o.l. With Aquatronic

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 10.2 Three phase Direct Start D.O.L. with AquaTronic The stators are wound for different voltages and can be internally Delta- or Star-connected. (XJ 25) (XJ 25-40)

  • Page 28: Three Phase Soft Start With Aquatronic

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 10.3 Three phase Soft Start with AquaTronic. The stators are wound for different voltages and can be internally Delta- or Star-connected. 00833235AC Figure 6: Soft Start with AquaTronic.

  • Page 29: Three Phase Direct Start D.o.l. 1000 V 50Hz With Terminal Block

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 10.4 Three phase Direct Start D.O.L. 1000 V 50Hz with terminal block The stators are wound for 1000V 50Hz and connected Star. (Figure 2). When optimal ground check diode is used see figure 5 and 6.

  • Page 30: Winding Data

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 10.5 Winding data...

  • Page 31: Fuses

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 10.6 Fuses Fuses are to be installed in the power circuits as a short circuit protection. Fuses with a time lag are recommended. The table shows the nominal current and starting current factor. Multiply factor with nominal current to get the pumps starting current.

  • Page 32: Sectional Drawing

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Sectional drawing Contactor AquaTronic Ball bearing, upper Motor housing Stator Ball bearing, lower Bearing house Upper di user Rotor and shaft Lower di user Impeller Wear ring...
  • Page 33 Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Contactor AquaTronic Ball bearing, upper Motor housing Stator Ball bearing, lower Rotor and shaft Bearing house Di user Volute Impeller...

  • Page 34: Troubleshooting

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Troubleshooting 12.1 Troubleshooting in field Error Probable cause Solution Dead incoming power lines. Check power lines. Blown fuses or breakers. Check fuses and breakers. The pump will not start.

  • Page 35: Troubleshooting/Service Inspection With Service Diagnostic Program For Aquatronic

    Workshop manual XJ 25 - 80, XJC 50 - 80, XJS 25 - 80 Defective shaft seal. Change primary seal. Faulty assembly of o-rings, mechanical Replace parts. Water in the oil chamber. seal or upper diffuser. Replace parts and dry motor.
  • Page 36 Sulzer Pump Solutions Nordmaling AB, Åsgatan 3, SE-914 32 Nordmaling, Sweden Phone +46 (0)10 130 1700, Fax +46 (0)930 100 57, www.sulzer.com 2013 Copyright © Sulzer...

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