Sulzer XJ Series Instruction manual

www.sulzer.com
Submersible drainage pump XJ
Submersible drainage center-line pump XJC
Submersible sludge pump XJS
EN Workshop manual
00833219 AM 07.2019

2
Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
The manufacturer reserves the right to alter specications due to technical developments !
Submersible drainage pump XJ
XJ 25 ND (50/60 Hz) XJ 25 HD (50/60 Hz)
XJ 40 ND (50/60 Hz) XJ 40 HD (50/60 Hz)
XJ 50 ND (50/60 Hz) XJ 50 HD (50/60 Hz) XJ 50 LD (50/60 Hz)
XJ 80 ND (50/60 Hz) XJ 80 HD (60 Hz) XJ 80 LD (50/60 Hz) XJ 80 SD (50/60 Hz)
XJ 110 ND (50/60 Hz) XJ 110 HD (50/60Hz)
XJ 25 ND AT (50/60 Hz) XJ 25 HD AT (50/60 Hz)
XJ 40 ND AT (50/60 Hz) XJ 40 HD AT (50/60 Hz)
XJ 50 ND AT (50/60 Hz) XJ 50 HD AT (50/60 Hz) XJ 50 LD AT (50/60 Hz)
XJ 80 ND AT (50/60 Hz) XJ 80 HD AT (60 Hz) XJ 80 LD AT (50/60 Hz) XJ 80 SD (50/60 Hz)
XJ 110 ND AT (50/60 Hz) XJ 110 HD AT (50/60 Hz)
Submersible drainage center-line pump XJC
XJC 50 ND (50/60 Hz) XJC 50 HD (50/60 Hz) XJC 50 LD (50/60 Hz)
XJC 80 ND (50/60 Hz) XJC 80 HD (60 Hz) XJC 80 LD (50/60 Hz) XJC 80 SD (50/60 Hz)
XJC 110 ND (50/60 Hz) XJC 110 HD (50/60 Hz)
XJC 50 ND AT (50/60 Hz) XJC 50 HD AT (50/60 Hz) XJC 50 LD AT (50/60 Hz)
XJC 80 ND AT (50/60 Hz) XJC 80 HD AT (60 Hz) XJC 80 LD AT (50/60 Hz) XJC 80 SD (50/60 Hz)
XJC 110 ND AT (50/60 Hz) XJC 110 HD AT (50/60 Hz)
Submersible sludge pump XJS
XJS 25 (50/60 Hz) XJS 25 AT (50/60 Hz)
XJS 40 (50/60 Hz) XJS 40 AT (50/60 Hz)
XJS 50 (50/60 Hz) XJS 50 AT (50/60 Hz)
XJS 80 (50/60 Hz) XJS 80 AT (50/60 Hz)
XJS 110 (50/60 Hz) XJS 110 AT (50/60 Hz)
Standard version AquaTronic version
Accessories
AquaPlug
Level sensor
Service Data Kit

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
Contents
1 General.............................................................................................................................................. 5
1.1 Service intervals.................................................................................................................................5
1.2 AquaTronic version ............................................................................................................................5
1.3 Repair kits and o-ring kits...................................................................................................................5
1.4 Tools...................................................................................................................................................5
1.5 Complete pump overhaul ...................................................................................................................5
1.6 Cleaning of pump before service ....................................................................................................... 5
1.7 Recycling in case of scrapping the pumps......................................................................................... 6
2 Service inspection ...........................................................................................................................7
2.1 Service Data Kit .................................................................................................................................7
2.2 Pump start and cable check............................................................................................................... 7
2.3 Dismantling cover...............................................................................................................................7
2.4 Insulation test .....................................................................................................................................8
2.5 Thermal sensors ................................................................................................................................9
3 Oil / Motor check ............................................................................................................................10
3.1 AquaTronic version ..........................................................................................................................10
3.2 Standard version and AquaTronic version ....................................................................................... 10
4 Hydraulic check.............................................................................................................................. 11
4.1 Wear ring ND, HD ............................................................................................................................ 11
4.1.1 Adjustment of wear ring ................................................................................................................... 11
4.2 Di󰀨user ND, HD, LD......................................................................................................................... 12
4.2.1 Dismantling of di󰀨user...................................................................................................................... 12
4.2.2 Assembly of di󰀨user......................................................................................................................... 12
4.3 Impeller ND, HD, LD ........................................................................................................................13
4.3.1 Dismantling of impeller.....................................................................................................................13
4.3.2 Assembly of impeller ........................................................................................................................13
5 XJ 80 SD, change of di󰀨users, impellers and guide vane plate ................................................14
5.1 Dismantling ......................................................................................................................................14
5.2 Assembly..........................................................................................................................................15
6 Primary seal and upper di󰀨user ...................................................................................................17
6.1 Dismantling of primary seal and upper di󰀨user................................................................................ 17
6.2 Assembly of primary seal and upper di󰀨user ...................................................................................17
7 Complete pump overhaul / dismantling.......................................................................................19
7.1 Electronics........................................................................................................................................19
7.1.1 AquaTronic version ..........................................................................................................................19
7.1.2 Standard version ..............................................................................................................................19
7.2 Oil/motor, hydraulic, primary seal and upper di󰀨user.......................................................................19
7.3 Secondary seal ................................................................................................................................ 19
7.3.1 Dismantling of secondary seal .........................................................................................................19
7.4 Rotor unit..........................................................................................................................................20
7.4.1 Dismantling of rotor unit ...................................................................................................................20
7.5 Dismantling of ball bearings .............................................................................................................21
7.6 Stator................................................................................................................................................21
7.6.1 Insulation check ...............................................................................................................................21
7.6.2 Dismantling of stator ........................................................................................................................21

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
8 Complete pump overhaul / assembly........................................................................................... 22
8.1 General ............................................................................................................................................22
8.2 Assembly of ball bearings ................................................................................................................22
8.3 Assembly of stator............................................................................................................................22
8.4 Secondary seal ................................................................................................................................ 23
8.5 Primary seal and upper di󰀨user ....................................................................................................... 23
8.6 Impeller ............................................................................................................................................23
8.7 Assembly of di󰀨user......................................................................................................................... 23
8.8 Base plate and strainer ....................................................................................................................23
8.8.1 With distances.................................................................................................................................. 23
8.8.2 Without distances............................................................................................................................. 23
8.9 Relling of oil....................................................................................................................................24
8.10 Change of cable gland .....................................................................................................................24
8.10.1 Change of cable gland .....................................................................................................................24
8.10.2 Change of AquaTronic connection interface ....................................................................................24
8.11 Assemble the top cover.................................................................................................................... 25
9 Testing.............................................................................................................................................25
10 Electrical information and wiring diagrams ................................................................................26
10.1 Three phase Direct Start D.O.L. with contactor ............................................................................... 26
10.2 Three phase Direct Start D.O.L. with AquaTronic ...........................................................................27
10.3 Three phase Soft Start with AquaTronic...........................................................................................28
10.4 Three phase Direct Start D.O.L. with terminal block ........................................................................ 29
10.5 Winding data ....................................................................................................................................30
10.6 Fuses ...............................................................................................................................................31
11 Sectional drawing ..........................................................................................................................32
12 Troubleshooting .............................................................................................................................34
12.1 Troubleshooting on eld...................................................................................................................34
12.2 Troubleshooting/service inspection without service program...........................................................34
12.3 Troubleshooting/service inspection with Service Diagnostic Program for AquaTronic..................... 35

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
1. General
1.1 Service intervals
This workshop manual can be used for both regular inspection and complete overhaul on the pump. For assistance con-
tact Sulzer workshop or by Sulzer authorized workshop.
- For regular inspection on the pump such as electrical check, oil/motor check and check of hydraulic parts,
proceed and follow chapter 1 to 5 in this manual.
- For complete overhaul on the pump proceed and follow chapter 1 to 9 in this manual.
- For electrical information and wiring diagrams see chapter 10.
Submersible drainage pumps XJ 25-110, Submersible drainage center-line pumps XJC 50-110 and Submersible sludge
pumps XJS 25-110 are built for long periods of trouble free operation. The pumps can “run on snore” without any risk for
the mechanical seals. They get su󰀩cient cooling from the pumped media and su󰀩cient lubrication and cooling from the oil
in the housing between the seals. All the ball bearings are sealed and prelled with high performance bearing grease for
life time duty.
Regular inspection and preventive maintenance will ensure more reliable operation. The pump should be inspected every
six months and should have a complete overhaul once a year. If the operating condition of the pump is severe it may be
required more frequently. A reason for inspection could be if a drop in capacity is being noticed.
1.2 AquaTronic version
Check the pump data in the Service Diagnose Program (see separate manual) before dismantling AquaTronic version.
1.3 Repair kits and o-ring kits
The repair kits include preselected spare parts which secure a fast and e󰀩cient maintenance and avoids unnecessary
downtime for the pump. The o-ring kit is included in the repair kit and can be ordered separately. For contents of repair and
o-ring kits see spare part lists, positions marked 1 and 2 .
Repair kits: XJ 25-40, XJS 25-40: 00863347 XJ 50-110, XJC 50-110, XJS 50-110: 00863348
O-ring kits: XJ 25-40, XJS 25-40: 00863349 XJ 50-110, XJC 50-110, XJS 50-110: 00863350
1.4 Tools
The submersible drainage pumps can be maintained with standard tools. Sulzer does not recommend the use of impact
tools for removal and installation of screws and nuts.
Torque rating
Size M4 M5 M8 M10
Nm 1.0 4.1 17 33
lb-ft 1.5 3.0 12.5 24.3
Cable gland: A specic torque value cannot be given for the cable gland. Tighten it until the rubber o󰀨ers resistance, and
thereafter, one more full rotation.
1.5 Complete pump overhaul
A complete overhaul of the pump should be carried out if there has been water or oil in the motor housing or if the pump
has been in daily operation for more than a year. At low utilization of the pump the overhaul intervals can be extended. 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 resources section of the Sulzer web site at www.sulzer.com.
1.6 Cleaning of pump before service
Before overhaul or maintenance is started the pump should be cleaned. High pressure water is recommended. If the pump
has been operating in tough applications additional solvents can be used. To clean the pump from lime deposits it is rec-
ommended to lower the pump in a bath containing formic acid (15%) and 85% water for some hours. If needed leave the
pump longer. Clean the pump again with high pressure water. Another example is to use Beto 2000 which is a solvent for
concrete deposits.

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1.7 Recycling in case of scrapping the pumps
Recycling of individual pump parts is benecial 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. Wear parts
which consists of rubber/polyurethane/aluminium/steel and cables/stators with copper must be treated before recycling is
possible. Environmental white oil should be left to designated areas.
Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
Standard versionAquaTronic version XJC
2. Service inspection
2.1 Service Data Kit
Contact Sulzer.
2.2 Pump start and cable check
Check the cable for damage and that there is no water or corrosion in the connecting plug.
Test the insulation between cable end / plug and earth.
Check if the pump starts by connecting it to the power supply.
2.3 Dismantling cover
Unscrew and lift o󰀨 the cover and disconnect the power cables from the contactor/terminal block.
If the water has penetrated through the cable gland and the cable seal, the cable gland and the cable seal should be re-
placed. Remove strain relief clamp prior to unscrewing cable gland body. Pull out cable, cable gland, washer and unscrew
the cable seal.
cDANGER! Always check that the pump is disconnected from the electric power supply
before opening any part of the pump.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
2.4 Insulation test
Disconnect stator leads. Check that the contact points are not burned. Measure insulation resistance between the di󰀨erent
phase windings, between windings and earth and between windings and thermal sensor circuit.
The insulation resistance should be measured with 500 V megohmeter (megger) and the reading should be at least 1 MΩ.
If the insulation resistance is lower, the stator unit should be dried in an oven. If the stator insulation reading after drying is
still low, the stator unit should be replaced. See chapter 7.
The insulation between the separate turns in the winding should also be checked. This can be done by measuring the
resistance of the phase windings, which should give the same reading for all three windings for 3-phase motors. For resist-
ance values and wiring diagrams check chapter 9.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
2.5 Thermal sensors
The circuit thermal sensors with the two built-in NTC thermistors (TU1+TV1) S , 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 thermal contacts (TC1+TC2) T should be checked for continuity, using an ohm-
meter or buzzer.
If one sensor has much too high or low resistance it should be removed from terminals at AquaTronic module.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
Models litres US gallon
XJ/XJS 25 0.4 0.11
XJ/XJS 40 0.4 0.11
XJ/XJC/XJS 50 0.9 0.24
XJ/XJC/XJS 80 0.9 0.24
XJ/XJC/XJS 110 0.9 0.24
OIL
OIL
M
3. Oil / Motor check
3.1 AquaTronic version
See separate manual for Service Diagnostic Program.
3.2 Standard version and AquaTronic version
Unscrew the two oil plugs and drain o󰀨 the oil in a clean can and inspect it. Oil should be clear and without impurity.
For relling of oil see chapter 8.9.
The motor plug gives access to the motor housing.
Unscrew and check to make sure no oil or water has leaked
into the motor housing.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
4. 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.
4.1 Wear ring ND, HD
4.1.1 Adjustment of wear ring
m
CAUTION!
Do not place the pump directly on the AquaTronic unit.
It will break.
Adjust the clearance with the three screws that hold the
wear ring.
Check clearance between wear ring and impeller. Clear-
ance should be less than 0.3 mm. Loosen the wear ring to
make adjustments.
Turn the pump upside down and remove the base plate and
strainer.
Fasten wear ring with remaining three screws.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
4.2 Di󰀨user ND, HD, LD
4.2.1 Dismantling of di󰀨user
Remove the screws which hold the upper di󰀨user and bear-
ing house together.
Check the di󰀨user for scratches. The rubber should have a
smooth surface.
Fasten the upper di󰀨user on the bearing house.
4.2.2 Assembly of di󰀨user.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
4.3 Impeller ND, HD, LD
4.3.1 Dismantling of impeller
Hold the impeller with a large screwdriver or similar, be-
tween the vanes and unscrew the impeller washer.
Mount the new impeller on the shaft, securing it with key,
washer and screw.
4.3.2 Assembly of impeller
Remove the key from the shaft.
Pry the impeller loose with two screwdrivers under the im-
peller hub.
Check that the impeller runs free of upper di󰀨user with a
clearance of 0.5 - 1 mm (0.02 - 0.04”). Adjust the clearance
with shims between impeller and the shaft if necessary.

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5. XJ 80 SD, change of di󰀨users, impellers and guide vane plate
5.1 Dismantling
Turn the pump upside down Loosen the bottom nuts and
remove the base plate and the rubber sleeves.
Loosen the dual nuts and washers that hold the lower dif-
fuser but make sure to leave three nuts to keep the di󰀨user
in place (loosen them a few turns only).
Then loosen the strainer by adding leverage from the dif-
fuser by inserting two screwdrivers in the strainer and press
against the di󰀨user.
Hold the impeller with a large screwdriver or similar, be-
tween the vanes and unscrew the impeller screw with an 6
mm Allen key.
Turn the impeller so the three marks on the impeller side
meet the channels of the guide vane plate. Pry the lower
impeller loose with screwdrivers on the marks of the impel-
ler sides. Remove the key from the shaft. If the impeller
is stuck, hit it carefully in circles with a hammer and use a
creeping lubricant if needed.
Remove the remaining three nuts and then the lower dif-
fuser by pulling it gently straight out.
Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110

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5.2 Assembly
Place the shims and then the tube distance between the
impellers on the shaft.
Remove the distance sleeve between the impellers and
pull out the guide vane plate. Note the number of 0.5 shims
on top of the distance sleeve before removing them, also
check for shims under the distance sleeve and or top of the
lower impeller.
Pull out the upper di󰀨user. Turn the impeller so the three
marks on the impeller side meet the channels of the wear
plate. Pry the upper impeller loose with screwdrivers on the
marks of the impeller sides. Remove the key from the shaft.
If the impeller is stuck hit it carefully in circles with a ham-
mer. Check if there are shims on top of the upper impeller,
if so remove them too.
Mount the new lower impeller on the shaft securing it with
the key, spring washer and screw. Check that the impel-
ler runs free of guide vane plate. Adjust the clearance with
shims between the tube distance and upper impeller if nec-
essary.
Put the shims on the shaft, then the upper key in place on
the shaft and mount the new upper impeller. Check that the
impeller runs free of wear plate. Adjust the clearance with
shims between impeller and shaft if necessary.
Put on the upper di󰀨user and then the guide vane plate on
the stud bolts and push them in place. Check that the dis-
tances are in place in the di󰀨user.
Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110

16
Mount the lower di󰀨user on the stud bolts and screw two
screws onto each stud bolt. Check that the distances are
in place in the di󰀨user.
Grease and mount o-ring on the oil casing. Put the strainer
in place and then the rubber sleeves and the base plate.
Tighten it up with the bottom nuts.
Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
6. Primary seal and upper di󰀨user
6.1 Dismantling of primary seal and upper di󰀨user
Remove the circlip and pull out the rotating part of the pri-
mary seal. Remove the screws which hold the di󰀨user and
bearing house together.
Withdraw the upper di󰀨user by using two screwdrivers.
Remove the stationary ring with o-ring, of the
primary seal.
Remove the rubber foam and o-ring in the bearing house.
6.2 Assembly of primary seal and upper di󰀨user
Mount stationary ring of primary seal with o-ring in its seat
in the bearing house.
Before the outer o-ring is mounted on the bearing house,
check that upper di󰀨user is compressing the o-ring in the
stationary seal enough to give e󰀩cient sealing.
mAlways use new mechanical seals for assembly.
For repair kit part nos see chapter 1.2.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
Place the rubber foam in the bearing house. Grease and
mount o-ring on the bearing house, and mount upper dif-
fuser with screws. Tighten gradually crosswise.
Grease and mount a new primary seal o-ring on the shaft.
Oil the sealing surfaces of the mechanical seal and push
the rotating ring onto the shaft

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
7. Complete pump overhaul / dismantling
Perform all dismantling operation in chapter 2 then continue with:.
7.1 Electronics
7.1.1 AquaTronic version
Turn the pump and remove AquaTronic
7.1.2 Standard version
Turn the pump and remove the contactor from the omega
rail.
7.2 Oil/motor, hydraulic, primary seal and upper di󰀨user
Perform all dismantling operation in chapter 3-5 then continue with:
7.3 Secondary seal
7.3.1 Dismantling of secondary seal
Remove circlip and rotating parts of secondary seal from
the shaft.
Remove the stationary ring with two screwdrivers.

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Workshop manual
XJ 25 - 110, XJC 50 - 110, XJS 25 - 110
mOn AquaTronic
units, remove leakage
sensor. Be careful not to
damage cable.
7.4 Rotor unit
7.4.1 Dismantling of rotor unit.
Remove the jacket (for easy dismantling of jacket use lifting
tool).
Remove the stator and motor housing from the rotor unit. Remove the external circlip with a pair of circlip pliers
(diameter 25 mm) and remove washer (holding the bearing).
Place the rotor into a tube or similar of the same length as
the rotor shaft and with an inner diameter slightly larger
then the outer diameter of the bearing seat. Press against
the end of the shaft until the rotor comes loose. The bear-
ing seat can be heated quickly with LP-gas to facilitate the
removal.
m If high pressure is
needed, screw the impeller
nut fully on the shaft end in
order to protect it
254
280
11 (2x)
Remove the jacket on XJC.
Lifting tool for XJ 50 - XJ 110.