Wacker Neuson PSA21503L User manual

Operator’s Manual

Pump

PS2 1503L / 2203L

PSA2 1503L / 2203L

0179830en 001 0210

0179830EN

Copyright

notice

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the machine. Any

other type of reproduction is prohibited without express written permission from

Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by Wacker Neuson Corporation

represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their respective owners.

Manufacturer

Wacker Neuson Corporation

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Original

instructions

This Operator’s Manual presents the original instructions. The original language of this

Operator’s Manual is American English.

Foreword

wc_tx001295gb.fm 3

Foreword

Machines

covered by

this manual

Machine

documentation

 Keep a copy of the Operator’s Manual with the machine at all times.

 Use the separate Parts Book supplied with the machine to order replacement

parts.

 Refer to the separate Repair Manual for detailed instructions on servicing and

repairing the machine.

 If you are missing any of these documents, please contact Wacker Neuson

Corporation to order a replacement or visit www.wackerneuson.com.

 When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

Expectations

for

information in

this manual

 This manual provides information and procedures to safely operate and main-

tain the above Wacker Neuson model(s). For your own safety and to reduce the

risk of injury, carefully read, understand, and observe all instructions described

in this manual.

 Wacker Neuson Corporation expressly reserves the right to make technical

modifications, even without notice, which improve the performance or safety

standards of its machines.

 The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson Corporation reserves the right

to change any portion of this information without notice.

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

 Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

 Approved modifications are those performed by an authorized Wacker Neu-

son service center according to written instructions published by Wacker Neu-

son.

 Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following

consequences:

 Serious injury hazards to the operator and persons in the work area

 Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

Machine Item Number Machine Item Number

PS2 1503L 0620461

0620462

PSA2 1503L 0620463

PS2 2203L 0620464

0620465

PSA2 2203L 0620466

Foreword

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Table of Contents PS2/PSA2 1503L/2203L

wc_bo0179830en_001TOC.fm 5

Foreword 3

1. Safety Information 7

1.1 Machine Description and Intended Use ............................................... 8

1.2 Operating and Electrical Safety .......................................................... 10

1.3 Informational Labels ........................................................................... 10

2. Operation 11

2.1 Names of Parts ................................................................................... 11

2.2 Prior to Operation ............................................................................... 12

2.3 Preparing for Installation .................................................................... 12

2.4 Installation .......................................................................................... 14

2.5 Electrical Wiring .................................................................................. 16

2.6 Cable Assembly ................................................................................. 18

2.7 Electrical Circuit Diagram ................................................................... 19

2.8 Operation ............................................................................................ 20

2.9 Operating Water Level ....................................................................... 22

2.10 Starting Water Level (PSA2 models) .................................................. 23

2.11 Circle Thermal Protector .................................................................... 26

2.12 Emergency Shutdown Procedure ....................................................... 26

3. Maintenance 28

3.1 Periodic Maintenance Table ............................................................... 28

3.2 Maintenance and Inspection .............................................................. 29

3.3 Disassembly/Reassembly .................................................................. 31

3.4 Disassembly ....................................................................................... 32

3.5 Reassembly ........................................................................................ 34

3.6 Troubleshooting .................................................................................. 35

4. Technical Data 36

4.1 Standard Specifications ...................................................................... 36

4.2 Operating Specifications .................................................................... 37

4.3 Dimensions ........................................................................................ 38

PS2/PSA2 1503L/2203L Table of Contents

6 wc_bo0179830en_001TOC.fm

PS2/PSA2 1503L/2203L Safety Information

wc_si000366gb.fm 7

1 Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE, and

NOTE signal words which must be followed to reduce the possibility

of personal injury, damage to the equipment, or improper service.

NOTICE: Used without the safety alert symbol, NOTICE indicates a situation

which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

This is the safety alert symbol. It is used to alert you to potential personal hazards.

f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

f To avoid death or serious injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in

death or serious injury.

f To avoid possible death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in

minor or moderate injury.

f To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

Safety Information PS2/PSA2 1503L/2203L

8 wc_si000366gb.fm

1.1 Machine Description and Intended Use

This machine is a submersible water pump. The Wacker Neuson

Submersible Pump consists of an electric motor, an impeller, a strainer,

and a metal casing with ports for water suction and discharge. Power is

supplied to the pump through a corded plug or a hard-wired connection,

depending on the installation. The operator connects hoses to the pump

and routes them so that water is pumped from the work area and

discharged into an appropriate location.

This machine is intended to be used for general de-watering applications.

This machine is intended for the pumping of clear water, or water

containing solids up to the size stated within the products specifications,

and up to the flow, head, and suction lift limits also stated within the

product specifications.

This machine has been designed and built strictly for the intended use

described above. Using the machine for any other purpose could

permanently damage the machine or seriously injure the operator or other

persons in the area. Machine damage caused by misuse is not covered

under warranty.

The following are some examples of misuse:

• Pumping flammable, explosive, or corrosive fluids

• Pumping hot or volatile fluids that result in pump cavitation

• Operating the pump outside of product specifications due to incorrect

diameter hoses, incorrect length hoses, other inlet or outlet

restrictions, or excessive suction lift or head

• Using the machine as a ladder, support, or work surface

• Using the machine to carry or transport passengers or equipment

• Operating the machine outside of factory specifications

• Operating the machine in a manner inconsistent with all warnings

found on the machine and in the Operator’s Manual.

This machine has been designed and built in accordance with the latest

global safety standards. It has been carefully engineered to eliminate

hazards as far as practicable and to increase operator safety through

protective guards and labeling. However, some risks may remain even

after protective measures have been taken. They are called residual

risks. On this machine, they may include exposure to:

• Electric shock from improper electrical connections or high voltage

• Personal injury from improper lifting techniques

• Projectile hazard from discharge

PS2/PSA2 1503L/2203L Safety Information

wc_si000366gb.fm 9

To protect yourself and others, make sure you thoroughly read and

understand the safety information presented in this manual before

operating the machine.

Operator qualifications

Only trained personnel are permitted to start, operate, and shut down

the machine. They also must meet the following qualifications:

• have received instruction on how to properly use the machine

• are familiar with required safety devices

The machine must not be accessed or operated by:

•children

• people impaired by alcohol or drugs

Personal Protective Equipment (PPE)

Wear the following Personal Protective Equipment (PPE) while

operating this machine:

• Close-fitting work clothes that do not hinder movement

• Safety glasses with side shields

• Hearing protection

• Safety-toed footwear

Safety Information PS2/PSA2 1503L/2203L

10 wc_si000366gb.fm

1.2 Operating and Electrical Safety

To reduce risk of electric shock, connect only to a properly grounded,

grounding-type receptacle.

Risk of electric shock—this pump has not been investigated for use in

swimming pool areas.

An acceptable motor-control switch shall be provided at the time of

installation according to local codes and regulations.

To reduce risk of electric shock, follow instructions in this manual for

proper installation.

CAUTION: This pump may automatically restart. Prior to working on

the pump or control panel, all supply circuits must be disconnected.

CAUTION: Risk of shock—do not remove cord and strain relief.

1.3 Informational Labels

Label Meaning

A nameplate listing the model number, item

number, revision number, and serial number is

attached to each unit. Please record the

information found on this plate so it will be

available should the nameplate become lost or

damaged. When ordering parts or requesting

service information, you will always be asked to

specify the model number, item number, revision

number, and serial number of the unit.

WARNING

JAPAN

PS2/PSA2 1503L/2203L Operation

wc_tx001296gb.fm 11

2 Operation

2.1 Names of Parts

Ref Description Ref Description

1 Lifting handle 9 Lubricant

2 Coupling 10 Seal-dust (V-ring)

3 Protective packing 11 Shaft sleeve

4 Oil plug 12 Rear liner

5 Pump casing 13 Oil casing

6 Strainer stand 14 Impeller

7 Cable assembly 15 Electrode (if equipped)

8 Seal-mechanical — —

1

14

13

3

5

12

11

10

4

7

8

2

6

9

15

wc_gr007328

Operation PS2/PSA2 1503L/2203L

12 wc_tx001296gb.fm

2.2 Prior to Operation

When the pump is delivered, first perform the following checks:

• Inspection

While unpacking, inspect the product for damage during shipment, and

make sure all bolts and nuts are tightened properly.

• Specification check

Check the model number to make sure it is the product that was

ordered. Be certain it is the correct voltage and frequency.

Note: If there is any problem with the product as shipped, contact your

nearest dealer or Wacker Neuson representative at once.

• Product specifications

Do not operate this product under any conditions other than those for

which it is specified. Failure to observe this precaution can lead to

electrical shock, current leakage, fire, water leakage or other

problems.

2.3 Preparing for Installation

Preparing for Installation

Observe the following points when preparing to install the pump.

• Be aware that leakage of pump lubricants may cause pollution of

water.

• An appropriate plug or electrical connection must be provided

according to local codes and standards. Refer to the wiring

diagram.

• Use with a power supply voltage within ±5% of the rated voltage.

Operating Safety

• Do not operate the pump if the maximum water pressure in the

area exceeds 0.3 Mpa–discharge pressure.

• Do not use this pump in liquids other than water, such as oil, salt

water, or organic solvents. Contact your Wacker Neuson dealer

with questions about specific fluids.

• Do not use in water temperatures outside the range of 0–40°C

(32–104°F) which can lead to failure, electrical leakage or shock.

• Do not use in the vicinity of explosive or flammable materials.

• Do not operate the pump if any parts are loose or missing.

CAUTION

PS2/PSA2 1503L/2203L Operation

wc_tx001296gb.fm 13

Preparing for installation

Before installing the pump at a work site, you will need to have the

following tools and instruments ready:

• Insulation resistance tester (megohmmeter)

• AC voltmeter

• AC ammeter (clamp-on type)

• Bolt and nut tighteners

• Power supply connection tools (screwdriver or box wrench)

Note: Please also read the instructions that come with each of the test

instruments.

Measure resistance

Use a megohmmeter to measure the insulation resistance between

each core lead and the ground lead to verify the insulation resistance

of the motor.

• Reference insulation resistance: 20MΩ or greater

Note: The reference insulation resistance (20M

Ω

or greater) is the value

when the pump is new or has been repaired. For the reference value after

installation, see “Periodic Maintenance Table.”

Description Description

U Power Lead (Brown) W Power Lead (Black)

V Power Lead (Blue or Gray) G Ground (Green/Yellow)

wc_gr007262

Operation PS2/PSA2 1503L/2203L

14 wc_tx001296gb.fm

2.4 Installation

If the pump is used for outdoor fountains, garden ponds and similar

places, or to drain a swimming pool, the pump must be supplied by an

isolating transformer or connected to a Residual Current Device (RCD)

with a residual operating current not exceeding 30 mA.

The pump must not be used when people are in the water.

Leakage of pump lubricants may cause pollution of water.

Proper plug must be provided according to local codes and standards.

Refer to wiring diagram.

Do not use this pump in liquids other than water, such as oil, salt water,

or organic solvents.

Use with a power supply voltage within ±5% of the rated voltage.

Do not use in water temperatures outside the range of 0–40°C

(32–104°F) which can lead to failure, electrical leakage or shock.

Do not use in the vicinity of explosive or flammable materials.

Use only in fully assembled state.

Note: Consult your local dealer or Wacker Neuson representative

before using with any liquids other than those indicated in this manual.

WARNING

PS2/PSA2 1503L/2203L Operation

wc_tx001296gb.fm 15

Checks to make before installation

• When a grounded plug is used:

Use the megohmmeter to measure the insulation resistance between

the cable assembly prongs and ground.

• When connection leads are used:

With the megohmmeter, measure the insulation resistance between

each core lead and the ground lead.

Reference insulation resistance: 20MΩ or greater

Note: The reference insulation resistance (20M

Ω

or greater) is the

value when the pump is new or has been repaired. For the reference

value after installation, see “Periodic Maintenance Table.”

Improper ways to measure insulation resistance

See Graphic: wc_gr007330

All models 1 Between the plug prongs.

PSA2 1503L

PSA2 2203L

2 Between the electrode and the pump body.

3 Between the electrode and each lead wire.

1

wc_gr007330

2

3

Operation PS2/PSA2 1503L/2203L

16 wc_tx001296gb.fm

2.5 Electrical Wiring

General information

• Electrical wiring should be performed by a qualified electrician in

accord with all applicable regulations. Failure to observe this

precaution not only risks breaking the law, but is extremely

hazardous.

• Make sure the pump is equipped with the specified overload

protectors, fuses, and/or breakers. These items are designed to

guard against electrical shock from a current leak or pump

malfunction.

• Operate within the capacity of the power supply and wiring.

Grounding the pump

• Do not use the pump without first grounding it properly.

• Do not attach the grounding wire to a gas pipe, water pipe,

lightning rod, or telephone grounding wire.

Connecting the power supply

• Before connecting leads to the terminal strip, make certain the

power supply is disconnected (i.e. through circuit breakers) to

avoid electrical shock, shorting, or unexpected starting of the

pump.

• Do not use the pump with the cable assembly connected loosely.

• Draw power from a dedicated power outlet rated at 15 A or

above. Sharing the outlet with other equipment may cause

overheating at the branch outlet and could result in fire.

• Use a dedicated power supply with a ground leakage circuit

breaker.

• Tighten the ends of the cable assembly securely against the

terminal board.

WARNING

An improperly wired pump can result in current leakage, personal injury, electrical

shock, fire, or permanent equipment damage.

f Observe the safety considerations below when performing electrical wiring.

PS2/PSA2 1503L/2203L Operation

wc_tx001296gb.fm 17

Description Description

U Power Lead (Brown) W Power Lead (Black)

V

Power Lead (Blue or Gray)

G Ground (Green/Yellow)

wc_gr007264

Operation PS2/PSA2 1503L/2203L

18 wc_tx001296gb.fm

2.6 Cable Assembly

Extending the cable

If it is necessary to extend the cable assembly, use a core size equal

to or larger than the original. This is necessary to avoid a performance

drop and cable overheating which may result in current leakage,

electrical shock, or fire.

Avoiding cable damage

• Do not suspend the pump by the cable.

• Make sure the cable does not become excessively bent or

twisted.

• Do not allow the cable to rub against a structure in a way that

might damage it.

• Repair or replace a cut or damaged cable immediately.

Submerging the cable

• Do not submerge a cable with cut insulation or other damage.

• If it is necessary to submerge the connection wires of the cable

assembly in water, first seal the wires completely in a molded

protective sleeve.

• Do not allow the cable assembly wires or power supply plug to

become wet.

WARNING

Current leakage, electrical shock, or fire hazards.

f Observe the safety considerations below when handling the cable assembly.

PS2/PSA2 1503L/2203L Operation

wc_tx001296gb.fm 19

2.7 Electrical Circuit Diagram

See Graphic: wc_gr007099

If connected to a circuit protected by a fuse, use a time-delay fuse with

this pump.

Ref. Description Ref. Description

1 Circle thermal protector 3 Ground

2Coil ——

Wire Colors

B Black V Violet Or Orange

G Green W White Pr Purple

L Blue Y Yellow Sh Shield

P Pink Br Brown LL Light Blue

R Red Cl Clear G/Y Green/Yellow

T Tan Gr Gray L-Gr Blue or Gray

wc_gr007099

1

2

3

Br

L-Gr

B

G/Y

CAUTION

Operation PS2/PSA2 1503L/2203L

20 wc_tx001296gb.fm

2.8 Operation

Before starting

2.8.1 Make sure once again that the product is of the correct voltage and

frequency rating.

NOTICE: Using the product at other than rated voltage and frequency

will not only lower its performance but may damage the product.

Note: Confirm the rated voltage and frequency on the model

nameplate.

2.8.2 Confirm the wiring, supply voltage, circuit breaker capacity, and motor

insulation resistance.

Reference insulation resistance = 20 MΩ or greater.

Note: The reference insulation resistance (20 MΩ or greater) is the

value when the pump is new or has been repaired. For the reference

value after installation see “Periodic Maintenance Table.”

2.8.3 The setting on the circuit breaker or other overload protector should be

made in accord with the rated current of the pump.

Note: See “Operating Specifications” for the rated current of the pump.

2.8.4 When powering the pump with a generator, be certain the generator is

sized to supply the required power for the pump and any other

equipment powered by the generator.

Safety

considerations

• Make sure no extraneous objects such as pins, nails or other

metal objects are sucked into the pump.

• Never start the pump while it is suspended. The pump may jerk

and crush extremities.

• Never start the pump when people are standing next to it. A

current leak can result in electrical shock.

• Never insert your hand or any other object into the inlet opening

on the underside of the pump casing while the pump is connected

to the power supply.

• The pump may become hot during operation. Do not touch an

operating pump. Allow the pump to cool before handling.

WARNING

Personal injury and machine damage hazards.

f To avoid personal injury or machine damage, observe the safety considerations

listed below while operating this pump.

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