Wacker Neuson ASP400 User manual

OPERATOR’S MANUAL / PARTS BOOK

Submersible Pump

ASP400

0114751 002

0100

0114751

BELGIE

1730 ASSE-MOLLEM ASSESTEENWEG 17 Tel. (32) 02-4528509+07

4040 Herstal 4 Avenue

9800 Deinze Kortrijkse Steenweg 400 Tel. (09)-386 8529

B - 6041 Gosselies Rue Adrienne Bolland s/n Tel. 071-372450

ÇESKÁ REPUBLIKA

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CALLE PRIMAVERA 11

08780 PALLEJA (Barcelona) PRAT DE LA RIBA, 184 Tel. (93)-6632273

41700 Dos Hermanas (Sevilla) Poligono Industrial La Palmera Tel. (95)-4691129

Nave 14 Tel. (95)-4691129

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15890 Santiago de Compostela (La Coruña) Poligono Industrial el Tambre, Via Pasteur, 47a Tel. (981) 573366 / 67

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PORTUGAL

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TURKIYE

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Ostim 06370 Ankara Alinteri Bulvari No. 210 Tel. (90) 312 385 6438/6439

ASP400

This manual provides information and procedures to safely operate and maintain this WACKER model. For your

own safety and protection from injury, carefully read, understand and observe the safety instructions described

in this manual. THE INFORMATION CONTAINED IN THIS MANUAL WAS BASED ON MACHINES IN PRODUC-

TION AT THE TIME OF PUBLICATION. WACKER CORPORATION RESERVES THE RIGHT TO CHANGE ANY

PORTION OF THIS INFORMATION WITHOUT NOTICE.

This manual is divided into the sections listed below:

Item Number:

0007651

1 Operation

2 Parts

Keep this manual or a copy of it with the machine. If you lose this manual or need an

additional copy, please contact WACKER Corporation. This machine is built with user

safety in mind, however, it can present hazards if improperly operated and serviced.

Follow operating instructions carefully! If you have questions about operating or

servicing this equipment, please contact WACKER Corporation.

ASP400

MENOMONEE FALLS, WI USA 53051

110581

Serial No.

MADE IN

JAPAN

Yr.

Man.

Rev.

hzhp

kW V

gpm

lbsm3/hr

Model

Item No.

IP68

Serial Number

My machine’s numbers are:

RevisionItem Number

Model number

ASP400

0007651

101

5010101

Nameplate

A nameplate listing the Model Number, Item Number, Revision, 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, item

number, revision number, and serial number of the unit.

1027SD23

PATENT PENDING

111545

This machine may be covered by one or more of the following patents:

111891

OF THESE U.S. PATENTS:

4643611; 4555238; 5564375; 5586630; 4419048

WACKER MACHINES PROTECTED BY ONE OR MORE

Table of Contents

1.1 Safety Notes............................................................................... 1A-2

1.2 Operating Safety ........................................................................ 1A-3

1.3 Service Safety ............................................................................ 1A-3

1.4 Technical Data............................................................................ 1A-4

1.5 Accessories ................................................................................ 1A-4

1.6 Application.................................................................................. 1A-4

1.7 Connection to Power Supply ...................................................... 1A-4

1.8 Installation .................................................................................. 1A-5

1.9 Operation.................................................................................... 1A-5

1.10 Use of Extension Cords.............................................................. 1A-6

1.11 Motor Protection ......................................................................... 1A-6

1.12 Periodic Maintenance................................................................. 1A-6

1.13 Lubrication.................................................................................. 1A-6

1.15 Troubleshooting.......................................................................... 1A-7

1.14 Cleaning Impeller........................................................................ 1A-7

1.16 Wiring Diagram........................................................................... 1A-8

ASP400

Operating Information

1A-1

1A OPERATION

ASP400

1A-2

1.1 Safety Notes

This manual contains NOTES, CAUTIONS, and WARNINGS which must be followed to prevent the possibility of

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

Notes:

Notes contain additional

information important to a procedure.

CAUTION: Cautions provide information important to prevent

errors which could damage machine or components.

WARNING

Warnings warn of conditions or practices which

could lead to personal injury or death!

OPERATION 1A

ASP400

1A-3

1.2 Operating Safety

Familiarity and proper training are required for the safe operation of equipment! Equipment operated improperly or

by untrained personnel can be dangerous! Read the operating instructions and familiarize yourself with the

location and proper use of all instruments and controls.

WARNING

NEVER use pump to pump low flash point fluids or

fluids containing corrosive chemicals.

NEVER start or operate pump near flammable liquids

or in areas exposed to flammable gases.

NEVER operate pump with covers loose or missing.

NEVER operate pump if power cord is damaged, cut

or worn. Inspect power cable and extension cords

often for damage.

NEVER operate pump if strainer is clogged or dam-

aged.

NEVER lift or pull pump using the power cord.

NEVER disconnect power cord by yanking cable.

1.3 Service Safety

Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly

over a long period of time, periodic maintenance and occasional repairs are necessary.

WARNING

DO NOT move, clean or service pump while it is

still connected to the power source.

DO NOT allow untrained personnel to service this

equipment. Only trained electrical technicians

should be allowed to service the electrical compo-

nents of this equipment.

ALWAYS replace all covers and seals before start-

ing or operating pump.

ALWAYS do Periodic Maintenance as recommended

in Operator’s Manual.

ALWAYS replace worn or damaged components

with spare parts designed and recommended by

WACKER.

NEVER operate pump if seals are leaking.

ALWAYS check power supply before connecting

pump, and make sure it matches the power require-

ments of the pump.

ALWAYS use extension cords rated for outdoor use

when operating pump outside.

ALWAYS be sure pump is positioned so it will not tip,

roll, slide, or fall when being operated.

ALWAYS make sure discharge line is open and free

of kinks.

ALWAYS make sure pump is properly grounded

before starting.

1A OPERATION

ASP400

1A-4

1.7 Connection to Power Supply

This pump is equipped with a 3-wire cord rated for

outdoor use.

It is recommended that the pump be connected to a

power source equipped with a ground fault interrupt

circuit (GFIC). Circuits protected by a ground fault

interrupt provide added protection against electrical shock.

WARNING

This pump must be grounded to reduce the risk of

electrical shock. Use only 3-wire plugs and connect

pump only into receptacles which are properly

grounded and equipped with a third wire ground. DO

NOT use 2-pronged adapters to connect pump to

power source.

1.4 Technical Data

1.6 Application

This pump is designed and intended for dewatering non-

corrosive liquids containing little or no debris, or solids up

to 1/4 in. (6 mm). It is designed to run automatically,

starting when liquid level is high and stopping when level

is low.

DO NOT use pump to pump flammable fluids or water

containing corrosive chemicals. These fluids could

become explosive and pose severe health and envi-

ronmental hazards. Contact local authorities for as-

sistance.

WARNING

1.5 Accessories

This pump is originally supplied with a power cable,

lowering rope, hose adapter, and Operator’s Manual.

Optional accessories can be ordered from WACKER

Corporation and include: discharge hoses, quick discon-

nect fittings, hose clamps, and hose couplings.

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OPERATION 1A

ASP400

1A-5

1.8 Installation

1. Check the voltage at the installation site matches the

voltage requirements of the pump. Refer to Section

1.4

Technical Data

2. Adjust the upper and lower floats

(a) to the desired

levels. The pump will start when the liquid level is high

and shut off when the level is low.

Note:

The maximum allowable gap is 18.5 in. (470mm).

3. Attach a hose to the discharge fitting on the pump

using a hose clamp. The hose should have the same

inside diameter as the fitting on the pump for best

operation.

Use the shortest length of hose possible. Check that

the hose is free of creases, sharp bends, and other

obstructions that may interfere with the discharge flow

of water.

Note:

In stationary installations the use of a check

valve in the discharge hose is suggested to prevent

water in hose from flowing back into the pump when

it is shut off.

4. Check that the screen around the bottom of the pump

is clean.

5. Lower or place the pump in water. Make sure the

pump is resting on a firm, level surface and will not tip

while operating.

Note:

If the pump is being placed on a sandy or soft,

muddy bottom, it may be necessary to suspend it

several inches above bottom to prevent it from pulling

in large amounts of sand and dirt.

CAUTION: Check the lower float position. If the lower

float becomes obstructed, the pump could run dry,

causing damage to the pump.

6. Connect the pump to the power supply.

DO NOT use the power cord to carry, lower, or

suspend pump. The cord cannot support the weight

of the pump. Use a rope tied through the pump

handle.

WARNING

1.9 Operation

Check the pump after startup to ensure water is flowing

freely from the discharge hose.

If debris is collecting around the pump screen, blocking

it, place a large basket screen around the pump to hold

debris back. Clean the pump screen as often as neces-

sary to maintain a continuous flow of water.

CAUTION: DO NOT let the pump run dry. Running the

pump dry will cause it to overheat. If necessary, adjust

the lower float.

Pump capacity is directly proportional to the height of the

discharge hose above the pump. The higher the dis-

charge hose is above the water the less water the pump

will move. The maximum discharge height is listed in the

Technical Data as “Maximum Head”.

CAUTION: The lower housing of this pump is filled with

oil to lubricate and cool the pump seal. If the seal is

ruptured, this lubricating oil can escape and contaminate

the liquid being pumped.

1027SD23

1A OPERATION

ASP400

1A-6

1.10 Use of Extension Cords

Extension cords should be used only when absolutely

necessary. When a long extension cord is used, a

voltage loss occurs. The longer the cord the greater the

voltage loss. This results in less voltage being supplied

to the pump and increases the amount of current used. A

thicker cord with a larger wire size will reduce the voltage

loss.

For extension cords over 100' (34 m) a larger wire size

may be necessary. Consult a WACKER Service Center

for more information on wire sizes.

Use only extension cords rated for outdoor use and

equipped with a third wire ground.

CAUTION: Operating the pump at low voltage caused

by the use of the improper extension cord can cause it to

overheat.

If the pump stops during operation, disconnect it

from the power supply immediately. NEVER re-

move or handle the pump while it is still connected.

WARNING

1.11 Motor Protection

This pump is equipped with built-in motor protection. If the

pump overheats, it will automatically turn itself off. The

pump will automatically reset itself and resume operation

after it has cooled.

Possible conditions which may cause the pump to turn off

include:

1. Pump operating at the wrong voltage.

2. Pump strainer blocked.

3. Pump running dry.

4. Impeller blocked.

5. Discharge hose blocked.

1.12 Periodic Maintenance

Before Use - Check cable and extension cords for wear

and damage.

Before Use - Check external hardware and tighten when

necessary.

Before Use - Check that hose connections are tight.

Every 3 Months - Change oil in pump housing.

Every 10–12 months - Check the suction cover and the

impeller for wear

1.13 Lubrication

To change oil in pump housing, remove pipe plug (a)

from side of pump housing using a 6 mm hex wrench. Tip

pump on its side and allow oil to to drain. Add approxi-

mately 5 oz. (150 ml) of Shell Tellus 30W oil through plug

hole. Apply pipe sealant to plug threads and replace

plug.

Keep all electrical cords in good condition. DO NOT

use worn, bare, or frayed cords. Worn cords in-

crease the risk of electrical shock.

WARNING

1004SD10

OPERATION 1A

ASP400

1A-7

1.14 Cleaning Impeller

If pump performance drops off, check for impeller wear

and dirt accumulation in volute housing

(b).

Remove three hex nuts (c) from bottom of pump and

remove strainer

(d) from pump.

Remove nuts (e) holding suction cover (f) to pump and

remove cover to expose impeller. Check that area around

impeller is clean. Remove any dirt or debris from inside

volute housing.

Install cover and strainer on pump.

WARNING

Impeller (g) may have sharp edges. Be careful to

avoid cutting yourself when cleaning around

impeller.

1.15 Troubleshooting

Problem / Symptom Reason / Remedy

Pump does not start. 1. Wrong voltage. Check voltage requirements of pump.

2. Blown fuse or open circuit breaker in power source.

3. Damaged power cable or extension cord.

4. Impeller blocked. Clean impeller.

5. Motor damaged. Have motor checked and repaired.

Pump stops. 1. Impeller or screen blocked.

2. Pump running dry/overheated.

3. Liquid contains too many solids.

4. Water temperature too high.

Pump delivers less water 1. Screen or impeller partially blocked.

than normal or no water. 2. Pump impeller and volute worn.

3. Discharge hose diameter too small.

4. Discharge hose too long.

5. Discharge hose too high above water.

6. Discharge hose kinked or twisted.

7. Pump rotating in wrong direction.

1003SD14

1A OPERATION

ASP400

1A-8

1.16 Wiring Diagram

1023SD77

1 MOTOR WINDINGS

2 MOTOR PROTECTION SWITCH

3 CONNECTOR

4 CENTRIFUGAL SWITCH

5 CAPACITOR

6 RESISTOR

7 CONNECTOR

8 GROUND CONNECTION

9 POWER CABLE

10 CONTROL CIRCUIT

2-1

ASP400

WACKER Corporation maintains a complete supply of replacement parts.

All service and repairs must be made using quality WACKER service

parts. Use of service parts from sources other than those recommended

by WACKER could result in premature wear, product malfunction, or

bodily injury.

Recommended Spare Parts

Part Numbers appearing in Boldface type are recommended spare parts. This means that these parts are subject

to wear under normal operating conditions and may require periodic service or replacement. It is recommended that

these items be stocked to meet the expected service requirements of this model. Actual stocking quantities of these

and other parts used in more extensive repairs will depend on the service practices of each customer.

Table of Contents

Submersible Pump Parts

2.1 Pump...........................................................................................................................................2-2

2.2 Wiring Schematic ........................................................................................................................2-4

2-2

ASP400

1037SD91

2.1 Pump

2-3

ASP400

Ref. Part No. Qty. Description

1 0071756 2 Screw M6x25, Hx.Hd.

2 0026624 1 Handle-lifting

3 0054911 2 Screw M5x15, Hx.Hd., stainless

4 0079498 1 Clamp-half, float

5 0113100 1 Cable assembly

6 0079483 1 Sleeve

7 0079462 1 Cover

8 0054913 4 Screw M6x16, Hx.Hd., stainless

9 0079500 1 Cover-head, pump

10 0079504 8 Screw M4x6

11 0115408 2 Nut, stainless steel

12 0011478 2 Screw M5x10 DIN933 Hx. Hd.

13 0072232 1 Regulator-water level indicator

14 0079497 1 Clamp-half, float

15 0115405 2 Clamp-plastic

16 0115406 1 Rod-support, upper

17 0115407 1 Rod-support, lower

18 0118600 1 Kit-cntrl circuit upgrade

(incl. 19 - 30)

19 0079452 2 Screw M4x10

0118596 2 Washer M4, lock

20 0079481 1 Clamp-capacitor

21 *0079444 1 Resistor, 2.2K OHM

22 *0079450 1 Capacitor 170MFD x 125 VAC

23 0112066 1 Control-circuit, 115V

24 0118598 3 Fitting, relay

25 0118599 1 Bracket

26 0118595 2 Screw M4x15

0118596 2 Washer M4, lock

27 0079460 1 Guard-motor 115V

28 0072755 2 Screw M4x8

0118596 2 Washer M4, lock

Ref. Part No. Qty. Description

29 0118594 1 Screw M4x30

0118596 1 Washer M4, lock

0118597 2 Washer M4

30 0079485 1 Block-receptacle

31 0079482 1 Shim

32 0079454 1 Shim

33 0051263 1 Bearing-radial ball, 6201

34 0079463 1 Switch-stationary

35 0079457 1 Rotor

36 0079459 1 Key

37 2006013 1 Bearing-radial ball, 6202

38 0079495 1 Stator-115V

39 0079446 1 Gasket

40 0079447 1 Housing-motor, pump

41 0079464 1 Plug

42 0073361 1 Seal-shaft 15x30x7,1B

43 0079448 1 Fitting-barbed, hose, 50MMx2B

44 0079470 1 O-Ring, G90

45 0079471 1 Seal-mechanical 14mm Dia.

46 0079466 1 Volute

47 0079453 3 Screw M6x16

48 0079472 1 Seal-shaft SC14x24x6

49 0079467 1 Impeller 60Hz

50 0079479 1 Washer-lock M10

51 0079478 1 Nut M10, Acorn cap

52 0079476 1 Plate-suction

53 0079474 3 Screw M6x12

54 0079475 1 Strainer

55 0079484 3 Stud M6x58

56 0079456 1 Switch-centrifugal

2-4

ASP400

UPPER

FLOAT

LOWER

FLOAT

2.2 Wiring Schematic

1023SD77

2-5

ASP400

Ref. Part No. Qty. Description

1 0079495 1 Motor Windings

2 0079488 1 Connector

3 0079460 1 Motor Protection Switch

4 0079456 1 Centrifugal Switch

5 0079450 1 Capacitor

6 0079444 1 Resistor

7 0079488 1 Terminal-receptacle

0079487 2 Block-pin

8 0113100 1 Power Cable

9 * 1 Ground Connection

10 0112066 1 Control Circuit 115V

* Normally fitted on the power cable.

2-6

ASP400

Notes

ASP400INDEX / VERZEICHNIS / INDICE

Part No. Page(s)Part No. Page(s)Part No. Page(s)

0011478 2-3

0026624 2-3

0051263 2-3

0054911 2-3

0054913 2-3

0071756 2-3

0072232 2-3

0072755 2-3

0073361 2-3

0079444 2-3, 2-5

0079446 2-3

0079447 2-3

0079448 2-3

0079450 2-3, 2-5

0079452 2-3

0079453 2-3

0079454 2-3

0079456 2-3, 2-5

0079457 2-3

0079459 2-3

0079460 2-3, 2-5

0079462 2-3

0079463 2-3

0079464 2-3

0079466 2-3

0079467 2-3

0079470 2-3

0079471 2-3

0079472 2-3

0079474 2-3

0079475 2-3

0079476 2-3

0079478 2-3

0079479 2-3

0079481 2-3

0079482 2-3

0079483 2-3

0079484 2-3

0079485 2-3

0079487 2-5

0079488 2-5

0079495 2-3, 2-5

0079497 2-3

0079498 2-3

0079500 2-3

0079504 2-3

0112066 2-3, 2-5

0112100 2-5

0113100 2-3

0115405 2-3

0115406 2-3

0115407 2-3

0115408 2-3

0118594 2-3

0118595 2-3

0118596 2-3

0118597 2-3

0118598 2-3

0118599 2-3

0118600 2-3

2006013 2-3

ASP400 INDEX / VERZEICHNIS / INDICE

Part No. Page(s) Part No. Page(s) Part No. Page(s)

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Wacker Neuson ASP400 User manual

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