Wacker Neuson PSC42203 User manual

Category
Water pumps
Type
User manual

This manual is also suitable for

Operator’s Manual
Pump
PSC2 0753
PSC3 1503
PSC4 2203
PSC4 3703
0179832en 001 0210
0179832EN
Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
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_tx001305gb.fm 3
Foreword
Machines covered in 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
maintain 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
Neuson service center according to written instructions published by Wacker
Neuson.
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
PSC2 0753
PSC3 1503
PSC4 2203
PSC4 3703
0620467
0620468
0620469
0620470
Foreword
4 wc_tx001305gb.fm
Table of Contents PSC
wc_bo0179832en_001TOC.fm 5
1. Foreword 3
2. Safety Information 7
2.1 Machine Description and Intended Use ............................................... 8
2.2 Operating and Electrical Safety .......................................................... 10
2.3 Informational Labels ........................................................................... 10
3. Operation 11
3.1 Names of Parts ................................................................................... 11
3.2 Prior to Operation ............................................................................... 12
3.3 Preparing for Installation .................................................................... 12
3.4 Installing the Pump ............................................................................. 15
3.5 Electrical Wiring .................................................................................. 18
3.6 Cable Assembly ................................................................................. 20
3.7 Electrical Circuit Diagram ................................................................... 21
3.8 Operation ............................................................................................ 22
3.9 Operating Water Level ...................................................................... 24
3.10 Motor Protector ................................................................................... 25
3.11 Emergency Shutdown Procedure ....................................................... 25
4. Maintenance 26
4.1 Periodic Maintenance Table ............................................................... 26
4.2 Maintenance and Inspection .............................................................. 27
4.3 Disassembly/Reassembly .................................................................. 29
4.4 Disassembly ....................................................................................... 30
4.5 Reassembly ........................................................................................ 31
4.6 Troubleshooting .................................................................................. 32
5. Technical Data 34
5.1 Standard Specifications ...................................................................... 34
5.2 Operating Specifications .................................................................... 35
5.3 Dimensions ........................................................................................ 36
PSC Table of Contents
6 wc_bo0179832en_001TOC.fm
PSC Safety Information
wc_si000370gb.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 PSC
8 wc_si000370gb.fm
1.1 Machine Description and Intended Use
This machine is a submersible cutter pump. The Wacker Neuson
Submersible Cutter Pump consists of an electric motor, an impeller with a
carbide tip and cutter plate, a stand, and a metal casing with ports for
water or sewage suction and discharge. During operation, the impeller
cuts solid material until it is small enough to pass through the discharge
port. Power is supplied to the pump through a corded plug or a hard-wired
connection, depending on the installation. The operator connects pipes to
the pump and routes them so that water or sewage is pumped from the
work area and discharged into an appropriate location.
This machine is intended to be used for residential, commercial, and
industrial pumping of waste water with variable solids inclusion. This
machine is designed and intended to operate efficiently up to the flow,
head, and suction lift limits 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 pipes, incorrect length pipes, 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
PSC Safety Information
wc_si000370gb.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 PSC
10 wc_si000370gb.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 num-
ber, revision number, and serial number is
attached to each unit. Please record the informa-
tion found on this plate so it will be available
should the nameplate become lost or damaged.
When ordering parts or requesting service infor-
mation, you will always be asked to specify the
model number, item number, revision number,
and serial number of the unit.
WARNING
JAPAN
JAPAN
PSC Operation
wc_tx001306gb.fm 11
2 Operation
2.1 Names of Parts
See Graphic: wc_gr007098
Ref Description Ref Description
1 Cable 8 Oil lifter
2 Pump casing 9 Oil plug
3 Impeller 10 Lubricant
4 Suction cover 11 Discharge bend
5 Stand 12 Air release valve
6 Mechanical seal 13 Flange
7 Oil seal 14 Eye bolt
1
2
3
11
4
13
7
8
9
10
14
13
12
5
6
wc_
g
r007098
Operation PSC
12 wc_tx001306gb.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
PSC Operation
wc_tx001306gb.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 PSC
14 wc_tx001306gb.fm
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.”
PSC Operation
wc_tx001306gb.fm 15
2.4 Installing the Pump
Overview
This pump requires careful installation to operate at peak efficiency.
Observe the following recommendations when installing the pump.
Placing the pump
A sample installation diagram is provided below. Contact your Wacker
Neuson dealer for help in installing the pump for your particular
application.
Install the pump on a flat, smooth surface, such as a concrete
pad.
Do not place the pump in areas that may be susceptible to
turbulence or may allow the pump to take in air—for example,
near the inlet of a water tank. Install a baffle if it is impossible to
keep the pump away from these areas.
Install piping so that air pockets cannot form anywhere in the
system.
NOTICE: If the pump is being controlled automatically, discharged water could flow backwards.
This backflow may trigger the water surface control immediately, forcing the pump to continuously
cycle ON and OFF. Permanent damage to the pump may result.
Install a check valve if the pump tank is deep, or if the vertical
head or the lateral distance is long.
Description Description
a Cable g Manhole cover
b Baffle plate h Control panel
c Start position j Gate valve
d Stop position k Check valve
e Hook l Pipe
f Chain m Pump
wc_gr007263
a
e
h
j
g
f
k
l
m
b
c
d
Operation PSC
16 wc_tx001306gb.fm
If the pump is being installed in a permanent location where it is
not readily accessible after installation, request a duplicate
nameplate from Wacker Neuson. The duplicate nameplate
should be installed at the wellhead or on the control box for ready
visibility.
Suspending the pump
The pump may be suspended by a chain. Use a shackle (a) to fasten
the chain to the pump eye bolt (b) as shown in the illustration.
Safety
considerations
Do not lift or suspend the pump by the cable.
The chain and lifting apparatus must be capable of supporting the
pump. See Technical Data for weight and dimensional
information.
Make sure that the chain does not become twisted during
installation. A twisted chain may break, causing the pump to fall.
Do not operate the pump if the cable is hanging loose. An
unrestrained cable can be sucked into the impeller.
CAUTION
Personal injury or equipment damage hazards. An improperly suspended pump
may fall unexpectedly, causing injury or equipment damage.
f Observe the following safety considerations when suspending the pump.
wc_gr007208
a
b
PSC Operation
wc_tx001306gb.fm 17
Notes:
Operation PSC
18 wc_tx001306gb.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.
PSC Operation
wc_tx001306gb.fm 19
Description Description
U Power Lead (Brown) W Power Lead (Black)
V
Power Lead (Blue or Gray)
G Ground (Green/Yellow)
wc_gr007264
Operation PSC
20 wc_tx001306gb.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.
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Wacker Neuson PSC42203 User manual

Category
Water pumps
Type
User manual
This manual is also suitable for

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