Wacker Neuson PS 2 1503 User manual

Pump
PS (3-Phase)
Series
OPERATOR’S MANUAL
0154626en 002
0409
0154626EN

PS (3-Phase) Series Table of Contents
wc_bo0154626002enTOC.fm 1
1. Foreword 3
2. Safety Information 4
2.1 Operating and Electrical Safety ............................................................ 5
2.2 Information Labels ................................................................................ 5
3. Technical Data 6
3.1 Standard Specifications ........................................................................ 6
3.2 Operating Specifications (50 Hz) .......................................................... 7
4. Operation 11
4.1 Names of Parts ................................................................................... 11
4.2 Prior to Operation ............................................................................... 12
4.3 Installation .......................................................................................... 13
4.4 Electrical Wiring .................................................................................. 16
4.5 Operation ............................................................................................ 19
5. Maintenance 23
5.1 Periodic Maintenance Schedule ......................................................... 23
5.2 Maintenance and Inspection .............................................................. 24
5.3 Disassembly and Reassembly ........................................................... 26
5.4 Troubleshooting .................................................................................. 33

Table of Contents PS (3-Phase) Series
wc_bo0154626002enTOC.fm 2

Foreword
wc_tx000001gb electric.fm 3
1. Foreword
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.
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.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Corporation reserves the
right to change any portion of this information without notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2007by Wacker Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, without
express written permission from Wacker Corporation.
Any type of reproduction or distribution not authorized by Wacker
Corporation represents an infringement of valid copyrights and will be
prosecuted. We expressly reserve the right to make technical
modifications, even without due notice, which aim at improving our
machines or their safety standards.

Safety Information PS 3-Phase Series
wc_si000041gb.fm 4
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION: Used without the safety alert symbol, CAUTION indicates
a potentially hazardous situation which, if not avoided, may result in
property damage.
Note:
Contains additional information important to a procedure.
DANGER
WARNING
CAUTION

PS 3-Phase Series Safety Information
wc_si000041gb.fm 5
2.1 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, see instruction 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.
2.2 Information Labels
Label Meaning
A nameplate listing the Model Number, Item
Number, Revision, 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, item number, revision number, and serial
number of the unit.
WARNING

Technical Data PS(3-Phase)Series
wc_td000041gb.fm 6
3. Technical Data
3.1 Standard Specifications
ApplicableLiquids,
Consistency and
Temperature
Work drainage and Sand-Carrying Water
0–40°C (32–104°F)
Pump Impeller Open Type
Shaft Seal Double Mechanical Seal
Bearing Shielded Ball Bearing
Motor Specification Dry Submersible Induction Motor (2-Pole)
Insulation Class B: 7.5 to 11 kW
Class E: 1.5 to 5.5 kW
Protection System Circle Thermal Protector
Lubricant SAE 10W/20W
Such as:
–Turbine Oil ISO VG #32
–Shell Victrolia Oil #27
–British Pet Energol THB #32
–Gulf Paramount #32
–Tellus #T22 Shell Oil
–Shell Turbo T32
Connection Coupling (Barb, BSP, QD)
Refer to BOM Product Matrix in Parts Section

PS (3-Phase) Series Technical Data
wc_td000041gb.fm 7
3.2 Operating Specifications (50 Hz)
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly.
PS 2 1503
0009186
0008801-
0008806
PS 3 1503
0009187
0009188
0008807-
0008812
PS 2 2203
0009189
0009190
0008813-
0008818
PS 3 2203
0009191
0009192
0008819-
0008824
Pump
Bore mm
(in.) 50 (2) 80 (3) 50 (2) 80 (3)
Phase 3 3 3 3
Starting Method Direct
Online Direct Online Direct Online Direct Online
Output kW (Hp) 1.5 (2) 1.5 (2) 2.2 (3) 2.2 (3)
Rated Current A
(V) 3.4
(400) 5.5 (400)
Maximum Head m (ft.) 21.5 (71) 14.4 (47) 26 (85) 20.4 (67)
Maximum Capacity L/min
(GPM) 430
(114) 670 (177) 500 (132) 800 (211)
Solid Size Capacity mm (in.) 8.5 (0.3) 8.5 (0.3) 8.5 (0.3) 8.5 (0.3)
Weight* Kg (lbs.) 29 (64) 29 (64) 32 (71) 32 (71)

Technical Data PS(3-Phase)Series
wc_td000041gb.fm 8
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly.
PS 2 3703
0009193
0009194
0008825-
0008830
PS 3 3703
0009195
0009196
0008831-
0008836
PS 4 3703
0009197
0009198
0008837-
0008842
Pump
Bore mm (in.) 50 (2) 80 (3) 100 (4)
Phase 3 3 3
Starting Method Direct Online Direct Online Direct Online
Output kW (Hp) 3.7 (5) 3.7 (5) 3.7 (5)
Rated Current A
(V) 7.5
(400)
Maximum Head m (ft.) 36.5 (120) 29 (95) 18 (59)
Maximum
Capacity L/min
(GPM) 450
(119) 900 (238) 1440 (380)
Maximum
Pressure psi 50 44 26.4
Solid Size
Capacity mm (in.) 8.5 (0.3) 8.5 (0.3) 8.5 (0.3)
Weight* Kg (lbs.) 55 (121) 55 (121) 55 (121)

PS (3-Phase) Series Technical Data
wc_td000041gb.fm 9
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly.
PS 3 5503
0009199
0009200
0008843-0008848
PS 4 5503
0009201
0009202
0008849-0008854
Pump
Bore mm (in.) 80 (3) 100 (4)
Phase 3 3
Starting Method Direct Online Direct Online
Output kW (Hp) 5.5 (7.5) 5.5 (7.5)
Rated Current A
(V) 10.8
(400)
Maximum Head m (ft.) 32 (105) 22.5 (74)
Maximum Capacity L/min (GPM) 1100
(291) 1750 (462)
Maximum Pressure psi 54 34.6
Solid Size Capacity mm (in.) 8.5 (0.3) 8.5 (0.3)
Weight* Kg (lbs.) 66 (146) 66 (146)

Technical Data PS(3-Phase)Series
wc_td000041gb.fm 10
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly.
PS 4
7503HH
0009203
0009204
0008855-
0008860
PS 4
7503HF
0009205
0009206
0008861-
0008866
PS 4
11003HH
0009207
0009208
0008867-
0008870
0008876
0008877
PS 4
11003HF
0009209
0009210
0008871-
0008874
0008878
0008879
Pump
Bore mm
(in.) 100
(4) 100 / 150 (4 / 6) 100 (4) 100 / 150 (4 / 6)
Phase 3 3 3 3
Starting
Method Direct Online Direct Online Direct Online Direct Online
Output kW (Hp) 7.5 (10) 7.5 (10) 11 (15) 11 (15)
Rated Current A
(V) 14.3
(400) 21.0 (400)
Maximum
Head m (ft.) 40 (131) 31 (102) 49 (159) 32.5 (107)
Maximum
Capacity L/min
(GPM) 1400
(370) 2040 (539) 1440 (380) 2440 (645)
Maximum
Pressure psi 60 44 73 46
Solid Size
Capacity mm
(in.) 8.5
(0.3) 8.5 (0.3) 20 (0.8) 20 (0.8)
Weight* Kg (lbs.) 93 (205) 93 (205) 130 (287) 130 (287)

PS (3-Phase) Series Operation
wc_tx000123gb.fm 11
4. Operation
4.1 Names of Parts
See Graphic: wc_gr000327
Note: This diagram shows the parts layout of a typical PS (Three-Phase) model. The external
appearance and the internal construction may vary slightly, depending on your particular model.
Ref. Description Ref. Description
1. Discharge Outlet 8. Lifting Handle
2. Coupling 9. Mechanical seal
3. Oil Housing 10. Oil plug
4. Lubricant 11. Sleeve
5. Impeller 12. Volute
6. Suction cover 13. Strainer
7. Cable Assembly 14. Plate
wc_gr000327
7
1
2
8
9
10
11
12
13
14
6
5
4
3

Operation PS (3-Phase) Series
wc_tx000123gb.fm 12
4.2 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 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.
CAUTION

PS (3-Phase) Series Operation
wc_tx000123gb.fm 13
4.3 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 my 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.
The supply voltage should be 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.
The pump should be used only for pumping plain water. The pump
should not be used to pump fluids such as oil, salt water, or organic
solvents.
The pump must never be used to pump explosive liquids and should
never be operated in an area where explosive elements might be
present.
The pump must not be used in a partially disassembled state.
Note: Consult your local dealer or Wacker representative before using
with any liquids other than those indicated in this document.
Critical Pressure
Do not use the pump in an area where the water pressure exceeds the
values given below, as it may damage the pump, or cause a short or
electrical shock.
Model Critical Pressure
PS2 1503
PS2 2203
PS2 3703
PS4 3703
PS4 5503
PS3 1503
PS3 2203
PS3 3703
PS3 5503
0.5 MPa (71 PSI)
– discharge pressure during use
= critical pressure
PS4 7503HH
PS4 11003HH PS4 7503HF PS4 11003HF critical pressure = 0.5 MPa (71 PSI)
WARNING
CAUTION

Operation PS (3-Phase) Series
wc_tx000123gb.fm 14
Checks to Make Before Installation
With the megohmmeter, measure the insulation resistance between
each of the power wires and grounding wire to verify the insulation
resistance of the motor.
Reference insulation resistance: 20MWor greater
Note: The reference insulation resistance (20M W or greater) is the
value when the pump is new or has been repaired. For the reference
value after installation, see Maintenance and Inspection.
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.
Precautions During Installation
When installing the pump, pay close attention to its center of gravity
and weight. If it is not suspended properly, it may fall and be damaged
or cause injury.
When transporting the pump manually, be sure to employ manpower
commensurate with the weight of the pump. To avoidback injury when
lifting the pump, bend the knees to pick it up rather than bending your
back only.
Do not under any circumstances install or move the pump by
suspending it from the cable assembly. The cable may be damaged,
causing electrical leakage, shock, or fire.
4.3.1 This pump series is offered with a variety of discharge fittings. Please
refer to theBOM Product Matrix in the Parts Section to identify the type
of discharge fitting used on your pump. Follow procedures noted
below to assure a proper discharge connection.
Threaded Discharge Fitting (BSP) –
Tighten hose coupling or discharge pipe securely and with proper
gaskets.
Quick Disconnect Coupling (QD) –
Assure coupling is tightened securely to pump discharge fitting and
WARNING
CAUTION

PS (3-Phase) Series Operation
wc_tx000123gb.fm 15
companion coupling is securely fastened with proper gaskets.
Barbed Discharge Fitting (Barb) –
Place hose clamp over hose and push hose to the base of the
discharge fitting. Tighten the hose clamp to secure the hose in place.
4.3.2 Avoid dropping the pump or other strong impact. Lift the pump by
holding it firmly with the hands or by attaching a wire rope (a) or chain
to the handle.
Note: For proper procedures for handling the cable assembly, refer to
Section Electrical Wiring in this manual.
Do not operate the pump dry. Doing so will prevent the pump from
attaining its full potential and may also damage the pump and lead to
a short and electrical shock.
In order to properly discharge water, provide adequate piping to the
area where the pump is mounted. Improper piping may lead to water
leakage or other malfunctions.Install the pump only in an area that can
maintain a proper water level.
4.3.3 Install the pump only in an area that can maintain a proper water level.
Note: For details on the water level necessary for pump operation,
refer to “Water Level During Operation” in the Operation section.
4.3.4 When using a hose to provide piping to the pump, observe the
following:
Use the shortest possible length of discharge hose and minimize the
number of bends. Verify that the end of the hose (discharge side) is
lifted above the water surface (a). If the end of the hose is submerged
in water, it may cause the water to flow back (b) when the pump has
been stopped. If the end of the hose is located at a level that is lower
than that of the source water surface, water may continue to flow out
even after the pump has been stopped.
Note: Appropriate piping materials must be provided by the user.
Piping materials are not included with the product
..
If large quantities of sediment are drawn into the pump, damage
resulting from wear to the pump can lead to current leakage and
electrical shock.
4.3.5 Use the pump in the upright position. To prevent the pump from
becoming submerged in mud, mount it on a block or other firm base if
necessary.
4.3.6 If used in a permanent installation, where the pump is not readily
accessible after installation, please contact Wacker for a duplicate
nameplate to be installed at the wellhead or on the control box so that
it will be readily visible.
See Graphic: wc_gr000328, wc_gr000329, and wc_gr000330
CAUTION
CAUTION

Operation PS (3-Phase) Series
wc_tx000123gb.fm 16
4.4 Electrical Wiring
Performing electrical wiring
Electrical wiring should be performed by a qualified person in accord
with all applicable regulations. Failure to observe this precaution not
only risks breaking the law but is extremely dangerous.
Incorrect wiring can lead to current leakage, electrical shock or fire.
ALWAYS make sure the pump is equipped with the specified overload
protectors andfuses or breakers, soas topreventelectrical shockfrom
a current leak or pump malfunction.
Operate within the capacity of the power supply and wiring.
Grounding
DO NOT use the pump without first grounding it properly. Failure to
ground it can lead to electrical shock from a current leak or pump
malfunction.
DO NOT attach the grounding wire to a gas pipe, water pipe, lightning
arrestor or telephone grounding wire. Improper grounding can result in
electrical shock.
Cable Assembly
If it is necessary to extend the cable assembly, use a core size equal
to or larger than the original. This is necessary not only for avoiding a
performance drop, but to prevent cable overheating which can result in
fire, electrical leakage or electrical shock.
wc_gr000329
b
c
wc_gr000330
wc_gr000328
a
WARNING
WARNING
CAUTION
CAUTION

PS (3-Phase) Series Operation
wc_tx000123gb.fm 17
If a cable with cut insulation or other damage is submerged in the
water, there is a danger of damage to the pump, electrical leakage,
electrical shock, or fire.
Be careful not to let the cable assembly be cut or become twisted. This
may result in damage to the pump, electrical leakage, electrical shock,
or fire.
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, to prevent electrical leakage, electrical shock, or fire.
DO NOT allow the cable assembly wires or power supply plug to
become wet.
Make sure the cable does not become excessively bent or twisted, and
does not rub against a structure in a way that might damage it.
If used in a deep-well installation, the cable assembly should be
secured every twenty feet.
Connecting the power supply
Before connecting leads to the terminal strip, make certain the power
supply is turned off (circuit breaker, etc.), to avoid electrical shock,
shorting, or unexpected starting of the pump, leading to injury.
This pump series is offered with a variety of cable assembly
connections. Please refer to the BOM Product Matrix in the Parts
Section 2 to identify the type of cable assembly connection used on
your pump. Follow the procedures noted below to assure proper cable
assembly connection.
Without Plug –
Tighten the ends of the cable assembly securely against the terminal
board. If installation of grounded plug is required, use only properly
rated and approved CEE plug and secure ends of the cable assembly
securely to power and ground terminals in accordance with plug
manufacturer’s instructions.
Grounded Plug –
Connect only to receptacle of proper voltage and current rating
matching that of the plug provided with the cable assembly.
See Graphic: wc_gr000339
WARNING
UVWG
Br LBG/Y
wc_gr000339

Operation PS (3-Phase) Series
wc_tx000123gb.fm 18
Wiring Diagram
Direct-on-line starting
Wiring Diagram
See Graphic: wc_gr000340
If connected to a circuit protected by a fuse, use a time-delay fuse with
this pump.
Ref. Description Ref. Description
1. Coil 2. Circle thermal protector
Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light Blue
1
2
G/Y
B
L
Br
wc_gr000340
CAUTION