Wacker Neuson PS 2 500 User manual

Pump
PS 2 500
PS 2 750
PSA 2 500
OPERATOR’S MANUAL
0154625en 003
0409
0154625EN

PS 2 500/PS 2 750/PSA 2 500 Table of Contents
wc_bo0154625003enTOC.fm 3
1. Foreword 4
2. Safety Information 5
2.1 Operating and Electrical Safety ............................................................ 6
2.2 Information Labels ................................................................................ 6
3. Technical Data 7
3.1 Standard Specifications ........................................................................ 7
3.2 Operating Specifications (50 Hz) .......................................................... 8
3.3 Dimensions ........................................................................................... 9
4. Operation 10
4.1 Names of Parts ................................................................................... 10
4.2 Prior to operation ................................................................................ 11
4.3 Installation .......................................................................................... 11
4.4 Electrical Wiring .................................................................................. 15
4.5 Electrical Circuit Diagrams ................................................................. 17
4.6 Operation ............................................................................................ 20
5. Maintenance 25
5.1 Periodic Maintenance Table ............................................................... 25
5.2 Maintenance and Inspection .............................................................. 26
5.3 Disassembly/Reassembly .................................................................. 28
5.4 Disassembly ....................................................................................... 29
5.5 Reassembly ........................................................................................ 30
5.6 Troubleshooting .................................................................................. 31

Foreword
4
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 2007 by 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.

PS 2 500 / PS 2 750 / PSA 2 500 Safety Information
wc_si000040gb.fm 5
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, NOTICE 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 a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE:Used without the safety alert symbol, NOTICE indicates a
hazardous situation which, if not avoided, could result in property
damage.
Note: Contains additional information important to a procedure.
DANGER
WARNING
CAUTION

Safety Information PS 2 500 / PS 2 750 / PSA 2 500
wc_si000040gb.fm 6
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 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
MADE IN TAIWAN

PS 2 500 / PS 2 750 / PSA 2 500 Technical Data
wc_td000040gb.fm 7
3. Technical Data
Machines discussed in this manual:
3.1 Standard Specifications
Part No. PS2 500
0008793, 0008794
0008795, 0008796
0009176, 0009177
0009178, 0620124
PSA 2 500
0008787, 0008790
0008791, 0008792
0009179, 0009180
0009181, 0620125
PS2 750
0008797, 0008798
0008799, 0008800
0009182, 0009183
0009184, 0620126
Applicable Liquids,
Consistency and
Temperature
Rain Water, Fountain Water, Ground Water,
Sand-Carrying Water
0–40°C (32–104°F)
Pump Impeller Semi-Vortex Type: (PS 2 500, PSA 2 500)
Open Type: (PS 2 750)
Shaft Seal Double Mechanical Seal
Bearing Shielded Ball Bearing
Motor Specification Dry Submersible Induction Motor (2-Pole)
Insulation Class E
Protection System Miniature Protector: (PS 2 500, PSA 2 500)
Circle Thermal Protector: (PS 2 750)
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 Hose Coupling (Barb, BSP, QD–2")

Technical Data PS 2 500 / PS 2 750 / PSA 2 500
wc_td000040gb.fm 8
3.2 Operating Specifications (50 Hz)
* The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly.
Part No. PS 2 500 PSA 2 500 PS 2 750
0008793
0008794
0008795
0008796
0009176
0009177
0620124
0009178
0008787
0008790
0008791
0008792
0009179
0009180
0620125
0009181
0008797
0008798
0008799
0008800
0009182
0009183
0620126
0009184
Pump
Electric Power V/Ph/Hz 230/1/50 110/1/50 230/1/50 110/1/50 230/1/50 110/1/50
Rated Current A2.9 6.2 2.9 6.2 6.3 13.9
Starting
Method
Capacitor-Run
Discharge mm (in.) 50 (2)
Output kW (Hp) 0.48 (2/3) 0.75 (1)
Max. Head m (ft.) 11 (36) 16 (52.2)
Max. Capacity L/min
(GPM) 220 (58) 276 (73)
Max. Pressure kg/cm2
(psi)
1.19 (17) 1.83 (26)
Soild Size
Capacity
mm (in.) 6 (0.2)
Weight* Kg (lbs.) 9.5 (21) 10.0 (22) 16.0 (35)

PS 2 500 / PS 2 750 / PSA 2 500 Technical Data
wc_td000040gb.fm 9
3.3 Dimensions
PS 2 750
185
(7.3)
185
(7.3)
414
(16.3)
PSA 2 500
PS 2 500
305
(12)
305
(12) 229
(9)
200
(11)
229
(9)
200
(11)
185
(7.3)
185
(7.3)
185
(7.3)
222
(8.8)
mm (in.)

Operation PS 2 500 / PS 2 750 / PSA 2 500
wc_tx000121gb.fm 10
4. Operation
4.1 Names of Parts
See Graphic: wc_gr001185
Ref. Description Ref. Description
1. Lifting Handle 8. Seal-mechanical
2. Coupling 9. Lubricant
3. Oil Lifter 10. Seal-dust
4. Oil Plug 11. Sleeve
5. Cover-suction 12. Housing-oil
6. Strainer 13. Wear Ring
7. Cable Assembly 14. Impeller
1
27
8
9
10
11
12
13
14
3
4
5
6
wc_gr001185

PS 2 500 / PS 2 750 / PSA 2 500 Operation
wc_tx000121gb.fm 11
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.
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 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 representative before using
with any liquids other than those indicated in this document.
CAUTION
WARNING

Operation PS 2 500 / PS 2 750 / PSA 2 500
wc_tx000121gb.fm 12
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.
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: 20MWor greater
Note: The reference insulation resistance (20MWor greater) is the
value when the pump is new or has been repaired. For the reference
value after installation, see Maintenance and Inspection.
DO NOT measure the insulation resistance with insulation resistance
tester for the following parts. It will cause damage (Model PSA 2 500).
Improper ways to measure insulation resistance
See Graphic: wc_gr000258
1. Between the plug prongs.
2. Between the electrodes on the level relay unit.
3. Between the electrodes on the level relay unit and the plug prongs.
CAUTION
12
wc
_
gr000258
3

PS 2 500 / PS 2 750 / PSA 2 500 Operation
wc_tx000121gb.fm 13
Precautions During Installation
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.
When installing the pump, pay close attention to its center of gravity
and weight. If it is not lowered into place correctly, it may fall and be
damaged or cause injury.
When transporting the pump by hand, be sure to employ manpower
commensurate with the weight of the pump. To avoid back injury when
lifting the pump, bend the knees to pick it up rather than bending your
back only.
4.3.1 This pump series is offered with a variety of discharge fittings. 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
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 rope or chain to the
handle.
Note: On cable assembly handling, see Electrical Wiring.
4.3.3 Install the pump in a location with sufficient water level, where water
collects readily.
Note: See “Operating Water Level” for the water level necessary for
operation. The discharge end of the hose should be located higher
than the water surface. If the end of the hose is submerged, water may
flow back to the pump when the pump is stopped; and if the hose end
is lower than the water surface, water may overflow when the pump is
turned off.
4.3.4 The hose should be run as straight as possible, since excessive
bending will hinder the water flow, preventing sufficient lift, and can
even cause the hose to become clogged with earth. If the hose is
crimped near the pump, air can become trapped in the pump and
cause idle running.
WARNING
CAUTION

Operation PS 2 500 / PS 2 750 / PSA 2 500
wc_tx000121gb.fm 14
If large quantities of earth are sucked up, damage resulting from
friction in the pump can lead to electrical leakage and 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.
DO NOT lift or hang the pump by the level relay unit (1). It will lead to
damage and may cause leakage, electric shock, and fire (Model PSA
2 500).
See Graphic: wc_gr000259
CAUTION
CAUTION
1
wc_gr000259

PS 2 500 / PS 2 750 / PSA 2 500 Operation
wc_tx000121gb.fm 15
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 and fuses or breakers, so as to prevent electrical shock from
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.
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.
Before inserting the power supply plug, 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.
Do not use the pump with the cable assembly or plug connected
loosely, which can result in electric shock, shorting, or fire.
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.
NOTICE:Be sure to use a dedicated power supply with a ground
leakage circuit breaker.
Grounded Plug –
Connect only to receptacle of proper voltage and current rating
matching that of the plug provided with the cable assembly.
WARNING
WARNING
CAUTION
WARNING
CAUTION

Operation PS 2 500 / PS 2 750 / PSA 2 500
wc_tx000121gb.fm 16
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.
See Graphic: wc_gr000309
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.
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.
Br
L
L1 L2
G/Y
wc
_
gr000309
G
CAUTION

PS 2 500 / PS 2 750 / PSA 2 500 Operation
wc_tx000121gb.fm 17
4.5 Electrical Circuit Diagrams
See Graphic: wc_gr001261, wc_gr001259, wc_gr001260
PS 2 500 POWER SOURCE SINGLE PHASE
Ref. Description Ref. Description
1. Capacitor 4. Protector
2. Main Coil 5. Frame Grounding
3. Auxiliary Coil 6. Ground
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
Br R1
LW
BL
3
2
5
4
6
G/Y
G/Y
wc_gr001261

Operation PS 2 500 / PS 2 750 / PSA 2 500
wc_tx000121gb.fm 18
PSA 2 500 POWER SOURCE SINGLE PHASE
Ref. Description Ref. Description
1. Level Relay Unit 6. Main Coil
2. Transformer 7. Auxiliary Coil
3. Electrode 8. Miniature Protector
4. Capacitor 9. Frame Grounding
5. Triac 10. Ground
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
Br B
1
LW
BL
7
6
9
8
10
G/Y
G/Y
3
5
2
4
W
R
W
wc_gr001259

PS 2 500 / PS 2 750 / PSA 2 500 Operation
wc_tx000121gb.fm 19
PS 2 750 POWER SOURCE SINGLE PHASE
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 5. Centrifugal Switch
2. Auxiliary Coil 6. Capacitor
3. Heater 7. Frame Grounding
4. Main Coil 8. Ground
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
Br R2
LW
R
5
7
4
8
G/Y LL
6
R
1
1
2
G/Y
3
3
wc
_
gr001260
CAUTION

Operation PS 2 500 / PS 2 750 / PSA 2 500
wc_tx000121gb.fm 20
4.6 Operation
Before starting
4.6.1 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.
4.6.2 Confirm the wiring, supply voltage, circuit breaker capacity, and motor
insulation resistance.
Reference insulation resistance = 20 MΩor greater.
Note: The reference insulation resistance (20 MΩor greater) is the
value when the pump is new or has been repaired. For the reference
value after installation see Maintenance and Inspection.
4.6.3 The setting on the circuit breaker or other overload protector should be
made in accord with the rated current of the pump.
Note: See Standard Specifications for the rated current of the pump.
4.6.4 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.
Non-Automatic Models (PS 2 500, PS 2 750)
Test Operation
NEVER operate the pump while it is suspended in the air. The recoil
may result in injury or other major accident.
NEVER start the pump when people are standing next to it. A current
leak can result in electrical shock.
Run the pump for a short time (3–10 minutes) and confirm the
following:
• Using an ammeter (clamp-on type), measure the operating
current at the L1 and L2 phase wires on the terminal.
COUNTERMEASURE: If the operating current exceeds the rated
value, pump motor overload may be a cause. Make sure the pump has
been installed under proper conditions as described in Installation.
• Using an AC voltmeter (tester), measure voltage at the terminals.
Supply voltage tolerance: within ±5% of rated voltage.
WARNING
WARNING