Wacker Neuson PS2 1503 User manual

Pump
PS (3-Phase)
Series
OPERATOR’S MANUAL
0154623en 002
0107
0154623EN

PS (3-Phase) Series Table of Contents
wc_bo0154623002enTOC.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 (60 Hz) .......................................................... 7
4. Operation 11
4.1 Names of Parts ................................................................................... 11
4.2 Prior to Operation ............................................................................... 12
4.3 Installation .......................................................................................... 12
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 ........................................................... 27
5.4 Troubleshooting .................................................................................. 34

Table of Contents PS (3-Phase) Series
wc_bo0154623002enTOC.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 1500 / PS 3 2200
wc_si000044gb.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 1500 / PS 3 2200 Safety Information
wc_si000044gb.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
Wacker Corporation
Menomonee Falls, WI 53051 USA
Model ItemNo. Rev.
Serial No.
VHz
kWkgMax.L/minMax.m
MADEIN
JAPAN
HPlbsMax.GPMMax.
ft CUS
L
I
S
T
E
D
R
Phase
C22.2No.108-M89
2001992
Conforms to UL Std.778
Cert. to CAN/CSA Std.
Amp.
Man.Y/M
THERMALLY PROTECTED
INDOORS OR OUTDOORS
CSA ENCLOSURE 3

Technical Data PS(3-Phase)Series
wc_td000044gb.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: 10 to 15 HP
Class E: 2 to 7.5 HP
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 (NPT)

PS (3-Phase) Series Technical Data
wc_td000044gb.fm 7
3.2 Operating Specifications (60 Hz)
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly
Part No. PS2 1503
0009120
0009121
0009122
PS3 1503
0009123
0009124
0009125
PS2 2203
0009126
0009127
0009128
PS3 2203
0009129
0009130
0009131
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) 6.1/3.1/2.3
(220/440/575) 9.3/4.7/3.5 (220/440/575)
Maximum Head m (ft.) 23 (75) 14.4 (47) 30.5 (100) 20.4 (67)
Maximum
Capacity L/min
(GPM) 400
(106) 680 (180) 500 (132) 770 (203)
Maxmum
Pressure psi 33 21 43 29.4
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_td000044gb.fm 8
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly
Part No. PS2 3703
0009132
0009133
0009134
PS3 3703
0009135
0009136
0009137
PS4 3703
0009138
0009139
0009140
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) 13.3/6.8/5.3
(220/440/575)
Maximum Head m (ft.) 35 (115) 31 (102) 18.5 (61)
Maximum
Capacity L/min
(GPM) 540
(143) 830 (219) 1460 (386)
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_td000044gb.fm 9
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly
Part No. PS3 5503
0009141
0009142
0009143
PS4 5503
0009144
0009145
0009146
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) 19.5/9.8/7.3
(220/440/575)
Maximum Head m (ft.) 38 (125) 24 (79)
Maximum Capacity L/min (GPM) 985
(260) 1620 (428)
Maximum Pressure psi 54 34.6
Solid Size Capacity mm (in.) 8.5 (.3) 8.5 (.3)
Weight* Kg (lbs.) 66 (146) 66 (146)

Technical Data PS(3-Phase)Series
wc_td000044gb.fm 10
*The weight (mass) given above is the operating weight of the pump itself, not including the cable
assembly.
Part No. PS4 7503HH
0009147
0009148
0009149
PS4 7503HF
0009150
0009151
0009152
PS4 11003HH
0009153
0009154
0009155
PS4 11003HF
0009156
0009157
0009158
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) 25.5/12.8/9.7
(220/440/575) 38.0/19.0/14.3 (220/440/575)
Maximum
Head m (ft.) 42 (137) 31 (102) 51 (167) 32.5 (107)
Maximum
Capacity L/min
(GPM) 1320
(349) 2079 (549) 1427 (377) 2440 (645)
Maximum
Pressure psi 60 44 72.7 45.8
Solid Size
Capacity mm
(in.) 8.5 (.3) 8.5 (.3) 8.5 (.3) 8.5 (.3)
Weight* Kg (lbs.) 93 (205) 93 (205) 130 (287) 130 (287)

PS (3-Phase) Series Operation
wc_tx000131gb.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
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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 to drain a swimming pool, the pump must be
connected to a Ground Fault Interruptor (GFI).
If the pump is used in fountains, the pump must be connected to a
Ground Fault Interruptor (GFI).
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.
CAUTION
WARNING

PS (3-Phase) Series Operation
wc_tx000131gb.fm 13
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.
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
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.
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)
CAUTION

Operation PS (3-Phase) Series
wc_tx000131gb.fm 14
Precautions During Installation
4.3.1 The pump is supplied with a threaded discharge fitting. Tighten hose
coupling or discharge pipe securely and with proper gaskets.
When installing the pump, be mindful of the pump’s center of gravity
and weight. If the pump is not suspended properly, the pump may fall
and break, which may lead to injury.
When installing or moving the pump, do not suspend the pump by the
cable assembly. Doing so will damage the cable, which may cause a
short, electrical shock, or fire.
When transporting the pump manually, be sure to have a sufficient
number of people to carry out the task. To prevent back injury when
lifting, bend your knees without bending your back.
4.3.2 Handle the pump carefully. Do not drop it or expose it to strong
impacts. When suspending the pump to raise or to lower it, attach a
wire rope (a) or a chain to the pump’s lifting handle.
Note: For proper procedures for handling the cable assembly, refer to
“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.
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 Operation.
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 (b). If the end of the hose is submerged
in water, it may cause the water to flow back (c) 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 an excessive amount of sediment is drawn into the pump, it may
cause the pump to wear, which can lead to current leakage or electrical
shock.
4.3.5 The pump must be placed upright during operation. If there is a risk
that the pump could be buried under the sediment, place the pump on
a base made up of materials such as concrete blocks.
WARNING
CAUTION
CAUTION

PS (3-Phase) Series Operation
wc_tx000131gb.fm 15
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
wc_
g
r000330
wc_
g
r000329
b
c
wc_gr000328
a

Operation PS (3-Phase) Series
wc_tx000131gb.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 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.
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
protectivesleeve, to prevent electrical leakage, electrical shock, orfire.
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.
WARNING
WARNING
CAUTION
CAUTION

PS (3-Phase) Series Operation
wc_tx000131gb.fm 17
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.
4.4.1 Tighten the ends of the cable assembly securely against the terminal
board.
4.4.2 The figure shows how to connect the cable assembly properly.
See Graphic: wc_gr000331
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
WARNING
UVWG
RWBG
wc_
g
r000331

Operation PS (3-Phase) Series
wc_tx000131gb.fm 18
Wiring Diagram
Direct-on-line starting
See Graphic: wc_gr000332
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
B
W
R
wc_gr000332
CAUTION