Wacker Neuson PS3 1500 User manual

5000187821 03 0112
5000187821
Operator’s Manual
Pump
PS3 1500
PS3 2200
EN

Copyright
notice
© Copyright 2011 by Wacker Neuson Production Americas LLC
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 Production Americas LLC.
Any type of reproduction or distribution not authorized by Wacker Neuson Production
Americas LLC 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 Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com
Original
instructions
This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.

PS3 1500 / PS3 2200 Foreword
wc_tx002040gb.fm 3
Foreword
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine models below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machines.
Machines discussed in this manual:
Machine
documentation
From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
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 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 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 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
Part No. PS3 1500
0009117, 0009118 PS3 2200 0009119

Foreword PS3 1500 / PS3 2200
4wc_tx002040gb.fm
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.

wc_bo5000187821_03TOC.fm 5
Table of ContentsPS3 1500 / PS3 2200
Foreword 3
1 Safety Information 7
1.1 Signal Words Used in this Manual ....................................................... 7
1.2 Machine Description and Intended Use ............................................... 8
1.3 Operating and Electrical Safety ............................................................ 9
1.4 Service Safety .................................................................................... 10
1.5 Labels ................................................................................................. 11
2 Lifting and Transporting 12
3 Installation 13
3.1 Components ....................................................................................... 13
3.2 Preparing the Machine for First Use ................................................... 14
3.3 Application Area ................................................................................. 14
3.4 Maximum Allowable Water Pressure ................................................. 15
3.5 Preparing for installation ..................................................................... 15
3.6 Checks to Make Before Installation .................................................... 17
3.7 Changing the Operating Voltage ........................................................ 18
3.8 Precautions in Installation .................................................................. 20
3.9 Electrical Wiring .................................................................................. 21
3.10 Connecting the power supply ............................................................. 21
3.11 Cable Assembly ................................................................................. 22
4 Operation 23
4.1 Before Starting ................................................................................... 23
4.2 Operating Water Level ..................................................................... 25
4.3 Motor Protection System .................................................................... 25
4.4 Emergency Shutdown Procedure ....................................................... 26
5 Maintenance 27
5.1 Periodic Maintenance Schedule ......................................................... 27
5.2 Maintenance and Inspection .............................................................. 28
5.3 Storage ............................................................................................... 28
5.4 Disassembly and Reassembly ........................................................... 30
5.5 Disassembly ....................................................................................... 31
5.6 Reassembly ........................................................................................ 32
5.7 Troubleshooting .................................................................................. 33

6 wc_bo5000187821_03TOC.fm
Table of Contents PS3 1500 / PS3 2200
6 Technical Data 34
6.1 Standard Specifications .......................................................................34
6.2 Operating Specifications (60 Hz) .........................................................35
7 Schematics 36
8 AEM Safety Manual 39

PS3 1500 / PS3 2200 Safety Information
wc_si000036gb.fm 7
1 Safety Information
1.1 Signal Words Used in this Manual
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.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo avoid death or serious injury from this type of hazard, obey all safety messages that
follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fTo 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.
fTo avoid possible minor or moderate injury from this type of hazard, obey all safety
messages that follow this signal word.

Safety Information PS3 1500 / PS3 2200
8wc_si000036gb.fm
1.2 Machine Description and Intended Use
This machine is a submersible water pump. The Wacker Neuson
Submersible Pump consists of an electric motor, an impeller, a strainer,
and a metal casing with ports for water suction and discharge. Power is
supplied to the pump through a corded plug or a hard-wired connection,
depending on the installation. The operator connects hoses to the pump
and routes them so that water is pumped from the work area and
discharged into an appropriate location.
This machine is intended to be used for general de-watering applications.
This machine is intended for the pumping of clear water, or water
containing solids up to the size stated within the products specifications,
and up to the flow, head, and suction lift limits also 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 hoses, incorrect length hoses, 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

PS3 1500 / PS3 2200 Safety Information
wc_si000036gb.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
Replacement parts
When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to the
original in all types of specifications, such as physical dimensions,
type, strength, and material.
1.3 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.
WARNING

Safety Information PS3 1500 / PS3 2200
10 wc_si000036gb.fm
1.4 Service Safety
Service training
Before servicing or maintaining the machine:
• Read and understand the instructions contained in all manuals
delivered with the machine.
• Familiarize yourself with the location and proper use of all
controls and safety devices.
• Only trained personnel shall troubleshoot or repair problems
occurring with the machine.
• Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
• Do not allow improperly trained people to service or maintain the
machine. Personnel servicing or maintaining the machine must
be familiar with the associated potential risks and hazards.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
servicing or maintaining this machine:
• Close-fitting work clothes that do not hinder movement
• Safety glasses with side shields
• Hearing protection
• Safety-toed footwear
In addition, before servicing or maintaining the machine:
• Tie back long hair.
• Remove all jewelry (including rings).
Replacing parts and labels
• Replace worn or damaged components.
• Replace all missing and hard-to-read labels.
• When replacing electrical components, use components that are
identical in rating and performance as the original components.
• When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to
the original in all types of specifications, such as physical
dimensions, type, strength, and material.

PS3 1500 / PS3 2200 Safety Information
wc_si000036gb.fm 11
1.5 Labels
A nameplate listing the model number, item number,
revision number, and serial number is attached to each
unit. Please record the information found on this nameplate
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
number, item number, revision number, and serial number
of the unit.
CAUTION
Do not attempt to operate this product before reading the
Operator’s Manual and understanding its contents.
Mishandling of this product may result in explosion, fire, or
electrical shock.
Do not pull on the power cord or use the power cord to lift
the pump.
Always use a dedicated ground leakage circuit breaker.
Be sure to install the ground wire securely.
Be sure to disconnect the power supply before handling
or inspecting the pump.
Never insert your hand into the pump inlet holes while the
pump is connected to the power supply.
MenomoneeFalls,WI53051USA
Model ItemNo. Rev.
Serial No.
VHz
kWkgMax.L/minMax.m
MADEIN
JAPAN
HPlbsMax.GPMMax.ft &86
/
,
6
7
(
'
5
Phase C22.2 No.108-M89

Conformsto UL Std.778
Cert. to CAN/CSA Std.
Amp.
Man.Y/M YTHERMALL PROTECTED
INDOORS OR OUTDOORS
CSA ENCLOSURE 3
Wacker Neuson ProductionAmericas LLC

Lifting and Transporting PS3 1500 / PS3 2200
12 wc_tx001959gb.fm
2 Lifting and Transporting
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.
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.
WARNING
CAUTION

PS3 1500 / PS3 2200 Installation
wc_tx001974gb.fm 13
3 Installation
3.1 Components
Ref. Description Ref. Description
1. Coupling 9. Dust Seal
2. Mechanical Seal 10. Wear Ring
3. Gasket 11. Oil Housing
4. Sleeve 12. Impeller
5. Cable Assembly 13. Volute
6. Lifting Handle 14. Strainer
7. Lubricant 15. Retainer Plate
8. Oil Plug
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
wc
_
gr000321

Installation PS3 1500 / PS3 2200
14 wc_tx001974gb.fm
3.2 Preparing the Machine for First Use
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.
3.3 Application Area
If the pump is used to drain a swimming pool, the pump must be
connected to a Ground Fault Interrupter (GFI).
If the pump is used in fountains, the pump must be connected to a
Ground Fault Interrupter (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.
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, current 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 Neuson representative
before using with any liquids other than those indicated in this
document.
CAUTION
WARNING

PS3 1500 / PS3 2200 Installation
wc_tx001974gb.fm 15
3.4 Maximum Allowable Water Pressure
NOTICE:Do not use at greater than the water pressure shown, which
can damage the pump resulting in electrical leakage and electrical
shock.
3.5 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.
Model Maximum Allowable Water Pressure
PS 3 1500/2200 0.3 MPa (43 PSI)

Installation PS3 1500 / PS3 2200
16 wc_tx001974gb.fm
Notes

PS3 1500 / PS3 2200 Installation
wc_tx001974gb.fm 17
3.6 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: 20MW or greater
Note: The reference insulation resistance (20MW or 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
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

Installation PS3 1500 / PS3 2200
18 wc_tx001974gb.fm
3.7 Changing the Operating Voltage
The operating voltage of the motor can be changed from 110V to
220V depending on the available power source.
Requirements
• Pump disconnected from the power source
• Hand tools (screwdriver and wrench)
Procedure
Follow the procedure below to change the operating voltage of the
motor.
3.7.1 Remove the four bolts (c), lockwashers (d), and flat washers (e) that
fasten the housing cover (j) to the motor bracket.
3.7.2 Carefully lift the housing cover.
NOTICE: Avoid entangling the power cord lead wires with internal compo-
nents such as the centifugal switch (p) or the capacitor (o). Be careful not to
damage the O-ring (w) while lifting the housing cover.
3.7.3 Support the housing cover so that it allows access to the terminal box
(q).
WARNING
Electric shock hazard.
fEnsure that the pump is disconnected from the power source before changing
the operating voltage.
wc_gr008856
p

PS3 1500 / PS3 2200 Installation
wc_tx001974gb.fm 19
3.7.4 Remove the plastic cover (not shown) from the front face of the
terminal box. Using a screwdriver, detach and move the lead wires as
needed to configure the operating voltage.
3.7.5 Reinstall the plastic cover.
3.7.6 Make sure that the O-ring (w) and gasket (x) are properly seated.
NOTICE: Replace the O-ring or gasket if either shows signs of damage or
wear.
3.7.7 Lower the housing cover onto the motor bracket. Align the housing
cover as shown.
3.7.8 Fasten the housing cover to the motor bracket.
Result
The operating voltage of the motor has now been changed.
Desired
voltage Terminal block Wire locations
110V Upper L2 and T2 together at position 2 (from left)
Lower T1 and T3 together at position 3 (from left)
220V Upper T2 at position 5 (from left)
Lower T1 at position 4 (from left)
T3 at position 5 (from left)

Installation PS3 1500 / PS3 2200
20 wc_tx001974gb.fm
3.8 Precautions in Installation
3.8.1 The pump is supplied with a threaded discharge fitting. Tighten hose
coupling or discharge pipe securely and with proper gaskets.
3.8.2 Install the pump in a location with sufficient water level, where water
collects readily.
Note: See Operation (“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 thehoseendis lower thanthewatersurface, water may
overflow when the pump is turned off.
3.8.3 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.
If large quantities of earth are sucked up, damage resulting from
friction in the pump can lead to electrical leakage and shock.
NOTICE:When the pump is installed at a work site, make sure the
hose is connected in such a way as to ensure proper drainage.
Otherwise water may leak out and cause damage to surrounding walls
or flooring, or to equipment.
3.8.4 Use the pump in the upright position. To prevent the strainer from
becoming submerged in mud, causing it to suck in sand or debris,
mount it on a block or other firm base.
3.8.5 If used in a permanent installation, where the pump is not readily
accessible after installation, please contact Wacker Neuson for a
duplicate nameplate to be installed at the wellhead or on the control
box so that it will be readily visible.
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.
CAUTION
CAUTION