Wacker Neuson PSA2 500 User manual

Operator’s Manual
Pump
PS2 500
PSA2 500
Type PS2 500, PSA2 500
Document 5000185024
Date 1019
Revision 06
Language EN
5000185024

Copyright notice © Copyright 2019 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.

PS2 500 / PSA2 500 Foreword
wc_tx001355gb.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.
For spare parts information, please see your Wacker Neuson Dealer, or visit
the Wacker Neuson website at http://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.
The illustrations, parts, and procedures in this manual refer to Wacker Neuson
factory-installed components. Your machine may vary depending on the
requirements of your specific region.
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.
Part No. PS2 500
0008793, 0008794
0008795, 0008796
0009176, 0009177
0009178, 0620124
PSA 2 500
0008787, 0008790
0008791, 0008792
0009179, 0009180
0009181, 0620125

Foreword PS2 500 / PSA2 500
4 wc_tx001355gb.fm
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.

PS2 500 / PSA2 500 Table of Contents
wc_bo5000185024_06TOC.fm 5
Foreword 3
1 Safety Information 7
1.1 Signal Words Used in this Manual ................................................................ 7
1.2 Machine Description and Intended Use ........................................................ 7
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 Preparing for Installation ............................................................................. 15
3.5 Checks to Make Before Installation ............................................................. 15
3.6 Discharge Fittings ........................................................................................ 16
3.7 Electrical Wiring ........................................................................................... 17
3.8 Connecting the Power Supply ..................................................................... 17
3.9 Cable Assembly .......................................................................................... 19
4 Operation 20
4.1 Before Starting ............................................................................................ 20
4.2 Operating Water Level ................................................................................ 22
4.3 Motor Protection System ............................................................................. 23
4.4 Operating Cycle of Automatic Type ......................................................... 23
4.5 Emergency Shutdown Procedure ................................................................ 24
5 Maintenance 25
5.1 Periodic Maintenance Schedule .................................................................. 25
5.2 Maintenance and Inspection ....................................................................... 26
5.3 Storage ........................................................................................................ 26
5.4 Inspecting and Replacing Lubricant ............................................................ 26
5.5 Replacement Parts ...................................................................................... 27
5.6 Disassembly and Reassembly .................................................................... 28
5.7 Disassembly ................................................................................................ 28

Table of Contents PS2 500 / PSA2 500
6 wc_bo5000185024_06TOC.fm
5.8 Reassembly ................................................................................................. 30
5.9 Troubleshooting ........................................................................................... 31
6 Technical Data 32
6.1 Standard Specifications ............................................................................... 32
6.2 Operating Specifications ............................................................................. 32
6.3 Dimensions .................................................................................................. 33
7 Schematics 34
8 AEM Safety Manual 36
9 EC Declaration of Conformity 55

wc_si000405gb.fm 7
PS2 500 / PSA2 500 Safety Information
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.
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 is the safety alert symbol. It is used to alert you to potential personal hazards.
►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.
►To 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.
►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.
►To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.

wc_si000405gb.fm
8
Safety Information PS2 500 / PSA2 500
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 product’s specifications, and up to the flow, head, and suction lift limits
also stated within the product’s 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
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

wc_si000405gb.fm 9
PS2 500 / PSA2 500 Safety Information
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
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.
WARNING
Electric shock hazard.
►To reduce risk of electric shock, connect only to a properly grounded, ground-
ing-type receptacle.
►To reduce risk of electric shock, follow instructions in this manual for proper
installation.
CAUTION
Electric shock hazard. This pump may automatically restart.
►Prior to working on the pump or control panel, all supply circuits must be discon-
nected.
►Do not remove cord and strain relief.

wc_si000405gb.fm
10
Safety Information PS2 500 / PSA2 500
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 to 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.

wc_si000405gb.fm 11
PS2 500 / PSA2 500 Safety Information
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.
MADE IN TAIWAN
Wacker Neuson Corporation
Menomonee Falls, WI 53051 USA

Lifting and Transporting PS2 500 / PSA2 500
12 wc_tx001591gb.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.
Model PSA2 500—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
WARNING
CAUTION
CAUTION
1
wc_gr000259

PS2 500 / PSA2 500 Installation
wc_tx001592gb.fm 13
3Installation
3.1 Components
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

Installation PS2 500 / PSA2 500
14 wc_tx001592gb.fm
3.2 Preparing the Machine for First Use
When the pump is delivered, first perform the following inspection
checks:
• While unpacking, inspect the product for damage during
shipment, and make sure all bolts and nuts are tightened
properly.
• 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.
3.3 Application Area
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 Neuson representative
before using with any liquids other than those indicated in this
manual.
3.3.1 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
CAUTION!
Personal injury hazard. Failure to observe this caution can lead to electrical shock,
current leakage, fire, water leakage, or other problems.
Do not operate this product under any conditions other than those for which it is
specified.
WARNING

PS2 500 / PSA2 500 Installation
wc_tx001592gb.fm 15
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.
3.3.2 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.
3.3.3 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.
3.4 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.
3.5 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: 20MΩor 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.”
CAUTION!
Personal injury hazard. If large quantities of earth are sucked up, damage resulting
from friction in the pump can lead to electrical leakage and shock.
Use the pump in the upright position. To prevent the pump from becoming sub-
merged in mud, mount it on a block or other firm base if necessary.

Installation PS2 500 / PSA2 500
16 wc_tx001592gb.fm
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
3.6 Discharge Fittings
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.
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_gr00025
8
3

PS2 500 / PSA2 500 Installation
wc_tx001592gb.fm 17
3.7 Electrical Wiring
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.
3.8 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.
WARNING
Personal injury hazard. Incorrect wiring can lead to current leakage, electrical
shock or fire.
Electrical wiring should be connected by a qualified person in accordance with all appli-
cable regulations. Failure to observe this precaution not only risks breaking the law but
is extremely dangerous.
WARNING
Electrical shock hazard. Failure to ground the pump properly 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 arrester or
telephone grounding wire.
WARNING
CAUTION

Installation PS2 500 / PSA2 500
18 wc_tx001592gb.fm
Grounded plug
Connect only to receptacle of proper voltage and current rating
matching that of the plug provided with the cable assembly.
Without Plug
Tighten the ends of the cable assembly securely against the terminal
board. If installation of a grounded plug is required, use only a
properly rated and approved CEE plug and secure the ends of the
cable assembly securely to power and ground terminals in
accordance with the plug manufacturer’s instructions.
Br
L
L1 L2
G/Y
wc_gr00030
9
G

PS2 500 / PSA2 500 Installation
wc_tx001592gb.fm 19
3.9 Cable Assembly
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 6 m (20 ft).
CAUTION!
Fire, electrical leakage or electrical shock hazard.
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 to avoid a performance drop, but to prevent
cable overheating.

Operation PS2 500 / PSA2 500
20 wc_tx001356gb.fm
4Operation
4.1 Before Starting
4.1.1 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.
4.1.2 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 “Periodic Maintenance Table.”
4.1.3 The setting on the circuit breaker or other overload protector should
be made in accord with the rated current of the pump.
Note: See “Operating Specifications” for the rated current of the
pump.
4.1.4 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 Model
Test Operation
Do not operate the pump while it is suspended in the air. The recoil
may result in injury or other major accident.
Do not 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 cur-
rent 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.
COUNTERMEASURE: If the supply voltage is outside the tolerance,
possible causes are the power supply capacity or an inadequate
extension cable. Look again at the wiring diagram and make sure the
conditions are proper.
WARNING
WARNING
CAUTION