Wacker Neuson PSA2 500 Operator's Manual
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Wacker Neuson PSA2 500 Operator's Manual

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Date
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Operator's Manual
PS2 500
PSA2 500
PS2 500, PSA2 500
5000185024
1019
06
EN
5
0
0
0
Pump
1
8
5
0
2
4

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  • Page 1 Operator’s Manual Pump PS2 500 PSA2 500 Type PS2 500, PSA2 500 Document 5000185024 Date 1019 Revision Language...
  • Page 2 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.
  • Page 3 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 ...
  • Page 4 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. wc_tx001355gb.fm...

  • Page 5: Table Of Contents

    PS2 500 / PSA2 500 Table of Contents Foreword Safety Information Signal Words Used in this Manual ..............7 Machine Description and Intended Use ............7 Operating and Electrical Safety ..............9 Service Safety ..................... 10 Labels ......................11 Lifting and Transporting Installation Components ....................
  • Page 6 Table of Contents PS2 500 / PSA2 500 Reassembly ....................30 Troubleshooting ................... 31 Technical Data Standard Specifications ................32 Operating Specifications ................32 Dimensions ....................33 Schematics AEM Safety Manual EC Declaration of Conformity wc_bo5000185024_06TOC.fm...

  • Page 7: Safety Information

    Note: A Note contains additional information important to a procedure. 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.
  • Page 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.

  • Page 9: Operating And Electrical Safety

     Safety-toed footwear  Replacement When replacement parts are required for this machine, use only Wacker Neuson parts replacement parts or those parts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.

  • Page 10: Service Safety

    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.

  • Page 11: Labels

    PS2 500 / PSA2 500 Safety Information Labels A nameplate listing the model number, item number, revision number, and serial number is attached to each Wacker Neuson Corporation unit. Please record the information found on this nameplate Menomonee Falls, WI 53051 USA so it will be available should the nameplate become lost or damaged.

  • Page 12: Lifting And Transporting

    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...

  • Page 13: Installation

    PS2 500 / PSA2 500 Installation Installation Components wc_gr001185 Ref. Description Ref. Description Lifting handle Seal-mechanical Coupling Lubricant Oil lifter Seal-dust Oil plug Sleeve Cover-suction Housing-oil Strainer Wear ring Cable assembly Impeller wc_tx001592gb.fm...

  • Page 14: Preparing The Machine For First Use

    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. CAUTION! Personal injury hazard. Failure to observe this caution can lead to electrical shock, current leakage, fire, water leakage, or other problems.

  • Page 15: Preparing For Installation

    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.

  • Page 16: Discharge Fittings

    Installation PS2 500 / PSA2 500 DO NOT measure the insulation resistance with insulation resistance tester for the following parts. It will cause damage (Model PSA 2 500). CAUTION Improper ways to measure insulation resistance Between the plug prongs. Between the electrodes on the level relay unit.

  • Page 17: Electrical Wiring

    PS2 500 / PSA2 500 Installation Electrical Wiring 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.
  • Page 18 Installation PS2 500 / PSA2 500 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.

  • Page 19: Cable Assembly

    PS2 500 / PSA2 500 Installation Cable Assembly 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.

  • Page 20: Operation

    Operation PS2 500 / PSA2 500 Operation 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.
  • Page 21 Operation In case of very excessive vibration, unusual noise or odor, turn off the power immediately and consult your nearest dealer or Wacker Neuson representative. Continuing to operate the pump under abnormal conditions may result in electrical shock, fire, or current leakage.

  • Page 22: Operating Water Level

    (2 in.) PSA 2 500 PS 2 500 wc_gr007106 Operating water level (PSA2 500 only) Starting the Pump: This pump starts when water reaches the electrodes on the level relay unit, conducting current between them. Note: The necessary water level to operate the pump is 115 mm (4-½") from the bottom of the pump.

  • Page 23: Motor Protection System

    PS2 500 / PSA2 500 Operation Motor Protection System The pump has a built-in motor protection system. If an excessive current is detected or the motor overheats, for reasons such as the following, the pump will automatically stop operating regardless of the...

  • Page 24: Emergency Shutdown Procedure

    Operation PS2 500 / PSA2 500 wc_gr000312 Emergency Shutdown Procedure If a breakdown/accident occurs while the machine is operating, follow the procedure below. 4.5.1 Turn off the pump. 4.5.2 Disconnect the power supply. 4.5.3 Contact the rental yard or machine owner.

  • Page 25: Maintenance

    (2) See Inspecting Lubricant and Replacing Lubricant in this section. (3) Specialized know-how is required for inspecting and replacing the mechanical seal. Consult with your nearest dealer or Wacker Neuson representative. (4) Consult with your nearest dealer or Wacker Neuson representative regarding overhauls. wc_tx001357gb.fm...

  • Page 26: Maintenance And Inspection

    Note: Touch-up paint is not supplied. Note that some kinds of damage or looseness may require that the unit be disassembled for repairs. Please consult your nearest dealer or Wacker Neuson representative. Storage When the pump is out of use for an extended period, wash it and dry it thoroughly, then store it indoors.

  • Page 27: Replacement Parts

    PS2 500 / PSA2 500 Maintenance Note: Worn lubricant and other waste products should be disposed of by a qualified agent, in accord with applicable laws. The oil plug gasket should be replaced each time the lubricant is inspected or changed.

  • Page 28: Disassembly And Reassembly

    The procedure for disassembly and reassembly is shown here to the extent necessary for impeller replacement. A specialized environment and facilities are necessary for work on the mechanical seal and the motor parts. Contact your nearest dealer or Wacker Neuson representative in the event such repairs are necessary. Disassembly See Graphic: wc_gr001206 5.7.1...
  • Page 29 PS2 500 / PSA2 500 Maintenance wc_gr001206 wc_tx001357gb.fm...

  • Page 30: Reassembly

    Maintenance PS2 500 / PSA2 500 Reassembly See Graphic: wc_gr001206, wc_gr001205 5.8.1 Mount the dust seal (11) onto the outside of the sleeve (10) as shown in the drawing. When doing so, do not apply oil or other lubrication to the surface where the dust seal contacts the sleeve (a).

  • Page 31: Troubleshooting

    PS2 500 / PSA2 500 Maintenance Troubleshooting Before ordering repairs, carefully read through this manual, then repeat the inspection. If the problem remains, contact your nearest dealer or Wacker Neuson representative. ALWAYS turn off the power before inspecting the pump. Failure to observe this precaution can result in serious accident.

  • Page 32: Technical Data

    Technical Data PS2 500 / PSA2 500 Technical Data Standard Specifications Applicable Liquids, Rain Water, Fountain Water, Ground Water, Consistency and Sand-Carrying Water Temperature 0–40°C (32–104°F) Pump Impeller Semi-Vortex Type Shaft Seal Double Mechanical Seal Bearing Shielded Ball Bearing Motor...

  • Page 33: Dimensions

    PS2 500 / PSA2 500 Technical Data Starting Capacitor-Run Method Discharge 50 (2) mm (in.) Output 0.48 (2/3) kW (Hp) Max. Head 11 (36) m (ft.) Max. Capacity 220 (58) L/min (GPM) Max. Pressure 1.19 (17) kg/cm 2 (psi) Soild Size mm (in.)

  • Page 34: Schematics

    Schematics PS2 500 / PSA2 500 Schematics wc_gr001261 PS2 500 POWER SOURCE SINGLE PHASE Ref. Description Ref. Description Capacitor Miniature protector Main coil Frame grounding Auxiliary coil Ground Wire Colors Black Violet Orange Green White Purple Blue Yellow Shield Pink...
  • Page 35 PS2 500 / PSA2 500 Schematics wc_gr001259 PSA2 500 POWER SOURCE SINGLE PHASE Ref. Description Ref. Description Level Relay Unit Main Coil Transformer Auxiliary Coil Electrode Miniature Protector Capacitor Frame Grounding Triac Ground wc_tx001593gb.fm...
  • Page 36 PORTABLE PUMPS Table of Contents Acknowledgment ..............2 Foreword .................3 Safety Alerts ................4 A Word to the User/Operator ..........5 Follow a Safety Program............6 Prepare for Safe Operation ..........10 Start Safely ................14 Operate Safely ..............16 Shut Down Safely ..............23 Perform Maintenance Safely ..........24 Final Word to the User ............35 Acknowledgment We wish to thank the members of the Association of Equipment Manufacturers for their invaluable...

  • Page 37: Foreword

    Foreword This safety manual is intended to point out some common safety situations that may be encountered during the normal operation and maintenance of your Read and understand pump and to instruct you in safety practices for dealing manuals before with these conditions.

  • Page 38: A Word To The User/Operator

    A Word to the User/Operator It is YOUR responsibility to read and understand this Remember that YOU are the key to safety. Good safety manual and the manufacturer’s manual(s) before safety practices not only protect you but also protect operating this equipment. This safety manual takes you the people around you.
  • Page 39 Follow a Safety Program Be Careful! Human error is the result of many factors: carelessness, fatigue, sensory overload, preoccupation, unfamiliarity with the machine or attachments, or drugs and alcohol, to name a few. You can avoid death or serious injury caused by these and other unsafe work practices.

  • Page 40: Prepare For Safe Operation

    Follow a Safety Program • Never allow children to play near, ride on or Keep in mind that rain, snow, ice, loose gravel, soft operate the equipment ground, slopes, and other site conditions can affect your machine’s operating capabilities. Make sure you •...
  • Page 41 Prepare for Safe Operation Use Caution When Fueling Ultra-Low Sulfur Diesel (ULSD) Fuel Hazard WARNING! Avoid injury from fire or explosion. Never fill the fuel tank with the engine running, while Avoid Static Electricity Risk When Fueling smoking or when near an open flame. WARNING! Ultra-Low Sulfur Diesel (ULSD) poses a Never overfill the tank or spill fuel.

  • Page 42: Start Safely

    Prepare for Safe Operation Loading & Transporting Pumps • Any fitting that is not securely attached to the pump must be removed and secured separately before WARNING! Before loading or unloading any type of transport pump, make sure to wear all necessary PPE such as •...

  • Page 43: Operate Safely

    Start Safely Starting Aids Ether/cold start fluid is HIGHLY FLAMMABLE. Before If you have trouble starting the engine and need to use using it, always read the instructions on the ether/ jumper cables, follow the instructions in manufacturer’s cold start fluid container and the instructions in the operating manual(s).
  • Page 44 Operate Safely Pumps in General Keep hands and feet clear of moving parts. DO NOT stick fingers into a pump when in operation. Check suction strainer and hose regularly for proper Safe Working Procedures submergence and to be sure it is free of obstructions. USE COMMON SENSE! Most accidents can be NEVER operate a self-priming pump unless the volute avoided by using common sense and concentrating...
  • Page 45 Operate Safely Before Starting • Be sure to open all manual valves slowly to prevent Check the pump thoroughly at delivery for any shipping WATER HAMMER damage. • Check all warning and safety devices and indicators Locate the pump in an accessible location, as close to •...
  • Page 46 Operate Safely Electric Motor Driven Pumps If circuit breaker or fuse is tripped, examine the system for the problem before restarting pump. Allow only qualified personnel to INSTALL, WIRE and NEVER use the power cord to aid lifting the pump. OPERATE electric motor driven pumps.

  • Page 47: Shut Down Safely

    Shut Down Safely WARNING! Avoid death or serious injury. Never leave a machine unattended with the engine running. Safe Shutdown The detailed shutdown procedure is given in your manufacturer’s manual(s). In general, this includes: • Stop machine • Position controls in neutral or locked position Shut engine off, •...
  • Page 48 Perform Maintenance Safely WARNING! Avoid death or serious injury from entanglement. Do not wear loose clothing or accessories. Stay away from all rotating components when the engine is running. Contact, wrapping or entanglement with rotating or moving parts could result in Avoid rotating parts death or serious injury.
  • Page 49 Perform Maintenance Safely Attach a “DO NOT OPERATE” warning tag to the control Sizing Extension Cords levers. Lock out the unit according to the manufacturer’s Use the following chart to select the correct size exten- operating manual. If there is a key, remove it and take it sion cord to prevent excessive amperage draw or volt- with you.
  • Page 50 Perform Maintenance Safely Ultra-Low Sulfur Diesel (ULSD) Hazard Hydraulic System Hazards WARNING! Ultra-Low Sulfur Diesel (ULSD) poses a Be sure to follow manufacturer’s instructions for relieving greater static ignition hazard than earlier diesel fluid pressure before performing any maintenance. The formulations with higher sulfur content.
  • Page 51 Perform Maintenance Safely Battery Hazards The liquid in batteries contains acid, which is a POISON and could cause SEVERE CHEMICAL BURNS. Avoid injury: • Wear a face shield to prevent contact with your eyes • Wear chemical-resistant gloves and clothing to keep Wear hand electrolyte off your skin and regular clothing protection...
  • Page 52 Perform Maintenance Safely Complete Service and Repairs Before Machine is Released Tighten all bolts, fittings, and connections to torques Recheck all fluid levels before releasing the equipment specified by the manufacturer. for operation. Are there any missing cotter pins, washers, locknuts, All parts should be inspected during repair and replaced etc.? Are there any parts left over? if worn, cracked or damaged.

  • Page 53: Final Word To The User

    Final Word to the User You have just finished reading the AEM Portable Pumps Safety Manual. It is impossible for this manual to cover every safety situation that you may encounter on a daily basis. Your knowledge of these safety precautions and your application to the basic rules of safety will help to build good judgment in all situations.
  • Page 54 AEM Safety Manual AEM Safety chapter-pump.fm...
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  • Page 59 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI. 53051 Tel.: (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

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