Wacker Neuson PSG2 500 Operator's Manual
0171940en 002
1008
Pump
PSG2 500
OPERATOR’S MANUAL
0171940EN
PSG2 500 Table of Contents
Foreword 4
1. Safety Information 5
1.1 Operating and Electrical Safety ............................................................ 6
1.2 Information Labels ................................................................................ 6
2. Operation 7
2.1 Names of Parts ..................................................................................... 7
2.2 Prior to Operation ................................................................................. 8
2.3 Installation ............................................................................................ 8
2.4 Electrical Wiring .................................................................................. 10
2.5 Wiring Diagram ................................................................................... 13
2.6 Operation ............................................................................................ 14
3. Maintenance 17
3.1 Periodic Maintenance Table ............................................................. 17
3.2 Maintenance and Inspection .............................................................. 18
3.3 Disassembly/Reassembly .................................................................. 20
3.4 Disassembly ....................................................................................... 21
3.5 Reassembly ........................................................................................ 22
3.6 Troubleshooting .................................................................................. 23
4. Technical Data 25
4.1 Standard Specifications ...................................................................... 25
4.2 Operating Specifications (60 Hz) ........................................................ 26
4.3 Dimensions ......................................................................................... 27
wc_bo0171940en_002TOC.fm 3
Foreword
Foreword
This manual provides information and procedures to safely operate
and maintain this Wacker Neuson 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 Neuson
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 Neuson
Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Neuson Corporation
reserves the right to change any portion of this information without
notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2008 by Wacker Neuson 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 Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker
Neuson 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.
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PSG2 500 Safety Information
1. 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.
DANGER
WARNING
CAUTION
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
situation which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
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Safety Information PSG2 500
1.1 Operating and Electrical Safety
To reduce risk of electric shock, connect only to a properly grounded,
grounding-type receptacle.
WARNING
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.
If the power source is protected by a fuse, use a time-delay fuse with
this pump.
CAUTION
1.2 Information Labels
Label Meaning
Wacker Neuson Corporation
Model Item No. Rev.
Serial No.
VHz
Phase
Menomonee Falls, WI 53051 USA
Man. Y/M
THERMALLY PROTECTED
INDOORS OR OUTDOORS
CSA ENCLOSURE 3
Amp.
Conforms to UL Std. 778
Cert. to CAN/CSA St d.
kWkgMax. L/minMax. m
HPlbsMax. GPMMax. ft
CUS
MADE IN TAIWAN
C22.2 No. 108-M89
L
I
S
2001993
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 plate so it will be
available should the nameplate become lost or
damaged. When ordering parts or requesting
R
D
E
T
service information, you will always be asked to
specify the model number, item number, revision
number, and serial number of the unit.
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PSG2 500 Operation
2. Operation
2.1 Names of Parts
See Graphic: wc_gr004637
1
2
7
8
10
3
4
12
14
15
16
wc_gr004637
Ref. Description Ref. Description
1 Lifting handle 9 Lubricant
2 Coupling 10 Shaft
3 Oil lifter 11 Shaft sleeve
4 Oil plug 12 Oil casing
5 Suction cover 13 V-ring
13
11
9
5
6
6 Strainer 14 Impeller
7 Cable assembly 15 Stud bolt
8 Mechanical seal 16 Pump casing
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Operation PSG2 500
2.2 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 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
CAUTION
electrical shock, current leakage, fire, water leakage or other
problems.
2.3 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)
WARNING
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 manual.
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PSG2 500 Operation
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:
WARNING
CAUTION
With the megohmmeter, measure the insulation resistance between
each core lead and the ground lead.
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.”
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.
2.3.1 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.
2.3.2 Install the pump in a location with sufficient water level, where water
collects readily.
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Operation PSG2 500
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.
2.3.3 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.
CAUTION
2.3.4 Use the pump in the upright position. If there is a risk of the pump
drawing in debris or sediment, operate the pump inside a basket or by
enclosing it in a net.
2.3.5 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.
2.4 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
WARNING
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
WARNING
malfunction.
CAUTION
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PSG2 500 Operation
DO NOT attach the grounding wire to a gas pipe, water pipe, lightning
arrester 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,
WARNING
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.
CAUTION
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.
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.
See Graphics: wc_gr000242 and wc_gr004659
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RD
WH
L1
L2
G
GR
wc_gr004659
Operation PSG2 500
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 to avoid a
CAUTION
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.
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PSG2 500 Operation
2.5 Wiring Diagram
See Graphic: wc_gr004640
RD
WH
GN GN
6
RD
BK
WH
2
5
4
1
BU
3
wc_gr004640
Ref. Description Ref. Description
1 Capacitor 6 Ground
2 Main coil 7 Circle thermal protector
3 Auxiliary coil 8 Float switch (normally open
contact)
4 Miniature protector 9 Heater
5 Frame grounding
Wire Colors
BK Black RD Red YL Yellow OR Orange
GN Green TN Tan BR Brown PU Purple
BU Blue VIO Violet CL Clear SH Shield
PK Pink WH White GY Gray LB Light blue
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