Wacker Neuson PS 43703, Operator'S Manual

Page 1: ...Pump PS 3 Phase Series OPERATOR S MANUAL 0154623en 002 0107 0 1 5 4 6 2 3 E N ...

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Page 3: ...s 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 ...

Page 4: ...Table of Contents PS 3 Phase Series wc_bo0154623002enTOC fm 2 ...

Page 5: ... 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 2007 by Wacker Corporation No part of this publication may be reproduced in any...

Page 6: ...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 a...

Page 7: ...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...

Page 8: ...er 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 Co...

Page 9: ...8 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 ...

Page 10: ...009137 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 ...

Page 11: ...09141 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 ...

Page 12: ...7 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...

Page 13: ...del 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 ...

Page 14: ...s 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 Re...

Page 15: ...ection 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 20MW or greater Note The reference insulation resistance...

Page 16: ...ectrical 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 p...

Page 17: ... 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_gr000330 wc_gr000329 b c wc_gr000328 a ...

Page 18: ...ck 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 l...

Page 19: ...orting 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 U V W G R W...

Page 20: ...ted 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 ...

Page 21: ... may jerk and cause a serious accident involving injury NEVER start the pump where people are present as they may suffer electrical shock from current leakage Be sure to check the pump s direction of rotation when the pump is exposed to atmosphere a Utilize a hoist to stabilize the pump on a level surface while performing this check Operating the pump in reverse while it is submerged in water will...

Page 22: ... state Operating voltage Use an AC voltmeter tester to measure the voltage at the terminal board Power supply voltage tolerance within 5 of the rated voltage COUNTERMEASURE If the power supply voltage deviates from the tolerance value the deviation may be caused by the capacity of the power supply or the extension cable that is used Refer to Section Electrical Wiring in this manual to provide corr...

Page 23: ... including electrical shock a short and injury During a power outage disconnect the power supply to the pump Unintentional operation of the pump after power resumption would be extremely dangerous to people around the pump Unless the cause of a problem is removed the pump will repeat the stop and go cycle eventually resulting in damage to the pump and causing current leakage and electrical shock T...

Page 24: ...eakage and electrical shock The table below shows the water level during operation by output Make sure that the water level will not be under these levels See Graphic wc_gr000335 Model Continuous Running Water Level PS2 1503 PS2 2203 PS3 1503 PS3 2203 120 mm 4 PS2 3703 PS4 3703 PS4 5503 PS3 3703 PS3 5503 150 mm 6 PS4 7503HH PS4 11003HH PS4 7503HF PS4 11003HF 190 mm 7 CAUTION a wc_gr000335 ...

Page 25: ...e the clogged debris and replace any worn parts Lubricant inspection Change lubricant Designated lubricant SAE 10W 20W 2 Change mechanical seal 3 Overhaul This should be carried out even if there are no problems with the pump The frequency depends on how continuously the pump is in use 4 1 If the insulation resistance has become noticeably lower than the previous inspection an inspection of the mo...

Page 26: ...pump motor 5 2 1 Washing the pump Remove accumulated matter from the surface of the pump and wash it with clean water Take special care to remove any debris from the impeller 5 2 2 Inspecting the pump exterior Look for any peeling or chipped paint and make sure the nuts and bolts are fastened tightly Any cracks in the surface should be repaired by cleaning that area drying it and then applying a t...

Page 27: ...he oil can be extracted easily by tilting the pump so that the oil plug faces downward If the oil appears discolored or intermixed with water a likely cause is a defective shaft sealing device i e mechanical seal which requires that the pump be disassembled and repaired See Graphic wc_gr000336 Changing Lubricant Remove the oil plug and drain the oil completely Pour a specified volume of oil into t...

Page 28: ... ml 25 0 fl oz PS2 3703 PS4 3703 PS3 3703 960 ml 32 5 fl oz PS4 5503 PS3 5503 1100 ml 37 2 fl oz PS4 7503HH PS4 11003HH PS4 7503HF PS4 11003HF 760 ml 25 7 fl oz Part Replacement Frequency Mechanical seal Lubrication oil discolored Lubricant SAE 10W 20W Every 6 000 hours or 12 months whichever comes first Gasket and O ring Each time pump is disassembled or inspected Oil seal 1 5 to 5 5 kW 2 to 2 7 ...

Page 29: ...y If the pump was assembled improperly it may lead to abnormal operation electrical shock or water damage This section explains the disassembly and reassembly processes that are involved up to the casing or oil casing in the case of 7 5 kW and 11 kW 10 15 HP models Refer to the structural drawing for the respective model before disassembling Operations involving the disassembly and reassembly of t...

Page 30: ...Maintenance PS 3 Phase Series wc_tx000132gb fm 28 1 2 3 4 5 AA CC 8 9 10 BB DD 11 12 13 14 15 16 17 18 19 20 21 22 23 24 wc_gr000337 ...

Page 31: ...ove the strainer 22 from the pump 5 3 2 Removing the suction cover Remove the bolt and the nut except 2 HP 3 HP washer 20 and the stud bolt 21 and remove the suction cover 19 from the pump 5 3 3 Removing the impeller 14 An impeller puller is available from manufacturer Using a box wrench remove the acorn nut 17 lockwasher 16 and thread cover 15 then remove the impeller 14 sleeve 12 except 5 HP 7 5...

Page 32: ...completing reassembly do not forget to pour the specified amount of lubricant into the pump Note The gaskets and O rings must be replaced with new parts Also replace any parts that are worn or damaged 5 3 6 Using a clean rag without lubricant wipe the sliding surface of the mechanical seal 5 Apply lubricant to the outer circumference of the cushion rubber to facilitate insertion Note For further d...

Page 33: ...PS 3 Phase Series Maintenance wc_tx000132gb fm 31 wc_gr000338 1 2 3 10 8 9 BB DD AA CC 11 6 7 12 13 15 16 17 14 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 ...

Page 34: ... strainer 30 from the pump 5 3 10 Removing the suction cover 25 After removing the bolt 27 washer 26 stud bolt 29 and the lockwasher 28 remove the suction cover 25 from the pump Ref Description Ref Description 1 Bolt 17 O Ring 2 Lock washer 18 Sealing ring 3 Mechanical seal 19 Shim AA Screw 20 Impeller BB Oil Lifter 21 Thread cover CC Screw 22 Nut DD Retaining plate 23 Acorn nut 6 O Ring 24 Gasket...

Page 35: ...arately as a spare part See Graphic wc_gr000338 Reassembly Procedure 5 3 14 The reassembly procedure is the reverse sequence of disassembly Note After completing reassembly do not forget to pour the specified amount of lubricant into the pump Note The gaskets and O rings must be replaced with new parts Also replace any parts that are worn or damaged 5 3 15 Using a clean rag without lubricant wipe ...

Page 36: ...heck if there is an open circuit in the cable assembly or wiring Impeller is obstructed Inspect the pump and remove the obstruction Pump starts but stops imme diately causing the motor pro tector to actuate Impeller is obstructed Inspect the pump and remove the obstruction Voltage drop Correct the voltage to the rated volt age or use an extension cable that meets the stan dard A 50 Hz model is ope...

Page 37: ...a meshed enclo sure The strainer is obstructed or buried Remove the obstruction Place a concrete block under the pump to prevent the pump from picking up debris The motor rotates in reverse Interchange the power supply terminal leads The pump generates noise or vibration The bearing of the motor may be damaged To replace the bearing contact the dealer from whom you purchased the equipment or the W...

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