Operator’s Manual Pump PSG2 500 EN 5000187941 5 0 0 0 1 0112 03 8 7 9 4 1
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.
PSG2 500 Foreword 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.
Foreword PSG2 500 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. 4 wc_tx002041gb.
PSG2 500 1 Table of Contents Foreword 3 Safety Information 7 1.1 1.2 1.3 1.4 1.5 Signal Words Used in this Manual ....................................................... 7 Machine Description and Intended Use ............................................... 8 Operating and Electrical Safety ............................................................ 9 Service Safety .................................................................................... 10 Labels ........................................
PSG2 500 Table of Contents 6 Technical Data 6.1 6.2 6.3 29 Standard Specifications .......................................................................29 Operating Specifications (60 Hz) .........................................................30 Dimensions ..........................................................................................31 7 Schematics 32 8 AEM Safety Manual 33 6 wc_bo5000187941_03TOC.
PSG2 500 1 1.1 Safety Information Safety Information 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. This is the safety alert symbol. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.
Safety Information 1.2 PSG2 500 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.
PSG2 500 Safety Information 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.
Safety Information 1.4 PSG2 500 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.
PSG2 500 1.5 Safety Information Labels Wacker Neuson Corporation Menomonee Falls, WI 53051 USA Model Item No. Man.Y/M Serial No. V Hz Phase THERMALLY PROTECTED INDOORS OR OUTDOORS CSA ENCLOSURE 3 Amp. Max.m Max.L/min kg kW Max. ft Max.GPM lbs HP Rev. Conforms to UL Std. 778 Cert. to CAN/CSA St d. C22.2 No.108-M89 R C L I STED 2001993 A nameplate listing the model number, item number, revision number, and serial number is attached to each unit.
Lifting and Transporting 2 PSG2 500 Lifting and Transporting WARNING 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.
PSG2 500 3 Installation Installation 3.1 Components 1 2 7 8 10 4 13 11 3 9 12 14 15 16 5 6 wc_gr004637 Ref. Description Ref. 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 6 Strainer 14 Impeller 7 Cable assembly 15 Stud bolt 8 Mechanical seal 16 Pump casing wc_tx001977gb.
Installation 3.2 PSG2 500 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.
PSG2 500 Installation 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. 3.3.
Installation 3.5 PSG2 500 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: 20MΩ or greater Note: The reference insulation resistance (20MΩ or greater) is the value when the pump is new or has been repaired.
PSG2 500 3.7 Installation Connecting the Power Supply WARNING CAUTION 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.
Installation 3.8 PSG2 500 Cable Assembly CAUTION 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 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.
PSG2 500 4 4.1 Operation 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. 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 MΩ or greater.
Operation CAUTION WARNING PSG2 500 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. In case of very excessive vibration, unusual noise or odor, turn off the power immediately and consult your nearest dealer or Wacker Neuson representative.
PSG2 500 4.2 Operation Operating Water Level CAUTION Do not operate the pump below the C.W.L. (Continuous running Water Level) indicated below. Failure to observe this condition may result in damage to the pump, current leakage or electrical shock. 5 mm (0.20") wc_gr004663 4.3 Emergency Shutdown Procedure If a breakdown/accident occurs while the machine is operating, follow the procedure below. wc_tx001992gb.fm 4.3.1 Turn off the pump. 4.3.2 Disconnect the power supply. 4.3.
Maintenance 5 PSG2 500 Maintenance 5.1 Periodic Maintenance Schedule The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. Pump Weekly Measure insulation resistance. Reference insulation resistance = 1MΩ or greater. (1) Measure operating current. Compare with rated current. Measure supply voltage.
PSG2 500 5.2 Maintenance Maintenance and Inspection WARNING 5.2.1 Regular maintenance and inspections are a necessity for continued efficient functioning of the pump. If any abnormal conditions are noticed, refer to the Troubleshooting section and take corrective measures immediately. It is recommended that a spare pump be kept ready in case of any problems. Prior to inspecting Before inspecting the pump, make certain the power supply (circuit breaker, etc.) is turned off.
Maintenance PSG2 500 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. 1 1 2 2 3 3 4 wc_gr004661 Ref. Description Ref. Description 1. Oil inlet 3. Oil plug 2. Gasket 4. Allen wrench Pump Model Lubricant Capacity PSG2 500 150 ml (5.1 fl. oz.) 5.4 Replacement Parts The table lists the parts that need to be replaced periodically.
PSG2 500 5.5 Maintenance Disassembly and Reassembly WARNING Before disassembling the pump, make certain the power supply (circuit breaker, etc.) is turned off. Then, unplug the cable assembly from the receptacle or detach it from the terminals. To avoid electrical shock, do not work with wet hands. Do not check the operation of any parts (impeller rotation, etc.) by turning on the power while the unit is partially assembled. Failure to observe these precautions may result in a serious accident.
Maintenance 5.6 PSG2 500 Disassembly CAUTION Note: To enhance serviceability, the PSG2 500 has been designed so that the entire pump portion illustrated below can be disassembled with a 12mm box wrench. . Stand the pump upside down with the discharge connection facing downward during disassembly and reassembly. Exercise care to prevent the pump from tipping, which may lead to injury.. 5.6.1 Remove the three hex bolts with washers (1), then remove the strainer (2) and suction cover (3). 5.6.
PSG2 500 5.7 Maintenance Reassembly The reassembly procedure is in the reverse sequence of disassembly. 5.7.1 Remove sand and other debris from the impeller (5), pump casing (6) and suction cover (3) before reassembly. 5.7.2 Install the V-ring (8) on the outside of the shaft sleeve (7). During the installation, be careful not to apply oil to the area in which the V-ring contacts the shaft sleeve. 5.7.3 During assembly of the pump casing, make sure to press it firmly against the contact surface.
Maintenance 5.8 PSG2 500 Troubleshooting WARNING 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. Problem / Symptom Reason / Remedy Pump will not start • Power is off. Restore power. • Cable assembly is cut or not connected properly.
PSG2 500 6 Technical Data Technical Data 6.1 Standard Specifications Model: PSG2 500 Applicable liquids, consistency and temperature Pump Motor Connection wc_td000252gb.
Technical Data 6.2 PSG2 500 Operating Specifications (60 Hz) Model: PSG2 500 BOM: 0620412 Pump Electric power V/Ph/Hz Rated current A 110/1/60 6.1 Starting method Capacitor-run Discharge mm (in.) 50 (2-inch NPT) Output kW (Hp) 0.48 (2/3) m (ft.) 12 (39.5) Max. capacity L/min (GPM) 240 (62) Max. pressure kg/cm2 (psi) 1.19 (17) Solid size capacity mm (in.) 6 (0.2) Weight* Kg (lbs.) 10.5 (23) Max.
PSG2 500 6.3 Technical Data Dimensions mm (in.) 285 (11.19) 228 (9) 271 (10.69) 210 (8.25) 231 (9.13) 210 (8.25) 174 (6.81) 5 (0.20) wc_gr004656 wc_td000252gb.
Schematics 7 PSG2 500 Schematics RD 1 RD BU WH BK WH GN GN 6 Ref. 3 2 5 4 Description Ref. wc_gr004640 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 Lt.
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, D-80809 München, Tel.: +49-(0)89-3 54 02-0 Fax: +49 - (0)89-3 54 02-390 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.
