Powerhorse 52618 User manual

SAVE THESE INSTRUCTIONS
2-Wire Deep Well Submersible Pump
Owner’s Manual
WARNING: Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item #52618,52607,52608,52611

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Thank you very much for choosing a Powerhorse™product!
For future reference, please complete the owner’s record below:
Serial Number/Lot Date Code: ________________________________
Purchase Date: ____________________________________________
Save the receipt, warranty, and this manual. It is important that you read
the entire manual to become familiar with this product before you begin
using it.
This Deep Well Submersible Pump is designed for certain applications
only. Northern Tool & Equipment is not responsible for issues arising
from modification or improper use of this product such as an application
for which it was not designed. We strongly recommend that this product
not be modified and/or used for any application other than that for which
it was designed.
For technical questions, please call 1-800-222-5381.

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Table of Contents
Intended Use..........................................................................................................................................4
Technical Specifications......................................................................................................................4
Important Safety Information...............................................................................................................4
Grounding..............................................................................................................................................6
Installation Instructions........................................................................................................................6
Connecting to Water Tank..................................................................................................................11
Troubleshooting..................................................................................................................................13
Replacement Parts..............................................................................................................................15
Limited Warranty.................................................................................................................................16

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Intended Use
The Powerhorse 2-Wire Deep Well Submersible Pump is designed to supply water at the required
pressure with high efficiency and a long service life. The pump features an energy-efficient operation
and is designed for use in wells with inside diameters of at least 4 inches.
Very Important: This item is not certified for use with potable water systems. These pumps are
intended for agriculture and grey water applications. Please consult a licensed plumbing contractor
before using in residential water systems.
Technical Specifications
All wiring must meet the National Electrical Code or Canadian Electrical Code requirements, as well
as local code requirements. Use only copper wiring for connections to the pump and control box.
Wiring Connections
Item
HP
Volts
Fuse Size
Standard Dual Elem
#52618
1/2
115
20
10
#52607
1/2
230
20
10
#52608
3/4
230
25
5
#52611
1
230
30
20
Important Safety Information
⚠WARNING
Read and understand all instructions. Failure to follow all instructions may result in serious injury
or property damage.
The warnings, cautions, and instructions in this manual cannot cover all possible conditions or
situations that could occur. Exercise common sense and caution when using this pump. Always
be aware of the environment and ensure that the pump is used in a safe and responsible
manner.
Do not allow persons to operate or assemble the pump until they have read this manual and
have developed a thorough understanding of how it works.
Do not modify this pump in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the product. There are specific applications for which the
product was designed.
Use the right tool for the job. DO NOT attempt to force small equipment to do the work of larger
industrial equipment. There are certain applications for which this equipment was designed.
Products are safer and do a better job at the capacity for which it was intended. DO NOT use
this equipment for a purpose for which it was not intended.
Industrial or commercial applications must follow OSHA requirements.
Installation of this pump must be completed by a certified electrician familiar with local building
codes.

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⚠WARNING
WORK AREA SAFETY
Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.
Using the deep well submersible pumps in confined work areas may put you dangerously close
to other cutting tools and rotating parts.
Do not use the pump where there is a risk of causing a fire or an explosion; e.g., in the presence
of flammable liquids, gases, or dust. The product can create sparks, which may ignite the
flammable liquids, gases, or dust.
Keep children and bystanders away from the work area while operating the pump. Do not allow
children to handle the deep well submersible pumps.
Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in your
work area. Some of these hazards may be hidden from your view and may cause personal injury
and/or property damage if contacted.
⚠WARNING
PERSONAL SAFETY
Stay alert, watch what you are doing, and use common sense when operating the pump. Do not
use it while you are tired or under the influence of drugs, alcohol, or medication. A moment of
inattention while operating the tool may result in serious personal injury.
Wear the proper personal protective equipment when necessary. Use ANSIZ87.1 compliant
safety goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust
mask in dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection
systems, and hearing protection when appropriate. This applies to all persons in the work area.
Do not overreach. Keep proper footing and balance at all times.
Ensure the power is off prior to installation of the pump.
⚠WARNING
ELECTRICAL SAFETY
Permanently ground pump, motor and control box before connecting power cable to power
supply. Connect ground wire to approved ground first, and then connect to equipment being
installed
Motor is supplied with copper grounding wire. Splice wire to copper conductor that matches wire
size shown. See the splicing instruction under Installation.
Do not allow the product to come into contact with an electrical source. The tool is not insulated
and contact will cause electrical shock.
Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators.
There is an increased risk of electric shock if your body is grounded.
Do not expose the control box to rain or wet conditions. Water entering the control box will

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increase the risk of electric shock.
Do not ground to gas line. Fire, explosion, and serious injury could result.
Use only copper wiring for connections to pump and control box.
⚠CAUTION
PUMP USE AND CARE
Do not over exert the deep well submersible pump. Products are safer and do a better job when
used in the manner for which they are designed. Plan your work, and use the correct product for
the job.
Do not run the pump dry.
Check for damaged parts before each use. Carefully check that the pump will operate properly
and perform its intended function. Replace damaged or worn parts immediately. Never operate
the pump with a damaged part.
Disconnect the power from the product and place the switch in the locked or off position before
making any adjustments, changing accessories, or storing the tool. Such preventive safety
measures reduce the risk of starting the tool accidentally.
Use only accessories that are recommended by the manufacturer for use with your pump.
Accessories that may be suitable for one product may create a risk of injury when used with
another tool. Never use an accessory that has a lower operating speed or operating pressure
than the tool itself.
Grounding
Note: Power supply wire (cable) length in feet.
Cable Size
Volts
HP
14
12
10
8
6
4
3
2
1
0
115
1/2
400
650
1020
1610
2510
3880
4810
5880
7170
8720
230
1/2
400
650
1020
1610
2510
3880
4810
5880
7170
8720
230
3/4
300
480
760
1200
1870
2890
3580
4370
5330
6470
230
1
250
400
630
990
1540
2380
2960
3610
4410
5360
Installation Instructions
Install for the Wire Splicing
Splice wire to the motor leads. Use only copper wire for connections to the pump/motor assembly and
control box.
Taped Splice Instructions
(wire size No. 8 [7 mm2] and larger)
1. With a wire cutting tool, cut off the motor leads. Stagger the lead and wire length so that the
second lead is 2"(50.8 mm) longer than first lead and third lead is 2" (50.8 mm) longer than
second.
2. With a wire cutting tool, cut off the power supply wire ends. Match the colors and lengths of wires

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with the colors and lengths of the motor leads.
3. With a wire stripping tool, trim the insulation back 1/2" (12.7 mm) from the ends of the supply wire
and motor leads.
4. Insert the motor lead ends and supply wire ends into the butt connectors (see Figure 2). Match
the colors of the supply wires with the colors of the motor leads.
5. With crimping pliers, indent the butt connector lugs (see Figure 3) to attach the wires.
6. With a knife, cut ScotchfillTM electrical insulation putty into three parts of equal length. Mold the
putty tightly around the butt connectors. Make sure it partially covers the insulated part of the wire.
Note: For wire sizes larger than No. 8 (7mm2), use a soldered joint rather than ScotchfillTM putty
(see Figure 4).
7. Wrap #33 Scotch® tape around each joint tightly. Cover the wire about 1-1/2" (38.1 mm) on each
side of the joint. Make four passes with the tape. When finished, you should have four layers of
tape tightly wrapped around the wire. Press the edges of the tape firmly against the wire (see
Figure 5).

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Note: Carefully wrap the tape around the wire. This will prevent water from entering the splice.
Heat shrink Splice Instructions
(wire sizes No. 14, 12 and 10 AWG [2, 3 and 5mm2])
1. Remove 3/8" (9.5 mm) insulation from the ends of the motor leads and the power supply wires.
2. Place the heat shrink tubing over the motor leads. Position the tubing between the power supply
and the motor.
3. Match the colors of the supply wires with the colors of the motor leads.
4. Insert the supply wire and lead ends into the butt connector and crimp (see Figures 2 and 3).
Match the colors of the supply wires with the colors of the motor leads. Check the lead
connections by gently pulling on them.
5. Center the tubing over the butt connector and apply heat evenly with a torch (a match or lighter
will not supply enough heat). Keep the torch moving. Too much concentrated heat may damage
the tubing (see Figure 6).
Instructions for Mechanical Splice Kit with Plastic Insulators
(wire sizes 14, 12, and 10 AWG [2, 3, and 5 mm2])
1. With a wire cutting tool, cut off the motor leads. Stagger the lead and wire length so that the
second lead is 4" (101.6 mm) longer than the first lead and the third lead is 4" (101.6 mm) longer
than the second.
2. With a wire cutting tool, cut off the wire ends. Match the colors and lengths of wires between the
power supply and the motor.
3. With a wire stripping tool, trim the insulation back 1/2" (12.7 mm) from the power supply wire and
the motor lead ends.
4. Unscrew the plastic caps from the insulators. Place a cap and neoprene gasket sleeve on each
wire to be spliced (see Figure 7).

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5. Slide the insulator body onto one wire end (Figure 7).
6. Insert the wire end into the butt connector and crimp. Match the wire colors between the power
supply and the motor (see Figure 8).
7. Center the insulator body over the splice and slide the gasket sleeves into the body as far as they
will go. Screw the caps onto the insulator body (Figure 9) and tighten by hand for a strong,
waterproof splice.
Power Supply Wire Installation
1. To test the pump, connect it to a proper power supply for a short amount of time (no more than 30
seconds).
2. The power supply frequency and voltage must be within 10% of the frequency and voltage shown
on the product nameplate.
3. Fasten the power supply wire leads to the pump discharge block. Then fasten the leads to the
plastic pipe within 6" (150mm) of the discharge block. Use centering guides to prevent the wire
and pipe from rubbing the well casing.
4. Connect the copper grounding wire to the motor bracket. The grounding wire must have a
diameter at least that of the wires supplying current to the motor. Consult National Electrical Code
or Canadian Electrical Code, as well as local code, for grounding information and safety
guidelines.
5. Use only submersible power supply wires supplied by the pump manufacturer. When lowering the

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pump into the well, secure the supply wires to discharge the pipe at 10 ft. (3.1 m) intervals with
Scotch® #33 electrical tape. Be sure not to damage the pump wires.
Note: To avoid dropping the pump down the well or damaging wires or splices, NEVER allow the
pump wires to support the weight of the pump.
Pump Installation
1. If a standard air-over-water pressure tank is used, install two bleeder orifices about 2 ft. (0.6 m)
apart as shown in Figure 12. Orifices will automatically charge the tank with air. See Figure 12 to
help determine orifice location.
Note: If a precharged tank is used, DO NOT install bleeder orifices. If a pump and pre-charged
tank are replacing a standard tank system, remove bleeder orifices before installing the pump in
the well.
2. To prevent losing the pump down the well, connect a safety rope strong enough to support the
pump and drop the pipe (minimum 5/16" [8 mm] twisted polypropylene or pronila rope) to the
eyelet on the pump discharge. Tie off the other end of the safety rope securely to the well seal,
the well cap, or the pitless adapter.
3. Install piping based on these guidelines:
For installations up to 100’ (30.5 m) in depth, use a 100 psi (689.5 kPa) rated polyethylene
plastic pipe.
For installations up to 220’ (67.1 m) in depth, use a 160 psi (1103.2 kPa) rated polyethylene
plastic pipe.
For depths beyond 220’ (67.1 m), use a galvanized steel pipe for the entire drop pipe.
Initial Start-Up / New Wells
Note: Never operate the pump with the discharge valve completely closed. This can cause significant
pump damage and will void the warranty.
Note:To prevent sand-locking the pump, follow these procedures when starting pump for the first
time. Do not start the pump with the discharge valve completely open unless you have followed
these procedures first.
1. Connect a pipe elbow, a short length of pipe, and a gate valve to the pump discharge (at the
well head).
2. Mount the motor control box (for a 3-wire pump) or fused disconnect switch (for a 2-wire
pump) in a permanently weatherproof place. Make sure that the controls will not be subjected
to extreme heat or excess moisture.
3. Make sure the controls are in the OFF position.
4. Connect the motor leads and the power supply to the motor control box or magnetic starter.
(See the installation wiring diagrams.) Do not start the pump yet.
5. Open the gate valve on the discharge one-third of the way. Start the pump (see Figure 10).