2-Wire Deep Well Submersible Pump

Transcription

1 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 SAVE THESE INSTRUCTIONS

2 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 Page 2 of 17

3 Table of Contents Intended Use... 4 Technical Specifications... 4 Important Safety Information... 4 Grounding... 6 Installation Instructions... 6 Connecting to Water Tank Troubleshooting Replacement Parts Limited Warranty Page 3 of 17

4 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 # / # / # / # 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. Page 4 of 17

5 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 Page 5 of 17

6 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. Note: Power supply wire (cable) length in feet. Grounding Cable Size Volts HP / / / Install for the Wire Splicing Installation Instructions 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 Page 6 of 17

7 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 Scotchfill TM 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 Scotchfill TM 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). Page 7 of 17

8 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). Page 8 of 17

9 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 Page 9 of 17

10 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 ( 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). Page 10 of 17

11 6. Let water run until it is clear. (To check the solids in the water, fill a container with water from the pump. If any solids settle after a minute, continue running the pump.) 7. Once the water runs clear, open the gate valve two-thirds of the way and repeat step Once water runs clear at this setting, open the gate valve completely and run the pump until the water is completely clear. 9. Remove the gate valve. (See Figures 11 and 12.) 10. Install a sanitary well seal or pitless adapter unit, well unit, electrical conduit, and surface piping. Installation must meet all applicable national and local codes. Connecting to Water Tank WARNING High pressure and tank explosion hazard! To prevent over-pressurization, install a pressure relief valve capable of releasing pump air flow at 75 psi (517.1 kpa) when using an air-over-water pressure tank. When using a precharged pressure tank, install a pressure relief valve that will release the entire air flow at 100 psi (690 kpa). Install this valve between the pump and the tank. Note: Use only Teflon tape on joints in plastic pipe. Pipe joint compounds can cause cracking in plastics. Do not allow the pump or piping system to freeze. Failure to do so could result in serious damage to the equipment and will void the warranty. Note: Do not allow the pump or piping system to freeze. Failure to do so could result in serious damage to the equipment and will void the warranty. Connecting to Tank/Water System See Figure 11 for illustration of the piping connections to pre-charged pressure tanks. Before starting the pump, check to make sure that pre-charged air pressure is 2 psi (13.8 kpa) below Page 11 of 17

12 the pump cut-in setting. (For example, in a tank used with a psi pressure switch, the precharged pressure should be 28 psi [193.1 kpa].) Adjust the pressure by adding or releasing air from the tire valve located on the top of the tank. Check the precharged pressure annually and adjust as needed. Standard Tank Hook-Up See Figure 12 for an illustration of the piping connections to a standard pressure tank as well as the distance between the air release ports and the tank. Page 12 of 17

13 Troubleshooting Use the table below to troubleshoot problems before contacting service personnel or your local dealer. If the problem continues after troubleshooting, call your local dealer for assistance. Failure Possible Cause Corrective Action Motor will not start but fuses are not blown. Fuses blow or overload protector trips when motor starts. Fuses blow or overload protector trips when motor starts. No voltage at control box or disconnect switch. No voltage at pressure switch. No voltage at control box. Control box is incorrectly wired. Wrong size fuse or wrong size time delay fuse. Wire size too small. Start capacitor defective, blown, or wrong size. Low or high voltage. Power supply wire leads not properly connected to control box. Broken wire in control box. Pump or motor stuck or binding. Install correct fuse or time delay fuse. Replace faulty pressure switch. Rewire supply to control box. Reconnect the control box correctly. Install fuse or time delay fuse of correct size. Install wire of correct size. Start capacitor defective, blown, or wrong size. If voltage variation is greater than 10% of nameplate rating, call power company or water supply to adjust voltage. Reconnect leads to match wiring diagram in control box cover. Reconnect power supply wires so wire color code matches motor lead color code. Disconnect power. Repair or replace defective wire. Make all possible aboveground checks. Page 13 of 17

14 Failure Possible Cause Corrective Action Fuses blow or overload protector trips while motor is running. Pump starts too frequently. Little or no water pumped. Air or milky water discharges from faucets Wire splices for power supply or motor leads grounded, shorted, or open. Low or high voltage. Ambient temperature too high. Control box uses wrong voltage or horsepower rating. Wire size too small. Leaks in system. Defective pressure switch or switch out of adjustment. Leak in check valve(s.) Waterlogged tank. Leak in drop pipe. Pressure switch is too far from tank. Check valve stuck or installed backwards (standard tank only). Low water level (water source). Low voltage. Clogged intake screen. Check valve at pump discharge stuck. Worn impellers and diffusers. Gas in well water. If necessary, pull pump. If pump is locked, replace it. Clean well of all sand and lime before reinstalling pump. Consult licensed electrician or qualified serviceperson. Do not attempt to disassemble pump or motor. If voltage variation is greater than 10% of nameplate rating, call power company to adjust voltage. Check temperature of control box. If necessary, move pump out of direct sunlight. Replace control box if voltage and horsepower ratings on control box nameplate do not match those shown inside box cover. Install wire of correct size. Check tank connections with soapy water. Check plumbing for leaks. Ensure system is airtight and watertight. Adjust or replace pressure switch. Replace if needed. Pre-charged tanks: Adjust air pressure to 2 psi (13.8 kpa) less than cut-in pressure. Replace bladder if needed. Raise drop pipe by increments of one length until water stands in pipe. Replace pipe above that point. Position switch within 1 foot (0.3 m) of tank. If stuck, free valve. If installed backwards, reverse valve position. Determine lowest water level in well while pump is running. Compare to pump depth setting. Lower pump further into well, but at least 5 feet (1.5 m) from bottom of well. Throttle pump discharge until discharge equals recovery rate of well. Notice: Running pump while airlocked can cause loss of prime and serious damage to pump. Install larger wire from meter to control box. Install larger wire from control box to pump. Have power company raise supply voltage if needed. Clean or replace if needed. Free check valve. Make sure system is clear of debris and that pump is running normally in clear water. If there are no obstructions in system, replace pump. Remove air release ports and plug tees. Make sure plugged tees do not leak. If necessary, separate gas from air before it enters pressure tank. Page 14 of 17

15 Failure Possible Cause Corrective Action Air volume control (AVC) not working properly (standard tanks only). Make sure ports and ball check valves are clear. Replace air volume control if needed. Replacement Parts For replacement parts and technical questions, please call Customer Service at Not all product components are available for replacement. The illustrations provided are a convenient reference to the location and position of parts in the assembly sequence. When ordering parts, the following information will be required: item description, item model number, item serial number/item lot date code, and the replacement part reference number. The distributor reserves the rights to make design changes and or improvements to product lines and manuals without notice. Page 15 of 17

16 Limited Warranty Northern Tool and Equipment Company, Inc. ("We'' or "Us'') warrants to the original purchaser only ("You'' or Your ) that the Powerhorse product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of one year from date of purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions. There are no other warranties, express or implied, including the warranty of merchantability or fitness for a particular purpose. If the product does not comply with this limited warranty, Your sole and exclusive remedy is that We will, at our sole option and within a commercially reasonable time, either replace the product or product component without charge to You or refund the purchase price (less shipping). This limited warranty is not transferable. Limitations on the Warranty This limited warranty does not cover: (a) normal wear and tear; (b) damage through abuse, neglect, misuse, or as a result of any accident or in any other manner; (c) damage from misapplication, overloading, or improper installation; (d) improper maintenance and repair; and (e) product alteration in any manner by anyone other than Us, with the sole exception of alterations made pursuant to product instructions and in a workmanlike manner. Obligations of Purchaser You must retain Your product purchase receipt to verify date of purchase and that You are the original purchaser. To make a warranty claim, contact Us at , identify the product by make and model number, and follow the claim instructions that will be provided. The product and the purchase receipt must be provided to Us in order to process Your warranty claim. Any returned product that is replaced or refunded by Us becomes our property. You will be responsible for return shipping costs or costs related to Your return visit to a retail store. Remedy Limits Product replacement or a refund of the purchase price is Your sole remedy under this limited warranty or any other warranty related to the product. We shall not be liable for: service or labor charges or damage to Your property incurred in removing or replacing the product; any damages, including, without limitation, damages to tangible personal property or personal injury, related to Your improper use, installation, or maintenance of the product or product component; or any indirect, incidental or consequential damages of any kind for any reason. Assumption of Risk You acknowledge and agree that any use of the product for any purpose other than the specified use(s) stated in the product instructions is at Your own risk. Governing Law This limited warranty gives You specific legal rights, and You also may have other rights which vary from state to state. Some states do not allow limitations or exclusions on implied warranties or incidental or consequential damages, so the above limitations may not apply to You. This limited warranty is governed by the laws of the State of Minnesota, without regard to rules pertaining to conflicts of law. The state courts located in Dakota County, Minnesota shall have exclusive jurisdiction for any disputes relating to this warranty. Page 16 of 17

17 Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota Made in China Page 17 of 17