BIG FLO
Submersible Pumps
INSTA L L ATION, OPERATION,
SERVICE & REPAIR PA R TS
by
by
125 Powder Forest Drive • Simsbury, CT 06070
Tel:
(860) 651-2700
• Fax:
(860) 651-2719
125
Powder
Forest Drive
• Simsbury,
CT 06070
Tel: (860) 651-2700 • Fax: (860) 651-2719
051-023-1 Rev. D
051-023-1 Rev. D
051 023 1 Re
C 12/96
R E D J A C K E T P E T R O L E U M E Q U I P M E N T L I M I T E D WA R R A N T Y
OUR PROMISE OF QUALITY:
Marley Pump Company, a United Dominion Company, guarantees Red Jacket products as to
workmanship, material, and performance when they are properly installed, used and cared for.
OUR COMMITMENT WITHIN THE CONTINENTAL UNITED STATES:
Should any part(s) fail within the parts period specified below, it will be repaired or replaced and returned,
free of charge, provided the part(s) is returned to Red Jacket’s point of manufacture transportation
prepaid.
Should any part(s) fail within the labor period specified below, Red Jacket will also pay for the reasonable
services of an authorized service representative for on-site repair or replacement of the defective part(s).
SCHEDULE OF WARRANTY PERIODS:
Parts
From Date of
Manufacture
Labor
From Date of
Installation*
Submersibles
Except:
Solvent Pumps
18 Months
12 Months
6 Months
3 Months
Leak Detectors
Except:
Solvent Leak Detectors
18 Months
6 Months
6 Months
3 Months
Retractors
6 Months
None
Electronic Systems
Except:
Vapor Probes
Printers
18 Months
12 Months
6 Months
6 Months
None
3 Months
Product
* Installation date will revert to the Date of Manufacture without a previously submitted Installation Report #WAF01 which
was received within 15 days after the installation. Regardless of installation date, under no condition can labor warranty
extend beyond the parts warranty.
EXCLUSIONS:
Normal (Routine) Maintenance:
Normal or routine maintenance such as cleaning, lubricating or adjusting components and assemblies or
for replacing consumable items such as paper, ribbons, filters, bulbs, etc., are excluded from this warranty.
Transportation Damage to Equipment:
Should equipment be damaged in transit or handling, it is the responsibility of the distributor or customer
to file a damage claim with the responsible carrier. Latent damage must be reported to the carrier within
14 days of the date of delivery and an inspection by the carrier must be requested. Damage caused in
transit or by handling is not the responsibility of Red Jacket and is not covered.
WARRANTY DISCLAIMER AND LIMITATION OF LIABILITY:
THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, AND ALL IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE
AFORESAID EXPRESSED WARRANTIES ARE HEREBY DISCLAIMED AND EXCLUDED FROM THIS AGREEMENT.
MANUFACTURER EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL
DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ARISING IN CONNECTION WITH THIS
PRODUCT, INCLUDING WITHOUT LIMITATION PURCHASER’S LOSS OF STORED LIQUIDS OR DAMAGE TO THE
GROUND, UNDERGROUND OR ENVIRONMENT, WHETHER ARISING UNDER THEORIES OF TORT, NEGLIGENCE,
STRICT LIABILITY, CONTRACT OR OTHERWISE.
Some states do not allow the exclusion or limitation of incidental or consequential damages or limitation
on the duration of implied warranties so the above limitation or exclusion may not apply to you. This
warranty gives you specific legal rights and you may also have other rights which vary from state to state.
INSTALLATION, OPERATION,
SERVICE & REPAIR PARTS MANUAL
— FOR —
RED JACKET
“Big-Flo® ”—High Capacity Gasoline Pumps
Submersible Type
Model Numbers - P100H1-1MB**, P150H1-1HB*, P200H1-2MB*,
P200H3-2MB*, P300H3-1K*, P300H3-2HB*, P500H3-2K*
* A Suffix number is added to the end of these model numbers designating the pump length in inches. A suffix “S” after the model number
designates syphon.
** Discontinued February, 1988.
NOTICE
This pumping system requires the following elements:
1. Discharge Manifold Assembly — Installed below grade (NEC/Class I, Group D, Division I area)
2. Motor-Pump Unit Assembly — Installed below grade (NEC/Class I, Group D, Division I area)
3. Control Box/Magnetic Starter
All of the above are U.L. listed when used as a complete system.
An “all inclusive” name plate will be found attached to the extractor nipple seal and can be inspected by removing
the manhole cover directly over the pump. An additional name plate will be found on the control box.
NOTICE
It is important to give the model number and serial number of this pump when corresponding with the factory for
any reason.
ATTENTION INSTALLER
READ THIS IMPORTANT SAFETY INFORMATION BEFORE BEGINNING WORK
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning the life of the product.
DANGER
indicates presence of a hazard which will cause severe personal injury, death or substantial property damage if
ignored.
WARNING
indicates presence of a hazard which can cause severe personal injury, death or substantial property damage if
ignored.
DANGER
CAUTION
indicates presence of a hazard which will or can cause minor
personal injury or property damage if ignored.
NOTICE
indicates special instructions on installations, operations, or
maintenance which are important but not related to
personal injury hazards.
Portions of this product are to be installed and operated in the highly combustible environment of a gasoline storage tank. It is essential that you carefully read and follow the warnings and instructions in this manual to protect
yourself and others from hazards which will result in serious personal injury, death or severe property damage.
byby
125 Powder Forest Drive • Simsbury, CT 06070
125 Powder Forest Drive • Simsbury, CT 06070
Tel: (860) 651-2700 • Fax: (860) 651-2719
Tel: (860) 651-2700 • Fax: (860) 651-2719
WARNING Failure to follow all instructions in proper order can cause personal injury or death. Read all
instructions before installing. All installation work must comply with local code requirements.
If no other codes apply, the latest issue of the National Electrical Code should be followed.
Installation of Red Jacket Petroleum Equipment should be performed only by personnel who
are trained and qualified to do so.
1.
Units should be installed with manholes, or with discharge manifold casting above grade, to allow for ease in servicing.
WARNING Red Jacket line leak detection systems do not function if the submersible pump runs continuously. Running a pump continuously will cause line leak detection systems to not function
which results in a hazard that can cause severe personal injury, death or property damage.
2.
Never wire a submersible pump to run continuously at less than minimum flow rate. The units are designed to operate
continuously at or above minimum flow rate, or with an intermittent duty cycle, not to exceed 20 on/off cycles per hour.
Should it be necessary to operate a unit continuously or when the demand is at a rate less than required per the
paragraph above, a bypass pipe should be installed in the piping to allow for continual product recirculation back into
the storage tank. Regulation of the bypass flow back to the tank can be accomplished by correct sizing of the bypass
line or use of a gate valve.
Single Stage Units
Two Stage Units
P150H1-1HB=10 GPM
P200H1-2MB=15 GPM
P300H3-1K=20 GPM
P200H3-2MB=15 GPM
P300H3-2HB=20 GPM
P500H3-2K=25 GPM
3.
Red Jacket submersibles are not designed to handle abrasives or foreign particles in the product being pumped.
4.
Product temperature must never exceed 85°F as the submersible motors are equipped with thermal overload
protection. Product temperature higher than 85°F may result in tripping of the thermal overload protector.
5.
Pumping water will overload the motor and damage the motor bearings.
6.
These units are designed for use in Class I, Group D atmospheres.
7.
Install pumping system in accordance to applicable codes.
WARNING Proper motor protection must be used on the 2, 3, and 5 H.P. three phase pump models, or motor
warranty is void. To maintain warranty, the magnetic starters used must be supplied by Red
Jacket, or have equivalent protection features defined as follows: 3 leg protection, properly
sized quick trip heaters, and ambient temperature compensated overloads.
FOLLOW DIRECTIONS CAREFULLY
A. Installing Pumping Unit
NOTICE
a.
b.
c.
PACKER
CAUTION
DISCHARGE
MANIFOLD
-2-
Use waterproof non-setting thread sealant approved
for gasoline service on all threads.
2.
Install 6" Riser and Flange into tank opening.
3.
Apply gasket compound to gasket and place on riser flange. Place
Discharge Manifold on gasket to line up outlets as desired. Insert
and tighten four cap screws.
4.
Install piping from Discharge Manifold outlets to Dispensers and/
or loading rack. One or both outlets can be used.
NOTICE
Fig. I
Check these points before installing:
Power supply against equipment voltage rating. For 3 phase
units, request power company identify and tag service wires
for L1-L2-L3 phase sequence. All pumps are designed for use
with 208, 220, 230 or 240 nominal system voltages.
Be certain that pump with syphon valve is installed in proper
tank.
Check equipment received against table on Fig. VII for tank
diameter and bury depth.
Installation of a Ball Valve is recommended on the
discharge side of the pump or discharge of the Big
Flo leak detector housing if used. This will aid in
troubleshooting and line testing.
Line check valves are not required as the pump is
equipped with a built-in Check Valve. However,
whenever two pumps are manifolded together to the
same discharge piping, check valves with expansion
relief are required and should be installed in the
piping in discharge of each pump, as close to
pump housing as possible.
Fig. II
5.
Install 1-1/4" Conduit.
a. On some installations, the short piece of 1-1/4" conduit
furnished with the pump is of proper length.
b. If not of proper length, a new piece of 1-1/4" conduit must
be cut and threaded. Measure the length of the 8" diameter extractor nipple pipe. Cut and thread the 1-1/4"
conduit 1-1/2" longer than the 8" diameter extractor
nipple pipe. Thread the new piece of 1-1/4" conduit into
the packer and tighten. Thread sealant should be used.
Tighten the two set screws in the packer securely against
the 1-1/4" conduit.
6.
Install Pumping Unit.
a. Apply a small amount of lubricating oil to each “O” ring
on Packer. Also lubricate the “O” ring sealing surfaces
inside the Discharge Manifold.
b. Install the Pumping Unit through the Discharge Manifold. Care should be taken to lower the unit as near
vertical as possible, and slowly to prevent damage to “O”
rings or expansion relief valves.
c. Refer to Figures I, II and III. The two “stops” on the
locking ramps at the top of the packer must be lined up
with the corresponding “tabs” at the top of the discharge
manifold (see Fig. I).
Lower the pumping unit through the manifold using
rocking force, if needed, until the packer is down as far as
possible (see Fig. II).
Using a pipe wrench on the 1-1/4" conduit, turn counterclockwise (to the left when viewed from the top), to lock
the pumping unit in.
As soon as the locking ramps engage under the “tabs” the
unit is locked in place and does not require any further
tightening (see Fig. III).
NOTICE
The locking action does not cause the “O” rings to
make a seal; the weight of the unit maintains the
sealing of the “O” rings.
NOTICE
LOCK PUMP
AS SHOWN
IN FIG. III
Fig. III
-3-
B. Wiring Instructions — 208-230V Single Phase
Pumps
SCREWS SHOULD BE TIGHTENED
EVENLY TO INSURE PROPER SEAL.
The motor control box must be located away from the loading
rack in a non-hazardous location (see Fig. Va page 6).
JUNCTION
BOX
1.
Connect the single phase 208 or 230V power supply
from the distribution panel to terminals L1 and L2 in
the motor control box. Each control box should be
wired through a separate fused disconnect switch or
circuit breaker (including neutral, when used), furnished by customer.
2.
Using properly color coded wires, connect wires from
terminals red, black and orange on motor control box
terminal strip to the corresponding color coded wires
in the junction box of the proper submerged pump.
MOTOR
LEADS
a.
CONDUIT SEAL ASSEMBLY
Fig. IV
7.
8.
On some installations, the short piece of 1/4"
vacuum pipe furnished with the syphon pumps
is of proper length.
b.
If not of the proper length, replace with length of
1/4" pipe, 1" longer than the 8" diameter Extractor Nipple. Cover top of 1/4" pipe to keep clean
during installation.
4.
On 1-1/2 and 2 HP pumps, connect wires from terminal Blue-1 and terminal 3 in motor control box to
dispenser control switches (if dispensers are used)
and “on-off” switch at loading rack as shown in Fig.
Va.
Position the end with set screws onto the rubber
ring gasket on the Discharge Manifold. Tighten
the four set screws evenly to pull the 8" pipe
down on the ring gasket.
5.
Manual Overload Reset Switch. The 1 HP pump has
an automatic reset overload protector built into the
motor. Power to the pump must be shut off 5 minutes
to permit the protector to reset. The 1-1/2 and 2 HP
pumps are equipped with a no-liquid, over-temperature switch in the motor and an overload switch in the
motor control box which will cut out if the motor is
overloaded. If the pump fails to operate, or stops,
when there is sufficient product in the storage tank,
check the manual overload reset switch in the control
box cover. Wait 10 minutes for the overload protector
to cool off and then press the reset button.
Install Extractor Nipple Seal.
a.
Install the extractor seal in position as shown on
Fig. VI. After this seal is in place, tighten the
four bolts to force the sealing rings against the
extractor nipple and the conduit. Tighten nut
which compresses the gasket around the 1/4"
vacuum pipe on syphon pumps.
10. Install Elbow, Fittings & Syphon Check Valve. (This
step applies to syphon units only.)
a.
CAUTION If the reset button will not stay in position
this indicates an overloaded motor, or a
short to ground. This condition must be
corrected. If the reset button stays in but
the motor will not pump or continue to
run, the tank is dry.
Install elbow and syphon check valve on top of
the 1/4" vacuum pipe and then run 3/8" copper
tubing from the elbow to the bushing at the high
point of the syphon manifold shown on Page 10.
6.
11. Install Junction Box.
a.
-4-
On 1 HP pumps, connect wires from terminals D1 and
D0 in motor control box to dispenser control switches
(if dispensers are used) and “on-off” controls at loading
rack, as shown on Fig. Va and Vc. The “on-off” control
station must be of explosion-proof construction.
Where loading racks and dispensers are served by the
same submerged pump, the 2-wire switches must be
connected in parallel so the submerged pump can be
controlled from any dispenser or any loading rack.
Install 8" Diameter Extractor Nipple (see table on
page 9, Fig. VII for length).
a.
9.
3.
Pumps with Built-In Syphon Valve (see Fig. VI, page
9).
a.
On 1-1/2 and 2 HP units, run two blue wires from
two blue terminals on motor control box terminal
strip, and connect to two blue wires in the junction box of the pump.
Next, install the Junction Box on top of the
conduit. If necessary to readjust position, do so
by tightening box if possible (not loosening box).
When tightening Junction Box, hold 1-1/4" conduit secure with pipe wrench to prevent unlocking packer in discharge manifold. Replace rubber seal into bottom of Junction Box as shown on
Fig. IV. After positioning as shown, tighten
screws firmly to form a tight seal.
-2-
If an external pilot light is desired to indicate when
the submerged pump is operating, wire as shown in
Fig. Va. Should this light continue to burn when all
switches at dispensers and loading racks are off, this
indicates that one of the dispenser switches is out of
adjustment. On installations with no external pilot
light, the submerged pump should be checked to make
sure it is not operating when all switches are turned
off.
C. Wiring Instructions — 208-230V Three Phase
Pumps
CAUTION
1.
Connect the pump motor leads to terminal T1, T2 and
T3 of the magnetic starter observing color code
shown in Fig. Ve. With gasoline in the tank and the
system purged of air, start the motor and make a
pressure gauge reading of the system pressure with
the discharge valves closed; or, open one valve and
calculate pumping rate.
On some installations “phase converters” are used to obtain a three phase
power supply from a single phase power
source. The use of phase converters may
cause an imbalance between the three
phases and cause damage to the motor.
For this reason, warranty coverage will
not be extended on units installed with
phase converters.
Next, reverse power leads at L1 and L2. Repeat either
head or capacity tests, as described above. If results
are higher than the first test, the rotation of the
second test is correct. If the second test gives lower
performance than the first, reconnect the power
leads to L1 and L2 (as under test 1) for correct
rotation.
Installations where magnetic starter is located away
from the loading rack in a non-hazardous location.
(See Fig. Vb.)
a.
Connect the three phase 208 or 230V power
supply from the master panel to terminals L1, L2
and L3 in the magnetic starter.
b.
Using properly color coded wires, connect a
black wire from terminal T 1 in the magnetic
starter to the black motor lead, in the junction
box of the proper submerged pump. Connect an
orange wire from starter terminal T 2 to the
orange motor lead and a red wire from terminal
T3 to the red motor lead. (See Fig. Ve and Vf.)
c.
There are two remaining blue wires in the submerged pump junction box. Connect either blue
wire to terminal L3 in the Magnetic Starter.
Connect the other blue wire to one side of the
“on-off” controls. The “on-off” controls, if furnished by customer, must be of explosion proof
construction.
d.
Installations using dispensers must be connected for 2-wire control as shown on Fig. Vb
and Ve. Connect a black wire from the other side
of the “on-off” switch to terminal 3 in the magnetic starter.
e.
Installations using loading racks only, may be
connected for two or three wire control. (See Fig.
Ve and Vf.) For three wire control, connect a
black wire from terminal 3 in the magnetic
starter to the “on-off” switch. Connect a red wire
from terminal 2 in the magnetic starter to the
“on-off” switch.
NOTICE
Where the power supply has been properly marked
L1, L 2 and L 3 in accordance with accepted phase
rotation standards, it is possible to predetermine the
proper rotation of these units. The motor power
leads are color coded black, orange and red, and if
connected through the magnetic starter to L1, L2 and
L3 respectively, the motor pump unit will rotate in
the correct direction. (See Fig. Ve.) It is recommended, however, that the performance tests always be made whether or not the power supply has
been properly “phased out”.
D. Starting the System and Completing the Installation
3-wire control requires the use of an
auxiliary contact in the magnetic
starter. This auxiliary contact is not
standard equipment in the starters supplied by Red Jacket, and must be ordered as an option.
1.
Do not start pumps unless ample product is in the
storage tanks.
2.
Pump sufficient product through each dispenser
(150 gallons each is recommended) to purge the
entire system of air. If all air is not purged, the
computers may “creep” slightly when the dispenser
switch is turned on, but no product has been dispensed.
3.
On pumps equipped with built-in syphon, it is necessary to run the submerged pump at least 10 to 20
minutes continuously to purge the air from the
syphon manifold.
4.
After the above checks have been made, the backfill
can be completed and the manholes installed as
shown on Fig. VII.
WARNING Installations with the magnetic starter
in a hazardous location require explosion proof starters. The wiring is the
same as for general purpose enclosures.
2.
Motor Rotation.
Where it is not convenient to predetermine the
power supply phase rotation, proper rotation can be
determined by pump performance. Pump head pressure and capacity will be considerably less than
rated when rotating backwards.
-3-
-5-
WARNING
REPRESENTATIVE WIRING DIAGRAM, 1Ø, TWO WIRE CONTROL
L2
CONTACTOR COIL
L1
230 V
N
115 V 115 V
L1
BLUE
LINE 1
LINE 2
T1
BLACK
START
Fig. Va
ORANGE
L3
T2
T3
THERMAL OVERLOAD
PROTRACTOR
ORANGE
BLACK
L2
BLACK
BLACK
BLACK
MOTOR
RED
RED
RED
START
BLUE
THERMAL
OVERLOAD
RUNNING
CAPACITOR
STARTING
CAPACITOR
WHITE
RED
BLUE
1
BLUE
BLUE
2
TWO WIRE CONTROL
3
EXT
PILOT
TO NEUTRAL OF 115/230 V SUPPLY
WHITE
WHITE
2
6
3 4
STARTING RELAY
WHITE
BLACK
WARNING
115 V EXTERNAL
PILOT LIGHT
(50 WATT MAX)
BLUE
1
BLUE
THREE WIRE CONTROL
STOP
START
BLACK
2
3
MOTOR CONTROL BOX
WIRING DIAGRAM
1-1/2 & 2 H.P.
The control box must be
grounded for personal
safety. Refer to the National Electrical Codes and
applicable local codes for
proper grounding procedures.
Fig. Vc
Fig. V
WARNING
-6-
The warnings on this page and throughout this manual indicate the presence of
a hazard which can cause severe personal injury, death or substantial property
damage if ignored.
If 115V is not available from
power supply, pilot lights
may be operated from any
115V lighting circuit by controlling with a 4-pole
starter. Otherwise, 230V pilot lights must be used.
NOTICE
WARNING
The control box must be grounded
for personal safety. Refer to the National Electrical Codes and applicable local codes for proper grounding procedures.
REPRESENTATIVE WIRING DIAGRAM, 3Ø, TWO WIRE CONTROL
Fig. Vb
The control box must be grounded
for personal safety. Refer to the National Electrical Codes and applicable local codes for proper grounding procedures.
WARNING
208/230V, 3 PHASE
POWER SUPPLY
L1
L2
WARNING
208/230V, 3 PHASE
POWER SUPPLY
BLUE
L3
L1
L2
The control box must be grounded
for personal safety. Refer to the National Electrical Codes and applicable local codes for proper grounding procedures.
BLUE
L3
SWITCH AT LOADING RACK
STOP
BLACK
230V
COIL
BLUE
RED
SWITCHES AT LOADING
RACKS AND/OR IN
DISPENSERS CONNECTED
IN PARALLEL
BLACK
START
230V
COIL
NOTICE
BLUE
T1
T2
T1
T3
T2
T3
BLUE
BLUE
TO EXIT
PILOT LITE
115V SUPPLY
TO EXIT
PILOT LITE
115V SUPPLY
RED
BLACK
BLACK
NOTE:
OBSERVE COLOR CODE L1, L2,
L3 PHASE SEQUENCE FOR
PROPER ROTATION OF MOTOR.
208/230V, 3 PHASE
POWER SUPPLY
THERMAL
OVERLOAD
NOTE:
OBSERVE COLOR CODE L1, L2,
L3 PHASE SEQUENCE FOR
PROPER ROTATION OF MOTOR.
208/230V, 3 PHASE
POWER SUPPLY
THERMAL
OVERLOAD
THREE WIRE CONTROL
TWO WIRE CONTROL
3 PHASE MOTOR WIRING DIAGRAM
Fig. Vd
RED
ORANGE
ORANGE
3-wire control requires the use of an
auxiliary contact
in the magnetic
starter. Furnas interlock
kit
or
49D221251 or equivalent.
3 PHASE MOTOR WIRING DIAGRAM
Fig. Ve
Fig. V
WARNING
The warnings on this page and throughout this manual indicate the presence of
a hazard which can cause severe personal injury, death or substantial property
damage if ignored.
-7-
BIG-FLO® LEAK DETECTOR SUGGESTED INSTALLATIONS MANIFOLD DIMENSIONS
24" x 24" Steel Manholes
116-036-5
Leak Detector as Pilot Valve
Electrical Conduit
(5 Wires)
24"
Grade
250 G.P.M. Leak Detector (3") Diaphragm Valve
Model 116-039-5 (Incl. 116-036-5)
Pump Discharge Outlet to Leak
Detector (Usually 3" or 4")
Red Jacket “Big-Flo”
Submersible Pump
6" Riser
Concrete
Blocks
Discharge To Dispensers
or Loading Rack, etc.
3" Diaphragm Valve
Submerged Pump Junction Box
Storage Tank
Flex Connector
Pit a Cover By Contractor
(Depth Of Pit Varies With Tank Bury Depth)
Electrical Conduit
116-036-5 Leak
Detector as Pilot Valve
24"
(Recommended
Minimum)
Pump
250 G.P.M. Leak Detector
3" Flanged Diaphragm Valve
Model 116-039-5
(Incl. 116-036-5)
Discharge Line
Flex Connector
(Usually 3")
6"
11"
6"
10-5/8"
8"
Storage Tank
6" Pump Riser & Flange
42" (Recommended Minimum)
PRODUCT LINE
TO DISPENSER
As an option in troubleshooting, install a BALL VALVE downstream
from the discharge of the pump.
-8-
MALE UNION
PULL ELBOW
ELBOW
EXPANSION UNION
CONDUIT
JUNCTION BOX
SYPHON CHECK
VALVE
REDUCER
008-168 CONDUIT BOX BY RED JACKET
10"
176-026 NIPPLE SEAL BY
RED JACKET
4"
3/4"
EXPANSION
UNION
EXTRACTOR
NIPPLE SEAL
3/4" VACUUM
PIPE
1-1/4" CONDUIT
“E”
COVER
DEPTH
LOCATE SEAL
WHERE REQUIRED
BY LOCAL CODE
PACKER
ASSEMBLY
6-3/4"
3-1/16"
1/4" VACUUM PIPE
8" EXTRACTOR
NIPPLE
CONDUIT BY CONTRACTOR
“C” 8" EXTRACTOR NIPPLE
#60169 BY RED JACKET
3" PIPING BY CONTRACTOR
CONDUIT
BY CONTRACTOR
“D”
DISCHARGE LINE TO
LOADING RACK OR
TO DISPENSERS
SEAL
BY CONTRACTOR
151-001 DISCHARGE MANIFOLD
BY RED JACKET
PLUG IF
NECESSARY
“D” 6" RISER & FLANGE #60303
BY RED JACKET
“B”
6"RISER & FLANGE
“A”
TANK DIA.
PUMP & MOTOR
Fig. VI
4"
NOTICE
Fig. VII
NOTICE
Distance between center line of
pump motor and center line of bottom fill tube should be 3' minimum.
Air locking of pump may occur at
distances less than this distance.
Use table below for single wall
steel tank applications only.
Example: A 10'-6" diameter tank buried 3'-0" will require a 10'-6" long pump, 4" long riser & 16" long extractor nipple.
TABLE OF PUMP RISER & EXTRACTOR NIPPLE LENGTHS FOR
VARIOUS TANK DIAMETERS & VARIOUS BURY DEPTHS
Diameter Storage Tank “A”
Pump Length “B”
Riser Length “D”
Extractor Nipple “C” Length
When Tank is Covered:
2'-0" Bury
2'-6" Bury
3'-0" Bury
3'-6" Bury
4'-0" Bury
5'-4"
5'-3"
5"
6'-0" 6" 3-1/2" 7'-0"
6'-3"
6'-3"
7'-3"
7"
4"
7"
5"
10"
16"
22"
28"
5"
7"
13"
19"
25"
5"
10"
16"
22"
28"
5"
7"
13"
19"
25"
7'-6"
8'-3"*
13"
5"**
5"**
7"
13"
19"
8'-0" 8' 3-1/2" 9'-0"
8'-3"
8'-3"
9'-3"
7"
4"
7"
5"
7"
13"
19"
25"
5"
10"
16"
22"
28"
5"
7"
13"
19"
25"
10'-0" 10'-6" 11'-0"
10'-7" 10'-7" 11'-3"
11"
5"
7"
5"
5"
10"
16"
22"
5"
10"
16"
22"
28"
5"
7"
13"
19"
25"
12'-0"
12'-3"
7"
5"
7"
13"
19"
25"
* Pump length for 2' bury will be 7'7" long with a 5" riser length.
** 5" nipple not required.
WARNING A variety of tank types with various materials of construction are currently in use. The inside diameter,
(I.D.) which is critical to determining correct pump length, can differ appreciably though outside
diameters may be similar. Red Jacket Pumps are built to order to accommodate individual tank and bury
depth requirements. Accurate tank and site measurements are critical to achieve the proper pump length
and avoid damage to the pump or tank which can result in substantial property damage, personal injury
or death. Petro Express Bulletin RJ 23-25 (5/92) explains the information required for proper pump sizing.
-9-
HEAD EQUIVALENTS
1 PSI = 2.31 Feet of Water
= 3.2 Feet Gasoline
(.72 Sp. Gr.)
= 2.9 Feet Kerosene
(.80 Sp. Gr.)
= 2.6 Feet Heating Oil
(.89 Sp. Gr.)
VACUUM LINE MINIMUM 3/8" COPPER TUBING TO
HIGH POINT OF SYPHON LINE, BY CONTRACTOR
TUBING MUST BE FORMED DOWN TO CLEAR
LOWER EDGE OF MANHOLE.
Fig. VIII
FILL PIPE
BUSHING
VENT PIPE
MINIMUM - 2" SYPHON LINE BY CONTRACTOR
MUST PITCH UPWARD ABOUT 1/8"
PER FOOT FROM ADDITIONAL
TANKS TO POINT OF CONNECTING 3/8" COPPER TUBING
CONDUIT
RED JACKET PUMP
FILL PIPE
VENT PIPE
TYPICAL
SYPHON
SYSTEM
3" LINE TO
DISPENSERS
AND/OR LOADING
RACK
3"
FROM ADDITIONAL TANKS
WHERE REQUIRED
NOTICE
All piping must conform to local fire regulations at installation.
3"
ELECTRICAL DATA
Model Number
Pump Motor
Assembly
UMP100H1-1MB**
UMP150H1-1HB
UMP200H1-2MB
UMP200H3-2MB
UMP300H3-1K
UMP300H3-2HB
UMP500H3-2K
Winding Resistances (OHMS)
HP
Volt
Phase
1
1.5
2
2
3
3
5
208-230
208-230
208-230
208-230
208-230
208-230
208-230
1
1
1
3
3
3
3
Yellow to Red
9.5-10.5
7.2-8.3
5.4-6.2
2.3-3.2
1.7-2.3
1.7-2.3
1.0-1.1
Yellow to Blk
3.0-3.6
2.0-2.5
1.5-2.0
2.3-3.2
1.7-2.3
1.7-2.3
1.0-1.1
Red to Blk
12.5-14.1
9.2-10.8
6.9-8.2
2.3-3.2
1.7-2.3
1.7-2.3
1.0-1.1
Blue to Blue
—
0-1.0
0-1.0
0-1.0
0-1.0
0-1.0
0-1.0
** Discontinued February, 1988
NOTICE
DANGER
The above readings do not include the added resistance of the power supply wires to the submersible pump.
Therefore, in order for the readings to fall within the above limits, the resistance should be checked at the
submersible pump junction box. If the resistance readings are taken at the control box or magnetic starter, they will
be slightly higher.
Always make a complete power disconnect before taking resistance readings.
RECOMMENDED FLOATING
SUCTION INSTALLATION
Manhole:
Should be larger than manhole
welded on tank. Keep area
open down to tank.
Opening for Gauging
and Adjusting Cable
NOTICE We supply adapter only; not the apparatus.
•
The floating suction arm can be
mounted to pump previous to
installing in tank.
See example of adaptation to
floating suction assembly below.
•
Easy service access is
provided by unbolting
manhole lid through which
pump is mounted and
removing entire assembly.
1-1/2" N.P.T.
14"
3" N.P.T.
Female Thread
Male Thread
14"
Bottom of the Tank
Bottom of the Tank
4" Petroleum Adapter
Adaptation to Floating Suction Assembly
(Use standard NPT threaded fittings).
14" Approx.
4" Approx.
Min. 3"
-10-
1-1/2" Nipple
1-1/2" by 2" Bell Reducer
NOTICE
2" Nipple
2" Companion Flange (threaded or welded)
6" Petroleum Adapter
Use proper thread sealant and insert
gasket between flanges of floating
suction and pump. This prevents
hindrance to pump performance
when product level
is below this point.
Red Jacket petroleum and solvent pumps
are centrifugal type pumps and as such
are not designed to pump product
when the level is below the bottom end of
the pump/motor assembly.
ELECTRICAL DATA
(continued)
Service
HP
Volts
Locked
Phase Factor Cur. Rotor Cur.
Branch Ckt. Protection
Fusetron
Ckt. Brkr.
Wire Size for Max Length of Run Shown*
NEMA
(From Control Box or Controller to Pump)
Codes
(Amps)
(Amps)
(Amps)
(Amps)
No. 14
No. 12
No. 10
No. 8
No. 6
1**
208-230
1
7.5
35
15
15
150 ft.
250 ft.
400 ft.
600 ft.
1000 ft.
K
1-1/2
208-230
1
9.5
47
15
15
125 ft.
200 ft.
300 ft.
500 ft.
800 ft.
J
2
208-230
1
12.0
61
20
20
—
150 ft.
250 ft.
375 ft.
600 ft.
H
2
208-230
3
7.2
45
15
15
450 ft.
700 ft.
1200 ft. 1900 ft.
—
K
3
208-230
3
10.5
62
15
20
350 ft.
550 ft.
850 ft. 1400 ft.
2000 ft.
K
5
208-230
3
17.2
96
25
30
—
350 ft.
550 ft.
1500 ft.
J
900 ft.
* Figures represent maximum length in feet for 220 or 230 volt system. Use 75% of length for 208 volt systems.
** Discontinued February, 1988.
INSTALLING DUAL SUBMERSIBLES MANIFOLDED IN THE SAME SYSTEM
This type of system is often used when greater flow
rates are needed. If installed according to the illustration below (Fig. IX), manifolded systems offer back-up
support in that operations could continue should one
unit fail.
The check valves shown installed in the discharge line
of each pump are necessary to prevent product from
being pumped through the pressure relief system of
the adjacent pump, if that pump is not running. This is
because the expansion relief valve operates at below
pump pressures. If check valves without pressure relief
were used, there would be no provision for thermal
expansion between the valves and the dispensers.
It is preferable that the wiring allow both submersibles
to operate simultaneously with any combination of
dispensers turned on. To operate individually, the appropriate switch could be turned off manually.
Pressure Relief
type check valves
(50 PSI)
As an option for trouble shooting
and maintenance, install a ball
valve downstream of the check
valve.
NOTICE
The drawing shown here is to illustrate the
requirement for in-line, pressure relief type
check valves. It is not a recommended guide for
installation of piping downstream of the check
valves.
Fig. IX
-11-
REPAIR PARTS LIST — PACKER ASSEMBLY
(Packer Assembly is the same on All Model Big-Flo® Pumps)
Upper End
5
4
39 40
35
34
33
32
31
30
29
19
36
28
27
37
26
EXPANSION RELIEF VALVE
25 ON BOTTOM SIDE OF PACKER
(NOT SHOWN)
24
1
2
3
14 38
6
7
9
8
10 11 12 13
16
15
Key No.
Part No.
2
3
3
4
5
6
7
8
9
9
10
11
N/S
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
N/S
N/S
N/S
008-168-1
110-038-4
110-039-4
027-065-1
060-048-1
031-097-1
031-106-1
031-105-1
176-026-5
176-025-5
065-073-1
013-147-1
164-045-5
164-046-5
026-219-1
188-241-5
058-029-1
072-110-1
026-414-1
008-167-3
072-108-1
151-011-5
031-108-1
065-786-3
065-xxx-3
882-2xx-x
208-271-5
065-785-3
072-107-1
076-085-3
026-627-1
079-161-1
111-065-4
138-049-5
072-104-1
072-129-3
060-057-1
882-2xx
027-068-1
027-138-1
031-107-1
066-164-3
144-191-5
026-198-1
064-025-3
17
18
19
20
19
21
22
23
7
Description
Conduit Junction Box with Cover
Conduit Seal Assembly, All Models Except P100H1-1MB
Conduit Seal Assembly, Model P100H1-1MB
1/4 x 3/8 Fitting Syphon Take Off
Packing Nut Syphon Tube
Packing Nut Gasket
Extractor Nipple Gasket Outer
Extractor Nipple Gasket Inner
Extractor Nipple Seal Assembly Non-Syphon
Extractor Nipple Seal Assembly Syphon
1/4" Galvanized Syphon Pipe (Obtain Locally or Specify Length)
1-1/4" Conduit Pipe (Obtain Locally or Specify Length)
Packer Assembly without Syphon
Packer Assembly with Syphon
Locking Capscrew 3/4 x 16 x 3/8 (Obtain Locally)
Syphon Check Valve
Syphon Packing Nut and Nozzle
“O” Ring - Syphon Packing Nut (5/8 x 13/16 x 3/32)
Hex Head Cap Screw
Syphon Venturi
“O” Ring - Packer Assembly (5-1/2 x 6 x 1/4)
Discharge Manifold
Gasket - Mainfold to Riser
Air Eliminator Tube (Specify Length)
3" Column Pipe (Specify Length)
Pump Riser (Specify Length)*
Expansion Relief Valve
3/4" Alum. Conduit (Specify Length)
“O” Ring - Check Valve Seat (3-1/4 x 3-1/2 x 1/8)
Check Valve Seat
Check
Machine Screws (1/4 x 20 x 1/2)
Valve
Check Valve Spring
Components
Cap & Stem Assembly Check Valve
Disc & Holder Assembly for Check Valve
“O” Ring - Seal Conduit (1 x 1-1/4 x 1/8)
Locking Ring
Packing Nut
Extractor Nipple (Specify Length) (Includes 1 Gasket 031-106)
Elbow 3/8"
Brass Elbow
Bolt Gasket
Top Plate
Syphon Conversion Kit
Manifold Screw
Packer Casting Only
* Effective approximately in June 1992, Big-Flo pump risers are manufactured with two tank vent ports (1/4" NPT, 180° apart).
This allows venting back to the tank and from the tank for testing purposes.
-12-
PUMP TANK RISER
(NOT SHOWN)
No. Req’d.
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
4
1
3
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
4
1
1
4
1
REPAIR PARTS LIST — BIG-FLO® SUBMERSIBLE PUMPS
Lower End
1
6
2
4
3
5
9
7
8
Number Required
Key No.
Part No.
1
2
3
4
4
4
5
6
7
7
7
8
9
036-043-3
3/8 x 16 x 2
3/8
213-064-5
213-065-5
213-069-5
072-379-1
011-143-1
001-157-3
001-026-3
001-158-3
072-109-1
072-578-1
Description
Motor Head 1
Cap Screw (Obtain Locally)
Washer (Obtain Locally)
Plug & Pigtail Assembly
Plug & Pigtail Assembly
Plug & Pigtail Assembly
“O” Ring
Discharge Casting
Floating Suction Adaptor
Floating Suction Adaptor
Floating Suction Adaptor
“O” Ring (5-5/8 x 5-7/8 x 1/8)
“O” Ring (1-7/8 x 2-1/8 x 1/8)
1
4
4
1
—
—
—
1
—
—
1
1
1
1
4
4
—
1
—
—
1
1
—
—
1
1
1
4
4
—
1
—
—
1
1
—
—
1
1
1
4
4
—
1
—
—
1
—
—
1
1
1
1
4
4
—
1
—
—
1
—
1
—
1
1
1
4
4
—
1
—
—
1
1
—
—
1
1
4
4
—
—
1
—
1
—
1
—
1
1
Only the above listed parts are available for repairs of the lower end of pump. If any other parts need replacing, order Red Jacket pump-motor assemblies.
See back cover for ordering numbers.
-13-
MOTOR CONTROL BOX FOR 1-1/2 & 2 HP PUMPS
MODELS P150H1-CB & P200H1-CB
DIMENSIONS:
15-1/4" Height
10-1/8" Width
4" Depth
Key No.
Part No.
1
108-402-1
P150H1-CB Complete General Purpose Motor Control Box
1
1
108-403-1
P200H1-CB Complete General Purpose Motor Control Box
1
2
071-047-1
Starting Relay (3ARR3-J3V2)
1
3
071-061-1
Line Contactor Relay (RMB #109152-8)
1
4
011-402-1
Starting Capacitor (160MFD-250 Volt) P150H1-CB)
1
4
011-085-1
Starting Capacitor (200MFD-250 Volt) (P200H1-CB)
1
5
012-253-1
Running Capacitor (15MFD-370 Volt) (P150H1-CB)
1
5
012-253-1
Running Capacitor (15MFD-370 Volt) (P200H1-CB)
1
6
008-180-1
Terminal Block
1
7
071-062-1
Overload Protector (Cutler Hammer 10-2149)
1
8
023-008-1
Overload Protector Heater Element (Cutler Hammer 10177H-30A) (P150H1-CB)
1
8
023-009-1
Overload Protector Heater Element (Cutler Hammer 10177H-33A) (P200H1-CB)
1
WARNING
-14-
Description
No. Req’d.
Three phase model Big-Flo pumps require the use of a magnetic starter. Please see price sheet
#5858 for part numbers.
MAGNETIC STARTER FOR 2, 3 & 5 HP 3 PHASE PUMPS
MODELS P200H3-2MB, P300H3-1K, P300H3-2HB, P500H3-2K
DIMENSIONS:
10-1/2" Height
6-1/4" Width
4-1/2" Depth
NOTICE
The only parts that are available for the Magnetic Starter from Red Jacket are the
Overload Heaters. (See chart below).
HP
Volts
Phase
Magnetic
Starter
2
208-230
3
279231-5
K-43
036-072-1
3
208-230
3
279231-5
K-53
036-076-1
5
208-230
3
279231-5
K-61
036-080-1
CAUTION
Overload Heaters
Heater No.
Part No.
Three phase model Big Flo pumps require the use of a magnetic starter.
-15-
RED JACKET REPLACEMENT SOLVENT PUMP MOTORS
BIG-FLO® SUBMERSIBLE PUMPS
Ordering
Number
Model
Number
HP
Length
Weight
(lbs.)
Volts
Phase
882-841
UMP150H1-1HB
1-1/2
28-3/4"
106
230
1
882-839
UMP200H1-2MB
2
32-1/8"
116
230
1
882-840
UMP200H3-2MB
2
29-5/8"
116
230
3
882-209
UMP300H3-1K
3
31-5/8"
120
230
3
882-842
UMP300H3-2HB
3
34-5/16"
120
230
3
882-211
UMP500H3-2K
5
42-1/2"
162
230
3
PROCEDURE FOR REMOVAL OF PLUG-IN TYPE
PUMP-MOTOR ASSEMBLY
1. Remove Red Jacket Pump from product storage tank.
2. Lay pump in horizontal position.
3. Block pump so that pump end is two inches above surface.
4. Remove four 3/8" cap screws.
5. Using hands, grip pump at extreme bottom and rock in arch not exceeding 1/4" path. This
allows pump to free past dowel pin.
6. Slide pump away from column. Watch to be sure electrical (Bayonet type) plug-in separates.
7. If plug-in does not disconnect, continue sliding pump motor until plug-in is exposed for hand
separating.
8. Assemble new pump motor in reverse order. Check plug-in connection and dowel pin location.
9. Use new pump seal “O” ring which is supplied with pump motor assembly.
10. Lubricate pump “O” ring with silicone lubricant.
11. When drawing up 3/8" cap screws, be sure to draw evenly.
Printed in U.S.A.