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.