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TRANSCRIPT
D042-153, Rev. E
4" Submersible Petroleum and AG Pump
Installation, Operation & Service Manual
TABLE OF CONTENTS
Table of Figures & Tables ......................................................................................................................ii
About This Manual ................................................................................................................................iii
Abbreviations and Symbols ..................................................................................................................iv
CHAPTER 1: RED JACKET 4" SUBMERSIBLE PUMP .................................................................................... 1
Overview ...................................................................................................................................... 1
Leak Detector Installation and Manifold Dimensions.................................................................... 2
Recommended Floating Suction Installation ................................................................................ 3
Dimensions for Pump Selection.................................................................................................... 4
Specifications ................................................................................................................................6
CHAPTER 2: INSTALLATION ...................................................................................................................... 9
Installation Safety Notices ............................................................................................................ 9
Attaching the UMP ........................................................................................................................ 9
Installing the Pump .................................................................................................................... 10
Conduit Box Wiring ....................................................................................................................13
Installing Two Pumps for Tandem Operation ..............................................................................16
Adjusting the Functional Element ................................................................................................18
CHAPTER 3: TESTING THE INSTALLATION ..................................................................................................20
Testing Piping ..............................................................................................................................20
Testing Tank ................................................................................................................................20
CHAPTER 4: SERVICE AND REPAIR ..........................................................................................................21
Technical Support ........................................................................................................................21
Removing the Pump ....................................................................................................................21
Replacing the UMP ......................................................................................................................22
Replacing the Functional Element ..............................................................................................23
Replacing the Capacitor in Packer ..............................................................................................24
Installing a Replacement Extractable Pump ................................................................................24
Parts Lists ................................................................................28....................................................
APPENDIX A: 4'' STANDARD RED JACKET SAFETY INSTRUCTIONS................................................................A-1
i
Table A: Specific Gravity and Maximum Viscosity ................................................................................1
Figure 1.1 Leak Detector and Manifold Dimension ..............................................................................2
Figure 1.2 Floating Suction Installation ................................................................................................3
Figure 1.3 Floating Suction Adapter......................................................................................................3
Figure 1.4 Measuring the Tank..............................................................................................................4
Table B: Pump Selection ......................................................................................................................5
Table C: Distance from Eye Bolt to Inlet ..............................................................................................6
Table D: Weights and Lengths ..............................................................................................................7
Table E: Attaching the UMP ..................................................................................................................9
Figure 2.1 Attaching the UMP ............................................................................................................10
Figure 2.2 Aligning the Gasket ............................................................................................................10
Figure 2.3 Measuring the Tank............................................................................................................11
Figure 2.4 Loosen the Fittings ............................................................................................................11
Figure 2.5 Adjusting the Pump............................................................................................................12
Figure 2.6 Wiring Schematic ..............................................................................................................13
Figure 2.7 Conduit Box Wiring ............................................................................................................13
Figure 2.8 230 VAC Remote Control Box with 110 VAC Coil ............................................................14
Figure 2.9 Suggested Wiring Diagram without Control Box ..............................................................14
Figure 2.10 230 VAC Remote Control Box with 110 VAC Coil and Capacitor....................................15
Figure 2.11 230 VAC Remote Control Box with 230 VAC Coil ..........................................................15
Figure 2.12 Tandem Pumps ................................................................................................................16
Figure 2.13 Suggested Wiring for Tandem Pumps ............................................................................16
Figure 2.14 Functional Element ..........................................................................................................18
Table F: Approximate Operating Pressures ........................................................................................19
Figure 3.1 Closing the Check Valve ....................................................................................................20
Figure 3.2 Line Test Port ....................................................................................................................20
Figure 4.1 Packer ................................................................................................................................21
Figure 4.2 Removing the UMP............................................................................................................22
Figure 4.3 Replacing the Gasket ........................................................................................................22
Figure 4.4 Packer with Functional Element ........................................................................................23
Figure 4.5 Functional Element ............................................................................................................23
Figure 4.6 Loosen the Fittings ............................................................................................................25
Figure 4.7 Adjusting the Pump............................................................................................................25
Figure 4.8 Wiring Schematic ..............................................................................................................26
TABLE OF FIGURES & TABLES
ii
Figure 2.11a Isotrol to IQ System Wiring - 120 Volt Dispenser Signals ..........................................15a
Figure 2.11b Isotrol to IQ System Wiring - 230 Volt Dispenser Signals .........................................15b
ABOUT THIS MANUAL
This preface describes the organization of this manual, explains symbols and typo-graphical conventions used, and defines vital terminology. This manual is for personnelwho install Red Jacket submersible pumps for petroleum. It contains the informationrequired for working in the pit. It also contains a table of figures, a list of abbreviations,appendixes with the warranty and parts list, and an index.
NOTICE
WARNING
DANGER
CAUTION
The following defined terms are used throughout this manual to bring attention to thepresence of hazards of various risk levels, or to important information concerning useof the product.
ORGANIZATION
This manual is organized into four chapters:
Chapter 1: Red Jacket Submersible Pump describes the basic components of the system.
Chapter 2: Installation provides safety notices and gives step-by-step instructions forinstalling and wiring the pump, tandem pumps and control boxes. It also describes howto adjust the Functional Element.
Chapter 3: Testing the installation describes testing the various components of the system after it has been installed.
Chapter 4: Service and Repair describes how to remove a pump and replace the UMP,information on replacing the Functional Element, capacitor, and replacement pumpinstallation instructions.
TYPOGRAPHICAL CONVENTIONS
The various symbols and typographical conventions used in this manual are described here.
Indicates a tip or reminder.
TERMINOLOGY
Indicates the presence of a hazard that will cause severe per-sonal injury, death, or substantial property damage if ignored.
Indicates the presence of a hazard that can cause severe per-sonal injury, death, or substantial property damage if ignored.
Indicates the presence of a hazard that will or can cause minorpersonal injury or property damage if ignored.
Indicates special instructions on installation, operation, ormaintenance that are important but not related to personalinjury hazards.
iii
Chassis ground (see also GND)
Earth ground
Ohm, resistance
Microfarad (10-6 farad)
Alcohol-gasoline blends
Centigrade
Domestic
Environmental Protection Agency
Fahrenheit
Fixed Length
Floating Suction Adapter
Foot-pound
Ground
Gallons per hour; Gallons per minute
Horsepower
Hertz
International
International Organization for Standardization
KiloPascals
Millimeter
Newton-meter
National Electrical Code
National Fire Protection Association
National Pipe Thread
Petroleum
Phase
Pounds per square inch; Pounds per square inch gauge
Specific Gravity
Saybolt Seconds Universal, a measure of viscosity
Underwriters Laboratories Inc.
Unit motor pump; Pump-motor assembly
Voltage—alternating current
Volt
Voltage—direct current
ΩµF
AG
C
DOM
EPA
F
FL
FSA
ft-lb
GND
gph; gpm
hp
Hz
INTL
ISO
kPa
mm
N•m
NEC
NFPA
NPT
Petro
PH
psi; psig
SG
SSU
UL
UMP
VAC
V
VDC
ABBREVIATIONS AND SYMBOLS
iv
CHAPTER 1: RED JACKET 4" SUBMERSIBLE PUMP
OVERVIEW Red Jacket pumps are designed to be compatible with 100% gasoline or diesel. All
UMPs having the model numbers including the AG prefix are designed to be compatible
with 100% gasoline, methanol, ethanol or diesel and 80% gasoline with 20% TAME,
ETBE or MTBE. Single phase pumps are UL listed Class 1, Group D atmosphere.
TABLE A: SPECIFIC GRAVITY AND MAXIMUM VISCOSITY
The Quick-Set feature is an adjustable column pipe and electrical conduit that allows the
overall length to be adjusted to cover a wide range of overall pump lengths. By loosening
a collet on the column pipe, the length of the pump may be varied by extending or
compressing the column pipe.
Four Quick-Set sizes are available, covering most pump length requirements, for precise
lengths, see the sizing charts within this chapter.
ledoMPMU ytivarGcificepSmumixaM ytisocsiVmumixaM
1R33PMUGA1R33PMU
59. )C°51(F°06taUSS07
1S57PMUGA1S57PMU
59. )C°51(F°06taUSS07
1S051PMUGA1S051PMU
59. )C°51(F°06taUSS07
3-3S57PMUGA3-3S57PMU
59. )C°51(F°06taUSS07
3-3S051PMUGA3-3S051PMU
59. )C°51(F°06taUSS07
1S051PMUGA3X1S051PMU3X
08. )C°51(F°06taUSS07
1S051PMUGA5X1S051PMU5X
08. )C°51(F°06taUSS07
3S051PMUGA4X3S051PMU4X
68. )C°51(F°06taUSS07
3-71S57PMUGA3-71S57PMU
59. )C°51(F°06taUSS07
3-71S051PMUGA3-71S051PMU
59. )C°51(F°06taUSS07
71S051PMUGA4X71S051PMU4X
68. )C°51(F°06taUSS07
— 1 —
.95
.95
.95
.95
.95
.80
.80
.86
.95
.95
.86
20"
20"
12"
11"
PUMP
RED JACKET LEAK
DETECTOR
DRIVEWAY
GRADE
ELECTRICAL
CONDUIT BOX
4" RISER
RED JACKET LEAK
DETECTOR
RED JACKET
SUBMERSIBLE
PUMP
20" X 20" MANHOLE RED JACKET
LEAK DETECTOR
RED JACKET
SUBMERSIBLE PUMP
2" OUTLET
TO DISPENSERS
TANK
Figure 1.1 Leak detector and manifold dimensions
TANK
FLEX
CONNECTOR
LEAK DETECTOR INSTALLATION AND MANIFOLD DIMENSIONS
6”
8 ”
10”
13”
5.5”
— 2 —
4” Petroleum & AG
34
• Easy service access is provided by unbolting manhole lid through which pump is
mounted and removing entire assembly. Use proper thread sealant and insert gas-
ket between flanges of floating suction and pump. This prevents hindrance to pump
performance when product level is below this point.
Red Jacket pumps are centrifugal type pumps and as such are not designed to pump product when the level is below thebottom end of the UMP.
14" APPROX.
4" APPROX.
OPENING FOR GAUGING AND
ADJUSTING CABLE
MANHOLE:
SHOULD BE LARGER THAN MANHOLE
WELDED ON TANK. KEEP AREA OPEN
DOWN TO TANK.
NOTICE
NOTICE
Figure 1.2 Floating suction installation
RECOMMENDED FLOATING SUCTION INSTALLATION
Distance between center line of pump motor and center line of bottom fill tube should be 3’ minimum. Air locking of pumpafter product delivery may occur at distances less than this.
We supply adapter only; not the apparatus. Floating suctionadapter is not available for the X5 Model pump.
• The floating suction arm can be mounted to pump previous to installing in tank.
See example of adaptation to floating suction assembly below.
Figure 1.3 Floating Suction Adapter
2" N.P.T.FEMALETHREAD14"
BOTTOM OF THE TANK
NOTICE
— 3 —
Figure 1.4 Measuring the tank (See TABLE B for adjustment range.)
DIMENSIONS FOR PUMP SELECTION
NOTICE Distance between center line of pump motor and center line of bottom fill tube should be 3’ minimum. Air locking of pumpafter product delivery may occur at distances less than this.
11"
5" STANDARD INLET AND TRAPPER14" FOR FLOATING SUCTION ADAPTER
4" min.
A
D
C
B
— 4 —
4” Petroleum & AG
— 5 —
TABLE B: DISTANCE
SPECIFICATIONS
TELNIOTTLOBEYEMORFECNATSID
#LEDOM DESSERPMOC DEDNETXE
ni mm ni mm
1T1R33PGA,1T1R33P 0.86 7271 0.59 2142
2T1R33PGA,2T1R33P 0.19 1132 0.521 4713
3T1R33PGA,3T1R33P 0.521 4713 0.291 6784
4T1R33PGA,4T1R33P 0.521 4713 0.951 8304
1T1S57PGA,1T1S57P 5.07 3971 5.79 9742
2T1S57PGA,2T1S57P 5.39 7732 5.721 1423
3T1S57PGA,3T1S57P 5.721 1423 5.491 3494
4T1S57PGA,4T1S57P 5.721 1423 5.161 4014
1T1S051PGA,1T1S051P 5.37 5681 5.001 1552
2T1S051PGA,2T1S051P 5.69 0542 5.031 3133
3T1S051PGA,3T1S051P 5.031 3133 5.791 5105
4T1S051PGA,4T1S051P 5.031 3133 5.461 7714
1T1S051PGA3X,1T1S051P3X 5.47 7881 5.101 3752
2T1S051PGA3X,2T1S051P3X 5.79 1742 5.131 5333
3T1S051PGA3X,3T1S051P3X 5.131 5333 5.891 7305
4T1S051PGA3X,4T1S051P3X 5.131 5333 5.561 9914
1T1S051PGA5X,1T1S051P5X 0.48 2312 0.111 7182
2T1S051PGA5X,2T1S051P5X 0.701 6172 0.141 9753
3T1S051PGA5X,3T1S051P5X 0.141 9753 0.802 1825
4T1S051PGA5X,4T1S051P5X 0.141 9753 0.571 3444
1T3-3S57PGA,1T3-3S57P 0.37 3581 0.001 9352
2T3-3S57PGA,2T3-3S57P 0.69 7342 0.031 1033
3T3-3S57PGA,3T3-3S57P 0.031 1033 0.791 3005
4T3-3S57PGA,4T3-3S57P 0.031 1033 0.461 5614
1T3-3S051PGA,1T3-3S051P 0.57 7091 0.201 2952
2T3-3S051PGA,2T3-3S051P 0.89 1942 0.231 4533
3T3-3S051PGA,3T3-3S051P 0.231 4533 0.991 6505
4T3-3S051PGA,4T3-3S051P 0.231 4533 0.661 8124
1T3S051PGA4X,1T3S051P4X 5.57 0291 5.201 6062
2T3S051PGA4X,2T3S051P4X 5.89 4052 5.231 8633
3T3S051PGA4X,3T3S051P4X 5.231 8633 5.991 3705
4T3S051PGA4X,4T3S051P4X 5.231 8633 5.661 2324
1T3-71S57PGA,1T3-71S57P 0.27 8281 0.99 4152
2T3-71S57PGA,2T3-71S57P 0.59 2142 0.921 6723
3T3-71S57PGA,3T3-71S57P 0.921 6723 0.691 7794
4T3-71S57PGA,4T3-71S57P 0.921 6723 0.361 9314
1T3-71S051PGA,1T3-71S051P 0.47 8781 0.101 4652
2T3-71S051PGA,2T3-71S051P 0.79 2642 0.131 6233
3T3-71S051PGA,3T3-71S051P 0.131 6233 0.891 8205
4T3-71S051PGA,4T3-71S051P 0.131 6233 0.561 9814
1T71S051PGA4X,1T71S051P4X 5.47 2981 5.101 8752
2T71S051PGA4X,2T71S051P4X 5.79 6742 5.131 0433
3T71S051PGA4X,3T71S051P4X 5.131 0433 5.891 1405
4T71S051PGA4X,4T71S051P4X 5.131 0433 5.561 3024
— 6 —
4” Petroleum & AG
TABLE C: ELECTRICAL SERVICE INFORMATIONRequired power supply rating for 60HZ, 1 phase motors is 208-230VAC. For 50HZ 1 phase motors, required rating is 220-240VAC,
3 phase motors required rating is 380-415 VAC.
NOITAMROFNIECIVRESLACIRTCELE
PMUledoM
.oNPH ZH HP
egatloVnoitautculF
egnaRdaoL.xaM
spmArotoRdekcoL
spmA
)smhO(ecnatsiseRgnidniW)smhO(ecnatsiseRgnidniW roticapaC
)Fµ(tiK.niM .xaM wolleY-kcalB wolleY-deR deR-kcalB
1R33PMUGA1R33PMU
3/1 06 1 002 052 0.4 0.31 9.9-1.8 3.91-8.51 3.92-8.32 )5.71(5-422-441
1S57PMUGA1S57PMU
4/3 06 1 002 052 5.6 0.22 3.3-7.2 0.81-7.41 4.12-3.71 )5.71(5-422-441
1S051PMUGA1S051PMU
2/1-1 06 1 002 052 5.01 0.24 3.2-8.1 5.6-3.5 9.8-2.6 )52(5-522-441
1S051PMUGA3X1S051PMU3X
2/1-1 06 1 002 052 5.01 0.24 3.2-8.1 5.6-3.5 9.8-2.6 )52(5-522-441
1S051PMUGA5X1S051PMU5X
2/1-1 06 1 002 052 5.01 0.24 3.2-8.1 5.6-3.5 9.8-2.6 )52(5-522-441
PMUledoM
.oNPH ZH HP
egatloVnoitautculF
egnaRdaoL.xaM
spmArotoRdekcoL
spmA)smhO(ecnatsiseRgnidniW roticapaC
)Fµ(tiK.niM .xaM kcalB-eulB kcalB-nworB nworB-eulB
3-3S57PMUGA3-3S57PMU
4/3 05 1 002 052 8.5 6.81 3.4-5.3 3.82-1.32 7.23-5.62 )5.71(5-422-441
3-3S051PMUGA3-3S051PMU
2/1-1 05 1 002 052 0.01 5.43 4.3-7.2 2.51-4.21 7.81-0.51 )52(5-522-441
3S051PMUGA4X3S051PMU4X
2/1-1 05 1 002 052 0.01 5.43 4.3-7.2 2.51-4.21 7.81-0.51 )52(5-522-441
3-71S57PMUGA3-71S57PMU
4/3 05 3 243 754 2.2 0.11 9.13-1.62 9.13-1.62 9.13-1.62 ---
3-71S051PMUGA3-71S051PMU
2/1-1 05 3 243 754 8.3 8.51 8.41-1.21 8.41-1.21 8.41-1.21 ---
71S051PMUGA4X71S051PMU4X
2/1-1 05 3 243 754 8.3 8.51 8.41-1.21 8.41-1.21 8.41-1.21 ---
— 7 —
The weights and lengths listed above are approximate values and will vary due to manufacturing tolerances.
The optional Trapper inlet screen is available as a field installed accessory. The field installedoption adds 3.625 inches (92 mm) to the listedvalues. For installation instructions see RedJacket literature for #051-256-1. For models with floating suction adapter, add 2.375 inches (59 mm) and 4 lbs (1.8 Kg).
TABLE D: WEIGHTS AND LENGTHS
LEDOMPMU PHHTGNEL THGIEW
ni mm bl gk
1S33PMUGA1S33PMU
3/1 51 083 42 0.11
1S57PMUGA1S57PMU
4/3 2/171 744 82 7.21
1S051PMUGA1S051PMU
2/11 2/102 915 43 5.51
1S051PMUGA3X1S051PMU3X
2/11 4/112 145 53 8.51
1S051PMUGA5X1S051PMU5X
2/11 13 587 83 2.71
3-3S57PGA 4/3 02 705 5.03 9.31
3-3S051PGA 2/11 4/122 065 43 5.51
3S051PGA4X 2/11 4/322 675 53 9.51
3-71S57PGA 4/3 91 284 82 7.21
3-71S051PGA 2/11 12 235 13 1.41
71S051PGA4X 2/11 2/112 745 23 5.41
NOTICE
NOTICE
R1R1
— 8 —
4” Petroleum & AG
— 9 —
CHAPTER 2: INSTALLATION
INSTALLATION SAFETY NOTICES
ATTENTION INSTALLER: Read this important safety information before beginning work.
This product operates in the highly combustible atmosphere of a gasoline storage tank. To protect yourself and others from serious injury, death, or substantial property damage, carefully read and follow all warnings and instructions in this manual.
Failure to follow all instructions in proper order can causepersonal injury or death. Read all instructions before beginninginstallation. All installation work must comply with the latestissue of the National Electrical Code (NFPA 70), the Automotiveand Marine Service Code (NFPA 30A), and any national, state,and local code requirements that apply.
Only trained and qualified personnel may install, program, andtroubleshoot Red Jacket equipment. Hazards can cause severepersonal injury, death, or substantial property damage ifignored.
Before installing pipe threads apply an adequate amount offresh, UL Classified for petroleum, Non-setting thread sealant.
WARNING
DANGER
WARNING
WARNING
TABLE E: ATTACHING THE UMPdlofinaM/rekcaP PMU
1R33PGA1R33P
1R33PMUGA1R33PMU
1S57PGA1S57P
1S57PMUGA1S57PMU
1S051PGA1S051P
1S051PMUGA1S051PMU
1S051PGA3X1S051P3X
1S051PMUGA3X1S051PMU3X
1S051PGA5X1S051P5X
1S051PMUGA5X1S051PMU5X
3-3S57PGA3-3S57P
3-3S57PMUGA3-3S57PMU
3-3S051PGA3-3S051P
3-3S051PMUGA3-3S051PMU
3S051PGA4X3S051P4X
3S051PMUGA4X3S051PMU4X
3-71S57PGA3-71S57P
3-71S57PGA3-71S57PMU
3-71S051PGA3-71S051P
3-71S051PMUGA3-71S051PMU
71S051PGA4X71S051P4X
71S051PMUGA4X71S051PMU4X
ATTACHING THE UMP
The UMP is identified by a model number marked on the shell. The Packer/Manifoldassembly with attached piping is identified by the catalog number on the capacitor covernameplate. The catalog number will be followed by T1, T2, T3, or T4 on adjustablelength pumps or a four digit number indicating the original pump length in feet and inches (a 9 ft. 6 inch pump would have 0906 after the model number.)
Figure 2.2 Aligning the gasket
PACKER/MANIFOLDWITH PIPING
UMPKIT (144-328-4)
Figure 2.1 Attaching the UMP
The attachment hardware kit to be used to connect the UMP to the Packer/Manifoldassembly piping consists of four Grade 8 5/16-18 socket head cap screws, four 5/16spring lock washers, and one discharge head gasket. It is identified by the kit number144-328-4 marked on the bag.
Suggested tools (non-sparking): 3/4” wrench, pipe wrench, 1/4” allen wrench, 9/16” wrench, screw driver, wire cutter and wire stripper.
1: Place the new gasket on the new UMP so that all the holes align.
Gaskets from competitive UMPS will not seal properly and performance will be reduced.
Visually inspect the pigtail connector in the discharge head. Replace if damaged. Be certain the indexing tab of the pigtail is seated in the notch of the discharge head.
2: Lubricate the o-ring and pigtail with petroleum based jelly.3: Align the UMP positioning dowel and boss with the proper holes in the discharge
head and push the UMP into position using hand force only. The UMP should besnug against the discharge head prior to installing the UMP retaining bolts.
Use hand force to put the UMP on the discharge head. If the UMP does not seat properly, snug against the discharge head, remove the UMP and correct the problem.
Do not use the bolts to pull the UMP into position. Use the cross pattern to snug and torque bolts. Do not over torque the bolts. Not following these instructions may cause parts to fail.
4: Install the UMP retaining bolts and lock washers. Snug and then torque the boltsusing a cross pattern. Torque to 7 ft-lb. (11 N•m).
INSTALLING THE PUMP
Red Jacket petroleum pumps are designed to operate in Class 1, Group D locations.
NOTICE
NOTICE
NOTICE
— 10 —
4” Petroleum & AG
CAUTION
NOTICE
Figure 2.3 Measuring tank
Specifications and installation instructions may change if the manufacturer recommends changes.
The product temperature must not exceed 105°F (41°C)because the thermal overload protectors in the submersiblemotors may trip.
To Install Quick-Set Pump: For Fixed Length Pump Go to Step 7
1: Install the riser pipe into the 4-inch tank opening. Use thread sealant. Tighten the
riser pipe in the tank until watertight.
2: Measure the distance from the bottom of the tank to the top of the 4-inch riser pipe shown in figure 2.3.
3: Uncoil the pigtail and lay it flat so it will feed into the packer without knotting or kinking.
4: Loosen the clinch assembly, starting by loosening the set screw in the side of thelocking nut, then loosen the locking nut.
Figure 2.4 Loosen fittings
— 11 —
NOTICE
NOTICE
— 12 —
4” Petroleum & AG
Take care not to damage the pigtail. If pump is to be adjustedshorter, tension must be kept on pigtail to eliminate kinking.
6: Tighten locking nut and torque to 150 ft-lb (200 N•m) minimum, then torque the set
screw to 30-35 in-lb (3.5 – 4 N•m).
Return line should be installed on every application to insureagainst nuisance trips of electronic tank monitoring.
7: Attach tubing to barbed fitting, secure with clamp.
8: Lay tubing beside column pipe. Cut off 1-3 inches (25-76 mm) above the
discharge head.
9: Secure tube to column pipe with tie straps. Locate tie straps approximately 6 inches
(152 mm) from packer, 6 inches (152 mm) from discharge head and middle of tubing.
10: Install the pump onto the riser pipe using thread sealant while making the proper
alignment of the manifold and piping. Tighten the manifold until watertight.
For fixed length pump, skip to conduit box wiring
11: Remove cover from wiring compartment.
12: Pull pigtail wires into wiring compartment.
13: Cut pigtail wires extending approximately 8-inches (200 mm) out of
wiring compartment.
14: Strip back insulation of all wires 3/8-inch (10 mm).
15: Using supplied wire nuts, attach like colored pump pigtail wires to wires.
See figure 2.6 to verify connections.
NOTICE
NOTICE
Figure 2.5 Adjust pump length
5: Pull the UMP end until the distance between the bottom of the manifold and the of the UMP is 5 inches (125 mm) (14 inches (356 mm) for floating suction) shorterthan the distance measured in step 2 (see figure 2.5)
If UMP is equipped with floating suction adapter, see recommended floating suction installation in Chapter 1.
NOTICE
13
16: Install excess wire into wiring compartment. Replace wiring compartment cover.
Torque to 35 ft lb (50 N¥m). Thread sealant should not be used.
17: Install eyebolt plug, use approved non-setting thread sealant and torque to
50 ft lb (70 N¥m).
CONDUIT BOX WIRING
ALWAYS DISCONNECT and LOCK or TAG OUT the powerbefore starting to service the pump.
1: Connect electrical conduit through approved fittings to conduit box.
2: Remove cover from conduit box.
3: Connect wires from power supply to wires in the conduit box. Install ground wire as
shown if applicable. Replace cover, do not use thread sealant on dual box. Thread
sealant required on single box.
Figure 2.6 Wiring schematic
ORANGE
BLACK
CAPACITOR
ORANGE
BLACK
RED
IN FROMELECTRICAL CONNECTOR
OUT TOPUMP PIGTAIL
Figure 2.7 Conduit box wiring
ELECTRICAL
CONNECTOR ASSY.
GREEN GROUNDING
SCREW
GROUND WIRE
CUP WASHER
TERMINAL
EXTERNAL TOOTH
LOCK WASHER
POWER LEADS
TO PUMPS
CONDUIT BOX
CONDUIT
DUAL BOX
SINGLE BOXCONDUIT
ELECTRICAL
CONNECTOR ASSY.
GREEN GROUNDING
SCREW
GROUND WIRE
CUP WASHER
TERMINAL
EXTERNAL TOOTH
LOCK WASHER
POWER LEADS TO
PUMP
CONDUIT BOX
DANGER
NOTE: FOR EUROPEAN INSTALLATIONS,THE END USER MUST USE AN ATEXEEx d IIB CERTIFIED CABLE GLAND OR STOPPING BOX.
— 14 —
4” Petroleum & AG
CONTINUOUS
DUTY
CAPACITOR
SUGGESTED WIRING DIAGRAM WITHOUT OPTIONAL CONTROL BOX
DISPENSERLIGHTINGFROMSEPARATECIRCUIT
115 VOLT
EXT PILOT
LIGHT BY
CONTRACTOR
WIRING TROUGH
INHERENT
OVERLOAD
PROTECTOR2 POLE DISPENSER SWITCHES
MAKE GROUND CONNECTION
IN ACCORDANCE WITH LOCAL
CODES
15 AMP 3 POLE
SWITCH
(N.E.C. REQUIRES
DISCONNECT
BREAK
ALL WIRES TO
DISPENSERS)
PUMP
JUNCTIONBOX
PACKER
LOAD CENTER 230V 1Ø 3 WIRE
Figure 2.8
Figure 2.9
230 VAC REMOTE CONTROL BOX WITH 110 VAC COILUL LISTED, RED JACKET MODEL 880-041-5
COMBINATION OF 2 POLE DISPENSER SWITCHES OR EXTERNAL PILOT LIGHT.• RATED FOR TWICE THE FULL LOAD CURRENT OF THE MOTOR:
1/3 HP-8 AMPS, 3/4 HP-13 AMPS, 1-1/2 HP-21 AMPS• RATED FOR HANDLING LOCKED ROTOR CURRENT OF THE MOTOR:
1/3 HP-13 AMPS, 3/4 HP-22 AMPS, 1-1/2 HP-42 AMPS
LINE STARTER
PILOT LIGHT
L2 L1
LOAD CENTER208 OR 230 VOLT
1 PHASE, 3 WIRE15A-2P SWITCHEDNEUTRAL BREAKER
OPTIONALOTHERDISPENSER(MAX. TOTALOF 6 DISPENSERS)
EXTERNALPILOT LIGHT(115 VOLTS)25 WATT MAX.
MOTOR
3 P.S.T. TOG-GLE SWITCH
WIRING TROUGH
JUNCTIONBOX INMANIFOLD
DISPENSER LIGHTS
ELECTRICALINTERLOCK
OPTIONALSOLENOIDVALVE (76 VOLT AMPS. MAX)
DISPENSER
PACKER
CONTINUOUSDUTYCAPACITOR
N
INTERNALOVERLOADPROTECTOR
15A-3P SWITCHEDNEUTRAL BREAKER
P
MAKE GROUNDCONNECTION INACCORDANCE WITHLOCAL CODES
— 15 —
Figure 2.11
Figure 2.10
230 VAC REMOTE CONTROL BOX WITH 230 VAC COIL
UL LISTED, RED JACKET MODEL 880-042-5
230 VAC REMOTE CONTROL BOX WITH 110 VAC COIL AND CAPACITOR
UL LISTED, RED JACKET MODEL 880-045-5 (1/3 & 3/4 HP) & 880-046-5 (1-1/2 HP)
LOAD CENTER208 OR 230 VOLT
DISPENSER
OPTIONALSOLENOIDVALVE (76 VOLT AMPS. MAX) MOTOR
CAPACITOR
PILOT LIGHT
LINE STARTER
115 VOLT25 WATTMAX.
3 P.S.T.TOGGLESWITCH
MAKE GROUNDCONNECTION INACCORDANCE WITHLOCAL CODES
EXTERNALPILOT LIGHT(240 VOLTS)25 WATT MAX.
OPTIONALOTHERDISPENSER(MAX. TOTAL OF6 DISPENSERS)
OPTIONALSOLENOIDVALVE (76 VOLT AMPS. MAX)
MAKE GROUNDCONNECTION INACCORDANCE WITHLOCAL CODES
JUNCTIONBOX INMANIFOLD
PACKER
15A-2P SWITCHEDNEUTRAL BREAKER
NEUTRAL PHASE
PILOT LIGHT
2 P.S.T.TOGGLESWITCH
LOAD CENTER220 OR 240 VOLT
1 PHASE, 2 WIRE15A-2P SWITCHEDNEUTRAL BREAKER
LINE STARTER
ELECTRICALINTERLOCK
DISPENSER
CONTINUOUSDUTYCAPACITOR
INTERNALOVERLOADPROTECTOR
MOTOR
WIRING TROUGH
DISPENSER LIGHTS
P
ELE
CT
RIC
AL
INT
ER
LOC
K
CO
NT
INU
OU
SD
UT
YC
APA
CIT
OR
INT
ER
NA
LO
VE
RLO
AD
PR
OT
EC
TOR
JUN
CT
ION
BO
X IN
M
AN
IFO
LD
CO
M+
C23 TB
1
D2
CO
M-
SH
LDD
1M
2L1
M1
L2G
ND
Z2 Z3
IQ C
ON
TR
OL
BO
X (
P/N
880
-051
-1)
ISO
TR
OL
CO
NT
RO
L B
OX
(P
/N 8
80-0
49-1
)
MO
TOR
ST
P
NE
UT
RA
L(F
RO
M S
UP
PLY
PA
NE
L)
208/
230
VO
LT
FR
OM
SU
PP
LYP
AN
EL
CH
AN
NEL
1C
HA
NN
EL 2
CH
AN
NEL
3C
HA
NN
EL 4
CH
AN
NEL
5C
HA
NN
EL 6
CH
AN
NEL
7C
HA
NN
EL 8
120
VOLT
DIS
PEN
SER
SIG
NA
LSUN
SWIT
CH
EDN
EUTR
AL
TO T
B2
TB1
208/
230
VO
LT
UN
SW
ITC
HE
D N
EU
TR
AL
NO
TU
SE
DN
OT
US
ED
NO
TU
SE
DN
OT
US
ED
ISO
TR
OL
CO
NT
RO
L B
OX
WIR
ING
PR
EC
AU
TIO
NS
T
his
devi
ce is
inte
nded
to p
rovi
de e
lect
rical
isol
atio
n be
twee
n th
e di
spen
ser
pum
p en
able
(H
ook)
sig
nal
and
the
subm
ersi
ble
turb
ine
pum
p (S
TP
) co
ntro
l rel
ay. O
ther
ene
rgiz
ed s
ourc
es o
f pow
er c
an s
till e
xist
with
in th
e di
spen
ser
even
with
this
dev
ice.
T
he n
eutr
al c
onne
ctio
n to
the
N te
rmin
al o
f TB
1 an
d N
term
inal
of T
B2
mus
t be
from
the
serv
ice
pane
l and
be
a p
erm
anen
tly c
onne
cted
, uns
witc
hed
conn
ectio
n.
The
N c
onne
ctio
n on
TB
1 an
d th
e ei
ght N
con
nect
ions
on
TB
2 m
ay b
e sp
liced
to a
com
mon
neu
tral
wire
from
the
serv
ice
pane
l des
crib
ed a
bove
.
Mak
e on
ly o
ne "
wire
" co
nnec
tion
on e
ach
N te
rmin
al o
n T
B2.
T
he p
hase
of L
1 (T
B1)
mus
t mat
ch th
e ph
ase
of th
e po
wer
sup
plyi
ng th
e AT
G d
evic
e in
ord
er to
pre
vent
cr
oss
phas
ing
whi
ch m
ay d
amag
e th
e in
put o
n so
me
ATG
equ
ipm
ent.
GE
NE
RA
L W
IRIN
G P
RE
CA
UT
ION
S
Wiri
ng m
ust b
e ra
ted
90°C
min
imum
.
Mak
e gr
ound
con
nect
ion
in a
ccor
danc
e w
ith lo
cal c
odes
.
12
34
56
78
DIS
PE
NS
ER
INP
UT
SP
HA
SE
ON
L1
MU
ST
BE
SA
ME
AS
DE
VIC
E
CO
NN
EC
TE
D T
O A
TG
TE
RM
INA
L
HO
T
NE
UT
RA
L
TB
2
ATG
NL1
L2M
2M
1S
Dan
ger
!!
Dan
ger
!!
Cau
tio
n
The
follo
win
g te
rms
are
used
in th
is d
ocum
ent t
o br
ing
atte
ntio
n to
th
e pr
esen
ce o
f haz
ards
of v
ario
us r
isk
leve
ls, o
r to
impo
rtan
t inf
orm
atio
nco
ncer
ning
use
of t
he p
rodu
ct.
Indi
cate
s th
e pr
esen
ce o
f a h
azar
d th
at w
ill c
ause
sev
ere
pers
onal
inju
ry,
deat
h, o
r su
bsta
ntia
l pro
pert
y da
mag
e if
ign
ore
d.
Indi
cate
s th
e pr
esen
ce o
f a h
azar
d th
at w
ill o
r ca
n c
ause
min
or
pers
onal
inju
ry o
r pr
oper
ty d
amag
e if
ign
ore
d.
Indi
cate
s sp
ecia
l ins
truc
tions
on
inst
alla
tion,
ope
ratio
n, o
r m
aint
enan
ce th
atar
e im
port
ant b
ut n
ot r
elat
ed to
per
sona
l inj
ury
haza
rds.
Dan
ger
!!
Cau
tio
n
yyN
oti
cepp
yyN
oti
cepp
RS-
485
CO
NN
ECTI
ON
S IN
STAL
L IN
CO
ND
UIT
(M
ANIF
OLD
ED U
NIT
S O
NLY
)
CO
NN
ECT
TO
ELEC
TRIC
AL
GR
OU
ND
CO
NN
ECT
TO
ELEC
TRIC
AL G
RO
UN
D
FR
OM
SU
PP
LYP
AN
EL
120
VO
LT IS
OLA
TE
D O
UT
PU
T T
O IQ
CO
NT
RO
L B
OX
FIG
UR
E 2
.11a
: IS
OT
RO
L T
O IQ
SY
ST
EM
WIR
ING
- 1
20 V
OL
T D
ISP
EN
SE
R S
IGN
AL
S
15a
ELE
CT
RIC
AL
INT
ER
LOC
K
CO
NT
INU
OU
SD
UT
YC
APA
CIT
OR
INT
ER
NA
LO
VE
RLO
AD
PR
OT
EC
TOR
JUN
CT
ION
BO
X IN
M
AN
IFO
LD
CO
M+
C23 TB
1
D2
CO
M-
SH
LDD
1M
2L1
M1
L2G
ND
Z2 Z3
IQ C
ON
TR
OL
BO
X (
P/N
880
-052
-1)
ISO
TR
OL
CO
NT
RO
L B
OX
(P
/N 8
80-0
50-1
)
MO
TOR
ST
P
NE
UT
RA
L(F
RO
M S
UP
PLY
PA
NE
L)
FR
OM
SU
PP
LYP
AN
EL
NE
UT
RA
L
CH
AN
NEL
1C
HA
NN
EL 2
CH
AN
NEL
3C
HA
NN
EL 4
CH
AN
NEL
5C
HA
NN
EL 6
CH
AN
NEL
7C
HA
NN
EL 8
230
VOLT
DIS
PEN
SER
SIG
NA
LSUN
SWIT
CH
EDN
EUTR
AL
TO T
B2
TB1
230
VO
LT
UN
SW
ITC
HE
D N
EU
TR
AL
NO
TU
SE
DN
OT
US
ED
NO
TU
SE
DN
OT
US
ED
ISO
TR
OL
CO
NT
RO
L B
OX
WIR
ING
PR
EC
AU
TIO
NS
T
his
devi
ce is
inte
nded
to p
rovi
de e
lect
rical
isol
atio
n be
twee
n th
e di
spen
ser
pum
p en
able
(H
ook)
sig
nal
and
the
subm
ersi
ble
turb
ine
pum
p (S
TP
) co
ntro
l rel
ay. O
ther
ene
rgiz
ed s
ourc
es o
f pow
er c
an s
till e
xist
with
in th
e di
spen
ser
even
with
this
dev
ice.
T
he n
eutr
al c
onne
ctio
n to
the
N te
rmin
al o
f TB
1 an
d N
term
inal
of T
B2
mus
t be
from
the
serv
ice
pane
l and
be
a p
erm
anen
tly c
onne
cted
, uns
witc
hed
conn
ectio
n.
The
N c
onne
ctio
n on
TB
1 an
d th
e ei
ght N
con
nect
ions
on
TB
2 m
ay b
e sp
liced
to a
com
mon
neu
tral
wire
from
the
serv
ice
pane
l des
crib
ed a
bove
.
Mak
e on
ly o
ne "
wire
" co
nnec
tion
on e
ach
N te
rmin
al o
n T
B2.
T
he p
hase
of L
1 (T
B1)
mus
t mat
ch th
e ph
ase
of th
e po
wer
sup
plyi
ng th
e AT
G d
evic
e in
ord
er to
pre
vent
cr
oss
phas
ing
whi
ch m
ay d
amag
e th
e in
put o
n so
me
ATG
equ
ipm
ent.
GE
NE
RA
L W
IRIN
G P
RE
CA
UT
ION
S
Wiri
ng m
ust b
e ra
ted
90°C
min
imum
.
Mak
e gr
ound
con
nect
ion
in a
ccor
danc
e w
ith lo
cal c
odes
.
12
34
56
78
DIS
PE
NS
ER
INP
UT
SP
HA
SE
ON
L1
MU
ST
BE
SA
ME
AS
DE
VIC
E
CO
NN
EC
TE
D T
O A
TG
TE
RM
INA
L
HO
T
NE
UT
RA
L
TB
2
ATG
NL1
L2M
2M
1S
Dan
ger
!!
Dan
ger
!!
Cau
tio
n
The
follo
win
g te
rms
are
used
in th
is d
ocum
ent t
o br
ing
atte
ntio
n to
th
e pr
esen
ce o
f haz
ards
of v
ario
us r
isk
leve
ls, o
r to
impo
rtan
t inf
orm
atio
nco
ncer
ning
use
of t
he p
rodu
ct.
Indi
cate
s th
e pr
esen
ce o
f a h
azar
d th
at w
ill c
ause
sev
ere
pers
onal
inju
ry,
deat
h, o
r su
bsta
ntia
l pro
pert
y da
mag
e if
ign
ore
d.
Indi
cate
s th
e pr
esen
ce o
f a h
azar
d th
at w
ill o
r ca
n c
ause
min
or
pers
onal
inju
ry o
r pr
oper
ty d
amag
e if
ign
ore
d.
Indi
cate
s sp
ecia
l ins
truc
tions
on
inst
alla
tion,
ope
ratio
n, o
r m
aint
enan
ce th
atar
e im
port
ant b
ut n
ot r
elat
ed to
per
sona
l inj
ury
haza
rds.
Dan
ger
!!
Cau
tio
n
yyN
oti
cepp
yyN
oti
cepp
RS-
485
CO
NN
ECTI
ON
S IN
STAL
L IN
CO
ND
UIT
(M
ANIF
OLD
ED U
NIT
S O
NLY
)
CO
NN
ECT
TO
ELEC
TRIC
AL
GR
OU
ND
CO
NN
ECT
TO
ELEC
TRIC
AL G
RO
UN
D
230
VO
LT
FR
OM
SU
PP
LYP
AN
EL
230
VO
LT IS
OLA
TE
D O
UT
PU
T T
O IQ
CO
NT
RO
L B
OX
FIG
UR
E 2
.11b
: IS
OT
RO
L T
O IQ
SY
ST
EM
WIR
ING
- 2
30 V
OL
T D
ISP
EN
SE
R S
IGN
AL
S
15b
— 16 —
4” Petroleum & AG
Adjust the Functional Element on both packers to maximumrelief pressure by rotating fully clockwise. If maximum pumppressures are NOT a minimum of 5 psi (34 kPa) below theFunctional Element relief setting then proper check valveswith pressure relief are required to be installed in the discharge line of each pump to prevent product from beingpumped through the pressure relief system of the adjacentpump when it is not operating.
The in line check valves and 115 VAC relay are not available fromRed Jacket and should be purchased locally. See figure 2.13.
Ball valves should be installed at the pump end of the dischargeline for ease of maintenance and troubleshooting. See figure 2.12.
Figure 2.12 Tandem pumps
BALL VALVES
WARNING
INSTALLING TWO PUMPS FOR TANDEM OPERATION
When greater flow rates are needed, two pumps may be installed in the same pip-
ing system by means of a manifold. If installed according to the illustration below
(figure 2.12), tandem systems offer backup support so operations can continue if
one pump stops working.
— 17 —
P
EXTPILOTLIGHT S1 S2 M2 M1 N L1 L2
P
EXTPILOTLIGHT S1 S2 M2 M1 N L1 L2
N
L1 L2
N
L1 L2
MOTORMOTOR
S2
S1
S1
S2
DISPENSER SW. 110-350V
Figure 2.13
Single Phase
This diagram (Fig 2.13) shows the wiring allowing both submersibles to operate simulta-
neously with any combination of dispensers turned on. To operate individually, the appro-
priate toggle switch, located externally on the side of the control box can be turned off
manually.
SUGGESTED WIRING FOR TANDEM PUMPS
115 VOLT RELAY
ALLEN BRADLEY
700-C201
— 18 —
4” Petroleum & AG
Figure 2.14 Functional Element cap and adjustment screw
ADJUSTING THE FUNCTIONAL ELEMENT
ALWAYS DISCONNECT and LOCK or TAG OUT the powerbefore starting to service pump.
The Functional Element contained in this package is an adjustable model. All new
Functional Elements are factory set at relief pressures of 11.5 (79 kPa) to 16 psi (93 kPa)
but can be adjusted to a maximum of approximately 30 psi (207 kPa) by turning down the
adjustment screw.
This adjustment feature allows the use of the Red Jacket pump with electronic line leak
detection systems that require higher relief pressures and enhances performance of
electronic line leak detection systems where field conditions have necessitated minor
adjustments to the relief pressure.
To adjust the relief pressure:
1: Remove the cap (Fig. 2.14).
2: Turn down the adjustment screw (Fig. 2.14). Tightening the screw clockwise will
increase the pressure. When the adjusting screw is fully down, the relief pressure is
approximately 30 psi (207 kPa). Positions between fully up and fully down will result
in relief pressures between approximately 3 psi (21 kPa) and 30 psi (207 kPa).
3: Replace cap by turning it until it touches the functional element body. Hand
tightening is sufficient as the o-ring completes the seal when it is trapped between
the body and cap.
There are two methods to verify the relief pressure setting:
– The pressure reading can be taken from the control unit of an electronic line
leak detection system if one is in operation. Observe the pressure that occurs
after the pump turns off— this is the adjusted relief pressure.
– Pressure may be observed using a gauge attached at the impact valve or the
line test port at the pump. Observe the pressure that occurs after the pump
turns off. This is the adjusted relief pressure.
DANGER
CAP
ADJUSTMENT SCREW
— 19 —
When the adjustable functional element is installed, thepump/motor unit must operate at a minimum of 5 psi (34 kPa)greater than the relief (seating) pressure that the functionalelement has been set to. An improper pressure setting maycause mechanical damage and will void the warranty.
If a siphon system is being utilized, it is especially importantto follow the 5 psi (34 kPa) rule, that is, the pump must create5 psi (34 kPa) more than what the relief pressure has been set to.
For example: If a relief pressure of 25 psi (172 kPa) is desired, the pump in use must be capable of producing 30 psi(207 kPa) minimum.
WARNING
NOTICE
TABLE F:
FFO-TUHSTAERUSSERPETAMIXORPPA–PMUPTEKCAJDER
1R33PMUGA1R33PMU
)aPk271(isp52 )C°51(F°06@GS47.
1S57PMUGA1S57PMU
)aPk391(isp82 )C°51(F°06@GS47.
1S051PMUGA1S051PMU
)aPk702(isp03 )C°51(F°06@GS47.
1S051PMUGA3X1S051PMU3X
)aPk792(isp34 )C°51(F°06@GS47.
1S051PMUGA5X1S051PMU5X
)aPk713(isp64 )C°51(F°06@GS47.
3-3S57PMUGA3-3S57PMU
)aPk702(isp03 )C°51(F°06@GS47.
3-3S051PMUGA3-3S051PMU
)aPk022(isp23 )C°51(F°06@GS47.
3S051PMUGA4X3S051PMU4X
)aPk572(isp04 )C°51(F°06@GS47.
3-71S57PMUGA3-71S57PMU
)aPk002(isp92 )C°51(F°06@GS47.
3-71S051PMUGA3-71S051PMU
)aPk022(isp23 )C°51(F°06@GS47.
71S051PMUGA4X71S051PMU4X
)aPk762(isp93 )C°51(F°06@GS47.
— 20 —
4” Petroleum & AG
Figure 3.1 Closing thecheck valve
Figure 3.2 Line test port
REMOVE THREADED
PLUG
VENT CLOSING
SCREW
CHAPTER 3: TESTING THE INSTALLATION
ALWAYS DISCONNECT and LOCK or TAG OUT the powerbefore starting to service pump.
To Test Piping
1: Block lines at each dispenser. (Trip dispenser shear valve.) Remove line test plug
for this test.
2: Close pump check valve by turning the vent closing screw as far down as possible.
(See Fig 3.1)
Excessive pressure (above normal test pressure of 50–55 psi(345–380 kPa)) may damage check valve seat and other system components.
3: Apply line test pressure at line test port. (50 psi (345 kPa) maximum). (See Fig 3.2)
To Test Tank
1: Close pump check valve by turning the vent closing screw as far down as possible.
Apply tank test pressure at tank test port. (See fig. 3.2)
2: After completion of line and/or tank tests, release pressure by turning the vent
closing screw as far up as possible.
3: After the installation is completed and tests have been made, purge system of air
by pumping at least 15 gallons (57 liters) through each dispenser. Begin with the
dispenser furthest from pump and work toward the pump.
NOTICE
CAUTION
LINE TEST PORT
TANK TEST PORT
— 21 —
DANGER
CHAPTER 4: SERVICE AND REPAIR
TECHNICAL SUPPORT
For technical assistance 24 hours a day, call
1-800-777-2480.
Please have your Red Jacket Technical Support ID number when calling.
See the Parts List in Appendix A.
See Limited Warranty on back cover.
REMOVING THE PUMP
ALWAYS DISCONNECT and LOCK or TAG OUT the powerbefore starting to service the pump.
1: Back out the electrical connector disconnect bolt. (See fig. 4.1)
2: Swing the electrical connector aside.
Figure 4.1 Packer
ELECTRICAL
CONNECTOR
LOCK DOWN BOLT
LOCK DOWN BOLT
ELECTRICAL
CONNECTOR
DISCONNECT BOLT
3: If a siphon system is in place, disconnect the siphon tubing. If ball valves areinstalled, close them.
4: Remove the two lock-down bolts. To relieve pressure, rock the pump to allow excesspressure to flow into the tank or back out Functional Element screw.
5: Lift out the extractable unit.
DO NOT damage the surface above the discharge port. Theo-ring below the leak detector port seals on this surface.
Before replacing the extractable portion, make sure that thepacker o-ring and discharge o-ring seal surfaces are clean.New o-rings should be installed.
REPLACING THE UMP
ALWAYS DISCONNECT and LOCK or TAG OUT the powerbefore starting to service the pump.
1: Remove the extractable portion of the old pump from the tank as described in removing the pump.
2: Remove the old UMP by removing the four bolts holding the discharge head asshown in figure 4.2.
3: Rock the unit while pulling away from the discharge head until it is free.
4: Replace the old gasket with a new one provided. Place the new gasket on the newUMP so that all the holes align.
Gaskets from competitive UMPS will not seal properly and performance will be reduced.
Visually inspect the pigtail connector in the discharge head. Replace if damaged. Be certain the indexing tab of the pigtail is seated in the notch of the discharge head
5: Lubricate o-ring and pigtail with petroleum based jelly.
6: Align the UMP positioning dowel and boss with the proper holes in the dischargehead and push the UMP into position using hand force only. The UMP should besnug against the discharge head prior to installing the UMP retaining bolts.
— 22 —
4” Petroleum & AG
NOTICE
Figure 4.2 Removing the UMP Figure 4.3 Replacing the gasket
DANGER
Use hand force to put the UMP onto the discharge head. If the UMP does not seat properly, snug against the discharge head, remove the UMP and correct the problem.
Do not use the bolts to pull the UMP into position. Use the cross pattern to snug and torque bolts. Do not over torque the bolts. Not following these instructions may cause parts to fail.
CAUTION
CAUTION
NOTICE
NOTICE
NOTICE
— 23 —
Figure 4.4 Packer with Functional Element
7: Install the UMP retaining bolts and lock washers. Snug and then torque the bolts
using a cross pattern. Torque to 7 ft-lb.(11 N•m).
Before replacing the extractable, make sure that the surfacesof the packer o-ring and the discharge o-ring seals are clean.
8: Replace the packer o-ring and the discharge o-ring seals.
9: Reinstall the extractable portion into the tank, using the steps previously described
under Installing the Pump in Chapter 2.
10: Refer to Chapter 3 to test system.
REPLACING THE FUNCTIONAL ELEMENT
ALWAYS DISCONNECT and LOCK or TAG OUT the powerbefore starting to service the pump. Then bleed off any residual pressure from the system.
Disable the Pump
1: Back out the electrical connector disconnect bolt. (See fig. 4.4)
2: Swing the electrical connector aside.
3: To relieve the pressure, back out Functional Element adjustment screw.
Replace the Functional Element
1: Disconnect the siphon tubing (if siphon is installed).
2: Remove the two 3/8” bolts.
3: Carefully lift the functional element and remove it from the packer. The old check
valve and spring will be resting inside the packer.
FUNCTIONAL
ELEMENT3/8” BOLTS
ELECTRICAL
CONNECTOR
DISCONNECT
BOLT
ELECTRICAL CONNECTOR
CAP
ADJUSTMENT
SCREW
Figure 4.5 Functional Elementcap and adjustment screw
NOTICE
DANGER
— 24 —
4” Petroleum & AG
4: Be certain all mating surfaces are clean. Install new functional element o-rings on
functional element (see figure 4.5). Install small o-ring in groove of packer. Carefully
set new functional element in place. Replace two 3/8” bolts and torque to 20-35 ft lb
(27-50 N•m).
5: If no siphon is used, make sure the vacuum port on the functional element is plugged
with a 3/8” NPT plug.
6: Check the seating pressure of the adjustable Functional Element for proper setting.
REPLACING THE CAPACITOR IN PACKER
Serious injury or death can result from using a generic–typecapacitor. Generic–type capacitors do not contain internalbleed resistors.
ALWAYS DISCONNECT and LOCK or TAG OUT the powerbefore starting to service the pump.
Capacitor is 440V, 17.5 µF continuous duty with internal bleedresistor for 1/3 & 3/4 HP models. Capacitor is 440V, 25 µF continuous duty with internal bleed resistor for 1-1/2 HPmodels.
1: Remove wiring compartment cover.
2: Remove retaining clip
3: Pull out capacitor.
4: Pull quick connectors.
5: Push connectors onto new capacitor.
6: Push capacitor into wiring compartment. Clip into place.
7: Reinstall capacitor cover. Do not use thread sealant. Torque to 35 ft lb (50 N•m).
INSTALLING A REPLACEMENT EXTRACTABLE PUMP
If fixed length, skip to step 7
1: Remove existing Red Jacket pump. (See “Removing the Pump” in Chapter 4).
Make Sure that the packer o-ring and discharge o-ring seal surfaces are clean.
Confirm length of pump prior to installation.
Do not damage the surface above the discharge port. The o-ring below the leak detector port seals on this surface.
2: Attach the UMP (see “Attaching the UMP” in Chapter 2)
3: Measure the distance from the bottom of the tank to the sealing surface of the
manifold.
NOTICE
DANGER
DANGER
NOTICE
CAUTION
— 25 —
4: Uncoil pigtail and lay flat so it will feed into the packer without knotting or kinking.
5: Loosen the clinch assembly, starting by loosening the set screw in the side of thelocking nut, then loosen the locking nut.
6: Pull the UMP end until the distance between the bottom of the manifold and the of the UMP is 5 inches (125 mm) (14 inches (356 mm) for floating suction) shorterthan the distance measured in step 2 (see figure 4.7)
If UMP is equipped with floating suction adapter, see recommended floating suction installation in Chapter 1.
Take care not to damage the pigtail. If pump is to be adjustedshorter, tension must be kept on pigtail to eliminate kinking.
7: Tighten locking nut and torque to 150 ft-lb (200 N•m) minimum, then torque the set
screw to 30-35 in-lb (3.5 – 4 N•m).
Return line should be installed on every application to insureagainst nuisance trips of electronic tank monitoring.
Figure 4.6 Loosen fittings
NOTICE
NOTICE
Figure 4.7 Adjust pump length
NOTICE
— 26 —
4” Petroleum & AG
8: Attach tubing to barbed fitting, secure with clamp.
9: Lay tubing beside column pipe. Cut off 1-3 inches (25-76 mm) above the
discharge head.
10: Secure tube to column pipe with tie straps. Locate tie straps approximately 6 inches
(152 mm) from packer, 6 inches (152 mm) from discharge head and middle of tubing.
For fixed length pump, skip to conduit box wiring
11: Remove cover from wiring compartment.
12: Pull pigtail wires into wiring compartment.
13: Cut pigtail wires extending approximately 8-inches (200 mm) out of
wiring compartment.
14: Strip back insulation of all wires 3/8-inch (10 mm).
15: Using supplied wire nuts, attach like colored pump pigtail wires to wires.
See figure 4.8 to verify connections.
16: Install excess wire into wiring compartment. Replace wiring compartment cover.
Torque to 35 ft lb (50 N•m). Thread sealant should not be used.
17: Install the pump into the manifold.
Before replacing the extractable, make sure that the surfacesof the packer o-ring and the discharge o-ring seals are clean.
18: Align the positioning dowels of the manifold with the holes in the packer.
19: Push the packer as far as possible against the manifold.
Figure 4.8 Wiring Schematic
ORANGE
BLACK
CAPACITOR
ORANGE
BLACK
RED
IN FROMELECTRICAL CONNECTOR
OUT TOPUMP PIGTAIL
NOTICE
— 27 —
20: Insert the lock-down bolts and torque to 45-55 ft lb (61-75 N•m).
21: Loosen the bolts that hold the conduit box to the manifold. Do not remove.
22: Swing the electrical connector into position.
23: Torque the electrical connector bolt to 25-50 ft lb (34-68 N•m).
24: Torque the conduit box bolts to 30-45 ft lb (40-61 N•m).
Suggested tools (non-sparking): 3/4” wrench, pipe wrench, 1/4” allen wrench, 9/16” wrench, screw driver, wire cutter and wire stripper.
— 28 —
4” Petroleum & AG
PARTS LIST
CUSTOMER SERVICE NUMBER
After unpacking the equipment, please inspect the parts. Make sure all accessories
are included and that no damage occurred during shipping. Report any damage to the
shipper immediately and inform a customer service representative at 1-800-873-3313
of any equipment damage or missing equipment.
The following pages list the parts for the functional element, pump, Quick-Set feature,
and UMP.
A dash in a table cell indicates the item is not required for that type of pump.
— 29 —
YOKE ASSEMBLY AND CONDUIT BOX PARTS
METI #TRAP NOITPIRCSED YTQ
1 5-501-311 )ERIW-2(ELAM—ROTCENNOC 1
1 5-555-311 )NWOHSTON()ERIW-3(ELAM—ROTCENNOC 1
2 1-294-270 PANS—GNIR 1
3 5-510-313 GA)ERIW-2(RIAPER—ROTCENNOC 1
3 5-120-313 )NWOHSTON(GA)ERIW-3(RIAPER—ROTCENNOC 1
3 5-200-313 )NWOHSTON(ORTEP)ERIW-2(RIAPER—ROTCENNOC 1
3 5-910-313 )NWOHSTON(ORTEP)ERIW-3(RIAPER—ROTCENNOC 1
4 5-694-801 ORTEPELGNIS—XOBTIUDNOC 1
4 5-945-801 GAELGNIS—XOBTIUDNOC 1
1
4
3
2
4” Petroleum & AG
PACKER-MANIFOLD ASSEMBLY PARTS
SIDE VIEW
8
12
13
14
11
10
9
TOP VIEW
6 6
4
7
2
2
5
1
3
— 30 —
— 31 —
METI #TRAP NOITPIRCSED MOD L'TNI
1 1-502-620 CNU4/11X31-2/1–WERCS 2 2
2 1-130-720 TPN"4/1EPIP—GULP 2 2
3 1-480-720 TPN"8/3EPIP—GULP 1 1
4 1-671-620 CNU4/3X61-8/3—WERCS 2 2
5 1-350-882 ORTEPEVLAVKCEHCNOHPIS 1 1
5 5-332-881 GAEVLAVKCEHCNOHPIS 1 1
6 5-182-760 )NWOHSTONNOITPOXOBLAUD(XOBTIUDNOCYSSA—GULP 2 2
6 3-680-720 )YLNOXOBELGNIS(TPN"2EPIP—GULP 1 1
7 5-922-441 )NWOHSTON(ORTEPXOBTIUDNOCLAUD&ROTCENNOCLACIRTCELEERIW2—TIK 1 1
7 5-122-441 )NWOHSTON(ORTEPXOBTIUDNOCLAUD&ROTCENNOCLACIRTCELEERIW3—TIK 1 1
7 5-222-441 )NWOHSTON(GAXOBTIUDNOCLAUD&ROTCENNOCLACIRTCELEERIW3—TIK 1 --
8 5-480-311 GNIR-OHTIWREVOCROTICAPAC1R33P 1 --
8 5-580-311 GNIR-OHTIWREVOCROTICAPAC1S57P 1 --
8 5-913-311 GNIR-OHTIWREVOCROTICAPAC1S051P 1 --
8 5-635-311 GNIR-OHTIWREVOCROTICAPAC1S051P3X 1 --
8 5-735-311 GNIR-OHTIWREVOCROTICAPAC1S051P5X 1 --
8 5-345-311 GNIR-OHTIWREVOCROTICAPAC3S051P4X -- 1
8 5-023-311 GNIR-OHTIWREVOCROTICAPAC3-3S051P -- 1
8 5-974-311 GNIR-OHTIWREVOCROTICAPAC1R33PGA 1 --
8 5-084-311 GNIR-OHTIWREVOCROTICAPAC1S57PGA 1 --
8 5-184-311 GNIR-OHTIWREVOCROTICAPAC1S051PGA 1 --
8 5-835-311 GNIR-OHTIWREVOCROTICAPAC1S051PGA3X 1 --
8 5-935-311 GNIR-OHTIWREVOCROTICAPAC1S051PGA5X 1 --
8 5-445-311 GNIR-OHTIWREVOCROTICAPAC3-71S57P -- 1
8 5-545-311 GNIR-OHTIWREVOCROTICAPAC3-71S051P -- 1
8 5-645-311 GNIR-OHTIWREVOCROTICAPAC71S051P4X -- 1
8 5-995-311 GNIR-OHTIWREVOCROTICAPAC3-3S57PGA -- 1
8 5-006-311 GNIR-OHTIWREVOCROTICAPAC3-3S051PGA -- 1
9 1-091-270 ORTEP)332-(ANUBGNIR-OREVOCROTICAPAC 1 1
9 1-345-270 GA)332-(NOTIVGNIR-OREVOCROTICAPAC 1 1
01 5-831-462 ORTEPYSSAREKCAPTNEMECALPERERIW2 1 1
01 5-241-462 GAYSSAREKCAPTNEMECALPERERIW2 1 1
01 5-141-462 ORTEPYSSAREKCAPTNEMECALPERERIW3 1 1
11 5-290-111 Fµ5.71ROTICAPAC 1 1
11 5-166-111 Fµ52ROTICAPAC 1 1
21 1-981-270 ORTEP)344-(ANUB—GNIR-O 1 1
21 1-245-270 GA)344-(NOTIV—GNIR-O 1 1
31 5-381-441 ORTEPGNIRPS&EVLAVKCEHC—TIK 1 1
31 5-481-441 GAGNIRPS&EVLAVKCEHC—TIK 1 1
41 5-100-323 ORTEPYSSATNEMELELANOITCNUF 1 1
41 5-200-323 GAYSSATNEMELELANOITCNUF 1 1
Packer-Manifold Assembly Parts List
4” Petroleum & AG
FSA
1
2
34
4
4
PUMP PARTS
— 32 —
— 33 —
METI #TRAP NOITPIRCSED MOD L'TNI
1 5-190-441 LIATGIP—TIK 1 1
2 1-601-270 ORTEP)311-(ANUBGNIR-O 1 1
2 1-825-270 GA)311-(TLFGGNIR-O 1 1
3 5-400-258 1R33PMU 1 --
3 5-420-258 ASF/W1R33PMU 1 --
3 5-500-258 1S57PMU 1 --
3 5-520-258 ASF/W1S57PMU 1 --
3 5-110-258 3-3S57PMU -- 1
3 5-270-258 ASF/W3-3S57PMU -- 1
3 5-850-258 3-71S57PMU -- 1
3 5-440-258 1S051PMU 1 --
3 5-240-258 ASF/W1S051PMU 1 --
3 5-840-258 3-3S051PMU -- 1
3 5-370-258 ASF/W3-3S051PMU -- 1
3 5-950-258 3-71S051PMU -- 1
3 5-811-258 1S051PMU3X 1 --
3 5-331-258 ASF/W1S051PMU3X 1 --
3 5-351-258 3S051PMU4X -- 1
3 5-451-258 ASF/W3S051PMU4X -- 1
3 5-551-258 71S051PMU4X -- 1
3 5-651-258 ASF/W71S051PMU4X -- 1
3 5-611-258 1S051PMU5X 1 --
3 5-380-258 1R33PMUGA 1 --
3 5-431-258 ASF/W1R33PMUGA 1 --
3 5-480-258 1S57PMUGA 1 --
3 5-531-258 ASF/W1S57PMUGA 1 --
3 5-701-258 3-3S57PMUGA -- 1
3 5-111-258 ASF/W3-3S57PMUGA -- 1
3 5-580-258 1S051PMUGA 1 --
3 5-631-258 ASF/W1S051PMUGA 1 --
3 5-801-258 3-3S051PMUGA -- 1
3 5-211-258 ASF/W3-3S051PMUGA -- 1
3 5-821-258 1S051PMUGA3X 1 --
3 5-231-258 ASF/W1S051PMUGA3X 1 --
3 5-421-258 1S051PMUGA5X 1 --
4 4-823-441,TEKSAGSEDULCNI(PMU/NOHPYSXELF—TIK
)STLOBDNASREHSAWKCOL1 1
-- 5-491-441 )NWOHSTON(TIFORTER—REPPART 1 1
-- 5-212-441 )NWOHSTON(GNIR-OTESKCIUQ,RIAPER—TIK 1 1
Pump Parts List
4” Petroleum & AG
1
2
3
4
5
)ZH06(LIOCV511/WXOBLORTNOC5-140-088
METI #TRAP NOITPIRCSED YTQ
1 4-275-801 XOBLORTNOC 1
2 1-600-741 YLBMESSATHGILTOLIP 1
3 1-327-410 YALERROTCATNOCENIL 1
4 1-858-080 HCTIWSELGGOT 1
5 1-202-800 KCOLBLANIMRET 1
)ZH06/05(LIOCV032/WXOBLORTNOC5-240-088
METI #TRAP NOITPIRCSED YTQ
1 4-275-801 XOBLORTNOC 1
2 1-600-741 YLBMESSATHGILTOLIP 1
3 1-027-410 YALERROTCATNOCENIL 1
4 1-260-080 HCTIWSELGGOT 1
5 1-202-800 KCOLBLANIMRET 1
CONTROL BOXES — PART 1
— 34 —
— 35 —
)LIOCV511(ROTICAPAC/WXOBLORTNOCPH4/3&3/15-540-088
METI #TRAP NOITPIRCSED YTQ
1 1-141-321 XOBLORTNOC 1
2 1-600-741 YLBMESSATHGILTOLIP 1
3 1-327-410 YALERROTCATNOCENIL 1
4 1-858-080 HCTIWSELGGOT 1
5 1-202-800 KCOLBLANIMRET 1
6 5-290-111 ROTICAPAC 1
)LIOCV511(ROTICAPAC/WXOBLORTNOCPH2/1-1LLA5-640-088
METI #TRAP NOITPIRCSED YTQ
1 1-141-321 XOBLORTNOC 1
2 1-600-741 YLBMESSATHGILTOLIP 1
3 1-327-410 YALERROTCATNOCENIL 1
4 1-858-080 HCTIWSELGGOT 1
5 1-202-800 KCOLBLANIMRET 1
6 5-166-111 ROTICAPAC 1
1
2
3
4
56
CONTROL BOXES — PART 2
A-1
Appendix A: 4’’ Standard Red Jacket STP Safety Instructions
1. ATEX Directive 94/9/EC approved Red Jacket Submersible Turbine Pump (STP) marked with the following information defining its limits for safe use.
Location Classification:
CE 0539 Ex II2G
EEx ds IIA T3
Special Conditions for Safe Use:
“The pump motor must not be allowed to run dry. This assembly must be used with appropriately certified equipment that ensures that the motor either remains fully submersed or that there is a continuous presence of fluid inside the pump motor.”
Certification Number:
DEMKO 03 ATEX 0237289X
2. For European installations, electrical conduit must be connected through an ATEX EEx d IIB certified cable gland or stopping box.
3. Initial start-up of this pump requires that the pump motor be fully submersed in fuel.
4. The Red Jacket 4” Standard Submersible Turbine Pump requires no periodic maintenance or calibration.
125 Powder Forest Drive • Simsbury, CT 06070Tel: (860) 651-2700 • Fax: (860) 651-2719
By