Petroleum Products

RED JACKET Service Manual

RJ 5190 3/93
 It is imperative that time is taken in reading
and understanding this manual thoroughly
before installing and using Red Jacket
Petroleum Equipment.

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.
indicates presence of a hazard which will indicates presence of a hazard which will
DANGER cause severe personal injury, death or sub- CAUTION or can cause minor personal injury or
stantial property damage if ignored. property damage if ignored.

indicates presence of a hazard which can indicates special instructions on installa-

WARNING NOTICE
cause severe personal injury, death or sub- tions, operation, or maintenance which are
stantial property damage if ignored. important but not related to personal in-
jury hazards.

For Technical Assistance Call:

1-800-2-MARLEY (262-7539)

NOTICE Specifications and/or installation instructions are subject to

change per manufacturer’s recommendations.
 T able of Contents
Description Section Page No.

4" “Extracta”/4" “AG” Petroleum Pumps ..................................................................................................... 1

Petroleum Pump (Prior to 1963) ............................................................................................................................................ 2
“Extracta” Petroleum Pump - Parts List ................................................................................................................................. 3
“AG” Petroleum Pump - Parts List ......................................................................................................................................... 4
Pump/Motor Assembly ........................................................................................................................................................... 5
Piping/Seals ........................................................................................................................................................................... 6
Discharge Manifold Assembly/Functional Element ................................................................................................................ 7
Check Valve/Troubleshooting ................................................................................................................................................ 8
Removing the “Extracta” Portion ............................................................................................................................................ 9
Packer Seals .......................................................................................................................................................................... 10
Line and Tank Testing Guidelines ......................................................................................................................................... 11
Control Box ............................................................................................................................................................................ 12
Pump/Motor Assembly Wiring ............................................................................................................................................... 13
Pump/Motor Assembly Troubleshooting ................................................................................................................................ 14
Replacing the Pump/Motor Assembly .................................................................................................................................... 15
Wiring Diagrams .................................................................................................................................................................... 16
Capacitor ................................................................................................................................................................................ 17
Dimensions and Pump Length ............................................................................................................................................... 18

6" Big-Flo® Petroleum Submersible Pump .................................................................................................... 2

Installation .............................................................................................................................................................................. 20
Wiring Diagrams .................................................................................................................................................................... 24
Manifold Dimensions ............................................................................................................................................................. 26
Pump Dimensions .................................................................................................................................................................. 27
Cutaway View ........................................................................................................................................................................ 28
Troubleshooting/Electrical Data ............................................................................................................................................. 29
Three Phase Unbalance ........................................................................................................................................................ 30
Replacement Parts List .......................................................................................................................................................... 31
Control Box ............................................................................................................................................................................ 33
Magnetic Starter .................................................................................................................................................................... 34
Pump/Motor Assembly ........................................................................................................................................................... 35

Syphon Systems. ............................................................................................................................................ 3

Engineering Report - Installation/Testing ............................................................................................................................... 38
Parts List ................................................................................................................................................................................ 43
Illustration ............................................................................................................................................................................... 44
Troubleshooting ..................................................................................................................................................................... 45

Floating Suction and Manifolded Pumps ...................................................................................................... 4

Recommended Installation .................................................................................................................................................... 48
Adapter for pre-1982 Pumps ................................................................................................................................................. 49
Dual Pumps 4" ...................................................................................................................................................................... 50
Dual Pumps 6" ...................................................................................................................................................................... 51

Warranty ........................................................................................................................................................... 5
Warranty Statement ............................................................................................................................................................... 54
Date Codes ............................................................................................................................................................................ 55

®
RJ 5190© 3/93 i
Introduction

The information and recommendations contained

in the “Troubleshooting” sections of this manual are
presented as a suggested guide to expedient solu-
tions of problems specified. No attempt has been
made to identify all possible problems. Even as to
problems discussed, the information available to
you may dictate different procedures and solutions.

Our liability with respect to the product and informa-

tion herein is limited solely to the product warranty
set forth in the Red Jacket Warranty Manual #5194
and on page 54 of this manual.

SOLVENT PUMPS
(4" Extracta and 6" Big-Flo)

The design of these units is basically the same as the petroleum

pump. However, modifications are made including utilization of
appropriate seals.

The product, which the unit was designed to pump, is specified on the
pump identification nameplate.

See applicable petroleum pump sections for technical data.

For specific information on solvent pumps, see the following

literature:
#5174 4" Solvent Pump
#051-116 4" Solvent Pump Parts & Installation
#5174 6" Solvent Pump
#051-121 6" Solvent Pump Parts & Installation
#5179 Solvent Specification Sheet

®
ii RJ 5190© 3/93
 4" “Extracta”/4"“AG” Petroleum Pump
Section
1
“Extracta” Model Numbers: Usage:
P33R1 — 1/3 HP • Standard fuels -
P75S1 — 3/4 HP Gasoline & Diesel
P150S1 — 1-1/2 HP - up to 10% MTBE
- up to 10% Ethanol
- up to 10% Methanol
NOTICE “Extracta” model pumps can be identified by their red paint.

“AG” Model Numbers: Usage:

AG/P33R1 - 1/3 HP • 100% Gasoline
AG/P75S1 - 3/4 HP • 100% Ethanol
AG/P150S1 - 1-1/2 HP • 100% Methanol
• Any combination
of the above
• 100% Diesel
• Up to 15% MTBE
NOTICE “AG” model pumps can be identified by their orange paint.

RJ 5190© 3/93 1
4" Petroleum Pump
(Manufactured prior to June 1963)
PARTS LIST - REMOTE PETROLEUM PUMP UNITS
(Models P33E1-6/6S, P33E1-8/8S, P50F1-6/6S, P50F1-8/8S &
other length pump units with E or F in the model number)
UPPER END Key No.
No. Description Req’d.
4 6 19 18 22 24
1 Junction Box Complete ............................................... 1
2 Conduit Seal Assembly ............................................... 1
5 1" Approved Conduit — Obtain Locally ....................... 1
6 3/8"-16 x 3/4" Sq. Hd. Cup Point Set Screw ............... 2
10 Packing Nut ................................................................. 1
11 Gasket ......................................................................... 1
15 “O” Rings ..................................................................... 2
17 “O” Rings (Replaces 72-76) ........................................ 2
18 Check Valve Spring .................................................... 1
19 Check Valve Disc & Holder ......................................... 1
31 1 2 26 10 11 25 5 21 15 8 9 15 29 32 21 Syphon Check Valve Assembly .................................. 1
24 “O” Ring for Check Valve Seat .................................... 1
30 EXPANSION RELIEF VALVE 25 1/4" Galvanized Pipe — Obtain Locally ...................... 1
ON BOTTOM SIDE OF PACKER
(NOT SHOWN)
26 #10-32 x 1/4" Brass Binding Hd. Mach. Screw ............
(for check valve seat not shown) ................................ 2
LOWER END
28 Tube Fitting 1/4" Pipe x 3/8" Tube .............................. 1
29 Syphon Injector Body & Tube Assembly ..................... 1
30 Expansion Relief Valve (not shown) ........................... 1
31 Cover only for Junction Box ........................................ 1

PARTS LIST - MOTOR CONTROL FOR ABOVE PUMPS

Key No.
No. Description Req’d.
1 Overload & Capacitor Assembly ................................. 1
2 Starting Capacitor Only (50Mfd.-250V AC) ................. 1
3 Overload Protector Only (“Klixon” MTA 1104) ............ 1
4 Motor Starting Relay* (RBM91255-452-230V-5 HP)* . 1
6 Pilot Light Only (General Electric NE51) ..................... 1
8 ON-OFF Switch (2 pole) .............................................. 1

2 Starting Capacitor (50Mfd.-250V AC) ......................... 1

4 Motor Starting Relay* (RMB91255-452-230V-5 HP)* . 1
4 Motor Starting Relay—2 Pole**(GE3ARR3BH3V2)** . 1
6 Pilot Light Only (General Electric NE51) ..................... 1
8 ON-OFF Switch (2 pole) .............................................. 1
8 ON-OFF Switch (3 pole) .............................................. 1
In June of 1963, pump models P33E1, 1/3 HP, and P50F1, 1/2 HP, were
discontinued. Both of these old models have been replaced with the new
P33R1 and P75S1 pumps, and the pump/motor assemblies are inter-
changeable with the old models.
A 111-092 run capacitor is needed when replacing the old P33E1 and
P50F1 pump/motors with either of the new models. The new P33R1 has
nearly the same flow rate as the old P50F1. Where capacity is vital, the
old P50F1 should be replaced with a new P75S1, 3/4 HP. The 1/3 HP
replacement pump/motor model number is UMP33R1 and the 3/4 HP
replacement unit model number is UMP75S1.
After disconnecting power supply, connect the 111-092 capacitor
across RED and BLACK terminals in the control box as shown. Insulate
the two connections on the capacitor with electrical tape and lay in the
bottom of the control box.

NOTICE Only various “O” Rings remain available for the above model. No other parts are available. However, current UMP
complete pump-motor assemblies are interchangeable with above models. For instructions and modifications,
please turn to p. 15.

2 RJ 5190© 3/93
 4" “Extracta” Petr
oleum Pumps
Parts List
PARTS LIST — “EXTRACTA” MODELS (RED) P33R1, P75S1 & P150S1
(Current Models — Manfactured after 1963)
Key Qty.
No. Part No. Part Description Req’d.
1 139-040-4 Eye Bolt Assembly 1
2 017-165-5 Diaphragm (see p. 7) 1
3 027-086-3 Galv. Steel Pipe Plug 2
4 026-176-1 Steel Hex Hd. Cap Screw 2
5 188-079-5 Syphon Check Valve Assy. 1
6 141-062-5 Functional Element Assy. w/“O” Rings 1
7 027-031-1 Galv. Steel Pipe Plug 2
8&9 144-183-5 Stainless Steel Check Valve Kit (incl. check VIV. & spring) 1
080-125-1 Spring 1
188-238-4 Stainless Check Valve 1
10 172-003-5 Functional Element “O” Ring Pkg. 1
11 113-084-5 1/3 HP Capacitor Cover Assy w/“O” Ring 1
113-085-5 3/4 HP Capacitor Cover Assy w/“O” Ring 1
113-319-5 1-1/2 HP Capacitor Cover Assy w/“O” Ring 1
12 072-190-1 “O” Ring Capacitor Cover Assy. 1
13 113-098-5 Capacitor Clip & Screw Pkg. 1
15 111-092-5 Capacitor 1
16 113-105-5 Connector Snap Ring Type 1
17 313-002-5 Connector Yoke Assy. 1
18 176-033-5 Contractors Plug Assy. 1
19 026-205-3 Steel Hex Hd. Cap Screws 2
20 108-496-5 Conduit Junction Box 1
21 151-002-4 Manifold Assy. 1
22 call Red Jacket Complete Packer/Manifold Assy. 1
23 076-382-1 Packer Discharge Seal 1
24 072-189-1 “O” Ring - Packer Manifold 1
25 065-149-3 Riser Pipe (Specify Length) 1
26 144-090-5 Plug & Lead Assy. 1
26A 144-091-5 Plug & Lead Assy. 17 ft. 1
27 026-355-3 Stainless Steel Hex Hd. Cap Screws 4
28 031-136-1 Discharge Head Gasket 1
29 852-004-5 1/3 HP Pump & Motor 1
852-005-5 3/4 HP Pump & Motor 1
852-044-5 1-1/2 HP Pump & Motor 1
N/S 144-087-5 Conduit Seal Assy. 1
N/S 072-195-1 Connector Yoke Snap Ring 1
30 136-056-5 1-1/2" Discharge Head Assy. 1
N/S 136-057-5 2" Discharge Head Assy. 1
N/S 166-169-5 Manifold Cover 1
N/S 144-106-5 Syphon RetroFit Kit 1
(when not ordered w/pump)
N/S 072-106-1 “O” Ring 1
WARNING N/S 078-522-3 Conduit Sleeve 1
N/S 072-196-1 Conduit Sleeve “O” Ring
Failure to follow all instructions in proper order can N/S 076-146-1 Vent Closing Screw 1
cause personal injury or death. Read all instruc- N/S 066-794-1 Orange Cap 1
N/S 072-106-1 “O” Ring for Vent Closing Screw 1
tions before installing. All installation work must
comply with local code requirements. If no other
codes apply, the latest issue of the National Electri-
cal Code should be followed.
1. Red Jacket gasoline pumps are designed and U. L. listed to pump gasoline or diesel fuels only, having a maximum specific gravity of .95 and maximum viscosity
of 70 S.S.U. at 15°C (the approximate weight and viscosity of diesel fuel). Red Jacket bears no responsibility if the installation is outside these parameters.
NOTICE Accessories and parts of models P33R1, P75S1, and P150S1 are not intended to be used in AG model pump applications.
2. Units should be installed with manholes or with the packer head above grade to allow for ease in servicing. Refer to p. 18.
3. Unit is cooled and lubricated by product pumped. Minimum flow required is 10% of maximum capability (1/3 HP-4 GPM, 3/4 HP-6 GPM, 1-1/2 HP-8 GPM).
WARNING Red Jacket line leak detection systems do not function if the submersible pump runs continuously.
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.
4. Red Jacket gasoline pumps are not designed to handle abrasives or foreign particles in the product being pumped.
5. 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.
6. Pumping water will overload the motor and damage the bearings.
7. Standard-type line check valves should not be used, as the pump is equipped with a built-in check valve. Use of this type check valve will negate the pressure
relief function of the pump and the effectiveness of the leak detector. However, whenever two pumps are manifolded together to the same discharge piping, check
valves with expansion relief are required. (See p. 50 for details).
8. Red Jacket gasoline pumps are designed for Class 1 Group D atmosphere.
9. Red Jacket gasoline pumps are designed to run at 3450 RPM.
10. Maximum pressure applied to line when testing should not exceed 50 psi.

RJ 5190© 3/93 3
4" “AG” Petroleum Pump
Parts List
PARTS LIST — “AG” MODELS (ORANGE) AG/P33R1, AG/P75S1 & AG/P150S1
Key Qty.
No. Part No. Part Description Req’d.
1 139-041-4 Eyebolt Assembly 1
2 (N/S) 017-526-1 Diaphragm (see p. 7) 1
3 027-225-3 Pipe Plug 2" NPT 2
4 026-176-1 Plated Hex Head Cap Screw 2
6 233-025-5 Precision Functional Element Assy
w/O-Rings (see p. 6) 1
7 027-031-5 Pipe Plug 1/4" NPT 2
8 188-240-4 Stainless Check Valve 1
9 080-125-1 Spring 1
144-184-5 Stainless Check Valve Kit (incl. check vlv & spring) 1
10 144-150-5 O-Ring Kit for Precision Functional Element 1
11 113-479-5 1/3 HP Capacitor Cover Assy w/O-Ring 1
113-480-5 3/4 HP Capacitor Cover Assy w/O-Ring 1
113-481-5 1-1/2 HP Capacitor Cover Assy w/O-Ring 1
12 072-555-5 O-Ring Capacitor Cover Assy (B401) 1
13 113-098-5 Capacitor Clip & Screw Pkg. 1
15 111-092-5 Capacitor 1
16 113-105-5 Connector Snap Ring Type 1
17 313-015-5 Connector Yoke Assy 1
18 176-067-5 Contractors Plug Assy 1
19 026-205-3 Plated Hex Head Cap Screws 2
20 108-549-5 Conduit Junction Box 1
21 151-044-4 Manifold Assembly 1
22 164-138-4 Packer (casting only) 1
22A 264-132-4 Complete Packer/Manifold Assy
23 076-370-1 Seal — Packer Discharge 1
24 072-556-5 O-Ring — Packer Manifold 1
25 065-149-3 Riser Pipe (specify length) 1
26 144-161-5 Plug & Lead Assy 13' 1
26A 144-162-5 Plug & Lead Assy 17' 1
27 026-355-3 Hex Head Cap 5/16"-18" 4
27A 026-435-3 Lockwashers 5/16" 4
28 031-136-1 Discharge Head Gasket 1
WARNING 29 852-083-5 1/3 HP AG Pump & Motor 1
852-084-5 3/4 HP AG Pump & Motor 1
Failure to follow all instructions in proper order can 852-085-5 1-1/2 HP AG Pump & Motor 1
cause personal injury or death. Read all instruc- 30 136-339-5 Discharge Head Assy 1
tions before installing. All installation work must N/S 144-163-5 Conduit Seal Assy 1
comply with local code requirements. If no other N/S 072-492-1 Connector Yoke Snap Ring 1
codes apply, the latest issue of the National Electri- N/S 079-980-3 Conduit Sleeve 1
cal Code should be followed. N/S 072-536-1 Conduit Sleeve O-Ring 1
1. Red Jacket AG model pumps are designed and U.L. listed to pump 100% gasoline, methanol, ethanol and any combination of these, 100% diesel and up to 15%
MTBE. These fuels must have a maximum specific gravity of .95 and maximum viscosity of 70 S.S.U. at 15°C (the approximate weight and viscosity of diesel
fuel). Red Jacket bears no responsibility if the installation is outside these parameters.
2. Units should be installed with manholes of sufficient size to allow access for servicing. Refer to p. 18.
3. Unit is cooled and lubricated by product pumped. Minimum flow required is 10% of maximum capability (1/3 HP-4 GPM, 3/4 HP-6 GPM, 1-1/2 HP-8 GPM).
WARNING Red Jacket line leak detection systems do not function if the submersible pump runs continuously.
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.
4. Red Jacket AG model pumps are not designed to handle abrasives or foreign particles in the product being pumped.
5. 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.
6. Pumping water will overload the motor and damage the bearings.
7. Standard-type line check valves should not be used, as the pump is equipped with a built-in check valve. Use of this type check valve will negate the pressure
relief function of the pump and the effectiveness of the leak detector. However, whenever two pumps are manifolded together to the same discharge piping, check
valves with expansion relief are required. (See p. 50 for details).
8. Red Jacket AG model pumps are designed for Class 1 Group D atmosphere.
9. Red Jacket AG model pumps are designed to run at 3450 RPM.
10. Red Jacket AG model pumps are orange in color (castings and intake) for easy identification.
11. Red Jacket AG model pumps are in accord with Rule 1170 (c) (1) of the South Coast Air Quality Management District.

4 RJ 5190© 3/93
 4" Petroleum Pump
Pump/Motor Assembly

Column Pipe
Conduit Pipe

“O” Ring for

Pigtail Body
Std. Model: 072-106-1
AG Model: 072-528-1

Current pump motor intake since second

week of October, 1990.

Discharge
Head Gasket
031-136-1
(Both Std. & AG Models)

Pump End
From 9/1/82 through 10/5/90

Pump End
Prior to 9/1/82

RJ 5190© 3/93 5
4" “Extracta” Petr
oleum Pump
Piping/Seals
#3
Conduit Top seal is accomplished as follows: column
Seal Assy.
Std. Model pipe threads into discharge manifold while
144-087-5 conduit (2-5/8" longer) seals into manifold via
AG Model
144-163-5 “O” ring No. 072-196 on conduit sleeve No.
078-094, prior to 6/6/84 or No. 078-522 after
6/6/84. If failure of this seal (“O” ring) should
occur, product could flow into conduit. This
may result in the appearance of product in the
capacitor cavity.

In order to present the most favorable condi-

tions for maintaining an efficient seal when
field adjusting the length of the pump, begin-
ning 6/6/84 (date code 10684), we are using a
new, longer conduit sleeve seal. Part No.
078-522-3 on petroleum pumps (prior to
6/6/84, No. 078-094-3) and No. 079-980-3 on
AG and solvent pumps (prior to 6/6/84, No.
079-772-3). The “O” ring used on the conduit
sleeve seal for petroleum pumps is No.
072-196-1 for AG and for solvent pumps is
VITON 072-536-1 or EPR 072-424-1.
Riser:
Not schedule Conduit While the sleeve seal used prior to 6/6/84 (No.
40 Pipe—must Sleeve
clear 4-1/64" Prior 6/6/84 078-094-3 petroleum or No. 079-772-3 sol-
Max. I.D. Std. Model 078-094
After 6/6/84 vent) can be used on all units regardless of
Std. Model 078-522
AG Model date of manufacture, we recommend the use
079-980-3
of appropriate new sleeve seal (No. 078-522-3
#2 petroleum, No. 079-980-3 solvent).
Column Conduit
Pipe: 1-1/2" Sleeve
Steel Pipe “O” Ring However, it may be necessary, when using the
Std. Model new sleeve seal on units built prior to 6/6/84
072-196
AG Model (date code 10684) to shorten the conduit 1/4"
072-536-1
Conduit: in order to prevent the conduit seal (bottom
1/2" plate or compression screws) from bottoming
Std. Model
Aluminum out on the conduit sleeve seal. This could
AG Model result in an inadequate seal.
Black Steel

#1
“O” Ring
Std. Model
072-106-1
AG Model
072-528-1

NOTICE For troubleshooting information regarding

the seals shown on this page, see page 8,
section E.

6 RJ 5190© 3/93
 4" “Extracta” Petr
oleum Pump
Discharge Manifold Assembly/Functional Element

TOP VIEW OF DISCHARGE MANIFOLD

Syphon
Check
Valve
Lockdown Bolt
Port
Line
Test Lifting Eyebolt
Port
Junction Box Cover

Optional
Leak Detector
Opening

Tank Test Port

Lockdown Bolt Bayonet

Electrical
Capacitor Cover Connector

Leak 5
Detector
6
Port
10

7 Excess line pressure

To Discharge Line

STANDARD MODEL AG MODEL

FUNCTIONAL ELEMENT ASSEMBLY PRECISION FUNCTIONAL ELEMENTPlug
ASSEM-
Plug
BLY
Spring
066-794-1

066-794-1 080-125-1
Spring
080-125-1 Poppet 4
066-796-1
Poppet 4
066-796-1 Screw
076-146-1
Screw 3
076-146-1
3 Diaphragm 1
017-526-1
Diaphragm 1
017-165-1
"O" Ring/Relief Valve
"O" Ring/Relief Valve 2 072-528-1
072-106-1
2

"O" Ring/Venturi "O" Ring/Functional Element

072-535-1 072-533-1
"O" Ring/Functional Element
"O" Ring/Venturi 072-192-1 To remove functional element assembly: disconnect syphon tubing
072-133-1
(if syphon installation). Remove two 3/8" cap screws. Disassemble to
To remove functional element assembly: disconnect syphon check and clean. Reassemble by carefully aligning diaphragm into
tubing (if syphon installation). Remove two cap screws. Disas- cap recess and diaphragm tabs into body recess. Tighten all screws
semble to check and clean. until cap is metal to metal with the body.
RJ 5190© 3/93 7
4" “Extracta” Petr
oleum Pump
Check V alve/Troubleshooting
All Red Jacket submersible petroleum pumps manufactured prior to November 7, 1984 (Date code 21184) were supplied
with a brass check valve. After this date, pumps were supplied with plastic check valves. Effective February 1993, pumps
are supplied with a stainless steel check valve. Replacement should be as follows:
• Replace a brass check valve with a brass check valve #138-056.
• Replace a plastic check valve (white or red) with a red check valve #188-214.
• Replace a grey check valve with a grey check valve #144-143-5. (AG Pump PPM 4000 and RLM 9000)
• After February 1993 the stainless steel check valve was introduced:
— 144-183-5 replaces 138056 and 188214 in standard pumps.
— 144-184-5 replaces 144184-5 and replaces 144143-5 in AG pumps and Line Pressure Kits.

Symptom Probable Cause Suggested Action

A. Total or partial loss of vacuum Obstruction in product flow path through functional element and Remove functional element, clean out passageway, including
and/or build up of pressure. “S” tube. nozzle and venturi, and reinstall.
—In port from check valve to cavity over nozzle (#1, p. 7) Use caution when disassembling functional
—Nozzle and/or venturi (#2, p. 7) NOTICE element as spring, boot and shims con-
tained in cap are loose (#10, p. 7).
—“S” Tube/Air Eliminator Tube (#8, p. 7) Run flexible wire down “S” tube and air eliminator tube.
—Vent screw not all the way up (#4, p. 7) Adjust to full up position.
Do not screw vent screw down with exces- * Excessive sediment on the bottom of the tank can cause
NOTICE sive torque. Always replace dust cap. reoccurance of this problem. Turbulence occuring during filling
of the tank places this sediment in suspension, allowing it to be
drawn into the functional element or syphon check valve via the
vacuum line or the pressure relief system. Removal of sedi-
ment from tank bottom may be necessary.

B. Excess Line Pressure See above (*Static)

Pump oversized for application. Refigure head loss and check performance curve.
Line type check valve installed in discharge line. Remove.
(Expansion or pressure equalizing type is acceptable—not stan-
dard type.)

C. Loss of Line Pressure

*(Static—Pump off, all dis-
Failure of Seal
(#5, p. 7) “O” Ring under functional element.
Examine seal and surface involved.
Clean surfaces and replace seals if necessary.
charge outlets closed.) (#6, p. 7) “O” Ring on vent screw.
(#7, p. 7) Check valve seal. Same as above, plus if surface on discharge manifold is
(#9, p. 7) Seal at top of discharge, between packer and manifold. scratched, apply Permatex to area under “O” Ring.
Check valve can be isolated by closing same
NOTICE via vent closing screw.
Thermal Contraction
Loss of Line Pressure Leaking Check Valve Check Valve Isolation
1. Install gauge in line test port.
2. Energize pump—Observe pressure reading on gauge.
3. Close vent screw.
4a. If pressure drops off, this is an indication that there is a leak
down-stream of the functional element (2" Packer-Discharge
O-ring, or a possible leak in the product line).
b. If pressure holds, shut off submersible.
5. If pressure then drops, re-energize the submersible.
6. If system re-pressurizes, this is an indication that the check
valve is faulty.
Pressure drop, after drop provided by pres-
NOTICE
sure relief valve (to approx. 8-14 psi), will
probably be slower with thermal contraction
than by faulty seal.
Plunger over diaphragm binding (#10, p. 7). Check and clean area and reinstall.

D. Motor runs, but partial or no Vent screw not up all the way (#4, p. 7). Back vent screw full up.
output by pump. Prevents full opening of check valve.

E. Fuel in Capacitor Housing Leaking seals or incorrect re-assembly after length of pump was If pump is still in warranty period and length has not been altered,
altered in the field. (Seals #1, #2 and/or #3 shown on p. 6). send unit back for warranty consideration. If pump is out of
warranty period or length has been altered, the seals shown on
page 6 will require replacement.

F. Excess Line Pressure Standard line type check valve installed in discharge line. Only Remove check valve from line and install the proper type check
(Pump not running) expansion or pressure equalizing type check valves can be used valve (expansion or pressure equalizing type).
if a check valve is installed in the line.
Excess Line Pressure Dispenser pressure relief not operating or blocked. Recalculate head loss in system and check performance curve.
(Pump running) Hydraulic Hammer Pump oversized for application.

8 RJ 5190© 3/93
 4" “Extracta” Petr
oleum Pump
Removing the “Extracta” Portion
REMOVING THE PUMPING UNIT

1. ALWAYS DISCONNECT and LOCK or 2. Backout bayonet electrical disconnect 3. Swing electrical connector aside.
TAG OUT the power before starting to bolt.
service the pump.

4. IF SYPHON SYSTEM: Disconnect 5. Remove the two lockdown bolts. 6. Lift unit. Replace unit by reversing
syphon tubing. these steps.

Never rest pump/motor on surface (A) when pulling extractable portion

of unit.

If surface (A) is damaged, seal with “O” rings at location (B) may be
impaired, resulting in loss of line pressure.

(See Loss of Pressure, Symptom C on p. 8)

RJ 5190© 3/93 9
4" “Extracta” Petr
oleum Pump
Packer Seals
7" Packer-Manifold O-ring
Std. Model #072-189-1
AG Model #072-556-5

2" Packer-Discharge Seal

Std. Model #076-382-1
AG Model #076-370-1

WARNING Careful attention must be paid to cleaning both

the 2" sealing surface and the 7" sealing surface.
Any foreign object, on either surface, will not
allow either surface to seal properly.

Any damage, mars or scratches on the 2" surface

may not allow a good seal of the 2" seal.

INSTALLATION OF THE SEAL RING (Std. Model 076-382-1 or AG Model 076-370-1)

When installing the seal ring, first lay the seal flat. The seal has two different degrees of thickness. The thickest
part of the seal angled inward with a retaining lip is the top of the seal. The narrowest or thinnest part of the seal
is the bottom. (See drawing below). To install the seal, place the top part of the seal with the retaining lip into
the bottom of the packer having the top of the seal facing away from the pump motor. A mating recess in the
retaining sleeve will hold the seal in place while the pump is being lowered onto the packer. If the seal is not
properly installed it will not maintain product line pressure and will release product back inside the tank.

CAUTION The 7" Packer-Manifold O-ring is designed to

keep water out of the Packer-Manifold as-
sembly. RETAINING LIP

If pressurizing the tank, for a tank tightness

test, no more than 5 psi should be applied to TOP
this seal.

BOTTOM

10 RJ 5190© 3/93
 4" “Extracta” Petr
oleum Pump
Line and Tank Testing Guidelines
LINE TESTING
The vent closing screw, located on the functional element, is designed to perform
two functions.
1. To secure the check valve in its closed position.
2. To disable the pressure relief function of the functional element.

NOTICE The use of this vent closing screw allows the technician to pressurize the
fuel piping system against the submersible pump. It is important to note
that the 2" packer-discharge seal is still an active part of the piping system.
A leak in this 2" seal will show up as a leak in the piping system.

1. TO TEST PIPING. Block lines at each 2. Close pump check valve by turning the 3. Apply line test pressure at line test
dispenser. (Trip dispenser shear vent closing screw as far down as pos- port. (50 psi maximum.)
valve.) Remove line test plug for this sible. DO NOT OVER TORQUE.
test. CAUTION Excessive pressure (above nor-
mal test pressure of 50-55 psi)
may damage check valve seat
and other system components.
TANK TESTING
When pressurizing a fuel tank to perform a tank tightness test, that pressure will
also be seen through the riser pipe and into the packer-manifold assembly. The
7" packer-manifold O-ring is designed to hold 5 psi.

4. TO TEST TANK. Close pump check 5. After completion of line and/or tank 6. After the installation is completed and
valve by turning the vent closing screw tests, release pressure by turning the tests have been made, purge system of
as far down as possible. Apply tank vent closing screw as far up as pos- air by pumping at least 15 gallons
test pressure at tank test port. sible. through each dispenser. Begin with
CAUTION Excessive pressure (above nor- the dispenser furthest from pump and
mal test pressure of 50-55 psi)
may damage check valve seat. work toward the pump.

RJ 5190© 3/93 11
4" Petroleum Pump
Contr ol Box

(PRIOR 4/1/81) (AFTER 4/1/81)

1/3 & 3/4 HP CONTROL BOX 1/3 & 3/4 HP CONTROL BOX
880-002 880-029-5 PILOT
LOAD CENTER
208 OR 230 VOLT
Built Prior Built After 1/3 & 3/4 H.P. 230 VOLT REMOTE CONTROL BOX LIGHT
3 P.S.T. 1 PHASE, 3 WIRE
TOGGLE 15A-2P SWITCHED
Key To 4/1/81 4/1/81 Qty. SWITCH NEUTRAL BRKR.
LINE STARTER L1 L2
No. Part No. Part No. Part Description Req’d.
1 108-321 108-514-4 Control Box 1
2 010-050 115V Bulb (NE-51) 1
3 147-004 247-001-5 Pilot Light Assy. 1 EXTERNAL
PILOT
LIGHT
4 079-250 079-425-1 Line Contactor Relay 1 (115 VOLTS)
25 WATT
MAX.
5 080-037 080-064-1 Toggle Switch 1 15A-3P SWITCHED
WIRING ELECTRICAL INTERLOCK NEUTRAL BRKR.
6 008-202 008-202-1 Terminal Block 1 TO OTHER DIS-
TROUGH PACKER
CONTINUOUS
PENSER DUTY
(MAX. TOTAL OF CAPACITOR
6 DISPENSERS) DISPENSER LIGHTS
JUNCTION

NOTICE Approved component only—Total system in- BOX

IN
DISPENSER MANIFOLD
stalled shall comply with all local codes. OPTIONAL INTERNAL
SOLENOID (76 VOLT AMPS MAX.) OVERLOAD
VALVE PROTECTOR

MOTOR

1-1/2 HP CONTROL BOX 1-1/2 HP CONTROL BOX

PILOT
LIGHT LOAD CENTER
880-002 880-030-5
1-1/2 HP, 230 VOLT REMOTE CONTROL BOX 2 P.S.T.
TOGGLE
208 OR 230 VOLT
1 PHASE 3 WIRE Built Prior Built After
SWITCH
LINE STARTER
L1 L2
Key To 4/1/81 4/1/81 Qty.
No. Part No. Part No. Part Description Req’d.
1 108-321 108-514-4 Control Box 1
2 010-050 115V Bulb (NE-51) 1
EXTERNAL
PILOT
LIGHT
3 147-004 247-001-5 Pilot Light Assy. 1
(115 VOLTS)
25 WATT
MAX.
4 079-425 079-425-1 Line Contactor Relay 1
WIRING
TROUGH ELECTRICAL INTERLOCK
15A-3P SWITCHED
NEUTRAL BRKR.
5 080-062 080-062-1 Toggle Switch 1
MAKE GROUND CONNECTION PACKER
IN ACCORDANCE WITH
LOCAL CODES
CONTINUOUS
DUTY
6 008-202 008-202-1 Terminal Block 1
CAPACITOR
JUNCTION
BOX IN
MANIFOLD
NOTICE Approved component only—Total system in-
INTERNAL
OPTIONAL
SOLENOID VALVE
OVERLOAD
PROTECTOR
stalled shall comply with all local codes.
(76 VOLT AMPS MAX.)
MOTOR

12 RJ 5190© 3/93
 4" “Extracta” Petr
oleum Pump
Pump/Motor Assembly
A) The permanent split capacitor motor gives you the option (To determine position of overload, see procedure below.)
of using a control box or direct wiring.
(1) Overload protector opens at approximately this tem-
perature and stops motors.
B) An on-winding thermal over-current protector prevents
premature motor failure from overheating. (2) Motor is continuous duty rated. Temperature rises to
approximately 120°F and holds.
Ambient temperature overload can occur as follows:
(1) 205°F = Overload Temperature Unit is cooled and lubricated by the prod-
CAUTION
Overload protector opens at approximately this tem- uct it pumps. Approximately 10% of maxi-
perature and stops the motor. When the motor tem- mum flow capability is required to prop-
perature drops to approximately 85°, the overload erly cool and lubricate unit (i.e., 1/3 HP —
switch will re-engage allowing the motor to run. 4 GPM, 3/4 HP — 6 GPM, 1-1/2 HP — 8
GPM). NEVER RUN DRY.
(2) 120°F = Motor Heat Rise
85°F If ambient temperature or product is above
D) Unit is designed to pump petroleum fuels with a maximum
this temperature, overload may occur.
specific gravity of .95 and maximum viscosity of 70 S.S.U.
(Check amperage draw before accepting this as cause for at 60°F. Attempts to exceed these limits will result in
motor cut-off. If high amperage draw is present, it is overheating.
probably not ambient temperature overload.)

NOTICE See page 14 for Troubleshooting of the Pump/Motor Assembly.

Per Figure 1, when the inherent overload (on-winding Pin and lead arrangement on plug to motor connection.
thermal over-current protector) is closed, resistance
readings will be per chart below. If the inherent overload
is open, readings between black & yellow or red & yellow
will indicate an open circuit.
Black
Black

L1 PUMP
JUNCTION
BOX PACKER
OIL FILLED
CAPACITOR

L2 Red
Yellow

INHERENT
OVERLOAD
PROTECTOR Yellow Red
(Overload) (Start winding)
Yellow to Black 240V
Red to Yellow 300V MOTOR
Red to Black 370V

ELECTRICAL SERVICE INFORMATION

Model Volts Max. Load Locked Winding Resistance (Ohms)
No. HP Min. Max. Amps Rotor Amps Blk-Yellow Red-Yellow Black-Red
P33R1 1/3 200 250 4.0 13 7.4-8.3 16.1-17.9 23.5-26.2
P75S1 3/4 200 250 6.5 22 3.6-4.1 9.6-10.6 13.2-14.6
P150S1 1-1/2 200 250 10.5 42 2.0-2.1 5.2-5.6 7.2-7.7
50 Hz Single Phase Models
P75S3-2 3/4 200 250 4.6 14.3 5.8-6.2 12.2-13.5 18.0-20.0
P75S3-3 3/4 200 250 5.8 18.6 4.5-4.9 11.7-13.0 16.2-17.9
P150S3-3 1-1/2 200 250 10.0 34.5 2.2-2.4 7.9-8.7 10.1-11.2
RJ 5190© 3/93 13
 4" “Extracta” Petr
oleum Pump
T roubleshooting: 4" Pump/Motor Assembly
Symptom Probable Cause Suggested Action
Pump/motor will not start. Capacitor Failure Test capacitor — Replace if needed.
May Hum (See Page 17)
May Show High Amperage Draw
Locked Rotor Check amperage draw — replace pump-
motor if amperage draw indicates locked
rotor. (See Page 13)

Improper Electrical Connection Check wiring for continuity and impedance.

(See Page 13)

Pump/motor runs & pumps Improper Electrical Connection (See Above)

intermittently
Binding of pump due to foreign Remove extractable portion of unit. Remove
object in impeller/diffuser area. center end cap from pump/motor
(Abnormal noise usually present assembly (friction fit). Check freedom &
with this problem.) This will cause continuity of rotation of rotor shaft. Replace
overheating of motor and subsequent pump/motor if findings indicate resistance to
cut-off by overload protector. (See free rotation or excessive play or wobble.
Page 13 “B”)

Excessive or erratic bearing wear. Check amperage draw*. (Intermittent

(Usually caused by running unit dry excessive amperage draw may occur.) Also
or continuously.) Will affect overload see above suggestion on checking shaft
and noise level as stated above. rotation and appropriate actions to take.
*See Page 13.

Motor runs, but pump output Impeller Wear (Pump/Motor) Check static pressure of pump ( NOTICE below).
partially or totally impaired. Replace unit if findings warrant.

Foreign material obstruction. Intake Investigate appropriate area for same and
ports or pump impellers. (i.e. rags, remove.
paper)

Vent closing screw not all the way up. Adjust to full-up position.

Partially closed gate valve. Open same.

Malfunctioning Solenoid Valve Replace if defective.

Improper Voltage (High or Low) Check voltage. Must be within 10%± of

rated voltage (208/230V).

Clogged filter or strainer. Clean or replace.

NOTICE Pump performance can be checked by installing a pressure gauge in the line test port in the discharge
manifold.
Approximate Normal Operating Pressure

Model PSI Gas PSI Diesel

1/3 HP 25 31
3/4 HP 27 34 Model Shipping
1-1/2 HP 29 36 Number HP Length Weight
UMP33R1 or AG/UMP33R1 1/3 15-1/2" 30 lbs.
50 Hz Single Phase Models UMP75S1 or AG/UMP75S1 3/4 17-1/2" 32 lbs.
UMP150S1 or AG/UMP150S1 1-1/2 20-1/2" 38 lbs.
3/4 HP/2 stage/50 Hz 21 26 1o — 60 Hz — 208/230V
3/4 HP/3 stage/50 Hz 30 37
1-1/2 HP/3 stage/50 Hz 32 39

Previous to assuming motor failure, check capacitor.

14 RJ 5190© 3/93
 4" “Extracta” Petr
oleum Pump
Replacement of Pump/Motor Assemblies
(All require 4" openings.) All units are interchangeable, only the length varies.
Maintain proper clearance from tank bottom — 5" optimum, 3" minimum.
NOTICE Due to fluid incompatibilities, the standard UMP cannot be used to replace AG/UMP units.

PROCEDURE
Please note the brand name and manufacture dates below: 3/4 HP, or UMP150S1 — 1-1/2 HP. These units are
Manufacturer Motor Used Date First Mfg. interchangeable (only the length varies). Maintain
Red Jacket Red Jacket June 1, 1963 proper clearance off the tank bottom, optimum 5"
Bennett Franklin 1963 minimum 3".
Bowser/Keene Red Jacket October, 1965 A 111-092 split phase capacitor will be needed, see
Gilbarco Red Jacket October, 1964 steps 1 through 5 in Section A and steps 12, 13 & 14 in
A.O. Smith Franklin 1963
Section B
Wayne-Dresser Franklin October, 1963
Tokheim Franklin October, 1972 SECTION A
On these units, the R.J. pump motor assembly is a direct
A. For units with the above manufacture dates or later, replacement & requires no other parts.
see Section “A”. 1. Disconnect power.
B. For units with manufacture dates prior to the above, 2. Remove extractable portion of old pump from tank.
see Section “B”. 3. Remove old pump-motor assembly.
C. For a Red Jacket unit with manufacture date prior to the 4. Replace the old gasket with the new one provided.
5. Align the positioning dowel of new pump-motor into the
above, see the following: hole in the discharge head, push the new pump-motor
In June of 1963, models UMP33E1 1/3 HP and as far as possible against the discharge head, insert
UMP50F1 1/2 HP were discontinued. These can be the four cap screws and retighten.
replaced by either UMP33R1 — 1/3 HP, UMP75S1 — 6. Reinstall extractable portion in tank and test.

1. Remove the four screws holding 2. Rock unit while pulling away from 3. TO RE-ASSEMBLE: Replace gasket,
motor to the head casting. discharge head until free. align dowel pin, draw in place with cap
screws.
SECTION B
These units commonly used Reda, Leland, or General
Electric Motors. The following Red Jacket parts will be ing sure slip-fit connector at top end of conduit is
needed to make the conversion: secured properly. Use proper pipe dope on all male
One (1) UMP33R1, UMP75S1 or UMP150S1; threads.
One (1) 111-092 Capacitor; 8. Insert new plug and lead wire assembly through con-
One (1) 144-090 Plug & Lead Assembly; duit from discharge head to the packer assembly at the
One (1) 136-056 (1-1/2") or 136-057 (2") Discharge Head. top of the unit.
1. Disconnect power. 9. Apply the new gasket (provided) to the discharge head.
2. Remove extractable portion of old pump from tank. (It 10. Align the positioning dowel of the new pump-motor into
is recommended that conversion be done at the work- the hole in the discharge head. Push the new pump-
shop). motor up against the discharge head as far as possible.
3. Remove old pump-motor assembly. Insert the four cap screws and retighten.
4. Disconnect wires in packer assembly at top of unit. 11. Resplice the three wires (red, black, yellow) to the
5. Remove discharge head casting from column pipe & existing wires in the packer assembly, following the
pull conduit & lead assembly from inside column pipe. existing color coding.
Noting how it comes out will assist you in reinstalling 12. To convert the old control box, remove everything but
the new wires. the terminal strip, insert the new #111-092 capacitor,
6. Remove old wire and plug from conduit and remove and make connections per wiring diagram on top of
conduit from discharge head. page 16.
7. Thread 1/2" conduit into 136-056 (1-1/2") or 136-057 13. Incoming power lines should run through a circuit
(2") discharge head casting. (1/2" conduit must be breaker or a fused disconnect.
used.) Thread discharge head onto column pipe, mak- 14. Test the system.
RJ 5190© 3/93 15
4" “Extracta” Petr
oleum Pump
Suggested W iring Diagrams
WIRING AFTER CONVERTING CONTROL BOX

CONTROL BOX
111-092
CAPACITOR

TERMINAL STRIP

BLACK
RED
ORANGE
DISPENSER SWITCHES
WIRES TO PUMP MOTOR

L1 N L2
230 VOLTS POWER SUPPLY

Suggested wiring diagram WITHOUT optional control box.

LOAD CENTER
230V 10 3 WIRE

Combination of 2 pole dispenser 15 AMP 3 POLE

L1
DISPENSER
L2 LIGHTING FROM
switches or external pilot light. SWITCH
(N.E.C. REQUIRES SEPARATE
• Rated for twice the full load current of the DISCONNECT BREAK
ALL WIRES TO
CIRCUIT

motor: DISPENSERS)

1/3 HP - 8 amps, 3/4 HP - 13 amps, WIRING TROUGH

1 1/2 HP - 21 amps. 115 VOLT EXT
PILOT LIGHT
• Rated for handling locked rotor current of the BY
CONTRACTOR
motor: PUMP
JUNCTION PACKER
1/3 HP - 13 amps, 3/4 HP - 22 amps, MAKE GROUND CONNECTION IN BOX OIL FILLED
ACCORDANCE WITH LOCAL CODES CAPACITOR
1 1/2 HP - 42 amps.

INHERENT
OVERLOAD
PROTECTOR

2 POLE DISPENSER SWITCHES MOTOR

Suggested wiring diagram WITH optional control box.

LOAD CENTER
PILOT 208 OR 230 VOLT PILOT
LIGHT LIGHT LOAD CENTER
1/3 & 3/4 H.P. 230 VOLT REMOTE CONTROL BOX 1-1/2 HP, 230 VOLT REMOTE CONTROL BOX
3 P.S.T. 1 PHASE, 3 WIRE 2 P.S.T. 208 OR 230 VOLT
TOGGLE 15A-2P SWITCHED TOGGLE 1 PHASE 3 WIRE
SWITCH NEUTRAL BRKR. SWITCH
LINE STARTER
LINE STARTER L1 L2 L1 L2

EXTERNAL EXTERNAL
PILOT PILOT
LIGHT LIGHT
(115 VOLTS) (115 VOLTS)
25 WATT 25 WATT
MAX. MAX.
15A-3P SWITCHED WIRING 15A-3P SWITCHED
WIRING ELECTRICAL INTERLOCK NEUTRAL BRKR. TROUGH ELECTRICAL INTERLOCK NEUTRAL BRKR.
TROUGH PACKER MAKE GROUND CONNECTION PACKER
TO OTHER DIS- CONTINUOUS IN ACCORDANCE WITH CONTINUOUS
PENSER DUTY LOCAL CODES DUTY
(MAX. TOTAL OF CAPACITOR CAPACITOR
6 DISPENSERS) DISPENSER LIGHTS
JUNCTION JUNCTION
BOX BOX IN
IN MANIFOLD
DISPENSER MANIFOLD
OPTIONAL INTERNAL INTERNAL
OPTIONAL OVERLOAD
SOLENOID (76 VOLT AMPS MAX.) OVERLOAD SOLENOID VALVE
VALVE PROTECTOR (76 VOLT AMPS MAX.) PROTECTOR

MOTOR MOTOR

NOTICE Use control box if solenoid in dispenser is

rated at less than 1-1/2 HP.

16 RJ 5190© 3/93
 4" “Extracta” Petr
oleum Pump
Capacitor
REPLACING THE CAPACITOR NOTICE Capacitor is 370V, 17.5 MFD,
continuous duty.

DANGER
1. ALWAYS DISCONNECT the power 2. Remove retaining clip. Pull 3. Remove capccitor. TO REPLACE:
Remove the capcaitor cover. quick-connectors reverse these steps.

The permanent split phase capacitor motor gives you the option of using a control box or direct wiring. Values — 370V
17.5 MFD.

Symptom Probable Cause Suggested Action

Motor will not start. Capacitor failure. *Test capacitor — replace if needed.
— May hum
— May show high amperage draw.

(Also see Pump/Motor Assembly, page 14.)

*Testing the 111-092 Capacitor

1. Place volt ohmmeter at x1000 range.
2. Place test leads on capacitor terminals (one on each). Needle should go all the way up and slowly fall back.
3. Reverse test leads on capacitor terminals. Reaction should be the same as in Step 2.
4. If needle on volt ohmmeter does not rise, or if it does not fall back, capacitor has failed and should be replaced.

WIRING

DANGER ALWAYS DISCONNECT 2. Remove cover from junction box. Re- 3. Connect wires from power supply to
and LOCK or TAG OUT the move compression seal. Provision has wire in the junction box. Make water-
power before starting to been made for 2 wire, or 3rd wire op- proof splice. Replace cover using wa-
service the unit. tional ground. Pull wires from power terproof thread sealant. Install optional
supply through seal and replace. ground wire if applicable.
1. Connect electrical conduit through ap- Tighten seal securely.
proved fittings to junction box.

RJ 5190© 3/93 17
 4" “Extracta” Petr
oleum Pump
Dimensions
TABLE OF DIMENSIONS FOR PUMP SELECTION LEAK DETECTOR INSTALLATION AND
MANHOLE & COVER MANIFOLD DIMENSIONS
D PUMP
COVER
TO
BY RED JACKET
OPTIONAL LEAK DETECTOR BY RED JACKET
1-1/2"
Pump ±6" Red Jacket
Leak Detector

2" PIPING BY
CONTRACTOR 20" ±4" 8"
11"

4-1/2"
1-1/2"
B BURY
DEPTH ±6"

CONDUIT BY
CONTRACTOR E RISER
LENGTH 20"

4" RISER BY Driveway Red Jacket

12"
RED JACKET Grade Leak Detector

C PUMP
LENGTH

13"

A TANK
DIA. Electrical
Red Jacket
Submersible Pump
Conduit
5-5/8" ±1/8"
4" Riser Flex Connector

Tank

20" x 20" Manhole

Red Jacket
Leak Detector

10"

13"
BOTTOM APPROX.
CLEARANCE 5"
Red Jacket
Submersible Pump

NOTICE Distance between center line of pump motor and center

line of bottom fill tube should be 3' minimum. Air 2" Outlet
To Dispensers
locking of pump after product delivery may occur at Tank
distances less than this.
NOTICE Use this table for single wall tank applications only that
8' Fiberglass 8' Steel
do not involve manways or sumps. Tanks Tanks
"B"
Bury 42" 46" 48" 64" 72" 75 1/2" 84" 90" 92" 95" 96" 99 1/2" 108" 120" 126"
Depth “A” Tank Diameter 3’6" 3’10" 4’0" 5’4" 6’0" 6’3 1/2" 7’0" 7’6" 7’8" 7’11" 8’0" 8’3 1/2" 9’0" 10’0" 10’6"
2’0" “C” Pump Length 0409 0501 0501 0607 0701 0707 0801 0809 0809 0901 0901 0907 1001 1101 1109
24" “D” Pump to Cover 4 4 6 4 6 4 6 4 6 5 6 4 6 6 4
“E” Riser Length 9 9 7 9 7 9 7 9 7 8 7 9 7 7 9
2’6" “C” Pump Length 0501 0507 0509 0701 0709 0801 0809 0901 0901 0907 0909 1001 1009 1109 1201
“D” Pump to Cover 6 4 4 4 4 4 4 6 8 5 4 4 4 4 6
“E” Riser Length 13 15 15 15 15 15 15 13 11 13 15 15 15 15 13
3’0" “C” Pump Length 0509 0601 0601 0707 0801 0807 0901 0909 0909 1001 1001 1007 1101 1201 1209
36" “D” Pump to Cover 4 4 6 4 6 4 6 4 6 5 6 4 6 6 4
“E” Riser Length 21 21 19 21 19 21 19 21 19 20 19 21 19 19 21
3’6" “C” Pump Length 0601 0607 0609 0801 0809 0901 0909 1001 1001 1007 1009 1101 1109 1209 1301
42" “D” Pump to Cover 6 4 4 4 4 4 4 6 8 5 4 4 4 4 6
“E” Riser Length 25 27 27 27 27 27 27 25 23 26 27 27 27 27 25
4’0" “C” Pump Length 0609 0701 0701 0807 0901 0907 1001 1009 1009 1101 1101 1107 1201 1301 1309
48" “D” Pump to Cover 4 4 6 4 6 4 6 4 6 5 6 4 6 6 4
“E” Riser Length 33 33 31 33 31 33 31 33 31 32 31 33 31 31 33
4’6" “C” Pump Length 0701 0707 0709 0901 0909 1001 1009 1101 1101 1107 1109 1201 1209 1309 1401
54" “D” Pump to Cover 6 4 4 4 4 4 4 6 8 5 4 4 4 4 6
“E” Riser Length 37 39 39 39 39 39 39 37 35 38 39 39 39 39 37

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 environmental damage. Petro Express
Bulletin, RJ 23-25 (10/90) explains the information required for proper pump sizing.

18 RJ 5190© 3/93
 ®
6" Big-Flo Petroleum Submersible Pump
Section
2
Model Numbers:*
P100H1-1MB** 1 HP 1Ø, 1 stage
P150H1-1HB 1-1/2 HP 1Ø, 1 stage
P200H1-2MB 2 HP 1Ø, 2 stage
P200H3-2MB 2 HP 3Ø, 2 stage
P300H3-1K 3 HP 3Ø, 1 stage
P300H3-2HB 3 HP 3Ø, 2 stage
P500H3-2K 5 HP 3Ø, 2 stage

*An “S” at the end of the model number designates pump includes syphon capability.
**This model was discontinued February, 1988.

The Big-Flo® pumping system includes 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. Controls

A. Single phase units require use of the appropriate control box:

for Model P150H1-1HB use Control Box No. 108-402-1
for Model P200H1-2MB use Control Box No. 108-403-1
B. Three phase units require use of the appropriate magnetic starter:
Models: P200H3-2MB
P300H3-1K
use Starter No. 279-231-5
P300H3-2MB
P500H3-2K

When starter is ordered, we will supply the appropriate heaters. All of the above are U.L. Listed when used as a
complete system. An “all inclusive” nameplate will be found attached to the extractor nipple seal and can be
inspected by removing the manhole cover directly over the pump. An additional nameplate 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.

RJ 5190© 3/93 19
 ®
6" Big-Flo
Installation
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, 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.

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
CAUTION Check these points before installing:
Packer
a.
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
Discharge are designed for use with 208, 220, 230 or 240 nominal
system voltages.
Manifold
b. Be certain that pump with syphon valve is installed in
proper tank.
c. Check equipment received against table on Fig. VII for
tank diameter and bury depth.
CAUTION 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 Dispens-
ers and/or loading rack. One or both outlets can be used.

Fig. I
20 RJ 5190© 3/93
 ®
6" Big-Flo
Installation
NOTICE 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. How-
ever, whenever two pumps are manifolded to-
gether 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.
5. Install 1-1/4" Conduit.
a. On some installations, the short piece of 1-1/4" conduit fur-
nished 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
Fig. II 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 counter-clock-
wise (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

RJ 5190© 3/93 21
 ®
6" Big-Flo
Installation
SCREWS SHOULD BE TIGHTENED by tightening box if possible (not loosening box).
EVENLY TO INSURE PROPER SEAL. When tightening Junction Box, hold 1-1/4" con-
duit secure with pipe wrench to prevent unlock-
JUNCTION ing packer in discharge manifold. Replace rub-
BOX ber seal into bottom of Junction Box as shown on
Fig. IV. After positioning as shown, tighten
screws firmly to form a tight seal.

B. Wiring Instructions — 208-230V Single Phase Pumps

The motor control box must be located away from the
loading rack in a non-hazardous location (see Fig. Va).

1. Connect the single phase 208 or 230V power supply

from the distribution panel to terminals L1 and L2 in the
MOTOR
LEADS 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.
CONDUIT SEAL ASSEMBLY
2. Using properly color coded wires, connect wires from
Fig. IV 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.
7. Pumps with Built-In Syphon Valve (see Fig. VI, page a. On 1-1/2 and 2 HP units, run two blue wires from
9). two blue terminals on motor control box terminal
a. On some installations, the short piece of 1/4" strip, and connect to two blue wires in the junc-
vacuum pipe furnished with the syphon pumps is tion box of the pump.
of proper length.
3. On 1 HP pumps, connect wires from terminals D1 and
b. If not of the proper length, replace with length of D0 in motor control box to dispenser control switches
1/4" pipe, 1" longer than the 8" diameter Extrac- (if dispensers are used) and “on-off” controls at load-
tor Nipple. Cover top of 1/4" pipe to keep clean ing rack, as shown on Fig. Va and Vc. The “on-off”
during installation. control station must be of explosion-proof construc-
tion. Where loading racks and dispensers are served
8. Install 8" Diameter Extractor Nipple (see table on by the same submerged pump, the 2-wire switches
page 27 for length). must be connected in parallel so the submerged
a. Position the end with set screws onto the rubber pump can be controlled from any dispenser or any
ring gasket on the Discharge Manifold. Tighten loading rack.
the four set screws evenly to pull the 8" pipe
down on the ring gasket. 4. On 1-1/2 and 2 HP pumps, connect wires from
terminal Blue-1 and terminal 3 in motor control box to
9. Install Extractor Nipple Seal. dispenser control switches (if dispensers are used)
and “on-off” switch at loading rack as shown in Fig.
a. Install the extractor seal in position as shown on Va.
Fig. VI. After this seal is in place, tighten the four
bolts to force the sealing rings against the extrac- 5. Manual Overload Reset Switch. The 1 HP pump has
tor nipple and the conduit. Tighten nut which an automatic reset overload protector built into the
compresses the gasket around the 1/4" vacuum motor. Power to the pump must be shut off 5 minutes
pipe on syphon pumps. to permit the protector to reset. The 1-1/2 and 2 HP
pumps are equipped with a no-liquid, over-tempera-
10. Install Elbow, Fittings & Syphon Check Valve. (This ture switch in the motor and an overload switch in the
step applies to syphon units only.) motor control box which will cut out if the motor is
overloaded. If the pump fails to operate, or stops,
a. Install elbow and syphon check valve on top of
when there is sufficient product in the storage tank,
the 1/4" vacuum pipe and then run 3/8" copper
check the manual overload reset switch in the control
tubing from the elbow to the bushing at the high
box cover. Wait 10 minutes for the overload protector
point of the syphon manifold shown on page 41.
to cool off and then press the reset button. If the reset
button will not stay in position this indicates an over-
11. Install Junction Box.
loaded motor, or a short or ground. This condition
a. Next, install the Junction Box on top of the must be corrected. If the reset button stays in but the
conduit. If necessary to readjust position, do so motor will not pump or continue to run, the tank is dry.

22 RJ 5190© 3/93
 ®
6" Big-Flo
Installation
CAUTION If the reset button will not stay in position NOTICE
this indicates an overloaded motor, or a 3-wire control requires the use of an
short to ground. This condition must be auxiliary contact in the magnetic starter.
corrected. If the reset button stays in but This auxiliary contact is not standard
the motor will not pump or continue to equipment in the starters supplied by
run, the tank is dry. Red Jacket, and must be ordered as an
option.
6. If an external pilot light is desired to indicate when the
submerged pump is operating, wire as shown in Fig. WARNING Installations with the magnetic starter
Va. Should this light continue to burn when all in a hazardous location require explo-
switches at dispensers and loading racks are off, this sion proof starters. The wiring is the
indicates that one of the dispenser switches is out of same as for general purpose enclo-
adjustment. On installations with no external pilot sures.
light, the submerged pump should be checked to
make sure it is not operating when all switches are 2. Motor Rotation.
turned off. Where it is not convenient to predetermine the power
supply phase rotation, proper rotation can be deter-
C. Wiring Instructions — 208-230V Three Phase Pumps mined by pump performance. Pump head pressure
and capacity will be considerably less than rated
On some installations “phase convert- when rotating backwards.
CAUTION
ers” are used to obtain a three phase
power supply from a single phase power Connect the pump motor leads to terminal T1, T2 and
source. The use of phase converters may T3 of the magnetic starter observing color code shown
cause an imbalance between the three in Fig. Ve. With gasoline in the tank and the system
phases and cause damage to the motor. purged of air, start the motor and make a pressure
For this reason, warranty coverage will gauge reading of the system pressure with the dis-
not be extended on units installed with charge valves closed; or, open one valve and calcu-
phase converters. late pumping rate.
1. Installations where magnetic starter is located away Next, reverse power leads at L1 and L2. Repeat either
from the loading rack in a non-hazardous location. head or capacity tests, as described above. If results
(See Fig. Vb.) are higher than the first test, the rotation of the second
test is correct. If the second test gives lower perform-
a. Connect the three phase 208 or 230V power ance than the first, reconnect the power leads to L1
supply from the master panel to terminals L1, L2 and L2 (as under test 1) for correct rotation.
and L3 in the magnetic starter.
Where the power supply has been properly marked
b. Using properly color coded wires, connect a L1, L2 and L3 in accordance with accepted phase
black wire from terminal T1 in the magnetic rotation standards, it is possible to predetermine the
starter to the black motor lead, in the junction box proper rotation of these units. The motor power leads
of the proper submerged pump. Connect an are color coded black, orange and red, and if con-
orange wire from starter terminal T2 to the orange nected through the magnetic starter to L1, L2 and L3
motor lead and a red wire from terminal T3 to the respectively, the motor pump unit will rotate in the
red motor lead. (See Fig. Ve and Vf.) correct direction. (See Fig. Ve.) It is recommended,
c. There are two remaining blue wires in the sub- however, that the performance tests always be made
merged pump junction box. Connect either blue whether or not the power supply has been properly
wire to terminal L3 in the Magnetic Starter. Con- “phased out”.
nect the other blue wire to one side of the “on-off”
controls. The “on-off” controls, if furnished by D. Starting the System and Completing the Installation
customer, must be of explosion proof construc-
tion. 1. Do not start pumps unless ample product is in the
storage tanks.
d. Installations using dispensers must be con-
nected for 2-wire control as shown on Fig. Vb and 2. Pump sufficient product through each dispenser (150
Ve. Connect a black wire from the other side of gallons each is recommended) to purge the entire
the “on-off” switch to terminal 3 in the magnetic system of air. If all air is not purged, the computers
starter. may “creep” slightly when the dispenser switch is
turned on, but no product has been dispensed.
e. Installations using loading racks only, may be
connected for two or three wire control. (See Fig. 3. On pumps equipped with built-in syphon, it is neces-
Ve and Vf.) For three wire control, connect a sary to run the submerged pump at least 10 to 20
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.
RJ 5190© 3/93 23
 ®
6" Big-Flo
W iring Diagrams
SINGLE PHASE SCHEMATIC
WARNING The control box must be grounded
230 VOLTS FROM 1-1/2 & 2HP, 230V, 1Ø for personal
WARNING: The controlsafety.
box Refer to the
1HP, 230V., 1Ø must National
be groundedElectrical
for
115/230V., 1Ø SUPPLY CONTROL BOX
115/230V, 1Ø , SUPPLY CONTROL BOX Codes and ap-
personal safety. Refer
NEUT L1 to theplicable local codes for proper
National Electrical
L1 L2 Codes grounding procedures.
and applicable
ORANGE local codes for
L2 ORANGE proper grounding
ORANGE BLACK
DOUBLE POLE ORANGE BLACK procedures.
MOTOR SWITCH BLACK RED
BLACK RED
PILOT LIGHT RED BLUE
115 VOLT RED BLUE BLUE
50 WATT MAX. BLACK
D1 BLUE1
BLUE
DIAL AND BLUE
DOME LIGHTS D0 2
TO NEUTRAL OF
EXT 3 115/230V. SUPPLY
PILOT ON-OFF
EXT SWITCH
NEUT. PILOT

BLACK
CUSTOMER’S 115V. CUSTOMER’S 115V. EXTERNAL
PILOT LIGHT, 50 WATT MAX. BLACK BLUE
PILOT LIGHT, 50 WATT MAX.
GREY

LOADING RACK
TO NEUTRAL OF
115/230V. SUPPLY
SEAL
GREY (NEUT) 115V. LIGHTING CIRCUIT
LIGHTING DISPENSERS (WHERE NEEDED) FROM
CIRCUIT DISTRIBUTION PANEL
WHITE

PUMP LOCATE SEALS WHERE

MOTOR CONTROL AND MOTOR REQUIRED BY LOCAL CODE
PILOT LIGHT CIRCUIT

D0 OR BL1
(BLUE) SEAL

D1 OR 3
(BLACK)

REPRESENTATIVE WIRING DIAGRAM, 1Ø, TWO WIRE CONTROL Fig. Va

SINGLE PHASE SCHEMATIC

NOTICE WARNING The control box must be grounded for personal

safety. Refer to the National Electrical Codes
If 115V is not available from power
and applicable local codes for proper grounding
supply, pilot lights may be oper- WARNING: The control box must
ated from any NOTE: IF 115V IS NOT AVAILABLE FROM
115V lighting 120/208 V. OR 115/230 V. THREE be procedures.
grounded for personal safety.
POWER SUPPLY, PILOT circuit
LIGHTS MAY BE PHASE (4-WIRE) POWER SUPPLY Refer to the National Electrical
by controllingOPERATED FROM ANY
with a 115V LIGHTING
4-pole (SEE NOTE)
CIRCUIT BY CONTROLLING WITH A 4-POLE Codes and applicable local codes
starter. Otherwise, 230V230V
STARTER. OTHERWISE, pilot
PILOT LIGHTS for proper grounding procedures.
MUST BE USED.
lights must be used

(2-WIRE SHOWN)

DISPENSER ON-OFF
SWITCH
NO LIQUID PROTECTOR

PILOT LIGHT
120 VOLT 230 V.
COIL
BLACK
BLUE

DOUBLE POLE
MOTOR SWITCH
BLACK
BLUE

BLACK BLUE
CIRCUIT

DOME AND
BLUE
BLUE

DIAL LIGHTS
REMOTE DISPENSER 115 V. LIGHTING
GREY (PILOT LT. NEUT.) CIRCUIT (WHERE SEAL
RED REQUIRED) FROM
LIGHTING CIRCUIT
NEUT

ORANGE
DISTRIBUTION
BLACK

PANEL.
JUNCTION BOX BLACK

MOTOR CONTROL AND LOCATE SEALS

PILOT LIGHT CIRCUIT WHERE REQUIRED
BY CODES.

SEAL
THERMAL
OVERLOAD

REPRESENTATIVE WIRING DIAGRAM, 3Ø, TWO WIRE CONTROL Fig. Vb

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.

24 RJ 5190© 3/93
 ®
6" Big-Flo
W iring Diagrams
SINGLE PHASE SCHEMATICS

WARNING The control box must be grounded

for personal safety. Refer to the Na- CONTACTOR COIL

tional Electrical Codes and appli- LINE 1

cable local codes for proper ground- LINE 2

ing procedures. ORANGE

ORANGE
THERMAL OVERLOAD
PROTECTOR
BLACK
BLACK

RED RUNNING STARTING

MOTOR RED
CAPACITOR CAPACITOR
L2 230 V L1
BLUE
BLUE
115 V 115 V
WHITE BLUE
NEUT BLUE WHITE
1

WHITE STARTING RELAY

BLUE 2
LINE 1 TWO WIRE
CONTROL
WHITE
3
BLACK
LINE 2
STARTING RELAY
TO NEUTRAL OF EXT BLACK
YELLOW 5 2 PILOT
THERMAL 115/230 V SUPPLY
OVERLOAD BL 115 V EXTERNAL
ORANGE AC
ORANGE K PILOT LIGHT
(50 WATT MAX)
6 BLACK
4 1
BLACK BLACK
MOTOR BLACK
BLUE
3 POLE 1
SWITCH
RED
RED RED
RED 2
THREE WIRE
STARTING CONTROL
DISPENSER CONTROL SWITCHES CAPACITOR 3
BLUE
D1
CONTROL
SWITCH
BLUE
D0

EXT BROWN
PILOT
WARNING The control box must be grounded
WHITE BROWN

115 V EXT
NEUT for personal safety. Refer to the Na-
PEDESTAL
PILOT LIGHTS
PILOT LIGHT
(50 WATT MAX)
WHITE
tional Electrical Codes and appli-
cable local codes for proper ground-
ing procedures.

MOTOR CONTROL BOX WIRING DIAGRAM - 1 H.P.

(5 TERMINAL RELAY) MOTOR CONTROL BOX WIRING DIAGRAM
(DISCONTINUED FEBRUARY, 1988) Fig. Vc 1-1/2 & 2 H.P. Fig. Vd

Fig. V
THREE PHASE SCHEMATICS

WARNING The control box must be grounded WARNING The control box must be grounded
for personal safety. Refer to the Na- for personal safety. Refer to the Na-
tional Electrical Codes and appli- tional Electrical Codes and appli-
cable local codes for proper ground- cable local codes for proper ground-
208/230V, 3 PHASE ing procedures. 208/230V, 3 PHASE ing procedures.
POWER SUPPLY POWER SUPPLY

L1 L2 L3 BLUE L1 L2 L3 BLUE
SWITCH AT LOADING RACK

STOP BLUE
BLACK
RED
SWITCHES AT LOADING
RACKS AND/OR IN
DISPENSERS CONNECTED
IN PARALLEL BLACK START
230V
COIL 230V
COIL

NOTICE

BLUE
3-wire control re-
quires the use of an
T1 T2 T3 T1 T2 T3
BLUE BLUE auxiliary contact
in the magnetic
TO EXIT TO EXIT
PILOT LITE PILOT LITE starter. Furnas in-
115V SUPPLY 115V SUPPLY
RED RED terlock kit or
ORANGE
49D221251 or equi-
ORANGE
valent.
BLACK BLACK

NOTE: THERMAL NOTE: OBSERVE COLOR CODE L1, L2, THERMAL

OBSERVE COLOR CODE L1, L2,
208/230V, 3 PHASE OVERLOAD L3 PHASE SEQUENCE FOR 208/230V, 3 PHASE OVERLOAD
L3 PHASE SEQUENCE FOR
PROPER ROTATION OF MOTOR. POWER SUPPLY PROPER ROTATION OF MOTOR. POWER SUPPLY
TWO WIRE CONTROL THREE WIRE CONTROL
3 PHASE MOTOR WIRING DIAGRAM
3 PHASE MOTOR WIRING DIAGRAM
Fig. Ve Fig. Vf

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.
RJ 5190© 3/93 25
 ®
6" Big-Flo
Manifold Dimensions
BIG-FLO® PACKER/MANIFOLD ASSEMBLY WITH SYPHON ATTACHMENTS
PULL ELBOW

CONDUIT JUNCTION BOX SYPHON CHECK VALVE

EXPANSION UNION
EXTRACTOR NIPPLE SEAL
3/8 " VACCUUM PIPE

LOCATE SEAL WHERE

1 1/4" CONDUIT REQUIRED BY LOCAL CODE

1/4" VACCUUM PIPE

PACKER ASSEMBLY
DISCHARGE LINE TO
8" EXTRACTOR NIPPLE
LOADING RACK OR
TO DISPENSERS

FIG. V1 6" RISER & FLANGE

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)

250 G.P.M. Leak Detector (3") Diaphragm Valve

Model 116-039-5 (Incl. 116-036-5)
Grade 24"

Pump Discharge Outlet to Leak Concrete

Red Jacket “Big-Flo” Detector (Usually 3" or 4") Blocks
Submersible Pump

6" Riser Discharge To Dispensers

3" Diaphragm Valve or Loading Rack, etc.
Storage Tank Submerged Pump Junction Box Flex Connector

Electrical Conduit Pit a Cover By Contractor

(Depth Of Pit Varies With Tank Bury Depth)

116-036-5 Leak
24" Detector as Pilot Valve
(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)

26 RJ 5190© 3/93
 ®
6" Big-Flo
Table of Dimensions for Pump Selection
MALE UNION
ELBOW
EXPANSION UNION REDUCER

008-168 CONDUIT BOX BY RED JACKET

10"
176-026 NIPPLE SEAL BY
3/4" 4" RED JACKET

“E”
COVER
DEPTH CONDUIT BY CONTRACTOR
CONDUIT
6-3/4" BY CONTRACTOR “C” 8" EXTRACTOR NIPPLE
#60169 BY RED JACKET
3-1/16" 3" PIPING BY CONTRACTOR
SEAL
BY CONTRACTOR 151-001 DISCHARGE MANIFOLD
BY RED JACKET
“D”
PLUG IF
NECESSARY “D” 6" RISER & FLANGE #60303
BY RED JACKET

“B”

“A” TANK DIA.

PUMP & MOTOR

4" NOTICE
Distance between center line of
pump motor and center line of bot-
tom fill tube should be 3' minimum.
Air locking of pump may occur at
Fig. VII distances less than this distance.

NOTICE Use this table for single wall tank applications only that do not involve manways or sumps.

Example: An 8' dia. steel tank buried 3'-0" will require a 99" long pump, 7" long riser & 13" long extractor nipple.
TABLE OF PUMP RISER & EXTRACTOR NIPPLE LENGTHS FOR
VARIOUS TANK DIAMETERS & VARIOUS BURY DEPTHS
Diameter Storage Tank “A” 5'-4" 6'-0" 6'-3 1/2" 7'-0" 7'-6" 8'-0" 8'-3 1/2" 9'-0" 10'-0" 10'-6" 11'-0" 12'-0"
Pump Length “B” 5'-3" 6'-3" 6'-3" 7'-3" 8'-3"* 8'-3" 8'-3" 9'-3" 10'-7" 10'-7" 11'-3" 12'-3"
Riser Length “D” 5" 7" 4" 7" 13" 7" 4" 7" 11" 5" 7" 7"
Extractor Nipple “C” Length
When Tank is Covered:
2'-0" Bury 5" 5" 5" 5" 5"** 5" 5" 5" 5" 5" 5" 5"
2'-6" Bury 10" 7" 10" 7" 5"** 7" 10" 7" 5" 10" 7" 7"
3'-0" Bury 16" 13" 16" 13" 7" 13" 16" 13" 10" 16" 13" 13"
3'-6" Bury 22" 19" 22" 19" 13" 19" 22" 19" 16" 22" 19" 19"
4'-0" Bury 28" 25" 28" 25" 19" 25" 28" 25" 22" 28" 25" 25"

* Pump length for 2' bury will be 7'-7" long with a 5" riser length.
** 5" nipple not required.
A variety of tank types with various materials of construction are currently in use. The inside diameter, (I.D.) which is critical
WARNING 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 environmental damage.
Petro Express Bulletin, RJ 23-25 (10/90) explains the information required for proper pump sizing.

RJ 5190© 3/93 27
 ®
6" Big-Flo
Cutaway V iew

SYPHON
CHECK
VALVE

PACKER
SEALS
SYPHON
NOZZLE &
VENTURI 3

CHECK
VALVE

PACKER
SEALS

AIR 3
ELIMINATOR
TUBING

EXPANSION
RELIEF
VALVE

NOTICE See page 29 for Troubleshooting Instructions.

28 RJ 5190© 3/93
 ®
6" Big-Flo
T roubleshooting/Electrical Data
Symptoms Probable Cause Suggested Action
Total or partial loss of vacuum and/or Obstruction in syphon nozzle/venturi (#1) or air elimi- Remove nozzle/venturi, clean and reinstall. Run flex-
pressure reading at vacuum line. nator tubing (#2) is clogged. O.D. of this tubing must be ible wire down air eliminator tubing. Replace tubing if
3/8" min. it’s too small.

Loss of line pressure. *(Static — Failure of packer assembly seals (#3) or check valve Remove and inspect areas to ascertain that cause for
pump off all discharge outlets seal (#4). failure is not still present (i.e., burr or damaged seal
closed.) Should be 25-35 PSI. Thermal contraction (see par. XIV & XV “Report on surface). Replace seal.
Leak Detectors” pg 51).
Expansion relief valve not sealing (#5). Should relieve Remove, clean and reinstall or replace.
static line pressure to approx. 20-35 PSI.
Excess line pressure. Failure of expansion relief valve (#5) (*Static) Remove, clean and reinstall or replace.
Pump oversized for applications. Refigure head loss and check performance curve.
Line type check valve installed in discharge line. (Ex- Remove same.
pansion or pressure equalizing type is acceptable, not
standard type.)
Low pump output on new installation Motor running in reverse. Switch any two power leads L1, L2 or L3 at starter.
of 3-phase unit.
Pump/motor runs and pumps inter- Binding of pump due to foreign object in impeller/ Check amperage draw. (Constant or intermittent ex-
mittently. diffuser area. (Abnormal noise usually present with this cessive amperage draw may occur. See Electrical
problem.) This will cause overheating of motor and Data below.)
subsequent cut-off by overload protection device. Replace unit if findings dictate.
Overload opens at 113°F, closes at 87°F-90°F. Do not
operate pump with an ambient temperature higher than
132°F.
Excessive or erratic bearing wear. (Usually caused by
running unit dry or continuously.)
Improper electrical connection or voltage. Check wiring for continuity and impedance (see be-
low). Voltage must be within 10% ± of rated voltage.

Repetitive premature motor failure. (see above)

If 3ø unit, possible phase unbalance is present. See p. 30.
Short in power supply leads to pump. Check for ground with ohmmeter.
Slight power drain via break in power lead wire insula- Check with 500V megger. Reading should be greater
tion. than 100,000 ohms to ground.

Motor runs, but pump output partially Foreign material obstructing intake ports or pump im- Investigate appropriate area for same and remove.
or totally impaired. pellers (i.e., rags, paper).
Partially closed gate valve. Open same.
Malfunctioning solenoid valve. Replace if defective.
Improper voltage. Check voltage, must be within 10% ± of rated voltage
(208/230V).
Clogged filter or strainer. Clean or replace.
Confirm that motor is a two stage unit instead of a single Check output PSI of pump to determine motor unit
stage unit. (A two stage motor unit is needed on any type. A single stage unit will have approximately one-
application involving a dispenser). half the output PSI of a two stage unit.

NOTICE Pump performance can be checked by installing a pressure gauge at the discharge side of unit.
APPROXIMATE NORMAL OPERATING PRESSURE
Model PSI Gas PSI Diesel Model PSI Gas PSI Diesel
1 HP, 1 Stage 19 24 3 HP, 1 Stage 16 21
1-1/2 HP, 1 Stage 15 18 3 HP, 2 Stage 30 37
2 HP, 2 Stage 38 48 5 HP, 2 Stage 36 44
ELECTRICAL DATA
Service Locked Branch Ckt. Protection
Factor Cur. Idle Rotor Cur. Fusetron Ckt. Brkr. Overload
HP Volts Phase (Amps) (Amps) (Amps) (Amps) (Amps) Heaters*
1 208-230 1 7.5 4.4 35 15 15 NA
1-1/2 208-230 1 9.5 4.6 47 15 15 NA
2 208-230 1 12.0 5 61 20 20 NA
2 208-230 3 7.2 4.2 45 15 15 K-43
3 208-230 3 10.5 6 62 15 20 K-53
5 208-230 3 17.2 8.3 96 25 30 K-61
*Appropriate heaters are supplied with starters.

RJ 5190© 3/93 29
 ®
6" Big-Flo
Thr ee Phase Unbalance
Three phase current unbalance is a factor which can result in 1st Connection 2nd Connection 3rd Connection
premature motor failure. It causes reduced starting torque, T1 = 51 Amps T3 = 50 Amps T2 = 50 Amps
excessive and uneven heating and excessive motor vibration. T2 = 46 Amps T1 = 48 Amps T3 = 49 Amps
Therefore, it is important that the electrical load to the submers- T3 = 53 Amps T2 = 52 Amps T1 = 51 Amps
ible motor be balanced. The purpose of this service information
Begin by adding the three readings for the 1st connection.
is to describe how to check and correct phase unbalance, and
T1 = 51 T2 = 46 T3 = 53 Total = 150 Amps
what to do if it cannot be corrected.
Divide the total by three to obtain the average:
1. Check for correct motor rotation by installing a pressure 150 ÷ 3 = 50 Amps
gauge in the discharge line. Start the pump and make a
mental note of the pressure reading. Turn off the pump and Calculate the greatest Amps difference from the average:
change any two of the red, yellow or black leads in the 50 - 46 = 4 Amps
control box. Restart the pump and again note the pressure
reading. The rotation that gives the highest pressure is Divide this difference by the average to obtain the percentage
always the correct one. of unbalance:
4 ÷ 50 = .08 or 8%
CAUTION Remember, before working inside the control
box, always disconnect the power supply. In this case, the current unbalance for the 1st connection is 8%.
Using the same procedure, the maximum current unbalance for
2. When the correct motor rotation is established, the amount the 2nd connection is 4%, and for the 3rd connection is 2%. By
of current unbalance between the three legs of the power comparing the percentage of unbalance on the three possible
supply should be calculated. connections, connection #1 exceeds 5% and therefore should
not be used. The 2nd and 3rd connections are less than 5%
Current unbalance between legs should not exceed 5%. unbalance and therefore either is satisfactory. Since the 3rd
The percent of current unbalance is defined and calculated connection had the lowest percentage of unbalance, it should
as follows: be used to obtain maximum motor efficiency and reliability.
Max. current diff.
Percent Current Unbalance = average current x 100 By observing where the highest current reading is on each leg
Average Current on the various connections, you can determine if the unbalance
is caused by the power source or the submersible motor. In the
Current readings in amps should be checked on each leg using above example, the highest Amp reading was always on the
the three possible connections shown in the illustration below. same incoming power leg, L3. This indicates that most of the
The best connection is the one that has the lowest percentage unbalance was from the power source.
of unbalance.
If the high current were on a different incoming leg each time the
To prevent changing motor rotation when taking these read- motor leads were changed, this indicates the motor, or a poor
ings, the motor leads should be moved across the starter connection, caused most of the unbalance.
terminals by always moving them in the same direction, as
shown in the illustration below. If an unbalance problem appears to be in the power supply and
none of the three possible connections will reduce the percent-
The following is an example of current readings at maximum age of unbalance to 5% or below, the power company should
pump load (highest gpm) of each leg of the three-wire connec- be contacted for additional aid in correcting the current unbal-
tion. ance to an acceptable level.

1st Connection 2nd Connection 3rd Connection Supply

L
1
= L
=
2
L
3
= L
1
= L
2
= L
3
= L
1
= L
=
2
L
3
= Starter

T T T
2 1 3
T T T T T T Motor
1 3 3 2 2 1

30 RJ 5190© 3/93
 ®
6" Big-Flo
Replacement Parts List
REPLACEMENT PARTS LIST — PACKER ASSEMBLY
(Packer Assembly is the same on All Model Big-Flo® Pumps)
Upper End

5 39 40 35 34 33 32 31 30 29 19
4 36
28
37 27

26
EXPANSION RELIEF VALVE
25 ON BOTTOM SIDE OF PACKER
(NOT SHOWN)

PUMP TANK RISER

24 (NOT SHOWN)

1 2 3 14 38 6 7 9 8 10 11 12 13 16 18 19 20 19 21 22 23
15 17 7

Key No. Part No. Description No. Req’d.

2 008-168-1 Conduit Junction Box with Cover 1
3 110-038-4 Conduit Seal Assembly, All Models Except P100H1-1MB 1
3 110-039-4 Conduit Seal Assembly, Model P100H1-1MB 1
4 027-065-1 1/4 x 3/8 Fitting Syphon Take Off 1
5 060-048-3 Packing Nut Syphon Tube 1
6 031-097-1 Packing Nut Gasket 1
7 031-106-1 Extractor Nipple Gasket Outer 2
8 031-105-1 Extractor Nipple Gasket Inner 1
9 176-026-5 Extractor Nipple Seal Assembly Non-Syphon 1
9 176-025-5 Extractor Nipple Seal Assembly Syphon 1
10 065-073-1 1/4" Galvanized Syphon Pipe (Obtain Locally or Specify Length) 1
11 013-047-1 1-1/4" Conduit Pipe (Obtain Locally or Specify Length) 1
N/S 164-045-5 Packer Assembly without Syphon 1
12 164-046-5 Packer Assembly with Syphon 1
13 026-219-1 Locking Capscrew 3/4 x 16 x 3/8 (Obtain Locally) 2
14 188-079-5 Syphon Check Valve 1
15 058-029-3 Syphon Packing Nut and Nozzle 1
16 072-110-1 “O” Ring - Syphon Packing Nut (5/8 x 13/16 x 3/32) 1
17 026-414-1 Hex Head Cap Screw 4
18 008-167-3 Syphon Venturi 1
19 072-108-1 “O” Ring - Packer Assembly (5-1/2 x 6 x 1/4) 3
20 151-011-5 Discharge Manifold 1
21 031-108-1 Gasket - Mainfold to Riser 1
22 085-100-x Air Eliminator Tube (Specify Length) 1
23 013-145-x 3" Column Pipe (Specify Length) 1
24 882-2xx-x Pump Riser (Specify Length) 1
25 208-271-5 Expansion Relief Valve 1
26 013-882-3 3/4" Alum. Conduit (Specify Length) 1
27 072-107-1 “O” Ring - Check Valve Seat (3-1/4 x 3-1/2 x 1/8) 1
28 076-085-3 Check Valve Seat Check 1
29 026-627-1 Machine Screws (1/4 x 20 x 1/2) 2
30 079-161-1 Check Valve Spring
Valve 1
31 111-065-4 Cap & Stem Assembly Check Valve Components 1
32 138-049-5 Disc & Holder Assembly for Check Valve 1
33 072-104-1 “O” Ring - Seal Conduit (1 x 1-1/4 x 1/8) 2
34 072-129-3 Locking Ring 1
35 060-057-3 Packing Nut 1
36 882-2xx Extractor Nipple (Specify Length) (Includes 1 Gasket 031-106) 1
37 027-068-1 Elbow 3/8" 1
38 027-138-1 Brass Elbow 1
39 031-107-1 Bolt Gasket 4
40 066-164-3 Top Plate 1
N/S 144-056-5 Syphon Conversion Kit 1
N/S 026-198-1 Manifold Screw 4
N/S 064-025-3 Packer Casting Only 1
N/S 144-186-5 Check Valve Kit 1

RJ 5190© 3/93 31
 ®
6" Big-Flo
Replacement Parts List

REPLACEMENT PARTS LIST — BIG-FLO® SUBMERSIBLE PUMPS

Lower End

1 2 3 8

6 4 9 7

Number Required
P100H1-1MB

P200H1-2MB

P200H3-2MB
P150H1-1HB

P300H3-2HB
P300H3-1K

P500H3-2K
Key No. Part No. Description

1 036-043-3 Motor Head 1 1 1 1 1 1 1

2 3/8 x 16 x 2 Cap Screw (Obtain Locally) 4 4 4 4 4 4 4
3 3/8 Washer (Obtain Locally) 4 4 4 4 4 4 4
4 213-064-5 Plug & Pigtail Assembly 1 — — — — — —
4 213-065-5 Plug & Pigtail Assembly — 1 1 1 1 1 —
4 213-069-5 Plug & Pigtail Assembly — — — — — — 1
6 011-143-1 Discharge Casting 1 1 1 1 1 1 1
7 001-157-3 Floating Suction Adaptor — 1 1 — — 1 —
7 001-026-3 Floating Suction Adaptor — — — — 1 — 1
7 001-158-3 Floating Suction Adaptor 1 — — 1 — — —
8 072-109-1 “O” Ring (5-5/8 x 5-7/8 x 1/8) 2 2 2 2 2 2 2
9 072-578-1 “O” Ring (1-7/8 x 2-1/8 x 1/8) 1 1 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 page 35 for ordering numbers.

32 RJ 5190© 3/93
 ®
6" Big-Flo
Contr ol Box for 1-1/2 & 2 HP Pumps

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. Description No. Req'd.

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 (10MFD-330 Volt) (P150H1-CB) 1
5 012-253-1 Running Capacitor (15MFD-370 Volt) (P200H1-CB & P200H1CB) 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

RJ 5190© 3/93 33
 ®
6" Big-Flo
Magnetic Starter for 2, 3 & 5 HP 3 Phase Pumps

MODELS P200H3-2MB, P300H3-1K, P300H3-2HB, P500H3-2K

Overload Heaters

NOTICE The only parts that are available for the Magnetic Starter from Red Jacket are the Overload
Heaters. (See chart below)

WARNING Three phase model Big-Flo pumps require the use of a magnetic starter.

Magnetic Overload Heaters

HP Volts Phase Starter Heater No. Part No.
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

34 RJ 5190© 3/93
 ®
6" Big-Flo
Pump/Motor Assembly
Ordering Model Pump Motor Pump Motor
Number Number HP Volts Phase Assy. Length Assy. Weight
882-841 UMP150H1-1HB 1.5 230 1 28-3/4" 106#
882-839 UMP200H1-2MB 2 230 1 32-1/8" 116#
882-840 UMP200H3-2MB 2 230 1 29-5/8" 116#
882-209 UMP300H3-1K 3 230 3 31-5/8" 120#
882-842 UMP300H3-2HB 3 230 3 34-5/16" 120#
882-211 UMP500H3-2K 5 230 3 42-1/2" 162#

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.

CONVERSION DATA
1 Atmosphere = 14.7 PSI 1 Imperial Gal. = 1.20 U.S. Gals. 1 PSI = 2.04 In. of Hg.
= 29.92 In. Hg. 1 Inch Hg. = .491 PSI = .0703 Kg./Sq. CM
1 Barrel = 42 Gals. (oil) 1 Kilogram = 2.2 Pounds 1 Lb. = .4536 Kg.
1 Cu. Ft. = 7.48 Gals. 1 Liter = .264 U.S. Gals. 1 Kg./Sq. CM = 14.22 PSI
1 Cu. Meter = 264.17 Gals. 1 Meter = 3.28 Ft. 1 U.S. Gal. = .833 Imp. Gal.
1 Ft. Water = .433 PSI = 39.37 Inches = 3.79 Liters

HEAD EQUIVALENTS
1 PSI = 2.31 Feet of Water 1 In. Hg. = 1.13 Feet Water
= 3.2 Feet Gasoline (.72 Sp. Gr.) = 1.57 Feet Gasoline (.72 Sp. Gr.)
= 2.9 Feet Kerosene (.80 Sp. Gr.) = 1.42 Feet Kerosene (.80 Sp. Gr.)
= 2.6 Feet Heating Oil (.89 Sp. Gr.) = 1.27 Feet Heating Oil (.89 Sp. Gr.)

ELECTRICAL DATA
Model Number Winding Resistances (OHMS)
Pump Motor HP Volt Phase
Assembly Yellow to Red Yellow to Blk Red to Blk Blue to Blue
UMP100H1-1MB 1 208-230 1 9.5-10.5 3.0-3.6 12.5-14.1 —
UMP150H1-1HB 1.5 208-230 1 7.2-8.3 2.0-2.5 9.2-10.8 0-0.1
UMP200H1-2MB 2 208-230 1 5.4-6.2 1.5-2.0 6.9-8.2 0-0.1
UMP200H3-2MB 2 208-230 3 2.3-3.2 2.3-3.2 2.3-3.2 0-0.1
UMP300H3-1K 3 208-230 3 1.7-2.3 1.7-2.3 1.7-2.3 0-0.1
UMP300H3-2HB 3 208-230 3 1.7-2.3 1.7-2.3 1.7-2.3 0-0.1
UMP500H3-2K 5 208-230 3 .9-1.2 .9-1.2 .9-1.2 0-0.1

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.

RJ 5190© 3/93 35
 ®
6" Big-Flo
Notes

36 RJ 5190© 3/93
 Section
Syphon Systems 3

RJ 5190© 3/93 37
Syphon Systems
Engineering Report
While syphon systems for submersible gasoline pumps have in the pump tank falls below the end of this tube. The end of this
become fairly common, problems are still encountered with the tube is roughly 27 inches off the bottom of the tank.
priming and maintenance of prime. An outline is herein provided
of the system, its proper operation, and means of checking when Situations Which Cause Loss of Prime
the system is not working. The indication of an improperly operating system is the fact
that the fluid levels of the tanks do not drop together. A series of
Proper Installation relatively simple tests can be made to isolate the problem which
A syphon loop in the form of an inverted “U” is connected can be categorized into five areas:
between two or more tanks. The syphon primer on the submers- (1) The submersible pump syphon primer not working.
ible pump is connected to the high point of the “U” loop so that air (2) A syphon check valve not holding.
or vapor can be continually removed while the submersible pump (3) A leak in the tube, fittings, or pipe of the syphon loop.
is operating. The horizontal pipe should be provided with mini- (4) One of the syphon pipes shorter than specified, causing
mum of 1/8 inch per foot of rise to the primer connection, or more the syphoning to cease operating at a given level.
where room allows, to allow for settling of the tanks. The ends of (5) Blockage of the syphon pipe due to foreign material,
the syphon loop, terminated in the tanks, should be between two such as a rag, or due to caving in of the tank bottom (or
and five inches off the bottom of the tank. If they are closer than top) such that it can block the syphon loop pipe.
this, it is possible to pull dirt or water from the bottom, or even to
have the ends sealed off against the bottom if the tank should be Troubleshooting Syphon System
flattened due to handling or backfilling.
A minimum number of fittings and pieces of pipes should be
CAUTION Disable Power To The Pump
used to reduce the number of joints where a leak can occur. Install the valves and vacuum gauge* assembly (Fig. 1)
between the syphon check valve and the syphon loop.
Occasionally, a syphon loop will be con- Special care should be taken to pretest this assembly to
NOTICE nected between tanks of different grades make sure that all of the fittings and valve bonnets are tight.
and isolated by a valve so that the auxil- Note the use of clear plastic (Ti-gon). This can save many
iary tanks can be shifted to store differ- hours of troubleshooting.
ent products. Many states’ weights and
measure authorities do not allow such a Steps for Isolating Problems When Clear Plastic Tube is
connection, but where it is allowed, care Used Wtih Test Assembly
should be taken to see that the bonnets 1. Syphon Primer
of the valves are tight and there is no Start pump, leave dispenser nozzle closed, open valve No.
possibility of a leak. 2, and observe the gauge. 10 to 25 inchesof mercury is
considered normal. A reading below 10 inches may indicate
Operation of Syphon Primer
a partially plugged nozzle or venturi in the pump or the
All remote submersibles of today use a nozzle-venturi com-
passage leading to or from these parts, or a significant leak
bination for creating vacuum used for priming the syphon loop.
in the vacuum line. A zero pressure reading indicates a
Depending upon the design, this nozzle-venturi combination will
develop a vacuum of 10 to 25 inches of mercury by injecting completely inoperative primer, or a completely plugged line
some of the fluid of the discharge from the pump through the from the primer to the valve assembly, or a plugged air
nozzle into the venturi causing a low pressure area (vacuum). eliminator 1/4-inch pipe which runs down to the submersible
One inch of mercury is equal to approximately 1.5 feet of motor. A significant leak in the vacuum line connected to the
gasoline; therefore, these primers are capable of priming gaso- pump will also cause the same indication.
line syphon systems a vertical distance of 15-20 feet, depending
on the vapor pressure of the product. 2. Leaving valve No. 2 closed, turn off the submersible pump.
Again, depending on design, the depth of gasoline, the size The system should hold the vacuum (10 to 25 inches) for at
of the tanks, and the size of the pipe and its length, the empty loop least 15 minutes. If it fails immediately, recheck all the test
priming time will take from less than two minutes to as much as fittings and, if tight, then the syphon check valve is not
ten minutes for large tanks, nearly empty. Once the loop is holding and should be replaced with a new one.
primed, the purpose of the primer is to continue to remove any It may be that the check valve will hold adequately under
bubble of vapor or dissolved air which come out of the gasoline a high vacuum, but may leak under a low vacuum. It is
and form in top of the loop due to the low pressure in the loop. recommended that if it holds satisfactorily at the higher
The syphon primer system requires a syphon check valve to reading, then the vacuum should be bled off and a retest
prevent the back flow of gasoline and the entrance of air when the made to see if the check valve will hold properly at five
pump is turned off. This check valve becomes necessary when inches.
the lower end of the syphon air-eliminator tube is above the level See Operation of Syphon Primer.
NOTICE
of liquid. Without the check valve, air would enter the tube and *A compound gauge is recommended as
break the vacuum in the syphon loop. a plugged primer valve can cause pres-
It should be noted that most manufacturers extend the sure under certain conditions.
syphon-priming air-elimination discharge tube down to the head
of the pump motor. With this arrangement, the leaking check 3. Syphon Loop
valve will not cause loss of prime in the syphon loop until the level Start the pump, then open both valve No. 1 and No. 2; leave

38 RJ 5190© 3/93
 Syphon Systems
Engineering Report (cont.)
the dispenser nozzles closed and observe the gauge for ten When the horizontal pipe is finally drained, then the fluid will
minutes. Normal priming will take from two to ten minutes. begin to lower in the vertical pipes and the vacuum will begin to
It will be noted that at first the vacuum gauge will indicate fall off as indicated by the gauge. It should be noted that the
zero; after a while it will begin to show some vacuum. higher the level of fluid in the tanks, the longer the period of time
Remember, for every one inch of mercury vacuum, the level required for this action to take place. With nearly full tanks, it will
in the pipes above the fluid level in the tanks is about 1-1/2 be almost impossible to accurately determine this without visual
feet. As the fluid rises in the pipes, the vacuum increases observation, as could be obtained with a plastic tube.
accordingly. Therefore, the maximum primer reading of 10 If there is no change in the vacuum reading, after one hour,
to 25 inches will not be obtained on this test. then attention should be directed to the syphon check valve. The
When fluid enters the primer tube, it will first appear valve No. 1 can then be opened and if the gauge begins dropping
mixed with bubbles. It will be noticed that the gauge needle shortly after, then the syphon check valve is suspected and may
will dance as the mixture of air bubbles and gasoline passes be operating erratically. This test should be repeated, but the
through the test assembly. As the bubbles disappear and long period of time is not necessary and both valves should
only fluid is in the tube, the gauge will settle down to a slightly remain open. If the loss of vacuum occurs in a much shorter
higher value than was obtained just before fluid entered the period of time than the original test, then it is very likely that there
plastic tube. is a leak inside the syphon check valve and it should be replaced.
These bubbles should disappear in less than five min-
utes, if the system is tight, although it might take a little longer Pressure Testing the Syphon Loop
if the fluid levels in the tanks are considerably unequal. If If the storage tanks are nearly full, it may be difficult to locate
bubbles continue to appear (the gauge needle will continue a leak in the syphon “U” with the vacuum tests. An alternate
to dance) after 20 minutes, it can be definitely ascertained method is suggested using pressure. For this test it is necessary
that there is a leak in the syphon loop, the tube, or in the to have an accurate pressure gauge with 1/2-psi-or-finer divi-
connection to the loop. sions. (The maximum reading in a 12-foot tank will be less than
With the above tests, the main causes of syphon trouble 4 psi.)
should have been isolated. If all of the tests appear positive Connect the gauge to the syphon primer system and install.
and there is no indication of leaks or malfunction, then a Connect a tube with a “Shroeder” valve so that air pressure can
period of time (see chart No. 1) should be used to gauge the be applied and held, as shown in figure 2.
levels in the tanks to see if the fluid is transferring after the Apply air until it bubbles from the bottom of the syphon “U.”
system has primed. If the tanks level in the estimated period Stop the air and read the gauge. The gauge reading in psi x 3.1
of time, it can be assumed that the system is operating (gasoline sp. gr. 0.74) indicates the feet of gasoline over end of
properly at the time of the check. If the priming system the vertical pipe with the least submergence. Observe the gauge
appears to work properly but the tanks do not level within the for one hour. If the gauge drops, then levels off at a value above
expected amount of time, it may be assumed that the zero, there is a leak in the vertical “U” pipe under fluid at the new
syphon “U” is plugged. psi reading x 3.1 feet under the gasoline levels. If the gauge drops
If the problem cannot be located, it might be caused by to zero, there is a leak above the fluid levels.
a leak below the present level of fluid in the tanks or due to For Example:
a short vertical syphon pipe in one or both tanks. It is Two six-foot storage tanks connected by a syphon “U” with
possible to determine this roughly by the test indicated ends four inches off the bottom and tank levels at 68 and 60
“Pressure Method of Testing.” inches (above the bottom) would give an initial psi reading of 1.5
psi.
Syphon Test Made Without a Clear Plastic Tube (60" - 4" = 56")
= 1.5 psi
If clear plastic has not been used in the test set-up, then an 12"/ft. x 3.1 ft.
additional series of tests are necessary to isolate the problem, as psi
follows:
Repeat steps No. 1 and 2 under “Steps for Isolating Prob- If the pressure gradually fell to .75 psi and held, it would
lems…” Next, repeat step No. 3 and as soon as the system is indicate a loose joint or crack approximately 28 inches down from
primed, as indicated by a sharp change in the gauge reading or the fluid surface in either of the vertical pipes. (If there is more
needle dancing momentarily or continuously, allow the system to than one leak, accurate determination becomes very difficult) .75
continue to operate for approximately 20 minutes. If the needle psi x 3.1ft./psi = 2.3 feet = 28" under the surface of the tank level.
continues to dance, it is strong evidence that air is continually This would place it at 40 inches above the bottom of tank No. 1
being pulled in. To further verify this, valve No.1 between the (68-inch level) or 32 inches above bottom of tank No. 2 (60-inch
gauge and the syphon primer check valve is then closed. The level).
reading on the gauge will indicate approximately the height of the Eliminating a Troublesome Syphon Check Valve Problem
fluid in the loop above that in the tanks to the gauge. This should Experience has shown that on a few installations the syphon
be observed for at least 30 to 40 minutes. The gauge will hold check valve cannot be made to hold consistently. This could be
constant for a while, even if there is a leak in the loop. This is in a station located near a subway or heavy truck traffic. The
because all of the fluid must drain out of the horizontal pipes first, constant vibration of the check valve prevents its seating consis-
and since there is not appreciable fall in level, it will be hardly tently. It could also be a condition where an extreme amount of
noticed by the gauge reading. dirt is being pulled into the check valve. This is only a problem

RJ 5190© 3/93 39
Syphon Systems
Engineering Report (cont.)
after the fluid level drops below the end of the combination air- Approximate Transfer Rates in GPM Between Tanks at
eliminator syphon-priming tube just above the motor, and is Various Differential Levels
further aggravated in cases where only two or three feet of
gasoline are normally kept in the storage tank. Chart No. 1
If the dealer reports, “The syphon works fine until the level (Assume: 25 feet pipe, two 90° elbows)
drops below about 27 inches in the pump tank, the product won't
come over then from the other tank,” this is a clue that the syphon Tank Level Transfer Rate—GPM
check isn’t holding at the time when the bottom end of the air- Differential—Feet 1-1/2" Pipe 2" Pipe 2-1/2" Pipe
eliminator syphon-purge tube is above the liquid, and air goes up 1/4 8 16 25
the tube and the vacuum in the loop is broken. (It could also be 1/2 11 23 35
a short syphon loop pipe.) Once it is broken, the submerged
1 16 33 50
pump usually must be run continuously to re-purge the loop and
be kept running until the tank is level. 2 23 46 70
Where the replacement of the syphon check valve still does 3 28 56 86
not cure the complaint, and a short syphon pipe has been 4 32 64 100
eliminated as the cause, the solution is to eliminate the need for 5 35 70 112
the syphon check. One is never needed if the air-eliminator 6 40 80 125
syphon-purge tube is extended to the bottom of the tank, or at 8 45 90 150
least to a point below the submerged pump intake. This is not a
simple task since the pump-motor and tube will not pass through
the riser at the same time. However, it can be done by following Approximate time for Tanks to Equalize
these instructions. For a rough approximation of the time necessary to equalize
1) Turn off the power and remove submerged pump from the level in two tanks, the means average flow rate may be used:
storage tank.
2) Take off the 1/4-inch air-eliminator syphon-purge tube e.g., Two 6000-gallon tanks 6'3" diameter
which terminates near top of the motor. (1/8-inch copper Connect with two-inch pipe
tubing was used on some pumps.)
No. 1 tank 24-inch fluid (1740 gallons)
3) Obtain a piece (about 30 inches) of high grade, gasoline
resistant rubber tubing, such as driveway alarm bell No. 2 tank 60-inch fluid (5300 gallons)
hose. Clamp this securely to the end of the 1/4-inch Differential level (H) = 36 inches = 3 feet
tubing. Flow rate at 3 feet differential head = 56 GPM
4) Insert the pump back into the tank, just far enough to Average flow rate = 56/2 = 28 GPM
pass the motor through the top of the tank, and hold the
pump right there. Gallons to equalize 5300-1740 = 1780 gallons
5) Insert the rubber tubing down alongside the 1-1/2 inch 2
vertical pipe and into the tank, also. Time to level (approx.) 1780 gal. = 64.5 min.
6) Now, replace the upper end of the 1/4-inch tube back into 28 g/m
position from which it was removed.
This solution assumes velocity and therefore flow rate to be
7) Securely clamp the 1/4-inch pipe to the 1-1/2 inch pipe
linear, which it is not. It is actually parabolic, but for estimating
at both top and bottom ends.
purposes the linear assumption will give an adequate answer.
8) Next, lower the submersible pump all the way into the
tank and lock it in place securely by replacing all bolts,
etc. In so doing, the rubber end of the air-eliminator
Approximate Priming Time
syphon will extend to, or near, the bottom of the tank.
The time shown in the chart is based on two-inch piping, two
9) Turn on power supply and pump five or ten gallons
tanks, ten feet of horizontal syphon piping, and the fluid levels
through each dispenser to purge air from the system.
approximately equal. If the levels are not equal, an average may
10) Repeat test No. 2. Check the Syphon Check Valve. With
be used for estimating purposes.
the rubber tube extension hanging below the pump
intake and possibly right on the bottom of the tank, the
Chart No. 2
vacuum on the vacuum gauge will hold a value equal to
the fluid column indefinitely, with the pump turned off,
Distance to Fluid Level-Feet Time to Prime-Minutes
and assuming there are no leaks in the piping.
1.0' 2.0
2.0' 2.3
3.0' 2.7
4.0' 3.0
5.0' 3.3
6.0' 3.7
7.0' 4.0
8.0' 4.3

40 RJ 5190© 3/93
 Syphon Systems
Engineering Report (cont.)

SYPHON LINE MUST PITCH UPWARD

A MIN. OF 1/8" PER FT. OF LINE FROM
ADDITIONAL TANKS TO POINT OF
CONNECTING TUBING
BUSHING FOR CONNECTION OF TUBING
FILL PIPE
TUBE MUST BE CONNECTED VENT LINE
TO HIGH POINT OF SYPHON
MINIMUM 3/8" TUBING & FITTINGS 1 1/2" SYPHON LINE (MINNIMUM)
FURNISHED BY CUSTOMER
FILL PIPE
REMOVE 3/8" PIPE PLUG FROM VENT LINE
SYPHON CHECK VALVE &
INSTALL COPPER TUBING TO
HIGH POINT OF SYPHON

SUBMERSIBLE PUMP

PUMP DISCHARGE
OUTLET LINE TO SYPHON "U"
DISPENSERS VERTICAL PIPE

SYPHON LINE FROM

ADDITIONAL TANKS
WHERE REQUIRED
3"

RJ 5190© 3/93 41
Syphon Systems
Engineering Report (cont.)

VACUUM GAUGE IN HG

VALVE NO 1 VALVE NO 2

To High Point of
To Syphon Connection Syphon Loop
of Pump

CLEAR PLASTIC
SHROEDER VALVE

FIGURE 1 — VACUUM TEST

ACCURATE PRESSURE GAUGE

VALVE NO 1 VALVE NO 2

To High Point of
To Syphon Connection Syphon Loop
of Pump

SHROEDER VALVE

FIGURE 2 — PRESSURE TEST

42 RJ 5190© 3/93
 Syphon Systems
Parts List

“EXTRACTA” MODELS P33R1, P75S1 & P150S1

Effective March 1, 1991, the following changes were implemented on the
subject units.

STANDARD “EXTRACTA” UNITS are shipped less syphon capability

unless specifically ordered (less the coupling, and the 1/4" syphon pipe,
that is attached to the “S” pipe leading from the bottom of the manifold and
to the column pipe by steel bands, as well as the syphon check valve). This
does not affect the operation of the unit in non-syphon installations.
Syphon capability is an optional add-on.

UNITS ORDERED WITH SYPHON will be shipped with the syphon

coupling, pipe and syphon check valve complete.

FIELD RETROFIT SYPHON KIT

A field retrofit syphon kit is available in order to provide syphon
capability to pumps already in the field. The retrofit part number is
144-106-5.

BIG-FLO® MODELS
UNITS ORDERED WITH SYPHON will be shipped with items listed
below. These items are also available in a field retrofit kit, part number
144-056-5.
2
SYPHON CHECK VALVE 1 3
3/8" ELBOW Item Description Part No.
1 Brass Elbow 027-138-1 4
BRASS ELBOW 8
1/4" X 3/8" REDUCER
BUSHING
2 Syphon Check Valve 188-079-5
12
PACKING NUT 3 3/8" Elbow 027-068-1 6
13
EXTRACTOR 4 Reducer Bushing 027-065-1 7
NIPPLE SEAL
5 3/8" Coupling 027-122-1 5
EXTRACTOR GASKET 6 Packing Nut 060-048-1
NIPPLE
1/4" X 11-1/2" PIPE
7 Gasket 031-097-1 8
8 1/4" x 11-1/2" Nipple 065-073-1 13
PACKER 5
SYPHON INJECTOR NOZZLE 9 Syphon Nozzle 058-029-3
O-RING 10 O-Ring 072-110-1 13
PACKER SYPHON INJECTOR BODY 11 Syphon Injector Body 008-167-3
MANIFOLD
12 Reducer Coupling 027-027-1 9

13 3/8" x 24" Pipe 065-523-3 10

Packer O-Rings 072-108-1 11

RJ 5190© 3/93 43
Syphon Systems
Illustration

SYPHON CHECK VALVE

PACKER ASSEMBLY

MANIFOLD

“S” PIPE

COUPLING

RISER PIPE

1/4" SYPHON PIPE

STEEL BAND & CLIP

DISCHARGE HEAD

44 RJ 5190© 3/93
 Syphon Systems
T roubleshooting

Symptom Probable Cause Suggested Action

Use of the test apparatus (Fig. #1, Pg. 42) with the instructions (beginning Pg. 38) are recommended as the
NOTICE
most efficient method of determining the cause for malfunction.
Total or partial loss of vacuum and/or Obstruction in syphon nozzle, venturi (#1) Remove nozzle & venturi clean &
pressure reading at vacuum line. or air flexible wire down air eliminator tubing. reinstall. Run eliminator tubing (#2).*
4" Vent closing screw on functional Adjust to full-up position.
element not all the way up (#3).

Vacuum will not hold. Malfunction syphon check valve (#4).* Test same, replace if defective.
(See engineering report pg. 38.)
*Excessive sediment on the bottom of the tank can cause reoccurrence of this problem. Turbulence occurring during filling of the tank
places this sediment in suspension, allowing it to be drawn into the functional element via the vacuum line or the pressure relief system.
Removal of sediment from tank bottom may be necessary.

RJ 5190© 3/93 45
Syphon Systems
Notes

46 RJ 5190© 3/93
 Section
Floating Suction & Dual Pumps
Manifolded to Same Discharge System4

RJ 5190© 3/93 47
Floating Suction
Recommended Installation
Red Jacket supplies the
RECOMMENDED FLOA TING NOTICE
adapter only; not the appa-
ratus.
SUCTION INST ALLA TION
NOTICE Red Jacket petroleum and
solvent pumps are centrifu-
gal type pumps and as such
are not designed to pump
Manhole:
product when the level is
Opening for Gauging
Should be larger than manhole
welded on tank. Keep area and Adjusting Cable below the bottom end of the
open down to tank. pump/motor assembly.

14" Approx.
4" Approx. 1-1/2" Nipple
1-1/2" by 2" Bell Reducer
2" Nipple

• The floating suction arm can be mounted to • Easy service access is provided by unbolting
pump previous to installing in tank. manhold lid through which pump is mounted and
removing entire assembly.
See example of adaptation to floating suction
assembly below.

1-1/2"
3" N.P.T.
N.P.T.
Male
14" Female
14" Thread
Thread

Bottom of the Tank

Bottom of the Tank

4" Petroleum Adapter 6" Petroleum Adapter

Adaptation to Floating Suction Assembly Use proper thread sealant and insert gasket be-
(use standard NPT threaded fittings). tween flanges of floating suction and pump.

48 RJ 5190© 3/93
 Floating Suction
Adapter for Pumps Manufactured Prior to9/1/82

Units manufactured after this date cannot be retrofitted. If floating suction

adapter is desired, unit must be ordered equipped with same.

1. Remove cap (A) (no longer needed) by inserting tool under edge and prying upware (i.e., screwdriver, chisel, etc.).
2. Remove all screws (B & C); save for reuse.
3. Remove in order of appearance, spacers (D, E, F) last. The solid ring (G) “O” ring retainer is not to be removed.
4. Place gasket* on top of (G) ring.
5. Place floating suction adapter on gasket.
6. Replace in reverse order, as removed, spacers (F, E, D).
7. Replace screws (C & B) in original position and tighten as specified on drawing.

*Use ring (G) as a template and construct gasket of any gasoline resistant 1/8" gasket stock. A good improvision is to
remove the center from a discharge head gasket part no. 031-136, shown as item 28 on page 3 of 4" Petroleum Pump
Parts List in this manual.

NOTICE Apply sealant to threads. Torque 27-33 inch/lbs.

G F E G F E

D D

B
B

C C

D
G D
E G F E
F

RJ 5190© 3/93 49
Dual Pumps
4" Pump Installation

Installing dual submersibles manifolded in the same system. Fig. 2

This type of system is often used when greater flow rates are
needed. If installed according to the illustration below (Fig. 1),
manifolded systems offer back-up support in that operations
could continue should one unit fail.

WARNING Proper check valves, with pressure relief,

must be installed in the discharge line of
each pump to prevent product from being
pumped through the pressure relief sys-
tem of the adjacent pump when it is not
running. Check valves must be compat-
ible with the fuel blend being pumped.

This diagram (Fig. 2) shows the wiring allowing both

submersibles to operate simultaneously with any combination
of dispensers turned on. To operate individually, the appropri-
ate toggle switch, located externally on the side of the control
box must be turned off manually. The check valves and 220/240
volt relay are not available from Red Jacket and should be
purchased locally. 115 V. RELAY
DISPENSER SW
ALLEN BRADLEY
700-C201

Suggested diagram for wiring dual manifold system.

PRESSURE RELIEF
TYPE CHECK VALVES
Fig. 1 (Set at approximately
40 PSI on 4" pumps)

NOTICE The drawing shown here is to

illustrate the requirement for
in-line pressure relief type
check valves. It is not a recom-
mended guide for installation
of piping downstream of the
check valves.

50 RJ 5190© 3/93
 Dual Pumps
®
6" Big-Flo Pump Installation

INST ALLING DUAL BIG-FLO ® SUBMERSIBLES

MANIFOLDED IN THE SAME SYSTEM
This type of system is often used when greater flow rates the expansion relief valve operates at below pump pres-
are needed. If installed according to the illustration below sures. If check valves without pressure relief were used,
(Fig. IX), manifolded systems offer back-up support in there would be no provision for thermal expansion be-
that operations could continue should one unit fail. tween the valves and the dispensers.

The check valves shown installed in the discharge line of It is preferable that the wiring allow both submersibles to
each pump are necessary to prevent product from being operate simultaneously with any combination of dispens-
pumped through the pressure relief system of the adja- ers turned on. To operate individually, the appropriate
cent pump, if that pump is not running. This is because switch could be turned off manually.

PRESSURE RELIEF
Fig. IX TYPE CHECK VALVES
(Set at approximately
50 PSI on 6" pumps)

NOTICE The drawing shown here is to

illustrate the requirement for
in-line pressure relief type
check valves. It is not a recom-
mended guide for installation
of piping downstream of the
check valves.

RJ 5190© 3/93 51
Floating Suction & Dual Pumps
Notes

52 RJ 5190© 3/93
 Section
W arranty5

For complete details

on Red Jacket’s
Warranty Policy and Procedures,
see Manual #5194.

RJ 5190© 3/93 53
W arranty
Procedur es
OUR PROMISE OF QUALITY:
The Marley Pump Company, a division of the Marley 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 Labor
From Date of From Date of
Product Manufacture Installation*
Submersibles 18 Months 12 Months
Except:
Solvent Pumps 6 Months 3 Months

Leak Detectors 18 Months 6 Months

Retractors 6 Months None

Electronic Systems 18 Months 6 Months

Except:
Vapor Probes 6 Months None

* 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 CONNEC-
TION WITH THIS PRODUCT, INCLUDING WITHOUT LIMITATION PURCHASER’S LOSS OF STORED LIQUIDS
OR DAMAGE TO THE GROUND, UNDERGROUND OR ENVIRONMENT, WHETHER ARISING UNDER THEO-
RIES 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.

54 RJ 5190© 3/93
 W arranty
Location of Date Codes

DATE CODES PRIOR TO JANUARY 1, 1978

The location of the date code stamp is shown on the opposite side of this letter. On pumps manufactured prior
to January 1978, the date code was stamped as shown below, using a letter code system.

Year J F M A M J J A S O N D
1972 AG BG CG DG EG FG GG HG KG LG MG NG
1973 AH BH CH DG EG FG GH HH KH LH MH NH
1974 AK BK CK DK EK FK GK HK KK LK MK NK
1975 AL BL CL DL EL FL GL HL KL LL ML NL
1976 AM BM CM DM EM FL GM HM KM LM MM NM
1977 AN BN CN DN EN FN GN HN KN LN MN NN

DATE CODES AFTER JANUARY 1, 1978

To eliminate the necessity of checking the above cross-reference table, all pumps manufactured after January
1, 1978, use the following date code system.

Example — 1 01 78

Year of Manufacture (1978)

Month of Manufacture (January)

Week of Month of Manufacture (1st Week)

RJ 5190© 3/93 55
W arranty
Notes

For Additional Assistance,

Contact theTechnical Support Group-Petroleum Products
The Marley Pump Company
5800 Foxridge Drive
Mission, KS 66202
Phone: 1-800-2-MARLEY
(1-800-262-7539)

56 RJ 5190© 3/93
 W arranty
Notes

RJ 5190© 3/93 57
W arranty
Notes

58 RJ 5190© 3/93
 Section
Floating Suction & Dual Pumps
Manifolded to Same Discharge System4

RJ 5190© 3/93 47
Floating Suction
Recommended Installation
Red Jacket supplies the
RECOMMENDED FLOA TING NOTICE
adapter only; not the appa-
ratus.
SUCTION INST ALLA TION
NOTICE Red Jacket petroleum and
solvent pumps are centrifu-
gal type pumps and as such
are not designed to pump
Manhole:
product when the level is
Opening for Gauging
Should be larger than manhole
welded on tank. Keep area and Adjusting Cable below the bottom end of the
open down to tank. pump/motor assembly.

14" Approx.
4" Approx. 1-1/2" Nipple
1-1/2" by 2" Bell Reducer
2" Nipple

• The floating suction arm can be mounted to • Easy service access is provided by unbolting
pump previous to installing in tank. manhold lid through which pump is mounted and
removing entire assembly.
See example of adaptation to floating suction
assembly below.

1-1/2"
3" N.P.T.
N.P.T.
Male
14" Female
14" Thread
Thread

Bottom of the Tank

Bottom of the Tank

4" Petroleum Adapter 6" Petroleum Adapter

Adaptation to Floating Suction Assembly Use proper thread sealant and insert gasket be-
(use standard NPT threaded fittings). tween flanges of floating suction and pump.

48 RJ 5190© 3/93
 Floating Suction
Adapter for Pumps Manufactured Prior to9/1/82

Units manufactured after this date cannot be retrofitted. If floating suction

adapter is desired, unit must be ordered equipped with same.

1. Remove cap (A) (no longer needed) by inserting tool under edge and prying upware (i.e., screwdriver, chisel, etc.).
2. Remove all screws (B & C); save for reuse.
3. Remove in order of appearance, spacers (D, E, F) last. The solid ring (G) “O” ring retainer is not to be removed.
4. Place gasket* on top of (G) ring.
5. Place floating suction adapter on gasket.
6. Replace in reverse order, as removed, spacers (F, E, D).
7. Replace screws (C & B) in original position and tighten as specified on drawing.

*Use ring (G) as a template and construct gasket of any gasoline resistant 1/8" gasket stock. A good improvision is to
remove the center from a discharge head gasket part no. 031-136, shown as item 28 on page 3 of 4" Petroleum Pump
Parts List in this manual.

NOTICE Apply sealant to threads. Torque 27-33 inch/lbs.

G F E G F E

D D

B
B

C C

D
G D
E G F E
F

RJ 5190© 3/93 49
Dual Pumps
4" Pump Installation

Installing dual submersibles manifolded in the same system. Fig. 2

This type of system is often used when greater flow rates are
needed. If installed according to the illustration below (Fig. 1),
manifolded systems offer back-up support in that operations
could continue should one unit fail.

WARNING Proper check valves, with pressure relief,

must be installed in the discharge line of
each pump to prevent product from being
pumped through the pressure relief sys-
tem of the adjacent pump when it is not
running. Check valves must be compat-
ible with the fuel blend being pumped.

This diagram (Fig. 2) shows the wiring allowing both

submersibles to operate simultaneously with any combination
of dispensers turned on. To operate individually, the appropri-
ate toggle switch, located externally on the side of the control
box must be turned off manually. The check valves and 220/240
volt relay are not available from Red Jacket and should be
purchased locally. 115 V. RELAY
DISPENSER SW
ALLEN BRADLEY
700-C201

Suggested diagram for wiring dual manifold system.

PRESSURE RELIEF
TYPE CHECK VALVES
Fig. 1 (Set at approximately
40 PSI on 4" pumps)

NOTICE The drawing shown here is to

illustrate the requirement for
in-line pressure relief type
check valves. It is not a recom-
mended guide for installation
of piping downstream of the
check valves.

50 RJ 5190© 3/93
 Dual Pumps
®
6" Big-Flo Pump Installation

INST ALLING DUAL BIG-FLO ® SUBMERSIBLES

MANIFOLDED IN THE SAME SYSTEM
This type of system is often used when greater flow rates the expansion relief valve operates at below pump pres-
are needed. If installed according to the illustration below sures. If check valves without pressure relief were used,
(Fig. IX), manifolded systems offer back-up support in there would be no provision for thermal expansion be-
that operations could continue should one unit fail. tween the valves and the dispensers.

The check valves shown installed in the discharge line of It is preferable that the wiring allow both submersibles to
each pump are necessary to prevent product from being operate simultaneously with any combination of dispens-
pumped through the pressure relief system of the adja- ers turned on. To operate individually, the appropriate
cent pump, if that pump is not running. This is because switch could be turned off manually.

PRESSURE RELIEF
Fig. IX TYPE CHECK VALVES
(Set at approximately
50 PSI on 6" pumps)

NOTICE The drawing shown here is to

illustrate the requirement for
in-line pressure relief type
check valves. It is not a recom-
mended guide for installation
of piping downstream of the
check valves.

RJ 5190© 3/93 51
Floating Suction & Dual Pumps
Notes

52 RJ 5190© 3/93
 Section
W arranty5

For complete details

on Red Jacket’s
Warranty Policy and Procedures,
see Manual #5194.

RJ 5190© 3/93 53
W arranty
Procedur es
OUR PROMISE OF QUALITY:
The Marley Pump Company, a division of the Marley 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 Labor
From Date of From Date of
Product Manufacture Installation*
Submersibles 18 Months 12 Months
Except:
Solvent Pumps 6 Months 3 Months

Leak Detectors 18 Months 6 Months

Retractors 6 Months None

Electronic Systems 18 Months 6 Months

Except:
Vapor Probes 6 Months None

* 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 CONNEC-
TION WITH THIS PRODUCT, INCLUDING WITHOUT LIMITATION PURCHASER’S LOSS OF STORED LIQUIDS
OR DAMAGE TO THE GROUND, UNDERGROUND OR ENVIRONMENT, WHETHER ARISING UNDER THEO-
RIES 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.

54 RJ 5190© 3/93
 W arranty
Location of Date Codes

DATE CODES PRIOR TO JANUARY 1, 1978

The location of the date code stamp is shown on the opposite side of this letter. On pumps manufactured prior
to January 1978, the date code was stamped as shown below, using a letter code system.

Year J F M A M J J A S O N D
1972 AG BG CG DG EG FG GG HG KG LG MG NG
1973 AH BH CH DG EG FG GH HH KH LH MH NH
1974 AK BK CK DK EK FK GK HK KK LK MK NK
1975 AL BL CL DL EL FL GL HL KL LL ML NL
1976 AM BM CM DM EM FL GM HM KM LM MM NM
1977 AN BN CN DN EN FN GN HN KN LN MN NN

DATE CODES AFTER JANUARY 1, 1978

To eliminate the necessity of checking the above cross-reference table, all pumps manufactured after January
1, 1978, use the following date code system.

Example — 1 01 78

Year of Manufacture (1978)

Month of Manufacture (January)

Week of Month of Manufacture (1st Week)

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For Additional Assistance,

Contact theTechnical Support Group-Petroleum Products
The Marley Pump Company
5800 Foxridge Drive
Mission, KS 66202
Phone: 1-800-2-MARLEY
(1-800-262-7539)

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