Veeder-Root Red Jacket Maxxum Big-Flo Quick-Set Series, Red Jacket Maxxum Big-Flo Quick-Set P200R1 Installation, Operation & Service Manual

D051-301, Rev. V

Installation, Operation, & Service

Maxxum® Big-Flo

®

6” Submersible Pump

Red Jacket® Quick-Set® Submersible Pump

Notice

Veeder-Root makes no warranty of any kind with regard to this publication, including, but not limited to, the implied warranties of
merchantability and fitness for a particular purpose.

Veeder-Root shall not be liable for errors contained herein or for incidental or consequential damages in connection with the
furnishing, performance, or use of this publication.

Veeder-Root reserves the right to change system options or features, or the information contained in this publication.

This publication contains proprietary information which is protected by copyright. All rights reserved. No part of this publication
may be photocopied, reproduced, or translated to another language without the prior written consent of Veeder-Root.

Contact Red Jacket Technical Support for additional troubleshooting information at 800-323-1799.

DAMAGE GOODS/LOST EQUIPMENT

Thoroughly examine all components and units as soon as they are received. If any cartons are damaged or missing, write a
complete and detailed description of the damage or shortage on the face of the freight bill. The carrier's agent must verify the
inspection and sign the description. Refuse only the damaged product, not the entire shipment.

VR must be notified of any damages and/or shortages within 30 days of receipt of the shipment, as stated in our Terms and
Conditions.

VEEDER-ROOT’S PREFERRED CARRIER

1. Fax Bill of Lading to V/R Customer Service at 800-234-5350.

2. Call V/R Customer Service at 800-873-3313 with the specific part numbers and quantities that were received damaged or
lost.

3. VR will file the claim with the carrier and replace the damaged/missing product at no charge to the customer. Customer
Service will work with production facility to have the replacement product shipped as soon as possible.

CUSTOMER’S PREFERRED CARRIER

1. Customer files claim with carrier.

2. Customer may submit a replacement purchase order. Customer Service will work with production facility to have the
replacement product shipped as soon as possible.

3. If “lost” equipment is delivered at a later date and is not needed, VR will allow a Return to Stock without a restocking fee.

4. VR will NOT be responsible for any compensation when a customer chooses their own carrier.

RETURN SHIPPING

For the parts return procedure, please follow the instructions in the “General Returned Goods Policy” pages of the “Policies and
Literature” section of the Veeder-Root North American Red Jacket Mechanical Products Price Book. Veeder-Root will not accept
any return product without a Return Goods Authorization (RGA) number clearly printed on the outside of the package.

 Veeder-Root 2017. All rights reserved.

Introduction

Safety Precautions ............................................................................................................1

Warnings and Instructions ................................................................................................3

IMportant Safety Information ....................................................................................3

Preliminary Precautions............................................................................................3

Requirements For Use .............................................................................................4

Operating Precautions..............................................................................................4

Fuel Compatibilities ..........................................................................................................4

Installation

Installation Safety Notices Attention Installer ....................................................................5

Follow These Directions Carefully ....................................................................................6

Installing The Pumping Unit ..............................................................................................6

Attaching the Expansion Relief Vent Line .........................................................................7

Wiring the Conduit Box .....................................................................................................8

Wiring Instructions- 208-230 Volt Single Phase Pumps ...........................................9

Wiring Instructions - 208-230, 380/415 or 575 Volt Three-Phase Pumps ................9

Starting the System and Completing the Installation ......................................................16

Floating Suction Installation Information .........................................................................19

Installing A Big Flo Diaphragm Valve ..............................................................................20

Attaching the Siphon & Vacuum Lines with Factory Installed Siphon Assemblies .........22

Installing Two Pumps for Tandem Operation ..................................................................23

Table of Contents

Testing the Installation

Testing the Piping ...........................................................................................................26

Testing the Tank .............................................................................................................27

Purging the System ........................................................................................................27

Adjusting the Pressurstat Line Relief Pressure ...............................................................28

Service and Repair

Removing the Extracta Assembly ...................................................................................29

Procedure for Removal of Plug-in Type Pump - Motor Assembly ..................................30

Installing the Extracta Assembly (Ref. Figure 19) ...........................................................31

Replacing the Check Valve Assembly ............................................................................33

Repairing the Check Valve Lock-down Screw And Seals ...............................................34

Parts

6” Maxxum Big Flo - Repair Parts Packer Manifold Assembly Parts - Side View ...........37

6” Maxxum Big Flo - Repair Parts Packer Manifold Assembly Parts - Top View ............38

6” Maxxum Big Flo - Repair Parts Yoke Assembly .........................................................39

UL Listed Motor Control Box For 2HP Pumps Model P200H1-CB .................................40

Red Jacket Replacement Pump Motors .........................................................................41

Magnetic Contactor For 2, 3, And 5 HP 3-Phase Pumps ...............................................41

Appendix A: ATEX Safety Instructions

Appendix B: Declaration of Conformity

Appendix C: FDNY Certificate of Approval

Appendix D: ANZe Conditions of Certification

iii

Figures

Table of Contents

Figure 1. Maxxum Packer-Manifold Assembly .......................................................7

Figure 2. Conduit Box - Yoke Assembly ................................................................8

Figure 3. Typical Mechanical Dispenser Representative Wiring Diagram,

1-Phase, Two-Wire Control ..................................................................11

Figure 4. Typical Mechanical Dispenser Motor Control Box, Wiring

Diagram, 2HP .......................................................................................12

Figure 5. Representative Wiring Diagram For Use With Switched

“Hot” Feed 208-230 Vac, 2HP Single-Phase Control Box ....................13

Figure 6. Representative Wiring Diagram, Three-Phase, Two-Wire Control .......14

Figure 7. Three-Wire, Three-Phase Motor Wiring Diagram .................................15

Figure 8. ..............................................................................................................16

Figure 9. ..............................................................................................................19

Figure 10. ..............................................................................................................21

Figure 11. ..............................................................................................................22

Figure 12. ..............................................................................................................23

Figure 13. Suggested Diagram For Wiring Dual Manifold System,

Two-Wire Control, 208/230 Single Phase .............................................24

Figure 14. Suggested Diagram For Wiring Dual Manifold System,

Three-Wire Control, 208/230 Single Phase ..........................................24

Figure 15. Suggested Diagram For Wiring Dual Manifold System,

Two-Wire Control, Three Phase ...........................................................25

Figure 16. Suggested Diagram For Wiring Dual Manifold System,

Three-Wire Control, Three Phase .........................................................25

Figure 17. Maxxum Packer-Manifold Assembly: Line And Tank Testing ...............26

Figure 18. Pressurstat - Pressure Adjustment .......................................................27

Figure 19. Maxxum - Extractable Section ..............................................................29

Figure 20. UMP - Discharge Head Assembly ........................................................32

Figure 21. Maxxum Check Valve Assembly ..........................................................33

Figure 22. Pressurstat And Check Valve Lock-Down Screw Assembly ................35

Figure 23. Check Valve And Pressurstat Assembly ..............................................36

Figure 24. Check Valve And Electrical Bushing Assembly ....................................37

Figure 25. Maxxum Packer-Manifold Assembly .....................................................38

Figure 26. Maxxum Yoke and Contractors Box Assembly .....................................39

Figure 27. 2HP, 1-Phase Control Box ....................................................................40

Tables

Table A. ..................................................................................................................5

Table B. ................................................................................................................17

Table C. ................................................................................................................17

Table D. ................................................................................................................18

Table E. ................................................................................................................30

Table F. ................................................................................................................32

Table G. ................................................................................................................36

Table H. ................................................................................................................37

Table I. ................................................................................................................38

Table J. ................................................................................................................39

Table K. ................................................................................................................40

Table L. ................................................................................................................41

Table M. ................................................................................................................41

iv

Introduction

OFF

WARNING

CAUTION

NOTICE

This manual provides step-by-step instructions for installing and wiring the Maxxum pump, tandem Maxxum pumps,
pump testing procedures, and pump service and repair.

Safety Precautions

The following safety symbols are used throughout this manual to alert you to important safety hazards and
precautions.

EXPLOSIVE

Fuels and their vapors are extremely explosive
if ignited.

ELECTRICITY

High voltage exists in, and is supplied to, the
device. A potential shock hazard exists.

WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.

NO SMOKING

Sparks and embers from burning cigarettes or
pipes can ignite fuels and their vapors.

EYE PROTECTION

Wear eye protection when working with pres­surized fuel lines or epoxy sealant to avoid pos­sible eye injury

READ ALL RELATED MANUALS

Knowledge of all related procedures before you
begin work is important. Read and understand
all manuals thoroughly. If you do not understand
a procedure, ask someone who does.

FLAMMABLE

Fuels and their vapors are extremely flammable.

TURN POWER OFF

Live power to a device creates a potential shock
hazard. Turn Off power to the device and associ­ated accessories when servicing the unit.

GLOVES

Wear gloves to protect hands from irritation or
injury.

NO OPEN FLAMES

Open flames from matches, lighters, welding
torches, etc. can ignite fuels and their vapors.

TURN OFF CELL PHONES/PAGERS

Sparks from electronic devices in the vicinity of
gasoline storage tanks could cause an explosion
or fire resulting in bodily injury or death.

CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.

NOTICE is used to address practices not
related to physical injury..

1

Introduction Safety Precautions

OFF

WARNING

This product operates in the highly combustible atmosphere of a gasoline storage
tank.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY
PRECAUTIONS COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT,
RESULTING IN SERIOUS INJURY OR DEATH.

1. All installation work must comply with the latest issue of the National
Electrical Code (NFPA 70), the Code for Motor Fuel Dispensing Facilities and
Repair Garages (NFPA 30A), and any European, national, state, and local
code requirements that apply.

2. Turn off, tag, and lockout power to the STP before connecting or servicing the
STP.

3. Before installing pipe threads apply an adequate amount of fresh, UL
classified for petroleum, non-setting thread sealant.

4. When servicing unit, use non-sparking tools and use caution when removing
or installing equipment to avoid generating a spark.

5. To protect yourself and others from serious injury, death, or substantial
property damage, carefully read and follow all warnings and instructions in
this manual.

In addition to the specified torque values noted in this manual, when properly tightened, all flanged fittings should
have metal-to-metal contact.

2

Introduction Warnings and Instructions

WARNING

WARNING

Warnings and Instructions

IMPORTANT SAFETY INFORMATION

This section introduces the hazards and safety precautions associated with installing,
inspecting, maintaining or servicing this product. Before performing any task on this
product, read this safety information and the applicable sections in this manual, where
additional hazards and safety precautions for your task will be found. Fire, explosion,
electrical shock or pressure release could occur and cause damage to property,
environment, resulting in serious injury or death, if these safe service procedures are
not followed.

PRELIMINARY PRECAUTIONS

You are working in a potentially dangerous environment of flammable fuels, vapors,
and high voltage or pressures. Only trained or authorized individuals knowledgeable in
the related procedures should install, inspect, maintain or service this equipment.

Read the Manual

Read, understand and follow this manual and any other la
you do not understand a procedure, call 1-800-323-1799 to locate a qualified technician. It is imperative to your
safety and the safety of others to understand the procedures before beginning work. Make sure your

employees and any service contractors read and follow the instructions.

Follow the Regulations

Applicable information is available in National Fire Protection Association (NFPA) 30A; Code for Motor Field
Dispensing Facilities and Repair Garages, NFPA 70; National Electrical Code (NEC), Occupational Safety and

Hazard Association (OSHA) regulations and federal, state, and local codes. All these regulations must be
followed. Failure to install, inspect, maintain or service this equipment in accordance with these codes, regulations
and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment.

Prevent Explosions and Fires

Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels cause vapors. Even filling customer
tanks will cause potentially dangerous vapors in the vicinity of the dispenser or island.

Working Alone

It is highly recommended that someone who is capable of rendering first aid be present during servicing.
Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, if you work with or around high voltages.
This information is available from the American Red Cross. Always advise the station personnel about where you
will be working, and caution them not to activate power while you are working on the equipment. Use the OSHA
Lockout/Tagout procedures. If you are not familiar with this requirement, refer to OSHA documentation.

Working With Electricity Safely

Ensure that you use safe and established practices in working with electrical devices. Poorly wired devices may
cause a fire, explosion or electrical shock. Ensure that grounding connections are properly made. Ensure that you
do not pinch wires when replacing covers. Follow OSHA Lockout/Tagout requirements. Station employees and
service contractors need to understand and comply with this program completely to ensure safety while the
equipment is down. Before you start work, know the location of the Emergency Power Cutoff Switch (the E­STOP). This switch cuts off power to all fueling equipment and submerged turbine pumps and is to be used in the
event of an emergency. The buttons on the console at the cashier’s station WILL NOT shut off electrical power to
the pump/dispenser. This means that even if you press a button on the console labeled EMERGENCY STOP,
ALL STOP, PUMP STOP, or something similar, fuel may continue to flow uncontrolled.

bels or related materials supplied with this equipment. If

3

Introduction Fuel Compatibilities

WARNING

Hazardous Materials

Some materials may present a health hazard if not handled correctly. Ensure that you clean hands after handling
equipment. Do not place any equipment in the mouth.

FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY
PRECAUTIONS COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT, RESULTING
IN SERIOUS INJURY OR DEATH.

FIRE HAZARD! Do NOT use power tools (Class I Division I and Class I Division II) during the installation or

maintenance of equipment. Sparking could ignite fuel or vapors, resulting in fire.

CHEMICAL EXPOSURE HAZARD! Wear appropriate safety equipment during installation or maintenance of
equipment. Avoid exposure to fuel and vapors. Prolonged exposure to fuel may cause severe skin irritations and
possible burns.

REQUIREMENTS FOR USE

• The Maxxum is designed for use only at facilities dispensing motor fuels.

• Application of the Maxxum must be consistent with NFPA Code 30A, OSHA regulations, and federal, state and
local fire codes, and other applicable local regulations.

• The selection of any Veeder-Root product must be based upon physical specifications and limitations and the
product’s compatibility with the materials to be handled. Veeder-Root makes no warranty of fitness for a
particular purpose.

• All Veeder-Root products should be used in accordance with applicable federal, state and local laws,

ordinances and regulations.

OPERATING PRECAUTIONS

• NO SMOKING. Extinguish all open flames and pilot lights, such as on RV appliances.

• TURN OFF cell phones and other electronic devices to avoid distractions while fueling.

Fuel Compatibilities

Pumps are designed to operate in a Class 1, Group D atmosphere and in accordance with CENELEC standard
and the European Directive 94/9/EC “Equipment for Potentially Explosive Atmoshpere” (II2 G Ex IIA T4).

All Models of the Maxxum are UL Listed for the Following Fuel Compatibility

Gasoline and up to

15%

Diesel Gasoline

Ethanol

The Maxxum is designed to be compatible with 100 percent gasoline, or diesel and 80 percent gasoline with 20
percent methanol, ethanol, TAME, ETBE, or MTBE .

15%

Methanol

20%

MTBE

20%

ETBE

20%

TAME

4

Installation

WARNING

This pumping system requires the following elements:

1. Discharge Manifold Assembly - Installed below grade (NEC/Class I, Group D, Division I area)

2. Motor-Pump Unit Assembly - Installed below grade (NEC/Class I, Group D, Division I area)

3. Control Box/Magnetic Starter

An “all inclusive” name plate will be found attached to the Extracta Head and can be inspected by removing
the manhole cover directly over the pump.

An additional name plate will be found on the control box. It is important to give the model number and serial
number of this pump when corresponding with the factory for any reason.

INSTALLATION SAFETY NOTICES ATTENTION INSTALLER

Read This Important Safety Information Before Beginning Work.

1. Units should be installed with manholes, or with discharge manifold casting above grade, to allow for ease in

servicing.

Red Jacket line leak detection systems do not function if the submersible pump runs
continuously. Running a pump continuously will cause line leak detection systems to
not function which results in a hazard that can cause damage to property, environment,
resulting in serious injury or death.

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 information below, 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. The recommended minimum bypass
per unit is shown in Table A.

Table A.

60 Hz, 208-240, 575 Volt

Two Stage Units

P200J1-2MB = 15 GPM P300J17-3HB = 20GPM

P200J4-2MB = 15 GPM P500J17-3K = 25 GPM

P300J4-2HB = 20 GPM P300J16-3HB = 20GPM

P500J4-2K = 25 GPM P500J16-3K = 25 GPM

P200J6-2K = 25 GPM

50 Hz 380-415 Volt

Three Stage Units

3. Red Jacket submersibles are not designed to handle abrasives or foreign particles in the product being

pumped.

4. Product temperature must never exceed 105°F (41°C) as the submersible motors are equipped with thermal

overload protection. Product temperature higher than 105°F (41°C) may result in tripping of the thermal
overload protector.

5

Installation Follow These Directions Carefully

WARNING

WARNING

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 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.

8. The UMP (Unitized-Motor-Pump) contains no serviceable parts (other than the foot valve) and should not be

modified or adjusted.

Follow These Directions Carefully

Check these points before installing.

1. The power supply against the equipment voltage rating. For 3 phase units, request the power company identify

and tag the service wires for L-1, L-2, L-3 phase sequence.

2. Be certain that the pump with the siphon valve is installed into the correct tank.

3. Check the equipment which was received against Table B and Figure 8 for the tank diameter and bury depth.

Before installing pipe threads apply an adequate amount of fresh, UL classified for pe­troleum, non-setting thread sealant.

4. Apply thread sealant to the six-inch riser/flange male threads. Thread it into the tank port. Tighten the riser/

flange until the joint is water tight.

Installing The Pumping Unit

1. Apply a gasket compound to the bottom surface of the manifold and press the gasket onto the manifold’s

mating surface so the holes in the gasket and manifold align (reference Figure 1).

2. Coat the exposed surface of the gasket with gasket compound.

WARNING

3. Insert three 3/4-inch bolts, provided, and torque them to 200 ft-lb (271 N•m).

Confirm that the lifting eyebolts are properly torqued to 10 ft-lbs (13.6 N•m) with a
minimum of 6 full threads installed. Occasionally, eyebolts are removed after pump in­stallation and corrosion may occur in the threaded areas of the extractable and the
eyebolt. If corrosion has occurred, the extractable and eyebolt should be replaced.

Utilize BOTH lifting eyebolts to suspend the pump vertically and lower the pumping
unit into position. Do not allow the gasket to contact the riser flange until the bolt
holes in the flange are aligned with those in the manifold and the discharge port is
aimed in the desired direction.

6

Installation Attaching the Expansion Relief Vent Line

Lifting eyes

Bolt torque 200 ft-lb. (3 places)

Manifold

Vent line

6" NPT riser
flange

3" NPT or BSP
discharge port

rj/051-301-1.eps

WARNING

NOTICE

Attaching the Expansion Relief Vent Line

1. Remove the metal protective shipping caps from the flare fittings (reference Figure 1).

2. Attach the vent line taking care not to cross thread the fittings.

3. Tighten the fittings 1/6 to 1/4 turn beyond hand tight.

4. Install the piping to the manifold discharge port. Pipe sealant should be used in this joint.

Line check-valves are not required since the pump has a built in check-valve. However, whenever two pumps are
manifolded together to the same discharge piping, check valves with expansion relief are required and should be
installed in the discharge piping of each pump, as close to the pump manifold as possible.

See instructions “INSTALLING TWO PUMPS FOR TANDEM OPERATION” and Figure 12.

Figure 1. Maxxum Packer-Manifold Assembly

Before installing pipe threads apply an adequate amount of fresh, UL classified for pe­troleum, nonsetting thread sealant.

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.

7

Installation Wiring the Conduit Box

(1" Conduit)
Conduit from control box

Power and thermal overload
leads to pump

O-ring

Ground wire

Ground wire screw

1. For European installations, the End User must
use an ATEX EEX d IIB certified cable gland or
stopping box.

2. Use suitable AUS EX, ANZEx or IECEx certified
cable gland or flameproof entry device when
equipment is installed in accordance with ANZEx
certification for connection of the external circuit
conductors to the motor conductors used to close
the 1" NPT conduit connection.

Cup washer terminal

External toothed washer

rj/051-301-2.eps

WARNING

OFF

WARNING

Wiring the Conduit Box

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

1. Connect the electrical conduit through the approved fittings to the conduit box.

2. Remove the conduit box cover.

3. Connect the wires from the power supply to the wires in the conduit box.

4. Install the gound wire from the power panel.

5. Sparingly lubricate the o-ring before screwing the cover into the manifold. Use light grease, oil, or petroleum

jelly. Replace the conduit box cover. Do not use pipe sealant on the conduit box cover’s threads. Torque to 35
ft-lb (50 N•m).

Figure 2. Conduit Box - Yoke Assembly

Disconnect, lock out, and tag power at the panel before servicing the
pump.

8

Installation Wiring the Conduit Box

CAUTION

NOTICE

Wiring Instructions- 208-230 Volt Single Phase Pumps

The motor control box must be located away from the fueling area in a non-hazardous location (see Figure 3).

1. Connect the single phase 208-230 V power supply from the distribution panel to terminals L1 and L2 in the

motor control box. Each control box should be wired through a separate fused disconnect switch or circuit
breaker (including neutral, when used), furnished by customer.

2. Using properly color coded wires, connect wires from the red, black, orange and two blue terminals on motor

control box terminal strip to the corresponding color coded wires in the junction box of the proper submerged
pump.

The “on-off” control station must be of explosion-proof construction. Where loading racks and dispensers are
served by the same submerged pump, the 2-wire switches must be connected in parallel so the submerged
pump can be controlled from any dispenser or any loading rack.

3. Connect wires from terminal Blue-1 and terminal 3 in motor control box to dispenser control switches (if

dispensers are used) and “on-off” switch at loading rack as shown in Figure 3.

4. The pumps are equipped with a no-liquid, over-temperature switch in the motor and an overload switch in the

motor control box which will cut out if the motor is overloaded. If the pump fails to operate, or stops, when
there is sufficient product in the storage tank, check the manual overload reset switch in the control box cover.
Wait 10 minutes for the overload protector to cool off and then press the reset button.

If the reset button will not stay in position this indicates an overloaded motor, or a
short to ground. This condition must be corrected. If the reset button stays in but the
motor will not pump or continue to run, the tank is dry.

5. If an external pilot light is desired to indicate when the submerged pump is operating, wire as shown in

Figure 3, Figure 4 or Figure 5. Should this light continue to burn when all switches atdispensers and loading
racks are off, this indicates that one of the dispenser switches is out of adjustment. On installations with no
external pilot light, the submerged pump should be checked to make sure it is not operating when all switches
are turned off.

6. The magnetic contactor coil is shipped ready to accept 208-230 volts. No changes are required unless a 110-

120 volt coil is desired.

Wiring Instructions - 208-230, 380/415 or 575 Volt Three-Phase Pumps

On some installations, “phase converters” are used to obtain a three-phase power supply
from a single-phase power source. The use of phase converters may cause an imbalance
between the three phases and cause damage to the motor. For this reason, these
requirements must be followed in order to maintain warranty coverage.

• Static phase converters must not be used. Only rotary or electric phase converters are
allowed.

• The horsepower rating of the phase converter must be equal to at least three times the
horsepower rating of the pump(s).

• Current imbalance must not exceed 10% under varying flow conditions.

• Proper three-leg quick trip overloads must be used.

1. Installations where the magnetic starter is located away from the loading rack in a nonhazardous location. (See
Figure 6)

a. Connect the three phase power supply from the master panel to terminals L1, L2 and L3 in the magnetic

starter.

b. Using properly color coded wires, connect a black wire from terminal T1 in the magnetic starter to the

black motor lead, in the junction box of the proper submerged pump. Connect an orange wire from starter
terminal T2 to the orange motor lead and red wire from terminal T3 to the red motor lead. (See Figure 6
and Figure 7.)

9

Installation Wiring the Conduit Box

NOTICE

WARNING

c. There are two remaining blue wires in the submerged pump junction box. Connect either blue wire to one

side of the ‘on-off’ controls or switched ‘hot’ from the electronic dispenser or Isotrol (dispenser handle
isolation). The ‘on-off’ controls must be of explosion-proof construction if located in a hazardous location.
Connect the other blue wire to the appropriate terminal on the other side of the ‘on-off’ controls. See
specific wiring diagrams provided with the magnetic starters matching pump voltage, coil voltage and type
of pump control.

d. Installations using loading racks only, may be connected for 2- or 3-wire control. For 3-wire control

(Figure 7), connect a black wire from terminal 3 in the magnetic starter to the ‘on-off’ switch. Connect a
red wire from terminal 2 in the magnetic starter to the ‘on-off’ switch. Connect either blue wire to the other
side of the ‘on-off’ switch and connect the other blue wire to L1 of the magnetic starter.

3-wire control requires the use of an auxiliary contact in the magnetic starter. This auxiliary
contact is standard equipment in the G.E. starters supplied by Red Jacket.

Installations with the magnetic starter in a hazardous location require explosion-proof
magnetic starters. The wiring is the same as for general purpose enclosures. (Section

1).

2. Install proper overload heaters in magnetic starter matching starter manufacturer and amperage rating of the

pump.

3. Motor Rotation

Where it is not convenient to predetermine the power supply phase rotation, proper rotation can be deter­mined by pump performance. Pump head pressure and capacity will be considerably less than rated when ro­tating backwards.

Connect the pump motor leads to terminal T1, T2 and T3 of the magnetic starter observing color code shown
in Figure 6 and Figure 7. With ample product in the tank and the system purged of air, start the motor and
make a pressure gauge reading of the system pressure with the discharge valves closed; or, open one valve
and calculate pumping rate.

Next, reverse power leads at L1 and L2. Repeat either pressure or capacity tests, as described above. If re­sults are higher than the first test, the rotation of the second test is correct. If the second test gives lower per­formance than the first, reconnect the power leads to L1 and L2 (as under test 1) for correct rotation.

Where the power supply has been properly marked L1, L2 and L3 in accordance with accepted phase rota­tion standards, it is possible to predetermine the proper rotation of these units. The motor power leads are col­or coded black, orange and red, and if connected through the magnetic starter to L1, L2 and L3 respectively,
the motor pump unit will rotate in the correct direction. It is recommended, however, that the performance
tests always be made whether or not the power supply has been properly “phased out”.

10

Installation Wiring the Conduit Box

LINE

1

230V

115 115

LINE

2

ORANGE

BLACK

RED
BLUE
BLUE

1
2

3

EXT

PILOT

Grey

White

Seal

Seal

(Blue)1

Orange
Black

Red

(Black)3

On/Off
switch

To neutral of

115/230V

supply

Black

Customers 115V external

pilot light 50W max.

To neutral of
115/230V supply

The control box
must be grounded
for personal safety.
Refer to the National
Electrical Codes and
applicable local codes
for proper grounding
procedures.

115V Lighting circuit
(where needed) from
distribution panel

Locate seals where
required by local code

Motor control
and pilot light
circuit

Lighting circuit

Dial and dome lights

Pilot light 115V, 50W max.

Double pole motor switch

Blue

rj/051-301-3.eps

P200R1, 208-230V, 2HP
SINGLE PHASE

Figure 3. Typical Mechanical Dispenser Representative Wiring Diagram, 1-Phase, Two-Wire Control

11

Installation Wiring the Conduit Box

230V

115

Low liquid

protector

Two wire control

115V External

pilot light

(50W max.)

Three wire control

115

Motor

Stop
Start

Orange

Blue

Black

Black

Blue

Red

Red

Blue

Line

1

Line

2

Orange

Black

Red

Blue

Blue

1
2

3

Ext

pilot

BLUE

1
2

3

Blue

Black

Black

Red

Orange

White

White

Black

Black

Blue

L2

L1

T1 T2

Black

White

Red

Red

Red

Starting relay

L3

T3

2

5

Red

1

Contactor coil
terminals

Contactor

Overload relay
reset button

Running
capacitor

White

Starting
capacitor

WARNING

Approved component only - total system installed
shall comply with all local codes. Make Ground
Connection In Accordance With Local Codes.

The control box must be grounded for personal
safety. Refer to the National Electrical Codes and
applicable local codes for proper grounding
procedures.

Ground screw

Figure 4. Typical Mechanical Dispenser Motor Control Box, Wiring Diagram, 2HP

12

Installation Wiring the Conduit Box

Line

1

230V

115

Line

2

Orange

Orange

Black

White

White

White

Starting relay

Starting
capacitor

Running
capacitor

Overload relay
reset button

Contactor

Contactor coil
terminals

1

5

2

T3

L3

L2

L1

T1 T2

White

Orange

Red

Red

Red

Black

115V

Coil

Red

Black
Black

Black

Blue

Blue

Black

Black

Red

Red

Blue

Blue

Motor

Blue

Blue

1
2

3

Ext

pilot

Ground screw

Hot

115V External

pilot light

(50W max.)

Low liquid

protector

115

208-230, 2HP 1Ø CONTROL BOX

1. Remove red wire (coil to L2).

2. Relocate orange wire at L1 to coil.

3. Change to 115V coil assembly.

The control box must be grounded for personal
safety. Refer to the National Electrical Codes and
applicable local codes for proper grounding
procedures.

Approved component only - total system installed
shall comply with all local codes. Make Ground
Connection In Accordance With Local Codes.

WARNING

Figure 5. Representative Wiring Diagram For Use With Switched “Hot” Feed 208-230 Vac, 2HP Single-Phase Control Box

13

Installation Wiring the Conduit Box

rj/051-301-6.eps

L1

Coil

L2 L3

T1

3

Red

Orange

Black

T2 T3

Blue

Local seals

where required

by code

Blue

BlueBlack

(2-Wire shown)

On-Off

switch

Seal

Black

No liquid protector circuit

If 115V is not available from power supply,
pilot lights may be operated from any 115V
lighting circuit by controlling with a
4-pole starter. Otherwise, 230V pilot lights
must be used.

3-PHASE POWER SUPPLY

The control box must be grounded for personal
safety. Refer to the National Electrical Codes and
applicable local codes for proper grounding
procedures.

WARNING

NOTICE

Figure 6. Representative Wiring Diagram, Three-Phase, Two-Wire Control

14

Installation Wiring the Conduit Box

L1 L2 L3

T1 T2 T3

Switch at loading rack

Stop

Start

Thermal
overload

To ext. pilot

light 115V

supply

W

V

Blue

Red

Red

Orange

Black

Blue

Blue

Black

Coil

3-PHASE POWER SUPPLY

Observe color code L1, L2, L3 phase
sequence for proper rotation of motor.

rj/051-301-9.eps

3-wire control requires the use of
an auxiliary contract in the magnetic
contactor. Furnas auxiliary interlock
field kit 49D22125001 or equivalent.

NOTICE

NOTICE

The control box must be grounded for personal
safety. Refer to the National Electrical Codes and
applicable local codes for proper grounding
procedures.

WARNING

Figure 7. Three-Wire, Three-Phase Motor Wiring Diagram

15

Installation Starting the System and Completing the Installation

36.0" Diameter

18.0" Radius

3" NPT or BSP
by contractor

6" NPT riser with
flange ordered
separately

Center

of

sump

9.6"

1.3"

4.0" Minimum

4.0"

14.6"

"A"

Bury depth

"B" Max.

riser length

"D"

"C" Tank diameter

rj/051-301-10.eps

Distance between center
line of pump motor and
centerline of fill pipe
should be 3 feet minimum.
Air locking of pump may
occur at distances less
than this distance.

NOTICE

Starting the System and Completing the Installation

1. Do not start pumps unless ample product is in the storage tank.

2. Pump sufficient product through each dispenser to purge the entire system of air. If all air is not purged, the
computers may “creep” slightly when the dispenser switch is turned on, but no product has been dispensed.

3. On pumps equipped with built-in siphon, it is necessary to run the submerged pump at least 10 to 20 minutes
continuously to purge the air from the siphon manifold.

4. After the above checks have been made, the backfill can be completed and the manholes installed as shown
in Figure 8.

Figure 8.

16

Installation Starting the System and Completing the Installation

NOTICE

Table B.

Bury

Depth

“A”

30” 10” (883-442-1) C = 72” / D = 78” C = 84” / D = 90” C = 96” / D = 102” C = 120” / D = 126” C = 144” / D = 150”

36” 16” (883-445-1) C = 72” / D = 84” C = 84” / D = 96” C = 96” / D = 108” C = 120” / D = 132” C = 144” / D = 156”

42” 21” (883-449-1) C = 72” / D = 89” C = 84” / D = 101” C = 96” / D = 113” C = 120” / D = 137” C = 144” / D = 161”

48” 27” (883-449-1) C = 72” / D = 95” C = 84” / D = 107” C = 96” / D = 119” C = 120” / D = 143” C = 144” / D = 167”

60” 36” (883-451-1) C = 72” / D = 104” C = 84” / D = 116” C = 96” / D = 128” C = 120” / D = 152” C = 144” / D = 176”

72” 51” (883-454-1) C = 72” / D = 119” C = 84” / D = 131” C = 96” / D = 143” C = 120” / D = 167” C = 144” / D = 191”

Riser Length

“B” Tank Diameters “C” / Pump Length Requirements “D”

Table C.

Model Number

Pump Motor

Assembly HP Volt Phase

UMP200J1-2MB 2 208-230 1 5.4 - 6.6 1.6 - 2.0 7.0 - 8.6 0.0 - 1.0

UMP200J4-2MB 2 208-230 3 2.6 - 3.3 2.6 - 3.3 2.6 - 3.3 0.0 - 1.0

UMP300J4-2HB 3 208-230 3 1.9 - 2.3 1.9 - 2.3 1.9 - 2.3 0.0 - 1.0

UMP300J17-3HB 3 380-415 3 7.6 - 9.3 7.6 - 9.3 7.6 - 9.3 0.0 - 1.0

UMP500J4-2K 5 208-230 3 1.0 - 1.3 1.0 - 1.3 1.0 - 1.3 0.0 - 1.0

UMP500J17-3K 5 380-415 3 4.0 - 4.9 4.0 - 4.9 4.0 - 4.9 0.0 - 1.0

UMP500J6-2K 5 575 3 6.3 - 7.6 6.3 - 7.6 6.3 - 7.6 0.0 - 1.0

NOTE: The above readings do not include the added resistance of the power supply wires to the submersible pump. Therefore, 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 sightly higher.

WARNING

Disconnect, lock out, and tag power at the panel before servicing the pump and taking
these resistance readings.

Orange to Red

Winding Resistances (Ohms)

Orange to

Black Red to Black Blue to Blue

When servicing equipment, use non-sparking tools and use caution when removing or in­stalling equipment to avoid generating a spark.

17

Installation Starting the System and Completing the Installation

Table D.

Branch Ckt.

Protection

Service

Factor

Cur.

HP Volts Phase

2 208-230* 1 12.0 61.0 20 20 172 274 929 673 1048 H

2 208-230* 3 7.2 45.0 15 15 361 574 899 1410 2197 K

3 208-230* 3 10.5 62.0 15 20 255 406 635 997 1552 K

3 380-415 3 5.4 29.0 15 15 787 1250 1956 3070 --- K

5 208-230* 3 17.2 92.0 25 30 --- 240 376 590 920 J

5 380-415 3 8.8 49.0 15 15 472 750 1173 1841 2867 G

5 575 3 7.0 37.0 15 15 929 1477 2311 3627 --- K

*Figures represent maximum length in feet for 220 or 230 volt system. Use 75% of length for 208 volt system.

(Amps) (Amps) (Amps) (Amps) No. 14 No. 12 No. 10 No. 8 No. 6

Locked

Rotor

Cur.

Fusetron

Ckt.

Brkr.

Wire Size for Max. Length of Run Shown
(From Service Entrance to Pump in Feet)

Nema

Codes

18

Installation Floating Suction Installation Information

rj/051-301-11.eps

4.0" Approx.

3" NPT male

thread

Pump

Veeder-Root only supplies
the adapter.

Red Jacket pumps are
centrifugal type and as
such are not designed to
pump product when level
is below the bottom of the
pump.

Before installing pipe
threads apply an adequate
amount of fresh, UL
classified for petroleum,
non-setting thread sealant.

1.

2.

3.

NOTICE

Floating Suction Installation Information

Figure 9.

19

Installation Installing A Big Flo Diaphragm Valve

OFF

WARNING

NOTICE

Installing A Big Flo Diaphragm Valve

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

The installation described herein is for a single pump system (reference Figure 10). If
two pumps are to be installed in tandem, contact your service representative for
instructions for your specific system.

1. Since the leak detector only checks for leaks down stream from itself it should be installed as close to the
pump as possible while still maintaining clearance for the removal of the pump check valve housing.

2. Install the “Big-Flo”diaphragm valve per the instructions included with the “Big-Flo” Diaphragm Valve.

3. Install the vent line from the FXV to the 1/4 NPT port in the six inch flange using tubing and fittings supplied
with the leak detector.

4. Test the installation per the instructions included with the “Big-Flo” diaphragm valve.

20

Installation Installing A Big Flo Diaphragm Valve

WARNING

If Big Flo valve is installed in separate sump, a
passage way must be run between the two
sumps. The FX vent line can be easily routed
back to the tank through this passage way.

48" Diameter sump

3" NPT flanged Big Flo
valve (117-182-5). To be
used in conjunction with the
FX Series Leak Detector.

11.0" 13.0"

1.5"

2.0"

sump

Center of

16.5"

18.3"

1.8"

20.5"

riser

Center of

4" Min.

3" NPT Ball valve
(recommended for
service)

FX leak detector
vent line

Figure 10.

Storage

tank

6" NPT
Flanged
riser

21

Installation Attaching the Siphon & Vacuum Lines with Factory Installed Siphon Assemblies

rj/051-301-13.eps

Vacuum line minimum
3/8" tubing to high
point of piping system

Minimum 2" NPT siphon line by
contractor must pitch upward (to
tank with pump) about 1/8" per foot.

3" (76mm)

3" NPT line
to dispenser

3" (76mm)

Vent pipe

Fill
pipe

Fill
pipe

3/8" NPT elbow

3/8" Bushing

1/4" NPT
nipple

Siphon
nozzle

3/8" tubing
elbow

3/8" tubing
provided by
contractor

Siphon line
check valve

OFF

WARNING

NOTICE

WARNING

Figure 11.

Attaching the Siphon & Vacuum Lines with Factory Installed Siphon Assemblies

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

1. Remove the 1/4 inch pipe plug from the siphon nozzle.

Care should be taken to insure that the internal portions of the siphon nozzle and parts in­cluded in the siphon kit are clean and free of debris or contamination during assembly.

Before installing pipe threads apply an adequate amount of fresh, UL classified for pe­troleum, non-setting thread sealant.

2. Coat both of the male threads of the 1/4 X 2 inch long nipple with pipe sealant. Thread one end of the nipple
into the siphon nozzle and the other end into the 1/4 x 3/8 inch reduction bushing.

3. Apply pipe sealant to the male threads of the reduction bushing and thread it into the 3/8 inch female elbow.

4. Apply pipe sealant to the male threads of the siphon check valve and thread it into the 3/8 inch female elbow.

5. Apply pipe sealant to the male pipe threads of the compression fitting elbow and thread it into the 1/4 inch
hole in the siphon check valve.

22

Installation Installing Two Pumps for Tandem Operation

WARNING

NOTICE

Installing Two Pumps for Tandem Operation

When greater flow rates are needed, two pumps may be required in the same piping system by means of a
manifold. If they are installed according to the illustration, a tandem system offers backup support so operations
can continue if one pump stops working. Install the pump as outlined above with the following additions.

1. If a siphon system is required, each pump must have 3/8 inch siphon vacuum line attached to the same
location on the siphon line (reference Figure 11).

Adjust the Pressurstat (see “Adjusting the Pressurstat Line Relief Pressure” on
page 28) on both packers to maximum relief pressure by rotating fully clockwise. If
maximum pump pressures are NOT a minimum of 5 psi below the Pressurstat relief
setting then proper check valves with pressure relief are required to be installed in the
discharge line of each pump to prevent product from being pumped through the pres­sure relief system of the adjacent pump when it is not operating. Readjust the Pres­surstat to the desired pressure relief value for proper operation of the siphon system.

Installation of a ball valve is recommended on the discharge side of the pressure relief check
valve. This will aid in troubleshooting and line testing.

Figure 12 illustrates the requirement for in-line, pressure relief type check valves. It is not a
recommended guide for installation of piping downstream of the check valves.

As an option, install ball
valves downstream for
trouble shooting and
maintenance

WARNING

The check valves shown installed in
the discharge line of each pump are
necessary to prevent product from
being pumped through the pressure
relief system of the adjacent pump, if
that pump is not running. This is
because the expansion relief valve
operates at below pump pressures. If
check valves without pressure relief
were used, there would be no
provision for thermal expansion

between the valves and the
dispensers.

rj/051-301-14.eps

Figure 12.

23

Installation Installing Two Pumps for Tandem Operation

BL2

2

XPL

Dispenser Sw.

115V Relay

Allen Bradley

700C201

NEU

3

BL2

2

XPL

NEU

3

115V

PUMP 2PUMP 1

rj/051-301-15.eps

BL2

2

XPL

115V Relay

Allen Bradley

700C201

Switch at loading rack

NEU

3

BL2

XPL

NEU

3

2

115V

PUMP 1 PUMP 2

rj/051-301-16.eps

Start

Stop

It is preferable that the wiring allow both submersibles to operate simultaneously with any combination of
dispensers turned on. To operate individually, the appropriate disconnect switch must be turned off manually. (See
Figure 13 through Figure 16 for suggested wiring diagrams.)

Figure 13. Suggested Diagram For Wiring Dual Manifold System, Two-Wire Control, 208/230 Single Phase

Figure 14. Suggested Diagram For Wiring Dual Manifold System, Three-Wire Control, 208/230 Single Phase

24

Installation Installing Two Pumps for Tandem Operation

Coil

L1 L2 L3

T1 T2 T3

Coil

L1 L2 L3

T1 T2 T3

Thermal overload

Dispenser sw.

Relay

Blue

Blue

Blue

Blue

Red

Orange

Black

Red

Orange

Black

Thermal
overload

To ext. pilot

light 115V

supply

To ext. pilot

light 115V

supply

Voltage rating of relay coil
must match power supply.

rj/051-301-17.eps

PUMP 2PUMP 1

Observe color code L1, L2, L3 phase
sequence for proper rotation of motor.

NOTICE

NOTICE

L1 L2 L3

T1 T2 T3

Thermal overload

Blue

Blue

Red

Orange

Black

Thermal
overload

To ext. pilot

light 115V

supply

To ext. pilot

light 115V

supply

208/230V or 400V

three-phase power supply

Switch at loading rack

rj/051-301-18.eps

PUMP 2PUMP 1

Coil

L1 L2 L3

T1 T2 T3

Blue

Blue

Red

Orange

Black

Coil

Stop

Start

Voltage rating of relay coil
must match power supply.

Observe color code L1, L2, L3 phase
sequence for proper rotation of motor.

NOTICE

NOTICE

Figure 15. Suggested Diagram For Wiring Dual Manifold System, Two-Wire Control, Three Phase

Figure 16. Suggested Diagram For Wiring Dual Manifold System, Three-Wire Control, Three Phase

25

Testing the Installation

OFF

WARNING

WARNING

1" NPT port

1/4" NPT line test port

Two 1/4" NPT tank test ports

(180 degrees apart)

Check valve

lockdown screw

Screw out

(normal position)

Screw in for

line and tank

pressure testing

rj/051-301-19.eps

Testing the Piping

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

1. Block the lines at each dispenser. (Trip the dispenser shear valve.)

2. Lock down the pump check valve by turning the check valve lock down screw clockwise as far as it will turn
(see Figure 17).

3. Remove the 1/4” NPT line test port plug and apply the line test pressure at the line test port (50 psi (345 kPa)
maximum).

Excessive pressure (above normal test pressure of 50-55 psi (345-380 kPa) may dam­age the pump check valve seat and other system components.

4. After the completion of the test, release the pressure by:
a. Turning the check valve lock down screw counter clockwise as far as it will go.

b. Remove the protective cover from the Pressurstat (see Figure 18) and turn the Pressurstat adjustment

screw counter clockwise until the screw protrudes 3/4”, this will relieve the line pressure to “0” psi.
Apply an adequate amount of fresh, UL classified for petroleum, non-setting thread sealant on the 1/4”

NPT line test port plug and replace it. Torque the plug to 14 - 24 ft-lbs (19.4 - 29 N•m).
Adjust desired relief pressure per instructions on page 28 and replace the protective cover.

5. If applicable, unblock lines at each dispenser.

Figure 17. Maxxum Packer-Manifold Assembly: Line And Tank Testing

26

Testing the Installation Testing the Tank

OFF

WARNING

rj/051-301-20.eps

Protective cover

Adjustment screw
(as shown 0 - 3 psi setting)

Testing the Tank

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

1. Lock down the pump check valve by turning the check valve lock down screw clockwise as far as it will turn
(see Figure 17).

2. Remove the Tank Test Plug from the riser flange.

3. Apply tank test pressure at the tank test port.

4. After the completion of the test, release the pressure by:

a. Turning the check valve lock down screw counter clockwise as far as it will go.

b. Remove the protective cover from the Pressurstat (see Figure 18) and turn the Pressurstat adjustment

screw counter clockwise until the screw protrudes 3/4”, this will relieve the line pressure to “0” psi.

Apply an adequate amount of fresh, UL classified for petroleum, non-setting thread sealant on the 1/4”
NPT line test port plug and replace it. Torque the plug to 14 - 24 ft-lbs (19.4 - 29 N•m).

Adjust desired relief pressure per instructions on page 28 and replace the protective cover.

Purging the System

1. Pump a minimum of fifteen gallons (57 liters) of product through each dispenser.

2. Start with the dispenser furthest from the pump and work toward the pump.

Figure 18. Pressurstat - Pressure Adjustment

27

Testing the Installation Adjusting the Pressurstat Line Relief Pressure

Adjusting the Pressurstat Line Relief Pressure

NOTICE

Pressurstat line relief pressure is the line pressure after the pump stops.

1. All pumps are factory set to a line relief pressure of 23-28 psi (160-195 kPa).

2. Remove the protective cover (see Figure 18).

3. Adjust the relief pressure to the desired level. Turning the adjusting screw clockwise will increase the line relief
pressure. With the adjusting screw fully down the line relief pressure should be from 40 to 45 psi. With the
adjusting screw all the way up the pressure should be from 0 to 3 psi.

4. The line relief pressure can be verified in three locations:

a. The pressure can be observed from the control unit of the electronic line leak detector.

b. The pressure can be observed by attaching a gauge to the impact valve.

c. The pressure can be observed by attaching a gauge to the line test port.

5. After setting the desired line relief pressure replace the protective cap. DO NOT USE PIPE SEALANT.
Lubricate the o-ring with petroleum jelly. Tighten to just snug after the protective cover has fully bottomed out.

28

Service and Repair

OFF

WARNING

WARNING

1/2-13 Hex bolt

5/8-11 Hex bolt

Protective cover

Yoke-disconnect
(disengaged and
rotated)

Check valve lockdown
screwed in (optional)

Lifting eyes

Removing the Extracta Assembly

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

1. If a ball valve is installed down line from the pump, close it.

2. Unscrew the 5/8-inch bolt and pull the yoke up and rotate it 90° counterclockwise (see Figure 19).

3. Remove the protective cover from the Pressurstat. Rotate the adjustment screw counterclockwise to relieve pressure in
the packer/manifold assembly.

4. Unscrew and remove the four 1/2-inch Extracta retaining bolts.

Confirm that the lifting eyebolts are properly torqued to 10 ft-lbs (13.6 N•m) with a
minimum of 6 full threads installed. Occasionally, eyebolts are removed after pump in­stallation and corrosion may occur in the threaded areas of the extractable and the
eyebolt. If corrosion has occurred, the extractable and eyebolt should be replaced.

Utilize BOTH lifting eyebolts to suspend the pump vertically. A vertical lift will ensure
that the o-ring in the manifold will not be damaged. Remove the pumping unit and
place it on a clean surface.

Removal of the extractable section of the pump must be conducted with caution. Make
certain that the extractable section remains centered within the riser pipe and that no
portion of the extractable binds during the removal process. If binding occurs during
removal, stop and determine the cause of the binding and correct the situation before
proceeding with removal

.

Figure 19. Maxxum - Extractable Section

29

Service and Repair Procedure for Removal of Plug-in Type Pump - Motor Assembly

WARNING

WARNING

NOTICE

Procedure for Removal of Plug-in Type Pump - Motor Assembly

NOTICE

Not all installed pump/motor units will have a locknut securing the pump shell. Steps 3A and
11 can be skipped if no locknut is present.

The UMP (Unitized-Motor-Pump) contains no serviceable parts (other than the foot valve)
and should not be modified or adjusted.

1. Place pump in a horizontal position on a clean surface.

2. Block up under the 3-inch column pipe so that the pump/motor assembly is about 2 inches above supporting
surface.

3A. If a locknut is present; loosen setscrew in locknut. Unscrew the locknut from the discharge head. Slide the

adapter tube up to expose the four hex head machine bolts.

3B. Loosen and remove the four hex head machine bolts on the top of the pumping unit just above the shell and

around the motor.

4. Do not let the pump roll. Using your hands, (do not use a wrench) hold pump at the extreme bottom end and
use a slight up and down motion to pull the pump from the casting attached to the 3-inch pipe.

Up and down motion to remove the pump unit should not be greater than 1/4 inch.
Motion greater than 1/4 inch could damage a positioning dowel pin in the top of the
motor.

5. If the motor leads tend to stay plugged into the motor, finish removing the motor until the leads can be pulled
out of the top of the motor by hand (this is a “plug in” type connection). Verify the number of wires. If there are
only three wires, the pigtail and conduit seal must be replaced with the proper 5-wire version.

6. Pull the pigtail connector in the discharge head out far enough to see the o-ring in the sidewall of its socket.
Remove the connector’s o-ring from the connector’s socket and discard it. Get a 1.234” ID x 0.139” (-218 P/
N 072-712-1) wide o-ring and lubricate it with petroleum jelly. Slide the new o-ring over the pigtail connector
and push it in the groove in the wall of the connector’s socket. Lubricate the pigtail connector body with
petroleum jelly and push it back into its socket, making sure the index tab is in the socket’s notch.

Table E.

HP Pigtail Buna Seal Seal & Pigtail Kit

3 213-065-4 110-038-4 213-065-5

5 213-069-4 110-038-4 213-069-5

Installed pump/motor units with 3-wire pigtails must be upgraded to the proper 5-wire
pigtail and conduit seal assemblies.

7. Remove the block from the top of the new pump/motor.

8. Look at bottom of the discharge head casting which remains screwed to the 3-inch pipe. Note the position of
the one hex head bolt. Place the four machine bolts through the four bolt holes.

One hole (180 degrees away from the hex head) remains open, this is the locating pin hole.

9. Find the locating pin on top of the motor. This pin must go into the remaining open hole referred to in notice
following Step 8.

10. Place the new pump/motor assembly in position by starting the locating pin into the hole referred to above.
Gently push the motor into place until the shell starts to pass over the large “O”ring. Position the four machine
bolts into the bolt holes and start threads. Draw all bolts down evenly until all are snug. After all bolts are snug,
torque bolts to 24-34 ft-lbs (32-46 N•m).

30

Service and Repair Installing the Extracta Assembly (Ref. Figure 19)

WARNING

OFF

WARNING

WARNING

Draw all bolts down evenly until all are snug. This will help avoid damaging the con­nector and dowel pin.

11. If a locknut is present; slide the adapter tube down over the discharge head so that it sets against the shell.
Thread the locknut onto the discharge head and tighten until the adapter tube is firmly held in place against
the pump shell. Torque the locknut to 55-75 ft-lbs (75-102 N•m). Torque the setscrew in the locknut to 25-50
in-lbs (2.8-5.6 N•m).

Installing the Extracta Assembly (Ref. Figure 19)

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

1. Replace the lower o-ring (see Figure 24, Item #4) in the manifold and the one in the lower face of the Extracta
head (see Figure 24, Item #3).

2. Sparingly lubricate the lower o-ring located in the inside the manifold and the o-ring in the lower face of the
Extracta head. Use light grease, oil, or petroleum jelly.

Confirm that the lifting eyebolts are properly torqued to 10 ft-lbs (13.6 N•m) with a
minimum of 6 full threads installed. Occasionally, eyebolts are removed after pump in­stallation and corrosion may occur in the threaded areas of the extractable and the
eyebolt. If corrosion has occurred, the extractable and eyebolt should be replaced.

Utilize BOTH lifting eyebolts to suspend the pump vertically. Lower the Extracta into
position through the manifold assembly. Care should be taken to keep the unit as near
to vertical as possible to avoid damaging the o-rings. Start the four 1/2 inch Extracta
retaining bolts. DO NOT TIGHTEN THEM AT THIS TIME.

3. Rotate the yoke-disconnect into position so that the brass boss aligns with the disconnect port in the packer
assembly.

4. Tighten the 5/8 inch bolt to fully engage the yoke.

5. Torque the four 1/2 inch Extracta retaining bolts to 50 ft lbs.(68 N•m).

6. Torque the 5/8 inch bolt to 50 ft lbs.(68 N•m).

7. Rotate the adjustment screw on the Pressurstat to reset line relief pressure.

8. Lubricate the o-ring on the Pressurstat with petroleum jelly and install the protective cover by rotating it until it
contacts the Pressurstat body. Hand tightening is sufficient, as the o-ring completes the seal.

9. Visually inspect the pumping unit for leaks while the pump is running. This is to ensure that no seals or sealing
surfaces were damaged during removal or installation of the Extracta assembly.

31

Service and Repair Installing the Extracta Assembly (Ref. Figure 19)

rj/051-301-22.eps

Figure 20. UMP - Discharge Head Assembly

Table F.

Number Required

Item Part No. Description

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

2 213-065-5 Pigtail & Conduit Seal - 2, 3, HP 1 1 --

2 213-069-5 Pigtail & Conduit Seal - 5 HP -- -- 1

3 072-712-1 Pigtail O-ring 1 1 1

4 072-714-1 Motor Shell O-ring 1 1 1

5 026-179-1 Bolt - 3/8-16 x 1 Hex 1 1 1

6 072-309-1 Receptacle Housing O-ring 1 1 1

7 031-328-1 Gasket Bolt 8 8 8

8 026-110-1 Lockwasher 3/8” Spring 4 4 4

9 579025-004 Bolt - 3/8-16 x 2-3/16 Hex-Gr. 5 4 4 4

10 038-241-1 Housing Pigtail 1 1 1

11 026-448-1 Set Screw Fastener - 1/4” 2 2 2

NS 001-157-3 Floating Suction Adaptor - HB -- 1 --

2 HP 3 HP 5 HP

NS 001-026-3 Floating Suction Adaptor - K -- -- 1

NS 001-158-3 Floating Suction Adaptor - MB 1 -- --

Only the parts listed above are available for repairs of the lower end of the pump. If any other parts need replacing,
order Red Jacket pump-motor assemblies. See page 33 for ordering numbers.

32

Service and Repair Replacing the Check Valve Assembly

OFF

WARNING

WARNING

rj/051-301-23.eps

1/2-13 Hex bolt

O-ring

Check valve

Vent line

Thread
protector

Pressure
adjustment
screw

Protective
cover

Replacing the Check Valve Assembly

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

Close the ball valve in the discharge line if it has been installed.

Care should be taken to ensure that the internal portions of the vent line and check
valve assembly are clean and free of debris or contamination during servicing.

1. Relieve system pressure by removing the protective cover and then backing out the pressure adjustment
screw (see Figure 21).

2. Disassembly

a. Loosen or disconnect the lower vent line fitting.

b. Disconnect the upper vent line fitting.

c. Remove the four 1/2 inch hex bolts.

d. Pull the check valve housing assembly straight out of the manifold.

Figure 21. Maxxum Check Valve Assembly

33

Service and Repair Repairing the Check Valve Lock-down Screw And Seals

OFF

WARNING

WARNING

3. Assembly

a. Be certain the two o-rings on the sealing face of the check valve housing are in place.

b. Lower the check valve assembly back down into the manifold taking care not to damage the rubber seal

on the check valve assembly.

c. Install the four 1/2 inch bolts. Torque these bolts to 50 ft-lbs (68 N•m).

d. Remove and discard the thread protector.

e. Re-attach the upper vent fitting then tighten both the upper and lower fittings1/6 to 1/4 turn beyond hand

tight.

4. Readjust the pressure adjustment screw to the desired pressure setting.

5. Replace the protective cover.

6. If applicable, open ball valve down line from the pump.

Repairing the Check Valve Lock-down Screw And Seals

Disconnect, lock out, and tag power at the panel before servicing the
pump.

When servicing equipment, use non-sparking tools and use caution when removing or installing
equipment to avoid generating a spark.

Care should be taken to ensure that the internal portions of the check valve housing
are clean and free of debris or contamination during servicing.

1. Close the ball valve in the discharge line if it has been installed.

2. Lock down screw removal (see Figure 22).

a. Remove the four wiper housing retaining screws.

b. Lift off the wiper housing from the lock-down screw.

c. Remove the wiper from the wiper housing. Avoid damaging the bores in the housing.

d. Unscrew the lock-down screw and remove it from the check valve housing.

3. Lock-down screw re-installation.

a. Replace the two o-rings on the lock-down screw. These o-rings should be installed from the non-threaded

end of the lock-down screw so as to avoid nicking or damaging the o-rings.

b. Sparingly lubricate the two o-rings before screwing the lock-down screw into the check valve housing.

Use light grease, oil, or petroleum jelly.

c. Using a flat piece of metal at least 1/2 inch larger than the OD of the wiper, carefully drive the new wiper

into the wiper housing, orienting the wiper as shown in Figure 22.

d. Sparingly lubricate the wiper ID lip before sliding it over the lock-down screw onto the check valve

housing. Use light grease, oil, or petroleum jelly.

e. Re-install the four #6 wiper housing retaining screws and torque to 20 in-lb (2.23 N•m).

4. If applicable, open the ball valve in the discharge line if it has been installed.

34

Service and Repair Repairing the Check Valve Lock-down Screw And Seals

rj/051-301-24.eps

Protective cover

Adjustment screw

Pressurstat body

Spring
Plunger

Diaphragm

Lockdown screw

#8 Screw

Wiper seal

Wiper housing

O-ring

O-ring

1/4 Screws w/
lockwashers

Vent line disconnected
and rotated out of the way

NOTICE

Figure 22. Pressurstat And Check Valve Lock-Down Screw Assembly

35

Parts

rj/051-301-25.eps

8

9

1
2

3
4

7

6
5

Figure 23. Check Valve And Pressurstat Assembly

Table G.

Item Part No. Description Qty.

1 076-447-1 Screw - Adjustment 1

2 080-944-1 Spring - Expansion Relief 1

3 067-278-1 Plunger 1

4 017-573-1 Diaphragm - Expansion Relief 1

5 072-642-1 O-Ring (-112) 1

6 072-699-1 O-Ring (-240) 1

7 026-752-1 Lockwasher 4

8 026-748-1 Screw - Hex Socket 4

9 072-684-1 O-Ring (-910) 1

36

Parts 6” Maxxum Big Flo - Repair Parts Packer Manifold Assembly Parts - Side View

rj/051-301-26.eps

1

2

6

3

4
5

6” Maxxum Big Flo - Repair Parts Packer Manifold Assembly Parts - Side View

Figure 24. Check Valve And Electrical Bushing Assembly

Table H.

Item Part No. Description Qty.

1 144-320-5 Kit - Lock Down Screw 1

2 144-317-5 Kit - Check Valve 1

3 072-695-1 O-Ring (-366) 1

4 072-696-1 O-Ring (-439) 1

5 031-334-1 Gasket Flange 1

6 144-321-5 Kit - 5 Wire Bushing 1

37

Parts 6” Maxxum Big Flo - Repair Parts Packer Manifold Assembly Parts - Top View

rj/051-301-27.eps

9

7

8

12

10 - Not shown

1

2

11

3, 3A
shown with
siphon plug
installed

4

5

6

6” Maxxum Big Flo - Repair Parts Packer Manifold Assembly Parts - Top View

Figure 25. Maxxum Packer-Manifold Assembly

Table I.

Item Part No. Description Qty.

1 036-470-1 Handle - Lifting 2

2 026-750-1 Bolt - Hex 1/2-13 x 1-1/2 6

3 144-307-5 Kit - Siphon Components 1

3a 066-163-3 Plug - Siphon Plug 1

4 026-759-1 Bolt - Hex 3/4-10 x 1-3/4 3

5 086-010-1 Line - Steel Vent 1

6 027-240-1 Plug - Square 1/4 NPT 1

7 027-276-1 Fitting - Tube 2

8 026-757-1 Bolt - Hex 1/2-13 x 1 4

9 067-265-1 Plug - 2” NPT With O-Ring 1

10 072-686-1 O-Ring (-228) 1

11 072-642-1 O-Ring (-112) 1

12 144-322-5 Kit-Expansion Relief 1

38

Parts 6” Maxxum Big Flo - Repair Parts Yoke Assembly

rj/051-301-28.eps

6

1

2

3

4

5

6” Maxxum Big Flo - Repair Parts Yoke Assembly

Figure 26. Maxxum Yoke and Contractors Box Assembly

Table J.

Item Part No. Description Qty.

1 072-700-1 O-Ring (-223) 1

2 072-689-1 Internal Retaining Ring 1

3 114-319-5 Kit - 5 Wire Connector Assembly 1

4 072-710-1 O-Ring (-130) 1

5 072-697-1 External Retaining Ring 1

6 110-064-5 Conduit Box Assembly - 5 Wire 1

39

Parts UL Listed Motor Control Box For 2HP Pumps Model P200H1-CB

rj/051-301-29.eps

UL Listed Motor Control Box For 2HP Pumps Model P200H1-CB

Figure 27. 2HP, 1-Phase Control Box

Table K.

Item Part No. Description Qty.

1 108-403-1

2 071-047-1 Starting Relay (3ARR3-J3V2) 1

3 071-061-1 Line Contactor Relay 1

4 011-085-1 Starting Capacitor (200MFD-250 Volt) 1

5 012-253-1 Running Capacitor (15MFD-370 Volt) 1

6 008-180-1 Terminal Block 1

7 071-062-1 Overload Protector (Cutler Hammer 10-2149) 1

8 023-009-1

P200H1-CB Complete General Purpose Motor Control Box
(4” D x 10.125” W x 15.125” L) 1

Overload Protector Heater Element (Cutler Hammer 10177H­33A) (P200H1-CB) 1

40

Parts Red Jacket Replacement Pump Motors

WARNING

Red Jacket Replacement Pump Motors

Table L.

Ordering

Number Model Number HP Length in. (mm) Weight lbs. (kg) Volts Phase

UMP

882-839-5 UMP-P200J1-2MB 2 32.1 (815) 116 (53) 208-230 1

882-840-5 UMP-P200J4-2MB 2 29.6 (752) 116 (53) 208-230 3

882-842-5 UMP-P300J4-2HB 3 34.3 (871) 120 (54) 208-230 3

882-211-5 UMP-P500J4-2K 5 42.5 (1080) 162 (74) 208-230 3

883-434-5 UMP-P300J17-3HB 3 37.4 (950) 125 (57) 380-415 3

886-511-5 UMP-P500J17-3K 5 47.0 (1200) 167 (76) 380-415 3

883-226-5 UMP-P500J6-2K 5 41.1 (1050) 162 (74) 575 3

UMP WITH DISCHARGE HEAD

883-460-5 UMP-P300J17-3HB W/DH 3 40.1 (1020) 380-415 3

886-454-5 UMP-P500J17-3K W/DH 5 49.7 (1270) 380-415 3

Magnetic Contactor For 2, 3, And 5 HP 3-Phase Pumps

Three phase pump/motor units must have proper overload and quick trip heaters in­stalled in the control box. Heaters must match starter manufacturer.

Table M.

SIEMENS (FURNAS) GENERAL ELECTRIC

Control Box

HP Voltage Hz Heaters (3 Req’d.)

2 208-230 60 036-072-1

3 208-230 60 036-076-1 410649-006

5 208-230 60 036-080-1 410649-008

5 575 60 036-100-1 279-230-5 (575V) 410649-009

3 380-415 50 036-070-1 279-231-5 (230V) 410649-005

(Coil V) Heaters (3 Req’d.)

410649-004

279-231-5 (230V)

Control Box

(Coil V)

410648-001 (120V)

410648-002 (240V)

410648-003 (575V)

5 380-415 50 036-074-1 279-231-5 (230V) 410649-007

41

Appendix A: 6” Maxxum STP ATEX Safety Instructions

For European Installations

1. ATEX Directive 94/9/EC approved 6” Maxxum Submersible Turbine Pumps (STP) marked with the
following information defining its limits for safe use.

• Location Classification:

Duncansville, PA U.S.A.
CE 1180 Ex II2G

2. Special Conditions for Safe Use:

• Certification Nu

• All submerged turbine pumps,

accordance with the manufacturer’s Installation, Operation and Service Manuals supplied.

• All installations shall provide reliable electrical connection between the pump/motor, frame, pipe,

manifold or junction box and the tank structure for both electrical protection and equipotential
bonding.

• The minimum fuel level shall be set 30mm above the highest product intake level at the botto

the pump motor.

• Where terminal boxes are used for termination of the cables from the motor and the supply

source, they shall be ATEX certified for use in gas group IIA and category 2.

• Where a differential pressure switch or transducer is installed, each must be capable of ensuring

that the nominated temperature classification is not exceeded.

• Fasteners

Ex ds IIA T4

mber: LCIE 05 ATEX 6120 X

non m

are

e

manifolds and associated equipment shall be installed in

m of

tric. They shall be replaced only with identical fasteners.

The City of New York Fire Department Condi

tions of Approval

Certificate of Approval #4970

1. Motor wiring shall be in accordance with the New York City Electrical code for hazardous locations.

2. The installation and use of pumps shall comply with applicable New York City Code, ru
3RCNY § 21-20 and/or 3RCNY § 21-21. Manufacturer’s and Underwriters Laboratories Inc.’s safety requirements
and limitations shall be complied with.

Note: To obtain a copy of the New York City Administrative Fire Code you may contact Citybooks Store at 212-669-

8246. For a copy of the Fire Department Rules of the City of New York please contact Command Information Services,
Legal Publishing Division at 518-436-8647.

3. Pumps shall b
requirements of Underwriters Laboratories Inc.

4. Equipment sh
requirements. The use of this product shall be limited to the indicated intent and has not been acceptable for other
uses or applications.

5. Certificate of Approval number shall be plainly and permanently stamped or
manufacturer. NOTE: Product must already be identified
York City job site.

6. The Certificate of Appr
patent, trade name, trade secret or other intellectual right.

7. The Fire Department Certificate of Approval does not constitute
by the Fire Department, but is a certification that your product, as represented, meets the standards as of the date of
issuance.

8. The Fire Department reserves the right to
that the product does not operate or perform as required by code, the conditions of this resolution or as represented in
your application.

9. The Fire Department’s conditions of approval shall be enumerated in th
provided to New York City buyers, users and installers.

10. As the manufacturer of th
condition as outlined in the approval will be subject to enforcement action which may include fines and imprisonment.

e Underwriters Laboratories Inc. listed and pump manufacturer shall retain follow up service

all have secured and shall maintain all required approvals and shall meet all applicable Federal and State

otherwise fixed upon each pump by the

with Certificate of Approval number before it arrives at New

oval is issued upon condition that the material or equipment’s technology does not violate any

an endorsement or recommendation of your product

withdraw this approval at any time in the event there is a reasonable doubt

e installation manuals and brochures that will be

is equipment/material, you should be aware that any end user who fails to comply with the

les and regulations including

ANZEx CONDITIONS OF CERTIFICATION:

1. It is a condition of manufacture that each motor be subjected to the routine high
voltage test of clause 6.2 of AS2380.1.

2. It is a condition of safe use that all submerged turbine pumps, manifolds and
associated equipment be installed in accordance with the manufacturer’s
Installation, Operation and Service Manuals supplied

3. It is a condition of safe use that all installations must provide reliable electrical
connection between the pump motor, frame, pipe, manifold or junction box and
the tank structure for both electrical protection and equipotential bonding.

4. It is a condition of safe use that, where terminal boxes are used for termination of
the cables from the motor and the supply source, they shall be Australian certified
for use in Gas Group IIA and Zone I hazardous areas.

5. It is a condition of safe use that where a differential pressure switch or transducer
is installed, each must be capable of ensuring that the nominated temperature
classification is not exceeded.

For technical support, sales or

other assistance, please visit:

www.veeder.com