Lifting of Pump ............................................................................................................................................................ 3
Optional Guide Rail or Lift-Out System ....................................................................................................................... 3
Wiring and Grounding .................................................................................................................................................4
Selecting and Wiring Pump Control Panels and Switches ........................................................................................... 4-5
Float Switch and Panel Chart ........................................................................................................................................6
Engineering Data ..........................................................................................................................................................7
Pump Model Number:
Pump Serial Number:
Control Model Number:
Dealer:
Dealer Phone No.
Date of Purchase: Installation:
Current Readings at Startup:
1Ø
Amps:
Volts:
2
DANGER
WARNING
CAUTION
WARNING
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING
WARNING
SAFETY INSTRUCTIONS
TO AVOID SERIOUS OR FATAL PERSONAL
INJURY OR MAJOR PROPERTY DAMAGE, READ
AND FOLLOW ALL SAFETY INSTRUCTIONS IN
MANUAL AND ON PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE
INSTALLATION AND OPERATION OF THIS UNIT
AND MUST BE KEPT WITH THE PUMP.
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the pump
or in the manual, look for one of the following signal words and be alert to the
potential for personal injury or property
damage.
Warns of hazards that WILL cause
serious personal injury, death or major
property damage.
Warns of hazards that CAN cause
serious personal injury, death or major
property damage.
Warns of hazards that CAN cause personal injury or property damage.
NOTICE: INDICATES SPECIAL INSTRUCTIONS
WHICH ARE VERY IMPORTANT AND
MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS
AND WARNINGS PRIOR TO PERFORMING ANY
WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
All electrical work must be performed
by a qualified technician. Always follow
the National Electrical Code (NEC), or the Canadian
Electrical Code, as well as all local, state and provincial
codes. Code questions should be directed to your local
electrical inspector. Failure to follow electrical codes and
OSHA safety standards may result in personal injury or
equipment damage. Failure to follow manufacturer’s
installation instructions may result in electrical shock, fire
hazard, personal injury or death, damaged equipment,
provide unsatisfactory performance, and may void manufacturer’s warranty.
Standard units are not designed for use in
swimming pools, open bodies of water,
hazardous liquids, or where flammable gases exist. These
fluids and gases may be present in containment areas.
Tank or wetwell must be vented per local codes.
Only pumps specifically Listed for Class 1, Division 1
are allowable in hazardous liquids and where flammable
gases may exist. See specific pump catalog bulletins or
pump nameplate for all agency Listings.
Disconnect and lockout electrical power
before installing or servicing any electrical
equipment. Many pumps are equipped with automatic
thermal overload protection which may allow an overheated pump to restart unexpectedly.
PRE-INSTALLATION CHECKS
Open all cartons and inspect for shipping damage. Report
any damage to your supplier or shipping carrier immediately.
Important: Always verify that the pump nameplate Amps,
Voltage, Phase, and HP ratings match your control panel
and power supply.
Many of our sewage pumps are oil-filled. If there are any
signs of oil leakage or if the unit has been stored for an
extended period check the oil level in the motor dome
and the seal housing, if so equipped.
Check the motor cover oil level through the pipe plug on
top of the unit. The motor chamber oil should just cover
the motor. Do not overfill, leave room for expansion!
If low, refill with an ASTM 150 turbine oil. Replace the
plug.
Oil is available in 5 gallon cans through our distributors.
You can also source oil locally at motor repair shops.
Typical oil brands are: Shell Turbo 32, Sunoco Sunvis
932, Texaco Regal R&O 32, Exxon Nuto 32 and Mobil
DTE Light.
Check the strain relief nut on power cable strain assemblies. Power cables should be torqued to 75 in. lbs. for
#16 cables and 80 in. lbs. for all other cable assemblies.
Warranty does not cover damage caused by connecting
pumps and controls to an incorrect power source (voltage/phase supply).
Record the model numbers and serial numbers from the
pumps and control panel on the front of this instruction
manual for future reference. Give it to the owner or affix
it to the control panel when finished with the installation.
LIFTING OF PUMP
DO NOT LIFT, CARRY OR HANG
PUMP BY THE ELECTRICAL
CABLES. DAMAGE TO THE
ELECTRICAL CABLES CAN CAUSE
SHOCK, BURNS OR DEATH.
Lift the pump with an adequately sized chain or cable attached to the lifting eye bolt. DO NOT damage electrical
and sensor cables while raising and lowering unit.
OPTIONAL GUIDE RAIL
OR LIFT-OUT SYSTEM
In many effluent and sewage basins or lift stations it
is advisable to install the pump on a guide rail system
or on a lift-out adapter to facilitate installation and
removal for inspection and/or service. Most codes
do not allow personnel to enter a wetwell without
the correct protective equipment and training. Guide
rails are designed to allow easy removal of the pump
without the need for entry into the wetwell or need
to disturb piping. The guide rail or lift-out adapter
should locate the pump opposite the influent opening
preventing stagnate areas where solids can settle. The
basin or pit must be capable of supporting the weight
of the pump and guide rail. The pit floor must be flat.
NOTICE: FOLLOW THE INSTRUCTIONS THAT
ARE PROVIDED WITH THE GUIDE RAIL
ASSEMBLY.
3
WARNING
Hazardous
voltage
WARNING
WARNING
PIPING
Discharge piping should be no smaller than the pump
discharge diameter and kept as short as possible, avoiding
unnecessary fittings to minimize friction losses.
Install an adequately sized check valve to prevent fluid
backflow. Backflow can allow the pump to “turbine”
backwards and may cause premature seal and/or bearing
wear. If the pump is turning backwards when it is called
on to start the increased torque may cause damage to the
pump motor and/or motor shaft and some single-phase
pumps may actually run backwards.
Install an adequately sized gate valve AFTER the check
valve for pump, plumbing and check valve maintenance.
Important – Before pump installation. If pumping waste
water containing solids, drill a 3⁄16” (4.8mm) relief hole
in the discharge pipe. It should be located within the
wetwell, 2” (51mm) above the pump discharge but below
the check valve. The relief hole allows any air to escape
from the casing. Allowing liquid into the casing will
insure that the pump can start when the liquid level rises.
Unless a relief hole is provided, a bottom intake pump
could “air lock” and will not pump water even though
the impeller turns.
All piping must be adequately supported, so as not to
impart any piping strain or loads on the pump.
The pit access cover must be of sufficient size to allow for
inspection, maintenance and crane or hoist service.
WIRING AND GROUNDING
Important notice: Read Safety Instructions before
proceeding with any wiring.
Use only stranded copper wire to pump/motor and
ground. The ground wire must be at least as large
as the power supply wires. Wires should be color
coded for ease of maintenance and troubleshooting.
Install wire and ground according to the National
Electrical Code (NEC), or the Canadian Electrical
Code, as well as all local, state and provincial codes.
Install an all leg disconnect switch where required
by code.
Disconnect and lockout electrical power before
performing any service or installation.
The electrical supply voltage and phase must match
all equipment requirements. Incorrect voltage or
phase can cause fire, motor and control damage, and
voids the warranty.
All splices must be waterproof. If using splice kits
follow manufacturer’s instructions.
Select the correct type and NEMA grade
junction box for the application and location. The junction box must insure dry,
safe wiring connections.
Seal all controls from gases present which
may damage electrical components.
FAILURE TO PERMANENTLY
GROUND THE PUMP, MOTOR AND
CONTROLS BEFORE CONNECTING
TO POWER CAN CAUSE SHOCK,
BURNS OR DEATH.
4
SELECTING AND WIRING
PUMP CONTROL PANELS AND SWITCHES
FLOAT SWITCH TYPES
There are two types of float switches available for use
with 2 HP, single phase grinder pumps; single action control switches and wide angle mechanical switches.
Single action control switches can only be connected
through a control panel. Connecting them directly to a
pump will cause rapid cycling and may burn up the motor, and/or the motor start switch and/or the float switch.
If using single action switches with a control panel please
see the Float Switch and Panel Section.
Model A2G33 wide angle pump float switches can be
hard wired directly to the pump. Wide angle switches can
operate the pump via connection to a control panel. The
tether length or distance from the switch body to the pivot point controls the On and Off points and the amount
pumped in one cycle. The pivot point is where the float is
attached to the discharge pipe. See Figures 1 and 2.
SETTING THE FLOAT SWITCHES
There are no absolute rules for where to set the float
switches, it varies from job to job.
Suggested Rules to Follow:
All floats should be set below the Inlet pipe!
Off Float: Best: set so the water level is always above the
top of the pump (motor dome). Next Best: set so the water level is not more than 6” below the top of the pump.
On Float: set so the volume of water between the On and
Off floats allows two (2) HP and larger pumps to run a
minimum of 2 minutes. Basin literature states the gallons
of storage per inch of basin height.
Lag/Alarm Float(s): should be staggered above the Off
and On floats. Try to use most of the available storage
provided by the basin, save some space for reserve storage capacity. See Diagrams and Charts in Float Switch
Chart Section.
PANEL WIRING DIAGRAMS
Our control panels are shipped with instructions and wiring diagrams. Use those instructions in conjunction with
this IOM. Electrical installation should be performed
only by qualified technicians. Any problem or questions
pertaining to another brand control must be referred
to that control supplier or manufacturer. Our technical
people have no technical schematics or trouble shooting
information for other companies’ controls.
ALARMS
We recommend the installation of an alarm on all Wastewater pump installations. Many standard control panels
come equipped with alarm circuits. If a control panel is
not used, a stand alone high liquid level alarm is available. The alarm alerts the owner of a high liquid level in
the system so they can contact the appropriate service
personnel to investigate the situation.
SINGLE PHASE PUMPS
WARNING
Hazardous voltage
can shock, burn or
cause death.
PLUG-CONNECTED UNITS MUST
BE CONNECTED TO A PROPERLY
GROUNDED, GROUNDING TYPE
RECEPTACLE.
ON NON-PLUG UNITS, DO NOT REMOVE CORD AND STRAIN RELIEF.
DO NOT CONNECT CONDUIT TO
PUMP.
Pumps with bare lead power cords can be hard-wired
to a float switch, wired to a 1Ø contactor, a Simplex
controller or a Duplex controller. Always verify that the
float switch is rated for the maximum run amperage,
maximum starting amperage, and the HP rating on the
pump. Single-phase wastewater pumps contain on-winding overloads, unless noted on the pump nameplate. See
Figure 1.
SINGLE PHASE CONTROL PANELS:
Control panels are available as Simplex (controls 1
pump) or Duplex (controls 2 pumps). Our standard
control panels are available with many standard features
and can be built with our most popular options. We also
custom build panels which offer many more design options than the standard panels. Custom control panels are
available in many different configurations. Custom panel
quote requests may be forwarded to Customer Service
through any authorized distributor.
Our standard duplex panels feature a solid-state printed
circuit board design with standard high level alarm circuits. Other standard features are: an auxiliary dry alarm
contact for signaling a remote alarm and float switch position indicator lights. Most standard panels are in stock
for immediate delivery.
INSTALLATION
STANDARD PUMP INSTALLATION
Connect the pump(s) to the guide rail pump adapters
or to the discharge piping. Guide rail bases should be
anchored to the wetwell floor.
Complete all wiring per the control panel wiring diagrams and NEC, Canadian, state, provincial and/or local
codes.
!
DANGER
Hazardous Machinery
Connect the piping per local codes and the drawings in
Typical Drawings Section.
DO NOT PLACE HANDS IN PUMP
SUCTION WHILE CHECKING
MOTOR ROTATION. TO DO SO
WILL CAUSE SEVERE PERSONAL
INJURY.
Lower the pump(s) into the wetwell.
Check to insure that the floats will
operate freely and will not contact the
piping.
OPERATION
Once the piping connections are made and checked you
can run the pumps.
Hard Wired Float Switch Operation – Turn circuit breaker or fused disconnect to On. Test the pump by filling the
wetwell until the pump goes On. If the pumps run but
fail to pump, they are probably air locked, drill the relief
holes per the instructions in the Piping Section.
Check the operating range to insure a minimum two minute run time and that the pump goes Off in the correct
position.
Control Panel Operation – Fill the wetwell with clear
water.
Use the pump H-O-A (Hand-Off-Automatic) switches in
Hand to test the pumps. If they operate well in Hand
proceed to test Automatic operation. If the pumps run
but fail to pump, they are probably air locked, drill the
relief holes per the instructions in the Piping Section.
Place Control Panel switch(es) in Automatic position and
thoroughly test the operation of the ON, OFF, and Alarm
floats by filling the wetwell with clear water. Important:
Failure to provide a Neutral from the power supply to
a 1Ø, 230 volt Control Panel will not allow the panel
control circuit to operate. The Neutral is necessary to
complete the 115 volt control circuit.
Check voltage and amperage and record the data on the
front of this manual for future reference. Compare the
amperage readings to the pump nameplate maximum
amperage. If higher than nameplate amperage investigate
cause. Operating the pump off the curve, i.e. with too
little head or with high or low voltage will increase amperage. The motor will operate properly with voltage not
more than 10% above or below pump nameplate ratings.
Performance within this range will not necessarily be the
same as the published performance at the exact rated
nameplate frequency and voltage. Correct the problem
before proceeding.
Reset the Alarm circuit, place pump switch(es) in the
Automatic position and Control Switch in ON position.
The system is now ready for automatic operation.
Explain the operation of the pumps, controls and alarms
to the end user. Leave the paperwork with the owner or
at the control panel if in a dry, secure location.
5
FLOAT SWITCH AND PANEL CHART
Inlet
Alarm SW4
Lag Pump On
SW3
Pump Off
SW1
Discharge
Lead Pump On
SW2
The purpose of this chart is to show the required switch
quantities and the function of each switch in a typical
wastewater system. The quantities required vary depending on the switch type, single-action or wide-angle.
Switch quantities also vary by panel type: simplex with
and without alarms, and duplex with alarms.
Discharge
Duplex Panels using single-action switches:
Three Float Panel Wiring
SW1 Bottom Pumps Off
SW2 Middle 1st Pump On
SW3 Top 2nd Pump & Alarm On
Four Float Panel Wiring ➁
SW1 Bottom Pumps Off
SW2 2nd 1st Pump On
SW3 3rd 2nd Pump On
SW4 Top Alarm On
Duplex Panels using wide-angle switches:
Three Float Panel Wiring
SW1 Bottom 1st Pump On/Both Off
SW2 Top 2nd Pump & Alarm On
Four Float Panel Wiring
SW1 Bottom 1st Pump On/Both Off
SW2 Middle 2nd Pump On
SW3 Top Alarm On
Simplex Panel using single-action switches:
Simplex Panel with Alarm ①
SW1 Bottom Pump Off
SW2 Middle Pump On
SW3 Top Alarm On/Off
Simplex Panel with No Alarm
SW1 Bottom Pump Off
SW2 Top Pump On
Inlet
Alarm SW3
Pump On SW2
Pump Off SW1
Simplex ➀
Simplex Panel using wide-angle switches:
Simplex Panel with Alarm
SW1 Bottom Pump On/Off
SW2 Top Alarm On/Off
Simplex Panel with No Alarm
SW1 Pump On/Off
6
Duplex ➁
ENGINEERING DATA
PUMP OPERATION
Minimum Submergence
Continuous
Duty
Intermittent
Duty
A2G33 - Hard Wired
Fully Submerged
6” Below Top of Motor
Maximum Fluid Temperature
Continuous
Operation
Intermittent
Operation
Determining Pumping Range
104º F 40º C
140º F 60º C
Figure 1
Wide-Angle Float Switch
Pump plug
Piggyback
switch plug
Pumping
range
Figure 2
Figure 3
Single-Action Float Switch
“Typical” Installation
WEIGHT
6" (15.3 cm)
8" (20.3 cm) TURN ON LEVEL
6" (15.3 cm)
Figure 4
7
INSULATION RESISTANCE READINGS
Normal Ohm and Megohm Values between all leads and ground
Condition of Motor and Leads Ohm Value Megohm Value
A new motor (without drop cable). 20,000,000 (or more) 20 (or more)
A used motor which can be reinstalled in well. 10,000,000 (or more) 10 (or more)
Motor in well. Readings are for drop cable plus motor.
New motor. 2,000,000 (or more) 2 (or more)
Motor in good condition. 500,000 - 2,000,000 .5 - 2
Insulation damage, locate and repair. Less than 500,000 Less than .5
Insulation resistance varies very little with rating. Motors of all HP, voltage and phase ratings have similar values
of insulation resistance.
Insulation resistance values above are based on readings taken with a megohmmeter with a 500V DC output.
Readings may vary using a lower voltage ohmmeter, consult factory if readings are in question.
TYPICAL PLUMBING AND INSTALLATION
INFLUENT
SERVICE
POLE
CONTROL
PANEL
INLET HUB
MERCURY SWITCH
HIGH LEVEL ALARM
(OPTIONAL)
MERCURY SWITCH
ALARM LIGHT
HINGED ACCESS DOOR
GUIDE
RAIL
VENT
VALVE
OPERATING
ROD
DISCHARGE
CHECK VALVE
LOWER
PUMP GUIDE
INFLUENT
SERVICE
POLE
CONTROL
PANEL
INLET HUB
MERCURY SWITCH HIGH
LEVEL ALARM (OPTIONAL)
MERCURY SWITCH
ALARM LIGHT
HINGED ACCESS DOOR
GUIDE
RAIL
VENT
VALVE
OPERATING
ROD
DISCHARGE
CHECK VALVE
LOWER PUMP
GUIDE
SIMPLEX
DUPLEX
8
TYPICAL INSTALLATIONS (continued)
RUN
AUTO
OFF
HAND
S1
FLASH HIGH
SILENCE
R1
R2
R2
R2
HORN
FLASHER
56
T1
T2
PUMP
1T
Simplex Single Phase Wiring Diagram S10020
115/230 VAC (FOR 115 VAC, USE TERMINALS L1 AND N, JUMP L2 AND N).
SINGLE PHASE, 60 Hz
L1
L2
N
NOTE: WHEN USING SEPARATE 115 VAC CONTROL POWER SUPPLY, REMOVE
GND
J1
JUMPER (J1) FROM TERMINALS (L1) AND LL1). CONNECT 15 AMP MAX.
LL1
PROTECTED 115 VAC SUPPLY TO TERMINALS (LL1) AND (N) WITH
THE NEUTRAL OF THE SUPPLY TO (N).
S1
T1
PUMP
T2
A 230 VOLT SYSTEM
REQUIRES A 4 WIRE
POWER SUPPLY LINE
L1, L2,
N AND GND.
WITHOUT A
NEUTRAL THE
CONTROL CIRCUIT
WILL NOT WORK.
2
FOR 115 VAC OPERATION,
USE TERMINALS L1 AND N,
JUMP TERMINALS L2 AND N.
115/230 VAC
SINGLE PHASE
60 Hz
CONTROL
ON-OFF
RUN
S1-AUX
123
OFF FLOATON FLOAT
4
ALARM FLOAT
TEST
R1
HIGH LEVEL ALARM
DRY CONTACTS
HAND
OFF
AUTO
FLASHER
R2
SILENCE
R2
S1
FLASH HIGH
R1
HORN
R2
J1
L1L2LL1N1 23456T
2
R1
2
ALARM
DRY CONTACTS
FLOAT
ON FLOAT
PUMP
OFF FLOAT
9
TROUBLESHOOTING
WARNING
Hazardous
voltage
FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL
POWER BEFORE ATTEMPTING ANY SERVICE CAN CAUSE
SHOCK, BURNS OR DEATH.
SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION
MOTOR NOT RUNNING Motor thermal protector tripped. Allow motor to cool. Insure minimum pump submergence. Clear debris from casing and impeller.
NOTE: If circuit breaker
“OPENS” repeatedly,
Open circuit breaker or blown fuse. Determine cause, call a qualified electrician.
DO NOT reset. Call
Pump impeller binding or jammed. Check motor amp draw. If two or more times higher
qualified electrician.
than listed on pump nameplate, impeller is locked,
a) Manual operation Power cable is damaged. motor bearings or shaft is damaged. Clear
Resistance between power leads and ground should
b) Automatic operation No neutral wire read infinity. If any reading is incorrect, call a connected to control panel. qualified electrician.
Inadequate electrical connection Inspect control panel wiring. Call a qualified in control panel. electrician.
NOTE: Check the pump
Defective liquid level switch. With switch disconnected, check continuity while
in manual mode first to
activating liquid level switch. Replace switch, as
confirm operation. If pump
required.
operates, the automatic
Insufficient liquid level to Allow liquid level to rise 3” to 4” (76 mm - 101 mm)
control or wiring is at fault.
activate controls. above turn-on level.
If pump does not operate,
Liquid level cords tangled. Untangle cords and insure free operation.
see above.
PUMP WILL NOT Liquid level cords tangled. Untangle cords and insure free operation.
TURN OFF
Pump is air locked. Shut off pump for approximately one minute, then
restart. Repeat until air lock clears. If air locking
persists in a system with a check valve, a 3⁄16” (4.8 mm)
hole may be drilled in the discharge pipe approximately
2” (51 mm) above the discharge connection.
Influent flow is matching pump’s Larger pump may be required. discharge capacity.
LITTLE OR NO LIQUID Check valve installed backwards, Check flow arrow on valve and check valve
DELIVERED BY PUMP plugged or stuck closed. operation.
Excessive system head. Consult with dealer.
Pump inlet plugged. Inspect and clear as required.
Improper voltage or wired Check pump rotation, voltage and wiring.
incorrectly. Consult with qualified electrician.
Pump is air locked. See recommended action, above.
Impeller is worn or damaged. Inspect impeller, replace as required.
Liquid level controls defective Inspect, readjust or replace as required.
or improperly positioned.
PUMP CYCLES Discharge check valve inoperative. Inspect, repair or replace as required.
CONSTANTLY
Liquid level controls defective or Inspect, readjust or replace as required. improperly positioned.
Influent excessive for this size Consult with dealer.
pump.
Sewage containment area too small. Consult with dealer.
Inadequate electrical connection
in control panel.
dealer.
debris from cutter, casing and impeller, consult with
10
This warranty applies to all water systems pumps manufactured by Red Jacket Water Products.
Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period. The war-
ranty period shall exist for a period of twelve (12) months from date of installation or eighteen (18) months from date of manufacture, whichever
period is shorter.
A dealer who believes that a warranty claim exists must contact the authorized Red Jacket Water Products distributor from whom the pump was
purchased and furnish complete details regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the Red Jacket Water
Products Customer Service Department.
The warranty excludes:
(a) Labor, transportation and related costs incurred by the dealer;
(b) Reinstallation costs of repaired equipment;
(c) Reinstallation costs of replacement equipment;
(d) Consequential damages of any kind; and,
(e) Reimbursement for loss caused by interruption of service.
For purposes of this warranty, the following terms have these definitions:
(1) “Distributor” means any individual, partnership, corporation, association, or other legal relationship that stands between Red Jacket Water Products
and the dealer in purchases, consignments or contracts for sale of the subject pumps.
(2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing
pumps to customers.
(3) “Customer” means any entity who buys or leases the subject pumps from a dealer. The “customer” may mean an individual, partnership, corpora-
tion, limited liability company, association or other legal entity which may engage in any type of business.
THIS WARRANTY EXTENDS TO THE DEALER ONLY.
RED JACKET WATER PRODUCTS LIMITED WARRANTY
Xylem, Inc.
2881 East Bayard Street Ext., Suite A
Seneca Falls, NY 13148
Phone: (866) 325-4210
Fax: (888) 322-5877
www.xyleminc.com/brands/redjacketwaterproducts
Red Jacket Water Products is a trademark of Xylem Inc. or one of its subsidiaries.