Red Jacket CoreDEF Series Installation, Service, & Parts Lists Download Page 28

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Installation

Wiring Diagrams

Figure 24. Isotrol To 400 Vac Remote Control Box (Starter) W/240 Vac Coil And Three Heaters

(Model 410648-002 Starter And 3x 410649-003 Heaters)

NEUTRAL

PEN

ER INPUT

HOT

TB2

TB1

ATG

CHANNEL 1

CHANNEL 2

CHANNEL

CHANNEL 4

CHANNEL 5

CHANNEL 6

CHANNEL 7

CHANNEL

PHASE ON L1 MUST BE SAME AS DEVICE

CONNECTED TO ATG TERMINAL

PHASE

UNSWITCHED NEUTRAL

UNSWITCHED

NEUTRAL TO TB2

ISOTROL CONTROL BOX (P/N 880-050-1)

240 VOLT

DISPENSER

SIGNALS

240 VOLTS FROM

SUPPLY PANEL

240 VOLT ISOLATED OUTPUT

TO CONTROL BOX OR ATG

NOT

USED

NOT

USED

NOT

USED

NOT

USED

Grey

Black

Brown

To 380/415 V Supply

240 V Coil

3 Ambient
Compensated
Heaters

COIL

To UMP

LEGEND

Overload

heater

Normally

closed

contact

Normally

open

contact

Screw

terminal

Wire added

by installer

Wire added

by manufacturer

DISCONNECT, LOCK OUT,

AND TAG POWER AT THE

POWER PANEL BEFORE

WIRING THE PUMP.

WARNING

OFF

Make ground connection in
accordance with local codes.

NOTICE

Make ground connection in
accordance with local codes.

NOTICE

Connect To

Electrical Ground

Connect To

Electrical Ground

Starter is wired for 380/415 V
to pump motor, 240 V from
Isotrol or dispenser switch.
Remove red wire connecting
9 to L2.

NOTICE

Summary of Contents for CoreDEF Series

Page 1: ...Manual No 577014 360 Revision E Installation Service Parts Lists CoreDEF Series Submersible DEF Pump ...

Page 2: ...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 miss...

Page 3: ...agrams 17 Wiring Diagrams 17 Single Tank Installations 17 Manifolded Tank Installations 17 Operational Precautions 30 Initial Start Up of Pump 30 Maintenance 30 Troubleshooting 31 General Repair 33 Parts Lists Submersible Pump And Accessories 35 Capacitor Kits 35 Control Boxes 36 Figures Figure 1 Typical Submersible DEF Pump System Components 1 Figure 2 Example Opening Locations In Manway Cover Fo...

Page 4: ... Model 410648 002 Starter And 3x 410649 003 Heaters 24 Figure 25 Isotrol To 240 Vac Remote Control Box Starter W 120 Vac Coil And Three Heaters Model 410648 001 Starter And 3x 410649 010 Heaters 25 Figure 26 Isotrol W Relay To Manifolded 240 Vac Remote Control Boxes With 120 Vac Coil And Capacitor Models 880 045 5 Or 410861 001 26 Figure 27 Isotrol W Relay To Manifolded 240 Vac Remote Control Boxe...

Page 5: ... System Components ATG TLS 350 or TLS 4XX With Control Relay Three Phase Magnetic Starter 3 Heaters DEF System Control Submersible DEF Pump Controllers DEF Tank Product Level Monitoring UMP Riser Cap S S Mag Probe W Alt Fluids Float Kit Check Valve Fixed Bypass Pressure Relief Valve Assembly Optionally In Sump Clinch Fitting To Manway Submersible DEF Pump OR AND For Multiple Dispenser Applications...

Page 6: ...vision for other options such as vents thermal relief adjustable pressure relief system only remote fill probes and the electrical cord grip The cord grip shall not be installed in the same opening as a product flow RECOMMENDED BULKHEAD AND MANWAY COVER OPENINGS Installer to determine system needs and configuration prior to specification of manway lid and bulkhead see Figure 2 Typical size require...

Page 7: ...ye injury WEAR GLOVES Wear gloves to protect hands from irritation or injury CLEAN WORK AREA Remove spilled liquid and dispose of it in an environmentally sound man ner WARNING The Red Jacket Submersible DEF Pump and wiring shall not be installed within a hazardous environment as defined by NFPA 70 NEC FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECAUTIONS COULD CAUSE DAMAGE TO PROPE...

Page 8: ... 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 ISO Standard For DEF The production handling and transportation of Diesel Exhaust Fluid DEF are go...

Page 9: ...lkali earth metal ions therein However if distilled water or de ionized water is not readily available the material may be cleaned with tap water provided the last rinse is done using DEF SAFETY INSTRUCTIONS The maximum operating pressure and the operating temperature must be observed High operating pressure may result in the containers fittings pipelines or the hoses bursting or becoming loose Ma...

Page 10: ... 8 1 9 11 D1 with 1 2 Pressure Relief 3 4 HP D2 with 1 2 Pressure Relief 3 4 HP D1 with 1 1 4 Pressure Relief 2 HP D2 with 1 1 4 Pressure Relief 2 HP 66 0 1676mm 96 0 2438mm 73 0 1854mm 103 0 2616mm DESCRIPTION RETRACTED PUMP LENGTH A B EXTENDED 1 2 3 4 5 6 7 8 9 10 11 14 UMP 1 1 4 Nipple Hex SST 1 1 4 to 1 1 2 Bushing 1 1 2 Tee 1 1 2 Nipple Check Valve Install W Flow Arrow UP 1 1 2 Pipe Clinch Fi...

Page 11: ...ealants and plumbing compatible with DEF per ISO 22241 Bottom of UMP to bottom of bulk head B 6 7 5 4 3 2 1 8 10 D1 W O fixed pressure relief 3 4 HP D2 W O fixed pressure relief 3 4 HP D1 W O fixed pressure relief 2 HP D2 W O fixed pressure relief 2 HP DESCRIPTION RETRACTED PUMP LENGTH A B EXTENDED MIN 6 SUBMERSION MIN 3 CLEARANCE 9 A ITEM DESCRIPTION 1 UMP 2 Nipple Hex 1 25 SST 3 Reducer Bushing ...

Page 12: ...e Length B Figure 3 Weight 410852 001 DP75U1 3 4 230 60 1 16 81 427mm 22 lbs 10kg 410852 002 DP75U3 3 4 230 50 1 16 81 427mm 22 lbs 10kg 410852 003 DP200U1 2 230 60 1 23 94 608mm 34 2 lbs 15 5kg 410852 004 DP200U17 2 400 50 3 23 94 608mm 34 2 lbs 15 5kg 410852 005 DP200U4 2 230 60 3 23 94 608mm 34 2 lbs 15 5kg Part Number Description 410869 001 D1 with 1 2 Pressure Relief 3 4 HP 410869 002 D2 with...

Page 13: ... 045 5 410861 001 240V hook 410860 003 410860 001 Three Phase Starter With 3 Heaters 120V hook 410648 001 3 410649 010 240V hook 410648 002 3 410649 003 410648 002 3 410649 010 Single Phase Control Box and Capacitor Kit 120V hook 880 041 5 410164 001 880 041 5 410164 003 240V hook 880 042 5 410164 001 880 042 5 410164 003 Item Part Number Description NPT to BSP Adapters SST Stated adjust ment rang...

Page 14: ...Operating Temperature Fluid 12 F to 104 F 11 C to 40 C Table 1 Electrical Service Information Model HP KW Voltage 6 10 Hz PH Max Current A Locked Rotor Amps Capacitor F UMP Resistance Including Cable Min Transformer Rating KVA Black Grey Black Brown Grey Brown DP75U1 3 4 0 56 230 60 1 4 5 13 17 5 440V 5 9 7 3 13 2 16 2 18 9 23 2 1 8 DP75U3 3 4 0 56 230 50 1 4 6 10 17 5 440V 8 3 10 2 17 5 21 5 25 7...

Page 15: ...ng and plumbing routing size and materials to assure adequate performance and material compatibility per ISO 22241 Installing the Pump 1 Before installing pipe threads apply an adequate amount of fresh UL classified for DEF non setting thread sealant Loctite 567 sealant is recommended with Loctite 7090 primer for all field serviceable pipe threads Loctite 8009 is to be used as the DEF compatible a...

Page 16: ...pple tighten to 125 ft lbs 170 N m Figure 7 Attaching UMP to 1 1 4 Nipple 4 Apply primer and attach 2 NPT column pipe with sealant to an ISO 22241 compliant manway cover and torque to 150 ft lbs 203 N m 5 Loosen the clinch assembly on the column pipe by unscrewing the three set screws in the side of locking nut then backing off the locking nut see Figure 8 Top of manway 1 1 4 NPT Hex Nipple 1 1 2 ...

Page 17: ...d UMP cable through strain relief supplied and tighten cord grip to 3 ft lbs 4 N m after removing excess slack in the tank Thread sealant is not required between cord grip and bushings Threads are 1 2 NPT 9 Secure the UMP cable to the column pipe with tie straps Locate the tie straps approximately as shown in Figure 10 Ensure the UMP cable is not in front of blocking the pressure relief nozzle if ...

Page 18: ...ple Ball valve not supplied should be installed to contain DEF in lines to dispenser for servicing If DEF recirculation option is selected return flow pressure gauge and ball valve are re quired 1 Install optional pressure gage if desired Carefully apply sealant to port to avoid contamination of gauge NOTICE Ball valve DEF discharge line to dispensers UMP cable strain relief Return flow piping bac...

Page 19: ...the check valve Figure 12 Adjustable Pressure Relief Installation Example When routing the return to the tank it may be required to extend the return line near the bottom of the tank to avoid any potential disruptions to the probe s accuracy Return flow from adjustable relief valve should be separate from recirculation loop if present The adjustable pressure relief valve can be used in conjunction...

Page 20: ...Control Box with capacitor it is imperative to verify the wiring connections between the pump and the Control Box Energizing a pump with incorrect connections can cause the thermal overload in the pump to trip open resulting in a very lengthy wait for the thermal protector to reset Resistance tests are always made with the power off and the wires disconnected from the Control Box Set up the electr...

Page 21: ...turbine pump STP control relay Other energized sources of power can still exist within the dispenser even with this device The neutral connection to the N terminal of TB1 and N terminal of TB2 must be from the service panel and be a permanently connected unswitched connection The N connection on TB1 and the eight N connections on TB2 may be spliced to a common neutral wire from the service panel d...

Page 22: ...y capacitor L1 L2 Submersible DEF pump Motor Brown Black Green Grey Liquid Tight Junction Box NOTICE DISCONNECT LOCK OUT AND TAG POWER AT THE POWER PANEL BEFORE WIRING THE PUMP WARNING OFF 115 volt 25 watt max Load center 208 or 230 volt L2 L1 N 3 P S T toggle switch Pilot light Line starter Capacitor P EXT PILOT LIGHT S1 S2 S3 M3 N M1 M2 L1 L2 UMP Dispenser Optional solenoid valve 76 volt amps ma...

Page 23: ...ection in accordance with local codes NOTICE Connect To Electrical Ground Dispenser lights External pilot light 115 volts 25 watt max Optional other dispenser max total of 6 dispensers EXT PILOT LIGHT 15A 3P switched neutral breaker 1 phase 3 wire 15A 2P switched neutral breaker Load center 208 or 230 volt 3 P S T toggle switch Pilot light Line starter Dispenser Wiring trough Optional solenoid val...

Page 24: ...RAL BREAKER PILOT LIGHT PHASE NEUTRAL 3P S T TOGGLE SWITCH EXTERNAL PILOT LIGHT 240 VOLTS 25 WATT MAX WIRING TROUGH DISPENSER LIGHTS DISPENSER S3 S2 S1 P EXT EXT PILOT PILOT LIGHT LIGHT M1 M2 L2 L1 S3 S2 S1 DISCONNECT LOCK OUT AND TAG POWER AT THE POWER PANEL BEFORE WIRING THE PUMP WARNING OFF Make ground connection in accordance with local codes NOTICE Cable Strain Relief Internal overload protec...

Page 25: ...1 L2 N L3 L2 L3 T2 T3 To 380 415 V Supply 240 V Coil COIL 2 9 3 Dispenser 3 Ambient Compensated Heaters Connect To Electrical Ground Brown Grey Black To UMP UMP DP200U4 410852 004 STARTER 410648 002 HEATERS 3X 410649 003 NOTE Starter is wired to 2380 415V to pump motor 240 V to dispenser switch LEGEND Overload heater Normally closed contact Normally open contact Screw terminal Wire added by instal...

Page 26: ...BOX P N 880 049 1 120 VOLT DISPENSER SIGNALS 120 VOLTS FROM SUPPLY PANEL 120 VOLT ISOLATED OUTPUT TO CONTROL BOX OR ATG NOT USED NOT USED NOT USED NOT USED 115 volt 25 watt max Load center 208 or 230 volt L2 L1 N 3 P S T toggle switch Pilot light Line starter Capacitor P EXT PILOT LIGHT S1 S2 S3 M3 N M1 M2 L1 L2 UMP BLACK BROWN GREEN YELLOW GREY DISCONNECT LOCK OUT AND TAG POWER AT THE POWER PANEL...

Page 27: ...ROL BOX P N 880 050 1 240 VOLT DISPENSER SIGNALS 240 VOLTS FROM SUPPLY PANEL 240 VOLT ISOLATED OUTPUT TO CONTROL BOX OR ATG NOT USED NOT USED NOT USED NOT USED LOAD CENTER 220 OR 240 VOLT L2 L1 M1 M2 M3 S3 S2 S1 P 3 P S T TOGGLE SWITCH PILOT LIGHT LINE STARTER EXT PILOT LIGHT 240 VOLT 25 WATT MAX CAPACITOR PH N BLACK BROWN UMP GREEN YELLOW GREY Connect To Electrical Ground DISCONNECT LOCK OUT AND ...

Page 28: ...LT ISOLATED OUTPUT TO CONTROL BOX OR ATG NOT USED NOT USED NOT USED NOT USED Grey Black Brown T1 L1 L1 L2 N L3 L2 L3 T2 T3 To 380 415 V Supply 240 V Coil 3 Ambient Compensated Heaters COIL 2 9 3 To UMP LEGEND Overload heater Normally closed contact Normally open contact Screw terminal Wire added by installer Wire added by manufacturer or DISCONNECT LOCK OUT AND TAG POWER AT THE POWER PANEL BEFORE ...

Page 29: ...T ISOLATED OUTPUT TO CONTROL BOX OR ATG NOT USED NOT USED NOT USED NOT USED Grey Black Brown T1 L1 L1 L2 N L3 L2 L3 T2 T3 To 208 240 V Supply 120 V Coil 3 Ambient Compensated Heaters COIL 2 9 3 To UMP Starter is wired for 208 240 V to pump motor 120 V from Isotrol or dispenser switch Remove red wire connecting 9 to L2 LEGEND Overload heater Normally closed contact Normally open contact Screw termi...

Page 30: ...O ATG TERMINAL 120 VOLT TO CONTROL BOX 120 VOLT TO CONTROL BOX DISCONNECT LOCK OUT AND TAG POWER AT THE POWER PANEL BEFORE WIRING THE PUMP WARNING OFF Make ground connection in accordance with local codes NOTICE Make ground connection in accordance with local codes NOTICE Make ground connection in accordance with local codes NOTICE Connect To Electrical Ground Connect To Electrical Ground Connect ...

Page 31: ... OUT AND TAG POWER AT THE POWER PANEL BEFORE WIRING THE PUMP WARNING OFF Make ground connection in accordance with local codes NOTICE Make ground connection in accordance with local codes NOTICE Make ground connection in accordance with local codes NOTICE Connect To Electrical Ground Connect To Electrical Ground Connect To Electrical Ground 240 VOLT TO CONTROL BOX 240 VOLT TO CONTROL BOX JUMPER TO...

Page 32: ...Brown T1 L1 L1 L2 N L3 L2 L3 T2 T3 To 380 415 V Supply 240 V Coil 3 Ambient Compensated Heaters COIL 2 9 3 To UMP Grey Black Brown T1 L1 L1 L2 N L3 L2 L3 T2 T3 To 380 415 V Supply 240 V Coil 3 Ambient Compensated Heaters COIL 2 9 3 To UMP 240 VOLT TO CONTROL BOX DISCONNECT LOCK OUT AND TAG POWER AT THE POWER PANEL BEFORE WIRING THE PUMP WARNING OFF Make ground connection in accordance with local c...

Page 33: ...k Brown T1 L1 L1 L2 N L3 L2 L3 T2 T3 To 208 240 V Supply 120 V Coil 3 Ambient Compensated Heaters COIL 2 9 3 To UMP Grey Black Brown T1 L1 L1 L2 N L3 L2 L3 T2 T3 To 208 240 V Supply 120 V Coil 3 Ambient Compensated Heaters COIL 2 9 3 To UMP 120 VOLT TO CONTROL BOX DISCONNECT LOCK OUT AND TAG POWER AT THE POWER PANEL BEFORE WIRING THE PUMP WARNING OFF Make ground connection in accordance with local...

Page 34: ...erably less than rated when rotating backwards Connect the pump leads to terminal T1 T2 and T3 of the magnetic starter observing color code shown in Figure 21 Figure 24 Figure 25 Figure 28 and Figure 29 With ample product in the tank and the system purged of air start the pump and make a pressure gauge reading of the system pressure with the ball valve closed or open valve and calculate pumping ra...

Page 35: ...sition c Restriction in piping sys tem c Confirm flow direction of check valve is correct Confirm ball valves and plumbing in sump is correct d Insufficient DEF in tank d Check fluid level in tank Confirm minimum of 6 inches 150mm above the pump strainer inlet e Frozen DEF in piping sys tem e DEF freezes at 12 F 11 C Installation of pipe heat ers or a DEF recirculation system may be necessary f Wr...

Page 36: ... pressure relief type are only 0 psi upstream of check valve Downstream pressure is trapped by check valve Table 3 Pressure Expectations By Pressure Relief Type UMP Pump Off Pump On Fixed Adjustable Fixed Adjustable 3 4 HP 28 psi 193 1 kPa 0 45 psi 310 3 kPa As Set 2 HP NOTICE ...

Page 37: ...6 Determine clean safe workspace and carefully set down motor assembly plumbing and manway cover All surfaces in direct contact with DEF shall be free of foreign matter fuel oil grease detergent dust and any other substance See Cleanliness Of Surfaces In Contact With DEF on page 5 7 Remove device that is being replaced UMP fixed pressure relief or check valve from system Ensure check valve s flow ...

Page 38: ...n Pipe Locking Clinch Nut 150 ft lbs 203 N m Column Pipe Locking Clinch Nut Set Screw 10 ft lbs 14 N m UMP to 1 1 4 Nipple 125 ft lbs 170 N m 1 2 Small Fixed Pressure Relief 65 ft lbs 88 N m 1 1 4 Large Fixed Pressure Relief 125 ft lbs 170 N m 1 NPT Adjustable Pressure Relief Valve 100 ft lbs 136 N m Adjustable Pressure Relief Valve Hex Cover 30 ft lbs 41 N m Cable Cord Grip 3 ft lbs 4 N m UMP Cab...

Page 39: ...able Repair Kit 410886 001 Miscellaneous Accessories 3 4 HP Relief Valve Kit 1 2 NPT 410882 001 2 HP Relief Valve Kit 1 1 4 NPT 410883 001 Check valve kit 410875 001 1 1 4 Adapter Kit NPT To BSP 410878 001 2 Adapter Kit NPT To BSP 410879 001 Pressure Gauge Kit 410880 001 Table 6 Capacitor Kits Item ref Figure 31 Part Number Description Qty Figure 31 Capacitor Kits 1 410164 001 17 5 F Capacitor 1 1...

Page 40: ...acitor Kit 410164 001 410164 002 410164 003 2 014 723 1 Line Contactor Relay 1 1 1 3 247 001 5 Pilot Light Assy 1 1 1 4 080 858 1 Toggle Switch 1 1 1 5 008 202 1 Terminal Block 1 1 1 Table 8 Control Box W Capacitor 240V Coil Item Refer Figure 32 Qty Part Number Description 0410860 003 0410860 002 0410860 001 CB 3 4 HP 17 5 µF 240V Coil CB 1 1 2 HP 25 µF 240V Coil CB 2 HP 40 µF 240V Coil 1 1 Capaci...

Page 41: ...1 108 572 4 Control box 1 1 2 247 001 5 Pilot light ass y 1 1 3 1 Line contactor relay 014 723 1 014 72 1 4 080 858 1 Toggle switch 1 1 5 008 202 1 Terminal block 1 1 Table 8 Control Box W Capacitor 240V Coil Item Refer Figure 32 Qty Part Number Description 0410860 003 0410860 002 0410860 001 CB 3 4 HP 17 5 µF 240V Coil CB 1 1 2 HP 25 µF 240V Coil CB 2 HP 40 µF 240V Coil 1 2 3 4 5 Electrical inter...

Page 42: ...For technical support sales or other assistance please visit www veeder com ...

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