Wayne ISP40 User's Manual
Contents
1. 4 Motor Cord amp FI Switch iS 3 Stainless eee ft Steel ae Filter Replacement Parts List Ref No IsP40 1 Filter Cap 40020 001 2 Through Bolts 67048 001 3 Stainless Steel Filter 11024 001 4 Motor Power Cord amp Float Switch 66079 WYN1 5 Power Cord Grommet amp Clamp 66080 WYN1 6 Impeller Rotor 32085 001 7 Volute and Shaft 66081 WYN1 8 Conical Nut Thrust Washer Thrust Bearing 66082 WYN1 9 Jumper Wire 31029 001 10 Shield 43005 001 11 Power Supply Battery Charger 30215 001 Not Shown Operating Instructions And Parts Manual Model ISP40 Battery Information Continued nearby in case battery acid contacts clothing skin or eyes Wear eye and clothing protection when working around lead acid batteries Avoid touching your eyes when working around lead acid batteries If battery acid AWARNING contacts your eye s flush with cold running water for 10 minutes and seek immediate medical attention If acid contacts your skin or clothing wash immediately with soap and water Never smoke or AAWARNING allow a spark or flame in the vicinity of the battery Avoid dropping LAWARNING metal tools on the battery posts because they may spark or short circuit the system or battery causing an explosion PS BC Features e Provides power to the pump e Automatically charges and maintains the charge to the batteries e Operates on 122. necessary remove the filter for cleaning If the pump is used in a dirty environment frequent cleaning is necessary to assure adequate performance Never sweep dirt or garbage into the sump pit NOTICE Do not operate the pump without the filter in place The filter protects critical areas inside the pump from damage due to foreign objects Operating the pump without the filter will void the warranty N OTI CE Before disabling your pump have ready an appropriate way to evacuate the sump pit should it refill with water while your pump is out of commission Disconnect the power cord from the Power Supply Battery Charger PSIBC to the pump Simply unplugging the PSIBC from the AC power will not shut off the pump FILTER IMPELLER AND THRUST BEARING 1 Remove the pump from the sump pit Loosen the three 3 through bolts that hold the filter cap in place NOTICE Be careful not to damage the float switch which is permanently installed in the motor housing Attempting to remove the float switch will cause irreversible motor damage 10 Loosen the conical nut using an 1 8 Allen wrench Carefully remove thrust washer and thrust bearing taking note of their orientation The thrust washer can crack if it is dropped on a hard surface Using needlenose pliers remove the impeller rotor Take care not to damage the mounting face of the thrust washer with
3. overload condition still exists the cycle will repeat Regardless of what is causing the circuit breaker to cycle unattended or routine operation in this manner could result in serious damage to the PS BC and the battery 1 Discharged battery 2 Shorted cell battery If the battery is in otherwise good condition it is normal for the circuit breaker to cycle ON and OFF several times before the battery recovers enough to allow a normal charge rate If this happens on a regular basis however the batteries may be too large for the PS BC and it could be damaged Replace batteries A battery in this condition may cause the breaker to cycle continuously The battery will not accept a charge Replace both batteries Www waynepumps com Operating Instructions and Parts Manual Model ISP40 For Replacement Parts call 1 800 237 0987 Please provide following information Model number Serial number if any Part description and number as shown in parts list Harrison OH 45030 U S A 11 Power Supply Battery Charger Address parts correspondence to Wayne Water Systems 100 Production Drive 5 Power Cord 1 Filter Cap Grommet amp cl M ae 8 Conical Nut amp Thrust Washer ras M Thrust O Bearing Ga a 10 aN 2 Through X Bolts 3 7
4. plugged into a ground fault circuit interrupter outlet that is properly installed and grounded in accordance with all local codes and ordinances If you ever feel even a sight shock from this or any electrical appliance or equipment connected to it STOP Turn off electricity to outlet and have it inspected by an electrician You may have a dangerous improperly wired outlet IMPORTANT Never cut off the round grounding prong Cutting the cord or plug will void the warranty and make the pump inoperable 3 Insert the PS BC power cord plug directly into the GFCI outlet See Figure 4 TO TEST Make certain there AWARNING is at least 6 inches of water in the sump prior to connecting the pump to the PS BC Failure to do so may cause damage to pump 1 Fill sump with water The pump will start automatically when the water has filled the sump to a depth of approximately 12 The pump will stop when the water depth is approximately 6 The pump will recycle thereafter as required Always disconnect ADAN G ER the electrical supply before attempting to install service relocate or perform any maintenance If the power source is out of sight lock and tag in the open off position to prevent unexpected power application Failure to do so could result in fatal electrical shock Only qualified electricians should repair this unit Improper repair could result in fatal electrical shock N OT l CE When
5. 0 volt AC or 24 volt DC two 12 volt batteries e Sounds alarm if fuse is blown or battery power is low e The PS BC can be left on the batteries indefinitely Light Emitting Diodes LEDs keep you informed of the system s status see Chart 2 The Power Supply Battery Charger is a 7 ampere 24 volt automatic battery charger for conventional wet cell and gelled electrolyte type deep cycle lead acid batteries The PS BC is designed for use with your Wayne Water System pump DO NOT USE for any other purpose PS BC Installation aKa NOTICE Use Power Negative Supply Battery Battery Cable i Mo Charger PSIBC indoors in a well j ventilated area Do not expose PSIBC e to rain or snow Do not use an Red extension cord Do not disassemble A V7 if PSIBC Be sure PS BC ventilation holes Z are unobstructed If PSIBC is dropped taf Vi eee 1 able Positive PS BC or damaged do not operate return to manufacturer for service 12V 7 i Battery Risk of electrical i AWARNING shock Use a GFCI Ground Fault Circuit Interrupter Jumper Wire receptacle to reduce the risk of fatal q r i Figure 3 Series connection two 12 electrical shock Grounded receptacle A y must be rated for at least 5 amps volt batteries equals a 24 volt battery 12V Battery AAWARNING pi ae AC 10 Reinstall pump fuse The green LED power and remove pump fuse before will light If it does not light make
6. 4 Check for proper pump operation BATTERY TEST Unplug AC power Fill sump with water Pump will start automatically when water reaches edge of filter cap If low battery light yellow LED illuminates batteries should be replaced Replace batteries as a set See Battery Information on Pages 2 and 3 Notes WWW waynepumps com Www waynepumps com
7. Impellef s20csiesencdees cadeetinedes nl NARE TEET ET TILTALT TETT Discharge Float switch FRET 2 2 2 cccceciaw seen baited eae ees EEE ETETETT Cast Iron Pa ee E Glass filled Ryton SETTAT TETTE 410 Stainless Steel P 7 2 position ni biiathd aqesdece TERE Stainless Steel REMINDER Keep your dated proof of purchase for warranty purposes Attach it to this manual or file it for safekeeping 2002 Wayne Water Systems For parts product amp service information visit www waynepumps com 351900 001 4 02 Operating Instructions And Parts Manual Model ISP40 General Safety Information Continued If the A DANG ER basement has water or moisture on the floor do not walk on wet area until all power is turned off If the shutoff box is in the basement call an electrician Remove pump and either repair or replace Failure to follow this warning could result in fatal electrical shock Pump Installation NOTICE installation may take several hours Do not disable an existing sump pump until you have established an appropriate way to evacuate sump pit 1 Install pump in a sump pit with minimum size as shown in Figure 2 Construct sump pit of tile concrete steel or plastic If the sump pit already exists disconnect power to existing pump and make certain pit is the correct size 10 Dia Figure 2 Min 2 The sump pump sho
8. Operating Instructions and Parts Manual Model ISP40 Limited Warranty For two years from the date of purchase Wayne Water Systems Wayne will repair or replace at its option for the original purchaser any part or parts of its Sump Pumps or Water Pumps Product found upon examination by Wayne to be defective in materials or workmanship Please call Wayne 800 237 0987 for instructions or see your dealer Be prepared to provide the model and serial number when exercising this warranty All transportation charges on Products or parts submitted for repair or replacement must be paid by purchaser This Limited Warranty does not cover Products which have been damaged as a result of accident abuse misuse neglect improper installation improper maintenance or failure to operate in accordance with Wayne s written instructions THERE IS NO OTHER EXPRESS WARRANTY IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED TO THREE YEARS FROM THE DATE OF PURCHASE THIS IS THE EXCLUSIVE REMEDY AND ANY LIABILITY FOR ANY AND ALL INDIRECT OR CONSEQUENTIAL DAMAGES OR EXPENS ES WHATSOEVER IS EXCLUDED Some states do not allow limitations on how long an implied warranty lasts or do not allow the exclusions or limitations of incidental or consequential damages so the above limitations might not apply to you This limited warranty gives you specific legal rights and you may also have other leg
9. al rights which vary from state to state In no event whether as a result of breach of contract warranty tort including negligence or otherwise shall Wayne or its suppliers be liable for any special consequential incidental or penal damages including but not limited to loss of profit or revenues loss of use of the products or any associated equipment damage to associated equipment cost of capital cost of substitute products facilities services or replacement power downtime costs or claims of buyer s customers for such damages You MUST retain your purchase receipt along with this form In the event you need to exercise a warranty claim you MUST send a copy of the purchase receipt along with the material or correspondence Please call Wayne 800 237 0987 for return authorization and instructions DO NOT MAIL THIS FORM TO WAYNE Use this form only to maintain your records MODEL NO SERIAL NO INSTALLATION DATE ATTACH YOUR RECEIPT HERE WWww waynepumps com Operating Instructions and Parts Manual Model ISP40 Please completely read and save these instructions Read carefully before attempting to assemble install operate or maintain the product described Protect yourself and others by observing all safety information Failure to comply with instructions could result in personal injury andlor property damage Retain instructions for future reference AC DC Sump Pump System Record Serial Number here Se
10. connecting or disconnecting battery sure polarity of batteries and PS BC cables are identical to Figure 3 The voltage at the PS BC cables must be at least 18 volts or the PS BC will not operate Once the green LED is on it will stay on unless the 1 Select a suitable position on the floor near the sump pit to place the battery case Be certain that the PS BC power cord will reach AC power and that the sump pump power cord will reach the PS BC Make sure the combined batteries voltage falls battery case vent holes are below 7 volts unobstructed Make no connections 11 Be sure pump is submerged in at at this time least 6 inches of water 2 Make sure the PS BC power cord is 12 Connect pump to PS BC by inserting disconnected locking ring of pump power cord 3 Remove pump fuse and keep it ina into opening on front of PS BC safe place see Figure 1 4 Place batteries side by side in battery case see Figure 3 Operation 5 Feed PS BC battery cables through Always disconnect side access hole in battery case ADANGER the electrical supply j before attempting to install service 6 Carefully check battery polarity relocate or maintain the Power A Supply Battery Charger PS BC Never 1 Attach Jumper wire as shown in handle PSIBC with wet hands or when Figure 3 to achieve 24 volts standing on wet or damp surface or in 8 Connect PS BC battery cables to water Fatal electrical shock could occur i aes Ris
11. ed in the surrounding area If battery acid AWARNING contacts your eye s flush with cold running water for 10 minutes and seek immediate medical attention If acid contacts your skin or clothing wash immediately with soap and water Never smoke or AWARNING zio allow a spark or flame in the vicinity of the battery Avoid dropping AWARNING metal tools on the battery posts because they may spark or short circuit the system or battery causing an explosion Follow battery manufacturer s maintenance procedures and schedules Be certain that the area around the batteries is well ventilated Before servicing the batteries blow away gasses by waving a piece of cardboard near the batteries disconnect W the electrical supply before attempting to install service 4 relocate or perform any maintenance 1 Unplug the PS BC 2 For batteries with top caps that can be removed the electrolyte level should be checked and filled to manufacturer s specifications The charge for each cell should be checked with a hydrometer A specific gravity of 1 265 indicates the battery is at full charge If the specific gravity of any of the cells varies more than 050 the battery should be replaced NOTE An inexpensive hydrometer can be purchased at an automotive parts dealer Inspect the terminals and clamps for corrosion and tightness Clean and tighten as required
12. gnize this information observe the following symbols Danger indicates ADANGER an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Caution indicates a AACAUTION potentially hazardous situation which if not avoided may result in minor or moderate injury Notice indicates NOTI CE important information that if not followed may cause damage to equipment I Power Cord Figure 1 System Components AT Power Battery d f a Supply z mt o Battery Jumper Wire wo AC Circuit Breaker Battery Charger PS BC i ES _V Power Supply Battery Charger PS BC Power Cord Pump Fuse Pump Specifications Power supply requirements Motor Normal water removal Liquid temperature range Circuit requirements Pump Dimensions Pump starts at factory set Pump stops at factory set E E dvecbv ete e eaysce 120V 60 Hz 2 Brushless Integral Processor sig eteedse te 36 GPM 10 Feet 40 F to 120 F P 4 amps AC min 1112 high x 9 4 base e Taneesat 12 Water Level TEPEE deem FETTE 6 Water Level Pump Construction Motor housing volute filter cap
13. k of electrical batteries as shown in Figure 3 PNAS Shock The Power 9 Tighten all battery connections Supply Battery Charger PSIBC is supplied with a grounding conductor and grounding plug Use a grounded receptacle to reduce the risk of fatal electrical shock securely CHART 2 PS BC STATUS LIGHTS Www waynepumps com LIGHT ON WHEN ACTION REQUIRED Red AC power is connected None Green Battery connected None Yellow Battery voltage is below 23 2 volts buzzer sounds Replace batteries flooding is possible Pump fuse blown buzzer sounds Replace fuse WWwW waynepumps com 3 Operating Instructions And Parts Manual Model ISP40 Operation Continued PROPER GROUNDING OF AC POWER CORD 1 A ground fault circuit interrupter GFCI is required See Figure 4 2 Do not operate the pump unless it is submerged in water Dry running causes pump failure 3 While the pump is draining the pit verify that the discharge piping is carrying the water to a point several feet away from the foundation 4 If pump discharge line is exposed to freezing temperature the exposed line must be pitched to drain Trapped water will freeze and damage the pump Maintenance Grounding Blade Figure 4 Required GFCI Receptacle 2 The PS BC is only for use on 120 volt single phase 60 hz service and is equipped with a 3 conductor cord and 3 prong grounding type plug The plug MUST be
14. logging or damaging the pump 8 Fill sump with at least 6 inches of water Battery Information The system is designed to operate most efficiently with sealed lead acid SLA batteries at 24 volts Two 12 volt 40 amp hour SLA batteries provide enough energy to pump more than 10 000 gallons of water from a basement Deep cycle marine batteries or automotive style batteries can also be used Sealed lead acid batteries cost slightly more but they can last up to 10 years Deep cycle marine and automotive batteries may have a shorter life one to two years Among the manufacturers of sealed lead acid batteries are Hawker Panasonic PowerSonic Yuasa and Eagle Picher The oversize battery case included will accommodate two 12 volt SLA batteries or two 12 volt deep cycle marine batteries up to a 27 frame size Use new identical batteries from the same manufacturer and of the same capacity When batteries wear out replace them as a set Chart 1 illustrates the expected performance with various battery combinations Do not use batteries rated below 40 amp hours Be certain that the area around the batteries is well ventilated Before servicing the batteries blow away gasses by waving a piece of cardboard near the batteries Dangerous ADANGER hydrogen gas can be released from batteries while charging Sparks can ignite the gas in an enclosed space Wear safety goggles when connecting batteries Battery connection
15. olarity Replace batteries Lower float stuck 2 Pump too low in sump Pump will not stop No Remove filter and clean Remove debris from float switch area Place a brick under the pump Pump will not start 1 Pump power cord 1 Check for proper installation of power cord into the PS BC 2 Upper float switch stuck 2 Remove filter and clean Remove debris from float switch area 3 Impeller rotor jam 3 Remove filter and clean Remove debris from float switch area Pump starts stops too 1 Backflow from discharge 1 Install or replace check valve often pipe 2 Pump too low in sump 3 Clogged pump filter Place a brick under the pump Remove filter and clean Pump operates but 1 Blocked discharge pipe delivers little or no water 2 Partially clogged pump filter 3 Broken thrust bearing Check for restrictions in discharge line flood is immanent Shut off AC power before entering flooded area Remove impeller check for debris in inlet Remove and inspect thrust bearing CHART 1 STANDBY POWER PUMPING CAPACITY Amp Hours Per Battery 40 0 80 0 120 0 Assumes the sump pump is lifting water 10 Total Gallons Pumped 11 000 22 000 33 000 Www waynepumps com Click inside PS BC An overload is indicated when you hear a distinct click from the DC circuit breaker internal to the PS BC A 3 5 minute cooling off period occurs before the PS BC resets itself If the
16. rial Number is found on Pump Housing General Safety Information Description The AC DC Sump Pump System includes a submersible sump pump and a Power Supply Battery Charger PS BC Backup power is supplied by two 12 volt batteries not included The system is designed for home sump applications When an electrical power outage occurs the PS BC automatically switches the sump pump to battery power so it will continue to pump water There is no need for a back up sump pump Using LED s Light Emitting Diodes the PS BC also alerts you to potential problems Safety Guidelines pump flammable or explosive fluids such as gasoline fuel oil kerosene etc Do not use in a flammable andlor explosive atmosphere Personal injury and or property damage could result Only use pump to pump clear water Do not use to wW NOTICE This pump is not designed to handle salt water brine laundry discharge water softener sewage graywater or any other application which may contain caustic chemicals andlor foreign materials Pump damage could occur if used in these applications and will void warranty All wiring must be AWARNING performed by a qualified electrician Pump N Stainless Steel ai Fi Filter Cables This manual contains information that is very important to know and understand This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS To help reco
17. s should be made in a well ventilated area Working in the A DANGER vicinity of lead acid batteries can be dangerous Before making connections or servicing the batteries read and follow instructions in all applicable instruction manuals To reduce the risk of battery explosion follow the instructions in this manual and those published by the battery manufacturer as well as those of any other equipment used in the surrounding area An assistant should be present or close enough to come to your aid in the event of an emergency Have a reliable source of fresh water and soap Operating Instructions and Parts Manual Model ISP40 Troubleshooting Chart Problem Possible Cause s AC Power Indicator 1 Power outage red light is not on 2 Blown AC breaker 3 GFCI tripped 4 Low AC voltage Corrective Action 1 None 2 Push AC breaker to reset If breaker trips again do not reset Have unit checked by qualified electrician Reset GFCI Have outlet checked by electrician Alarm sounds yellow 1 Pump fuse may be blown light is on 2 Pump impeller may be damaged No Replace pump fuse Use Bussmann AGC10 or Littlefuse 312010 Remove impeller Check for damage to bore or bearing Alarm sounds yellow light is on and red light is off Low battery Apply AC power or replace batteries Green Light is off Battery polarity is incorrect 2 Battery voltage too low No Recheck battery p
18. the pliers Thoroughly clean the filter with soapy water Remove any debris from impeller vanes and passages Wash impeller in soapy water Impeller magnet will crack if it is dropped on a hard surface Inspect thrust bearing If its thickness is less than 0 15 or if it is cracked or damaged replace Inspect the three impeller drives that engage with the thrust washer Replace impeller if they are worn Inspect thrust washer Replace if the thrust surface is worn Reassemble parts in reverse order as shown in Figure 5 For proper orientation of the thrust washer refer to Figure 6 Do not overtighten the conical nut Be careful not to damage the float when installing the filter cap Figure 5 Figure 6 Correct Incorrect Operating Instructions and Parts Manual Model ISP40 BATTERIES Dangerous AADANGER hydrogen gas can be released from batteries while charging Sparks can ignite the gas in an enclosed space Wear safety goggles when connecting batteries Battery connections should be made in a well ventilated area Working in the A DANG ER vicinity of lead acid batteries can be dangerous Before making connections or servicing the batteries read and follow instructions in all applicable instruction manuals To reduce the risk of battery explosion follow the instructions in this manual and those published by the battery manufacturer as well as those of any other equipment us
19. uld be located on a solid level foundation Do not place pump directly on clay earth gravel or a sandy surface These surfaces contain small stones gravel sand etc that may clog or damage the pump and cause pump failure Remove any silt or debris from the sump pit and surrounding area Flood risk If LAWARNING flexible discharge hose is temporarily used make sure pump is secured in sump pit to prevent movement Failure to secure pump could result in flooding and property damage NOTICE Flexible discharge hose is intended for temporary use only Rigid PVC or metal pipe is required for a permanent installation 3 Thread check valve not included into pump body Avoid stripping or cross threading Do not use pipe joint sealant 4 The pump has a 1 1 2 NPT discharge If the existing piping is smaller use an adapter Smaller diameter piping will reduce the pump flow rate and decrease its performance 5 Connect rigid pipe to rubber boot on check valve Tighten hose clamps AWARNING piho nen ond assembling and after installation Failure to do so could cause piping or check valve to break pump to fail etc which could result in property damage andlor personal injury 6 Protect electrical cord from sharp objects hot surfaces oil and chemicals Avoid kinking the cord Replace a damaged cord immediately 7 Asump pit cover must be installed to prevent debris from c
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