Wayne 353601-001 User's Manual
Contents
1. ESP45 PS BC Installation Continued 1 Place battery box within six feet of the sump and a 115 VAC separately fused outlet The outlet must be protected by a ground fault circuit interrupter GFCI The area must also be clean dry and well ventilated 2 Wave cardboard over batteries to blow away any gas that may be present 3 Connect jumper wire between batteries as shown on Figure 1 4 Connect power wires from PS BC to battery terminals as shown in Figure 1 Connect the red wire to the unconnected positive terminal of battery A and then connect the black wire to the unconnected negative terminal of battery B The yellow light should now be on 5 Plug the pump and then the float into the PS BC The connections are marked 6 Test pump operation by filling the sump with water while the main pump is unplugged If the pump operates properly plug the PS BC into the GFCI protected outlet to begin charging the battery NOTE Protect electrical cord from sharp objects hot surfaces oil and chemicals Avoid kinking the cord and replace damaged components immediately Operation A DANGER Always disconnect the power source before attempting to install service relocate or maintain the pump Never touch sump pump pump motor water or discharge Piping when pump is connected to electrical power Never handle a pump or pump motor with wet hands or when standing on wet or damp surface or in wa2. For Replacement Parts call 1 800 237 0987 Please provide following information Address parts correspondence to Model number Wayne Water Systems Serial number if any 101 Production Drive Part descriptions and number as shown in parts list Harrison OH 45030 U S A Ref Part No Description Number Qty 1 Pump 06710 1 2 PS BC power supply battery charger 30260 001 1 3 Impeller assembly 29884 001 1 4 Wear ring 28183 001 1 5 Impeller plate 15958 1 6 Seal 21203 001 1 7 Float Kit ESP45 60120 001 1 Service Part Only WwWww waynepumps com Operating Instructions and Parts Manual Limited Warranty For three 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 THER
3. 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 Www waynepumps com Operating Instructions and Parts Manual Maintenance Continued 4 Unplug the main pump and fillsump 5 with water until back up pump turns 3 Inspect the terminals and clamps for corrosion and tightness Clean and tighten as required on Repeat process two times to be sure pump is operating normally If pump operates normally plug PS BC into wall outlet turn on main pump If pump fails to operate normally see Troubleshooting guide and correct problem Repeat step 5 Troubleshooting Chart Symptom Pump won t run Possible Cause s 1 2 3 4 Connections not secure Low or defective battery Float switch stuck Defective or blown fuse Corrective Action 1 2 3 4 Check all connections Check battery and replace if low or defective Make sure nothing is interfering with operation of switch Check internal fuse located on the PS BC Pull the charger from the wall outlet and remove If th
4. DANGER ei 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 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 www waynepumps com If battery acid A WARNING 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 A WARNING ilow a spark or flame in the vicinity of the battery Avoid dropping A WARNING metal tools on the battery posts because they may spark or short circuit the system or battery causing an explosion PS BC Features CHART 1 STANDBY POWER PUMPING CAPACITY Amp Hours Total Gallons Per Battery Pumped 40 0 11 000 80 0 22 000 120 0 33 000 Assumes the sump pump is lifting water 10 POWER CIRCUITS e Power Supply
5. for a permanent installation Figure 2 Method 1 Check Valve See Step 6 1 44 or 1h PVC Pipe Existing Pump 5 Place the pump with the 4 section of PVC pipe on a solid level surface in the sump pit on an elevated surface 6 Attach a rubber check valve sold separately to the top of the discharge pipe This will allow the pump or check valve to be removed easily for servicing 7 Check valve is required for effective operation of system NOTE Check valves can be placed directly in the pump discharge if desired However for ease of disassembly it is recommended that check valves be placed above the sump as shown in Figure 2 The remainder of the discharge pipe installation will vary depending on individual circumstances Using sound plumbing practices route the discharge pipe to an exterior wall by the shortest path Keep turns to a minimum because they reduce flow output of the pump The pipe that exits the building structure should be sloped downward so that water will not freeze in the pipe When installing the separate discharge pipe drill through the outside wall with appropriate drilling equipment Seal the hole to prevent water from entering Method 2 If a separate dedicated discharge is not possible as in Method 1 the ESP45 pump can be tied in to the AC operated pump s discharge pipe by installing
6. purchase for warranty purposes Attach it to this manual or file it for safekeeping 2008 Wayne Water Systems For parts product amp service information visit WWw waynepumps com 353601 001 7 08 Operating Instructions and Parts Manual Battery Information The system is designed to operate most efficiently with sealed lead acid SLA batteries Deep cycle marine batteries can also be used Sealed lead acid batteries cost slightly more but they can last longer Wayne offers a 40 amp hour battery WSB1240 and a 75 amp hour battery WSB1275 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 Retain blue foam pad to support Wayne sealed lead acid batteries 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 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
7. Battery Charger PS BC monitors power availability and automatically switches to battery operation during power outage e Charger will run pump motor or charge batteries when plugged into AC power e Automatically charges the batteries e Operates on 120 VAC and 24 VDC Using 2 batteries e The PS BC can be left connected to the batteries indefinitely e The PS BC is designed for the Wayne Water Systems pump only DO NOT Use For Any Other Purpose SYSTEM WILL ALARM IF e You will hear a beeping alarm if pump motor is running e You will hear a continuous alarm if the pump fuse on front panel is blown e You will hear a continuous alarm if the battery voltage drops below 21 6 NOTE The alarm must be on for the mute function to activate LIGHTS e Green Light indicates AC power is available e Yellow Light indicates battery is connected correctly e Red Light is on when battery voltage is low or if the pump motor fuse on the front panel is blown PUMP e The pump will turn on when the float switch rises The pump motor will keep running for 15 seconds after the float drops Black Negative Battery Cable Jumper Wire Figure 1 Battery connection two 12 volt batteries equals a 24 volt battery ESP45 Pump Installation NOTICE Installation of this NOTICE unit may take several hours Before disabling your main pump have ready an appropriate means of evacuating the sum
8. E 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 legal 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 f
9. Operating Instruction and Parts Manual ESP45 Please 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 and or property damage Retain instructions for future reference WAYN 24 Volt Backup Sump Pump Description The ESP45 is a battery operated back up sump pump It does not replace a regular pump It is designed to provide protection in the event household electrical power fails or main pump fails Unpacking Inspect this unit before it is used Occasionally products are damaged during shipment If the pump or components are damaged return the unit to the place of purchase for replacement Failure to do so could result in serious injury or death Safety Guidelines 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 recognize this information observe the following symbols Danger indicates an A DANGER imminently hazardous situation which if not avoided will result in death or serious injury Warning indicates a A WARNING potentially hazardous situation which if not avoided could result in death or serious injury Caution indicates a A CAUTION p
10. a Y connector Two check valves will be required 1 Locate the ESP45 on a solid level surface in the sump pit Do not place the pump on a loose or sandy surface Small stones or sand may damage the pump resulting in potential pump failure 2 This pump has a 1 2 NPT discharge If a 1 4 discharge pipe is desired an adapter not included will be necessary Smaller diameter piping will reduce pump flow rate and performance Www waynepumps com Operating Instructions and Parts Manual Pump Installation Continued 3 A check valve will be required in the discharge line of BOTH the Main AC pump and the ESP45 pump to prevent recirculation of water into the sump pit System will not function without two check valves 4 Cut a 4 section of 1 or 1 42 diameter rigid PVC pipe Cement 1 2 pipe to a threaded fitting Cement 1 4 pipe into pipe coupling Attach 1 4 pipe section to the ESP45 discharge adapter 5 Screw on to pump discharge Be careful not to NOTICE strip or cross thread plastic fittings or check valves Flex hose is not recommended Rigid PVC or metal Pipe is required for a permanent installation 6 Place the pump with the 4 section of PVC pipe on the sump floor or on an elevated surface if required 7 Attach a rubber check valve sold separately to the top of the discharge pipe This will allow the pump or check valve to be removed easily for servicing 8 Dupl
11. be used on the primary sump pump discharge A WARNING A ground fault circuit interrupter is required LaL This pump must NOTICE only be used to pump clear water This pump is not designed to handle effluent salt water brine laundry discharge or any other application which may contain caustic chemicals andlor foreign materials Pump damage may occur if used in these applications and will void warranty Power supply requirements MO ton 2 2 ood eee ened Gee ed RAE See Normal water removal Liquid temperature range Circuit requirements 0 Pump Dimensions Pump run time 0000e eee eens Pump Construction EEE ine wang dsecg a Goats a ROD 120V 60 Hz PONIRE RTE Perminent Magnet DC Motor abe EEEE a 2880 GPH 5 Feet 26V DC Ba Mang aen Reta alai aii 40 F to 120 F OE E TAE EEE 5 amps AC min a ee E E cet 11 in high x 8 4 in base 2 iss ety dia E eats pr ata 15 Seconds Motor housing volute seal plate impeller e3ei stead ad doled dao eee een 3 Shanti eicere e dus EEEE dane 4 Discharge 00 0ec eee eee eee Float switch 00 000e eee eens D geaplags Sues weds Gus OE Cast Iron ss fades due a fuerte er mecca Thermoplastic E E Gates AE EE Stainless Steel TE AE RSE E E E EI ENES 1 2 in NPT N SE atid cus laghe asa pees Reed Style REMINDER Keep your dated proof of
12. dition follow the steps that Maintenance the power source is out of sight lock and repair this unit Improper repair could are listed below BATTERIES Dangerous A DANGER 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 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 A WARNING If battery acid 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 A WARNING Never smoke or allow a spark or flame in the vicinity of the battery A WARNING Avoid dropping 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
13. ds do not interfere with float switch pump inlet or main pump operation Backup pump must not be allowed to run dry PS BC Installation Use Power Supply NOTICE Battery Charger PSIBC indoors in a well ventilated area Do not expose PS BC to rain or snow Do not use an extension cord Do not disassemble PS BC Be sure PS IBC ventilation holes are unobstructed If PSIBC is dropped or damaged do not operate return to manufacturer for service Risk of electrical A WARNING shock Use a GFCI Ground Fault Circuit Interrupter receptacle to reduce the risk of fatal electrical shock Grounded receptacle must be rated for at least 5 amps 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 battery case vent holes are unobstructed ELEVATE PS BC BY MOUNTING ON WALL OR SETTING ON A SHELF SLOTS IN THE BACK SIDE OF PS BC ARE AVAILABLE FOR WALL MOUNTING Control Box Installation If cables are A CAUTION reversed damage to the PS BC or battery could result and warranty will be void Dangerous 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 Www waynepumps com
14. e fuse is blown replace it with an automotive type fuse of the same amp ratio Motor hums but pump won t run Defective battery Impeller is locked Check battery and replace if low or defective Unplug pump volute and check to see if impeller is free to turn If impeller is locked remove the obstruction Reassemble pump and reconnect Pump runs but pumps very little or no water Check valve missing or improperly installed Obstruction in discharge pipe or pump inlet Discharge pipe length and or height exceeds capacity of pump Low or defective battery 1 Check to make sure check valves installed between primary pump discharge and Backup Sump Pump are functioning properly Check for obstruction and clear if necessary If discharge is too high a separate line may be required with a lower discharge height Check battery and replace if low or defective Pump cycles too frequently No yellow light Check valve problem Battery connection problem Check to make sure check valves installed between primary pump discharge and Backup Sump Pump are functioning properly Verify battery connection is correct Red light is on with alarm Blown pump fuse Low battery voltage Check fuse and replace with a fuse of same rating and size Check battery voltage PS BC will not charge batteries with a combined voltage of 21 6 VDC or less Www waynepumps com ESP45
15. icate the discharge piping arrangement for the primary AC pump if the existing discharge line has to be adjusted to accommodate a second pump 9 Glue a 45 elbow to the short pipe on the ESP45 pump Glue a Y adapter to the short pipe on the existing pump as shown in illustration for Method 2 10 Glue a short piece of PVC pipe between the 45 elbow and the Y NOTE Check valves can be placed directly in the pump discharge if desired However for ease of disassembly it is recommended that check valves be placed above the sump as shown in Figure 3 The remainder of the discharge pipe installation will vary depending on individual circumstances Using sound plumbing practices route the discharge pipe to an exterior wall by the shortest distance Joist Connector ae y Rigid PVC Pipe 45 Elbow bn Check Valve PS BC See Step 10 con Batteries f Battery Box ESP45 Pump Existing Pump Figure 3 Method 2 Always disconnect Methods 1 ane 2 A WARNING pes deren Install float switch at least 10 12 remove pump fuse before connecting or above bottom of sump pit so that disconnecting battery backup unit turns on only when the water level is higher than the normal on level for main pump Use the hose clamps provided to secure the switch to the discharge pipe Make sure power wires and hose clamp en
16. orm only to maintain your records MODEL NO SERIAL NO INSTALLATION DATE ATTACH YOUR RECEIPT HERE Www waynepumps com
17. otentially hazardous situation which if not avoided may result in minor or moderate injury NOTICE Notice indicates NOTICE important information that if not followed may cause damage to equipment General Safety Information CALIFORNIA PROPOSITION 65 A WARNING This product or its power cord may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling GENERAL SAFETY A DANGER Do not use to pump flammable or explosive fluids such as gasoline fuel oil kerosene etc Do not use ina flammable andlor explosive atmosphere Pump should only be used to pump clear water Fatal injury and or A DANGER If the basement has water or walk on wet area until all a power is turned off If the shutoff box Remove pump and either repair or replace Failure to follow this warning property damage could result moisture on the floor do not is in the basement call an electrician could result in fatal electrical shock Pump Specifications All wiring must be A WARNING performed by a qualified electrician A WARNING KL Do not expose battery to d sparks or flames as an explosion or fire could result A WARNING m Battery acid is corrosive i Avoid spilling on skin or K clothing Eye protection must be worn when handling the battery A WARNING A check valve must
18. p 1 Turn power to main pump off 2 Pump must be installed using 11 4 or 1 2 rigid PVC piping Pump Installation The ESP45 can be installed as a back up system with a separate dedicated discharge line Method 1 or tied into an existing sump pump line Method 2 Unplug the existin Re pia Failure Fel follow this warning could result in fatal electrical shock 1 Verify that the existing AC pump is in good working order If the AC pump is questionable it is typically recommended that the unit be replaced with a 1 3 or 1 2 HP pump 2 Remove any silt or accumulated debris from the sump pit and surrounding area Method 1 Preferred 1 Locate the ESP45 on a solid level surface in the sump pit Do not place the pump on a loose or sandy surface Small stones or sand may damage the pump resulting in potential pump failure 2 This pump has a 1 2 NPT discharge If a 14 discharge pipe is desired an adapter not included will be necessary Smaller diameter piping will reduce pump flow rate and performance 3 Cuta4 section of 1 4 or 1 42 diameter rigid PVC pipe Cement 1 4 pipe to a threaded fitting Cement 1 4 pipe into pipe coupling Attach 1 pipe section to the ESP45 discharge adapter 4 Screw on to pump discharge NOTICE Be careful not to NOTICE strip or cross thread plastic fittings or check valves Flex hose is not recommended Rigid PVC or metal Pipe is required
19. ter Fatal electrical shock could occur A DANGER Risk of electrical shock Use a GFCI receptacle to reduce the risk of fatal electrical shock Cutting the cord or plug will void the warranty and make the pump inoperable CHART 2 PS BC STATUS LIGHTS LIGHT ON WHEN ACTION REQUIRED Red Low Voltage or Blown Fuse Check Fuse or Replace Batteries Yellow Battery OK None Green AC power on None 1 After installation the backup pum A DANGER Working in the will start when the water levei Ties ADANGER vicinity of lead acid above the depth that the primary pump should start 2 The PS BC has a DC charger designed to shorten the recharging time of your battery and to prevent overcharging In addition the control box has a time delay which keeps the pump from repeated short cycles when it shuts off This time delay feature will allow the pump to run 15 seconds after the switch reaches the off position A DANGER Unplug main AC pump and the charger Risk of electrical w shock Always disconnect the W electrical supply before amp attempting to install service relocate or per form any maintenance If 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 result in fatal electrical shock Once a month NOTICE check the condition of the battery In order to review the battery con
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