Pentair FG200-A1, FG100-A1 User Manual

OWNER’S MANUAL

Battery Backup System

NOTICE D’UTILISATION

Système de secours à batterie

MANUAL DEL USUARIO

Systema de respaldo de la batería

FG100-A1

Installation/Operation/Parts

For further operating, installation, or maintenance assistance:

Call 1-888-957-8677

English ........................ Pages 2-15

Installation/Fonctionnement/Pièces

Pour plus de renseignements concernant l’utilisation, l’installation ou l’entretien,

Composer le

1 (888) 957-8677

Français .................. Pages 16-29

ALWAYS READ WARNINGS IN INSTRUCTION

A.C.POWER ON

MANUAL BEFORE USING.

PUMP RUN ALARM

AUDIBLE ALARM

MICRO PROCESSOR CONTROLLED

SILENCE

5 STAGE BATTERY CHARGE/MAINTAINER

12 VOLT 8 AMP

LOW BATTERY ALARM

CHARGING - YELLOW CHARGED - GREEN

AUDIBLE ALARM

DISABLE

ALARM RESET SOFT RESET

FG200-A1

Instalación/Operación/Piezas

Para mayor información sobre el funcionamiento, instalación o mantenimiento de la bomba:

Llame al 1-888-957-8677

Español .................. Paginas 30-44

293 WRIGHT STREET, DELAVAN, WI 53115 WWW.HYDROMATIC.COM PH: 8889578677

Safety 2

READ AND FOLLOW

SAFETY INSTRUCTIONS!

This is the safety alert symbol. When you see this

symbol on your pump or in this manual, look for one of the following signal words and be alert to the potential for personal injury!

DANGER warns about hazards that will

cause serious personal injury, death or major property damage if ignored.

can cause minor personal injury or property damage if ignored.

The word NOTICE indicates special instructions which are important but not related to hazards.

1. To avoid risk of serious bodily injury due to electrical

shock or burns and property damage due to flooding, read the safety instructions carefully before installing pump.

WARNING warns about hazards that can

CAUTION warns about hazards that will or

5. Pump clear water only with this pump.

6. Pump is permanently lubricated at the factory. Do not try to lubricate it!

7. Keep battery charger and battery box off of the floor and in a dry, cool, well ventilated area.

NOTICE: If a Carbon Monoxide (CO) sensor is

installed, it must be at least 15 feet away from battery charger in order to avoid nuisance CO alarms. Please refer to your CO detector’s installation guidelines for more information.

8. To avoid danger of fire or explosion, keep sparks and flame (pilot light) away from battery.

9. Maximum vertical pumping distance is 16 feet (4.9M) for Model FG100-A1 and 18 feet (5.5M) for Model FG200-A1.

10. Make sure sump is clear of debris. Debris can damage the pump which can result in flooding.

California Proposition 65 Warning

This product and related accessories contain chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Battery acid is corrosive. Do not spill on

skin, clothing, or battery charger. Wear eye and head

protection when working with battery. Connect and disconnect DC output terminals only after removing the charger from the AC outlet. Never allow the DC terminals to touch each other.

fatal electrical shock. Do not plug in or unplug battery charger while standing on a wet floor or in water. Be sure one hand is free when plugging in or unplugging charger. If basement floor is wet, disconnect power to basement before walking on floor.

To do so will damage seals and can cause leaking and property damage.

2. Follow local and/or national plumbing and electrical codes when installing the system. A ground fault circuit interrupter (GFCI) is recommended for use on any electrical appliance submerged in water.

3. Use this system only for backup sump pump duty in a residential application. It is not designed as a primary sump pump.

4. Do not lift pump by electrical cord.

pump by the electrical cord; lift pump only by the discharge pipe, lifting ring or handle on the pump. Lifting by the cord can damage the cord.

Hazardous Voltage. Can cause severe or

Risk of flooding. Do not run pump dry.

Risk of electrical shock. Do not lift the

GENERAL INFORMATION

The battery back-up sump system is not a sub stitute for your primary sump pump. It is designed to temporarily back up your primary sump pump during a power outage or other problem which prevents normal operation of the primary pump. Do not use this system to pump flammable liquids or chemicals. Pump clear water only with this pump.

Keep battery charger dry and protected from damage. In an emergency (such as an extended power outage)

which depletes the system deep cycle battery, your automobile battery may be temporarily substituted. Be sure to replace the system deep cycle battery as soon as possible. Use of an automobile battery instead of a deep cycle battery in this system will significantly reduce system total performance. Automobile batteries are not designed for this type of application and will be quickly ruined by the repeated charge/discharge cycling. Do not use GEL-type batteries or maintenance-free (sealed) batteries with this charger. GEL-type batteries require a lower voltage than the charger is designed for; they may overcharge. Maintenance-free (sealed) batteries require a higher voltage and may never reach full charge.

NOTICE: This unit is not designed for applications involving salt water or brine! Use with salt water or brine will void warranty.

Table of Contents 3

Page

General Safety .....................................................................................................2

Warranty..............................................................................................................3

Installation ......................................................................................................4-12

Operation .....................................................................................................13-14

Troubleshooting .................................................................................................14

Repair Parts .......................................................................................................15

Limited Warranty

HYDROMATIC warrants to the original consumer purchaser (“Purchaser” or “You”) of HYDROMATIC Sump Pumps, Effluent Pumps, Sewage Pumps (other than 2-1/2”), and Package Systems, that they will be free from defects in material and workmanship for the Warranty Period of 36 months from date of manufacture.

Our warranty will not apply to any product that, in our sole judgement, has been subject to negligence, misapplication, improper installation, or improper maintenance. Without limiting the foregoing, operating a three phase motor with single phase power through a phase converter will void the warranty. Note also that three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of the recommended size or the warranty is void.

Your only remedy, and HYDROMATIC’s only duty, is that HYDROMATIC repair or replace defective products (at HYDROMATIC’s choice). You must pay all labor and shipping charges associated with this warranty and must request warranty service through the installing dealer as soon as a problem is discovered. No request for service will be accepted if received after the Warranty Period has expired. This warranty is not transferable.

EXCEPTIONS: Hydromatic Special Application Pumps, Battery Back-Up Sump Pumps, Filtered Effluent Pumps, Grinder Pumps, and 2-1/2” Sewage Pumps are warranted for a period of 12 months from date of purchase or 18 months from date of manufacture, whichever comes first.

HYDROMATIC SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGESWHATSOEVER.

THE FOREGOING LIMITED WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING LIMITED WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION PROVIDED HEREIN.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on the duration of an implied warranty, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights and You may also have other rights which vary from state to state.

This Limited Warranty is effective June 1, 2011 and replaces all undated warranties and warranties dated before June 1, 2011.

HYDROMATIC

293 Wright Street, Delavan, WI 53115

Phone: 888-957-8677 • Fax: 800-426-9446 • Web Site: hydromatic.com

Installation 4

BATTERY BACKUP SYSTEM

INSTALLATION AND OPERATION

NOTICE:

• Install this system during a time when the primary pump will not be needed. Gather all supplies before starting. Read all warnings and installation steps before you start.

• Bepreparedforwatertoleakfromthecouplingor

piping when disassembling or cutting the discharge pipe. Protect system components, tools and supplies from getting wet. Dry any work areas that get wet.

BASIC TOOLS AND

MATERIALS NEEDED

Channel locks or large pliers Tape measure Socket wrench or 5/16" Nut driver Side cutters Hacksaw (to cut PVC pipe) Medium size pliers Pencil PTFE pipe thread sealant tape PVC glue (solvent weld) PVC pipe cleaner Cloth towel Size 24M Marine Deep Cycle Battery (sold separately) or a Size 27M Marine Deep Cycle Battery (sold separately)

Required Battery Capacity:

FG100-A1 – 100 ampere-hour maximum. FG200-A1 – 130 ampere-hour maximum.

Personal injury and flood hazard. Do not

turn the pump on until all the fittings are glued and the glue has dried. Loose fittings can explode off of pipes and cause personal injury and flooding.

Remove Primary Pump From Sump Pit:

1. Locate the “on” water level of the primary sump pump. Mark this location on the discharge pipe with a pencil. See Figure 1.

2. Drain the sump pit. The water level must be pumped down as low as possible before going on to the next step. To drain the sump pit follow either step “2A” or “2B” (below).

2A. Raise the float on the float switch until the

2B. If the sump pump has a piggy-back type power

pump turns on. Use a wooden broom handle or a stick to do this.

cord, remove the float switch power cord plug from the outlet and plug the pump power cord plug directly into the outlet. See Figure 2.

Electrical shock hazard. Shock can

burn or kill. Do not use metal or any other electrical conducting material to raise the float. Do not make contact with the water in the sump pit. Failure to follow this warning can result in personal injury or death.

3. Drain the sump. NOTICE: Do not let the pump run dry. This will

damage the pump.

4. Unplug the pump.

Support the Pipe before cutting.

'Turn on' water level of Primary Pump

Check Valve

Sump Pit

Grounded Electrical Outlet

4166 0402

Remove the hose coupling or mark the 1st cut here.

Mark pipe with pencil here (2nd cut).

Figure 1 – Mark and cut pipe as shown

Unplug the "Piggy-back" float switch cord plug and the pump power cord plug from the grounded electrical outlet.

Separate the float switch cord plug from the sump pump cord plug.

Plug the pump power cord plug directly into the outlet.

Figure 2 - To bypass the float switch

Installation 5

Backup Pump Installation

5. To separate the primary pump from the discharge pipe: 5A. For applications with hose couplings: remove

the coupling clamps with a nut driver.

5B. For applications without rubber couplings: cut

the PVC discharge pipe with a hacksaw above the basement floor, at a comfortable level. New rubber couplings are included for reassembly. See Figure 1 on Page 4.

NOTICE: The discharge pipe is filled with water.

Drain the water from the discharge pipe assembly. Keep the work area dry.

Risk of pinching hands or fingers. To

avoid a hand injury from a collapse of plumbing, support the pipe above the separation before cutting or disassembly. See Figure 1.

6. Lift the primary pump and discharge pipe assembly out of the sump.

Risk of electrical shock. Do not lift the

pump by the electrical cord; lift pump only by the lifting ring, discharge pipe, or handle on the pump. Lifting by the cord can damage the cord.

INSTALL BACKUP PUMP

There are two ways to install the Battery Back-up Pump. Method A and Method B. See Figure 3 to determine which method to use. Both methods are acceptable.

Not to Scale

Switches and Wiring omitted for clarity

Hose Coupling with Clamps

Cut-Off piece of discharge pipe.

1-1/2"x1-1/4" Reducer bushing

Tee 1-1/2"x 1-1/2" slip x 1-1/4" FNPT

1-1/2"x1-1/4" Reducer bushing

Short Length of Discharge Pipe (may vary)

Primary Sump Pump Check Valve to prevent recirculation into the sump.

(Method A)

First Cut:

Second Cut: at Marked Water Line

Close Pipe Nipple (1-1/4" x 1-1/4") (1 Nipple is included with the back-up pump package)

1-1/4" Elbow

Check Valve Assembly

Sump Pit

Diameter at

base at least

18"?

Yes

Sump Pit Depth

18-22"?

Yes

Method A

No No

Sump Pit Diameter at base at least

13.5"?

Sump Pit Depth

at least 22"?

Method B

BBU System may still

Yes

be installed but the installation may need to be changed.

Yes

Figure 3 - Choose an installation method

Method A

Method A suggests installing both of the pumps on the floor of the sump pit. See Figure 4. The minimum required sump basin diameter, at the bottom of the pit and the recommended depth of the sump basin is 18".

Some additional materials you will need are 2 1-1/4" 90° elbows and 2 1-1/4" close pipe nipples.

1-1/4" Elbow

Primary Pump Discharge Port

Back-up Pump Discharge Port

Figure 4 - Method A installation diagram

Close Pipe Nipple

Elbow

Check Valve Assembly

Battery Back-up Pump comes preassembled with the check valve assembly installed on the discharge.

Remove this check valve assembly.

Back-up Pump Discharge

Water Flow through valve

(The valve flap opens away from the pump outlet)

Tee

Figure 5 - Remove the pre-assembled check valve

Installation 6

1. Make the second cut in the discharge pipe at the pencil mark as shown in Figure 1 on page 4, and in Figure 4, on Page 5. Clean the pipe ends with a cloth towel and set the cut-off piece of discharge pipe aside.

2. Remove the check valve assembly (Key No. 4 on Page 15) from the battery back-up pump (Key No. 5) discharge and set it aside. See Figure 5. The check valve assembly will be used later, during assembly.

3. Thread a 90° elbow (purchased locally) onto the discharge of the back-up pump.

4. Wrap the threads of all 3 of the close pipe nipples (Key No. 3) with 2 turns of PTFE pipe thread sealant tape and thread one of them into the elbow. Set the other 2 aside.

5. Thread the check valve assembly, removed back in step 2, onto the close pipe nipple.

NOTICE: Make sure the check valve is installed in the

correct direction. See the inset drawing in Figure 5.

6. Thread a close pipe nipple into the other end of the check valve.

7 Thread the second 90° elbow onto the pipe nipple.

8. Thread the last pipe nipple into the elbow.

9. Thread the tee onto the pipe nipple and set this assembly aside.

10. Install a short length of pipe into the top of the check valve in the primary pump discharge. See Figure 6.

NOTICE: There must be a check valve installed in

the Primary Sump Pump discharge pipe between the tee and the Primary Sump Pump. This will prevent recirculation into the Primary Pump when the Backup Sump Pump comes on.

11. Slip a reducer bushing (Key No. 2A) onto the end of the pipe coming from the primary pump discharge. Do not glue this connection yet.

NOTICE: If your discharge pipe diameter is 1-1/4",

you will need to glue the reducer bushings into the tee first and then slip the cut off piece of discharge pipe into the bushing.

12. Slip the tee and the back-up pump subassembly onto the reducer bushing.

13. Glue the cut off piece of pipe into the top of the reducer bushing in the top of the tee.

14. Mount the float switch assembly (Key No. 7) loosely to the discharge pipe with the cable ties (Key Nos. 7A & 7B). See Figure 6. Approximately 2.5” (63.5 mm) of cord length should be left between the float and the clamp. Do not tighten the cable ties. Adjustments may be needed later.

15. Skip to the section “Cut the Discharge Pipe”, Page 7.

Method B

Method B suggests installing the back-up pump above the primary sump pump. See Figure 7. The minimum required sump basin diameter for this type of installation is 13.5" at the bottom of the pit, and the minimum recommended depth of the basin is 22".

1. Make a second cut in the discharge pipe at the pencil mark made in step 1, on Page 4, and set the cut-off piece of discharge pipe aside. See Figures 1 and 7.

Backup Pump Installation

(Method B)

Discharge Pipe

Hose Coupling and Clamps

Cable Ties

2" Minimum

Te e

Short length of discharge Pipe (length may vary).

Check valve

Float Switch Tether Length

2.5" (63.5 mm)

To the back-up pump discharge pipe.

Primary Sump Pump Discharge Pipe

Figure 6 - Back-up pump float switch tether length and discharge pipe

Not to Scale

Switches and Wiring omitted for clarity

Hose Coupling with Clamps

First Cut:

Cut-Off piece of discharge pipe.

Backup Sump Pump

Check Valve Assembly (Included)

Primary Sump Pump Check Valve to Prevent Recirculation into Sump

Close Pipe Nipple

Second Cut: at Marked Water Line

1-1/2"x1-1/4" Reducer Bushing

Tee

1-1/2"x1-1/4" Reducer Bushing

Primary Pump Discharge Pipe

Figure 7 – Method B installation diagram

Basement Floor

Sump Pit

Installation 7

2. Wrap the threads of the close nipple (Key No. 3 on Page 12) counterclockwise with 2 turns of PTFE pipe thread sealant tape and set aside.

NOTICE: There must be a check valve installed in

the Primary Sump Pump discharge pipe between the tee and the Primary Sump Pump. This will prevent recirculation into the Primary Pump when the Backup Sump Pump comes on.

3. The backup pump (Key No. 6) and check valve assembly (Key Nos. 4 and 5) come preassembled. Thread the close pipe nipple into the check valve.

4. To thread the tee (Key No. 2B - also included reducer bushings) into the close nipple:

Hold the check valve assembly with the channel

locks, insert the screwdriver into the tee for leverage, and tighten the tee with the screwdriver. Finish with the tee in a straight up and down (vertical) position.

5. Clean the pipe ends with the cloth towel.

6. Glue the cut-off piece of discharge pipe into the top of the tee.

NOTICE: If your pipe is 1-1/4", you will need to

glue the reducer bushings into the tee and glue the pipe into the bushing. Place the assembly onto the primary discharge pipe. Do not glue the tee onto the primary pump discharge pipe.

7. Mount the back-up pump float switch assembly (Key No. 7) loosely to the discharge pipe with the cable ties (Key Nos. 7A & 7B). See Figure 6, on Page 6. Approximately 2.5" (63.5 mm) of cord length should be left between the float and the clamp. Do not tighten the cable ties. Adjustments may be needed later.

Cut the Discharge Pipe:

1. Put the double pump assembly into the sump pit.

NOTICE: The discharge pipe now overlaps the

discharge pipe that leads outside.

Method A Method B

Exterior discharge pipe

Make the Third Cut (the overlap plus the 1/4" air gap).

overlap

1/4" air gap

overlap

Exterior discharge pipe

Sump basin inlet pipe (from drain tiles to sump basin).

Recommended Minimum

Previously marked "on" water level of Primary Sump Pump. (See Figure 1, Page 4)

2. Mark the discharge pipe where it should be cut. Be sure to leave a 1/4" air gap between the ends of the pipes. This gap will absorb the noise from vibration and allow for flexibility.

3. Make the third cut. See Figure 8.

TRIAL ASSEMBLY OF DOUBLE PUMP

ASSEMBLY IN THE SUMP PIT:

1. Connect the discharge pipe to the exterior discharge pipe with the rubber coupling and clamp kit (Key No. 1). Do not tighten the clamps until all the final adjustments are complete.

2. Make the final adjustments. Make sure the pumps and the switches do not interfere with each other. Make sure there is plenty of room for the float switches to either swing or to move up and down from their “off” to their “on” positions.

Mark and Glue Assembly:

1. Mark the pipe and the fittings at all the connections with a pencil. These marks will be used as a reassembly guide while gluing to be sure everything is still in the right place and nothing has moved.

2. Loosen the rubber coupling and clamp connection.

3. Carefully pull the double pump assembly back out of the pit.

4. Take the tee assembly off of the primary discharge pipe. Do Not unscrew any of the PTFE pipe thread sealant taped pipe nipple connections.

5. Clean all the PVC pipe ends with the PVC cleaner.

and cleaner manufacturers instructions. Use the PVC cement in a well ventilated area away from fire or flames.

6. Glue the PVC fittings where indicated by the pencil marks. Wait 10 minutes for the glue to cure.

Final Assembly:

1. Put the double pump assembly back into the pit.

2. Install and tighten the rubber coupling and clamp kit.

3. Make the final float switch adjustments and tighten the cable ties.

Hazardous fumes. Follow the cement

Note: Always install the back-up sump pump as close to the bottom of the sump pit as possible.

Figure 8 – Make the third cut to remove the excess discharge pipe

Installation 8

ELECTRICAL CONNECTIONS

Hazardous voltage. Can cause serious or fatal electrical shock. Review safety instructions before operating charger. Do not modify cord or plug.

4 STAGE LEAD-ACID BATTERY CHARGER

BLACK TERMINAL NEGATIVE (-)

RED TERMINAL POSITIVE (+)

COMPLETE

CHARGE

FAULT

BATTERY CONNECTION

–

CHARGER CONNECTION

–

FLOAT SWITCH CONNECTION

REPLACE FUSE WITH SAME 25 AMP 36V TYPE AND RATING ONLY

PUMP FUSE & CONNECTION

–

DISABLE ENABLE

AUDIBLE ALARM

DISABLE WHEN LIT

BATTERY CONNECTION

CHARGER CONNECTION

FLOAT SWITCH CONNECTION

REPLACE FUSE WITH SAME 20 AMP 36V TYPE AND RATING ONLY

PUMP FUSE & CONNECTION

–

CHARGER/BATTERY INSTALLATION

NOTICE: An alarm, located in the junction box,

automatically sounds when the system runs if the alarm is in the “Enable” position. The alarm is silenced when the alarm switch is in the “Disable” position.

Model Number FG100-A1:

1. Apply two pieces of two-sided tape (provided, Key No. 9) to the back of the junction box. Press the junction box onto the battery box as illustrated in Figure 9 and on Page 15 (Exploded View).

2. Connect the charger as shown in Table I and Figure 9.

3. Plug the charger into a 115-120 Volt AC outlet deliv er ing at least 15 amps. Do not use a switch controlled outlet. Mark circuit in main power panel “Backup sump pump power supply; do not turn off”.

4. With the charger properly connected and plugged in, the panel on the front of the charger will show one of the conditions illustrated in Figure 10.

Red LED - AC power is present

DISABLE ENABLE

AUDIBLE ALARM

DISABLE WHEN LIT

Figure 9 – Wiring Connections FG100-A1

TABLE I - FG100-A1 Wiring Connections

Connect the To the Junction Box’s

Positive (+) lead from the battery Positive battery connection Negative (–) lead from the battery Negative battery connection Positive lead from the charger Positive charger connection Negative lead from the charger Negative charger connection Backup sump pump Float switch

float switch (2 wires) connection (2 wires) Positive lead from the pump Positive pump connection Negative lead from the pump Negative pump connection

Red

Green

Yellow

Figure 10 – FG100-A1 LED Panel

Yellow LED - Prequalification test stage is complete and testing

or charging in process

Green/Occasional Yellow - Charger turns on intermittently to maintain proper charge

Green LED - Charging complete

Green/Yellow LEDs Alternately Flashing - System is in Error Mode

(see Table II, Page 9)

NOTICE: For more detailed information, see “Charger Operation” on Page 13.

Installation 9

TABLE II - 800 mA Charger Error Table (Green and Yellow LEDs will flash alternately)

Error Description Possible Causes Fix

The Battery Failed The battery is highly sulfated Replace the battery with a 12-Volt deep-cycle Pre-Qualification Test marine battery

The charger is connected to a Replace the battery with a 12-Volt deep-cycle six-volt battery marine battery

Battery Over-Voltage The Charger is connected to a Replace the battery with a 12-Volt deep-cycle 24 Volt Battery marine battery

Charge Time Monitor Battery took too long to complete its charge: A. Load applied (e.g. the pump motor Be sure pump cannot start during charging; started) during charging reset the charger

B. The battery ampere-hour rating Replace with correct size battery (see Page 4) is too large (Max. 96 ampere-hours)

Excessive Battery Pump motor ran during charging Check primary sump pump. The BBU generally Drain (that is, with the main A.C. power ON), runs only when the main A.C. power is out. causing the system to shut down If there has not been any power outage and the BBU has run, the primary pump itself may have failed

Reverse Battery Charger is connected backwards Reconnect Charger (+) to Battery (+)/(-) to (-) Connection to the battery. (That is, Charger (+) to Battery (-) and vice versa)

Battery Overheated Cells in an old battery may Replace battery with a 12-Volt deep-cycle deteriorate with age marine battery

TABLE III - 800 mA Charger Light Indications

Charger Light On/Off/Flashing Indicates

All Lights Off System is not receiving AC power

Power (Red Light) On System is receiving AC power Off System is NOT receiving AC power or battery leads are reversed

Charging (Yellow Light) Flashing 1x/Second Charger is running “Pre-Qualification” test (this lasts 45 seconds to 6 hours)

On, steady Charger is either in “Constant Current” or “Constant Voltage” stage. This may last up to 96 hours

Flashing alternately System is in an ERROR mode (see Table II, above) with green light

Charged (Green Light) On, yellow light Off Battery is fully charged Flashing alternately System is in an ERROR mode (see Table II, above)

with yellow light

Installation 10

Model Number FG200-A1:

1. Connect charger as shown in Table IV and Figure 11.

A.C.POWER STATUS

PUMP RUN STATUS

ALARM SILENCE

ÉTAT DU COURANT ALTERNATIF. ESTADO DE LA CORRIENTE ALTERNA.

ÉTAT DE FONCTIONNEMENT DE LA POMPE. ESTADO DE FUNCIONAMIENTO DE LA BOMBA.

ARRÉT D'ALARME. SILENCIO DE ALARMA.

PUMP/POMPE/BOMBA (+)

FLOAT/FLOTTEUR/FLOTADOR (+)

PUMP/POMPE/BOMBA (–)

BATTERY/BATTERIE/BATERÍA (–)

FLOAT/FLOTTEUR/FLOTADOR (–)

BATTERY/BATTERIE/BATERÍA (+)

PUMP/POMPE/BOMBA (+)

FLOAT/FLOTTEUR/FLOTADOR (+)

PUMP/POMPE/BOMBA (–)

BATTERY/BATTERIE/BATERÍA (–)

FLOAT/FLOTTEUR/FLOTADOR (–)

BATTERY/BATTERIE/BATERÍA (+)

Figure 11 – Wiring Connections FG200-A1

TABLE IV - FG200-A1 Wiring Connections

To the position indicated Connect the below, on the charger

Positive (+) lead from the battery Positive battery terminal (leads are provided)

Negative (–) lead from the battery Negative battery terminal (leads are provided)

Positive (+) “Backup sump Pump” Positive pump lead terminal lead (BROWN wire)

Negative (–) “Backup sump Pump” Negative pump lead terminal lead (BLACK wire)

Positive (+) Float switch Lead Positive float switch terminal (WHITE wire)

Negative (–) Float Switch Lead Negative float switch terminal (BLACK wire)

BATTERY STATUS

CHARGER MODE

SILENCE

ARRÉT/SILENCIO

ÉTAT DE LA BATTERIE. ESTADO DE LA BATERÍA.

MODE DU CHARGEUR. MODO DE CARGADO.

ALARM

ALARME/ALARMA

RESET/RÉARMEMENT

REPOSICIÓN

3464 0799

Figure 12 – FG200-A1 LED Panel

Red “AC Power Status” LED - AC power is present

Yellow (bicolor) LED on continuously - Prequalification test is

complete and charging is in process

Yellow “Charging” LED flashing on and off quickly - Equalization charge stage

Green (bicolor) LED is on - Battery is being maintained at full charge

Bicolor LED flashing yellow/green alternatively - See Error Charge Table (Table VI, Page 11)

Test the Assembly:

1. Plug the primary pump into a properly grounded 3-prong outlet.

2. Fill the sump with water to start the primary pump. Check for leaks.

3. Unplug the primary pump and fill the sump with water to start the backup system pump. Check for leaks.

4. Plug the primary pump back into a properly grounded 3-prong outlet. The system is now ready for operation.

2. Plug the charger into a 115 Volt AC outlet deliv er-

ing at least 15 amps. Do not use a switch controlled outlet. Mark the circuit in the main power panel “Backup sump pump power supply; do not turn off”.

3. With the charger properly connected and plugged in, the panel on the front of the charger will show one or more of the following conditions (See Figure 12).

Installation 11

TABLE V - 8 Amp Charger Error Table

Error Description Possible Causes Fix

The Battery Failed The battery is highly sulfated Replace the battery with a 12-Volt deep-cycle Pre-Qualification Test marine battery

The charger is connected to a Replace the battery with a 12-Volt deep-cycle six-volt battery marine battery

Battery Over-Voltage The Charger is connected to a Replace the battery with a 12-Volt deep-cycle 24 Volt Battery marine battery

Charge Time Monitor Battery took too long to complete its charge: A. Load applied (e.g. the pump motor Be sure pump cannot start during charging; started) during charging reset the charger

B. The battery ampere-hour rating Replace with correct size battery (see Page 4) is too large (Max. 130 ampere-hours)

Reverse Battery Charger is connected backwards Reconnect Charger (+) to Battery (+)/(-) to (-) Connection to the battery. (That is, Charger (+) to Battery (-) and vice versa)

Battery Overheated Cells in an old battery may Replace battery with a 12-Volt deep-cycle deteriorate with age marine battery

Charging Error An internal error occurred in the charger Unplug the charger during one of the charging stages

in again. If error occurs again, refer to Table VI, below

for 10 seconds and then plug it

TABLE VI - 8 Amp Charger Error Light Indications

NOTE: This chart identifies light codes indicating various char-

ger error modes. It only applies when the ‘Charger Mode’ light flashes YELLOW/GREEN alternately. The light codes listed here DO NOT relate directly to the legends on the charger housing

A.C. Power Pump Run Alarm Charge Status Status Silence Mode Error Mode

Flashing Off Off Flashing Yellow/Green Battery Overheated Flashing Off Flashing Flashing Yellow/Green Charge Time Monitor Flashing Flashing Off Flashing Yellow/Green Excessive Battery Drain Flashing Flashing Flashing Flashing Yellow/Green Failed Pre-Qualification Test Off Off Flashing Flashing Yellow/Green Battery Over-Voltage Off Flashing Off Flashing Yellow/Green Reverse Battery Connection Off Flashing Flashing Flashing Yellow/Green Output Over-Current

(A.C. Power Status, Pump Run Status, Alarm Silence, etc.). The legends on the charger apply ONLY when the ‘Charger Mode’ light is NOT flashing yellow/green.

LED Status

“Silence Alarm/Reset” Rocker Switch:

Push the LEFT side of the rocker switch on the front of the charger to silence the alarm. NOTE: This will NOT silence the alarm when the battery is below 8.2 volts or the system is in ERROR mode.

Push the RIGHT side of the rocker switch to reset the ‘Pump System Status’ LED after the pump has run, or to reset the system from an error mode. When you reset the system, the charger will start its diagnostic procedure (pre-qualification test, etc.) from the beginning. If the cause of the ERROR mode is not corrected, the system will go into the ERROR mode again.

Installation 12

TABLE VII - 8 Amp Charger Light Indications

Charger Light On/Off/Flashing Alarm Buzzer Indicates

All LEDs Flash ONCE Off Connected system to AC power or to battery; or, pressed ‘Reset’ when in ERROR mode

AC Power On Off System is receiving AC power

Status

Very Slow Flash Off System is not receiving AC power

Pump Run Fast Flash (2x/second) Beep in synch Pump is running. Press LEFT side of rocker Status with LED flash switch to silence alarm

Slow Flash (1x/2 seconds) Off Pump has run, but is not running now Off Off Pump has not run

Alarm Silence On Alarm is silenced Off Alarm is active

Battery Status On Off System is not connected to a battery or is connected to a battery charged to less than 1 volt DC

Slow Flash On Battery voltage less than 10.9 volts. Alarm can be silenced

Fast Flash On Battery voltage is less than 8.2 volts Alarm CANNOT be silenced

Off Off System is properly connected to a battery

Charger Mode Slow YELLOW Flash Off System is in the “pre-qualification” stage. This will last from 1 minute to 5 hours, depending on the condition of your battery

Solid YELLOW Off System is in the “Constant Current Charge” stage. This will continue until the battery voltage reaches approximately 14.3 volts

Fast YELLOW Flash Off System is in the “Constant Voltage Charge stage”. This could last up to 14.5 hours

Solid GREEN Off Battery is fully charged Flashing alternately On - Beeping System is in an ERROR mode. Alarm will beep in synch

YELLOW/GREEN with one or more of the ‘AC Power Status’, ‘Pump Run Status’, or ‘Alarm Silence’ LEDs. See Tables V and VI, Page 11, for more information

TABLE VIII - 8 Amp Charger Audio Alarm Indications

Audio Alarm Mode Indicates Action

On - Beeping Slow Beep in Synch with Battery is Investigate cause; battery is very low. You ‘Battery Status’ LED down to about have limited pump run time left. Press

10.9 Volts and release LEFT side of toggle switch to silence alarm

On - Beeping Fast Beep in Synch with Battery is Investigate cause; battery is nearly dead. ‘Battery Status’ LED down to about You have almost no pump run time left.

8.2 Volts Alarm CANNOT be silenced

On - Beeping Fast Beep in Synch with one or more System is Refer to ERROR Mode Charts, Page 11 for of the ‘AC Power Status’, ‘Pump Run Status’, in ERROR more information or ‘Alarm Silence’ LEDs and with the mode ‘Charger Mode’ LED flashing alternately YELLOW/GREEN

On - Beeping Fast Beep in Synch with Pump is None. Alarm will stop when pump stops ‘Pump Run Status’ LED running running. To silence alarm, press and release LEFT side of toggle switch

Operation 13

CHARGER OPERATION

The backup pump will activate automatically when the backup sump water level rises far enough to trip the float switch.

If the power to the charger circuit is interrupted, the length of time that the backup pump will run depends on the Ampere-hour capacity of the battery used, the battery charge level, and the required vertical pumping distance.

Extended periods of operation (for example, during an extended power outage) may exhaust the battery. The battery charger will begin charging the battery as long as the battery has a voltage differential of 3 Volts or more.

Recharge Time:

FG100-A1: Approximately 100+ hours to fully recharge a 27M battery in a “dead battery condition”. The approximate recharge time for a 24M battery is 75 hours.

FG200-A1: Approximately 19 hours to fully recharge a 27M battery in a “dead battery condition”. The approximate recharge time for a 24M battery is 15 hours. Industrial standards define a “dead battery condition” as 9 Volts or less.

The 5 Stages of the Charging Process for Model Number FG100-A1:

NOTICE: The LED’s will only illuminate once the AC

power has been applied. They will not light up if the charger is not plugged in.

1. Yellow LED light flashing on and off indicates:

Prequalification test stage is in progress. Normal

duration of this stage ranges from 18 minutes to 27 hours. If a battery has been left in a state of discharge for long periods this stage may require 27 hours to determine if the battery will even accept a charge.

2. Yellow LED light continuously on indicates:

Constant current charge stage. Charger is charging

battery at the full rated output. This stage ends when the battery terminal voltage reaches the factory preset voltage level.

3. Yellow LED light continuously on also indicates:

Constant voltage charge stage. Battery cells are being

equalized.

4. Green LED light on indicates:

Float charge stage. Battery is charged and ready

for use. Charging has stopped. To maintain a full charge on the battery, the yellow and green LED may alternately turn back on. This means the charger is briefly turning back on to keep the battery voltage from falling below a preset voltage level.

5. Recycle charge stage: The charger automatically initiates a charge cycle that

begins with the prequalification test stage. This occurs once the battery has been in the float charge stage for 84 days.

The 5 Stages of the Charging Process for Model Number FG200-A1:

NOTICE: The LED’s will only illuminate once the AC

power has been applied. They will not light up if the charger is not plugged in.

1. Yellow “charging”(bicolor) LED flashing slowly indicates:

A. Prequalification test stage is in progress. The normal

duration of this stage is 20 seconds to 3 minutes. However, if a battery has been left in a state of discharge for long periods or if the initial voltage is less than 10.5 volts, this stage may require 5 hours to determine if the battery will even accept a charge.

2. Yellow (bicolor)“charging” LED continuously on indicates:

Constant current charge stage. Charger is charging

battery at full rated output.

3. Yellow (bicolor)“charging” LED flashing quickly indicates:

Constant voltage charge stage. Battery cells are being

equalized. This could last up to 14.5 hours.

4. Green (bicolor) “charging” LED indicates:

Float charge stage. Battery terminal voltage is reduced

to a regulated voltage and battery is being maintained at full charge.

TABLE IX – Capacity Ratings with 27M Marine Battery

VERTICAL PUMPING DISTANCE 8 FEET 10 FEET 12 FEET

Model Numbers FG100-A1 FG200-A1 FG100-A1 FG200-A1 FG100-A1 FG200-A1

Gallons Per Hour 1,440 2,088 1,200 1,770 840 1,380 Hours Available 10 6.8 11 6.0 13 6.0 Total Gallons Pumped 8,500 8,500 7,000 7,000 5,000 5,000

* These flow rates were obtained with a constant 12.7 VDC battery source. The actual GPH will vary due to a reduction in output voltage from battery.

Operation / Troubleshooting 14

5. Recycle charge stage: The charger automatically initiates a charge cycle that

begins with the prequalification test stage. This occurs once the battery has been in the float charge stage for 84 days.

Special Features:

• Thechargersareequippedwithreversebattery,short

circuit, and “run-away charge” protection.

• Abuilt-insafetytimerstartswhenthechargerenters

the Constant Current/Constant Voltage Charge stage (Yellow LED is continuously on). The FG100-A1 system has a 90 hour safety timer and the FG200-A1 system has a 20.5 hour safety timer.

NOTICE: To reset the charger unplug it from the 120V

outlet for 10 seconds and then plug it back in.

BATTERY REQUIREMENTS

Hazardous electrical current. Can cause

severe burns and start a fire if battery terminals are short circuited. Install the battery in a battery box (See Key No. 8, Page 15). To prevent accidental shorting across battery terminals, strap cover securely (See Figure 13) on the battery box. Do not leave battery uncovered. Do not allow children to play around the battery backup system installation.

Use only the recommended battery or one of the same type and size so it will fit in the battery box (maximum size 12-5/8" long, 7" wide and 9-3/8" high [320.7mm x 177.8mm x 238mm] including terminals) and supply enough voltage for full performance.

BATTERY MAINTENANCE

Severe burn hazard. A filled battery contains

sulfuric acid. Avoid contact with skin, eyes or clothing. NOTICE: To protect battery case from chipping and

gouging, do not let battery sit on concrete floor. Install battery on a shelf or protective pad (plywood, 2x4s, etc.). Always install battery in a dry location that is protected from flooding.

Follow the battery manufacturer’s recommendations for maintenance and safe use of battery.

TROUBLESHOOTING

Pump won’t run.

1. Check all wiring connections.

2. Check for low or defective battery.

3. Check that automatic switch is free to swing up and

down.

4. Check for a blown fuse in the junction box of the

FG100-A1 system or in the charger of the FG200-A1 system.

Figure 13 – Battery Hold-down Strap Threading

Your backup sump pump depends on the battery used with it for power. The better the battery, the better the performance of the pump. We recommend the use of a size 27M Marine Deep Cycle Battery or a size 24M Marine Deep Cycle Battery. They will perform as indicated in Table IX, on Page 13, and they stand up well to long periods of little or no use.

NOTICE: A 24M battery will provide the same performance as a 27M, but for a shorter length of time.

Use of a standard automobile battery, GEL type, or a Maintenance Free (sealed) battery with this charger is not recommended. An automobile battery may require charging after only 1-2 hours of continuous use, and the repeated charging cycles may cause early plate failure in the battery. GEL-type batteries require a lower voltage than the charger is designed for; they may overcharge. Maintenance-free (sealed) batteries require a higher voltage; they may never reach full charge.

Motor hums but pump won’t run:

1. Check for low or defective battery.

Pump runs but pumps very little or no water:

1. Make sure a check valve is installed and functioning

between primary pump discharge and Backup Sump Pump tee.

2. Check for obstruction in discharge pipe.

3. Discharge pipe length and/or height exceeds capacity

of pump. See Table IX, Page 13, for pump capacity.

4. Check for low or defective battery.

5. Positive (+) and negative (–) wires are reversed.

Pump cycles too frequently:

1. Tether length too short on automatic float switch.

Make sure that tether is at least 2.5" (63.5mm); see Figure 6, Page 6.

2. Main check valve located between discharge of

primary pump and the Backup Sump Pump tee is not installed or is not working properly. Install or repair as required.

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