PHCC Pro C22 User Manual

Pro Series C22
Combination Primary and
Backup Sump Pump System
Instruction Manual & Safety Warnings
Table of Contents
Important Safety Warnings and Instructions
Electrical precautions 1 Battery preparation 1 Battery precautions 1
Introduction
Items included in system 2 Additional items needed 2 System specifications 2
Installing the Pipe and Pump 3
Battery Instructions 4,5
System Connections
Connecting the backup pump 5 Installing the battery fluid sensor 5 Connecting the battery 6 Connecting the charger 6 Connecting the primary pump 6
Product Operation
Float switches 6 1/8” weep holes 6 Controllers 6
Understanding the Warning Lights and Alarms
Silencing the alarm during an emergency 7 Battery alarm 7 Cleaning battery terminals 7,8 Replacing the battery 8,9 Fuse alarm 9 Fluid alarm 9,10 Backup pump activated 10 Replacing the backup pump 10,11 Replacing the primary pump 11-13 Power alarm 13 Charging 13 System operating 13
Testing the System
Test-Reset-Silence button 13 Testing the backup float switch 13,14 Testing the primary float switch 14
Parts & Service Information
Technical support 14
Replacement Parts Diagram & List 15
Troubleshooting Guide 16
This manual is for the systems that have the PHCC1730-A backup controller, which can accommodate maintenance or maintenance free batteries. See pages 2-6 for additional information.
IMPORTANT: Even if you have the Pro Series C22 Combination Sump Pump System installed by someone else, you must read and follow the safety information contained in this manual. Failure to do so could result in property damage, serious injury, or death.
Important Safety Warnings & Instructions
SAVE THESE INSTRUCTIONS. This manual
contains important SAFETY WARNINGS and OPERATING INSTRUCTIONS for the Pro Series combination sump pump system. You will need to refer to it before attempting any installation or maintenance. ALWAYS keep these instructions with the unit so that they will be easily accessible.
Failure to read and follow these warnings and instructions could result in property damage, serious injury, or death. It is important to read this manual, even if you did not install the Pro Series combination sump pump system, since this manual contains safety information regarding the use and maintenance of this product. DO NOT DISCARD THIS MANUAL.
ELECTRICAL PRECAUTIONS
DANGER
!
Risk of electrical shock and fire hazard. May result in death, serious injury, shock or burns. To help reduce these risks, observe the following precautions:
DO NOT walk on wet areas of the basement
until all power has been turned off. If the main power supply is in a wet basement, call an electrician.
ALWAYS disconnect the pumps from the power
source before servicing or making adjustments.
ALWAYS unplug the control units and
disconnect the cables from the battery before attempting any maintenance or cleaning.
NEVER handle the pump or control unit with
wet hands or when standing on a wet or damp surface while the pump is plugged into the power source.
MAKE SURE THERE IS A PROPERLY GROUNDED RECEPTACLE AVAILABLE. This pump is wired with a 3-prong grounded plug. To reduce the risk of electric shock, be certain that it is only connected to a properly grounded 3-prong receptacle. If you have a 2­prong receptacle, have a licensed electrician replace it with a 3-prong receptacle according to local codes and ordinances.
NEVER bypass grounding wires or remove the
ground prong from the plug.
DO NOT use an extension cord. The electrical
outlet should be within the length of the pump's power cord, and at least 4 feet above the floor level to minimize potential hazards from flood conditions.
DO protect the electrical cord from sharp
objects, hot surfaces, oil and chemicals. Avoid kinking the cord.
MAKE SURE the supply circuit has a fuse or
circuit breaker rated to handle the power requirements noted on the nameplate of the pump.
DO NOT use an attachment not recommended
or sold by the manufacturer. It may result in a risk of fire or injury from an electrical shock.
CAUTION
To reduce the risk of hazards that can cause injury or property damage, observe the following precautions:
DO NOT use the power cord or strain relief to
carry the pumps. Use the handle.
DO NOT pull on the cord to disconnect the
system or the pump. Pull the plug.
DO NOT expose the control units to rain or
snow.
DO NOT operate the pumps or control units if
they have been damaged in any way.
DO NOT use pumps in pits handling raw
sewage, salt water, or hazardous liquids.
DO NOT disassemble the pumps or control
units. When service is required, contact Glentronics' technical support at 800-991­0466, option 3. Return the product to the manufacturer for any repairs at the following address:
Glentronics, Inc.
645 Heathrow Drive, Lincolnshire, IL 60069
BATTERY PREPARATION
WARNING / POISON
!
Sulfuric acid can cause blindness or severe burns. Avoid contact with skin, eyes or clothing. In the event of accident, flush with
water and call a physician immediately. KEEP OUT OF REACH OF CHILDREN.
To help reduce these risks, observe the following precautions:
• Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
• Wear eye and clothing protection and avoid touching your eyes while working with battery acid or working near the battery.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with run­ning cold water for at least 15 minutes and get medical attention.
• Battery posts and terminals contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
BATTERY PRECAUTIONS
DANGER
!
Explosive gases could cause serious injury or death. Cigarettes, flames or sparks could cause battery to explode in enclosed spaces. Charge in well-ventilated area. Always shield eyes and face from battery. Keep vent caps tight and level.
To help reduce these risks, observe the following precautions:
NEVER smoke or allow a spark or flame in the vicinity of the battery.
• Use the Pro Series control unit for charging a LEAD-ACID battery only. DO NOT use the control unit for charging dry-cell batteries that are most commonly used with home appliances.
• Be sure the area around the battery is well­ventilated.
• When cleaning or adding water to the battery, first fan the top of the battery with a piece of cardboard or another non-metallic blow away any hydrogen or oxygen gas that may have been emitted from the battery.
material to
DO NOT drop a metal tool onto the battery. It
might spark or short-circuit the battery and cause an explosion.
• Remove personal metal items such as rings, bracelets, watches, etc. when working with a lead-acid battery. A short circuit through one of these items can melt it causing a severe burn.
ALWAYS remove the charger from the electrical outlet before connecting or disconnecting the battery cables. Never allow the rings to touch
each other.
• Check the polarity of the battery posts. The POSITIVE (+) battery post usually has a larger diameter than the NEGATIVE (-) post.
POSITIVE POST HAS LARGER DIAMETER
• When connecting the battery cables, first connect the small ring on the end of the BLACK wire to the NEGATIVE (-) post of the battery, and then connect the large ring on end of the RED wire to the POSITIVE (+) post of the battery.
POSITIVE
POST
Do not use system to pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc.
NEGATIVE POST HAS SMALLER DIAMETER
DANGER
!
NEGATIVE
POST
Page 1
Introduction
The Pro Series Pair of Pumps combination system is designed to provide both primary and backup pumping capabilities. The primary pump will operate as long as it is receiving AC power. If the power is interrupted, or more water is coming into the sump than the AC pump can handle, the backup sump pump will begin pumping automatically. The backup system has unique monitoring features that diagnose a problem and sound an alarm. A light on the display panel of the control unit will indicate the cause of the alarm and the corrective action. The two systems have been pre-assembled for easy installation.
For added reliability, the float switches have, not one, but two floats. Should one float fail to operate, the second float will automatically activate the pump.
The Pair of Pumps Combination Sump Pump System includes:
• A 1/3 HP primary pump with a caged dual float switch, and a blue piggyback controller that plugs into the wall outlet
• A blue backup pump
• A gray control unit with a battery fluid sensor, a dual float switch, battery cables, and a 20-amp fuse
• A battery charger
• A battery cap with a hole to accommodate the fluid sensor
• A battery box
• A rubber union
• A battery filler bottle for adding distilled water to the battery
You will also need to supply:
• A Pro Series 2200 Standby Battery*
DO NOT use an automotive battery with this
system
DO NOT use a Pro Series 1000 battery with
this system. It will not run the pump as long as the Pro Series 2200 battery
• A surge protector (recommended - backup controller only)
• Six (6) quarts of 1.265 specific gravity battery acid
*PHCC Pro Series standby batteries are
specifically designed to work with your battery backup sump pump system. Glentronics can not guarantee the compatibility of other brands of batteries. For optimal performance the use of a PHCC Pro Series standby battery is recommended.
Backup
Pump
Controller
Battery Box
Backup Pump
Float Switch
Backup
Pump
Cable Tie
Primary
Pump Float
Switch
Battery Wires
Primary Pump
Primary Pump Controller
Battery
Filler
Bottle
Fluid Sensor
Rubber Union
Battery Cap
For some installations you may need additional items:
• 1-1/2” rigid PVC pipe to connect to the existing plumbing
• A PVC pipe connector or a rubber union
• PVC pipe cleaner and cement
System Specifications
Power supply requirements.......115 volts, 60 Hz
AC pump pumping capacity..... 2770 GPH @ 10’
............................................. 46 GPM @ 10’
DC pump pumping capacity..... 1730 GPH @ 10’
............................................. 29 GPM @ 10’
Overall dimensions................. 11” W x 23¾” H
Page 2
BACKUP
PUMP
CHARGER
END OF
PIPE
2
3
3
/4”
CUT
P
VC TO THIS
LENGTH
Installing the Pipe and Pump
The Pro Series Pair of Pumps combination system is compact and will fit in a sump pit as small as 12” wide. It measures 23¾” inches from the bottom of the pump stand to the top of the Y­connector where it will be attached to the discharge pipe.
Use a pit that conforms to all local codes, and check the code to see if a gate valve or ball valve is required.
The path of the existing vertical discharge pipe to an exterior wall should have the shortest path with the fewest turns. The more turns will reduce the pumping capacity. The horizontal discharge pipe must be positioned in a downward slope when it exits the building, so any remaining water will drain away. Failure to do this will prevent water from exiting the pit, and damage the pump if the line freezes. (see Diagram A)
The system should be placed on a flat surface free from dirt and debris. If the bottom of the sump
Diagram A
233/4“
pit is not clean, remove as much of the debris as possible. The pumps are attached to a sump foot (stand) to raise them above any debris.
If you are replacing an old sump pump, unplug
the pump from the outlet.
1. Remove the check valve or rubber union.
Discard the check valve. The Pro Series system contains built-in check valves, so the old check valve will not be needed. If the
existing system is installed without a check valve or rubber union, saw the pipe apart above the sump pit. (Refer to the diagram in step 3)
2. Remove the old pump from the pit, and unscrew the pipe and pipe adapter from the pump. You can use this pipe to extend the discharge pipe, if needed.
3. Measure the distance from the bottom of the sump pit to the end of the discharge pipe. Subtract 24¾” inches (the height of the pump system + 1 inch). Cut a piece of 1-1/2” rigid PVC pipe to that length.
4. Connect this piece to the discharge pipe by cementing the two pieces together with a 1­1/2” PVC pipe connector. (Follow the instructions on the PVC pipe cleaner and cement.) OR,
(b) connect the two pieces of
pipe together with a rubber union.
5. Remove the attached cords and controllers from the carton and place them next to the pump system. MAKE SURE THE CORDS AND CONTROLLERS DO NOT FALL INTO THE SUMP PIT.
6. Loosen the hose clamps on the enclosed rubber union, and slide the union up on the discharge pipe until it is even with the bottom of the pipe.
7. Lift the combination system by the handle on the primary pump and lower it into the sump pit. Make sure it is level.
8. Inspect the two float switches. They should both be vertical.
9. Position the top of the pump system pipe so that it is directly below the discharge pipe. Slide the rubber union down until ½ of the rubber union is covering the pipe on the pumps, and the other half is covering the bottom of the discharge pipe. Tighten the hose clamp screws securely.
1
5
2
4a3
4b
6
LIFT
7
8 9
Page 3
Battery Instructions
2nd LEVEL
1st LEVEL
P
LATES
CE LL WAL L
BATTERY TERMINALS
BATTERY CAP RINGS
CROSS SECTION OF BATTERY
A new Pro Series 2200 Standby Battery will run this system for a minimum of 7.5 hours. However, most of the time the pump will turn on and off, and this battery will run the pump intermittently for days.
In addition, the unique materials in the Pro Series 2200 Standby batteries enable them to last longer in standby service.
Note: The battery will no
The use of automotive batteries is NOT recommended. Automotive batteries are not designed for this application. They will only run the pump for a short time and will have a shorter life than a standby battery.
• The battery fluid sensor and cap are designed to fit the Pro Series Standby batteries. Measuring the battery fluid is one of the most important features of the system, since about 80% of backup sump pump failures are the result of a battery that has dried out.
• PHCC Pro Series standby batteries are specifically designed to work with your battery backup sump pump system. Glentronics can not guarantee the compatibility of other brands of batteries. For optimal performance the use of a PHCC Pro Series standby battery is recommended.
DO NOT insert the fluid sensor into any battery except a Pro Series Standby battery. DO NOT use the enclosed cap on any battery except a Pro Series battery. DO NOT drill a hole in another brand of battery to accommodate the fluid sensor. Batteries emit explosive gases which can cause serious injury or death.
PREPARING THE PRO SERIES STANDBY BATTERY
The Pro Series Standby batteries are shipped dry (without acid) so they never lose power before you take them home. A battery is activated when the acid is added, and then it slowly begins to deteriorate as it ages. By adding the acid just before use, the battery will always be fresh. Use 1.265 specific gravity battery acid to
t run the primary pump.
CAUTION
DANGER
!
fill the battery. It is available where you purchased the battery.
NOTE: PRO SERIES BATTERIES NOW COME IN TWO CONFIGURATIONS. THE TOPS OF THE BATTERIES LOOK DIFFERENT, AND THE DIRECTIONS FOR FILLING THE BATTERIES AND CONNECTING THE FLUID SENSOR WILL VARY SLIGHTLY. INSTRUCTIONS FOR BOTH BATTERIES FOLLOW. IF THE TOP OF YOUR BATTERY LOOKS LIKE THE PHOTO OF BATTERY A, FOLLOW THE INSTRUCTIONS ON THIS PAGE. IF THE TOP OF YOUR BATTERY LOOKS LIKE THE PHOTO OF BATTERY B, FOLLOW THE INSTRUCTIONS ON PAGE 5.
DANGER/POISON
!
Contains sulfuric acid. Wear eye and clothing protection. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eyes, flush with water for 15 minutes, and get prompt medical attention. Review the safety instructions on page 1.
TO FILL THE BATTERY
1. Place the battery box on the floor. Place the dry (unfilled) battery into the battery box.
2. Remove the foil seal on the top of the battery.
3. Carefully push in the perforated tab at the top of the acid pack. Lift up the large tab and
BATTERY A
1
2
DO NOT throw an old battery in the trash. Take it to a service station or recycling center.
pull out the dispensing hose. Hold the hose upright above the pack and squeeze the hose forcing all the acid back into the pack.
4. Position the acid pack and battery as shown below. Pinch the end of the hose together and cut off the tip. Insert the end of the hose into each cell. Control the flow by pinching
3
4
Diagram B
1. Fill to 1st level, cover the plates
2. Then fill to 2nd level, just below the bottom of the cap rings
the hose with thumb and forefinger. Fill each
cell of the battery to a level just covering the battery plates, and then go back and top off each cell equally. It is important to have all the cells filled equally battery will not operate properly. The acid
should reach a level about ¼” below the cap ring as shown in the diagram above. DO NOT OVERFILL THE BATTERY. (Diagram B)
A newly filled battery will sometimes require additional acid after about 20 minutes. Re­examine the fill level, and add additional acid if necessary. The battery acid may bubble at this time and give off a sulfur-like smell, but this is normal. After the battery has been filled, screw the caps securely on the top of the battery.
CAUTION
When you fill the battery for the FIRST time, it will be the ONLY time you add acid to the battery. In the future, when the fluid level is low, add distilled water to the cells. NEVER add more acid.
or the
Page 4
BATTERY B
If your battery looks like the battery above, follow these directions.
1. Place the battery box on the floor. Place the dry (unfilled) battery into the battery box.
2. Remove the two battery caps by lifting them up with a screwdriver. DO NOT lift the cap by prying it up from the groove on the back of the cap. It may damage the vent.
3. Carefully push in the perforated tab at the top of the acid pack. Lift up the large tab and pull out the dispensing hose. Hold the hose upright above the pack and squeeze the hose forcing all the acid back into the pack.
4. Position the acid pack and battery as shown at the right. Pinch the end of the hose together and cut off the tip. Insert the end of the hose into each cell. Control the flow by pinching the hose with thumb and
3
4
forefinger. Fill each cell of the battery to a level just covering the battery plates, and then go back and top off each cell equally. It is important to have all the cells filled equally or the battery will not operate properly. The acid should reach a level about
¼” below the cap ring as shown in Diagram B on the previous page. DO NOT OVERFILL THE BATTERY (See Diagram B).
A newly filled battery will sometimes require additional acid after about 20 minutes. Re­examine the fill level, and add additional acid if necessary. The battery acid may bubble at this time and give off a sulfur-like smell, but this is normal. After the battery has been filled, press the caps securely on the top of the battery.
eye protection. Work in a well-ventilated area. DO NOT smoke or allow a spark or flame in the vicinity of the battery. Avoid dropping metal tools on the battery. If battery acid contacts eyes, flush with water for 15 minutes. Review the safety instructions on page 1.
When you position the battery with the control unit on the top, be sure the charger cord will reach the AC power outlet, and the pump cable and the float switch will reach the bottom of the sump. Position the unit in a well-ventilated area. (Diagram C)
1. Connecting the backup pump: Remove the
security tag from the pump and plug the pump wires into the pump connector on the back of the control unit.
2. Installing the battery fluid sensor: Remove
the cover of the battery box by pushing in the tabs on the front and back, then lifting up.
Diagram C
Fan the area around the top of the battery with a piece of cardboard (or another non­metallic material) to remove any hydrogen or oxygen gas that may have been emitted from the battery.
3. If you are using BATTERY A, replace the battery cap that is 2nd from the POSITIVE (+) post with the battery cap that is provided in the Pro Series package. An arrow on the top of the battery marks this position. There are two holes in the battery cap. Insert the fluid sensor in the hole that is off-center on the top of the cap. Do not glue the sensor into the cap.
1
PUMP
CHARGER
FUSE
1
2
Page 5
CAUTION
When you fill the battery for the FIRST time, it will be the ONLY time you add acid to the battery. In the future, when the fluid level is low, add distilled water to the cells. NEVER add more acid.
System Connections
DANGER
!
Risk of electrical shock or battery explosion, which can cause serious injury or death. Wear
2
3
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