Wayne 352205-001 User Manual

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

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.

Description

The ESP25 is a battery operated backup sump pump. It does not replace a regular pump. It is designed to provide protection in the event household electrical power 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 imminently hazardous situation which, if not avoided, will result in death or serious injury.

Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Operating Instruction and Parts Manual ESP25

352205-001 4/07

Notice indicates important information, that if not followed, may cause damage to equipment.

General Safety Information

Do not use to pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in a flammable and/or explosive atmosphere. Pump should only be used to pump clear water. Fatal injury and/or property damage could result.

If the 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.

All wiring must be performed by a qualified electrician.

Do not expose battery to

sparks or flames as an

explosion or fire could result.

Battery acid is corrosive.

Avoid spilling on skin or

clothing. Eye protection must

be worn when handling the battery.

A check valve must be used on the primary sump pump discharge.

A ground fault circuit interrupter is required.

This pump must 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 and/or foreign materials. Pump damage may occur if used in these applications and will void warranty.

Battery Information

The system is designed to operate most efficiently with sealed lead acid (SLA) batteries. Deep cycle marine batteries or automotive style batteries can also be used.

Sealed lead acid batteries cost slightly more, but they can last longer. Among the manufacturers of sealed lead acid batteries are Hawker, Panasonic, PowerSonic, Yuasa and Eagle Picher.

The oversize battery case (included) will accommodate a 12-volt SLA battery or a 12-volt deep cycle marine battery (up to a 27-frame size).

12-Volt Backup Sump Pump

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Battery Information

(Continued)

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 wellventilated area.

Working in the 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 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 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 allow a spark or flame in the vicinity of the battery.

Avoid dropping metal tools on the battery posts because they may spark or short-circuit the system or battery, causing an explosion.

Installation

Installation of this unit may take several hours. Before disabling your main pump, have ready an appropriate means of evacuating the sump.

1. Turn power to main pump off.

2. Pump must be installed using 11/4” or 11/2” rigid PVC piping.

Pump Installation

The ESP25 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, page 3).

Unplug the existing AC pump. Failure to 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.

Operating Instructions and Parts Manual

2. Remove any silt or accumulated debris from the sump pit and surrounding area.

Method 1 (Preferred)

1. Locate the ESP25 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 11/2” NPT discharge. If a 11/4” discharge pipe is desired, an adapter (not included) will be necessary. Smaller diameter piping will reduce pump flow, rate and performance.

3. Cut a 4’ section of 11/4" or 11/2" diameter rigid PVC pipe. Cement 11/4" pipe to a threaded fitting. Cement 11/4" pipe into pipe coupling. Attach 11/4" pipe section to the ESP25 discharge adapter.

4. Screw on to pump discharge.

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Figure 1 - Method 1

Floor

Joist

Charger

Ridgid

PVC

Pipe

Check Valve

(See Step 6)

11/4” or

11/2”

PVC Pipe

ESP25 Pump

Existing Pump

Check Valve

(See Step 6)

Slope

Pipe

Down

Battery Box

Be careful not to 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.

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.

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 1.

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 ESP25 pump can be tied in to the ACoperated pump’s discharge pipe by installing a “Y” connector. Two check valves will be required.

1. Locate the ESP25 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 11/2” NPT discharge. If a 11/4” discharge pipe is desired, an adapter (not included) will be necessary. Smaller diameter piping will reduce pump flow, rate and performance.

3. A check valve will be required in the discharge line of BOTH the Main AC pump and the ESP25 pump to prevent recirculation of water into the sump pit. System will not function without two check valves.

4. Cut a 4’ section of 11/4" or 11/2" diameter rigid PVC pipe. Cement 11/2" pipe to a threaded fitting. Cement 11/4" pipe into pipe coupling. Attach 11/4" pipe section to the ESP25 discharge adapter.

5. Screw on to pump discharge.

Be careful not to 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. Duplicate 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 45º elbow to the short pipe on the ESP25 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 45º 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 2.

ESP25

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Figure 2 - Method 2

Charger

Floor Joist

“Y”

Connector

45° Elbow

Rigid PVC

Pipe

Check Valve

(See

Step 10)

Battery Box

Check Valve

(See Step 10)

ESP25 Pump

Existing Pump

Installation

(Continued)

Operating Instructions and Parts Manual

Methods 1 and 2

Install float switch at least 10”-12” above bottom of sump pit so that backup unit turns on only when the water level is higher than the normal “on” level for main pump. Use the wire ties provided to secure the switch to the discharge pipe. Make sure power wires do not interfere with float switch, pump inlet, or main pump operation. Backup pump must not be allowed to run dry.

Control Box Installation

1. Attach control box to the side of battery box as shown in Figure 3. Place battery in box, attach red cable to positive battery post and black cable to negative post. Put lid on box.

If cables are reversed, damage to the control box or battery could result, and warranty will be void.

2. 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 wellventilated.

3. Plug the float switch, pump and charger into the control box. The connections are marked on the control box.

4. Test pump operation by filling the sump with water while the main pump is unplugged. If the pump operates properly, plug the charger into the GFCI protected outlet to begin charging the battery.

5. Protect electrical cord from sharp objects, hot surfaces, oil and chemicals. Avoid kinking the cord and replace damaged components immediately.

Operation

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 water. Fatal electrical shock could occur.

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.

1. After installation, the backup pump will start when the water level rises above the depth that the primary pump should start.

2. The control box 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 20-25 seconds after the switch reaches the off position.

3. The control box contains a multicolored indicator light. When AC power is present, the light will indicate the charging state, and not reflect actual battery voltage, particularly with a defective battery. In order for the indicator light to provide an accurate reading, steps “a” through “d” must be followed.

Unplug main AC pump and the charger. Risk of electrical shock!

a. After main AC pump and charger are unplugged, a power off alert tone will sound for 30 seconds.

b. Lift and release the float switch to activate the backup pump.

c. When the pump stops, read the test light:

Green: Indicates battery is

charged. Yellow: Voltage is low,

indicating battery is partially charged.

Red: Battery is completely discharged or defective.

d. Plug in charger and main AC pump.

When AC power is out, and when pump has been running, the light will indicate battery status.

4. A chirping sound from the control box will accompany the red light, indicating that the battery may require attention or replacement. Voltage is only an indicator of battery condition and may not reflect the true condition of the battery. See Maintenance for instruction on assessing battery condition.

5. A single thirty-second tone will sound when power to the system is interrupted. The unit will reset automatically when power is restored. A three-second tone will sound every time the pump starts.

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Figure 3

Control box screw

Battery box bottom

Lead Wires

Control box

Installation

(Continued)

ESP25

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Maintenance

Always disconnect 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.

Once a month, check battery condition. To check battery condition follow steps listed below:

1. Unplug the wall charger.

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.

3. Inspect the terminals and clamps for corrosion and tightness. Clean and tighten as required.

4. Unplug the main pump and fill sump with water until back up pump turns on. Repeat process two times to be sure pump is operating normally.

5. If pump operates normally, plug charger into wall outlet, turn on main pump. If pump fails to operate normally, see Troubleshooting guide and correct problem. Repeat step 5.

BATTERIES

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.

Never smoke or allow a spark or flame in the vicinity of the battery.

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.

Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

Pump won’t run

Motor hums but pump won’t run

Pump runs but pumps very little or no water

Pump cycles too frequently

Operating Instructions and Parts Manual

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1. Check all connections

2. Check battery and replace if low or defective

3. Make sure nothing is interfering with operation of switch

4. Check internal fuse located inside the control box. Pull the charger from the wall outlet and remove. If the fuse is blown, replace it with a 20 amp automotive type fuse

1. Check battery and replace if low or defective

2. Unplug pump, remove screen, and check to see if impeller is free to turn. If impeller is locked, remove the 7 screws on the bottom of the pump to release the housing around the impeller. Remove the obstruction. Reassemble pump and reconnect

1. Check to make sure check valves installed between primary pump discharge and Backup Sump Pump are functioning properly

2. Check for obstruction and clear if necessary

3. If discharge is too high, a separate line may be required with a lower discharge height

4. Check battery and replace if low or defective

1. Check to make sure check valves installed between primary pump discharge and Backup Sump Pump are functioning properly

1. Connections not secure

2. Low or defective battery

3. Float switch stuck

4. Defective or blown fuse

1. Defective battery

2. Impeller is locked

1. Check valve missing or improperly installed

2. Obstruction in discharge pipe

3. Discharge pipe length and/or height exceeds capacity of pump

4. Low or defective battery

1. Check valve problem

Address parts correspondence to:

Wayne Water Systems 101 Production Drive Harrison, OH 45030 U.S.A.

For Replacement Parts, call 1-800-237-0987

Please provide following information:

-Model number

-Serial number (if any)

-Part descriptions and number as shown in parts list

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1 Bracket 46049-001 1 2 Charger 30221-001 1 3 Control box 30222-002 1 4 Screw - control box 16119-002 4 5 Pump 58324-001 1 6 Float switch 30033-001 1

Ref. Part No. Description Number Qty.

ESP25

Operating Instructions and Parts Manual

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Limited Warranty

For two years from the date of purchase, Wayne Water Systems (“Wayne”) will repair or re place, 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 work man ship. Please call Wayne (800-237-0987) for instructions or see your dealer. Be pre pared to provide the model and serial number when exercising this warranty. All trans por ta tion 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 main te nance, or failure to operate in accordance with Wayne’s written instructions.

THERE IS NO OTHER EXPRESS WARRANTY. IM PLIED WARRANTIES, IN CLUD ING THOSE OF MER CHANT ABIL I TY AND FITNESS FOR A PARTICULAR PUR POSE, ARE LIMITED TO TWO YEARS FROM THE DATE OF PUR CHASE. THIS IS THE EXCLUSIVE REM E DY AND ANY LIABILITY FOR ANY AND ALL IN DI RECT OR CON SE QUEN TIAL DAM AG ES OR EX PENS 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 lim i ta tions might not apply to you. This limited war ran ty 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 (in clud ing 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 equip ment, cost of capital, cost of substitute products, facilities, services or replacement power, downtime costs, or claims of buyer’s cus tom ers 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

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Wayne 352205-001 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual