Wayne ISP40 User Manual 2

Operating Instructions and Parts Manual

Model ISP40

Limited Warranty

For two years from the date of purchase, Wayne Water Systems (“Wayne”) will repair or replace, at its option, for the original purchaser any part or parts of its Sump Pumps or Water Pumps (“Product”) found upon examination by Wayne to be defective in materials or workmanship. Please call Wayne (800-237-0987) for instructions or see your dealer. Be prepared to provide the model and serial number when exercising this warranty. All transportation charges on Products or parts submitted for repair or replacement must be paid by purchaser.

This Limited Warranty does not cover Products which have been damaged as a result of accident, abuse, misuse, neglect, improper installation, improper maintenance, or failure to operate in accordance with Wayne’s written instructions.

THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THREE YEARS FROM THE DATE OF PURCHASE. THIS IS THE EXCLUSIVE REMEDY AND ANY LIABILITY FOR ANY AND ALL INDIRECT OR CONSEQUENTIAL DAMAGES OR EXPENSES 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 form only to maintain your records.

MODEL NO._______________ SERIAL NO.__________________________

INSTALLATION DATE_____________

ATTACH YOUR RECEIPT HERE

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Please completely read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Description

The AC/DC Sump Pump System includes a submersible sump pump and a Power Supply/Battery Charger (PS/BC). Backup power is supplied by two 12 volt batteries (not included). The system is designed for home sump applications. When an electrical power outage occurs, the PS/BC automatically switches the sump pump to battery power so it will continue to pump water. There is no need for a back up sump pump. Using LED’s (Light Emitting Diodes), the PS/BC also alerts you to potential problems.

Safety Guidelines

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.

Notice indicates

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

Model ISP40

351900-001 4/02

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. Personal injury and/or property damage could result. Only use pump to pump clear water.

This pump is not

designed to handle salt water, brine, laundry discharge, water softener, sewage, graywater or any other application which may contain caustic chemicals and/or foreign materials. Pump damage could occur if used in these applications and will void warranty.

All wiring must be

performed by a qualified electrician.

AC/DC Sump Pump System

Operating Instructions and Parts Manual

Pump Specifications

Pump Construction

Motor housing, volute, filter cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron

Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass-filled Ryton

Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410 Stainless Steel

Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

/2” NPT

Float switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-position

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stainless Steel

Power supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120V, 60 Hz

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brushless Integral Processor

Normal water removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 GPM @ 10 Feet

Liquid temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°F to 120°F

Circuit requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 amps AC (min)

Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

/2” high x 93/4” base

Pump starts at (factory set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12” Water Level

Pump stops at (factory set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6” Water Level

Stainless Steel Filter

Power Supply/ Battery Charger (PS/BC)

Battery Cables

Pump Power Cord

Power Supply/Battery Charger (PS/BC) Power Cord

Figure 1 – System Components

Battery Jumper Wire

Record Serial Number here. (Serial

Number is found on Pump Housing)

For parts, product & service information

visit www.waynepumps.com

Pump Fuse

AC Circuit Breaker

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

Pump

NOTICE

WARNING

DANGER

WARNING

CAUTION

NOTICE

Operating Instructions and Parts Manual

Model ISP40

Troubleshooting Chart

Problem Possible Cause(s) Corrective Action

1. Power outage

2. Blown AC breaker

3. GFCI tripped

4. Low AC voltage

1. Pump fuse may be blown

2. Pump impeller may be damaged

Low battery

1. Battery polarity is incorrect

2. Battery voltage too low

1. Lower float stuck

2. Pump too low in sump

1. Pump power cord

2. Upper float switch stuck

3. Impeller rotor jam

1. Backflow from discharge pipe

2. Pump too low in sump

3. Clogged pump filter

1. Blocked discharge pipe

2. Partially clogged pump filter

3. Broken thrust bearing

1. Discharged battery

2. Shorted cell battery

1. None

2. Push AC breaker to reset. If breaker trips again, do not reset. Have unit checked by qualified electrician

3. Reset GFCI

4. Have outlet checked by electrician

1. Replace pump fuse. Use Bussmann AGC10 or Littlefuse 312010

2. Remove impeller. Check for damage to bore or bearing

Apply AC power or replace batteries

1. Recheck battery polarity

2. Replace batteries

1. Remove filter and clean. Remove debris from float switch area

2. Place a brick under the pump

1. Check for proper installation of power cord into the PS/BC

2. Remove filter and clean. Remove debris from float switch area

3. Remove filter and clean. Remove debris from float switch area

1. Install or replace check valve

2. Place a brick under the pump

3. Remove filter and clean

1. Check for restrictions in discharge line, flood is immanent. Shut off AC power before entering flooded area

2. Remove impeller, check for debris in inlet

3. Remove and inspect thrust bearing

1. If the battery is in otherwise good condition, it is normal for the circuit breaker to cycle ON and OFF several times before the battery recovers enough to allow a normal charge rate. If this happens on a regular basis, however, the batteries may be too large for the PS/BC and it could be damaged. Replace batteries

2. A battery in this condition may cause the breaker to cycle continuously. The battery will not accept a charge. Replace both batteries

AC Power Indicator (red light) is not on

Alarm sounds - yellow light is on

Alarm sounds - yellow light is on and red light is off

Green Light is off

Pump will not stop

Pump will not start

Pump starts/stops too often

Pump operates but delivers little or no water

“Click” inside PS/BC. An overload is indicated when you hear a distinct “click” from the DC circuit breaker internal to the PS/BC. A 3-5 minute cooling off period occurs before the PS/BC resets itself. If the overload condition still exists, the cycle will repeat. Regardless of what is causing the circuit breaker to cycle, unattended or routine operation in this manner could result in serious damage to the PS/BC and the battery.

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General Safety Information (Continued)

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.

Pump Installation

Installation may

take several hours. Do not disable an existing sump pump until you have established an appropriate way to evacuate sump pit.

1. Install pump in a sump pit with

minimum size as shown in Figure 2. Construct sump pit of tile, concrete, steel or plastic. If the sump pit already exists, disconnect power to existing pump and make certain pit is the correct size.

2. The sump pump should be located

on a solid, level foundation. Do not place pump directly on clay, earth, gravel or a sandy surface. These surfaces contain small stones, gravel, sand, etc. that may clog or damage the pump and cause pump failure. Remove any silt or debris from the sump pit and surrounding area.

Flood risk. If

flexible discharge hose is temporarily used, make sure pump is secured in sump pit to prevent movement. Failure to secure pump could result in flooding and property damage.

Flexible discharge

hose is intended for temporary use only. Rigid PVC or metal pipe is required for a permanent installation.

3. Thread check valve (not included)

into pump body. Avoid stripping or cross threading. Do not use pipe joint sealant.

4. The pump has a 1-1/2” NPT discharge.

If the existing piping is smaller, use an adapter. Smaller diameter piping will reduce the pump flow rate and decrease its performance.

5. Connect rigid pipe to rubber boot on

check valve. Tighten hose clamps.

Support pump and

piping when assembling and after installation. Failure to do so could cause piping or check valve to break, pump to fail, etc., which could result in property damage and/or personal injury.

6. Protect electrical cord from sharp

objects, hot surfaces, oil and chemicals. Avoid kinking the cord. Replace a damaged cord immediately.

7. A sump pit cover must be installed to

prevent debris from clogging or damaging the pump.

8. Fill sump with at least 6 inches of

water.

Battery Information

The system is designed to operate most efficiently with sealed lead acid (SLA) batteries at 24 volts. Two 12-volt 40amp hour SLA batteries provide enough energy to pump more than 10,000 gallons of water from a basement. Deep cycle marine batteries or automotive style batteries can also be used.

Operating Instructions And Parts Manual

Sealed lead acid batteries cost slightly more, but they can last up to 10 years. Deep cycle marine and automotive batteries may have a shorter life – one to two years. Among the manufacturers of sealed lead acid batteries are Hawker, Panasonic, PowerSonic, Yuasa and Eagle Picher.

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

Use new, identical batteries (from the same manufacturer and of the same capacity). When batteries wear out replace them as a set. Chart 1 illustrates the expected performance with various battery combinations. Do not use batteries rated below 40 amp hours.

Be certain that the area around the batteries is well ventilated. Before servicing the batteries, blow away gasses by waving a piece of cardboard near the batteries.

Dangerous

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

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

Model ISP40

Figure 2

15”

Min.

10” Dia.

Min.

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Amp Hours Per Battery Total Gallons Pumped*

40.0 11,000

80.0 22,000

120.0 33,000

* Assumes the sump pump is lifting water 10’

CHART 1 - STANDBY POWER PUMPING CAPACITY

WARNING

DANGER

NOTICE

WARNING

DANGER

Operating Instructions and Parts Manual

Model ISP40

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

Please provide following information:

-Model number

-Serial number (if any)

-Part description and number as shown in parts list

Address parts correspondence to:

Wayne Water Systems 100 Production Drive Harrison, OH 45030 U.S.A.

1. Filter Cap

2. Through Bolts (3)

3. Stainless Steel Filter

4. Motor, Power Cord & Float Switch

5. Power Cord,

Grommet & Clamp

6. Impeller Rotor

7. Volute & Shaft

8. Conical Nut & Thrust Washer

Thrust Bearing

10. Shield

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1 Filter Cap 40020-001

2 Through Bolts 67048-001

3 Stainless Steel Filter 11024-001

4 Motor, Power Cord & Float Switch 66079-WYN1

5 Power Cord, Grommet & Clamp 66080-WYN1

6 Impeller Rotor 32085-001

7 Volute and Shaft 66081-WYN1

8 Conical Nut, Thrust Washer, Thrust Bearing 66082-WYN1

9 Jumper Wire * 31029-001

10 Shield 43005-001

11 Power Supply/Battery Charger 30215-001

* Not Shown

Replacement Parts List

Ref. No. Description ISP40

11. Power Supply/Battery Charger

Operating Instructions And Parts Manual

Model ISP40

Battery Information (Continued)

nearby in case battery acid contacts clothing, skin or eyes.

Wear eye and clothing protection when working around lead acid batteries.

Avoid touching your eyes when working around lead acid batteries.

If battery acid

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.

PS/BC Features

• Provides power to the pump

• Automatically charges and maintains

the charge to the batteries

• Operates on 120-volt AC or 24-volt

DC (two 12-volt batteries)

• Sounds alarm if fuse is blown or

battery power is low

• The PS/BC can be left on the

batteries indefinitely. Light Emitting Diodes (LEDs) keep you informed of the system’s status (see Chart 2).

The Power Supply/Battery Charger is a 7 ampere, 24 volt automatic battery charger for conventional wet cell and gelled electrolyte type deep cycle leadacid batteries. The PS/BC is designed for use with your Wayne Water System pump. DO NOT USE for any other purpose.

PS/BC Installation

Use Power

Supply/Battery Charger (PS/BC) indoors, in a wellventilated area. Do not expose PS/BC to rain or snow. Do not use an extension cord. Do not disassemble PS/BC. Be sure PS/BC ventilation holes are unobstructed. If PS/BC is dropped or damaged, do not operate; return to manufacturer for service.

Risk of electrical

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.

Always

disconnect AC power and remove pump fuse before connecting or disconnecting battery.

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. Make no connections at this time.

2. Make sure the PS/BC power cord is

disconnected.

3. Remove pump fuse and keep it in a

safe place.

4. Place batteries side by side in

battery case (see Figure 3).

5. Feed PS/BC battery cables through

side access hole in battery case.

6. Carefully check battery polarity.

7. Attach jumper wire as shown in

Figure 3 to achieve 24 volts.

8. Connect PS/BC battery cables to

batteries as shown in Figure 3.

9. Tighten all battery connections

securely.

NOTICE

10. Reinstall pump fuse.The green LED will light. If it does not light, make sure polarity of batteries and PS/BC cables are identical to Figure 3. The voltage at the PS/BC cables must be at least 18 volts or the PS/BC will not operate. Once the green LED is on, it will stay on unless the combined batteries’ voltage falls below 7 volts.

11. Be sure pump is submerged in at least 6 inches of water.

12. Connect pump to PS/BC by inserting locking ring of pump power cord into opening on front of PS/BC – see Figure 1.

Operation

Always disconnect

the electrical supply before attempting to install, service, relocate or maintain the Power Supply/Battery Charger (PS/BC). Never handle PS/BC with wet hands or when standing on wet or damp surface or in water. Fatal electrical shock could occur.

Risk of electrical

shock! The Power Supply/Battery Charger (PS/BC) is supplied with a grounding conductor and grounding plug. Use a grounded receptacle to reduce the risk of fatal electrical shock.

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Jumper Wire

(Red) Positive Battery Cable

(Black) Negative Battery Cable

Figure 3 - Series connection: two 12volt batteries equals a 24-volt battery

CHART 2 - PS/BC STATUS LIGHTS

LIGHT ON WHEN ACTION REQUIRED

Red AC power is connected None Green Battery connected None Yellow Battery voltage is below 23.2 volts – buzzer sounds Replace batteries – flooding is possible

— OR —

Pump fuse blown – buzzer sounds Replace fuse

PS/BC

WARNING

12V

Battery

DANGER

12V

Battery

2. Loosen the conical nut using an 1/8” Allen wrench.

3. Carefully remove thrust washer and thrust bearing, taking note of their orientation. The thrust washer can crack if it is dropped on a hard surface.

4. Using needlenose pliers, remove the impeller rotor. Take care not to damage the mounting face of the thrust washer with the pliers.

5. Thoroughly clean the filter with soapy water.

6. Remove any debris from impeller vanes and passages. Wash impeller in soapy water. Impeller magnet will crack if it is dropped on a hard surface.

7. Inspect thrust bearing. If its thickness is less than 0.15” or if it is cracked or damaged, replace.

8. Inspect the three impeller drives that engage with the thrust washer. Replace impeller if they are worn.

9. Inspect thrust washer. Replace if the thrust surface is worn.

10. Reassemble parts in reverse order, as shown in Figure 5. For proper orientation of the thrust washer, refer to Figure 6. Do not overtighten the conical nut. Be careful not to damage the float when installing the filter cap.

2. Do not operate the pump unless it is submerged in water. Dry running causes pump failure.

3. While the pump is draining the pit, verify that the discharge piping is carrying the water to a point several feet away from the foundation.

4. If pump discharge line is exposed to freezing temperature, the exposed line must be pitched to drain. Trapped water will freeze and damage the pump.

Maintenance

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.

When necessary,

remove the filter for cleaning. If the pump is used in a dirty environment, frequent cleaning is necessary to assure adequate performance. Never sweep dirt or garbage into the sump pit.

Do not operate

the pump without the filter in place. The filter protects critical areas inside the pump from damage due to foreign objects. Operating the pump without the filter will void the warranty.

Before disabling

your pump, have ready an appropriate way to evacuate the sump pit should it refill with water while your pump is out of commission. Disconnect the power cord from the Power Supply/Battery Charger (PS/BC) to the pump. Simply unplugging the PS/BC from the AC power will not shut off the pump.

FILTER, IMPELLER AND THRUST BEARING

1. Remove the pump from the sump

pit. Loosen the three (3) through bolts that hold the filter cap in place.

Be careful not to

damage the float switch, which is permanently installed in the motor housing. Attempting to remove the float switch will cause irreversible motor damage.

Operating Instructions and Parts Manual

Operating Instructions And Parts Manual

Model ISP40 Model ISP40

Operation (Continued)

PROPER GROUNDING OF AC POWER CORD

1. A ground fault circuit interrupter (GFCI) is required (See Figure 4).

2. The PS/BC is only for use on 120 volt

(single-phase), 60 hz service and is equipped with a 3-conductor cord and 3-prong, grounding type plug. The

plug MUST be plugged into a ground fault circuit interrupter outlet that is properly installed and grounded in accordance with all local codes and ordinances. If you ever feel even a

sight shock from this or any electrical appliance, or equipment connected to it, STOP. Turn off electricity to outlet, and have it inspected by an electrician. You may have a dangerous, improperly wired outlet.

IMPORTANT: Never cut off the round grounding prong. Cutting the cord or plug will void the warranty and make the pump inoperable.

3. Insert the PS/BC power cord plug

directly into the GFCI outlet (See Figure 4).

TO TEST

Make certain there

is at least 6 inches of water in the sump prior to connecting the pump to the PS/BC. Failure to do so may cause damage to pump.

1. Fill sump with water. The pump will

start automatically when the water has filled the sump to a depth of approximately 12“. The pump will stop when the water depth is approximately 6”. The pump will recycle thereafter as required.

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Figure 6

Correct

Incorrect

Power

Cord

Grounding

Blade

Figure 4 – Required GFCI Receptacle

Figure 5

BATTERIES

Dangerous

Working in the

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.

Always

disconnect the electrical supply before attempting to install, service, relocate or perform any maintenance.

1. Unplug the PS/BC.

2. For batteries with top caps that can

be removed, the electrolyte level should be checked and filled to manufacturer’s specifications. The charge for each cell should be checked with a hydrometer. A specific gravity of 1.265 indicates the

battery is at full charge. If the specific gravity of any of the cells varies more than .050, the battery should be replaced.

NOTE: An inexpensive hydrometer can be purchased at an automotive parts dealer.

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

4. Check for proper pump operation.

BATTERY TEST

1. Unplug AC power.

2. Fill sump with water. Pump will start automatically when water reaches edge of filter cap.

3. If low battery light (yellow LED) illuminates, batteries should be replaced. Replace batteries as a set. See Battery Information on Pages 2 and 3.

Notes

DANGER

WARNING

RESET

TEST

DANGER

WARNING

NOTICE

DANGER

WARNING

DANGER

Wayne ISP40 User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual