Wayne ISP40 User Manual 2
Operating Instructions and Parts Manual
8
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
© 2002 Wayne Water Systems
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
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
1
/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
!
DANGER
!
WARNING
!
CAUTION
NOTICE
7
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.
!
2
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
NOTICE
!
WARNING
!
DANGER
!
DANGER
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