Wayne 370100-001, WCP85 User Manual

Caution indicates a

potentially
hazardous situation which, if not
avoided, MAY result in minor or
moderate injury.

Notice indicates

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

General Safety
Information

1. Know the pump application,

limitations, and po ten tial hazards.

Do not

use to
pump flammable or explosive
fluids such as gasoline, fuel
oil, kerosene, etc. Do not use
in flammable and/or explosive
atmospheres. Use pump only with liquids
compatible with pump component
materials. Failure to follow this warning
can result in personal injury and/or
property damage.

2. Make certain that the power supply

conforms to the requirements of
the unit.

Disconnect power before
servicing. If the power dis ­con nect is out of sight, lock

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

A condensate unit removes
condensation from air conditioning
and high efficiency furnaces. The
compact design of the unit consists of a
3/8” ID discharge and 6 ft. long power
cord. The unit also contains a safety
switch to automatically shut off pump
in the event of a failure.

Unpacking

Inspect this unit before it is installed.
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.

This pump is not

designed to handle
salt water, brine, laundry discharge, 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. Use for clear water application
only.

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.

Operating Instructions WCP85

370100-001 4/05

in the open po si tion and tag it to
prevent unexpected application of
power. Failure to do so could result in
fatal electrical shock!

3. Release all pressure within the
system before ser vic ing any
component.

4. Drain all liquids from the system
before servicing.

5. Secure the discharge line before
starting the pump. An unsecured
discharge line will whip, possibly
causing personal injury and/or
property damage.

6. Check hoses for weak and worn
condition before each use, making
certain that all connections are
secure.

7. Periodically inspect the pump and
system com po nents. Perform
routine maintenance as required
(See Maintenance Section).

8. Provide a means of pressure relief
for pumps whose discharge line can
be shut-off or obstructed.

9. Personal Safety:

a. Wear safety glasses at all times

when working with pumps.

b. Keep work area clean,

uncluttered and properly lighted;

Condensate Unit

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

© 2005 Wayne Water Systems

Specifications

Power supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .120V, 60 Hz, 1 phase

Motor duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intermittent

Liquid temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40°F to 125°F

Max. operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45ofrom vertical

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10” X 5” X 4-3/4”

Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3/8"ID

Power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6' 3 conductor with ground

Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 quart plastic

For parts, product & service information

visit www.waynepumps.com

will void the warranty and make
the pump inoperable.

Where a 2-prong wall receptacle is
encountered, it must be replaced with
a properly grounded 3-prong re cep ta ­cle installed in accordance with the NEC
and local codes and ordinances.

12. All wiring should be performed by a
qualified elec tri cian.

13. It is strongly recommended that this
unit is plugged into a Ground Fault
Circuit Interrupter (GFCI). Con sult a
local electrician for installation and
availability.

14. Protect electrical cord from sharp
objects, hot sur fac es, oil, and
chemicals. Avoid kinking the cord.
Re place or repair damaged or worn
cords im me di ate ly. Use wire of
adequate size to minimize voltage
drop at the motor.

15. Do not handle a pump
or pump motor with
wet hands or when
standing on a wet or
damp surface, or in
water.

16. Do not use an extension cord.

Do not

walk on wet area
until all power has been turned off. If
the shut-off box is in basement, call the
electric company to shut-off service to
the house, or call the local fire
department for instructions. Remove
pump and repair or replace. Failure to
follow this warning can result in fatal

General Safety
Information

(Continued)

replace all unused tools and
equipment.

c. Keep visitors a safe distance from

the work area. Make workshop
child-proof with pad locks, master
switch es, and by re mov ing starter
keys.

10. When wiring an elec tri cal ly driven
pump such as this, fol low all electrical
and safety codes, as well as the most
recent National Electrical Code (NEC)
and the Oc cu pa tion al Safety and
Health Act (OSHA).

Risk of electric shock!
Never connect the green
(or green and yellow) wire
to a live terminal!

11. This equipment is only for use on
120 volt (single-phase) and is
equipped with an ap proved 3-con ­duc tor cord and 3-prong,
grounding-type plug as shown in
Fig ure 2.

To reduce the risk of electric shock, the
motor must be securely and adequately
grounded. This can be ac com plished by
inserting plug directly into a properly
installed and grounded 3-prong,
grounding-type re cep ta cle (as shown in
Figure 2).

Risk of electrical

shock! This pump is
supplied with a grounding conductor
and grounding type attachment plug.
Use a grounded receptacle to reduce
the risk of fatal electric shock.

Never cut off the round grounding
prong. Cutting the cord or prong

Operating Instructions

electrical shock.

Installation

In any installation

where property
damage and/or personal injury might
result from an inoperative or leaking
pump due to power outages, discharge
line blockage or any other reason, use
a backup system(s).

STEP 1: INSTALLATION OF PIPE

A. Insert the discharge pipe or pipe

nipple into the 3/8” ID plastic tube.

Before removing

pump from its
mounting position for service, always
disconnect electrical power to pump
and control switch. For any work on
pump or switch, ALWAYS unplug the
power cord. Do not just turn off circuit
break er or unscrew fuse.

STEP 2: MOUNTING
CONDENSATE UNIT

A. Position the pump below the

evaporator drain and/or furnace
drain.

B. The pump can be installed to the

wall or side of the appliance using
the two mounting brackets. Refer to
Figure 3.

STEP 3: INSTALLATION OF
CONDENSATE DRAIN LINES

A. To prevent pipe blockage in the

reservoir, modify the end of pipe or
tubing as illustrated in Figure 4.

B. Plumb flexible tube or pipe from the

condensate drain, and from the

Grounding
Blade

Figure 2 - Grounding

2

Figure 3 - Mounting location

GFCI Outlet

Mounting
brackets

6 1/2” above floor

High efficiency
gas furnace

3

WCP85

Installation

(Continued)

furnace drain (if applicable), to the
inlet holes on the pump. Refer to
Figure 5.

STEP 4: INSTALLATION OF
DISCHARGE LINE

NOTE: Use 3/8” I.D. (max.) flexible

tubing.. A hose clamp is recommended
(not provided).

A. Extend discharge pipe from barbed

check valve to the highest point
possible. Refer to Figure 6.

B. From this point, direct the

discharge line to the location of the
drainage source. Maintain a
continuous downward slope.

NOTE: Construct an inverted “U” (see
Figure 6) at the highest point of
discharge line if a continuous
downward slope is not possible.
Exercise care not to kink or “pinch off”
the flow of condensate liquid.

STEP 5: INSTALLATION OF
SAFETY SWITCH (IF APPLICABLE)

Connect power cord

to a constant
voltage source. Do not connect to a fan
or other device that may run
intermittently.

A. The pump can be wired directly to

the appliance thermostat to shut
the pump and appliance down in
the event of pump failure. Refer to
Figure 7 for typical wiring diagram.

NOTE: The alarm can be wired in the
safety switch at the normally open
(“NO”) contact.

TIPS FOR EASY INSTALLATION

1. After reading instructions, check to

make sure installation does not
exceed a maximum of 15 feet of
vertical lift.

2. Make sure pump is level. No part of

the pump base should be more
than 1/8” off of level plane.

3. Use soapy water on unit when

performing cleaning maintenance.
(Refer to Maintenance guidelines.)

4. For optimum performance, drain

and discharge lines should have a
continuous downward slope. Test
operation of pump to make sure
lines have enough downward slope

Figure 4 - Modification of pipe end to prevent blockage

Figure 5 - Plumbing pipe from drain to inlet holes on pump

Main Drain from Coil

Overflow Drain from
Coil When Required

GFCI
Outlet

Overflow Drain
from Furnace

Condensate Neutralizer
Cartridge (If Required)

Main Drain
from Furnace

High efficiency
gas furnace

Figure 6 - Installation of discharge line

15 Ft.
Max

Inverted “U”

To Main Drain

Hose clamp

(recommended, not included)

GFCI
Outlet

Do not kink or pinch

3/8” ID Tubing

Operating Instructions

4

for efficient operation.

5. Avoid overtightening of check valve
after cleaning. (Refer to
Maintenance gudelines.)

6. Use constant voltage power source.
Do not plug into a device that runs
intermittently.

7. Locate model number and date
code on pump and take note of
them.

8. To assure proper performance, the
highest point of discharge line
should be higher than 5’ off the
floor.

9. Clean any debris in the pump
reservoir if necessary.

10. Do not handle the pump until you
have disconnected it from the
power source. Follow all guidelines
for electrical safety discussed in
General Safety.

11. Do not use a pump discharge pipe
smaller than the pump discharge
size.

12. After installation, test pump to
make sure that system is working
properly.

13. Make sure that installation
conforms to all local and national
codes.

14. Local codes may require the use of a
condensate neutralizer when using
this pump.

Figure 7 - Typical wiring diagram for pumps provided with safety switch

NOTE: The alarm can be wired into the safety

switch at the normally open (“NO”) contact.

Maintenance

Make certain that

the pump is
unplugged before attempting to
service or remove any component. This
pump is assembled in the factory using
special equipment; therefore only
authorized service dealers or qualified
electricians should attempt to repair
this unit. Improper repair can cause an
electrical shock hazard.

CLEANING RESERVOIR AND
IMPELLER

1. Unscrew two screws through

mounting brackets, and remove
pump from wall, if mounted.

2. Remove reservoir from deck by

unscrewing the four screws located
at the corners of the reservoir cover.

3. Remove the impeller cover by

unscrewing the five screws on the
underside of the motor. Pull out the
impeller shaft assembly.

4. Use a damp cloth to wipe off the

gasket and the motor assembly.

5. Reassemble impeller to motor. Then

reassemble reservoir to reservoir
cover.

CLEANING CHECK VALVE

1. Disconnect discharge line from
check valve (see Figure 8).

2. Remove check valve with 9/16”
wrench.

3. Visually check for obstructions or
damage.

4. If check valve is not damaged,
replace valve by hand-tightening.
Then tighten 1/2” turn with 9/16”
wrench.

Do not overtighten.
Damage to O-ring

seal may occur.

Typical Thermostat

Typical Thermostat Connections of Appliance

Overflow

Safety Switch

check valve

Figure 8 - Check valve