Wayne Plumbing Product ESP45 User Manual

Operating Instruction and Parts Manual  
ESP45  
Operating Instructions and Parts Manual  
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.  
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.  
24-Volt Backup  
Sump  
Pump  
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 TWO YEARS FROM THE DATE OF PURCHASE. THIS IS THE  
EXCLUSIVE REMEDY AND ANY LIABILITY FOR ANY AND ALL INDIRECT OR CONSEQUENTIAL DAMAGES OR EXPENS-  
ES WHATSOEVER IS EXCLUDED.  
All wiring must be  
performed by a  
qualified electrician.  
General Safety  
Information  
Description  
The ESP45 is a battery operated back-up  
sump pump. It does not replace a  
CALIFORNIA PROPOSITION 65  
regular pump. It is designed to provide  
protection in the event household  
electrical power fails or main pump fails.  
This product or its  
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.  
Do not expose battery to  
sparks or flames as an  
explosion or fire could result.  
power cord may  
contain chemicals known to the State of  
California to cause cancer and birth  
defects or other reproductive harm. Wash  
hands after handling.  
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.  
Unpacking  
Battery acid is corrosive.  
Avoid spilling on skin or  
clothing. Eye protection must  
be worn when handling the battery.  
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.  
GENERAL SAFETY  
Do not use to pump  
A check valve must  
be used on the  
primary sump pump discharge.  
flammable or explosive fluids  
such as gasoline, fuel oil,  
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.  
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.  
A ground fault  
circuit interrupter is required.  
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  
Safety Guidelines  
This pump must  
only be used to  
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.  
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.  
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.  
Danger indicates an  
imminently  
hazardous situation which, if not avoided,  
will result in death or serious injury.  
Pump Specifications  
Warning indicates a  
potentially  
hazardous situation which, if not avoided,  
could result in death or serious injury.  
Power supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120V, 60 Hz  
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perminent Magnet DC Motor  
Normal water removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2880 GPH @ 5 Feet @ 26V DC  
Liquid temperature range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°F to 120°F  
Circuit requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 amps AC (min)  
Caution indicates a  
potentially  
hazardous situation which, if not avoided,  
may result in minor or moderate injury.  
3
4
Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 in. high x 8 / in. base  
Pump run time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Seconds  
Pump Construction  
Notice indicates  
important  
information, that if not followed, may  
cause damage to equipment.  
Motor housing, volute, seal plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Iron  
Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermoplastic  
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stainless Steel  
1
2
Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 / in. NPT  
Float switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reed Style  
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.  
For parts, product & service information  
© 2008 Wayne Water Systems  
353601-001 7/08  
8
 
Operating Instructions and Parts Manual  
ESP45  
Pump Installation  
Maintenance  
5. If pump operates normally, plug  
PS/BC into wall outlet, turn on main  
pump. If pump fails to operate  
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.  
Installation of this  
(Continued)  
unit may take  
several hours. Before disabling your  
main pump, have ready an appropriate  
means of evacuating the sump.  
3. Inspect the terminals and clamps  
for corrosion and tightness. Clean  
and tighten as required.  
Floor  
Joist  
normally, see Troubleshooting guide  
and correct problem. Repeat step 5.  
Slope  
Pipe  
Down  
Ridgid  
PVC  
Pipe  
1. Turn power to main pump off.  
1
4
2. Pump must be installed using 1 / ”  
Troubleshooting Chart  
1
2
or 1 / ” rigid PVC piping.  
Symptom  
Possible Cause(s)  
Corrective Action  
Pump Installation  
Check Valve  
(See Step 6)  
The ESP45 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).  
Pump won’t run  
1. Connections not secure  
2. Low or defective battery  
3. Float switch stuck  
1. Check all connections  
2. Check battery and replace if low or defective  
3. Make sure nothing is interfering with operation of switch  
PS/BC  
Unplug the existing  
AC pump. Failure to  
follow this warning could result in fatal  
electrical shock.  
4. Defective or blown fuse  
4. Check internal fuse located on the PS/BC. Pull the charger from  
the wall outlet and remove. If the fuse is blown, replace it with  
an automotive type fuse of the same amp ratio.  
Batteries  
1
4
1 / ” or  
1
2
1 / ”  
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.  
2. Remove any silt or accumulated  
debris from the sump pit and  
surrounding area.  
PVC Pipe  
Motor hums but 1. Defective battery  
pump won’t run 2. Impeller is locked  
1. Check battery and replace if low or defective  
2. Unplug pump, volute, and check to see if impeller is free to turn.  
If impeller is locked, remove the obstruction. Reassemble pump  
and reconnect  
Battery  
Box  
ESP45  
Pump  
Existing Pump  
Pump runs but  
pumps very little  
or no water  
1. Check valve missing or improperly  
installed  
1. Check to make sure check valves installed between primary  
pump discharge and Backup Sump Pump are functioning  
properly  
Method 1 (Preferred)  
Figure 2 - Method 1  
1. Locate the ESP45 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  
5. Place the pump with the 4’ section of  
PVC pipe on a solid, level surface in  
the sump pit on an elevated surface.  
sloped downward so that water will  
not freeze in the pipe.  
2. Obstruction in discharge pipe  
or pump inlet  
3. Discharge pipe length and/or  
height exceeds capacity of pump  
4. Low or defective battery  
2. Check for obstruction and clear if necessary  
When installing the separate discharge  
pipe, drill through the outside wall with  
appropriate drilling equipment. Seal the  
hole to prevent water from entering.  
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  
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.  
potential pump failure.  
1
2
2. This pump has a 1 / ” NPT discharge.  
1
4
If a 1 / ” discharge pipe is desired,  
Method 2  
an adapter (not included) will be  
necessary. Smaller diameter piping  
will reduce pump flow, rate and  
performance.  
Pump cycles too  
frequently  
1. Check valve problem  
1. Check to make sure check valves installed between primary  
pump discharge and Backup Sump Pump are functioning  
properly  
If a separate, dedicated discharge is  
not possible as in Method 1, the ESP45  
pump can be tied in to the AC-  
operated pump’s discharge pipe by  
installing a “Y” connector. Two check  
valves will be required.  
7. Check valve is required for effective  
operation of system.  
1
1
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.  
4
2
3. Cut a 4’ section of 1 / " or 1 / "  
No yellow light  
1. Battery connection problem  
1. Verify battery connection is correct  
diameter rigid PVC pipe. Cement  
1
4
1 / " pipe to a threaded fitting.  
Red light is on  
with alarm  
1. Blown pump fuse  
2. Low battery voltage  
1. Check fuse and replace with a fuse of same rating and size  
2. Check battery voltage. PS/BC will not charge batteries with a  
combined voltage of 21.6 VDC or less  
1. Locate the ESP45 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.  
1
4
Cement 1 / " pipe into pipe  
1
4
coupling. Attach 1 / " pipe section  
to the ESP45 discharge adapter.  
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  
4. 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.  
1
2
2. This pump has a 1 / ” NPT discharge.  
1
4
If a 1 / ” discharge pipe is desired,  
an adapter (not included) will be  
necessary. Smaller diameter piping  
will reduce pump flow, rate and  
performance.  
6
3
 
Operating Instructions and Parts Manual  
ESP45  
Pump Installation  
CHART 2 - PS/BC STATUS LIGHTS  
ON WHEN ACTION REQUIRED  
PS/BC Installation  
LIGHT  
(Continued)  
(Continued)  
Red  
Low Voltage or Blown Fuse  
Check Fuse or  
Replace Batteries  
3. A check valve will be required in  
the discharge line of BOTH the  
Main AC pump and the ESP45  
pump to prevent recirculation of  
water into the sump pit. System will  
not function without two check  
valves.  
Floor  
Joist  
1. 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 well-ventilated.  
“Y”  
Connector  
Yellow  
Green  
Battery OK  
None  
None  
Rigid PVC  
Pipe  
AC power on  
Working in the  
vicinity of lead acid  
45°  
Elbow  
1. After installation, the backup pump  
will start when the water level rises  
above the depth that the primary  
pump should start.  
Check Valve  
(See Step 10)  
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  
2. Wave cardboard over batteries to  
blow away any gas that may be  
present.  
PS/BC  
1
1
4
2
4. Cut a 4’ section of 1 / " or 1 / "  
diameter rigid PVC pipe. Cement  
1
2. The PS/BC has a DC charger designed  
to shorten the recharging time of  
your battery, and to prevent  
2
1 / " pipe to a threaded fitting.  
3. Connect jumper wire between  
batteries as shown on Figure 1.  
1
4
Cement 1 / " pipe into pipe  
1
4
coupling. Attach 1 / " pipe section  
Batteries  
4. Connect power wires from PS/BC to  
battery terminals as shown in  
overcharging. In addition, the  
to the ESP45 discharge adapter.  
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 15 seconds after the  
switch reaches the off position.  
surrounding area.  
Figure 1. Connect the red wire to  
the unconnected positive terminal  
of battery A and then connect the  
black wire to the unconnected  
negative terminal of battery B. The  
yellow light should now be on.  
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.  
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.  
5. Plug the pump and then the float  
into the PS/BC. The connections are  
marked.  
Maintenance  
Battery  
Box  
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  
ESP45  
Pump  
Existing Pump  
Unplug main AC pump and the  
charger. Risk of electrical  
shock!  
6. Test pump operation by filling the  
sump with water while the main  
pump is unplugged. If the pump  
operates properly, plug the PS/BC  
into the GFCI protected outlet to  
begin charging the battery.  
Never smoke or allow a spark or flame  
in the vicinity of the battery.  
Figure 3 - Method 2  
Methods 1 and 2  
Always disconnect  
AC power and  
discharge pipe. This will allow the  
pump or check valve to be removed  
easily for servicing.  
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 hose  
clamps provided to secure the switch to  
the discharge pipe. Make sure power  
wires and hose clamp ends do not  
interfere with float switch, pump inlet,  
or main pump operation. Backup pump  
must not be allowed to run dry.  
Always disconnect the  
electrical supply before  
attempting to install, service,  
Avoid dropping metal tools on the  
battery posts because they may spark  
or short-circuit the system or battery,  
causing an explosion.  
remove pump fuse before connecting or  
disconnecting battery.  
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 ESP45 pump. Glue a “Y”  
adapter to the short pipe on the  
existing pump, as shown in  
NOTE: Protect electrical cord from sharp  
objects, hot surfaces, oil and chemicals.  
Avoid kinking the cord and replace  
damaged components immediately.  
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.  
relocate or per-form 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.  
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.  
Operation  
Once a month,  
check the condition  
of the battery. In order to review the  
battery condition, follow the steps that  
are listed below:  
ELEVATE PS/BC BY MOUNTING ON  
WALL OR SETTING ON A SHELF. SLOTS  
IN THE BACK SIDE OF PS/BC ARE  
AVAILABLE FOR WALL MOUNTING.  
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.  
1. Unplug the PS/BC.  
illustration for Method 2.  
10. Glue a short piece of PVC pipe  
between the 45º elbow and the “Y”.  
PS/BC Installation  
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.  
Use Power Supply/  
Battery Charger  
(PS/BC) indoors, in a well-ventilated  
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.  
Control Box Installation  
If cables are  
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 3.  
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 distance.  
BATTERIES  
Dangerous  
hydrogen gas can  
reversed, damage  
to the PS/BC or battery could result,  
and warranty will be void.  
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.  
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.  
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.  
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.  
NOTE: An inexpensive hydrometer  
can be purchased at an automotive  
parts dealer.  
4
5
 

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