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
visit www.waynepumps.com
8
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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
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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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