Operating Instructions and Parts Manual
Model ISP40
Operating Instructions and Parts Manual
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.
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.
AC/DC Sump Pump System
Record Serial Number here. (Serial
This pump is not
designed to handle
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.
!
NOTICE
Number is found on Pump Housing)
DANGER
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.
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.
Description
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.
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. Using LED’s (Light Emitting
Diodes), the PS/BC also alerts you to
potential problems.
All wiring must be
!
WARNING
performed by a
qualified electrician.
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.
Battery Jumper Wire
Pump
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.
Stainless Steel
Filter
AC Circuit
Breaker
Power
Safety Guidelines
Battery
Cables
Supply/
Battery
Charger
(PS/BC)
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.
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_____________
Power
Supply/Battery
Charger (PS/BC)
Power Cord
Danger indicates
Pump
Power Cord
Pump Fuse
!
DANGER
an imminently
hazardous situation which, if not avoided,
will result in death or serious injury.
ATTACH YOUR RECEIPT HERE
Warning indicates a
potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
Figure 1 – System Components
!
WARNING
Pump Specifications
Caution indicates a
!
CAUTION
potentially
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111/2” high x 93/4” base
Pump starts at (factory set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12” Water Level
Pump stops at (factory set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6” Water Level
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.
NOTICE
General Safety
Information
Pump Construction
Do not
!
DANGER
use to
Motor housing, volute, filter cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cast Iron
Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Glass-filled Ryton
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410 Stainless Steel
Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11/2” NPT
Float switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-position
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stainless Steel
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.
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
© 2007 Wayne Water Systems
351905-001 3/07
8
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Operating Instructions And Parts Manual
Operating Instructions and Parts Manual
Model ISP40
Model ISP40
CHART 2 - PS/BC STATUS LIGHTS
ON WHEN
AC power is connected
Battery connected
Battery voltage is below 23.2 volts –
buzzer sounds
Battery Information
(Continued)
WYN1, and a 75 amp hour battery,
66901-WYN1.
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). Retain blue foam pad to support
Wayne sealed lead-acid batteries.
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
For Replacement Parts, call 1-800-237-0987
LIGHT
Red
Green
Yellow
ACTION REQUIRED
None
None
Replace batteries –
flooding is possible
Please provide following information:
-Model number
Address parts correspondence to:
Wayne Water Systems
-Serial number (if any)
100 Production Drive
-Part description and number as shown in parts list
Harrison, OH 45030 U.S.A.
— OR —
Pump fuse blown – buzzer sounds
Replace fuse
2. Through
Bolts (3)
Avoid dropping
metal tools on the
battery posts because they may spark
or short-circuit the system or battery,
causing an explosion.
PS/BC Installation
!
WARNING
Use Power
Supply/Battery
1. Filter Cap
5. Power Cord,
Grommet &
Clamp
NOTICE
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.
8. Conical Nut
& Thrust
Washer
PS/BC Features
• Provides power to the pump
Thrust
Bearing
• Automatically charges and
maintains the charge to the
batteries
• Operates on 120-volt AC or 24-volt
DC (two 12-volt batteries)
batteries rated below 40 amp hours.
Risk of electrical
shock! Use a GFCI
11. Power
!
WARNING
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. Do not place
batteries directly on concrete floor.
Dangerous
Supply/Battery
Charger
(Ground Fault Circuit Interrupter)
receptacle to reduce the risk of fatal
electrical shock. Grounded receptacle
must be rated for at least 5 amps.
10. Shield
• Sounds alarm if fuse is blown or
battery power is low
6. Impeller
Rotor
Always
• The PS/BC can be left on the
!
WARNING
disconnect AC
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 lead-acid
batteries. The PS/BC is designed for use
with your Wayne Water System pump.
DO NOT USE for any other purpose.
power and remove pump fuse before
connecting or disconnecting battery.
!
DANGER
hydrogen gas can
4. Motor, Power
Cord & Float
Switch
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.
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.
7. Volute
& Shaft
3. Stainless
Steel
Filter
Working in the
vicinity of lead acid
batteries can be dangerous. Before making
connections or servicing the batteries,
read and follow instructions in all
!
DANGER
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.
(Black)
Negative
Battery Cable
Replacement Parts List
Ref.
No.
PS/BC
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 nearby
in case battery acid contacts clothing,
skin or eyes.
Description
ISP40
1
Filter Cap
40020-001
67048-001
11024-001
66079-WYN1
66080-WYN1
32085-002
66081-WYN1
66082-WYN1
31029-001
43005-001
30215-001
2
Through Bolts
(Red)
3
Stainless Steel Filter
Positive Battery Cable
4
Motor, Power Cord & Float Switch
Power Cord, Grommet & Clamp
Impeller Rotor
Wear eye and clothing protection when
working around lead acid batteries.
5
Avoid touching your eyes when
working around lead acid batteries.
If battery acid
6
7
Volute and Shaft
!
WARNING
contacts your
8
Conical Nut, Thrust Washer, Thrust Bearing
Jumper Wire *
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.
9
10
Shield
Jumper Wire
11
Power Supply/Battery Charger
Never smoke or
* Not Shown
!
WARNING
allow a spark or
Figure 5- Battery connection: two 12-volt batteries equals a 24-volt battery
flame in the vicinity of the battery.
6
3
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Operating Instructions And Parts Manual
Model ISP40
Operating Instructions and Parts Manual
Model ISP40
BATTERIES
!
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.
1. Unplug the PS/BC.
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 slight 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,
PS/BC Installation
(Continued)
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 5).
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 5 to achieve 24 volts.
8. Connect PS/BC battery cables to
batteries as shown in Figure 5.
Maintenance
Maintenance
(Continued)
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.
Dangerous
hydrogen gas can
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.
Always disconnect
DANGER
!
DANGER
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
Working in the
vicinity of lead acid
!
DANGER
electricians should repair this unit.
Improper repair could result in fatal
electrical shock.
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
improperly wired outlet.
NOTE: An inexpensive hydrometer
can be purchased at an automotive
parts dealer.
When necessary,
remove the filter
for cleaning. If the pump is used in a
dirty environment, frequent cleaning is
necessary to assure adequate
NOTICE
IMPORTANT: Never cut off the round
grounding prong. Cutting the cord or
plug will void the warranty and make
the pump inoperable.
3. Inspect the terminals and clamps for
corrosion and tightness. Clean and
tighten as required.
performance. Never sweep dirt or
garbage into the sump pit.
3. Insert the PS/BC power cord plug
directly into the GFCI outlet (See
Figure 6).
surrounding area.
9. Tighten all battery connections
securely.
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.
If battery acid
4. Check for proper pump operation.
NOTICE
!
WARNING
contacts your
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 5. 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.
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.
BATTERY TEST
Power
Cord
1. Unplug AC power.
2. Fill sump with water. Pump will start
automatically when water reaches
edge of filter cap.
Before disabling
your pump, have
Never smoke or
NOTICE
!
WARNING
allow a spark or
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.
flame in the vicinity of the battery.
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.
Avoid dropping
metal tools on the
Figure 7
TEST RESET
!
WARNING
battery posts because they may spark
or short-circuit the system or battery,
causing an explosion.
Grounding
Blade
10. Reassemble parts in reverse order,
as shown in Figure 7. For proper
orientation of the thrust washer,
refer to Figure 8. Do not
overtighten the conical nut. Be
careful not to damage the float
when installing the filter cap.
Figure 6 – Required GFCI Receptacle
Follow battery manufacturer’s
maintenance procedures and
12. Connect pump to PS/BC by
inserting locking ring of pump
power cord into opening on front
of PS/BC – see Figure 1.
TO TEST
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.
FILTER, IMPELLER AND THRUST
BEARING
Make certain there
is at least 6 inches
!
WARNING
of water in the sump prior to
connecting the pump to the PS/BC.
Failure to do so may cause damage to
pump.
1. Remove the pump from the sump
pit. Loosen the three (3) through
bolts that hold the filter cap in
place.
Operation
Always disconnect
!
DANGER
the electrical
Always
disconnect
!
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.
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.
DANGER
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.
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.
the electrical supply before
attempting to install, service,
relocate or perform any
maintenance.
NOTICE
Correct
Figure 8
Incorrect
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.
!
DANGER
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.
PROPER GROUNDING OF AC POWER
CORD
1. A ground fault circuit interrupter
(GFCI) is required (See Figure 6).
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.
4
5
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