NexPump Ai Single User manual
NexPump Ai Users Manual
NexPump, Inc.
Phone: 630-365-4NE (4639)
Fax: 630-365-6919
Email: [email protected]
Web Address: www.nexpump.com
Users Manual 4.00.0002
NexPump is a Registered Trademark of NexPump, Inc.
Copyright © 2003-2013 NexPump, Inc., All Rights Reserved
Patent Pending
NexPump Users Manual The NexPump Ai is the World's Most Reliable Sump Pump
Box Contents
Qty. 1 - NexPump Ai System Unit
(AN - Phone Notification Module Installed)
(ANi – Wired Internet Notification Module Installed)
(ANiw – Wireless Internet Notification Module Installed)
Model Ai Single
Qty. 1 - High Capacity Pump w/Adapter
Model Ai Dual
Qty. 2 - High Capacity Pumps w/Adapters
Model Ai Jet
Qty. 1 - Ultra Capacity Pump w/Adapter
Model Ai Turbo
Qty. 1 - High Capacity Pump w/Adapter
Qty. 1 - Ultra Capacity Pump w/Adapter
Model Ai Rage
Qty. 2 - Ultra Capacity Pumps w/Adapters
Qty. 1 - Gray Sensor with SS mounting clamp (Sensor 1)
Qty. 1 - Black Sensor with SS mounting clamp (Sensor 2)
Qty. 1 - Battery Extension Cable
Qty. 1 - Surge Protector (Supplied With Phone Line
Notification)
Qty. 1 - Owners Manual
Purchased Separately: (Required to operate)
1 - Deep-Cycle Marine Battery (See Appendix for more
information)
You will also need to supply for installation:
1-1/2" or 2” rigid PVC pipe and fittings
PVC cement and primer
Check Valves (if applicable)
Please take a moment and review this manual before
starting installation or powering up your NexPump Ai
System.
2
TABLE F C NTENTS
AC Power Input ....... 14
Alerts/Alarm ........ 8
Appendix ....... 16
Battery Operations ....... 10
Char er Operations ....... 13
Code Chart ....... 17
Function Button ........ 8
Installation Examples ....... 20
Installation Procedures ........ 5
Internal Fan Status ....... 15
Mode Selection ........ 7
NexPump Display ........ 7
NexPump Precautions ........ 4
Personal Precautions ........ 3
Pump Operations ....... 12
Quick Reference ....... 18
Safety Instructions ........ 3
Sensor Operations ....... 14
Stats Information ........ 8
System Operatin Status ........ 7
Testin ....... 15
Warranty Information ....... 19
SAFETY INSTRUCTI NS:
SAVE THESE INSTRUCTI NS - This manual contains
important safety and operating instructions for the
NexPump. Follow these important safety precautions.
Failure to follow safety precautions can result in personal
injury or damage to the NexPump.
CAUTION - To reduce the risk of injury, charge only
lead type rechargeable batteries. Other types of
batteries may burst causing personal injury and damage.
Do not expose the NexPump System Unit to rain or snow.
Do not install the NexPump System Unit where
temperatures will be below freezing (32 degrees
Fahrenheit).
Do not charge a battery that may be frozen. Allow battery
to sit at room temperature before connecting to the
NexPump.
If an extension cord must be used, make sure
A: That the pins on the plug or extension cord are the
same number, size and shape as those of the
plug on the NexPump System Unit.
B: That the extension cord is properly wired and in
good electrical condition.
C: That the wire size is large enough for the AC
ampere rating of the NexPump System Unit.
Do not operate the NexPump System Unit if it has
received a sharp blow, been dropped, or otherwise
damaged in anyway; take it to a qualified serviceman.
Do not operate the NexPump System Unit with a damaged
cord or plug – have them replaced or repaired immediately.
Do not disassemble the NexPump System Unit; take it to a
qualified serviceman when service or repair is required.
Disassembly may result in a risk of electric shock or fire
and void the warranty.
Never pull directly on any wiring connected to pumps,
battery, AC power or sensor. Disconnect by pulling on
connectors only.
Never force the connectors out of place, they should
disconnect and connect easily. Some connectors have
safety latches, so make sure they are depressed.
Never attempt any maintenance and/or cleaning with the
NexPump powered up. Risk of electric shock may result.
WARNING - RISK F EXPL SIVE GASES
W RKING IN THE VICINITY F A LEAD-ACID
BATTERY CAN BE DANGER US.
BATTERIES GENERATE EXPL SIVE GASES
DURING N RMAL BATTERY PERATI N.
F R THIS REAS N, IT IS F THE UTM ST
IMP RTANCE THAT EACH TIME BEF RE
USING Y UR NEXPUMP C NTR L UNIT Y U
READ THIS MANUAL AND F LL W THE
INSTRUCTI NS EXACTLY.
Be sure the area around the battery is well
ventilated.
A SPARK NEAR THE BATTERY MAY
CAUSE AN EXPL SI N.
PERS NAL PRECAUTI NS:
If LEAD-ACID Battery is used
Someone should be within range of your voice and/or
close enough to come to your aid when you work near a
lead-acid battery.
Have plenty of fresh water and soap nearby in
case battery acid contacts skin, clothing or eyes.
Wear complete eye protection and clothing
protection. Avoid touching your eyes while
working near the battery.
If battery acid contacts skin and/or clothing, wash
immediately with soap and water. If acid enters the
eye, immediately flood eye with running cold water for at
least 10 minutes and get medical attention immediately.
When the battery fluid level is low, add distilled water in
each cell until the level reaches the
indicator on each cell. Do not overfill.
Precautions for all Batteries:
NEVER smoke or allow a spark or flame in the vicinity of
the battery.
Be extra cautious to reduce the risk of dropping a metal
tool onto the battery. It might spark or short-circuit the
battery or another electrical part that may cause an
explosion.
Remove personal metal items such as rings, bracelets,
necklaces and/or watches when working with a battery. A
battery can produce a short-circuit current high enough to
weld a ring (or the like) to metal, causing a severe burn.
When Cleaning the battery terminals. Be careful to keep
corrosion from coming in contact with eyes.
Do not use the system unit for charging Dry-Cell batteries,
that are most commonly used with household appliances.
These batteries may burst and cause injury to persons and
damage to property.
3
NEXPUMP PRECAUTI NS:
NexPump SYSTEM Unit Location
Locate the NexPump System Unit as far away
from the battery as the DC cables permit.
Do not operate the NexPump System Unit in an area with
restricted ventilation.
Do not set a battery on top of the NexPump
System Unit.
Do Not allow the NexPump System Unit to sit on top of
the battery.
Do not block NexPump System Unit ventilation in any
way. Allow at least 6 inches of free space from the fan
exhausts on the right side of the NexPump Unit.
Do not install the NexPump System Unit where
temperatures will be below freezing (32 degrees
Fahrenheit).
Do not install the NexPump System Unit where it will be
exposed to outside elements.
DC C NNECTI N PRECAUTI NS
The NexPump Unit requires a connected marine type
deep-cycle battery for proper operation. You must assure
the battery is connected while the NexPump Unit is
operating.
When attaching the battery cables to the battery posts,
secure them to insure a good connection.
The BLACK wire from the NexPump System Unit
connects to the NEGATIVE (-) post of the battery.
The RED wire from the NexPump System Unit
connects to the POSITIVE (+) post of the battery.
The ‘REVERSE POLARITY LED’ will illuminate if
the battery connections are reversed.
AC P WER REQUIREMENTS
The NexPump System Unit must be operated from 120
volt household current from the AC outlet.
GROUNDING AND AC CORD INSTRUCTIONS
The NexPump System Unit should be plugged into
an outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
DANGER
Never alter the AC cord or plug provided – if it will not fit
the outlet, have a proper outlet installed by a qualified
electrician. Improper connection can result in a risk of an
electric shock.. An adapter should not be used with this
NexPump System Unit.
Important Safe Guards:
Never allow other items that discharge into the sump pit to
be unsecured. Unsecured items such as garden hoses,
laundry hoses and other medium used to discharge water
may interfere with the NexPump pumps or sensors. Be
sure to secure all items that may be used to discharge water
into the sump pit and verify that secured items will not
interfere will any NexPump operations.
4
INSTALLATION PROCEDURES:
Installing the NexPump does require some plumbing
expertise. You can use the installation diagrams at the end
of this document as a reference for proper installation. For
a Dual Pump NexPump System, separate discharges are
recommended for maximum discharge rates and multiple
output paths. If a Dual Pump NexPump System is installed
as a Backup, then you can us a WYE, however install one
NexPump Pump on the straight through of the WYE and
your normal electric pump on the 45 degree of the WYE.
The remaining NexPump Pump should be installed as a
separate discharge. You can install all the pumps in a
multiple wye configuration, however this type of
installation may reduce the total discharge capacity about
fifteen (15%) percent at high discharge rates.
Below are some important points for a proper installation.
Tighten hose clamps on check valves if applicable.
Tighten pump adapters securely.
Install separate discharges for maximum discharge rate.
IMP RTANT: When using a check valve a small 1/8”
hole must be drilled in the vertical discharge pipe of
each pump. D N T DRILL INT THE PUMP R
THE ELB W. The hole should be drilled at a 45
degree downward angle to prevent water spraying
upwards and position the hole about 2” above the Top
of the Elbow.
Note: For very narrow sump pits, pumps can be
stacked on top of each other. Pump 1 must be the
lowest pump.
Note: Make sure the RED filter screen is securely
attached to each pump.
IMP RTANT: Ai Turbo NexPump. Pump ne (1)
must be the pump with the RED WIRE L M.
IMP RTANT: REVIEW ALL SAFETY
PRECAUTI NS AND INSTRUCTI NS BEF RE
PR CEEDING!
Finishing Installation:
Step 1: Positioning the Sensors:
Sensor 1 is the main sensor and will turn on the pump(s)
when the water rises above the sensor. The Gray Sensor
should be used for Sensor 1. Sensor 2 does not operate
exactly like Sensor 1 however, functions as a backup and
high water alarm. (See Sensor Operations). The Black
Sensor should be used for Sensor 2. Attach the sensors to
any discharge pipe securely with the supplied stainless
steel clamps (float side down,sensor cable up, mounting
bracket up, remove any shipping tape). Float on each
sensor should move freely up and down.
Position the sensors as described below.
Sensor 1 (Left Sensor Receptacle):
NexPump in Backup Mode:
Position Sensor 1 approximately 4 - 6 inches above the
activation level of the Main pump. If not, the NexPump
may show the pumps have been activated prematurely.
NexPump in Primary Mode (Only Sump Pump):
Position Sensor 1 approximately 2 - 4 inches above the
pumps.
NexPump in Primary Mode (With Electric Sump Pump):
Position Sensor 1 above the level of the NexPump pumps
and below the level that the AC pump will turn on.
Sensor 2 (Right Sensor Receptacle):
Sensor 2 is used as a backup and alert for high water.
When activated the NexPump will begin operation in a
special emergency mode and with ‘Auto Notification’ will
alert immediately. Position sensor 2 about 6 inches above
all other trigger points.
IMP RTANT : If a vent hole is drilled in the discharge
pipe make sure a sensor or sensor clamp does not block
the vent hole. Do not position the sensor on the side of
the discharge pipe facing the drain tile or any incoming
rush of water.
Be sure the sensor is positioned vertically with the
mounting bracket at the top. Verify the sensor is not
tilted in any way.
Step 2: Secure Wires:
Secure the pump and sensor wires to discharge pipes with
nylon wire ties.
IMP RTANT : Make sure the wire ties or wires do not
interfere with the operation of the sensor.
5
Step 3: Position Battery and System Unit:
Place the battery in a battery box (if used) on the floor or
on a secure shelf, rack or ledge. Position the NexPump
System Unit in a secure place ideally above the floor. The
pump wires and sensor wires should be long enough to
position the NexPump System Unit approximately 3-4 feet
above the floor. Be sure the power cord will reach the AC
power socket. Secure the electrical power cord as needed.
Do not plug in at this time. Make sure battery cables will
reach battery. Do not connect battery cables at this time.
Step 4: Pump and Sensor Connections:
IMP RTANT: Ai Turbo NexPump. Pump ne (1)
must be the pump with the RED WIRE L M.
Plug the pump connectors into the NexPump System Unit.
If both pumps are not on the bottom of the pit then Pump 1
must be the lowest pump. Plug in the Sensors. Primary
Sensor (Sensor 1) to bottom receptacle. Backup Sensor
(Sensor 2) to top receptacle. The sensor connectors plug in
with the security latch to the right of the NexPump System
Unit. Verify the sensor connectors are securely attached.
IMP RTANT: Ai Turbo NexPump. Pump ne (1)
must be the pump with the RED WIRE L M.
IMP RTANT: To disconnect a pump connector,
slightly depress the security latch on the bottom of the
connector and pull out the connector.
To disconnect a sensor connector, slightly depress the
security latch on the right side of the connector and
pull out the connector.
Step 5: Connecting the AC Power Cord:
IMP RTANT: Make sure that the AC outlet is a
grounded outlet.
Plug in the NexPump's AC power cord and verify a secure
connection. The display will illuminate and ‘Operating
Status’ Green LED should be blinking.
Note: An Alarm may sound at this time because the
battery is not connected.
Step 6: Connect Battery:
Attach the battery cables to the battery, the BLACK wire
to the NEGATIVE(-) post, the RED wire to the POSITIVE
(+) post and tighten securely.
IMP RTANT: Check the ‘Battery Reverse’ LED on
the NexPump System Unit and if it is illuminated the
connections are reversed.
Step 7: Check Your NexPump:
All alarms should be off at this time. Set your preferred
mode setting (See Mode Selection). The NexPump will
schedule an automatic self-test approximately two minutes
after power up. If there are any alerts they will be
displayed on the LCD display and an alarm will sound.
Step 8: Secure Battery Boxes:
If Battery Boxes are used, place each Battery in the Battery
Box.
Step 9: Set Battery Amp Hours and Enable Charger:
Refer to Quick reference or Function Button section to set
battery amp hours and enable the charger.
Note: Always perform this step when installing new
batteries.
Your NexPump is ready for use!!
6
NEXPUMP DISPLAY STATUS:
Display Note: Alert messages will display on second line
of display. They will display one alert at a time, however
will let you know how many there are in the format of
“Alert X of X”, followed by the alert message.
SYSTEM PERATING STATUS:
The ‘Normal Operation’ LED must be blinking to
indicate the NexPump Unit is operating. In addition, the
mode location (last digit on display) will also be blinking
with the mode the NexPump is in. If both of these are NOT
blinking then there may be problem with the NexPump
Unit.
M DE SELECTI N:
Primary Mode - Used when pump is the primary pump
o Mode switch in up position. The letter ‘P’ will
be blinking in the mode position on display.
o NexPump WILL NOT display or sound an alarm
if pump(s) are activated.
Backup Mode - Used when pump is a backup pump
o Mode switch in down position. The letter ‘B’ will
be blinking in the mode position on display.
o NexPump WILL display and sound an alarm
if pump(s) are activated. Indicated by ‘A’ in the
corresponding pump location.
Manual Mode – Used to manually turn on both pumps
o Switch in up position manual mode is ON and in
down position manual mode is OFF.
o The letter ‘M’ will be blinking in the mode
position on display.
o When operating on battery power the NexPump
will not calculate Battery Life Remaining.
o Clog or Vapor Lock detection is disabled.
o Pumps will turn off for 5 seconds each minute to
clear possible Vapor Lock Conditions.
o Auto Self-Test is disabled
Emergency Mode – Automatically selected
o The letter ‘E’ will be blinking in the mode
position on display.
o Alarm will sound with display indicting the reason
NexPump went into the Emergency mode.
Note: The Emergency mode is automatically selected
if the NexPump detects certain conditions. Below is an
example of the display when operating in the
Emergency Mode.
7
(G) Mode, Function
FUNCTI N BUTT N:
The Function Button is used to access Menu items. The
Display Digit (G) will display an alpha character and
change about every 3 seconds as you press and hold the
FDB, in addition you will hear a beep each time the
character changes. Release the function button when the
display reads the function you would like to run.
The following are a list of functions:
‘C’ – Clears alerts - Clears alerts. If there are no alarms
currently active then NexPump will display that there are
no alarms to clear.
Note: When you clear alarms, the notification system
will automatically set a counter so notifications will not
occur for about one to two hours to prevent repetitive
notifications.
‘S’ or ‘U’– Silence or Un-Silence Alarm – Can ONLY be
used during AC Power Loss or Pumps have been Activated
Do this if you do not want to hear the alarm. Automatically
clears after 24 Hours
‘U’ – Un-Silence alarm
Re-Enables Alarm that was already Silenced
‘T’ – Run Manual Test.
‘K’ – Runs Configuration Menu
‘I’ - Runs Stats Information Menu
‘D’ - Disable Alarm – This will totally disable the alarm in
the NexPump Unit. Notifications will still occur during the
time the alarm is disabled. Automatically clears after five
(5) Days
‘E’ - Re-Enable Alarm after being disabled.
‘-’ - Function End, NO Other Menu Items Available
Function 'I' (Statistics):
This will display statistics, information and configuration
setting:
Unit Serial Number
Unit Model
Pump Hours and Type
P1=xxxxxH (xx) (Pump Hours)
Type = 'H' (Pump Type)
Power Up Time
CPU=xxxxx Day(s) (Current Power Up)
TPU=xxxxx Day(s) (Total Power Up)
Number of Auto and Manual Tests
Auto Tests=xxxxx (Number of Auto Self-Tests)
Man Tests=xxxxx (Number of Manual Tests)
Battery and Monitor Configuration
LM=On/Off (LAN Monitor.)
PM=On/Off (Phone Monitor)
BA=xxxA/H (Battery Amp Hours)
E/S=On/Off (Empty Sump Function)
Batt=Wet/AGM (Battery Type)
Replace Battery In: xxxx Days
Network Information (W/Installed Network Module)
Disp Alert History? (Displays Last 10 Alerts)
8
(G) Mode, Function
ALERTS:
Normal Alerts:
Pump Activations
AC Power Loss
Notifications: After Approximately thirty (30) Minutes
Special Note: Pump Activations let ou know there ma be
an issue with our Main Pump. If ou find ou have a
problem with our Main Pump ou can switch the
NexPump Mode to 'Primar ' until the Main Pump problem
is corrected.
Critical Alerts:
All Other Alerts
Notifications: After Approximately five (5) Minutes,
except a High Water Alert which is Approximately one (1)
Minute.
Silencing or Un-Silencing the Alarm:
The Alarm can be Silenced for Normal Alerts Only. Use
Function 'S' to silence or Function 'U' to Un-Silence
Alarm. A Silenced Alarm clears automatically after 24
Hours.
Note: When the alarm is silenced the identifiers will
blink to notify which conditions are in the alarm state.
Disabling or Enabling the Alarm:
The alarm can be disabled if needed. When disabled, the
alarm will not sound for any reason. The alarm will be
disabled for five (5) days and automatically enabled after
that time. You can Enable the Alarm before the five (5)
Day period with Function 'E'. The Display will toggle
'ALDIS' with the (E) Battery Status anytime the Alarm is
Disabled.
Note: All Notifications will take place while the alarm is
disabled, disabling the alarm simply turns off the
sound.
Alert History:
Using Function 'I' you can Retrieve the History of the Last
ten (10) Alerts Registered. Press and hold Function Button
at this menu screen, cursor will toggle between 'Y' and 'N'.
Release at desired position.
Displaying Alerts:
Below are two (2) examples of what the display will look
like when there are alerts on the NexPump. Line two (2) of
the display will show you each alert approximately every 3
seconds. The first example let's you know the number of
alerts and the current number it's will be displaying. The
format will be 'Alert x of x'. The second example is the
actual alert that follows the first example.
9
BATTERY STATUS:
Battery Status:
‘XX.XX’ Battery voltage
Normal readings ‘12.40-13.20’ (Charger Off)
‘Disc’ Battery disconnected
Displa s when Batter is disconnected or Batter voltage
is below 1.50 volts
‘Rep_’ Replace Battery
(The ‘_ ‘ indicates the reason for failure “numeric value”)
See (Battery Troubleshooting)
If Notification is Installed:
Notification will occur on a Battery Disconnected or Low
Battery or Battery Replacement Alert after approximately
five (5) Minutes. After an AC Power Outage when running
on Battery, Notification will occur after approximately
thirty (30) Minutes.
Clear Battery Alerts:
Only Battery Replacement Alerts can be cleared. To Clear
a Battery Replacement Alert, use Function 'C'
Testing:
Battery is tested on 12 Hour Self-Tests or Manual Tests.
Exceptions: Charge System is Active, Battery Disconnect,
Battery Replacement Alert is Active.
Menu ptions for Battery perations:
Function 'K' Battery perations:
Menu Item to set or reset Battery Amp Hours:
(Set Total Amp Hours of Batteries Connected. Press and
hold Function Button at this menu, number will increment
by 5. Release at desired amount. Defaults to 105 AH)
Menu Item to turn on Battery Charger:
(Turn on Charger when system is first installed or when
replacing Batteries. Press and hold Function Button at this
menu, cursor will toggle between 'Y' and 'N'. Release at
desired position)
Menu Item to reset Battery Life Timer:
(Batteries have a lifespan and should be replaced when the
NexPump reports this time frame has expired. This should
also be reset when replacing batteries. Defaults for battery
type selected. WET = '1300 Days, 3.5 Years', AGM =
'1600 Days, 4.5 Years'')
Menu Item for Battery Type:
(Select Battery Type to type installed. Press and hold
Function Button at this menu, cursor will toggle between
'W' and 'A'. Release at desired position)
Function 'I' Battery perations:
Info Item to check Battery Amp Hours and Type:
BA=Battery Amp\Hours, Batt=Battery Type
Running n Battery Power:
Location '(C) AC Power Status' above indicats an AC
Power Loss 'O'. If the alarm is silenced this location will
be blinking to indicate the alarm is silenced. Location '(F)
Battery Life' will indicate the Battery Life in Hours
Remaining when AC Power fails. ‘999’ Hours is the
maximum number displayed. The Battery Life Monitor
calculates the remaining life about 4 times an hour. When
running on battery power you should closely monitor the
Battery Life when the Hours Indicated are ten (10) or
below. Fluctuating pump(s) times, battery condition and
battery state before going to battery power will affect the
calculated time throughout the power loss, in addition this
number may not be accurate if the Battery Amps Hours are
not set correctly before the Power Outage began. The
alarm will also sound from the loss of electric power,
which may silenced by performing a Function 'S'. Once
AC power is restored the display will again display a
normal status. A charge cycle may also be enabled at the
time AC Power is restored.
10
(E) Battery or Notification Status
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