Zoeller Pump Company

Important Safety Information

WARNINGS

1. Testing for ground: Use an Underwriters Laboratory listed circuit analyzer to check electrical outlets for proper ground connection. If not correctly wired, contact a qualified electrician.
2. For protection, always disconnect power from the source before handling components of the DC backup pump or the primary pump.
3. Installation and servicing of electrical circuits and hardware should be performed by a qualified, licensed electrician.
4. Follow all electrical and safety codes, including the National Electrical Code and applicable local codes.
5. Owners must check the battery and battery connection monthly. Batteries contain acid; handle with caution.
6. Risk of electric shock: These pumps have not been investigated for use in swimming pools and marine areas.
7. California Proposition 65 Warning: Cancer and Reproductive Harm - www.P65Warning.ca.gov.

FCC Compliance: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy. If not installed and used according to instructions, it may cause harmful interference to radio communications. If interference occurs, try to correct it by reorienting or relocating the product, increasing separation between equipment and the receiver, or consulting a dealer or TV technician.

CAUTIONS

1. Ensure a properly grounded 115 V receptacle is available. Do not use the primary pump circuit. The location must be within 6 ft (1.8 m) of the control box and battery. Do NOT use an extension cord.
2. Ensure the 115 V electrical supply circuit is equipped with appropriately rated fuses or circuit breakers.
3. DC emergency pumps are designed for clear water only. Do not use in septic tanks or sewage pits.
4. Repair and service should be performed by an authorized service station.
5. DC automatic backup pumps require a variable level float switch for operation. Ensure the float switch operates freely and is secured to turn the pump on and off correctly. A pit diameter of 18 inches (45.7 cm) or larger is recommended for accommodating both primary and DC backup pumps.
6. For indoor use only.

Turbulence Caution: High-velocity incoming water can cause sump pumps to airlock. If this occurs, the incoming water must be baffled to avoid excessive turbulence.

Limited Warranty

Zoeller Pump Company warrants new products to be free from defects in material and workmanship for 3 years from the date of purchase by the end user. Zoeller batteries also have a 3-year warranty. Proof of purchase is required. Defective parts will be repaired, replaced, or remanufactured at Zoeller's option. This warranty does not cover products that have been disassembled without approval, misused, neglected, altered, or damaged by accident or acts of nature, or not installed/operated according to instructions. It also excludes damage from substances like sand, gravel, cement, mud, tar, hydrocarbons, or abrasive/corrosive materials.

Contact Zoeller Pump Company at 3649 Cane Run Road, Louisville, KY 40211, Attention: Customer Support Department for repair or replacement information.

Zoeller expressly disclaims liability for special, consequential, or incidental damages. Implied warranties of fitness for a particular purpose and merchantability are limited to the duration of this expressed warranty. Some states may have different regulations regarding warranty limitations.

In cases of alleged product failure causing property damage, the property owner must retain possession of the product for investigation.

Description

The AquaNot 507 Key is a 12 Volt DC battery backup system designed to protect against flooding during power outages or primary pump failure. It features a self-priming pump and a controller with built-in smart diagnostics. The controller can detect and alarm for conditions like a disconnected or jammed pump, or a missing/unplugged float switch. It differentiates between pumping air and water to purge air locks and prevent run-dry conditions. Zoeller uses a normally open operational float switch. The advanced controller technology aims to remedy many conditions automatically and extend battery life through intelligent charging.

Specifications

* When AC power is available, the controller will replace the power used by the pump once the pump shuts off.

Battery Selection

The DC emergency pump system requires a good quality, 12-volt, deep-cycle battery for maximum pumping time during a power outage. A 90 amp-hour or larger marine battery is recommended. A 100+ amp hour battery can provide approximately 7.5 hours or more of continuous pumping time with 8 ft (2.4 m) of head pressure. Batteries with top terminals are recommended for ease of installation. "Wet" cell batteries contain acid and require proper handling precautions. The battery box accommodates a maximum battery size of 13.5 inches (34.3 cm) Length x 7 inches (17.8 cm) Width x 9.5 inches (24.1 cm) Height. AGM batteries are also recommended. Do not use gel batteries or automotive batteries.

Installation

The installation kit includes necessary fittings and a check valve in the discharge of the backup pump.

1. Remove all parts from the shipping carton and verify contents.
2. Select a location for the battery and controller. The controller must be within 6 ft (1.8 m) of a 115 V wall outlet and within 6 ft (1.8 m) of the pump and basin. It is recommended that the controller be plugged into a separate circuit from the primary pump. Ensure the controller is not installed in a small, poorly ventilated space.
3. If the primary pump is installed, disconnect its power.
4. Discharge piping must be 1-1/2" SCH 40 PVC.
5. Remove the discharge pipe from the pump and set aside.
6. Solvent weld the DC pump to a tee at a 30-degree angle as shown in Figure 4. Install the in-line check valve into the primary pump discharge.
7. Measure the distance between the in-line check valve and the tee to cut the discharge pipe. Solvent weld the cut piece to the tee, then to the check valve. Tighten the hose clamp. Ensure hose clamp screws do not interfere with the primary pump's float operation.
8. Assemble the operational float switch per Figure 3 and install it as seen in Figure 1.
9. Mount the operational float switch bracket above the "on" level of the primary pump using the provided clamp. Ensure the clamp is tight. The "off" level of the float must be at least 1 inch (2.5 cm) above the DC backup pump's outlet. Position pumps in the sump, moving the float up and down to ensure free movement without obstructions. Adjust float stops or cut extra float rod length as needed.
10. Mount the Key™ Controller to a sturdy location using the provided zip tie, or to the battery box.
11. Connect the controller leads to the battery terminals: positive (+) lead to the positive terminal and negative (-) lead to the negative terminal.
12. Caution: Correct battery hook-up is essential. Use wing nuts and eyelet connectors. On batteries with different post sizes, the positive terminal is larger (3/8" or 10mm), and the negative is smaller (5/16" or 8mm). Apply grease to terminals to prevent corrosion.
13. Connect the pump, operational switch, and power supply plugs into the appropriate receptacles on the controller.
14. Plug the controller into the 115 V wall outlet. Ensure the primary sump pump and controller are on separate circuits.
15. After verifying all connections, reconnect power to the primary sump pump.

Figure 1: System Diagram
Illustrates the DC pump installed in-line with a submersible pump, showing the controller, battery box, primary pump outlet, and the critical placement of the float switch assembly's "off" level, which must be higher than the DC backup pump's intake by a minimum of 1 inch.

Figure 2: Aquanot® Key™ Controller Diagram
Labels the controller's components: System Ready LED, Battery LED, AC Power Adapter Port, 30 Amp Fuse, Silence Button, Float Status LED, Test Button, DC Pump LED, DC Pump connection, and Operational Float connection.

Figure 3: Aquanot® Key™ Float Switch Diagram
Shows the float switch assembly with its Molex 4-pin connector and the importance of installing the locking pin under the float rod.

Figure 4: 507 DC Pump Diagram
Depicts the 507 DC Pump, highlighting the discharge pipe (customer supplied) and the intake, with an important note to set the intake at a 30-degree angle above the primary pump's intake to minimize air lock risk.

Initial Start-Up and Operation

1. Test the installation for leaks by running water into the sump, allowing the primary pump to operate normally.
2. Check the controller: The System Ready light should be green when plugged into the 115 V outlet. The battery condition is indicated when the controller has DC power. Upon initial plug-in, all lights will flash and an alarm will sound to verify functionality. Note: The charger may take several minutes to begin charging.
3. Disconnect the primary pump from its power source before touching any component in the sump pit.
4. Lift the operational float switch. After a few seconds, the DC backup pump will run, and the alarm will sound after another second. Lower the float switch. Ensure the DC pump's intake is set above the primary pump's inlet. Press the Silence button for 3 seconds to clear the alarm and reset the unit. Caution: Continuous dry running can damage pump seals. The pump will shut off when the float switch is released. Ensure no obstructions are around the float.
5. Complete final testing: With the primary pump still disconnected, unplug the Key controller from the 115 V outlet. Run water into the sump until the DC backup pump activates. Check all connections for leaks.
6. When the pump is running, press the Silence button to silence the alarm. The pump will continue until the operational float is deactivated.
7. Reconnect the controller and primary pump to their AC wall outlets. The primary pump may activate to lower the water level. Both systems are now ready for use.
8. Hold the Silence button for several seconds to reset the unit. The LED will be yellow during normal charging. See page 6 for controller function descriptions.

Note: It is normal for water to spray from the 1/8" (3 mm) air relief hole when the pumps are running.

Note: The Key controller monitors the switch connection and provides an alarm if the switch becomes disconnected.

Key™ Controller Functions

The controller has two buttons:

• Silence/Reset: Press to silence current alarms for 24 hours. Hold for over 3 seconds to reset the alarm and clear flashing lights.
• Test: Runs the pump to check amp draw. The controller self-tests the pump every 24 hours. Pressing the test button initiates the 24-hour self-test timer.

Note: Holding both Silence/Reset and Test buttons simultaneously for 5 seconds performs a factory reset.

LED Status Indicators

Maintenance

Inspect and test the system at least every 3 months. Check electrolyte levels in wet cell batteries monthly (not required for maintenance-free types).

1. Ensure the green "System Ready" indicator light is on, signifying AC power is active and no alarms are present.
2. Unplug the primary pump and the controller from the power supply.
3. Fill the sump with water to the "on" level for the DC pump and let it run for a few minutes.
4. The alarm should sound approximately 1 second after the pump starts.
5. Press the Silence/Reset button to turn off the alarm. The pump will stop when the water level lowers and the float drops to the "off" position.
6. Hold the Silence/Reset button for 3 seconds to reset the controller and clear any alarms.
7. Plug the controller and primary pump back into the wall outlet. The primary pump may activate to lower the water level. The battery light will turn yellow during charging, indicating the charger is replenishing consumed energy. The green light will appear once charging is complete.

Troubleshooting Information

1. DC Pump won't run: Check connections, terminal points (clean if needed), battery charge (service if required), and the 30 amp fuse on the controller. Replace fuse with a 30 amp automotive blade fuse if blown.
2. Pump runs but pumps very little or no water without AC power: Check battery charge. The battery will recharge if the System Ready light is green and the float switch is off. If immediate use is needed, replace the battery. Low batteries may cause the pump to run continuously without removing water until the battery voltage is critically low. Weak batteries, even when recharged, may not store sufficient energy for full service; professional load testing is recommended for frequently used systems.
3. Pump runs but pumps very little or no water: Verify pump connection. Ensure the pump weep hole is clear and the unit is not airlocked. Check that discharge piping is not blocked.
4. Pump cycles too frequently: Check the position of rubber stops on the operational float rod and adjust the upper rubber float stop as needed.
5. Float switch in "on" position for more than 3 seconds, pump won't run: Remove the pump and check for obstructions preventing impeller rotation.
6. Pump runs, but pumps water intermittently: This may indicate an air lock caused by turbulent incoming water. Baffle the incoming water stream or divert it against the basin wall. Ensure the "off" level of the float is higher than the DC pump's intake.
7. Water level stays high, DC Pump continues to run: Battery may be low. If the water level remains high after power is restored, check the primary pump. The battery should restore to full charge after several hours.
8. Alarm sounds during battery recharge cycle: To silence the alarm if it doesn't reset, unplug the charger from the 115 V outlet. Disconnect the black lead from the charger's negative battery post. Check the battery and replace if necessary. Reconnect and refer to Installation (step 11).

The Aquanot® Battery

Zoeller Pump Company offers its own line of batteries to ensure consistent quality and prevent damage to controller charging circuits. They offer both water/acid deep-cycle and maintenance-free AGM batteries. These can provide over 7.5 hours of continuous pumping at 8 ft (2.4 m) static head, though actual times vary with conditions.

Recommendations:

• Use a BCI size 27 deep-cycle battery, 175 minute reserve capacity, or larger.
• Do NOT use "maintenance-free" batteries unless they are AGM type.
• Replace your battery every 3 years.
• Prevent corrosion buildup on battery terminals.
• Check specific gravity on wet cell batteries using a hydrometer.
• Use the included plastic battery box to keep the battery safe and clean.

Protect Your Warranty:

• Check water levels in batteries monthly (wet cell batteries only).

Carbon Monoxide Detectors

Batteries used in backup pump systems can produce gaseous by-products during charging, which may cause a rotten egg odor or trigger false CO detector alarms. Zoeller Pump Company recommends moving the battery away from CO detectors or venting the battery to the exterior to help prevent false activations. These are guidelines and do not supersede detector instructions or manufacturer advice.

If your CO detector alarm activates:

1. Take immediate action for personal safety as recommended by the detector's literature.
2. Contact the appropriate agency to determine if CO is being produced by other household appliances (furnace, water heater).
3. If no CO is being produced, a charging battery might be the cause. Contact the battery or pump manufacturer for recommendations.

Notes

(Space for user notes)