Little GIANT EC-1-DV Mini Condensate Pump Owner’s Manual

Little GIANT EC-1-DV Mini Condensate Pump

Product Information

This pump is designed to automatically remove condensate water that drips from wall-mount ductless air conditioners up to 34,000 BTU/hr. The EC-1-DV pump is only suitable for intermittent use in applications with a maximum 50% pump duty cycle and a maximum 3-minute pump ON cycle. To maintain a maximum 50% duty cycle, the pump must have at least twice the flow rate of the condensate produced at the head required by the application. This product is covered by a Limited Warranty for a period of 2 years from the date of original purchase by the consumer. For complete warranty information, refer to www.LittleGiant.com.

Specifications

Model

| ****

Item Number

| Gallons (Liters) per Hour at Height| ****

Shut Off ft (m)

---|---|---|---
0 ft

(0.0 m)

| 1 ft

(0.3 m)

| 5 ft

(1.5 m)

| 10 ft

(3.0 m)

| 20 ft

(6.1 m)

EC-1-DV| 553507| 2.7 (10.2)| 2.5 (9.5)| 1.8 (6.8)| 1.5 (5.7)| 1.2 (4.5)| 33 (10)
EC-1K-DV| 553517

SAFETY INSTRUCTIONS

This equipment should be installed and serviced by technically qualified personnel who are familiar with the correct selection and use of appropriate tools, equipment, and procedures. Failure to comply with national and local electrical and plumbing codes and within Little Giant recommendations may result in electrical shock or fire hazard, unsatisfactory performance, or equipment failure. Know the product’s application, limitations, and potential hazards. Read and follow instructions care-fully to avoid injury and property damage. Do not disassemble or repair unit unless described in this manual. Failure to follow installation or operation procedures and all applicable codes may result in the follow-ing hazards:

Danger

Risk of death, personal injury, or property damage due to explosion, fire, or electric shock.

• Do not use to pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc.
• Do not use in explosive atmospheres or hazardous locations as classified by the NEC, ANSI/NFPA70.
• Do not handle a pump or pump motor with wet hands or when standing on a wet or damp surface, or in water.
• When a pump is in its application, do not touch the motor, pipes, or water until the unit is unplugged or electrically disconnected.
• If the power disconnect is out of sight, lock it in the open position and tag it to prevent unexpected application of power.

Warning

Risk of severe injury or death by electrical shock.

• To reduce risk of electrical shock, disconnect power before working on or around the system.
• Wire pump system for correct voltage.
• Be certain that this pump is connected to a circuit equipped with a ground fault circuit interrupter (GFCI) device if required by code.
• Check electrical outlets with a circuit analyzer to ensure power, neutral, and ground wires are properly connected.
• These pumps are designed to be used with an earth-grounding conductor. To reduce the risk of electrical shock, connect the earth lead to a properly-grounded circuit in accordance with electrical code.
• Some pumps are supplied with lead wires and are intended to be hardwired using a junction box or other approved enclosure. The pumps include a grounding connector. To reduce risk of electric shock, be certain that it is properly connected to ground.
• All wiring must comply with the National Electrical Code and local codes.
• Check local electrical and building codes before installation. The installation must be in accordance with their regulations as well as the most recent National Electrical Code (NEC) and the Occupational Safety and Health Association (OSHA).
• Do not use the power cord for lifting the pump.
• Do not use an extension cord.
• The pump should only be used with liquids compatible with pump component materials. If the pump is used with liquids incom-patible with the pump components, the liquid can cause failure to the electrical insulation system resulting in electrical shock.
• This pump has not been investigated for use in swimming pool or marine areas.
• To reduce risk of electric shock, install with all electrical components above the top grade level of the pump.

CAUTION

Risk of bodily injury, electric shock, or equipment damage.

• This equipment must not be used by children or persons with reduced physical, sensory or mental abilities, or lacking in experi-ence and expertise, unless supervised or instructed. Children may not use the equipment, nor may they play with the unit or in the immediate vicinity.
• Equipment can start automatically. Lockout-Tagout before servicing equipment.
• The pump motor is not submersible. Do not allow water to rise and contact motor.
• This pump has been evaluated for use with water only. The pump should not be insulated. A space must be left around the pump to allow for cooling in the event of prolonged operation.
• An inoperative or malfunctioning pump could lead to flooding, resulting in personal injury or property damage.
• Operation of this equipment requires detailed installation and operation instructions provided in this manual. Read entire manual before starting installation and operation. End User should receive and retain manual for future use.

Notice

Risk of damage to pump or other equipment.

• • Before installing pump, allow air conditioner to cycle several times, collecting condensate in a separate container to help flush any residual oils that may remain in the system. Failure to flush the system can result in damage to the pump and drain line plumbing components.
  When operating in a gas furnace environment, care must be taken to ensure acidity of condensate does not fall below the average pH of 3.4 (to prevent a localized pocket of acid that acts like a battery causing pitting) by routinely cleaning or flushing tank with fresh water.

• Do not run pump dry. Running dry will cause serious damage to the pump.

• Support pump and piping when assembling and when installed. Failure to do so may cause piping to break, pump to fail, motor bearing failures, etc.

• Do not install the pump in a manner that will subject it to splashing or spraying.

• Periodically inspect pump and system components. Regularly check hoses for weakness or wear, making certain that all connec-tions are secure.

• Schedule and perform routine maintenance as required and in accordance with the Maintenance section of this manual.

• Pump is for indoor use only.

• Do not use this pump inside an air plenum.

Installation

Typical Installation

1. Reservoir adapter

2. Outlet port (1 of 3)

3. Reservoir

4. Reservoir sensor cable

5. Pump power cable

6. Pump

7. Discharge adapter

8. Pump bracket, EC-1-DV

9. Reservoir tubing

10. Vent tubing

11. Hook-and-loop square

12. Reservoir bracket
    (kit sold separately)

13. Pump bracket, EC-1K-DV

14. Pump enclosure base

15. Straight duct base

16. Elbow duct base

17. Gasket trim

18. Elbow duct cover

19. Straight duct cover

20. Pump duct cover

Physical Installation

EC-1-DV Installation
Reservoir

1. Position the reservoir on a flat, level surface within reach of the air handler drain hose.
   • Ensure the reservoir inlet can be gravity-fed by the air handler’s drip tray.
2. Secure the reservoir’s positioning with the included hook-and-loop square.
3. Ensure that the reservoir is level.

Reservoir bracket (kit sold separately)

1. Determine bracket location.
   • Ensure the reservoir will have adequate clearance for future maintenance.

2. Use the bracket to mark two level screw hole locations.

3. Attach bracket to wall, using supplied wall anchors and fasteners.

4. Clip the reservoir within the bracket.

5. Ensure that the reservoir is level.

Control Pump

1. Determine bracket location.

   • The pump can be above, below, or adjacent to the air handler.
   • Do not install the pump any more than 3 feet away from the reservoir.

2. Pierce the mounting bracket grommet with the two remaining screws.

3. Use the bracket and screws to mark future screw location.

4. Attach bracket to wall, using supplied wall anchors and fasteners.
   IMPORTANT: Make sure the screw head does not push through the bracket’s rubber grommet.

5. Slide pump onto bracket, aligning the bracket grommet flanges with the pump mounting slots. IMPORTANT: The imprinted arrow on the pump points from intake to discharge.

6. Plug the reservoir sensor cable into the pump’s sensor socket.

7. Install the pump power cable.

   • Refer to “Electrical Connections” on page 8.

Tubing Connections:

Drain Hose-to-Reservoir: The drain hose varies with the design of the air handler used. Connect the air handler drain hose to the reservoir inlet.

Reservoir-to-Pump: The reservoir has three outlet ports, one vertical and two horizontal. Ensure that the two unused outlet ports remain capped. Uncap the desired outlet port, connect the reservoir tubing to the uncapped port, and secure with a supplied cable tie. Connect the tubing to the pump intake and secure with a supplied cable tie.

Pump Discharge: Connect the discharge tubing to the tubing adapter and secure it with a cable tie or hose clamp. Guide the tubing so that it leads into the nearest gravity-fed drain or along the refrigeration lines.

Vent Tubing: Connect the 1/4-inch (6 mm) ID tubing to the reservoir vent port and route it upward.

EC-1K-DV Installation
Duct Bases

1. Knock out the air handler line set opening.

2. Use a level to position the elbow base 1/2 inch from the air handler’s line set opening.

3. Mark screw hole locations and attach the base using the supplied wall fasteners.

4. Draw a guideline from the center line arrow molded on the elbow base to the ceiling.

5. Use a level to set the pump enclosure against the wall aligning the center screw slots with the guideline.
   IMPORTANT: The pump must not be installed more than 3 feet above the reservoir.

6. Mark screw hole locations and attach the base using the supplied wall fasteners.

7. Trim the straight duct base to fit between elbow and pump base.

8. Mark screw hole locations and attach the base, using the supplied wall fasteners.

9. Attach at least two line set zip tie clips in the channel rails of the straight duct base. NOTE: The clips’ twist-lock feature allows easy clip adjustment along the base.

10. Position the line set within the duct base.

    • Secure the line set to the pump duct base with zip tie(s).
    • Carefully bend the line set to conform to the 90° transition of the reservoir elbow.
    • Loosely thread but do not tighten zip ties along the rest of the line set.

Control Pump

NOTICE

Risk of damage to pump or other equipment.

• Always provide adequate support to the assembly components and ensure the tubing is never kinked, twisted, broken, or otherwise damaged.
• Always reinforce tubing connections with cable ties.

1. Attach the reservoir tubing to the pump.

2. Slide pump onto bracket, aligning the twin bracket grommet flanges with the pump mounting slots.

3. Slide the pump bracket into pump enclosure, aligning the four bracket grommet flanges with the enclosure’s mounting slots.
   IMPORTANT: The imprinted arrow on the pump points from intake to discharge.

4. 4. Connect the discharge tubing to the pump.

   • Refer to “Pump Discharge” on page 6.

5. Install the pump power cable.

   • Refer to “Electrical Connections” on page 8.

Reservoir

1. Install the vent tube onto the top of the reservoir.

2. Connect the reservoir tubing to the top port and secure with a zip tie.

   • Ensure the other outlet ports remain capped.
     IMPORTANT: Ensure the free end of the tubing reaches above the highest level of the air han-dler’s drip tray.

3. Slip the reservoir in the elbow base.

   • Ensure that the reservoir is level.

4. Guide the reservoir sensor cable up the line set under the zip ties and connect to the pump’s sen-sor socket.

5. Attach the reservoir drain hose to the air handler drain hose.

   • Refer to “Drain Hose-to-Reservoir” on page 6.

6. Tighten the zip ties to secure tubing, pump cables, and line set.
   IMPORTANT: Do not pinch or squeeze tubing.

Finalizing Installation

1. Test pump operation.
   • Refer to “Operation Testing” on page 10.
   • Ensure there are no leaks in the system.
2. Measure and cut the straight duct cover to fit between the elbow and pump duct bases. NOTE: The straight duct cover will be shorter than the straight duct base.
3. Install the straight duct cover.
4. Snap the pump enclosure duct cover onto the enclosure base.
5. Attach gasket trim at the elbow cover and air handler.
   • Adjust to close any gaps.
6. Snap the elbow enclosure duct cover onto the enclosure base.

Electrical Connections

Warning

High voltages capable of causing severe injury or death by electrical shock are present in this unit.

• • To reduce risk of electrical shock, disconnect power before working on or around the system. More than one dis-connect switch may be required to de-energize the equipment before servicing.
• All wiring must comply with the National Electrical Code and local codes. Employ a licensed electrician.

1. Connect pump power cable to 6-pin pump electrical connector.
2. Run the pump power cable under the zip ties along the line set and connect to the air handler power terminal.
   • Wire to a constant source of power matching the pump nameplate voltage.
   • Wire the pump to the air handler power panel if the air handler unit uses 110-240 V.
   • Ensure that the fuses or circuit breaker are of ample capacity in the electrical circuit.
   • Connect pump to a dedicated GFCI circuit.

Some models are supplied with a stripped wire cord end. Wires are color-coded as follows:

NOTE: It is recommended to install an UL-listed inline fuse with a .50A nominal rating in the line lead.
IMPORTANT: If the supplied power cord is missing or damaged, it must be replaced with a spe-cial cord available from the manufacturer or its service representative.

High Water Level Switch Connection

Caution

Risk of bodily injury or property damage.

• In applications where property damage and/or personal injury might result from an inoperative or leaking pump due to power outages, discharge line blockage, or any other reason, a backup system(s) (e.g. auxiliary switch) and/or alarm should be used and monitored.
• The high level switch should be connected to a Class 2 Low Voltage circuit.

This unit is equipped with an overflow protection switch with a maximum rated switching current (resistive load) of 3 amps at 250 VAC or 3 amps at 30 VDC. The high water level switch is electronic and requires power from the pump circuit to operate.

IMPORTANT : Refer to the air handler’s Operating Manual for expected switch operation and wiring connections. The high level switch can be wired so that, in the event of high water levels in the reservoir, the circuit will open (break) or close (complete).
For example , opening or closing the circuit can be used to:

• shut off the heating/cooling system and stop condensate
• activate an external alarm or relay (purchased separately).

Wires are color coded as follows:

OPERATION TESTING

1. Remove front fascia of air handler to expose coil and drip tray.

2. Turn on air conditioner.

3. Slowly pour several ounces of water into the air handler drip tray.
   NOTE: The reservoir will hold approximately 4 liquid ounces before triggering pump operation.
   IMPORTANT: Do not overfill the drip tray and create an overflow condition in the pump reservoir.

4. Confirm that the pump and switches are functioning as intended.
   NOTE: The switch should activate before the float contacts the tank cover.

   • Confirm that there are no leaks in the system plumbing.
   • Operate the pump through several ON/OFF cycles.

MAINTENANCE

Caution

Risk of bodily injury or property damage.

• Disconnect power to the unit before attempting to perform maintenance functions.

Notice

Risk of damage to pump or other equipment.

• Warranty is limited to replacement only and will be void if the pump is tampered with. There are no user-service-able parts inside the pump.

Periodic Service

Inspect and clean the reservoir tank every six months and at the beginning of each season.

1. Remove the reservoir from the pumping installation.

2. Release the side latch and gently slide the reservoir top out.

3. Remove the mesh screen and thoroughly rinse under running water.
   IMPORTANT : Do not bend or fold the screen.

4. Clean dust and debris from reservoir, using a damp cloth.

5. Check the float for dirt or impeded movement. If either conditions are met, do the following:

   • Slide the float retaining clip and float from the post.
   • Clean float and post with a damp cloth.
   • Slide the float and float retaining clip back onto the post.

6. Replace the mesh screen into the reservoir, aligning with the reservoir groove.

7. Return the reservoir top to the reservoir and securely latch.

8. Reinstall the reservoir to the pumping installation.

   • Refer to “Physical Installation”

Troubleshooting

Pump does not start when tank is full of condensate water

| Pump is not connected to elec- trical power| Connect pump to a dedicated GFCI circuit.
Circuit breaker off or fuse removed| Turn on circuit breaker or replace fuse.
Accumulation of debris or build-up on float| Clean float; a dirty float could be too heavy to operate correctly.
Float movement obstruction| Remove the tank. Check float movement path. Remove any debris or obstruction.
Defective switch| Replace pump.
Defective motor| Replace pump.

Condensate is over- flowing from the tank

| Pump is not connected to elec- trical power| Connect pump to a dedicated GFCI circuit.

Liquid inflow matches or exceeds pump output capacity

| Larger pump required.

The high level switch should shut off the A/C unit or signal an alarm in this condition if connected in the circuit correctly. Check to ensure that the pump high level switch is connected to the A/C unit (or alarm circuit), and that the leads are connected to the correct switch terminals for the application. Refer to

Pump is not level

| Check to ensure that the pump is level. If the pump is not level, it may not activate, causing water to overflow from the tank. Place unit on a flat and level surface.
Accumulation of debris or build-up on float| Clean float. A dirty float could be too heavy to operate correctly.
Check valve stuck or plugged| Remove check valve and inspect for proper operation.
Outlet flow is blocked| Check outlet tubing to ensure that it is not kinked or blocked. Clear blocked tubing of slime and debris. Clean inlet and outlet piping.
Defective switch| Replace pump.
Defective motor| Replace pump.

Pump will not shut off

| Float movement obstruction| Remove the tank. Check float movement path. Remove any debris or obstruction.

Liquid inflow matches or exceeds pump output capacity

| Larger pump required.

The high level switch should shut off the A/C unit or signal an alarm in this condition if connected in the circuit correctly. Check to ensure that the pump high level switch is connected to the A/C unit (or alarm circuit), and that the leads are connected to the correct switch terminals for the application. Refer to

Defective switch| Replace pump.

Pump runs but does not discharge liquid

| Check valve stuck or plugged| Remove check valve and inspect for proper operation.
Lift too high for pump| Check rated pump performance.
Outlet flow is obstructed| Check outlet tubing to ensure that it is not kinked or blocked. Clear blocked tubing of slime and debris. Clean inlet and outlet piping.
Pump does not deliver rated capacity| Check valve stuck or plugged| Remove check valve and inspect for proper operation.
Lift too high for pump| Check rated pump performance.
Low voltage, speed too slow| Check that supply voltage matches nameplate rating.
Pump cycles continu- ally| Discharge tubing improperly located or reservoir is further than 3 ft from the pump| Perform proper installation. Refer to

Replacement Parts

800.701.7894 | littlegiant.com 998755 Rev. 001 08/22

References

• HVAC and Wastewater Pumps & Systems | Little Giant
• HVAC and Wastewater Pumps & Systems | Little Giant

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