Whale EP1632 Manual de usuario

Thank you for purchasing this Whale® product.

For over 40 years, Whale® has led the way in the design and manufacture of freshwater and waste systems

including: pumps, plumbing faucets, showers for low voltage applications. The company and its products have built a

reputation for quality, reliability and innovation backed up by excellent customer service.

Typical Installation

The Watermaster® IC is designed for use in recreational vehicles to simplify the supply of freshwater to caravans

and motorhomes, where a Whale® High Flow Watermaster® pump is used to supply the taps and showers.

The Watermaster® socket (already installed or available separately) must be mounted so that the rear of the socket

is accessible from within the vehicle.

Ensure at least 30mm clearance below the socket to allow for wiring. Following a “once only” calibration the

Watermaster® IC unit removes the need for adjustment of the pressure switch, removes the requirement to have a

surge damper in the system and switches off the pump when it runs dry. For information on our full product range

visit: www.whalepumps.com

This product is designed for use with freshwater. If it is intended for use with any other liquid, it is the user’s

responsibility to ensure that the materials are fully compatible with the liquids to be used and that a system of safe

working practice is applied to installation, use and maintenance.

SPECIFICATION

High Flow Watermaster Pump with Intelligent Control (IC) EP1632

INSTALLATION & USE INST UCTIONS

Product Codes EP1632

Voltage Voltage range 9.5V d.c. to 14.5V d.c. (normal operation)

Voltage range 8.5V d.c. to 9.5V d.c. (limited operation, see Section 1)

Nominal Current Operating 3.7 Amps

Standby 0.007 Amps

Recommended Fuse Size 5 Amp automotive

Weight 0.65kg

Materials

Pump Body: ABS, Seals: Nitrile®, Strainer: Polypropylene

Impeller: PBT, Cable: PVC, Grease Seal: Nitrile®

Wire: PVC insulated copper, Hose: PVC, Plug: PBT

Watermaster IC: Polycarbonate

Accessories WF1230 – inline water filter (available separately)

Service Kits Watermaster® IC is not a serviceable part

EP1612 - Replacement High Flow plug and pump kit

Performance Data @ 13.6V

Discharge Head -

0 m (0ft)

1 m (3ft)

3 m (9ft)

Flow Rate Per Minute / Current Draw -

15.8 ltrs / 3.8 amps

14.8 ltrs / 3.7 amps

12.8 ltrs / 3.5 amps

Compatible Pumps For use with Whale® High Flow Watermaster® (EP1612) only

Operating Temperature Range 3ºC to 40ºC

Storage Temperature Range -30ºC to 60ºC

Whale’s policy is one of continuous improvement and we reserve the right to change specifications without prior

notice.

CONTENTS

1. Principles of Operation

2. Application

3. Warnings

4. Parts ist

5. Optional Extras

6. Installation

7. Instructions for Use

8. Maintenance

9. Helpful Hints

10. Trouble Shooting

11. Winterising

12. Service Support Details

13. EU Declaration of Conformity, Standards & Approvals

14. Patents and Trademarks

15. Warranty Statement

LIST OF IMAGES

Fig. 1 Watermaster® IC Features

Fig. 2 Wiring Connections Watermaster® Socket

Fig. 3 Preparing Watermaster® Socket For Connecting Watermaster® IC

Fig. 4 Place Securing Screw Into Watermaster® IC

Fig. 5 Insert Screw Into Watermaster® IC

Fig. 6 Installing The System

Fig. 7 Calibrating The System

Fig. 8 Storing Pump Plug Kit

The Watermaster® IC is a means of control for the Whale® Watermaster® High Flow system, which allows it to

operate without the need for pressure switch adjustment. It offers three key features, eliminates rapid water pulsation,

ensures that the pump turns off at low battery voltages and in a run-dry situation when the water supply runs out.

This (patent applied for), Intelligent Control is achieved by a pressure switch turning on the pump when the pressure

drops to a low level and the microprocessor turning off the pump at programmed current levels, which are set during

the “one time” calibration process. This calibration process may have to be repeated if the pump is replaced.

Additionally “soft” start/stop control is used to control the pump motor.

To the Fitter:

Check that the product is suitable for the intended application, follow these installation instructions and ensure all

relevant personnel read the points listed below. Also ensure that these operating instructions are passed on to the

end user.

To the User:

Please read the following carefully before installation

• Removes the need for adjustment of the pressure switch, and removes the requirement to have a surge

damper or inline pressure switch in the system.

• Watermaster® IC is pre-programmed and must initially be calibrated before use - see Section 6.

• When the system has shut down due to running out of water, reset by turning the pump isolation switch off

and back on after refilling the tank.

1. P INCIPLES OF OPE ATION

• If the battery voltage is very low (8.5V-9.5V), the Watermaster® IC is designed to shut down after

approximately 30 seconds operation to prevent the battery being drained further. Restart the system by

turning the pump isolation switch off and back on. This can be repeated to provide a limited operating mode

but the battery should be recharged as soon as possible.

Please note that Watermaster® IC is designed to work with the Whale® Pressure Switched Socket

ES1001 / ES5001, and with the Whale® High Flow Watermaster® pump kit ON Y, and is not compatible with

other sockets or pump systems

For users with other Whale® or non-Whale® products, their systems may be upgraded to IC by purchase of the

Whale product codes - socket ES1001 / ES5001 and Pump & Watermaster® IC (EP1632).

Contact the technical helpline (Whale® 02891 270531) for additional advice on this product or its installation.

2. APPLICATION

3. WA NINGS

• This product is not designed for any other purpose than supplying water to a caravan or other

recreational vehicle system.

• Always disconnect power sources before installing or making connections.

• Fire hazard. Wiring must comply with applicable electrical standards and include a properly sized fuse or

circuit breaker. Improper wiring can cause a fire resulting in injury or death. Suggested wiring information is

given as a guide only.

• Please note that incorrect installation may invalidate the warranty.

• The Watermaster® IC is designed to work in conjunction with a 5 Amp automotive fuse (see fuse box for fuse

marked ‘pump’).

• There must be access to the back of the socket for a once only calibration, and the socket must not be

mounted at floor level as cables need to plug in to the bottom of the socket.

• Please note that incorrect wiring will result in a blown fuse.

• Please note that Watermaster® IC is designed to work in conjunction with the EP1612 Watermaster® High

Flow 12V d.c. pump and the ES1001 / ES5001 Pressure Switched Socket ON Y and will not operate with

any other Whale® products.

• With all applications it is important that a system of safe working practice is applied to installation, use and

maintenance.

• Please note that the Watermaster® IC controller unit is enclosed to protect the electronics. Opening the unit

will result in damage and will invalidate warranty.

• Do not use the pump in water temperatures above 40ºC (100ºF).

• It is best to stand the pump vertically in the tank.

5Qty 1 Watermaster® IC - controller

Qty 1 Securing screw

Qty 1 Watermaster® with plug and 12V d.c. High Flow Pump

• No extra parts are required to complete the system

• If you need to replace the pressure switched socket – part number ES1001

• If you need to replace your Watermaster® pump – part number EP1612

Please note - The manufacturer cannot be held responsible for claims arising from incorrect installation, unauthorised

modification or misuse of this product.

Before installing, please check that the submersible pump can reach the bottom of the water container and that there

is access to the back of the socket.

TO CONNECT THE IC CONTRO UNIT (BACK OF SOCKET)

Step 1 - Switch off the 12V d.c. supply at the main panel (isolator switch)

Step 2 - Unplug the spade connections on the water inlet socket – ensuring that you note the order of wires for

reconnection with the Watermaster® IC (see Fig. 1 & Fig. 2)

Step 3 - Unscrew and remove the pressure switch adjusting screw and locking nut (see Fig 2)

Step 4 - Remove securing screw (see Fig. 3)

Step 5 - Take Watermaster® IC and place countersunk screw into screw hole (see Fig. 4)

5. OPTIONAL EXT AS

6. INSTALLATION

Fig. 1 Watermaster®IC features

Pressure switch

adjusting screw & lock

nut (REMOVE)

Fig. 2 Wiring connections Watermaster®socket

Fig. 4 Place Securing Screw into

Watermaster®IC

Fig. 3 Preparing Watermaster®socket for

Connecting Watermaster®IC and Removing the

Securing Screw

4. PA TS LIST

Step 6 - Plug Watermaster® IC onto socket (see Fig. 5) and tighten screw (N.B – DO NOT OVER TIGHTEN)

Step 7 - Reconnect spade connectors ensuring correct order of wires (as per step 1)

TO CONNECT THE P UG AND PUMP KIT

Priming:

Step 1 - Place pump into a full water container (Fig. 6).

Step 2 - Insert plug into wall socket and close lid to lock plug in place.

Step 3 - Adjust dust cover over opening in container (please note dust cover should not be secured to water.

container as air must be allowed to enter container to replace water being pumped out).

Step 4 - Switch on 12 volt supply at main panel (Isolator switch) - the pump should start to run.

Step 5 - Open one cold tap (eg. kitchen sink).

Step 6 - After trapped air has been expelled water will flow from the open tap.

Step 7 - When air has been expelled turn off tap, the pump should turn off after approximately 10 seconds.

TO CA IBRATE THE SYSTEM

Step 1 - Press and hold the calibration button until the green ED starts to flash after 1-3 seconds (Fig. 7).

Step 2 - Open the tap and the pump should start (there maybe a short delay).

Step 3 - After approximately 30 seconds, turn off the tap.

Step 4 - After approximately 10 seconds, (the pump should still be running), press the calibration button again.

Step 5 - The ED should turn solid green and the pump will stop after approximately 10 seconds. The green ED

should turn off and blink briefly every 5 seconds. The system is now calibrated.

The Watermaster® IC is now installed and ready for use.

Please Note: In normal operation the pump may run for up to 15 seconds after the tap is closed.

Fig. 5 Insert screw into Watermaster®IC

Ensure Watermaster®IC is plugged securely onto back of socket & tighten screw.

Fig. 6 and 7 Installing and calibrating the system

Green calibration ED

Pump hose can be inserted into groove on plug to keep pump off ground while refilling water container (Fig. 8). The

plug should always be removed before moving the caravan/motorhome.

When removing plug:

Step 1 - ift the lid to unlock the plug

Step 2 - Pull out plug from socket using hand grip

Step 3 - Shut lid

This IC control unit (located on the back of the socket) is designed to be service free and does not contain

serviceable parts. Please note that the unit is enclosed to protect the electronics. Opening the unit will result in

damage, and will invalidate warranty.

For information on service kits, please visit www.whalepumps.com

• Note - If at any stage the user experiences less than optimum performance from the Whale® Watermaster®

IC, recalibrate the system as per steps above in Section 6.

• To obtain efficient running and maximum pump life, ensure the following:

• There is sufficient water in the container.

• Maximum pumping period is not more than 15 minutes.

• All hose connections are firm and water tight.

• The power supply is adequate - low performance could result from a weak battery or

reduced voltage due to undersized wiring (we recommend wiring should be a minimum

thickness of 2.5mm²).

• When replenishing the water supply, it is possible to create an air lock in the pump. As a

result, the pump will run noisily and give no discharge. To remedy, unplug from the socket

while keeping the pump submerged to dislodge the air pocket in the pump. Also shaking the

dual hose gently may dislodge the air pocket in the pump, or switch off pump at main panel,

open a tap outlet and switch pump on again at the main panel.

Fig. 8 Storing pump plug kit

7. INST UCTIONS FO PUMP STO AGE WHEN NOT IN USE

8. MAINTENANCE

9. HELPFUL HINTS

(a) If the pump will not run:

• Check at least one tap is open

• Turn the pump isolation switch off and on again

• Check the battery condition

• Check the mains isolator switch is on

• Check the pump isolator switch is on

• Check the contacts in the plug and socket are clean and making contact

• Check wiring connections

• Check fuse (see fuse box)

(b) If the pump cycles on/off with all taps and shower closed:

• Check for air or water leaks in taps and piping

• Check that non return valve in socket is free from grit by pushing a suitable blunt object, for example

a ballpoint pen into the socket nipple against the non-return valve holding the valve open to dislodge

trapped grit

• Recalibrate the system (see calibration section of the installation section)

• Check all connections in pipework

• Recalibrate the system

Diagnostic Codes

To aid with troubleshooting the ED on the back of the Watermaster® IC has a number of different flash codes as

described in the table below

Watermaster® IC does not require any additional winterizing. For details of how to drain your water system for

winterizing please visit www.whalepumps.com/rv

For installation or serviceable parts advice please contact Whale®Customer Support:

Tel: +44 (0)28 9127 0531

Fax: +44 (0)28 9146 6421

Email: [email protected]

www.whalepumps.com

10. T OUBLE SHOOTING

LED State Description

Green Constant On Tap open, pump running

Green Fast Flash (< 1 sec) In Calibration Mode

Green 200ms blink every 5 sec Calibrated and ready for use

Green 200ms blink every 10 sec Un-calibrated

Green 200ms blink every 15 sec Suspended due to dry run need to turn pump switch on and off

Green 200ms blink every 20 sec Suspended due to low battery voltage, turn pump switch on/off,

need to charge battery

12. SE VICE SUPPO T DETAILS

11. WINTE ISING

Declaration no.: EU-753.133-000

We the undersigned:

Name of manufacturer: Munster Simms Engineering td

Address: 277 – 279 Old Belfast Road, Bangor, BT19 1 T

Country: Northern Ireland

Declare under our sole responsibility that the following apparatus:

Product description: Pump controller

Model name and no.: Watermaster® IC EP1632

Brand name: Whale

Is in conformity with the following relevant EU egislation:

EMC directive 2004/108/EC

VD directive 2006/95/EC

Based on the following harmonized standards:

EN55014-1:2000 EMC Emissions

EN55014-2:1997 EMC Immunity

And therefore complies with the essential requirements of those directives.

Additional information:

Technical file number: TF-753.133-000

ocation of technical file: Munster Simms Engineering td, 277-279 Old Belfast Road , Belfast, BT19 1 T

Year mark first applied: 2012

imitations of use: For use with EP1612 12V submersible pump only

Name and position of person binding the manufacturer or authorized representative:

Signature:

Name: Stanley McFarland

Function: Engineering Director

ocation: Munster Simms Engineering td

277 – 279 Old Belfast Road, Northern Ireland, BT19 1 T

Date of Issue: 27.03.12

CE marked

Watermaster® IC is protected by the following pending Patent Application

Patent UK patent application no. 1017025.6

WHA E® and Watermaster® are registered trademarks of Munster Simms Engineering imited, Bangor, Northern

Ireland trading as Whale®. WHA E IC™ and IC Intelligent Control™ logo device are trademarks pending registration

of Munster Simms Engineering imited, Bangor, Northern Ireland trading as Whale®.

14. PATENTS AND T ADEMA KS

13. EU DECLA ATION OF CONFO MITY, STANDA DS & APP OVALS

This product is protected by a 1 year warranty, for full details of our warranty statement please see enclosed leaflet.

WHA E®, is a registered trademark of Munster Simms Engineering imited, Bangor, Northern Ireland trading as

Whale. Whale’s policy is one of continuous improvement and we reserve the right to change specifications without

prior notice. Illustrations are for guidance purposes only.

Please note that by contacting Whale Support you will be indicating your consent to receiving product updates, recall

information, help guides and appropriate marketing messages from us via post, email or telephone unless you

indicated an objection to receiving such messages.

Munster Simms Engineering td.

Old Belfast Road, Bangor, N. Ireland BT19 1 T

Tel: +44 (0)28 9127 0531 Fax: +44 (0)28 9146 6421

Web: www.whalepumps.com Email: [email protected]

15. WA ANTY

Ref: cmcc_180.156_v1_0312

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