Whale BP1558B Installation and operation manual

Automatic Pumped Shower
Drainage Systems
Model Number BP1558B Shower Tray Kit
Model Number BP1578 Wet Floor Kit
Installation guidelines for
This booklet should be read before installation

2
This kit has been designed for the pumping of
shower waste water. When the shower is turned
on the flow switch(s) provides a signal to the
transformer to supply dc voltage to the pump.
When the shower is turned off the flow switch
sends a signal to the transformer and after a
pre-set time delay stops the supply of dc voltage
to the pump. After a further 15 minutes the pump
will then switch on automatically for a short time at
a reduced pumping speed removing any run-off
water left in the shower tray/floor.
Thank you for purchasing this Whale Shower Drain
Pump Kit product.
Since 1995 Whale has been the leading
manufacturer of pump kits for use with shallow
shower trays and wet floors. These kits have the
reputation of working reliably for many years
without requiring maintenance.
The front cover illustrates the product in a typical
Healthcare installation. Assess your installation
prior to fitting so as to ensure that the pump,
transformer and flow switch are situated in
accessible positions.
Typical installations would have these components
in an adjacent cupboard i.e. airing cupboard or in a
false wall with an access panel.
Note: Incorrect installation
may invalidate the warranty.
Principles of Operation
Electric Shower Installation
Mixer Shower Installation

3
Warnings
Before installation read the instructions.
Contact the Technical Helpline
(0845 0694 253) if you are unsure.
• The maximum flow rate the pump is designed
to work with is 8 ltrs/min (electric showers) or
12 ltrs/min (mixer shower).
• Do not plumb the pump outlet into waste piping
that other appliances drain into as there is a risk
of induced syphoning. Use an antisyphon trap
where necessary.
• All electrical and mechanical components
(transformer, pump, flow switch and filter)
must be accessible after installation.
• The shower floor must have a fall of 25 mm
in 1 m.
• Plumbing installation must comply to latest
WRAS regulations.
• The electrical wiring must conform to EU wiring
regulations BS7671:2001 Amdt2:2004.
Note: For optimum performance the transformer settings
will normally require adjustment.
This is a non-gravity installation. It is advisable
where the property is left unattended for an
extended period of time, that the water supply to
the shower is shut off.
If there is a reduction in pump performance after
installation please contact your installer.
Installation
User Warning

4
1.1 Pump Orientation 5
1.2 Rotation of Pump Head 5
1.3 Clamping Ring Fixing 5
1.4 Waste Pipe Layout 6
1.5 Pump Head Fitting Connections 6
1.6 Tray Gulley Installation 7
1.7 Wet Floor Gulley Installation 7
1.8 Plumbing 'Waste Fittings' 8
1.9 Macerator Connections 8
1.10 Flow Switch and Filter Layout 9
1.11 Wiring Diagram 9
1.12 Shower Zone Area 10
1.13 Transformer Mounting 10
1.14 Transformer Setting 11
1.15 Pump Head Cross Section 12
Illustrations
Pump Installation and Plumbing 5,6,7
Plumbing of Waste Pipe 8
Flow Switch Connection 9
Electrical Connection 9
Transformer Installation 10
Transformer Settings 11
Pump Operation 12
Commissioning Checklist 12
Safety, Maintenance and Specification 13
Warranty 14
Declaration of Conformity 15
Dimensioned Drawings 16,17,18
Fault Diagnosis Chart 19
Contents

1.1
1.1 Before mounting the pump refer to the
plumbing diagram on page 6 for maximum
pipe runs. The pump is IP45 compliant and
may be installed in Zone 2 of the bathroom
(see page 10).
Mount the pump on a solid wall to prevent
vibration. Use a back board if this is not
possible.
The pump is mounted vertically, as shown,
within 3 m of the gulley.
To aid servicing the head of the pump must be
above the floor by at least 150 mm (maximum
height of 500 mm).
Remove the pump cover and place the pump
in the back plate and position where the pump
is to be fixed. Mark the pump mounting points
through the 4 slots in the back plate.
(See additional Quick Guide insert).
1.2 Rotate the pump head if necessary to give a
straight run of pipe to the waste. Loosen the
clamping ring on the pump head and rotate
the head before retightening clamping ring.
Note: Do not remove the pump head.
Using the screws and washers provided fix the
pump and backplate in position.
Clip the pump cover onto the backplate once
the pipework has been fitted.
5
Pump Installation
1.2
1.3

6
Maximum and minimum pipe length
Key Description Minimum Maximum
H1 in From gully to vertical lift 0.1 m 3 m
V in Vertical from floor to level of pump 0.15 m 0.5 m
H2 in Inlet distance from vertical to pump 0.1 m
H1 out From outlet to vertical rise 0.2 m 0.4 m
V out Vertical head 0 m 2.5 m
H2 out Horizontal to waste pipe *See notes below
*If > 1 metre use 1 1/4” or 1 1/2” waste pipe on gravity fall no maximum if on gravity fall
If < 1 m then 22 mm copper may be used to the stack.
1.4
2.1 Push fit fittings are provided to connect the
pump to inlet and discharge pipework.
For electric shower installations pipework
from the gulley into the pump must be 15 mm
to give a flow rate of 8 litres/min. (Do not use
22 mm pipework on the inlet as this will
increase the noise level when pumping).
For mixer shower installations pipework from
the gulley into the pump must be 22 mm to
give a flow rate of 12 litres/min.
Note: For mixer shower installation an additional
flow switch and fittings are required. Order
Part No. AK1570.
2.2 •Only one vertical lift on the inlet to the
pump and the discharge from the pump is
allowed.
• When laying the pipe under the floor use
only slow radius bends.
• Use slow radius bends above the floor if
possible to ease the flow of water and
reduce loading on the pump.
• Use of copper pipe is recommended to
reduce risk of air leaks at connections.
• Ensure edges are burr-free. Burrs may
cause a build up of hair etc. that will reduce
flow.
• Pipework must be secured to prevent any
vibration and noise.
•‘Twist Lock’ the securing ring on the
push fit fittings after the fittings have
been pushed home.
•If semi rigid pipe is being used follow the
manufacturer’s instructions to prevent air
leaks.
Plumbing Specification
1.5
Plumbing for electric installation shown.
(15mm inlet pipework).

3.1 Whale have developed a unique pumped drain
gulley that has a profile of 35 mm enabling
shower tray installers to fit the drain in a screed
floor without penetrating the damp-proof
membrane.
When fitting in solid floors, remove enough
material for the installation of the waste water
pipe and gulley. Copper pipe must be lined
externally to prevent corrosion.
Use silicone on top of the seal to ensure
proper sealing beneath tray. Using the hand
tool provided to tighten the locking flange, fit
the gulley cover into the sockets and push
down to secure.
Top Tip: Leave the hand tool in place to prevent
building debris, grout etc. falling into the gulley.
Only remove the hand tool and fit the gulley cover
when the installation is complete.
For alternative gulley options see last section
of these instructions.
3.2 The Wet Floor Kit (BP1578) is the same as the
Standard Shower Tray Kit (BP1558B) apart
from the gulley which is designed for use in
wet floor situations.
Gully supports are provided to maintain the
gully level whilst being installed.
7
Plumbing Gulley
1.6
1.7
1.5

8
4.1 The outlet of the pump may be connected into
the waste stack as there are three non return
valves in the pump head to prevent odours
from passing back into the bathroom.
Put the discharge from the pump into the
waste using the black rubber fittings provided.
Do not plumb pump outlet into the waste
piping that other appliances drain into as there
is a risk of induced siphoning.
4.2 In confined bathrooms you can plumb the
pump discharge into the sink waste pipe.
McAlpine™ offer waste adaptors with 22 mm
inlets. At time of print A10V and V33T offer a
solution.
Use with a Macerator Pump
4.3 Where the situation demands, or if the pipe run
is greater than that specified for the Whale
pump (see diagram 1.4 page 6) a macerator
pump may be used.
The discharge from the Whale pump must go
into the top of the macerator box and not into
lower side entries.
Do not use the bottom entries.
It is preferable to have two separate discharge
lines to waste and drainage when used in the
same room as a macerator pump.
Any failure of the macerator will not be
detected by the Whale pump.
Plumbing of Waste Pipe
1.8
1.9
A10V V33T
From pump

Fitting of Flow Switch and Filter
5.1 Install the flow switch and filter in the water
supply to the electric shower downstream of
any other connections to the water supply.
Ensure the flow switch is accessible
and mounted in a length of straight
unstressed pipe.
5.2 If a mixer valve is being used then an
additional flow switch and filter must be
installed in the hot water supply (Order Part
No. AK1570). The wires must be joined
together in parallel.
5.3 The flow switch is not polarity sensitive. Prior to
installation flush through the pipe to remove
any debris. Only use the push-fit fittings
supplied to connect the flow switch.
The arrow must be in the direction of water
flow. The flow switch may be mounted in any
orientation.
6.1 Electrical connections are as shown.
6.2 Mains supply to the transformer should be
made using a 5 amp fused spur.
6.3 Flow switch connections to the transformer
bell-wire are not polarity sensitive and can be
made using the electrical connector block
supplied.
6.4 The transformer 24v RED and BLACK cable
supply to the pump should be terminated
using the crimp connectors supplied. Connect
to the pump RED and BLACK male crimps.
The polarity of the connection must be correct
for the pump to operate.
9
Flow Switch Connect
Electrical Connections 1.11
1.10
Flow Switch Operation
The flow switch is operated by a float with an
internal magnet housed in the copper pipe. In a
plastic housing on the outside of the pipe is a
magnetic reed switch. When the water flows
the float pushes against a spring. At above 1.5
litres/minute the magnet moves sufficiently to
activate the magnetic reed switch. When the
contacts are joined this signals the transformer
to switch power to the pump.
Note: The electric motor in the pump creates a strong
magnetic field which can hold the magnetic reed
switch open or closed. We recommend the flow
switch is not placed within 1 meter of the pump.

Location of transformer
7.1 The transformer is IP45 compliant with the
base plate fitted. The transformer must be
mounted vertically with wires exiting from the
base of the transformer. Locate the
transformer outside the showering area (as per
BS7671: 2001 in zone 2 or 3) as shown.
7.2 Use the transformer backplate to mark the
position of mounting screws. Fit back cover
plate with clean mating surfaces to the
transformer and secure to a flat surface.
7.3 Connect transformer to 240V AC supply via a
5 amp fused spur.
Test Button
8.1 The transformer has a built in Test Button on
the face of the transformer above the cable
entry points.
8.2 The Test Button bypasses the flow switch
enabling a quick and convenient way to test
the transformer and pump operation.
8.3 Pressing and releasing the button energises
the transformer. When the button is released
the pump should continue to run for the time
set by the Off Delay jumper.
10
1.13
Transformer Installation
1.12
Mark screw location Drill holes Insert plugs
Fix to Wall Complete
Test Button

Note: For optimum performance the transformer
settings will normally require adjustment.
8.1 To make adjustments move the jumpers on the
base of the transformer to connect pairs of
contacts to suit the particular installation as
follows:-
Setting 1
Start Delay (1 or 2) This adjusts the delay
between the pump being switched on and the
pump starting so that the gully is full of water
before the pump starts.
1Short Delay (Default Setting) for small
shower trays.
2Long Delay is designed for wet floor and
standard shower installations.
Setting 2
Mixer Electric (M/E) Select your type of
installation.
M(Default Setting) for Mixer Valve
EElectric shower setting.
Setting 3
Off Delay (10, 30, 90, 180 seconds) Adjust
the time that the pump will over-run to clear
the shower tray/area to suit the installation.
10 Seconds: Suitable for most electric shower
installations.
30 Seconds: (Default Setting) Designed for
wet floor areas.
90 & 180 Seconds:
These settings are suitable for larger wet
floor areas.
Setting 4
M & R - unused
8.2 Purge Cycle After 15 minutes the transformer
will reactivate the pump for approx 10 seconds
to remove any run-off or condensation that has
collected in the gully to leave the shower
area dry.
11
Transformer Settings
Factory default settings
1.14

9.1 The Whale Gulper pump uses a single
membrane to pump the water away. On the
suction stroke water and debris are drawn in
through the inlet valve. With a chamber full of
water the pump discharges the water through
the two non-return outlet valves on the purge
stroke. The two outlet valves protect the pump
against losing prime.
9.2 The aggressive flushing keeps the pump valves
clear of debris resulting in a pump which does
not require regular maintenance.
9.3 Unlike other pumps, the Whale Gulper has the
ability to run dry without causing damage to
the pump.
9.4 An additional advantage of the three non-
return valves in the pump head, is that no
smells can be passed back from the waste
stack into the shower area.
10.1 Before setting up the shower and running
water through the system ensure that the
shower area and gully are completely free of
building debris.
10.2 Check the following:-
a. All push fit fittings must have the twist
lock in the locked position.
b. Ensure flow switch is unstressed.
c. Check plumbing for leaks whilst pump
is running.
d. Turn the shower on and check for
correct operation.
Note: 15 minutes after showering is finished, the pump
will switch on for a brief period in order to remove any
water that may have pooled.
12
Pump Operation
Commissioning Checklist
1.15

The Transformer is for indoor use only.
The Transformer contains no user serviceable
parts. External components for service are fuse
and adjustment jumpers only.
Where there is damage to the transformer or
cabling, contact your Whale distributor for a
replacement.
Do not connect mains to the pump as this will
cause permanent damage and result in an
electrical hazard.
Installation must conform to EU Wiring Regulations
BS7671:2001 Amdt2:2004
Pump
• Model: Gulper 220
• Voltage: 21.5 V DC
• Dry running current: 1.2 amp
• Maximum Head: 2.5 m
• Maximum Lift: 500 rnm
• Maximum Head & Lift: 2.5 m
Transformer
• 92 Watts intermittent rating
• Double insulated
• Thermal protected
• Mains cable 1.8 m (2 core, 0.5 mm2)
• Low voltage cables 5 m (10 amp rating)
• Pump control cable (2 core 5 m)
• Start delay - short or long
• Shower type selector
• Off Delay of 10, 30, 90, 180 seconds
• 5 amp Slow blow fuse
Whale’s policy is one of continuous improvement
and we reserve the right to change specifications
without prior notice.
• Isolate the electrical transformer supply from
mains supply.
• Remove the pump head clamping ring.
Unscrew the clamping screw to release pump
head. Do not take clamping ring apart.
(Note: to catch water spillage, place tray
under pump head).
• Check diaphragm and internal valves and
tricupsid valve for wear, damage or cracks and
replace if necessary. Service kit: AK1550.
• Ensure that the outer sealing edge of the
diaphragm is located securely in the groove
between the body and gear housing (failure to
do this will cause the pump not to prime)
• Refit clamping ring and tighten screw.
13
Safety Warning Maintenance
Specification

The Whale Shower Drain System is guaranteed for
two years from date of purchase against defects
in materials and workmanship. If the system proves
faulty, return it to your distributor with proof of
purchase and purchase date. The manufacturer
cannot be held responsible for claims arising from
incorrect installation, unauthorised modification or
misuse of the product.
For full warranty statement please see
whalepumps.com
14
Warranty

15
Description of Equipment: Shower Drain System
Manufacturer’s Declaration
We hereby declare, under our sole responsibility,
that the above equipment complies with the
provisions of the following EC Directives.
Electromagnetic Compatibility Directive
89/336/EEC, amended by 92/31/EEC and
93/68/EEC on the approximation of the laws of the
Member States relating to electromagnetic
compatibility.
Low Voltage Directive 73/23/EEC amended by
93/68/EEC on the harmonization of the laws of the
Member States relating to electrical equipment
designed for use within certain voltage limits.
CE mark affixed: 03/06/05
Basis on which conformity is declared
The above equipment complies with the protection
requirements of the EMC Directive and the
principal elements of the safety objectives of the
Low Voltage Directive.
Standards applied
EN 60335-1:2002/A11:2004 Safety of household
and similar electrical appliances
EN 60335-2-41:2003 Particular requirements for
pumps
EN 55014-1:2000 Electromagnetic compatibility.
Requirements for household appliances, electric
tools and similar apparatus. Emission
EN 55014-2:1997 Electromagnetic compatibility.
Requirements for household appliances, electric
tools and similar apparatus. Immunity.
Signed
David Cresswell
Engineering Director
Munster Simms Engineering Ltd.
277-279 Old Belfast Road
Bangor, Co. Down, BT19 1LT
EU Declaration of Conformity

16
Transformer - 755.199
Pump - SDS021T

17
50mm Gulley - 755.140
Pump Cover

18
200 mm
155 mm
22 mm
16 mm
22 mm
13 mm
200 mm
22 mm
16 mm
38 mm
122 mm
Vinyl Floor Gulley - AK1610
Spares for BP1558B and BP1578
Pump Only SDS021T
Flow Switch AK1568
Diaphragm Service Kit AK1550
Mixer Valve Conversion Kit AK1570
Transformer 755.199
Tiled Floor Gulley - AK1615
90mm Gulley - AK1695

19
Pump will not startPump will not stop
No, no further action
Remove and check
the wire and flow
switch. Back-flush it
through, gently
tapping the side of
the flow switch, to
free any debris or
replace it if necessary
(AK1568).
Note: Always protect
the flow switch with
filter/strainer.
Switch off the pump
at the mains and
allow the
transformer to cool
and reset. If this
does not solve the
problem replace the
transformer
(755.199).
The transformer has an overrun to allow the
pump to continue to run after the shower has
been turned off. The overrun is factory set to 30
seconds and adjustable to 10, 90 or 180 seconds.
Allow overrun to run its allotted time. Does pump
continue to run even after the set over run time?
With the power supply switched on disconnect
the small, white “bell” type wire between the
transformer & flow switch. Do not allow the two
disconnected wires to touch each other. This will
simulate the flow switch, switching off.
Does pump stop after overrun time has passed?
Ensure power is connected and turned on and
that the correct fuse has been fitted.
Press the TEST button above the cable entry on
the transformer. This simulates the switching on
action of the flow switch. The pump will run for
the period of time set for the off delay either 10,
30, 90 or 180 seconds.
Remove and check the
wire and flow switch.
Back-flush it through,
gently tapping the side
of the flow switch, to
free any debris or
replace it if necessary
(AK1568).
Note: Always protect
the flow switch with
filter/strainer.
Yes, no further action
No, replace transformer
(755.199).
Remove the transformer and
check the fuse fitted on the
base. Replace it if it has
blown – 5.0A(T).
Does pump start?
Note: If fuse blows
persistently, check
the pump cable to
make sure it is not
damaged or short
circuiting.
Does pump start?
With shower turned
on, check for 21 volts
at pump. Is voltage
present?
Check all
electrical
connections If
problem
persists,
replace the
pump
(SDS021T).
No
Yes No
Yes Yes
Yes No
What is the fault?
Pump does not pump properly
Check flow rate
of shower. The
pump is capable
of 8 l/min on
15mm (electric
showers only) or
12 l/min on
22mm (mixer
showers only).
If the flow rate is
exceeded it must
be reduced.
Strong
suction is felt
Low or Intermittent
suction is felt
Check suction at pump inlet.
Low / no
suction felt
Inlet pipe is blocked
with debris. (Often a
screw cap, pivots in
the pipe vertically to
block it. Once the
pump stops it falls
horizontal and allows
the pump to suck
when used next).
Rod or blow back
down the inlet pipe
until debris appears
in the gully.
Ensure fittings are
locked and airtight.
Check the tricuspid
valve on pump
discharge is closed
and undamaged.
Ensure outlet
pipework is not
blocked.
Remedy any
problems.
Strong
suction felt
Remove pump head by removing the blue retaining
clamps. Examine the inlet and outlet flap valves for
traces of hard debris such as grout. Wash out debris and
ensure the valves are seated correctly. Check diaphragm
is undamaged. These rubber parts are contained in
Service Kit (AK1550).
Yes, no further
action
Ensure that no hair or debris blocks the gully.
Press the TEST button on the transformer to start
the pump. Assess the suction at the waste fitting
in the tray by placing your hand over it or over
the gully hole.
No
BP1558B/BP1578 Fault Diagnosis Chart
Does this solve the
problem?

Whale
Old Belfast Road, Bangor BT19 1LT, N. Ireland.
UK Technical Helpline: 0845 0694 253
whalepumps.com
[email protected]
tel: [phone]
fax: [phone]
Ref No: 182.78/0807/v1
Contact Details