Whale WH/WI0802 Administrator Guide

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |1 of 32
Water Heater
Whale Water Heater WH/WI . . .
– How To Guide
Note: Images shown are for illustration purposes only.
This document is solely for guidance purposes and must only be used for reference by Whale®
Approved Service Engineers when servicing or repairing Whale® Water Heaters.

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |2 of 32
Water Heater
Contents
Contents..................................................................................................................................................2
1.0 General..............................................................................................................................................3
1.1 Application....................................................................................................................................3
1.2 Warnings ................................................................................................................................3
2.1 Product Description ......................................................................................................................5
2.2 Product Operation ........................................................................................................................6
3.0 Fault Trees.........................................................................................................................................8
4.0 Troubleshooting..............................................................................................................................14
4.1 Lock outs/Fault codes .................................................................................................................14
4.1.1 Clear lockout procedure Analog and Duo Control Panel.....................................................14
4.1.1.1 Heaters manufactured BEFORE mid 2016 ........................................................................14
4.1.1.2 Heaters manufactured AFTER mid 2016 (heaters with reset button)..............................14
4.1.1.3 –1 Flash/Bar: No flame detected ...................................................................15
4.1.1.4 –2 Flashes/Bars: Overheat ...............................................................................15
4.1.1.5 –3 Flashes/Bars: Low/High supply voltage ............................................16
4.1.1.6 –5 Flashes/Bars: Water Heater issues ............................................16
4.1.2 Clear lockout procedure iVan Control Panel........................................................................16
4.1.2.1 Heaters manufactured BEFORE mid 2016 ........................................................................17
4.1.2.2 Heaters manufactured AFTER mid 2016 (Heaters with reset button)..............................17
4.2 Whale returns procedure............................................................................................................18
4.3 DC polarity check, PCB fuse replacement AK1219......................................................................20
4.4 Cable Harness / loom connections AK1218, AK1217, AK1204, AK1202.....................................21
4.5 Replacement of hydraulic components......................................................................................22
4.5.1 Replace PRV/Drain valve AK1205 ........................................................................................22
4.5.2 Replacement of cold water connection AK1223..................................................................22
4.6 PCB replacement procedure AK1264..........................................................................................23
4.7 Overheat O/H Thermostat check and replacement AK1212, AK1213........................................24
4.8 Thermistor check and replacement AK1208/AK1210, AK1209/AK1211 ....................................25
4.9 Replacement of ignition electrode AK1220, AK1221..................................................................25
4.10 Assessment and replacement of electric element AK1225, AK1224........................................26
4.11 iVan Communication PCB AK1226............................................................................................27
4.12 System commissioning..............................................................................................................29
5.0 Spare parts......................................................................................................................................29
6.0 Contact details ................................................................................................................................32

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |3 of 32
Water Heater
1.0 General
For over 60 years Whale® has lead the way in the design and manufacture of freshwater and waste
systems including: plumbing, taps, showers and pumps for low voltage applications. Now providing
water and space heating systems for recreational vehicles, the company and its products have built a
reputation for quality, reliability and innovation backed up by excellent customer service.
For information on our full product range visit: www.whalepumps.com
1.1 Application
The components described in this manual have been designed for use only with Whale® Water
Heaters listed as compatible. The Whale® Water Heaters these instructions are applicable to are:
Figure 1 –Product range covered in this How to Guide
Water heater part number
Description
WH0802xx
Water Heater 8 litre gas and electric with analogue
control
WH0822xx
Water Heater 8 litre gas only with analogue control
WI0802xx
Water Heater 8 litre gas and electric with iVan
touchscreen control
WH1302xx
Water Heater 13 litre gas and electric with analogue
control
Please note:
- xx denotes packaging/shipping variations.
1.2 Warnings
This document is solely for guidance purposes and must only be used for reference by Whale®
Approved Service Engineers when servicing or repairing Whale® WH Water Heaters.
Observe all warnings.
In the unlikely event of leaks in the gas system, or if there is a smell of gas:
- Extinguish all naked flames
- Switch off all appliances and do not operate any electrical switches
- Open windows and doors for ventilation
- Do not smoke
- Shut off gas connection

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |4 of 32
Water Heater
Immediately ensure that the system is thoroughly checked by a Whale® Engineer, a Whale®
Approved Service Centre or a by a member of the Whale® Approved Service Engineer Network.
This appliance is not intended for use by persons (including children) with reduced physical, sensory
or mental capabilities, or lack of experience and knowledge, unless they have been given supervision
or instruction concerning its use by a person responsible for their safety. Children must not play with
the appliance or its components.
Any alteration to the appliance or its components or use of non-Whale® spare parts/accessories and
non-observation of the installation and operation instructions shall lead to cancellation of the
warranty and exclusion of liability claims and may result in it becoming illegal to use the appliance
and the vehicle.
To install and repair this Whale product you must have completed an official Whale training course
and have the appropriate technical documentation, tools and equipment. ALWAYS carefully follow
this Whale Technical How To Guide for this product and heed all warnings. Whale rejects liability for
problems and damage caused by the system being installed by untrained or incompetent personnel.
For Gas Products
Installation, servicing and repair under warranty of this appliance must only be carried out by
competent persons registered with the Gas Safe Register (GB) of the relevant national organisation
(e.g. STGW or ACoPs), in accordance with the relevant regulatory and safety requirements. Improper
installation of repair of Whale heating systems can cause fire or the leakage of deadly carbon
monoxide which can lead to serious injury or death.
Please note: The appliance must be installed in accordance with any relevant regulations in the
country where the appliance is installed. For this appliance in Europe the standard is BS EN
1949:2011 “Specification for the installation of LPG systems for habitation purposes in leisure
accommodation vehicles and in other road vehicles.”
For Electrical Products
Electrical –230V mains: ALWAYS carefully follow the Whale Technical How To Guide for this product
and heed all warnings. Whale rejects liability for problems and damage caused by the system being
installed by untrained or incompetent personnel.
All Whale gas products must be installed and serviced by a Whale trained Qualified
Gas Engineer in accordance with the installation instructions and BS EN 1949-2011.
All work must be carried out by a competent person as defined by
BS7671 PART 2.
All work must be carried out by a competent person as defined by
BS7671 PART 2.
Please note if incorrectly installed a risk of electrocution exists.

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |5 of 32
Water Heater
Please note: For the remainder of the document where reference is made to actions to be carried
out by service engineer, or by a competent/ willing person only, this is in accordance with the
stipulations/ warnings above.
Before installation ensure the components have been supplied in good condition and if damaged do
not install. Contact Whale® Support [phone], [e-mail]
Winterising/ Draining
When using the Water Heater in winter, ensure that the flue is not blocked by snow or fallen leaves
etc. When not in use, the Water Heater must be fully drained. This is particularly important during
the winter months as a precaution against freezing. To drain, switch off the water pump at either the
pump switch or main switch. Open all the hot water Taps in the vehicle and operate the drain valve
fitted in the system. The drain valve must be left in the “open” position to ensure all the water
drains out, see image below:
Figure 2 –Drain valve positions
2.1 Product Description
The Whale® Water Heater uses gas only or gas and electric to provide hot water for mobile
applications. It is suitable for the internal installation in a caravan or motorhome which is not in
permanent use. Any maintenance work must be carried out by suitably qualified personnel and the
product must be left fully tested and operational when returning it to the user. Figure 3 summarises
the technical data of the Whale® range of Water Heaters.
Whale Water Heater Drain Valve
Closed
Open
X

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |6 of 32
Water Heater
Figure 3 –Water Heater technical data
Product
-type [-]
WH/WI0802
WH0822
WH1302
-weight (dry) [kg]
8.0
10.0
-L x W x H [mm]
330 x 330 x 258
271 x 385 x 470
-min. heat up time (55K) [mns]
15
33
22
Water
-content [l]
8.5
13.0
-cold/hot connections [-]
12mm Quick ConnectTM/12mm stem
-max. supply pressure [bar]
1.9
-max. operating pressure [bar]
2.6
-max. temperature [°C]
70
Gas
-type [-]
Butane / Propane
-pressure [mbar]
28-30 / 30-37
-connection [mm]
8mm compression fitting
-consumption [g/h]
90
-heat input [kW]
1.25
DC power
-voltage [V]
10.4 ≤ 12.0 ≤ 14.5
-current operation [A]
standby [A]
0.7
0.01
AC power
-voltage [V]
230
N/A
230
-power [kW]
0.75/1.50
N/A
0.60/1.20
-max. current [A]
6.5
N/A
6.0
User Instructions
-before mid 2016 (no reset button)
-after mid 2016 (with reset button)
181.191
181.279
181.230
181.332
181.192
181.333
2.2 Product Operation
The Whale® Water Heaters are operated from the user interface. Whale® offers a range of user
interfaces as shown in Figure 4. No user interaction is required at the Water Heater itself, except for
operating the drain valve and reset button. For a full description of the operation of the product
please refer to the “User Instructions”as referenced in Figure 3.

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |7 of 32
Water Heater
Figure 4 –User interfaces Whale®Water Heaters
The product can be operated from both, external or internal water supplies with either a
submersible pump or an on-board pump. The supply pressure to the Whale® WH Water Heaters
must not exceed 1.9bar and the cold feed must be equipped with a non-return valve to avoid warm
water back-feeding into the cold-water supply pipe work.
The product is fitted with a pressure relief valve (PRV) –this will relieve at 3.0 bar. It is normal for
the PRV to relieve slightly during heat-up.
A typical system installation is shown in Figure 5.
Gas and electric user interface
WH0802 and WH1302
iVan user interface
WI0802
Gas only user interface
WH0822

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |8 of 32
Water Heater
Figure 5 –Typical installation Whale®Water Heater
As detailed in Figure 4, the hot water temperature cannot be chosen by the user with all control
panels. The water can reach temperatures more than 70°C. Should there be a risk of scalding, a
thermostatic mixing valve must be used to ensure safe operation of the hot water system.
3.0 Fault Trees
The fault tree over the following pages shows the various fault modes that the Water Heater might
encounter. At the end of each possible issue, the chapter reference is given to help locating the
relevant corrective action or a brief description to rectify the fault.
other gas
appliances
R

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |9 of 32
Water Heater
Water Heater
Fault Tree
Lock out fault codes
indicated by
red LED
1 Flash
Chapter 4.1.1.3
No flame detected
2 Flashes
Chapter 4.1.1.4
Overheat
3 Flashes
Chapter 4.1.1.5
Low/high voltage
supply
5 Flashes
Chapter 4.1.1.6
Other/internal fault
Gas related issues
Smell of gas
Gas leak at Heater
Tighten nut and
olive
OK?
Replace nut and
olive
OK?
Return Heater to
Whale Chapter 4.2
Heater not
working
Gas bottle
open/full
Open/replace gas
bottle
Engage approved
Service Engineer
Gas
soundness
test
Analogue Panel
iVan Panel
Chapter 4.1.2

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |10 of 32
Water Heater
Isolating
valves open
Open isolating
valves
Lockout LED
flashing
Chapter 4.1
DC power related
issues
10.4≤V≤14.5
Chapter 4.3
Correct supply
voltage issue
Polarity?
JST loom
connections
Chapter 4.4
Return Heater to
Whale
Chapter 4.2
Correct gas type?
<5°C use Propane
Change gas bottle
to Propane
Correct gas
pressure
Adjust/maintain/
replace regulator
AC power related
issues
230V
available?
Chapter 4.10
Check mains
supply/fuse
230V at Water
Heater?
Check Electronic/DC
issues
Chapter 4.2
Check/replace
electric element
Check mains
supply/fuse to
Heater
Heater
operating
Heater
operating
Heater
operating
Return Heater to
Whale

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |11 of 32
Water Heater
Water related issues
Dripping at
heater
From
PRV/drain
valve
Cold water
connection
From Water
Heater
Valve open
Heater
operating
Close valve
Wait for heat up
process to finish
Replace PRV/drain
valve
Chapter 4.5.1
Replace connection
fitting
Return Heater to
Whale
Chapter 4.2
Not flowing
at taps
Pump
working
Re-commission
system
Chapter 4.12
Fault find pump
Check pipe work for
connections/
blockages and taps
Only cold water
available at hot taps
See other fault
issues
Chapter 4.5.2

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |12 of 32
Water Heater
Electronic/
component related
issues
Click/Click/
tick sound
Heater
working
See “Lockout fault
codes” above
Heater switch = ON,
12 V DC ok
After repeats Heater
locks out –red LED
flashing
Check DC fuse
Chapter 4.3
Check O/H stat
Chapter 4.7
Heater
working
Check Thermistor
Chapter 4.8
Heater
working
Check Electrode
Chapter 4.9
Heater
working
Return Heater to
Whale
Chapter 4.2
Relay
Solenoid
Replace PCB
Chapter 4.6
Heater
working
Electrode

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |13 of 32
Water Heater
iVan/Coms PCB
related issues
iVan Panel
working
iVan Panel
working
See user
instructions
No display on iVan
Panel
Press screen/home
button
Check 12V supply to
iVan Panel
Chapter 4.11
Check Water Heater
settings on
iVan Panel
Fault find iVan Panel
Heater
working
Heater
operating on
gas
See DC power/gas
related issues
Heater
operating on
electric
See DC/AC power
related issues
Check pairing of
Heater and
iVan Panel
Chapter 4.11
Heater
working
Check
communications PCB

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |14 of 32
Water Heater
4.0 Troubleshooting
4.1 Lock outs/Fault codes
4.1.1 Clear lockout procedure Analog and Duo Control Panel
The Whale® Water Heaters are equipped with an electronic diagnostic system which will detect fault
conditions ranging from poor gas or DC supply to internal Water Heater malfunctions. In the unlikely
event of failure, follow the steps below to identify and resolve the issue.
The Heater must not have just completed a heat up cycle with the water still at its maximum
temperature when attempting to clear the lockout –should this be the case, please allow to cool or
draw some water for the temperatures to be low enough for the Heater to re-heat –if in doubt,
draw water until cold water flows from hot water tap.
4.1.1.1 Heaters manufactured BEFORE mid 2016
For guidance on how to identify and clear a lockout on the Analog and Duo Control Control Panels
please see Figure 6a.
Figure 6a –Clear lockout procedure Analog and Duo Control Panel
4.1.1.2 Heaters manufactured AFTER mid 2016 (heaters with reset button)
If the Water Heater lockout condition has been identified by 3 or 5 flashes, the lockout must be
cleared by turning the DC power ‘off’ and then ‘on’ again at the master switch in the vehicle. If the
first attempt is unsuccessful, you can retry an additional 4 times. If the lockout still will not clear
(identified by a solid LED or all bars lit), please press the RED reset button on the Water Heater once
as indicated in Figure 4b.
If the Water Heater lockout condition has been identified by 1 or 2 flashes/ bars lit or by a solid red
LED/ all bars lit, the lockout must be cleared by pressing the RED Reset Button on the Water Heater
for 1 second (see Figure 4b).
NB. Attempt to resolve the indicated issue before clearing the lockout.
1“!” will light red to indicate fault.
2Press Water Heater button –bar will light up to
indicate fault code (example shows fault 3).
3Resolve issue (see relevant table below) and then press
and at the same time and hold for 2s to clear
lockout.
❶
❷,❸
❷
❸
1Red LED will flash to indicate fault –count flash sequence.
2Resolve issue –see relevant table below.
3Toggle Water Heater on/off at least two times within 2.5s
to clear the lockout.
❶
❶
❸
❸

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |15 of 32
Water Heater
Figure 6b –Location of RED reset button on Water Heater
4.1.1.3 –1 Flash/Bar: No flame detected
Process
Actions
•Note: the system should attempt 5 x ignition cycles before going
into lockout
•Try clear lockout (see 4.1.1)
This should cure most simple
problems.
•Check Gas Supply –
oAre other gas appliances working?
oCan the gas supply pressure be checked? Should be
between 27 –34 mbar
oType of gas- Butane not suitable in cold weather
oGas Level in Bottle
oGas valve open on bottle
oRegulator Reset Button (If required)
oGas Manifolds open
oIsolation Gas Taps open (possibly near appliance)
Try to operate the Heater again on
gas. If this has not solved the issue,
proceed to next stage.
Connect a regulated supply directly to
the heater to check if system fault
exists.
•Check the Flue –if competent/willing
oRemove the flue cover (2 screws) and metal plate
oCheck for:
▪Obstructions
▪Water Build up(Condensate)
Clear obstructions or water if
present.
Try to operate the Heater again on
gas after the flue is re-assembled.
•Listen for solenoid opening. Should be a click/clunk noise
See page 10 Electronic/ component related issues for detail of
ignition cycle
If not heard, then replace solenoid
coil –Service Engineer only.
•Listen for ticking sound from Spark generator
If not heard, replace PCB –Service
Engineer only.
4.1.1.4 –2 Flashes/Bars: Overheat
Process
Actions
•Wait 5-10mins before trying to clear the lockout or flush Heater
with cold water. This is to allow the overheat stat to reset (see
4.1.1)
This should cure most simple
problems.
RED reset button
located on front face
of Water Heater

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |16 of 32
Water Heater
•Check there is water in the appliance.
oEnsure the following
▪Water Pump is connected
▪Pump Isolator Switch is turned on
▪Drain Valve is closed
▪When the hot tap is opened water comes out.
Run the Heater and check if it
overheats.
•Overheating when operating on gas?
oEnsure Heater is filled with water
oCheck temperature sensor
oCheck over-heat stat –should be normally closed circuit.
Run the Heater and check if it
overheats.
•Limescale –electric only
Should a fizzing/popping/boiling noise be noticeable, the element
is most likely covered in limescale.
•Regular flush out for limescale is recommended if in hard water
areas. Inspection for limescale should be part of annual
maintenance checks.
Clean and flush/ purge system.
Replace element if unable to
remove the limescale build up.
4.1.1.5 –3 Flashes/Bars: Low/High supply voltage
Process
Actions
•Try to clear lockout (see 4.1.1).
This should cure most simple
problems.
•Check battery voltage on Control Panel and supply at the Heater.
•Check battery terminals are tight and have a sound connection.
•Check output from PSU and the wire gauge is correct.
•Have either a generator/ motor mover been in use?
•Where two batteries are fitted, ensure they are correctly wired in
parallel, not in series as this will increase the voltage.
•Solar Panel - check supplies to the system from the charge
controller/ switch. Ensure no more than 15 volts is supplied during
periods of high levels of sunshine.
•Panel may need to be removed from system to check Heater.
If the voltage is below or around
10.4V charge the battery.
If the voltage is above 14.5V, then
there is a power supply issue.
Check alternator/ external battery
charging/ solar over charge.
4.1.1.6 –5 Flashes/Bars: Water Heater issues
Process
Actions
•Try to clear lockout (see 4.1.1).
This should cure most simple
problems.
•Test Loom and Panel
NOTE:
-PCB should have no jumper connected to location CN8.
-Check thermistor plug is fully engaged in PCB connection.
Check using test loom and panel
by Service Engineer.
If not successful carry out
continuity test by Service
Engineer.
•Replace PCB
Change the PCB by Service
Engineer.
4.1.2 Clear lockout procedure iVan Control Panel
iVan is equipped with an electronic diagnostic system which will detect fault conditions ranging from
poor gas or d.c. supply to internal Water Heater malfunctions. In the unlikely event of a fault, this
will be indicated by a red ‘!’ on the Water Heater icon on the Home Screen.

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |17 of 32
Water Heater
Figure 6c –Water Heater fault indicator
The Water Heater will not operate when a fault is indicated on the home screen. A pop-up screen
will appear when you attempt to operate the Water Heater. The pop-up screen identifies the fault.
As soon as you have completed the suggested actions on the fault screens below, you must clear the
fault code by following the instructions on screen and pressing OK.
When the lockout has been cleared successfully, the Water Heater will default to ‘Off’. The user
must select the desired power operation to operate the Water Heater.
4.1.2.1 Heaters manufactured BEFORE mid 2016
Figure 6d –Fault display iVan Control Panel
Fault
iVan display
Action
Check gas supply
- Make sure that there is gas in the bottle and no blockage in the gas
line. At temperatures below 5°C use Propane rather than Butane.
- Press “Retry” once the checks are complete.
- If there is a problem with the gas supply which cannot be dealt with
immediately, press “Gas off” and select an electric water heating
option instead.
Please refer to chapter 4.1.1.3 for additional recommended checks.
Check water
supply
- The Water Heater is not completely full of water. Run the Pump with
one hot tap open until water flows smoothly out of the Tap.
- Wait at least 5 to 10 minutes to allow the Water Heater to cool before
pressing “Retry”.
Please refer to chapter 4.1.1.4 for additional recommended checks.
Check voltage
supply
Ensure that voltage is above 10.4V DC. and below 14.5V DC at the Water
Heater. This can be done by recharging/maintaining the battery voltage.
Please refer to chapter 4.1.1.5 for additional recommended checks.
Fault on Water
Heater
Contact Whale Heater Support on [phone] or your national
service centre and quote the fault number shown on the screen.
4.1.2.2 Heaters manufactured AFTER mid 2016 (Heaters with reset button)
Figure 6e –Fault display iVan Control Panel AFTER mid 2016
Fault
iVan display
Action
Check gas supply (1)
Check gas level in the gas bottle and that there is no blockage in the gas
line. At temperatures below 5°C, use Propane gas rather than Butane.
Once the checks are complete, press the red Reset Button on the front
of the Water Heater once, then press OK on the iVan® Control Panel to
clear lockout. If there is a problem with the gas supply which cannot be
dealt with immediately, select an electric heating option.
Please refer to chapter 4.1.1.3 for additional recommended checks.

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |18 of 32
Water Heater
Gas overheat fault (2)
OR
Electric overheat fault (3)
Check that the Water Heater is completely full of water. Run the Pump
with one hot Tap open until water flows smoothly out of the Tap. Wait
at least 10 minutes to allow the Water Heater to cool, press the red
Reset Button on the front of the Water Heater once, then press OK on
the iVan® Control Panel. This will clear the fault code.
Please refer to chapter 4.1.1.4 for additional recommended checks.
Check voltage supply (4)
Ensure that voltage is above 10.4V DC. and below 14.5V DC at the
Water Heater. This can be done by recharging/maintaining the battery.
Check alternator or external battery charging. Clear lockout by turning
the Master Switch ‘off’ then ‘on’, then press OK on the iVan® Control
Panel to clear the fault code. If this does not clear the fault, please
press the Reset button located on the Heater.
Please refer to chapter 4.1.1.5 for additional recommended checks.
Air pressure fault (5)
Check the flue ends (outside the vehicle) and clear any
obstructions away from them. When the check is complete, turn the
Master Switch ‘off’ then ‘on’ again, then press OK on the iVan® Control
Panel. If this does not clear the fault, please press the Reset button
located on the Heater.
Thermistor fault (6)
Flame simulation fault (7)
Relay sense fault (8)
Start-up fault (9)
Configuration fault (10)
Switch fault (11)
An internal fault has occurred, to clear the
Lockout, turn the Master Switch ‘off’ then ‘on’
again, then press OK on the iVan® Control
Panel. This will clear the fault code.
If this does not clear the fault, please press
the Reset button located on the Heater.
Fault on Water Heater (15)
Two faults have occurred at the same time OR at least five or more
lockout clearing attempts have been unsuccessful. Clear lockout by
pressing the red Reset Button on the Water Heater once.
4.2 Whale returns procedure
Should this fault-finding procedure identify the product to be faulty, please return to Whale
accompanied by a completed copy of the form shown in Figure 7. Before returning the Water Heater
to Whale, please contact our Customer Service Team, to ensure the warranty process is adhered to.
Figure 7 –Whale returns form (see next page –please copy to use)

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |19 of 32
Water Heater
1 Please return this form to the Quality Department at Munster Simms Engineering Limited.
2 Where applicable, replacement goods will be sent to the form initiator as listed below.
Initiator details
Name, Initial(s)
Address
Telephone/Mobile
Fax
e-mail
1
Date of Claim
(dd/mm/yy)
CLAIM 1
CLAIM 2
CLAIM 3
2
End user details
Name, Initial(s)
Address
3
Installation type
Domestic



Marine



RV



Make & model (1)
4
Year of model
5
Product
(incl. part no.)
6
Date of purchase
(dd/mm/yy)
7
Quality assurance no.
(on silver sticker)
8
Description of fault
(“faulty” is not a
description)
9
Distributor’s action
10
Details of action taken
by retailer or Whale
11
Repair kit issued
Product issued
Labour cost
sold/foc(2)
sold/foc(2)
sold/foc(2)
12
For Whale use only
Complaint no.
(1) Marine and RV only.
(2) Delete as appropriate.

Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. –Northern Ireland
tel.: [phone] fax.: [phone] in[email protected]m www.whalepumps.com
Page |20 of 32
Water Heater
4.3 DC polarity check, PCB fuse replacement AK1219
Please note: It is imperative for the DC supply to be connected correctly. The red lead is to be
connected to the +12V supply, the white lead to OV ground.
Reverse polarity will damage the internal PCB/fuse on PCB.
Equipment: Low resistance multimeter set to DC Voltage
12V DC power supply connected
Step 1 insert meter probes into Water Heater 8-way connector block
+12V pin 7 red probe
0V pin 8 black probe
Figure 8 –Meter probe connections for DC polarity check
Step 2 measure supply voltage polarity, ensure meter is set to appropriate DC range, to achieve a
display of at least 1 decimal place for voltage reading
Figure 9 –Measurement of supply voltage polarity
1
6
7
4
3
5
8
2
Multimeter connection
0V
+12V
8-way Connector block pin allocation
Correct polarity
Incorrect polarity

✓