Whale BP2083B User manual

INSTALLATION AND OPERATION MANUAL
Whale® Bilge IC Waste Pump Range
Page 2 English
Page 14 rench
Page 26 German
Page 38 Italian
Page 50 Spanish
Page 62 Swedish
Page 74 innish
Model Number Description
BP2083B Gulper IC - 12 V d.c.
BP2085B Gulper IC - 24 V d.c.
SI8284 Retail Bilge IC - Remote Mounted Bilge Kit
12 V d.c.
SI8484 Retail Bilge IC - Remote Mounted Bilge Kit
24 V d.c.
SI8222B Bulk Strainer IC and Gulper IC-
12 V d.c with 2m (6ft) cable
SI8224B Bulk Strainer IC and Gulper IC-
12 V d.c with 4m (12ft) cable
SI8422B Bulk Strainer IC and Gulper IC-
24 V d.c with 2m (6ft) cable
SI8424B Bulk Strainer IC and Gulper IC-
24 V d.c with 4m (12ft) cable
CO TE TS
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INSTALLATION AND OPERATION MANUAL
Whale® Bilge IC Waste Pump Range
Thank you for purchasing this Whale® product.
or over 40 years, Whale® has led the way in the design and manufacture of
freshwater and waste systems including: pumps, plumbing, faucets and 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.
or information on our full range of products visit www.whalepumps.com
This Gulper® IC is a high capacity waste pump with intelligent control electronics
inside designed to be installed in recreational marine vessels as a remote mounted
bilge pump - Suitable as a primary bilge pump for boats up to 12 metres / 39.4 ft
(designed to ISO15083), or as a secondary bilge pump on any vessel.
ig 1 - Typical
Installation Gulper®
IC as a Remote
Mounted Bilge
Pump
I STALLATIO & USER I STRUCTIO S
1. TYPICAL I STALLATIO
Gulper IC
Remote Mounted bilge pump
with integrated intelligent
control.
Strainer IC
3/4” strainer
with integrated
intelligent
control
Model Number Description
BP2083B Gulper IC - 12 V d.c.
BP2085B Gulper IC - 24 V d.c.
SI8284 Retail Bilge IC - Remote Mounted Bilge Kit 12 V d.c.
SI8484 Retail Bilge IC - Remote Mounted Bilge Kit 24 V d.c.
SI8222B Bulk Strainer IC and Gulper®IC- 12 V d.c with 2m (6ft) cable
SI8224B Bulk Strainer IC and Gulper®IC- 12 V d.c with 4m (12ft) cable
SI8422B Bulk Strainer IC and Gulper®IC- 24 V d.c with 2m (6ft) cable
SI8424B Bulk Strainer IC and Gulper®IC- 24 V d.c with 4m (12ft) cable
ENG
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Note - Output capacity depends on installation and operating conditions.
Whale's policy is one of continuous improvement and we reserve the right to change
specifications without prior notice.
2. SPECIFICATIO
Model Bilge IC bilge water kit
Product Code BP2083B SI8284 SI8222B SI8224B BP2085B SI8484 SI8422B SI8424B
Cable Length / 4m
(12ft)
2m
(6ft)
4m
(12ft) /4m (12ft)
2m
(6ft)
4m
(12ft)
Voltage 12V d.c. 24V d.c.
Voltage Range 10 v d.c. to 13.6 V d.c. 21.6 V d.c. to 27.2 V d.c
Current Profile Soft start / soft stop
Recommenced use
Size 10 Amp Automotive 5 Amp Automotive
Minimum Wire Size 1.5mm²(16 AWG)
Weight 2.6 kg (5.7 lbs)
Materials
Pump head - Glass filled Nylon. Valves and Diaphragm - Santoprene®
Pump Body - Aluminium. Gear Wheel - Delrin®
Fasteners - Stainless Steel
Service Kits /
Accessories
AK2050 - Replacement Gulper® Pump Head
AK2086B - Deutsch Connector Extension Cable 6m (18ft)
Hose Connections Gulper® IC - Barbed connections - either 19mm (¾") or 25mm (1")
Strainer IC - 19mm (3/4") port
Port Orientation for
Strainer IC Horizontal (easily changed to vertical / side)
Maximum Suction Lift
(Vertical) 3m (10 ft)
Maximum Discharge
Head (Vertical) 3m (10 ft)
Maximum Discharge
Head and Suction Lift
Combined (vertical vent)
4m (13.5 ft)
Operational Time
Delays 1 second on delay / 45 second off delay
Current Draw On
Standby Low power 0.01 Amps supply
PERFORMANCE DATA
Suction Lift 0m / 0ft 0m / 0ft 1m / 3ft 1m / 3ft
Discharge Head 1m / 3ft 1m / 3ft 1m / 3ft 1m / 3ft
Hose Size 19mm / ¾" 25mm/ 1" 19mm / ¾" 25mm/ 1"
low Rate per min 19 ltrs
(5 US gals)
17.5 ltrs
(4.6 US gals)
17.5 ltrs
(4.6 US gals)
15.5 ltrs
(4.1 US gals)
low Rate per hour 1140 ltrs
(300 US gals)
1050 ltrs
(276 US gals)
1038 ltrs
(270 US gals)
930 Ltrs
(246 US gals)
Current Draw (12 V d.c.) 7.5 amps 8 amps 7.5 amps 8 amps
Current Draw (24 V d.c.) 3.25 amps 4 amps 3.25 amps 4 amps
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1. TYPICAL INSTALLATION 12. PLUMBING
2. SPECI ICATION 13. INSTRUCTIONS OR USE
3. CONTENTS AND DIAGRAMS 14. MAINTENANCE
4. PRINCIPLES O OPERATION 15. HELP UL HINTS
5. TO THE USER 16. TROUBLE SHOOTING
6. TO THE ITTER 17. WINTERIZING
7. APPLICATION 18. SERVICE SUPPORT DETAILS
8. WARNINGS 19. PATENTS/ TRADEMARKS
9. PARTS LIST 20. WARRANTY STATEMENT
10. OPTIONAL EXTRAS 21. EU DECLARATION O
11. INSTALLATION CON ORMITY, APPROVALS
LIST OF DIAGRAMS:
IG 1 GULPER® IC - TYPICAL INSTALLATION AS A REMOTE MOUNTING
BILGE PUMP OR USE WITH WHALE STRAINER IC
IG 2 PUMP ORIENTATION
IG 3 GULPER® IC INSTALLATION
IG 4 INSTALL P CLAMP
IG 5 STRAINER IC CONNECTION
IG 6 STRAINER IC CONNECTION
IG 7 WIRING GULPER® IC TO STRAINER IC
IG 8 CONNECTING SWITCHING CABLE THROUGH BULKHEAD
IG 9 CONNECT DEUTSCH® CONNECTORS
IG 10 SECURING PIPEWORK
IG 11 STRAINER IC OPERATION TEST
IG 12 OR CLEANING - DETACH TOP COVER O STRAINER IC
IG 13 OR CLEANING - UNSCREW VALVE HOUSING
IC - Intelligent Control Technology
At the heart of every Whale® IC product lies innovative electronic control circuitry built
in. This enables IC sensor accessories to communicate directly with IC pumps to
control their performance. These accessories send signals to built-in intelligent
software which then control the pumps to react as required.
Gulper® IC
The Gulper® IC fully automatic self-priming pump is designed as a remote mounting
bilge pump. Output capacity depends on installation and operating conditions.
REMOTE MOUNTED BILGE APPLICATION
Save time and money by reducing four separate components to one pre-wired
system. Remote mounting automatic Gulper® IC receives signals from Strainer IC
3. LIST OF CO TE TS A D LIST OF DIAGRAMS
4. PRI CIPALS OF OPERATIO
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and switches on and off automatically (See ig 1). Suitable for a primary bilge pump
for boats smaller than 12 metres/39.4 ft (designed to ISO15083), or as a secondary
bilge pump on any recreational marine vessel.
Read the following instructions carefully.
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.
Gulper® IC is designed for installation in recreational marine vessels only and
operated on 12 or 24 V d.c. electrical supply only. If it is intended for use for any other
purpose or with any other liquid, it is the user's responsibility to ensure that the pump
is suitable for the intended use and, in particular, that the materials are fully
compatible with the liquids to be used. The Whale Gulper® IC pump is not
recommended for domestic applications.
• This pump must not be mounted below the water line when
connected to an intake or outlet unless the system has a
vented loop (see ig 1).
• Not suitable for pumping flammable liquids, diesel,
chemicals etc. Suitable for bilge water only.
•NOTE: Bilge pump capacities may not be sufficient to prevent flooding
from rapid accumulation of water due to storms, rough weather and/ or
rapid leaks created by hull damage and or unsafe navigational conditions.
• With all applications, it is important that a system of safe working practice
is applied to installation, use and maintenance. Ensure the electric supply
is turned off and waste water system is drained before installation. In order
to securely fasten the unit, ensure that the mounting surface is a minimum
thickness of 19mm (3/4") (when fitted with the screws supplied).
•NOTE Do not screw directly to the hull - must be mounted on a bulkhead
or on an additional board.
•NOTE - DO NOT unscrew the rear section, as interference with the
internal electrics will render the pump unfit for use. - this is a non-
serviceable part of the pump.
•WARNING: ire hazard. Wiring must comply with applicable electrical
standards and include a properly rated fuse or circuit breaker (See section
11v.) Improper wiring can cause a fire resulting in injury or death. Switch
off the power while making connections.
6. TO THE FITTER
7. APPLICATIO
8. WAR I GS
5. TO THE USER
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Suggested wiring information is given as a guide only. or full information, refer to the
USCG, ABYC and ISO regulations for marine applications and wiring gauges,
connectors and fuse protection.
Contact Whale® Support team for further technical advice [phone] or
email: [e-mail]
Qty 1 Gulper® IC bilge pump Qty 1 Strainer IC
Qty 3 No.8 self tappers and washers Qty 1 Inline fuse assembly
AK2050 - Service kit - Replacement head for all Gulper® pumps
AK2086B - Deutsch® Connector Extension Cable 6m (18ft)
NOTE: Incorrect installation will invalidate warranty
Preparation - Always disconnect power sources before installing.
11.i Location
• Choose a position to mount the pump that is dry and away from standing
water and is free from obstacles.
• Mount in a position with the shortest possible pipe run lengths.
11.ii Mounting Instructions - Gulper® IC
• Gulper® IC can be mounted on a horizontal or vertical surface.
• When mounted vertically ensure that the pump head is lower most (see
ig 2).
NOTE -It is recommended that the outlet is mounted above the water line and anti-
syphon loops are fitted where applicable- see typical installation ( ig. 1)
• When mounting, position the pump on surface and work out the best
angles for the hose (to prevent kinking) and mark the 3 hole positions
using the pump feet.
•NOTE: The pump head may be rotated to suit the hose connections.
9. PARTS LIST
10. OPTIO AL EXTRAS
11. I STALLATIO
ig. 2 - Pump Orientation
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Loosen the screw, adjust and ensure diaphragm remains in place.
Reposition the head to the required position (fig 3) and tighten the screw
• Drill pilot holes of 3.2mm (1/8").
NOTE: Do not drill through hull, ensure that pump is mounted to additional board or
bulkhead.
• Use the three No.8 self tappers and washers (included) to secure the
pump.
• Use 19mm (3/4") or 25mm (1") smooth bore reinforced hose to connect to
the pump with hose clips.
NOTE: Barbed connections mean no need to cut inlets or outlets to size.
NOTE: Ensure tight connections, but do not over-tighten clamp rings/ screws/hose
clips
ig 3 - Gulper® Installation ig 4 - it P clamp
• Screw p clamp to bulkhead ensuring it is located Approx. 100 mm (4")
from rear housing ( ig 4).
NOTE: In order to securely fasten the unit, ensure that the p clamp mounting surface
is at least 19mm (3/4") minimum thickness.
11.iii Mounting Instructions - Strainer IC
• Mount in a position with the shortest pipe run lengths.
• Drill pilot holes. NOTE: do not drill through hull; ensure that strainer is
mounted to additional board or bulkhead ( ig 5).
• Use 19mm (3/4”) smooth bore reinforced hose to connect to the strainer
with hose clips ( ig 6).
ig 5 Connect Strainer IC to bulkhead ig 6 Attaching jubilee clips
P Clamp
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• Secure cable by screwing ‘P’ clamp to bulkhead ensuring it is located
approx. 100 mm (4”) from strainer outlet ( ig 4).
11.iv Electrical Wiring
• or installation use pre-wired Deutsch® connectors (attached).
• If you are not familiar with applicable electrical standards, ensure that the
unit is installed by a qualified electrician/ technician.
WARNING: ire hazard. Wiring must comply with applicable electrical standards and
include a properly rated fuse or circuit breaker. Improper wiring can cause a fire
resulting in injury or death.
NOTE Switch off the power prior to making connections. Suggested wiring information
is given as a guide only. or full information, refer to the USCG, ABYC and ISO
regulations for marine applications and wiring gauges, connectors and fuse protection.
CONNECT POWER CABLES
The polarity is indicated by coloured cable (Positive - red, Negative - black).
The white wire can be connected to a running light to indicate when the system is in
use and / or as a manual override switch.
NOTE The pump is protected against reverse polarity connection (the inline fuse will
blow)
NOTE: Undersized wire in the circuit before the pump will reduce voltage when the
pump is under load, thus giving poor performance and potential motor failure.
• Ensure all power cables installed are at least the minimum wire size -
1.5mm² (16 AWG).
• To control the pump, an isolator switch must be fitted between the
positive live terminal on the battery and the positive lead on the pump.
(See section 11 v)
WARNING Ensure that there are no loops of electrical cable that could be a hazard.
11.v FITTING THE FUSE
use rating for BP2082B (12 V d.c.) pumps 10 Amp automotive.
use rating for BP2084B (24 V d.c.) pumps 5 Amp automotive
The in-line fuse assembly supplied must be fitted to the positive side of the pump.
(see ig 7)
PURPOSE OF FUSE: The purpose of this fuse is to protect the pump from serious
damage in the event of system blockages, therefore please ensure all valves are fully
open before operating the pump.
If the fuse blows:
a) Check that all system valves/stop cocks are open
b) Check that the inlet and outlet ports are not blocked
c) Check that the rest of the system is not blocked
d) Check for reverse polarity connection
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11.vi. Wiring Diagrams:
ig 7 Wiring Gulper® IC to Whale Strainer IC
11.vii CONNECT SWITCHING CABLE
If switching cable must be fitted through bulkhead, ensure a minimum hole diameter
25mm (1") is drilled.
ig 8 - Connecting switching cable
through bulkhead
11.vii CONNECTING GULPER IC TO STRAINER IC (SEE FIG 1)
Connect the pre-wired Deutsch connectors on Gulper® IC and Whale Strainer IC.
ig 9. Connect Deutsch Connectors
Use 19mm (3/4") or 25mm (1") smooth bore reinforced pipework to connect to the
pump.
Secure the pipework on inlet and outlet with worm drive hose clip ( ig 10)
Gulper IC
Strainer IC
Deutsch
Connectors
Black
Red
Override
Switch
Battery
Isolator
Switch
On
Off White
Off
use
On
Hole diameter 25mm (1”) minimum
12. PLUMBI G
Running
Light
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ig 10 Secure pipework
Ensure that pump installation is thoroughly tested before first use.
NOTE - These are all automatic or semi-automatic applications - ensure that isolator
switch is turned on.
BILGE APPLICATION
Gulper® IC with Strainer IC - Place finger over sensor area to check pump is
activated, remove finger and wait for the pump to stop (45 seconds).
ig 11 Testing Strainer IC
This Whale Gulper® IC is designed to only require minimal maintenance.
WARNING: Before servicing pump, turn off pump and drain water from system.
Annual Checks
• Whale advise that the boat's plumbing system is checked annually for
leaks and obstructions. Also a pump electrics check is advisable.
• Before inspecting or replacing the diaphragm, disconnect the electrical
supply.
Optimal Performance
• Ensure this product is clear of debris
IF THE PUMP IS NOT OPERATING AS E PECTED:-
• Loosen the hose clips to release the pump from plumbing.
• Unscrew the Ezi-clamp clamping ring to release the pump head - see ig
3 - This will release the pump head, and allow easy access to the valves
& diaphragm.
• The diaphragm and valves should be checked for any excessive wear,
damage or cracks, and should be replaced if necessary (service kit
AK2050 - replacement pump head).
13. I STRUCTIO S FOR USE
14. MAI TE A CE
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Cleaning
Bilge IC should be wiped clean regularly to maintain optimal performance and ensure
no clogging occurs. See ig 12 and ig 13 for cleaning Strainer IC.
WARNING: Do not use abrasive cleaners.
ig 12 or Cleaning - Detach Top Cover ig 13 or Cleaning - Unscrew
of Strainer IC Valve Housing
The unique ezi-clamp ring makes installation and maintenance of the pump easier
with a retaining screw which means the head can be fitted or replaced easily by one
fitter, without the risk of dropping screws.
15. HELPFUL HI TS
16. TROUBLESHOOTI G
PROBLEM POSSIBLE CAUSES POTENTIAL SOLUTION
Gulper IC fails
to operate
The Strainer IC may need
cleaned.
Blockage in valve housing
Unclip the top cover of the Strainer IC, clean and
inspect for debris ( ig 5). Carefully remove the lid
and clean the inside walls, if necessary unscrew the
valve housing assembly for further cleaning.
Isolator switch not working /
not switched on.
Pump circuit has no power.
Check the isolator switch is on and working.
Check electrical connections to ensure pump is
receiving power as normal and free from corrosion.
Check power supply.
Main power (Isolator switch)
supply O /not working.
Loose wiring connection
Check the isolator switch is on.
Pump circuit has no
power
Check electrical connections to ensure pump is
receiving power as normal and free from corrosion.
Check there is 12/24 volts from the battery
use blown or loose
electrical connection
Check the in-line fuse & ensure all electrical
connections are tight and free from corrosion. If fuse
has blown, check for reverse polarity, closed valves
or seacocks, then for debris in pump head and clean
out if necessary (refer to installation section).
Replace fuse and run pump.
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WARNING: DO NOT unscrew the rear section as interference with the internal
electrics will render the pump unfit for use - this is a non-serviceable part of the pump.
NOTE: Winterizing - ully drain system
Whale® cannot guarantee warranty if the system is not fully drained for winterizing
or installation or service advice please contact Whale® customer support:
UK Tel: [phone] USA Tel: [phone]
UK ax: [phone] USA ax: 1 802 367 1095
UK Email: [e-mail] Email USA: [e-mail]
Trade marks - Whale® and Gulper ® are registered trademarks to Munster Simms
Engineering limited (also trading as Whale® Water Systems)
Whale® Gulper® IC products are protected by the following patent applications:
P92580GB00 P92043GB00
ailure to
prime - Motor
operates, but
no pump
discharge
Debris under flap valves
/ not seated properly
Turn off electrics and disconnect plumbing
check valves for blockages and remove
debris (See section 14)
Air leak in intake line
Check hose connections are airtight. Open
pump head and check valves and
diaphragm (see section 14)
Punctured pump
diaphragm
Replace the damaged part using service kit
- Part number AK2050
Restricted intake or
discharge line
Check all hose connections are airtight,
free from blockages, and hose has not
collapsed/kinked.
Pump fails to
turn off when
required
Strainer IC bilge strainer,
not working
Check Strainer IC is operating properly
(see section 13).
Defective/ debris on
grey waste float switch Clear debris/ replace float switch.
Insufficient voltage to
the pump Check power supply to pump.
Override switch activated Turn off override switch
Low flow
Air leak at pump intake Check the hose connections are airtight.
Debris inside pump and
plumbing
Turn off electrics and disconnect plumbing,
check for blockages and remove (See
section 14)
Punctured pump
diaphragm
Replace the damaged part using service
kit- Part number AK2050
Defective electronic
control
Replace pump. If within specified warranty
period contact Whale (see contact details)
17. WI TERIZI G
18. SERVICE SUPPORT DETAILS
19. PATE TS A D TRADEMARKS
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DEUTSCH® is a registered trade name of Deutsch Group. Santoprene® is a
registered trade name of Advanced Elastomer Systems, LP, an Exxonmobil Chemical
Affiliate Delrin,® Teflon® and Neoprene are registered trade names of Dupont
Neumeurs and Co. Monprene® is a registered trade name of Technore Apex.
This Whale® product is covered by 2 year warranty - Please see enclosed document
for details of our statement of limited warranty
This product complies with all relevant European directives and standards. Please
contact Whale® if further details are required
Manufacturer’s Declaration
We hereby declare, under our sole responsibility, that the enclosed equipment
complies with the provisions of the following EC Directives.
Electromagnetic Compatibility Directive 2004/108/EC, 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: 19/04/10
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
EN60335 - 1:2002 Safety household and similar electrical appliances
EN60335 - 2-41:2003 Particular requirements for pumps
EN55014 - 1:2000 Electromagnetic compatibility. Requirements for household
appliances, electric tools and similar apparatus. Emission
EN55014 - 2:1997 Electromagnetic compatibility. Requirements for household
appliances, electric tools and similar apparatus. Immunity. Product family standard
Date: 31st May 2010
Position: Engineering Director
20. WARRA TY STATEME T
21. DECLARATIO OF CO FORMITY, STA DARDS, APPROVALS
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