Whale EP1632 User manual

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.
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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
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• 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)
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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.
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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.
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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)
(c) If pump motor runs steadily and does not stop after 30-40 seconds:
• 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: [phone]
Fax: [phone]
Email: [email protected]
www.whalepumps.com
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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®.
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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.
©Copyright Whale 2011- All rights reserved.
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: [phone] Fax: [phone]
Web: www.whalepumps.com Email: [email protected]
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15. WA ANTY
Ref: cmcc_180.156_v1_0312