Whale WH/WI0802 How-To Manual
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Whale WH/WI0802 How-To Manual

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tel.: +44 (0)2891 270 531
Whale Water Heater WH/WI . . .
– How To Guide
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.
Note: Images shown are for illustration purposes only.
Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland
fax.: +44 (0)2891 466 421
Water Heater
info@whalepumps.com
www.whalepumps.com
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Summary of Contents for Whale WH/WI0802

  • Page 1 Whale Water Heater WH/WI . . . – How To Guide 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. Note: Images shown are for illustration purposes only.

  • Page 2: Table Of Contents

    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 ..................

  • Page 3: General

    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.
  • Page 4 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.

  • Page 5: Product Description

    Open 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.

  • Page 6: Product Operation

    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”...
  • Page 7 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.

  • Page 8: Fault Trees

    Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com Figure 5 – Typical installation Whale Water Heater ® other gas appliances As detailed in Figure 4, the hot water temperature cannot be chosen by the user with all control panels.
  • Page 9 Tighten nut and Gas leak at Heater Gas related issues Smell of gas Service Engineer olive Replace nut and olive Return Heater to Chapter 4.2 soundness Whale test Open/replace gas Heater not Gas bottle working open/full bottle Page 9 of 32...
  • Page 10 DC power related Correct supply 10.4≤V≤14.5 issues voltage issue JST loom Chapter 4.4 Chapter 4.3 Polarity? connections Return Heater to Chapter 4.2 Whale AC power related Check mains 230V issues available? supply/fuse Check mains Check/replace 230V at Water Chapter 4.10 supply/fuse to...
  • Page 11 Replace PRV/drain Chapter 4.5.1 valve Replace connection Cold water Chapter 4.5.2 connection fitting Return Heater to From Water Chapter 4.2 Whale Heater Re-commission Not flowing Pump Chapter 4.12 working system at taps Check pipe work for Fault find pump connections/...
  • Page 12 Check DC fuse Heater Chapter 4.3 working Check O/H stat Heater Chapter 4.7 working Check Thermistor Heater Chapter 4.8 working Check Electrode Heater Chapter 4.9 working Replace PCB Heater Chapter 4.6 working Return Heater to Chapter 4.2 Whale Page 12 of 32...
  • Page 13 Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com See user iVan/Coms PCB No display on iVan Press screen/home iVan Panel instructions related issues...

  • Page 14: Troubleshooting

    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.

  • Page 15: Flash/Bar: No Flame Detected

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com Figure 6b – Location of RED reset button on Water H eater RED reset button located on front face of Water Heater...

  • Page 16: Flashes/Bars: Low/High Supply Voltage

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com • Run the Heater and check if it Check there is water in the appliance. o Ensure the following overheats.

  • Page 17: Heaters Manufactured Before Mid 2016

    Heater. This can be done by recharging/maintaining the battery voltage. supply Please refer to chapter 4.1.1.5 for additional recommended checks. Contact Whale Heater Support on +44 (0)845 217 2933 or your national Fault on Water service centre and quote the fault number shown on the screen.

  • Page 18: Whale Returns Procedure

    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)
  • Page 19 (dd/mm/yy) Quality assurance no. (on silver sticker) Description of fault (“faulty” is not a description) Distributor’s action Details of action taken by retailer or Whale Repair kit issued Product issued Labour cost sold/foc sold/foc sold/foc For Whale use only Complaint no.

  • Page 20: Dc Polarity Check, Pcb Fuse Replacement Ak1219

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com 4.3 DC polarity check, PCB fuse replacement AK1219 Please note: It is imperative for the DC supply to be connected correctly.

  • Page 21: Cable Harness / Loom Connections Ak1218, Ak1217, Ak1204, Ak1202

    4.4 Cable Harness / loom connections AK1218, AK1217, AK1204, AK1202 The Whale Water Heater uses one pin on the connector block for the gas-on signal. Figure 9 shows the relevant pin combination and the voltage that should be read when the +12V DC power supply is connected and the Heater is switched on.

  • Page 22: Replacement Of Hydraulic Components

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com 4.5 Replacement of hydraulic components 4.5.1 Replace PRV/Drain valve AK1205 The following images indicate the procedure for replacing the PRV/Drain valve.

  • Page 23: Pcb Replacement Procedure Ak1264

    +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com 4.6 PCB replacement procedure AK1264 The following images indicate the replacement procedure of the Whale Water Heater PCB. Figure 14 – PCB replacement procedure Before you start: ! Ensure Water Heater is cold to touch.

  • Page 24: Overheat O/H Thermostat Check And Replacement Ak1212, Ak1213

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com 4.7 Overheat O/H Thermostat check and replacement AK1212, AK1213 The overheat thermostat can be checked at the Water Heater without DC power being supplied to the unit by measuring its continuity.

  • Page 25: Thermistor Check And Replacement Ak1208/Ak1210, Ak1209/Ak1211

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com 4.8 Thermistor check and replacement AK1208/AK1210, AK1209/AK1211 The thermistor can be assessed by unplugging the device from the PCB as indicated. To access the PCB please see Chapter 4.6.

  • Page 26: Assessment And Replacement Of Electric Element Ak1225, Ak1224

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com - unplug spark electrode from PCB at - replace spark electrode as shown - secure with self-tapping screw connection J7 - ensure spark electrode is secure in...

  • Page 27: Ivan Communication Pcb Ak1226

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com ! Ensure 230V supply is isolated before commencing work on the product. Should the above not resolve the issue: check resistance of electric element replace electric element...
  • Page 28 Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com Figure 19 – iVan pairing and hardware diagnostics procedure ! Ensure 230V supply is isolated before commencing work on the product. Check pump Check water Pump...

  • Page 29: System Commissioning

    Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com 4.12 System commissioning When re-filling the Water Heater with water and re-connecting to the gas supply, the following simple steps must be followed: Figure 20 –...
  • Page 30 Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com AK1210 WtrHtr 8L G+E Temp Sens M5 AK1211 WtrHtr 13L G+E Temp Sens M5 AK1212 WtrHtr 13L Gas OH Stat AK1213...
  • Page 31 Water Heater Munster Simms Engineering Ltd., 2 Enterprise Road, Bangor, Co Down, BT19 7TA, U.K. – Northern Ireland tel.: +44 (0)2891 270 531 fax.: +44 (0)2891 466 421 info@whalepumps.com www.whalepumps.com AK1224 WtrHtr ElctrElmnt Assy 1.2kW AK1225 WtrHtr ElctrElmnt Assy 1.5kW AK1226 WtrHtr PCB Zigbee AK1264...

  • Page 32: Contact Details

    Email: info@whalepumps.com 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. ©Copyright Whale 2018 - All rights reserved. Reproduction in whole or in part without permission is prohibited.

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