A.O. Smith ZIP User manual

User Manual
Water Heater
ZIP

Contents
What’s in the box?
1. Tankless Electric Water Heater
2. User Manual
3. Wall Mounting Accessories
General Information .......................................................................1
Safety Instructions ......................................................................... 2
Specications..............................................................................3
Safety Precautions .........................................................................4
Installation ................................................................................5
Plumbing instructions .....................................................................7
Operation .................................................................................8
Troubleshooting..........................................................................11
Circuit Diagram ...........................................................................12

General Information
On Receipt
It is our policy to promote safe delivery of all orders. This product shipment has been thoroughly
checked, packed and quality certied before leaving our factory.
Visible Loss or Damage
If any of the goods called for on the bill of lading or express receipt are damaged or the quantity
is short, do not accept them until the freight or express delivery agent makes an appropriate
notation on your freight bill or receipt.
Concealed Loss or Damage
When a shipment has been delivered to you in apparent good condition, but upon opening the
packaging if any loss or damage has taken place while in transit, inform the carrier’s agent / A. O.
Smith representative immediately.
About this manual
This manual is a guide to good practice for operating and periodic maintenance of the A. O.
Smith ZIP Water Heater. Do not operate the Water Heater before reading the user manual.
Please follow instructions in this manual to ensure personal safety and proper operation of
this product. Always install, operate, inspect and maintain this product in accordance with all
applicable standards. Please store this user manual carefully for any future reference.
Disposal of this Product
(Waste Electrical and Electronic Equipment)
This marking on the product, accessories or User Manual indicates that the product and its
electronic accessories should not be disposed of with other household waste at the end of their
working life. To prevent possible harm to the environment or human health from uncontrolled
waste disposal, please separate these items from other types of waste and recycle them
responsibly to promote the sustainable re-use of material resources.
Household users should contact their local government oce, for details of where and how
they can take these items for environmentally safe recycling. This product and its electronic
accessories should not be mixed with other commercial wastes for disposal.
1

Safety Instructions
Your safety and the safety of your loved ones is paramount. There are several safety related
messages in this manual, which have been provided during various steps such as the installation,
operation and maintenance of your ZIP Water Heater. These messages point out potential
hazards and also educate on how to reduce any potential risks. Please always read and follow all
safety messages as provided in this user manual.
This is the safety alert symbol. This symbol alerts you to potential hazards
that can hurt you and others. All safety messages will follow the safety alert
symbol and either the word“DANGER” or “WARNING”.
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
Indicates a potentially hazardous situation, which if not avoided, could result
in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury or property damage.
WARNING
Do not use this Water Heater if any part has been under water. Immediately contact an
Authorised Service Technician to inspect the Water Heater and contact A. O. Smith Service
personnel to replace any part of the control system which has been under water. Failure to
follow this instruction can result in property damage, serious injury or death.
IMPORTANT
These instructions have been written as a guide for the proper installation and operation of
your Water Heater. A. O. Smith will not accept any liability where these instructions have not
been followed. However, for your safety and to avoid damage caused by improper installation,
it is recommended that Water Heater must be installed by an Authorised Service Technician.
Before proceeding with the installation instructions:
1. Inspect the Water Heater and its component parts for possible damage. Do Not install or
attempt to repair any damaged component parts. If you detect any damage in the Water
Heater, please contact the dealer where the Water Heater was purchased or call A. O. Smith
Customer Care Centre.
2. Verify that the voltage being supplied corresponds to that which is marked on the Water
Heater manual.
2

Specications
Model ZIP
Power [W] 5500
Voltage/Frequency [V/Hz] 230~/50
Rated Current [Amps] 24
Required circuit breaker [Amps] 32
Min. water ow to activate unit [ltr/min.] 1.2
Working water
pressure
N/cm22 - 60
Water head (metres) 2 - 61.2
Inlet/Outlet connections [inch] ½ BSP
Net Weight (kgs.) 2.1
Dimensions
Figure 1
252 mm
250 mm
Front view Side viewRear view
90 mm
3

Figure 2
3
Front view without
Service cover
Front view with
Service cover
Rear view
15
14
11
10
12
13
3
2
4
1
5
6
9
8
7
Part Description Part Description
1 Cold water inlet 9 Rear cover
2 Hot water outlet 10 Terminal blocks
3 LED display 11 Cable faster
4Outlet Temperature sensor 12 Triac
5 Transformer 13 Flow sensor
6 Filter plate 14 Service cover
7 Heating chamber 15 Mounting bracket
8 Thermal Cut-out
Safety Precautions
During Installation
Do not install the Water Heater where there is
direct sunlight or rain. It is has to be installed
indoors only.
Figure 3
CAUTIO
N
Do not install the Water Heater where water
splashes on the Water Heater.
Figure 4
CAUTIO
N
4

Installation
Before installing, ensure the tools Adjustable wrench, Teon tape, Measuring tape, Hammer,
Bubble level indicator and Impact drill tool are available.
Mounting the Water Heater
•It is recommended as per IS 302-1 to have 6
inches clearance from wall.
•Select a place to mount Water Heater in a
vertical position nearby water ttings.
Figure 5
Water
Heater
6 inch.
6 inch.
CeilingCeiling
Wall
Wall
•Water Heater must be located within 2 ft.
(approx.) from a 230 V power supply with
proper grounding.
•Make sure that the wall can withstand at
least twice the weight of the Water Heater
when completely lled with water.
Figure 6
2 ft.
False
Wall
Solid
Concrete
Wall
Solid
Concrete
Wall
Solid
Concrete
Wall
Solid
Concrete
Wall
OFF
ON
5

Installation (contd...)
•Remove the Mounting bracket from the
back side of the product.
•Mark the holes using Mounting bracket
(Step 1).
•Drill 4 holes of diameter 6 mm (Step 2).
Figure 7
1
2
Holes
Drilling
Tool
Mounting
bracket
•Insert the Expansion Anchor into the hole
(Step 1).
•Insert the Mounting screw over the
Expansion Anchor through the Mounting
bracket and tighten the Mounting screw by
rotating it till it gets xed steadily (Step 2).
Figure 8
Expansion
Anchor
Mounting
screw
Mounting
bracket
Concrete
Wall
Concrete
Wall
Concrete
Wall
Concrete
Wall
1
2
Mount the Water Heater on the Mounting bracket. Tug downwards on the Water Heater to
ensure that the Water Heater is xed steadily on the Mounting bracket.
Figure 9
Mounting
bracket
Mounting
screw
Water
Heater
2
Concrete
Wall
Concrete
Wall
Concrete
Wall
Water
Heater
Water
Heater
1
6

Plumbing instructions
Figure 10 Installation Diagram
Hot
Water Ta p
Hot
Water Ta p
Cold
Water Ta p
Cold
Water Ta p
*Flexible
Hose
1
2
Teon
tape
Upward
installation
Downward
installation
*Flexible Hoses to be procured by the customer, not part of standard product.
1. Wrap the Teon tape around the inlet and outlet connections of the Water Heater to prevent
leakage.
2. Make necessary plumbing with reference to the Installation Diagram. (Refer“Installation
Diagram”)
3. Install rubber seal rings at the inlet and outlet connections.
4. Connect the cold water pipe to the inlet.
5. Connect the hot water pipe to the outlet.
7

CAUTION
•Make sure a suitable Teon tape is used for all plumbing connections to prevent leakage.
•Use only Nylon/ Stainless Steel (SS) braided hoses (Flexible Hoses) having a minimum
pressure rating of 6 Bar and hoses should be compatible for hot water applications.
•Failure to follow this instruction can result in property damage.
Operation
Figure 11 1. Open a nearby hot water faucet to permit air to escape.
2. Open the cold water inlet valve completely and allow water to ow
to the unit.
3. Close hot water faucet when water ows.
4. When all water connections are completed, check for leaks and
take corrective action before operating.
Note: The minimum water ow to switch ON the unit is 1.2 L/min.
CAUTION
•This Water Heater should not be operated with insucient amount of water. Failure to do
so may result in damage to the Water Heater and injuries to the user. This will also make the
warranty null and void.
•Once the Mounting and Plumbing is completed, then only the power supply should be
switched ON.
•Do not splash water directly or clean with benzene, pesticides, thinner, alcohol, etc., but use
a soft, dry cloth to clean the Water Heater.
Connecting to Electrical Supply
Figure 12
OFF
ON
•Customer should procure a circuit breaker of 32 Amps ratings with
IS certication for 5.5 kW unit.
•Ensure that wires are connected to circuit breaker and reliable
earthing has been done.
•Ensure that the unit should be connected to a single circuit (single
phase supply).
•Ensure a separate electric supply cable of 2.5 sq. mm from main
electrical supply with IS certication and protected by a double
pole breaker is used.
8

CAUTION
•Connect the Water Heater using circuit breaker, do not use any adapters. Use multimeter to
check whether the live line and neutral line are not reverse, to ensure complete safety.
•Before installing the Water Heater, conrm that the power of Water Heater matches electric
meter capacity and electric supply cable of 2.5 sq. mm is used.
•The Water Heater should be earthed reliably. It is prohibited to connect the earth wire to
neutral wire or faucet water pipe.
•If the power supply cord is damaged, it must be replaced by the manufacturer or Authorised
Service Technician in order to avoid a hazard.
CAUTION
In order to avoid a hazard due to inadvertent re-setting of the Thermal cut-out, this Water
Heater must not be supplied through an external switching device, such as a timer, or
connected to a circuit that is regularly switched ON and OFF by the utility.
Figure 13
Temperature setting
touch button
LED
displa
y
Power
touch
button
Ser
vice
cover
1. Switch ON the Water Heater’s power supply and Power touch button in the water heater. The
LED display glows as shown.
2. Turn ON/OFF the cold water inlet supply for the heater to start/stop heating.
3. Press the“+” or “-” touch button until the required temperature is displayed on the LED display.
Wait for few seconds without pressing any buttons, the value ashing in the display will be
changed as set temperature and stored in memory. It will return to its normal mode and
the heating of the water is based on the new set temperature. Temperature setting range is
between 30°C to 55°C.
4. Check hot water with hand before you taking a shower.
9

Sleep mode: Sleep mode is activated when the Water Heater is in standby mode and no button
is touched on Touch panel or user intervention for 15 seconds. Touch any of the buttons on the
Touch panel to enable normal mode.
•If the heater has been paused, you may initially get a short burst of very hot water while you
turn on again. Please run the water through for a few seconds to let the temperature settle
down. Please check hot water with hand before you taking a shower.
Turning LED display upright: When the Water heater is installed Downward position (Refer
page 7), the LED display will be upright. To turn the LED display to correct orientation, make
sure the heater is in OFF mode, now touch and hold“+” and “-” touch buttons at the same time
for 5 seconds the Touch panel will be turned to correct orientation.
Auto mode: In this mode, there is an automatic memory function to avoid repetitive operation,
while you turn on the heater, the default set temperature will be the same as last time set.
Overheating function: When the outlet temperature reaches over 65°C, the heater will
enter into pause mode. The heater will resume to work again automatically when hot water
temperature drops to 50°C.
Dry heating protection: When the outlet temperature reaches over 75°C, the power supply will
be cut-o. The heater will switch ON when the thermal-cutout is reset. Call Customer Care Centre
to reset.
Flow base operation: This is a safety feature and the Water heater will switch ON only when the
inlet water ow is ≥1.2 ltr/min.
Pressure relief valve function: This valve protects the heater by relieving pressure and
discharge water in case the pressure overshoots the pre-set limits.
Electricity Leakage protection: There is real-time electricity leakage detection function, while
there is a electricity leakage, the heater will stop working automatically and E2 error will appear
on LED display.
DANGER
HOT
Scalding
Hot water is dangerous, especially for the young children, aged or the
disabled. The Water Heater allows you to control the temperature of your
hot water. Water temperatures over 52°C can cause severe burns instantly
or death from scalds. Do not leave a child or an inrm person in the bath
unsupervised.
10

Troubleshooting
The information in the following troubleshooting chart may help you diagnose and/or x a
problem you may be experiencing. Please review this chart before calling for Customer Care
Centre.
Problems Possible Cause(s) Solution
Inlet and outlet
ttings leaking.
Fittings not tight. Tighten ttings.
Rubber washer worn-out at the
inlet.
Replace Rubber washer at the
inlet.
LED display does
not glow and no hot
water.
No power supply to the heater. Check and connect power supply
to the heater.
PCB problem. Call Customer Care Centre.
Thermal cut-out tripped. Call Customer Care Centre.
Step down transformer problem. Call Customer Care Centre.
LED display glows
and no hot water.
Check water supply. Turn ON water supply.
Check for blockage at the inlet. Remove blockage at the inlet.
Heating element or Triac problem. Call Customer Care Centre.
Touch buttons not
working.
Water droplets on LED display. Wipe water droplets on LED
display.
Water pressure too low. Open inlet valve completely to get
water.
Touch buttons or PCB damage. Call Customer Care Centre.
Water too hot. Set temperature is high. Set to lower temperature.
Inlet water ow is low. Increase inlet water ow.
Water too cold. Set temperature is low. Set to higher temperature.
Inlet water ow is high. Reduce water ow.
Outlet water ow
gets reduced over
time.
Inlet strainer or shower clogged. Remove blockage at the inlet or
clean the shower.
Heating chamber clogged. Call Customer Care Centre.
Foul smell from hot
water.
Presence of organic matter in input
water.
Provide treated water at the input.
High electrical conductivity of
water due to dissolved solids in
input water.
Call Customer Care Centre.
11

Error Messages and Actions
Error Code Reason Self-diagnostic / Action
E1 Outlet temperature is over 65°C. Increase inlet water ow.
Malfunction of PCB Call Customer Care Centre.
E2 Electricity leakage Call Customer Care Centre.
Power cord not pass through leakage
sensor
Call Customer Care Centre.
Malfunction of PCB Call Customer Care Centre.
E3 Loose wire connections Call Customer Care Centre.
Temperature sensor failure Call Customer Care Centre.
Malfunction of PCB Call Customer Care Centre.
Note: Call Customer Care No. 1800-103-2468/1860-500-2468.
Circuit Diagram
Figure 14
Red
Red
Red Red
Transformer
Heating element
Yellow &
Green
Yellow & Green
Yellow & Green
Red
Red
Brown
LNE
Blue
Red
Red
Red
Red
Yellow
Black
Black
Terminal
block
Black
Black
White
White
White
Flow sensor
Outlet water
temperature sensor
Thermal cut-out
(Hi-limit)
Le
akage
current
sensor
Black
White
Filter
board
Yellow Yellow
PCB board
SRC
LD
WAT
OUT
T1
TRIAC
T2
G
CAUTION
In order to avoid a hazard due to inadvertent re-setting of the Thermal cut-out, this Water
Heater must not be supplied through an external switching device, such as a timer, or
connected to a circuit that is regularly switched ON and OFF by the utility.
12

Product colour and image shown may vary from the actual product.
Part No. : 335271-109_A Date: 13-07-2021