A.O. Smith ZIP User manual

User Manual
Tankless Electric
Water Heater
Smart.
Compact.
Powerful.
7.5 kW and 9 kW

Contents
What’s in the box?
1. Tankless Electric Water Heater
2. User Manual
3. Wall Mounting Accessories
General Information .......................................................................1
Safety Instructions ......................................................................... 2
Technical Specications....................................................................3
Safety Precautions .........................................................................4
Installation ................................................................................5
Installation (contd...) .......................................................................6
Plumbing instructions .....................................................................6
Operation .................................................................................7
Troubleshooting ..........................................................................10
Circuit Diagram ...........................................................................12
Warranty Terms and Conditions ...........................................................13

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
The safety of you and 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

Technical Specications
Model ZIP
Power [kW] 7.5 9
Voltage/Frequency [V/Hz] 230~/50
Rated Current [Amps] 32.7 39.2
Circuit Breaker (MCB) rating [Amps] 50 63
RCCB rating (Earth leakage protector) 63Amps, 30mA AC
Eciency Δt=25°C [ltr/min.]* 4.3 5.1
Wire size for wiring [sq.mm] 6 6
Shower head size [inch] maximum 6 8
Temperature range [°C] 30-55**
Working water
pressure
N/cm22 - 60
Water head (metres) 2 - 61.2
Inlet/Outlet connections [inch] ½ BSP
Net Weight (kgs.) 3.4 3.8
*Output water temperature may reduce if the ow rate is more than above values.
**The maximum set temperature may vary ± 5 °C.
Dimensions
Figure 1
360 mm
220 mm
Front view Side viewRear view
90 mm
3

Figure 2
Front view without
Service cover
Front view with
Service cover
3
5
6
7
8
9
4
11
10
2
1
Part Description Part Description
1 Cold water inlet 7 Terminal block
2 Hot water outlet 8 Thermal Cut-out
3 Flow sensor 9 Heating chamber
4 Temperature sensor 10 Front cover
5 Rear cover 11 LED display
6 Control board
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.
MCBRCC
B
False
Wall
Solid
Concrete
Wall
Solid
Concrete
Wall
Solid
Concrete
Wall
Solid
Concrete
Wall
OFF
ON
OFF
ON
•Mark the holes using Mounting template
(Step 1).
•Drill 3 holes of diameter 6 mm (Step 2).
Figure 7
1
2
Holes
Hole
Mounting
Template
Mounting
Template
Drilling
Tool
•Insert the Expansion Anchor into the hole
(Step 1).
•Insert the Mounting screw over the
Expansion Anchor and tighten the
Mounting screw by rotating it till it gets
xed steadily (Step 2).
Figure 8
Expansion
Anchor
Mounting
screw
Concrete
Wall
Concrete
Wall
Concrete
Wall
Concrete
Wall
1
2
5

Installation (contd...)
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
screw
Mounting
screw
Water
Heater
2
Concrete
Wall
Concrete
Wall
Concrete
Wall
Water
Heater
Water
Heater
1
Plumbing instructions
Figure 10 Installation Diagram
Hot
Water Tap
Cold
Water Tap
*Flexible
Hose
12
Teon
tape
*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.
6

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.
•Water Heater must be mounted in vertical position only as shown in Installation Diagram.
•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 1.8 L/min.
CAUTION
•The Water Heater will not run unless there is a minimum water ow (1.8 L/min). 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 suitable circuit breaker MCB ratings
and RCCB with BIS certication as per Technical Specications
(Refer Page 3).
•Ensure that wires are connected to circuit breaker MCB and RCCB
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 (Refer Page 3) from main
electrical supply with BIS certication and protected by a double
pole breaker is used.
Note : Installation of MCB and RCCB for unit (Safety purpose) is strictly recommended.
7

CAUTION
•Electrical connection to the Water Heater should have 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 (Refer Page 3).
•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
Temperatur
e
setting
L
ock
LED
display
Power
ON/OFF
1. Switch ON the Water Heater’s power supply.
2. Press Power ON/OFF on the water heater. The LED display glows for 2 seconds along with
beep sound and enter into standyby mode. The LED display shows actual water temperature
of the outlet.
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.
8

Lock mode: Touch and hold for 5 seconds to lock/unlock the Operation panel of the water
heater. InLock mode the hand icon will glow, then touch and hold for 5 seconds
to unlock the operation panel and will turn o.
Screen saver mode: Screen saver mode is activated when the Water Heater is in standby mode
and no button is touched on Touch panel or user intervention for 30 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.
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.
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.
9

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/outlet.
Replace Rubber washer at the
inlet/outlet.
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 problem. Call Customer Care Centre.
Touch buttons not
working.
Water droplets on Touch panel. Wipe water droplets on Touch
panel.
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.
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.
10

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.
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.
11

Circuit Diagram
Figure 14
Flow sensor
Outlet water
temperature
sensor
Inlet water
temperature
sensor
Red
Red
Red
Terminal
block
Heating element
Yellow &
Green
Yellow &
Green
Yellow &
Green
Br
own
Blue
NEL
Water
PH4
Display
CON1
VCC
T1
Control
Board
Display
Board
Temp1, PH2
(Blue, Inlet)
Temp2, PH3
(Red, Outlet)
Yelllow
Black
Black
Black
Thermal
Cut-out
Black
Black
TRIAC
Red
T1 T2
G
Black
Black
Black
Black
ZIP 7.5 kW
Flow sensor
Outlet water
temperature
sensor
Inlet water
temperature
sensor
Red
Red
Red
Terminal
block
Heating element
Yellow &
Green
Yellow &
Green
Yellow &
Green
Br
own
Blue
NEL
Water
PH4
Display
CON1
VCC
T2
Control
Board
Display
Board
Temp1, PH2
(Blue, Inlet)
Temp2, PH3
(Red, Outlet)
Yelllow
Black
Black
Black
Thermal
Cut-out
Black
Black
Black
TRIAC
Red
T1 T2
G
Black
Black
Black
Black
Red
Heating element
Yellow &
Green
T2
Black
TRIAC
T1 T2
G
ZIP 9 kW
12

Warranty Terms and Conditions
Product Warranty
Your A. O. Smith Water Heater is warranted against defects arising from faulty design,
workmanship and materials for a period of 2 years from the date of the invoice, subject to the
following conditions:
1. The customer will notify the Company promptly about defects noticed and give the Company
or its Authorised Service Provider adequate opportunity to inspect, test and remedy them, for
which the customer will deposit the goods, if necessary, with the Company’s Oce/Authorised
Service Provider along with the original invoice.
2. Warranty from the date of purchase are mentioned below:
•Heating Element Warranty: 3 Years
•Product Warranty: 2 Years
3. Inspection and Test Report of the Company’s Oce/Authorised Service Provider will be
treated as nal and binding under the warranty for determining the defects, repairs/alterations
required or carried out, or certifying working of the goods thereafter.
4. The Company or its Authorised Service Provider will be entitled to retain any defective part
replaced under the warranty.
5. The Company’s liability under the warranty will be limited only to defects which occur under
conditions of proper installation, normal operation and under proper use. It excludes defects
occurring because of abuse, faulty care or maintenance and repairs/alterations to product or
the parts by an unauthorised person.
6. The customer will have no claim under this warranty in respect of any personal injury, damage
of property or consequential damages, or for utilisation of the goods not in accordance with
the user guide.
7. Warranty does not cover:
•Plastic parts.
•Any damages to Water Heater occurring due to site conditions like electrical works and
plumbing works.
•Damage to Water Heater or its surroundings due to non usage Pressure reducing valve or
non-recommended reducing valve in plumbing lines.
•Product installed in direct sunlight exposure or rain or non-serviceable areas.
•Damage to Water Heater at customer house during installation or serviceable procedures by an
Unauthorised Service Technician.
8. Any service related issues/replacements due to non A. O. Smith connecting hoses. Calls which
are related to the site e.g. plumbing, tap leakage, electricity etc., but not related to the product
functionality will be charged to the customer as per rate card* (even during the warranty
period). *Refer rate card www.aosmithindia.com
Dealer’s Stamp and Signature
Customer's Name and Address: Model No:
Serial No:
Invoice No:
Dated:
13

Product colour and image shown may vary from the actual product.
Part No. : 335271-122_A Date: 03-08-2022