tepeo ZEB-40R User manual

ZEB®- Zero Emission Boiler
Installation and User Manual
ZEB-40R
Keep these instructions in a safe place for future reference

Document Purpose
To instruct competent persons how to safely install a ZEB®.Competent persons are
those suitably qualified to carry out plumbing and electrical work and have
successfully completed product training by tepeo or an authorised training partner.
Contents
General Information 5
Installation and Operating Instructions 5
Symbols and Hazard Statements 5
User Competence, Qualification, and Approval 5
Compliance with Safety Laws and Regulations 6
Service and Support 7
Safety Instructions 7
Intended Use 7
Clearance Requirements 7
Mechanical Safety 8
Electrical Safety 9
Water Safety 9
Post-Installation Safety 9
Servicing and Maintenance 10
ZEB® Product Details 11
Introduction 11
Product Options 11
Technical Specifications 12
Product Drawings 14
Accessories 16
Pre-Installation 16
Electrical Supply 16
Communications Box 17
Hydraulic System 18
Location and Space Requirements 20
Installation 21
Preparation 21
Electrical and Wiring Installation 22
Communications Box Wiring 23
Hydraulic Installation 24
Commissioning 25
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Installer Application 25
Commissioning Process 25
End User Handover 27
Operation 29
Switch On/Off 29
LED Indicators and Status 29
User App 30
Maintenance 31
Front panel removal 32
Cleaning 32
Recycling and Disposal 33
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1. General Information
1.1. Installation and Operating Instructions
The ZEB®must be installed in accordance with these instructions and in
accordance with current regulations in force. Please read these instructions
carefully before installing or using the appliance.
1.2. Symbols and Hazard Statements
A triangle symbol is used to indicate a hazard; a circle symbol indicates a point of
information. Hazards are divided into three categories of severity - CAUTION,
WARNING and DANGER. The table below gives a generic explanation. Specific
hazards are detailed in the manual at the appropriate juncture.
Symbol
Hazard and Explanation
DANGER
Indicates a hazardous situation that if not avoided will result
in death or serious injury
WARNING
Death/Serious injury
Potential risk
CAUTION
Minor or moderate personal injury
Potential risk
TAKE NOTICE
Important information regarding the usage or installation of
the appliance
1.3. User Competence, Qualification, and Approval
● ONLY competent persons who are suitably qualified to carry out
plumbing and electrical work and have successfully completed product
training by tepeo or an authorised training partner may undertake
installations, repairs or relocations
● DO NOT allow children or any other unqualified or unapproved persons
to install, repair, clean, relocate, interfere or tamper with the product
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● This product is not designed for use by children, or persons with reduced
physical, sensory or mental capabilities, and should not be used by such
persons unless they can do so safely. Where necessary, such persons
(or anyone with lack of experience or knowledge) should first be given
supervision or instruction concerning use of the product by a person
responsible for their safety
● tepeo accepts no responsibility of unsatisfactory performance of the
ZEB®that is the result of failure to comply with the user instructions
● tepeo is not responsible for the selection or specification of the
equipment, unless stated in writing. Responsibility lies with the
customers and any experts or consultants involved in design or
installation
● If the ZEB®is to be re-installed in an alternative location or re-sold it must
be re-registered with tepeo
1.4. Compliance with Safety Laws and Regulations
● The ZEB®meets the standards and regulations applicable under UKCA
marking:
○ Household and similar electrical appliances - Safety EN60335
○Electromagnetic Compatibility Regulations 2016
○Electrical Equipment (Safety) Regulations 2016
○Radio Equipment Regulations 2017
○The Restriction of the Use of Certain Hazardous Substances in
Electrical and Electronic Equipment Regulations 2012
● tepeo declares that the materials used in the manufacturing of this
appliance are non-hazardous and that no substances harmful to health
are contained within the appliance
● Installations, repairs and relocations must comply with all relevant local
laws and regulations (‘statutory obligations’), particularly concerning
electrics, water supplies, building regulations and Manual Handling
Operations, as issued by the Government Health and Safety Executive
(‘HSE’). Water distribution and central heating installations (‘systems’)
must comply with all statutory obligations.
● Statutory obligations always override manufacturer documentation where
there is a conflict.
● Where applicable, this manual should be read in conjunction with
manufacturer documentation for any components specified in the
installer requirements of this manual.
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1.5. Service and Support
For safety information and technical support please contact:
tepeo Ltd
630 Wharfedale Road
Winnersh Triangle
Wokingham
RG41 5TP
customer[email protected]
tepeo.com
Read the full Safety Instructions in Section 2 of this
manual before you install this product
2. Safety Instructions
tepeo Ltd is not responsible for the failure of components not specified in the manual
and/or supplied by other manufacturers.
2.1. Intended Use
The intended use of the ZEB®is to provide heat to a wet central heating
system. The ZEB®is a dry core storage boiler incorporating electric heating
elements and a smart charging algorithm. It uses live data via the internet to
optimise for the lowest cost of heating and the greenest electricity.
The regular and system-ready ZEB®configurations can provide heating of
potable water via a separate indirect water cylinder (not supplied).
Only use this product for the intended purpose described in this manual.
2.2. Clearance Requirements
CAUTION
Hot Surface
Minor or moderate personal injury
- Outer panels may get hot during normal operation
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● Clearance requirements are critical to safe operation of the ZEB®. The
clearances outlined in this manual must be adhered to and maintained
for safe installation of the ZEB®.
● If installed in an enclosed space, ventilation must be provided
● Combustible materials must under no circumstances be placed against
or on top of the ZEB®or any of its ancillaries
2.3. Mechanical Safety
CAUTION
Crushing of Feet
Minor or moderate personal injury
- Wear safety shoes when handling the product
The ZEB®requires correct lifting equipment and handling. The unit is heavy - do
NOT try and lift the unit or move the unit without the correct moving and lifting
equipment. Failure to do so may result in personal injury or/and damage to the
product.
tepeo is not responsible for damage to property, personal injury and damage to the
product that has arisen from incorrect handling.
● DO NOT install outdoors. This product is only suitable for indoor
installations in a frost-free environment
● DO NOT tilt the product more than 30 degrees during the transportation
or installation process
● The ZEB®should be moved into position using appropriate lifting and
mechanical handling equipment, and should NOT be moved in a way
that knocks or jolts it
● Install the product on a hard, solid, flat and level surface that can support
its weight.
● Care MUST be taken during all hot works (such as soldering or brazing)
to protect the paint and panels on the ZEB®
● DO NOT immerse this product in water or any other liquid
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2.4. Electrical Safety
DANGER
Electric Shock
Death or serious personal injury
- Switch off the power supply before starting any work
● The product must be earthed correctly and have its own independent
electrical supply (with correct voltage and circuit breakers)
● The point of connection to the mains should be readily accessible, visible
and adjacent to the ZEB®installation
● Connection must allow double-pole isolation of the electrical supply. The
means of isolation must be accessible to the end user after installation
● The dedicated electrical supply to the ZEB®must be protected by a
Residual Current Device (Type A)
2.5. Water Safety
CAUTION
Pressurised System
Minor or moderate personal injury
- Before dismantling pipework, close isolating valve on
the flow and return to the ZEB®and drain the system. The
water may be hot and under pressure.
●Maximum working pressure of the ZEB®must not exceed 0.6MPa (6 bar)
● The ZEB does not have an integrated pressure relief valve. Therefore a
pressure relief valve MUST be fitted within the connected primary water
system, set to relieve at or below 0.6MPa (6 bar)
2.6. Post-Installation Safety
● All goods are sold subject to tepeo’s ‘Terms & Conditions of Sale’, as listed
on our website.
● As tepeo continuously improves products, they may be modified without
notice. In such circumstances this manual and other relevant
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documentation should be disregarded. Updated documentation will be
produced, supplied with new product ranges and made available on
request.
● Once installed:
○ Perform all test procedures as detailed in the Commissioning section
○ Explain all safety precautions to the end user
○ Provide a copy of this manual to the end user
● It is the responsibility of the end user to supply this manual to any other
subsequent users.
2.7. Servicing and Maintenance
CAUTION
Hot Surface
Minor or moderate personal injury
- Outer panels may get hot during normal operation.
Allow to cool and wear suitable PPE
CAUTION
Safe Handling of Materials
Minor or moderate personal injury
- Some insulating materials within the ZEB®are delicate
and fibrous. NB this product contains bio-soluble
Alkaline-Earth Silicate (AES) wools
- Care should be taken when handling insulation to
minimise dust emissions
- Suitable PPE, including an appropriate respirator, must
be worn
● DO NOT attempt to carry out repairs or maintenance before the core is
below 10% State of Charge and other system components have cooled
down to ambient room temperature. To speed up the process, disable
charging in the user app and set the house thermostat high.
● DO NOT attempt to move an assembled system without using appropriate
lifting equipment
● If the ZEB®is to be re-installed in an alternative location or re-sold it must
be re-registered with tepeo
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● There are no user serviceable, adjustable, or settable parts in this product.
SAVE THESE INSTRUCTIONS AND
PROVIDE A COPY TO THE END USER
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3. ZEB®Product Details
3.1. Introduction
The ZEB®(Zero Emission Boiler) is an electrically heated dry core storage
boiler. The smart charging algorithm uses grid electricity to heat a solid
storage medium. It can then deliver this stored energy on demand to heat a
central heating and indirect hot water system.
The ZEB®is:
● Designed to heat a wet central heating system to a maximum flow
temperature of 80°C
● A suitable replacement for gas and oil boilers without the need for
larger radiators or extensive plumbing rework
● Suitable for hot water systems using an indirect cylinder as part of an
S, Y, or W-plan system
● Internet-enabled to optimise charging for the lowest cost of heating and
greenest electricity
● Compatible with OpenTherm smart thermostats
● Compatible with time-of-use tariffs and PV self-generation
● A class I stationary appliance using mains voltage electricity
For more information please visit our website at www.tepeo.com
3.2. Product Options
The ZEB®can be supplied in 2 variants:
● ZEB-40R (regular)
● ZEB-40S (system-ready)
The ZEB-40R is a 40kWh storage capacity unit designed to replace a
regular boiler. The unit has no internal circulating pump, as it is intended to
supply power to an external pump.
The ZEB-40S has 40kWh storage capacity and is designed as a
system-ready boiler. This unit includes an integral circulating pump.
Both units will require an external pressure relief valve and expansion vessel
appropriately sized for the water circuit where they are installed in unvented
systems.
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3.3. Technical Specifications
ZEB®40 - Technical Specifications
Type Designation
Unit
Value
See Notes
Central Heating (CH)
Rated Heat Output
kW
1-15
1
Design Water Pressure
MPa / Bar
1.0 / (10)
Max. CH Working Pressure
MPa / Bar
0.6 / (6)
Min. CH Working Pressure
MPa / Bar
0.025 / (0.25)
Recommended Water Pressure
MPa / Bar
0.1 - 0.15 / (1 - 1.5)
Max. CH Water Temperature Output
℃
80
2
Min. Flow rate
l/min
3.5
Max. Flow rate
l/min
40
Electrical Data
Electrical Supply Voltage (AC)
V
230V +10%, -6%
Electrical Frequency
Hz
50
Rated Current Draw (@230V)
A
38.5
Internal Current Protection Limit
A
50
3
Internal RCD Protection
30mA Type A RCBO
Pump - ZEB-40S only
Model Name
Grundfos UPS3 15-50/60
Available Head
See Graph below
Boiler Dimensions and Weight
Height
mm
980
Width
mm
598
Depth
mm
660
Weight
kg
375
IP Rating
IPX1
Heat Storage Data
Heat Storage Capacity
kWh
40
Max temperature rise on panels
℃
60
4
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Max ambient temperature - operation
℃
40
Max ambient temperature - storage
℃
55
Standard Clearances - See installation section for details
Above Casing
mm
75
Sides
mm
50
Rear of unit
mm
50
Front (during operation)
mm
50
Front (withdrawal space for servicing)
mm
500
Notes
1. Rated power output may be reduced at low State of Charge
2. Flow temperature may be reduced at low State of Charge
3. The ZEB®is not specified with an external protective device having a higher
protective current rating
4. Max temperature rise is the temperature of the outer panels above the
ambient temperature (EN60335)
Pump Performance Curve
Figure 1: Integral pump performance curve
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3.4. Product Drawings
User Interfaces
Figure 2: ZEB®User interfaces
Note
Description
1
Communication box (on 2m loom to ZEB®)
2
Mains power cable (supplied as 2.5m flying lead)
3
Central heating - Flow
4
Central heating - Return
Mains Voltage Cable Schematic
DANGER
Electric Shock
Death or serious personal injury
- Switch off the power supply before starting any work
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Figure 3: ZEB®mains voltage wiring schematic
Internal Hydraulic Layout
Figure 4: ZEB®internal hydraulic system layout
Item
Description
Item
Description
1
Heat exchanger
7
Gate valve (if fitted)
2
Pressure Sensor
8
Circulation pump (if fitted)
3
Flow sensor
9
Drain point
4
Flow temperature sensor
10
Flow connection
5
Return temperature sensor
11
Return connection
6
Over-temperature cutoff
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3.5. Accessories
There are accessory items available to provide additional functionality to the ZEB.
These are listed in the table below:
Note
Description
1
200A EnOcean CT clamp - for current monitoring of building electricity supply
2
TP Link ethernet power line adapter
4. Pre-Installation
The following sections outline the necessary steps to take in preparation for installing
a ZEB®. Use a tepeo approved installer.
4.1. Electrical Supply
TAKE NOTICE
The use of voltage limiting devices, voltage optimisers and
other equipment that interfere with the electrical supply to
the property may adversely affect the performance of the
ZEB®
The ZEB requires a dedicated electrical supply from the distribution board. All wiring
from the distribution board up to and including the local isolation switch must be
completed by a qualified electrician and in accordance with the applicable electrical
wiring installation regulations (e.g. BS7671 Requirements for Electrical Installations)
● Install a dedicated 50 Amp type B MCB at the distribution board
● Install RCD protection (30mA type A) at the distribution board
● Install a double pole isolation switch local to the ZEB®and ideally within 2m -
it must be accessible without reaching over the unit
● Ensure there is a suitable earth connection available
● Where necessary, install up to a 3A fused connection unit to supply an
existing wiring centre
● Ensure the distribution board supplying the property has sufficient capacity for
the ZEB®, allowing for diversity requirements
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4.2. Communications Box
The communication box is responsible for ethernet or WiFi connection to the ZEB®,
radio communication with EnOcean-enabled sensors, connection to the building
thermostat call-for-heat and an external pump (optional).
The ZEB®requires connection to the internet to optimise charging for the lowest cost
of heating and greenest electricity. The ZEB®can however tolerate temporary
interruptions to internet connectivity.
The communication box is on a 2m flying lead and is intended to be wall mounted.
● Prepare a mounting site for the communications box within the vicinity of the
ZEB®- it must be above the height of the unit to not impede wireless signals
● A wired ethernet connection for internet connection is preferred, check routing
for an ethernet cable to be made available
● If a wired ethernet connection is not available, there is the option to connect
the ZEB via WiFi. Check for good WiFi strength in the area the
communication box is to be mounted. If in an enclosed space check the WiFi
strength with the enclosure door closed
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● Check and prepare cable routing for the building thermostat call-for-heat, or
connection to wireless thermostat receiver
● Where an external pump is being used, check and prepare cable routing for
the pump power supply
4.3. Hydraulic System
Water System Requirements
CAUTION
Pressurised System
Minor or moderate personal injury
- The pressure relief valve is a safety device and if
activated may discharge boiling water or steam. Take care
when positioning the outlet pipe so it discharges to a safe
place such that it does not pose a hazard
● All installations should comply with relevant local regulations, for example
Building Regulations Part G and The Water Supply (Water Fittings)
Regulations
● A pressure relief valve MUST be installed in the primary water system
external to the ZEB®
● Isolation valves are recommended to be fitted to the flow and return pipework
close to the ZEB®. The values should be full bore to prevent a loss in flow
rate, gate valves recommended.
● A magnetic filter MUST be installed in the return pipework to the ZEB®to
prevent debris from fouling the heat exchanger
● An automatic bypass valve MUST be installed between flow and return
pipework where there are actuated radiator valves and no open circuit - to
ensure minimum flow rate through the ZEB. This must be adjusted to suit the
pump size and setting (refer to pump curve) to provide the minimum flow rate
of 3.5 l/min (210 l/hr). Typically this will need adjustment from default settings.
● For unvented systems an expansion vessel must be fitted in the primary water
system, ensure that the vessel is sized in accordance with the system volume
● The primary water system must be filled using a WRAS approved filling loop
or similarly approved device (with backflow protection if it remains connected).
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● It is recommended that a drain cock is installed at the lowest part of the
system; and air vent at all high points in the system. A deaerator may also be
installed
Flushing and filling the System
TAKE NOTICE
Debris from the system can damage the ZEB®and reduce
system efficiency. Failure to comply with the guidelines for
water treatment may require replacement of components
at the expense of the owner
It is required that an existing system is flushed and treated before the installation of
the ZEB®.
Ensure the system pipework is in good working condition before attempting to flush
the system. Where possible keep the existing boiler and circulating pump in place
when flushing the system.
Recommended Flushing procedure for the system:
● Fill the system with cold water and check for leaks
● Open all drain cocks and drain the system
● Close drain cocks and add a suitable flushing agent at the correct strength for
the system conditions and materials in accordance with the flushing agent
instructions
● Circulate the flushing agent before the existing boiler is fired up
● Run the boiler/system at normal operating temperature as directed by the
manufacturer of the flushing agent
● Drain and thoroughly flush the system to remove the flushing agent and debris
● It may be necessary to use a power flushing machine in some circumstances
● Close the drain cocks and refill with water to BS 7593:2019 utilising suitable
water treatment methods to prevent corrosion and fouling of heat exchanger.
● Vent any air from the boiler and system
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Inhibitor
TAKE NOTICE
The addition of sealing agents to the primary water
system is not recommended. It can adversely affect
performance of the ZEB®
Add a suitable inhibitor to the heating system in accordance with the DWTA code of
practice and manufacturer‘s guidelines.
4.4. Location and Space Requirements
The ZEB®utilises a highly efficient insulation system to minimise heat losses
however to get the best out of your ZEB®it is recommended that it is installed within
the heating envelope of the home.
Floor Loading
The ZEB®is intended to be installed on a level floor. The unit has a base plate to
spread the load. The floor loading of the appliance is 1300 kg/m2.
● Install the product on a hard, solid and level surface
● Ensure that the substrate is suitable for the floor loading
● It is recommended that the unit is installed on a solid concrete floor
Clearances
CAUTION
Hot Surface
Minor or moderate personal injury
- Clearances are important. Tepeo is not responsible for
damage to personnel or property as a result of failing to
comply with the clearances outlined
The ZEB®uses high-efficiency insulation, however some heat will radiate during use.
In order to avoid heat accumulation and excessive panel temperatures, the
clearances outlined below must be allowed for and adhered to.
● Standard clearances around the ZEB®are given in Figure 5
● Where the ZEB®is surrounded by non-combustible materials, the distances to
the sides and front of the unit can be reduced to 10mm
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