tepeo ZEB-40R User manual

ZEB
® - Zero Emission Boiler
Installation 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
1. General Information 4
1.1. Installation and Operating Instructions 4
1.2. Symbols and Hazard Statements 4
1.3. User Competence, Qualification, and Approval 4
1.4. Compliance with Safety Laws and Regulations 5
1.5. Service and Support 6
2. Safety Instructions 7
2.1. Intended Use 7
2.2. Clearance Requirements 7
2.3. Mechanical Safety 7
2.4. Electrical Safety 8
2.5. Water Safety 9
2.6. Post-Installation Safety 9
2.7. Servicing and Maintenance 10
3. ZEB® Product Details 11
3.1. Introduction 11
3.2. Product Details 11
3.3. Technical Specifications 12
3.4. Product Drawings 13
4. Pre-Installation 16
4.1. Electrical Supply 16
4.2. Communications Box 16
4.3. Water System 17
4.4. Location and Space Requirements 19
5. Installation 22
5.1. Preparation 22
5.2. Electrical and Wiring Installation 23
5.3. Communications Box Wiring 24
5.4. Plumbing Installation 25
6. Commissioning 26
6.1. Installer Application 26
6.2. Commissioning Process 27
6.3. End User Handover 29
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7. Operation 30
7.1. Switch On/Off 30
7.2. Comms Box Buttons, LED Indicators and Status 30
7.3. User App 31
8. Maintenance 33
8.1. Front panel removal 33
8.2. Cleaning 34
9. Recycling and Disposal 35
10. Appendices 36
10.1. Example Comms Box Wiring Diagrams 36
11. Notes 37
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1. General Information
1.1. Installation and Operating Instructions
The ZEB
® must be installed in accordance with these instructions (which we reserve
the right to amend or append from time to time) 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
DANGER
Indicates a hazard with a high level of risk, that if not
avoided, will result in death or serious injury
WARNING
WARNING
Indicates a hazard with a medium level of risk, that if not
avoided, could result in death or serious injury
CAUTION
CAUTION
Indicates a hazard with a low level of risk, that if not
avoided, could result in minor or moderate injury
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
ZEB Installation Manual ZEB-40R_03 rev 1.0 p 4 / 40

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.
● 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 required to install the ZEB (heating system or electrical
components), 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. Unless otherwise confirmed in writing,
reinstallation will not extend or reset our guarantee.
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 (according to EC No.1272/2008).
● 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
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(‘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.
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
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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 based on user-set tariff & preferences.
The regular ZEB
® can provide heating of potable water via a separate indirect water
cylinder (not supplied) or heat battery/thermal store.
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
● 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 suitable PPE when handling the product
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The ZEB
® requires suitable lifting equipment and handling. The unit is heavy - do
NOT try and lift the unit or move the unit without the suitable 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 the ZEB outdoors. This product is only suitable for indoor
installations.
● 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.
● Care should be taken not to cause damage when moving the ZEB.
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 mains isolator should be readily identifiable, 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.
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● 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) unless on a vented
system.
2.6. Post-Installation Safety
● All goods are sold subject to tepeo’s ‘Terms & Conditions of Sale’, as listed
on our website at www.tepo.com/terms
● As tepeo continuously improves products, they may be modified without
notice. Updated documentation will be produced, supplied with new
product ranges and made available on request. It is the responsibility of
the installer to ensure they are using the correct instructions for the
product being installed.
● 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.
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2.7. Servicing and Maintenance
CAUTION
Hot Surface
Minor or moderate personal injury
- Some components 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 (e.g. FFP2)
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 (e.g. by turning on Away Mode) and set the
house thermostat to call for heat. This will reduce the core temperature as
the ZEB discharges.
● If the ZEB
® is to be re-installed in an alternative location or re-sold it must
be re-registered with tepeo.
● 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 - depending on the
heating system design and heat load of the home.
● 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 Details
The ZEB-40R is a 40kWh storage capacity unit designed to replace a heat
only/regular boiler. The unit has no internal circulating pump, as it is intended to
supply power to an external pump.
When installing as part of a sealed system the unit will require an external pressure
relief valve and expansion vessel appropriately sized for the water circuit.
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3.3. Technical Specifications
ZEB-40R : 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)
CH Flow Temperature Setpoint
℃
35 - 80
2
Min. Flow rate
l/min (l/hr)
3.5 (210)
Max. Flow rate
l/min (l/hr)
40 (2400)
Electrical Data
Electrical Supply Voltage (AC)
V
230V +10%, -6%
Electrical Frequency
Hz
50
Rated Current Draw (@230V)
A
41.5
Boiler Dimensions and Weight
Height
mm
980
Width
mm
598
Depth
mm
660
Weight
kg
375
IP Rating
IPX1
CH Flow/Return pipe diameters
mm
22
Heat Storage and Temperature Data
Heat Storage Capacity
kWh
40
Max temperature rise on panels
℃
60
3
Max ambient temperature - operation
℃
40
Max ambient temperature - storage
℃
55
Min ambient temperature
℃
5
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. Max temperature rise is the temperature of the outer panels above the
ambient temperature (EN60335)
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3.4. Product Drawings
User Interfaces
Figure 1: ZEB
® User interfaces
Note
Description
1
Communication box (on 2m tether to ZEB
®
)
2
Mains power cable (supplied as 2m flying lead)
3
Central heating - Flow
4
Central heating - Return
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System Layout
Figure 2: Typical ZEB
® System Layout
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 Plumbing Schematic
Figure 4: ZEB
® internal plumbing schematic
Item
Description
Item
Description
1
Heat exchanger
6
Over-temperature cutoff
2
Pressure Sensor
7
Drain point
3
Flow sensor
8
Flow connection
4
Flow temperature sensor
9
Return connection
5
Return temperature sensor
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4. Pre-Installation
The following sections outline the necessary steps to take in preparation for installing
a ZEB
® . 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.
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.
● Ensure the main fuse & distribution board supplying the property has sufficient
capacity for the ZEB
®
, allowing for diversity requirements.
The ZEB
® is designed to supply power to an existing wiring centre, from the
communications (“comms”) box (see figure 8). Any load supplied with power from the
comms box requires fused protection, therefore it is also necessary to:
● Install a 3A unswitched fused spur in line with the power supply from the ZEB
®
comms box (i.e. between the comms box and an existing wiring centre).
4.2. Communications Box
The communication box is responsible for WiFi connection to the ZEB
® and
connection to the building thermostat call-for-heat, as well as providing a power
supply for the building wiring centre and/or an external pump.
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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, but optimal charging based on live sources of
data (weather, grid carbon intensity etc) will be compromised. If offline, the ZEB will
repeat the charging profile from the previous day.
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 should be above the height of the unit to not impede wireless
signals.
● 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.
● Check and prepare cable routing for the building thermostat call-for-heat, or
connection to wireless thermostat receiver.
● Check and prepare cable routing for the building wiring centre and/or external
pump power supply.
4.3. Water 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
® - however DO NOT FIT ISOLATION BETWEEN THE ZEB ®
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AND THE PRESSURE RELIEF VALVE. 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 ZEB’s 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 to provide the minimum flow rate of 3.5 l/min (210 l/hr).
Typically this will need adjustment from default settings.
● For sealed systems an expansion vessel must be fitted in the primary water
system, ensure that the vessel is sized in accordance with the system volume.
● In a sealed system the primary water system must be filled using a WRAS
approved filling loop or similarly approved device.
● It is recommended that a drain cock is installed at the lowest part of the
system and air vents at all high points in the system. A deaerator may
additionally 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
TAKE NOTICE
The addition of sealing agents to the primary water
system is not recommended. It can adversely affect
performance of the ZEB
®
The ZEB must only be installed on heating systems which comply with current
standards for water quality e.g. BS 7593:2019. This may require the system to be
flushed, but it is the responsibility of the installer to determine what treatment (if any)
is necessary for a given installation.
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.
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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.
4.4. Location and Space Requirements
The ZEB
® utilises a highly efficient insulation system to minimise heat losses.
Nonetheless, it is recommended that the ZEB is installed within the heating envelope
of the home for optimal performance.
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/m
2 .
● Install the product on a hard, solid and level surface.
● Ensure that the substrate is suitable for the floor loading.
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
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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 clearance
distances to the sides and front of the unit can be reduced to 10mm.
● The rear of the ZEB
® may be placed 10mm off a non-combustible wall.
● The ZEB
® requires withdrawal space to the front for access to serviceable
components (as per the Technical Specifications ).
● Do not place items on top of the ZEB
®
.
Installation in Enclosed Spaces
Where the ZEB
® is to be installed in an enclosed space, the clearances specified
above must be adhered to. Additionally, ventilation grilles must be provided at least
225mm x 150mm top and bottom of the enclosed space to provide continuous
ventilation.
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