Zip AP3/05 Mounting instructions

Please read these instructions carefully before commencing installation
of Aquapoint unvented water heaters.
Please leave these instructions with the end user after installation.
Zip Heaters (UK) Ltd
14 Bertie Ward Way
Dereham Norfolk NR19 1TE
Telephone [phone]
Facsimile 01362 692448
www.zipheaters.co.uk
[email protected]
The terms ‘Zip’ and ‘Aquapoint’ are registered trademarks.
Zip products described in the brochure are manufuctured
under one or more of the following patents: AU675601,
AU637412, AU635979, GBO422305, GB2065848,
US4354049, US5103859, US5099825. Other patents are
in force and patent applications are pending.
ZIPAquapoint lll
Models AP3/05, AP3/10, AP3/15,
AP3/05/OB, AP3/10/OB, AP3/15/OB
Direct unvented water heaters
Issued November 2008
Installation, Maintenance
and User Instructions
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AP3/05, AP3/10, AP3/15 Installation Instructions 3
Contents
Specification 4
Dimensions 5
Special Notices 5
Installation
Requirements 6
Positioning 7
Plumbing 9
Electrical 9
Commissioning 10
Maintenance
Precautions 11
Schedule 12
De-Installation 12
Fault Finding 13
Warranty 14
Installation must only be undertaken by a
competent person, familiar with unvented
electric water heaters.
The Zip Aquapoint must be installed in
accordance with these instructions and all
current legislation, codes of practice and
regulations governing the installation of
unvented hot water cylinders in force at
the time of installation.
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Specification
Product: Zip Aquapoint III
Type: Direct unvented multipoint
Capacity: 10 litre, 15 litre
Loading: 2.0kW
Thermostat: Adjustable 7ºC to 75ºC
Thermal cut-out: Manually re-settable set to 85+/-3ºC
Water vessel: Glass enamelled steel tested to 12 bar. Maximum working
pressure 6 bar
Safety Features: Expansion relief valve set to 6 bar (supplied)
Manually re-settable over temperature safety cut-out
Provision to fit Pressure and Temperature relief valve
(available as an optional accessory)
Sacrificial anode to provide anti-corrosion protection for the
vessel and element.
Approvals: Zip Aquapoint III complies with LVD and EMC directives and
is CE endorsed.
Zip Aquapoint III has been examåined, tested and found,
when correctly fitted, to comply with the requirements
of the United Kingdom Water Regulations/Byelaws
(Scotland). The product, therefore, is listed under the
WRAS (Water Regulations Advisory Scheme) Water
Fitting and Materials Directory.
Models: Underbasin Overbasin
5 litre AP3/05 AP3/05/OB
10 litre AP3/10 AP3/10/OB
15 litre AP3/15 AP3/15/OB
Performance: Model Heat up time Re-heat time Heat Loss
(15° to 65ºC) (70% vol.) (kW/24 hrs)
AP3/05 (OB) 11 mins 7 mins 0.25
AP3/10 (OB) 18 mins 12 mins 0.33
AP3/15 (OB) 32 mins 18 mins 0.44
4 AP3/05, AP3/10, AP3/15 Installation Instructions
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AP3/05, AP3/10, AP3/15 Installation Instructions 5
Dimensions
Model Capacity Dimensions Fixing Centres Weight Water
(litres) (mm) (mm) (kg) Connections
A B C D E F Empty Full
AP3/05 (OB) 6 376 256 260 100 252 140 6.7 12.7 1/2"BSP
AP3/10 (OB) 10 480 350 265 100 378 140 8.5 18.5 1/2"BSP
AP3/15 (OB) 15 480 350 310 100 378 140 9.8 24.8 1/2"BSP
Special notices
These instructions should guide you through the installation, maintenance and
use of the Zip Aquapoint III, however, if you require any further information
please call Zip Customer Service on 0845 602 4533.
• The Zip Aquapoint is an unvented water heater designed for connection
directly to the incoming mains water supply and can serve one or more
outlets using conventional taps.
• Care should be taken that the capacity of the unit chosen is sufficient to
meet the demands of the outlets being supplied.
• The casing is constructed from impact resistant plastic and heat losses are
minimised by the high efficiency polyurethane foam insulation.
• The inner vessel is constructed from glass enamelled steel sheet and
pressure tested to 12 bar.
• A manually re-settable safety cut-out automatically cuts off the electrical
supply to the heating element in the event of a malfunction.
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6 AP3/05, AP3/10, AP3/15 Installation Instructions
• A sacrificial magnesium anode is fitted to the vessel to provide anti-
corrosion protection for the vessel and element. Gradual erosion of the
anode will occur depending upon local conditions and, in extreme cases,
conditions may cause rapid erosion resulting in particles being deposited as
a residue or emitted from the heater. The Aquapoint should not, therefore,
be used in critical applications where water quality is paramount. Regular
preventive maintenance inspections are vital to achieve optimum
performance and durability of the appliance. The condition of the anode
should be checked regularly by an authorised Zip service provider as part
of the preventive maintenance programme.
If the hot water system is not used for two weeks or more, it is
recommended that a hot tap be turned on for several minutes at a sink,
basin or bath, but not at a dishwasher, clothes washer or other appliance
before returning to service.
Installation
Requirements
1. These instructions must be read and fully understood before commencing
the installation. If in doubt, or in need of further guidance, please call Zip
Customer Service on 0845 602 4533.
2. Zip Aquapoint unvented water heaters must be installed by a competent
installer, familiar with unvented electric water heaters.
3. Installations must comply fully with UK Water Regulations and any Local
Authority requirements.
4. The electrical installation including earthing and cross-bonding should comply
with the current IEE regulations and any Local Authority requirements.
5. The Zip Aquapoint is designed for connection direct to the incoming mains
water supply and accommodation must be made for the expanded water
that will occur with each heating cycle. Regulations permit expanded hot
water to be accommodated within the supply pipe work provided that no
check valve, stop valve with loose jumper or other fitting can prevent
reverse flow. (See diagram 1 on page 8).
Where the expanded water cannot be accommodated in the pipe work and
the static water supply pressure is under 4 bar fit accessory pack AQ2
(expansion vessel and check valve). Where static water pressures are likely
to exceed 4 bar fit accessory pack AQ2 and AQ3 (pressure reducing valve
and line strainer). ( See diagrams 2 and 3 on page 8).
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6. If required a Temperature and Pressure relief valve (accessory AQ1) can be
used with any installation by fitting securely into the locating point provided.
7. The 6 bar expansion relief valve must be fitted on the cold water supply.
Under no circumstances should the expansion relief valve be installed in an
inverted position as fouling of the seat caused by deposits may prevent it
from operating correctly.
Safety relief valve connections should not be used for any other purpose
and no valve should be fitted between the expansion relief valve and the
storage cylinder.
8. The drain connection from the expansion relief valve and the T&P valve, if
fitted, must be in accordance with Water Supply Regulations. The point of
discharge must be in a safe and visible position. The connection should be
made using 15mm pipe having a continuous fall to a maximum length of 3
metres. It shall not have more than 3 right-angled bends. If a waste
connection in excess of 3 metres is necessary the pipe diameter should be
22mm with continuous fall and no more than 4 right-angled bends with a
maximum resistance to flow equivalent to 9 metres of straight pipe.
9. An isolating valve must be fitted to the cold water supply.
10. Valves and fittings must be of a type required by Water Supply Regulations
Positioning
1. The Zip Aquapoint must be installed vertically. The connections should be
at the rear of the unit. When facing the heater the hot supply (red) is to
the left, and the cold feed (blue) to the right.
2. The heater may be mounted above or below the intended outlets providing
the water connections for the undersink models are at the top and for the
oversink models underneath. N.B. Undersink and oversink models are
not interchangeable. The fixings must be capable of supporting the heater
when full of water.
3. The undersink unit can be placed unsupported on the floor or cupboard
base, but if additional support is required, securing screws are supplied that
locate to the rear of the casing.
4. Position the Zip Aquapoint to allow for its removal for future inspection and
maintenance.
5. The Zip Aquapoint is not recommended for installation above false ceilings.
6. Do not install in a location where the unit or connecting pipe work can freeze.
AP3/05, AP3/10, AP3/15 Installation Instructions 7
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8 AP3/05, AP3/10, AP3/15 Installation Instructions
When deciding the final location of the heater consideration should be
given to the safe and visible disposal of any water resulting from leaks or
seepage.This is particularly relevant when the heater is located in a roof
space, cupboard or any concealed location. For guidance please call Zip
Customer Service on 0845 602 4533.
Underbasin model shown
Diagram 1.
Inlet pressure less than 4 bar
and expanded hot water can
be accommodated in the
pipe work.
Diagram 2.
Inlet pressure less than 4 bar
but expanded hot water
cannot be accommodated in
the pipe work. (Using pack
AQ2 expansion vessel and
check valve).
Diagram 3.
Inlet pressure greater than 4
bar. (Using pack AQ2 and AQ3
expansion vessel, check valve
and pressure reducing valve).
Minimum length of pipe – Length ‘A’
Size 15mm pipe 22mm pipe
5 litres 1.2m (4ft) 0.6m (2ft)
10 litres 2.7m (9ft) 1.2m (4ft)
15 litres 4.2m (14ft) 1.8m (6ft)
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Plumbing
1. Check the incoming water supply pressure as this will determine the layout
and safety controls required. Remember that the mains water pressure can
increase considerably at night.
2. Refer to diagrams 1 to 3 to determine accessories required and layout.
3. Position the heater and controls to allow for future maintenance.
4. All control and safety valves are marked to show the direction of water
flow and will not function if incorrectly orientated. Do not break any seals or
attempt to adjust any safety valve; to do so may impair the safety of the
installation and will invalidate the warranty.
5. To ensure a watertight seal use fibre washers for connecting the inlet
and outlet pipes to the heater. Complete the seal by applying PTFE tape
to the threads but do not over-apply or extend beyond the limits of the
thread as this will lessen the effectiveness of the joint. Do not use plumbers
paste to secure joints as this can impair the operation of any valves
connected to the heater.
6. An isolating service valve (not supplied) should be fitted in the cold water
supply pipe-work as shown in diagrams 1 to 3.
7. Flush all pipe work thoroughly before making the final connections to the
valves, accessories and cold feed to the heater to ensure that any debris is
removed. Failure to do this may result in irreparable damage to the controls
and will invalidate the warranty.
Electrical
1. Switch off the mains electrical supply before carrying out any work involving
a live circuit or access to components that may be live.
2. The Zip Aquapoint is pre-wired with a length of 3 core cable suitable for
connection to a mains 240v supply. Connection must be made in
accordance with current IEE wiring regulations to a double pole isolating
switch on a dedicated circuit or a double pole switched spur.
3. If the cable length is insufficient it is recommended that the entire length is
replaced and no joins made to the original. To replace the cable:
a. Prise the temperature control knob off the spindle and remove the fixing
screw located beneath
b. Release the two fixing screws at the top of the cover assembly
c. Remove the cover by lifting forwards and upwards
d. Release the locknut on the cable grommet assembly
AP3/05, AP3/10, AP3/15 Installation Instructions 9
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10 AP3/05, AP3/10, AP3/15 Installation Instructions
e. Remove the existing cable and pass the new cable through the
grommet assembly
f. Remake the cable connections and tighten the grommet locknut to
ensure the cable is securely clamped
g. Refasten the cover.
4. All internal wiring is factory mounted and should not be altered or modified.
This appliance must be earthed.
Do not switch on the electrical supply until the water heater is full of water.
Commissioning
1. Check that all the requirements under "Installation Requirements" have
been met.
2. Check that all water and electrical connections are correct and tight.
3. Open a hot water tap.
4. Open the isolating valve and permit the heater to fill.
5. Close the hot tap when water starts to flow from it.
6. Check for leaks and rectify as necessary.
7. Check the operation of the expansion relief valve and the T&P valve, if fitted.
8. Manually operate Expansion Relief Valve to ensure free water flow through
the discharge pipe by turning the knob to the left and holding in the
open position.
9. Set the temperature control knob to the desired position. The ‘E’ position
with a water temperature of approx. 55ºC is recommended for economical
operation while minimising lime-scale deposits and thermal losses.
Note:
• Rotating the temperature control knob varies the water temperature
over the range 7ºC to 75ºC.
• The maximum temperature can be limited by prizing the front cover off
the temperature control knob and re-positioning the limit pin from
position ‘O’ to position ‘A’ max 55ºC, ‘B’ max 45ºC or ‘C’ max 35ºC.
• Hot water at 55ºC or more can scald.
• The ‘*’ position provides frost protection while the heater is connected
to power.
10. Switch on the electrical supply to the unit. The red neon light will glow
during the heating cycle and will extinguish when the selected temperature
is reached until the next heating cycle.
11. During the heating cycle no water should escape to waste from either the
expansion relief or T&P relief valves.
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12. Allow the heater to reach the selected temperature when the pilot light will
extinguish. Check the water temperature and re-check water connections
adjusting as necessary
13. Pass these instructions to the person responsible for the building management
Maintenance
Precautions
1. The Zip Aquapoint is an unvented electric water heater and a competent
person, familiar with unvented systems, should carry out all servicing and
maintenance
2. Do not remove the cover whilst the unit is connected to the electrical supply
3. The over temperature safety cut-out is located inside the cover. Do not reset
the over temperature cut-out until the cause of its operation has been
diagnosed and necessary repairs have been undertaken
4. Do not use the water heater if it is suspected of being frozen. Switch off the
electrical supply if water ceases to flow and do not switch on again until a
competent person has checked that it is safe to do so
5. The heater should be visually inspected regularly. This is particularly important
if the heater is located in a cupboard, roof space or any other concealed
location. If there is any sign of leaks or seepage the heater should be
isolated from the water supply and switched off from the electrical supply
until a competent person has investigated the cause.
6. Do not block or restrict the discharge from any safety valve
7. Do not tamper with any safety valve
8. If water discharges from any safety valve switch off the electrical supply to
the unit, isolate the water supply and contact a competent person familiar
with unvented systems
9. Please note that lime-scale deposits form more readily at higher temperatures.
Damage or failures caused by the formation of lime-scale are specifically
excluded under the terms of the warranty. To reduce lime-scale formation to
a minimum the unit should always be operated at the lowest convenient
temperature. The ‘E’ temperature setting is recommended.
10. If the unit has been commissioned and is to be unused for more than two
weeks with the power supply still connected the thermostat should be set
to ‘*’ to maintain a temperature of approx. 7ºC and protect the unit from
freezing. NB this protection does not extend to connecting pipework.
AP3/05, AP3/10, AP3/15 Installation Instructions 11
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12 AP3/05, AP3/10, AP3/15 Installation Instructions
Schedule
It is recommended that all key components of the heater should be inspected
on a regular basis, no greater than twelve monthly intervals, for continued safe
and efficient operation. The inspection should be carried out by a competent
person familiar with unvented systems and the components to be inspected
should include the following:
1. Sacrificial anode. The condition of the anode should be checked regularly
by an authorised Zip service provider as part of the preventive maintenance
programme and to ensure its effectiveness in protecting the vessel and
element from corrosion.
To check the condition of the anode visually through the flange opening first
remove the thermostat temperature probe and disconnect the electrical
wires to the element before unscrewing the element assembly and
removing it.
If the anode is badly corroded it should be replaced after removing it by
grasping with long tongs or other suitable tool through the flange opening
while unscrewing the securing nut on top of the vessel.
2. Expansion relief valve. Check correct operation.
3. T&P relief valve, if fitted. Check for correct operation.
4. Expansion vessel, if fitted. Check pressure – refer to label on vessel for
correct pressure.
5. Integral line strainer, if pressure reducing valve fitted. Inspect and clean
as necessary.
6. Check that the discharge pipe-work is free of any obstructions.
7. Check that all electrical connections are tight.
De-Installation
To de-install the heater
1. Switch off and disconnect the electrical supply.
2. Close the mains water supply isolating valve.
3. Disconnect the inlet and outlet water connections at the top of the heater.
4. Remove the heater.
5. Drain the unit through the hot water supply connection.
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Fault Finding
NB All servicing and repairs must be undertaken by a competent person,
familiar with unvented systems.
Fault
Over temperature cut-out
operates
Regular, intermittent water
discharge from tundish
Continuous water discharge
from the tundish
No water flow from hot taps
Water from hot taps is cold
Possible Cause
The thermostat has failed
The thermostat is set at too
high a temperature
Loss of pressure from the
expansion vessel
Thermostat failure
Pressure reducing valve not
operating correctly
T&P relief valve not operating
correctly
Expansion relief valve not
operating correctly
Cold water mains supply
isolated
Integral line strainer in
pressure reducing valve has
become blocked
Pressure reducing valve
incorrectly fitted
Power supply not switched on
Over temperature cut-out has
operated
Faulty element
Thermostat failure
Solution
Reset. If the cut-out operates
again isolate the unit and
contact the installer.
NB Isolate the electrical
supply before removing the
electrical cover panel and
ensure that the panel is
correctly replaced and
secured before reconnecting
Isolate the heating system and
the mains cold water supply.
Partly drain the unit. Recharge
the expansion vessel to the
specified pressure and
re-commission.
Isolate the heating system and
check thermal controls when
discharge ceases. Replace
thermostat if faulty.
Check with pressure gauge and
replace as necessary
Check and replace if faulty
Check and replace if faulty
Restore mains supply to the
heater
Check and clean as necessary
Refit correctly with arrows in
direction of flow
Check and switch on
See fault "Over temperature
cut-out operates" above
Check and replace as necessary
Check and replace as necessary
AP3/05, AP3/10, AP3/15 Installation Instructions 13
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Warranty
The Zip appliance you have chosen is precision-built from the finest materials
available and should give many years of trouble free service.
Certain warranties may be implied by law into your contract with Zip. The
warranty provided below is additional to these implied warranties and nothing
set out below shall limit your statutory rights or rights at law.
Zip Heaters (UK) Ltd warrants that, should any part fail within 12 calendar
months of installation, that part will be repaired or replaced free of charge by Zip
or its Distributor or Service Provider, except as set out below, provided the
appliance is installed and used strictly in accordance with the instructions
supplied, and that failure is not due to accident, misuse, abuse, unsuitable
water conditions, or to any alteration, modification or repair by any party not
expressly nominated by Zip.
No costs are payable by the customer other than any mileage or travelling-time
charges incurred by a Zip Service Provider or the cost of removal, cartage and
re-installation of any component of the appliance if it needs to be returned for
repair to Zip or its Distributor.
This warranty does not cover damage resulting from non-operation of the
appliance or consequential damage to any other goods, furnishings or property.
Zip does not exclude, restrict or modify any liability that cannot be excluded,
restricted or modified or which cannot, except to a limited extent, be excluded,
restricted or modified as between the owner or user and Zip under the laws
applicable.
Furthermore, this warranty does not displace any statutory warranty, but, to the
extent to which Zip is entitled to do so, the liability of Zip under any statutory
warranty will be limited at Zip's option to the replacement of the appliance or
supply of equivalent appliance, the payment of the cost of replacing the
appliance or acquiring an equivalent appliance, or the payment of the cost of
having the appliance repaired or the repair of the appliance.
Zip Heaters (UK) Ltd
14 Bertie Ward Way
Dereham, Norfolk NR19 1TE
Telephone [phone]
Telefax 01362 692448
www.zipheaters.co.uk
14 AP3/05, AP3/10, AP3/15 Installation Instructions
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