Zip CEX-O Mounting instructions

Installation, Maintenance and User Instructions
Please read these instructions carefully before commencing installation of the InLine water heater.
Please leave these instructions with the end user after installation.
Zip Heaters (UK) Ltd
14 Bertie Ward Way
Dereham
Norfolk
NR19 1TE
Telephone [phone]
Fa simile 01362 692448
www.zipheaters. o.uk
Zip InLine
Electronically Controlled Instantaneous
Water Heaters
Models CEX-O & CEX-U
Issued August 2011
The terms ‘Zip’ and ‘InLine’
are registered trademarks.
9120 - 2546
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Contents
Description 2
Approvals 2
Warnings 3
Technical data 4
Dimensions 5
Spare parts 6
Installation
Requirements 7
Installation site 7
Installing the appliance 8
Electrical connection 9
Commissioning 10
Service menu 12
Operation 14
Cleaning and maintenance 17
Fault finding 17
Warranty 18
The use of this crossed out wheeled bin logo indicates that this product needs
to be disposed of separately to any other household waste.
Within each of the European Union member countries, provisions have been
made for the collection and recycling of unwanted electrical and electronic
equipment.
In order to preserve our environment we ask that you dispose of
this product correctly. Please contact Zip Customer ervice for
advice on 0845 602 4533.
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 ervice 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 ervice 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.
CEX-O & CEX-U Installation, Maintenance and User Instructions - August 2011 18
1 CEX-O & CEX-U Installation, Maintenance and User Instructions - August 2011
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CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011 2
Description
Zip nLine CEX-O and CEX-U instantaneous water heaters are micro-processor controlled,
pressure resistant water heaters suitable for supplying hot water to one or more outlets.
The heating element switches on automatically when the hot water tap is opened and
switches off automatically when the hot water tap is closed.
The electronic control system automatically regulates the power consumption
depending on the supply water temperature and flow rate to achieve the required outlet
temperature within the power limit of the appliance.
Power consumption is also regulated based on outlet temperature to ensure the
required temperature is achieved exactly to the degree and irrespective of fluctuations in
voltage and water pressure.
The power rating of the appliance can be selected as either 9.6kW or 7.2kW at 240V at
the time of installation.
The required outlet temperature can be entered on a keypad within the range 30°C to
55°C and can be read off the digital display.
The maximum inlet temperature of 70°C is suitable for use with preheated water e.g.
from solar heating systems.
Approvals
Zip nLine CEX-O and CEX-U are VDE approved to the LVD and EMC directives and are
CE endorsed.
Zip nLine CEX-O and CEX-U have been examined, tested and found when correctly
fitted to comply with the requirements of the United Kingdom Water Regulations /
Byelaws (Scotland). The products are listed under the WRAS (Water Regulations
Advisory Scheme) Water Fittings and Materials Directory.
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3 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
Warnings
• nstallation, commissioning and maintenance of this appliance must only be carried
out by a competent installer who will then be responsible for adhering to all relevant
standards and regulations.
• The appliance must only be used when correctly installed and in perfect working order!
• The appliance must be installed in a frost-free room! The appliance must never be
exposed to frost.
• The appliance must be earthed at all times!
• The appliance must only be used for heating potable water. The specific water
resistance must not fall below the required value indicated on the rating plate.The
appliance must not be used for any other purpose.
• The maximum water pressure must not exceed the value indicated on the rating plate.
• The incoming water temperature must not exceed 70°C.
• Before commissioning for the first time and each time the appliance is emptied (e.g. due
to work on the plumbing system, if there is a risk of freezing or in case of maintenance),
the appliance must be vented by opening and closing the hot water tap until all air has
been eliminated from the water heater and no more air emerges before re-connecting to
the electrical supply.
• The front cover of the appliance must never be opened before disconnecting the
appliance from the mains power supply!
• The appliance and its wiring and piping must not be modified in any way!
• Be careful! Temperatures in excess of approx. 43°C are perceived as hot, especially by
children, and may cause a feeling of burning. When the appliance has been in use for
some time, the fittings may be very hot!
• n case of malfunction isolate the power supply immediately. n case of leaks also
isolate the water supply. Repairs must only be carried out by Zip Heaters (UK) Ltd or
an authorized Zip service engineer.
• This appliance must not be used by any person (including children) with limited
physical, sensory or mental abilities or lacking suitable experience and/or knowledge
unless they are supervised by a person responsible for their safety or have received
instructions about how to use the appliance. Children should be supervised in order to
make sure that they do not play with the appliance.
• Zip Heaters (UK) Ltd cannot be held liable for any damages caused by failure to
observe these instructions.
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Technical data
odel CEX-O CEX-U
Application Over-sink Under-sink
Power rating 7.2kW / 9.6kW(1)
Rated current 30A (7.2kW) / 40A (9.6kW)
Power supply 1/N/PE~240V AC
Hot water (l/min)
aximum at t = 25K 4.1 (7.2kW) / 5.0(2) (9.6kW)
Rated volume (litres) 0.3
Rated pressure 1 MPa (10 bar)
Element type Bare wire heating system ES
Required specific water resistance >1100 Ωcm @ 15°C
aximum inlet temperature 70°C
Switch on flow rate (l/min) 2.0
aximum flow rate (l/min) 5.0(2)
Pressure loss
@ 2.5 l/min 0.2 bar
@ 9.0 l/min 1.3 bar(3)
Temperature setting range 30°C – 55°C
aximum weight (kg) 2.70
Dimensions H x W x D (mm) 294 x 177 x 108
Water connections ½” BSP
Protection class P25 P24
(1) Power rating selected at time of installation
(2) Flow rate limited to achieve optimum temperature rise
(3) Without flow regulator
• Minimum flow rate 2.0 litres/minute.
• A minimum water pressure of 2 bar is recommended for optimum performance.
• Maximum flow rate will be achieved at a water pressure of 6 bar.
CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011 4
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Dimensions
5 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
294
108
177
100
37
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Spare parts
When ordering spare parts, please always specify
the appliance model and serial number.
N89589 CEX-U
N89588 CEX-O
Front Cover
N82802
nlet Pipe
N82812 CEX-U
N82816 CEX-O
Control Panel
N82811
Main PCB
N82246
Non-return Valve
N82819
Flow Sensor
N86250
Terminal Block
N82806
Grommet
N82813
½” Water
Connection
N82512
Temperature
Sensor Set
N82810
Heating Element
c/w STDB
CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011 6
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Installation
Req irements
• These instructions must be read and fully understood before commencing the
installation. f in doubt, or in need of further guidance please ring Zip on 0845 602
4533.
• Zip nLine water heaters must be installed by a competent person familiar with
electric instantaneous water heaters.
• nstallations must comply fully with UK Water Regulations and any Local Authority
requirements.
• The electrical installation including earthing and cross bonding should comply with
current EE regulations and any Local Authority requirements.
• Zip nLine water heaters must be installed according to the specification on the rating
plate and the technical specifications.
• The appliance must be permanently connected to the electrical supply through an
isolation switch having a contact separation of at least 3mm on all poles.
• To protect the appliance, a circuit breaker must be fitted with a rating suitable for the
nominal current of the appliance.
• The cross sectional area of the connection cable must be in accordance with the
power rating of the appliance and the specific requirements of the installation site up
to a maximum cable size of 10mm2.
• Take care to protect the wiring from damage during installation and ensure that the
wiring is not directly accessible after installation.
• Check that the power supply is switched off prior to electrical connection.
•This appliance must be earthed.
Installation site
• The installation site must be free from frost at all times.
• The appliance is designed for wall mounted installation. CEX-O for over-sink
installation must be installed with the water connections downward. CEX-U for
under-sink installation must be installed with the water connections upward.
• The appliance complies with protection class P25 for over-sink installation,
protection class P24 for under-sink installation and may therefore be installed in
protection zone 1.
• n order to minimise thermal losses, the distance between the appliance and the
outlet fitting should be as short as possible. Recommended maximum distance 2
metres.
• For maintenance work a shut off valve should be installed in the water supply line
to he heater.
• Hot and cold water connecting pipes should be WRAS approved and of copper
or steel construction. Plastic pipes may only be used if conforming to D N 16893
Series 2. The hot water pipes must be thermally insulated.
• The specific resistance of the supply water must be at least 1,100 Ωcm at 15°C.
The specific resistance can be checked with the local water supply company.
7 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
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Fig 1
Fig 3
Fig 2
Installing the appliance
1. Thoroughly flush the water supply pipes
before installation to remove any water borne
debris.
2. Hold the appliance on the wall and mark the
drill lines at top and bottom, left and right,
corresponding to the small notches at the
edge of the front cover (see Fig 1).
3. Join the top and bottom marks vertically
(A-A) and the left and right marks horizontally
(B-B). The intersections of these lines are the
drill points (see Fig 2).
4. Drill the holes using a 6mm drill then insert
the dowels and screws provided leaving the
screws protruding 5mm from the wall.
5. Hang the appliance with the screws
engaging in the key-hole slots in the back
plate until it clicks into place (see Fig 3).
6. Attach the water connecting pipes to the
appliance water connections using the ½”
seals.
7. Ensure that all air is eliminated from the
water heater by opening and closing the hot
water tap until all air has been eliminated
from the water heater and no more air
emerges.
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9 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
Fig 4
Fig 5
Electrical connection
The electrical installation including earthing
and cross bonding should comply with current
EE regulations and any Local Authority
requirements.
The appliance must be installed according to
the specification on the rating plate and the
technical specifications.
The appliance must be earthed.
The appliance must be permanently connected
to the electrical supply through an isolation
switch having a contact separation of at least
3mm on all poles.
The cross sectional area of the connection
cable must be in accordance with the power
rating of the appliance and the specific
requirements of the installation site up to a
maximum cable size of 10mm2.
Take care to protect the wiring from damage
during installation and ensure that any
uninsulated wiring is not directly accessible
after installation.
To protect the appliance, a circuit breaker
must be fitted with a rating suitable for the
nominal current of the appliance.
Check that the power supply is switched off
prior to electrical connection!
1. With the appliance cover removed insert
the power cable through the water splash
protection grommet in the backplate. The
splash protection grommet must be used
and free from damage.
2. Remove inner and outer insulation from the
connecting cable to the lengths shown in
Fig 4.
3. Secure the cable using the cord grip. The
cord grip must be used.
4. Fit the connecting cables into the terminal
block according to the wiring diagram above.
Ensure all connections are fully tightened and
secure.
5. Re-fit the appliance cover taking care not to
trap the cable from the display panel and
secure the cover with the fixing screw
(see Fig 5).
Wiring Diagram
1. Circuit board
2. Heating element
3. Safety pressure switch and
safety thermal cut-out
4. Terminal block
1
23
4
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CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011 10
Fig 6
Fig 7
Commissioning
Before switching on the power supply, ensure the appliance
is completely filled with water by carefully opening and
closing the hot water tap until all air has been eliminated
from the water heater and no more air emerges.
Each time the appliance is drained (e.g. after work on the
plumbing system or following repairs to the appliance), the
heater must be re-vented in this way before reconnecting
the power supply.
f the appliance does not operate after connecting the
power supply check that the safety thermal cut-out (STDB)
did not trip during transportation. To do this open the cover
and, if necessary, re-set the STDB by pushing the switch in
(see Fig 6).
Note: Power Rating Selection
The maximum power rating of the appliance can be selected
as either 9.6kW or 7.2kW at the time of installation. The unit
will only commence normal operation after selection of the
power rating. The maximum power rating should only be
selected with reference to the technical data on page 4, after
ensuring that correct cable sizing and fuse protection is in
place and with regard to local site conditions and electrical
regulations.
This should only be done by a competent installer.
1. Switch on the power supply to the appliance. The digital
display will light up.
2. When switching on power for the first time “88” will flash
on the display (see Fig 7). f not, please refer to the section
below “Reinstallation”.
3. Use the arrow up and arrow down keys to select the
required maximum power rating. Display “88” for 8.8kW
at 230V (9.6kW at 240V) or display “66” for 6.6kW at
230V (7.2kW at 240V).
4. Press program key 1 to confirm the selection after which
the appliance will start to operate.
5. Mark the set power rating on the product rating plate.
6. After selecting the maximum power rating, the heating
element will activate after approximately 10 seconds of
continuous water flow.
7. Open the hot water tap and check the appliance is
functioning correctly.
8. Explain operation of the appliance to the end user and
leave the operating instructions for their reference.
9. Complete the product registration card and return it to
Zip Heaters or register the product on line at
www.zipheaters.co.uk
M ltiple Power System:
The maximum power
rating is 9.6kW and can
be changed to 7.2kW
during installation.
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11 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
Fig 8
Fig 9
Reinstallation
f the appliance is to be re-commissioned under
different installation conditions it may be
necessary to alter the maximum power rating.
This should only be done by a competent
installer.
To re-set the maximum power rating use a
screwdriver to short circuit the two pins as
shown in Fig 8.
This will reset all heater parameters to factory
settings.
Value “88” will flash in the display panel
until the maximum power rating has
been selected.
Lock level
Operation of the appliance can be restricted.
Refer to instructions under “Service Menu” to
set the lock level.
This should only be done by a competent
installer.
Activation of the Lock level:
1. Set the required lock level in the service
menu (refer to instructions under “Service
Menu”).
2. Disconnect the power supply to the unit.
3. Move the jumper on the main PCB from
pin 2 to pin 1 (see Fig 9).
4. Reconnect the power supply to the unit.
Deactivation of the Lock level:
1. Disconnect the power supply to the unit.
2. Move the jumper on the main PCB from
pin 1 to pin 2.
3. Reconnect the power supply to the unit.
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CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011 12
Fig 10
Service men
The service menu can be used for diagnostics
and to view and configure appliance settings.
Press program keys 1 and 2 simultaneously for
at least 2 seconds to enter the service menu
confirmed by the display “FL” and flashing
point (see Fig 10).
Scroll between menu items in the service menu
using the arrow up and arrow down keys.
Press program key 1 to display the value of the
currently selected menu item. The value flashes
in the display.
The values of some menu items can be
displayed by using the arrow up and arrow
down keys.
Press program key 1 to return to the menu
item list.
Press program key 2 to exit the service menu
and return to the standard display.
After two minutes without any key stroke the
system automatically returns to the standard
display.
enu item order of Service enu:
Flow: Flow rate (l/min)
Power: Power consumption (kW)
Temp in: nlet temperature (°C)
Temp out: Outlet temperature (°C)
Control value: Calibration value of the control system (40 - 60)
Power limit: Maximum power setting (kW)
Diagnostics: Last ten diagnostic messages (see below)
Lock level: Current lock level setting (see below)
Software version: nstalled software version
Radio channel: Radio channel of heater and remote control
Received strength: Signal quality of remote control (10% - 100%)
Signal: Quality of radio contact with diagnostic display
Press >2 secs
Display flashes
12
4
56
7
8
9
3
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13 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
“Er”: Diagnostics
The last ten diagnostic messages can be
displayed.
Pressing program key 1 displays the current
error code. A key explaining the error codes
can be found inside the front cover of the
appliance.
The arrow up and arrow down keys can be
used to view the last ten error codes displayed
in chronological order from “0” to “9” alongside
the corresponding error code with “0” being
the most recent.
“LL”: Lock level
The operating mode of the appliance can be
restricted.
Setting options:
“0” no restriction (factory setting)
“1” disables “Reset to factory setting”.
Parameters can be viewed but not
modified in service menu
“2” as “1”, additionally service menu cannot
be displayed
“3” as “2”, additionally program 1 and 2 set
temperature values cannot be changed
“4” as “3”, additionally set temperature value
on appliance cannot be changed
Note: when lock level 1, 2, 3 or 4 is selected
the system parameters cannot be modified in
the service menu.
n order to modify system parameters it is
necessary to remove the jumper from the main
PCB as described under “Deactivation of the
Lock level”.
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CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011 14
Operation
The appliance switches on automatically when
the hot water tap is opened and switches off
automatically when the hot water tap is closed.
Temperature setting
The required outlet temperature can be adjusted
gradually to a higher or lower value with the up
arrow and down arrow keys.
Pressing a key once briefly changes the
temperature by 0.5°C between 35°C and 42°C
and by 1°C outside that range.
Pressing a key for a longer time changes the
temperature continuously.
The required outlet temperature can be adjusted
between 30°C and 55°C.
Note: reducing the temperature below 30°C
displays “- -” and the heating function will not
operate.
Program buttons
The two program keys allow a preset
temperature to be selected quickly.
The factory setting is 35°C for program 1 and
48°C for program 2.
The preset temperature can be changed to
the current temperature setting by prolonged
pressing of the program key. The display
changes from “P1” or “P2” to the new
temperature value which becomes available
each time the corresponding program key is
pressed.
Set temperature
Store temperature
Set required
temperature
35.0 - 42.0ºC
-1ºC +1ºC
-0.5ºC +0.5ºC
Select preset temperature
Press >3
seconds
1
A1 A2
B1 B2
2
43
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15 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
Temperature limitation
Units are supplied with the temperature
limitation function deactivated.
To activate, select the limit temperature then
press the program 1 and up arrow function
keys simultaneously for at least 3 seconds.
“H ” is displayed briefly to confirm activation.
To deactivate, press the program 1 and down
arrow function keys simultaneously for at least
3 seconds.
“- -“ is displayed briefly to confirm deactivation.
Note: Programmed temperature settings may
need to be reset after deactivating temperature
limitation.
Reset to factory setting
To reset to factory settings press
the up arrow and down arrow
function keys simultaneously.
The display will count backwards
from “10” to “00” in one second
intervals.
The appliance is reset when the
counter reaches “00”.
Releasing the function keys earlier
will cancel the process.
Temperature limitation on
Temperature limitation off
Reset to factory setting
12
12
3
12
3
Confirms
activation
Press >3
seconds
Confirms
deactivation
Press >3
seconds
Press + hold!
Reset complete
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CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011 16
Energy saving
Set the required hot water temperature on the
appliance.
f the water is too hot reduce the temperature
on the appliance instead of mixing with cold
water.
Adding cold water wastes valuable energy that
has been used producing excessively hot water.
Also, any cold water added is not controlled
by the electronic circuitry meaning that
precise temperature control can no longer be
guaranteed when supplying more than one
outlet.
Power limit
f the maximum power available from the
appliance is insufficient to heat the volume
of hot water being drawn off to the required
temperature this will be indicated by “MAX”
on the display.
Reducing the flow rate will enable the required
temperature to be delivered.
Operation with solar systems
The appliance is suitable for use with solar
heating systems providing appropriate controls
are in place to ensure that the temperature of
the water entering the unit does not exceed
70ºC.
f the inlet temperature exceeds the set point,
the “SUN” symbol on the display indicates that
the heating power is switched off.
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17 CEX-O & CEX-U nstallation, Maintenance and User nstructions - August 2011
Problem Cause Solution
Water stays cold Circuit breaker tripped Reset circuit breaker
STDB tripped Contact Zip Service to reset STDB
Display flas es error Control system as Switc power supply off and on.
message ‘Er’ switc ed off If ‘Er’ still flas es contact Zip Service
Poor ot water flow rate Outlet fitting dirty or calcified Clean s ower ead or tap nozzle
Fine filter dirty or calcified Contact Zip Service to clean fine filter
Selected temperature not
ac ieved, “MAX” lig ts up Excessive water flow rate Reduce water flow rate at t e outlet
Selected temperature not Cold water as been added Set for required temperature and
ac ieved,“MAX” does not lig t at t e outlet tap ot water only
Symbol “SUN” flas es Inlet temperature exceeding Reduce inlet temperature
set point
Water eats but display fails Display lead plug not properly Contact Zip Service to connect
to operate connected display lead correctly
Cleaning and maintenance
N.B. Maintenance work must only be carried out by a competent person familiar with
instantaneous water heaters.
Plastic surfaces and sanitary fittings should only be wiped with a damp cloth. Never
use abrasive cleaning agents or solvents.
Outlet fittings (tap nozzles and shower heads) should be unscrewed and cleaned at
regular intervals.
The electrical and plumbing components should be inspected regularly by a competent
person to ensure proper functioning and operational safety. Water quality should be
considered when determining the frequency of inspection.
Each time the appliance is emptied (e.g. due to work on the plumbing system, if there
is a risk of freezing or in case of maintenance), the appliance must be vented by
opening and closing the hot water tap until all air has been eliminated from the water
heater and no more air emerges before re-connecting to the electrical supply.
Fault finding
Repairs should only be carried out by competent persons familiar with electric
instantaneous water heaters.
All service work should be performed by an authorized Zip service engineer – for details
of the full range of services available call Zip Service on 0845 602 4533.
When calling for service, please always specify the appliance model and serial number.
The following table will be helpful in determining the causes of some common
problems and their solutions.
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