Zip DEX 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 DEX & DBX
Issued April 2011
The terms ‘Zip’ and ‘InLine’
are registered trademarks.
9120 - 34136
DBX DEX cov r qxd:Varipoint cov r qxd 6/5/11 10:46 Pag 1

Contents
Description 1
Approvals 1
Warnings 2
Technical data 3
Dimensions 4
Spare parts 5
Installation
Requirements 6
Installation site 6
Installing the wall bracket 7
Installing the connection pieces 7
Installing the appliance 8
urface mounted installation 9
Electrical connection 9
Load shedding relay (DEX) 10
Electrical connection from below 10
Electrical connection from above 11
Commissioning 11
Maintenance 13
Operation (DEX) 14
Fa lt finding 16
Warranty 17
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.
DEX & DBX Installation, Maintenance and User Instructions - April 2011 17
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DEX & DBX Installation, aintenance and User Instructions - April 2011 1
Description
Zip InLine DEX and DBX 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.
For type DEX the required outlet temperature can be entered on a keypad
within the range 20°C to 60°C and can be read off the digital display.
For type DBX the factory set outlet temperature is 50°C and can be adjusted
inside the appliance within the range 30°C to 60°C.
Type DEX maximum inlet temperature of 70°C is suitable for use with preheated
water from solar heating systems.
Approvals
Zip InLine DEX and DBX are VDE approved to the LVD and E C directives
and are CE endorsed.
Zip InLine DEX and DBX 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 aterials Directory.
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2 DEX & DBX Installation, aintenance and User Instructions - April 2011
Warnings
• Installation, 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.
• 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!
• Incoming water temperature must not exceed 70°C for DEX and must not
exceed 30°C for DBX.
• In case of malfunction isolate the power supply immediately. In 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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DEX & DBX Installation, aintenance and User Instructions - April 2011 3
Technical data
Model
DEX 18-27 kW
DBX 18 DBX 21 DBX 24 DBX 27
Rating/Current 18kW (26A) 21kW (30A) 24 kW (35A) 27kW (39A)
Power supply 3/PE 380 – 415V AC 3/PE 400V AC(1)
Hot water (l/min)
Maximum at
L
L
t = 28K 9.2(2) 10.7(2) 12.3(2) 13.8(2)
Maximum at
L
L
t = 38K 6.8 7.9 9.0(2) 10.2(2)
Rated volume (litres) 0.4
Rated pressure 1 MPa (10 bar)
Element type Bare wire heating system IES
Required specific water
resistance
DEX >1100 Ωcm @ 15°C
DBX >1300 Ωcm @ 15°C
Maximum inlet temperature
DEX 70°C
DBX 30°C
Switch on flow rate (l/min) 2.5
Maximum flow rate (l/min)
DEX 8.0(3)
DBX 7.0(3) 8.0(3) 8.0(3) 9.0(3)
Pressure loss
@ 2.5 l/min 0.2 bar
@ 9.0 l/min 1.3 bar(4)
Temperature setting range
DEX 20°C – 60°C
DBX 30°C – 60°C
Maximum weight (kg) 3.70
Dimensions H x W x D (mm) 466 x 231 x 97
Water connections ½” BSP
Protection class IP25
(1) aximum 400V for DEX and DBX at 27kW
(2) ixed with cold water at the outlet
(3) Flow rate limited to achieve optimum temperature rise
(4) Without flow regulator
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4 DEX & DBX Installation, aintenance and User Instructions - April 2011
Dimensions
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DEX & DBX Installation, aintenance and User Instructions - April 2011 5
Spare parts
When ordering spare parts, please always specify
the appliance model and serial number.
Non-return valve
IN82246
Flow sensor
IN82526
DEX Thermal sensor
IN82512
Service Kit
comprising;
Heating Element,
Pressure and
Safety Switch,
PCB
DBX18 IN83118
DBX21 IN83121
DBX24 IN83125
DBX27 IN83127
DEX IN83227
DEX Thermal sensor
IN82512
DEX Control panel
IN82550
Flow limiter
DBX
IN89111
IN89110
IN89109
DEX
IN89110
Fine filter
IN82162
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6 DEX & DBX Installation, aintenance and User Instructions - April 2011
Installation
Requi ements
• These instructions must be read and fully understood before commencing
the installation. If in doubt, or in need of further guidance please ring Zip on
0845 602 4533.
• Zip InLine water heaters must be installed by a competent person familiar
with electric instantaneous water heaters.
• Installations must comply fully with UK Water Regulations and any Local
Authority requirements.
• The electrical installation including earthing and cross bonding should
comply with current IEE regulations and any Local Authority requirements.
• Zip InLine 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 of 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 applia ce must be earthed.
Installation site
• The installation site must be free from frost at all times.
• The appliance complies with protection type IP25 and may therefore be
installed in protection zone 1.
• In 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 the 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 DIN 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 for type DEX and at least 1,300 Ωcm at 15°C for type DBX. The
specific resistance can be checked with the local water supply company.
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DEX & DBX Installation, aintenance and User Instructions - April 2011 7
Fig 1
Fig 2
A
B
Installing the wall b acket
1.Thoroughly flush the water supply pipes before
installation to remove any water borne debris.
2.Using a 12mm hexagon key, screw the screw
in nipples into the wall connections. After
tightening the double nipples must protrude
by 12mm.
3.Hold the mounting template on the wall and
align it so that the holes in the template fit
over the connections. Use the template to
locate the drilling positions and drill them with
a 6mm bit, ensuring that there are no hidden
cables or pipe-work. Attach the wall bracket
using the fixings and screws supplied.
4.Offset tiling or uneven surfaces can be
compensated for by up to 30mm with the aid
of the spacers supplied. The spacers are fitted
between the wall and the wall bracket.
Installing the connection pieces
1.Screw the cold water connection piece (A) with
the union nut and the ½” seal onto the cold
water connection.
2.Screw the hot water connection piece (B) with
the union nut and the ½” seal onto the hot
water connection.
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8 DEX & DBX Installation, aintenance and User Instructions - April 2011
Fig 3
Fig 4
Fig 5
Installing the appliance
1.Remove the appliance cover by first
removing the fascia panel then
unscrewing the fixing screw.
2.If the power supply cable is to be
connected in the upper part of the
appliance follow instructions 1 to 3
for “Electrical Connection From
Above” on page 11.
3.Place the appliance on the wall
bracket with the threaded stud
through the fixing hole in the back
plate. If necessary the threaded
stud can be carefully bent through
a maximum of approximately 30°
to allow it to align with the fixing
hole (see Fig 4). However, it must
be ensured that that the water
connection pipes can be connected
to the appliance without applying
force.
4.Screw the two 3/8” union nuts on the
appliance’s water connection pipes,
each fitted with a 3/8” seal, onto the
fittings.
5.Screw the plastic knurled retaining
nut onto the threaded stud of the
wall bracket.
6.Open the water supply to the
appliance and slowly open the
shut-off valve (see Fig 5) in the
cold water connection piece to
position 1. Check all connections
for leaks.
7.Ensure that all air is eliminated
from the water heater by opening
and closing the hot water tap until
no more air emerges.
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DEX & DBX Installation, aintenance and User Instructions - April 2011 9
1
3
4
2
Wi ing Diag am
1. Circuit board
2. Heating element
3. Safety thermal cut-out
4. Terminal block
Fig 6
Su face mounted installation
1.For surface mounting, the two ½”
screw-in nipples and the ½” seals
must be screwed into the ½” union
nuts of the hot water and cold water
connectors.The two ½” caps of the
side outlets of the hot water and cold
water connectors must be removed
and screwed into the open end of the
screw-in nipples. The hot water and
cold water connectors must then be
screwed into the 3/8” union nut of the
appliance and delivery pipe, together
with the 3/8” seals.
2.When surface mounting, it is advisable
to install the appliance at a distance
from the wall as illustrated in Fig 6
using the spacer sleeves supplied. In
this case the two fixing holes near the
lower pipe connections should also
be used.
3.The flared end of the pipes must be
screwed into the ½” side outlets of the
hot water and cold water connectors
with ½” union nuts and ½” seals. The
holes required for the pipes must then
be broken out of the housing using a
blunt implement.
4.Ensure the line strainer is inserted into
the cold water connection.
Elect ical connection
Prior to commencing electrical connection
take time to re-read the ‘Installation
Requirements’ listed on page 6 and
ensure that all requirements pertaining to
electrical installation are observed.
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10 DEX & DBX Installation, aintenance and User Instructions - April 2011
Mode Descriptio
Normal operation,
0manufacturer’s
setting
Operation with
1normal load
shedding relay
Operation with
2sensitive load
shedding relay
Fig 7
Fig 8
Load shedding elay ( odel DEX only)
If further three-phase appliances are connected,
a load shedding relay (IN82250) can be connected
to phase conductor L2.
A special operating mode must be selected on
the appliance by pressing the four function keys
simultaneously until the required mode (0, 1 or 2)
is shown on the display then releasing the keys.
First select mode 1 to check correct operation of
the load shedding relay at low appliance output
(35° setpoint and low water flow rate).
Select mode 2 if the load shedding relay flickers.
Elect ical connection f om below
Check that the power supply is switched off
prior to electrical co ectio !
1.Remove inner and outer insulation from the
connecting cable to the lengths shown in Fig 7.
2.With the smaller opening foremost, slide the
water splash protection sleeve over the
connecting cable until the sleeve is flush with
the wall. This prevents any water leaks from
coming into contact with the electrical leads.
The protection sleeve must be used and free
from damage.
3.Open the control panel to the right.
4.Fit the connecting cables into the terminal block
according to the wiring diagram on page 9.
Ensure all connections are fully tightened and
secure.
5.The appliance must be earthed.
6.Pull the protection sleeve over the connecting
cables until it fits in the recess of the
intermediate panel.
7.Close the control panel.
8.Re-fit the appliance cover and secure with the
fixing screw before re-fitting the fascia panel.
Note: If required, the terminal block can be
re-positioned in the upper part of the appliance.
In this case the instructions in the following
section should be followed.
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DEX & DBX Installation, aintenance and User Instructions - April 2011 11
Fig 9
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.
Every 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.
Model DEX only
The maximum power rating of the appliance can be selected from 18, 21, 24
or 27kW at the time of installation. The maximum power rating should only be
selected with reference to the technical data on page 3, after ensuring that
correct cable sizing and fuse protection is in place and with regard to local
site conditions and electrical regulations.
This should o ly be do e by a compete t i staller.
1.Switch on the power supply to the appliance. The digital display will light up.
Elect ical connection f om above
1.Open the prepared breaking point (S) in the
upper part of the appliance by pressing with a
blunt instrument (e.g. Screwdriver)
2.Open the cable grommet to slightly smaller than
the cable size to ensure optimum protection
against water ingress. Fit the grommet into the
cable opening. N.B. The cable grommet must
be used.
3.Strip the cable 6cm above the point where it
emerges from the wall. Support the appliance
while the cable is routed through the grommet.
4.Unscrew the terminal block fixing screw.
Reposition the terminal block on the upper
mounting and secure with the fixing screw.
5.Fit the connecting cables into the terminal
block according to the wiring diagram on page
9. Ensure all connections are fully tightened
and secure.
6.The appliance must be earthed.
7.Re-fit the appliance cover and secure with the
fixing screw before re-fitting the fascia panel.
Check that the power supply is switched off prior to electrical co ectio !
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12 DEX & DBX Installation, aintenance and User Instructions - April 2011
DEX Rei stallatio
If the appliance is to be re-commissioned under different installation conditions
it may be necessary to alter the maximum power rating.
To re-set the maximum power rating use a
screwdriver to short circuit the two pins as
shown in Fig 10. Value ‘21’ will flash in the
display panel until the maximum power
rating has been selected.
Model DBX only
N.B. DBX27 for connection only to 3/PE 400V AC supply.
1.Switch on the power supply to the appliance.
2.Open the hot water tap and check the appliance is functioning correctly.
3.Explain operation of the appliance to the end user and leave the operating
instructions for their reference.
4.Complete the product registration card and return it to Zip Heaters or register
the product on line at: www.zipheaters.co.uk
DBX Temperature Adjustme t
The appliance is factory set to deliver hot water
at 50°C.
The hot water temperature can be adjusted
between 30°C and 60°C by turning the
potentiometer with a 2mm blade screwdriver
as shown in Fig 11.
Turning clockwise increases temperature and
turning anti-clockwise decreases temperature.
Fig 10
Fig 11
2.When switching on power for the first time “21” will flash on the display. If not,
please refer to the section below “Reinstallation”.
3.Use the arrow up and down function keys to select the required maximum
power rating. N.B.DEX at 27kW for connection only to 3/PE 400V AC supply.
4.Press function key 1 to confirm the selection after which the appliance will
start to operate.
5. ark the set power rating on the product rating plate.
6.After selecting the maximum power rating, the heating element will activate
after approximately 30 seconds of 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
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DEX & DBX Installation, aintenance and User Instructions - April 2011 13
1.Isolate the electrical supply to the unit.
2.Remove the appliance cover and close
the shut-off valve (see Fig 12) in the cold
water connection piece to position II.
3.Unscrew the screw plug (A) from the
cold water connection piece and take
out the strainer (B) (see Fig 13).
4.The strainer can now be cleaned or
replaced.
5.After re-fitting the strainer tighten the
screw plug.
6.Slowly open the shut-off valve in the cold
water connection piece to position 1.
7.Vent the unit by carefully opening and
closing the hot water tap several times
until all air has been eliminated from the
water heater and no more air emerges.
8.Re-fit the appliance cover and restore
power to the unit.
Fig 12
Fig 13
AB
Maintenance
N.B. aintenance 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.
Cleaning and eplacing the filte st aine
The cold water connection of the appliance is fitted with an integral shut-off
valve and filter strainer. Soiling of the strainer may reduce hot water output
from the unit.
The strainer should be cleaned or replaced as follows:
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14 DEX & DBX Installation, aintenance and User Instructions - April 2011
Set tempe atu e
Select p eset tempe atu e
Sto e tempe atu e
Tempe atu e limitation on
Tempe atu e limitation off
Ope ation ( odel DEX only)
Temperature setti g
The required hot water temperature can
be increased or decreased in increments
of 1°C by briefly pressing the up arrow
and down arrow function keys.
Depressing the function key for a longer
time changes the temperature continuously.
The temperature can be adjusted
between 20°C and 60°C.
Note. Reducing the temperature below
20°C displays ‘- -’ and the heating
function will not operate.
Program butto s
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.
Temperature limitatio
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.
‘HI’ is displayed briefly to confirm
activiation.
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
will need to be reset after deactivating
temperature limitation.
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DEX & DBX Installation, aintenance and User Instructions - April 2011 15
E ergy savi g
Set the required hot water temperature on the appliance.
If 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
If the maximum power available from the
DEX heater is insufficient to heat the
volume of hot water being drawn off to
the required temperature this will be
indicated by the LCD decimal point on
the display.
Reducing the flow rate will enable the
required temperature to be delivered
indicated by the decimal point remaining
solid.
Operatio with solar systems
The DEX 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 70°C.
If the inlet temperature exceeds the set point, the flashing decimal point on
the display indicates that the heating power is switched off.
Reset to facto y setting
Reset to factory setti g
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.
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16 DEX & DBX Installation, aintenance and User Instructions - April 2011
Problem Cause Solution
Water stays cold (DEX / DBX) Circuit breaker tripped Reset circuit breaker
Digital display does not light STDB tripped (DEX) Contact Zip Service to reset
up (DEX) STDB (DEX)
Display flashes error message Control system has Switch power supply off and on.
‘Er’ (DEX) switched off If ‘Er’ still flashes contact Zip Service
Poor hot water flow rate Outlet fitting dirty or calcified Clean shower head or tap nozzle
(DEX / DBX) ine strainer dirty or calcified Contact Zip Service to clean line filter
Selected temperature not
achieved (DEX / DBX) Excessive water flow rate Reduce water flow rate at the outlet
Decimal point flashes (DEX)
Selected temperature not
achieved and decimal point Cold water has been added Set for required temperature
does not flash (DEX) at the outlet and tap hot water only
Decimal point flashes (DEX) Inlet temeperature exceeding Reduce inlet temperature
set point
Delivered temperature Contact Zip Service to increase set
perceived to be too cold (DBX) Set temperature too low temperature
Delivered temperature Contact Zip Service to reduce set
perceived to be too hot (DBX) Set temperature too high temperature
No response to keypress Appliance cover not fitted Refit appliance cover correctly
(DEX) correctly
Fault finding
Repairs should o ly be carried out by compete t perso s familiar with
electric i sta ta eous 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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