Zip InLine ES3 Manual

1
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
ZIP
INLINE
INSTALLATION INSTRUCTIONS & USER MANUAL
MODEL NUMBER:
ES3, ES4, ES6
Electronically controlled instantaneous water heaters

02
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
TABLE OF CONTENTS
Safety information 3
WARNINGS 3
CAUTIONS 5
General product description 6
Approvals 6
Technical data 7
Dimensions 8
Spare Parts 9
Installation 10
Requirements 10
Installation site 10
Shower application 10
Installing the appliance 11
Electrical connection / Wiring diagram 14
Commissioning 14
Purging 14
Removing the cover 15
Temperature & flow adjustment 15
Maintenance & cleaning 17
Repairs 18
LED functions 18
Fault finding 19
End of life disposal 20
Warranty 21
Contact details 24
• Please read these instructions carefully before commencing installation of the instantaneous
water heater.
• Please leave these instructions with the end user after installation.
• To ensure you have a copy of the latest instructions visit www.zipwater.co.uk.

03
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
Safety Information
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 be disconnected from mains power supply before
carrying out any work involving live circuits.
• The appliance must be permanently connected to the supply through an
isolating switch with a contact separation of at least 3mm in all poles and
be protected by a suitably rated RCD.
• To protect the appliance, an MCB (miniature circuit breaker) or cartridge
fuse must be fitted with a rating suitable for the nominal current of the
appliance.
• The cross sectional area of the connection cable must be appropriate for
the power rating and location of the appliance. See Technical data, page 7.
• The connecting cable must be adequately secured.
• This appliance must be earthed at all times.
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SAFETY INFORMATION
WARNING:
Indicates a potentially hazardous situation, which, if not
avoided, could result in death and/or serious injury and/
or property damage.
CAUTION: Indicates a potentially hazardous situation, which, if not
avoided, may result in property damage.
IMPORTANT:
PLEASE READ THESE INSTRUCTIONS CAREFULLY.
NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND
CAUTIONS. USE THIS PRODUCT CORRECTLY AND WITH CARE FOR
THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY
CAUSE DAMAGE AND/OR PERSONAL INJURY, AND WILL INVALIDATE THE
WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.
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04
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
SAFETY INFORMATION
• Check that the power supply is switched off prior to electrical connection.
• The appliance, its wiring and piping must not be modified in any way.
• 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 a
competent person.
• Temperatures in excess of approximately 43°C are perceived as hot,
especially by children, and may cause a feeling of burning.
• This appliance must not be used by any person (including children) with
limited physical, sensorial or mental abilities or failing 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 shall not play with the appliance.
• Cleaning and user maintenance shall not be made by children without
supervision.
• When the appliance has been in use for some time, the fittings may be
very hot.
• If inlet temperature is up to 70°C (eg. fed from a solar supply) mixing with
cold water will be required to ensure a safe temperature at the outlet.
• Optimum operation is ensured at a water flow pressure of 0.2 to 0.4 MPa
(2-4 bar). The appliance must not be subjected to pressure exceeding 1.0
MPa (10 bar).
• The required water resistance may not fall below the value stated on the
rating plate at any time.
• The wall bracket must be secured with the supplied screws and dowels.
The ES system must be secured to the wall bracket, and may only be
operated if it has been properly mounted on the wall bracket.
• If the connection cable is damaged , it must be replaced with an original
spare cable from Zip, by an authorised technician, in order to avoid any
hazards.
To observe additionally for pressureless installation.
• The water outlet behind the device must not be blocked, and the water
flow must not be restricted.
• The water outlet facilities, such as shower head, jet control and other
outlet unit , must be de-calcified regularly. Deposits must be removed in
regular intervals.

05
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
SAFETY INFORMATION
• Only the fittings recommended by Zip may be used.
• If the ES system is fitted to a shower, (for instance via a preheated water
supply), only the shower heads recommended by Zip may be used. No
other fittings or appliances which decrease the water flow to the shower
may be installed. For advice on the limitations of the ES system for this
application, call Zip on 0345 6 005 005.
CAUTIONS
• The appliance must only be used when correctly installed and in perfect
working order.
• The appliance must be installed in a frost-free room and must never be
exposed to frost.
• The ES range is not intended for use with thermostatic mixing valves or
taps. If thermostatic mixing valves or taps are to be used, their compatibility
with the instantaneous water heater must be verified under site operating
conditions.
• The appliance must be completely filled with water before being switched
on.
• Before commissioning for the first time and each time the appliance or
the piping system is emptied (e.g. due to work on the plumbing system or
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 appliance must only be used for heating wholesome (cat 1) 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.
• Incoming water temperature must not exceed that stated in Technical data.
• The Zip InLine is intended for connection to mains supply only. In any other
case please contact Zip on 0345 6 005 005 for advice.
• The temperature of hot water produced by the ES is dependant upon flow
rate, supply voltage and incoming water temperature.
• At times of low incoming water temperature (below 12°C) it may be
necessary to reduce the flow rate through the appliance to increase the
hot water temperature.
• Zip Water UK cannot be held liable for any damages caused by failure
to observe these instructions.
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06
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
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06
GENERAL PRODUCT DESCRIPTION
APPROVALS
Zip InLine ES3, ES4 and ES6 instantaneous water heaters are compact electronically controlled
instantaneous water heaters for hand washing.
This small instantaneous water heater is intended to provide economical heating of water for a
wash basin when installed together with a sanitary water fitting. When the hot-water tap is opened,
the heater switches itself on automatically when the minimum water flow rate is exceeded and
heats the water as it passes through the appliance.
The heater is pre-set in the factory to an outlet temperature of about 38°C, which is ideal for
hand washing. When this temperature is reached, the electronic regulator reduces the power in
order to ensure that the outlet temperature does not exceed this value. This automatic temperature
regulation means that it is only necessary to open the hot water tap to obtain water at a constant,
safe temperature for washing hands. If the set outlet temperature is not reached, slightly reduce the
flow of water from the tap. Cold water may be added if a lower temperature is required.
If the flow rate is too low or if the hot water tap is closed, the appliance switches itself off
automatically. For an optimum flow of water, always fit the special aerator insert supplied with the
appliance. This regulator should be inserted into the threaded retainer on the tap outlet.
The maximum possible outlet temperature is determined by the temperature of the incoming
water, the flow rate and the heating power of the heater.
The temperature set point and flow rate can be preset, by an authorised technician, inside the
appliance to achieve an outlet temperature between about 30°C and 43°C.
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 maximum inlet temperature of 70°C is suitable for use with preheated water e.g. from solar
heating systems.
Zip InLine ES3, ES4 and ES6 are VDE approved to the LVD and EMC directives and CE endorsed.
Zip InLine ES3, ES4 and ES6 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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INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
TECHNICAL DATA
Zip InLine
Model ES3 ES4 ES6
Installation Underbasin
Declared load profile XXS
Energy efficiency class (1) A
Energy efficiency (ηwh)(1) % 39
Annual electricity consumption (1) kWh 478 475
Thermostat temperature setting °C 43
Specific precautions See installation and operating instructions
“Smart” value 0
Sound power level dB(A) 15
Rated volume l 0.2
Weight empty / full kg 1.3/1.5
Nominal supply voltage V AC 230
Power rating kW 2.8 4.4 5.5
Rated current A 12 19 24
Protection class IP25
Element type Bare wire
Rated pressure MPa 1.0
Factory set temperature (2) °C 38
Temperature adjustment range °C 30-43
Maximum inlet temperature °C 70
Factory set flow rate @3 bar l/min 2.0 2.5 3.3
Switch on flow rate l/min 1.2 1.5
Switch off flow rate l/min 1.0 1.3
Flow rate @ 38°C(3) l/min 1.5 2.4 3.0
Max temp rise at flows rates shown
above °C 26.7 26.2 26.2
Minimum differential pressure @ 38°C MPa 0.020 0.045 0.065
Specific water resistance @ 15°C Ω.cm >1,100 >800
Packaging dimensions mm 225 x 190 x 130
Water connections 1/2” BSP
(1) EU Regulation 812/2013, 814/2013
(2) Subject to incoming water temperature, flow rate and power available.
(3) Based on 12°C supply temperature, 3 bar dynamic pressure and nominal 230V supply voltage.
All data quoted at nominal supply voltage. Standard European voltage tolerances of -6% to +10% may be applied.
A minimum water pressure of 0.2 MPa (2 bar) is recommended for optimum performance.

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INSTALLATION INSTRUCTIONS & USER MANUAL
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DIMENSIONS
186mm
135mm
87mm
Instantaneous performance calculations
Temperature rise °C = (Nominal power rating (kW) x 14.3)
Flow per minute (litres)
TECHNICAL DATA

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INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
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SPARE PARTS
Front cover
IN80919
Heating cartridge
IN80916 ES3
IN80904 ES4
IN80917 ES6
Safety temperature
limiter
IN80911 ES3
N80912 ES4, ES6
Fine filter
IN80080
Wall bracket
IN80902
IN80910 Temperature sensor (not shown)
ZL011 Aerator insert for ES3 and ES4 (not shown)
ZL010 Aerator insert for ES6 (not shown)
When ordering spare parts, please always specify the appliance model and serial number.

10
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
INSTALLATION
Requirement
• 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 0345 6 005 005.
• 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.
• 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.
Installation site
• The installation site must be free from frost at all times.
• For maintenance work, install a shut off valve in the water supply line to the heater.
• The unit should be positioned as close as possible to the outlet to minimise heat loss. The
recommended maximum distance is 0.5 metres.
• When considering the location of the heater, consideration should be given to the safe and
visible disposal of any water resulting from leaks and seepage. This is particularly relevant
when the heater is located in a cupboard or any concealed location. For guidance please call
Zip on 0345 6 005 005.
• 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 >1,100Ωcm at 15°C for ES3 and
>800Ωcm at 15°C for ES4 and ES6. The specific resistance can be checked with the local
water supply company.
• For safe operation of this instantaneous water heater, a non return valve is not required. If,
nevertheless, a non return valve has to be installed, it may only be placed in the hot water
outlet line behind the instantaneous water heater.
• The minimum requirements for the required water resistance must be complied with. The
required water resistance of the can be obtained from your water supply company.
• For guidance please call Zip on 0345 6 005 005.
• The hot water temperature may not exceed 55 °C if the ES system is connected to a shower.
If the appliance is operated with preheated water, it must be ensured that its temperature is
also limited to 55 °C by the customer.
Shower application

11
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
INSTALLATION
Installing the appliance
• Secure the wall bracket to the wall with screws and wall plugs supplied (Fig. 1).
• Place the appliance on the wall bracket and snap into position (Fig. 2).
Note This appliance is intended for under-basin installation with the water connections pointing
vertically upwards.
Fig. 2Fig. 1
Drill size Ø 7mm.
Use the mounting bracket as
a guide for fixing marks.
Drilling width variable:
100mm minimum to
145mm maximum.
To remove the appliance from the wall bracket
Put the flat screwdriver tip into the interlock between the water connections until it stops and lift it
slightly upwards (Fig. A), tilt the appliance forward by max. 15° (Fig. B) and remove it upwards (Fig. C).
A
BC

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INSTALLATION INSTRUCTIONS & USER MANUAL
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INSTALLATION
Seal
Seal
Hot Water
Connection
(outlet)
Filter
Cold Water
Connection
(inlet)
Fig. 3
Plumbing connection (Fig. 3)
• The cold water inlet (blue) and hot water outlet (red) are marked on the rating plate. Connect
the appropriate pipes from the tap to the water inlet and outlet accordingly. Avoid exerting any
mechanical pressure on the appliance by applying a 13mm spanner on the flats of the inlet and
outlet connections when tightening the pipe connectors (Fig.3).
• When supplying mixer taps a non-return valve must be fitted to the hot water outlet and not to
the cold water inlet (Fig. 5).
• A flow control valve may be required on the cold supply to the mixer taps to balance the flow
(Fig. 5).
• Thoroughly flush the water supply pipes before connection to remove any water borne debris.
• Once the water connections have been made, check for any leaks and rectify as necessary.
• In order to obtain an optimum water jet at low flow rates, always screw the aerator insert
supplied with the unit onto the tap outlet. This insert fits commercially available sleeves with
an M22 or M24 thread.

13
INSTALLATION INSTRUCTIONS & USER MANUAL
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TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
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Typical installation
• Fig. 4 shows open vented installation.
• Fig. 5 show unvented installation with closed outlet tap.
Fig. 4
Fig. 5
Service Valve
Flow Control Valve
Mains Supply
Fit Aerator insert
Aerator insert
Rear Cable Entry
Non-return
valve
INSTALLATION

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INSTALLATION INSTRUCTIONS & USER MANUAL
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ELECTRICAL CONNECTION
Electrical connection
Do not switch on the electric power at this time.
Installation must be carried out by a competent electrician.
The electrical installation including earthing and cross bonding should comply with current IEE
regulations and any Local Authority requirements.
IMPORTANT The appliance must be installed according to the specification on the rating plate and
the technical specifications. Ensure that the voltage marked on the appliance matches the power
supply.
WARNING:
Check that the power supply is switched off prior to electrical connection!
Fig. 6
3
2
1
Wiring Diagram
1. Electronic regulator
2. Safety thermal cut-out
3. Heating element
PE
L L1
N L2
COMMISSIONING
Purging
Before turning on the electrical supply, open and close the hot water tap until the water runs
smoothly and no more air emerges.
Note Every time the appliance is drained (e.g. after work on the plumbing system, if there is a risk
of frost or following repair work), the heater must be purged in this way before reconnecting the
power supply.
WARNING! This appliance must be earthed
• Turn on the electrical supply, after a short power up delay the water heats up.
• Check everything is working as it should and the water temperature is achieving the desired
temperature. If not follow the guide on pages 15/16.
CAUTION
To prevent damage to the appliance, the instantaneous water heater must be purged of air
before using it for the first time
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15
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
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COMMISSIONING
Note When used to supply a mixer tap a flow restrictor may be required on the cold supply to the
tap to balance the flows.
For further information see the Fault Finding table, page 19.
When the unit has been commissioned, explain the functions of the heater to the end user and
ensure they know how to use the appliance.
Hand over these instructions for the user to keep.
Removing the cover (Fig. 7)
The rating plate and the hood screw are located under this cover.
• Push the cover back towards the wall bracket.
• At the rear corners press the cover down until the front edge lifts.
• Remove the cover by pulling forward.
The underside of the cover (Fig. 8) is the data plate and displays model
type, serial number etc.
Replacing the cover (Fig. 9)
• Push the cover towards the wall bracket under the edges of the
water connections.
• Press down the front edge of the cover and move it forward again
until it clips into place.
Fig. 8
Fig. 9
Fig. 7
Appliance must be earthed!
Zip Industries
ES3 1500-15001
012345-012345
MADE IN
GERMANY
Temperature & flow adjustment (to be undertaken by an authorised technician only)
The factory setting is 38°C. A maximum outlet temperature may be set between 30°C and 43°C.
Water too hot
• If the water is too hot reduce the temperature on the appliance by turning the potentiometer (Fig.10,
page 16) anticlockwise instead of mixing with cold water.
Any cold water added is not controlled by the electronic circuitry meaning that precise
temperature control can no longer be guaranteed.
Note Adding cold water wastes the energy used to heat it! This unit is not intended for use with a
‘thermostatic mixing valve’or tap.

16
INSTALLATION INSTRUCTIONS & USER MANUAL
210011 V2.02 MAY 2018 -ZIP ES
TECHNICAL SUPPORT TEL: [phone] EMAIL: SERVICE@ZIPINDUSTRIES .CO.UK
WWW.ZIPWATER.CO.UK
COMMISSIONING
Cover removed
Water too cold
May only be carried out by an authorised technician, call Zip on 0345 6 005 005.
Remove the cover (see Fig. 7), undo the hood screw underneath and remove the hood.
• Increase the temperature by turning the potentiometer clockwise until the desired temperature
is achieved.
• If the desired temperature cannot be achieved the red LED on the PCB will light (constant) to
show that the unit cannot achieve the preset temperature. (See LED functions on page 18).
• In this case it will be necessary to adjust the water flow through the unit.
• The flow rate can be adjusted with the adjustment screw (Fig. 11).
• Turning this screw clockwise reduces the flow rate; turning it anti-clockwise increases the flow
rate.
• Turn the adjustment screw clockwise; reducing the flow rate until the desired temperature is
achieved.
Fig. 10
min. max.
Green LED
Heat setting
potentiometer
Red LED
Fig. 11

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General cleaning
Plastic surfaces and fittings should only be wiped with a damp cloth. Do not use abrasive or
chlorine-based cleaning agents or solvents.
The outlet fittings (special tap aerators and shower heads) should be unscrewed and cleaned at
regular intervals.
The electrical and plumbing components should be inspected at least every 3 years by a
competent person familiar with instantaneous water heaters, to ensure proper functioning and
operational safety . Water quality should be considered when determining the frequency of
inspection.
MAINTENANCE
Note Maintenance work must only be carried out by a competent person familiar with
instantaneous water heaters.
Outlet fittings (aerator insert Fig. 5 page 13) should be unscrewed from the tap nozzle and
cleaned at regular intervals.
• Rinse the regulator with water and brush off the debris. For difficult to remove deposits,
soak in white vinegar (or a proprietary scale cleaner) for a few minutes and scrub with a
toothbrush.
• If any parts are cracked or broken, replace them. If the washer has hardened, it should be
replaced.
• With the debris cleaned out, screw the regulator back into the tap. Hand tightening should be
adequate.

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REPAIRS
Repairs
• 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 on 0345 6 005 005.
• When calling for service, please always specify the appliance model and serial number.
• The fault finding table on page 19 will be helpful in determining the causes of some common
problems and their solutions.
LED Functions
Green LED
Green LED flashing Standby mode
Green LED constantly on Appliance is heating water
Red LED
Red LED constantly on The required outlet temperature cannot be achieved
at maximum power
Red LED flash code
Long- short-long-short-long Heating element defective
Long-short-short-short Temperature sensor faulty
Long-short-long Air bubble in system

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Problem Possible cause Solution
No water flows Water supply is turned
off Open the main water valve / shut off valve
Water flows
more slowly than
expected
The aerator insert is not
fitted Fit the correct aerator insert, see Fig. 5
Water pressure is not
sufficient
Check the water flow pressure,
authorised technician to check the water flow
adjustment, see Fig. 11
Dirt in the pipes Remove any dirt from the
filter, valves and / or taps
The heater
switches itself on
and off
Water pressure is
varying, flow rate is too
low
Remove any dirt, increase the flow water pressure,
close other taps, open the shut off valve further
Water remains
cold
Water pressure is not
sufficient
Authorised technician to adjust the
water flow see Fig. 11
Open the shut-off valve
Fit the correct aerator insert, see Fig. 5
Check water pressure
Dirt in the inlet or outlet Remove dirt from the inlet and outlet
Temperature sensor
defective
Replace temperature sensor
(authorised technician)
Heating element
defective Replace heating element (authorised technician)
Hot water
temperature
varies
Supply voltage varies Check the supply voltage
Water connections
reversed Check installation
Hot water
temperature
too low & 1 LED
flashes
Flow rate is too high Adjust the flow rate, see Fig. 11
(authorised technician only)
Inlet temperature is
too low
Adjust temperature
potentiometer, see Fig. 10
(authorised technician only)
FAULT FINDING
If the connection cable is damaged, it must be replaced with an original spare cable from Zip by
an authorised technician in order to avoid any hazards.
If you cannot rectify the fault with the aid of the troubleshooting table, please contact Zip
customer service on 0345 6 005 005.

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END OF LIFE DISPOSAL
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 Service for advice on 0345 6 005 005.