Zip VP303 Mounting instructions

ZIP Varipoint III
Models VP303, VP503
VP803, VP953
direct unvented water heaters
Issued August 2008
Installation, Maintenance
and User Instructions
Please read these instructions carefully before commencing installation
of the Varipoint unvented 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]
Facsimile 01362 692448
www.zipheaters.co.uk
[email protected]
The terms ‘Zip’ and ‘Varipoint’ are registered trademarks.
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Contents
Specification 4
Dimensions 5
Parts List 5
Installation
Requirements 6
Positioning 9
Plumbing 10
Electrical 11
Commissioning 12
Maintenance
Precautions 13
Schedule 13
Fault Finding 14
Draining 15
De-Installation 15
Warranty 16
Installation must only be undertaken by a
competent person holding a current Registered
Operative Identity card for the installation of
unvented domestic hot water storage systems
issued by an accredited body.
The Zip Varipoint 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 Varipoint III
Type: Direct unvented
Capacity: 30 litre, 50 litre, 80 litre, 100 litre
Loading: 3.0kW / 240V~ (2,755W / 230V~)
Fuse Rating: 13A
Thermostat: Adjustable 37ºC to 75ºC
Thermal cut-out: Manually re-settable set to 84+0/-5ºC
Water vessel: Heavy gauge copper construction tested to 12 bar
Maximum working pressure 6 bar
Insulation: High performance CFC free polyurethane foam insulation
Controls: Pressure reducing valve set to 3.5 bar with line strainer
Expansion relief set to 6 bar with single check valve
Pressure and temperature relief valve set to 7 bar and 90ºC
External expansion vessel pre-charged to 3.5 bar
Expansion vessel capacity: 5 litre – 30 and 50L Varipoint
8 litre – 80 and 100L Varipoint
Approvals: Zip Varipoint III complies with the LVD and EMC directives
and is CE endorsed.
Zip Varipoint III has been examined, 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: Capacity: Heat up time: Re-heat time:
(litres) (15 to 65ºC) (70% volume)
minutes minutes
VP303 34 38 25
VP503 50 61 42
VP803 80 96 67
VP953 100 130 91
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Dimensions
Varipoint Capacity Width Height Depth Weight Weight
(litres) (mm) (mm) (mm) Empty (kg) Full (kg)
VP303 34 430 620 448 16 50
VP503 50 430 808 448 20 70
VP803 80 485 946 503 27 107
VP953 100 485 1091 503 33 133
Typical Installation
Parts List
To drain via tundish
Cold water supply
To drain via tundish
Hot water outlet
1
2
9
3
4
5
6
7
8
1 Temperature and pressure relief valve
2 Combined pressure reducing valve and strainer
3 Expansion relief and check valve
4 Balanced cold water take off
5 Expansion vessel
6 Tee piece and drain valve
7 Temperature control
8 Neon indicator
9 Service valve (not supplied)
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The Zip Varipoint hot water cylinder is delivered in its carton with the various
control valves and fittings supplied in a separate carton. Both should be left
packed until needed.
Factory Fitted Components
• Heating elements
• Thermostats with over temperature cut-outs
• Temperature and pressure relief valve
Components supplied with the unit for site fitting
• Inlet manifold assembly comprising pressure reducing valve with integral
line strainer and expansion relief valve with check valve and balanced
cold water take off.
• Expansion vessel and wall fixing bracket
• Tee piece and drain valve
• Zip Varipoint hot water cylinder wall locating bracket
• Tundish
Installation
Requirements
General
Prior to installation the Zip Varipoint should be kept upright in its original
packaging and handled with care always lifting from underneath.
The Zip Varipoint should be stored in a covered, dry area protected at all times
from the weather.
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.
Installation must only be undertaken by a competent person holding a
current Registered Operative Identity card for the installation of unvented
domestic hot water storage systems issued by an accredited body.
The Zip Varipoint 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.
All connections should be made to the Zip Varipoint and its safety devices using
the 15mm or 22mm compression fittings, nuts and olives supplied.
The electrical installation including earthing and cross bonding must comply
with the current IEE regulations and any Local Authority requirements.
The cold water feed manifold assembly comprises a pressure reducing valve
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with integral strainer, expansion relief and check valve, factory fitted pressure
and temperature relief valve and expansion vessel. All of these components
must be included in the installation. The pressure settings on these
components are factory set and indicated on the top of the valve. 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.
It is recommended that the unit is installed according to these instructions.
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.
An isolating valve must be fitted to the cold water supply to the inlet manifold.
The Zip Varipoint is designed for use with a supply pressure up to 12 bar. For
supply pressures exceeding 12 bar an additional pressure reducing valve must
be fitted in the cold water supply to the unit.
Secondary Circulation
The Zip Varipoint is not recommended for use with secondary circulation
systems.
Discharge
The expansion relief and temperature and pressure relief valves should drain
via a tundish which should be installed in a visible location and away from any
electrical devices.
The discharge pipe from the tundish should terminate in a safe place where
there is no risk to persons in the vicinity of the discharge, be of metal and:
a) Be at least one pipe size larger than the nominal outlet size of the safety
device unless its total equivalent hydraulic resistance exceeds that of a
straight pipe 9m long. Discharge pipes between 9m and 18m equivalent
resistance length should be at least 2 sizes larger than the nominal outlet
size of the safety device, between 18 and 27m at least 3 sizes larger, and
so on. Bends must be taken into account in calculating the flow resistance.
See diagram of typical discharge pipe arrangement on page 8 and table for
sizing copper discharge pipe on page 9.
b) Have a vertical section of pipe at least 300mm long, below the tundish
before any elbows or bends in the pipework.
c) Be installed with a continuous fall.
d) Have discharges visible at both the tundish and the final point of discharge
but where this is not possible or it is practically difficult there should be
clear visibility at one or other of these locations. Examples of acceptable
discharge arrangements are:
1. Ideally below a fixed grating and above the water seal in a trapped gully.
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2. Downward discharges at a low level: i.e. up to 100mm above external
surfaces such as car parks, hard standings, grassed areas etc. are
acceptable providing that where children may play or otherwise come
into contact with discharges, a wire cage or similar guard is positioned
to prevent contact, whilst maintaining visibility.
3. Discharges at high level: e.g. into metal hopper and metal down-pipe with
the end of the discharge pipe clearly visible (tundish visible or not) or onto
a roof capable of withstanding high temperature discharges of water and
3m from any plastic guttering system that would collect such discharges
(tundish visible).
4. Where a single pipe serves a number of discharges, such as in blocks of
flats, the number served should be limited to not more than 6 systems so
that any installation can be traced reasonably easily. The single common
discharge pipe should be at least one pipe size larger than the largest
individual discharge pipe to be connected. If unvented hot water storage
systems are installed where discharges from safety devices may not be
apparent e.g. in dwellings occupied by blind, infirm or disabled people,
consideration should be given to the installation of an electronically
operated device to warn when discharge takes place.
Note: The discharge will consist of scalding water and steam. Asphalt, roofing
felt and non-metallic rainwater goods may be damaged by such discharges.
Typical discharge pipe arrangement
Safety device
(e.g. temperature relief valve)
500mm maximum
Tundish
300mm
minimum
Metal discharge pipe (D1) from
temperature relief valve to tundish
Discharge below
fixed grating (3.9d
gives alternative
points of discharge)
Fixed grating
Trapped gulley
Metal discharge pipe (D2) from tundish,
with continuous fall. See 3.9d i-iv.
Table 1 and worked example
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Sizing of copper discharge pipe ‘D2’
for common temperature relief valve outlet sizes
Valve Minimum size Minimum size Maximum resistance Resistance
outlet of discharge of discharge allowed, expressed created by
size pipe D1 pipe D2 from as a length of straight each elbow
(mm) tundish pipe (i.e. no elbows or bend
(mm) or bends) (metres)
(metres)
22 up to 9 0.8
G ½ 15 28 up to 18 1.0
35 up to 27 1.4
28 up to 9 1.0
G ¾ 22 35 up to 18 1.4
42 up to 27 1.7
35 up to 9 1.4
G 1 28 42 up to 18 1.7
54 up to 27 2.3
Positioning
The Zip Varipoint should be installed vertically with the electrical cover panel and
water connections underneath.
The unit is designed to be wall mounted using the wall fixings supplied with the
product. Ensure that the wall where the unit is to be located is sufficiently strong
to support the full weight of the unit (see dimensions) and capable of accepting
suitable fixings.
Position the Zip Varipoint to allow for provision of the cold water supply,
discharge fittings and pipework as well as access for future maintenance, repair
of the unit or its replacement.
N.B. Reasonable clearance will be required to give access to pressure
controls, element assembly, draining facility, pipe connections and
expansion vessel.
A minimum distance of 250mm should be allowed between the locating
bracket and the ceiling. A gap of 400mm should be left between the bottom of
the unit and any floor or work surface.
Do not install in a location where the unit or connecting pipework can freeze.
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Fix the Zip Varipoint hot water cylinder locating bracket to the wall with suitable
fixings as shown in the diagram and table of dimensions below.
All dimensions (mm)
Position the Zip Varipoint securely on the locating bracket.
The expansion vessel should be securely fitted to a suitable and convenient
wall using the fittings supplied and positioned to enable its connection to the
manifold assembly.
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 ring Zip
Heaters on 0845 602 4533.
Plumbing
1. The unit should be provided with a cold water supply via 22mm pipework.
2. The water connections are at the bottom of the appliance and suitable for
either 15mm compression or ½” BSP fittings. When viewed from the front,
the cold feed connection is to the right and the hot outlet from the heater is
to the left.
3. The Tee piece and drain valve supplied should be installed on the cold feed
to the heater to enable it to be drained down for servicing or replacement.
Min. 250
85 70
A
B340 60 C
D
Min. 400
A B C D
(mm) (mm) (mm) (mm)
VP303 376 460 430 448
VP503 564 648 430 448
VP803 705 786 485 503
VP953 850 931 485 503
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4. An isolating valve (not supplied) must be fitted in the cold water supply
pipework to the inlet manifold assembly to enable isolation of the water
supply to the unit for servicing or replacement.
5. Fit the inlet manifold assembly to the 22mm supply pipework with the valve
caps facing upwards and in the correct direction of flow as indicated by
the arrows.
6. The pressure gauge connection point on the manifold assembly should be
accessible for connection of a pressure gauge if necessary.
7. Provide suitable drainage from the Expansion Relief and Temperature &
Pressure Relief Valves via the tundish using 15mm copper tube. Refer to
installation requirements.
8. Connect the expansion vessel to the manifold assembly using 15mm
copper tube.
9. A balanced mains pressure cold water supply for a shower may be
provided from the connection provided on the manifold assembly,
otherwise this should be blanked.
10. Flush all pipework thoroughly before making the final connections from the
cold supply to the manifold assembly to ensure that any debris is removed.
Failure to do this may result in irreparable damage to the controls and will
invalidate the warranty.
11. Connect the hot water supply pipe to the outlet from the heater.
12. Connect the discharge pipe from the tundish. Refer to Installation
Requirements on page 6 and Typical Installation drawing on page 5.
Electrical
Switch off the mains electrical supply before removing the electrical cover panel
or carrying out any work involving a live circuit or access to components that
may be live.
Do not switch on the electrical supply until the unit is full of water.
This appliance must be earthed.
The electrical connection to the heating elements must conform to current IEE
wiring regulations and be permanently connected to the electrical supply
through a double-pole isolating switch with at least 3mm contact separation in
each pole and with a minimum rating of 13A.
All internal wiring is factory mounted and should not be altered or modified.
After removing the electrical cover panel, a suitable supply cable should be fed
through the cable clamp on the underside of the appliance, connected to the
live and neutral connections on the terminal block and earth terminal on the
element plate before securing with the cable clamp.
Check all electrical connections for security and tightness before replacing the
electrical cover panel.
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The appliance has a working thermostat adjustable between 37ºC and 75ºC.
An over temperature cut-out is incorporated within the thermostat which is
designed to operate at 79-84ºC. Should this happen, press the reset button.
Important: Before resetting the over temperature cut-out or altering the
thermostat setting, isolate the electrical supply to the unit before
removing the electrical cover panel. Ensure that the cover panel is
replaced correctly and the retaining screws fitted before re-connecting
the electrical supply.
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. Check that the expansion vessel pressure is correct – refer to label on
vessel for correct pressure
4. Check that the drain valve on the inlet manifold is closed
5. Open hot water taps
6. Open the cold water supply valve and permit the heater to fill
7. Leave hot taps open until all air has been purged from the system and water
is flowing freely from all outlets
8. Check for leaks and rectify as necessary
9. Check the operation of both the T&P relief valve and the 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
10. Set the thermostat(s) to the desired temperature setting. A water
temperature of approx. 55ºC is recommended for economical operation
while minimising lime-scale deposits and thermal losses.
11. Switch on the electrical supply to the unit. The pilot light will illuminate to
indicate that the elements are operating.
12. During the heating cycle no water should escape to waste from either the
expansion relief or T&P relief valves
13. 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
14. Pass these instructions to the person responsible for the building
management
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Maintenance
Precautions
1. The Zip Varipoint 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 electrical cover panel whilst the unit is connected to the
electrical supply
3. 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.
10. If power has been disconnected it is recommended that the unit is drained
(see draining).
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. Expansion relief valve. Check correct operation
2. T&P relief valve. Check for correct operation
3. Check expansion vessel pressure – refer to label on vessel for correct pressure
4. Inspect integral line strainer and clean as necessary
5. Check that the discharge pipework is free of any obstructions
6. Check that all electrical connections are tight
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Fault Finding
NB All servicing and repairs must be undertaken by a competent person,
familiar with unvented systems.
Fault Possible Cause Solution
Over temperature The thermostat has failed Reset. If the cut-out operates
cut-out operates again isolate the unit and
The thermostat is set at contact the installer.
too high a temperature NB Isolate the electrical supply
before removing the electrical
cover panel and ensure that the
panel is correctly replaced and
secured before reconnecting
Regular, Loss of pressure from Isolate the heating system and
intermittent water the expansion vessel the mains cold water supply.
discharge from Partly drain the unit. Recharge
tundish the expansion vessel to the
specified pressure and
re-commission.
Thermostat failure Isolate the heating system and
check thermal controls when
discharge ceases. Replace
thermostat if faulty.
Continuous water Pressure reducing valve Check with pressure gauge and
discharge from not operating correctly replace as necessary
the tundish P&T relief valve not Check and replace if faulty
operating correctly
Expansion relief valve not Check and replace if faulty
operating correctly
No water flow Cold water mains supply Restore mains supply to the
from hot taps isolated heater
Integral line strainer in Check and clean as necessary
pressure reducing valve
has become blocked
Pressure reducing valve Refit correctly with arrows in
incorrectly fitted direction of flow
Water from hot Power supply not Check and switch on
taps is cold switched on
Over temperature See fault “Over temperature
cut-out has operated cut-out operates” above
Faulty element Check and replace as necessary
Thermostat failure Check and replace as necessary
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Draining
To drain the unit:
1. Isolate the electrical supply
2. Isolate the mains cold water supply to the unit
3. Open a hot water tap
4. Remove the plug from the drain point on the heater
5. Connect a suitable hose to the drain point to allow the contents to be
drained safely
6. Open the drain valve and allow the unit to drain
De-Installation
To de-install the heater
1. Switch off and disconnect the electrical supply
2. Close the mains water supply isolating valve
3. Drain the heater as described in “Draining”
4. Disconnect the cold water inlet connection from the manifold assembly
5. Disconnect the hot water supply pipe from the heater outlet
6. Remove the heater
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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 the cylinder fail within five (5) years
or any component fail within two (2) years 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
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