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 0845 6024533

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

DBX DEX cov r qxd:Varipoint cov r qxd 6/5/11 10:46 Pag 2

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.

DBX DEX q d:Varipoint q d 20/5/11 13:34 Page 1

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.

DBX DEX q d:Varipoint q d 20/5/11 13:34 Page 2

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

t = 28K 9.2(2) 10.7(2) 12.3(2) 13.8(2)

Maximum at

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

DBX DEX q d:Varipoint q d 20/5/11 13:34 Page 4

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.

DBX DEX q d:Varipoint q d 20/5/11 13:34 Page 6

DEX & DBX Installation, aintenance and User Instructions - April 2011 7

Fig 1

Fig 2

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.

DBX DEX q d:Varipoint q d 20/5/11 13:34 Page 7

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.

DBX DEX q d:Varipoint q d 20/5/11 13:34 Page 8

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