Contents
Specification 2
Performance 2
Dimensions 3
Parts List 3-4
Installation
Requirements 4-6
Positioning 7-8
Plumbing 8
Electrical 9
Commissioning 9-10
Maintenance
Precautions 10-11
Schedule 11
Fault Finding 12
Draining 13
De-Installation 13
Warranty 14
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 Aquapoint 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.
AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions 2 1 AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions
Specification
Product: Zip Aquapoint III
Type: Direct unvented
Capacity: 30 litre, 50 litre, 80 litre, 100 litre
Loading: 3.0kW/230v~
Fuse Rating: 15A
Thermostat: Adjustable 25ºC to 75ºC
Thermal cut-out: Manually re-settable set to 84+0/-5ºC
Water vessel: Glass enamelled steel tested to 13 bar. Maximum working
pressure 6 bar
Insulation: High performance foam insulation
Controls: Pressure reducing valve and line strainer set to 3.5 bar
Expansion relief and single check valve set to 6 bar
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 AP3/30, AP3/50
8 litre AP3/80, AP3/100
Approvals: Zip Aquapoint III complies with LVD and EMC directives and
is CE endorsed. Zip Aquapoint 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.
Performance
Size Model Heat up time Re-heat time
(15° to 65ºC) (70% vol.)
30 litre AP3/30 37mins 23mins
50 litre AP3/50 58mins 38mins
80 litre AP3/80 88mins 58mins
100 litre AP3/100 110mins 72mins
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
• Zip Aquapoint hot water cylinder wall locating bracket
• Tundish
Installation
Requirements
General
Prior to installation the Zip Aquapoint should be kept upright in its original
packaging and handled with care always lifting from underneath.
The Zip Aquapoint 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
0870 6088888.
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 Aquapoint 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 Aquapoint 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
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.
AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions 4
3 AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions
Dimensions
Aquapoint Capacity Width Height Depth Weight Weight
(litres) (mm) (mm) (mm) Empty (kg) Full (kg)
AP3/30 30 420 525 445 19 49
AP3/50 50 420 690 445 24 74
AP3/80 80 420 950 445 28 108
AP3/100 100 420 1125 445 31 131
Parts List
1 Temperature and pressure relief valve
2 Combined strainer and pressure reducing valve
3 Expansion relief and check valve
4 Balanced cold water take off
5 Expansion vessel
6 Temperature control
7 Neon indicator
The Zip Aquapoint hot water cylinder will be 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
• Pressure and temperature relief valve
1
2
3
4
5
7
To drain
via tundish
Hot water
outlet
Cold water
supply
6
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
notbe 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
Sizing of copper discharge pipe ‘D2’ for common temperature
relief valve outlet sizes
Maximum resistance Resistance
Valve Minimum size Minimum size of allowed, expressed as a created by
outlet of discharge discharge pipe D2 length of straight pipe each elbow
size pipe D1 from tundish (i.e. no elbows or bends) or bend
22mm up to 9m 0.8m
G
1
/
2 15mm 28mm up to 18m 1.0m
35mm up to 27m 1.4m
28mm up to 9m 1.0m
G
3
/
4 22mm 35mm up to 18m 1.4m
42mm up to 27m 1.7m
35mm up to 9m 1.4m
G 1 28mm 42mm up to 18m 1.7m
54mm up to 27m 2.3m
AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions 6
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 Aquapoint 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 Aquapoint 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 and
table for sizing copper discharge pipe.
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.
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
5 AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions
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 0870 608 8888.
Plumbing
1. The unit should be provided with a continuous cold water supply via
22mm pipework.
2. The water connections are
1
/
2" BSP at the bottom of the appliance. When
viewed from the front, the cold feed connection is to the right and colour
coded blue, the hot outlet from the heater is to the left and colour coded red.
3. The inlet and outlet pipes to the heater should be sealed using fibre
washers. Complete the seal by applying PTFE tape to the threads, but
do not over apply or extend beyond the limits of the thread as this will
lessen the effectiveness of the joint.
4. An isolating valve (not supplied) should 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.
Note: This connection should not be used to supply cold taps.
10. Flush all pipe work 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.
AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions 8
Positioning
The Zip Aquapoint 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 Aquapoint 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. Reasonable clearance will be required to
give access to pressure controls, element assembly, draining facility, pipe
connections and expansion vessel.
A gap of 250mm should be left between the top of the unit and the ceiling. A
gap of 350mm 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.
Fix the Zip Aquapoint hot water cylinder locating bracket to the wall with suitable fixings as shown in the diagram and table of dimensions below.
ABC
AP3/30 525 310 240
AP3/50 690 470 250
AP3/80 950 735 245
AP3/100 1125 900 245
Position the Zip Aquapoint 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.
++
7 AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions
through the discharge pipe by turning the knob to the left and holding
in the open position
11. Set the thermostat(s) to the desired temperature setting. The ‘E’ position
with a water temperature of approx. 55ºC is recommended for economical
operation while minimising lime-scale deposits and thermal losses
12. Switch on the electrical supply to the unit. The pilot light will illuminate to
indicate that the elements are operating
13. During the heating cycle no water should escape to waste from either the
expansion relief or T&P relief valves
14. 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
15. Pass these instructions to the person responsible for the building
management
Maintenance
Precautions
1. The Zip Aquapoint 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
AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions 10
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 15A.
All internal wiring is factory mounted and should not be altered or modified.
A suitable supply cable should be fed through the grommet on the underside
of the appliance, connected to the live, neutral and earth connections on the
terminal block and secured with the cable clamp provided.
Check all electrical connections for security and tightness.
The appliance has a working thermostat adjustable between 25ºC 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 the T&P relief valve
10. Manually operate Expansion Relief Valve to ensure free water flow
9 AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions
Fault Finding
Note: 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 contact
The thermostat is set at the installer. Note: Isolate the
too high a temperature electrical supply before
removing the electrical cover
panel and ensure that the
panel is correctly replaced and
secured before reconnecting
Regular, intermittent Loss of pressure from the Isolate the heating system and
water discharge from expansion vessel the mains cold water supply.
tundish Partly drain the unit. Recharge 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 Check and replace if faulty
not operating correctly
No water flow from Cold water mains supply Restore mains supply to the heater
hot taps isolated
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 taps Power supply not Check and switch on
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
AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions 12
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. The ‘E’ temperature setting is
recommended
10. If the unit has been commissioned and is to be unused for more than
two weeks with the power supply still connected the thermostat should
be set to ‘*’ to maintain a temperature of approx. 9ºC and protect the unit
from freezing. Note: this protection does not extend to connecting
pipework. It is recommended that the cold supply is turned off
and several litres of water drawn off through a hot tap. Note: The cold
supply must be re-opened prior to use. If power has been
disconnected it is recommended that the unit is drained (see draining)
11. The Zip Aquapoint is fitted with a sacrificial anode to provide additional
protection against corrosion. Gradual erosion of the sacrificial anode
will occur depending upon local conditions which in extreme cases
may cause rapid erosion of the anode resulting in particles being
deposited as a residue. The Aquapoint should not, therefore, be used
in applications where water quality is critical. Regular preventive
maintenance inspections are vital to achieve optimum performance and
durability of the appliance. The condition of the anode should be
checked regularly by an authorised Zip service provider as part of the
preventive maintenance programme.
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 for 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
7. Check condition of the sacrificial anode by disconnecting the wire
between the anode and vessel and verifying that the current between
anode and vessel exceeds 0.1mA ensuring that the wire is re-connected
afterwards. If the current between anode and vessel does not exceed
0.1mA the anode should be checked visually and replaced if necessary
11 AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions
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
13 AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions
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 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 0870 608 8888
Telefax 01362 692448
www.zipheaters.co.uk
AP3/30, AP3/50, AP3/80, AP3/100 Installation Instructions 14
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