Back cover Front cover A5_Booklet Installation, Maintenance and User Instructions AquaFlo II Unvented Water Heaters Issued October 2012 The terms ‘Zip’ and ‘InLine’ are registered trademarks Zip Heaters (UK) Ltd. 14 Bertie Ward Way Dereham Norfolk NR19 1TE Telephone: 0845 6024533 Fax: 01362 692448 Web: www.zipindustries.co.uk Please read these instructions carefully before commencing installation. Please leave these instructions with the end user after installation.
Inside Back cover Inside Front cover
Contents 1 Description 2 Approvals 2 Safety Information 3 Technical data 4 / 12 Parts List 13 Installation 14 Requirements 14 Installation Site 15 Installing the appliance 15 Electrical connection / circuit diagram 20 / 21 Commissioning 22 Annual servicing 23 Warranty 24 Please read these instructions carefully before commencing installation of the AquaFlo unvented Water Heater. Please leave these instructions with the end user after installation.
Description The corrosion resistant Zip AquaFlo Unvented cylinder is made from Duplex Stainless Steel. It is highly insulated with environmentally friendly foam enclosed in a rust resistant white steel case. It is available in Direct and Indirect versions in a family of 7 sizes from 90 – 300 litres. Triple element options are available on Direct 210 – 300 litre units. Twin Coil and Solar Direct units are available in 5 sizes from 150 - 300 litres.
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. WARNING: Indicates a potentially hazardous situation, which, if not avoided, could result in death and/or serious injury and/or property damage.
CAUTION! • 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 authorised Zip service engineer. • If siting outside the heating envelope of the dwelling such as a garage or outbuilding then frost protection should be provided and exposed pipework should be insulated. • The appliance must be completely filled with water before being switched on.
Connection Points AquaFlo Direct 45° Cold Inlet Immersion 15° T&P Valve AquaFlo Indirect and Solar Compatible 66° Sec Return 40° Primary Coil 25° Stat Pocket AquaFlo Installation, Maintenance and User Instructions 38° Cold Inlet 35° 15° Primary Coil T&P Valve Immersion Page 5 of 24 V 2.
AquaFlo Direct Dimensions Model AF3090 AF3120 AF3150 AF3180 AF3210 AF3250 AF3300 (Litres) 90 120 150 180 210 250 300 Diameter (mm) 545 545 545 545 545 545 545 Height (mm) A 727 915 1102 1290 1478 1728 2041 T & P Valve (mm) B 515 703 890 1078 1266 1516 1829 Sec.
AQUAfLo InDIrECT DImEnSIonS Model nominal Capacity (Litres) AF4090 AF4120 AF4150 AF4180 AF4210 AF4250 AF4300 90 120 150 180 210 250 300 545 545 545 545 545 545 545 Diameter (mm) Height (mm) A 727 915 1102 1290 1478 1728 2041 T & P valve (mm) B 515 703 890 1078 1266 1516 1829 Sec.
AquaFlo Solar Twin Coil Dimensions Model Nominal Capacity (Litres) AF5150 AF5180 AF5210 AF5250 AF5300 150 180 210 250 300 545 545 545 545 545 Diameter (mm) Height (mm) A 1102 1290 1478 1728 2041 Solar High Limit Thermostat Pocket (mm) B 890 1078 1266 1516 1829 Solar Auxillary Pocket (mm) C 890 1078 1266 1516 1829 T & P Valve (mm) D 890 1078 1266 1516 1829 Secondary Return (mm) E - - 1159 1409 1609 Boiler Dual Stat Pocket (mm) F 706 738 843 918
AquaFlo Solar Direct Dimensions (Fig. B) Model AF6150 AF6180 AF6210 AF6250 AF6300 Nominal Capacity (Litres) 150 180 210 250 300 Diameter (mm) 545 545 545 545 545 Height (mm) A 1102 1290 1478 1728 2041 Solar High Limit Thermostat Pocket (mm) B 890 1078 1266 1516 1829 Solar Auxillary Pocket (mm) C 890 1078 1266 1516 1829 T & P Valve (mm) D 890 1078 1266 1516 1829 Sec.
AF3150S* AF3180S* AF3210S* AF3250S* AF3300S* 300 1728 2041 1102 1290 1478 1728 2041 33 38 41 46 55 355 183 218 251 296 355 288 133 163 194 236 288 AF3250 250 AF3210 210 AF3180 180 AF3150 150 AF3120 300 Model AF3090 AF3300 AquaFlo Direct Specifications Storage Capacity (Litres) 90 120 150 180 210 250 Height (mm) x 545 Diam.
Model AF4090 AF4120 AF4150 AF4180 AF4210 AF4250 AF4300 AquaFlo Indirect Specifications Storage Capacity (Litres) 88 118 148 178 208 248 297 Height (mm) x 545 Diameter 727 915 1102 1290 1478 1728 2041 Weight Empty (kg) 23 30 38 42 45 51 60 Weight Full (kg) 111 148 186 220 253 299 357 Vol Within 10oC of Set Temperature (Litres) 74 105 132 160 188 232 285 Heat up 14.2 20.0 22.0 26.2 31.2 33.0 41.0 Re-heat (minutes) Following 70% draw off 12.0 16.0 17.
AquaFlo Solar Compatible Specifications Model AF5180 AF5210 AF5250 AF5300 AF6150 AF6180 AF6210 AF6250 AF6300 Solar Direct AF5150 Solar Twin coil Storage Capacity (Litres) 147 177 207 247 297 148 178 207 248 298 Height (mm) x 545 Dia. 1102 1290 1478 1728 2041 1102 1290 1478 1728 2041 Weight Empty (kg) 40 45 48 53 63 38 42 45 51 60 Weight Full (kg) 187 222 255 300 359 186 220 253 299 358 132 160 188 232 285 132 160 188 232 285 54.1 82.7 97.
Parts list Hot Outlet Cold Main Non Return Valve (not supplied) Isolating Valve (not supplied) 1 Temperature & Pressure Relief Valve 3 Pressure Reducing Valve Balanced Cold Connection Pump (not supplied) Secondary Return Non Return Valve 2 6 2 Port Valve Expansion Relief Valve Tundish Dual Stat Expansion Vessel with Wall Bracket 5 From cold Inlet Set take off Boiler Flow 7 4 DO NOT fit shut off valve between Cylinder and Expansion Valve Boiler Return Drain Via Cold Inlet (not supplied)
Installation Installation prerequisites Zip Aquaflo should only be installed by a competent installer holding their G3 unvented qualification. The installation of this product is also notifiable under the national building regulations. The electrical installation including earthing and cross bonding must comply with the current IEE regulations and any Local Authority requirements. Requirements Zip AquaFlo is capable of delivering over 50 litres per minute when connected to a suitable mains supply.
Installation site Zip AquaFlo can be positioned more or less anywhere in the building but it should be remembered that for every 1 meter that an outlet is above the AquaFlo, the pressure will be reduced by 0.01 MPa (0.1 bar). If siting outside the heated envelope of the dwelling such as in a garage or outbuilding then frost protection should be provided and exposed pipe work should be insulated.
is a requirement. There is a 22mm balanced connection on the inlet control set that must be used for this purpose. Hot water pipework Run the first part of the hot water distribution pipework in 22mm. This can be reduced to 15 mm and 10 mm as appropriate for the type of tap etc.. Your aim should be to reduce the volume of the hot draw off pipework to a practical minimum so that the time taken for the hot water is as quick as possible.
The electrical supply to each immersion heater must be fused at 13A via a double pole isolating switch to BS 3456. The cable must be 2.5mm2 heat resistant (85°C HOFR) sheathed flex complying to BS 6141:1981. Do not operate the immersion heater/s until the unit is full of water. If any sterilisation liquid is in the cylinder do not operate the immersion heater/s as this will cause premature failure.
Discharge arrangement General guidance is provide by the diagram on page 19, extracted from the G3 Building Regulation Guidance. This guidance is available as a free of charge download of the G3 Approved Document from www.planningportal.gov.uk. The discharge from both the Temperature relief and expansion relief valves can be joined together via a 15mm end feed Tee. It is important that any discharge water does not collect in this pipe-work and can run freely to the tundish.
• 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 six 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 i.e.
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Commissioning Filling Check all connections for water tightness including any factory made connections such as the immersion heater and the temperature and pressure relief valve. The pressure in the expansion vessel should be checked to ensure it is 0.3 MPa (3 bar) (45 psi). The valve is of the car tyre (Schrader) type. The hot tap furthest away from the AquaFlo should be opened before filling the system to let air out. The system should be flushed before use.
Annual servicing A competent installer should carry out the following checks on an annual basis, ideally at the same time as the annual boiler service. 1. The expansion relief valve on the inlet control set should be eased open allowing water to flow for 5 seconds. The valve should then be closed making sure it re-seats correctly. Repeat this procedure with the pressure/temperature relief valve. Always ensure that the discharge pipework is allowing the water to drain away adequately.
Warranty The AquaFlo stainless steel vessel carries a transferable 25 year warranty against faulty materials or manufacture provided that: • It has been correctly installed by a competent installer as per this document and all the relevant standards, regulations and codes of practice in force at the time. • It has not been modified in any way, other than by Zip Heaters (UK) Ltd. • No components supplied with the AquaFlo have been removed for unauthorised repair or replacement.
