Zenith HydroTap G5 User manual

1807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Model:
UltraCare BCU40
Installation Instructions
Zenith
HydroTap G5
PRODUCT LABEL
Visit our website to
download the manuals

02 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Contents
WARNINGS AND PRECAUTIONS................................... 03
Major components and accessories ............................. 05
Before installation ....................................................... 07
Installation instructions............................................... 08
Step 1 – Positioning ........................................................................08
Step 2 – Ventilation ........................................................................09
Step 3 – Tap installation...................................................................10
Step 4 – Command Centre installation ............................................11
Step 5 – External filter installation (optional) ..................................14
Step 6 – Commissioning ................................................................. 15
Troubleshooting...........................................................17
Operation & maintenance.............................................19
Cleaning .......................................................................19
End of life disposal .......................................................19
Thank you for choosing Zenith HydroTap!
Enjoy filtered boiling and chilled water from the Zenith HydroTap. The
HydroTap Command Centre, installed under the bench, has a colour
touchscreen display, energy saving mode and internal 0.2 micron filter.
Zenith HydroTap UltraCare adds anti-bacterial components and an ultraviolet
module to eliminate bacteria and other micro-organisms.
Due to the process of continuous improvement, Zenith reserves the right to
change details mentioned in this manual, without notice. Visit zenithwater.
co.nz to ensure you have the latest copy of this document.
Contents

03807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
WARNINGS AND PRECAUTIONS
1. For continued safety of this appliance it must be installed,
operated and maintained in accordance with the
manufacturer’s instructions.
2. This appliance may deliver water at high temperature. Refer
to the Plumbing Code of Australia (PCA), local requirements
and installation instructions to determine if additional delivery
temperature control is required.
3. Plumbing and electrical connections must be made in
accordance with local regulations and relevant standards. In AU/NZ:
Plumbing standard AS/NZS 3500 & Electrical Wiring Rules AS/NZS 3000.
4. This appliance must be earthed.
5. The power cord and general power outlet must be in a safe, accessible
position after installation. When positioning the appliance, ensure the
power supply cord is not trapped or damaged. If the power supply
cord is damaged it must be replaced by a Zenith service provider or a
qualified electrician.
6. Use only the power supply provided with the UV-C Module. An
ACM36US21 power supply is provided.
7. Do not locate multiple portable socket-outlets or portable power
supplies at the rear of the appliance.
8. Do not remove the cover of the appliance under any circumstances
without first isolating the appliance from the power supply.
9. This unit is designed for indoor use and must not be installed outdoors
or exposed to the elements of nature.
10. This unit must be installed with adequate clearances of 50mm on all
sides, and 200mm above. Additional means of ventilation is critical if the
vent kit, as supplied, cannot be fitted.
11. Flush water supply lines before any plumbing connections are made, to
prevent sediment from affecting operation.
12. This unit must not be cleaned by a water jet. This unit must not be
positioned in an area that may be cleaned by a water jet.
13. This appliance is intended to be used in: staff kitchen areas in shops,
offices and other working environments; farm houses and by clients in
hotels, motels and other residential type environments; bed and breakfast
type environments; catering and similar non-retail applications.
14. For safe operation, the HydroTap is designed to be installed,
commissioned and used within 48 hours. Should the HydroTap not be
required for an extended period of time (72 hours or more), do not fill
and commission the HydroTap until ready for first use.
!

04 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
WARNINGS AND PRECAUTIONS
Safety
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by
a person responsible for their safety. For products sold in Europe, this appliance can
be used by children aged from 8 years and above and persons with reduced physical,
sensory or mental capabilities or lack of experience and knowledge if they have been
given supervision or instruction concerning use of the appliance in a safe way and
understand the hazards involved. Children should be supervised to ensure that they
do not play with the appliance. Cleaning and user maintenance shall not be made by
children without supervision.
Refrigerant
HydroTap chilled models contain R134A refrigerant under pressure. Maintenance
of the refrigeration unit must be carried out by an accredited service provider or
qualified refrigeration technician.
Qualifications
If the power cable is damaged it must be replaced by a qualified technician. To
avoid hazards, all installation procedures must be carried out by a suitably qualified
tradesperson.
Venting
Occasionally steam and / or boiling water may discharge through a vent outlet on the
tap. Ensure the tap body is located so the tap outlet safely dispenses into the drip tray
or sink bowl area.
Lifting
Take care when lifting. The Command Centre may exceed safe lifting limits. If you feel
this is beyond your personal capabilities, please seek assistance with the lift. Do not
lift the Command Centre by the front cover or any of its connections. Refer to the
technical specification for the weight of the product.
Airflow
The ambient operating temperatures, when installed in a cupboard, must be between
5°C - 35°C. The system will operate satisfactorily only if the recommended air gaps of
50 mm on each side, and 200mm above the Command Centre are provided. If a vent
kit is supplied it must be fitted.
Frost Protection
If this appliance is located where the ambient air temperature could fall below 5°C
when the heater is not in use, do not turn off the appliance electrically. This safeguard
does not offer the same protection to the connecting pipework and fittings.
15. For water taste and quality reasons, following any non-use period of
more than 72 hours, Zenith recommends to perform a system flush.
Failure to flush the system may affect water quality.

05807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Accessories Description
Filter cartridge
1.5Z-CF, 0.2mic
part no. 93706NZ
Font kit
(to suit tap design)
part no. 93303NZ
Accessibility kit
(for Classic Tap)
part no. 93143NZ
Dual exhaust fan
kit
part no. 93156NZ
Parts supplied Description
1 x HydroTap Tap
+ hoses
Classic tap shown
part no. 91519NZ
chrome
1 x HydroTap
Command
Centre
(including water
filter cartridge)
1 x mains water
braided hose
part no. 90056NZ
Side Duct
part no. 91505NZ
Vent Kit
(BC Model)
1 x Inlet, 1 x Outlet,
9x screws
part no. 93257NZ
Vent tray kit
part no. 93540NZ
Major components and accessories
Parts supplied Description
UV-C Module
part no. 96863NZ
(809283NZ)
Power supply for
UV-C Module
part no. 96864NZ
1 x Installation
Instructions
(this book) and
1x User Guide
Install
Instruct
User
Guide

06 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Technical specification
UV-C Module*** Specification
Rated service flow 2.8 L/min
Maximum working pressure
(applies to UV-C Module, not Command Centre) 830 kPa
Maximum operating temperature 50 °C
Operating voltage 12 V DC
***This Class B system or component conforms to NSF/ANSI 55 for the
supplemental bactericidal treatment disinfected public drinking water
or other drinking water that has been tested and deemed acceptable for
human consumption by the state or local health agency having jurisdiction.
The system is only designed to reduce normally occurring non-pathogenic
nuisance microorganisms. Class B systems are not intended for treatment of
contaminated water.
UltraCare BCU40 Command Centre Specification
Boiling water (cups per hour)* 160
Chilled water (glasses per hour)* 125
Booster heater –
Power rating 220-240V, 50Hz, 1970W
220V, 60Hz, 1840W
Dimensions (W x D x H) (mm) 450 x 470 x 335
Dry weight (kg)** 23
Power outlets required 2x 220-240V, 50Hz, 10A
Rated mains inlet water pressure 150 - 700 kPa
Water connection ½” BSP (G ½”)
Ambient operating temperature 5 - 35 °C
Boiling water temperature setpoint 98°C
Chilled water temperature setpoint 6 - 11°C
Chilled water coolant R134a
* 1 cup = 167 mL, 1 glass = 200mL
** Add 5 kg when full of water

07807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Before installation, ensure that:
• All technical specifications and instructions have been reviewed.
• There is sufficient space in the cupboard to install the Command Centre
and other components (booster heater, carbon dioxide cylinder)
in accordance with these installation instructions. Check cable and
plumbing against inlet /outlet positions before proceeding.
• The underbench can support the product weight when full of water. See
Technical specifications.
• The appliance must be connected in accordance with current local
electrical regulations. See Technical specification for power ratings. Two
user easily-accessible 220-240V AC, 10A power outlets are required.
• The appliance must be connected to a potable water supply with min/
max working pressure as outlined in the Technical specifications, with
isolating valve within reach of the hose and positioned so that the valve
will not be obstructed.
• The new hose sets supplied with the product must be used. Do not re-
use old hose sets.
• The appliance must be placed upright with its base in a horizontal
position.
In addition to standard tools, the following special tools will be required:
• 35mm diameter sheet metal hole punch for sink tops (not supplied)
• 35mm diameter hole saw for timber bench tops (not supplied)
• Nut runner tube spanner (supplied) for fixing tap assembly.
• Jigsaw and 12mm drill (not supplied) for installation of ventilation.
• Keyhole or wall board saw (not supplied) for installation of ventilation.
IMPORTANT! Do not proceed with the installation if these requirements
are not met.
Before installation

08 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Clearance Envelope
50 50
450
cut-out
585 mm
Installation instructions
Filtered water tap
(Classic Tap shown)
HydroTap
Command Centre
Mains
power supply to
Command Centre
Power for UV-C
Module Vent tray Side duct Mains water inlet
(isolation valve not
supplied)
Step 1 – Positioning
Ensure there is adequate space in the installation area for all components, with
access to water and power. The ambient mains water braided hose length is
750mm. Electrical power cable length is 1.8m.
UV-C Module

09807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Installation instructions
Install vent tray kit
(supplied)
Install the vent tray in
the cupboard where
the Command Centre
is located. Refer to
instructions supplied with
the vent tray.
If vent tray is unable to be installed:
Additional ventilation will be required. Options
include vent grilles and a dual exhaust fan kit.
Contact your local service centre for more details.
2.3
93156 Dual Exhaust Fan Kit
2.2
Attach side duct
(supplied)
Insert into the slots in
the side of the HydroTap
Command Centre. Fasten
with a screw.
(18")
40
(1.5")
nom.
( --")
1
4
5
450
DETAIL: Vent Tray air outlet
cut-out in cabinet floor
Inlet vent
options
Fit the silicone door buffers to the inside edge of the
cupboard door to provide an air space.
Step 2 – Ventilation
IMPORTANT: Allow a minimum clearance envelope of 50mm either
side, and 200mm above the Command Centre. Proper air circulation
must be provided for the system to operate correctly. The top and front of
the Command Centre must remain accessible for servicing.
2.1
!
4 min.
Buffer Pad
Air Space
SCALE 1:5
SECTION A-A
5
326
max. 43
60
==
285
450 min.
45
60 min.
284
C. Cabinet Floor Cut-Out
A. Kickboard Cut-Out
B. Cabinet Floor Cut-Out
151
439.5
Ø60
Ø52
85
258
255
5°
226
220
Boiling & Chilled Outlet
Hot & Cold Outlet
Celsius AIO Tap Profile
100 min.
Hot water from
domestic heater
Mains cold water
isolation valve
(not supplied)
Connector
with Strainer
(Feeds Base Unit)
Inlet Vent
A
A
Outlet Vent
240 - 230V,
50Hz GPO
See Detail B
See Detail C
See Detail A
Sink shown
only
Ø50 Hole HydroTap®
Celsius AIO Tap
Position the Tap such that it
dispenses into the sink bowl
with ample clearance for a cup
or a tea pot
440
Celsius Style
All In One Tap
200 min.
333
280 50 min. 70 min.
IEC Flex & Plug
Clearance
Envelope
455
THIRD ANGLE
PROJECTION
R
Celsius AIO Tap BC 100/75
Mains Zip HydroTap G4
150
50
200
250
150 100 50 250 200 300 350 400
200 50 100 150
250
200
100
150
Dimensions in
millimetre s
Drawing to
BS8888:2004
Screw threads to
BS 8498:2008
Web : www.z ipindustries.com
Ema il : s ale s@ zipin dustrie s.com
100
400 250 300 350 600 450 500 550
550 650
500 450 600 700 800 750
500
350
400
300
450
550
350
300
450
400
550
500
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Zip Industries Pty Ltd
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Australia
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For the current revision ALW AYS refer to the NAT IVE electronic form as stated in the top left-hand corner of this sheet.
© copyright Zip Industries Pty Ltd, 17/0 4/2018
BKL002_2824AU0B0ZN1C
Sheet :
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Enginee r
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Manufacturing Instructions
Zip Industries
Drawing :
Model :
Description :
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De rived from :
Sca le :
Approved by :
Checked by :
Finish :
Material :
Mass
(g)
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De nsity
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Project :
Size
Rev
Colour :
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Property
Config
Property
Custom
Property
Outlet vent
450mm cut-out
100mm min
between cut-outs

10 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Step 3 – Tap installation
Installation instructions
Cut a hole to suit your tap (35mm)
in the sink or benchtop using a
sheet metal hole punch or hole saw
(not supplied).
3.2
Push spacer on to the base of the
tap, with a light smear of silicone
sealant on the underside of the
spacer to ensure a watertight fit.
3.3
Position the tap so that water from
the spout will fall into a sink/tray
fitted with a drain
3.1
Pass the hoses down through the
hole and locate the tap in place.
3.4
From below the benchtop, push
the washer over the hoses and
threaded rod, then push the spider
clamp onto the threaded rod.
Check the tap is in the correct position,
then secure the fastening nut.
3.5
Tap
Washer
Benchtop
Nut
Spider clamp
Spacer
For more detail, refer to installation instructions supplied with the tap.
The tap tube length permits installation of a tap
height extension (not included).
For good fall of the water hoses, the tap tubes may
be shortened using a PVC
cutter (conduit cutter).
Ensure the cut edges are
not sharp, before fitting
the hose.
3.6

11807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
No Mixer
Installation instructions
Step 4 – Command Centre installation
4.1 4.2
Mains water connection
Flush water supply lines before any plumbing connections are
made, to prevent sediment from affecting operation.
!
Connect electrical cable to the
side of the Command Centre.
Power must remain OFF until
commissioning.
4.3
Mains water
(isolation valve
not supplied)
Command
Centre
MAINS IN
Connect the USB
cable from the tap
to the USB cable
plug from the
Command Centre.

12 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Installation instructions
UV-C Module
4.4
Command Centre
CHILLED OUT
UV-C Module
Connect BLUE
hose from tap. Push
at least 15mm over
the fitting
Connect USB-C cable
from UV-C Module to
HydroTap
Ensure hose has
constant fall
Connect 12V power supply
to HydroTap.
Power must remain OFF
until commissioning.
Use only the power
supply provided.
Attach the L-shaped
bracket (supplied) with
adhesive tape to the
power supply to support
it against the wall.
!

13807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Installation instructions
Tap hose connections (refer to diagram on the following page)
4.5
Remove all other
connection caps
Remove the two red
mixer caps ONLY if
HydroTap Mixer is to
be fitted
Tips for hose connection
• Push the hose over the connector
for a minimum of 15mm.
• There a constant fall from the tap
down to the Command Centre.
• Hoses must be trimmed to avoid
loops and kinks. Take care when
positioning before cutting and be
sure to make a clean cut straight
across the hose, using a sharp blade.
• The hoses must not be under
tension when installed.
• Hoses must not be lengthened
beyond the maximum supplied
1-metre length.
• Ensure the cut edges are not sharp,
before fitting the hose.

14 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
UV-C Module
BRAIDED RED
USB
CLEAR
Installation instructions
Mixer Tap
(optional)
IN OUT
Bypass /Booster
(selected models)
OUT IN
BLUE
Step 5 – External filter installation (optional)
Without external filter
(factory setting) With external filter
Set bypass valve (optional)
The bypass valve diverts the boiling feed water to external filtration
(optional; internal filter is supplied with the unit). The valve is located at
the rear of the Command Centre. It is factory set to operate without an
external filter. If an external filter is installed, rotate the bypass valve as
shown.
Refer to the LCD screen to perform a filter flush of at least 10 litres.
UltraCare

15807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Refer to the LCD screen. Select language. Check the date and time
settings. The screen will continue to Filter Flush.
New filter cartridges must be flushed before use. Follow the steps on the
screen to flush the filter for approximately 2 minutes. This step cannot be
skipped.
Once complete, press NEXT.
Commissioning
Familiarise yourself with operation of the Tap
(refer to User Guide). Turn water ON.
Connect the electrical cables plugs from the
HydroTap to 2x 220-240V AC, 10A power outlets.
Turn electrical power ON at both the power outlets.
6.2
Step 6 – Commissioning
10L
(bucket not
supplied)
Open valve to
let water flow
Close valve
when complete
Do not commission your HydroTap until it is ready to be used! The HydroTap is
designed to be installed, commissioned and used within 48 hours.
If the HydroTap is left idle before use, a filter change and sanitisation may be required.
The filter cartridge must be installed at commissioning. A new filter
cartridge is provided, inside the filter door.
6.1
1
1
2
6.3
Unpack new filter
cartridge. Moisten
the top O-ring with
tap water. Do not
touch!
Write today’s
date on label.
Align the key tabs
and insert the new
cartridge upwards
into the filter head.
Turn the cartridge to
the right until it locks
into place.
ON

16 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Boiling calibration
Caution: hot steam may vent from the tap spout.
Boiling calibration will optimise the performance of the boiling unit. The
procedure will take approximately 10 minutes.
Upon completion, the External Booster screen will appear.
For best product performance, ensure the correct selection for the
booster:
• YES: booster is installed, OR
• NO: booster is not installed.
Commissioning
6.5
Tank flush (UltraCare models)
The HydroTap Command Centre is factory-sanitised. Residue from the
sanitising liquid may remain in the product, which requires the product
to be flushed with fresh water at installation, as shown on the Command
Centre screen. Each tank (boiling and chilled) must be emptied and filled
three times.
• For countertop font installations, ensure the dispensed water can
drain freely, or prepare a large container to collect the dispensed
water and remove it for disposal.
• Use the tap to dispense water from the tanks.
Caution: hot water may be dispensed. The “Safety lock” on the tap
must be covered in order to dispense from the boiling tank.
• Refer to the screen to view the current tank levels and the number
of tank flush cycles completed. If required, press the arrow icon to
restart the tank flush process.
• Once the tank flush is complete, the NEXT button appears. Press
NEXT to continue to the boiling calibration screen.
6.4

17807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
The HydroTap tap lights will flash to indicate when service is required. Refer to
the LCD screen in the Command Centre.
Call an electrician, a plumber, or Zenith service for assistance, service, spare
parts or enquiries.
System fault message Possible cause Recommended action
Power board fault Electrical disruption Check power supply and all fuses
Interface fault Internal fault Call Zenith Service
Level board fault Internal fault Call Zenith Service
Condenser screen blocked Blocked Air filter Remove blockage, clean filter - check user guide
Water leak, Isolate mains Water leak Turn off mains water supply / Call for service
Compressor over-run Compressor too Hot Check ventilation
Water supply failed No water Check water supply is turned ON
Hot sensor Open Internal fault Call Zenith Service
Hot sensor Closed Internal fault Call Zenith Service
Cold sensor Open Internal fault Call Zenith Service
Cold sensor Closed Internal fault Call Zenith Service
Flood sensor Open Internal fault Call Zenith Service
Condenser sensor Closed Internal fault Check Ventilation / Call Zenith Service
Condenser sensor Open Internal fault Check ventilation / Call Zenith service
Heater fuse / driver fault Internal fault Call Zenith Service
Heater driver fault No hot water Call Zenith Service
Compressor driver fault No chilled water Call Zenith Service
Hot sensor degraded Internal fault Call Zenith Service
Condenser overtemp. Blocked air filter Remove blockage, clean filter - check user guide
A DC Pump is faulty Internal fault Call Zenith Service
Steam is too cool Internal fault Call Zenith Service
Steam sensor Open Internal fault Call Zenith Service
Steam sensor Closed Internal fault Call Zenith Service
Over Steamed Internal fault Call Zenith Service
Hot tank overfilled Internal fault Call Zenith Service
Comp Fuse/Driver Fault Internal fault Call Zenith Service
Hot tank under filled Low water pressure Check water supply
Boil dry protection Safety activated Turn OFF / On power to reset
Flash Mem corrupted Internal fault Call Zenith Service
Flow Sensor Fault Internal fault Call Zenith Service
Troubleshooting

18 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
System fault
message Possible cause Recommended
action
Fault stops
showing when:
UV Not Present
a. UV-C Module USB-C
cable is not connected
correctly to the UV PCB
b. UV-C Module cable is
faulty
c. UV IO PCB is faulty
Check that the
UV-C Module USB
cable is correctly
plugged into the
HydroTap
UV-C Module
is connected
properly (power
does not have to
be on)
UV Over Temp
Internal
temperature is
greater than 55°C
a. There is a kink in the hose
preventing cold water
being dispensed
b. Cold Pump is not
dispensing water
c. UV-C Module is faulty
d. UV PCB is faulty
Verify that water
is flowing through
the UV-C Module
when attempting
to dispense
UV-C Module cools
down and reports
that its internal
temperature has
returned to 40°C or
lower
UV Under Current
Tried to dispense
cold water and
current of UV-C
Module not
at minimum
threshold.
a. The 12V external power
supply is not connected
to the mains power outlet
and/or the G5 HydroTap
b. The 12V external power
supply is faulty
c. UV-C Module is faulty
d. UV IO PCB is faulty
Check power
supply is correctly
plugged in and
turned on. Turn the
HydroTap off and
then on.
Power turned off,
then on.
UV Over Current
Tried to dispense
cold water and
current of UV
filter greater
than maximum
threshold.
a. UV-C Module is faulty
b. UV PCB is faulty
Turn power off,
then on.
Power turned off,
then on.
UV Comms Error
No communication
to the UV IO PCB.
a. UV PCB is faulty
b. Ribbon cable connecting
the UV PCB and the LCD
PCB is faulty.
N/A Communication
restored.
Troubleshooting
The UltraCare UV-C Module may cause the following fault codes.

19807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Operation & maintenance
Please refer to the User Guide for all operational and maintenance features of
the HydroTap. The User Guide is located in the HydroTap Command Centre
filter door.
Do not use strong, corrosive or abrasive cleaning
materials on the HydroTap tap or Command Centre.
Do not use “self-drying” disinfectant sprays.
Wipe external surfaces with a damp cloth or
antibacterial alcohol wipe, then immediately wipe
dry with a clean, dry microfibre cloth or paper towel.
Food-grade disinfection wipes may be used to clean
within the tap dispensing outlets.
Cleaning
In order to help preserve our environment we ask that
you dispose of this product correctly. Please contact
your local city council for collection centre details.
End of life disposal
The Zenith filter should be replaced as recommended on the filter, or earlier if
you notice a persistent reduction in water flow from the tap or an increase in
chlorine, taste or odour in the water. Not changing the filter cartridges when
required may affect the water quality.
For safe operation after periods of non-use longer than 72 hours, flush the
HydroTap for at least 60 seconds.

20 807042NZ v1.00 03.21 HydroTap G5 UltraCare Install Instruct
Refer to User Guide for operation and maintenance.
Zenith Heaters Limited
IRD/GST No. 95 640 729
18 Kawakawa Place, Westgate, Auckland 0814
New Zealand
Ph: +(64 9) 838 8612 | Free Call 0800 558 055
zenithwater.co.nz
AU02691
WMKA00099
AS 3498