Zenith HydroTap G5 User manual

1807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
Command Centre - UltraCare
BCU40, BCU60, BCU100
AFFIX PRODUCT LABEL HERE
Zenith
HydroTap G5
Installation Instructions
Visit our website to
download the manuals

02 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
Contents
SECTION 1: Using these instructions................................................................03
SECTION 2: IMPORTANT SAFETY INSTRUCTIONS .......................................... 04
SECTION 3: WARNINGS & REGULATORY INFORMATION ............................... 06
SECTION 4: Technical data.............................................................................. 08
SECTION 5: Parts supplied & tools required...................................................... 11
SECTION 6: General layout................................................................................12
SECTION 7: Set up the ventilation ....................................................................13
SECTION 8: Connect the water supply .............................................................15
SECTION 9: Set the bypass & install the limescale filter .................................. 16
SECTION 10: Fit the Booster..............................................................................17
SECTION 11: Connect the Booster.................................................................... 18
SECTION 12: Connect the Command Centre ................................................... 19
SECTION 13: Commissioning............................................................................ 22
Troubleshooting .............................................................................................. 27
Operation & maintenance................................................................................ 29
Cleaning ...........................................................................................................30
Performance data sheet ...................................................................................31
Thank you for choosing Zenith HydroTap !
Enjoy filtered boiling and chilled water from the Zenith HydroTap.
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 www.zenithwater.co.nz
to ensure you have the latest copy of this document.
Contents
Read the
instructions
Button/
coin battery

03807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 1: Using these instructions
This document is a Quick Start Installation Guide.
For further details on installing and operating your HydroTap
download & read the Command Centre installation and user
instructions , which can be found online at:
zenithwater.co.nz
!
Read and use the instructions supplied with individual kit
components for a safe installation.
Before you start
!
!
Explanation of symbols
Read the
instructions
WARNING
!
!
Danger of
electric shock
!
!
Hot surface
!UV
!
Highly
Flammable
Button/
coin battery

04 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 2: IMPORTANT SAFETY INSTRUCTIONS
Safety
This appliance is not intended for use by children under 8 years or persons
(including children under 8 years) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been
given supervision or instruction concerning the use of the appliance by
a person responsible for their safety. Children should be supervised to
ensure that they do not play with the appliance.
Intended Use
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.
Refrigerant
WARNING! KEEP VENTILATION OPENINGS IN THE APPLIANCE
ENCLOSURE OR IN THE BUILT-IN STRUCTURE CLEAR OF
OBSTRUCTION.
The Zenith HydroTap Command Centre range uses either FLAMMABLE
R290 (UK & EU markets), or R134a (all other markets) refrigerant under
pressure.
Check the rating plate or contact Zenith before commencing work.
Maintenance of the refrigeration unit must be carried out by an accredited
service provider or qualified refrigeration technician.
Do not use mechanical devices or other means to accelerate the defrosting
process, other than those recommended by the manufacturer.
!
!
Compliance
In NZ/Australia electrical installation must comply with AS/NZS3000.
In NZ/Australia plumbing installation must comply with AS/NZS3500.
In NZ/Australia for residential chilled models, all refrigeration must comply with
AS/NZS 60335.2.24.
In the UK the system must be installed in accordance with water supply byelaws,
current IEEE regulations and local authority byelaws.
!UV
!

05807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 2: IMPORTANT SAFETY INSTRUCTIONS
Do not store explosive substances such as aerosol cans with a flammable
propellant in this appliance.
Qualifications
To avoid hazards, all installation procedures must be carried out by a
suitably qualified tradesperson. The power cable and power outlet must be
in a safe visible position for connection.
Venting
Sometimes steam and / or boiling water droplets may discharge through a
vent outlet on the tap. If not using the font, ensure the tap body is located
so the tap outlet safely dispenses into the sink bowl.
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. The weight of the Command Centre is marked on
the packaging. Do not lift the Command Centre by the front cover or any of
its connections.
Airflow
The ambient operating temperatures, when installed in a cabinet, must be
between 5 - 35ºC. The system will operate satisfactorily only with proper
air ventilation. Air gaps of 50mm on each side, and 200mm above must be
provided.
See section 7 for correct ventilation details.
Altitude
Water boils at varying temperatures at different altitudes. The HydroTap
adjusts for this during startup calibration and will recalibrate itself on a
regular basis.
Frost protection
If the HydroTap is located where the ambient air temperature could fall
below 5ºC when the system is not in use, do not turn off the Command
Centre electrically. This safeguard does not offer the same protection to
the connecting pipework and fittings.

06 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 3: WARNINGS & REGULATORY INFORMATION
• The Zenith HydroTap must be earthed. Earthing is provided via the
supplied power cord. The resistance of the earth connection to each
exposed metal part must be less than 1Ω. Use the power cable supplied.
It is the responsibility of the installer to ensure the power point is
earthed.
• All installation and service work must be completed by trained and
suitably qualified tradespeople. Faulty operation due to unqualified
persons working on this product may void warranty coverage.
• As the installer, it is your responsibility to supply and install all valves as
required by local regulations and relevant standards.
• The HydroTap is rated for 220-240V 50Hz AC operation.
• Use only the power supply provided with the UV-C Module. An
ACM36US21 power supply is provided.
• Do not remove the cover of the appliance under any circumstances
without first isolating the appliance from the power supply.
• Connect only to a potable (wholesome, cat1) mains water supply.
• The new hose sets supplied with the product must be used. Do not
re-use old hose sets.
• Never locate the system near, or clean with water jets.
• Do not expose the Zenith HydroTap to the elements of nature.
• The booster complies with protection class IP 20.
• For UK, a pressure limiting valve must be fitted for mains water
!
!
• For continued safety of this appliance it must be installed,
operated and maintained in accordance with the
manufacturer’s instructions.
• 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.
• The button/coin battery is hazardous and is to be kept away
from children. It can cause severe or fatal injuries in 2 hours
or less if it is swallowed or placed inside any part of the
body. Medical attention should be sought immediately if it
is suspected the battery has been swallowed or placed inside
any part of the body.

07807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 3: WARNINGS & REGULATORY INFORMATION
pressures above the maximum limits stated.
• Use of tools can be hazardous. Assess the risks before you start.
• A clearance envelope around all Command Centres must be provided
to allow adequate ventilation for the safe and effective use of the
HydroTap system.
• Valve and fitting threads must be sealed appropriately with PTFE tape
where compression seals are not provided.
• Always flush new filter before use.
• Do not connect Booster to electrical supply until commissioning.
• Do not over tighten plumbing and hose connections.
• Braided hoses supplied cannot be lengthened.
• The power cord and general power outlet must be in a safe and
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.
• Do not locate multiple portable socket-outlets or portable power
supplies at the rear of the appliance.
• 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, do not fill and commission the
HydroTap until ready for first use.
• For water taste and quality reasons, following any non-use period of
more than 48 hours, Zenith recommends to perform a system flush.
Failure to flush the system may affect water quality.
• For UK, this appliance incorporates adequate backflow prevention
in accordance to S.I.1999 No.1148 The Water Supply (Water fittings)
Regulations 1999 Schedule 2 requirement. No further backflow
prevention is required for connection to the water supply.
• For UK, this appliance only contains materials that conform to the
requirements of BS6920:2014 ‘Suitability of non metallic materials
and products for use in contact with water intended for human
consumption with regard to their effect on the quality of water’.

08 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 4: Technical data
Electricity supply requirements
220-240V 50Hz AC.
A pressure limiting valve must be fitted for mains water pressures
above the maximum limits stated above in accordance with local
plumbing regulations.
Note: All models (excluding UK) have an internal pressure limiting device
to reduce the maximum mains regulated pressure (700kPa in Australia),
protecting the system against pressure surges above 500kPa.
!
Water supply pressure requirements
Component Min - Max pressure, kPA (bar)
Australia, NZ UK
HydroTap 170 (1.7) - 700 (7.0) 170 (1.7) - 500 (5.0)
Vented Mixer Tap 300 (3.0) - 700 (7.0) 200 (2.0) - 500 (5.0)
Booster 200 (2.0) - 700 (7.0) 200 (2.0) - 500 (5.0)
Limescale filter 200 (2.0) - 700 (7.0) 200 (2.0) - 500 (5.0)
Water supply connection
1/2” BSP (G1/2).
Country
Component Australia, NZ UK
Command Centre 1x 220 - 240V AC 10A socket 1x 220 - 240V AC 13A sockets
Booster 1x 220 - 240V AC 10A socket 1x 220 - 240V AC 13A sockets
UV-C module 1x 220 - 240V AC 10A socket 1x 220 - 240V AC 13A sockets

09807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
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 Command Centre BCU40 BCU60 BCU100
Boiling water (cups per hour)* 160 160 240
Chilled water (glasses per hour)* 125 175 175
Power rating @ 220-240V, 50Hz
(kW) 1.97 2.1 2.1 + 2.2**
Power rating @ 220V, 60Hz (kW) 1.84 2.0 2.0 + 2.2**
Dimensions (W x D x H) (mm)
395 x 464 x 333
With Duct and Vent Tray:
450 (500)#x 464 (520)#x 333 (373)#
Dry weight (kg)*** 30
Ambient operating temperature 5 - 35 °C
Boiling water temperature setpoint 98°C
Chilled water temperature setpoint 5 - 9°C
Chilled water coolant R134a or R290
* 1 cup = 167 mL, 1 glass = 200mL
** power rating of the Booster
*** Add 5 kg when full of water
# including vent tray
SECTION 4: Technical data

10 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 4: Technical data
UV-C module power supply specification
Model: XP Power ACM36US12
Specification Rating
Power supply 100 - 240V AC 50/60Hz
Power supply current* 1A (0.5@230V)
Output voltage and current* 12.0V 3.0A DC
*Figures above show the capacity of the power supply under full load.
Less will be drawn when used with the UV-C module.
Booster specification
Specification Rating
Power 230V 50/60Hz 2.20kW
Power 240V 50/60Hz 2.40kW
Flow rate 1.2 L/min

11807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 5: Parts supplied & tools required
Parts supplied with the HydroTap BCU40 BCU60 BCU100
Tap
HydroTap tap 
HydroTap pipes, tubes hoses and fittings 
Separate Mains mixer Tap & fittings Optional
Command Centre
UltraCare Command Centre 
Mains electrical supply cable 
Water supply inlet hose 
Water supply inlet adaptor and strainer 
Ventilation kit (incl. vent tray) 
Water block kit (UK only)
Booster
Booster & hoses Optional 
Filters
Water filter & instructions 
Limescale filter kit Optional
Font
Font kit Optional
Note: Mains water isolation valve is not supplied with the kit.
Contact Zenith for the full range of consumables and accessories.
In addition to standard tools, the following special tools will be required for
installation:
• 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.
Tools

12 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
BC U
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.
SECTION 6: General layout
Installation
Optional Booster &
lime scale filter
1
2
3
4
56
7 8 9
Mains water supply (isolation
valve not supplied)
1
2
Exhaust duct
3
4
5UV-C module
6
Command Centre
Vent tray
7
HydroTap
8
9
Command Centre mains
power cable
UV-C module power supply
Optional Booster mains
power cable

13807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 7: Set up the ventilation
!
A clearance envelope
around the Command
Centre must be provided
to allow ventilation for the
safe and effective use of the
HydroTap system.
Command Centre width
200mm
50mm 50mm
Use instructions supplied with individual kit parts.
!
!
Use of tools can be hazardous. Assess the risks before you start.
If cupboard temperature exceeds 35°C, additional ventilation is required.
Contact your Zenith service provider for options (including additional vents
and fan kit).

14 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
Vent tray
The supplied vent tray must be fitted. It provides a safe exhaust for
refrigerant gas in the unlikely event of a leak.
!
!
Vent tray dimensions WxDxH (mm): 500 x (515-555) x 40
• Refer to the instructions provided with the Vent Tray.
• Cold air is drawn in through the inlet vent and gap provided by the door
buffers.
• Inlet vent is mounted over cupboard side, door or floor cut-out.
• Warm air is exhausted through vent tray.
• Observe 100mm inlet / outlet vent separation.
Air outlet
100mm
4mm door buffers
(supplied)
Air inlet options
Vent tray exhaust cut-out
450
40
SECTION 7: Set up the ventilation
Absolute min. vent tray depth 490mm (limit of travel, may affect airflow).

15807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 8: Connect the water supply
!
Note correct strainer orientation.
Isolation valve
(not supplied) Strainer
(supplied)
Male - Female
adaptor
(supplied)
Connect together
Connect to
Command Centre,
see page 20
Connect to
Command Centre,
see page 20
Note Mixer tap installations also use a ‘Tee piece’ as part of the water supply
plumbing connections. See the Tap installation instructions supplied with the
Mixer Tap to connect the water supply if using the mixer tap option.
Valves and fittings must be sealed with PTFE
tape if compression seals are not included.

16 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 9: Set the bypass & install the limescale filter
Water
in
Bypass out
see page 20
Water
out
Bypass in
see page 20
Insert
Remove
Insert
Remove
For filter head and scale filter installation use the guide supplied
with the filter head and filter respectively.
Bypass valve
(Rear of the Command
Centre)
Available as optional accessory - UK only.

Quick Start Installation Guide
807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
17
SECTION 10: Fit the Booster
a
bc
d
e
f
10⁰
15⁰
Note Take care not to break the clips when removing or installing the Booster.
• Supplied with selected models, or available as
an optional accessory.
Booster

18 Quick Start Installation Guide
807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 11: Connect the Booster
Booster
Booster
Hold connections
with spanner
while tightening hoses
3/8" BSP
connections
!
Do not connect to electrical power until commissioning.
Do not over tighten hose connections.
Braided hoses supplied cannot be lengthened.
!
Strainer
Cold water into Booster,
connect to Command Centre
BYPASS OUT
see page 20
Hot water out of Booster,
connect to Command Centre
BYPASS IN
see page 20

19807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
SECTION 12: Connect the Command Centre
For HydroTap, mixer tap and any optional accessories, use
instructions supplied with individual kit components.
Connections key
HydroTap
Braided hose
Command
Centre
USB
Tap
Generic installation instructions
Mains power cable
Do not connect to the mains
socket until commissioning
Installation diagrams are for illustrative purposes only.
Hoses are not shown to scale and cannot be lengthened.
!
Tips for hose connection
• Push the silicone hose over the
connector for a minimum of 15mm.
• Ensure 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
make a clean cut straight across the
hose, using a sharp blade.
• The hoses must not be under
tension when installed.

20 807042NZ v1.02 08.22 HydroTap G5 UltraCare Install Instructions
USB CO2
IN
CHILLED
OUTLET
SPARKLING
OUTLET
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
CHILLED
OUTLET
SPARKLING
OUTLET
CO2
IN
USB
BCS comm
BCS res
BC comm
CHILLED
OUTLET
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
USB
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
CHILLED
OUTLET
USB
BC res
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
AMBIENT
OUTLET
USB
BA res comm
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
B res comm
USB
MAINS
IN
C 175 comm
USB
CHILLED
OUTLET
CS 175 comm
CO2
IN
CHILLED
OUTLET
SPARKLING
OUTLET
MAINS
IN
C res
CHILLED
OUTLET
MAINS
IN
USB
CS75 res
CO2
IN
CHILLED
OUTLET
SPARKLING
OUTLET
MAINS
IN
USB
check USB
position
check which way round
still / sparkling
USB CO2
IN
CHILLED
OUTLET
SPARKLING
OUTLET
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
CHILLED
OUTLET
SPARKLING
OUTLET
CO2
IN
USB
BCS comm
BCS res
BC comm
CHILLED
OUTLET
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
USB
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
CHILLED
OUTLET
USB
BC res
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
AMBIENT
OUTLET
USB
BA res comm
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
B res comm
USB
MAINS
IN
C 175 comm
USB
CHILLED
OUTLET
CS 175 comm
CO2
IN
CHILLED
OUTLET
SPARKLING
OUTLET
MAINS
IN
C res
CHILLED
OUTLET
MAINS
IN
USB
CS75 res
CO2
IN
CHILLED
OUTLET
SPARKLING
OUTLET
MAINS
IN
USB
check USB
position
check which way round
still / sparkling
Booster
Mains
Water
Lime- scale Filter
!
Zenith Vented
Mixer Tap
connections
(if supplied)
Fit foam insulation
(supplied) to the
BLUE pipe
BC U
Installation
BLUE
RED CLEAR
Booster (selected models) and
limescale filter (optional)
Diagram for illustrative purposes only.
Hoses are not shown to scale, as the
booster hoses cannot be lengthened.
UltraCare BCU40 -100 models
SECTION 12: Connect the Command Centre
UV-C Module
Optional booster
and limescale
filter