Zip 11061 Hydroboil User manual

Installation and Operating Procedures
Zip Hydroboil
Instant boiling water
11062 Hydroboil Electronic 15 Litre White
11061 Hydroboil Electronic 15 Litre S/S
12062 Hydroboil Electronic 25 Litre White
12061 Hydroboil Electronic 25 Litre S/S
04062 Hydroboil Electronic 40 Litre White
04061 Hydroboil Electronic 40 Litre S/S
®

Page 2 of 12 Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004
Read These Warnings First . . . . . . . . . . . . . .3
Installation Requirements . . . . . . . . . . . . . . .3
Installation Procedures . . . . . . . . . . . . . . . . .4
Step 1 – Positioning . . . . . . .4
Step 2 – Fastening . . . . . . . .4
Step 3 – Connecting . . . . . . .5
a) Plumbing . . . . . . . .5
b) Venting . . . . . . . . .5
c) Electrical . . . . . . . .6
Step 4 – Assembling . . . . . . .6
Step 5 – Commissioning . . . .6
Problem Solving . . . . . . . . . . . . . . . . . . . . . .7
Operating Procedures . . . . . . . . . . . . . . . . . .7
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . .8
Mounting Template . . . . . . . . . . . . . . . . . . . .9
Main PCB Settings . . . . . . . . . . . . . . . . . . . .10
Connecting John Guest Fitting . . . . . . . . . . .10
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . .11
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Contents

Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004 Page 3 of 12
Read These Warnings First
Please read all installation requirements, installation procedures and precautions
before installing any Hydroboil instant boiling water heater.
Never attempt to install any Hydroboil instant boiling water heater without reading
all of the applicable instructions.
In some hard water areas where mineral scale accumulation in the boiling
chamber of the Hydroboil may become a problem, consideration should be given
to the maintenance required. A suitable form of water treatment may be
necessary.
The cold water supply to this appliance must be portable and fall within your local
water authority guidelines.
All plumbing connections must be made in accordance with local authority
requirements.
The Hydroboil instant boiling water heater is not intended for use by young
children or infirm people without supervision.
Young children should be prevented from having access to ensure that they are
not able to use or play with the heater.
If the installation site is located more than 1000 metres above sea level, the
installer should contact a authorized agent to obtain alternate PCB settings.
If the power supply cable is damaged it must be replaced by a Authorized Service
Provider or a qualified electrician.
Do not remove the cover of the heater under any circumstances without first
isolating the heater from the power supply.
Do not use strong, corrosive or abrasive cleaners to clean the case of the heater.
Frost protection: If this heater is located where ambient air temperature could fall
below 5ºC 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.
The ambient temperatures this unit should operate with is 5 ºC - 50ºC
This heater is intended only for indoor use and should never be installed outdoors
or be exposed to the elements of nature.
This unit must not be positioned in an area that may be cleaned by a water jet.
This unit must not be cleaned by a water jet.
Before installing, ensure that the following are available:
a) Sufficient space to position the heater so there is at least 150 mm
clearance above the heater for service access, 65 mm to its left and
20 mm to its right – the tap outlet usually should be positioned at least
200 mm above a draining board or drip tray.
b) For units with 2.4 Kw element (15 ltr) standard 10 amp 220-240 volt power
cable positioned as shown on the paper mounting template for connection
from the rear of the heater to the terminal block within the heater, OR a
standard 10 amp 220-240 volt power outlet on the wall within 1500 mm of
the heater. For units with 3.6 Kw element (25 ltr) or multi element units (40 L)
an isolating switch in the fixed wiring and attached to a secure surface is
required.
Installation Requirements

Page 4 of 12 Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004
f) In all installation instances the walls of the heater must be verticle and the
base horizontal, there can be no exceptions to this rule.
Note: If the water pressure is likely to exceed 700 kPa, a 350 kPa pressure
reducing valve must be installed in the cold water supply line.
Before you begin
Locate the paper mounting-hole template packed with the heater.
Read the installation and operating instructions completely.
Decide whether to install with concealed or exposed plumbing and / or
electrical connections. Concealed connections are preferred for a superior
appearance.
If the heater is used for filling cups, then insert the flow restrictor into the
outlet pipe before securing tap assembly.
Step 1 - Positioning
Position the heater so the tap will drain onto the draining board or drip tray.
Position the base of the tap to be not less than 200 mm above the draining
board. ( height should be increased only if it is essential to accommodate
larger vessels.)
Minimum clearances for service are 150 mm top, 65 mm left and 20 mm right.
Mark corner position on wall so to position mounting-hole template.
Step 2 - Fastening
Position mounting-hole template on the wall and drill mounting holes where
shown.
Drill holes for water inlet, vent outlet and wiring if it is intended to install the
heater with concealed electrical and plumbing connections.
Remove cover fastening screws and lift cover away from chassis.
Install plumbing and wiring, and prepare pipe ends for connection as shown in
step 3.
Screw heater chassis to wall using screws or bolts suited to the wall surface.
Screws/bolts must be able to support the following weights when filled.
Installation Procedures
15 litre models 34.5 kgs
25 litre models 47 kgs
40 litre models 71 kgs
Installation Requirements continued
This switch must provide all-pole disconnection and a contact seperation of
at least 3 mm installed in accordance with wiring rules.
c) Cold water supply with a minimum working pressure of 100 kPa and a
maximum working pressure of 700 kPa connected via an isolation valve.
d) Outlet drainage to a sink draining board or to a drip tray.
e) Access to drainage from a vent situated at the base of the heater.

Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004 Page 5 of 12
Step 3 – Connecting
a) Plumbing
For exposed plumbing connection, connect the cold water inlet pipe from the base
of the heater directly to the 1/2” or 12.7 mm compression fittings.
For concealed plumbing connections, connect the cold water pipe through the rear
of the chassis using a 1/2” or 12.7 mm capillary elbow (# 63 Swivel Elbows).
Cold water pipes must be flushed before connection to the inlet. Any clogging
due to sediment or fines will adversely affect the operation of the heater.
It is recommended that the heater be installed with a isolating valve which
allows it to be isolated from the mains supply for servicing.
Water pressure requirements:
Minimum - 100 kPa, Maximum - 700 kPa.
Warning: If pressure is likely to exceed 700 kPa, a pressure limiting valve must
be installed in the cold water supply line. We recommend a valve rated at
350 kPa for this application.
b) Venting
A vent at the base of the heater must be plumbed to a safe visible location as,
under certain conditions, it may discharge cold or boiling water and/or steam.
For exposed vent plumbing, connect vent outlet from the base of heater to a 1/2” or
12.7 mm pipe which has a continuous fall, is no more than 3 metres long, has no
more than 3 right angle bends, and discharges to a waste water drain.
For concealed vent plumbing, connect plumbing to the vent outlet from the
heater rear using a capillary elbow protruding 45 mm from the wall.
Alternatively attach a tun dish to the wall as shown and plumb away to waste.
Wall mounted tundish - p/n 99017
Sink mounted tundish- p/n 99018
Installation Procedures Continued
COLD
INLET
VENT
OUTLET
INLET
POSITION
VENT
POSITION
45mm
Elbow
250mm
Wiring
Concealed
Vent
Concealed
Inlet
45 mm
Side View
Front View
Exposed vent
With Tundish

Page 6 of 12 Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004
c) Electrical
For concealed electrical connection, connect a power cable from the
rear of the heater to the terminal block within the heater as shown.
Do not turn the power ON until the heater is filled with water.
con
tinued
continued
Step 4 - Assembling
Place the heater case back onto the chassis and secure the two top and four
bottom fixing screws.
Screw the tap assembly clockwise onto the tap outlet tube using PTFE tape.
Screw the tap clockwise until the tap assembly touches the fascia without
pressure.
Continue to turn the tap a further one full turn until the tap lever is upright.
Step 5 - Commissioning
Check previous steps. Turn water supply ON, check connections for leaks.
Turn tap handle to the “lock down” side and leave open until water starts
flowing from the outlet. Return the handle to the closed position to stop water
flow and turn the handle 180º to the “cup fill” position.
See page 8 for LED Display information.
Turn power on. After a short time, boiling water will be available and will be
maintained close to boiling point thereafter. Initial heating periods are:
Inlet water temperature 15°C 10°C
15 Litre models 40 minutes 43 minutes
25 Litre models 47 minutes 50 minutes
40 Litre models 60 minutes 64 minutes
Installation Procedures continued
Single element
PCB and connections
Multiple element
PCB and connections
Terminal
block
Terminal
block
Size Kw Amps
15 Ltr 2.4 kW 10 A
25 Ltr 3.6 kW 15 A
40 Ltr 6.0 kW 25 A

Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004 Page 7 of 12
Problem Solving
Operating procedures
Tap Operation
Hydroboil is fitted with a two-way safety tap.
The tap assembly has two positions, one is the “cup fill” quick return mode.
This operation is achieved by having the handle with the curved cam at the
base of the tap handle facing you. When the handle is released this mode
allows instant water cutoff.
The second mode is “pot fill”, to use this position rotate the handle 180º from
the “cup fill” side so a flat face cam is showing at the handle base. This
operation allows a vessel to be filled without holding your hand where it may
be affected by steam.
“Pot fill” position
“Cup fill” position
Symptom Possible Cause Solution
Fails to dispense water.
Water isolating valve turned off.
Blocked filter, blocked meter tube,
blocked strainer, jammed ball valve
assembly, airlock in transfer tube.
Check water supply valve.
Contact a Zip authorised agent.
Water not boiling.
No power.
Faulty thermostat, faulty element,
faulty cutout, faulty contactor.
Check power supply.
Contact a Zip authorised agent.
Runs out of boiling water and fails to
refill.
Outlet tap drips.
Overflow from vent.
Excessive steam from vent.
Power “on” but no heat.
Overload repeatedly tripping with
excessive steam.
Overload repeatedly tripping without
excessive steam.
Internal adjustment. Contact a Zip authorised agent.

Page 8 of 12 Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004
# Section Heading
Factory dip switch
settings
single element.
Factory dip switch
settings
multi element.
Wiring Diagrams
Operating proceedures continued
15 Lt & 25Lt HB SINGLE ELEMENT
WITH PCB CONTROLLER
WIRING DIAGRAM
40 Lt HB MULTI - ELEMENT
WITH PCB CONTROLLER
WIRING DIAGRAM
Reading the Display Screen
Power On
When the text 'Power On' is illuminated this indicates that the power is
connected and turned on and that the heater is operating normally.
Boiling Water
When the text 'Boiling Water' is illuminated this indicates that the contents of
the boiling chamber has been brought to boiling point and is being maintained
(normally within 1°C of boiling point). During the initial heat-up the contents of
the boiling chamber may be below boiling point for a period, and during that
period the text 'Boiling Water' may not be illuminated.
Filter Active
If your Zip Hydroboil is specified with a filter the ‘ Filter Active’ text will normally
be illuminated. This indicated that the filter is within its specified lifespan.
Change Filter
If your Zip Hydroboil is specified with a filter the ‘Change Filter’ light will
illuminate when the filter is due to replacement. The local toll free number
(directly above) will also illuminate showing the Zip service number
1800 638 633.
Cleaning Case
Do not use strong, corrosive, spray or abrasive cleaners. Clean the case with a
soft cloth or brush and mild soap and water.
Boiling Water
Display Screen

Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004 Page 9 of 12
Mounting Template
Wall template for 15 litre, 25 litre & 40 litre models.
374 (15L, 25L)
499 (40L)
295 (15L, 25L)
420 (40L)
591 (15L, 25L)
771 (25L)
831 (40L)
188 (15L, 25L)
313 (40L)
EXTERNAL
PLUMBING
INTERNAL
PLUMBING
BENCH TOP
54 28
41
42
145
41 TYP
41
150
CLEAR
39.5
120
CLEAR
39.5
20
TYP
COLD
INLET
VENT

Page 10 of 12 Zip Hydroboil - Installation & Operating Instructions - 81419 - January 2004
Single Element 15 Lt & 25 Lt
The single element PCB is factory pre-set to give optimum performance in all
normal installation situations.
For high altitude installations (above 1000mtrs) there is an alternative dip
switch setting. See both settings at left.
Multi Element 40 Lt
The multi element PCB is factory pre-set to give optimum performance in all
normal installation situations.
For high altitude installations (above 1000mtrs) there is an alternative dip
switch setting. See both settings at left.
Note:
When altering the factory pre-set temperature of a multi element PCB it is
important that dip switch No.4. is in the OFF position.
Connecting John Guest Fittings
Single element factory preset.
Single element altitude setting above 1000 mtrs.
Multi element factory preset.
Multi element altitude setting above 1000 mtrs.
Main PCB Settings