Zip Econoboil HS403 User manual

Installation and Operating Instructions
Zip Econoboil
Budget priced instant boiling water for canteens and kitchens.
03592 Zip Econoboil 2.5 litre White HS403
05592 Zip Econoboil 5.0 litre White HS405
07592 Zip Econoboil 7.5 litre White HS407


Page 2 of 12 Zip Econoboil Installation & Operating Instructions - 82790 - January 2004

Zip Econoboil - Installation & Operating Instructions - 82790 - January 2004 Page 3 of 12
Table of Contents
Read These Warnings First . . . . . . . . . . . . . .4
Installation Requirements . . . . . . . . . . . . . . .4
Installation Procedures . . . . . . . . . . . . . . . . .5
Step 1 – Positioning . . . . . . . .5
Step 2 – Fastening . . . . . . . . .5
Step 3 – Connecting . . . . . . .6
a) Plumbing . . . . . . . .6
b) Venting . . . . . . . . .6
c) Electrical . . . . . . . .7
Step 4 – Assembling . . . . . . .7
Step 5 – Commissioning . . . .7
Operating Procedures . . . . . . . . . . . . . . . . . .7
Tap Operation . . . . . . . . . . . .7
Cleaning Case . . . . . . . . . . . .8
Earthing Continuity Verification . . . . . . . . . . .8
Problem Solving . . . . . . . . . . . . . . . . . . . . . .8
Wall Mounting Template
Dimensions & Electrical Diagram . . . . . . . . . .9
Temperature Setting . . . . . . . . . . . . . . . . . . .9
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . .10
Exploded View Diagram . . . . . . . . . . . . . . . . .11
Warranty Information . . . . . . . . . . . . . . . . . . .12

Page 4 of 12 Zip Econoboil Installation & Operating Instructions - 82790 - January 2004
Read These Warnings First
Please read all installation requirements, installation procedures and precautions
before installing any Zip Econoboil instant boiling water heater.
Never attempt to install any Zip Econoboil 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 Zip Econoboil 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 potable and fall within your local
authorities guidelines.
The Zip Econoboil 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 Zip for high altitude settings.
This appliance must be earthed. If the power supply cord is damaged it must be
replaced by 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 5ºC - 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) Power supply 13 amp fused spur for connection to the heater via a double
pole fused sur with a minimum break rating of 13 amps.
For units with 3.6 Kw element (25 ltr) or multi element units (40 ltr) an
isolating switch in the fixed wiring and attached to a secure surface is
required. 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 1.5 bar and a
maximum working pressure of 10 bar connected via an isolation valve.
Installation Requirements

Zip Econoboil - Installation & Operating Instructions - 82790 - January 2004 Page 5 of 12
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.
If the water pressure is likely to exceed a0 bar, a 3.5 bar pressure reducing
valve must be installed in the cold water supply line.
f) In all installation instances the walls of the heater must be vertical and the
base horizontal, there can be no exceptions to this rule.
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 superior appearance.
Step 1 – Positioning
Position the heater so the tap will drain on to a 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 essential for filling larger vessels).
Provide clearance for service access of not less than 150 mm top, 65 mm left,
20 mm right.
Mark corner positions for the heater on the wall so as to position the paper
mounting-hole template.
Step 2 – Fastening
Position mounting-hole template on wall and drill holes where shown.
Drill holes for water inlet, vent outlet and wiring if rear access is intended.
Remove cover fastening screws from heater and lift whole cover off heater.
Install plumbing and wiring and prepare pipe ends and wiring ends as required.
Screw heater chassis to the wall using screws or bolts suited to the walling.
Screws or bolts must be capable of supporting the heater weight when filled.
(Please refer to the table on the left).
2.5 Litre model 10 kg
5.0 Litre model 13 kg
7.5 Litre model 16 kg
Installation Procedures
Approximate Weight When Filled
Installation Requirements continued

Page 6 of 12 Zip Econoboil Installation & Operating Instructions - 82790 - January 2004
Step 3 – Connecting
a) Plumbing
For exposed plumbing connection, connect the cold water inlet pipe from the
base of the heater directly to the 15 mm or half-inch compression fittings with
the nuts and olives provided.
For concealed plumbing connections, connect the cold water pipe through the
rear of the chassis using a 15 mm or half-inch capillary elbow.
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 stop cock which allows it to
be isolated from the mains supply for servicing.
Water pressure requirements:
Minimum - 0.2 bar, maximum - 10 bar..
Warning: If pressure is likely to exceed 10 bar, a pressure limiting valve must be
installed in the cold water supply line. Zip recommends a valve rated at 3.5 bar
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
15 mm or half inch OD 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.
.
Installation Procedures Continued
Note: Ensure the brass hexagonal fitting is
securely held with an appropriate spanner
while tightening the plumbing connections.
Exposed power and water are
connected through base.
Concealed power and water are
connected through rear.

Zip Econoboil - Installation & Operating Instructions - 82790 - January 2004 Page 7 of 12
Inlet water Temperature 15°C 10°C
2.5 Litre models 16 minutes 17 minutes
5.0 Litre models 16 minutes 17 minutes
7.5 Litre models 23 minutes 24 minutes
Installation Procedures continued
c) Electrical
This unit is designed for connection to 220-240 volt AC power supply via a
concealed electrical connection.
For exposed electrical connection the unit is fitted with a power cable connected
directly to the terminal block through the heater base.
For concealed electrical connection, fit a power cable from the rear through the
chassis opening provided directly to the terminal block as shown.
Step 4 – Assembling
Without the cover on, turn the water on to check for any leaks. These should be
apparent in a couple of seconds. If all is dry then isolate water and replace cover.
If there are any leaks re-visit plumbing instructions.
With the cover on, fit the red escutcheon over the outlet tube and apply PTFE
tape to the threaded portion of the outlet tube.
Screw the tap assembly clockwise onto the outlet tube until it touches the
escutcheon without pressure. Continue to turn the tap one full rotation until the
handle is fully vertical. If the tap still “feels loose” continue to rotate one further
turn leaving the tap in a vertical position.
Step 5 – Commissioning
Check previous steps. Turn water supply ON, check connections for leaks.
Turn power ON. After a short period, boiling water will be available and will be
maintained close to boiling point thereafter. Initial heating periods are :
Applying PTFE tape
The escutcheon located
between the tap and case
Operating Procedures
Tap Operation
Zip Econoboil is fitted with a two-way safety tap for instant boiling water.
For instant boiling water, gently pull the top of the tap forward.
Boiling water will flow until the tap handle is released.
This operation gives fingertip flow control for safe filling of cups and mugs.
To fill larger vessels such as teapots and saucepans, rotate the tap 180
degrees and depress it until it locks into a horizontal position.
Boiling water will flow until the tap is returned to its normal vertical position.
This operation allows the vessel to be filled without holding your hand where it
may be affected by steam.

Page 8 of 12 Zip Econoboil Installation & Operating Instructions - 82790 - January 2004
Problem Solving
Earthing Continuity Verification
Warning: this appliance must be earthed.
Following installation or any remedial service the earthing continuity of the heater
must be checked by a qualified technician using an appliance tester, or continuity
tester of accuracy Class 5 or better. Class 5 denotes an accuracy of 5% full scale
deflection.
1. Isolate power supply.
2. Set meter to 0 ohm with leads connected together.
3. Connect one test lead to the earth pin on the three pin plug.
4. Connect the other test lead to a bare patch of metal (preferably on the edge)
of the top of the cover, then to the front cover of the unit, and then to the tap
top under the plastic paddle. This can be achieved by inserting the probe up
from behind the paddle without losing water.
Warning- the water may be boiling - show extra care.
5. Test that in every instance the electrical resistance does not exceed 1 ohm.
If required, an earth continuity test can be
performed by testing between the earth pin on
the products lead and a exposed piece of metal
on the case.
SYMPTOM POSSIBLE CAUSE SOLUTION
Fails to fill on inital startup. No power supply or no water supply.
Possible internal adjustment needed.
Check power and water is available and
turned on. If this does not rectify the
problem call Zip on 0870 608 8888.
Runs out of boiling water and fails to refill. Not
heating. Outlet tap dripping. Overflow from vent.
Excess team from the vent or overload tripping.
Overload tripping but no excess steam. Low water
temperature.
As above. As above.
Operating Procedures continued
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.

Zip Econoboil - Installation & Operating Instructions - 82790 - January 2004 Page 9 of 12
Temperature Setting
Factory setting for a
7.5 litre
Switch No. 1 is ON.
Factory setting for
2.5 litre to 5 litre
All switches OFF.
All models - when altitude is above
1000 meters or there is excessive
steam evident set No’s. 1 & 2 ON.
Wall Mounting Template Dimensions & Electrical Diagram
2.5 L, 5 L & 7.5 L HB SINGLE ELEMENT WITH MMS PCB
CONTROLLER WIRING DIAGRAM

Page 10 of 12 Zip Econoboil Installation & Operating Instructions - 82790 - January 2004
Spare Parts List
KEY PART NO. DESCRIPTION
1 90512 Escutcheon Kit
2 90502 Tap Assembly Kit Complete
3 90501 Tap Top Kit
4 90588 Silicon Elbows Kit
5 90578 Solenoid Assembly Kit - 240 volt - flow rate 0.5 ltr / minute
6 90586 Econoboil PCB Kit
7 90579 Overload Kit 90 deg
8 90585 Element Kit 7ltr
90584 Element Kit 5ltr
90583 Element Kit 3ltr
9 90577 Level Sensor Kit 7ltr
90576 Level Sensor Kit 5ltr
90575 Level Sensor Kit 3ltr
10 90581 Tank Gasket Kit 5 & 7ltr
90580 Tank Gasket Kit 3ltr
11 90587 Temperature Probe Kit