Zip HydroTap G4 BC100/75 User manual

802411 v3.05 09.20 HT BC Compact Instructions Page 1 of 28
Affix Model Number Label
Here
802411
BC100/75 range
Zip HydroTap G4
Installation and Operating Instructions
®

Page 2 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Tap Options
The Zip HydroTap G4 appliance series offers a range of interchangeable taps to suit the customer’s needs
Arc / Cube Mixer
Classic All-In-One Celsius All-In-One
Arc / Cube Tap
Classic Tap
Elite Tap
These taps are directly compatible with the HydroTap G4
Command Centre.
The All-In-One Tap is a stand alone tap that may be used
as an alternative to any of the above combinations.
The Mixer tap range is an additional series of taps that
may be used in conjunction with any one of the taps
shown above, to create 4-in-1 models

802411 v3.05 09.20 HT BC Compact Instructions Page 3 of 28
HydroTap Specifications
Installation Checklist .................................................................................................................... 4
General Product Features............................................................................................................ 5
Important Safety Instructions ....................................................................................................... 6
Warnings and Regulatory Information.......................................................................................... 7
Major Components and Accessories ........................................................................................... 8
Technical Specification ................................................................................................................ 9
Before Installation and Site Requirements................................................................................... 10
Installation Instructions
STEP 1 - Fit the tap to the benchtop or sink before installing the Command Centre.
(Refer to the Tap installation instruction book 803341)
STEP 2 - Check for adequate ventilation
Section 2- Ventilation
2.1- Ventilation for All Models............................................................................................ 11
2.2- Cupboard Air Circulation ............................................................................................ 12
STEP 3 - Install the Booster Heater (if required)
Section 3 - Booster Heater Installation
3.1- Product Description.................................................................................................... 14
3.2- Installation Procedure ................................................................................................ 15
3.3- To Remove / Install the appliance ............................................................................. 15
3.4- Braided Hose Connections ........................................................................................ 16
STEP 4 - Install the Command Centre
Section 4 - Command Centre Installation
4.1- External Bypass Valve .............................................................................................. 17
4.2- Hose and tube fitting.................................................................................................. 17
4.3- Model BC .................................................................................................................. 18
4.4- Model AIO Mains ....................................................................................................... 19
4.5- Model AIO Vented...................................................................................................... 20
4.6- Model 4-In-1 Vented .................................................................................................. 21
STEP 5 - Commission the HydroTap
Section 5 - Commissioning
5.1- Select the Language.................................................................................................. 22
5.2- Filter Flush ................................................................................................................. 22
5.3- Boiling Calibration...................................................................................................... 23
5.4- Booster....................................................................................................................... 23
5.5- Safety Sensor Calibration .......................................................................................... 24
5.6- Command-Centre Flush............................................................................................. 24
Troubleshooting Table ................................................................................................................. 25
End of Life Disposal ..................................................................................................................... 26
Contact Details............................................................................................................................. 28
Index

Page 4 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Before Installation:
A. Read the instructions and check if there is adequate space to mount all of the components.
B. Note: Not all fittings are supplied with the appliance kit. Isolation valves are not supplied.
C. Check the mains water pressure is between 172 - 700kPa and 200 - 700 kPa when a booster
is installed
D. Check the water quality to determine if extra filtration will be required.
NOTE: This product must be fitted to a potable water supply
E. Check the appliance rating plate and ensure correct power is available for the appliance.
F. Check the under counter cupboard supporting the appliance is adequate for
the total weight of the appliance, when full of water.
Before Commissioning:
1. Check the unit has been installed correctly.
2. Check all plumbing fittings have been tightened.
3. Ensure the outlet and vent pipes are positioned to drain correctly.
4. Ensure there is adequate ventilation.
5. Check all tubes from the Command Centre to the tap, have a constant rise and there are no
sags or kinks in the hoses.
6. Check all electrical connections are correct and there are no loose wires.
Commission: (see section 5)
7. Flush the supply line before connecting.
8. Turn on the water and check for leaks.
9. Flush the filter(s).
10. Where applicable, programme the unit to suit the customer’s requirements.
Installation Checklist

802411 v3.05 09.20 HT BC Compact Instructions Page 5 of 28
Thank you for purchasing a Zip HydroTap. Please read and follow these instructions carefully to ensure safe
and trouble free service. If service is required, please call 1800 460 222.
What is the Zip HydroTap ?
The Zip HydroTaps are electronically controlled, filtered, Boiling water and Chilled water drinking systems for
kitchens and tea rooms. The HydroTap units are under bench drinking water appliances with a dispensing
tap mounted on a sink or bench, which has been designed for commercial applications. These units utilise
a conventional refrigerant compressor to chill the water and an immersion heating element to boil the water.
These units dispense boiling water (factory set to 98°C) and chilled water (factory set to 6-10°C). These units
are NOT designed to be used for sanitary fixtures.
The Boiling water units are fitted with a tap mounted, child safety lock. In addition, there are various energy
saving options accessible via the main menu. Each unit is equipped with a self-calibrating program which
caters for altitude adjustment. The water filter is a disposable item which will require periodic replacement and
is covered by a limited OEM warranty.
It is important that the Installation be done safely, correctly and completely, in order to utilise all the benefits
the HydroTap can provide. Each unit can be ordered with the Tap Head Assembly for Disabled use. The
disabled levers are supplied with Braille caps for the visually impaired.
General Product Features
ON-OFF Switch
Command centre
Din plug
(for accessories)
IEC Socket

Page 6 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Important Safety Instructions
This manual contains important safety and installation instructions for the Zip HydroTap G4.
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. Children should be
supervised to ensure that they do not play with the appliance.
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 shall not play with the appliance. Cleaning and user maintenance shall not be
made by children without supervision.
Refrigerant
The Zip HydroTap unit contains 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 repaired only by a qualified technician. 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 condensed droplets may discharge through a vent outlet at the tap. If the tap is not
installed using the Font pedestal, ensure the tap body is located so the tap outlet safely dispenses into the
sink bowl area.
Lifting
Take care when lifting the Zip HydroTap unit. Some units may exceed safe lifting limits. If you feel this is
beyond your personal capabilities, please seek assistance with the lift. The weights of the units are marked
on the packaging. Do not lift the unit by the front cover or any connections at the top rear of the unit. Refer to
the technical specification for the weight of your product.
Airflow
The ambient operating temperatures, when installed in a cupboard, must be between 5ºC - 35ºC. The
system will operate satisfactorily only if proper air ventilation is provided and only if the recommended air
gaps of 50mm on each side are provided. See section 2 for correct Installation details.
Altitude
Water boils at varying temperatures at different altitudes. Your HydroTap adjusts for this during startup
calibration and will recalibrate itself on a regular basis.
Frost Protection
If this appliance is located where the 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.
!

802411 v3.05 09.20 HT BC Compact Instructions Page 7 of 28
Important Safety Instructions
Positioning
It is important to ensure the Command Centre is positioned in an accessible area close to the floor level. The
unit must have its base mounted in a horizontal position with all inlets and outlets facing up. The Tap must
be located above the Command Centre and positioned so that it dispenses into the sink bowl with ample
clearance for a cup or tea pot.
!
WARNINGS
1. The Zip HydroTap unit must be earthed. The resistance of the earth
connection from each exposed metal part must be less than 1 ohm.
2. All Installation and service work must be completed by trained and suitably
qualified Tradespeople. Faulty operation due to unqualified persons working
on this product, or any other Zip product may void warranty coverage.
3. Plumbing and electrical connections must be made in accordance with local
regulations and relevant standards. In Australia and New Zealand: Plumbing
standard AS/NZS 3500 & Electrical Wiring Rules AS/NZS 3000.
4. This HydroTap product is rated for 230V 50Hz AC operation.
5. This unit must be installed with adequate clearances of 50mm on all sides,
and 200mm above, to allow for air circulation. Additional means of ventilation
is critical if the vent kit, as supplied, cannot be fitted.
6. Flush water supply lines before any plumbing connections are made, to
prevent sediment from affecting operation.
7. The Command Centre must not be located near, or cleaned with water jets.
8. This product is designed for indoor use and must not be installed outdoors or
exposed to the elements of nature.
9. 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.
10. For water taste and quality reasons, following any non-use period of more
than 72 hours, Zip recommends to perform a system flush. Failure to flush
the system may affect water quality.
11. Due to the process of continuous improvement, Zip Water reserves the right
to change details mentioned in this manual, without notice.

Page 8 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Major Components and Accessories
Parts supplied Description
1 x Tap
option with hoses
(Classic tap shown)
1 x HydroTap
Command Centre
with air and water
filters
1 x Mains water
connection hose
1 x Connector +
Strainer Sub-assy
Vent Kit
1 x Inlet vent
1 x Outlet vent
9 x Screws
1 off
HydroTap Booster
Heater & hoses.
(supplied with
BCHAV model)
1 x Flow Restrictor
and Tee piece for
Mixer taps and select
models
1 x Mixer Tap
for 4-In-1 and select
models (with hoses)
1 x Installation
Instructions
(this book) and
1 x User Guide
Accessories Description
HydroTap Booster
Water System with
connection hoses
Font Kit for
Arc & Cube Models
Font Kit for Classic &
Elite Models
Replacement Filter
Disabled Lever Kit
Install
Instruct
User
Guide

802411 v3.05 09.20 HT BC Compact Instructions Page 9 of 28
Technical Specifications
** Add an extra 4-5 kg when full of water
Power
outlets
required
Power
Rating
(kW)
Boost
Rating
(kW)
Unit Dimensions
W x D x H (mm)
with air duct
**Dry
Weight
(kg)
Boiling Chilled
BC100/75 1x10A 2.05 N/A 280 x 470 x 335 24
4 in 1
BCHA 140/75 2x10A 2.05 2.2 280 x 470 x 335 24
All in One
BCHA-A 100/75 1x10A 2.05 N/A 280 x 470 x 335 24
BCHA-AV140/75 2x10A 2.05 2.2 280 x 470 x 335 24
Note:
• The Cup measurement =167ml and the Glass measurement = 200ml
• Chilled water will continue to be dispensed after the rated capacity has been used, although this may be
at slightly higher temperature.
Models
BC Boiling and Chilled
BCHA 4 in 1
A All in One - Mains
AV All in One - Vented
D Disabled lever controls (optional accessory)
Model
Cups of
Boiling
Water per
Hour
Glasses
of Chilled
Water per
Hour
BC 100 75

Page 10 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Before Installation
Before installing ensure that the following have been provided at the installation site:
• Review all the technical specifications.
• Ensure the underbench can support the product weight when full of water,
(allow an extra 4-5kg when full. )
• Sufficient space in the cupboard to install all of the Command Centres in accordance with these
Installation Instructions. Refer to technical specification for dimensions. Make allowance for a booster
heater and / or water softener if required. Refer to section 3 & 4, for Installation instructions.
• For Zip HydroTap 100/75 models, a 220-240V, 10A AC power outlet will be required. For Zip HydroTap
140/75 models, two 220-240V, 10A power outlets will be required (one power outlet for the Zip
HydroTap and the other for the Booster heater).
NoteNote: Check all cable and hose lengths against inlet /outlet positions before proceeding
(See section 5 for general layout).
• A potable water supply connection with isolating valve inside the cupboard within reach of the braided
hoses and positioned so that the connection point and the stop cock will not be obstructed when the
Command Centres are installed.
• For the mains pressure All-In-One, an external hot and cold water supply will be required.
• If an external filtration or water softening device is required, then it is important to allow extra space for
these items.
• A cold water supply with a minimum working pressure of 172kPa and a maximum working pressure of
700kPa connected via an isolation valve and 200 - 700kPa when a booster is installed.
• The fitting of an air flow duct, attached to the right hand side of the unit, requires a rectangular cut size
of 284mm x 45mm, to provide adequate warm air displacement. See section 2.
• The appliance must be placed with its base in a horizontal position.
IMPORTANT! Do not proceed with the installation if these requirements are not met.
!
Special Tools Required:
In addition to normal tools, the following will be required:
For the standard and Mixer taps:
• 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.
For the All-In-One tap:
• 50mm diameter sheet metal hole punch for sink tops (not supplied)
• 50mm diameter hole saw for timber bench tops (not supplied)
• Nut runner tube spanner (supplied) for fixing tap assembly.

802411 v3.05 09.20 HT BC Compact Instructions Page 11 of 28
!
4mm Buffer Pad to
ensure ventilation gap
2.1 Ventilation for All Models
Proper air circulation must be provided for all models. The system will operate correctly only if the recommend-
ed air gaps are achieved during installation.
It is important that the 4mm door buffers are fitted to the inside edge of the cupboard door to allow sufficient air
circulation inside the cupboard (see diagram below).
IMPORTANT: Allow clearance of 50mm either side, and 200mm above the Command Centre.
Section 2
Ventilation
Section 1
Tap Installation
Refer to the Tap installation instruction book 803341.

Page 12 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Ventilation
When installing air flow ducts, the following tools will be required:
• Jigsaw and a 12mm Drill
• Keyhole or Wall Board saw.
Cool air IN
Warm air
OUT
Air inlet vent position
Airflow through the cupboard
B
D
Door outlet vent
1. Drill four pilot holes
12mm dia.
2. Finish the cutout using
a jig saw and keyhole
or Wall Board saw
If the air flow, using the silicone door buffers, is insufficient, it will be necessary to fit a standard HydroTap
vent kit, which ensures heat dissipation through natural convection via installed vents.
For high use applications, where the cupboard space temperature is near 35°C, or higher, the inlet vent
(See Item B below) and silicon buffers, need to be fitted. If the airflow is still insufficient to maintain normal
operating temperatures then the door outlet vent (See item D below) will need to be fitted.
Alternatively a fan kit may be installed, using the AUX din plug of the right hand side of the appliance
(Contact your local service centre for availability).
Note: The vent kit has to be installed in a way that allows air to be drawn in from the bottom of the cupboard
and expelled through the top of the cupboard. Therefore placement of the outlet vent should be towards the
top of the door or on the side of the cupboard.
2.2 The following instructions are critical if there is insufficient cupboard air circulation
Cut-out details

802411 v3.05 09.20 HT BC Compact Instructions Page 13 of 28
Typical Cut out procedure for
B
Ventilation
Cut-out details
Air inlet vent
1. Mark out and cut the air inlet and door outlet holes as shown
2. Ensure the air inlet vent and air outlet vent are positioned at opposite ends
of the same cupboard space.
3. Fit the inlet vent, as shown and secure with 5 screws
4. Fit the outlet vent, as shown in the hottest part (top) of the cupboard and
secure with 4 screws
BD

Page 14 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Section 3
Booster Heater
Mount base
horizontally
3.1 Product Description
The boost unit is a compact, electronically
controlled auxiliary water heater. It is intended to
provide pre heating of water before it enters the
Zip HydroTap G4 boiling tank. The Booster is
supplied as standard equipment with all 140 cup
models. However, it may be later installed, as an
accessory for the 100 cup models, to increase
their delivery to 140 cups.
280mm
NoteNote 1: water connection
Blue marking: water in
Red marking: water out.
The braided hoses cannot be lengthened.
NoteNote 2: The electrical cable length is 1.0
metre.
NoteNote 3: Position the Booster within reach
of the fixed hose lengths, keeping the
Booster as close as possible to the Com-
mand Centre inlet/ outlet fittings.
NoteNote 4: Ensure the Booster heater is
mounted in an upright position (as shown)
with a horizontal base.
Booster Specifications:
Rating Unit
Nominal Power Rating 2.2 kW
Nominal Current 10 A
Electric Supply 50Hz AC 230 V
Elect ex and plug (black) - 1 metre length (with 90º Australian plug) 10 A
Fixed Flow Rate 1.2 L/min
Minimum water pressure 200 kPa

802411 v3.05 09.20 HT BC Compact Instructions Page 15 of 28
Booster Installation
3.2 Installation Procedure
Site requirements
• The appliance must only be installed in a frost-free area. Never expose the appliance to frost.
• The appliance is designed for wall mounted installation and must to be installed with water connectors
facing upwards.
• The appliance complies with protection class IP 25.
• The 400mm braided hoses supplied with the unit cannot be lengthened.
• The 90°elbow hose ends, should be fitted to the inlet and outlet connections on top of the Booster.
• The hot water outlet hose must be thermally insulated with the insulation provided.
Tilt Forward Lift UP
Release
NOTE: Remove the backing plate for wall mounting
3.3 To Remove / Install the appliance
1. Insert a flat head screwdriver all the way into the lock.
2. Gently angle the screwdriver upwards by approximately 10° as shown in the image below.
3. Pull the appliance forwards by approximately 15° as shown.
4. Carefully pull the appliance upwards to complete the removal process, taking care not to break the
lower clips
5. To install, place the appliance on the wall bracket and snap into position (see illustration below).
Take care
not to break
the lower
clips when
removing or
installing the
Booster
!
Installation

Page 16 of 28 802411 v3.05 09.20 HT BC Compact Instructions
NoteNote 1: This appliance is intended for use with the Zip HydroTap Command Centre.
NoteNote 2: Water connections must be pointing vertically upwards.
NoteNote 3: The booster unit should be installed as close as possible to the Zip HydroTap Unit as
the 400mm connection hoses cannot be lengthened.
Booster System
3.4 Braided hose connection s
1. The cold water inlet (blue) and hot water outlet (red) are marked on the rating plate. Connect the
braided hoses from the ‘Bypass Out’ fitting to the water inlet of the booster unit (Marked Blue) and
from the outlet of the booster unit (Marked Red) to the ‘Bypass IN’ fitting on the Zip HydroTap unit.
Avoid exerting any mechanical pressure on the appliance. This can be achieved by applying a spanner
on the flats of the inlet and outlet connections when tightening the braided hose connectors. Do not
overtighten! Tighten the braided hoses by hand, then turn an additional 90°- 180° with a spanner
2. Once the water connections have been made, check for any leaks and rectify as necessary.
Hot Water
Connection
(outlet, G1/2”)
Strainer
Cold Water
Connection
(inlet, G1/2”)
Hold the hexagon while
tightening the braided
hose fittings
Braided Hoses
Typical Installation

802411 v3.05 09.20 HT BC Compact Instructions Page 17 of 28
John Guest fittings (Insertion and removal)
Be careful when cutting the poly tube so that there are no rough edges and that the tube is not distorted.
1. Use a sharp knife to ensure the tube has a clean,
straight edge. Do not cut at an angle.
2. Remove any swarf or unwanted material.
3. Push the tube into the John Guest fitting making sure
all connections to the John Guest fittings are pushed
in past the “O”ring to full depth, at least 15-16mm.
4. Check for a good joint by pulling back on the tube. If
the tube comes out, of the fitting, repeat the above
step.
5. To remove the tube, press the collet into the fitting
and at the same time pull back on the tube.
If no external lter is in-
stalled, select position A.
If an external filter is
installed, select position B
NOTE: Before you install a unit, determine whether a water softener or an external filter is required.
4.1 External Bypass Valve
The diverter bypass valve allows the user to choose to have the boiling feed water bypass the internal filter
and only be filtered by external filtration. The diverter valve is located at the rear panel of the Zip HydroTap
Command Centre on the filter door side. Refer to the image below to determine the correct valve position.
Section 4
Command Centre Installation
A
Rotate 90°
only
1
2
3
4
B
Rotate 90°
only
1
2
3
4
4.2 Hose and tube fitting
• Remove all caps from the top of the Command
Centre (except the mixer caps)
• Only remove the mixer caps if a mixer tap is to be
fitted.
• Fit the foam insulation to the Blue and to the
White tubes after trimming them to length
• Install the mains water braided hoses to the
Command Centre before locating the unit in
place.
NOTE: Do not overtighten
Connector + Strainer
90° Bend end
of Braided Hose
To HydroTap
Command Centre
Braided hose for
Mains Water Supply
From Mains
Water Supply

Page 18 of 28 802411 v3.05 09.20 HT BC Compact Instructions
4.3 Model: Boiling Chilled BC100/75
Installation Instructions
Note: The tube lengths are matched to the pump performance and therefore CANNOT be lengthened
: Not required for standard BC HydroTap models.
280mm
RED
CLEAR
BLUE
BRAIDED
Max 1000mm
Min 70mm
USBMAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT CHILLED
OUT
Note:
- Mains hose
length is 750mm
- Plug and Cord
length is 1800mm
Position the
Command Centre
close to the outlet
tap, within reach of
the hose and cord
lengths supplied
Note:Note: the hosesthe hoses
need to have aneed to have a
constant downwardconstant downward
gradient to thegradient to the
Hydrotap to allowHydrotap to allow
all water to drainall water to drain
back into the tanks.back into the tanks.

802411 v3.05 09.20 HT BC Compact Instructions Page 19 of 28
Installation Instructions
Hot: Left
Cold: Right
H
Note: to activate the filter, flush at least 10L of water through the filter before connecting to a softener or to a
Booster heater.
: Not required for AIO mains pressure HydroTap.
Note: The tube lengths are matched to the pump performance and therefore CANNOT be lengthened
4.4 Model: All-In-One Mains Pressure
RED
CLEAR
BLUE
BRAIDED
USBMAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT CHILLED
OUT
Note:
- Mains hose
length is 750mm
- Plug and Cord
length is 1800mm
Position the
Command Centre
close to the outlet
tap, within reach of
the hose and cord
lengths supplied
Note:Note: the hosesthe hoses
need to have aneed to have a
constant downwardconstant downward
gradient to thegradient to the
Hydrotap to allow allHydrotap to allow all
water to drain backwater to drain back
into the tanks.into the tanks.
External HOT and COLD
isolation valves
(not supplied)
Tee piece
(supplied)

Page 20 of 28 802411 v3.05 09.20 HT BC Compact Instructions
Installation Instructions
4.5 Model: All-In-One Vented
Note: The tube lengths are matched to the pump performance and therefore CANNOT be lengthened
RED
CLEAR
BLUE
BRAIDED
USBMAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT CHILLED
OUT
Booster
HT Mixer
connections
BRAIDED BRAIDED BRAIDED BRAIDED
Note:
- Mains hose
length is 750mm
- Plug and Cord
length is 1800mm
Position the
Command Centre
close to the outlet
tap, within reach of
the hose and cord
lengths supplied
Note:Note: the hosesthe hoses
need to have aneed to have a
constant downwardconstant downward
gradient to thegradient to the
Hydrotap to allow allHydrotap to allow all
water to drain backwater to drain back
into the tanks.into the tanks.
COLD isolation valve
(not supplied)
Tee piece and Flow
Restrictor (supplied),
to Mixer