Zip HydroTap G4 User manual

804052 - CS Residential- Installation Instructions - Sept 2016 - v3.01 Page 1 of 20
Zip HydroTap G4
Installation Instructions
Filtered Boiling, Chilled and Sparkling drinking water for Residential kitchens and tea rooms.
®
Affix Model Number Label
Here
804052
CS Residential

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Tap options
Arc / Cube Tap
Celsius Tap
Classic Tap
Elite Tap
The HydroTap appliance series offers a range of interchangeable taps to suit the customer’s needs (See
options below). For ease of installation, it is recommended to fit the tap before installing the undersink unit.
The installation procedure for each of the taps is detailed in a separate tap installation instruction book No.
803341, supplied with the tap.
For all operational features of the HydroTap, please refer to the CS User manual No.801981.

804052 - CS Residential- Installation Instructions - Sept 2016 - v3.01 Page 3 of 20
HydroTap Specifications
Installation check list....................................................................................................................4
General product features.............................................................................................................5
Important Safety Instructions.......................................................................................................6
Warnings and Regulatory Information..........................................................................................7
Major components and Accessories............................................................................................8
Technical Specification................................................................................................................8
Before Installation and site requirements.....................................................................................9
STEP 1 - Measure and cut all the tap holes before fitting the taps
Section 1 - See Tap Installation instructions, (supplied with the tap ) No. 803341
STEP 2 - Check for adequate ventilation
Section 2 - Ventilation
2.1 - Ventilation - All Models.............................................................................................10
2.2 - Ventilation diagram - CS Models..............................................................................10-12
STEP 3 - Fit the CO2Gas cylinder
Section 3 - CO2Cylinder and Regulator
3.1 - Connect, secure and test the CO2 gas cylinder.......................................................13
3.2 - Connect the regulator...............................................................................................13
3.3 - Connect the gas hose to the regulator......................................................................13
STEP 4 -Install the underbench unit
Section 4 - Underbench unit installation
4.1- Hose and Tube fittings ; J.G. Fittings.........................................................................14
4.2- Connect the gas hose to the undersink unit...............................................................14
4.3- Test for gas leaks.......................................................................................................15
4.4- Installation and connection........................................................................................15
4.5- Chilled Sparkling Models CS175...............................................................................16
4.6- Celsius Chilled Sparkling Model CSHA175...............................................................16
STEP 5 -Commission the HydroTap
Section 5 - Commissioning
5.1- Select the language...................................................................................................17
5.2- CO Purge...................................................................................................................17
5.3- Filter Flush.................................................................................................................18
Trouble Shooting
Trouble Shooting Table................................................................................................................19
End of life disposal.......................................................................................................................19
Contact details.............................................................................................................................20
Index

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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 and special tools are
not supplied (See Technical Specifications for details).
C. Check the mains water pressure is between 250 - 700kPa
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. Flush the supply line before connecting to the undersink unit.
3. Check all plumbing fittings have been tightened.
4. Ensure the outlet and vent pipes are positioned to drain correctly.
5. Ensure there is adequate ventilation.
6. Check all tubes from the underbench unit to the tap, have a constant rise and there are no
sags or kinks in the hoses.
7. Check all electrical connections are correct and there are no loose wires.
Commission: (See section 5)
8. Turn on the gas and water and check for leaks.
9. Turn on the power.
10. Purge the CO2.
11. Flush the filter.
12. Where applicable, programme the unit to suit the customer’s requirements.
Installation checklist
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 638 633

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What is the Zip HydroTap ?
The Zip HydroTaps are electronically controlled, filtered, Boiling, Chilled and Sparkling 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 may be used for residential applications. These units
utilise a conventional refrigerant compressor to chill the water and (for BCS) an immersion heating element to
boil the water and all utilise a CO2gas cylinder to carbonate the chilled water. Depending on the model, these
units will dispense boiling water (factory set to 98°C) chilled water (factory set to 5-10°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 boiling unit is equipped with a self-calibrating program
which caters for altitude adjustment. The 2kg CO2bottle and the water filter are disposable items. Both will
require periodic replacement and are 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 Classic and AIO HydroTap 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
HydroTap CS and CSHA undersink unit
Usage:
The Zip HydroTap is intended for use in residential household and similar applications such as, Rural and
urban residential Kitchens, Hotels, Motels, Bed and Breakfast and other residential type environments
ON-OFF Switch
Command centre

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Important Safety Instructions
This manual contains important safety, 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 R134Arefrigerant 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
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 specifications 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 ventilation details.
Positioning
It is important to ensure the underbench unit is positioned in an accessible area close to the floor level. The
unit must have it’s base mounted in a horizontal position with all inlets and outlets facing up. The Tap must be
located above the underbench unit. See section 4 for details.

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Important Safety Instructions
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. All Plumbing must comply with AS/NZS3500.
4. All Electrical must comply with AS/NZS3000
5. All Plumbing and Electrical connections must be made in accordance
with local regulations.
6. This HydroTap product is rated for 230V 50Hz AC operation.
7. Underbench units must never be located near, or cleaned with water
jets.
8. Zip HydroTaps are not to be exposed to the elements of nature
9. Due to the process of continuous improvement, Zip Heaters reserves
the right to change details mentioned in this manual, without notice.
CO
2
Cylinder Warnings:
• Pressurised container.
• Protect from sunlight.
• Contains gas under pressure, may explode if heated.
• Do not expose to temperatures exceeding 50˚C.
• Do not pierce or burn, even after use.
• Do not refill – non rechargeable
• Ensure cylinder is empty before disposal.
• Do not expose to naked flame or any incandescent material.
• Keep out of reach of children.
• High concentration of gas may cause asphyxiation.
• Use only in ventilated areas.
• Unless well ventilated, store the cylinder in an area no less than
20 cubic meters for each kg of gas. (See section 4)
• Use only in an upright position.
• This bottle must be used with the approved pressure regulator.
• Avoid shock.
• Use according to MSDS. (Material Safety Data Sheet).

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Major components and accessories
Parts supplied Description
1 off 4
HydroTaps
with hoses
(Classic tap shown)
1 off
HydroTap
Undersink Unit with
air and water filters
1 off
Mains water
connection hose
Vent Kit
1 x Inlet vent
1 x Outlet vent
9 x Screws
1 x User guide and
1 x Quick start guide
1 off
CO2gas cylinder &
regulator assy.
Accessories Description
Font Kit for
Arc & Cube Models
Font Kit for Classic &
Elite Models
Replacement Filter
Disabled lever Kit
User
Manual Quick
start guide
Technical Specifications
CS = Chilled Sparkling, Filtered
CSHA = Chilled Sparkling, Hot & Ambient (Mains)
D = Disabled lever controls, (Order as an option)
Product covered by these
instructions:
** Add an extra 5 kg when full of water
GPO's
Required Power Rating
(W)
Booster
Rating
(W)
Unit Dimensions
W x D x H
(mm)
**Dry
Weight
(Kg)
Chilled Sparkling
CS 1x10A 1700 N/A 280 x 455 x 333 30
Celsius
CSHA 1x10A 1700 N/A 280 x 455 x 333 30
NOTE: chilled water will
continue to be dispensed
after the rated capacity has
been used, although this
may be at slightly higher
temperature.

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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 5kg when full. )
• Sufficient space in the cupboard to install all of the undersink units 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 CS and CSHA models, a 220-240Vac, 10A GPO will be required.
Note
Note: Check all cable and hose lengths against inlet /outlet positions before pro-
ceeding (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
undersink units are installed.
• For the mains pressure CSHA, an external hot and cold water supply will be required.
• A cold water supply with a minimum working pressure of 250kPa and a maximum working pressure
of 700kPa connected via an isolation valve.
• The appliance must be placed with it’s 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.
Section1
Tap Installation
Fit the Tap to the benchtop or sink before installing the undersink unit.
Refer to the tap installation book 803341

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2.1 Ventilation for All Models
Proper air circulation must be provided for all Boiling and Chilled models. The system will operate correctly
only if the recommended air gaps are achieved during Installation. The minimum requirement is for a 50mm air
gap either side and 300mm above of the undersink unit.
It is important that the 4mm door buffers (For all installations ) are fitted to the inside edge of the cupboard
door to allow suficient air circulation inside the cupboard. (See the diagram below).
IMPORTANT: See section 4 for clearances.
When installing air flow ducts, the following tools will be required:
• Jigsaw and 12mm Drill
• Keyhole or Wall Board saw.
Section 2
Ventilation
Min 300mm
455mm
4 min.
Buffer Pad
Clear Gap

804052 - CS Residential- Installation Instructions - Sept 2016 - v3.01 Page 11 of 20
Ventilation
Air inlet vent position
Airflow through the cupboard
B
D
rd
Cool air IN
Warm air
OUT
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 silicon 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 inlet vent and door outlet vent (See item D below) will need to be fitted.
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.
Cutout details

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Typical Cut out procedure for
B
Ventilation
Cutout deatils
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. If required, fit the outlet vent, as shown in the hottest part (top) of the
cupboard and secure with 4 screws
BD

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Section 3
CO2Cylinder
WARNING:
This cylinder mus be installed in an open plan area or in an enclosed room, with a volume no less than 20m3.
If more than 1 gas cylinder containing CO2is present within the same location, the recommended ventilated
area should be in proportion to the number of gas cylinders stored in that location.
A ventilated area is a non-enclosed area which could include the kitchen, living room etc.
See gas bottle and MSDS sheet for a complete list of warnings. (See: www.zipindustries.com)
3.1 Secure the cylinder mounting:
Secure the gas bottle supplied to a suitable wall, within 1 metre of the unit, in an upright position. This is done
by screwing the metal plate holding the Hook-and-loopstrap to a cupboard wall, 200mm above the floor or
base of the cupboard. Make sure the gas bottle can stand before securing to the wall.
Due to regulatory requirements the gas bottle must be stored securely and in an
upright position.
3.2Connect the regulator:
Make sure the regulator knob is turned fully anti-clockwise to the end-stop before fitting. Fit the regulator
to the gas bottle. Be aware that some CO2may be discharged from the connection to the regulator as the
bottle and the regulator are be assembled together. Any CO2released will be cold. Continue to screw on the
regulator to stop this leakage.
3.3Connect the gas hose:
Connect the braided gas hose to the threaded end to the regulator (Do not lose the small sealing olive).
NOTE: Care must be taken when working with high pressure carbon dioxide, and in no cases should the
normal operating pressure of 2.7-3.0 bar (270-300kPa) be exceeded.
Connect the unit to the mains power supply.

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Section 4
Undersink Unit Installation
John Guestfittings (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.
4.1 Hose and tube fitting. (Do not overtighten)
• Remove all caps from the top of the undersink unit
• 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 undersink unit before locating the unit in place.
4.2 Connect the gas hose:
Connect the braided gas hose to the top of the underbench unit via the John Guest fitting marked ‘Gas IN’ .
When commissioning, turn the gas ON by rotating the valve on top of the cylinder, anti-clockwise. Then adjust
the outlet pressure, by rotating the regulator knob in a clockwise direction, to between 2.7- 3.0 bar (green
zone)
NOTE: The arrow should sit in the green zone of the regulator gauge; it should not fall in the red or yellow
sections.
Installation

804052 - CS Residential- Installation Instructions - Sept 2016 - v3.01 Page 15 of 20
CO2pressure set zone: 2.7-3.0 bar
IMPORTANT:
4.3After replacing a bottle or after mak-
ing a gas connection, check for gas leaks:
Stage1:
1. Turn the gas OFF
2. Using soapy water applied with a sponge, or with a
brush, cover all of the gas joints with a liberal
amount of suds.
Stage 2:
1. Turn ON the gas
2. Inspect the joint for leaks
3. If any bubbles appear, the joint
will need to be resealed.
e
ak
s
t
h
j
i
t
Faulty seal joint
CO2Connections & Leak Testing
4.4
Installation and connection
• Install the undersink unit with the connections
shown below

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Installation Instructions
Note:
- Mains hose
length is 750mm
- Plug and Cord
length is 1800mm
Position the under
sink unit close
to the outlet tap,
within reach of
the hose and cord
lengths supplied
Note:
Note:
All
All
silicon tubes
silicon tubes
must be cut to
must be cut to
size. They must
size. They must
have a constant
have a constant
fall back to the
fall back to the
unit.
unit.
CS Models
CSHA Model

804052 - CS Residential- Installation Instructions - Sept 2016 - v3.01 Page 17 of 20
Section 5
Commissioning
5.2- CO2Purge
1. Press the [START] button to commence the purging
process.
2. Purge for 10 seconds and ensure all water has stopped
flowing through the tap. (You will hear the CO2gas
escaping from the tap).
3. Press the [Stop] button.
4. Press [Next] for the filter flush screen
The HydroTap is now ready to be commissioned.
• Turn ON the water and gas and check for any leaks.
• Turn the power ON at the GPO and at the side of the undersink unit
• Familiarise yourself with the operation of the Tap, in preparation for use (See User Manual)
• Follow the Installation instructions below (and review Section C of the User Manual).
• Initially you will be prompted to select a language
• After commissioning, the system may be customised by selecting further options in
Section G - Settings, within the User Manual.
5.1- Select the Language
Initial Commissioning screen Language selection screen

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OPEN Position
CLOSED Position
ON
OFF
Stop cock
operation
Commissioning
NOTE: For any subsequent filter changes or any operational procedures, please refer to the HydroTap user
guide, located inside the filter housing access door.
1. Press [Start] [Stop] buttons to start and stop the filter
flush.
2. Turn the flush line stop cock ON (See diagram).
3. Press [Start] and allow at least 10 litres of water to flush
through the filter.
4. The product details will be displayed in the screen.
5. Once the filter flush is finished, Turn the stop cock OFF
then press [Stop] to end filter flush mode.
6. Press [Next] for the Boiling Calibration screen.
Have a 10L bucket or similar container (not supplied) at the ready to hold a quantity of water that will be
ejected while the Filter Flush Mode is in operation. Open the filter access door on the front of the HydroTap
and the filter cartridge will be exposed. Located to the rear RHS of the cartridge is a flush line, approx 600mm
long and the flush line stop cock. Place the valve end of the flush line into the 10L bucket or container.
5.3- Filter Flush

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Trouble Shooting
System Fault
Message Possible Cause Solutions
Power board fault Electrical disruption Check power supply and all fuses
Interface fault Internal fault Call Zip Service
Level board fault Internal fault Call Zip 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
Cold sensor Open Internal fault Call Zip Service
Cold sensor Closed Internal fault Call Zip Service
Flood sensor Open Internal fault Call Zip Service
Condenser sensor Closed Internal fault Check Ventilation / Call Zip Service
Condenser sensor Open Internal fault Check ventilation / Call Zip service
Compressor driver fault No chilled water Call Zip Service
Condenser overtemp. Blocked air filter Remove blockage / Clean filter / check user guide
A DC Pump is faulty Internal fault Call Zip Service
Comp Fuse/Driver Fault Internal fault Call Zip Service
Flash Mem corrupted Internal fault Call Zip Service
Flow Sensor Fault Internal fault Call Zip Service
Call an electrician, a plumber, or Zip for a free call in Australia on 1800-638-633 for assistance, service, spare
parts or enquiries.
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

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Contact Details
The standard cup referred to in this publication is 167 ml (6 fl oz).
The standard glass is 200 ml (7 fl oz).
The terms “Zip” and “HydroTap” are registered trade marks of Zip Heaters
(Aust) Pty Ltd.
Zip products described in this publication are manufactured under one or more
of the following patents: AU675601, AU637412, AU635979, GB0422305,
GB2065848, US4354049, US5103859, US5099825 and SA2006/08043. Other
patents are in force and patent applications are pending.
Head Office
Zip Heaters (Aust) Pty. Ltd.
ABN: 46 000 578 727
67 Allingham Street
Condell Park NSW 2200
Postal: Locked Bag 80
Bankstown 1885 Australia
Website: www.zipwater.com
Facsimile: [phone]
Telephone: [phone]
Free Call: 1 800 638 633
As Zip policy is one of continuous product improvement, changes to
specifications may be made without prior notice. Images in this booklet have
been modified and may not be true representations of the finished goods. WMKA00099
AS 3498