Zip HydroTap G4 User manual

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 1 of 40
Zip HydroTap G4
Installation Instructions
Filtered Boiling, Chilled and Sparkling drinking water for Residential kitchens and tea rooms.
®
Residential Chilled Sparkling model
Residential Boiling Chilled Sparkling model
HydroTap AIO Tap
Affix Model Number Label
Here
802005
Residential
CS & BCS

Page 2 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
Tap options
The G4 applaince series offers a range of interchangeable taps to suit the customer’s needs
These three taps are directly compatible with the G4
under bench unit.
The All-In-One Tap is a stand alone tap that may be used
as an alternative to any of the above combinations. The
A-I-O is compatible with the G4 underbench unit.
The Mixer tap upgrade kits are additional kits that may be
used in conjunction with any one of the three taps shown
above, to create optional 4-In-1 and 5-In-1 models

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 3 of 40
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 ................................................................................................................ 9
Before Installation and site requirements..................................................................................... 10
STEP 1 - Measure and cut all the tap holes before fitting the taps
Section 1 - Tap Installation instructions
1.1 - HydroTap Classic and EliteTap Installation ............................................................ 11-13
1.6 - HydroTap Arc/Cube tap installations ....................................................................... 14-15
1.10 - Mixer tap installations ........................................................................................... 16-18
1.14 - All-In-One Tap Installations..................................................................................... 19-22
STEP 2 - Check for adequate ventilation
Section 2 - Ventilation
2.1 - Cut out details........................................................................................................... 23-25
STEP 3 - Install the Booster Heater (if required)
Section 3 - Booster heater Installation
3.1 - Booster Heater specifications and Installation.......................................................... 26-28
STEP 4 - Fit the CO2Gas cylinder
Section 4 - CO2Cylinder
4.1 - Connect and secure the CO2gas cylinder ................................................................ 29-30
STEP 5 - Install the undersink unit
Section 5 - Undersink unit installation
5.1 - Check the external bypass valve setting................................................................... 31
5.2 - mains water supply hose ......................................................................................... 31
5.3 - Model BCS................................................................................................................ 32
5.4 - Model CS .................................................................................................................. 33
5.5 - Model BCSHA - AIO Mains....................................................................................... 34
5.6 - Model BCSHAV - AIO Vented................................................................................... 35
STEP 6 - Commission the HydroTap
Section 6 - Commissioning
6.1 - CO2Purge................................................................................................................. 36
6.2 - Filter Flush ................................................................................................................ 36
6.3 - Boiling Calibration..................................................................................................... 37
6.4 - Booster activation ..................................................................................................... 37
6.5 - Sensor calibration ..................................................................................................... 38
Trouble Shooting
Trouble Shooting Table................................................................................................................ 39
End of life disposal....................................................................................................................... 39
Contact details ............................................................................................................................. 40
Index

Page 4 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
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 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. 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 undersink unit 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 6)
7. Flush the supply line before connecting.
8. Turn on the water and check for leaks.
9. Flush the filters (This commences auto calibration for Boiling models)
10. Activate / enable the Booster (If fitted)
11. Purge the CO2
12. Calibrate the safety sensor (for Boiling models)
13. Where applicable, programme the unit to suit the customer’s requirements.
Installation checklist

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 5 of 40
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, 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 has been designed 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 water filter and CO2bottle are disposable items which 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. The Classic and All-In-One taps may 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 BCS
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
Din plug
(for accessories)

Page 6 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
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 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
section 1.2 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.ed
Positioning
It is important to ensure the undersink 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 undersink unit. See section 1 for details.

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 7 of 40
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. Undersink 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.
CO2Cylinder 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).

Page 8 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
Major components and accessories
Parts supplied Description
1 off 3
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.
HydroTap Booster
Water System with
connection hoses.
(Model BCSHAV)
1 x Restrictaflow
valve and Tee piece
for BCSHAV and
select models
Accessories Description
Softener
and head assembly
Font Kit for
Arc & Cube Models
Font Kit for Classic &
Elite Models
Replacement Filter
Disabled lever Kit
4-In-1 and 5-in-1
upgrage Kits
Guide

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 9 of 40
Technical Specifications
BCS = Boiling, Chilled and Sparkling, Filtered,
CS = Chilled Sparkling, Filtered
A = All in One - Mains
AV = All in One - Vented
D = Disabled lever controls, (Order as an option)
Note: chilled water will continue to be dispensed after the rated capacity has been used, although this
may be at slightly higher temperature.
Note: the Cup measurement =167ml and the Glass measurement = 200ml
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)
Boiling Chilled Sparkling
BCS 1x10A 1700 N/A 280 x 470 x 335 24
Chilled Sparkling
CS 1x10A 300 N/A 280 x 392 x 335 24
All-In-One
BCSHA 1x10A 1700 N/A 280 x 470 x 335 24
BCSHAV 2 x 10A 1700 2200 280 x 470 x 335 24

Page 10 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
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 BCS & CS models, a 220-240Vac, 10A GPO will be required. For Zip HydroTap
BCSHAV model, a double 220-240Vac, 10A GPO will be required. (One outlet is for the Zip HydroTap
and the other for the Booster heater).
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 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 250kPa and a maximum working pressure
of 700kPa connected via an isolation valve.
• 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 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.
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.

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 11 of 40
Hole positioning:
Position the tap such that it dispenses into the sink bowl with ample clearance for a cup or tea pot.
Alternatively, the tap could be mounted away from the sink using a Zip Font, available as an accessory.
Section 1
Tap Installation
116
BC HydroTap Classic
TAP Recommended dispensing distance **
Elite 116 mm
HydroTap Classic 116 mm
HydroTap Arc/Cube 171 - 174 mm (Extended)
All-In-One 211 mm
Mixer - Arc neck 231 mm
Mixer - Classic 270 mm
Mixer - Cube neck 310 mm
** Check bowl depth and adjust accordingly
Single
Bowl
For
Elite,Classic
and Arc/Cube
35mm hole
For
A-I-O 50mm and
Mixer taps 35mm
hole
Double Bowl

Page 12 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
Apply a light smearing of silicon sealant on the
underside of the spacer to ensure a watertight fit.
1.2
Cut a 35mm hole in the bench / sink top.
BENCH TOP
1.1
Ø35mm
ALL THREAD
ROD
STAINLESS
STEEL
SPACER
SPIDER
CLAMP
NUT
BLACK PLASTIC
SPACER
Tap assembly exploded view and kitchen layout side view.
HydroTap Classic & Elite
HydroTap Classic
EliteTap
470mm
335mm Min 300mm

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 13 of 40
BLACK
PLASTIC
SPACER
1.3
Installation Instructions
Pass all the hoses, tubes and USB lead
through the 35mm hole.
1.4
35mm hole
Note: feed each of the three tubes and
electrical cable evenly in between the legs of
the SPIDER CLAMP when installing.
Fit the
STAINLESS STEEL
WASHER,
SPIDER CLAMP,
AND 6mm NUT. 6mm NUT
SPIDER CLAMP
STAINLESS
STEEL WASHER
Incoming water
Blue & White hoses to chilled
sparkling water outlet
Red hose to boiling
water outlet
Clear hose to Vent
Typical HydroTap Installation
(see section 5)
1.5
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: All
silicon tubes
must be cut to
size. They must
have a constant
fall back to the
unit.

Page 14 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
HydroTap Arc/Cube
The HydroTap Arc/Cube has a spout that may be fixed in one of 6 angular positions (depending on the
position of the rotary control) and fixed in one of two height positions. The spout is fixed and does not swivel.
NOTE: The tube kit must be fitted after the HydroTap has been mounted on the benchtop or sink.
Refer to the tube kit assembly instructions, supplied with the tap kit.
To reduce the risk of scalding, Position A should not
be selected with any of the Boiling water units. (See fig. 1.8)
1.6
1. Remove the 2 x spout locating screws and lower the spout to expose the plastic spring clip
NOTE: The plastic spring clip has two internal dimples that may be positioned in the 6 upper or 6 lower,
pre drilled holes in the spout (see diags. below & Figs. 1.7 & 1.8)
2. To reposition the spout, gently spread the plastic spring clip to release the dimples from the spout
holes. When released, slide the clip on the spout so that it ends up between the two rows of holes.
3. Rotate the plastic clip on the spout to orient the dimples, so they are in line with the newly selected
holes.
NOTE: When determining which of the 6 holes are required for the new spout height and orientation,
check the new plastic clip position will clear the undercut and that the wiring loom will not be pinched,
when assembled.
4. Slide the plastic clip up/down to engage with the selected holes, making sure the two dimples engage
simultaneously with the two selected holes.
NOTE: The clip will not fit correctly if one dimple engages before the other. Both dimples must engage at
the same time.
5. With the clip fitted to the newly selected holes,
carefully raise the spout (ensure the wiring loom is
a neat fit in the undercut and is located between the
open ends of the clip) until the clip locating holes are
in line with the spout locating screws.
6. Replace the 2 x locating screws.
7. If mounting on an uneven surface, apply a light
smearing of silicon sealant on the O ring to ensure a
watertight fit. (See fig. 1.9)
8. Pass the assembly through the 35mm hole and
position the tap so it discharges into the sink.
9. Fit the lower rubber seal to the threaded extension.
10. Secure the tap in position with the metal washer and
nut.
11. Fit the tube kit, as supplied.
To change the spout position
Spout locating
screws (2)
Plastic spring
clip
Upper locating
positions
Lower locating
positions
Clip locating
holes (2)
Undercut
for loom
Plastic spring clip
Dimples

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 15 of 40
Installation Instructions
Height adjustment (Fixed position options)
1.7
O-RING
LOWER
RUBBER
WASHER
WASHER
NUT
1.9 Mounting (See table on Page 11 )
Cut a 35mm hole in the bench / sink top.
BENCH TOP
Ø35mm
A A
Left Hand Control Right Hand Control
BCCB
50mm
Angular adjustment (Fixed position options)
1.8
NOTE: Position Ais
not recommended with
Boiling water units

Page 16 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
Cut a 35mm hole in the bench / sink top.
SINK TOP
1.10
35mm
Note: make sure the tap location will allow
the nozzle to drain into the sink.
Tap assembly exploded view and kitchen layout side view.
BRAIDED
HOSE x 3
Mixer Tap Installation
1.11
O-RING
LOWER
RUBBER
WASHER
WASHER
NUT
External Mains
Blue band
Mixer IN
Red band
Mixer Out
Note :
The mixer tap requires a Zip Restricta!ow
valve, as supplied, to be "tted in the cold
water supply line, from the isolation valve tee
piece, to the mixer tap. (See Fig. 1.13)
Min 300mm

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 17 of 40
1.12
Installing the Mixer Tap (Classic, Arc and Cube)
Installation Instructions
Sink top
O-ring
Lower seal
Washer
Securing nut
Mixer tap
Arc Mixer Tap
• Fit the O-ring into the recess on the underside of the Mixer tap. (Note: If mounting on an uneven
surface, a light smear of silicone on the O-ring will ensure a water tight seal)
• Pass the tap tubes and threaded extension through the 35mm hole and position the tap so that it
discharges into the sink.
• Fit the lower rubber seal to the threaded extension.
• Secure the tap in position with the metal washer and Nut.
• Affix the three hoses to the tap. Match the hose colours to the coloured bands on the copper extension
tubes. (See diag. 1.11)

Page 18 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
Installation Instructions
1.13
COLD isolation valve
(Not supplied)
Restricta!ow valve (Supplied)
Typical HydroTap 5-in-1 Installation (see section 5)
Tee piece (Supplied)
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: All
silicon tubes
must be cut to
size. They must
have a constant
fall back to the
unit.
Note: The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened
HydroTap
Mixer
Connections
RED
CLEAR
BRAIDED
POWER
CORD
USB
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
BLUE
BRAIDED
CLEAR
CHILLED
OUTLET
SPARKLING
OUTLET
CO2
IN
Booster

802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01 Page 19 of 40
Cut a 50mm hole in the bench / sink top.
SINK TOP
1.14
50mm
Note: make sure the tap location will allow the
nozzle to drain into the sink. (See Page 11)
All-In-One Tap
Installation
Min 300mm
335mm
1.15
• Fit the seal ring to the base of the tap and If mounting on an uneven surface, apply a light smear of silicone
sealant to ensure a watertight seal
• Mount the tap on top of the cut out hole after passing the usb cable and tubes through the 50mm hole
• Thread the cable and silicon tubes through the circular clamp block (Check the tube colour alignment with the
coloured dots on the clamp block). (See fig 1.16)
• Clamp the assembly in position using the threaded nut and clamp block
• Working from inside the cupboard, attach the braided hoses to the tube extensions (ensure the seals on the end of
the hoses are lubricated). Check the correct position for Hot and Cold connections by matching the colours on the
braided hoses with the coloured markings on the copper extension tubes. (See fig. 1.18)
• Test for leaks after all the connections have been secured.
Installation Procedure
470mm

Page 20 of 40 802005 - Sparkling HT-BCS; CS; AIO; Residential- Installation Instructions - June 2015 - v2.01
FIXING NUT
1.16
Installation Instructions
1.17 CLAMP BLOCK O-RING
AIO Vented assy
BLUE to Chiller
connection
CLEAR
to vent
RED to Boiling
connection
From Mixer
OUT
AIO Mains assy
BLUE mark
WHITE mark BLUE mark RED mark
Clamp Block markings and silicon tube positions,
viewed from underneath
RED to Boiling
connection
BLUE to Chiller
connection
Mains IN From HWS
connection
Mains IN
To Mixer
IN
R
SILICON TUBES
USB CABLE
R
C
B
C
B
R
R
C
B
B