Zip 203362 Clage- Hydroboil User manual

Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009 Page 1 of 16
Installation and Operating Instructions
Clage-Zip Hydroboil Electronic
Instant boiling water
203362 Clage-Zip Hydroboil 3 Litre White
203361 Clage-Zip Hydroboil 3 Litre Stainless Steel
205362 Clage-Zip Hydroboil 5 Litre White
205361 Clage-Zip Hydroboil 5 Litre Stainless Steel
207362 Clage-Zip Hydroboil 7.5 Litre White
207361 Clage-Zip Hydroboil 7.5 Litre Stainless Steel

Page 2 of 16 Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009
Note:
Read all instructions and precautions before proceeding. This unit must be
installed in accordance with water supply by-laws and relevant local authority
by-laws.
All plumbing and electrical installations must comply with national regulatory
requirements
Contents
Read these warnings first . . . . . . . . . . . . . . . 3
Descaling . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Requirements . . . . . . . . . . . . . . . 4
Installation Procedures . . . . . . . . . . . . . . . . . 5; 6
Step 1 – Positioning . . . . . . . . . . . . . . . 5
Step 2 – Fastening . . . . . . . . . . . . . . . . 5
Step 3 – Connecting . . . . . . . . . . . . . . . 6
a ) Plumbing . . . . . . . . . . . . . . . 6
b ) Venting. . . . . . . . . . . . . . . . . 6
c ) Electrical . . . . . . . . . . . . . . . 6
Step 4 – Assembling . . . . . . . . . . . . . . . 6
Step 5 – Commissioning . . . . . . . . . . . 6
Wall Mounting Template Dimensions . . . . . . 7
End of life disposal . . . . . . . . . . . . . . . . . . . . 7
Problem Solving. . . . . . . . . . . . . . . . . . . . . . . 8
Earthing Continuity Verification . . . . . . . . . . . 8
Tap Operating Procedures . . . . . . . . . . . . . . . 9
Operational Procedure Settings . . . . . . . . . . . 10
Default Settings . . . . . . . . . . . . . . . . . . . . . . . 11
Setting Operational Modes. . . . . . . . . . . . . . . 11
Normal Mode. . . . . . . . . . . . . . . . . . . . . . . . . 11
Configurational mode. . . . . . . . . . . . . . . . . . . 12,13
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 14; 15
Contact Details . . . . . . . . . . . . . . . . . . . . . . . 16

Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009 Page 3 of 16
Please read all installation requirements, installation procedures and precautions before
installing any Clage-Zip Hydroboil instant boiling water heater.
Never attempt to install any Clage-Zip Hydroboil instant boiling water heater without reading all
of the applicable instructions.
In some hard water areas where mineral scale accumulation in the boiling chamber of the
Clage-Zip Hydroboil may become a problem, consideration should be given to the maintenance
required. A suitable form of water treatment may be necessary.
All plumbing connections must be made in accordance with local regulations.
The Clage-Zip Hydroboil instant boiling water heater is not intended for use by young children
or infirm people without supervision.
Young children should be prevented from having access to ensure that they are not able to use
or play with the heater.
If the installation site is located more than 1000 metres above sea level, the installer should
contact a Clage-Zip authorised agent for high altitude settings.
This appliance must be earthed. If the power supply cord is damaged it must be replaced by a
Clage-Zip authorised agent or a qualified electrician.
Do not remove the cover of the heater under any circumstances without first isolating the
heater from the power supply.
Do not use strong, corrosive or abrasive cleaners to clean the case of the heater.
Frost protection: If this heater is located where ambient air temperature could fall below 5ºC
when the heater is not in use, do not turn off the appliance electrically. This safeguard does
not offer the same protection to the connecting pipework and fittings.
The ambient temperatures this unit must operate within 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.
Read These Warnings First

Page 4 of 16 Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009
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) Standard local requirement power cable positioned as shown on the paper mounting
template for connection from the rear of the heater to the terminal block within the heater,
this will require an isolating switch fitted in the fixed wiring and attached to a secure
surface. This switch must provide all pole disconnection and a contact separation of at least
3mm installed in accordance with the wiring rules. Alternatively a standard 220-240V, 10
amp general purpose outlet, within 1500 mm of the Hydroboil Unit.
NOTE: When installed with a plug and cord the plug must be accessible
c) Cold water supply with a minimum working pressure of 70 kPa and a maximum
working pressure of 700 kPa connected via an isolation valve.
d) Outlet drainage to a sink draining board or to a drip tray.
e) Access to drainage from a vent situated at the base of the heater.
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.
Note: If the water pressure is likely to exceed 7 bar, a 3.5 bar pressure reducing valve must
be installed in the cold water supply line.
Installation Requirements
Periodic descaling is recommended and is dependent on the hardness of the water. We
recommend a descaling procedure be carried out every 3 to 6 months in hard water areas
and 12-24 months in soft water areas.
NOTE: This procedure involves the partial dismantling of the appliance and should only be
carried out by a factory trained service provider. Failure to have the appliance correctly
serviced, by an authorised service provider, may affect the product’s warranty.
Descaling

Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009 Page 5 of 16
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 shown.
Screw heater chassis to the wall using screws or bolts suited to the wall.
Screws or bolts must be able to support the weight as shown in the chart on
the left.
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.
Installation procedure
Spout detail
COLD
INLET
VENT
OUTLET
INLET
POSITION
VENT
POSITION
45mm
Elbow

Page 6 of 16 Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009
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.
The heater must be installed with an isolating valve which allows it to be isolated
from the mains supply for servicing.
Water pressure requirements:
Minimum - 0.7 bar, maximum - 7 bar.
Warning: If pressure is likely to exceed 7 bar, a pressure limiting valve must be
installed in the cold water supply line. Clage-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, direct the vent outlet from the heater rear, using
a visible tundish. (see diag at left)
c) Electrical
For concealed electrical connection, connect a power cable through the rear
access opening of the heater to the terminal block within the heater as shown.
For exposed electrical connection, connect the flex and plug (fitted to the
heater) to a standard power outlet on the wall within 1500 mm of the heater
that will adequately cater for the units power needs.
Do not turn the power ON until the heater is filled to the tap level, with water.
Step 4 – Assembling
Place the heater case back on to the heater and secure the top 2 case screws.
Secure two bottom case screws.
Step 5 – Commissioning
Check previous steps. Turn water supply ON. Water is now flowing into heater,
check connections for leaks. Wait approximately 5 minutes and check outlet
tap for water. This is achieved by pressing the tap paddle.
Power is only to be turned on when water is available from this outlet.
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 shown in
the table on the left.
250mm
Wring
Concealed
Vent
Concealed
Inlet
45 mm
Visible TundishVent line
Special Note
Ensure the silicon outlet tube is
correctly positioned within the outlet
nozzle. Failure to do this may cause
internal flooding.
Aprox weight when filled
Installation Procedures (continued)
Inlet water
temperature 15°C 10°C
3.0 Litre models 16 min 17 min
5.0 Litre models 16 min 17 min
7.5 Litre models 23 min 24 min
3.0 Litre models 12.5 kg
5.0 Litre models 16.5 kg
7.5 Litre models 20.5 kg

Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009 Page 7 of 16
Wall Mounting Template Dimensions
274 (1.5 L & 3.O L)
304 (5.0 L & 7.5 L)
65 CLEAR
56
POSITIONING PIN
EXTERNAL PLUMBING
ELECTRICAL WIRING
POSITION
INTERNAL PLUMBING
72
15
25
35 42
COLD
INLET VENT
BENCH TOP
416 3.O L
448 5.O L
561 7.5 L
38 (1.5 L & 3.O L)
53 (5.0 L & 7.5 L)
150
CLEAR
19
20
End of life Disposal
The use of this crossed out wheeled bin logo indicates that this product needs
to be disposed of separately to any other household waste.
Within each of the European Union member countries, provisions have been
made for the collection and recycling of unwanted electrical and electronic
equipment. Outside of the EU it will be necessary to dispose of this product at
your local community waste collection or recycling centre.
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
Wall Mounting Template Dimensions

Page 8 of 16 Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009
Problem Solving
Symptom Possible Cause Solution
Fails to dispense water.
Water isolating valve turned off.
Blocked filter, blocked meter tube,
blocked strainer, jammed ball valve
assy, airlock in transfer tube.
Check water supply valve.
Contact Clage-Zip authorised agent.
Water not boiling.
No power.
Faulty PCB, faulty NTC, faulty element,
faulty cutout.
Check power supply.
Contact Clage-Zip authorised agent.
Runs out of boiling water and fails to
refill.
Outlet tap drips.
Overflow from vent.
Excessive steam from vent.
Power “on” but no heat.
Overload repeatedly tripping with
excessive steam.
Overload repeatedly tripping without
excessive steam.
Internal adjustment. Contact Clage-Zip authorised agent.
Warning: this appliance must be earthed.
Following 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.
Warning- the water may be boiling - show extra care.
5. Test that in every instance the electrical resistance does not exceed 1 ohm.
Earthing Continuity Verification
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.

Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009 Page 9 of 16
Operating Procedures
Tap Operation
Safety feature.
Clage-Zip Hydroboil has a unique safety device designed to reduce the incidence of accidental operation of the tap. The
tap can be “Locked” to prevent the Hydroboil from dispensing hot water
In order to “lock” the tap, ensure the safety button is protruding from the right hand side of the control panel and the
locked indicator is illuminated
This can be achieved by pressing the button and simultaneously rotating it until the groove in the head of the button
faces toward the body of the appliance. In this position an internal spring will push the button out. Once the button is in
the extended position, the tap will be “Locked” and unable to dispense hot water.
Disengage safety feature.
Press and simultaneously rotate (aprox 90 degrees) the safety button on the right hand side of the control panel, until it
latches in the closed position, and the unlocked indicator is illuminated.
Warning: The unit is now capable of dispensing boiling water without the safety feature.
Dispensing Boiling water:
Clage-Zip Hydroboil is fitted with a safety, two-way cool-touch safety tap for instant boiling water.
Normal operation (for filling cups and small containers)
To activate the tap, press the safety button on the right side of the control panel and while holding the button in, gently
push the lower end of the tap paddle inwards and boiling water will flow until the tap paddle is released.
Continuous operation (for filling, tea pots, saucepans and large containers )
Press the safety button on the right side of the control panel and while holding the button in, Lift the tap paddle until it
locks into a horizontal position, the button can now be released and boiling water will flow until the paddle is returned to
its normal vertical position. This operation allows a vessel to be filled without holding your hand where it may be affected
by steam.
Normal operation
Continuous operation
locked
Press to unlock
Press to unlock
Locked / unlocked indicators

Page 10 of 16 Clage-Zip Hydroboil Electronic - Installation & Operating Instructions - 87490 - June 2009
DESCRIPTION
The Electronic Hydroboil has user interface that consists of a graphic LCD and 4 Capacitive Sensor Switches, (CSS). The
user interface gives the current status of the Hydroboil and allows the user to configure it as required.
Legend:
1 = ZIP Symbol
2 = Day of the Week indicator
3 = Setpoint Value
4 = CHANGE FILTER indicator
5 = ON indicator
6 = OFF indicator
7 = Sleep Symbol
8 = Sleep mode ( Stand by ) Indicator
9 = Low light Symbol
10 = 24hour Clock
11 = BOILING WATER indicator
CSS1 = Capacitive Sensor Switch 1
CSS2 = Capacitive Sensor Switch 2
CSS3 = Capacitive Sensor Switch 3
CSS4 = Capacitive Sensor Switch 4
The LCD and capacitive sensor switches connect to the Controller PCB via a 4-way serial cable.
The DIP Switches on the Controller PCB should be configured as follows.
The Electronic Hydroboil has a real time clock that operates in 24 hour mode, and can have 2 ON-OFF times per day.
If the user selects either of the energy saver modes, (see below), ON-OFF mode cannot be used, (The user is not able
to access this part of the configuration). The real time clock is battery backed meaning the unit does not loose the
configuration data if power is removed.
The Hydroboil has two energy saver ( standby ) modes that can be used in an either/or configuration. The energy saver
modes differ from on/off mode in that the water in the tank is maintained at 65ºC rather than allowing it to drift back to
ambient.
1) Sleep Mode, and
2) Low Light Mode.
Sleep Mode can be set to 2 hours or 4 hours.
Sleep Mode is indicated by the Sleep symbol on the LCD.
Low Light Mode is indicated by the Low Light symbol on the LCD.
When the unit actually enters energy saver mode it is indicated by the Sleep Mode Indicator on the LCD.
Operating Procedures (setting the controls)
The user interface is shown below.