Zip HydroTap G4 User manual

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 1 of 36
Zip HydroTap G4
Installation Instructions
Affix Model Number Label
Here
802257
Filtered Boiling and Boiling Ambient drinking water for Residential kitchens and tea rooms.
®
B & BA Residential

Page 2 of 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
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 Mixer tap range is an additional series of taps that
may be used in conjunction with any one of the three taps
shown above, to create 4-IN-1 models
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.

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 3 of 36
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
Installation Instructions
STEP 1 - Measure and cut all the tap holes before fitting the taps
Section 1 - Tap Installation instructions
1.1 - HydroTap Classic and EliteTap installations............................................................. 11-13
1.6 - HydroTap Arc/Cube tap installations ........................................................................ 14-15
1.10 - Mixer Tap installation.............................................................................................. 16-18
1.14 - All-In-One Tap installation....................................................................................... 19-22
STEP 2 - Check for adequate ventilation
Section 2 - Ventilation
2.1- Details........................................................................................................................ 23
STEP 3 - Install the Booster Heater (if required)
Section 3 - Booster Heater installation
3.1- Booster Heater specifications and installation ........................................................... 24-26
STEP 4 - Install the undersink unit
Section 4 - Undersink Unit Installation
4.1- Check the external bypass valve setting.................................................................... 27
4.2- Fit the mains water supply hose ................................................................................ 27
4.3- Model B...................................................................................................................... 28
4.4- Model BA ................................................................................................................... 29
4.5- Model BHA 3-In-1 & BAHA 4-In-1.............................................................................. 30
4.6- Model BHA & BAHA All-In-One ................................................................................. 31
STEP 5 - Commission the HydroTap
Section 5 - Commissioning
5.1- Language selection.................................................................................................... 32
5.2- Filter flush .................................................................................................................. 32
5.3- Flow calibration.......................................................................................................... 33
5.4- Boiling calibration....................................................................................................... 33
5.5- Booster activation ...................................................................................................... 33
5.6- Safety sensor calibration............................................................................................ 34
Trouble Shooting
End of life disposal....................................................................................................................... 34
Trouble Shooting Table................................................................................................................ 35
Contact details ............................................................................................................................. 36
Index

Page 4 of 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
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 - 700kPa when a Booster
and / or filter softener is fitted
D. Check the water quality to determine if extra filtration will be required.
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 5)
7. Flush the supply line before connecting.
8. Turn on the water and check for leaks.
9. Flush the filter(s).
!0. Where applicable, programme the unit to suit the customer’s requirements.
Installation checklist

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 5 of 36
Thank you for purchasing a Zip HydroTap. Please read and follow these instructions carefully to ensure safe
operation and trouble free service. If service is required, please call 1800 460 222
What is the Zip HydroTap ?
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. The HydroTaps utilise an immersion heating element
to boil the water. These units dispense boiling water (factory set to 98°C) and ambient water. The HydroTaps
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.
The Zip HydroTaps are electronically controlled, filtered, Boiling water and Ambient water drinking systems for
kitchens and tea rooms. 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
Command centre
ON/OFF Switch
Boiling Ambient model
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.

Page 6 of 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
Important Safety Instructions
This manual contains important safety, installation instructions for the Zip HydroTap G4.
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.
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 this unit, when operated in a cupboard, must be between 5ºC - 35ºC.
Proper air circulation must be provided. The system will operate satisfactorily only if the recommended air
gaps of 50mm on each side are provided. If a vent kit is supplied it must be fitted. See technical specifications
for correct installation to prevent overheating.
Altitude
Water boils at varying temperatures at different altitudes. Your HydroTap adjust 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.
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.

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 7 of 36
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.

Page 8 of 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
Major components and accessories
Parts supplied Description
1 x Tap option
with hoses
(Classic tap shown)
1 x HydroTap
Undersink Unit with
water filter
1 x Mains water
connection hose
1 x HydroTap Booster
Heater & hoses.
(Supplied with
240 /175 models)
1 x Restrictaflow
valve and Tee piece
for Mixer taps and
select models
1 x User guide and
1 x Quick start guide
1 off
Installation
instructions
(This book)
1 x Mixer tap for
3-in-1 and 4-in-1
models (with hoses)
Accessories Description
HydroTap Booster
Water System with
connection hoses
Softener cartridge
and head assembly
Font Kit for
Arc & Cube Models
Font Kit for Classic &
Elite Models
Replacement Filter
Disabled lever Kit
3-in-1 and 4-in-1
Upgrade Kits
Guide

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 9 of 36
Technical Specifications
Note: the Cup measurement =167ml
Product covered by these instruction:
* Water from the H/T Mixer tap is unfiltered
** Add an extra 3-4 kg when full of water
H/T Tap
*Filtered
Boost
(10A)
GPO's
Required
Power
Rating
(kW)
Boost
Rating
(kW)
Unit Dimensions
W x D x H
(mm)
**Dry
Weight
(Kg)
Boiling Only
B Yes no 1x10A 1.425 NA 280 x 313 x 335 8
Boiling Ambient
BA Yes no 1x10A 1.425 NA 280 x 313 x 335 8
3 in 1*
BHA Yes yes 2x10A 1.425 2.2 280 x 313 x 335 8
4 in 1*
BAHA Yes yes 2x10A 1.425 2.2 280 x 313 x 335 8
All-In-One
BHA Yes yes 2x10A 1.425 2.2 280 x 313 x 335 8
BAHA Yes yes 2x10A 1.425 2.2 280 x 313 x 335 8
Residential Models
B Boiling Only
BA Boiling Ambient
BHA 3-in-1 and All-In-One
BAHA 4-in-1 and All-In-One
D Disabled lever controls (optional accessory)

Page 10 of 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
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 3-4kg 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 160 models, a 220-240Vac, 10A GPO will be required.
For Zip HydroTap 240 models, two 220-240Vac, 10A GPOs will be required. (One GPO 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.
• 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 (200kPa when a booster and /or
filter softener is fitted) 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 or 50mm for AIO. (Not supplied)
• 35mm diameter hole saw for timber bench tops or 50mm for AIO. (Not supplied)
• Nut runner tube spanner (supplied) for fixing tap assembly.

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 11 of 36
Hole positioning:
Position the tap such that it dispenses into the sink bowl with ample clearance for a cup or tea pot. Alternative-
ly, the tap could be mounted away from the sink using a Zip Font, available as an accessory.
Section 1
Tap Installation
116
BC HydroTap
** Check bowl depth and adjust accordingly
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
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 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
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.
335mm
HydroTap & Elite Installation
Min 300mm
HydroTap Classic
EliteTap

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 13 of 36
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
Blue hose
to chilled
water outlet
Typical HydroTap Installa-
tion (see section 5)
Red hose to boiling
water outlet
Incoming water
Clear hose to
Vent
Blue hose to
Ambient outlet
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 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
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

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 15 of 36
Installation Instructions
A A
Left Hand Control Right Hand Control
BCCB
50mm
Height adjustment (Fixed position options)
Angular adjustment (Fixed position options)
1.7
O-RING
LOWER
RUBBER
WASHER
WASHER
NUT
1.8
1.9 Mounting (See table on Page 11 )
Cut a 35mm hole in the bench / sink top.
BENCH TOP
Ø35mm
NOTE: Position Ais
not recommended with
Boiling water units

Page 16 of 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
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
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 diagrams)
Min 300mm
1.11
O-RING
LOWER
RUBBER
WASHER
WASHER
NUT
External Mains
Blue band
Mixer IN
Red band
Mixer Out
Red Band
Blue Band

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 17 of 36
Installation Instructions
Sink top
O-ring
Lower seal
Washer
Securing nut
Mixer tap
Arc Mixer Tap
1.12 Installing the Mixer Tap (Classic, Arc and Cube)
• 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 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
Installation Instructions
COLD isolation valve
(Not supplied)
280mm
335mm
Note: The mixer tap requires a Restricta!ow valve to be
"tted in the cold water supply line, from the isolation valve
tee piece, to the mixer tap. (See diagrams)
Restrictaflow valve
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.
1.13

802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00 Page 19 of 36
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 300mm335mm
470mm
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

Page 20 of 36 802257 - HydroTap B, BA, BHA, BAHA, Installation Instructions - July 2015 - v2.00
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