Zip HydroTap G4 User manual

801530 v3.05 09.20 HT B BA Commercial Instructions Page 1 of 28
Affix Model Number Label
Here
801530
B & BA Commercial
Zip HydroTap G4
Installation and Operating Instructions
®

Page 2 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Tap Options
The Zip HydroTap G4 appliance series offers a range of interchangeable taps to suit the customer’s needs
These three taps are directly compatible with the G4
Command Centre.
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
Arc / Cube Tap
Arc / Cube Mixer
Classic Tap
Elite Tap
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 Command Centre.
Classic All-In-One Celsius All-In-One

801530 v3.05 09.20 HT B BA Commercial Instructions Page 3 of 28
HydroTap Specifications
Installation Checklist .................................................................................................................... 4
General Product Features............................................................................................................ 5
Important Safety Instructions ....................................................................................................... 6
Warnings and Regulatory Information.......................................................................................... 7
Major Components and Accessories ........................................................................................... 8
Technical Specification ................................................................................................................ 9
Before Installation and Site Requirements................................................................................... 10
Installation Instructions
STEP 1 - Measure and cut all the tap holes before fitting the taps
(Refer to the Tap installation instruction book 803341)
STEP 2 - Check for adequate ventilation
Section 2 - Ventilation
2.1- Ventilation for All Models............................................................................................ 11
STEP 3 - Install the Booster Heater (if required)
Section 3 - Booster Heater installation
3.1- Product Description.................................................................................................... 12
3.2- Installation Procedure ................................................................................................ 13
3.3- To Remove / Install the appliance ............................................................................. 13
3.4- Braided Hose Connections ........................................................................................ 14
STEP 4 - Mount the Filter / Softening unit (if required)
Section 4 - Filter / Softener installation
4.1- Mounting the filter head ............................................................................................ 15
4.2- Cartridge installation .................................................................................................. 15
STEP 5 - Install the Command Centre
Section 5 - Command Centre Installation
5.1- External bypass valve................................................................................................ 16
5.2- Hose and tube fitting.................................................................................................. 16
5.3- Model B160................................................................................................................ 17
5.4- Model B240................................................................................................................ 18
5.5- Model BA160 ............................................................................................................. 19
5.6- Model BA240 ............................................................................................................. 20
5.7- Model BHA160 & BAHA160....................................................................................... 21
5.8- Model BHA240 & BAHA240....................................................................................... 22
5.9- Model BHA160 & BAHA160 All-In-One ..................................................................... 23
STEP 6 - Commission the HydroTap
Section 6 - Commissioning
6.1- Language selection.................................................................................................... 24
6.2- Filter flush .................................................................................................................. 24
6.3- Boiling calibration....................................................................................................... 25
6.4- Booster activation ...................................................................................................... 25
6.5- Safety sensor calibration............................................................................................ 26
6.6- Command-Centre Flush............................................................................................. 26
Troubleshooting ........................................................................................................................... 27
End of Life Disposal ..................................................................................................................... 27
Contact Details............................................................................................................................. 28
Index

Page 4 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Before Installation:
A. Read the instructions and check if there is adequate space to mount all of the components.
B. Note: Not all fittings are supplied with the appliance kit. Isolation valves are not supplied.
C. Check the mains water pressure is between 150 - 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 Command Centre has been installed correctly.
2. Check all plumbing fittings have been tightened.
3. Ensure the outlet and vent pipes are positioned to drain correctly.
4. Ensure there is adequate ventilation.
5. Check all tubes from the Command Centre to the tap, have a constant rise and there are no
sags or kinks in the hoses.
6. Check all electrical connections are correct and there are no loose wires.
Commission: (See section 6)
7. Flush the supply line before connecting.
8. Turn on the water and check for leaks.
9. Flush the filter(s).
!0. Where applicable, program the Command Centre to suit the customer’s requirements.
Installation Checklist

801530 v3.05 09.20 HT B BA Commercial Instructions Page 5 of 28
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 contact your Zip service provider.
What is the Zip HydroTap ?
The HydroTap Command Centres are under bench drinking water appliances with a dispensing tap mounted
on a sink or bench, which may be used for residential or commercial 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 Command Centres are fitted with a tap mounted, child safety lock. In addition, there are
various energy saving options accessible via the main menu. Each Command Centre 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 Command Centre 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 B160

Page 6 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Important Safety Instructions
This manual contains important safety and installation instructions for the Zip HydroTap G4.
Safety
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision
or instruction concerning use of the appliance by a person responsible for their safety. Children should be
supervised to ensure that they do not play with the appliance.
For products sold in Europe, this appliance can be used by children aged from 8 years and above and
persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they
have been given supervision or instruction concerning use of the appliance in a safe way and understand
the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be
made by children without supervision.
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 Command Centre. 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 Command Centre by the front cover or any connections at the top
rear of the Command Centre. Refer to the technical specification on page 9 for the weight of your product.
Airflow
The HydroTap Command Centre must operate within ambient operating temperatures between 5ºC - 35ºC,
when installed in a cupboard. The system will operate satisfactorily only with proper air circulation and with
the recommended air gaps of 50mm on each side. 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 Command Centre is positioned in an accessible area close to the floor level. The
Command Centre must have its base mounted in a horizontal position with all inlets and outlets facing up.
The Tap must be located above the Command Centre. See section 1 for details.
!

801530 v3.05 09.20 HT B BA Commercial Instructions Page 7 of 28
Important Safety Instructions
WARNINGS
1. The HydroTap Command Centre 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. Command Centres 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 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Major Components and Accessories
Parts supplied Description
1 x Tap option
with hoses
(Classic tap shown)
1 x HydroTap
Command Centre
with water filter
1 x Mains water
connection hose
1 x HydroTap Booster
Heater & hoses.
(Supplied with
240 /175 models)
1 x Installation
Instructions
(this book) and
1 x User Guide
1 x Mixer tap for
3-in-1 and 4-in-1
models (with hoses)
1 x Connector +
Strainer Sub-assy
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
User
Guide
Install
Instruct

801530 v3.05 09.20 HT B BA Commercial Instructions Page 9 of 28
Technical Specifications
Products covered by these instructions:
* Water from the H/T Mixer tap is unfiltered
** Add an extra 3-4 kg when full of water
Capacity
Boiling
(cups)
H/T Tap
*Filtered
Boost
(10A)
Power
outlet's
Required
Power
Rating
(kW)
Boost
Rating
(kW)
Unit Dimensions
W x D x H
(mm)
**Dry
Weight
(kg)
Boiling Only
B160 160 Yes no 1x10A 1.9 NA 280 x 313 x 335 8
B240 240 Yes yes 2x10A 1.9 2.2 280 x 313 x 335 8
Boiling Ambient
BA160 160 Yes no 1x10A 1.9 NA 280 x 313 x 335 8
BA240 240 Yes yes 2x10A 1.9 2.2 280 x 313 x 335 8
3 in 1
BHA160 160 Yes no 1x10A 1.9 NA 280 x 313 x 335 8
BHA240 240 Yes yes 2x10A 1.9 2.2 280 x 313 x 335 8
4 in 1
BAHA160 160 Yes no 1x10A 1.9 NA 280 x 313 x 335 8
BAHA240 240 Yes yes 2x10A 1.9 2.2 280 x 313 x 335 8
All-in-One
BHA160 160 Yes no 1x10A 1.9 NA 280 x 313 x 335 8
BHA240 240 Yes yes 2x10A 1.9 2.2 280 x 313 x 335 8
BAHA160 160 Yes no 1x10A 1.9 NA 280 x 313 x 335 8
BAHA240 240 Yes yes 2x10A 1.9 2.2 280 x 313 x 335 8
Commercial 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)
Note: Cup measurement =167ml

Page 10 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Before Installation
Before installing ensure that the following have been provided at the
Installation site:
• Review all the technical specifications.
• Ensure the underbench can support the product weight when full of water,
(allow an extra 3-4kg when full. )
• Sufficient space in the cupboard to install all of the Command Centres in accordance with these
Installation Instructions. Refer to technical specification for dimensions. Make allowance for a booster
heater and / or water softener if required. Refer to section 3 & 4, for Installation instructions.
• For Zip HydroTap 160 models, a 220-240V AC, 10A power outlet will be required.
For Zip HydroTap 240 models, two 220-240V AC, 10A power outlets will be required (one power
outlet for the Zip HydroTap and the other for the Booster heater).
NoteNote: Check all cable and hose lengths against inlet /outlet positions before 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
Command Centres 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 150kPa (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 its base in a horizontal position.
IMPORTANT! Do not proceed with the installation if these requirements are not met.
Special Tools Required:
In addition to normal tools, the following will be required:
For the standard and Mixer taps:
• 35mm diameter sheet metal hole punch for sink tops 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.
!

801530 v3.05 09.20 HT B BA Commercial Instructions Page 11 of 28
2.1 All Models
IMPORTANT: Proper air circulation must be provided. Allow a clearance envelope of 50mm either
side, and 200mm above the Command Centre. The system will operate correctly only if the recom-
mended clearances are provided.
It is important to adjust both cupboard door hinges and attach rubber door buffers to the doors to create a 4
mm air-gap between the doors and the cupboard. This is the minimum ventilation requirement for low usage
installations.
For high use applications, where the cupboard space temperature is near 35°C, or higher, a vent kit must be
fitted. Contact your local service centre for availability.
Section 2
Ventilation
4 mm
Buffer Pad
Clear Gap
Section 1
Tap Installation
Refer to the Tap installation instruction book 803341.
!

Page 12 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Booster specifications:
Rating Unit
Nominal Power Rating 2.2 kW
Nominal Current 10 A
Electric Supply 50Hz AC 230 V
Elect ex and plug - 1 metre length (with 90º Australian plug) 10 A
Fixed Flow Rate 1.2 L/min
Minimum water pressure 200 kPa
Section 3
Booster Heater
280mm
Mount base
horizontally
3.1 Product Description
The Booster is a compact electronically controlled
auxiliary water heater. It is intended to provide
pre heating of water before it enters the Zip
HydroTap G4 boiling tank. The Booster is
supplied as standard equipment with all 240 cup
models. However, it may be later installed, as an
accessory for the 160 cup models, to increase
their delivery to 240 cups.
Note 1: water connection
Blue marking - water in
Red marking - water out.
The braided hoses cannot be lengthened.
Note 2: The electrical cable length is 1.0
metre.
Note 3: Position the Booster within reach
of the fixed hose lengths, keeping the
Booster as close as possible to the Com-
mand Centre inlet/ outlet fittings.
Note 4: Ensure the Booster heater is
mounted in an upright position (as shown)
with a horizontal base

801530 v3.05 09.20 HT B BA Commercial Instructions Page 13 of 28
Booster Installation
3.2 Installation Procedure
Site requirements
• The appliance must only be installed in a frost-free area. Never expose appliance to frost.
• The appliance is designed for wall mounted Installation and must to be installed with water connectors
facing upwards.
• The appliance complies with protection class IP 25.
• The 400mm braided hoses supplied with the unit cannot be lengthened.
• The 90°elbow hose ends, should be fitted to the inlet and outlet connections on top of the Booster.
• The hot water outlet hose must be thermally insulated with the insulation provided.
Tilt Forward Lift UP
Release
NOTE: Remove the backing plate for wall mounting
3.3 To remove / install the appliance
1. Insert a flat head screwdriver all the way into the lock.
2. Gently angle the screwdriver upwards by approximately 10° as shown in the image below.
3. Pull the appliance forwards by approximately 15° as shown.
4. Carefully pull the appliance upwards to complete the removal process. Taking care not to break the
lower clips
5. To install, place the appliance on the wall bracket and snap into position (see diagrams below).
Take care
not to break
the lower
clips when
removing or
installing the
Booster
Installation
!

Page 14 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Booster System
NOTE 1: This appliance is intended for use with the HydroTap Command Centre.
NOTE 2: Water connections must be pointing vertically upwards.
NOTE 3: The booster unit should be installed as close as possible to the HydroTap Command Centre,
as the 400mm connection hoses cannot be lengthened.
3.4 Braided hose connection s
1. The cold water inlet (blue) and hot water outlet (red) are marked on the rating plate. Connect the
braided hoses from the ‘Bypass Out’ fitting to the water inlet of the booster unit (marked blue) and
from the outlet of the booster unit (marked red) to the ‘Bypass IN’ fitting on the Zip HydroTap unit.
Avoid exerting any mechanical pressure on the appliance. This can be achieved by applying a spanner
on the flats of the inlet and outlet connections when tightening the braided hose connectors. Do not
overtighten! Tighten the braided hoses by hand, then turn an additional 90°- 180° with a spanner
2. Once the water connections have been made, check for any leaks and rectify as necessary.
Hot Water
Connection
(outlet, G1/2”)
Strainer
Cold Water
Connection
(inlet, G1/2”)
Hold the hexagon while
tightening the braided
hose fittings
Braided Hoses
Typical Installation

801530 v3.05 09.20 HT B BA Commercial Instructions Page 15 of 28
Section 4
Filter / Softener installation
An external filter / softener may be fitted to reduce the incidence of scale build up in the hot tank or may be at
the customer’s request.
• Choose a suitable location, (cupboard back or side wall)
within the reach of the braided hoses.
• Mount the filter head bracket in an upright position, using the
screws supplied in the kit
• Ensure there is enough headroom for the filter cartridge to be
easily fitted and removed. *Allow a min 80mm base clearance
• Attach the hoses as shown in section 5, noting the flow
directions as marked on the filter head.
4.1 Mounting the filter head
*Min. 80mm
Clearance
Filter Label
Inlet
Outlet
4.2 Cartridge Installation
1. Unpack replacement cartridge, write today’s date where
shown on the label and remove the sanitary cap.
2. Avoid touching the filter O-rings and filter opening as this may
cause bacterial contamination of the cartridge.
3. Moisten the O-rings with water, align the front cartridge label
to the left and push the new cartridge into the filter head.
4. Turn the cartridge a quarter turn to the right until the cartridge
comes to a complete stop, with the front label facing forward.
5. Disconnect the filter outlet hose from the Command Centre
and direct the hose end into a container ready for flushing.
6. Turn the power and water ON and depress the tap’s Boiling
lever and allow water to run for 30 seconds to flush the tank.
7. Allow at least 10L to flow through the filter to ensure all
carbon particles have been flushed.
8. Turn the power and water off (after flushing 10L).
9. Reconnect the filter outlet hose to the Command Centre.
10. Turn the water supply back on and check for leaks.
11. Set the appropriate selection on the Internal Filter Bypass
valve located at the rear of the Command Centre (see Section
5.1).

Page 16 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Section 5
Command Centre installation
NOTE: Before you install, determine whether a water softener or an external filter is required.
5.1 External Bypass Valve
The diverter bypass valve allows the user to choose to have the boiling feed water bypass the internal filter and
be filtered externally. The diverter valve is located at the rear panel of the Zip HydroTap Command Centre on
the filter door side. Check the image below to determine which filter bypass position you need for your product.
B
Rotate 90°
only
1
2
3
4
A
Rotate 90°
only
1
2
3
4
A
B
If an external filter
is installed, select
position A.
If no external lter
is installed, select
position B.
5.2 Hose and tube fitting
• Remove all caps from the top of the
Command Centre (except the mixer caps)
• Only remove the mixer caps if a mixer tap is
to be fitted.
• Install the mains water braided hoses to the
Command Centre before locating the unit in
place.
NOTE: Do not overtighten
John Guest fittings (Insertion and removal)
Be careful when cutting the poly tube so that there are no
rough edges and that the tube is not distorted.
1. Use a sharp knife to ensure the tube has a clean,
straight edge. Do not cut at an angle.
2. Remove any swarf or unwanted material.
3. Push the tube into the John Guest fitting making
sure all connections to the John Guest fittings are
pushed in past the “O”ring to full depth, at least
15-16mm.
4. Check for a good joint by pulling back on the tube. If
the tube comes out, of the fitting, repeat the above
step.
5. To remove the tube, press the collet into the
fitting and at the same time pull back on the tube.
Connector + Strainer
90° Bend end
of Braided Hose
To HydroTap
Command Centre
Braided hose for
Mains Water Supply
From Mains
Water Supply

801530 v3.05 09.20 HT B BA Commercial Instructions Page 17 of 28
5.3 Model B160
Installation Instructions
: Not required for BO HydroTap.
USB
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
RED
CLEAR
BRAIDED
Min 70mm280mm
Note: The tube lengths are matched to the pump performance and therefore CANNOT be lengthened
Note:
- Mains hose length
is 750mm
- Plug and Cord
length is 1800mm
Position the Com-
mand Centre close
to the outlet tap,
within reach of
the hose and cord
lengths supplied
Note:Note: the hosesthe hoses
need to have aneed to have a
constant downwardconstant downward
gradient to thegradient to the
Hydrotap to allow allHydrotap to allow all
water to drain backwater to drain back
into the tanks.into the tanks.

Page 18 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Installation Instructions
5.4 Model B240
USB
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
RED
CLEAR
BRAIDED
Booster
: Not required for BO HydroTap.
Booster
option
Note: The tube lengths are matched to the pump performance and therefore CANNOT be lengthened
Note:
- Mains hose length
is 750mm
- Plug and Cord
length is 1800mm
Position the Com-
mand Centre close
to the outlet tap,
within reach of
the hose and cord
lengths supplied
Note:Note: the hosesthe hoses
need to have aneed to have a
constant downwardconstant downward
gradient to thegradient to the
Hydrotap to allow allHydrotap to allow all
water to drain backwater to drain back
into the tanks.into the tanks.

801530 v3.05 09.20 HT B BA Commercial Instructions Page 19 of 28
Installation Instructions
RED
CLEAR
BRAIDED
USB
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
AMBIENT
OUT
BRAIDED
BLUE
: Not required for BA HydroTap.
Note: To ensure ambient temperatures are maintained, fit the supplied insulation to the Blue tube.
5.5 Model BA160
Note: The tube lengths are matched to the pump performance and therefore CANNOT be lengthened
Note:
- Mains hose length
is 750mm
- Plug and Cord
length is 1800mm
Position the Com-
mand Centre close
to the outlet tap,
within reach of
the hose and cord
lengths supplied
Note:Note: the hosesthe hoses
need to have aneed to have a
constant downwardconstant downward
gradient to thegradient to the
Hydrotap to allow allHydrotap to allow all
water to drain backwater to drain back
into the tanks.into the tanks.

Page 20 of 28 801530 v3.05 09.20 HT B BA Commercial Instructions
Installation Instructions
5.6 Model BA240
RED
CLEAR
BRAIDED
Booster
USB
MAINS
IN
MIXER
OUT
MIXER
IN
BOILING
OUT
BYPASS
IN
VENT BYPASS
OUT
AMBIENT
OUT
BLUE
Note:
- Mains hose length
is 750mm
- Plug and Cord
length is 1800mm
Position the Com-
mand Centre close
to the outlet tap,
within reach of
the hose and cord
lengths supplied
Note:Note: the hosesthe hoses
need to have aneed to have a
constant downwardconstant downward
gradient to thegradient to the
Hydrotap to allow allHydrotap to allow all
water to drain backwater to drain back
into the tanks.into the tanks.
: Not required for BA HydroTap.
Note: To ensure ambient temperatures are maintained, fit the supplied insulation to the Blue tube.
Note: The tube lengths are matched to the pump performance and therefore CANNOT be lengthened