Service Manual Zip HydroTap Miniboil Boiling and ambient drinking water for kitchens and the home.

Transcription

1 Service Manual Zip HydroTap Miniboil Boiling and ambient drinking water for kitchens and the home. Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 1 of 28

2 Contents General information and warnings General Technical Description Technical Specifications Operation - General Tap Operation Sleep Mode Filter Light LED Indicators on Miniboil PCBA Fault Diagnosis Flow Chart Components Definition, Testing and Replacment Procedures - Tap Assembly Filter and Inlet Water Assembly Appliance Entry Earthing Continuity Test Solenoid Valves Boiling Water Level Sensors Thermal Overload Heating Element Temperature Sensor Boiling Water Module & Pump Leak Detector Fitting PCBA Exploded View & Parts List Wiring Diagram Page 2 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

3 General Information and Warnings This Service Manual contains the information you will need to service the wiring, plumbing, temperature sensors, valves and taps; and to gain access to the inside of the unit and main tank. It also shows how to deal with any mineral scale that may accumulate. You will also find the necessary diagrams and illustrations, and a detailed fault finding guide. This guide matches possible faults with probable causes; a summary of what to do; and finally the page reference to the place in this manual where the fault is dealt with in detail. Please read these warnings before servicing any Zip HydroTap appliance. Never attempt to service any Zip HydroTap appliance without reading all of the applicable servicing instructions. The Zip HydroTap Miniboil is an electronically controlled appliance designed to provide filtered boiling and ambient water for drinking and cooking purposes in residential kitchens. The models covered in this service manual are and The following points are important whenever you service any Zip HydroTap appliance. Whenever you remove a soft seal, a gasket, a pipe or an O ring, inspect it closely. If it is worn or damaged, or has deteriorated in any way, replace it. Zip recommends that you use only Molykote III as sealant grease. Other sealant greases may be hazardous to your health. Replace or re-insulate any wiring that you find is bare for any reason (this warning does not include the ends of the earth leads). WARNING The Zip HydroTap Miniboil unit must be earthed. The resistance of the earth connection from each exposed metal part must be less than 1 Ohm. All 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. All Plumbing must comply with AS & AS All Electrical must comply with AS3350.1, AS All Plumbing and Electrical connections must be made in accordance with local regulations. This service manual should be used in conjunction with the current version of the Operating and Installation Instructions. It requires qualified technical knowledge and offers support for the maintenance and repair by a qualified tradesperson only! Due to the process of continuous improvement, Zip Heaters reserves the right to change details mentioned in this manual without notice. Technical Description The Zip HydroTap Miniboil is an under-bench drinking water appliance with a dispensing tap mounted on a sink or bench and is designed for use in residential applications only. This product dispenses fi ltered Ambient and boiling water up to 98 C (factory set to 98 C) and is NOT designed to be used for washing up or to provide hot water for a kitchen sink or sanitary fi xture. The Miniboil Tap is fi tted with a Safety button which is permanently turned on and cannot be deactivated therefore to dispense boiling water you must use two (2) fi ngers and touch both the safety and boiling water buttons simultaneously. The water from the outlet once at temperature is boiling and if used for a purpose other than its intended use, could cause a serious scald or burn. Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 3 of 28

4 General Technical Description The HydroTap Miniboil uses three (3) level sensors in the boiling water tank and is fi lled at a metered rate via a solenoid valve. This metered rate allows the appliance to keep the water in the tank as close to its set temperature as possible as it fi lls or re-fi lls. The water is heated via the element and temperature control is achieved via the temperature sensor probe and the PCBA (Printed Circuit Board Assembly). There are three (3) temperature settings 92 C, 95 C and 98 C. These can be manually selected by moving the bridging connector on the PCBA. These three settings allow for operation at different altitudes. The boiling water is dispensed from the tap using a pump. A feature of the Miniboil is soft start which helps to prevent the boiling water splashing out of a cup. This ensures a smooth steady fl ow. The unit also features a safety time out of fi fteen (15) seconds when dispensing boiling water. The Hydrotap Miniboil also has a built in energy saving Sleep Mode. After 2 hours of non use the appliance will go to sleep allowing the temperature of the boiling water to decrease to 64 C at which point the appliance will use Power Pulse to maintain this temperature. During Sleep Mode the boiling water (red) LED will fl ash slowly, full recovery from 64 C to the factory setting of 98 C will take approximately two and a half minutes (2min 30 sec). The HydroTap Miniboil also dispenses Filtered Ambient water. This operates on a push through system therefore the fl ow rate from the tap can be affected by the inlet pressure to the appliance. Technical Specifications HydroTap Miniboil Elite & Classic Under-Sink Unit Specification Model Number Boiling Water Capacity 1.8L 1.8L Boiling Water Temperature (adjustable) 92 C - 98 C 92 C - 98 C Element Rating 2000 Watts (D.O.M. 04/ /2012) 1500 Watts (D.O.M. 08/2012 till current) 2000 Watts (D.O.M. 04/ /2012) 1500 Watts (D.O.M. 08/2012 till current) Weight (Empty) 6.5Kg 6.5Kg Weight (Full) 8.3Kg 8.3Kg Dimensions (mm) 212w x 272d x 338h 212w x 272d x 338h Factory Filter life setting 1 12 months 12 months Factory Filter life setting L 4000L Sleep Mode Yes Yes HydroTap Miniboil Elite & Classic Tap Assembly Specification Model Number Boiling water safety button Yes Yes Filter change indicator LED Yes Yes Distance (centre of Tap to Centre of Outlet) 92mm 110mm Height (Sink to Outlet) 125mm 135mm Hole size required for mounting 35mm 35mm Font required for Bench mounting* *Font is supplied with a 100mm tap shaft extension for Font dimensions refer to the Font installation instructions Page 4 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

5 Operating the Tap To dispense boiling water touch the Red Markers + Safety Lock simultaneously. To dispense ambient water touch the blue markers. Red Boiling Water Light ON all the time: Flashing Fast: Flashing Slowly: To Reset Sleep Mode Set Sleep Mode ON: Set Sleep Mode OFF: This indicates boiling water is ready to be dispensed. This indicates the boiling water is below usable temperature and the Sleep Mode is OFF. This indicates Sleep Mode is active. Touch the COLD markers and SAFETY lock simultaneously for at least 5 seconds, until both the RED and WHITE lights flash together, for a few flashes. Sleep mode maintains the water temperature at 64ºC and will only become active when the system has not been used for 2 hours. Operation of the tap will wake the system from sleep and boiling water will be available when the RED light is ON all the time. (This may take a few minutes) Touch the COLD markers and SAFETY lock simultaneously for at least 5 seconds, until both the RED and WHITE lights flash alternately, for a few flashes. White Filter Light Flashing: Set filter light OFF: Filter change: WARNING: This indicates the filter needs to be replaced. The WHITE light will start to flash when the counters have recorded 12 months of use or after dispensing 4000 Litres, whichever occurs first. Reset the system by touching continuously, the COLD and HOT markers. The flashing WHITE light will turn OFF after 10 seconds and the counters will be set to zero If the filter is changed early, reset the system by touching continuously, the COLD and HOT markers. The WHITE light will turn ON and after 10 seconds will turn OFF. The counters will be set to zero. When all the lights are flashing, the system has experienced a fault. Turn the power OFF to the undersink unit for at least 15 minutes. When the power is turned ON the system may revert to normal operation. If all the lights continue to flash then there is a system fault which must be rectified by an authorised service agent. Warning lights BLUE markers for Ambient water RED markers for Boiling Water Fig.1 - Miniboil tap top Safety lock Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 5 of 28

6 LED Indicators on Miniboil PCBA NOTE: The Zip HydroTap Miniboil does not have a display screen. To help identify the current status of the appliance refer to the table below and compare it with what is happening on the Miniboil PCBA. Status RED LED GREEN LED Internal leak On On Leak Detector Fault On Flashing Temperature Sensor Fault Flashing Off Fill Time out (Water supply Fault) Flashing Flashing Normal Operation Off Flashing Fig.2 - LED Indicator on Miniboil PCBA Page 6 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

7 Fault Diagnosis Flow Chart Miniboil Tap Does Not operate (no lights visible) Is there 230V at the power point? Check the Building circuit breaker. Is the Tap loom connected to the Under-sink unit? Connect Tap loom (USB connector). Are the Tap loom and main Power supply connected to the PCBA? Connect the Tap loom and main Power supply to the PCBA Are there any LED indicators illuminated on the PCBA? Replace PCBA. (See page 23) Replace Tap Head assembly. (See page 10) All the LED lights on the Miniboil Tap are flashing Press the boiling and safety button together. Can you hear the unit heating? If yes, the unit s red light will stop fl ashing when the unit has reached temperature. The white fl ashing light means the unit requires a fi lter change. If no, is the unit in sleep mode? Advise the customer of sleep mode and its operation (see page 5) The fi lter may require changing as well (see page 5). Has there been a blackout or an interruption to the power supply? Turn the power to the Miniboil off for 15 minutes, if when you turn the power back on all the LED indicators continue to fl ash proceed to the next step. Is the water supply turned on and is there water present on the outlet side of the fi lter? Reinstate the water supply to the Miniboil turn the power off for 15 minutes and the turn the power back on Is there any water damage or corrosion in the USB connection? Replace which ever lead (or both) that is damaged. (See page 10) Is there a fl ash code indicated on the PCBA LED s? Replace PCBA. (See page 23) Refer to Flash code table to identify the fault and repair. (See page 6) Slow ambient water flow and slow Boiling water recovery Make sure there are no restrictions or kinks in the hoses to the tap. Is there water supply to the fi lter? Check fi ltermate (DNR PLV valve) and water supply to unit. (See page 11) Is there water supply to the inlet on the unit? Replace the fi lter. (See page 11) If there is still no water supply to the unit replace the fi lter head. Is there good water fl ow through the safety solenoid? Change safety solenoid. (See page 13-14) Is there good water fl ow through both sides of the dual solenoid? (Boiling side is restricted to 0.5 litre a minute.) Replace double solenoid. Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 7 of 28

8 Setting Operational Modes Miniboil Tap LED lights are illuminated but there is no boiling water flow Ensure there is good fall in the silicone hose from the tap to the unit. Make sure there are no kinks or blockages in the hoses. Is the safety button being pressed at the same time as the boiling water button? The safety button is always on and can not be turned off. Advise customer of safety button. Is there corrosion in the USB connection or damage to the USB lead? Replace the USB lead and/or the tap head. (See page 10) Is there 12 Volts to the hot pump when the boiling and safety buttons are pressed? Replace the PCBA (see page 23). Replace the hot pump. Boiling Water is not hot Is the unit in sleep mode? Advise customer of sleep mode and its operation. (See page 5) Is the boiling water (red) LED indicator constantly illuminated? Is the unit dispensing water from the tap? See chart above for fault fi nding. Has the over temperature cut out tripped? Re-set the over temperature cut out and test the temperature sensor probe. (See page 19-20) Make sure there are no kinks or blockages in the vent line from the unit to the tap. If this problem is re-occurring, replace the overload and the sensor probe. Does the element have continuity through it, check for the correct resistance. (See Ohms test/ resistance formula page ) Is there 230 Volts at the heater terminals on the PCBA? Check the fuses, if they are both OK, replace the PCBA. (See page 23) Is there 230 Volts through both poles on the overload? Press the reset on the overload and check again. If there is still no circuit through the overload replace the overload. Replace the element. Unit is over filling. Check all water connections are correct. Does the unit over fi ll when the power supply is OFF to the unit? Change both solenoid valves. Is the level sensor lead plugged on to the PCBA? Plug lead on to correct terminal and test unit. Is the earth wire connected front the tank to the chassis? Fit the earth wire correctly. Are the securing screws holding the heat sink (part of the PCBA) done up tightly? (See fi g 35 on page 23) Tighten or fi t screws. Replace PCBA. Page 8 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

9 Setting Operational Modes (continued) Both lights on the PCBA are flashing. (Fill time out) Check with the customer if there has been an interruption to the buildings water supply. Turn power off to the unit and then back on. (to reset the fault) Is the water supply on to the unit? Turn on water supply. Turn off power to unit and turn back on. (to reset the fault) Is there good water fl ow to the fi lter head? Replace the multi valve. Is there good water fl ow through the fi lter? Replace the fi lter. If problem still persists replace the fi lter head as well. Check the water fl ow through both of the solenoid valves. Replace the one with poor water fl ow through it. If they both have good fl ow, replace the PCBA. Water leak inside unit. Check if there is any evidence of water leaking or dripping onto the base unit. Clean up all the water in the base of the unit and the fl ood sensor. Check all plumbing fi ttings in the unit. If any of the John Guest fi ttings are leaking, you can replace them or the o rings can be replaced. If one is leaking, replace all o rings or fi ttings in the unit. If all the plumbing fi ttings look good turn on the water to the unit and do a live visual test. If the leak is coming from the tank, Is the level sensor plugged onto the PCBA? Plug level sensor plug on to PCBA. Is the earth wire connected from the tank to the chassis? Fit earth wire. Are the securing screws holding the heat sink (part of the PCBA) done up tightly? (See fi g 35 on page 23) Tighten or fi t screws. Is there a circuit through each of the level probes to the level plug on the PCBA? (See page 14-15) Replace the level sensors. Replace the PCBA. (See fi g 35 on page 23) Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 9 of 28

10 Components Caution! Before you commence any service work on a HydroTap Miniboil isolate the power supply. DO NOT under any circumstances disconnect the supply tubes from the under-sink unit to the tap without first isolating the power. Failure to heed this warning could result in the under-sink unit dispensing water into the cupboard area causing damage and potential serious injury. Tap Assembly The HydroTap Miniboil Tap uses three (3) capacitive sensor switches (refer to page 5 & 6 for how to use the tap) it is connected to the under-sink unit via a data cable and USB plug and socket. This is a non repairable item and if found to be faulty should be replaced. Tap Head and Cap Removal 1. Isolate the electrical and water supply to the HydroTap Miniboil. 2. Disconnect the Tap loom (USB connector). 3. Disconnect the Boiling, Ambient and Vent outlet tubes from the underside of the tap. 4. Remove the securing nut from the threaded rod and remove tap from sink. 5. Remove second nut on threaded rod. 6. Gently remove the tap head from the tap body and pass the loom and USB plug through the tap body. Tap Head and Cap replacement 1. Perform the removal procedure in reverse. 2. Re-connect the Boiling, Ambient and Vent outlet tubes to the tap. 3. Turn on the water and power supply. 4. Test the new tap head to ensure it is working correctly. (see page 5 how to use) Fig.3 - Tap head removal picture Page 10 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

11 Filter and Inlet Water Assembly The HydroTap Miniboil has an externally mounted multi valve (double non-return & 350 kpa pressure limiting valve) and filter assembly. These items must be installed prior to the inlet connection on the Miniboil. (refer to Installation & Operation Instructions) Changing the filter 1. Isolate the mains water supply. 2. Touch the Ambient (blue) button on the Miniboil tap to release any trapped pressure. 3. Turn the filter a quarter turn to the left (clockwise) and pull the filter down gently. 4. Unpack the New filter ensuring you do not touch the o-ring seals. 5. Insert the new filter and rotate the cartridge a quarter turn to the right (counter clockwise). 6. Remove the inlet water supply John Guest pipe from the inlet fitting on the unit and hold the open end over a large bucket. 7. Turn on the water supply and flush a minimum or seven and a half (7.5Lt) of water through the cartridge. 8. Turn the water supply off and re-connect the John Guest inlet pipe to the MiniBoil. 9. Turn on the water supply and check for leaks and correct operation of the tap. 10. Reset the filter counter (refer to page 5). Turn the cartridge a quarter turn to the right until it locks into position. Reverse this procedure for removal. Flow Direction Inlet Fitting DNR & Pressure Limiting Valve Fig.4 - External filter connection Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 11 of 28

12 Appliance Entry 1. Isolate the electrical and water supply to the HydroTap Miniboil. 2. Disconnect the Tap loom (USB connector). 3. Disconnect the water supply John Guest fitting and the Boiling, Ambient and Vent outlet tubes. 4. Remove the Miniboil under-sink unit from the cupboard. 5. Remove the three (3) screws located on either sides of the under-sink unit. 6. Slide the outer case forwards. Fig.5 - Miniboil under-sink unit Earthing Continuity Test After each service, the earth continuity must be checked. Use a megameter, appliance tester or continuity tester with an accuracy of Class 5 or better (±5% at full-scale defl ection). To test the earthing continuity: 1. Isolate the appliance from the electricity supply. 2. Set the multimeter to the lowest ohms scale and set to a reading of 0 Ohms with the meter probes connected together. 3. Connect one of the meter probes to the earth pin on the three pin plug. 4. Connect the second meter probe to a bare patch of metal (the edge is best) on the top or the heater; and read the tester s display. This test is shown in Figure 6. Figure.6 Earthing continuity verifi cation 1 Megameter or appliance tester 2 One probe connected to chassis 3 Other probe connected to earth pin of power plug 4 Electricity cable 5. Repeat Steps 3 and 4 with the second test lead touching the front cover of the heater. 6. Repeat Steps 3 and 4 again, with the second test lead touching the metal body of the tap. All readings should be less than 1 Ohm. If any of the readings is more than this, check the earth connection inside the Miniboil. Page 12 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

13 Solenoid Valves There are two (2) solenoid valves in the Zip HydroTap Miniboil, the main or safety solenoid and a secondary or slave solenoid the latter has a single inlet and a double outlet one for the ambient water supply to the tap and the other for the cold fill supply to the boiling water tank. In order to identify which solenoid valve might be faulty check the resistance (Ohms Test) through the wiring loom PCBA connector. This will ensure you have continuity through the wiring loom and the coil on the valve. (Colour picture of this & correct resistance readings) If you have the correct resistance readings you will need to perform a live test to ensure there is 240V power at the terminals on the solenoids when they are supposed to be operating. If there is no power to the solenoids then the fault lies with the PCBA. (see page 23) Safety Solenoid Double Solenoid Fig.7 - Solenoid valve location Continuity Test of Solenoid Fig.8 - Continuity test of solenoid valves - Pass X Fig.9 - Continuity test of solenoid valves - Fail Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 13 of 28

14 Solenoid Valves Solenoid Removal 1. See page 12 for appliance entry. 2. Disconnect the spade connectors joining the wiring loom to the solenoid valves. 3. Disconnect both outlets from the secondary slave solenoid valve. 4. Remove the two (2) retaining bracket screws located on the rear of the Miniboil chassis. 5. Remove the mounting bracket and valve assembly. Fig.10 - Solenoid valves set up Solenoid Replacement 1. Replace the faulty solenoid valve. 2. Perform the removal procedure in reverse. 3. Make sure all wiring is fixed in place with cable ties. 4. Connect and turn on the water supply checking for any leaks. 5. Perform an earthing continuity test. (see page 14) 6. Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap. 7. Turn on the power supply to the HydroTap Miniboil. Level sensor Level Sensor The Zip HydroTap Miniboil uses three (3) level sensors in the boiling water tank these monitor the water level and depending on the level reading the PCBA will open or close the solenoid valves; the PCBA will also use this information for Power Pulse adjusting the energy supplied to the element. The level sensors work by reading the resistance (Ohms) between the sensor and the tank/element (i.e. when water is present there will be a circuit); therefore it is critical that the earth connection from the tank/element to the chassis is well connected as a loose connection could prevent the level sensors from getting a resistance reading potentially causing the tank to overfill. If you experience an overfilling fault also refer to page 8, PCBA earth.) Level Sensor Removal 1. See page 12 appliance entry. 2. Disconnect the level sensor wiring loom from the PCBA. 3. Remove the insulation lid from the boiling water tank. 4. Remove protective cover and the two (2) retaining nuts that secure the level sensor assembly to the lid of the boiling water tank. Fig.11 - Level sensor removal Page 14 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

15 Level Sensor Level Sensor Testing Fig.12 - Level sensor testing - pass X Fig.13 - Level sensor testing - Fail Level Sensor replacement 1. Replace the faulty level sensor assembly. 2. Perform the removal procedure in reverse. 3. Make sure all wiring is fixed in place with cable ties. 4. Perform an earthing continuity test. (see page 12) 5. Replace the outer case and connect the tap loom and supply tubes from the under-sink unit to the Miniboil tap. 6. Turn on the water and power supply to the HydroTap Miniboil and check operation. BLACK WIRE RED WIRE BLUE WIRE The holder is fixed in place with two (2) captive nuts housed here. A flat blade or phillips head screw driver is all that s needed to remove the nuts. HIGH LEVEL WATER LEVEL LENGTH SENSOR ASSY NO HIGH 57mm HydroTap Miniboil - Hot Tank MIDDLE 79mm Water level High Middle Low HYDROTAP BC 100/125-HOT TANK LOW 205mm HYDROTAP BC 150/175-HOT TANK WATER LEVEL LENGTH SENSOR ASSY NO HIGH MIDDLE LOW 57mm 79mm 258mm WATER LEVEL LENGTH SENSOR ASSY NO HIGH MIDDLE LOW Length 57mm 78mm 205mm 120mm 140mm 205mm A1224-LEVEL-SENSORS-HOTNCOLD.DRW PAGE 1 OF 2 MIDDLE LEVEL Sensor No DOMESTIC HYDROTAP BC 60/85-HOT TANK LOW LEVEL Ensure when removing the sensor holder you check the underside sealing gasket for any faults or imperfections. If needed replace. Fig.14 - Correct wiring Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 15 of 28

16 Thermal Overload Assembly Thermal overload assembly The thermal overload assembly is designed to isolate the element by disconnecting both poles preventing over boiling if the hot sensor or PCBA were to fail, or if the vent pipe becomes blocked. The thermal overload is a safety device and if tripped normally means something is wrong with the temperature control of the unit (PCBA or sensor). To reset the thermal overload, isolate the water and power supply to the HydroTap Miniboil. Ensure that the vent pipe is cool to touch then depress the red reset button in the middle of the thermal overload. You should hear a clicking noise as the overload resets. Note: If the thermal overload has been reset many times it may trip out at a lower temperature, thus causing false activation. Replacing the overload will resolve this problem. IMPORTANT! Do not reset the overload when hot. Allow the overload to cool down to room temperature before resetting. The overloads calibrated performance will be adversely effected if reset when hot. Thermal Overload Fig.15 - Location of overload Removal of the thermal overload 1. See page 12 for appliance entry. 2. Remove the two securing screws holding the overload in place. 3. Ensure you note down which way the wires are connected then remove the quick connectors from the thermal overload. (See fi gure 19 on page 18) Continuity test of overload Fig.16 - Continuity test of overload - pass X Fig.17 - Continuity test of overload - fail Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 16 of 28

17 Thermal Overload Assembly Re-installation of the thermal overload assembly 1. Perform the removal procedure in reverse. 2. Perform an earthing continuity test. (see page 12) 3. Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap. 4. Re-connect and turn on the water and power supplies to the HydroTap Miniboil. Important Note: When fitting new overload. There has been an upgrade to the overload. When fitting the new overload you must remove all heat transfer paste from the overload mounting plate. The wiring to the overload is also different. Please follow the diagram below when upgrading to the new overload. Do not mechanically adjust spade connectors on the overload. Excessive lateral force and deflection may result in deformation of tthe copper rivets. Old Overload From PCBA heater New Overload From PCBA heater Contact pair 1 Contact pair 2 Contact pair 1 Contact pair To element To element Fig.18 - Old and new overload NOTE: Numbering of the pairs on the black plastic housing. Page 17 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

18 Heating Element The element is used to heat the water. The element is designed to only be used while submerged in water. To test the element, isolate the mains power and water supplies to the Miniboil. Disconnect both element wires then using a multimeter, select ohms and test the resistance between both element wires. Element Fig.19 - Location of heating element The correct resistance of an element can be worked out by using the calculation: R = V / I, I = P / V, R = V² / P Where; V= voltage, I =current draw and R= resistance, P = power. Note: The actual reading you get should be within +/- 10% **The Miniboil only comes with a 2000 Watt element. The resistance reading will be 28.9 (approx.) **Element size for units manufactured from 04/2011 till 07/2012 is 2000watts. Units made from 08/2012 till current have a 1500watt element. Fig.20 - Continuity test of element Fig.21 - Blown Element Removal of element: 1. Isolate the water supply to the Miniboil. 2. Use the Miniboil Tap to drain the boiling water tank. 3. See page 12 for appliance entry. 4. Remove the insulation lid from the boiling water tank. 5. Disconnect the earth lead from the main chassis. 6. Disconnect the wiring from the PCBA to level sensors and temperature sensor. 7. Disconnect the wiring from the thermal overload to the element. 8. Unscrew the two (2) screws that fasten the lid to the boiling water tank and remove the tank lid and element assembly. 9. Remove the earth connection from the tank lid this will release the element. 10. Remove the element. Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 18 of 28

19 Heating Elements Installation of a new element: 1. Check the tank lid gasket, replace the gasket if worn. 2. Perform the removal procedure in reverse. 3. Turn on the water supply and check for any leaks. 4. Perform an earthing continuity test. (see page 12 ) 5. Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap. 6. Turn on the power supply to the Miniboil. Fig.22 - Live test of voltage to overload and element. **caution high voltage will be present** Temperature Sensor Probe There is one (1) temperature sensor probe in the HydroTap Miniboil. The red or hot sensor probe provides a temperature reading of the water in the boiling tank allowing the PCBA to regulate the element as required. The set temperature for the boiling water can be changed using the bridging connector on the PCBA (see fi g 33 on page 23). Signs the sensor may need replacing - Sensor is physically broken. - There is no continuity (resistance) through the sensor. - The sensor is brittle to touch. - The resistance to temperature reading is incorrect. (See resistance to temperature chart.) Fig.23 - Resistance to temperature chart Page 19 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

20 Continuity verses temperature reading test Temperature Sensor Probe Fig.24 - Continuity and temprature test on fl ow sensor - Pass Fig.25 - Continuity and temprature test on fl ow sensor - Fail X Fig.26 - Continuity test Temperature Sensor probe removal (Picture of sensor probe in pocket on top of tank) 1. See page 12 appliance entry. 2. Remove the top insulation panel from the boiling water tank. 3. Remove the hot (red) sensor probe from pocket on lid of the boiling tank. 4. Remove the cable ties and disconnect the sensor from the PCBA. **Servicing Tip** If the sensor probe feels like it is stuck in the tube; heat the tank with the element. When the unit is near boiling point the probe will become easy to remove (release itself from the tube). Fig.27 - Top of hot tank. Location of level sensors, element and hot sensor probe. Hot Sensor in Pocket Temperature sensor probe replacement 1. Perform the removal procedure in reverse. 2. Make sure hot sensor is inserted into the sensor pocket only as far as the maker on the sensor and fi x in place with a cable tie (Show photo). 3. Turn on the water supply and check for any leaks. 4. Perform an earthing continuity test (see page 12). 5. Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap. 6. Turn on the power supply to the HydroTap Miniboil. Page 20 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

21 Boiling Water Module & Pump Boiling water pump operation The Zip HydroTap Miniboil dispenses boiling water via a 12 Volt pump featuring a soft start to prevent water splashing out of your cup, the speed then increases to achieve a smooth steady fl ow. The pump also features a maximum run time of fi fteen (15) seconds at one time. This pump is controlled by the PCBA and the operational program includes a self priming feature to ensure that air does not get trapped in the pump. Every 5 minutes the PCBA will prime the pump by activating it for 0.06 seconds. Caution: If the pump has failed you will not be able to drain the boiling water tank prior to its removal. Adequate time should be allowed for the boiling water tank and its contents to cool to below 40 C prior to removal to avoid the risk of scalding. Failure to heed this warning may result in serious injury. Boiling water module & pump removal 1. See page 12 for appliance entry. 2. Remove the insulation panel from the top of the boiling water tank. 3. Disconnect the water inlet (copper tube) from the silicone elbow on the lid. 4. Disconnect the pump wiring, 2 earth connections, temperature sensor, heater connections and level sensor wiring from the PCBA and chassis. 5. Remove all cable ties. 6. Release the clip from the top packing strap that holds the tank assembly to the chassis. 7. Slide the boiling water outlet and vent pipe outlet fi tting from the chassis and carefully remove the tank assembly. TIP Ensure you do not let the outlet pipe drop below the top (height) of the tank as water will drain from it. Once the tank has been removed from the unit, remove the four screws holding the lid of the boiling water tank and remove it, together attached wiring, from the tank. Carefully drain the tank (completely) into a sink or other water receptacle. 8. Remove and slide the quick release clip from the pumps inlet hose and remove the cable tie on the outlet of the pump. 9. Remove the pump. Hot pump replacement 1. Perform the removal procedure in reverse. 2. Make sure all wiring is fi xed in place with cable ties. 3. Turn on the water supply and check for any leaks. 4. Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap. 5. Perform an earthing continuity test. (see page 12) 6. Turn on the power supply to the HydroTap Miniboil. Fig.28 - Outlet Fitting Fig.29 - Hot Tank Removed Fig.30 - Hot Pump Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 21 of 28

22 Leak Detector There is a Flood Detector located within the sealed safe tray of the HydroTap Miniboil under-sink unit. This allows the PCBA to isolate the water supply at the main Safety solenoid in the event of an internal leak. Signs the Leak detector may need replacing include broken or damaged wiring and corroded terminals. Leak Detector removal 1. See page 12 appliance entry. 2. Remove the retaining screw holding the detector in place. 3. Disconnect the wiring loom from the PCBA. Fig.31 - Flood sensor location Leak detector replacement 1. Perform the removal procedure in reverse. 2. Make sure all wiring is fi xed in place with cable ties. 3. Turn on the water supply and check for any leaks. 4. Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap. 5. Perform an earthing continuity test. (see page 12) 6. Turn on the power supply to the HydroTap Miniboil. Internal Leak TIP: If you have had an internal leak follow (leak detector removal steps 1-5) and dry up any water that is in the sealed safe tray. If the source of the leak is not immediately evident you will need to re-connect the Miniboil under-sink unit to the Miniboil tap, water and power supplies and test for leaks. **Caution high voltage will be present when doing live tests**. To do this you will need to leave the outer case removed so as to see the source of the leak. Once identifi ed you can once again disconnect the under-sink unit and repair the fault. In most cases the cause of internal leaks are aging o-rings that are used as a seal in the John Guest fi ttings. John Guest Fitting Tips Fitting Fig.32 - John Guest (JG) fittings - Assembly and Removal Prepare the tube: 1. Be careful when cutting the poly tube so that there are no rough edges and that the tube is not distorted. 2. Use a sharp knife to ensure the tube has a clean, straight edge. Do not cut at an angle. 3. Remove any swarf or unwanted material. Insertion: 4. Push the tube into the John Guest fi tting making sure all connections to the John Guest fi ttings are pushed in past the O ring to full depth, at least 15-16mm. 5. Check for a good joint by pulling back on the tube. If the tube comes out, of the fi tting, repeat the above step. Removal: 6. To remove the tube, press the collet into the fi tting and at the same time pull back on the tube. Page 22 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

23 PCBA The printed circuit board assembly is the brain of the whole unit. Signs that the PCBA may need replacement include burn marks and broken terminals on the board. Removal of PCBA 1. See page 12 appliance entry. 2. Disconnect all wiring looms from the PCBA. 3. Remove the two (2) retaining screws that secure the PCBA mounting bracket to the chassis. PCBA replacement 1. Perform the removal procedure in reverse. 2. Ensure you wire the PCBA as per the wiring diagram. 3. Perform an earthing continuity test (see page 12). 4. Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap. 5. Re-connect and turn on the water and power supply to the HydroTap Miniboil. Miniboil PCBA Altitude Adjustment To adjust for the correct altitude, select your preferred setting with the bridging connector. Failure to set the temperature to the correct altutude setting will result in HydroTap over boiling. Altitude Setting Guideline Temperature Altitude 98 C Sea level - 600m 95 C 600m m 92 C > 1400m *Factory set to 98 C. Fig.33 - Temperature settings on PCBA Miniboil PCBA Fuses There are two (2) fuses located on the PCBA the 1Amp fuse protects the PCBA and the 10Amp fuse protects the element. TIP: Overfi lling Tank Please be aware that there is no additional earth strap on the Miniboil PCBA. The PCBA is earthed via the retaining nut and bolt that secures the PCBA heat sink in place. If this nut is loose it may cause the boiling water tank to overfi ll. Please emsure this nut is tight Fig.34 - Miniboil PCBA Fuses Fig.35 - Miniboil PCBA heatsink earth connection Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 23 of 28

24 Miniboil Parts Diagram ELITE TAP CLASSIC TAP Page 24 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

25 Miniboil Parts List Item Part Description Qty GASKET ELBOWS KIT MINIBOIL ELEMENT KIT 1500W SAFETY SOLENOID KIT ADAPTOR 1/2BSPx1/4 JG CI3208 KIT DOUBLE SOLENOID BARBED KIT NUT ASSY FEMALE 3/4BSP x 1/4JG KIT OVERLOAD 2 POLE KIT BULKHEAD 1/4 JG KIT LOOM PCB TO TAP W GLAND HYDROTAP 12VDC PUMP KIT LEVEL SENSOR ASSY KIT PCB KIT LEAK DETECTOR KIT MINIBOIL LOOM PCB TO OVERLOAD KIT SOLENOIDS TO PCB LOOM KIT LEVEL SENSOR LOOM H-TANK KIT SENSOR PROBE HOT TANK KIT HTAP KIT APEX MULTI-VALVE 350Kpa SINGLE FILTER HEAD ASSY SUB-MICRON - TRIPLE ACTION HOT TANK KIT COPPER WELDED HydroTap MINIBOIL FILTER KIT MINIBOIL CLASIC TAP ASSY CAP ASSY KIT _ MINIBOIL CLASSIC FONT KIT STANDARD MINIBOILELITE TAP ASSY CAP ASSY KIT-MINIBOIL ELITE FONT KIT-MINIBOIL ELITE Stem Elbow Assy JG 1/4 Kit 1 Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 25 of 28

26 HydroTap Miniboil Wiring Diagram BLUE HIGH L. RED MIDDLE L. BLACK LOW L. HYDROTAP MINIBOIL Wiring diagram BLACK BLACK OVERLOAD SAFETY SOLENOID HOT TANK ELEMENT RED YELLOW DOUBLE SOLENOID TAP J10 GREY J2 J11 MAINS POWER 10A FUSE AMBIENT OUTLET BLUE HOT TANK FILLER RED HOT SENSOR RED J3 J7 J8 J12 J5 1A FUSE 0.5A BLUE RED BLACK BLACK RED HOT PUMP FLOOD DETECTOR YELLOW Zip HydroTap Miniboil - Service Manual September 2012 v1.02 Page 26 of 28

27 Notes Page 27 of 28 Zip HydroTap Miniboil- Service Manual September 2012 v1.02

28 Head Office Zip Heaters (Aust) Pty. Ltd ABN: Allingham Street Condell Park NSW 2200 Postal: Locked Bag 80 Bankstown 1885 Australia Website: Facsimile: (02) Telephone: (02) Free Call: Page 28 of 28 Zip HydroTap Miniboil - Service Manual September 2012 v1.02