Service Manual. Domestic and Commercial models. Service Manual. HydroTap. HydroTap with disabled levers

Transcription

1 Service Manual Zip HydroTap Compact 2 Service Manual HydroTap HydroTap with disabled levers Domestic and Commercial models Zip Hydrotap Compact 2 Service Manual November V1.01 Page 1 of 70

2 Contents Compact 2 underbench unit images Specifications, Approvals, Model range, Warnings General information General underbench layout, connections and dimensions Layout of major components Control panel display - model selection and operations Control panel display - fault diagnosis Control panel display - Service menu Control panel display - Recalibration procedure Fault flow charts Components John Guest fittings (Insertion and removal) Water supply Filter change Tap operation Child safety lock and disabled levers Tap assembly Tap and Font assembly Outer cover removal and appliance entry Internal components Solenoid valves Chiller Condenser fan Evaporator Compressor, Capacitor and Relay Compressor winding check test Compressor refrigeration and check test Refrigeration trouble shooting Chiller pump Chiller level and temperature sensors Temperature Resistance Chart Boiler Hot level and temperature sensors Hot tank Hot pump and transformer Element Thermal Overload Control (TOC) Electrical Printed Circuit Board and fuse assembly Leak detector & PCBA transformer Earth continuity test Wiring diagram Diagrams Plumbing layout Parts lists and diagrams Conversion tables Contact details Page 2 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

3 Compact 2 underbench unit Domestic model Commercial model Zip Hydrotap Compact 2 Service Manual November V1.01 Page 3 of 70

4 Specifications & Approvals HydroTap specifications Power : 220V - 240V AC 50Hz single phase Heating elements: 1500W (residential) and 2000W (Commercial) Min water pressure : 140kPa Max water pressure : 700kPa Refrigerant : 90 grams R134a Secop compressor PL50 Operating (ambient) temps : 5 C - 35 C Hot temp range : 98 C ± 2 C Hot water output : L/min Cold Temp range : 3 C - 6 C Cold water output : L/min Disposable Filter: Re-order type FX - Sub micron Approvals Watermark approved appliance C-Tick approved appliance NSF approved filter CE approved appliance Page 4 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

5 Technical description General information. This Service Manual contains information you will need to service the unit s, wiring, plumbing, sensors, valves and taps. It will show you how to gain access to the inside of the unit and how to service the heating and chilling modules. It also shows how to deal with any mineral scale that may accumulate. All the necessary diagrams, illustrations, and detailed fault finding guides are listed in the index and are referenced throughout the manual. The fault finding guide matches possible faults with probable causes and supplies a summary of detailed corrective actions. Please read these warnings before servicing any Zip HydroTap appliance. Never attempt to service any Zip HydroTap appliance without first reading all of the applicable servicing instructions. 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 or commercial applications. These units utilise a conventional refrigerant compressor to chill the water and an immersion heating element to boil the water. These units dispense boiling water (factory set to 98 C) and chilled water (factory set to 6 C). These units are NOT designed to be used for washing up or to provide hot water for a kitchen sink or for sanitary fixtures. These Boiling and Chilled water units are fitted with two safety locks, one for Boiling water isolation (via the main menu) and the other is a tap mounted, child safety lock. In addition, there are three 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 HydroTap is an electronically controlled, filtered, Boiling water and Chilled water drinking system for kitchens and tea rooms. The unit can be ordered with the Tap Head Assembly for Disabled use (with or without Braille caps). Model range Boiling / Chilled MODEL HT1002 (Dom.) HT1503 (Com.) Power (Max) 220/240V AC 50Hz 1.8 kw 220/240V AC 50Hz 2.3 kw Element rating (kw) Boiling cups / hr Chilling glasses / hr R134a charge 90 grams 90 grams Dimensions (mm) 385W x 380D x 350H 385W x 380D x 350H Fan kit option Not available Yes Zip Hydrotap Compact 2 Service Manual November V1.01 Page 5 of 70

6 Warnings WARNING! 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. Do not allow young children, handicapped or infirm persons, to use the Zip HydroTap without supervision. 3. 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. 4. All Plumbing must comply with AS/NZS & AS/NZS All Electrical must comply with AS/NZS , AS/NZS and AS/NZS All Plumbing and Electrical connections must be made in accordance with local regulations. 7. This service manual should be used in conjunction with the current version of the operating and Installation Instructions (Installation instructions are available from the Zip website). It requires qualified technical knowledge and offers support for the maintenance and repair by a qualified tradesperson only! 8. Due to the process of continuous improvement, Zip Heaters reserves the right to change details mentioned in this manual without notice. The following points are important whenever you service any Zip appliance. 1. 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. 2. 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.) 3. If you remove pipe union olives for any reason, replace them. This ensures the heater stays free from leaks. 4. If the Zip HydroTap is switched off for a long period of time (e.g. More than a weekend), run water through the chilled water outlet for at least 5 minutes before consumption. 5. If a temperature sensor, level probe or PCB is replaced you must re-calibrate the unit. 6. Do not operate the appliance without a water filter. 7. After each service the earth continuity must be checked. See page 59 Airflow and Ventilation Fan Kit information Commercial fan connection The ambient temperatures this unit should operate between are 5ºC - 35ºC. Proper air circulation must be provided. The system will operate satisfactorily only if the recommended air gaps are provided, these are 65mm min rear clearance and 50mm side clearance. Commercial model fan kit: (For Model HT1503) The commercial model has the option of fitting an auxiliary fan. The electrical connection point is on the top panel between the cold water inlet and chilled water outlet. The Page 6 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

7 General Information commercial fan kit is available as a spare part. The fan operates in parallel with the Condenser fan helping to remove heat from the cupboard space. This fan should be purchased and connected to the HydroTap if the airflow characteristics of the cupboard space are inadequate for the effective removal of hot air, thereby adversely affecting the operational performance of the HydroTap. The fan can be installed so that it extracts air from, or forces air into the cupboard space, whichever is the most effective for your installation. Application of the fan is of paramount importance in situations where the cupboard space reaches temperatures greater than 35ºC.This must be used in situations where adequate ventilation cannot be guaranteed. Make sure the ventilation grilles on the sides of the undersink unit are not obstructed in anyway or by anything. Refrigerant The Zip HydroTap Chilling unit contains R134A refrigerant under pressure. No part of the unit should be exposed to a naked flame. Maintenance of refrigeration unit must be carried out by an accredited service provider or qualified refrigeration mechanic. Qualifications If any power cord or plug 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. Venting Sometimes steam and / or boiling water may discharge through a vent outlet at the mouth of the tap. If the tap is not installed using the Font pedestal, ensure the tap body is located so the tap outlet drains safely into the sink bowl area. Note: On startup, the controls take the system through a calibration process which causes the unit to overboil for a period of aprox. 90 secs. This is normal operation, once the calibration process is complete, the system reverts back to normal operation. Lifting and Transporting Take care when lifting the Zip HydroTap undersink unit. Some units may exceed safe lifting limits. Do not lift without assistance. The weights of the units are given in the installation manual, under the heading Installation Requirements. Do not lift the unit by the doors. When transporting the unit, ensure it is in an upright position. Filtration The Zip HydroTap filter control is preset to 6000 Litres to provide trouble-free flow and operation in most installations. Local water quality conditions may require an alteration to this capacity. In areas where the water has a high concentration of sediment, the preset litre capacity may be shortened to avoid poor flow, taste or odour situations. In areas where the water quality is above average, lengthening the preset capacity may be desirable, but not essential. If any of these changes are needed, follow the instructions on page 11 or contact your Zip Service Provider. Altitude The Zip HydroTap is equipped with a self-calibrating program which caters for altitude adjustment. Frost Protection If this appliance is located where ambient air temperature could fall below 5ºC when the heater is not in use, do not turn off the appliance electrically. This safeguard does not offer the same protection to the connecting pipework and fittings. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 7 of 70

8 General under bench Layout 115 Min 15 Tap hole 35mm for HydroTap tap Sink Air gap Max 80 Buffer pad 4mm V-50Hz GPO Pressure limiting valve Min Min 65 Mains cold water isolation valve 348 Min Min Water Inlet Steam vent Chilled water outlet Hot water outlet Domestic model connections Page 8 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

9 Major components layout Condenser and Fan assembly Chiller module Solenoids Thermal Overload Filter assembly Heater module Zip Hydrotap Compact 2 Service Manual November V1.01 Page 9 of 70

10 Model selection READ THIS INSTRUCTION BEFORE COMMISSIONING!! Addendum to Instructions for ALL MODELS This procedure applies to HydroTap products with date of manufacture (DOM) after and including 30th July 2012 or with a serial number starting with xxxxx. The procedure covers model selection and cold temperature set point adjustment. HydroTap Model Selection Procedure Zip Industries Fig.1 1. Turn on the unit, the screen will display the general information of the product for approximately 2 seconds. The screen will display H Tap CP1.30E110 To Select Model Press ADJUST - 2. The screen will then display To Select Model Press ADJUST- as shown in Fig.2. Press ADJUST ^ or button to check the model number. Fig.2 Press ADJUST ^ or - Scroll Exit- compact 2 Res Fig.3 Press MENU ^ or to scroll through the model numbers. to exit 3. The screen will now display -Scroll Exit- on the first line and the model description on the second line as shown in Fig.3. The factory default model description displayed on the screen should match the product model description on your product labels. If the correct model description is displayed, (either Compact 2 Res or Compact 2 Comm.) select Exit by pressing ADJUST ^ or description selection setting. If the model description displayed is incorrect, select the Scroll option by pressing MENU ^ or button to scroll through the model description until the correct model description is displayed. Then select Exit by pressing ADJUST ^ or to confirm selection and exit the model description selection setting. to confirm selection and exit model Start Filt Flush Fig.4 4. The model selection is now complete. Start Filt Flush will be displayed. To continue with the filter flush and calibration, refer to the Testing and Commissioning within the main instruction. Page 10 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

11 Control panel display Menu Plus Button Plus Adjust Button Menu Minus Button Minus Adjust Button Note: Mode buttons change the screen options Adjust buttons select the screen options Important: All of the menu screens (except for 'Filter Flush' Mode) will revert to 'Normal Operation' if left unattended for 10 seconds. When in 'Normal Operation' press the Menu ^ button to return to the last mode used. When in 'Filter Flush' Mode it is important to manually exit by pressing the Menu or Menu button The model you have Normal Operation Monday On The model identification of the product you are working on will flash up for about 5 seconds after power is applied to the unit. This will occur each time power is restored after isolation. After the product I.D. is completed, the screen will default to show Normal Operation Compact 2. This will be displayed when the unit is operating regardless of programmed or unprogrammed settings. Press either Menu or Menu button until Monday On is displayed. To set time for the unit to turn on press Adjust button until required time is reached. To set time for unit to turn Off, press Menu button once and Monday Off will be displayed. Now press Adjust until required time is reached. If each individual day is to have an On / Off time, the previous steps will need to be repeated as you set each day and On / Off time. Note: The HydroTap may be temporarily activated during the On / Off Mode. By operating the levers, the unit will go into normal operation and then return to Off Mode after 30 Minutes. Monday To have continual operation press either Menu or Menu button until Monday On is displayed. Press adjust or until shows in the screen, duplicate for each following on/off for each day. Note, there must be one on period to start the process. Filter Life Factory set at 6000 Ltrs, press either Menu or Menu button until Filter Life is displayed. Press Adjust button to increase Filter Life or Adjust button to decrease Filter Life. Filter Life increases in 1000 Ltr increments to a maximum of Ltrs. Litres Filtered Don't forget to flush filter This counter displays the number of litres passed through the filter. Press adjust to reset litre counter. Then it asks are you sure Press adjust to disable the filter. Press adjust again and the screen will remind you to Flush the filter before proceeding. After aprox 5 secs the screen will reset the litre counter to Zero. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 11 of 70

12 Self - Diagnosis Fault Display Display operations continued Set Time Set Day Filter Flush Filter Life Filter use (Days) Press either Menu or Menu button until Set Time is on the display screen. Press Adjust button to increase time or Adjust button to decrease time. Time increases or decreases in minute increments. Hold the Adjust buttons down for rapid increases or decreases. Press either Menu Press Press either Menu or Menu button to select the filter flush mode. In this mode the water supply is isolated to facilitate filter removal. The unit will remain isolated until the screen is manually exited by using either Menu or Menu buttons. Press adjust to start the water flushing the cartridge. Allow water to run clear and press adjust to stop the flow. Refer to page15 of the Installation and Operating Instructions supplied with the unit. Adjust or or Menu Adjust to select day. button until Set Day is displayed. Press either Menu or Menu button to select this mode. The filter life is Factory set for 12 months = 365 days. To change by 1 month Press Adjust button to increase, or Adjust button to decrease, for a maximum of 14 months. After setting for 14 months. press adjust for "Filter Life Disabled" Press either Menu or Menu button to select Filter use mode. This counter shows how many days a filter has been in use. Press adjust Then it asks are you sure Don't forget to flush filter Sleep Mode Hot Isolation Dispense Hot Press adjust again and the screen will remind you to Flush the filter before proceeding. After aprox 5 secs the screen will reset the counter to Zero. In this menu the unit will go to sleep after a pre-determined period of inactivity. Press either Menu or Menu button until Sleep Mode is displayed. Option 1: Sleep to 65ºC after 2 hours of NO USE Press Adjust once to select Option 2: Auto OFF after 2 hours of NO USE. When the period of inactivity passes, the display will show Sleep Mode. During the Sleep Mode the Red LED on top of the tap lever will flash slowly. Sleep to OFF means the Boiling and Chilled circuits will be switched OFF To de-activate the sleep mode, momentarily operate the Hot lever and then allow sufficient time for the water to reach the set temperature Press adjust to enter Hot isolation mode. Now go to the Tap Head assy and press the Child Safety Lock (3) three times rapidly, the LED s will scroll from left to right (3) three times, this operation confirms the activation. This isolates the boiling tap only. The LCD shows isolation mode is active. De-activation is the same procedure again, LED s scroll right to left three times to confirm. If permanent de-activation is required, de-activate by scrolling through the menu and selecting de-activate when Hot isolation Mode is displayed on the screen. Press either Menu or Menu button to select Dispense hot mode. The maximun Hot water run time is factory set at 15 sec. Press Adjust button to increase or Adjust button to decrease the time. The minimum time is set at 5 sec. Page 12 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

13 Display operations continued Dispense Cold Press either Menu or Menu button to select Dispense cold mode. The maximun Cold water run time is factory set at 15 sec. Press Adjust button to increase or Adjust button to decrease the time. The minimum time is set at 5 sec. Self diagnosis fault display Hot Sensor Fault Cold Sensor Fault This indicates the Hot temperature sensor has lost connection at the main PCB. This fault indicates a possible disconnection at the probe connection point on the PCB or the probe is open circuit. This may result in temps over 120 C. This indicates the Cold temperature sensor has lost connection at the main PCB. This fault indicates a possible disconnection at the probe connection point on the PCB or the probe is open circuit. Compressor Overrun Compressor overrun indicates ventilation may be inadequate or not provided as described in the instructions. The compressor may have overheated or there is low or no refrigerant. Check water supply This indicates a problem with the incoming water supply. check the water is turned ON and there are no blockages or kinks in any of the supply lines. Water Leak Isolate Mains This indicates a water leak has been detected. Isolate the mains water supply and correct the fault before putting the unit back into operation. Flood Sensor Disconnected This indicates the flood sensor is disconnected or the circuit is broken. This indicates a problem with the software. Reload new software Flash Memory has failed test SRAM Battery If, at startup, the system continues to run through it's diagnostic checks, then there may be a problem with the battery. Replace the P.C. Board. SRAM Faulty This message indicates an electronic fault and will require the replacement of the P.C. Board Zip Hydrotap Compact 2 Service Manual November V1.01 Page 13 of 70

14 Service Menu HOT 98 C LVL3 In order to gain access to the service menus press and hold both the Adjust button and the Adjust buttons for aprox 3 sec. The screen will display the current Hot and Cold water temperatures as well as the water levels. NOTE: The Service Menu must be manually exited for normal operation Hot setpoint 98 Celsius Press either Menu or Menu button to select the Hot setpoint mode. Here the Max and Min Hot temperature set points may be adjusted. Press the Adjust button to increase the set point to a Max of 99 C (In 0.5 C increments). If higher temps are required Press the Adjust button again for 100 C however recalibration may be required before this can be achieved. By pressing the Adjust button, minimum temperatures may be set down to 68 C. Once the temperatures have been changed, the screen if left untouched, will default to the original service screen within 10 seconds. Litres Edit 0 Press either Menu or Menu button to select litres edit mode. NOTE: Before proceeding to reset the counter, check the existing litres filtered and record this figure for later use EG. when changing a PC Board. To reset, Press the Adjust button and reset the counter to the nearest 100L. Time (Min) HOT (ABS) Press either Menu Do not adjust or Menu button to select this mode. BOIL (Sec.) Press either Menu Do not adjust or Menu button to select this mode. Reserve Press either Menu Do not adjust or Menu button to select this mode. Auto Sleep Disabled Cold setpoint 6 Celsius Press either Menu or Menu button to select the auto sleep mode. This function is for the All In One Tap. Refer to The All In One Installation manual. Pressing the Adjust button will enable the auto sleep mode and pressing the Adjust button will disable this mode. Compact 2 models should be disabled. Press the Menu button, to enter the Cold Temperature Adjustment Screen :Here you can adjust the Cold temperature set point by pressing the adjust or temperature set point can be changed in 2ºC increments as follows: 5-9º ; 7-11º ; 9-13º or 11-15ºC. buttons. The cold HOT 98 C LVL3 Press either Menu or Menu button to return to the first service screen. NOTE: It is important to manually exit the service mode in order to return to normal operation. To exit press and hold both the Adjust button and the Adjust buttons for aprox 3 sec. Page 14 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

15 Re - Calibration Procedure NOTE: If hot probe or PCB is replaced or if the unit is relocated to a higher or lower altitude, you must re-calibrate the unit. Re-calibration can be used when you want to check to ensure the unit is running at peak performance levels. Turn the power OFF. Now switch the power back ON while depressing the two bottom buttons on the LCD. Zip Industries 1. the screen will display the general information of the product for approximately 2 seconds. The screen will display H Tap CP1.30E110 To Select Model Press ADJUST - Fig.2 Press ADJUST ^ or - Scroll Exit- compact 2 Res Fig.3 Press MENU ^ or to scroll through the model numbers. to exit 2. The screen will then display To Select Model Press ADJUST- as shown in Fig.2. Press ADJUST ^ or button to check the model number. 3. The screen will now display -Scroll Exit- on the first line and the model description on the second line as shown in Fig.3. The factory default model description displayed on the screen should match the product model description on your product labels. If the correct model description is displayed, (either Compact 2 Res or Compact 2 Comm.) select Exit by pressing ADJUST ^ or description selection setting. If the model description displayed is incorrect, select the Scroll option by pressing MENU ^ or button to scroll through the model description until the correct model description is displayed then select Exit by pressing ADJUST ^ or to confirm selection and exit model description selection setting. to confirm selection and exit model Start Filt Flush Fig.4 Calibrate system press Adj Empty Tank Boil sec Normal Operation 4. The model selection is now complete. The Start Filt Flush will be displayed. Warning: Boiling Water and Steam will be dispensed during Steps 5, 6 & 7, proceed with caution to avoid personal injury. 5. Press the adjust button to display Calibrate system. The calibration mode screen will appear, press adjust and the calibration cycle begins automatically. The display will show EMPTY TANK. 6. The hot tank will begin to empty so ensure all items are out of harms way and the drainage point is clear, it is possible that occasionally the tank won t fully empty itself, if this happens remove the hot outlet tube from the base of the tap assembly and locate the outlet at a lower point than the tank assembly this will allow the tank to fully empty. 7. Once empty, if the tank is below 95ºC the unit will heat to this temperature. When at 90ºC it stabilises for approx 120 seconds, once stabilised the unit will heat to boiling point and continue to Boil for a further 130 seconds. The unit now re-calibrates for the local conditions, once achieved the unit will default back to Normal operation. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 15 of 70

16 Unit does not turn on ( no power, no lights on the tap or the screen) Is there 230volts at the power point? Fault flow charts No Yes Check circuit breaker and advise customer to get an electrician to look at the circuit. Make sure the power lead is plugged in correctly. Is there continuity through the 3 fuses or are the fuses fi tted correctly to the PCBA? No Replace or refi t the fuses. If the fuse is blown, check what components the fuse protects (Page 57) and test them for electrical faults and repair/replace component.( open circuit, short circuit or a leak to earth) Yes Are all the cables plugged on to the PCBA? No Fit cables to the correct terminals on the PCBA and re-test unit. Yes Is there 230 volts to the PCBA? No Check the terminations in the green terminal on the PCBA are correct. Make sure there is a circuit between the lead and the terminal. Yes Check the output voltages on the supply transformer. Are they correct? (See page 58) No Yes Replace the transformer. Replace the PCBA. Can not get the unit to filter flush. Is the water supply on to the unit? No Turn on water supply, make sure there are no kinks or blockages in the supply line to the unit. Yes Is water getting to the fi lter? No Check the safety solenoid (see page 32) and the double non return valve. Replace which ever is faulty. Yes Is water passing through the fi lter? No Yes Use a fi lter plug (90211) in place of the fi lter. If the water now passes through, the fi lter is blocked and requires replacing. If the water still does not pass through replace the fi lter head assembly. Check the fi lter fl ush tap for any blockages. If it is all clear, change the display board and ribbon cable. Unit does not stop calibrating or stays in calibration mode. Are the hoses cut to length with no kinks, loops or blockages in them? No Cut hoses to length and remove any blockages or kinks. (See installation instructions P.5) Yes Is the unit heating? (is the temperature reading static ) No Overload might be tripped, reset overload and test unit. (See page 55). If the overload is not tripped see fault fi nding section on unit not heating. Yes Is the vent pipe blocked? Yes Remove blockage or replace vent pipe. Run the calibration cycle with the silicone vent pipe removed from the top of the unit. (See page 15) No Is the hot temperature sensor within the sensor range? No Replace the hot sensor probe and recalibrate. (See page 47) Yes Is the element electrically sound? (continuity test, earth leakage test and physical inspection) No Replace the element. (See page 54) Yes Replace the PCBA. (See page 57) Page 16 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

17 Unit is not heating. (Red light flashing on tap) Does it say normal operation on the display screen? No Yes Take unit out of sleep mode or resolve fault message on the display screen. Is the overload tripped? (do you have to reset it.) No Do a continuity and earth leakage test on the element and the hot temperature sensor. (See page 59) Yes Reset overload. Is the silicone vent hose or vent pipe from the hot tank blocked or kinked? Yes No Boiling Water is not Hot Is the unit in sleep mode? Unblock or unkink hose or pipe or replace. Do a temperature vs. resistance test on the hot temperature sensor. (see page 46) If it is out of the parameters, replace the hot sensor and recalibrate the unit (see page 15). If the sensor test ok, test the unit, is there a lot of steam produced from the vent pipe when the unit is heating? No Yes Fault flow charts Replace the overload. Replace the PCBA Yes Advise customer of sleep mode and its operation. (See page 12) No Is the boiling water (red) LED indicator constantly illuminated? Yes Is the unit dispensing water from the tap? See chart above for fault fi nding. No Has the over temperature cut out tripped? (See page 55) Yes Re-set the over temperature cut out and test the temperature sensor probe. (See page 46) 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. No Does the element have continuity through it, check for the correct resistance. (See Ohms test/ resistance formula page 53.) Yes Is there 230 Volts at the heater terminals on the PCBA? No Check the fuses, if they are both OK, replace the PCBA. (See page 57) Yes Is there 230 Volts through both poles on the overload? No Press the reset on the overload and check again. If there is still no circuit through the overload replace the overload. Yes Replace the element. (See page 51) Water is not chilling. Is there a fault message on the display screen? Yes No Rectify the fault and reset the unit. Is the fan running? No Check the chilled water fuse on the PCBA. If not blown, check that the fan is getting 230 v. If it is, replace the fan assembly. If the fuse is blown, go to next step. Yes Is the temperature reading of the chilled water at ambient temperature? No Yes Check the cold sensor probe reading against the resistance chart (page 46). If the resistance reading is out, replace the cold sensor probe. (see page 45) If it is correct, go to next step. Is the compressor getting 230 volts? No Replace PCBA. (See page 57) Yes Electrically test the relay, capacitor and compressor windings. (See Page 34) Replace faulty parts. If all are correct, the unit will have a refrigeration fault and needs to be serviced by a qualifi ed refrigeration technician. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 17 of 70

18 Fault flow charts Tap Does Not operate (no lights visible) Is there 230 V at the power point? No Check the Building circuit breaker. Yes Is the Tap loom connected to the Under-sink unit? No Connect Tap loom (USB connector). Yes Are the Tap loom and main Power supply connected to the PCBA? No Connect the Tap loom and main Power supply to the PCBA Yes Are there any LED indicators illuminated on the PCBA? No Replace PCBA. (See page 57) Yes Replace Tap Head assembly. (See page 27) All the LED lights on the 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? Yes Advise the customer of sleep mode and its operation (See page 12) The fi lter may require changing as well (See page 23). No Has there been a blackout or an interruption to the power supply? Yes No Yes Yes Turn the power to the unit 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? No Reinstate the water supply, turn the power off for 15 minutes and then turn the power back on Is there any water damage or corrosion in the USB connection? Replace whichever lead (or both) that is damaged. No Is there a fl ash code indicated on the PCBA LED s? No Replace PCBA. (See page 57) Yes Refer to Flash code table to identify the fault and repair. 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? No Check fi ltermate (DNR PLV multi function valve) and water supply to unit. (See page 22) Yes Is there water supply to the inlet on the unit? No Yes Replace the fi lter. (See page 23) 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? No Change safety solenoid. (See page 32) Yes Is there good water fl ow through both sides of the dual solenoid? (Boiling side is restricted to 0.5 litre a minute.) No Replace double solenoid. Page 18 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

19 Fault flow charts 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? No The safety button is always on. Advise customer of safety button. Yes Is there corrosion in the USB connection or damage to the USB lead? Yes Replace the USB lead and/or the tap head. (See page 27) No Is there 12 Volts to the hot pump when the boiling and safety buttons are pressed? No Replace the PCBA (See page 57). Yes Replace the hot pump. (See page 52) 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. Yes Turn power off to the unit and then back on. (to reset the fault) No Is the water supply on to the unit? No Turn on water supply. Turn off power to unit and turn back on. (to reset the fault) Yes Is there good water fl ow to the fi lter head? No Replace the multi function valve. (See page 22) Yes Is there good water fl ow through the fi lter? No Replace the fi lter. If problem still persists replace the fi lter head as well. Yes Check the water fl ow through both of the solenoid valves. (See page 30) Replace the one with poor water fl ow through it. If they both have good fl ow, replace the PCBA. 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? Yes Change both solenoid valves. No Is the level sensor lead plugged on to the PCBA? No Plug lead on to correct terminal and test unit. Yes Is the earth wire connected front the tank to the chassis? No Fit the earth wire correctly. Yes Are the securing screws holding the heat sink (part of the PCBA) done up tightly? (See page 57) No Tighten or fi t screws. Yes Replace PCBA. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 19 of 70

20 Fault flow charts Unit does not dispense cold water. Does the display screen say Normal operation? No Resolve fault written on the display screen. Yes When the cold lever is pressed can you hear a clicking from the PCBA? No The unit is not getting a signal from the tap. Check the USB connection between the tap and the unit for any corrosion or a bad/loose connection. Replace if there is any corrosion. Physically look for any cuts or nicks on both USB leads. Replace either lead if you fi nd some. If the USB connection and leads look in good condition, replace the tap top assembly. (See page 27) Yes Is the cold pump connected to the PCBA? No Reconnect pump to PCBA and test the unit. If there is still no cold water go to the next step. Yes Are you getting 14 volts from the PCB? No Replace the PCBA.( See page 57) Yes Check the cold tank, is it frozen? ( See page 35) Yes Replace cold sensor.( See page 45) No Replace cold pump.( See page 42) Unit does not dispense boiling water? check if the child safety lock is on. Is the unit in isolation mode? Yes scroll through the menu and turn Hot isolation' OFF. (See page 12) Test unit, if it still does not produce boiling water go to next question. No Is the red indicator light (on the tap) permanently on? No Yes go to 'Unit is not heating' fl ow chart. Can you hear the relay on the PCBA clicking when the boiling water lever is depressed? No Yes The unit is not getting a signal from the tap. Check the USB connection between the tap and the unit for any corrosion or a bad/loose connection. Replace if there is any corrosion. Physically look for any cuts or nicks on both USB leads. Replace either lead if you fi nd any faults. If the USB connection and leads look in good condition, replace the tap top assembly. (See page 27). Do you get a reading of volts from the hot pump transformer? No Replace the hot pump transformer. (See page 49) Yes Replace the hot pump. Page 20 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

21 CComponentCComponents CAUTION! Before you commence any service work on a HydroTap 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. When the litres filter timer or the days used (filter) timer is up, the filter light on the tap will indicate that the filter requires changing. ( Note- error message check water supply can also indicate that the filter may need replacing.) The default setting is 6000 Ltrs or one year, but this can be set in increments of 1,000 Ltrs from 1,000 Ltrs to 10,000 Ltrs. John GuestJ CComponentCJohn Guest fittings (Insertion and removal) John Guest Fitting Tips 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 fitting making sure all connections to the John Guest fittings 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 fitting, repeat the above step. Removal: 6. To remove the tube, press the collet into the fitting and at the same time pull back on the tube. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 21 of 70

22 Water supply The HydroTap is supplied with a 350 kpa double non return / pressure limiting valve. The water supply is then run through a ¼ inch John Guest tube to the inlet of the base unit. DNR Kpa PL Multi function valve Tap not supplied Mains supply Appliance Water inlet Page 22 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

23 Filter change Front cover Filter location Locking Clip To change the filter: 1. Scroll through the screen menu to Filter Flush Off this isolates the water supply. 2. Remove the front cover by unlocking clips on both sides and lift off to expose the filter. 3. Relieve system pressure via the filter flush stop cock, a quick open and close will do. 4. Grasp filter cartridge and twist LEFT to RIGHT one quarter turn until it stops. 5. Ease cartridge downwards to detach it from the filter head (socket). 6. Do not tilt the cartridge as dirty water may spill from it if tilted. 7. Unpack replacement cartridge and write today s date where shown on the label. 8. Avoid touching the filter O rings and filter opening as this may cause bacterial contamination of the cartridge. 9. Align cartridge tabs with the slots on the under-side of the filter head. 10. Slide cartridge upward into head and rotate RIGHT to LEFT until it stops. 11. Locate the filter flush hose situated behind the filter cartridge and run to a container ready for flushing. Open the flush hose tap lever. On the control panel press adjust ^, this will start the water flushing the cartridge. Allow at least 7.5 Litres of water to run through to activate the filter and then press adjust ^ to stop the flow. 12. Isolate the filter flush stop cock and re-fit behind the filter cartridge. 13. Wipe up any spills and dispose of spent filter cartridge and packaging thoughtfully. 14. Scroll through the menu to Litres Filtered, press adjust ^ to reset litre counter. Press adjust ^ and it asks are you sure. Press adjust ^ again to lock in the command. 15. Scroll through the menu to Filter Used (Days), press adjust ^ to reset the timer. Press adjust ^ and it asks are you sure. Press adjust ^ again to lock in the command. After approx 10 seconds it will default to the selected mode. 16. Refit the front cover to secure the appliance. 3M Filter - option Zip Hydrotap Compact 2 Service Manual November V1.01 Page 23 of 70

24 Tap operation Press or pull lever Lever Operation The Hydrotap will deliver Boiling water (98 C ± 2 C) at a rate of L/min and Chilled water (3 C - 6 C) at a rate of L/min. Boiling Water Lever: Depressing the Red lever allows dispensing of boiling water. Pulling up the Red lever allows the tap to operate in a no-touch mode. Water will flow from between 5 and 15 seconds (This is user adjustable). To reset, return the handle to the Off position and repeat the step. The lever has to be manually returned to the Off position. Chilled Water Lever: Depressing the Blue lever allows dispensing of Chilled water. Pulling up the Blue lever allows the tap to operate in a no-touch mode. Water will flow from between 5 and 15 seconds (This is user adjustable). To reset, return the handle to the Off position and repeat the step. The lever has to be manually returned to the Off position. Blue Chilled Water Light Boiling Filter Change Chilled On all the time: This indicates that the temperature of the chilled water is within the usable temperature range. Flashing slowly: This indicates that the chilled water is not at the right temperature. Wait up to 20 minutes. When the chilled water is at the right temperature, the light will stop flashing. During heavy usage, the temperature can rise out of this range. Red Boiling Water Light On all the time: This indicates that the boiling water is ready. Flashing slowly: This indicates that the boiling water is below usable temperature. Filter light Filter Change Light Off: This indicates the filter is operating within its normal specified lifespan. Filter Change light flashing slowly: The light will flash slowly when the filter is due for replacement and the LCD will show Filter Change. Refer to Replacing the filter section of this document. (See page 23). Page 24 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

25 Child Safety Lock Child safety Lock The child safety lock can be activated to prevent boiling water flowing if the hot lever is inadvertently activated. To activate: Simultaneously press the safety lock and the Blue Chilled water lever for a period of approximately ten seconds. The safety lock indicator light will now be illuminated. To deactivate: First press the safety lock then depress the Blue Chilled water lever for a period of approximately ten seconds. The safety lock indicator light will now extinguish. To operate when the lock is ON: Depress both the Red lever and the safety lock To Install Braille Caps 1. Submerge both braille caps in boiling water for one minute to soften the rubber. 2. Remove caps from boiling water using a spoon and shake off excess water. 3. Slide the braille caps over the lever, as shown in the picture on the right. 4. When placing the caps over the lever, pull the lever forward and support the inner side of the lever with your free thumb. Tap with Braille levers fitted Zip Hydrotap Compact 2 Service Manual November V1.01 Page 25 of 70

26 Tap assembly The tap assembly is the electronic control used for the safe dispensing of boiling, chiller and sparkling water. There are three (3) reed switches and magnets located in the tap assembly. See page 24 for correct tap operation. The levers are operated by a spring and cam system. These can be replaced if the levers are found not to be functioning correctly. Note: The positioning of the levers is very critical to the correct operation of the tap assembly. If they are not aligned correctly the reed switches will not activate and cause the unit to either dispense all for 15 seconds or not dispense water at all. The safety button is mounted on the support structure for the Tap PCBA, the safety button should be able to be moved by pressing towards the tap. It should then return to its starting position. If the button seems pushed in and does not move when pushed, it should be replaced. The reed switches are located in the white housing at the rear of the tap, below the tap levers. The reed switches are factory positioned and set, and no attempt to reposition them should be made. Due to the delicacy of the switches any excessive pressure applied to the switches can ultimately break the switch and cause the HydroTap to fail. Whenever either of the tap levers are operated (if the safety button is active it will need to be pressed along with the boiling water lever), you should be able to hear a relay clicking on the PCBA when first activated and when deactivated or 15 seconds has passed. If this can not be heard, the tap or loom would have a fault with it. Check the USB loom for any cuts or nicks in the loom. Replace the loom if there are any visible. Check the USB connection, between the two looms for any corrosion. Replace the corroded side of the loom. Also make sure that USB push fit connection is tight and does not wiggle from side to side too excessively. Connections that are of a poor fit can cause intermittent problems with the operation of the unit. To Test: In order to test, use the Tap Emulator No to comfirm the correct connections and tap operation. To Check: If the loom and USB look in good condition, remove the tap top. There is a securing screw located under the spout of the tap. Remove the screw. The safety button and tap PCB are also secured with a screw, remove the screw and remove the tap PCB. Check the PCB for any corrosion or burnt area s. Check the magnet on the safety button and the magnets in the rubbers of the tap levers. Replace any part that is corroded or burnt. Page 26 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

27 Tap assembly Tap Top removal. 1. Remove the phillip's headed screw located on the underside of the tap spout. 2. Lift off the top half of the tap head, be careful not to disturb the position of the nylon clamp block. 3. Thread the USB plug and cable through the tap body, the spider clamp may need to be removed for this to occur Access screw Reed switches Clamp block Stainless steel tube for carbonated water Zip Hydrotap Compact 2 Service Manual November V1.01 Page 27 of 70

28 Tap assembly Screw holes Pull apart Align holes for re-assembly Removal of the levers and springs: If the levers are to be replaced, isolate power, CO2 gas, water and USB connector, tilt the levers forward into the locked on position. Look to the back of the tap, by tilting the levers forward, this exposes the locking grub screw that secures the levers. With care, completely remove the 2 allen screws ( use a 1.5mm allen key), pull the levers horizontally apart until they are free from their locating shaft. Be careful not to disturb the small magnets that are embedded in the RED and BLUE rubber mouldings. They are for the activation of the reed switch. Checking Balls and springs: Removal of the circlip from the lever axle will allow access to the 3 balls and springs housed in the nylon carrier block. (See page 62) Ensure these are lightly lubricated with a food grade grease re-installation is the reverse procedure. Safety switch Reed switch For access to the safety switch 1. Disconnect the reed switch plug 2. Remove the small screw (#1 phillips) 3. Carefully Push out the safety switch For access to the reed switch 4. After removing the safety switch and light pipes 5. (Working from within the tap head) Push the reed switch out and away from the tap Page 28 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

29 Tap and Font assembly Removal of the tap assembly: SMEAR A SMALL AMOUNT OF SILICONE ON THE UNDERSIDE OF THE PLASTIC SPACER Normal assembly TAP BLACK PLASTIC SPACER ALL-THREADED ROD M6 BENCH TOP STAINLESS STEEL WASHER SPIDER M6 NUT This requires the water and power to be isolated and de-pressurised. Disconnect the supply tubes and Vent line from the HydroTap unit under sink, using a pair of pliers or any other suitable tool, release the spring clips that secure the supply tubes. Ensure you tag them correctly for correct re-installation. Using the tube spanner, that should be on-site from the original installation. Loosen and remove the fixing nut located on the threaded rod projecting from the underside of the Tap Assy. When this is done, slide down and off the Spider Clamp and if fitted, the large washer. The Tap Assy should now be free for removal from the sink surface. Take care in case the tap was fixed in place with an amount of silastic for security and water proofing. Replacement of a new tap or re-fitting the old tap is the reverse procedure. Note: New spring clamps are provided with replacement Taps. TAP BLACK PLASTIC SPACER FONT See Para 4 BENCH TOP SPACER RING UNDER FONT STAINLESS STEEL WASHER SPIDER Font assembly M6 NUT Zip Hydrotap Compact 2 Service Manual November V1.01 Page 29 of 70

30 Outer covers C Slide forward to remove A B Outer cover removal and appliance entry 1. Remove the front cover (A) by unlocking the clips on both sides and lift off to expose the filter 2. Remove the secondary cover (B) for access to the PC Board For appliance entry: 3. Isolate the electric and water supply to the unit. 4. Disconnect the Tap loom (USB connector) 5. Disconnect the water supply, John Guest fittings and the vent outlet tubes from the top of the unit 6. Remove the base unit from the cupboard. 7. Remopve the six (6) screws located around the sides of the undersink unit. 8. Slide the outer case (C) forward. Page 30 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

31 Internal components Cold tank & Evaporator Solenoids Thermal overload Condenser & Fan Hot Tank & Element Filter P.C.Board & fuse Assembly Transformers Zip Hydrotap Compact 2 Service Manual November V1.01 Page 31 of 70

32 Solenoid Valves / Replacement The solenoids let water into and out of the appliance. All the solenoids are 240 volt solenoids and should have a resistance reading of aprox ohms. Each solenoid is plastic bodied and marked with an arrow to show the correct direction for the water flow. The solenoid is supplied as a spare part without the JG fittings. Safety inlet solenoid valve NOTE: J.G. fittings are not supplied with replacement Solenoids. Order fittings separately Inspection Isolate power and water, remove the mains supply hose from the top of the undersink unit (via the JG fitting). Remove the outer covers (See page 30). When panels are off, the 2 solenoids will be revealed. If both boiling and chilled water are not dispensing, the safety inlet valve needs testing and possible replacement. No part of this valve is repairable. If either the boiling or chilled water is dispensing and the other isn t, then the double solenoid valve needs testing and possible replacement. No part of this valve is repairable. Removal remove the 2 electrical connectors from the coils, then release the valve from the pipework, these will be connected by John Guest fittings or spring clamps over silicone elbows. The final stage is releasing the valve from the fixing bracket, to do this you slide the valve upwards in the case of the double valve, or remove the 2 mounting bracket screws from the rear panel to release the single safety inlet valve. Replacement is the reverse procedure, ensure that all fittings are not damaged or are likely to leak, if any part looks suspect, replace it. Dual solenoid valve Page 32 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

33 Chilling Cycle Basic refrigeration in the HydroTap is achieved in several stages. First the R134a gas is compressed into a liquid, where the amount of work done in compressing the refrigerant causes excess heat, which is channelled away by the condenser fan. The next stage in the cycle allows the liquid to expand. The controlled rate of expansion causes the refrigerant to change it's state from a liquid to a gas. This change of state causes the rapidly cooling of the surrounding areas, allowing the water in the evaporator to be chilled. In the final stage the gas is returned to the compressor to continue the cycle. (see the diag below). NOTE All work on the refrigeration sealed system must be undertaken by a qualified refrigeration technician. Expansion Condenser Evaporator Chill tank Compressor Compression Condenser Fan The condenser fan removes the heat generated by the compression of the gas. The fan will operate while the refrigeration system is running. To keep the fan in good operating condition, the condenser needs to be kept clean. A soft bristle brush may be used. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 33 of 70

34 Condenser Fan 1. Isolate power and water, remove the mains supply hose from the top of the undersink unit (via the JG fitting). 2. Remove the outer covers (See page 30). When panels are off, the condenser will be accessible. 3. Disconnect the fan electrically by removing the two wires at the side of the fan. 4. When safely disconnected, remove the 2 fixing screws on the opposite edges of the plastic safety cowl. Once removed, the motor / fan assembly can be drawn back and will clear the condenser shroud. The assembly can now be removed from the HydroTap casing. 5. Installation is the reverse procedure. Fan motor check test: 1. Disconnect the two wires from the fan 2. Using a multimeter probe between the two metal tabs on the fan, 3. Reading should be 600 Ohms ± 5% Fan connection wires Fan mounting screws (2 off) Page 34 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

35 Evaporator Isolate power and water, remove the supply hoses connected to the tank with an appropriate tool and mark carefully so, not to get mixed when re-assembling. Remove the appliance outer covers and when panels are off, the chiller tank (white insulation) will be revealed. Carefully lift off the top insulation piece, this exposes the plastic tank assy lid assembly. Carefully remove the inlet and outlet JG fittings and disconnect the sensor and pump wires from the main PC Board. The pump and lid assembly may now be lifted away from the chill tank. Removal of any part of the refrigeration system will require a suitably qualified refrigeration trades person to undertake the job. Correct handling of the refrigerant in the discharge and recharge process is of utmost importance. Failure to do this may render your warranty void. Once the refrigerant is evacuated, the evaporator can be disconnected from the system, Once the evaporator is cleaned or a new one ready, refitting is the reverse procedure. Ensure the refrigeration system is re-activated by a suitably qualified trades person, once this is done, the reconnection of electrical and plumbing components can proceed. The last step is re-gassing the system. Refer to chart on page 5 for R134A gas weight requirements. Note: When you have the chiller tank disassembled it s a good opportunity to clean any foreign matter that may collect in the tank base. Use only soft rags and clean water, anything that scratches will damage the surface. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 35 of 70

36 Compressor, Capacitor and Relay Capacitor The 60 Uf capacitor is used to help start and run the compressor. If it is split or leaking it needs to be replaced. It is recommended to replace the relay at the same time as the capacitor. Compressor The compressor is the main heart of the refrigeration sealed system. It s function is to keep the Chilling Cycle (See Page 33) in motion by forcing the refrigerant to phase from gas to liquid. The chilling cycle is only operational when the compressor is running. Compressor Thermal overload control. The PL50 compressor motor is protected (internally) with a thermal overload control device. This device is automatically activated when the compressor is too hot, or is drawing excess current. When this occurs, the reason for the compressor overheating will need to be found. This device is not a serviceable item. Relay: The relay is an automatic switch which allows the compressor motor to change from it s start windings to the motor Run windings. (See page 37 for connection details) Page 36 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

37 Compressor winding check test Terminal A Terminal B Check Test for Compressor After gaining access to the compressor Isolate the power Remove the junction box cover to expose the Relay To avoid shock, discharge the capacitor before proceeding. Disconnect and remove the Relay to expose the compressor terminals Using a multimeter set on resistance scale Probe between A & B should read aprox 51.2 Ohms Terminal C Probe between A & C should read aprox 37.3 Ohms (Run windings) Probe between B & C should read aprox 14.2 Ohms (Start windings) Any discrepancy in these readings may require the unit to be returned to the service department for further investigation. a2 b c d Relay Cover Capacitor Cable entry block Zip Hydrotap Compact 2 Service Manual November V1.01 Page 37 of 70

38 Compressor Capacitor Compressor Page 38 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

39 Refrigeration check test What is Refrigeration? For heat transfer to occur, refrigerant needs to circulate within the refrigeration system. If temperatures within the system are outside normal working parameters, then basic operational principals need to be checked. Fig 1 NOTE: Some of these procedures require the machine to be operational, so always take great care when handling and testing live equipment. 1. To ensure the compressor is operational remove the relay cover as shown. (fig 1) Fig 2 2. Attach a clamp tester to the RED wire on the relay. Depending on compressor size this should read approx amps. (fig 2) Fig 3 3. When you have established the compressor is operational, you will need to determine you have the correct gas charge within the system. Remove the Schrader Valve Cap. (fig 3) 4. Attach your service hose as shown. (fig 4). Note, the service gauge is a single hose/gauge purely to show gas / charge/ pressure, not a charging unit. Fig 4 5. The optimal operating pressure is approx 140 Kpa (20psi), but pressures can vary depending on temperatures, usually no more than +/- 35 Kpa (5psi). (fig 5) NOTE: If at any time power is removed, the compressor can take up to several minutes to restart. See the trouble shooting matrix over page for a step by step guide to fault finding. Fig 5 Zip Hydrotap Compact 2 Service Manual November V1.01 Page 39 of 70

40 Refrigeration Trouble Shooting Gas pressure incorrect Pressure too High Pressure too Low Is compressor operating Gas leak or restriction No Yes Check current draw procedure Is there adequate ventilation Return for service No Yes Improve ventilation Is fan operating No Yes Is there 240V at fan motor Compressor inefficient ( return for service ) No Yes Replace PCB Replace Fan motor Page 40 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

41 Comompressor Trouble Shooting Compressor operating Is water temp above 10 C No Yes Wait till water temp is above 10 C Is there correct current draw ( Amps) No Yes Is there 240V between Red & Blue relay wires Check gas pressure procedure No Yes Replace PCB Assy. Is Capacitor OK No Yes Replace Capacitor & Relay Is Relay OK No Yes Replace Relay Compressor faulty (return for service) Zip Hydrotap Compact 2 Service Manual November V1.01 Page 41 of 70

42 Chiller Pump Chiller pump removal 1. Isolate power and water to the appliance 2. See page 30 for appliance entry 3. After removing the insulation securing tape, gently lift off the top insulation piece, this exposes the plastic tank lid assembly. 4. Carefully remove the inlet and outlet JG fittings and disconnect the sensor and pump wires from the main PC Board. 5. The pump and lid assembly may now be lifted away from the chill tank. Chiller pump installation: 6. Perform the removal procedure in reverse 7. Make sure all wires are connected correctly 8. Turn on the water and check for any leaks 9. Reassemble and perform an earth leakage test. (See page 59) Power supply Cable length Delivery rate Delivery height Power consumption Dia. / Height 12V DC 1metre 4-8 L/min (no load) 5.5 m (max) Watt 38mm / 104mm Page 42 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

43 Chilled water level sensors Chilled Water Level Sensor: This sensor controls the filling of the chilled tank. It has two levels of control: Low level: This indicates when the chilled tank water is at it s lowest capacity. (Plain white wire, low level indicator, longest rod). Top level: Isolates the filling process to stop overflow. (White wire with black stripe, high level indicator, shortest rod). The position of the sensor rods in relation to the colour coded wiring is critical to correct operation. The sensor rod holders are fixed in place in the chiller tank lid. Take great care not to damage the seals when removing for maintenance or repair. TIP: When testing or replacing Hot or Cold level sensors, it is important to make sure all electrical connections are secure and tight. This also relates to the earth wiring of the unit. Failure to do this can result in the unit over filling and going in to Water leak isolate mains mode. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 43 of 70

44 Chilled water level sensor replacement PLAIN WHITE WIRE WHITE WIRE WITH BLACK STRIPE HIGH LEVEL HYDROTAP BC 100/125-COLD TANK WATER LEVEL LENGTH SENSOR ASSY NO HIGH LEVEL 57mm Water Level LOW LEVEL 258mm High level Length 45 mm Low level 127 mm HYDROTAP BC 150/175-COLD TANK WATER LEVEL LENGTH SENSOR ASSY NO HIGH LEVEL 57mm LOW LEVEL 314mm LOW LEVEL NOTE: SENSOR RODS FOR COLD TANKS HAVE CRIMPING AT THE TOP END TO ACT AS STOPPER. INSTALL WITH WASHER P/No INTO PLASTIC HOLDER. Removal: 1. Isolate power and water to the appliance 2. See page 30 for appliance entry 3. Remove the insulation lid from the cold tank 4. Remove the top of the cold tank 5. Sensors are a push fit against a seal. Remove by pulling the sensor rod from the housing. NOTE: remember which wire fits with each sensor and check the seals for any damage Replacement: 6. perform the removal procedure in reverse 7. Make sure all wires and seals are mounted correctly 8. Turn on the water and check for any leaks 9. Reassemble and perform an earth leakage test. See page 59) Page 44 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

45 Chiller temperature Sensor To check for correct Chiller temperature sensor Operation: 1. Isolate unit electrically and remove access panels to reveal the Chilled tank assy. 2. Remove the top insulation piece from the Chiller tank, the probe has a Blue sleeving. Withdraw it from the sheath and disconnect it from the PCB. 3. Allow the sensor to sit at room temp for 5 minutes, check resistance with a Ohm meter against the room temperature, see chart on page 46. If out of range, change probe. 4. When re-installing reverse the dismantle procedure described above. Cold temperature sensor with BLUE sleeving Continuity verses temperature reading test Continuity and temperature test on sensor - Pass Continuity and temperature test on sensor - Fail Continuity test Temperature sensor probe replacement 1. Perform the removal procedure in reverse. 2. Make sure the sensor is inserted into the sensor pocket only as far as the maker on the sensor and fix in place with putty and a cable tie. 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 tap. 5. Perform an earthing continuity test (See page 59). 6. Turn ON the power supply to the HydroTap. 7. Perform the re-calibration procedure (See Page 15). Zip Hydrotap Compact 2 Service Manual November V1.01 Page 45 of 70

46 Temperature probe resistance chart TEMP (deg C) Low Limit (ohms) Nominal (ohms) High Limit (ohms) NOTE: From deg C are outside the range of stated tolerance: (0.2 Deg C) Page 46 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

47 HOT Temperature Sensor Continuity verses temperature reading test Continuity and temperature test on sensor - Pass Temperature Sensor probe removal Continuity and temperature test on sensor - Fail Continuity test 1. See page 30 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). Top of hot tank. Location of level sensors, element and hot temperature sensor probe. Hot temperature sensor with RED sleeving 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 fix in place with a cable tie. 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 tap. 5. Perform an earthing continuity test (See page 59). 6. Turn ON the power supply to the HydroTap. 7. Perform the re-calibration procedure (See Page15). Zip Hydrotap Compact 2 Service Manual November V1.01 Page 47 of 70

48 HOT level Sensors The HydroTap 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 check the PCB for a good earth connection. Hot Water Level Sensor: These sensors control the filling of the hot tank. There are three levels of control: Low level: (LVL 1) This indicates when the hot tank water is at it s lowest capacity. Mid Level: (LVL 2) Indicates that the water capacity will cover most situational needs. Top level: (LVL 3) Isolates the filling process to stop overflow. The position of the sensor rods in relation to the colour coded wiring is critical to correct operation. See below, Blue wire: high level indicator, shortest rod in the shortest insulator leg of the plastic housing. Red wire: middle level indicator, mid size rod in the centre insulator leg of the plastic housing. Black wire: low level indicator, longest rod in the longest plastic insulator leg of the plastic housing. TIP: When testing or replacing Hot or Cold level sensors, it is important to make sure all electrical connections are secure and tight. This also relates to the earth wiring of the unit. Failure to do this can result in the unit over filling and going in to Water leak isolate mains mode. Page 48 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

49 HOT level Sensors 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 HYDROTAP BC 100/125-HOT TANK Water level Length Sensor No. High 57mm WATER LEVEL LENGTH SENSOR ASSY NO HIGH Middle 57mm 79mm MIDDLE Low 79mm 205mm LOW 205mm MIDDLE LEVEL Ensure when removing the sensor holder you check the underside sealing gasket for any faults or imperfections. If needed, replace. HYDROTAP BC 150/175-HOT TANK WATER LEVEL LENGTH SENSOR ASSY NO HIGH 57mm MIDDLE 79mm LOW 258mm DOMESTIC HYDROTAP BC 60/85-HOT TANK WATER LEVEL LENGTH SENSOR ASSY NO HIGH 120mm MIDDLE 140mm LOW 205mm LOW LEVEL Zip Hydrotap Compact 2 Service Manual November V1.01 Page 49 of 70

50 Level Sensor Removal HOT level Sensors 1. See page 30 for 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. Level sensor sub assembly Level Sensor Testing Level sensor testing - Pass Level sensor testing - Fail Level Sensor replacement 1. Perform the removal procedure in reverse. 2. Make sure all wiring is fixed in place with cable ties. 3. Replace the outer case and connect the tap loom and supply tubes from the under-sink unit to the tap. 4. Perform an earthing continuity test. (See page 59) 5. Turn on the water and power supply to the HydroTap and check operation. Page 50 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

51 HOT Tank Hot pump in situ Hot tank assembly Boiling water module removal 1. See page 30 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 outlet (Black plastic) from the top of the back panel 5. Remove the screws from the thermal overload (which secure it to the back panel ) and remove the copper tube from the silicon elbow on top of the tank 6. Disconnect the pump wiring, 2 earth connections, temperature sensor, heater connections and level sensor wiring from the PCBA and chassis. 7. Remove all cable ties. 8. Release the clip from the upper packing strap that holds the tank assembly to the chassis. 9. The Hot tank, Pump and Element assembly may now be removed from the unit Boiling water module replacement 1. Perform the removal procedure in reverse. 2. Make sure all wiring is fixed 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 tap. 5. Perform an earthing continuity test. (See page 59) 6. Turn ON the power supply to the HydroTap. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 51 of 70

52 HOT Pump Boiling water pump operation The HydroTap dispenses boiling water via a 12 Volt pump. The pump features a maximum run time of fifteen (15) seconds at any one time. 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. Hot pump removal 1. See page 51 for Boiling module removal 2. remove the spring clip from the silicon tube connected to the tank outlet pipe 3. Remove the pump from the tank Hot pump replacement 4. Perform the removal procedure in reverse. 5. Make sure all wiring is fixed in place with cable ties. 6. Turn on the water supply and check for any leaks. 7. Replace the outer case and connect the supply tubes from the under-sink unit to the tap. 8. Perform an earthing continuity test. (See page 59) 9. Turn on the power supply to the HydroTap. Voltage Operting voltage Input power No Load current Load current Flow rate (Max) Flow distance Outlet dia Noise 12 VDC VDC 6.8 ± 3% Watts A A 6.8 zero head metres 9.7 mm 55 dba / 10 cm Page 52 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

53 HOT Pump Transformer The 12 Volts (DC) required for the pump to operate is supplied through a small transformer. This is located inside the appliance, behind the control panel display. Test the transformer for a 12 volt output with a multimeter. Replace if faulty. Transformer removal and Installation 1. See page 30 for appliance entry. 2. remove the transformer wires from the PCB Assembly 3. Remove the two screws securing the transformer to the chasis 4. Remove the transformer For installation, 5. perform the removal procedure in reverse Element The element is used to heat the water. The element is designed only to be used while submerged in water. To test the element, isolate the mains power and water supplies to the unit. Disconnect both element wires, then using a multimeter, select ohms and test the resistance between both element wires. 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% Continuity test of element Blown Element Zip Hydrotap Compact 2 Service Manual November V1.01 Page 53 of 70

54 Element (continued) Element replacement: Element gasket 1. Isolate power and water, remove the supply hoses connected to the unit with an appropriate tool and mark carefully so, not to get mixed when re-assembling. 2. Remove the outer covers to gain access to the Hot tank assembly (See page 30). When the white insulation panels are removed, the hot tank will be revealed. 3. Carefully lift off the top insulation piece, this exposes the tank assy lid that houses the element. Disconnect spring clips from pipework and side pipes out of silicone elbows, disconnect element leads and level sensor loom from the main PCB. Undo the 4 lid retaining screws. 4. Lift the lid assy out of the hot tank. Loosen and remove the element securing nut on the top side of the lid and withdraw the element assy out of position. 5. When replacing the element, check that an element gasket is located under the element flange to ensure a water tight seal. 6. Ensure that the baffle plate is correctly located prior to re-assembly. 7. Re-installation is the reverse procedure. Note: When you have the boiler tank disassembled it s a good opportunity to clean any foreign matter that may collect in the tank base. Use only soft rags and clean water, anything that scratches will damage the surface. 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. Replace the outer case and connect the supply tubes from the under-sink unit to the tap. 5. Perform an earthing continuity test. (See page 59 ) 6. Turn on the power supply to the unit Live test of voltage to overload and element. **caution high voltage will be present** Page 54 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

55 Thermal Overload Control (TOC) The thermal overload assembly is designed to isolate the element by disconnecting both poles preventing over boiling if the hot sensor or PCB Assembly 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. 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. NOTE: Numbering of the pairs on the black plastic housing. Manual Reset button Zip Hydrotap Compact 2 Service Manual November V1.01 Page 55 of 70

56 Removal 1. See page 30 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 page 55) Continuity test of overload Thermal Overload Control (TOC) Continuity test of overload - pass Continuity test of overload - fail Re-installation of the thermal overload assembly 1. Perform the removal procedure in reverse. 2. Replace the outer case and connect the supply tubes from the under-sink unit to the tap. 3. Perform an earthing continuity test. (See page 59) 4. Re-connect and turn on the water and power supplies to the HydroTap. Important Note: When fitting new overload. 1. 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 on page 55 when upgrading to the new overload. 2. Do not mechanically adjust spade connectors on the overload. Excessive lateral force and deflection may result in deformation of the copper rivets. Page 56 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

57 PC Board and fuse Assembly 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 PC Board Assembly 1. See page 30 for 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. Replace the outer case and connect the supply tubes from the under-sink unit to the tap. 4. Perform an earthing continuity test (See page 59). 5. Re-connect and turn on the water and power supply to the HydroTap. PCB fuse 1A - 2AG Refrigeration fuse 10A - 2AG Fuses located on the PC Heater fuse 10A - 3AG Zip Hydrotap Compact 2 Service Manual November V1.01 Page 57 of 70

58 PCBA Transformer The PCBA transformer supplies both 10V AC and 12V AC to the PC Board Asssembly. Transformer removal and Installation 1. See page 30 for appliance entry. Test Check the voltage input and outputs using a multimeter as follows 240V AC input - Blue / Brown 12V AC output - White / White 10V AC output - Yellow Yellow 2. remove the transformer wires from the PCB Assembly NOTE: A short circuit between the two secondary windings can cause the bridge rectifier on the PCB (at D15) to overheat, resulting in burnt tracks on the PCB. Check between the Yellow and Red wires on the transformer plug. If there is continuity between these wires then the transformer is faulty and will require replacement. 3. Remove the two screws securing the transformer to the chassis 4. Remove the transformer For installation, 5. Perform the removal procedure in reverse Leak Detector There is a Leak Detector located within the sealed safe tray of the HydroTap under-sink unit. It is in an awkward position beside the compressor, mounted on the back of the wall which supports the PCB Assembly. The leak detector allows the PCB assy 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. A Leak Detector removal 1. See page 30 appliance entry. 2. Remove the retaining screw A holding the detector in place. 3. Disconnect the wiring loom from the PCBA. Leak detector replacement 1. Perform the removal procedure in reverse. 2. Make sure all wiring is fixed in place with cable ties. 3. Turn on the water supply and check for any leaks. Flood sensor location 4. Replace the outer case and connect the supply tubes from the under-sink unit to the tap. 5. Perform an earthing continuity test. (See page 59) 6. Turn on the power supply to the HydroTap. Page 58 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

59 Leak Detector continued Internal Leak: TIP: If you have had an internal leak follow leak detector removal steps 1-3 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 under-sink unit to the 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 identified you can once again disconnect the under-sink unit and repair the fault. In most cases the cause of internal leaks are ageing o-rings that are used as a seal in the John Guest fittings. Earth Continuity test One probe connected to chassis One probe connected to plug's earth pin Megohn meter or appliance After each service, the earth continuity must be checked. Use an insulation tester, appliance tester or continuity tester with an accuracy of Class 5 or better (±5% at full-scale deflection). NOTE: All accessible metal parts must be earthed. To test the earthing continuity: 1. Isolate the appliance from the electricity supply. 2. Set the meter 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. 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. 7. All readings should be less than 1 Ohm. If any of the readings is more than this, check the earth connection inside the unit. Zip Hydrotap Compact 2 Service Manual November V1.01 Page 59 of 70

60 Wiring diagram Auxillary Fan/Transformer and Din Plug not fitted to Domestic models. FAN COLD PUMP RECTIFIER HOT PUMP CONNECTOR COMPRESSOR M TRANSFORMER SOLENOID (BOILER) RED SOLENOID (CHILLER) BLUE J14 SOLENOID (INLET) ORANGE TRANSFORMER 1A FUSE SLOW BLOW LCD DISPLAY COLD LEVEL HOT LEVEL 10 AMP 3AG FUSE 10 AMP 2AG FUSE ACTIVE NEUTRAL BLUE MAINS POWER EARTH FROM TANK FLOOD SENSOR HOT SENSOR COLD SENSOR RED BLUE TAPHEAD OVERLOAD FLOOD DETECTOR ELEMENT HOT TANK TAP WIRING DIAGRAM HYDROTAP DOMESTIC COMPACT Page 60 of 70 Zip Hydrotap Compact 2 Service Manual November V1.01

61 Plumbing layout Vent HOT sensors Bypass valve HOT pump & outlet Water Inlet HOT Tank DNR-350kPa PL Valve Filter Dual solenoid Inlet solenoid PCB Assembly Cold sensors COLD outlet Refrigeration sealed system Chilled tank (evaporator) Refrigeration lines Expansion condenser Chill pump Compression Zip Hydrotap Compact 2 Service Manual November V1.01 Page 61 of 70