Zip HydroTap. Service Manual. Service Manual. Filtered boiling and chilled water for kitchens and tea rooms.

Transcription

1 Service Manual Zip HydroTap Service Manual Filtered boiling and chilled water for kitchens and tea rooms. Commercial Models Zip HydroTap BC 100/ Zip HydroTap BC 150/ Zip HydroTap B10OF Zip HydroTap B150F Zip HydroTap B Zip HydroTap B150 Disabled Models Zip HydroTap BCD 100/ Zip HydroTap BCD 150/ Zip HydroTap BD10OF Zip HydroTap BD150F Zip HydroTap BD100 Domestic models Zip HydroTap BC 60/ Zip HydroTap BF 60F (ambient) Zip HydroTap B Zip HydroTap BCD 60/ Zip HydroTap BFD 60F (ambient) Zip HydroTap BD Zip HydroTap HT Zip HydroTap HTD Zip HydroTap HT60/ Zip HydroTap HTD60/ Zip HydroTap BD150 Zip Hydrotap Service Manual March 2009 Page 1 of 36

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3 Contents General Information and Warnings Problem Solving and Page References Product View Casing On Product View Casing Off Display Operations Boiling Module Spare Parts List and Diagram Chilled Module Spare Parts List and Diagram HT Series Boiling Only Spare Lists and Diagram Tap Head Assembly TeaTap to HydroTap adaptor installation Solenoid Valves / Replacement Element Replacement Evaporator Replacement Boiling Pump Module Replacement Chilled Module Pump Replacement Condenser Fan Replacement - BC 100/125, BC 60/ Condenser Fan Replacement - BC 150/ Electronics and PCB connection points - Boiling / Chilled Electronics and PCB connection points - Boiling / Ambient Electronics and PCB connection points - Boiling Only Electronics and PCB connection points - HT Series Boiling Only Service Check, Testing and Re-Calibration Modes Boiling and Chilled Sensor Probe Replacement and Resistance Chart Sensor Probe Resistance Chart Chilled Water Level Sensor Replacement Hot Water Level Sensor Replacement Basic Refrigeration Information Refrigeration Help Matrix Warranty Contact Details NOTE: If hot probe or PCB is replaced you must re-calibrate the unit. Refer page 28 Note: 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 Zip Hydrotap Service Manual Page 3 of 36

4 General Information and Warnings What is the Zip HydroTap? The Zip HydroTap is an electronically controlled, filtered, boiling water and chilled water drinking system for kitchens and tea rooms. It is also available in boiling only unfiltered, boiling only filtered, and boiling ambient filtered configurations. The unit can be ordered with the Tap Head Assembly for Disabled use in all the above configurations. Models covered in this manual Boiling / Chilled Model BC 60/85 BC 100/125 BC 150/175 Power Safety 220/240V 50hz 1.8 kw 220/240V 50hz 1.8 kw 220/240V 50hz 2.1 kw Element 1.5 kw 1.5 kw 1.8 kw Boil cups / hr Chill glass / hr R 134A grams 125 grams 125 grams 190 grams Boiling only / Boiling Ambient Model B60 / BF60 B100 B150 Do not allow young children, handicapped or infirm persons, to use the Zip HydroTap without supervision. 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 safely drains 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 90 secs. This is normal operation, once this menu is completed 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 table under the heading Installation Requirements. Do not lift the unit by the doors. When transporting unit ensure it is in an upright position. Power 220/240V 50hz 1.5 kw 220/240V 50hz 1.5 kw 220/240V 50hz 1.8 kw Element 1.5 kw 1.5 kw 1.8 kw Boil cups / hr NOTE: The specifications do not change whether the units are filtered, unfiltered or disabled models. Page 4 of 36 Zip Hydrotap Service Manual

5 General Information and Warnings Airflow and Ventilation Fan Kit information The ambient temperatures this unit should operate within is 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. An air vent and electronic fan is provided with each BC 150/175 for high usage applications, this must be installed in the top half of the cupboard door as a matter of course. Failure to do this may void warranty. The same fan kit is available as an option for all other HydroTap models and should be used in situations where adequate natural ventilation cannot be ensured. Make sure that the ventilation grilles on the sides of the undersink unit are not obstructed in anyway or by anything. Altitude (except the HT boiling only series) The Zip HydroTap is equipped with a self-calibrating program which caters for altitude adjustment. Filter For models : BC, BF 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 10 or contact your Zip Service Provider. 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. Considerations for Installation Surroundings This unit is intended only for indoor use and should never be installed outdoors or exposed to the elements of nature. This unit must not be positioned in an area that may be cleaned by a water jet. This unit must not be cleaned by a water jet. Zip Hydrotap Service Manual Page 5 of 36

6 Problem Solving and Page References Problem Possible Cause Solution No LED display, no tap head lights or, no water when tap levers are operated. Red LED flashes slowly Blue LED flashes slowly (BC models only) All LED s flashing once per second. No power. Plug is not located in mains power socket. Tap lead is not connected to HydroTap unit, or loom is not connected at the PCB Possible internal fault. Program in OFF cycle or the hot temperature is not in usable range. Not within chilled water usable range. Possible leak detected, flood sensor activated. Display screen will show leak fault. Check mains power supply. Ensure power plug is correctly fitted and switch is turned ON. Check lead and loom connections. Contact Zip Allow tank to re-heat or check display panel for mode. Wait for LED to go solid without draining off any water, if not solid in 30 minutes contact Zip. Isolate power and look for obvious leaks, if found rectify. Dry out safe tray then reset detector by turning power back on. If further problems contact Zip. No water flow. Slow water recovery after use. Water supply isolated. Water supply not connected. Power supply not connected. Tap loom is not connected to HydroTap unit. Program in OFF cycle. Pump failure Hot isolation mode On. Safety lock activated. Possible internal fault. Filter may require replacement. Faulty solenoid valve. Check water supply is on. Check water levels on display screen. page 28 Check to ensure plumbing connecting is made. Check mains power plug is correctly fitted and switch is turned on. Check for loom connection Check display for information. page 10 Check electrical connection at PCB, check for power from PCB to pump. If all checks out replace pump. pages 20, 21 Check display for information. page 10 Press safety button and hot lever simultaneously or Depress cold lever and safety lock simultaneously for 10 secs to dis-engage safety lock. Contact Zip service provider. Check filter usage on LCD screen, page 10, if filter change is displayed follow instructions. Also may require changing if water quality is poor. If solenoid valve, test and replace where necessary. Page 17 Unit overflowing Faulty solenoid valve, faulty level sensors, level sensors not fitted correctly, pump not shutting down Check solenoid valve operation, check level sensors for physical integrity and correct fitting. Operate the pumps to ensure they are closing down, if not, replace. pages 16,19,20,29,30 Page 6 of 36 Zip Hydrotap Service Manual

7 Problem Solving and Page References Problem Possible Cause Solution Unit is suspected of not operating at peak performance levels. Water not hot. NOTE: If hot probe or PCB is replaced you must re-calibrate the unit. Refer page 28 No water Minimal water dispensing PCB has moved out of calibration and the set temperatures are not registering correctly or you suspect the system is not operating at peak performance levels Unit in Sleep Mode. Unit has just come out of OFF mode. (Wait for red led to stop flashing) Overload tripping out. Faulty Hot probe. PCB not reading the probe values correctly. Element failure Pump failure. Blocked filter. Solenoid failure. Element failure. Possible internal fault. Faulty Tap Assembly Internal wiring incorrect at level sensor terminal block. Low level sensor is in contact with internal tank baffle. Faulty Pump Run the system re-calibration procedure. see page 28. Touch Hot lever and wait for Red LED to stop flashing. Blocked vent line or hot outlet. Incorrect hot probe location in sheath, ensure probe end is fully down in the sheath pocket. Check probe resistance values, refer to chart page 30. If resistance is out, change probe. page 29. Check probe connections to the PCB, if ok and probe resistance is ok, change the PCB. ( Note: Zip will not accept warranty returns on PCB s if the PCB is found to be operational on return and after testing). Check resistance reading on the element, if faulty replace element. Check connections at the overload and PCB. Refer to No water flow previous page. Refer to Slow water recovery after use previous page. Refer to Slow water recovery after use previous page. Refer to Element failure above, this page. Contact local Zip service provider. Replace Tap Assembly. Page 15 Check sensor wiring as shown on pages 31, 32. Check sensor rod and baffle location as shown on pages 20, 32. Ensure sensor rod does not touch baffle plate. Change pump assembly. Pages 20 and 21. Zip Hydrotap Service Manual Page 7 of 36

8 Problem Solving and Page References Water not chilled. Problem Possible Cause Solution Excessive use. Unit may be undersized for usage requirement. Look at upsizing. Unit refilling or chilling down to temperature. Faulty Cold probe. PCB not reading the probe values correctly. Unit has just come out of OFF mode. Compressor failure. Refrigeration system leak Wait for unit to recover. Check probe resistance values, refer to chart page 30. If resistance is out, change probe, page 31. Check probe connections to the PCB, if ok and probe resistance is ok, change the PCB. ( Note: resistance chart on page 30). Zip will not accept warranty returns on PCB s if the PCB is found to be operational on return and after testing). Pages 12,23,24,25 Allow unit to obtain normal temperature, wait for blue LED to stop flashing. Check compressor operation, if suspect contact Zip. If suspected, contact Zip. Boiling water overflow Incorrect level sensor location. Solenoid valve faulty. Earth lead disconnected at tank body, or from PCB to chassis. Possible internal fault. Check location and if necessary correct, refer to page 32. Check valve, if faulty replace, refer page 17. Check lead and reconnect, or check quality of connection. Contact Zip. Page 8 of 36 Zip Hydrotap Service Manual

9 Product View Casing On HydroTap BC model showing front cover closed. The LCD is on the RHS panel and filter is behind LHS panel door. HydroTap BC model showing rear panel. The air vent for the condenser is visible as well as electrical and water connections. HydroTap BC model showing RHS panel. The boiling and chilled tanks are located behind this panel. HydroTap BC model showing the LHS panel. Compressor, fan assy, solenoids and general access for service is behind this panel. Product View Casing Off HydroTap BC model front view with all panels off. Ribbon lead on the right is connection to the LCD. Filter, filter flush hose and PCB. HydroTap BC model with top cover removed. This shows water outlets and vent outlet. Also exposes some electronics. HydroTap BC model RHS view. Tank insulated in white is chilled water, tank insulated in black is boiled water. HydroTap BC model LHS view. The compressor, condenser, condenser fan, solenoids and non-return valve are exposed as well as much of the electrical circuitry. Zip Hydrotap Service Manual Page 9 of 36

10 Display Operations (not on HT boiling only series) The model you have 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. Normal Operation After the product I.D. is completed, the screen will default to show Normal Operation. This will be displayed when the unit is operating regardless of programmed or unprogrammed settings. Monday On Press either Menu or Menu button until Monday On is displayed. To set time for 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. > 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. > > Sleep Mode 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. Press Adjust once to select 2 Hours or Twice to select 4 Hours. When the period of inactivity passes, the display will show Sleep Menu. Another visual indicator is the Red LED on top of the tap lever will be flashing slowly. > 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 Press adjust to reset litre counter. Then it asks are you sure press adjust again to lock in the command. After approx 10 secs it will default to the selected menu. Set Time 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. > > Set Day Press either Menu Press Adjust or > or Menu > Adjust to select day. button until Set Day is displayed. Page 10 of 36 Zip Hydrotap Service Manual

11 Display Operations Filter Flush Press adjust, this will start the water flushing the cartridge. Allow water to run clear and press adjust to stop the flow. Refer to page 14 of the Installation and Operating Instructions supplied with the unit. Hot Isolation Press adjust to activate. 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. De-activation is the same procedure again, LED s scroll right to left three times to confirm. Note: Boiling only, Unfiltered models. Domestic and Commercial. The following program changes apply to the above models only. 1. Filter flush mode is not active in the calibration program. (Initial startup and normal operation) 2. Filter life settings i.e litres reminder programme is omitted. 3. Litres filtered will read Litres Used as an indication of water that has passed through the system to that point. Self-Diagnosis Fault Display Hot Sensor Fault This indicates the Hot Probe has lost connection at the main PCB. This fault can be a disconnection at the probe connection point on the PCB or the probe is open circuit. Cold Sensor Probe This indicates the Cold Probe has lost connection at the main PCB. This fault can be a disconnection at the probe connection point on the PCB or the probe is open circuit. Compressor Overrun This 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. Water Leak Isolate Mains This indicates a water leak has been detected, isolate mains supply and correct fault before putting the unit back into operation. This indicates the flood sensor is disconnected or the circuit is broken. Flood Sensor Disconnected Zip Hydrotap Service Manual Page 11 of 36

12 Boiling Module Spare Parts List and Diagram ITEM KIT NO DESCRIPTION ITEM KIT NO DESCRIPTION PLUMBING & FITTINGS KIT CONTROL PANEL KIT SAFETY SOLENOID KIT CLIPS KIT DOUBLE SOLENOID KIT STOP VALVE & JOHN GUEST FITTING KIT FILTER GASKET & ELBOWS KIT BC 100/ FLEXIBLE INLET HOSE KIT GASKET & ELBOWS KIT BC 150/ LEVEL SENSOR KIT HOT TANK BC 100/ OVERLOAD KIT LEVEL SENSOR KIT HOT TANK BC 150/ ELEMENT 1500W KIT LOOM-OVERLOAD KIT ELEMENT 1800W KIT LOOM+GLAND MAIN PCB TO TAP SENSOR PROBE KIT HOT TRANSFORMER KIT AUXILIARY FAN PUMP KIT HOT LOOM-LEVEL SENSOR KIT HOT PCB KIT FILTER HEAD KIT TRANSFORMER KIT CARTRIDGE-FIVE MICRON TRIPLE ACTION LEAK SENSOR KIT Page 12 of 36 Zip Hydrotap Service Manual

13 Chilled Module Spare Parts List and Diagram ITEM KIT NO DESCRIPTION ITEM KIT NO DESCRIPTION PLUMBING & FITTINGS KIT LEVEL SENSOR KIT COLD TANK BC 100/ SAFETY SOLENOID KIT LEVEL SENSOR KIT COLD TANK BC 150/ DOUBLE SOLENOID KIT RELAY COMPRESSOR KIT BC 100/ GASKET & ELBOWS KIT COLD TANK RELAY COMPRESSOR KIT BC 150/ DRYER-FILTER KIT W/ NUT & TUBE COMPRESSOR KIT BC 100/ EVAPORATOR KIT BC 100/ COMPRESSOR KIT BC 150/ EVAPORATOR KIT BC 150/ FAN MOTOR KIT BC 100/ SENSOR PROBE KIT COLD FAN MOTOR KIT BC 150/ PUMP KIT COLD CAPACITOR KIT BC 100/ PCB KIT BC100/125 & BC150/ CAPACITOR KIT BC 150/ PCB KIT DOMESTIC BC60/ LOOM LEVEL SENSOR KIT PCB KIT B100 & B TRANSFORMER KIT-AUXILIARY FAN PCB KIT DOMESTIC BC LOOM-SOLENOIDS KIT PCB KIT B100F & B150F ø35mm CHASSIS PUNCH PCB KIT DOMESTIC B60F ag - 10Amp FUSE PCB KIT DOMESTIC AMBIENT BF ag - 10Amp FUSE TRANSFORMER KIT ag - 1Amp FUSE LEAK SENSOR KIT LOOM-COMPRESSOR TO FAN KIT CONTROL PANEL KIT FILTER CARTRIDGE KIT STOP VALVE & JOHN GUEST FITTING KIT FILTER FILTER HEAD KIT FLEXIBLE BRAIDED INLET HOSE KIT Zip Hydrotap Service Manual Page 13 of 36

14 HT Series boiling only Spare Parts List and Diagram ITEM KIT NO. DESCRIPTION Plumbing and Fittings kit Safety Solenoid Kit Single Solenoid Kit Gasket and Elbow Kit BC 100/ Overload Kit Element 1500 watt Kit Sensor Probe Hot Pump Kit Hot PCB Kit Boiling Only Leak Sensor Kit Clips Kit Flexible Inlet Hose Kit Level Sensor Kit Hot Tank H/T 60/ Loom-Overload Kit Loom-Solenoids Kit Loom-Level Sensor Kit Hot Loom and Gland Main PCB to Tap Page 14 of 36 Zip Hydrotap Service Manual

15 Tap Head Assembly P/N Description Standard Tap Assembly complete kit Boiling/Chilled Disabled Tap Assembly complete kit Boiling/Chilled Standard Tap Assembly complete kit Boiling only Handicap Tap Handles KIT NO DESCRIPTION STANDARD TAP ASSY COMPLETE KIT BOILING/CHILLED DISABLED TAP ASSY COMPLETE KIT BOILING/CHILLED STANDARD TAP ASSY COMPLETE KIT BOILING ONLY DISABLED TAP ASSY COMPLETE KIT BOILING ONLY STANDARD TAP ASSY COMPLETE KIT DOMESTIC BOILING/AMBIENT DISABLED TAP ASSY COMPLETE KIT DOMESTIC BOILING AMBIENT Disabled Tap Assembly complete kit Boiling only Standard Tap Assembly complete kit Boiling /Ambient Domestic Disabled Tap Assembly complete kit Boiling/Ambient Domestic Tap Handle Kit Disabled Boiling/Ambient Tap Handle Kit Disabled Boiling/Chilled Tap Handle Kit Standard Boiling/Chilled Tap Handle Kit Standard Boiling/Ambient Tap Handle Kit Boiling Only Tap Handle Kit Disabled Boiling Only A1181 Head Assembly: The HydroTap head assembly has no repairable parts other than replacing Tap levers. Any other component failure requires full tap assy replacement. If the levers are to be replaced, isolate power and water, 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. Loosen and remove the screw, with care, pull the levers horizontally until they are free from the locating shaft re-installation is the reverse procedure. Removal of the Head Assy requires the water and power to be A1181 isolated. 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. Replacing a new tap or re-fitting the old tap is the reverse procedure. Note: New spring clamps are provided with replacement Taps. Zip Hydrotap Service Manual Page 15 of 36

16 Tap Head Assembly - Changeover - TeaTap to HydroTap. NOTE: This installation instruction is specifically for the installation of a Hydrotap head assy when replacing a Tea Tap, or when the need for a flange adaptor is Flange Adaptor Kit NEW HYDROTAP TAP HEAD LOWER SPOUT SPACER (BLACK) FLANGE ADAPTOR FOR NEW HYDROTAP TAP CLAMP ADAPTOR WASHER S/S M5 X 0.8 S/S SCREW 16MM LG SPIDER Steps: 1. THE HOLE ON THE BENCHTOP MUST BE AT LEAST 64mm IN DIAMTER. M6 NUT 2. PUT THE HOSES AND TUBES OF THE COMPLETED TAP THROUGH THE HOLE OF THE FLANGE ADAPTOR MAKE SURE THAT THE BLACK SPACER IS AT THE BOTTOM OF THE LOWER SPOUT OF THE TAP. 3. WHEN THE TAP ASSEMBLY, BLACK SPACER AND ADAPTOR ARE PLACED UPRIGHT ON THE BENCHTOP, INSTALL THE CLAMP FROM UNDER THE BENCHTOP AND FASTEN WITH THE STAINLESS STEEL WASHERS AND SCREWS. 4. THEN INSTALL THE SPIDER UNDER THE CLAMP AND TIGHTEN UP WITH THE M6 NUT. Page 16 of 36 Zip Hydrotap Service Manual

17 Solenoid Valves / Replacement Solenoids - Boiling and Chilled units. From filter To Hot tank To Cold tank Isolate power and water, remove the supply hoses from unit to tap connected to the tank with an appropriate tool and mark hoses carefully so as not to get mixed when re-assembling. Remove the top cover and left hand side panel by removing the fixing screws on the panels required. When panels are off the solenoids will be revealed. From mains From filter Safety solenoid To Double-Non return valve Solenoid - Boiling only units. To hot Double solenoid Single solenoid From mains Determining which valve needs to be replaced If both boiling and chilled water is not dispensing, the safety valve needs testing and possible replacement, no part of these valves are repairable. If either the boiling or chilled water is dispensing and the other isn t, then the double solenoid valve, or in the case of a boiling only model the boiling valve would need testing and possible replacement. No part of these valves are repairable. To replace, remove the electrical connectors from the coils, then release the valve from the pipework, these will be connected by either 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 unscrew in the case of the single safety 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. Safety solenoid To double non-return valve, (filtered and BO models) or to 2nd solenoid (unfiltered or BO units) Note: Secondary Solenoid- Boiling Filtered only. Zip Hydrotap Service Manual Page 17 of 36

18 Element Replacement 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 top cover and left hand side panel by removing the fixing screws on the panels required. The right hand side panel may need to be removed depending on access. When panels are off the hot tank (black insulation) will be revealed. 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. If available use special Zip pliers to remove the lid spring clips, if not available, use a suitable pair of long nose pliers to lever back the clips. Take care not to over stress these clips as they will lose tension. Lift the lid assy out of the hot tank. Loosen and remove the element securing nut on the top side of the lid and slide the element assy out of position. When replacing the element, check that an element gasket is located under the element flange to ensure a water tight seal. Ensure that the baffle plate is correctly located prior to re-assembly. Re-installation is the reverse procedure. Element gasket Element nut Pipe spring clips Lid spring clips x 4 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 Stainless Steel surface. Page 18 of 36 Zip Hydrotap Service Manual

19 Evaporator Replacement Cold level sensors Evaporator Pump 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 top cover and the left and right hand side panel by removing the fixing screws. When panels are off, the chiller tank (white insulation) will be revealed. Carefully lift off the top insulation piece, this exposes the tank assy lid that houses the evaporator. 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, disconnect the leads from the water level sensors and the chilled pump lead from the PCB and remove the chiller probe from it s sheath. When all connections are free, remove the six (6) retaining screws from the chiller lid and lift out the evaporator / pump assy. 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, reconnection of electrical and plumbing components can proceed. The last step is re-gassing the system. Refer to chart on page 3 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 Stainless Steel surface. Zip Hydrotap Service Manual Page 19 of 36

20 Boiling Pump Module replacement Baffle 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 top cover and left hand side panel by removing the fixing screws on the panels required. The right hand side panel may need to be removed depending on access. When panels are off the hot tank (black insulation) will be revealed. Carefully lift off the top insulation piece, this exposes the tank assy lid that houses the element. Disconnect spring clips from pipework and slide pipes out of silicone elbows, disconnect element leads, pump lead, and level sensor loom from the main PCB. If available use special Zip pliers to remove the lid spring clips, if not available, use a suitable pair of long nose pliers to lever back the clips. Take care not to over stress these clips as they will lose tension. Pump inner half Pump outer half Fixing screws Lift the lid assy out of the hot tank. This will expose the hot water pump in the base of the tank. To make this job easier it is recommended that the tank body housing the pump be removed from the HydroTap case. The insulation is held in place by two (2) plastic straps, undo these and put to one side, they are needed for re-assembly. There is a separation baffle in the tank, remove it by gripping it firmly and pulling upwards. This will make pump extraction easier. The pump is fixed in place by four (4) screws that pull the inner and outer halves together and seal on a grommet type silicone gasket positioned half in half out on the tank wall, see bottom diagram. Release the fixing screws and the two halves come apart, remove the pump pieces and the old grommet from the tank assy. If the same pump is being re-installed, ensure the gasket is free from any cuts or deformity, If for any reason you suspect the pump matting surfaces or the gasket are faulty, replace with a new pump kit. Ensure that the baffle plate is correctly located prior to re-assembly. Re-installation is the reverse procedure. Sealing grommet Page 20 of 36 Zip Hydrotap Service Manual

21 Chilled Module Pump Replacement Cold Pump 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 top cover and the left and right hand side panel by removing the fixing screws. When panels are off, the chiller tank (white insulation) will be revealed. Carefully lift off the top insulation piece, this exposes the tank assy lid that houses the evaporator. This insulated lid cannot be removed without disconnecting cables from the PCB. The small square stainless steel plate fixed with four (4) small nuts is the pump access point. There is no need to disconnect any other electrical lead other than the pump supply lead (white in colour) from the main PCB. Once this is done the four (4) nuts can be loosened and removed, the access plate can then be lifted off the main tank lid assembly. The pump should come up and out of the tank with the plate attached. When replacing the pump assy ensure the distance from the underside of the access plate to where the pump sits is noted and duplicated on installation of the new pump. Note: Failure to do this may cause operational problems. When replacing the pump assembly, ensure you check the silicone access plate gasket that seals onto the tank lid for any imperfections, if you suspect anything to be faulty replace gasket. Replacement is the reverse procedure, ensure that all fittings are not damaged or are likely to leak, if any part looks suspect replace it. Note: The Pump body fits through a locating section on the evaporator base, ensure the pump passes through this. Zip Hydrotap Service Manual Page 21 of 36

22 Condenser Fan Replacement - BC 100/125, BC 60/85, HT 60/85 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 top cover and the left hand side panel by removing the fixing screws. When panels are off, the fan assembly will be visible on the left back corner of the HydroTap unit. Disconnect the fan electrically by following the lead back to the plug connector. When safely disconnected, remove the fixing screw on the bottom edge of the plastic safety cowl. Once removed, grip the motor body and twist anticlockwise approximately 30º, the motor / fan assembly can now be drawn back and will clear the condenser shroud. The assembly can now be removed from the HydroTap casing. Installation is the reverse procedure. Fixing screw location. Not these four (4) screws Page 22 of 36 Zip Hydrotap Service Manual

23 Condenser Fan Replacement - BC 150/175 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 top cover and the left hand side panel by removing the fixing screws. When panels are off, the fan assembly will be visible on the left back corner of the HydroTap unit. Disconnect the fan electrically by following the electrical lead back to the plug connector. When safely disconnected, remove the fixing screws, one screw is located at bottom left and requires complete removal, the other is visible from top right and requires only loosening and a twist anticlockwise to facilitate removal of the fan / motor assembly. The assembly will now clear the condenser shroud. The assembly can now be removed from the HydroTap casing. Installation is the reverse procedure. Fixing screw bottom LHS removal required. Fixing screw top RHS loosening only required. Zip Hydrotap Service Manual Page 23 of 36

24 Electronics and PCB connection points - Boiling / Chilled 1 Amp Transformer Protection Element Protection Refrigeration and Solenoid Protection NOTE: If hot probe or PCB is replaced you must re-calibrate the unit. Refer page 28 Page 24 of 36 Zip Hydrotap Service Manual

25 Electronics and PCB connection points - Boiling / Ambient 1 Amp Transformer Protection Solenoid Protection Element Protection NOTE: If hot probe or PCB is replaced you must re-calibrate the unit. Refer page 28 Zip Hydrotap Service Manual Page 25 of 36

26 Electronics and PCB connection points - Boiling Only 1 Amp Solenoid Protection Element Protection NOTE: If hot probe or PCB is replaced you must re-calibrate the unit. Refer page 28 Page 26 of 36 Zip Hydrotap Service Manual

27 Electronics and PCB connection points - HT series boiling only NOTE: There is no re-calibration procedure with the HT series Boiling Only. Zip Hydrotap Service Manual Page 27 of 36

28 Service Check, Testing and Re-Calibration Modes (not HT boiling only series) Hot Temp Lvl Cold Temp Lvl Temperature and Water level screen: To access this mode press the adjust buttons together until the screen changes to Service Mode, it will show the following: Hot Temp Lvl Cold Temp Lvl The temperatures shown are actual, not the set temperatures. To revert back to the Normal Operation screen, press the adjust buttons together again until screen changes. Hot Set Point 98.5 Hot Temperature Adjustment Screen: You can adjust the Hot temperature set point while in the service screen by pressing the adjust or, the Hot temperature can be raised or lowered in 0.5ºC increments. Once the temperature has been changed the screen if left untouched, will default to the original service screen within 10 seconds. Do not raise temperature above 98.5ºC without consulting Zip first to discuss the service issue. > To change the screen back to Normal Operation, press the adjust buttons together until the screen changes back. Zip Industries Re-Calibration Procedure: NOTE: If hot probe or PCB is replaced 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 power off. Now switch power back on while depressing the two bottom buttons on the LCD. The screen will show: 1. Zip Industries. 2. Filter flush, press the adjust button twice to move past this function. The calibration mode screen will appear, press adjust and the calibration cycle begins automatically. The display will show EMPTY TANK. 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. Once empty, if the tank is below 95ºC the unit will heat to this temperature. Once at 95ºC it stabilises for approx 120 seconds, once stabilised the unit will heat to boiling point and hold it for a further 90 seconds. The unit now re-calibrates for the local conditions, once achieved the unit will default back to normal operation. Page 28 of 36 Zip Hydrotap Service Manual

29 Boiling and Chilled Sensor Probe replacement and Resistance Chart Chiller Probe goes in this sheath opening, ensure correct depth is reached and secure wire under catch. To check for correct Chiller Probe Operation: Isolate unit electrically and remove access panels to reveal the Chilled tank assy. Remove the top insulation piece from the Chiller tank, the probe has a Blue covering. Withdraw it from the sheath and disconnect from the PCB. Allow to sit at room temp for 5 minutes, check resistance with a Ohm meter against the room temperature, see chart on page 30. If out of range, change probe. When re-installing reverse the dismantle procedure described above. Boiler Probe goes in this sheath opening, ensure correct depth is reached. To check for correct Boiling Probe Operation: Isolate unit electrically and remove access panels to reveal the Boiling tank assy. Remove the top insulation piece from the Boiler tank, the probe has a Red covering. Withdraw it from the sheath and disconnect from the PCB. Allow to sit at room temp for 5 minutes, check resistance with a Ohm meter against the room temperature, see chart opposite. If out of range change probe. NOTE: If hot probe or PCB is replaced you must re-calibrate the unit. Refer page 28 When re-installing reverse the dismantle procedure described above. Zip Hydrotap Service Manual Page 29 of 36

30 Sensor 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 30 of 36 Zip Hydrotap Service Manual

31 Chilled Water Level Sensor Replacement 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. Top level, 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: White wire with black stripe, high level indicator, shortest rod. Plain white wire, low level indicator, longest rod. The sensor rod holders are fixed in place in the chiller tank lid by a quarter turn plastic nuts. Take great care not to damage them when removing for maintenance or repair. Quarter turn fixing nuts. 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 LOW LEVEL 258mm 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. Zip Hydrotap Service Manual Page 31 of 36

32 Hot Water Level Sensor Replacement Hot Water Level Sensor: This sensor controls the filling of the hot tank. It has three levels of control: Low level: this indicates when the hot tank water is at it s lowest capacity. Mid Level: indicates that the water capacity will cover most situational needs. Top level: 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. 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 HYDROTAP BC 100/125-HOT TANK MIDDLE LEVEL Water level Length Sensor No. WATER LEVEL High LENGTH 57mmSENSOR ASSY NO HIGH Middle 57mm 79mm MIDDLE Low 79mm 205mm LOW 205mm Hydrotap BC 150/175 - Hot Tank HYDROTAP BC 150/175-HOT TANK Water level Length Sensor No. WATER LEVEL LENGTH SENSOR ASSY NO HIGH High 57mm 57mm MIDDLE Middle 79mm 79mm LOW Low 258mm 256mm Ensure when removing the sensor holder you check the underside sealing gasket for any faults or imperfections. If needed replace. DOMESTIC HydroTap HYDROTAP BC 60/85 BC - 60/85-HOT Hot Tank TANK WATER Water LEVEL level LENGTH LengthSENSOR ASSY Sensor NO No. HIGH High 120mm 120mm MIDDLE 140mm Middle 140mm LOW 205mm Low 205mm LOW LEVEL Page 32 of 36 Zip Hydrotap Service Manual

33 Basic Refrigeration Information 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) 2. Attach a clamp tester to the RED wire on the relay. Depending on compressor size this should read approx amps. (fig 2) Fig 2 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) 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. 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) Fig 4 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 Service Manual Page 33 of 36

34 Basic Refrigeration Help Matrix - Gas Pressures Page 34 of 36 Zip Hydrotap Service Manual

35 Basic Refrigeration Help matrix - Compressor Zip Hydrotap Service Manual Page 35 of 36

36 Warranty Warranty table effective from 1st April Domestic HydroTap HydroBoil AutoBoil Commercial HydroTap All other Normal warranty Extended warranty Pro-Rata warranty on main Tank 1yr 2yr 3yr 4yr 5yr Parts & Labour Parts & Labour replacement @50%rrp Parts & Labour Parts & Labour replacement @50%rrp Parts & Labour Parts only Parts & Labour Parts only Parts & Labour Full warranty details may be found on the website Registering Your Purchase Registering your Zip installation on the Zip website may help to establish date of installation should it become necessary to service the appliance under terms of the Zip warranty. To register your installation go to and look under the heading Register your purchase/warranty information, or forward the completed product registration form (enclosed) to your nearest Zip head office. As Zip policy is one of continuous product improvement, changes to specifications may be made without prior notice. Images in this booklet have been modified and may not be true representations of the finished goods. 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: The standard cup referred to in this publication is 167 ml (6 fl oz). The standard glass is 200 ml (7 fl oz). The terms Zip and HydroTap are registered trade marks of Zip Heaters (Aust) Pty Ltd. Zip products described in this publication are manufactured under one or more of the following patents: AU675601, AU637412, AU635979, GB , GB , US , US , and US Other patents are in force and patent applications are pending. Page 36 of 36 Zip Hydrotap Service Manual March 2009