Zip ChillTap Sparkling (CS) Models

Service Manual Zip ChillTap Sparkling (CS) Models ChillTap - Sparkling and Still - Filtered CT 1003 - CS FX Residential CT 1504 - CS 125 FX Commercial Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 1 of 32

Contents GENERAL General Layout and technical description............................................ 3 Technical specifications......................................................... 4 Warnings.................................................................... 5 Underbench Layout and positioning................................................ 6 Major components position...................................................... 7 CONTROL SETTINGS and FAULT FINDING Fault flow charts.............................................................. 8 / 9 EXTERNAL COMPONENTS John Guest fittings (insertion and removal).......................................... 10 Water supply................................................................. 11 Tap operation................................................................ 12 Filter change................................................................. 12 CO2 gas bottle change......................................................... 13 / 14 Soap test.................................................................... 14 INTERNAL COMPONENTS Outer Covers and Appliance entry................................................. 15 Water regulator valve........................................................... 16 Chiller Pressure Pump.......................................................... 17 / 18 CHILLER Chilling Cycle & Condenser fan................................................... 19 Carbonator & Flow restrictor..................................................... 20 Temperature Stabilisation and the Cold Temperature thermostat probe..................... 20 Cold level Sensor............................................................. 21 Bad tasting sparkling water...................................................... 21 Sanitisation.................................................................. 22 Compressor & Components..................................................... 23 Compressor testing............................................................ 24 Compressor trouble shooting chart................................................ 25 ELECTRICAL P.C.Board and fuse assembly.................................................... 26 Thermostat.................................................................. 26 Earth Continuity test........................................................... 27 Wiring diagram............................................................... 28 DIAGRAMS Chilled Sparkling Hydronic flow diagram............................................ 29 ChillTap components........................................................... 30 Parts Lists................................................................... 31 Contact details................................................................ 32 Page 2 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

ChillTap - General layout ChillTap - Sparkling and Still General technical description General information. This Service Manual contains the information you will need to service the wiring, plumbing, temperature sensors, valves and taps. It will allow you to gain access to all of the components inside the unit. It will show you how to sanitise the unit and deal with any mineral scale that may accumulate inside it. You will also fi nd the necessary diagrams and illustrations and a detailed fault fi nding guide. This guide matches possible faults with probable causes, a summary of what to do and fi nally, a page reference to the places in this manual where the faults are dealt with in detail. Please read all the warnings before servicing any Zip appliance. Never attempt to service a Zip appliance without reading all of the applicable servicing instructions. The ChillTap is an electronically controlled appliance designed to provide fi ltered, chilled and sparkling water for drinking in residential and commercial kitchens. Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 3 of 32

Technical specifications The ChillTap, chilled and sparkling unit (CS), is an 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 a CO2 gas cylinder to carbonate the chilled water. These units dispense chilled water (factory set to 6 C) and sparkling water (factory set to 6 C) from the one tap. Both the water fi lter and CO2 cylinder are disposable items which will require periodic replacement and are covered by a limited OEM warranty. ChillTap specifications Power : 220V - 240V AC 50Hz Min water pressure : 140kPa Max water pressure : 700kPa Refrigerant : R134a Operating (ambient) temps : 5 C - 35 C Cold Temp range : 3 C - 6 C Disposable Filter: Re-order type FX - Sub micron - 91240. CO2 Disposable cylinder - Compressed Carbon Dioxide (Food Grade) Cylinder Specifications: UN : 1013 Class 2.2 Code: GTCD22Z Volume: 2.2 litres Contents: 1,000g Tare: 1,745g Test pressure: 12,000 kpa. Boiling Point: -78.5 C n Flammable Gas n Toxic Gas Std: EN12205 Temp range: -20 C to +65 C Re-order code: 91307 Page 4 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

CO2 Cylinder Warnings: Pressurised container. Protect from sunlight. Contains gas under pressure, may explode if heated. Do not expose to temperatures exceeding 50 C. Do not pierce or burn, even after use. Do not refill non rechargeable Ensure cylinder is empty before disposal. Do not expose to naked flame or any incandescent material. Keep out of reach of children. High concentration of gas may cause asphyxiation. Use only in ventilated areas. Use only in an upright position. This bottle must be used with the approved pressure regulator. Avoid shock. Use according to MSDS. (Material Safety Data Sheet). Warnings WARNINGS 1. The ChillTap unit must be earthed. The resistance of the earth connection from each exposed metal part must be less than 1 ohm. 2. All service work must be completed by trained and suitably qualifi ed Tradespeople. Faulty operation due to unqualifi ed persons working on this product, or any other Zip product may void warranty coverage. 3. All Plumbing must comply with AS/NZS3500.4.1 & AS/NZS3500.4.2 4. All Electrical must comply with AS/NZS60335.1, AS/NZS60335.2.75 and AS/NZS3000 5. All Plumbing and Electrical connections must be made in accordance with local regulations. 6. This service manual should be used in conjunction with the current version of the operating and Installation Instructions. It requires qualifi ed technical knowledge and offers support for the maintenance and repair by a qualifi ed tradesperson only! 7. 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 fi nd 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 ChillTap 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. Do not operate the appliance without a water fi lter. 6. After each service the earth continuity must be checked. See page 27. Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 5 of 32

Under bench layout Under bench connections Plumbing and Gas connections Power and Warning light Page 6 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Position of major components Sparkling water To and from filter CO2 Chilled water IN Carbonator outlet regulator Condenser Fan DNR Valve PCB Assembly Compressor Capacitor Chill Pump Assy Thermostat Water Regulator Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 7 of 32

Fault flow charts. Unit does not turn on. Is there 230volts at the power point? Yes Check circuit breaker and advise customer to get an electrical to look at the circuit. Make sure the power lead is plugged in correctly. Is there continunity through the fuse? Replace or refi t the fuse. (see page 26) If the fuse is blown, check all electrical components for a electrical fault. ( open circuit, short circuit or a leak to earth) Yes Are all the cables plugged on to the PCBA? Fit cables to the correct terminals on the PCBA and re-test unit. Yes Is there 230 volts to the PCBA? 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 Is there 230Volts to the thermostat? (see page 26) Check wiring. If all correct replace PCBA. (see page 26) Yes Replace the thermostat. Water does not come through the carafe tap. Is there water supply to the unit and is the water pressure above 140Kpa? Turn on the water supply or rectify the water supply problem. make sure none of the hoses to the unti are kinked or bent. Yes Is there water supply to the fi lter head? Check the water regulator for a blockage. Replace water regulator. (see page 16) Yes Is the power on to the unit? Yes Turn the power on. Does the pump engage when power is turned on to the unit? Check that the PCBA is giving 230volts to the pressure pump. If yes replace the pump, if no replace the PCBA. (see page 26) Yes Is the outlet fl ow regulator open? (see page 20) Yes Open the outlet fl ow regulator 1.5 turns. replace the carafe tap. Cold/sparkling water tastes funny? Is the CO2 regulator registering a CO2 pressure? Check the gas bottle for gas. Replace the bottle (See page 13) and perform a taste test Yes Perform a CO2 purge on the carbonator. (see page 13) Does the sparkling water still taste funny? Yes Adust the fl ow regulator on top of the carbonator. Adust to customers taste. (See page 20) Page 8 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Fault flow charts. Water is not chilling Is the power turned on to the unit? Yes Turn the power on to the unit. Is the red light fl ashing on top on the unit? Yes Go to fl ow chart on red fl ashing light. Are either of the fuses on the PCBA blown or do not has a circuit through them? Yes Replace or refi t the fuse. If the fuse is blown, check all electrical components for a electrical fault. (open circuit, short circuit or a leak to earth) Is there a circuit through the thermostat? Yes Replace the thermostat. Is the fan running? Is the fan getting 230volts. Yes replace the fan. replace the PCBA. Yes Test the compressor. (see page 24) The sparkling water is not sparkling. Is there a CO2 pressure reading on the regulator gauge? Check the gas bottle for gas. Replace the bottle if bottle is empty. (See page 13) Yes Perform a CO2 purge (See Page 13). Does the water get pushed through by the CO2? Look for a blockage in the regulator or CO2 gas line to the carbonator. Yes Perform the CO2 purge once again. Adjust the fl ow regulator on the top of the carbonator. (See page 20) Is the cupboard ambient temperature over 35oc? Yes The unit requires more ventilation. Installation of a vent kit is recommended. Turn the unit off and then back on to reset the fault Turn the unit off and then back on to reset the fault. When normal operation is displayed, can you hear the fan running? Check the temperature reading of the cold tank. If it is above 10 C replace the fan assembly. If it is below 10 C go to next step. Yes With a thermometer test the temperature of the chilled water coming out of the tap. Is the temperature within acceptable limits? Replace the thermostat (See page 26) Yes Remove the PCBA cover and test the fuses on the PCBA. If one of the fuses is blown, (refer to the circuit diagram on page 28) and test the components it protects for an electrical fault. Replace faulty part. If the fuses are ok, is the PCBA burnt or damaged. Is the compressor getting 230 volts to it? Replace the PCBA. (See page 26) Yes Has the compressor thermal overload control tripped out? Yes Check the capacitor is working correctly, (See page 23 & 24) Replace the capacitor and the relay, if found to be faulty. Do a check test on the compressor motor. (See page 24) Is the motor good? Yes Unit probably requires refrigeration repairs. Send unit back to workshop. Licensed refrigeration mechanic required. Compressor will need to be replaced. Send unit back to work shop. Licensed refrigeration mechanic required. Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 9 of 32

Components Caution! Before you commence any service work on the ChillTap, isolate the power, CO2 gas and water 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. John Guest fittings (Insertion and removal) John Guest fittings are screwless, quick connect fittings, specifically designed for the joining of tubes used in the plumbing industry. They are Watermark approved for use in all Zip appliances. tools are rerquired for the assembly or disassembly of tubes fitted with these fittings. 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: Removal: 4. Push the tube into the John Guest fi tting making sure all connections to the John Guest fi ttings are pushed in past the O ring to full depth, at least 15-16mm. 5. Check for a good joint by pulling back on the tube. If the tube comes out, of the fi tting, repeat the above step. 6. To remove the tube, press the collet into the fi tting and at the same time pull back on the tube. NOTE: The 'O' rings and collets may be replaced using 90015 and 90016 part numbers Page 10 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Water supply 350kPa DNR / PL Valve fi tted to an isolation tap 350kPa DNR / PL valve. NOTE the direction of fl ow Water Inlet Warning Light Top of base unit Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 11 of 32

Tap operation Sparkling filtered water (white) Chilled filtered water (blue) Operation: The lever on the right (Blue rings) is used for chilled still filtered water and the lever on the left (White rings) is used for chilled sparkling filtered water. Chilled water is obtained by rotating the lever on the right, to a horizontal position. The water is chilled by a refrigeration unit fitted within the cabinet stand, under the basin. With the carafe tap, you can obtain chilled water within the rated capacity of the appliance, for as long as you leave the lever in the open (horizontal) position. When finished, return the lever to the OFF (upright) position. Sparkling water is obtained in the same way as the chilled water, by rotating the lever on the left hand side of the carafe tap. NOTE: After dispensing sparkling water, a small amount will remain in the carafe tap. If the next drink is to be still water and you do not wish any trace of sparkling water, the still water should be running for approximately 1 second before filling your glass or bottle. The same is applicable if still water is dispensed prior to dispensing sparkling water. Filter change Filter Replacement For safe operation, the filter cartridge should be replaced every 6-12 months, or earlier if you notice a persistent reduction in water pressure from the appliance or an unpleasant taste or odour in the water. Filter Change 1. Turn OFF the water and power supply to the unit. 2. Turn the still water lever (blue ringed lever) ON, to release any water pressure in the unit. Once water has stopped running from the tap turn OFF the lever. 3. Turn the filter clock wise and gently pull the cartridge down. The cartridge should release from the filter head. Dispose of the filter cartridge responsibly. Clean any water that has pooled below the filter head. 4. Fit a new filter by turning filter anticlockwise and gently pushing up. The filter will click or lock into place. 5. Turn the still water tap ON. 6. Turn ON the water supply to the unit. Allow 7.5 liters to flow from the outlet. 7. Turn OFF the still water lever. 8. Turn ON the power supply to the unit. Page 12 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

CO2 Gas bottle change CO2: Before use, carefully read the product label. Use of safe work practices are recommended to avoid eye or skin contact and inhalation. Observe good personal hygiene, including washing hands before eating. Prohibit eating, drinking and smoking in contaminated areas (eg. If the container is damaged). Storage: Do not store near sources of ignition or incompatible materials. Cylinders should be stored below 50 C in a secure area, upright and restrained to prevent cylinders from falling. Cylinders should also be stored in a dry, well ventilated area constructed of non-combustible material with a fi rm level fl oor (preferably concrete), away from areas of heavy traffi c and emergency exits. A storage room must be larger than 38 cubic metres for each 1kg of CO2 gas. CO2 gas bottle The BCS unit requires a CO2 bottle for the correct operation of the sparkling water. This bottle is to be secured in an upright position to the wall of the cabinet it is located in and is supplied with a securing Velcro strap. The CO2 bottle is attached to the regulator valve, which should be set to 2.7 bar for correct carbonation of the sparkling water. The regulator can be adjusted via the screw valve which raises or lowers the pressure of the CO2. It is important to test for CO2 gas leaks when servicing the CS unit. This can be done by using soapy water. Applying the soapy water via an applicator (sponge or paint brush) to the regulator, gas line and connections should show up any CO2 leaks. (See page 14). CO2 Bottle change CT Models. -To change the bottle follow the steps bellow: Chilled sparkling unit (Carafe tap): Turn the CO2 bottle regulator OFF (Anti-clockwise). The knob will screw up and away from the bottle. Remove the bottle from the cupboard and disconnect the regulator. Fit the regulator to the new gas bottle. Be aware that some CO2 may be discharged from the bottle joint. Any CO2 released will be cold. NOTE: Be careful not to loose the plastic olive which is used in the connection between the regulator and the gas line/hose. It is small and easy to loose. Fit the new bottle in an upright position (use the velcro securing strap). Turn ON the regulator. Adjust the regulator to 2.7 bar. (Green zone on dial). Check for gas leaks using a sponge and soapy water. CO2 Purge Turn the sparkling levers to the ON position. Leave them on until all the water has been purged through the tap. Once the water has stopped flowing, let the tap run for a further 10 seconds to purge the CO2 through the tank. Turn OFF the sparkling levers. Turn ON the power supply. Wait 20 seconds and then turn ON the sparkling lever and wait for water to start to come through. Dispense some sparkling water from the tap. Perform a taste test. Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 13 of 32

CO2 Gas bottlechange (continued) CO2 pressure set zone -270kPa Soap Test After replacing a bottle or after making a gas connection: Stage1: 1. Turn the gas OFF 2. Using soapy water applied with a sponge, or with a brush, cover all of the gas joints with a liberal amount of suds. Stage 2: 3. Turn ON the gas 4. Inspect the joint for leaks If any bubbles appear, the joint will need to be resealed. Water regulator valve: Faulty seal joint Page 14 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Appliance Access Access to the Chilled Sparkling unit: 1. Depressurise the unit. 2. Disconnect the power, water and CO2 Gas lines 3. Remove the top cover by undoing the top screws 4. Remove the screws securing the front cover and slide the cover forward for full access to all components Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 15 of 32

Water Regulator Valve Incoming water must be controlled so that it's pressure and flow rate are maintained within set limits. There is a important balance between the incoming water pressure and flow rate and the quality of the outgoing carbonated water. To achieve this balance, a water rergulator, (set at 4 L/m) is placed between the 350kPa pressure reduction valve and the circulating pump. (See layout on Page 51) NOTE: The water regulator valve is factory pre-set and must not be adjusted. Any modifications will affect the quality of the carbonated water. **Caution high voltage will be present when doing live tests** Water regulator removal: 1. Depressurise the system after Isolating the water, power and gas to the unit. 2. Unscrew and remove the top and outer covers 3. Disconnect the water regulator by releasing the inlet and outlet tubes via the John Guest fittings (See page 10) Water regulator replacement: 1. Perform the removal procedure in reverse 2. Conduct an earth leakage test (See Page 27) 3. Perform a CO2 purge. (See page 13) Page 16 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Pressure Pump assembly Pressure pump. The pressure pump keeps the water supply for the chilled and sparkling water at a constant. Once the pressure drops the pump engages and brings the water up to the set fl ow rates. The chilled water is set to 4L/m, while the sparkling water is set to 1.2L/m (this can be adjusted see page 22) the pump requires a supply of 230volts. The pump has an externally mounted suppressor and an internal capacitor. The direction of fl ow of the pump is stamped onto the bottom of the pump. Warning light: The ChillTap sparkling has a safety cut out for the pressure pump. If the water supply is cut to the pump, the pump will shut down after one (1) minute of operation. This is to protect the rotary vane; a red fl ashing light can be seen on top of the chiller module when this safety feature has been engaged. To reset the pump, check the water supply, then turn the power supply off then back on. te: If the pressure pump seems noisy it could be because of poor fl ow or pressure to the unit. Make sure there is a minimum of 140kPa water pressure with 4L/M fl ow for the chilled water and 1.2L/m fl ow for the sparkling water. If the fi lter is blocked the pump can become noisy during the operation of the still water. Therefore replacement of the fi lter will be required. Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 17 of 32

Pressure Pump continued Pressure pump Pump motor check test: 1. Disconnect the utilux connector block near the base of the pump assembly 2. Probe between the Red and Blue wires with a multimeter 3. Reading should be 102 Ohms ± 5% Pump motor Removal of Pressure pump and motor. 1. Isolate the water supply, power and gas to the unit. 2. Remove the front panel and the top cover (6 x securing screws). 3. Disconnect the mutli-plug connected to the pressure pump motor. 4. Remove the capacitor and its yellow wiring. 5. While holding the pump, loosen the worm drive clamp holding the pump secure. 6. Disconnect the inlet and outlet tubes from the pump. See JG fi tting removal (See page 10) 7. Remove the worm drive clamp and the pressure pump assembly may now be lifted up and out of the appliance. 8. To separate the pump from the motor, unscrew and remove the metal joining band. This will free the pump for removal Page 18 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Chilling Cycle Basic refrigeration in the ChillTap 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 rapid cooling of the surrounding areas, allowing the water around the evaporator to be chilled. In the fi nal 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 qualifi ed refrigeration technician Condenser Expansion 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 can be used. Condenser Fan replacement: 1. Access to the fan is gained by removing the outer covers (See page 15). 2. Disconnect the two wires at the side of the fan 3. Remove the two securing screws and the fan can be withdrawn from the condensed assembly 4. Installation is the reverse 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% 4. Perform removal in reverse procedure. 5. Perform an earth leakage test. 6. Perform a CO2 purge. (See page 13) Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 19 of 32

Carbonator and Flow restrictor The heat exchange and carbonator can. The carbonator and the heat exchange are located at the rear of the unit. The heat exchange surrounds the carbonator can. Both are insulated and non repairable. The heat exchange is used to chill the water. It consists of a large aluminium block with a long run of stainless steel pipe running through it. As the water runs through the stainless steel pipe heat is absorbed by the aluminium block thus chilling the water in the stainless steel pipe. On the outlet of the heat exchange the chilled water is diverted from the carafe tap, via a DNR Valve, to the carbonator can. (See diagram on page 29). Carbonation happens when the CO2 gas is dissolved in water at a low temperature. The CO2 gas is set to 270kPa and is at constant pressure in the can (unless you have low or no CO2 in your bottle). The chilled water is pushed into the carbonator can by the pressure pump. This pump should keep the water pressure near to 400kPa. Because the water pressure is higher than the CO2 pressure, the CO2 dissolves into the water under this higher pressure. Flow restrictor There is a fl ow restrictor on the top of the carbonation can that regulates the dispensing fl ow rate. It is factory set to 1.2 1.8 litres a minute. The fl ow rate is set to optimise the taste of the sparkling water. It can be adjusted up or down but it is not recommended. The factory setting is 1.5 turns of the fl ow restrictor. Increased fl ow will reduce the carbonation effect, giving poor tasting water. The carbonation tank also has a pressure relief valve located on the tank of the unit. This will open if the pressure inside the tank rises above the set limits, it can also be used to purge the tank with CO2. te: The carbonation tank should be empty of water before opening the relief valve. Regulator valve From DNR Valve To DNR Valve Refrigeration lines Chilled water OUT Carbonated water OUT Ambient water IN (from pump) Cold level sensor Thermostat housing Pressure relief valve Temperature stabilisation and the Cold temperature thermostat probe The cold temperature sensor is located in the far corner of the carbonator heat exchanger and is an integral part of the thermostat. The thermostat will chill the heat exchange down to 2.5 C. The refrigeration system will stabilise and turn off when the temperature is below 2.5 C. Once the temperature of the heat exchange has risen above 4.5 C the refrigeration system will turn back on. This is all done via the cold thermostat sensor. If the heat exchange block or water pipes are freezing this can be due to an out of calibration thermostat. In this case the thermostat assembly will need to be replaced. (See page 26 for Thermostat removal) Page 20 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Cold level sensor Cold sensor probe Cold level sensor The cold level sensor is located on top of the carbonator. This sensor measures the level of water in the carbonator can and is monitored via the PCBA. Cold level sensor removal. 1. Isolate the water, power and gas to the unit. 2. Gain access by removing the outer covers (See Page 15) 3. Disconnect the cold level sensor lead from the PCBA. and from the top of the probe 4. Lift the insulation from the top of the Carbonator can to expose the sensor securing nut 5. Unscrew the plastic nut and withdraw the stainless steel sensor probe. 6. te the position of the o-ring seal (for reassembly) Cold level sensor replacement. 1. Perform the removal procedure in reverse 2. te the position of the probe so that the annular groove aligns with the top of the plastic nut. 3. Perform an earth leakage test. (See page 27) 4. Perform a CO2 purge. (See page 13) Plastic nut O-Ring seal Level sensor probe Bad tasting sparkling water. Bad tasting sparkling water can be due to a couple of factors. 1. If the water has an acidic after taste, the water fl ow from the unit is too fast. Close the fl ow restrictor and reset to 1.2 litres a minute. rmally 1.5 turns of the adjustment screw. 2. If the sparkling water tastes fl at. Check your CO2 gas pressure and gas bottle. Make sure it is set to 270kPa. Change the bottle if it is not holding pressure. If the CO2 pressure is correct, purge your carbonator can. Select the CO2 purge and wait till you are just getting gas through the tap. Turn the purge off and wait for 30 seconds. Repeat the CO2 purge. Wait for another 30 seconds and re-taste the water. 3. If you have not had a fi lter change in 12 months. Change you fi lter (See page 25), perform a fi lter fl ush and a CO2 purge (See page 11) on the unit, re taste the water. 4. Residue in the carbonation tank. If you are in a hard water area where mineral scale build up could cause a residue. The carbonation can, may be cleaned using a citric acid cleaning solution, such as 99089 & 99090 urn cleaner. Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 21 of 32

Sanitisation Important: It is recommended that the sanitising procedure be performed at least every 6 months. Prepare the Unit 1. Disconnect the electrical power to the unit and isolate from the water supply. 2. Open the carbonated water dispense tap until gas comes from the dispense nozzle. 3. Carefully follow the manufacturer s instructions and prepare a solution of proprietary sanitising fl uid such as Citric Acid cleaning solution (ref. 99089 & 99090 Urn cleaner). A 5 litre container is ideal for this operation. Sanitise the Water System 4. Where a fi lter is fi tted remove the cartridge, put sanitiser into the chamber. Where a complete fi lter is fi tted, dummy fi lters are available for this purpose. or alternatively 5. Disconnect the fl exible water inlet tube from the water supply and place the end into a container of sanitising fl uid. If the unit being sanitised does not incorporate a water pump, fl ushing through of the sanitising solution can be achieved by either using a pressurised container, or by using a siphon. In the latter case, the sanitising fl uid needs to be held at a height suffi cient to allow fl uid to fl ow through the chiller. 6. Switch on power & operate the still water tap to clear any air locks. Release & allow the carbonator chamber to fi ll. 7. Draw 1 cup of carbonated water followed by 1 cup of still water to ensure all tubes are full of sanitiser. 8. Switch off power & leave to stand for period recommended by the sanitiser manufacturer. 9. Follow Routine Clean procedure to clean dispensing tap outlets. Recommission the Unit 10. Empty the carbonator can of sanitiser by opening the tap until gas escapes. Reconnect the still water supply and fl ush through via the still tap until all sanitiser has been removed from the chiller. Switch on power supply. 11. Conduct a CO2 purge (see P. 13) ensuring a draw off at least 1 litre of still water and carbonated water is achieved. Page 22 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Compressor and components Compressor The compressor is the main heart of the refrigeration sealed system. It's function is to keep the Chilling Cycle (See Page 19) in motion by forcing the refrigerant to phase from gas to liquid. The chilling cycle is only operational when the compressor is running. Capacitor The capacitor is used to help start and run the compressor motor. If it is split or leaking a clear substance it needs to be replaced. It is recommended to replace the relay at the same time as the capacitor. Relay: The relay is an automatic switch which allows the compressor motor to change from it's start windings to the motor Run windings. Thermal overload control. The thermal overload control is a protection device for the compressor. If it trips out it is due to the compressor being too hot. It may not need to be replaced. The reason for the compressor overheating will need to be found. Capacitor Thermal Overload Control Compressor **Caution high voltage will be present when doing live tests** Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 23 of 32

Live testing NOTE: This procedure requires 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. 2. Attach a clamp tester to the active wire on the TOC. Depending on compressor size this should read approx. 0.5-1.1 amps. NOTE: If at any time power is removed, the compressor can take up to several minutes to restart. See the Fault Flow charts on pages 8-9, for a step by step guide to fault finding. Check Test for Compressor After gaining access to the compressor Isolate the power Remove the junction box cover to expose the Relay and Thermal Overload Control (TOC) 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 Terminal A Compressor winding test Probe between A & B should read aprox 18 Ohms (Run windings) Probe between A & C should read aprox 28 Ohms (Start windings) Probe between B & C should read aprox 46 Ohms Terminal C Terminal B Any discrepancy in these readings may require the unit to be returned to the service department for further investigation. Page 24 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Compressor Trouble shooting Compressor operating Is water temp above 10 C Yes Wait till water temp is above 10 C Is there correct current draw (0.5-1.1Amps) Yes Is there 240V between Red & Blue relay wires Faulty Gas pressure (return for service) Yes Replace PCB Assy. Is Capacitor OK Yes Replace Capacitor Is Relay OK Yes Replace Relay Compressor faulty (return for service) Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 25 of 32

PCB Assembly - Thermostat and Fuses The Chilled Sparkling PCB Assembly and Thermostat are located in the lower left hand corner of the Module. 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. The Thermostat regulates the temperature of the chilled water, it is located adjacent to (but is a separate item to), the PCB assembly. PCB Assembly Fuses 2 x 5AT Removal of PC Board Assembly 1. See page 15 appliance entry. 2. Disconnect all wiring looms from the PCBA. 3. Remove the four (4) retaining clips that secure the PCBA 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. 4. Perform an earthing continuity test (see p. 27). 5. Re-connect and turn on the water, gas and power supply. Fuses are: 2 x 5AT - 240V (See diagram for location). Chiller thermostat Removal of the thermostat 1. Remove the outer covers for access to the PCB and fuses. (See page 15) 2. Remove the elongated hex nut to gain access to the chiller thermostat. 3. Disconnect the 2 wires 4. Remove the probe from the carbonator so the thermostat assembly can be detached from the appliance Thermostat replacement 1. Perform the removal procedure in reverse 2. Replace the outer case. 3. Perform an earthing continuity test (see p. 27). 4. Re-connect and turn on the water, gas and power supply. 5. When stabilised, check the temperature of the water. (See page 20). Securing Hex nut Page 26 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Earth continuity test 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 defl ection). 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. One probe connected to chassis One probe connected to plug's earth pin Megohn meter or appliance tester Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 27 of 32

Wiring diagram Page 28 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

Flow diagram for Chilled Sparkling water Chilled water Sparkling water CO2 Gas Expansion Refrigeration lines DNR Valve Level sensor Pressure relief valve Filter Pump oc PCB Assembly Water Regulator Thermostat Pressure Reduction Valve Mains water IN Carbonator and heat exchanger tanks Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 29 of 32

ChillTap Components 91373 Carafe Page 30 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04

ChillTap parts list ITEM Part. DESCRIPTION 1 91310 CO2 Inlet Harness Kit 2 91309 CO2 Backcheck Assy Kit 3 91318 Flow Restrictor Kit 4 90752 Fan Condensor Kit 5 91308 Filter Dryer 5g Kit 6 91319 Compressor Kit 7 91314 Chill Water Pump Kit 8 91313 Thermostat Kit 9 91315 Water Regulator Kit 10 91311 PCB Kit 11 91317 Reducers DNRV Kit 12 91316 Double n Return Valve kit 13 91339 Relay Kit 14 91340 Capacitor Kit 15 91312 Silicon Tube Can Level Kit 16 91325 Olive CO2 Regulator Kit 17 91366 Plumbing Kit 18 91377 CO2 Regulator Kit 19 91295 CO2 Cylinder x 2 Kit 91373 ChillTap Carafe - complete Zip ChillTap Service Manual - 800721-CS - July 2013 V1.04 Page 31 of 32

Contact details Head Office Zip Heaters (Aust) Pty. Ltd. ABN: 46 000 578 727 67 Allingham Street Condell Park NSW 2200 Postal: Locked Bag 80 Bankstown 1885 Australia WMKA21821 ATS 5200.105 Website: www.zipheaters.com Facsimile: (02) 9796 3858 Telephone: (02) 9796 3100 Free Call: 1 800 638 633 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. 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, GB0422305, GB2065848, US4354049, US5103859, US5099825 and SA2006/08043. Other patents are in force and patent applications are pending. Page 32 of 32 Zip ChillTap Service Manual - 80072-CS - July 2013 V1.04