801314NZ HEAT_BC_instructions 8 15 V2.01 HT G4 BC Instructions
2016-12-15
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Installation Instructions ® Zenith HydroTap G4 Filtered boiling and chilled drinking water for commercial kitchens and tea rooms. BC Commercial Affix Model Number Label Here 801314NZ 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 1 of 40 Tap options The G4 appliance series offers a range of interchangeable taps to suit the customer’s needs These three taps are directly compatible with the G4 under bench unit. The Mixer tap range is an additional series of taps that may be used in conjunction with any one of the three taps shown above, to create 4-IN-1 models The All-In-One Tap is a stand alone tap that may be used as an alternative to any of the above combinations. The A-I-O is compatible with the G4 underbench unit. Page 2 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Index HydroTap Specifications Installation check list .................................................................................................................... 4 General Product Features ............................................................................................................ 5 Important Safety Instructions ....................................................................................................... 6 Warnings and Regulatory Information.......................................................................................... 7 Major components and Accessories ............................................................................................ 8 Technical Specification ................................................................................................................ 9 Before Installation, site requirements and special tools required ................................................. 10 Installation Instructions STEP 1 - Measure and cut all the tap holes before fitting the taps Section 1 - Tap Installation instructions 1.1 - HydroTap Classic and Elite Tap Installation ............................................................. 11-13 1.6 - HydroTap Arc/Cube Installation ................................................................................ 14-15 1.10 - Mixer Tap Installation .............................................................................................. 16-18 1.14 - All-In-One Tap with MAINS Installation................................................................... 19-22 STEP 2 - Check for adequate ventilation Section 2- Ventilation 2.1- Vent cut out details.....................................................................................................23-24 STEP 3 - Install the Booster Heater (if required) Section 3 - Booster heater Installation 3.1- Booster Heater specifications and Installation ........................................................... 25-27 STEP 4 - Mount the external filter / softener (if required) Section 4- Filter / Softener installation 4.1- Mounting the filter head & cartridge Installation ......................................................... 28 STEP 5 - Install the undersink unit Section 5 - Undersink unit installation 5.1- Check the external bypass valve setting ................................................................... 29 5.2- Fit the mains water supply hose ................................................................................ 29 5.3- Model BC 160/125 and BC 160/175 .......................................................................... 30 5.4- Model BC 240/175 ..................................................................................................... 31 5.5- Model AIO Mains ....................................................................................................... 32 5.6- Model AIO Vented...................................................................................................... 33 5.7- Model 4-In-1 Vented .................................................................................................. 34 STEP 6 - Commission the HydroTap Section 6 - Commissioning 6.1- Select the Language .................................................................................................. 35 6.2- Filter Flush ............................................................................................................... 35 6.3- Flow Calibration ......................................................................................................... 36 6.4- Boiling Calibration ...................................................................................................... 36 6.5- Booster activation ...................................................................................................... 36 6.6- Safety Sensor Calibration .......................................................................................... 37 Trouble Shooting End of life disposal ....................................................................................................................... 37 Trouble Shooting Table ................................................................................................................ 38 Contact details ............................................................................................................................. 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 3 of 40 Installation checklist Before Installation: A. Read the instructions and check if there is adequate space to mount all of the components. B. Note: Not all fittings are supplied with the appliance kit. Isolation valves are not supplied. C. Check the mains water pressure is between 172 - 700kPa and 200 - 700kPa when a booster and /or filter softener is fitted D. Check the water quality to determine if extra filtration will be required. NOTE: This product must be fitted to a potable water supply E. Check the appliance rating plate and ensure correct power is available for the appliance. F. Check the under counter cupboard supporting the appliance is adequate for the total weight of the appliance, when full of water. Before Commissioning: 1. Check the unit has been installed correctly. 2. Check all plumbing fittings have been tightened. 3. Ensure the outlet and vent pipes are positioned to drain correctly. 4. Ensure there is adequate ventilation. 5. Check all tubes from the undersink unit to the tap, have a constant rise and there are no sags or kinks in the hoses. 6. Check all electrical connections are correct and there are no loose wires. Commission: (See section 6) 7. Flush the supply line before connecting. 8. Turn on the water and check for leaks. 9. Flush the filter(s). 10. Where applicable, programme the unit to suit the customer’s requirements. Page 4 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 General Product Features Thank you for purchasing a Zenith HydroTap. Please read and follow these instructions carefully to ensure safe and trouble free service. If service is required, please call 0800 558055 What is the Zenith HydroTap ? The Zenith HydroTaps are electronically controlled, filtered, Boiling water and Chilled water drinking systems for kitchens and tea rooms. 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 5-10°C). These units are NOT designed to be used for sanitary fixtures. The Boiling water units are fitted with a tap mounted, safety lock. In addition, there are various 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. It is important that the Installation be done safely, correctly and completely, in order to utilise all the benefits the HydroTap can provide. The Classic and All-In-One taps may be ordered with the Tap Head Assembly for Disabled use. The disabled levers are supplied with Braille caps for the visually impaired. HydroTap Classic BC160/125 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 5 of 40 Important Safety Instructions This manual contains important safety, Installation instructions for the Zenith HydroTap G4. Safety This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. For products sold in Europe, this appliance can be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be made by children without supervision. Refrigerant The Zenith HydroTap unit contains R134A refrigerant under pressure. Maintenance of the refrigeration unit must be carried out by an accredited service provider or qualified refrigeration technician. Qualifications If the power cable is damaged it must be repaired only by a qualified technician. To avoid hazards, all Installation procedures must be carried out by a suitably qualified tradesperson. The power cable and power outlet must be in a safe visible position for connection. Venting Sometimes steam and / or condensed droplets may discharge through a vent outlet at the tap. If the tap is not installed using the Font pedestal, ensure the tap body is located so the tap outlet safely dispenses into the sink bowl area. Lifting Take care when lifting the Zenith HydroTap unit. Some units may exceed safe lifting limits. If you feel this is beyond your personal capabilities, please seek assistance with the lift. The weights of the units are marked on the packaging. Do not lift the unit by the front cover or any connections at the top rear of the unit. Refer to section 1.2 technical specification for the weight of your product. Airflow The ambient operating temperatures, when installed in a cupboard, must be between 5ºC - 35ºC. Proper air circulation must be provided. The system will operate satisfactorily only if the recommended air gaps of 50mm on each side are provided. If a vent kit is supplied it must be fitted. See technical specifications for correct Installation to prevent overheating. Altitude Water boils at varying temperatures at different altitudes. Your HydroTap adjusts for this during startup calibration and will recalibrate itself on a regular basis. Frost Protection If this appliance is located where the ambient air temperature could fall below 5ºC when the heater is not in use, do not turn off the appliance electrically. This safeguard does not offer the same protection to the connecting pipework and fittings. Page 6 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Important Safety Instructions Positioning It is important to ensure the undersink unit is positioned in an accessible area close to the floor level. The unit must have it’s base mounted in a horizontal position with all inlets and outlets facing up. The Tap must be located above the undersink unit and positioned so that it dispenses into the sink bowl with ample clearance for a cup or tea pot. See section 1 for details. WARNINGS 1. 2. 3. 4. 5. 6. 7. 8. 9. The Zenith HydroTap unit must be earthed. The resistance of the earth connection from each exposed metal part must be less than 1 ohm. All Installation and service work must be completed by trained and suitably qualified Tradespeople. Faulty operation due to unqualified persons working on this product, or any other Zenith product may void warranty coverage. All Plumbing must comply with AS/NZS3500. All Electrical must comply with AS/NZS3000 All Plumbing and Electrical connections must be made in accordance with local regulations. This HydroTap product is rated for 230V 50Hz AC operation. Undersink units must never be located near, or cleaned with water jets. Zenith HydroTaps are not to be exposed to the elements of nature Due to the process of continuous improvement, Zenith Heaters reserves the right to change details mentioned in this manual, without notice. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 7 of 40 Major components and accessories Parts supplied Description Accessories 1 off 4 Tap options with hoses (Classic tap shown) Description HydroTap Booster Water System with connection hoses 1 off HydroTap Undersink Unit with air and water filters Softener and head assembly 1 off Mains water connection hose Font Kit for Arc & Cube Models Duct kit 1 x Air Duct 1 x Mounting plate Font Kit for Classic & Elite Models Vent Kit 1 x Kickboard louvre 1 x Door vent louvre 1 x Front vent grill 1 off HydroTap Booster Heater & hoses. (Supplied with 240 /175 models) Replacement Filter Disabled lever Kit 1 x Restrictaflow valve and Tee piece for Mixer taps Guide 1 x User guide and 1 x Quick start guide KIT BC - 4-in-1 upgrade Kit 1 x Mixer Tap for 4-In-1 and select models (with hoses) (Arc tap shown) Page 8 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Technical Specifications Model Cups of Boiling Water per Hour Glasses of Chilled Water per Hour 160 125 BC Commercial Models BC Boiling and Chilled BCHA 4 in 1 A All in One - Mains AV All in One - Vented D Disabled lever controls (optional accessory) Note: 1. The Cup measurement =167ml and the Glass measurement = 200ml 2. Chilled water will continue to be dispensed after the rated capacity has been used, although this may be at slightly higher temperature. Product covered by these instructions: Capacity Capacity Boost Boiling Chilled (10A) (cups) (glasses) GPO's Required Power Rating (kW) Boost Rating (kW) Unit Dimensions W x D x H (mm) with air duct **Dry Weight (KG) 2.2 450 x 470 x 335 450 x 470 x 335 450 x 470 x 335 23 23 23 2.2 450 x 470 x 335 450 x 470 x 335 450 x 470 x 335 23 23 23 Boiling Chilled BC160/125 BC160/175 BC240/175 160 160 240 125 175 175 no no yes 1x10A 1x10A 2x10A 2.1 2.2 2.2 160 160 240 125 175 175 no no yes 1x10A 1x10A 2x10A 2.1 2.2 2.2 160 125 no 1x10A 2.1 450 x 470 x 335 23 160 175 no 1x10A 2.2 450 x 470 x 335 23 240 175 yes 2x10A 2.2 450 x 470 x 335 23 4 in 1 BCHA160/125 BCHA160/175 BCHA240/175 All in One AV160/125 A 160 /125 AV160/175 A 160 /175 AV240/175 A 240 /175 2.2 ** Add an extra 5 kg when full of water 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 9 of 40 Before Installation Before installing ensure that the following have been provided at the Installation site: • Review all the technical specifications. • Ensure the underbench can support the product weight when full of water, (allow an extra 5kg when full. ) • Sufficient space in the cupboard to install all of the undersink units in accordance with these Installation Instructions. Refer to technical specification for dimensions. Make allowance for a booster heater and / or water softener if required. Refer to section 3 & 4, for Installation instructions. • For Zenith HydroTap 160/125 &160/175 models, a 220-240Vac, 10A GPO will be required. For Zenith HydroTap 240/175 models, two 220-240Vac, 10A GPOs will be required. (One GPO is for the Zenith HydroTap and the other for the Booster heater). Note: Check all cable and hose lengths against inlet /outlet positions before proceeding (See section 5 for general layout). • A potable water supply connection with isolating valve inside the cupboard within reach of the braided hoses and positioned so that the connection point and the stop cock will not be obstructed when the undersink units are installed. • For the mains pressure All-IN-ONE, an external hot and cold water supply will be required. • If an external filtration or water softening device is required, then it is important to allow extra space for these items. • A cold water supply with a minimum working pressure of 172kPa (200kPa when a booster and /or filter softener is fitted) and a maximum working pressure of 700kPa connected via an isolation valve. • The fitting of an air flow duct, attached to the right hand side of the unit, requires a rectangular cut size of 284mm x 45mm, to provide adequate warm air displacement. See section 2. • The appliance must be placed with it’s base in a horizontal position. IMPORTANT! Do not proceed with the Installation if these requirements are not met. Special Tools Required: In addition to normal tools, the following will be required: For the standard and Mixer taps: • 35mm diameter sheet metal hole punch for sink tops. (Not supplied) • 35mm diameter hole saw for timber bench tops. (Not supplied) • Nut runner tube spanner (supplied) for fixing tap assembly. For the All-In-One tap: • 50mm diameter sheet metal hole punch for sink tops. (Not supplied) • 50mm diameter hole saw for timber bench tops. (Not supplied) • Nut runner tube spanner (supplied) for fixing tap assembly. Page 10 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Section 1 Tap Installation Hole positioning: Position the tap such that it dispenses into the sink bowl with ample clearance for a cup or tea pot. Alternatively, the tap could be mounted away from the sink using a Zenith Font, available as an accessory. TAP Elite HydroTap Classic HydroTap Arc/Cube All-In-One Mixer - Arc neck Mixer - Classic Mixer - Cube neck Recommended dispensing distance ** 116 mm 116 mm 171 - 174 mm (Extended) 211 mm 231 mm 270 mm 310 mm ** Check bowl depth and adjust accordingly For A-I-O 50mm and Mixer taps 35mm hole 116 Double Bowl For Elite,Classic and Arc/Cube 35mm hole Single Bowl 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 BC HydroTap Page 11 of 40 HydroTap Classic & Elite EliteTap Min 300mm HydroTap Classic 335mm ALL THREAD ROD STAINLESS STEEL SPACER BLACK PLASTIC SPACER SPIDER CLAMP 470mm NUT Tap assembly exploded view and kitchen layout side view. 1.1 BENCH TOP Ø35mm 1.2 Apply a light smearing of silicon sealant on the underside of the spacer to ensure a watertight fit. Cut a 35mm hole in the bench / sink top. Page 12 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Installation Instructions 1.4 1.3 BLACK PLASTIC SPACER Fit the STAINLESS STEEL WASHER, SPIDER CLAMP, AND 6mm NUT. STAINLESS STEEL WASHER SPIDER CLAMP 6mm NUT 35mm hole Pass all the hoses, tubes and USB lead through the 35mm hole. Note: feed each of the three tubes and electrical cable evenly in between the legs of the SPIDER CLAMP when installing. 1.5 Typical HydroTap Installation (see section 5) Red hose to boiling water outlet Blue hose to chilled water outlet Clear hose to Vent Incoming water Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Page 13 of 40 HydroTap Arc/Cube The HydroTap Arc/Cube has a spout that may be fixed in one of 6 angular positions (depending on the position of the rotary control) and fixed in one of two height positions. The spout is fixed and does not swivel. NOTE: The tube kit must be fitted after the HydroTap has been mounted on the benchtop or sink. Refer to the tube kit assembly instructions, supplied with the tap kit. To reduce the risk of scalding, Position A should not be selected with any of the Boiling water units. (See fig. 1.8) 1.6 To change the spout position Remove the 2 x spout locating screws and lower the spout to expose the plastic spring clip NOTE: The plastic spring clip has two internal dimples that may be positioned in the 6 upper or 6 lower, pre drilled holes in the spout (see diags. below & Figs. 1.7 & 1.8) 2. To reposition the spout, gently spread the plastic spring clip to release the dimples from the spout holes. When released, slide the clip on the spout so that it ends up between the two rows of holes. 3. Rotate the plastic clip on the spout to orient the dimples, so they are in line with the newly selected holes. NOTE: When determining which of the 6 holes are required for the new spout height and orientation, check the new plastic clip position will clear the undercut and that the wiring loom will not be pinched, when assembled. 4. Slide the plastic clip up/down to engage with the selected holes, making sure the two dimples engage simultaneously with the two selected holes. NOTE: The clip will not fit correctly if one dimple engages before the other. Both dimples must engage at the same time. 5. With the clip fitted to the newly selected holes, carefully raise the spout (ensure the wiring loom is a neat fit in the undercut and is located between the open ends of the clip) until the clip locating holes are Spout locating Undercut in line with the spout locating screws. screws (2) for loom 6. Replace the 2 x locating screws. 7. If mounting on an uneven surface, apply a light smearing of silicon sealant on the O ring to ensure a watertight fit. (See fig. 1.9) 8. Pass the assembly through the 35mm hole and position the tap so it discharges into the sink. Lower locating positions 9. Fit the lower rubber seal to the threaded extension. Clip locating 1. 10. Secure the tap in position with the metal washer and holes (2) nut. 11. Fit the tube kit, as supplied. Plastic spring clip Plastic spring clip Upper locating positions Dimples Page 14 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Installation Instructions 1.7 Height adjustment (Fixed position options) 50mm 1.8 Angular adjustment (Fixed position options) Left Hand Control Right Hand Control NOTE: Position A is not recommended with Boiling water units A 1.9 B C C B A Mounting (See table on Page 11 ) BENCH TOP O-RING LOWER RUBBER WASHER Ø35mm WASHER Cut a 35mm hole in the bench / sink top. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 NUT Page 15 of 40 Min 300mm Mixer Tap Installation BRAIDED HOSE x 3 Tap assembly exploded view and kitchen layout side view. 1.11 O-RING 1.10 SINK TOP LOWER RUBBER WASHER 35mm WASHER Cut a 35mm hole in the bench / sink top. NUT Note: make sure the tap location will allow the nozzle to drain into the sink. Red band Mixer Out Note: The mixer tap requires a Zenith Restrictaflow valve, as supplied, to be fitted in the cold water supply line, from the isolation valve tee piece, to the mixer tap. (See Fig. 1.13) Page 16 of 40 External Mains Blue band Mixer IN 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Installation Instructions 1.12 Installing the Mixer Tap (Classic, Arc and Cube) • Fit the O-ring into the recess on the underside of the Mixer tap. (Note: If mounting on an uneven surface, a light smear of silicone on the O-ring will ensure a water tight seal) • Pass the tap tubes and threaded extension through the 35mm hole and position the tap so that it discharges into the sink. • Fit the lower rubber seal to the threaded extension. • Secure the tap in position with the metal washer and Nut. • Affix the three hoses to the tap. Match the hose colours to the coloured bands on the copper extension tubes. (See diag. 1.11) Arc Mixer Tap Mixer tap Sink top O-ring Lower seal Washer Securing nut 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 17 of 40 Installation Instructions Typical HydroTap 4-in-1 Installation (see section 5) 1.13 POWER CORD USB CHILLED OUTLET MAINS IN CLEAR RED WHITE HydroTap Mixer Connections BLUE Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. MIXER OUT MIXER BOILING OUT IN BYPASS IN VENT BYPASS OUT Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Restrictaflow valve (Supplied) Tee piece (Supplied) COLD isolation valve (Not supplied) Note: The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened Page 18 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 All-In-One Tap Installation 335mm Min 300mm 1.14 470mm 1.15 SINK TOP 50mm Cut a 50mm hole in the bench / sink top. Note: make sure the tap location will allow the nozzle to drain into the sink. (See Page 11) Installation Procedure • Fit the seal ring to the base of the tap and If mounting on an uneven surface, apply a light smear of silicone sealant to ensure a watertight seal • Mount the tap on top of the cut out hole after passing the usb cable and tubes through the 50mm hole • Thread the cable and silicon tubes through the circular clamp block (Check the tube colour alignment with the coloured dots on the clamp block). (See fig 1.16) • Clamp the assembly in position using the threaded nut and clamp block • Working from inside the cupboard, attach the braided hoses to the tube extensions (ensure the seals on the end of the hoses are lubricated). Check the correct position for Hot and Cold connections by matching the colours on the braided hoses with the coloured markings on the copper extension tubes. (See fig. 1.18) • Test for leaks after all the connections have been secured. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 19 of 40 Installation Instructions 1.16 Clamp Block markings and silicon tube positions, viewed from underneath BLUE mark WHITE mark BLUE mark RED mark SILICON TUBES R B B R C C USB CABLE AIO Vented assy AIO Mains assy CLAMP BLOCK 1.17 O-RING Mains IN To Mixer IN From HWS connection Mains IN FIXING NUT B BLUE to Chiller connection From Mixer OUT RED to Boiling connection R RED to Boiling connection BLUE to Chiller connection R B CLEAR to vent C Page 20 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Installation Instructions Typical Vented assembly 1.18 • Screw the braided hoses into the extension tubes. Ensure the o-rings are lubricated prior to assembly and that the braided hoses, with coloured markings, are correctly matched with the colours on the extension tubes and on the clamp block (as indicated). Vented braided hose positions WHITE Mains IN CLAMP BLOCK Extension tubes • Make sure all tubes and hoses are firmly secured. RED from Mixer OUT BLUE to Mixer IN Mains braided hose positions BLUE Mains IN Braided hoses Underside view RED HOT IN from HWS Typical All-in-1 Mains Installation (see section 5) 1.19 Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. RED Hot Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm BLUE Chilled Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied External HOT & COLD isolation valves (Not supplied) Tee piece (Supplied) 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 21 of 40 Installation Instructions 1.20 Typical All-In-One Vented assembly with Booster heater Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. (See section 5) A-I-O Tap BC Unit Booster Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm 335mm Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied 400mm Restrictaflow valve & Tee piece (Supplied) Restrictaflow valve Note: The All-In-One vented taps require a Zenith Restrictaflow valve and Tee piece, as supplied, to be fitted in the cold water supply line, from the isolation valve (Not supplied), to the mixer tap. (See diagrams) Page 22 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Section 2 Ventilation When installing air flow ducts, the following tools will be required: • Jigsaw and 12mm Drill • Keyhole or Wall Board saw. Recommended Installation showing the correct air flow Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm MIN. 50mm Air Gap Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Cool Air IN via cabinet floor, front vent grille 2.1 **MIN. 100mm Warm Air OUT via kickboard louvre All Models Proper air circulation must be provided for all Boiling and Chilled models. The system will operate correctly only if the recommended air gaps are achieved during Installation. The vent duct and louvre panels must be installed for all under floor and /or door vent systems, as instructed. **Note: Inlet and outlet vents should be separated by a Min 100mm, to avoid hot air recirculation. IMPORTANT: See section 5.3 for clearances. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 23 of 40 Ventilation CUT OUT DETAILS 0 ATTENTION: Insure that: Cut outs 'A' and 'B' are on opposite side of cabinet. Cut out 'C' is straight behind'A' 12 .0 285.00 A - KICKBOARD CUT-OUT = 60.00 = 1.Drill 4 pilot holes Ø12 in corners 2.Finish cut-out using Jigsaw and Keyhole or Wall Board saw 314.00 B - CABINET FLOOR CUT-OUT max 43 5 .00 12 12 .00 Min 450mm 326.00 1.Drill two pilot holes Ø12 2.Finish cut-out using Jigsaw 45.00 C - CABINET FLOOR CUT-OUT A B 284 C For positioning of cutout C use the template marked on the cardboard carton 1.Drill 4 pilot holes Ø12 in corners 2.Finish cut-out using Jigsaw and Keyhole or Wall Board saw 12 .00 The following instructions are critical if the vent kit, as supplied, is not fitted: If the kick board vent kit cannot be used then it is important to fit a standard HydroTap vent kit, which ensures heat dissipation through natural convection via installed vents. For normal applications, where the cupboard space temperature is near 35°C, or higher, an auxiliary ventilation kit must be fitted. (Contact your local service centre for availability). Note: The vent kit has to be installed in a way that allows air to be drawn in from the bottom of the cupboard and expelled through the top of the cupboard. Therefore placement of the outlet vent should be towards the top of the door (Option 1) or on the upper side of the cupboard (Option 2). Side outlet vent (Option 2) Front inlet vent Door outlet louvre Warm Air OUT (Option 1) Cool Air IN Page 24 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Section 3 Booster Heater 3.1 Product Description The boost unit is a compact electronically controlled auxiliary water heater. It is intended to provide pre heating of water before it enters the Zenith HydroTap G4 boiling tank. The Booster is supplied as standard equipment with all 240 cup models. However, it may be later installed, as an accessory for the 160 cup models, to increase their delivery to 240 cups. Note 1: water connection :Blue marking - water in :Red marking - water out. The braided hoses cannot be lengthened. Note 2: The electrical cable length is 1.0 metre. Note 3: Position the Booster within reach of the fixed hose lengths, keeping the Booster as close as possible to the undersink unit inlet/ outlet fittings. Note 4: Ensure the Booster heater is mounted in an upright position (as shown) with a horizontal base Mount base Horizontally 400mm Booster Specifications: Nominal Power Rating Nominal Current Electric Supply 50Hz AC Elect flex and plug (black) - 1 meter length (with 90º Australian plug) Fixed Flow Rate Minimum water pressure 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Rating 2.2 10 230 10 Unit kW A V A 1.2 200 L/min kPa Page 25 of 40 Booster Installation 3.2 Installation Procedure Site requirements • Appliance must only be installed in a frost-free area. Never expose appliance to frost. • The Appliance is designed for wall mounted Installation and must to be installed with water connectors facing upwards. • The appliance complies with protection class IP 25. • The 400mm braided hoses supplied with the unit cannot be lengthened. • The 90° elbow hose ends, should be fitted to the inlet and outlet connections on top of the Booster. • The hot water outlet hose must be thermally insulated with the insulation provided. 3.3 1. 2. 3. 4. 5. To Remove / Install the appliance Insert a flat head screwdriver all the way into the lock. Gently angle the screwdriver upwards by approximately 10° as shown in the image below. Pull the appliance forwards by approximately 15° as shown. Carefully pull the appliance upwards to complete the removal process. Taking care not to break the lower clips To install; Place the appliance on the wall bracket and snap into position (See installation below). Note: Remove the backing plate for wall mounting Tilt Forward Lift UP Take care not to break the lower clips when removing or installing the Booster Release Installation Page 26 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Booster System Note 1: This appliance is intended for use with the Zenith HydroTap under sink unit. Note 2: Water connections must be pointing vertically upwards. Note 3: The booster unit should be installed as close as possible to the Zenith HydroTap Unit as the 400mm connection hoses cannot be lengthened. 3.4 Braided hose connections The cold water inlet (blue) and hot water outlet (red) are marked on the rating plate. Connect the braided hoses from the ‘Bypass Out’ fitting on the Zenith HydroTap, to the water inlet of the booster unit (Marked Blue) and from the outlet of the booster unit (Marked Red) to the ‘Bypass IN’ fitting on the Zenith HydroTap unit. Avoid exerting any mechanical pressure on the appliance. This can be achieved by applying a spanner on the flats of the inlet and outlet connections when tightening the braided hose connectors. Do not overtighten ! Tighten the braided hoses by hand, then turn an additional 90° - 180° with a spanner 2. Once the water connections have been made, check for any leaks and rectify as necessary. 1. Typical Installation Braided Hoses Strainer Cold Water Connection (inlet, G1/2”) Hot Water Connection (outlet, G1/2”) Hold the hexagon while tightening the braided hose fittings 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 27 of 40 Section 4 Filter / Softener Installation An external filter / Softener may be fitted to reduce the incidence of scale build up in the hot tank or may be at the customer’s request. 4.1 Mounting the filter head • Choose a suitable location, (cupboard back or side wall) within the reach of the braided hoses. • Mount the filter head bracket in an upright position, using the screws supplied in the kit • Ensure there is enough headroom for the filter cartridge to be easily fitted and removed. *Allow a Min 80mm base clearance • Attach the hoses as shown in section 5.5 - 5.7. Noting the flow directions as marked on the filter head. 4.2 Cartridge Installation 1. 2. Outlet Inlet 3. 4. 5. Filter Label 6. 7. 8. 9. 10. 11. *Min. 80mm Clearance Page 28 of 40 Unpack replacement cartridge, write today’s date where shown on the label and remove the sanitary cap. Avoid touching the filter O-rings and filter opening as this may cause bacterial contamination of the cartridge. Moisten the O-rings with water, align the front cartridge label to the left and push the new cartridge into the filter head. Turn the cartridge a quarter turn to the right until the cartridge comes to a complete stop, with the front label facing forward. Disconnect the filter outlet hose from the undersink unit and direct the hose end into a container ready for flushing. Turn the power and water ON and depress the tap’s Boiling lever and allow water to run for 30 seconds to flush the tank. Allow at least 10L to flow through the filter to ensure all carbon particles have been flushed. Turn the power and water off (after flushing 10L). Reconnect the filter outlet hose to the undersink unit. Turn the water supply back on and check for leaks. Set the appropriate selection on the Internal Filter Bypass valve located at the rear of the unit in accordance with Sections 5.1 and 5.2. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Section 5 Undersink Unit Installation Before you install an undersink unit, determine whether a water softener or an external filter is required. 5.1 External Bypass Valve The diverter bypass valve allows the user to choose to have the boiling water filtered either by the internal or by an optional external filter. This diverter valve is located at the rear panel of the Zenith HydroTap undersink unit on the filter door side, see the image below. NO EXTERNAL FILTER INSTALLED SELECT POSITION A 1 A 2 4 3 B 1 2 EXTERNAL FILTER INSTALLED SELECT POSITION B 4 3 PN: 801231 Check the table below to determine which filter bypass position you need for your product. If no external filter is installed, select position A If an external filter is installed, select position B B Rotate 90° only 1 1 A 2 4 2 4 Rotate 90° only 3 3 5.2 Hose and tube fitting. (Do not overtighten) • Remove all caps from the top of the undersink unit • Install the mains water braided hoses to the undersink unit before locating the unit in place. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 29 of 40 Installation Instructions POWER CORD USB CHILLED OUTLET MAINS IN CLEAR RED Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. BRAIDED Models BC 160/125 and BC 160/175 BLUE 5.3 MIXER OUT MIXER IN BOILING OUT BYPASS IN VENT BYPASS OUT Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm Max. 1000mm Min. 50mm Clearance Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Max. 500mm 400mm Note: The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened : Not required for standard BC HydroTap models. Page 30 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Installation Instructions USB CHILLED OUTLET MAINS IN CLEAR RED BRAIDED Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. POWER CORD Booster Model BC 240/175 BLUE 5.4 MIXER OUT MIXER BOILING OUT IN BYPASS IN VENT BYPASS OUT Booster option Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Note: The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened : Not required for standard BC HydroTap models 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 31 of 40 Installation Instructions POWER CORD USB CHILLED OUTLET MAINS IN CLEAR RED Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. BRAIDED Model All-In-One Mains Pressure BLUE 5.5 Booster MIXER OUT MIXER BOILING OUT IN BYPASS IN VENT BYPASS OUT Booster option Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Tee piece (Supplied) External HOT and COLD isolation valves (Not Supplied) Note: The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened Note: to activate the filter, flush at least 10L of water through the filter before connecting to a softener or to a Booster heater. : Not required for AIO mains pressure HydroTap. Page 32 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Installation Instructions POWER CORD USB CHILLED OUTLET MAINS IN CLEAR RED Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. HydroTap AIO Mixer Connections BRAIDED Model All-In-One Vented BLUE 5.6 Options MIXER OUT MIXER BOILING OUT IN BYPASS IN VENT BYPASS OUT Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Options Tee piece and Restrictaflow valve External COLD isolation valve (Not Supplied) Note: The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened Note: Take time to consider hose lengths when determining the mounting positions for the options 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 33 of 40 Installation Instructions Model HydroTap 4-In-1 Vented Note: All silicon tubes must be cut to size. They must have a constant fall back to the unit. POWER CORD USB CHILLED OUTLET MAINS IN CLEAR BLUE BRAIDED HydroTap Mixer Connections RED 5.7 MIXER OUT MIXER BOILING OUT IN BYPASS IN VENT BYPASS OUT Note: - Mains hose length is 750mm - Plug and Cord length is 1800mm Position the under sink unit close to the outlet tap, within reach of the hose and cord lengths supplied Tee piece and Restrictaflow valve (supplied) External COLD isolation valve (Not Supplied) Note: The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened Page 34 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Section 6 Commissioning • • • • • • Turn ON the water and check for any leaks. Turn the power ON at the GPO. If fitted, ensure the Booster is turned OFF. (The Booster is commissioned, later, at section 5.4) Familiarise yourself with the operation of the Tap, in preparation for use (See User Guide) Follow the Installation instructions below (and review Section C of the User Guide). After commissioning, the system may be customised by selecting further options in Section G Settings, within the User Guide. 6.1 - Select the Language Initial Commissioning screen Language selection screen 6.2 - Filter Flush Have a 10L bucket or similar container (not supplied) at the OPEN ready to hold a quantity of water that will be ejected while the Filter Flush Mode is in operation. Open the filter access door Stop cock on the front of the HydroTap and the filter cartridge will be operation exposed. Located to the rear RHS of the cartridge is a flush line, approx 600mm long and the flush line stop cock. Place CLOSED the valve end of the flush line into the 10L bucket or container. 1. 2. 3. 4. 5. Turn the stop cock ON Press [Start] [Stop] buttons to start and stop the filter flush. Allow at least 10 litres of water to flush through the filter. Once the filter flush is finished, Turn the stop cock OFF then press [Stop] to end filter flush mode. Press [Next] and the View screen will show the Flow calibration mode. NOTE: For any subsequent filter changes or any operational procedures, please refer to the HydroTap user guide, located inside the filter housing access door. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 35 of 40 Commissioning 6.3 - Flow Calibration Press the [Start] button and the tank will first empty then fill. This will take aprox 5 minutes. 2. Upon completion the actual pulse will be displayed. 3. Press [Next] for the Boiling Calibration screen. 1. 6.4 - Boiling Calibration • Press the calibration button and the system will commence the Boiling calibration procedure. This will take aprox 5-6 minutes. 6.5 - Booster • Upon completion, a Booster reminder screen will appear and allow you to return home by pressing the [Home] button. • Check the Date and Time settings (See Note below) Note: failing to make the correct selection for the “Booster”, will affect product performance. Note: Depending on your location you may need to re-set the internal clock. See section G of the user guide to check and if necessary, reset the Date and Time for your time zone. To enabled when a Booster unit is installed. HydroTap Booster Screen Page 36 of 40 1. Press the [MENU] button for main menu. 2. Press the [Install] button. 3. Press the [Booster] button. 4. In the next screen, press YES to enable the Booster. 5. Turn the Booster ON 6. Water must be run through the Booster for a min of 30 seconds, before the heater will activate. 7. Dispense boiling water for 30secs and check the Booster outlet hose is warm when the boiling water tank is replenishing. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Safety Sensor Calibration 6.6 - Sensor Light intensity varies from site to site, therefore it is recommended that a re-calibration be performed at the time of the installation. All direct natural sun light must be shaded from the HydroTap, during the calibration. This can be achieved by closing any nearby curtains, blinds, or by shielding the HydroTap with a dark cloth. 1. Pull both levers forward 2. 3. Safety sensor 4. 5. 6. 7. With the unit in Normal operating mode and with the safety enabled Turn the power OFF Pull both tap levers to the forward position Turn ON the power The unit will calibrate the safety switch Return the levers to the neutral position. To check the calibration, dispense Boiling water, in normal light conditions with the safety enabled. End of Life Disposal In order to help preserve our environment we ask that you dispose of this product correctly. Please contact your local city council for collection centre details. 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 37 of 40 Trouble Shooting System Fault Message Possible Cause Solutions Power board fault Interface fault Level board fault Condenser screen blocked Water leak, Isolate mains Compressor over-run Water supply failed Hot sensor Open Hot sensor Closed Cold sensor Open Cold sensor Closed Flood sensor Open Condenser sensor Closed Condenser sensor Open Heater fuse / driver fault Heater driver fault Compressor driver fault Hot sensor degraded Condenser over temp. Cold overload Steam is too cool Steam sensor Open Steam sensor Closed Hot overload Hot tank overfilled Outputs fuse fault Safety lock ON Safety lock OFF Hot Isolation ON Hot Isolation OFF Hot Isolation Enabled Hot Isolation Disabled Sleep mode Enabled Sleep mode Disabled Calibration Overload Reset Electrical disruption Internal fault Internal fault Blocked Air filter Water leak Compressor too Hot No water Internal fault Internal fault Internal fault Internal fault Internal fault Internal fault Internal fault Internal fault No hot water No chilled water Internal fault Blocked air filter Internal fault Internal fault Internal fault Internal fault Internal fault Internal fault Internal fault Safety button active Safety button Inactive Safety button active Safety button Inactive Safety button active Safety button Inactive Auto sleep mode active Auto sleep mode inactive Auto calibration reset Internal fault Check power supply and all fuses Call Zenith Service Call Zenith Service Remove blockage / Clean filter / check user guide Turn off mains water supply / Call for service Check ventilation Check water supply is turned ON Call Zenith Service Call Zenith Service Call Zenith Service Call Zenith Service Call Zenith Service Check Ventilation / Call Zenith Service Check ventilation / Call Zenith service Call Zenith Service Call Zenith Service Call Zenith Service Call Zenith Service Remove blockage / Clean filter / check user guide Call Zenith Service Call Zenith Service Call Zenith Service Call Zenith Service Turn OFF to reset / Call Zenith Service Call Zenith Service Call Zenith Service See User guide Section - G (Safety mode) See User guide Section - G See User guide Section - G See User guide Section - G See User guide Section - G See User guide Section - G See User guide Section - G (Energy Mode) See User guide Section - G (Energy Mode) Normal operation, once per month Call Zenith Service Call an electrician, a plumber, or Zenith on 0800 558055 for assistance, service, spare parts or enquiries. Page 38 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Notes 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01 Page 39 of 40 Contact Details Head Office Zenith Heaters Limited, IRD No. 95 640 729 Unit 2/15 Moselle Avenue, Henderson. Auckland. 0610 New Zealand. Website: www.zenithheaters.co.nz Int. Phone: +(64 9) 838 8612 Telephone: 0800 558055 Facsimile: 0800 559055 As Zenith 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. WMKA00099 AS 3498 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 “Zenith” and “HydroTap” are registered trade marks of Zip Heaters (Aust) Pty Ltd. Zenith 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 40 of 40 801314NZ - HydroTap BC, BCHA, AIO, Installation Instructions - August 2015 - V2.01
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