Zip 5053UK, 5061UK, HydroTap G4, 5261UK, 2924UK Installation Instructions Manual

1

Installation instructions

805845UK v1.02 July 2018 - G4 Command Centre

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VENTILATION

IS ESSENTIAL

READ SECTION 1

‘VENTILATION’

BEFORE YOU START

Installation instructions

Zip
HydroTap G4

The Worlds most advanced Drinking Water Appliance

Model :

Command Centre (see table of contents for specific models)

®

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Installation instructions

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Tap options

The G4 series offers a range of interchangeable taps to suit the customer's needs.

Classic range

Arc / Cube range

Elite range

All-in-One range

Mixer range

These standalone taps offer instant boiling, chilled
and sparkling water* and are directly compatible with
the G4 Command Centre.

The All-in-One tap may be used as alternatives to
the above HydroTap and mixer tap combinations*.

The mixer tap range may be used in conjunction with
any of the above to provide mixed hot and cold water
for sanitary use*.

Celsius range

The Celsius range offer instant boiling, chilled and
sparkling / boiling and chilled / boiling and ambient
/ chilled and sparkling / chilled or boiling* water
together with the an integral mixer to provide mixed
hot and cold water from the mains.

*Dependant upon model purchased.

3

Installation instructions

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HydroTap G4 specifications

Installation check list .................................................................................................................... 4

General product features ............................................................................................................. 5

Important safety instructions ........................................................................................................ 6

Warnings and regulatory information ........................................................................................... 7

Major components and accessories ............................................................................................. 8

Tap - Command Centre compatibility ........................................................................................... 9

Technical specifications ............................................................................................................... 11

Before installation and site requirements ..................................................................................... 12

Installation instructions
Step 1 -

Measure and cut all the tap holes, fit the taps : Refer to 803341UK Tap installation instructions.

Step 2

- Check for adequate ventilation.

Section 1 - Ventilation.

Section 1.1 - 1.9 Ventilation for all models ................................................................................... 13

Step 3

- Install the booster / scale filter / water block / carbonation valve (if required).

Section 2 - Booster installation ..................................................................................................... 21

Section 3 - Scale filter installation ................................................................................................ 24

Section 4 - CO2 cylinder installation ............................................................................................. 25

Section 5 - Water block installation .............................................................................................. 27

Section 6 - Carbonation valve installation .................................................................................... 29

Step 4

- Install the Command Centre.

Section 7 Commercial & residential Command Centre installation.

Section 7.1 - Generic Command Centre installation instructions ................................................. 30

Section 7.2 - External bypass valve ............................................................................................. 31

Section 7.3 - 5253UK & 5053UK BCS commercial installation .................................................... 33

Section 7.4 - 2957UK, 2857UK, 1456UK & 1256UK BCS comm. and res. compact installation . 38

Section 7.5 - 5261UK & 5061UK BC commercial installation ...................................................... 43

Section 7.6 - 2924UK, 2824UK,1414UK & 1214UK BC comm. and res. compact installation .... 48

Section 7.7 - 5200UK, 5201UK, 5000UK, 5001UK 1500UK, 1501UK, 1300UK,1301UK

BO, BA installation ....................................................................................................................... 53

Section 7.8 - 0053UK CS commercial installation ........................................................................ 60

Section 7.9 - 0061UK C commercial installation .......................................................................... 63

Section 7.10 - 0056UK CS residential installation ........................................................................ 66

Section 7.11 - 0015UK C residential installation .......................................................................... 69

Step 5

- Commission the HydroTap G4.

Section 8 - Commissioning

Section 8.1 - Generic commissioning instructions ....................................................................... 72

Section 8.2 - Select the language ................................................................................................ 72

Section 8.3 - CO2 purge ............................................................................................................... 72

Section 8.4 - Filter flush ............................................................................................................... 73

Section 8.5 - Boiling calibration .................................................................................................... 73

Section 8.6 - Booster enable ........................................................................................................ 73

Section 8.7 - Safety sensor calibration ......................................................................................... 74

Section 8.8 - System flush ........................................................................................................... 74

Trouble shooting

Trouble shooting table .................................................................................................................. 76

End of life disposal ....................................................................................................................... 77

Warranty ....................................................................................................................................... 78

Contact details ............................................................................................................................. 80

Table of contents

4

Installation instructions

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Before installation

• Read the instructions and check if there is adequate space to install all of the components.

• Note Not all fittings are supplied with the appliance kit. Isolation valves are not supplied.

• Check the mains water pressure is within min / max requirements (see page 11).

• Check the water quality to determine if extra filtration will be required.

• Note This product must be fitted to a wholesome water supply.

• Check the Command Centre rating plate and ensure correct power is available.

• Check the under counter cupboard floor supporting the Command Centre is adequate for its total
weight, when full of water.

Before commissioning

• Check the system has been installed correctly.

• Check all plumbing fittings for water tightness.

• Ensure the outlet and vent pipes are positioned to drain correctly.

• Ensure there is adequate ventilation.

• Check all tubes and pipes from the Command Centre to the tap have a constant rise and there are
no sags or kinks in the hoses.

• Check all electrical connections are correct and there are no loose wires.

Commission (see section 8)

• Flush the supply line before connecting.

• Turn on the water and check for leaks.

• Flush the filter(s).

• Activate / enable the booster (if fitted).

• Calibrate the safety sensor for boiling models.

• Where applicable, programme the Command Centre to suit the customer’s requirements.

Installation checklist

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Installation instructions

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Thank you for purchasing a Zip HydroTap G4. Please read and follow these instructions carefully to ensure
safe and trouble free operation. If help and advice is required, please call 0345 6 005 005.

What is the Zip HydroTap G4 ?

This Zip HydroTap G4

is an electronically controlled, filtered, boiling, chilled and sparkling (functionality is
dependant upon model purchased) drinking water system for the kitchen. The HydroTap G4 systems are
under counter drinking water appliances with a dispensing tap mounted on a sink or worktop, which have
been designed for commercial or residential applications. The HydroTap G4 utilises a conventional refrigerant
compressor to chill the water and an immersion heating element to boil the water.
These units are NOT designed to be used solely as sanitary fixtures.
The Zip HydroTap G4

models which dispense boiling water are fitted with a tap mounted safety lock. In
addition, there are various energy saving options accessible via the main menu. The system 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 undertaken safely, correctly and completely in order to utilise all the
benefits that the HydroTap G4

can provide. HydroTap G4

Classic taps can be ordered with the tap head

assembly for disabled use. The disabled levers are supplied with Braille caps for the visually impaired.

General product features

Command Centre

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Installation instructions

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IMPORTANT SAFETY INSTRUCTIONS

This manual contains important safety and installation instructions for the Zip HydroTap G4.
Please read all warnings, installation requirements and installation instructions before installing
any Zip HydroTap G4. This system must be installed in accordance with water supply byelaws,
current IEE regulations and relevant local authority byelaws.

Safety

This appliance is not intended for use by children under 8 years or persons (including children under 8 years)
with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have
been given supervision or instruction concerning the 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.

Refrigerant

The Zip HydroTap G4 Command Centre contains R134A refrigerant under pressure. Maintenance of the
refrigeration unit must be carried out by an accredited service provider or qualified refrigeration technician.

CO

2

You can have serious health problems if breathing air containing concentrations of CO2 up to 15000ppm
(1.5%) for more than 10 minutes. Proper ventilation must be provided to ensure that, in case of escape,
concentrations of CO2 remain below this level.

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 boiling water droplets may discharge through a vent outlet on the tap. If the tap
is not installed using the font, ensure the tap body is located so the tap outlet safely dispenses into the sink
bowl area.

Lifting

Take care when lifting. The Command Centre may exceed safe lifting limits. If you feel this is beyond your
personal capabilities, please seek assistance with the lift. The weight of the Command Centre is marked
on the packaging. Do not lift the Command Centre by the front cover or any of its connections. Refer to the
technical specification, see page 11, for the weight of the product.

Airflow

The Zip HydroTap G4 operates within the ambient temperature range 5ºC - 35ºC. Proper air circulation must
be provided. The system will operate satisfactorily only if the recommended air gaps are provided. See
Section 1 'Ventilation', page 13, for correct installation to prevent overheating. The vent kit supplied must be
fitted.

Altitude

Water boils at varying temperatures at different altitudes. The HydroTap G4 adjusts for this during startup
calibration and will recalibrate itself on a regular basis.

Frost protection

If the HydroTap G4 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.o

!

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Installation instructions

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WARNINGS AND REGULATORY INFORMATION

Warnings

• The Zip HydroTap G4 must be earthed. The resistance of the earth
connection from each exposed metal part must be less than 1Ω.

• 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 Zip product may void
warranty coverage.

• As the installer, it is your responsibility to supply (if necessary)
and install all valves as required by local regulations and relevant
standards.

• The HydroTap G4 is rated for 230V 50/60Hz AC operation (supply
frequency dependant upon model purchased).

• Do not remove the cover of the appliance under any circumstances
without first isolating the appliance from the power supply.

• Never locate the Command Centre near, or clean with water jets.

• Do not expose the Zip HydroTap G4 to the elements of nature.

• Due to the process of continuous improvement, Zip reserves the right
to change details mentioned in this manual, without notice.

• Visit www.zipwater.co.uk to ensure you have the latest copy of this
document.

!

IMPORTANT SAFETY INSTRUCTIONS

Positioning

It is important to ensure the Command Centre is positioned in an accessible area close to the floor level. The
Command Centre must have its base mounted in a horizontal position with all inlets and outlets facing up.
The tap must be located above the Command Centre. See Section 7, Command Centre installation.

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Major components and accessories

Accessories Description

Booster

(inc. connection

hoses)

Scale, taste &

odour filter

Scale filter

installation kit

(Filter not included).

Font, Integrated or

Stand alone

Replacement

internal 0.2 micron

filter

Disabled lever kit

(Classic HydroTap)

Mixer upgrade

All-in-One upgrade

(vented)

(mains)

Recommended

water block

Parts supplied Description

Tap options*

1 x HydroTap G4

1 x All-in-One

HydroTap G4

Mains or Vented

1 x mixer tap

Command Centre and components

Duct kit*

1 x Exhaust duct

1 x Mounting plate

2 x Outlet vent

1 x Inlet vent

1 x
Command Centre
with air and water

filters

1 x Mains water

connection hose

1 x Booster inc.

connection hoses

(supplied with

140 or 240 models)

1 x Installation

fittings (supplied

with vented mixer

tap models)

1 x User guide and

1 x Quick start guide

1 x Installation

instruction

801599 - HydroTap User Guide - Nov 2013 UK - V1.05 Page 1 of 20

ZIP HydroTap

User Guide

®

•

Tap Operation...................(Pages 2-5)

•

LCD Screen & Menu .......(Pages 6-18)

•

Maintenance.................... (Pages 18-20)

•

Date of Installation.........

Affix Model Number Label

Here

801599

BC160/125G4
BC240/175G4
BCH160/125G4
BCH240/175G4
AV160/125G4
AN160/125G4
AV240/175G4
AN240/175G4

801600 - Zip Quick Start Guide - October 2013 - V1.06

Parts Supplied Description Parts Supplied Description

1 off
Hydrotap Tap
and hoses

Duct kit
1x Air Duct

1 x Mounting

plate

1 off
Undersink Unit

with air and water-

filter

Vent kit

1 x Kickboard

louvre

1 x Door vent

louvre

1 x front vent grill

1 x Restrictaflow
valve and Tee
piece for Mixer

Taps

1 off
HydroTap
Booster heater
and hoses

(Supplied with
240/175 models)

1 off Mains water
connection hose

QUICK START GUIDE

Note: This quick start guide must be read in conjunction with
the main installation and user instructions

• Before proceeding, read the installation and user instructions

• Check all the components are present and correct.

• Check that you have all the necessary tools

• Ensure the underbench can support the product weight when full of water,

(Check the specifications in the main book and allow an extra 5-8kg when full. )

Before installing ensure the following have been provided at
the installation site:

• Sufficient space in the cupboard to install all of the undersink units in accordance
with these Installation Instructions. Refer to technical specification for dimensions. If
required, make allowance for a booster heater. (Refer to the main book, for detailed
installation instructions).

• A potable water supply connection with isolating valve inside the cupboard within
reach of the flexible braided hose and positioned so that the connection point and the
stop cock will not be obstructed when all the undersink units are installed.

• For Zip HydroTap 160/125 &160/175 models, a 220-240Vac, 10A GPO will be
required. For Zip HydroTap 240/175 models, two 220-240Vac, 10A GPOs will be
required. (One GPO is for the Zip HydroTap and the other for the Booster heater).

NOTE: Check the cable lengths and outlet positions before proceeding.

• A potable cold water supply with a minimum working pressure of 172kPa and a
maximum working pressure of 700kPa connected via an isolation valve.

• For the mains pressure All-IN-ONE, both a hot and cold water supply will be required.

• The undersink appliances must be mounted in upright positions as shown in the

diagrams.

IMPORTANT!

Do not proceed with the installation if these

requirements are not met.

STEP 1-

Prepare and fit the Taps

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 Zip Font, avail-
able as an accessory.

Apply a light smearing of silicon sealant
on the underside of the upper spacer to
ensure a watertight fi t.

For HydroTap and Mixer taps

cut a 35mm hole in the bench / sink top.

BENCH TOP

Ø35mm

HydroTap Tap

Mixer Tap

4-in-1

(If required)

NUT

LOWER RUBBER

WASHER

UPPER
RUBBER
WASHER

WASHER

BRAIDED
HOSE x 3

UPPER RUB-
BER WASHER

LOWER RUB-
BER WASHER

WASHER

NUT

White Hose
Ext. Mains

Blue band
Mixer IN

Red band
Mixer Out

O-RING

BASE
BLOCK
SPIDER

BASE
BLOCK
NUT

USB
CABLE

ALL
THREAD
ROD

NOTE: feed each of
the tubes and elec-
trical cable evenly in
between the legs of
the BASE BLOCK
SPIDER.

All-In-One Tap

(If required)

For AIO mains and vented Taps

Cut a 50mm hole in the bench / sink top.

NOTE: make sure the tap location will allow the nozzle to drain into the sink.

SINK TOP

50mm

ALL THREAD

ROD

STAINLESS
STEEL
WASHER

SPIDER
CLAMP

NUT

BLACK
PLASTIC
SPACER

NOTE: feed each of the three tubes and
electrical cable evenly in between the legs of
the SPIDER CLAMP when installing.

Fit the
STAINLESS STEEL
WASHER,
SPIDER CLAMP,
AND 6mm NUT.

6mm
NUT

SPIDER
CLAMP

Stainless
washer

Black plastic
spacer

35mm dia hole

Sink

O-RING

SINK TOP

Fit the O-ring to the underside of the AIO tap
then pass all hoses through the 50mm hole.

Chiller
connection
BLUE

From Mixer OUT to Tap - Vented version only

Boiler
connection
RED

Blue ring on
RHS mains IN to

Mixer IN

White ring
on LHS to

Mains in

Tap

O ring Base

Clear tube to Vent

For Accessories contact Zip:
Tel [phone]
Website: www.zipwater.co.uk

Email: [e-mail]

*Dependant on model purchased

9

Installation instructions

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Tap - Command Centre compatibility

Commercial B, BA, BC and BCS HydroTap G4 range

All-in-One Classic

Filtered Boiling and Chilled plus unfiltered Hot and Cold
Filtered Boiling, Chilled and Sparkling plus unfiltered Hot
and Cold

Filtered Chilled
Filtered, Chilled and Sparkling

Commercial C and CS HydroTap G4 range

HydroTaps

Filtered Chilled plus unfiltered Hot and Cold
Filtered Chilled and Sparkling plus unfiltered Hot and Cold

Celsius

Arc / Cube

Elite Classic

HydroTaps

Mixer taps

Classic Vented

+

Filtered Boiling
Filtered Boiling and Ambient
Filtered Boiling and Chilled
Filtered Boiling, Chilled and Sparkling

Plus unfiltered Hot and Cold.

Filtered Boiling plus unfiltered Hot and Cold
Filtered Boiling and Ambient plus unfiltered Hot and Cold
Filtered Boiling and Chilled plus unfiltered Hot and Cold
Filtered Boiling, Chilled and Sparkling plus unfiltered Hot
and Cold

Celsius & All-in-One Celsius Arc

All-in-One

Celsius Arc

Arc / Cube

Elite Classic

Celsius

Arc / Cube

All-in-One

Classic

Vented

Celsius

Arc / Cube

All-in-One

Classic

Mains

10

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Residential B, BA, BC and BCS HydroTap G4 range

Arc / Cube

Elite Classic

HydroTaps

Residential C and CS HydroTap G4 range

Filtered Chilled
Filtered, Chilled and Sparkling

Tap - Command Centre compatibility

Filtered Chilled plus unfiltered Hot and Cold
Filtered Chilled and Sparkling plus unfiltered Hot and Cold

Celsius

Arc / Cube

Celsius

All-in-One taps

All-in-One

Classic

Vented

Arc / Cube

Elite Classic

HydroTaps

Mixer taps

Arc Mains Cube Mains

+

Filtered Boiling
Filtered Boiling and Ambient
Filtered Boiling and Chilled
Filtered Boiling, Chilled and Sparkling

Filtered Boiling plus unfiltered Hot and Cold
Filtered Boiling and Ambient plus unfiltered Hot and Cold
Filtered Boiling and Chilled plus unfiltered Hot and Cold
Filtered Boiling, Chilled and Sparkling plus unfiltered
Hot and Cold

Celsius

Arc / Cube

Celsius & All-in-One Celsius Arc

All-in-One

Celsius Arc

Filtered Boiling and Chilled plus unfiltered Hot and Cold
Filtered Boiling, Chilled and Sparkling plus unfiltered Hot
and Cold

Plus unfiltered Hot and Cold

All-in-One

Classic

Mains

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Command

Centre

Capacity boiling

(167ml cups

/hr)

Capacity

chilled/

sparkling

(200ml

glasses/hr)

Power

rating

(kW)

230V

Boost
rating

(kW)
230V

Boost

(10A)

**13A sockets

required

Unit Dimensions****

W x D x H (mm) with air

duct

***Dry

weight

(kg)

Commercial Command Centres

Filtered Boiling, Chilled and Sparkling, with and without booster

5253UK

#

5053UK

160 / 240* 175 2.30 2.20 optional 1 / 2* 450 x 470 x 335 39

2957UK

#

2857UK

100 / 140* 75 2.13 2.20 optional 1 / 2* 338 x 461 x 335 30

Filtered Boiling and Chilled, with and without booster

5261UK

#

5061UK

160 / 240* 175 2.13 2.20 optional 1 / 2* 450 x 470 x 335 28

2924UK

#

2824UK

100 / 140* 75 2.05 2.20 optional 1 / 2* 280 x 470 x 335 22

Filtered Boiling and Ambient, with and without booster

5201UK

#

5001UK

160 / 240* - 1.90 2.20 optional 1 / 2* 280 x 313 x 335 13

Filtered Boiling, with and without booster

5200UK

#

5000UK

160 / 240* - 1.90 2.20 optional 1 / 2* 280 x 313 x 335 11

Filtered Chilled and Sparkling

0053UK - 175 0.45 - - 1 336 x 476 x 335 36

Filtered Chilled

0061UK - 175 0.3 - - 1 336 x 480 x 335 24

Residential Command Centres

Filtered Boiling, Chilled and Sparkling, with and without booster

1456UK

#

1256UK

1.7 2.2 optional 1 / 2* 338 461 x 335 30

Filtered Boiling and Chilled, with and without booster

1414UK

#

1214UK

1.55 2.2 optional 1 / 2* 280 x 470 x x335 21

Filtered Boiling and Ambient, with and without booster

1501UK

#

1301UK

1.43 2.2 optional 1 / 2* 280 x 313 x 335 13

Filtered Boiling, with and without booster

1500UK

#

1300UK

1.43 2.2 optional 1 / 2* 280 x 313 x 335 11

Filtered Chilled and Sparkling

0056UK 0.35 - - 1 280 x 405 x 335 30

Filtered Chilled

0015UK 0.13 - - 1 280 x 420 x 335 20

#

Supplied with venturi for vented mixer tap
* With boost
** One for the Command Centre, and one for the booster
*** Add 3 - 8Kg when full
**** Refer to Section 7, Command Centre installation, for clearance envelope.

Component Min. / Max. water supply pressure MPa (bar)

(in a G4 Hydrotap system)

HydroTap 0.17 (1.7) - 0.5 (5.0)

Sparkling Hydrotap 0.25 (2.5) - 0.5 (5.0)

Mixer tap 0.20 (2.0) - 0.5 (5.0)

Booster 0.20 (2.0) - 0.5 (5.0)

Scale filter 0.20 (2.0) - 0.5 (5.0)

Technical specifications

Water supply pressure requirements

12

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Before installation

Before installation ensure that the following have been
provided at the installation site

•

Review of all the technical specifications.

•

Ensure the under counter cupboard floor can support the product weight
when full of water (allow an extra 3-8kg when full).

•

Sufficient space in the cupboard to install the Command Centre and
other components in accordance with these installation instructions. See
Technical specification, page 11 for dimensions. Make allowance for a
booster if required. See sections 2 page 21 for installation instructions.

•

For Zip HydroTap G4 models without booster, 1 x 220-240V AC 13A socket
will be required.
For Zip HydroTap G4 models with booster, 2 x 220-240V AC 13A sockets will
be required.
(One socket is for the Command Centre and the other for the booster).

•

Both the Command Centre and booster must be installed in accordance
with IEE regulations, See Technical specification, page 11 for power
ratings.

Note Check all cable and hose lengths against inlet /outlet positions before

proceeding (see section 7 for general layout).

•

A wholesome water supply connection with a minimum working pressure
of: (see page 11 min. / max. water supply pressure) 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 Command Centre is installed.

•

For the All-in-One, Celsius and Mains mixer taps a hot and cold water
supply are required. (see page 11 for min/max. water supply pressure).

•

If external filtration or a lime-scale protection filter is required, then it is
important to allow extra space for it.

•

If pressure is likely to exceed 0.5 MPa (5 bar), install a 0.35 MPa (3.5
bar) pressure limiting valve.

•

The appliance must be placed with its base in a horizontal position.

•

Ensure proper ventilation for CO2, see Important safety instructions, page

6.

IMPORTANT!

Do not proceed with the installation if these requirements are

not met.

!

!

13

Installation instructions

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Section 1

Ventilation

Ventilation table of contents

1.1 Generic requirements ............................................................................................................. 13

1.2 BC,BCS Commercial Command Centre installation .............................................................. 14

1.3 BC, BCS Commercial compact Command Centre installation ............................................... 16

1.4 BO,BA Commercial and Residential Command Centre installation ....................................... 17

1.5 CS, C Commercial Command Centre installation .................................................................. 18

1.6 BC, BCS, CS, C Residential Command Centre installation ................................................... 20

Generic requirements

!

Important Read this section in conjunction with section 7 Command Centre installation,

page 30.

When installing air flow vents, the following tools will be required

•

Jigsaw and drill or equivalent equipment.

•

Keyhole or wall board saw.

1.1 Generic requirements

Clearance envelope

• A clearance envelope around all Command Centres must be provided to allow adequate
ventilation for the safe and effective use of the HydroTap G4 system.

!

535mm

50mm

50mm

Command Centre

width

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1.2.2 Preferred ventilation arrangement shown below.

The ducted vent kit supplied with the Command Centre exhausting through the kick-space should be used, to
provide adequate ventilation in all conditions. (Ancillary components are not shown in these diagrams).

A

B

C

100mm
min.

Inlet grille

Position vent grille on
either the kick board or the
cupboard ends

Inlet grille should be
fitted in baseboard

A

Cupboard back must be
fully closed to prevent
recirculation into
cupboard from
kick space.

1.2 BC, BCS Commercial Command Centres

Ventilation

1.2.1 Ventilation for all models

• The clearance envelope dimensions stated in the Specification sheets and Installation instructions must

be observed.

• Adequate ventilation must be provided to ensure that the cupboard temperature doesn't exceed 350C.

Vent cut-out details

A Air outlet vent

(flat vent)

B Air inlet vent

314

Ø

12 x 2

326

5

43max

285

60

Ø

12 X 4

=

=

45

284

Ø

12 x 4

C Ducted vent

15

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1.2.3 Alternative arrangement (Dual fan kit)

In situations where the preferred arrangement cannot be used or will not work effectively e.g.

• Single cupboard where the 100mm grille spacing cannot be achieved.

• Where there are openings in the back of the cupboard allowing exhaust air to recirculate into the cupboard

space.
An SP93156 Dual exhaust fan kit* must be fitted in either arrangement A or B shown below and connected to
the DIN socket on the Command Centre .

A Fan kit fitted to kick board and with kick space duct fitted to the Command Centre.
B Fan kit fitted to cupboard door (position B1) or side (position B2) and without kick space duct fitted to the

Command Centre.

*

For dual exhaust fan cut-out dimensions see the instructions provided with the kit.

B

A

B2

B1

Vent tray

100mm

min.

1.2 4 Alternative arrangement (Vent tray)

In situations where cupboard width is 1000mm or greater, without central pillar or where the rear of the
cupboard is not sealed and where vent grilles cannot be fitted in the kick board (e.g. hospitals) use a Vent
tray kit Call Zip on 0345 6 005 005.

A vent grille, supplied should be used as an inlet vent and fitted to the cabinet side (adjacent to the

Command Centre air inlet) as shown below. It must
take in air from the room or another ventilated
space. This space could be an adjacent cupboard,
(via a communicating port) on condition that it does
not contain a heat generating appliance. The vent
grille or the angled inlet grille supplied should be
fitted in the adjacent cupboard, observing 100mm
separation from the vent tray exhaust.

Ventilation

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1.3.1 Ventilation for all models

• The clearance envelope dimensions stated in the specification sheets and installation instructions must

be observed.

• Adequate ventilation must be provided to ensure that the cupboard space temperature does not exceed

350C.

1.3.2 Preferred arrangement

• The vent kit supplied with the Command Centre should be used to provide adequate ventilation by

convection in normal usage.

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. The outlet vent A should be towards the top of the door (position

A2) or side of the cupboard (position A1). (Where possible

air inlet vent and the air outlet vent should be positioned at
opposite ends of the same cupboard space).

A1

A2

Vent cut-out details

*A Air outlet vent

B

1.3.3 Alternative arrangement

In situations where the preferred arrangement does not
provide adequate ventilation by natural convection a Dual
exhaust fan kit* (SP93156) must be fitted to the cupboard
door or side (as shown in the illustration below) and
connected to the Command Centre DIN socket.

* For dual
exhaust
fan cut-out
dimensions
see the
instructions
provided with
the kit.

B

A1

A2

B Air inlet vent

Note Flat outlet vent detail shown above, louvred outlet vent

also supplied.

1.3 BC, BCS Commercial compact Command Centres

Ventilation

285

60

Ø

12 X 4

=

=

314

Ø

12 x 2

326

5

43max

17

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1.4.1 Ventilation for all models

• The clearance envelope dimensions stated in the specification sheets and installation instructions must
be observed.

• Adequate ventilation must be provided to ensure that the cupboard space temperature does not exceed
350C.

1.4.2 Preferred arrangement

• 4mm door buffers (at the four corners of each door) supplied with the Command Centre should be used
to provide adequate ventilation in normal usage, see illustration below.

Door buffer

1.4 BO & BA Commercial, BO & BA Residential Command Centres

Ventilation

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1.5.2 Preferred ventilation arrangements for CS models

The ducted vent kit supplied with the Command Centre exhausting through the kick-space should be used, to
provide adequate ventilation in all conditions. (Ancillary components are not shown in these diagrams).

1.5.1 Ventilation for all models

• The clearance envelope dimensions stated in the specification sheets and installation instructions must
be observed.

• Adequate ventilation must be provided to ensure that the cupboard space temperature does not exceed
350C.

B

A

C

100mm min.

Cupboard back must be fully

closed to prevent recirculation

into cupboard from kick space.

A

1.5 CS & C Commercial Command Centres

Ventilation

Vent cut-out details

A Air outlet vent

(flat vent)

B Air inlet vent

314

Ø

12 x 2

326

5

43max

285

60

Ø

12 X 4

=

=

45

284

Ø

12 x 4

C Ducted vent

19

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1.5.3 Alternative arrangement (Dual fan kit)

In situations where the preferred arrangement cannot be used or will not work effectively e.g.

• Single cupboard where the 100mm grille spacing cannot be achieved.

• Where there are openings in the back of the cupboard allowing exhaust air to recirculate into the cupboard

space.

An SP93156 Dual exhaust fan kit* must be fitted in either arrangement A or B shown below and connected to
the DIN socket on the Command Centre .

A Fan kit fitted to kick board and with kick space duct fitted to the Command Centre.
B Fan kit fitted to cupboard door (position B1) or side (position B2) and without kick space duct fitted

to the Command Centre.

*

For dual exhaust fan cut-out dimensions see the instructions provided with the kit.

B1

B2

A B

1.5.4 Alternative arrangement (Vent tray)

In situations where cupboard width is 1000mm or greater, without central pillar and where vent grilles cannot
be fitted in the kick board (e.g. hospitals) use a Vent tray kit (CS SP93541).

Vent tray

100mm

min.

A vent grille, supplied should be used as an inlet vent and fitted to the cabinet side (adjacent to the
Command Centre air inlet) as shown below. It must take in air from the room or another ventilated space.
This space could be an adjacent cupboard, (via a communicating port) on condition that it does not contain
a heat generating appliance. The
vent grille or the angled inlet grille
supplied should be fitted in the
adjacent cupboard, observing
100mm separation from the vent
tray exhaust.

Ventilation

20

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1.6.3 Alternative arrangement

• For high use applications where the cupboard space
temperature is near 350C or higher, the vent kit supplied can
be used to provide further ventilation by convection.

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. The outlet vent should be
towards the top of the door (position A1) or side of the cupboard
(position A2).
(Where possible air inlet vent and the air outlet vent should be
positioned at opposite ends of the same cupboard space).

1.6.1 Ventilation for all models

• The clearance envelope dimensions stated in the specification sheets and installation instructions must
be observed.

• Adequate ventilation must be provided to ensure that the cupboard space temperature does not exceed
350C.

1.6.2 Preferred arrangements

4mm door buffers (at the four corners of each door) supplied with the Command Centre should be used to
provide adequate ventilation in normal usage, see illustration below.

Door buffer

A1

A2

B

Vent cut-out details

A1 or A2 Air outlet vent

B Air inlet vent

Note Flat outlet vent

detail shown, louvred
outlet vent also supplied.

1.6 BC, BCS, CS, C Residential Command Centres

Ventilation

314

Ø

12 x 2

326

5

43max

285

60

Ø

12 X 4

=

=

21

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Note 5

Before you install a booster, determine whether an external water filter / softener is required. If an

external water filter / softener is required, the external bypass valve must be set correctly, see page 31.

Booster specifications

Rating Unit

Nominal power rating 2.2 kW
Nominal current 10 A
Electricity supply 50Hz AC 230 V

Electrical ex, white - 0.6m nom. length 13 A
Fixed ow rate 1.2 L/min

Section 2

Booster system

Mount base

horizontally

2.1 Product description

The booster system is a compact electronically
controlled auxiliary water heater. It is intended to

provide pre-heating of water before it enters the Zip
HydroTap G4 boiling tank. If the booster is used the
boiling water output will be increased.

Note 1 Water connection
blue cap - water in
red cap - water out.
The braided hoses cannot be
lengthened.

Note 2 The electrical cable
length is 0.6m.

Note 3 Position the booster
within reach of the fixed hose
lengths, keeping the booster
as close as possible to the
Command Centre inlet / outlet
connections.

Note 4 Ensure the booster
is mounted in an
upright position (as shown)
with a horizontal base.

22

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Booster system

2.2 Installation procedure

Site requirements

•

Booster must only be installed in a frost-free area. Never expose booster to frost.

•

The booster is designed for wall mounted installation and must be installed with water connectors
facing upwards.

•

The booster is protected against water ingress to class IP 25.

•

The 500mm braided hoses supplied with the booster 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.

Tilt forward Lift up

Release

Note Remove the wall mounting chassis from the rear of the booster for wall mounting.

Take care not

to break the

lower clips
when removing
or installing the

booster.

!

Attach

2.3 Booster installation see diagrams below

• To remove the mounting chassis, insert a flat blade screwdriver all the way into the lock.

• Gently angle the screwdriver upwards by approximately 10°.

• Pull the booster forwards by approximately 15°.

• Carefully pull the booster upwards to complete the removal process. Take care not to break the lower
clips.

• Attach the mounting chassis horizontally to the wall / cupboard wall.

• To install, clip the booster into the on the mounting chassis and snap into position (see installation
below).

Install

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Installation instructions

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Note 1 This appliance is intended for use with the Zip HydroTap G4 Command Centre
Note 2 Water connections must be pointing vertically upwards.
Note 3 The booster unit should be installed as close as possible to the Zip HydroTap G4 as the 500mm

connection hoses cannot be lengthened.

Booster system

2.4 Braided hose connection

s

• The cold water inlet (blue cap) and hot water outlet (red cap) are marked on the rating plate. Connect
the braided hoses from the ‘BYPASS OUT’ fitting on the Command Centre to the water inlet of the
booster (blue cap) and from the outlet of the booster (red cap) to the ‘BYPASS IN’ fitting on the
Command Centre. Avoid exerting mechanical force on the booster. This can be achieved by using a
spanner on the flats of the inlet and outlet connections when tightening the braided hose connectors.
Do not over-tighten ! Tighten the braided hoses by hand, then turn a further 90O to 180O with a spanner.

• Once the water connections have been made, check for any leaks and rectify as necessary.

Strainer

Cold water connection

(inlet, 3/8” BSP)

Hold the hexagon while
tightening the braided
hose fittings

Braided hoses

Hot water connection

(outlet, 3/8” BSP)

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Section 3 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
supplied at the customer’s request.

•

All information required to mount the filter head is available
separately in the following document :

•

Zip scale filter head installation and operating instructions
2017, supplied with the filter head.

3.1 Mounting the filter head

3.2 Cartridge installation and flush.

•

All information required to install and flush the cartridge is
available separately in the following documents:

•

Zip scale filter cartridge installation and operating instructions
2017, supplied with the filter cartridge.

•

Zip scale filter head installation and operating instructions 2017,
supplied with the filter head.

(From Bypass Out) Inlet

Outlet (To Bypass in)

Insert

Remove

Insert

Remove

Flush valve

25

Installation instructions

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STORAGE WARNING

The cylinder contains 1.2kg of CO2 and should be installed in a well ventilated area.

You can have serious health problems if breathing air containing concentrations of CO2 up to 15000ppm
(1.5%) for more than 10 minutes. Proper ventilation must be provided to ensure that, in case of escape,
concentrations of CO2 remain below this level.
See gas cylinder and MSDS sheet for complete list of warnings.

4.1 Secure the cylinder

Secure the gas cylinder supplied to a suitable wall, within 1 metre of the Command Centre, in an upright
position. This is undertaken by screwing the metal bar holding the hook-and-loop strap to a cupboard wall,
200mm above the floor or base of the cupboard. Make sure the gas cylinder can stand in place before
securing to the wall. Due to regulatory requirements the gas cylinder must be stored securely and in an
upright position.

4.2 Connect the regulator

Remove the gas cylinder from the strap. Make sure the regulator
knob is turned fully clockwise to the end-stop before fitting.
Screw the regulator (clockwise) onto the cylinder. Be aware that
some CO2 may be discharged from the connection between the
cylinder and the regulator when assembled together. Any CO2
released will be cold. Screw on the regulator to stop this leakage.

Note The leaking CO2 will be cold.

4.3 Connect the gas hose

Connect the threaded end of the braided gas hose to the regulator. Then connect the push fit fitting to the top
of the Command Centre via connection marked ‘CO2 IN’.
To turn the gas on, rotate the regulator knob anti - clockwise to
the end stop.

4.4 Test for gas leaks

Using soapy water perform a leak test. Apply the soapy water
to the gas connections using a sponge or brush. If any bubbles
appear and grow, there is a gas leak at the connection. Clean
away the soapy residue and tighten or refit the leaking connection. Make sure the gas is turned off when
tightening or refitting the leaking connection.
Refit the gas cylinder to the hook-and-loop strap. Ensure the cylinder is in an upright position.

!

Turn the knob fully

clockwise before fitting

the regulator

Closed

Open

Section 4

CO2 Cylinder installation

26

Installation instructions

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Note When removing hose, take care not to

lose plastic olive from the fitting.

After replacing a cylinder or
after making a gas connection,
perform a leak test to check for gas leaks

between regulator and cylinder, and between regulator and
braided hose.

Stage 1

• Turn the gas off.

• 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

• Turn the gas on.

• Inspect the joints for leaks.

• If any bubbles appear to grow, the joint will need to be

resealed and tested again.

Test for leaks at these two points

Leak test

CO2 Regulator

!

27

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Section 5 Water block installation

5.1 Description

• The Water Block is designed to be installed upstream of any Zip product and associated pipe-work
to minimise the potential for water leakage in the event of a system malfunction.

• The Water Block is ideal for limiting potential leakage and resulting water damage from water

heaters, water chillers etc. when tted in supply pipe work that is subject to mains water pressure.

• Once set, the Water Block will ensure that the volume of water that can ow through at one time is
limited to a pre-determined maximum, providing the ow rate through it exceeds 2 litres per minute.

• The Water Block also incorporates a non-return valve.

• The Water Block is WRAS approved.

5.2 Specication

5.3 Precautions

• The Water Block will help to contain leakage exceeding a rate of 2 l/min.

• Note The leakage at lower ow rates may not be detected by the Water Block and could remain

unchecked.

• Appropriate measures should be taken to contain leakage in these circumstances.

Flow control range 5 - 50 litres
Minimum / Maximum pressure 0.2 - 10.0 bar
Maximum ambient temperature 40ºC
Maximum water temperature 70ºC
Minimum operating flow rate 1.5 +/- 0.5 litres / min.
Inlet connection ¾" BSP female or 15mm
Outlet connection ¾" BSP male or 15mm

!

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Note. This device must be installed vertically with the

direction of ow downwards (inlet at the top , outlet at

the bottom. See Fig 1 adjacent).

• The Water Block should be installed in a convenient location on the water supply
line to the Zip product.

• Pointer ‘P’ (see Fig.3) should be rotated until in line with the maximum required

ow at one time. Each number on the scale corresponds to 5 litres of ow i.e. 1 =

5 litres, 10 = 50 litres.

• The adjustment key (see Fig.2) should be used to adjust the pointer.

• The inlet should be connected via an 15mm isolation valve (not supplied).

• The outlet shall be connected via the 15mm - 1/2” brass compression tting
supplied.

• Ensure that the direction of ow through the Water Block is correct and that

the lter screen (see Fig.2) is inserted correctly with the convex surface facing

towards the water supply.

5.4 Installation

Fig. 2

Fit key to adjust ow

Key

Reset lever

5.5 Reset Procedure

• The Water Block will activate and shut off the supply if more water than the set amount is drawn off
at one time.

• In this event rstly isolate and de-pressurise the water supply to the Water Block, identify and repair
the cause of the leak then remove the pipe-work downstream of the Water Block and press the reset
button ‘H’ (see Fig.3).

• The reset device (see Fig.2) may be tted to avoid disconnection. This allows the Water Block to be
reset by operating the lever in the direction shown in Fig.2.

• In the event of persistent tripping contact Zip for advice on 0345 6 005 005.

5.6 Maintenance

• The lter screen should be checked and cleaned periodically subject to water conditions and usage.

Fig. 1

Fig. 3

Direction of ow

Seal

Reset

device

Direction of

ow

Filter

screen

Isolation valve

(not supplied)

15mm - 1/2” brass

compression tting

Water block installation

!

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6.1 Description

The carbonation valve has been designed to provide the installer with the ability to preset the level of

carbonation of the sparkling water, to the taste of the user. The carbonation valve can be tted at the time of
installation, or retrotted to G4 Command Centres previously installed.

6.2 Installation

• Attach the carbonation valve to the Command Centre
using the 1/4” plastic tubing.

• Attach the sparkling pipe to the outlet .

water ow

Adjustment

Inlet

Outlet

+

-

6.3 Adjustment

The carbonation valve has an adjustable ow rate. The optimum setting for the valve is 1.6 litres/minute. Use a
6mm Allen key or large at blade screwdriver to adjust the ow rate of the valve.
To adjust the ow rate rotate the screw anti clockwise. Fitting this valve should reduce the splatter or spitting

of the sparkling water out of the tap. It should also produce more visible bubbles in the water. To measure

the ow rate, use a measuring cup and run the sparkling water for 15 secs. Multiply the amount of water
dispensed by 4 to get the ow rate per minute.

1.6litres/min. is the optimum ow rate.

If the ow rate is adjusted too high,

the carbonation can will be emptied
of water, leaving only CO2 to be

dispensed from the tap.

Section 6 Carbonation valve installation

• Fitted in sparkling systems only

!