Zip 802265 Installation Guide

Installation Instructions

®

Zip HydroTap

Filtered boiling, chilled and Sparkling drinking water for commercial kitchens and tea rooms.

BCS Compact models

Affix Model Number Label

Here

802265

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 1 of 28

Tap options

The HydroTap applaince series offers a range of interchangeable taps to suit the customer’s needs (See
options below). For ease of installation, it is recommended to fit the tap before installing the undersink unit.
The installation procedure for each of the taps is detailed in a separate tap installation instruction book No.
803341, supplied with the tap.
For all operational features of the HydroTap, please refer to the User manual No.802266.

Tap options:

These three taps are directly compatible with the G4
under bench unit.

The Mixer tap is an additional tap 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 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

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 and site requirements .....................................................................................10

Installation procedure:

STEP 1 -

(Refer to the Tap installation instruction book 803341)
STEP 2 - Check for adequate ventilation

Section 2 - Ventilation

STEP 3

Section 3 - Booster heater Installation

STEP 4 -

STEP 5

Section 5 - Undersink unit installation

STEP 6

Section 6 - Commissioning

Fit the tap to the benchtop or sink, before installing the undersink unit.

2.1 - Cut out details ..........................................................................................................11-13

- Install the Booster Heater (if required)

3.1 - Booster Heater specifications and Installation ..........................................................14-16

Fit the CO2 Gas cylinder

Section 4 - CO

4.1 - Connect and secure the 2.64kg CO

4.5 - Leak Test ..................................................................................................................18

- Install the undersink unit

5.1 - Check the external bypass valve setting ...................................................................19

5.2 - Mains water supply hose ..........................................................................................19

5.3 - Model BCS ................................................................................................................20

5.4 - Model BCSHA - AIO Mains .......................................................................................21

5.5 - Model BCSHAV - AIO Vented ...................................................................................22

5.6 - Model 5-IN-1 Vented .................................................................................................23

- Commission the HydroTap

6.1 - CO

6.2 - Filter Flush ................................................................................................................24

6.3 - Boiling Calibration .....................................................................................................25

6.4 - Booster activation .....................................................................................................25-26

6.5 - Sensor calibration .....................................................................................................26

6.6 - Check Date and Time settings ..................................................................................26

Cylinder

2

gas cylinder ....................................................17-18

2

Purge .................................................................................................................24

2

Trouble Shooting

Trouble Shooting Table ................................................................................................................27

End of life disposal .......................................................................................................................27

Contact details .............................................................................................................................28

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 3 of 28

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 250 - 700kPa
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 filters (This commences auto calibration for Boiling models)

10. Activate / enable the Booster (If fitted)

11. Purge the CO

12. Calibrate the safety sensor (for Boiling models)

13. Where applicable, programme the unit to suit the customer’s requirements.

Page 4 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

2

General Product Features

Thank you for purchasing a Zip HydroTap. Please read and follow these instructions carefully to ensure safe
and trouble free service. If service is required, please call 1800 638 633

What is the Zip HydroTap ?

The Zip HydroTaps are electronically controlled, filtered, Boiling, Chilled and Sparkling 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 (for BCS) an immersion
heating element to boil the water and all utilise a CO
on the model, these units will dispense boiling water (factory set to 98°C) 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, child safety lock. In addition, there are various energy
saving options accessible via the main menu. Each boiling unit is equipped with a self-calibrating program
which caters for altitude adjustment. The 2.64kg CO
nearest HydroTap agency for exchange, whereas the water filter is a disposable item. Both will require
periodic replacement and are 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. Each unit can be ordered with the Tap Head Assembly for Disabled use. The
disabled levers are supplied with Braille caps for the visually impaired.

gas cylinder to carbonate the chilled water. Depending

2

bottle is refillable and should be returned to your

2

Command centre

HydroTap BCS Compact

Din plug

(for accessories)

ON-OFF

Switch

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 5 of 28

Important Safety Instructions

This manual contains important safety, Installation instructions for the Zip 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 Zip 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 Zip 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 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. See section 2 for correct installation details

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.

ed

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. See page 12 for details.

Page 6 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Important Safety Instructions

WARNINGS

1.

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

2.

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.

3.

All Plumbing must comply with AS/NZS3500.

4.

All Electrical must comply with AS/NZS3000

5.

All Plumbing and Electrical connections must be made in accordance
with local regulations.

6.

This HydroTap product is rated for 230V 50Hz AC operation.

7.

Undersink units must never be located near, or cleaned with water jets.

8.

Zip HydroTaps are not to be exposed to the elements of nature

9.

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

2.64 Kg CO2 Cylinder Warnings:

•

Pressurised container.

•

Protect from sunlight.

•

Contains gas under pressure, may explode if heated.

•

Do not expose to temperatures exceeding 50˚C.

•

Do not pierce or burn, even after use.

•

Do not expose to naked flame or any incandescent material.

•

Keep out of reach of children.

•

High concentration of gas may cause asphyxiation.

•

Use only in ventilated areas.

•

Store in a location with a volume no less than 50 cubic meters for each

2.64 Kg bottle.

•

Use only in an upright position.

•

This bottle must be used with the approved pressure regulator.

•

Avoid shock.

•

Use according to MSDS. (Material Safety Data Sheet).

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 7 of 28

Major components and accessories

Parts supplied Description

1 off 4

HydroTaps

with hoses

(Classic tap shown)

1 off

HydroTap

Undersink Unit with

air and water filters

1 off

Mains water

connection hose

Vent Kit

1 x Inlet vent

1 x Outlet vent

9 x Screws

Accessories Description

Softener

and head assembly

Font Kit for

Arc & Cube Models

Font Kit for Classic &

Elite Models

Replacement Filter

User

Manual

Quick

start guide

1 x User manual and
1 x Quick start guide

1 off

CO

gas cylinder &

2

regulator assy.

HydroTap Booster

Water System with

connection hoses.

(Model BCSHAV

140/75)

1 x Restrictaflow

valve and Tee piece

for BCSHAV and

select models

Disabled lever Kit

5-in-1 upgrage Kit
(Arc mixer shown)

Page 8 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Technical Specifications

Glasses
of Chilled
Water per

Hour

Model

Cups of

Boiling

Water per

Hour

BCS 100 75

Models

BCS Boiling ; Chilled and Sparkling
BCSHA 5 in One
BCSHA-A All-In-One Mains option
BCSHA-AV All-In-One Vented option
D Disabled lever controls (optional accessory)

Note:

• the Cup measurement =167ml and the Glass measurement = 200ml

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

Boiling

(cups)

Capacity

Chilled

(glasses)

Boost
(10A)

GPO's

Required

Power
Rating

(kW)

Boost

Rating

(kW)

Boiling Chilled Sparkling

BCS100/75 100 75 no 1x10A 2.125 NA 339 x 460 x 335 30

Unit Dimensions
W x D x H (mm)

**Dry

Weight

(Kg)

All-In-One

BCSHA-A

100/75

BCSHA-AV

140/75

5-In-1

BCSHA

100/75

100 75 no 1x10A 2.125 NA 339 x 460 x 335 30

140 75 no 1x10A 2.125 2.2 339 x 460 x 335 30

100 75 no 1x10A 2.125 NA 339 x 460 x 335 30

** Add an extra 4-5 kg when full of water

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 9 of 28

Before Installation

Note

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 4-5kg 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 Zip HydroTap 100/175 models, a 220-240Vac, 10A GPO will be required. For Zip HydroTap
140/75 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 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 250kPa 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 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Section 2

Ventilation

When installing air flow ducts, the following tools will be required:

•

Jigsaw and 12mm Drill

•

Keyhole or Wall Board saw.

2.1

Ventilation for 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 minimum requirement is for a 50mm air
gap either side and 300mm above of the undersink unit.

It is important that the 4mm door buffers (For all installations ) are fitted to the inside edge of the cupboard
door to allow suficient air circulation inside the cupboard. (See the diagram below).

IMPORTANT:

See section 4 for clearances.

4 min.
Buffer Pad
Clear Gap

Min 300mm

460mm

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 11 of 28

Ventilation

2.2

The following instructions are critical if there is insufficient cupboard air

circulation.

If the air flow, using the silicon door buffers, is insufficient, it will be necessary to fit a standard HydroTap vent
kit, which ensures heat dissipation through natural convection via installed vents.

For high use applications, where the cupboard space temperature is near 35°C, or higher, the inlet vent
(See Item B below) and silicon buffers, need to be fitted. If the airflow is still insufficient to maintain normal
operating temperatures then the inlet vent and door outlet vent (See item D below) will need to be fitted.

Alternatively a fan kit may be installed, using the AUX din plug of the right hand side of the appliance
(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 or on the side of the cupboard.

Airflow through the cupboard

Warm air

OUT

Door outlet vent

Cutout details

1.

Drill four pilot holes
12mm dia.

2.

Finish the cutout using
a jig saw and keyhole
or Wall Board saw

D

Air inlet vent position

Cool air IN

B

Page 12 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Ventilation

Typical Cut out procedure for

1.

Mark out and cut the air inlet and door outlet holes as shown

2.

Ensure the air inlet vent and air outlet vent are positioned at opposite ends
of the same cupboard space.

3.

Fit the inlet vent, as shown and secure with 5 screws

4.

Fit the outlet vent, as shown in the hottest part (top) of the cupboard and
secure with 4 screws

B

D

B

Air inlet vent

Cutout deatils

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 13 of 28

Section 3

Booster Heater

3.1

The boost unit is a compact electronically
controlled auxillary water heater. It is intended
to provide pre heating of water before it enters
the Zip HydroTap G4 boiling tank. The Booster
is supplied with the BCSHAV model. However,
it may be later installed, as an accessory for the
BCS model, to increase its delivery.

Note1: water connection
:Blue marking - water in
:Red marking - water out.
The braided hoses cannot be
lengthened.
Note2: The electrical cable
length is 1.0 metre.
Note3: Position the Booster
within reach of the fixed hose
lengths, keeping the Booster
as close as possible to the
undersink unit inlet/ outlet
fittings.
Note4: Ensure the Booster
heater is mounted in an
upright position (as shown)
with a horizontal base

Product Description

Mount base
Horizontally

339 mm

Booster Specifications:

Nominal Power Rating 2.2 kW
Nominal Current 10 A
Electric Supply 50Hz AC 230 V
Elect fl ex and plug (black) - 1 meter length (with 90º Aus-

tralian plug)
Fixed Flow Rate 1.2 L/min
Minimum water pressure 200 kPa

Page 14 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Rating Unit

10 A

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

To Remove / Install the appliance

1.

Insert a flat head screwdriver all the way into the lock.

2.

Gently angle the screwdriver upwards by approximately 10° as shown in the image below.

3.

Pull the appliance forwards by approximately 15° as shown.

4.

Carefully pull the appliance upwards to complete the removal process. Taking care not to break the
lower clips.

5.

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

Release

Installation

Take care
not to break
the lower
clips when
removing or
installing the
Booster

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 15 of 28

Booster System

NOTE1: This appliance is intended for use with the Zip HydroTap under sink unit.
NOTE2: Water connections must be pointing vertically upwards.
NOTE3: The booster unit should be installed as close as possible to the Zip

HydroTap Unit as the 400mm connection hoses cannot be lengthened.

3.4

Braided hose connection

1.

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 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 Zip 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.

s

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

Page 16 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Section 4 - CO2 Cylinder

STORAGE WARNING:

A CO2 gas cylinder of 2.640kg must be installed in an open plan area or in an enclosed room, with a volume
no less than 50m
recommended ventilated area should be in proportion to the number of gas cylinders stored in that location.

A ventilated area is a non-enclosed area which could include the kitchen, living room etc.
See gas bottle and MSDS sheet for a complete list of warnings. (See: www.zipindustries.com)

3

. If more than 1 gas cylinder containing CO2 is present within the same location, the

4.1

After marking out the cradle location, secure it to a suitable wall, within 1 metre of the unit. Make sure the gas
bottle, regulator and cradle assembly can comfortably fit, with sufficient clearances, before securing the cradle
inside the cupboard. Due to regulatory requirements the gas bottle must be stored securely and in an upright
position. Secure the bottle with the hook-and-loop straps provided.

4.2

After removing all packing material, fit the regulator to the gas bottle as shown in the diagrams. Ensure the
plastic seal is fitted securely inside the large chrome nut, before attaching to the gas bottle. If the plastic seal
is not an easy fit over the spigot, soak it in hot water, before re-applying. Do not force the seal to fit.

Turn the regulator OFF by rotating the regulator knob, all the way out, in an anti-clockwise direction.

Secure the cylinder cradle

Connect the regulator:

NOTE: Two plastic seals are supplied with a new regulator. Only one is required, the other is supplied as

a spare part.

4.3

Connect the gas hose:

Connect the braided gas hose to the top of the underbench unit via the John Guest fitting marked ‘Gas IN’
Then connect the threaded end to the regulator (Do not lose the small sealing olive). When commissioning,
first, turn the regulator, grey knob, all the way out (anticlockwise). Then turn the gas ON by rotating the black
knob on top of the cylinder, anti-clockwise. Finally, adjust the outlet pressure by rotating the grey regulator
knob in a clockwise direction, to between 2.7- 3.0 bar (green zone)

NOTE:

sections.

The arrow should sit in the green zone of the regulator gauge; it should not fall in the red or yellow

4.4

Test for gas leaks:

When commissioning, use soapy water to 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.
Fit the gas bottle into the cradle and secure with the Hook-and-loop strap. Ensure the bottle is in an upright
position.

NOTE:

normal operating pressure of between 2.7- 3.0 bar be exceeded.

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 17 of 28

Care must be taken when working with high pressure carbon dioxide, and in no cases should the

CO2 Regulator

This gauge shows the pressure in the bottle
and indicates when the bottle is empty. Initial
bottle pressure will be 35-40 bar.

NOTE:

be careful not to lose the
small sealing olive in the
end of the braided hose.
This olive is necessary to
ensure a gas tight seal
between the braided hose
and the regulator.

This gauge shows the adjustable limit (2.7- 3.0 bar)
required for the HydroTap to function correctly

Green zone

Relief
valve

ON - OFF knob

Pressure regulating knob

4.5 - Leak Test

After replacing a bottle or after making a gas connection, perform a Leak Test:
Stage1:

1.

Turn the gas OFF

2.

Using soapy water applied with a sponge, or with a brush, cover all of the gas joints with a liberal
amount of suds.

Stage 2:

1.

Turn ON the gas

2.

Adjust the pressure to between 2.7- 3.0 bar

3.

Inspect the joint for leaks

4.

If any bubbles appear, the joint will need to
be resealed.

Page 18 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

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Undersink Unit Installation

NOTE:

5.1

Before you install a unit, determine whether a water softener or an external filter is required.

E

xternal Bypass Valve

The diverter bypass valve allows the user to choose to have the boiling feed water bypass the internal filter
and only be filtered by the external filtration. This diverter valve is located at the rear panel of the Zip HydroTap
undersink unit on the filter door side, see the image below.

If no external fi lter is installed, select position A

Check to determine
which filter bypass
position you need
for your product.

If an external filter is installed, select position B

5.2 Hose and tube fitting. (Do not overtighten)

•

Remove all caps from the top of the undersink unit (except the mixer caps)

•

Only remove the mixer caps if a mixer tap is to be fitted.

•

Fit the foam insulation to the Blue and to the White tubes after trimming them to length

•

Install the mains water braided hoses to the undersink unit before locating the unit in place.

John Guest fittings (Insertion and removal)

Be careful when cutting the poly tube so that there are no rough edges and that the tube is not distorted.

1.

Use a sharp knife to ensure the tube has a clean,
straight edge. Do not cut at an angle.

2.

Remove any swarf or unwanted material.

3.

Push the tube into the John Guest fitting making
sure all connections to the John Guest fittings are
pushed in past the “O”ring to full depth, at least
15-16mm.

4.

Check for a good joint by pulling back on the tube.
If the tube comes out, of the fitting, repeat the
above step.

5.

To remove the tube, press the collet into the fitting and at the same time pull back on the tube.

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 19 of 28

Installation Instructions

Note:

All

silicon tubes

must be cut to
size. They must
have a constant

fall back to the

unit.

5.3

MAINS INMIXER

Model BCS 100/75

BRAIDED

MIXER INBOILING

OUT

OUT

RED

BYP ASS INVENT BYPASS

CLEAR

OUT

BLUE

CHILLED

OUTLET

SPARKLING

WHITE

OUTLET

BRAIDED

USB

CO2

IN

Note:

silicon tubes

must be cut to
size. They must
have a constant

fall back to the

All

unit.

POWER

CORD

Note:

Note:

- Mains hose
length is 750mm

- Plug and Cord
length is 1800mm

Max.

1000mm

Position the under
sink unit close
to the outlet tap,
within reach of
the hose and cord
lengths supplied

Min.

50 mm side

Clearance

339mm

Max.

500mm

The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened

: Not required for standard BCS HydroTap models.

Page 20 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

5.4

Note:

All

silicon tubes

must be cut to
size. They must
have a constant

fall back to the

unit.

Installation Instructions

Model BCSHA 100/75 All-In-One (Mains)

Note:

silicon tubes

must be cut to
size. They must
have a constant

fall back to the

unit.

All

BRAIDED

MAINS INMIXER

OUT

RED

MIXER INBOILING

OUT

CLEAR

BYP ASS INVENT BYPASS

OUT

BLUE

CHILLED

OUTLET

SPARKLING

WHITE

OUTLET

BRAIDED

USB

CO2

IN

Note:

- Mains hose
length is 750mm

- Plug and Cord
length is 1800mm

POWER

CORD

Position the under
sink unit close
to the outlet tap,
within reach of
the hose and cord
lengths supplied

External HOT and COLD

isolation valves

(Not Supplied)

Note:

The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened

: Not required for standard BCSHA HydroTap models

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 21 of 28

5.5

Note:

All

silicon tubes

must be cut to

size. They must

have a constant

fall back to the

unit.

Installation Instructions

Model BCSHAV 140/74 All-In-One (Vented)

HydroTap

Mixer

Connections

BRAIDED

MAINS INMIXER

OUT

RED

MIXER INBOILING

OUT

Booster

BRAIDED

BRAIDED

CLEAR

BYP ASS INVENT BYPASS

OUT

BLUE

CHILLED

OUTLET

SPARKLING

OUTLET

WHITE

CO2

IN

Note:

silicon tubes

must be cut to

size. They must

have a constant

fall back to the

BRAIDED

POWER

USB

unit.

CORD

All

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)

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 Booster heater.

Page 22 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

5.6

Note:

All

silicon tubes

must be cut to
size. They must
have a constant

fall back to the

unit.

Installation Instructions

Model BCSHA 140/75 HydroTap 5-In-1 Vented

HydroTap

Mixer

Connections

Booster

Note:

silicon tubes

must be cut to
size. They must
have a constant

fall back to the

unit.

All

BRAIDED

MAINS INMIXER

OUT

Note:

- Mains hose
length is 750mm

- Plug and Cord
length is 1800mm

RED

MIXER INBOILING

OUT

BRAIDED

BRAIDED

CLEAR

BYP ASS INVENT BYPASS

OUT

BLUE

CHILLED

OUTLET

SPARKLING

OUTLET

WHITE

CO2

IN

BRAIDED

POWER

USB

CORD

Position the under
sink unit close
to the outlet tap,
within reach of
the hose and cord
lengths supplied

Restrictafl ow valve

(Supplied)

Note:

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 23 of 28

The tube lengths are matched to the pumps performance and therefore CANNOT be lengthened

COLD isolation valve

(not supplied)

Tee piece
(Supplied)

Section 6

Commissioning

The HydroTap is now ready to be commissioned.

•

Turn ON the water and gas and check for any leaks.

•

Turn the power ON at the GPO and at the side of the undersink unit

•

If fitted, ensure the Booster is turned OFF. (The Booster is commissioned, later, at section 6.4)

•

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).

•

Initially you will be prompted to select a language

•

After commissioning, the system may be customised by selecting further options in
Section G - Settings, within the User Guide.

6.1 - CO

Purge

2

1.

Press the [START] button to commence the purging
process.

2.

Purge for 10 seconds and ensure all water has stopped
flowing through the tap. (You will hear the CO
escaping from the tap).

3.

Press the [Stop] button.

4.

Press [Next] for the filter flush screen

gas

2

6.2 - Filter Flush

Have a 10L bucket or similar container (not supplied) at the ready to hold a quantity of water that will be
ejected while the Filter Flush Mode is in operation. Open the filter access door on the front of the HydroTap
and the filter cartridge will be exposed. Located to the rear RHS of the cartridge is a flush line, approx 600mm
long and the flush line stop cock. Place the valve end of the flush line into the 10L bucket or container.

1.

Press [Start] [Stop] buttons to start and stop the filter
flush.

2.

Turn the flush line stop cock ON (See diagram).

3.

Press [Start] and allow at least 10 litres of water to flush
through the filter.

4.

The product details will be displayed in the screen.

5.

Once the filter flush is finished, Turn the stop cock OFF
then press [Stop] to end filter flush mode.

6.

Press [Next] for the Boiling Calibration screen.

Page 24 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Commissioning

OPEN Position

ON

Stop cock
operation

CLOSED Position

NOTE: For any subsequent fi lter changes or any operational procedures, please refer to the HydroTap user
guide, located inside the fi lter housing access door.

OFF

6.3 - Boiling Calibration (Boiling models)

6.4 - Booster

•

Press the calibration button and the system will
commence the Boiling calibration procedure. This
will take aprox 5-6 minutes.

•

Upon completion, a Booster reminder screen will
appear and allow you to return home by pressing
the [Home] button.

NOTE: failing to make the correct selection for the “Booster”, will affect product performance.

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 25 of 28

Commissioning

To enabled when a Booster unit is installed.

Zip

BC Sparkling

Booster

Disable

10:30 Wed 14, Nov 2013

Enable

1. Press the [MENU] button for main menu.

2. Press the [Install] button.

3. Press the [Booster] button.

4. In the next screen, press button to enable the

A

A

Booster.

HOME

5. Water must be run through the Booster for a min of 30
seconds, before the heater will activate.

6. Dispense boiling water for 30secs and check the Boost­er outlet hose is warm when the boiling water tank is
replenishing.

6.5- Safety Sensor Calibration (Classic and All-In-One models)

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.

With the unit in Normal operating mode and with
the safety enabled

2.

Turn the power OFF

3.

Pull both tap levers to the forward position

4.

Turn ON the power

5.

The unit will calibrate the safety switch

6.

Return the levers to the neutral position.

7.

To check the calibration, dispense Boiling water,
in normal light conditions with the safety enabled.

6.6 - Date and Time check

Pull both levers

forward

Safety
sensor

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.

Page 26 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01

Trouble Shooting

System Fault

Possible Cause Solutions

Message

Power board fault Electrical disruption Check power supply and all fuses

Interface fault Internal fault Call Zip Service

Level board fault Internal fault Call Zip Service

Condenser screen blocked Blocked Air filter Remove blockage / Clean filter / check user guide

Water leak, Isolate mains Water leak Turn off mains water supply / Call for service

Compressor over-run Compressor too Hot Check ventilation

Water supply failed No water Check water supply is turned ON

Hot sensor Open Internal fault Call Zip Service
Hot sensor Closed Internal fault Call Zip Service
Cold sensor Open Internal fault Call Zip Service

Cold sensor Closed Internal fault Call Zip Service
Flood sensor Open Internal fault Call Zip Service

Condenser sensor Closed Internal fault Check Ventilation / Call Zip Service

Condenser sensor Open Internal fault Check ventilation / Call Zip service

Heater fuse / driver fault Internal fault Call Zip Service

Heater driver fault No hot water Call Zip Service

Compressor driver fault No chilled water Call Zip Service

Hot sensor degraded Internal fault Call Zip Service

Condenser overtemp. Blocked air filter Remove blockage / Clean filter / check user guide

A DC Pump is faulty Internal fault Call Zip Service

Steam is too cool Internal fault Call Zip Service

Steam sensor Open Internal fault Call Zip Service

Steam sensor Closed Internal fault Call Zip Service

Over Steamed Internal fault Call Zip Service

Hot tank overfilled Internal fault Call Zip Service

Comp Fuse/Driver Fault Internal fault Call Zip Service

Hot tank under filled Low water pressure Check water supply

Boil dry protection Safety activated Turn OFF / On power to reset

Flash Mem corrupted Internal fault Call Zip Service

Flow Sensor Fault Internal fault Call Zip Service

Call an electrician, a plumber, or Zip for a free call in Australia on 1800-638-633 for assistance, service, spare
parts or enquiries.

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.

802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01 Page 27 of 28

Contact Details

Head Office

Zip Heaters (Aust) Pty. Ltd.
ABN: 46 000 578 727
67 Allingham Street
Condell Park NSW 2200
Postal: Locked Bag 80
Bankstown 1885 Australia

Website: www.zipwater.com
Facsimile: [phone]
Telephone: [phone]
Free Call: 1 800 638 633

As Zip policy is one of continuous product improvement, changes to
specifications may be made without prior notice. Images in this booklet have
been modified and may not be true representations of the finished goods.

The standard cup referred to in this publication is 167 ml (6 fl oz).
The standard glass is 200 ml (7 fl oz).
The terms “Zip” and “HydroTap” are registered trade marks of Zip Heaters
(Aust) Pty Ltd.
Zip products described in this publication are manufactured under one or more
of the following patents: AU675601, AU637412, AU635979, GB0422305,
GB2065848, US4354049, US5103859, US5099825 and SA2006/08043. Other
patents are in force and patent applications are pending.

WMKA00099

AS 3498

Page 28 of 28 802265 - Sparkling HT- BCS Compact Commercial - Installation Instructions - 09.16 - v3.01