Zip Heaters Hydroboil Plus 3 Installation And Operating Instructions

Installation and Operating Instructions

Zip Hydroboil Plus

Filtered instant boiling water plus filtered ambient drinking water

03481 Zip Hydroboil Plus 3 Litre

®

85680 - February 2004
Page 2 of 16 Zip Hydroboil Plus- Installation & Operating Instructions - 85680 - February 2004

Read These Warnings First . . . . . . . . . . . . . .3

Installation Requirements . . . . . . . . . . . . . . .3

Installation Procedures . . . . . . . . . . . . . . . . .5

Step 1 – Positioning . . . . . . . .5

Step 2 – Fastening . . . . . . . . .5

Step 3 – Connecting . . . . . . .5

a) Plumbing . . . . . . . .5

b) Filtration . . . . . . . .6

c) Venting . . . . . . . . .6

5) Venting 6

d) Electrical . . . . . . . .7

Step 4 – Assembling . . . . . . .7

Step 5 – Commissioning . . . .7

Wall Mounting Diagram . . . . . . . . . . . . . . . .8

Electrical Diagram . . . . . . . . . . . . . . . . . . . . .8

Problem Solving . . . . . . . . . . . . . . . . . . . . . .9

Earthing Continuity Verification . . . . . . . . . . .9

Operating Procedures . . . . . . . . . . . . . . . . . .9

How to Replace the Filter . . . . . . . . . . . . . . .11

Information for Ambient Chilled Conversions .12

Connecting John Guest Fittings . . . . . . . . . . .13

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . .14

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Contents

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 3 of 16

Read These Warnings First

Please read all installation requirements, installation procedures and
precautions before installing any Zip Hydroboil Plus instant boiling water heater.

Never attempt to install any Zip Hydroboil Plus instant boiling water heater
without reading all of the applicable instructions.

In some hard water areas where mineral scale accumulation in the boiling
chamber of the Zip Hydroboil Plus may become a problem, consideration
should be given to the maintenance required. A suitable form of water
treatment may be necessary.

In areas where the water supply is known to have high sediment levels,
installation of a Zip Hydroboil Plus model equipped with sub-micron filtration is
not recommended. A model equipped with five micron filtration should perform
more satisfactorily.

All plumbing connections must be made in accordance with local plumbing
regulations.

The Zip Hydroboil Plus instant boiling water heater is not intended for use by
young children or infirm people without supervision.

Young children should be prevented from having access to ensure that they are
not able to use or play with the heater.

If the installation site is located more than 1000 metres above sea level, the
installer should contact Zip for high altitude thermostat.

This appliance must be earthed. If the power supply cord is damaged it must
be replaced by a Zip Service Provider or a qualified electrician.

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

Do not use strong, corrosive or abrasive cleaners to clean the case of the
heater.

Frost protection: If this heater is located where ambient air temperature could
fall below 5ºC when the heater is not in use, do not turn off the appliance
electrically. This safeguard does not offer the same protection to the connecting
pipework and fittings.

The ambient temperatures this unit should operate with is 5ºC - 50ºC.

This heater is intended only for indoor use and should never be installed
outdoors or be exposed to the elements of nature.

This unit must not be positioned in an area that may be cleaned by a water jet.
This unit must not be cleaned by a water jet.

Before installing, ensure that the following are available:

a) Sufficient space to position the heater so there is at least 150 mm

clearance above the heater for service access, 65 mm to its left and
20 mm to its right – the tap outlet usually should be positioned at least
200 mm above a draining board or drip tray.

Installation Requirements

Page 4 of 16 Zip Hydroboil Plus- Installation & Operating Instructions - 85680 - February 2004

b) Standard 220-240 volt power cable positioned as shown on the

paper mounting template for connection from the rear of the heater to the
terminal block within the heater, OR a standard 10 amp 220-240 volt
power outlet on the wall within 1500 mm of the heater. For units with 3.6
Kw element (25 ltr) or multi element units (40 ltr) an isolating switch in the
fixed wiring and attached to a secure surface is required.

This switch must provide all-pole disconnection and a contact seperation of
at least 3 mm installed in accordance with wiring rules.

c) Cold water supply with a minimum working pressure of 100 kPa and a

maximum working pressure of 700 kPa connected via an isolation valve.

d) Outlet drainage to a sink draining board or to a drip tray.

e) Access to drainage from a vent situated at the base of the heater.

If the water pressure is likely to exceed 700 kPa, a 350 kPa pressure
reducing valve must be installed in the cold water supply line.

f) In all installation instances the walls of the heater must be vertical and the

base horizontal, there can be no exceptions to this rule.

Installation Requirements Continued

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 5 of 16

3.0 Litre models 12.5 kg

5.0 Litre models 16.5 kg

7.5 Litre models 20.5 kg

COLD
INLET

VENT

OUTLET

INLET

POSITION

VENT

POSITION

250mm

Wiring

Concealed

Vent

Concealed

Inlet

45 mm

45 mm

Approximate Weight When Filled

Installation Procedures

Before You Begin

Locate the paper mounting-hole template packed with the heater.

Read the installation and operating instructions completely.

Decide whether to install with concealed or exposed plumbing and/or electrical
connections. Concealed connections are preferred for superior appearance.

Step 1 – Positioning

Position the heater so the tap will drain on to a draining board or drip tray.

Position the base of the tap to be not less than 200 mm above the draining
board (height should be increased only if essential for filling larger vessels).

Provide clearance for service access of not less than 150 mm top, 65 mm left,
20 mm right.

Mark corner positions for the heater on the wall so as to position the paper
mounting-hole template.

Step 2 – Fastening

Position mounting-hole template on wall and drill holes where shown.

Drill holes for water inlet, vent outlet and wiring if rear access is intended.

Remove cover fastening screws from heater and lift whole cover off heater.

Detach both nozzles from base of heater by removing fastening screws.

Install plumbing and wiring and prepare pipe ends and wiring ends as shown.

Screw heater chassis to the wall using screws or bolts suited to the wall.

Screws or bolts must be capable of supporting the heater weight when filled.
(See table to the left).

Step 3 – Connectinga) Plumbing

Connect cold water inlet pipe from base of heater to 15 mm-to-quarter­inch reducing bush (supplied) and then connect filtration system as instructed
below.

Important precaution:- All cold water inlet pipes must be flushed before
connection to avoid the risk of the heater clogging due to sediment or
metal fines.

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 6 of 16

b) Filtration

Fasten filter head assembly to an under-sink internal cupboard wall
as closely as possible to directly beneath the heater.

The filter should be positioned where it can be accessed readily for cartridge
changing. Allow 300 mm clearance beneath the filter for ease of access.

Fit an isolating valve (not supplied) to the water supply and connect to the
double-non-return valve (supplied).

Trim a length of quarter-inch flexible tube (supplied) to connect the outlet on
the double-non-return valve to the inlet on the filter head assembly. If
necessary fasten the tube to the wall with cleats provided.

Unpack the filter cartridge and write the date where shown on the label.

Avoid handling cartridge top whilst inserting into head.

Align cartridge tabs with the slots on the under-side of the filter head.

Slide cartridge up into head and rotate left to right one quarter turn until it
stops.

Fit the balance of the quarter-inch tube (supplied) to the outlet of the filter. To
purge air from the filter cartridge, run the tube to drain in the sink. Open the
isolating valve, and run water through the filter (into the sink) for 2 minutes or
until water flows freely.

Note: Freshly installed filters may cause water to appear milky. Water should
clear after running a few litres through the filter.

Turn isolating valve OFF and remove quarter-inch tube from the sink drain.

For superior appearance, fix a chrome plated tube between the sink top and
heater underside as a conduit for the flexible tube.

Trim the quarter-inch tube (supplied) to connect from the outlet of the filter
head assembly to the inlet of the 15 mm-to-quarter-inch reducing bush on
heater inlet. Fasten tube to wall using cleats provided.

Purging procedure

To purge air from a new filter cartridge, disconnect the quarter inch tube from
the outlet of the filter head, connect a temporary tube to drain into the sink,
and use the isolating valve to run water through the filter for two minutes or
until the water runs clear. Disconnect temporary tube and reconnect.

c) Venting

A vent at the base of the heater must be plumbed to a safe visible location as,
under certain conditions, it may discharge cold or boiling water and/or steam.

For exposed vent plumbing, connect vent outlet from the base of heater to a
15 mm or half inch OD pipe which has a continuous fall, is no more than 3
metres long, has no more than 3 right angle bends, and discharges to a waste
water drain.

For concealed vent plumbing, connect plumbing to the vent outlet from the
heater rear using a capillary elbow protruding 45 mm from the wall.

Alternatively attach a tun dish to the wall as shown and plumb away to waste.

Installation Procedures Continued

Filter head assembly mounted on
cupboard wall.

Heater inlet showing
connection with flexible tube.

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 7 of 16

Check previous steps. Turn water supply ON, check connections for leaks.

Push tap paddle inwards until water flows, release to stop flow of water.

Turn power ON. After a short period, boiling water will be available and will be
maintained close to boiling point thereafter. Initial heating periods are:

Warning: this appliance must be earthed.

Inlet water temperature 15°C 10°C

3.0 Litre models 16 minutes 17 minutes

5.0 Litre models 16 minutes 17 minutes

7.5 Litre models 23 minutes 24 minutes

d) Electrical

For concealed electrical connection, connect a power cable through the rear
access opening of the heater to the terminal block within the heater as shown.

For exposed electrical connection, connect the flex and plug (fitted to the
heater) to a standard 15 amp 220-240 volt power outlet on the wall within
1500 mm of the heater.

Do not turn the power ON until the heater is filled with water.

Step 4 – Assembling

Place the heater case back on to the heater and secure the top 2 case screws.
Place outlet nozzles on nozzle fascias at base of the heater and secure screws.
Secure two bottom case screws.

Step 5 – Commissioning

Installation Procedures continued

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 8 of 16

274 (1.5 L & 3.O L)

304 (5.0 L & 7.5 L)

38 (1.5 L & 3.0 OL)

53 (5.0 L & 7.5 L)

65 CLEAR

56

POSITIONING PIN

EXTERNAL PLUMBING

ELECTRICAL WIRING
POSITION

INTERNAL PLUMBING

72

15

25

35 42

COLD
INLET

VENT

BENCH TOP

318 5.O L
416 3.O L
448 5.O L
561 7.5 L

38 (1.5 L & 3.O L)

53 (5.0 L & 7.5 L)

150
CLEAR

19

20

Wall Mounting Template Dimensions

reset t.o.l.

thermostat

t º

element assembly

element

t.o.l.

fascia lights

Electrical Diagram

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 9 of 16

Following remedial service the earthing continuity of the heater must be
checked by a qualified technician using an appliance tester, or continuity tester
of accuracy Class 5 or better. Class 5 denotes an accuracy of 5% full scale
deflection.

1. Isolate power supply.

2. Set meter to 0 ohm with leads connected together.

3. Connect one test lead to the earth pin on the three pin plug.

4. Connect the other test lead to a bare patch of metal (preferably on the edge)
of the top of the cover, then to the front cover of the unit, and then to the tap
top under the plastic paddle. This can be achieved by inserting the probe up
from behind the paddle without losing water.

Warning- the water may be boiling - show extra care.

5. Test that in every instance the electrical resistance does not exceed 1 ohm.

Earthing Continuity Verification

TESTER
CONNECT BETWEEN THE
EARTH ON THE THREE PIN
PLUG OR EARTH CABLE
AND EXPOSED METAL
PARTS AS PER POINT 4 AT
RIGHT

Symptom Possible Cause Solution

Fails to dispense water.

Water isolating valve turned off.

Blocked filter, blocked meter tube,

blocked strainer, jammed ball valve

assy, airlock in transfer tube.

Check water supply valve.

Contact Zip Service Provider

Water not boiling.

No power.

Overload Tripped, faulty element, faulty

thermostat.

Check power supply.

Contact Zip Service Provider

Runs out of boiling water and fails to

refill.

Outlet tap drips.

Overflow from vent.

Excessive steam from vent.

Power “on” but no heat.

“Power on”, “Boiling water” light on

but no heat.

No heat, no”Power on” light.

Overload repeatedly tripping with

excessive steam.

Overload repeatedly tripping without

excessive steam.

No water from ambient button.

Internal adjustment.

Contact Zip Service Provider

Problem Solving

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 10 of 16

Reading Display Screen

Power On / Boiling Water

When the text 'Power On' is illuminated this indicates that the power is
connected and turned on and that the heater is operating normally.

Cleaning Case

Do not use strong, corrosive, spray or abrasive cleaners. Clean the case with a
soft cloth or brush and mild soap and water.

Tap Operation

Boiling water

Zip Hydroboil Plus is fitted with a two-way cool-touch safety tap for filtered
instant boiling water.

For filtered instant boiling water, gently press the lower end of the tap paddle
inwards.

Boiling water will flow until the tap paddle is released.

This operation gives fingertip flow control for safe filling of cups and mugs.

For filtered instant boiling water to fill larger vessels such as teapots and
saucepans, lift the tap paddle until it locks into a horizontal position.

Boiling water will flow until the paddle is returned to its normal vertical
position. This operation allows the vessel to be filled without holding your hand
where it may be affected by steam.

Drinking water

Zip Hydroboil Plus is also fitted with a chrome plated push button tap for
filtered drinking water.

For filtered drinking water, press the push button inwards. Filtered ambient
temperature water will flow until the button is released.

Filtered water dispensed by the Zip Hydroboil should be stored chilled as the
process of filtration removes chlorine from the water supply.

Operating Procedures

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 11 of 16

Depending on local water quality conditions and usage, the filter may require
changing every 6 to 12 months. You may also need to replace the filter if you
notice unpleasant odours or tastes, or if the flow rate of the tap is persistently
slow.

Some water may drip from the filter head (socket) and attached water lines
during replacement. Keep a bucket and towel handy to catch drips and mop up
any spills.

1. Locate service valve in the water supply line and turn off the water supply.

2. Grasp filter cartridge and twist right to left one quarter turn until it stops.

3. Ease cartridge downwards to detach it from the filter head (socket).

4. Do not tilt the cartridge as dirty water may spill from it if tilted.

5. Unpack replacement cartridge and write date where shown on the label.

6. Avoid bacterially contaminating cartridge top whilst inserting into head.

7. Align cartridge tabs with the slots on the under-side of the filter head.

8. Slide cartridge upward into head and rotate left to right until it stops.

9. Disconnect the filter hose from the heater inlet fitting and direct it into a
sink, bucket or similar receptical. Hold the tube in the receptical securely.

10. Open the service valve and flush the cartridge out to remove any loose
particles from the cartridge. When the water is clean and clear, shut the
service valve and reconnect the filter hose to heater inlet.

11. Open the service valve and check filter head for leaks. Refit if leaking.

12. Wipe up any spills and dispose of spent filter cartridge and packaging
thoughtfully.

Note: Freshly installed filters may cause water to appear milky. The water
should clear after running a few litres of water through the filter.

How to Replace the Filter

Filter Head

Filter Cartridge

To remove cartridge,
turn cartridge one
quarter turn right to
left, and draw
downwards.

To replace cartridge
align lugs on filter
cartridge with socket on
filter head. Push
upwards, turn one
quarter turn left to right
until secure

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 12 of 16

Information for Ambient Chilled Conversions

Hydroboil Plus Series 2003

Models: 3 Litre, 5 Litre, and 7.5 Litre. All filter configerations.

Removal of case assembly

NOTE: All procedures described below require the special key supplied with

your Hydroboil Plus.

1. Use the key supplied with your Hydroboil Plus heater and turn the chrome
plated locking ring anti-clockwise to remove it. The button will also be
released at this point.

2. The tap body retaining ring is now exposed, using the key, turn the ring
anti-clockwise and remove it. This now allows the case to be removed.

3. The removal of the case assembly will expose the chilled / cold outlet tap
assembly and access to the tap cartridge.

Cartridge Removal

To remove the tap cartridge use the key so the two (2) prongs locate in the
cartridge retainer screw. This is also to be turned anti-clockwise to remove it.
Once removed, the tap cartridge can be extracted from the tap body.

Flow Adjustment

Adjustment for flow from the chilled / cold outlet is achieved by turning the
flow adjuster located at the end of the cartridge with a flat blade screwdriver.
Turning clockwise increases flow, where turning anti-clockwise decreases flow.

Re-assembly of the tap is the reverse of the dismantling proceedure. Ensure
when locating the cartridge assembly in the tap body the transfer pipes on the
base of the cartridge slip into their locating holes in the tap base. Failure to do
this will cause damage to the cartridge.

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 13 of 16

Connecting John Guest Fittings

Ambient / Filtered water supply

Refer to diagram at left for setup of a Hydroboil with connection to a
ambient / filtered water supply.

This product layout is a “as supplied” configuration from factory.

In this configuration the 1/4” bulkhead fitting is not used, please do not
connect to it.

Chilled water supply

Refer to diagram at left for setup of a hydroboil with connection to a chilled
water unit.

1. When using water from a Zip chiller unit, ensure that the relief valve
supplied has it’s outlet plumbed away to a safe waste relief point as per
local regulations.

2. The tap body is to be wrapped with 1/8” x 2” cork insulation tape for
moisture protection.

3. The outlet pipe from the chilled water supply is run up to the 1/4” bulkhead

connector. It is situated just in front of the cold inlet and vent entries. If
possible, insulation of the line from the chiller to the bulkhead fitting will
help the chilled water remain at it’s best usable temperature.

4. Internal changes will be the removal of the 1/4” branch pipe leading to
the button assembly and a plug inserted into the “t” piece at the branch.

5. A new section of tube is needed approximately 40mm longer than the
existing piece to connect from the elbow to the internal side of the bulk
head fitting. In some smaller models the alternate pieces may be a series
of fixed elbows and tubing.

Note: The bulk head connection is only used when chilled water is required to
be dispensed. If ambient water is required you leave the unit in the “as
supplied” configuration.

Information for Ambient Chilled Conversionscontinued

cold
inlet

vent
outlet

cold
outlet

cold
inlet

chilled
water
supply

vent
outlet

chilled
outlet

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 14 of 16

Spare Parts

Key Part No Description

1 90487 Cistern Lid Clamp kit 2000B

2 90488 Cistern Lid and Gasket kit 2000B

3 90490 Gasket kit Hydroboil 2000b

4 90083 Float valve kit w/ seals

5 90069 Jumper valve kit w/ seals

6 90102 Cistern float kit w/ nut and screw

7 90493 Metering tube kit 1500w 2000B

90494 Metering tube kit 2400w 2000B

8 90495 Banjo screw Hydroboil 2000B

9 90496 O-Ring kit Hydroboil 2000B

10 90574 Fascia lens kit 2000B (coated)

11 90561 PCB Lights kit

12 90454 Thermostat

13 90127 Overload kit Hydroboil 2000B

14 90560 Tap Handle Kit (Coated)

15 90562 Outlet Nozzle Kit (S/S)

16 90503 Strap and key kit 1.5 & 3L 2000B

90504 Strap and key kit 5 & 7.5L 2000B

17 90505 Tap nut kit Hydroboil 2000B

18 90509 Tap body kit Hydroboil 2000B

19 90485 Element kit 1500W / 240V 2000B

90486 Element kit 2400W / 240V 2000B

20 90491 Clean hole cover kit

21 90492 Drain cap & seal kit

22 90587 Sensor Probe Kit

23 90107 Filter kit Cold Inlet Bush

24 90223 Cartridge Valve Kit

25 90593 John Guest Fittings Kit

26 90592 Conversions Kit Ambient to Chilled Unit

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 15 of 16

Spare Parts

1

2

4

3

5

7

8

9

16

17

18

19

25

26

10

20

15

14

13

11

12

24

6

25

26

21

23

Zip Hydroboil Plus - Installation & Operating Instructions - 85680 - February 2004 Page 16 of 16

Head Office

Franke Kitchen Systems (Pty) Ltd
1194 South Coast Road,
Mobeni 4060 South Africa
Postal Address: P.O. Box 72395
Mobeni 4060 South Africa

Tel: [phone]
Fax: [phone]
E-Mail: Linda Serrao
www.franke.co.za

Gauteng

Franke Kitchen Systems (Pty) Ltd
13th Road
Erand Gardens Midrand 1685
Postal Address: PO Box 11284
Vorna Valley 1686 South Africa

Tel: [phone]
Fax: [phone]
E-mail: Nico Claase www.franke.co.za

Cape Town

Franke Kitchen Systems (Pty) Ltd
Unit 25/49
Cnr Freedom & Koeberg Road
Milnerton 7441
Postal Address: PO Box 34
Milnerton 7435 South Africa

Tel: [phone]
Fax: [phone]
E-mail: Mark Stoltz
www.franke.co.za

Port Elizabeth

Shop 2, Block E
Figtree Access Park
Cnr William Moffat & Circular Drive
Walmer
Postal Address: PO Box 2473
North End 6056

Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
www.franke.co.za

The Zip appliance you have chosen is precision-built from the finest materials
available and should give many years of trouble free service.

Certain warranties may be implied by law into your contract with Zip. The
warranty provided below is additional to these implied warranties and nothing
set out below shall limit your statutory rights or rights at law.

Zip Heaters (Aust) Pty Ltd warrants that, should any part fail within 12 calendar
months of installation, that part will be repaired or replaced free of charge by
Zip or its Distributor or Service Provider, except as set out below, provided the
appliance is installed and used strictly in accordance with the instructions
supplied, and that failure is not due to accident, misuse, abuse, unsuitable
water conditions, or to any alteration, modification or repair by any party not
expressly nominated by Zip.

No costs are payable by the customer other than any mileage or travelling-time
charges incurred by a Zip Service Provider or the cost of removal, cartage and
re-installation of any component of the appliance if it needs to be returned for
repair to Zip or its Distributor.

This warranty does not cover damage resulting from non-operation of the
appliance or consequential damage to any other goods, furnishings or property.

No warranty applies to the life of any filtration cartridge installed with the
appliance as cartridge life may vary according to water quality and the rate of
water consumption.

Zip does not exclude, restrict or modify any liability that cannot be excluded,
restricted or modified or which cannot, except to a limited extent, be excluded,
restricted or modified as between the owner or user and Zip under the laws
applicable.

Furthermore, this warranty does not displace any statutory warranty, but, to the
extent to which Zip is entitled to do so, the liability of Zip under any statutory
warranty will be limited at Zip's option to the replacement of the appliance or
supply of equivalent appliance, the payment of the cost of replacing the
appliance or acquiring an equivalent appliance, or the payment of the cost of
having the appliance repaired or the repair of the appliance.

Registering Your Purchase

Registering your Zip installation on the Zip website may help to establish date
of installation should it become necessary to service the appliance under terms
of the Zip warranty. To register your installation go to www.zipheaters.com and
look under the heading "Warranty".

Warranty Information

The standard cup referred to in this publication is 167 ml (6 fl oz).
The terms "Zip" and "Hydroboil" 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, and
US5099825. Other patents are in force and patent applications are pending.