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Zip HydroTap BCS160, Installation Instructions Manual

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Zip HydroTap BCS160 Installation Instructions Manual Download Page 22

Page 22 of 40 

   801910 - Zip Sparkling HydroTap - Installation Instructions - July 2014 - v1.00

Booster Specifications:

 

Rating

Unit

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)

10

A

Fixed Flow Rate

1.2

L/min

Section 3 

Booster Heater

Mount base 
Horizontally

 

3.1 

Product Description 

The boost unit is a compact electronically 
controlled auxiliary water heater. It is intended to 
provide pre heating of water before it enters the 
Zip HydroTap G4 boiling tank. The Booster is 
supplied as standard equipment with all 240 cup 
models. However, it may be later installed, as an 
accessory for the 160 cup models, to increase 
their delivery to 240 cups.  

400mm 

Note1: 

water connection 

:Blue marking - water in     
:Red marking - water out.
The braided hoses cannot be 
lengthened.

Note2:

 The electrical cable 

length is1.0 metre. 

Note3:

 Position the Booster 

within reach of the fixed hose 
lengths, keeping the Booster 
as close as possible to the 
underbench unit inlet/ outlet 
fittings.

Note4:

 Ensure the Booster 

heater is mounted in an 
upright position (as shown) 
with a horizontal base 

Summary of Contents for HydroTap BCS160

Page 1: ...1 00 Page 1 of 40 Zip HydroTap Installation Instructions Filtered boiling chilled and Sparkling drinking water for commercial kitchens and tea rooms Chilled Sparkling model Boiling Chilled Sparkling model Mixer Tap HydroTap AIO Tap Affix Model Number Label Here 801910 ...

Page 2: ... Booster heater Installation 3 1 Booster Heater specifications and Installation 22 24 STEP 4 Mount the external filter softener if required Section 4 Filter Softener installation 4 1 Mounting the filter head cartridge Installation 25 STEP 5 Fit the CO2 Gas cylinder Section 5 CO2 Cylinder and Regulator 5 1 Connect secure and test the CO2 gas cylinder 26 27 STEP 6 Install the underbench unit Section...

Page 3: ...en 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 underbench 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 7...

Page 4: ...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...

Page 5: ...ight 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 an area no less than 100 cubic meters for each 2 64 Kg bottle Use only in an upright pos...

Page 6: ...1 x Air Duct 1 x Mounting plate Vent Kit 1 x Kickboard louvre 1 x Door vent louvre 1 x Front vent grill 1 off HydroTap Booster Heater hoses Supplied with 240 175 models 1 x Restrictaflow valve and Tee piece for Mixer taps 1 x User guide and 1 x Quick start guide 1 off CO2 gas cylinder regulator assy Accessories Description HydroTap Booster Water System with connection hoses Softener and head assem...

Page 7: ...167ml the Glass measurement 200ml Product covered by these instructions Add an extra 5 8 kg when full of water Capacity Boiling cups Capacity Chilled glasses Boost 10A GPO s Required Power Rating kW Boost Rating kW Unit Dimensions W x D x H mm with air duct Dry Weight Kg Boiling Chilled Sparkling BCS160 175 160 175 no 1x10A 2 30 NA 450 x 470 x 335 29 BCS240 175 240 175 yes 2 x 10A 2 30 2 20 450 x ...

Page 8: ...the Booster heater NOTE Check all cable and hose lengths against inlet outlet positions before proceeding See section 6 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 underbench units are installed For the mains pressure All ...

Page 9: ...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 When installing a font unit the following will be required 108mm diameter sheet metal or hole saw to suit surface being cut Hole positioning Position the tap such that it dispenses into the sink bowl with ample...

Page 10: ...ilicon sealant on the underside of the spacer to ensure a watertight fit 1 2 Cut a 35mm hole in the bench sink top BENCH TOP 1 1 Ø35mm ALL THREAD ROD STAINLESS STEEL SPACER SPIDER CLAMP NUT BLACK PLASTIC SPACER Tap assembly exploded view and kitchen layout side view 470mm 335mm HydroTap Tap Installation Min 300mm ...

Page 11: ...ACER 1 3 Pass all the hoses tubes and USB lead through the 35mm hole 35mm hole 1 4 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 STEEL WASHER White sparkling Blue chilled ...

Page 12: ...BER WASHER UPPER RUBBER WASHER Tap assembly exploded view and kitchen layout side view WASHER BRAIDED HOSE x 3 Mixer Tap Installation 1 7 UPPER RUBBER WASHER LOWER RUBBER WASHER WASHER NUT White Hose Ext Mains Blue band Mixer IN Red band Mixer Out Note The mixer tap requires a Zip Restrictaflow valve as supplied to be fitted in the cold water supply line from the isolation valve tee piece to the mix...

Page 13: ...ixer Connections RED CLEAR BLUE BRAIDED Note All plastic tubes must be cut to size They must have a constant fall back to the unit Restrictaflow valve Supplied Typical HydroTap 5 in 1 Installation see section 6 Tee piece Supplied POWER CORD USB CHILLED OUTLET MAINS IN MIXER OUT MIXER IN BOILING OUT BYPASS IN VENT BYPASS OUT SPARKLING OUTLET CO2 IN WHITE BRAIDED ...

Page 14: ...50mm NOTE make sure the tap location will allow the nozzle to drain into the sink O RING SINK TOP Fit the O ring to the underside of the AIO tap then pass all hoses through the 50mm hole All In One Tap Mains Installation O RING BASE BLOCK SPIDER BASE BLOCK NUT USB CABLE ALL THREAD ROD 161 50 Min 300mm 4mm Buffer Pad to ensure ventilation gap ...

Page 15: ...o the underside of the All In One Tap BASE BLOCK SPIDER NOTE feed each of the tubes and electrical cable evenly in between the legs of the BASE BLOCK SPIDER FIXING NUT External HOT COLD isolation valves Not supplied Tee piece supplied Typical All in 1 Installation with options see section 6 Note All plastic tubes must be cut to size They must have a constant fall back to the unit ...

Page 16: ...d as shown 2 Check the RED tube is to the LHS and the Blue tube the RHS 3 The braided hose from the Mixer Out fitting is attached to the central position 4 The clear silicon tube is the vent line from the underbench unit to the tap Min 300mm O RING BASE BLOCK SPIDER BASE BLOCK NUT USB CABLE ALL THREAD ROD BLUE Chiller connection for Tee piece to JG hoses From Mixer OUT to Tap for Vented version on...

Page 17: ...allation Instructions 1 15 1 16 O RING SINK TOP Fit the O ring to the underside of the AIO tap then pass all hoses through the 50mm hole Mount the BASE BLOCK SPIDER to the underside of the All In One Tap BASE BLOCK SPIDER NOTE Feed each of the tubes and electrical cable evenly in between the legs of the BASE BLOCK SPIDER ...

Page 18: ...estrictaflow valve Tee piece Supplied Note The All In One vented taps require a Zip Restrictaflow valve and Tee piece as supplied to be fitted in the cold water supply line from the isolation valve Not supplied to the mixer tap See diagrams Note All plastic tubes must be cut to size They must have a constant fall back to the unit Note Fit the insulation supplied to the JG tubes used for Boiling and ...

Page 19: ... recommended to install vent duct and louvre panels for under floor and or door vent systems Note Inlet and outlet vents should be separated by a Min 100mm to avoid hot air recirculation IMPORTANT See section 6 3 for clearances When installing air flow ducts the following tools will be required Jigsaw and Keyhole or Wall Board saw Section 2 Ventilation Cool Air IN via cabinet floor front vent gril...

Page 20: ...gement for Chilled Sparkling models with kickboard venting via a left hand appliance duct Typical Cut out arrangement for Boiling Chilled Sparkling models with kickboard venting via a right hand appliance duct A A B C B C Ventilation 2 2 Chilled Sparkling ventilation 2 3 Boiling Chilled Sparkling ventilation ...

Page 21: ...lied is not fitted If the kick board vent kit cannot be used then it is important to fit a standard HydroTap vent kit which ensures heat dissipation through natural convection via installed vents For high use applications where the cupboard space temperature is near 35 C or higher an auxiliary ventilation kit must be fitted Contact your local service centre for availability Note The vent kit has t...

Page 22: ...rovide pre heating of water before it enters the Zip HydroTap G4 boiling tank The Booster is supplied as standard equipment with all 240 cup models However it may be later installed as an accessory for the 160 cup models to increase their delivery to 240 cups 400mm Note1 water connection Blue marking water in Red marking water out The braided hoses cannot be lengthened Note2 The electrical cable l...

Page 23: ...ections 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 backing plate for wall mounting 3 3 To Remove Install the appliance 1 To remove 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 applian...

Page 24: ... 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 b...

Page 25: ...ry cap 2 Avoid touching the filter O rings and filter opening as this may cause bacterial contamination of the cartridge 3 Moisten the O rings with water align the front cartridge label to the left and push the new cartridge into the filter head 4 Turn the cartridge a quarter turn to the right until the cartridge comes to a complete stop with the front label facing forward 5 Disconnect the filter ...

Page 26: ...tic 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 NOTE Two plastic seals are supplied with a new regulator Only one is required the other is supplied as a spare part 5 3 Connect the gas hose Connect the braided gas hose to the top of th...

Page 27: ...ar 3 Inspect the joint for leaks 4 If any bubbles appear the joint will need to be resealed CO2 Regulator Leak Test This gauge shows the pressure in the bottle and indicates when the bottle is empty Initial bottle pressure will be 35 40bar This gauge shows the adjustable limit 2 7 3 0 bar required for the HydroTap to function correctly Pressure regulating knob ON OFF knob Green zone Relief valve I...

Page 28: ... 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 Section 6 Underbench Unit Installation If no external filter is installed select position A A Rotate 90 only 1 2 3 4 John Guest fittings Insertion and removal Be careful when cutting the poly tube so that there are no rough e...

Page 29: ...CS HydroTap models Min 50 mm side Clearance 400mm Note All plastic tubes must be trimmed to size They must have a constant fall back to the unit RED CLEAR BRAIDED Max 1000mm Max 500mm Note Mains hose length is 750mm Plug and Cord length is 1800mm Position the underbench unit according to the hose and cord lengths supplied POWER CORD USB CHILLED OUTLET MAINS IN MIXER OUT MIXER IN BOILING OUT BYPASS...

Page 30: ...engthened 6 4 Model BCSHA 240 175 Booster and Filter Softener options Note All plastic tubes must be cut to size They must have a constant fall back to the unit RED CLEAR BRAIDED POWER CORD USB CHILLED OUTLET MAINS IN MIXER OUT MIXER IN BOILING OUT BYPASS IN VENT BYPASS OUT SPARKLING OUTLET GAS IN CO2 IN BLUE WHITE Note Mains hose length is 750mm Plug and Cord length is 1800mm Position the underbe...

Page 31: ...er and Ext filter softener CANNOT be lengthened External HOT and COLD isolation valves Not Supplied Tee piece Supplied 6 5 Model All In One Mains Pressure Note All plastic tubes must be cut to size They must have a constant fall back to the unit RED CLEAR BRAIDED GAS IN POWER CORD USB CHILLED OUTLET MAINS IN MIXER OUT MIXER IN BOILING OUT BYPASS IN VENT BYPASS OUT SPARKLING OUTLET CO2 IN BLUE WHIT...

Page 32: ...ining the mounting positions for the options Tee piece and Restrictaflow valve External COLD isolation valve Not Supplied Note All plastic tubes must be cut to size They must have a constant fall back to the unit RED CLEAR BRAIDED Booster option POWER CORD USB CHILLED OUTLET MAINS IN MIXER OUT MIXER IN BOILING OUT BYPASS IN VENT BYPASS OUT SPARKLING OUTLET GAS IN CO2 IN BLUE WHITE Note Mains hose l...

Page 33: ...D Note All plastic tubes must be cut to size They must have a constant fall back to the unit Tee piece and Restrictaflow valve supplied External COLD isolation valve Not Supplied GAS IN POWER CORD USB CHILLED OUTLET MAINS IN MIXER OUT MIXER IN BOILING OUT BYPASS IN VENT BYPASS OUT SPARKLING OUTLET CO2 IN BLUE Booster option Booster CLEAR WHITE Note Mains hose length is 750mm Plug and Cord length is...

Page 34: ...stic tubes must be cut to size They must have a constant fall back to the unit GAS IN BRAIDED Note Mains hose length is 750mm Plug and Cord length is 1800mm Position the underbench unit according to the hose and cord lengths supplied Note The connection tubes supplied with the Tap Booster and Ext filter softener CANNOT be lengthened Take time to consider hose lengths when determining the mounting ...

Page 35: ...is finished Turn the stop cock OFF then press Stop to end filter flush mode 6 Press Next for the Boiling Calibration screen Have a 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 ...

Page 36: ...calibration procedure This will take approx 5 6 minutes Upon completion a Booster reminder screen will appear and allow you to return home by pressing the Home button Check the Date and Time settings See Note below NOTE failing to make the correct selection for the Booster will affect product performance NOTE Depending on your location you may need to re set the internal clock See section G of the...

Page 37: ...alibration This can be achieved by closing any nearby curtains blinds etc Pull both levers forward Safety sensor 7 5 Safety Sensor Calibration Boiling models Disable Booster 10 30 Wed 14 Nov 2013 BC Sparkling Zip 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 Booster 5 Water must be run through the Booster...

Page 38: ...all Zip Service Condenser Overtemp Blocked airfilter Remove blockage Clean filter check user guide Steam too Cool Internal fault Call Zip Service Steam Sensor Open Internal fault Call Zip Service Steam Sensor Closed Internal fault Call Zip Service Hot Overload Internal fault Turn OFF to reset Call Zip Service Hot Tank Overfilled Internal fault Call Zip Service Safety Lock ON Safety button active S...

Page 39: ...801910 Zip Sparkling HydroTap Installation Instructions July 2014 V1 00 Page 39 of 40 Notes ...

Page 40: ...AU635979 GB0422305 GB2065848 US4354049 US5103859 US5099825 and SA2006 08043 Other patents are in force and patent applications are pending 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 zipheaters com Facsimile 02 9796 3858 Telephone 02 9796 3100 Free Call 1 800 638 633 As Zip policy is one...

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