service manual zenith hydrotap compact 2 - zip...

Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 of 66

Domestic model:

HT1002

Zenith HydroTap Compact 2

Commercial Model:HT1503

®

Service Manual

HydroTap

HydroTap with disabled levers

of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00

Compact 2 underbench unit images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Specifications, Approvals, Model range, Warnings . . . . . . . . . . . . . . . . . . . . .4 - 6

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

General underbench layout, connections and dimensions . . . . . . . . . . . . . . .8

Layout of major components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Control panel display - model selection and operations . . . . . . . . . . . . . . . . .10 - 13

Control panel display - fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 - 14

Control panel display - Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 - 15

Control panel display - Recalibration procedure . . . . . . . . . . . . . . . . . . . . . . .15

Fault flow charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 - 20

ComponentsJohn Guest fittings (Insertion and removal) . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Filter change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Tap operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Child safety lock and disabled levers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Tap and font assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Tap assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Outer cover removal and appliance entry . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

ChillerCondenser fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 - 32

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Compressor, Capacitor and Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Compressor winding check test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Compressor refrigeration and check test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 - 37

Refrigeration trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 - 39

Chiller pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Chiller level and temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 - 43

BoilerHot level and temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 - 46

Hot tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Hot pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 - 49

Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 - 50

Thermal Overload Control (TOC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 - 52

ElectricalPrinted Circuit Board and fuse assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Leak detector & PCBA transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 - 55

Earth continuity test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

DiagramsPlumbing layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Parts lists and diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 - 63

Conversion tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Contact details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Contents


Compact 2 underbench unit

Commercial model


HydroTap specifications

• Power : 220V - 240V AC 50Hz single phase

• Heating elements: 1500W (residential) and 2000W (Commercial)

• Min water pressure : 140kPa

• Max water pressure : 700kPa

• Refrigerant : 90 grams R134a

• Secop compressor PL50

• Operating (ambient) temps : 5°C - 35°C

• Hot temp range : 98°C ± 2°C

• Hot water output : 3.0 - 3.6 L/min

• Cold Temp range : 3°C - 6°C

• Cold water output : 4.0 - 5.6 L/min

• Disposable Filter: Re-order type FX - Sub micron - 91240NZ.

Approvals• Watermark approved appliance

• C-Tick approved appliance

• NSF approved filter

• CE approved appliance

Specifications & Approvals


Technical description

Boiling / Chilled

General information.

This Service Manual contains information you will need to service the unit’s, wiring, plumbing,

sensors, valves and taps. It will show you how to gain access to the inside of the unit and how to

service the heating and chilling modules. It also shows how to deal with any mineral scale that may

accumulate. All the necessary diagrams, illustrations, and detailed fault finding guides are listed in the

index and are referenced throughout the manual. The fault finding guide matches possible faults with

probable causes and supplies a summary of detailed corrective actions. Please read these warnings

before servicing any HydroTap appliance. Never attempt to service any HydroTap appliance without

first reading all of the applicable servicing instructions.

What is the Zenith HydroTap ?

The HydroTap units are under bench drinking water appliances with a dispensing tap mounted on a

sink or bench, which may be used for residential or commercial applications. These units utilise a

conventional refrigerant compressor to chill the water and an immersion heating element to boil the

water. These units dispense boiling water (factory set to 98°C) and chilled water (factory set to 6°C).

These units are NOT designed to be used for washing up or to provide hot water for a kitchen sink or

for sanitary fixtures.

These Boiling and Chilled water units are fitted with two safety locks, one for Boiling water isolation

(via the main menu) and the other is a tap mounted, child safety lock. In addition, there are three

energy saving options accessible via the main menu. Each unit is equipped with a self-calibrating

program which caters for altitude adjustment. The water filter is a disposable item which will require

periodic replacement and is covered by a limited OEM warranty.

The HydroTap is an electronically controlled, filtered, Boiling water and Chilled water drinking system

for kitchens and tea rooms. The unit can be ordered with the Tap Head Assembly for Disabled use

(with or without Braille caps).

MODEL HT1002 (Dom.) HT1503 (Com.)Power (Max) 220/240V AC 50Hz 1.8 kW 220/240V AC 50Hz 2.3 kW

Element rating (kW) 1.5 2.0

Boiling cups / hr 100 120

Chilling glasses / hr 60 60

R134a charge 90 grams 90 grams

Dimensions (mm) 385W x 380D x 350H 385W x 380D x 350H

Fan kit option Not available Yes

Model range


1. The Zenith HydroTap unit must be earthed. The resistance of the earth connection from each

exposed metal part must be less than 1 ohm.

2. Do not allow young children, handicapped or infirm persons, to use the HydroTap without

supervision.

3. All service work must be completed by trained and suitably qualified Tradespeople. Faulty

operation due to unqualified persons working on this product, or any other Zenith product may

void warranty coverage.

4. All Plumbing must comply with AS/NZS3500.4.1 & AS/NZS3500.4.2

5. All Electrical must comply with AS/NZS60335.1, AS/NZS60335.2.75 and AS/NZS3000

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

7. This service manual should be used in conjunction with the current version of the operating

and Installation Instructions (Installation instructions are available from the Zenith website). It

requires qualified technical knowledge and offers support for the maintenance and repair by a

qualified tradesperson only!

8. Due to the process of continuous improvement, Zenith Heaters Ltd reserve the right to change

details mentioned in this manual without notice.

The following points are important whenever you service any Zenith

appliance.1. Whenever you remove a soft seal, a gasket, a pipe or an O ring, inspect it closely. If it is worn

or damaged, or has deteriorated in any way, replace it. We recommends that you use only

Molykote III as sealant grease. Other sealant greases may be hazardous to your health.

2. Replace or re-insulate any wiring that you find is bare for any reason (this warning does not

include the ends of the earth leads.)

3. If you remove pipe union olives for any reason, replace them. This ensures the heater stays

free from leaks.

4. If the HydroTap is switched off for a long period of time (e.g. More than a weekend), run water

through the chilled water outlet for at least 5 minutes before consumption.

5. If a temperature sensor, level probe or PCB is replaced you must re-calibrate the unit.

6. Do not operate the appliance without a water filter.

7. After each service the earth continuity must be checked. See page 55

Warnings

WARNING!

Airflow and Ventilation Fan Kit information

The ambient temperatures this unit should operate

between are 5ºC - 35ºC. Proper air circulation must be

provided. The system will operate satisfactorily only if the

recommended air gaps are provided, these are 65mm min

rear clearance and 50mm side clearance.

Commercial model fan kit: (For Model HT1503)

The commercial model has the option of fitting an auxiliary

fan. The electrical connection point is on the top panel

between the cold water inlet and chilled water outlet. The

Commercial fan

connection


commercial fan kit is available as a spare part. The fan operates in parallel with the Condenser fan

helping to remove heat from the cupboard space. This fan should be purchased and connected to

the HydroTap if the airflow characteristics of the cupboard space are inadequate for the effective

removal of hot air, thereby adversely affecting the operational performance of the HydroTap. The fan

can be installed so that it extracts air from, or forces air into the cupboard space, whichever is the

most effective for your installation.

Application of the fan is of paramount importance in situations where the cupboard space reaches

temperatures greater than 35ºC.This must be used in situations where adequate ventilation cannot

be guaranteed. Make sure the ventilation grilles on the sides of the undersink unit are not obstructed

in anyway or by anything.

RefrigerantThe HydroTap Chilling unit contains R134A refrigerant under pressure. No part of the unit should be

exposed to a naked flame. Maintenance of refrigeration unit must be carried out by an accredited

service provider or qualified refrigeration mechanic.

QualificationsIf any power cord or plug 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.

VentingSometimes steam and / or boiling water may discharge through a vent outlet at the mouth of the tap.

If the tap is not installed using the Font pedestal, ensure the tap body is located so the tap outlet

drains safely into the sink bowl area.

Note: On startup, the controls take the system through a calibration process which causes the unit to over-

boil for a period of aprox. 90 secs. This is normal operation, once the calibration process is complete,

the system reverts back to normal operation.

Lifting and TransportingTake care when lifting the HydroTap undersink unit. Some units may exceed safe lifting limits. Do

not lift without assistance. The weights of the units are given in the installation manual, under the

heading “Installation Requirements”. Do not lift the unit by the doors. When transporting the unit,

ensure it is in an upright position.

Filtration The HydroTap filter control is preset to 6000 Litres to provide trouble-free flow and operation in most

installations. Local water quality conditions may require an alteration to this capacity. In areas where

the water has a high concentration of sediment, the preset litre capacity may be shortened to avoid

poor flow, taste or odour situations. In areas where the water quality is above average, lengthening

the preset capacity may be desirable, but not essential. If any of these changes are needed, follow

the instructions on page 11 or contact your Zenith Service Provider.

Altitude The HydroTap is equipped with a self-calibrating program which caters for altitude adjustment.

Frost ProtectionIf this appliance 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.

General Information


385

46

12

5

Min 50 Min 50

115

20

8

Mains cold waterisolation valve

Pressure limitingvalve

230V-50HzGPO

Min 65

382

34

8

218.50

108

115

10

0

Min

20

0

22

5

Air gap

Bu!er pad4mmMax 80

Min 15

Tap hole 35mmfor HydroTap tap

Sink

Chilled water

outlet

Water Inlet

Steam vent

Hot water

outlet

General under bench Layout

Domestic model connections


Major components layout

Filter assembly Heater module

Condenser and Fan

assembly

Chiller module

Solenoids

Thermal

Overload


1. Turn on the unit, the screen will display the general

information of the product for approximately 2 seconds.

The screen will display

H Tap CP1.30E110

2. The screen will then display “To Select Model Press

ADJUST->“ as shown in Fig.2. Press ADJUST ^ or

>

button to

check the model number.

Zenith Industries

Fig.1

4. The model selection is now complete. “Start Filt Flush“ will

be displayed. To continue with the filter flush and calibration,

refer to the Testing and Commissioning within the main

instruction.

Addendum to Instructions for ALL MODELS

3. The screen will now display “<-Scroll Exit->“ on the first

line and the model description on the second line as shown in

Fig.3. The factory default model description displayed on the

screen should match the product model description on your

product labels. If the correct model description is displayed,

(either Compact 2 Res or Compact 2 Comm.) select “Exit” by

pressing ADJUST ^ or > to confirm selection and exit model

description selection setting. If the model description displayed

is incorrect, select the “Scroll” option by pressing MENU ^

or > button to scroll through the model description until the

correct model description is displayed. Then select “Exit” by

pressing ADJUST ^ or >to confirm selection and exit the

model description selection setting.

This procedure applies to HydroTap products with date of manufacture (DOM) after and

including 30th July 2012 or with a serial number starting with 20120730xxxxx.

The procedure covers model selection and cold temperature set point adjustment.

READ THIS INSTRUCTION BEFORE COMMISSIONING!!

HydroTap Model Selection Procedure

Model selection

Fig.2

To Select Model

Press ADJUST ->

Fig.3

Press ADJUST ^ or > to exit

Press MENU ^ or >

to scroll through the

model numbers.

<- Scroll Exit->

compact 2 Res

Fig.4

Start Filt Flush


Menu Plus Button

Menu Minus Button

Plus Adjust Button

Minus Adjust Button

Note:

Mode buttons change the screen options

Adjust buttons select the screen options

The model identification of the product you are working on will

flash up for about 5 seconds after power is applied to the unit.

This will occur each time power is restored after isolation.

The model you

have

Normal

Operation

Monday On

After the product I.D. is completed, the screen will default to show

“Normal Operation Compact 2”. This will be displayed when the

unit is operating regardless of programmed or unprogrammed

settings.

Press either Menu

<

or Menu

>

button until Monday On is

displayed. To set time for the unit to turn on press

<

Adjust button

until required time is reached. To set time for unit to turn Off,

press Menu

<

button once and Monday Off will be displayed.

Now press

<

Adjust until required time is reached. If each

individual day is to have an “On / Off” time, the previous steps

will need to be repeated as you set each day and On / Off time.

Note: The HydroTap may be temporarily activated during the On

/ Off Mode. By operating the levers, the unit will go into normal

operation and then return to Off Mode after 30 Minutes.

Filter Life

Litres Filtered

Factory set at 6000 Ltrs, press either Menu

<

or Menu

>

button

until Filter Life is displayed. Press

<

Adjust button to increase

Filter Life or

>

Adjust button to decrease Filter Life. Filter Life

increases in 1000 Ltr increments to a maximum of 10000 Ltrs.

This counter displays the number of litres passed through the

filter. Press adjust

<

to reset litre counter. Then it asks “are you

sure” Press adjust

<

to disable the filter.

Monday

--|--To have continual operation press either Menu

<

or Menu

>

button

until Monday On is displayed. Press adjust

<

or

>

until --|-- shows

in the screen, duplicate for each following on/off for each day.

Note, there must be one “on” period to start the process.

Important:All of the menu screens (except for 'Filter Flush' Mode) will revert to 'Normal Operation' if left unat-

tended for 10 seconds.

When in 'Normal Operation' press the Menu ^ button to return to the last mode used.

When in 'Filter Flush' Mode it is important to manually exit by pressing the Menu

<

or Menu

>

button

Don't forget to flush

filter

Press adjust

<

again and the screen will remind you to Flush the

filter before proceeding. After aprox 5 secs the screen will reset

the litre counter to Zero.

Control panel display


In this menu the unit will go to “sleep” after a pre-determined pe-

riod of inactivity. Press either Menu

<

or Menu

>

button until Sleep

Mode is displayed.

Option 1: Sleep to 65ºC after 2 hours of NO USE

Press > Adjust once to select

Option 2: Auto OFF after 2 hours of NO USE.

When the period of inactivity passes, the display will show “Sleep

Mode”. During the “Sleep Mode” the Red LED on top of the tap

lever will flash slowly.

Sleep to OFF means the Boiling and Chilled circuits will be

switched OFF

To de-activate the sleep mode, momentarily operate the Hot lever

and then allow sufficient time for the water to reach the set tem-

perature

Filter use (Days)

Filter Life

Dispense Hot

Sleep Mode

Filter Flush

Hot Isolation

Press either Menu

<

or Menu

>

button to select the filter flush

mode. In this mode the water supply is isolated to facilitate filter

removal. The unit will remain isolated until the screen is manually

exited by using either Menu <

or Menu

>

buttons. Press adjust <

to start the water flushing the cartridge. Allow water to run

clear and press adjust >

to stop the flow. Refer to page 16 of the

Installation and Operating Instructions supplied with the unit.

Press adjust

<

to enter Hot isolation mode. Now go to the Tap

Head assy and press the Child Safety Lock (3) three times

rapidly, the LED’s will scroll from left to right (3) three times, this

operation confirms the activation. This isolates the boiling tap

only. The LCD shows isolation mode is active. De-activation is

the same procedure again, LED’s scroll right to left three times

to confirm. If permanent de-activation is required, de-activate by

scrolling through the menu and selecting de-activate when Hot

isolation Mode is displayed on the screen.

Set Day

Press either Menu

<

or Menu

>

button until Set Day is displayed.

Press

<

Adjust or

>

Adjust to select day.

Set Time

Press either Menu

<

or Menu

>

button until Set Time is on the

display screen. Press

<

Adjust button to increase time or

>

Adjust

button to decrease time. Time increases or decreases in minute

increments. Hold the Adjust buttons down for rapid increases or

decreases.

Press either Menu <

or Menu

>

button to select this mode. The

filter life is Factory set for 12 months = 365 days. To change by 1

month Press <

Adjust button to increase, or

>

Adjust button to de-

crease, for a maximum of 14 months. After setting for 14 months.

press adjust

<

for "Filter Life Disabled"

Press either Menu

<

or Menu

>

button to select ‘Filter use’ mode.

This counter shows how many days a filter has been in use. Press

adjust

<

Then it asks “are you sure”

Don't forget to flush

filter

Press adjust

<

again and the screen will remind you to Flush the

filter before proceeding. After aprox 5 secs the screen will reset

the counter to Zero.

Press either Menu

<

or Menu

>

button to select ‘Dispense hot’

mode. The maximun Hot water run time is factory set at 15 sec.

Press

<

Adjust button to increase or

>

Adjust button to decrease

the time. The minimum time is set at 5 sec.

Self - Diagnosis Fault DisplayDisplay operations continued


Dispense Cold

Flash Memory

has failed test

Press either Menu

<

or Menu

>

button to select ‘Dispense cold’

mode. The maximun Cold water run time is factory set at 15 sec.

Press

<

Adjust button to increase or

>

Adjust button to decrease

the time. The minimum time is set at 5 sec.

Self diagnosis fault display

Hot Sensor

Fault

This indicates the Hot temperature sensor has lost connection

at the main PCB. This fault indicates a possible disconnection

at the probe connection point on the PCB or the probe is open

circuit. This may result in temps over 120°C.

Cold Sensor

Fault

This indicates the Cold temperature sensor has lost connection

at the main PCB. This fault indicates a possible disconnection

at the probe connection point on the PCB or the probe is open

circuit.

Compressor

Overrun

‘Compressor overrun’ indicates ventilation may be inadequate

or not provided as described in the instructions. The compressor

may have overheated or there is low or no refrigerant.

Water Leak

Isolate Mains

This indicates a water leak has been detected. Isolate the mains

water supply and correct the fault before putting the unit back

into operation.

Flood Sensor

Disconnected

This indicates the flood sensor is disconnected or the circuit is

broken.

This indicates a problem with the software. Reload new software

Display operations continued

Check water

supply

This indicates a problem with the incoming water supply. check

the water is turned ON and there are no blockages or kinks in any

of the supply lines.

SRAM Battery

SRAM Faulty

If, at startup, the system continues to run through it's diagnostic

checks, then there may be a problem with the battery. Replace the

P.C. Board.

This message indicates an electronic fault and will require the

replacement of the P.C. Board


Hot setpoint

98° Celsius

Litres Edit

0

In order to gain access to the service menus press and hold both

the

>

Adjust button and the

<

Adjust buttons for aprox 3 sec. The

screen will display the current Hot and Cold water temperatures

as well as the water levels.

NOTE: The Service Menu must be manually exited for normal

operation

Press either Menu

<

or Menu

>

button to select the Hot setpoint

mode. Here the Max and Min Hot temperature set points may be

adjusted. Press the

<

Adjust button to increase the set point to a

Max of 99°C (In 0.5°C increments). If higher temps are required

Press the

<

Adjust button again for 100°C however recalibration

may be required before this can be achieved. By pressing the

>

Adjust button, minimum temperatures may be set down to 68°C.

Once the temperatures have been changed, the screen if left

untouched, will default to the original service screen within 10

seconds.

Press either Menu

<

or Menu

>

button to select ‘litres edit’ mode.

NOTE: Before proceeding to reset the counter, check the existing

litres filtered and record this figure for later use EG. when changing

a PC Board.

To reset, Press the

<

Adjust button and reset the counter to the

nearest 100L.

Time (Min) - - - -

HOT (ABS)

BOIL (Sec.)

- - - -

Reserve

Press either Menu

<

or Menu

>

button to select this mode.

Do not adjust

Press either Menu

<

or Menu

>


Do not adjust

Press either Menu

<

or Menu

>


Do not adjust

HOT 98°C

LVL3

Service Menu

Auto Sleep

Disabled

Press either Menu

<

or Menu

>

button to select the ‘auto sleep’

mode. This function is for the All In One Tap. Refer to The All In

One Installation manual.

Pressing the

<

Adjust button will enable the auto sleep mode and

pressing the

>

Adjust button will disable this mode. Compact 2

models should be disabled.

Press either Menu

<

or Menu

>

button to return to the first service

screen.

NOTE: It is important to manually exit the service mode in order to

return to normal operation.

To exit press and hold both the

>

Adjust button and the

<

Adjust

buttons for aprox 3 sec.

HOT 98°C

LVL3

Press the Menu

>

button, to enter the Cold Temperature

Adjustment Screen :Here you can adjust the Cold temperature

set point by pressing the adjust > or > buttons. The cold

temperature set point can be changed in 2ºC increments as

follows: 5°-9º ; 7°-11º ; 9°-13º or 11°-15ºC.

Cold setpoint

6° Celsius


Re - Calibration Procedure

5. Press the adjust

<

button to display ‘Calibrate system’. The

calibration mode screen will appear, press adjust

<

and the

calibration cycle begins automatically. The display will show

‘EMPTY TANK’.

6. The hot tank will begin to empty so ensure all items are out

of harms way and the drainage point is clear, it is possible that

occasionally the tank won’t fully empty itself, if this happens

remove the hot outlet tube from the base of the tap assembly and

locate the outlet at a lower point than the tank assembly this will

allow the tank to fully empty.

7. Once empty, if the tank is below 95ºC the unit will heat to this

temperature. When at 90ºC it stabilises for approx 120 seconds,

once stabilised the unit will heat to boiling point and continue to

‘Boil’ for a further 130 seconds. The unit now re-calibrates for

the local conditions, once achieved the unit will default back to

‘Normal operation’.

Zenith Industries

Empty Tank

Normal

Operation

Fig.2

To Select Model

Press ADJUST ->

Fig.3

Press ADJUST ^ or > to exit

Press MENU ^ or >

to scroll through the

model numbers.

<- Scroll Exit->

compact 2 Res

Fig.4

Start Filt Flush

1. the screen will display the general information of the product for

approximately 2 seconds. The screen will display

H Tap CP1.30E110

2. The screen will then display

“To Select Model Press ADJUST->“ as shown in Fig.2.

Press ADJUST ^ or >

button to check the model number.

4. The model selection is now complete. The “Start Filt Flush“ will

be displayed.

3. The screen will now display “<-Scroll Exit->“ on the first

line and the model description on the second line as shown in

Fig.3. The factory default model description displayed on the

screen should match the product model description on your

product labels. If the correct model description is displayed,

(either Compact 2 Res or Compact 2 Comm.) select “Exit” by

pressing ADJUST ^ or > to confirm selection and exit model

description selection setting. If the model description displayed

is incorrect, select the “Scroll” option by pressing MENU ^

or > button to scroll through the model description until the

correct model description is displayed then select “Exit” by

pressing ADJUST ^ or >to confirm selection and exit model

description selection setting.

Calibrate system

> press Adj

<

Boil - 130 sec

NOTE: If hot probe or PCB is replaced or if the unit is relocated to a higher or lower altitude, you

must re-calibrate the unit.

Re-calibration can be used when you want to check to ensure the unit is running at peak

performance levels. Turn the power OFF. Now switch the power back ON while depressing the two

bottom buttons on the LCD.


Can not get the unit to filter flush.Is the water supply on to the unit ?

No Turn on water supply, make sure there are no kinks or blockages in the supply line to the unit.

Yes Is water getting to the fi lter ?

No Check the safety solenoid (see page 30) and the double non return valve. Replace which ever is faulty.

Yes Is water passing through the fi lter ?

No Use a fi lter plug (90211NZ) in place of the fi lter. If the water now passes through, the fi lter is

blocked and requires replacing. If the water still does not pass through replace the fi lter head

assembly.

Yes Check the fi lter fl ush tap for any blockages. If it is all clear, change the display board and ribbon

cable.

Unit does not turn on ( no power, no lights on the tap or the screen)

Is there 230volts at the power point ?

No Check circuit breaker and advise customer to get an electrician to look at the circuit.

Yes Make sure the power lead is plugged in correctly. Is there continuity through the 3 fuses or are the fuses fi tted correctly to

the PCBA ?

No Replace or refi t the fuses. If the fuse is blown, check what components the fuse protects (Page 53) and test

them for electrical faults and repair/replace component.( open circuit, short circuit or a leak to earth)

Yes Are all the cables plugged on to the PCBA ?

No Fit cables to the correct terminals on the PCBA and re-test unit.

Yes Is there 230 volts to the PCBA ?

No Check the terminations in the green terminal on the PCBA are correct . Make sure

there is a circuit between the lead and the terminal.

Yes Check the output voltages on the supply transformer. Are they correct ? (See page 54)

No Replace the transformer.

Yes Replace the PCBA.

Unit does not stop calibrating or stays in calibration mode.Are the hoses cut to length with no kinks, loops or blockages in them ?

No Cut hoses to length and remove any blockages or kinks. (See installation instructions P5)

Yes Is the unit heating ? (is the temperature reading static )

No Overload might be tripped, reset overload and test unit. (See page 51). If the overload is not tripped see fault

fi nding section on ‘unit not heating’.

Yes Is the vent pipe blocked ?

Yes Remove blockage or replace vent pipe. Run the calibration cycle with the silicone vent pipe

removed from the top of the unit. (See page 15)

No Is the hot temperature sensor within the sensor range ?

No Replace the hot sensor probe and recalibrate. (See page 44)

Yes Is the element electrically sound? (continuity test, earth leakage test and physical

inspection)

No Replace the element. (See page 50)

Yes Replace the PCBA. (See page 53)

Fault flow charts


Unit is not heating. (Red light flashing on tap)Does it say normal operation on the display screen ?

No Take unit out of sleep mode or resolve fault message on the display screen.

Yes Is the overload tripped ? (do you have to reset it.)

No Do a continuity and earth leakage test on the element and the hot temperature sensor. (See Page 55)

Yes Reset overload. Is the silicone vent hose or vent pipe from the hot tank blocked or kinked ?

Yes Unblock or unkink hose or pipe or replace.

No Do a temperature vs. resistance test on the hot temperature sensor . (see page 44) If it is

out of the parameters, replace the hot sensor and recalibrate the unit (see page 15). If the

sensor test ok, test the unit, is there a lot of steam produced from the vent pipe when the

unit is heating?

No Replace the overload.

Yes Replace the PCBA

Unit does not dispense boiling water ?check if the child safety lock is on. Is the unit in isolation mode ?

Yes scroll through the menu and turn ‘Hot isolation' OFF. (See page 12) Test unit, if it still does not produce boiling water go

to next question.

No Is the red indicator light (on the tap) permanently on ?

No go to 'Unit is not heating' fl ow chart.

Yes Can you hear the relay on the PCBA clicking when the boiling water lever is depressed?

No The unit is not getting a signal from the tap. Check the USB connection between the

tap and the unit for any corrosion or a bad/loose connection. Replace if there is any

corrosion. Physically look for any cuts or nicks on both USB leads. Replace either lead if you

fi nd any faults. If the USB connection and leads look in good condition, replace the tap top

assembly. (See page 27).

Yes Do you get a reading of 12-14 volts from the hot pump transformer?

No Replace the hot pump transformer. (See page 49)

Yes Replace the hot pump.

Water is not chilling.Is there a fault message on the display screen?

Yes Rectify the fault and reset the unit.

No Is the fan running?

No Check the chilled water fuse on the PCBA. If not blown, check that the fan is getting 230 v. If it is, replace

the fan assembly. If the fuse is blown, go to next step.

Yes Is the temperature reading of the chilled water at ambient temperature ?

No Check the cold sensor probe reading against the resistance chart (page 43). If the resistance

reading is out, replace the cold sensor probe. (see page 42) If it is correct, go to next step.

Yes Is the compressor getting 230 volts?

No Replace PCBA. (See page 53)

Yes Electrically test the relay, capacitor and compressor windings. (See Page 34)

Replace faulty parts. If all are correct, the unit will have a refrigeration fault

and needs to be serviced by a qualifi ed refrigeration technician.

Fault flow charts


Tap Does Not operate (no lights visible)Is there 230 V at the power point?

No → Check the Building circuit breaker.

Yes → Is the Tap loom connected to the Under-sink unit?

No → Connect Tap loom (USB connector).

Yes → Are the Tap loom and main Power supply connected to the PCBA?

No → Connect the Tap loom and main Power supply to the PCBA

Yes → Are there any LED indicators illuminated on the PCBA?

No → Replace PCBA. (See page 53)

Yes → Replace Tap Head assembly. (See page 27)

All the LED lights on the Tap are flashingPress the boiling and safety button together. Can you hear the unit heating? If yes, the unit’s red light will stop fl ash-

ing when the unit has reached temperature. The white fl ashing light means the unit requires a fi lter change. If no, is

the unit in sleep mode?

Yes → Advise the customer of sleep mode and its operation (See page 12) The fi lter may require changing as

well (See page 23).

No → Has there been a blackout or an interruption to the power supply?

Yes → Turn the power to the unit OFF for 15 minutes, if when you turn the power back ON all the LED indica-

tors continue to fl ash proceed to the next step.

No → Is the water supply turned on and is there water present on the outlet side of the fi lter?

No → Reinstate the water supply, turn the power off for 15 minutes and then turn the power back

on

Yes → Is there any water damage or corrosion in the USB connection?

Yes → Replace whichever lead (or both) that is damaged.

No → Is there a fl ash code indicated on the PCBA LED’s?

No → Replace PCBA. (See page 53)

Yes → Refer to Flash code table to identify the fault and repair.

Slow ambient water flow and slow Boiling water recoveryMake sure there are no restrictions or kinks in the hoses to the tap. Is there water supply to the fi lter?

No → Check fi ltermate (DNR PLV multi function valve) and water supply to unit. (See page 22)

Yes → Is there water supply to the inlet on the unit?

No → Replace the fi lter. (See page 23) If there is still no water supply to the unit replace the fi lter

head.

Yes → Is there good water fl ow through the safety solenoid?

No → Change safety solenoid. (See page 30)

Yes → Is there good water fl ow through both sides of the dual solenoid? (Boiling

side is restricted to 0.5 litre a minute.)

No → Replace double solenoid.

Fault flow charts


Tap LED lights are illuminated but there is no boiling water flowEnsure there is good fall in the silicone hose from the tap to the unit. Make sure there are no kinks or blockages in the

hoses. Is the safety button being pressed at the same time as the boiling water button?

No → The safety button is always on and can not be turned off. Advise customer of safety button.

Yes → Is there corrosion in the USB connection or damage to the USB lead?

Yes → Replace the USB lead and/or the tap head. (See page 27)

No → Is there 12 Volts to the hot pump when the boiling and safety buttons are

pressed?

No → Replace the PCBA (See page 53).

Yes → Replace the hot pump. (See page 48)

Boiling Water is not hotIs the unit in sleep mode?

Yes → Advise customer of sleep mode and its operation. (See page 12)

No → Is the boiling water (red) LED indicator constantly illuminated?

Yes → Is the unit dispensing water from the tap? See chart above for fault fi nding.

No → Has the over temperature cut out tripped? (See page 51)

Yes → Re-set the over temperature cut out and test the temperature sensor probe. (See page 44) Make sure

there are no kinks or blockages in the vent line from the unit to the tap. If this problem is re-occurring,

replace the overload and the sensor probe.

No → Does the element have continuity through it, check for the correct resistance. (See Ohms

test/ resistance formula page 49.)

Yes → Is there 230 Volts at the heater terminals on the PCBA?

No → Check the fuses, if they are both OK, replace the PCBA. (See page 53)

Yes → Is there 230 Volts through both poles on the overload?

No → Press the reset on the overload and check again. If there is

still no circuit through the overload replace the overload.

Yes → Replace the element. (See page 50)

Unit is over filling.Check all water connections are correct. Does the unit over fi ll when the power supply is OFF to the unit?

Yes → Change both solenoid valves.

No → Is the level sensor lead plugged on to the PCBA?

No → Plug lead on to correct terminal and test unit.

Yes → Is the earth wire connected front the tank to the chassis?

No → Fit the earth wire correctly.

Yes → Are the securing screws holding the heat sink (part of the PCBA) done up

tightly? (See page 53)

No → Tighten or fi t screws.

Yes → Replace PCBA.

Fault flow charts


Both lights on the PCBA are flashing. (Fill time out)Check with the customer if there has been an interruption to the buildings water supply.

Yes → Turn power off to the unit and then back on. (to reset the fault)

No → Is the water supply on to the unit?

No → Turn on water supply. Turn off power to unit and turn back on. (to reset the fault)

Yes → Is there good water fl ow to the fi lter head?

No → Replace the multi function valve. (See page 22)

Yes → Is there good water fl ow through the fi lter?

No → Replace the fi lter. If problem still persists replace the fi lter

head as well.

Yes → Check the water fl ow through both of the solenoid valves.

(See page 30) Replace the one with poor water fl ow through

it. If they both have good fl ow, replace the PCBA.

Water leak inside unit.Check if there is any evidence of water leaking or dripping onto the base unit. Clean up all the water in the base of the

unit and the fl ood sensor. Check all plumbing fi ttings in the unit. If any of the John Guest fi ttings are leaking, you can

replace them or the o’rings can be replaced. If one is leaking, replace all o’rings or fi ttings in the unit. If all the plumbing

fi ttings look good turn on the water to the unit and do a “live visual test. If the leak is coming from the tank, Is the level

sensor plugged onto the PCBA?

No → Plug level sensor plug on to PCBA.

Yes → Is the earth wire connected from the tank to the chassis?

No → Fit earth wire.

Yes → Are the securing screws holding the heat sink (part of the PCBA) done up tightly? (See

page 53)

No → Tighten or fi t screws.

Yes → Is there a circuit through each of the level probes to the level plug on the

PCBA? (See page 41 and 46)

No → Replace the level sensors.

Yes → Replace the PCBA. (See page 53)

Unit does not dispense cold water.Does the display screen say Normal operation ?

No→ Resolve fault written on the display screen.

Yes→ When the cold lever is pressed can you hear a clicking from the PCBA ?

No→ The unit is not getting a signal from the tap. Check the USB connection between the tap and the unit for

any corrosion or a bad/loose connection. Replace if there is any corrosion. Physically look for any cuts or

nicks on both USB leads. Replace either lead if you fi nd some. If the USB connection and leads look in good

condition, replace the tap top assembly. (See page 27)

Yes→ Is the cold pump connected to the PCBA ?

No→ Reconnect pump to PCBA and test the unit. If there is still no cold water go to the next step.

Yes→ Are you getting 14 volts from the PCB ?

No→ Replace the PCBA.( See page 53)

Yes→ Check the cold tank, is it frozen? ( See page 33)

Yes→ Replace cold sensor.( See page 42)

No→ Replace cold pump.( See page 40)

Fault flow charts


When the litres filter timer or the days used (filter) timer is up, the filter light on the tap will indicate that

the filter requires changing. ( Note- error message check water supply can also indicate that the filter

may need replacing.)

The default setting is 6000 Ltrs or one year, but this can be set in increments of 1,000 Ltrs from 1,000

Ltrs to 10,000 Ltrs.

Before you commence any service work on a HydroTap isolate the power supply. DO NOT under any

circumstances disconnect the supply tubes from the under-sink unit to the tap without first isolating

the power. Failure to heed this warning could result in the under-sink unit dispensing water into the

cupboard area causing damage and potential serious injury.

CComponentCComponents

John Guest Fitting Tips

John Guest (JG) fittings

Assembly and Removal

Prepare the tube:1. Be careful when cutting the poly tube so that there are no rough edges and that the tube is not

distorted.

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

3. Remove any swarf or unwanted material.

Insertion:4. 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.

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

the above step.

Removal:6. To remove the tube, press the collet into the fitting and at the same time pull back on the tube.

John GuestJ

CAUTION !

CComponentCJohn Guest fittings (Insertion and removal)


The HydroTap is supplied with a 350 kPa double non return / pressure limiting valve. The water supply

is then run through a ¼ inch John Guest tube to the inlet of the base unit.

DNR - 350 Kpa PL

Multi function valve

Tap not

supplied

Mains supply

Appliance Water inlet

Water supply


To change the filter:1. Scroll through the screen menu to “Filter Flush Off” this

isolates the water supply.

2. Remove the front cover by unlocking clips on both sides

and lift off to expose the filter.

3. Relieve system pressure via the filter flush stop cock, a

quick open and close will do.

4. Grasp filter cartridge and twist LEFT to RIGHT one

quarter turn until it stops.

5. Ease cartridge downwards to detach it from the filter

head (socket).

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

tilted.

7. Unpack replacement cartridge and write today’s date

where shown on the label.

8. Avoid touching the filter “O” rings and filter opening as

this may cause bacterial contamination of the cartridge.

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

the filter head.

10. Slide cartridge upward into head and rotate RIGHT to

LEFT until it stops.

11. Locate the filter flush hose situated behind the filter

cartridge and run to a container ready for flushing. Open

the flush hose tap lever. On the control panel press

adjust ^, this will start the water flushing the cartridge.

Allow at least 7.5 Litres of water to run through to

activate the filter and then press adjust ^ to stop the flow.

12. Isolate the filter flush stop cock and re-fit behind the filter

cartridge.

13. Wipe up any spills and dispose of spent filter cartridge

and packaging thoughtfully.

14. Scroll through the menu to “Litres Filtered”, press adjust ^

to reset litre counter. Press adjust ^ and it asks “are you

sure”. Press adjust ^ again to lock in the command.

15. Scroll through the menu to “Filter Used (Days)”, press

adjust ^ to reset the timer. Press adjust ^ and it asks “are

you sure”. Press adjust ^ again to lock in the command.

After approx 10 seconds it will default to the selected

mode.

16. Refit the front cover to secure the appliance.

Filter location

Locking Clip

Front cover

Filter change

3M Filter - option


Lever Operation

The Hydrotap will deliver• Boiling water (98°C ± 2°C) at a rate of 3.0 - 3.6 L/min and

• Chilled water (3°C - 6°C) at a rate of 4.0 - 5.6 L/min.

Boiling Water Lever:Depressing the “Red” lever allows dispensing of boiling water.

Pulling up the Red lever allows the tap to operate in a “no-touch” mode.

Water will flow from between 5 and 15 seconds (This is user adjust-

able).

To reset, return the handle to the “Off” position and repeat the step. The

lever has to be manually returned to the “Off” position.

Chilled Water Lever:Depressing the “Blue” lever allows dispensing of Chilled water.

Pulling up the Blue lever allows the tap to operate in a “no-touch” mode.

Water will flow from between 5 and 15 seconds (This is user

adjustable). To reset, return the handle to the “Off” position and repeat

the step. The lever has to be manually returned to the “Off” position.

Blue Chilled Water Light

On all the time:This indicates that the temperature of the chilled water is within the

usable temperature range.

Flashing slowly:This indicates that the chilled water is not at the right temperature. Wait

up to 20 minutes. When the chilled water is at the right temperature, the

light will stop flashing.

During heavy usage, the temperature can rise out of this range.

Red Boiling Water Light

On all the time:This indicates that the boiling water is ready.

Flashing slowly:

This indicates that the boiling water is below usable temperature.

Filter lightFilter Change Light Off:

This indicates the filter is operating within its normal specified lifespan.

Filter Change light flashing slowly:

The light will flash slowly when the filter is due for replacement and the

LCD will show “Filter Change”. Refer to “Replacing the filter” section of

this document. (See page 23).

Press or pull lever

Boiling Filter

ChangeChilled

Tap operation


To Install Braille Caps

1. Submerge both braille caps in boiling

water for one minute to soften the rubber.

2. Remove caps from boiling water using a

spoon and shake off excess water.

3. Slide the braille caps over the lever, as

shown in the picture on the right.

4. When placing the caps over the lever, pull

the lever forward and support the inner

side of the lever with your free thumb.

Tap with Braille levers fitted

The child safety lock can be activated to prevent

boiling water flowing if the hot lever is inadvert-

ently activated.

To activate:Simultaneously press the safety lock and the

Blue Chilled water lever for a period of approxi-

mately ten seconds. The safety lock indicator

light will now be illuminated.

To deactivate:First press the safety lock then depress the Blue

Chilled water lever for a period of approximately

ten seconds. The safety lock indicator light will

now extinguish.

To operate when the lock is ON:Depress both the Red lever and the safety lockChild safety Lock

Child Safety Lock


TAP

BLACK

PLASTIC

SPACER

FONT

BENCH TOP

STAINLESS STEEL

WASHER

See Para 4

SPIDER

M6

NUT

SPACER RING

UNDER FONT

Removal of the tap assembly:

This requires the water and power to be isolated

and de-pressurised.

Disconnect the supply tubes and Vent line

from the HydroTap unit under sink, using a

pair of pliers or any other suitable tool, release

the spring clips that secure the supply tubes.

Ensure you tag them correctly for correct

re-installation.

Using the tube spanner, that should be on-site

from the original installation. Loosen and remove

the fixing nut located on the threaded rod

projecting from the underside of the Tap Assy.

When this is done, slide down and off the “Spider

Clamp” and if fitted, the large washer.

The Tap Assy should now be free for removal

from the sink surface. Take care in case the tap

was fixed in place with an amount of silastic for

security and water proofing.

Replacement of a new tap or re-fitting the old

tap is the reverse procedure.

Note: New spring clamps are provided with replacement

Taps.

TAP

BLACK

PLASTIC

SPACER

STAINLESS STEEL

WASHER

SPIDER

M6

NUT

ALL-THREADED

ROD M6

BENCH TOP

SMEAR A SMALL

AMOUNT OF SILICONE

ON THE UNDERSIDE

OF THE PLASTIC

SPACER

Normal assembly

Font assembly

Tap and Font assembly


P/N Description

90648NZ Standard Tap Assembly complete kit

90649NZ Disabled Tap Assembly complete kit

90675NZ Tap Handle Kit Disabled Boiling/Chilled

90676NZ Tap Handle Kit Standard Boiling/Chilled

99052NZ T/Tap to HydroTap Sink Adapter Kit.

Reed switch

Safety switch

Screw

holes

Align holes for re-assembly

Pull apart

Removal of the levers and springs:

If the levers are to be replaced, isolate power, gas

and water, tilt the levers forward into the ‘locked

on’ position. Look to the back of the tap, by tilting

the levers forward, this exposes the locking ‘grub’

screw that secures the levers.

Wth care, Loosen and remove the allen screw

using a 1.5mm allen key, pull the levers

horizontally until they are free from the locating

shaft.

Be careful not to disturb the small magnets that are

embedded in the RED and BLUE rubber moldings.

They are for the activation of the reed switch.

Removal of the circlip from the lever axle will allow

access to the 3 balls and springs housed in the

nylon carrier block.

Re-installation is the reverse procedure.

For access to the safety switch1. Disconnect the reed switch plug

2. Remove the small screw (#1 phillips)

3. Carefully Push out the safety switch

For access to the reed switch

4. After removing the safety switch and light

pipes

5. (Working from within the tap head) Push the

reed switch out and away from the tap

Tap assembly


1. Remove the front cover (A) by unlocking the clips on both sides and lift off to

expose the filter

2. Remove the secondary cover (B) for access to the PC Board

For appliance entry:3. Isolate the electric and water supply to the unit.

4. Disconnect the Tap loom (USB connector)

5. Disconnect the water supply, John Guest fittings and the vent outlet tubes from

the top of the unit

6. Remove the base unit from the cupboard.

7. Remopve the six (6) screws located around the sides of the undersink unit.

8. Slide the outer case (C) forward.

A

C

B

Slide fo

rward to

remove

Outer cover removal and appliance entry

Outer covers


Cold tank &

Evaporator

Condenser &

Fan

P.C.Board & fuse As-

sembly

Filter

Hot Tank &

Element

Thermal

overload

Solenoids

Transformers

Internal components


Solenoid Valves / Replacement

Inspection

Isolate power and water, remove the mains supply

hose from the top of the undersink unit (via the JG

fitting).

Remove the outer covers (See page 28). When

panels are off, the 2 solenoids will be revealed.

If both boiling and chilled water are not

dispensing, the safety inlet valve needs testing

and possible replacement. No part of this valve is

repairable.

If either the boiling or chilled water is dispensing

and the other isn’t, then the double solenoid valve

needs testing and possible replacement. No part

of this valve is repairable.

Removal

remove the 2 electrical connectors from the coils,

then release the valve from the pipework, these

will be connected by John Guest fittings or spring

clamps over silicone elbows. The final stage is

releasing the valve from the fixing bracket, to do

this you slide the valve upwards in the case of the

double valve, or remove the 2 mounting bracket

screws from the rear panel to release the single

safety inlet valve.

Replacement

is the reverse procedure, ensure that all fittings

are not damaged or are likely to leak, if any part

looks suspect, replace it.

Safety inlet solenoid valve

Dual solenoid valve

The solenoids let water into and out of the appliance. All the solenoids are 240 volt solenoids and

should have a resistance reading of aprox. 4300 ohms. Each solenoid is plastic bodied and have, fac-

tory fitted, John Guest ( JG) fittings attached. The bodies are marked with an arrow to show the correct

direction for the water flow. The solenoid will come as a spare part with these fittings already fitted.


Basic refrigeration in the HydroTap is achieved in several stages. First the R134a gas is compressed

into a liquid, where the amount of work done in compressing the refrigerant causes excess heat, which

is channelled away by the condenser fan. The next stage in the cycle allows the liquid to expand. The

controlled rate of expansion causes the refrigerant to change it's state from a liquid to a gas. This

change of state causes the rapidly cooling of the surrounding areas, allowing the water in the evapora-

tor to be chilled. In the final stage the gas is returned to the compressor to continue the cycle. (see the

diag below).

NOTEAll work on the refrigeration sealed system must be undertaken by a qualified refrigeration technician.

Expansion

Compression

Condenser

Compressor

Evaporator

Chill tank

Chilling Cycle

Condenser FanThe condenser fan removes the heat generated by the compression of the gas. The fan will operate

while the refrigeration system is running. To keep the fan in good operating condition, the condenser

needs to be kept clean. A soft bristle brush may be used.


1. Isolate power and water, remove the mains supply hose from the top of the undersink unit (via

the JG fitting).

2. Remove the outer covers (see page 28). When panels are off, the condenser will be

accessible.

3. Disconnect the fan electrically by removing the two wires at the side of the fan.

4. When safely disconnected, remove the 2 fixing screws on the opposite edges of the plastic

safety cowl. Once removed, the motor / fan assembly can be drawn back and will clear the

condenser shroud. The assembly can now be removed from the HydroTap casing.

5. Installation is the reverse procedure.

Fan motor check test:1. Disconnect the two wires from the fan

2. Using a multimeter probe between the two metal tabs on the fan,

3. Reading should be 600 Ohms ± 5%

Condenser Fan

Fan connection wires

Fan mounting screws (2 off)


Isolate power and water, remove the supply

hoses connected to the tank with an appropriate

tool and mark carefully so, not to get mixed when

re-assembling.

Remove the appliance outer covers and when

panels are off, the chiller tank (white insulation)

will be revealed.

Carefully lift off the top insulation piece, this

exposes the plastic tank assy lid assembly.

Carefully remove the inlet and outlet JG fittings

and disconnect the sensor and pump wires from

the main PC Board. The pump and lid assembly

may now be lifted away from the chill tank.

Removal of any part of the refrigeration system

will require a suitably qualified refrigeration trades

person to undertake the job. Correct handling

of the refrigerant in the discharge and recharge

process is of utmost importance. Failure to do this

may render your warranty void.

Once the refrigerant is evacuated, the evaporator

can be disconnected from the system, Once the

evaporator is cleaned or a new one ready, refitting

is the reverse procedure. Ensure the refrigeration

system is re-activated by a suitably qualified

trades person, once this is done, the reconnection

of electrical and plumbing components can

proceed.

The last step is re-gassing the system. Refer

to chart on page 5 for R134A gas weight

requirements.

Note:

When you have the chiller tank disassembled it’s

a good opportunity to clean any foreign matter

that may collect in the tank base. Use only soft

rags and clean water, anything that scratches will

damage the surface.

Evaporator


Compressor, Capacitor and Relay

CapacitorThe 60 Uf capacitor is used to help start and run the compressor. If it is split or

leaking it needs to be replaced. It is recommended to replace the relay at the same

time as the capacitor.

CompressorThe compressor is the main heart of the

refrigeration sealed system. It’s function is

to keep the Chilling Cycle (See Page 31) in

motion by forcing the refrigerant to phase

from gas to liquid. The chilling cycle is only

operational when the compressor is running.

Thermal overload control.The PL50 compressor motor is protected

(internally) with a thermal overload control

device. This device is automatically activated

when the compressor is too hot, or is drawing

excess current. When this occurs, the reason

for the compressor overheating will need to

be found. This device is not a serviceable

item.

Relay:The relay is an automatic switch which allows the compressor motor to

change from it’s start windings to the motor Run windings. (See page 35

for connection details)

Compressor


Compressor winding check test

Check Test for CompressorAfter gaining access to the compressor

• Isolate the power

• Remove the junction box cover to expose the Relay

• To avoid shock, discharge the capacitor before proceeding.

• Disconnect and remove the Relay to expose the compressor

terminals

• Using a multimeter set on resistance scale

• Probe between A & B should read aprox 51.2 Ohms

• Probe between A & C should read aprox 37.3 Ohms (Run windings)

• Probe between B & C should read aprox 14.2 Ohms (Start windings)

Any discrepancy in these readings may require the unit to be returned to the

service department for further investigation.

Terminal A

Terminal C

Terminal B

a2 Relay

b Cover

c Capacitor

d Cable entry block


Capacitor Compressor

Compressor


What is Refrigeration?

For heat transfer to occur, refrigerant needs to circulate within the

refrigeration system. If temperatures within the system are outside

normal working parameters, then basic operational principals need

to be checked.

NOTE: Some of these procedures require the

machine to be operational, so always take great

care when handling and testing live equipment.

1. To ensure the compressor is operational remove the relay cover

as shown. (fig 1)

2. Attach a clamp tester to the RED wire on the relay. Depending

on compressor size this should read approx. 0.5 - 1.1 amps. (fig 2)

3. When you have established the compressor is operational, you

will need to determine you have the correct gas charge within the

system. Remove the Schrader Valve Cap. (fig 3)

4. Attach your service hose as shown. (fig 4). Note, the service

gauge is a single hose/gauge purely to show gas / charge/

pressure, not a charging unit.

5. The optimal operating pressure is approx 140 Kpa (20psi), but

pressures can vary depending on temperatures, usually no more

than +/- 35 Kpa (5psi). (fig 5)

NOTE: If at any time power is removed, the compressor can

take up to several minutes to restart.

See the trouble shooting matrix over page for a step by step guide

to fault finding.

Fig 2

Fig 1

Fig 3

Fig 4

Fig 5

Refrigeration check test


Pressure too High

Gas leak or restrictionIs compressor

operating

Is there adequate

ventilation

Return for

service

Improve ventilation

Gas pressure

incorrect

Is fan operating

Is there 240V at fan motor

Compressor ineffi cient( return for service )

Replace Fan motorReplace PCB

No Yes

No Yes

No Yes

No Yes

Pressure too Low

Check current draw

procedure

Refrigeration Trouble Shooting


Is water temp

above 10° C

Is there correct current

draw (0.5-1.1Amps)

Wait till water temp

is above 10° C

Is there 240V between

Red & Blue relay wires

Check gas pressure

procedure

Replace PCB Assy.

Compressor

operating

Is Capacitor OK

Replace Capacitor Is Relay OK

Compressor faulty

(return for service)Replace Relay

No Yes

No Yes

No Yes

No Yes

No Yes

Compressor Trouble Shooting


Chiller Pump

Chiller pump removal1. See Page 28 for appliance entry

2. After removing the insulation securing tape, gently lift

off the top insulation piece, this exposes the plastic

tank assy lid assembly.

3. Carefully remove the inlet and outlet JG fittings and

disconnect the sensor and pump wires from the main

PC Board.

4. The pump and lid assembly may now be lifted away

from the chill tank.

Chiller pump installation5. perform the removal procedure in reverse

Power supply 12V DC

Cable length 1metre

Delivery rate 4 - 8 L/min (no load)

Delivery height 5.5 m (max)

Power consumption 15 - 24 Watt

Dia. / Height 38mm / 104mm


WATER LEVEL LENGTH SENSOR ASSY NO

HIGH LEVEL 57mm 83301

LOW LEVEL 258mm 83302


HIGH LEVEL 57mm 83301

LOW LEVEL 314mm 83303

HYDROTAP BC 100/125-COLD TANK

WHITE WIRE

WITH BLACK

STRIPE

PLAIN WHITE

WIRE

HIGH LEVEL

LOW LEVEL

NOTE:

SENSOR RODS FOR COLD TANKS

HAVE CRIMPING AT THE TOP

END TO ACT AS STOPPER. INSTALL

WITH WASHER P/No. 83178 INTO

PLASTIC HOLDER.

HYDROTAP BC 150/175-COLD TANK

Chilled Water Level Sensor:

This sensor controls the filling of the chilled tank. It has two

levels of control:

Low level, this indicates when the chilled tank water is at it’s

lowest capacity.

Top level, isolates the filling process to stop overflow.

The position of the sensor rods in relation to the colour coded

wiring is critical to correct operation. See below:

White wire with black stripe, high level indicator, shortest rod.

Plain white wire, low level indicator, longest rod.

The sensor rod holders are fixed in place in the chiller tank lid.

Take great care not to damage the seals when removing for

maintenance or repair.

Chilled water level sensor replacement

Water Level Length

High level 45 mm

Low level 127 mm


To check for correct Chiller temperature

sensor Operation:

1. Isolate unit electrically and remove access panels

to reveal the Chilled tank assy.

2. Remove the top insulation piece from the Chiller

tank, the probe has a Blue sleeving. Withdraw it

from the sheath and disconnect it from the PCB.

3. Allow the sensor to sit at room temp for 5 minutes,

check resistance with a Ohm meter against the

room temperature, see chart on page 43. If out of

range, change probe.

4. When re-installing reverse the dismantle

procedure described above.

Chiller temperature Sensor

Continuity verses temperature reading test

Continuity and temperature

test on sensor - Pass


test on sensor - Fail

Continuity test

Temperature sensor probe replacement

1. Perform the removal procedure in reverse.

2. Make sure the sensor is inserted into the sensor

pocket only as far as the maker on the sensor and fix

in place with putty and a cable tie.

3. Turn ON the water supply and check for any leaks.

4. Replace the outer case and connect the supply tubes

from the under-sink unit to the tap.

5. Perform an earthing continuity test (See page 55).

6. Turn ON the power supply to the HydroTap.

7. Perform the re-calibration procedure (See Page 15).

Cold temperature sensor with

BLUE sleeving


TEMP (deg C) Low Limit (ohms) Nominal (ohms) High Limit (ohms)

0 32327 32660 32993

5 25146 25400 25654

10 19006 19190 19374

15 15572 15720 15868

20 12378 12490 12602

25 9912 10000 10088

30 7987 8056 8125

35 6476 6530 6584

40 5965 6014 6063

45 5282 5325 5368

50 4334 4367 4400

55 3574 3601 3628

60 2964 2985 3006

65 2470 2487 2504

70 1740 1752 1764

75 1470 1480 1490

80 1248 1256 1264

85 1064 1071 1078

90 910 916 922

95 782 787 792

100 675 679 683

105 584 587 590

110 507 510 513

115 442 444 446

120 387 389 391

125 339 341 343

130 229 230 231

135 264 265 266

140 233 234 235

145 207 208 209

150 184 185 186

NOTE: From 75- 150 deg C are outside the range of stated tolerance: (0.2 Deg C)

Temperature probe resistance chart


Continuity verses temperature reading test


test on sensor - Pass


test on sensor - Fail

Temperature Sensor probe removal

1. See page 11 appliance entry.

2. Remove the top insulation panel from the boiling water tank.

3. Remove the hot (red) sensor probe from pocket on lid of the boiling tank.

4. Remove the cable ties and disconnect the sensor from the PCBA.

**Servicing Tip** If the sensor probe feels like it is stuck in the tube; heat the tank with the element.

When the unit is near boiling point the probe will become easy to remove (release itself from the tube).

Top of hot tank. Location of level

sensors, element and hot tem-

perature sensor probe.

Temperature sensor probe replacement


2. Make sure hot sensor is inserted into the sensor pocket only as far as the maker on the sensor

and fix in place with a cable tie.

3. Turn ON the water supply and check for any leaks.

4. Replace the outer case and connect the supply tubes from the under-sink unit to the tap.



7. Perform the re-calibration procedure (See Page 16).

Hot temperature

sensor with

RED sleeving

Continuity test

HOT Temperature Sensor


Level sensor testing - Fail

Level Sensor Removal

1. See page 11 appliance entry.

2. Disconnect the level sensor wiring loom from the

PCBA.

3. Remove the insulation lid from the boiling water

tank.

4. Remove protective cover and the two (2) retaining

nuts that secure the level sensor assembly to the lid

of the boiling water tank.Level sensor removal

Level sensor

The HydroTap uses three (3) level sensors in the boiling water tank these monitor the water level and

depending on the level reading the PCBA will open or close the solenoid valves; the PCBA will also

use this information for Power Pulse™ adjusting the energy supplied to the element.

The level sensors work by reading the resistance (Ohms) between the sensor and the tank/element

(i.e. when water is present there will be a circuit); therefore it is critical that the earth connection from

the tank/element to the chassis is well connected as a loose connection could prevent the level sen-

sors from getting a resistance reading potentially causing the tank to overfill. If you experience an

overfilling fault also check the PCB for a good earth connection.

Level Sensor Testing

Level Sensor replacement

1. Replace the faulty level sensor assembly.


3. Make sure all wiring is fixed in place with cable ties.

4. Replace the outer case and connect the tap loom and supply tubes from the under-sink unit to

the tap.

5. Perform an earthing continuity test. (See page 55)

6. Turn on the water and power supply to the HydroTap and check operation.

XLevel sensor testing - Pass

HOT level Sensors



HIGH 57mm

83299MIDDLE 79mm

LOW 205mm


HIGH 57mm

83300MIDDLE 79mm

LOW 258mm


HIGH 120mm

83343MIDDLE 140mm

LOW 205mm

BLUE

WIRE

RED

WIRE

BLACK

WIRE

HYDROTAP BC 100/125-HOT TANK

A1224-LEVEL-SENSORS-HOTNCOLD.DRW

HIGH LEVEL

MIDDLE LEVEL

LOW LEVEL

HYDROTAP BC 150/175-HOT TANK

DOMESTIC HYDROTAP BC 60/85-HOT TANK

Hot Water Level Sensor:

This sensor controls the filling of the hot tank. It has

three levels of control:

Low level: this indicates when the hot tank water is at

it’s lowest capacity.

Mid Level: indicates that the water capacity will cover

most situational needs.

Top level: Isolates the filling process to stop overflow.

The position of the sensor rods in relation to the colour

coded wiring is critical to correct operation. See below,

Blue wire: high level indicator, shortest rod in the

shortest insulator leg of the plastic housing.

Red wire: middle level indicator, mid size rod in the

centre insulator leg of the plastic housing.

Black wire: low level indicator, longest rod in the

longest plastic insulator leg of the plastic housing.

The holder is fixed in place with

two (2) captive nuts housed

here. A flat blade or phillips

head screw driver is all that’s

needed to remove the nuts.

Ensure when removing the

sensor holder you check the

underside sealing gasket for

any faults or imperfections.

If needed, replace.

Water level Length Sensor No.

High 57mm

90629Middle 79mm

Low 205mm

HOT level Sensors


HOT Tank

Hot pump in situ

Hot tank assembly

Boiling water module removal

1. See page 28 for appliance entry.

2. Remove the insulation panel from the top of the boiling water tank.

3. Disconnect the water inlet (copper tube) from the silicone elbow on the lid.

4. Disconnect the pump outlet (Black plastic) from the top of the back panel

5. Remove the screws from the thermal overload (which secure it to the back

panel ) and remove the copper tube from the silicon elbow on top of the tank

6. Disconnect the pump wiring, 2 earth connections, temperature sensor, heater

connections and level sensor wiring from the PCBA and chassis.

7. Remove all cable ties.

8. Release the clip from the upper packing strap that holds the tank assembly to

the chassis.

9. The Hot tank, Pump and Element assembly may now be removed from the unit

Boiling water module replacement



3. Turn on the water supply and check for any leaks.

4. Replace the outer case and connect the supply tubes from the under-sink unit

to the tap.




HOT Pump

Boiling water pump operationThe HydroTap dispenses boiling water via a 12 Volt pump. The pump features a maximum run time of

fifteen (15) seconds at any one time.

Caution: If the pump has failed you will not be able to drain the boiling water tank prior to its remov-

al. Adequate time should be allowed for the boiling water tank and its contents to cool to below 40°C

prior to removal to avoid the risk of scalding. Failure to heed this warning may result in serious

injury.

Hot pump removal

1. See page 47 for Boiling module

removal

2. remove the spring clip from the

silicon tube connected to the tank

outlet pipe

3. Remove the pump from the tank

Hot pump replacement

4. Perform the removal procedure in

reverse.

5. Make sure all wiring is fixed in place

with cable ties.

6. Turn on the water supply and check

for any leaks.

7. Replace the outer case and connect

the supply tubes from the under-sink

unit to the tap.

8. Perform an earthing continuity test.

(See page 55)

9. Turn on the power supply to the

HydroTap.

Voltage 12 VDC

Operting voltage 10 - 14 VDC

Input power 6.8 ± 3% Watts

No Load current 0.52 - 0.65 A

Load current 0.42 - 0.78 A

Flow rate (Max) 6.8 L/min @ zero head

Flow distance 2.4 - 3.0 metres

Outlet dia 9.7 mm

Noise < 55 dBA / 10 cm


The element is used to heat the water. The element is designed only to be used while submerged in

water. To test the element, isolate the mains power and water supplies to the unit. Disconnect both

element wires, then using a multimeter, select ohms and test the resistance between both element

wires.

The correct resistance of an element can be worked out by using the calculation:

R = V / I, I = P / V, R = V² / P

Where; V= voltage, I =current draw and R= resistance, P = power.

Note: The actual reading you get should be within +/- 10%

Continuity test of element Blown Element

Element

Element

The 12 Volts (DC) required for the pump to operate is supplied through a small transformer. This

is located inside the appliance, behind the control panel display. Test the transformer for a 12 volt

output with a multimeter. Replace if faulty.

Transformer removal and Installation


2. remove the transformer wires from the PCB Assembly

3. Remove the two screws securing the transformer to the chasis

4. Remove the transformer

For installation, 5. perform the removal procedure in reverse

HOT Pump Transformer


Live test of voltage to overload and element. **caution high voltage will be present**

Installation of a new element:1. Check the tank lid gasket, replace the gasket if

worn.



4. Replace the outer case and connect the supply

tubes from the under-sink unit to the tap.

5. Perform an earthing continuity test. (See page 55 )

6. Turn on the power supply to the unit

Element replacement:

1. Isolate power and water, remove the supply

hoses connected to the unit with an appropriate

tool and mark carefully so, not to get mixed when

re-assembling.

2. Remove the outer covers to gain access to the

Hot tank assembly (See Page 28). When the

white insulation panels are removed, the hot tank

will be revealed.

3. Carefully lift off the top insulation piece, this

exposes the tank assy lid that houses the

element. Disconnect spring clips from pipework

and side pipes out of silicone elbows, disconnect

element leads and level sensor loom from the

main PCB. Undo the 4 lid retaining screws.

4. Lift the lid assy out of the hot tank. Loosen and

remove the element securing nut on the top side

of the lid and withdraw the element assy out of

position.

5. When replacing the element, check that an

element gasket is located under the element

flange to ensure a water tight seal.

6. Ensure that the baffle plate is correctly located

prior to re-assembly.

7. Re-installation is the reverse procedure.

Note:

When you have the boiler tank disassembled it’s a good

opportunity to clean any foreign matter that may collect

in the tank base. Use only soft rags and clean water,

anything that scratches will damage the surface.

Element gasket

Element (continued)


The thermal overload assembly is designed to isolate the element by disconnecting both poles

preventing over boiling if the hot sensor or PCB Assembly were to fail, or if the vent pipe becomes

blocked.

The thermal overload is a safety device and if tripped normally means something is wrong with the

temperature control of the unit (PCBA or sensor). To reset the thermal overload, isolate the water and

power supply to the HydroTap .

Ensure that the vent pipe is cool to touch then depress the red reset button in the middle of the ther-

mal overload. You should hear a clicking noise as the overload resets.

Note: If the thermal overload has been reset many times it may trip out at a lower temperature, thus

causing false activation. Replacing the overload will resolve this problem.

IMPORTANT! Do not reset the overload when hot. Allow the overload to cool down to room

temperature before resetting. The overloads calibrated performance will be adversely effected if reset

when hot.

Thermal Overload Control (TOC)

Manual Reset button

NOTE: Numbering of

the pairs on the black

plastic housing.


Removal 1. See page 28 for appliance entry.

2. Remove the two securing screws holding the overload in place.

3. Ensure you note down which way the wires are connected then remove the quick connectors

from the thermal overload. (See page 51)

Continuity test of overload

Continuity test of overload - pass Continuity test of overload - fail

Re-installation of the thermal overload assembly



3. Perform an earthing continuity test. (see page 55)

4. Re-connect and turn on the water and power supplies to the HydroTap.

Important Note: When fitting new overload.

1. There has been an upgrade to the overload. When fitting the new overload you must remove

all heat transfer paste from the overload mounting plate. The wiring to the overload is also

different. Please follow the diagram on page 51 when upgrading to the new overload.

2. Do not mechanically adjust spade connectors on the overload. Excessive lateral force and

deflection may result in deformation of the copper rivets.

Thermal Overload Control (TOC)


PC Board and fuse Assembly

The printed circuit board assembly is the brain of the whole unit. Signs that the PCBA may need

replacement include burn marks and broken terminals on the board.

Removal of PC Board Assembly1. See page 28 for appliance entry.

2. Disconnect all wiring looms from the PCBA.

3. Remove the two (2) retaining screws that secure the PCBA mounting bracket to the chassis.

PCBA replacement1. Perform the removal procedure in reverse.

2. Ensure you wire the PCBA as per the wiring diagram.



5. Re-connect and turn on the water and power supply to the HydroTap.

Fuses located on the PC

Refrigeration fuse

PCB fuse

1A - 2AG

Heater fuse

10A - 2AG

10A - 3AG


Leak Detector

There is a “Flood Detector” located within the sealed safe tray of the HydroTap under-sink unit. It is in

an awkward position beside the compressor, mounted on the back of the wall which supports the PCB

Assembly.

The flood detector allows the PCB assy to isolate the water supply at the main “Safety” solenoid in the

event of an internal leak. Signs the Leak detector may need replacing include broken or damaged wir-

ing and corroded terminals.

Leak Detector removal1. See page 28 appliance entry.

2. Remove the retaining screw A holding the detector in

place.

3. Disconnect the wiring loom from the PCBA.

Leak detector replacement1. Perform the removal procedure in reverse.



4. Replace the outer case and connect the supply tubes from

the under-sink unit to the tap.


6. Turn on the power supply to the HydroTap.

Fig. 37 - Flood sensor location

A

PCBA Transformer

The PCBA transformer supplies both 10V AC and 12V AC to the

PC Board Asssembly.

Test Check the voltage input and outputs using

a multimeter as follows• 240V AC input - Blue / Brown

• 12V AC output - White / White

• 10V AC output - Yellow Yellow

Transformer removal and Installation


2. remove the transformer wires from the PCB Assembly

3. Remove the two screws securing the transformer to the

chassis

4. Remove the transformer

For installation, 5. Perform the removal procedure in reverse


After each service, the earth continuity must be checked.

Use an insulation tester, appliance tester or continuity tester

with an accuracy of Class 5 or better (±5% at full-scale

deflection).

To test the earthing continuity:1. Isolate the appliance from the electricity supply.

2. Set the meter to the lowest ohms scale and set to a

reading of 0 Ohms with the meter probes connected

together.

3. Connect one of the meter probes to the earth pin on

the three pin plug.

4. Connect the second meter probe to a bare patch of

metal (the edge is best) on the top or the heater; and

read the tester’s display.

5. Repeat Steps 3 and 4 with the second test lead

touching the front cover of the heater.

6. Repeat Steps 3 and 4 again, with the second test

lead touching the metal body of the tap.

7. All readings should be less than 1 Ohm. If any of

the readings is more than this, check the earth

connection inside the unit.

One probe

connected

to plug's

earth pin

One probe

connected to

chassis

Megohn meter

or appliance

Earth Continuity test

Internal LeakTIP: If you have had an internal leak follow leak detector removal steps 1 - 3 and dry up any water that

is in the sealed safe tray. If the source of the leak is not immediately evident you will need to re-con-

nect the under-sink unit to the tap, water and power supplies and test for leaks. **Caution high voltage

will be present when doing live tests**. To do this you will need to leave the outer case removed so as

to see the source of the leak. Once identified you can once again disconnect the under-sink unit and

repair the fault.

In most cases the cause of internal leaks are ageing o-rings that are used as a seal in the John Guest

fittings.

Leak Detector continued


FAN

COMPRESSOR

M

10 AMP 2AG FUSE

LCD

DIS

PLA

Y

COLD LEVEL

HOT LEVEL

FLOOD SENSOR

RED

BLUE

TAPHEAD

HOT SENSOR

COLD SENSOR

FLOODDETECTOR

ELEMENT

HOT TANK

EARTHFROMTANK

MA

INS

PO

WE

R

BLUET

RA

NS

FO

RM

ER

SOLENOID (INLET)

SOLENOID (CHILLER)

SOLENOID (BOILER)

ORANGE

RED

BLUE

COLDPUMP

HOTPUMP

TAP

CONNECTOR

NE

UTR

AL

AC

TIV

E

J14

1A FUSESLOW BLOW

10 AMP 3AG FUSE

89743

TRANSFORMER

RECTIFIER

OVERLOAD

WIRING DIAGRAM HYDROTAP DOMESTIC COMPACT 2

Auxillary Fan/Transformerand Din Plug not fitted toDomestic models.

Wiring diagram


HOT

Tank

Expansion

Filter

HOT pump & outlet

COLD outlet

Water Inlet

Inlet solenoid

Dual solenoid

Refrigeration

linesChilled tank

(evaporator)

Chill

pumpCompression

condenser

DNR-350kPa

PL Valve

Bypass valve

Refrigeration sealed system

Cold sensors

HOT sensors

PCB Assembly

Vent

Plumbing layout


1

1

2 24

3

56

7

5 5

6

6

52

5

Tap and Font parts diagram


ITEM Kit No. DESCRIPTION

1 90648NZ Standard tap assembly Boiling/Chilled

90649NZ Disabled tap assembly Boiling/Chilled

2 90675NZ Tap handle kit Disabled Boiling/Chilled

90676NZ Tap handle kit Standard Boiling/Chilled

3 90645NZ PCB & Lead assembly kit

4 90800NZ Reed switch sub assembly kit

5 99142NZ H/T BC Tap, Chrome head assembly

6 99189NZ H/T Chrome head assy for BC taps

7 90046NZ HydroTap Font assembly kit

Tap parts list


1

2

13

14

12

45

6

78

3

1010

10

11

9

15

10

19

16

17

18

Boiling unit parts diagram


ITEM KIT No. DESCRIPTION

1 90959NZ PLASTIC CASE FRONT

2 90625NZ CONTROL PANEL KIT

3 90624NZ LEAK SENSOR KIT

4 90960NZ SAFETY SOLENOID KIT

5 90579NZ OVERLOAD KIT

6 90961NZ DOUBLE SOLENOID ASSY KIT

7 90962NZ HOT PUMP TRANSFORMER KIT

8 90623NZ TRANSFORMER KIT

9 90790NZ HOT PUMP KIT

10 91256NZ GASKETS AND ELBOWS KIT

11 90629NZ LEVEL SENSOR KIT

12 90618NZ ELEMENT KIT

13 90620NZ SENSOR PROBE KIT HOT

14 90189NZ LOOM LEVEL SENSOR HOT

15 90951NZ PCB KIT

16 91251NZ MULTIFUNCTION VALVE KIT

17 91261NZ ELEMENT LOOM KIT

18 91259NZ SOLENOID LOOM KIT

19 90965NZ THERMO PROBE POCKET KIT

Boiling unit parts list


2

3

6 6

89

7

5

4

5

5

5

1011

12

13

1

14

17

15

16

Chiller unit parts diagram


ITEM KIT No. DESCRIPTION

1 90021NZ COMPRESSOR PL50 KIT

2 90752NZ FAN KIT

3 90185NZ LOOM LEVEL SENSOR KIT

4 90966NZ PLASTIC LID KIT

5 90967NZ GASKETS AND ELBOW KIT

6 90968NZ JOHN GUEST FITTINGS KIT

7 90969NZ LEVEL SENSOR KIT COLD

8 90634NZ PUMP KIT COLD

9 90633NZ SENSOR PROBE KIT COLD

10 90753NZ FILTER DRYER KIT

11 99108NZ FILTER HEAD KIT

12 91241NZ 5 MICRON FILTER CARTRIDGE KIT

13 90437NZ CAPACITOR KIT FOR PL50

14 90092NZ RELAY COMPRESSOR KIT PL50

15 91260NZ COMPRESSOR LOOM KIT

16 90190NZ LOOM & GLAND PCB-TAP

17 90970NZ EVAPORATOR TANK KIT

Chiller unit parts list


To convert… into… Multiply by:atm bar 1.01325

kg/cm2 1.0332PSI 14.696MPa 0.101325KPa 101.325

bar atm 0.98692kg/cm2 1.01971PSI 14.504MPa 0.1KPa 100

kg/cm2 atm 0.96784bar 0.98067PSI 14.223MPa 0.098067KPa 98.0665

MPa atm 9.869232bar 10kg/cm2 10.1971PSI 145.04KPa 1,000

KPa atm 0.009869bar 0.01kg/cm2 0.010197PSI 0.145037MPa 0.001

PSI atm 0.068046bar 0.068947kg/cm2 0.070307MPa 0.0068948KPa 6.89475

CONVERSION TABLESCONVERSION TABLES

PRESSURE

FLOWTo convert… into… Multiply by:cm2 ft2 0.0010764

in2 0.155m2 0.0001mm2 100

ft2 cm2 929.0304in2 144m2 0.092903mm2 92903.04

in2 cm2 6.4516ft2 0.006944m2 0.0006451mm2 645.16

m2 cm2 10,000ft2 10.76391in2 1,550mm2 1,000,000

mm2 cm2 0.01ft2 0.000010764in2 0.00155m2 0.000001

AREA

LINEAR VOLUME

deg F = (deg C x 1.8) + 32deg C = (deg F – 32) / 1.8

TEMPERATURE

To convert… into… Multiply by:cc ft3 0.00003531

in3 0.06102litre 0.001m3 0.000001US quart 0.0010567US Gallon 0.0002642

ft3 cc 28,317in3 1728litre 28.317m3 0.028317US quart 29.92US Gallon 7.4805

in3 cc 16.387ft3 0.0005787litre 0.016387m3 0.0000163US quart 0.01732US Gallon 0.004329

litre cc 1,000ft3 0.03531in3 61.023m3 0.001US quart 1.057US Gallon 0.2642

m3 cc 1,000,000ft3 35.31in3 61,023litre 1,000US quart 1056.8US Gallon 264.2

US quart cc 946.25ft3 0.03342in3 57.75litre 0.9463m3 0.0009463US Gallon 0.25

US Gallon cc 3,785ft3 0.1337in3 231litre 3.785m3 0.003785US quart 4

To convert… into… Multiply by:cm ft 0.032808

in 0.3937metres 0.01microns 10,000mm 10

ft cm 30.48in 12metres 0.3048microns 304,800mm 304.8

in cm 2.54ft 0.08333metres 0.0254microns 25,400mm 25.4

metres cm 100ft 3.28083in 39.37microns 1,000,000mm 1,000

microns cm 0.0001ft 0.000003281in 0.00003937metres 0.000001mm 0.001

mm cm 0.1ft 0.003281in 0.03937metres 0.001microns 1000

To convert… into… Multiply by:cc/min ft3/min 0.0000353145

gal/min US 0.0002642in3/min 0.061L/min 0.001

ft3/min cc/min 28,320gal/min US 7.48in3/min 1728L/min 28.32

gal/min cc/min 3785.4US ft3/min 0.1337

in3/min 231L/min 3.7854

in3/min cc/min 16.39ft3/min 0.00057L/min 0.016gal/min US 0.004

L/min cc/min 1,000ft3/min 0.03531in3/min 61.02gal/min US 0.26417

Conversion tables


Notes


Contact details

The standard cup referred to in this publication is 167 ml (6 fl oz).

The standard glass is 200 ml (7 fl oz).

The terms “Zenith” and “HydroTap” are registered trade marks of

Zip Heaters (Aust) Pty Ltd.

Zenith products described in this publication are manufactured

under one or more of the following patents: AU675601,

AU637412, AU635979, GB0422305, GB2065848, US4354049,

US5103859, US5099825 and SA2006/08043. Other patents are

in force and patent applications are pending.

As Zenith Heaters Limited 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.

Head Office

Zenith Heaters Limited,

IRD No. 95 640 729

Unit 2/15 Moselle Avenue,

Henderson.

Auckland. 0610

New Zealand.

www.zenithheaters.co.nz

Telephone: 0800 558055

Facsimile: 0800 559055

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