Zip Hydroboil

Intended Use

This appliance is intended for use in commercial applications such as:

• Staff kitchens, shops, offices and other working environments.
• Small hotels and bed and breakfast type environments.
• Catering and similar non-retail applications.

Warnings and Precautions

This manual contains important safety and installation instructions for the Zip Hydroboil. Please read all warnings, installation requirements and instructions before installing.

General Warnings:

• The Zip Hydroboil must be earthed. Earth connection resistance from exposed metal parts must be less than 1Ω.
• All installation and service work must be completed by trained and qualified tradespeople. Faulty operation due to unqualified persons may void warranty.
• Never attempt installation without reading all applicable instructions.
• Do not remove the cover without first isolating the power supply.
• In hard water areas, mineral scale accumulation may require maintenance. Water treatment may be necessary.
• The Hydroboil is not intended for use by young children or infirm people without supervision.
• Prevent children from accessing the unit to ensure they do not play with it.
• Do not use strong, corrosive, or abrasive cleaners on the case.
• Operate within ambient temperatures of 5°C - 50°C.
• Intended for indoor use only; do not install outdoors or expose to the elements.
• Do not position in areas cleaned by a water jet.
• Installers are responsible for supplying and installing all necessary valves as per local regulations.
• The Hydroboil is rated for 230V 50Hz AC operation.
• Zip reserves the right to change manual details without notice due to continuous improvement.
• Visit www.zipwater.co.uk for the latest document copy.

Safety Considerations:

• This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless supervised.
• Children should be supervised to ensure they do not play with the appliance. Cleaning and user maintenance must not be done by children.
• This appliance is intended for commercial applications.

Qualifications:

• If the power cable is damaged, it must be repaired by a qualified technician. All installation procedures must be carried out by a suitably qualified tradesperson.

Venting:

• Steam and/or boiling water may discharge through the vent outlet or tap. Ensure the tap body is positioned so the outlet safely dispenses into a drip tray or sink bowl area. The vent must be plumbed to a safe location. See page 8 for details.

Lifting:

• The Hydroboil may exceed safe lifting limits. Seek assistance if needed. Do not lift by the tap, fascia, or connections. Refer to Technical Specification (page 5) for weight.

Positioning:

• Ensure the Hydroboil is positioned in an accessible area. The base must be mounted horizontally.

Before Installation

Ensure the following provisions are made:

• Review all technical specifications.
• Ensure the mounting wall can support the product's weight when full of water (See Technical Specification, page 5).
• Sufficient space is available for installation of the Hydroboil and other components as per instructions.
• Position the heater with at least 150 mm clearance above for service access, 65 mm to the left, and 20 mm to the right. The tap nozzle is typically positioned 360 mm above a draining board, drip tray, or sink bowl area.
• For models under 3kW, an accessible 1 x 230V AC 13A double pole isolation switch or correctly rated socket is required.
• For 5.6kW models, connect via a separate 230V AC ring main rated at no less than 32A, isolated by an accessible double pole isolation switch.
• The Hydroboil must be connected in accordance with IEE regulations.

Technical Specification

Check cable and plumbing against inlet/outlet positions before proceeding.

• A wholesome water supply connection with an isolating valve within reach of the Hydroboil, positioned so the stop cock is not obstructed.
• Vent/outlet drainage to a draining board, drip tray, or sink bowl area.
• A wholesome cold water supply with a minimum working pressure of 0.07 MPa (0.7 bar) up to a maximum of 0.5 MPa (5.0 bar).
• A 0.35 MPa (3.5 bar) pressure limiting valve must be fitted if incoming mains water pressure exceeds 0.5 MPa (5.0 bar).
• The Hydroboil must be placed with its base in a horizontal position.

IMPORTANT: Do not proceed with installation if these requirements are not met.

Min / Max water supply pressure: Hydroboil: 0.07 MPa (0.7 bar) - 0.5 MPa (5.0 bar)

WARNING: If the incoming mains water pressure is likely to exceed 0.5 MPa (5.0 bar), a 0.35 MPa (3.5 bar) pressure limiting valve must be installed in the cold water supply line.

Note: An optional Water Block is recommended in the water supply line to minimise potential damage from leakage. Contact Zip on 0345 6 005 005.

Installation Instructions

Before You Begin

• Locate the paper mounting-hole template packed with the Hydroboil (see pages 13, 14).
• Read the installation and operating instructions completely.
• Decide whether to install with concealed or exposed plumbing connections. Concealed connections are preferred for appearance.

Step 1 - Positioning

• Position the Hydroboil so the spout drains onto a draining board or drip tray.
• Position the tap nozzle base no less than 280mm (nominally 360mm) above the draining board. Increase height if necessary for filling larger vessels.
• Provide clearance: 150mm top, 65mm left, 20mm right for service access.
• Mark corner positions on the wall using the mounting-hole template.

Step 2 - Fastening

• Position the mounting-hole template on the wall and drill holes as indicated.
• Drill holes for water inlet and vent outlet if rear access is intended.
• Install plumbing and wiring, preparing pipe ends as shown.
• Remove cover fastening screws and lift off the cover.
• Screw the Hydroboil chassis to the wall using appropriate screws or bolts (supplied). Fasteners must support the product's full weight.

Diagram Description (3-7.5 Litre Models): Shows the rear of the unit with inlet and vent connections, terminal block, strain relief bush, and tap assembly. Illustrates concealed access options.

Diagram Description (10-40 Litre Models): Similar to the 3-7.5 litre models, showing the chassis layout with terminal block, strain relief bush, and tap assembly for larger capacity units.

Step 3 - Connection and Venting

Plumbing

• For exposed plumbing, connect the cold water inlet pipe from the Hydroboil base to the 1/2" BSP compression fittings (nuts and olives supplied).
• For concealed plumbing, connect the cold water pipe through the rear chassis using a 1/2" BSP capillary elbow.
• Flush cold water pipes before connecting to the inlet to prevent clogging, which affects operation.
• Install an isolating valve for servicing the Hydroboil from the mains water supply.
• Refer to Technical Specification (page 5) for water pressure requirements.

Venting

The Hydroboil is an open vented water heater; an air gap in the venting arrangement is essential.

• The vent at the base of the Hydroboil must be plumbed to a safe location, as it may discharge cold, boiling water, or steam.
• For concealed or exposed vent plumbing, connect the vent outlet to a Ø15 mm pipe with a continuous fall, no more than 3m long, with no more than 3 right-angle bends, discharging to a waste water drain. The vent outlet must be visible.
• For concealed vent plumbing, direct the vent outlet from the rear of the Hydroboil.
• Alternatively, install a visible tundish and plumb to a trapped waste.

Diagram Description (Venting): Illustrates concealed and external plumbing connections for water inlet and vent outlet. Shows an external tundish for vent discharge.

Electrical Connection

Electrical Circuit Diagrams:

Single Element Models up to 3kW: Shows a diagram with mains input, terminal block, thermostat, overload, heating element, and indicator light.

40 Litre Model with Contactor: Shows a more complex diagram including a contactor, overload protection, and multiple heating elements.

Cable Rating:

• Connect products rated under 3kW via a 3-core cable (min. 1.5mm² cross-sectional area).
• Connect 5.6kW rated products via a dedicated ring main and a 3-core cable (min. 4.0mm² cross-sectional area).
• Refer to current IEE guidelines for cable size and selection based on local installation conditions.

Exposed Electrical Connection: Connect the cable to the terminal block via the strain relief bush. Tighten the bush to secure the cable.

Concealed Electrical Connection: Connect the power cable through the rear access opening to the terminal block via the strain relief bush. Tighten the bush to secure the cable.

• Do not turn power ON until the Hydroboil can dispense water from the tap outlet.
• Verify earth continuity (see page 11).

Step 4 - Assembly

• Refit the outer case and secure screws (see pages 6-7).
• Before installing the tap, apply sufficient PTFE thread tape to the thread.
• With the cover fitted, place the red escutcheon over the outlet tube and secure with the locknut.
• Screw the tap assembly clockwise onto the outlet tube until it meets the escutcheon locknut. Continue turning the tap until the handle is fully vertical. Tighten the locknut against the tap using the provided spanner.

Diagram Description (Assembly): Shows using a spanner to tighten the tap lock nut. Also indicates fitting the boiling water safety label in a visible position.

Step 5 - Commissioning

• Check previous steps.
• Check earth continuity (see below).

Warning! This appliance must be earthed.

Upon installation or service, earthing continuity must be tested by a qualified technician using a resistance meter (min. accuracy 5% full scale deflection).

• Isolate power supply.
• Verify meter ohms range; connect leads together; reading should be 0 ohms.
• Connect one test lead to the earth of the power lead.
• Connect the other test lead to a cover fixing screw, then the tap.
• Verify that electrical resistance does not exceed 1 ohm.

Note: Depending on installation, connect to the earth pin of the 3-pin plug or the earth conductor of the mains cable.

Warning! The water may be boiling.

• Do not turn power ON until the Hydroboil can dispense water from the tap outlet.
• Turn water supply ON. Water will flow into the Hydroboil; check connections for leaks. Wait approximately 5 minutes, then pull the tap forward to test water flow.
• Turn mains electrical power ON only after water flows freely from the outlet.
• After a short period, boiling water will be available and maintained near boiling point.

Diagram Description (Commissioning): Shows a multimeter connected for earth continuity testing, illustrating connection points to the power lead earth and a cover fixing screw/tap.

Trouble Shooting

Operation

Tap Operation

Boiling Water:

• The Zip Hydroboil has a two-way tap for instant boiling water.
• For instant boiling water, gently pull the top of the tap forward. Boiling water flows until the tap handle is released. This provides fingertip flow control for filling cups and mugs.
• To fill larger vessels (teapots, saucepans), rotate the tap 180° and depress it until it locks horizontally. Boiling water flows until the tap is returned to its vertical position.
• This operation allows filling vessels without holding your hand near potential steam.

Diagram Description (Tap Operation): Illustrates pulling the tap forward for instant flow and rotating it 180° to lock for filling larger vessels.

Appendix

Mounting Templates

Refer to pages 13 and 14 for wall mounting dimension diagrams for 3-7.5 Litre and 10-40 Litre models respectively. These diagrams provide critical measurements for installation clearances and hole positioning.

Spare Parts

Spare Parts List (3-7.5 Litre Models): Lists part numbers and descriptions for various components including tank assemblies, fascia, tap parts, thermostat, elements, vent bushes, inlet and tap assemblies, gaskets, cistern components, overload protection, and lenses.

Spare Parts Diagram (3-7.5 Litre Models): A visual representation with numbered components corresponding to the spare parts list.

Spare Parts List (10-40 Litre Models): Lists part numbers and descriptions for components specific to larger capacity models, including tank assemblies, covers, drain caps, tap parts, thermostat, escutcheon, fascia, cistern components, contactor, overload protection, elements, vent bushes, inlet assemblies, and looms.

Spare Parts Diagram (10-40 Litre Models): A visual representation with numbered components corresponding to the spare parts list for 10-40 litre models.

End of Life Disposal

The crossed-out wheeled bin logo indicates this product requires separate disposal from household waste. Follow European Union provisions for collection and recycling of electrical and electronic equipment to preserve the environment. Contact Zip Customer Service on 0345 6 005 005 for advice.

Diagram Description (Disposal): A symbol of a crossed-out wheeled bin.

Cleaning

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

Diagram Description (Cleaning): An illustration showing a spray bottle with a cross over it, indicating not to use spray cleaners.

Contact Details

Zip Water UK

14 Bertie Ward Way, Dereham, Norfolk NR19 1TE

Phone: 0345 6 005 005

Email: sales@zipindustries.co.uk

Website: www.zipwater.co.uk

Technical Support: Tel: 0345 6 005 005, Email: service@zipindustries.co.uk