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Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 1 of 66
Domestic model:
HT1002
Zenith HydroTap Compact 2
Commercial Model:HT1503
®
Service Manual
HydroTap
HydroTap with disabled levers
Page 2 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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 3 of 66
Compact 2 underbench unit
Commercial model
Page 4 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 5 of 66
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
Page 6 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 7 of 66
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
Page 8 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Page 9 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
Major components layout
Filter assembly Heater module
Condenser and Fan
assembly
Chiller module
Solenoids
Thermal
Overload
Page 10 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Page 11 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Page 12 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 13 of 66
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
Page 14 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
>
button to select this mode.
Do not adjust
Press either Menu
<
or Menu
>
button to select this mode.
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
Page 15 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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.
Page 16 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 17 of 66
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
Page 18 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 19 of 66
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
Page 20 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 21 of 66
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)
Page 22 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 23 of 66
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
Page 24 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 25 of 66
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
Page 26 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 27 of 66
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
Page 28 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 29 of 66
Cold tank &
Evaporator
Condenser &
Fan
P.C.Board & fuse As-
sembly
Filter
Hot Tank &
Element
Thermal
overload
Solenoids
Transformers
Internal components
Page 30 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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.
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 31 of 66
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.
Page 32 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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)
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 33 of 66
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
Page 34 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 35 of 66
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
Page 36 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
Capacitor Compressor
Compressor
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 37 of 66
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
Page 38 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 39 of 66
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
Page 40 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 41 of 66
WATER LEVEL LENGTH SENSOR ASSY NO
HIGH LEVEL 57mm 83301
LOW LEVEL 258mm 83302
WATER LEVEL LENGTH SENSOR ASSY NO
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
Page 42 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Continuity and temperature
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 43 of 66
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
Page 44 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
Continuity verses temperature reading test
Continuity and temperature
test on sensor - Pass
Continuity and temperature
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
1. Perform the removal procedure in reverse.
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.
5. Perform an earthing continuity test (See page 12).
6. Turn ON the power supply to the HydroTap.
7. Perform the re-calibration procedure (See Page 16).
Hot temperature
sensor with
RED sleeving
Continuity test
HOT Temperature Sensor
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 45 of 66
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.
2. Perform the removal procedure in reverse.
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
Page 46 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
WATER LEVEL LENGTH SENSOR ASSY NO
HIGH 57mm
83299MIDDLE 79mm
LOW 205mm
WATER LEVEL LENGTH SENSOR ASSY NO
HIGH 57mm
83300MIDDLE 79mm
LOW 258mm
WATER LEVEL LENGTH SENSOR ASSY NO
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 47 of 66
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
1. Perform the removal procedure in reverse.
2. Make sure all wiring is fixed in place with cable ties.
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.
Page 48 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 49 of 66
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
1. See page 28 for appliance entry.
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
Page 50 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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.
2. Perform the removal procedure in reverse.
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 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)
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 51 of 66
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.
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 52 of 66
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
1. Perform the removal procedure in reverse.
2. Replace the outer case and connect the supply tubes from the under-sink unit to the tap.
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)
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 53 of 66
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.
3. Replace the outer case and connect the supply tubes from the under-sink unit to the tap.
4. Perform an earthing continuity test (See page 55).
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
Page 54 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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.
2. Make sure all wiring is fixed in place with cable ties.
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.
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
1. See page 28 for appliance entry.
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 55 of 66
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
Page 56 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 57 of 66
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
Page 58 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
1
1
2 24
3
56
7
5 5
6
6
52
5
Tap and Font parts diagram
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 59 of 66
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
Page 60 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
1
2
13
14
12
45
6
78
3
1010
10
11
9
15
10
19
16
17
18
Boiling unit parts diagram
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 61 of 66
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
Page 62 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
2
3
6 6
89
7
5
4
5
5
5
1011
12
13
1
14
17
15
16
Chiller unit parts diagram
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 63 of 66
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
Page 64 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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
Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00 Page 65 of 66
Notes
Page 66 of 66 Hydrotap Compact 2 Service Manual - 800560NZ - October 2012 - V1.00
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