800557UK - HT_Miniboil Service Manual_UK_09-12

Service Manual
Zip HydroTap Miniboil
®
Boiling and ambient drinking water for kitchens and the home.
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 1 of 28
Contents
General information and warnings . . . . . . . . . 3
General Technical Description . . . . . . . . . . . . 4
Technical Specifications . . . . . . . . . . . . . . . . 4
Operation - General . . . . . . . . . . . . . . . . . . . . 5
- Tap Operation . . . . . . . . . . . . . . . . . . . 5
- Sleep Mode . . . . . . . . . . . . . . . . . . . . 5
- Filter Light . . . . . . . . . . . . . . . . . . . . . 5
LED Indicators on Miniboil PCBA . . . . . . . . . . 6
Fault Diagnosis Flow Chart . . . . . . . . . . . . . . 7 - 9
Components . . . . . . . . . . . . . . . . . . . . . . . . . 10
Definition, Testing and Replacment Procedures
- Tap Assembly. . . . . . . . . . . . . . . . . . . 10
- Filter and Inlet Water Assembly . . . . . 11
- Appliance Entry . . . . . . . . . . . . . . . . . 12
- Earthing Continuity Test . . . . . . . . . . . 12
- Solenoid Valves . . . . . . . . . . . . . . . . . 13 - 14
- Boiling Water Level Sensors . . . . . . . . 14 - 15
- Thermal Overload. . . . . . . . . . . . . . . . 16 - 17
- Heating Element. . . . . . . . . . . . . . . . . 18 - 19
-Temperature Sensor . . . . . . . . . . . . . . 19 - 20
- Boiling Water Module & Pump . . . . . . 21
- Leak Detector. . . . . . . . . . . . . . . . . . . 22
- Fitting. . . . . . . . . . . . . . . . . . . . . . . . . 22
- PCBA . . . . . . . . . . . . . . . . . . . . . . . . . 23
Exploded View & Parts List . . . . . . . . . . . . . . 24 - 27
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 28
Page 2 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
General Information and Warnings
This Service Manual contains the information you will need to service the wiring, plumbing, temperature sensors, valves
and taps; and to gain access to the inside of the unit and main tank. It also shows how to deal with any mineral scale
that may accumulate. You will also find the necessary diagrams and illustrations, and a detailed fault finding guide.
This guide matches possible faults with probable causes; a summary of what to do; and finally the page reference to
the place in this manual where the fault is dealt with in detail. Please read these warnings before servicing any Zip
HydroTap appliance. Never attempt to service any Zip HydroTap appliance without reading all of the applicable servicing
instructions. The Zip HydroTap Miniboil is an electronically controlled appliance designed to provide filtered boiling and
ambient water for drinking and cooking purposes in residential kitchens.
The models covered in this service manual are 39118 and 39119
The following points are important whenever you service any Zip HydroTap appliance.
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. Zip recommends that you use only Molykote III as sealant grease. Other sealant
greases may be hazardous to your health. 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).
WARNING
The Zip HydroTap Miniboil unit must be earthed. The resistance of the earth connection from each exposed metal part
must be less than 1 Ohm.
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 Zip product may void warranty coverage.
All Plumbing must comply with AS3500.4.1 & AS3500.4.2
All Electrical must comply with AS3350.1, AS3350.2.15
All Plumbing and Electrical connections must be made in accordance with local regulations.
This service manual should be used in conjunction with the current version of the Operating and Installation Instructions.
It requires qualified technical knowledge and offers support for the maintenance and repair by a qualified tradesperson
only!
Due to the process of continuous improvement, Zip Heaters reserves the right to change details mentioned in this manual
without notice.
Technical Description
The Zip HydroTap Miniboil is an under-bench drinking water appliance with a dispensing tap mounted on a sink or bench
and is designed for use in residential applications only. This product dispenses filtered Ambient and boiling water up to
98°C (factory set to 98°C) and is NOT designed to be used for washing up or to provide hot water for a kitchen sink or
sanitary fixture.
The Miniboil Tap is fitted with a Safety button which is permanently turned on and cannot be deactivated therefore to
dispense boiling water you must use two (2) fingers and touch both the safety and boiling water buttons simultaneously.
The water from the outlet once at temperature is boiling and if used for a purpose other than its intended use,
could cause a serious scald or burn.
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 3 of 28
General Technical Description
The HydroTap Miniboil uses three (3) level sensors in the boiling water tank and is filled at a metered rate via a solenoid
valve. This metered rate allows the appliance to keep the water in the tank as close to its set temperature as possible as it
fills or re-fills. The water is heated via the element and temperature control is achieved via the temperature sensor probe
and the PCBA (Printed Circuit Board Assembly). There are three (3) temperature settings 92°C, 95°C and 98°C. These can
be manually selected by moving the bridging connector on the PCBA. These three settings allow for operation at different
altitudes. The boiling water is dispensed from the tap using a pump. A feature of the Miniboil is “soft start” which helps to
prevent the boiling water splashing out of a cup. This ensures a smooth steady flow. The unit also features a safety time
out of fifteen (15) seconds when dispensing boiling water.
The Hydrotap Miniboil also has a built in energy saving “Sleep Mode”. After 2 hours of non use the appliance will “go to
sleep” allowing the temperature of the boiling water to decrease to 64°C at which point the appliance will use Power
Pulse™ to maintain this temperature. During “Sleep Mode” the boiling water (red) LED will flash slowly, full recovery from
64°C to the factory setting of 98°C will take approximately two and a half minutes (2min 30 sec).
The HydroTap Miniboil also dispenses Filtered Ambient water. This operates on a “push through” system therefore the flow
rate from the tap can be affected by the inlet pressure to the appliance.
Technical Specifications
HydroTap Miniboil Elite & Classic Under-Sink Unit
Specification
Model Number
39118
39119
1.8L
1.8L
92°C - 98°C
92°C - 98°C
2000 Watts
2000 Watts
(D.O.M. 04/2011 – 07/2012)
(D.O.M. 04/2011 – 07/2012)
1500 Watts
1500 Watts
(D.O.M. 08/2012 till current)
(D.O.M. 08/2012 till current)
Weight (Empty)
6.5Kg
6.5Kg
Weight (Full)
8.3Kg
8.3Kg
212w x 272d x 338h
212w x 272d x 338h
Factory Filter life setting 1
12 months
12 months
Factory Filter life setting 2
4000L
4000L
Yes
Yes
Boiling Water Capacity
Boiling Water Temperature (adjustable)
Element Rating
Dimensions (mm)
Sleep Mode
HydroTap Miniboil Elite & Classic Tap Assembly
Specification
Model Number
39118
39119
Boiling water safety button
Yes
Yes
Filter change indicator LED
Yes
Yes
Distance (centre of Tap to Centre of Outlet)
92mm
110mm
Height (Sink to Outlet)
125mm
135mm
Hole size required for mounting
35mm
35mm
Font required for Bench mounting*
90046
90915
*Font is supplied with a 100mm tap shaft extension for Font dimensions refer to the Font installation instructions
Page 4 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Operating the Tap
•
•
To dispense boiling water touch the Red Markers + Safety Lock simultaneously.
To dispense ambient water touch the blue markers.
Red Boiling Water Light
ON all the time:
Flashing Fast:
Flashing Slowly:
This indicates boiling water is ready to be dispensed.
This indicates the boiling water is below usable temperature and the Sleep Mode is OFF.
This indicates Sleep Mode is active.
To Reset Sleep Mode
Set Sleep Mode ON:
Set Sleep Mode OFF:
Touch the COLD markers and SAFETY lock simultaneously for at least 5 seconds, until both
the RED and WHITE lights flash together, for a few flashes. Sleep mode maintains the water
temperature at 64ºC and will only become active when the system has not been used for 2
hours. Operation of the tap will wake the system from sleep and boiling water will be available
when the RED light is ON all the time. (This may take a few minutes)
Touch the COLD markers and SAFETY lock simultaneously for at least 5 seconds, until both the
RED and WHITE lights flash alternately, for a few flashes.
White Filter Light
Flashing:
This indicates the filter needs to be replaced. The WHITE light will start to flash when the
counters have recorded 12 months of use or after dispensing 4000 Litres, whichever occurs
first.
Set filter light OFF:
Reset the system by touching continuously, the COLD and HOT markers. The flashing WHITE
light will turn OFF after 10 seconds and the counters will be set to zero
Filter change:
If the filter is changed early, reset the system by touching continuously, the COLD and HOT
markers. The WHITE light will turn ON and after 10 seconds will turn OFF. The counters will be
set to zero.
WARNING:
When all the lights are flashing, the system has experienced a fault. Turn the power OFF to the
undersink unit for at least 15 minutes. When the power is turned ON the system may revert to
normal operation. If all the lights continue to flash then there is a system fault which must be
rectified by an authorised service agent.
BLUE markers for
Ambient water
Warning lights
RED markers for
Boiling Water
Fig.1 - Miniboil tap top
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Safety lock
Page 5 of 28
LED Indicators on Miniboil PCBA
NOTE: The Zip HydroTap Miniboil does not have a display screen. To help identify the current status of the appliance refer
to the table below and compare it with what is happening on the Miniboil PCBA.
Status
RED LED
GREEN LED
Internal leak
On
On
Leak Detector Fault
On
Flashing
Temperature Sensor Fault
Flashing
Off
Fill Time out (Water supply Fault)
Flashing
Flashing
Off
Flashing
Normal Operation
Fig.2 - LED Indicator on Miniboil PCBA
Page 6 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Fault Diagnosis Flow Chart
Miniboil Tap Does Not operate (no lights visible)
Is there 230V 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 23)
Yes →
Replace Tap Head assembly. (See page 10)
All the LED lights on the Miniboil Tap are flashing
Press the boiling and safety button together. Can you hear the unit heating? If yes, the unit’s red light will stop flashing
when the unit has reached temperature. The white flashing light means the unit requires a filter change. If no, is the unit
in sleep mode?
Yes →
Advise the customer of sleep mode and its operation (see page 5) The filter may require changing as well
(see page 5).
No →
Has there been a blackout or an interruption to the power supply?
Yes →
Turn the power to the Miniboil off for 15 minutes, if when you turn the power back on all the LED indicators continue to flash proceed to the next step.
No →
Is the water supply turned on and is there water present on the outlet side of the filter?
No →
Reinstate the water supply to the Miniboil turn the power off for 15 minutes and the turn
the power back on
Yes →
Is there any water damage or corrosion in the USB connection?
Yes →
Replace which ever lead (or both) that is damaged. (See page 10)
No →
Is there a flash code indicated on the PCBA LED’s?
No →
Replace PCBA. (See page 23)
Yes →
Refer to Flash code table to identify the fault and repair. (See page 6)
Slow ambient water flow and slow Boiling water recovery
Make sure there are no restrictions or kinks in the hoses to the tap. Is there water supply to the filter?
No →
Check filtermate (DNR PLV valve) and water supply to unit. (See page 11)
Yes →
Is there water supply to the inlet on the unit?
No →
Replace the filter. (See page 11) If there is still no water supply to the unit replace the filter
head.
Yes →
Is there good water flow through the safety solenoid?
No →
Change safety solenoid. (See page 13 - 14)
Yes →
Is there good water flow through both sides of the dual solenoid? (Boiling
side is restricted to 0.5 litre a minute.)
No →
Replace double solenoid.
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 7 of 28
Setting Operational Modes
Miniboil Tap LED lights are illuminated but there is no boiling water flow
Ensure 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 10)
No →
Is there 12 Volts to the hot pump when the boiling and safety buttons are
pressed?
No →
Replace the PCBA (see page 23).
Yes →
Replace the hot pump.
Boiling Water is not hot
Is the unit in sleep mode?
Yes →
Advise customer of sleep mode and its operation. (See page 5)
No →
Is the boiling water (red) LED indicator constantly illuminated?
Yes →
Is the unit dispensing water from the tap? See chart above for fault finding.
No →
Has the over temperature cut out tripped?
Yes →
Re-set the over temperature cut out and test the temperature sensor probe. (See page 19 - 20) 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 18 - 19.)
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 23)
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.
Unit is over filling.
Check all water connections are correct. Does the unit over fill 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?
Page 8 of 28
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 fig 35 on page 23)
No →
Tighten or fit screws.
Yes →
Replace PCBA.
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Setting Operational Modes (continued)
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 flow to the filter head?
No →
Replace the multi valve.
Yes →
Is there good water flow through the filter?
No →
Replace the filter. If problem still persists replace the filter
head as well.
Yes →
Check the water flow through both of the solenoid valves.
Replace the one with poor water flow through it. If they both
have good flow, 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 flood sensor. Check all plumbing fittings in the unit. If any of the John Guest fittings are leaking, you can
replace them or the o’rings can be replaced. If one is leaking, replace all o’rings or fittings in the unit. If all the plumbing
fittings 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 fig
35 on page 23)
No →
Tighten or fit screws.
Yes →
Is there a circuit through each of the level probes to the level plug on the
PCBA? (See page 14 - 15)
No →
Replace the level sensors.
Yes →
Replace the PCBA. (See fig 35 on page 23)
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 9 of 28
Components
Caution! Before you commence any service work on a HydroTap Miniboil 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.
Tap Assembly
The HydroTap Miniboil Tap uses three (3) capacitive sensor switches (refer to page 5 & 6 for how to use the tap) it is connected to the under-sink unit via a data cable and USB plug and socket. This is a non repairable item and if found to be
faulty should be replaced.
Tap Head and Cap Removal
1.
Isolate the electrical and water supply to the HydroTap Miniboil.
2.
Disconnect the Tap loom (USB connector).
3.
Disconnect the Boiling, Ambient and Vent outlet tubes from the underside of the tap.
4.
Remove the securing nut from the threaded rod and remove tap from sink.
5.
Remove second nut on threaded rod.
6.
Gently remove the tap head from the tap body and pass the loom and USB plug through the tap body.
Tap Head and Cap replacement
1.
Perform the removal procedure in reverse.
2.
Re-connect the Boiling, Ambient and Vent outlet tubes to the tap.
3.
Turn on the water and power supply.
4.
Test the new tap head to ensure it is working correctly. (see page 5 how to use)
Fig.3 - Tap head removal picture
Page 10 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Filter and Inlet Water Assembly
The HydroTap Miniboil has an externally mounted multi valve (double non-return & 350 kPa pressure limiting valve) and
filter assembly. These items must be installed prior to the inlet connection on the Miniboil. (refer to Installation & Operation
Instructions)
Changing the filter
1.
Isolate the mains water supply.
2.
Touch the Ambient (blue) button on the Miniboil tap to release any trapped pressure.
3.
Turn the filter a quarter turn to the left (clockwise) and pull the filter down gently.
4.
Unpack the New filter ensuring you do not touch the o-ring seals.
5.
Insert the new filter and rotate the cartridge a quarter turn to the right (counter clockwise).
6.
Remove the inlet water supply John Guest pipe from the inlet fitting on the unit and hold the open end over a
large bucket.
7.
Turn on the water supply and flush a minimum or seven and a half (7.5Lt) of water through the cartridge.
8.
Turn the water supply off and re-connect the John Guest inlet pipe to the MiniBoil.
9.
Turn on the water supply and check for leaks and correct operation of the tap.
10.
Reset the filter counter (refer to page 5).
Turn the cartridge a quarter turn to the right until it locks into position.
Reverse this procedure for removal.
Flow Direction
Inlet Fitting
DNR &
Pressure Limiting Valve
Fig.4 - External filter connection
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 11 of 28
Appliance Entry
1.
2.
3.
4.
5.
6.
Isolate the electrical and water supply to the HydroTap Miniboil.
Disconnect the Tap loom (USB connector).
Disconnect the water supply John Guest fitting and the Boiling, Ambient and Vent outlet tubes.
Remove the Miniboil under-sink unit from the cupboard.
Remove the three (3) screws located on either sides of the under-sink unit.
Slide the outer case forwards.
Fig.5 - Miniboil under-sink unit
Earthing Continuity Test
After each service, the earth continuity must be checked. Use a megameter, 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 multimeter 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. This test is shown in Figure 6.
Figure.6 – Earthing continuity verification
1
Megameter or appliance tester
2
One probe connected to chassis
3
Other probe connected to earth pin of power plug
4
Electricity cable
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.
All readings should be less than 1 Ohm. If any of the readings is more than this, check the earth connection inside the
Miniboil.
Page 12 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Solenoid Valves
There are two (2) solenoid valves in the Zip HydroTap Miniboil, the main or “safety” solenoid and a secondary or “slave”
solenoid the latter has a single inlet and a double outlet one for the ambient water supply to the tap and the other for the
cold fill supply to the boiling water tank. In order to identify which solenoid valve might be faulty check the resistance
(Ohms Test) through the wiring loom PCBA connector. This will ensure you have continuity through the wiring loom and
the coil on the valve. (Colour picture of this & correct resistance readings)
If you have the correct resistance readings you will need to perform a “live test” to ensure there is 240V power at the
terminals on the solenoids when they are supposed to be operating. If there is no power to the solenoids then the fault
lies with the PCBA. (see page 23)
Safety Solenoid
Double Solenoid
Fig.7 - Solenoid valve location
Continuity Test of Solenoid

Fig.8 - Continuity test of solenoid valves - Pass
X
Fig.9 - Continuity test of solenoid valves - Fail
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 13 of 28
Solenoid Valves
Solenoid Removal
1.
2.
3.
4.
5.
See page 12 for appliance entry.
Disconnect the spade connectors joining the wiring loom to the solenoid valves.
Disconnect both outlets from the secondary “slave” solenoid valve.
Remove the two (2) retaining bracket screws located on the rear of the Miniboil chassis.
Remove the mounting bracket and valve assembly.
Fig.10 - Solenoid valves set up
Solenoid Replacement
1.
2.
3.
4.
5.
6.
7.
Replace the faulty solenoid valve.
Perform the removal procedure in reverse.
Make sure all wiring is fixed in place with cable ties.
Connect and turn on the water supply checking for any leaks.
Perform an earthing continuity test. (see page 14)
Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap.
Turn on the power supply to the HydroTap Miniboil.
Level Sensor
The Zip HydroTap Miniboil 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 sensors from getting a resistance reading potentially causing the
tank to overfill. If you experience an overfilling fault also refer to page 8, PCBA earth.)
Level sensor
Level Sensor Removal
1.
2.
3.
4.
See page 12 appliance entry.
Disconnect the level sensor wiring loom from the PCBA.
Remove the insulation lid from the boiling water tank.
Remove protective cover and the two (2) retaining nuts that
secure the level sensor assembly to the lid of the boiling water
tank.
Fig.11 - Level sensor removal
Page 14 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Level Sensor
Level Sensor Testing

X
Fig.12 - Level sensor testing - pass
Fig.13 - Level sensor testing - Fail
Level Sensor replacement
1.
2.
3.
4.
5.
6.
Replace the faulty level sensor assembly.
Perform the removal procedure in reverse.
Make sure all wiring is fixed in place with cable ties.
Perform an earthing continuity test. (see page 12)
Replace the outer case and connect the tap loom and supply tubes from the under-sink unit to the Miniboil tap.
Turn on the water and power supply to the HydroTap Miniboil and check operation.
BLACK
WIRE
RED
WIRE
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.
BLUE
WIRE
HIGH LEVEL
MIDDLE LEVEL
Ensure when removing the sensor holder
you check the underside sealing gasket
for any faults or imperfections. If needed
replace.
HYDROTAP BC 100/125-HOT TANK
WATER LEVEL
HIGH
LENGTH
SENSOR ASSY NO
57mm
HydroTap MIDDLE
Miniboil 79mm
- Hot Tank
83299
205mm
Water LOW
Length
Sensor No.
levelHYDROTAP BC 150/175-HOT TANK
High
WATER LEVEL
HIGH
Middle
MIDDLE
LOW
LENGTH
57mm
57mm
79mm
78mm
258mm
SENSOR ASSY NO
83300
93126
LowDOMESTIC HYDROTAP
205mmBC 60/85-HOT TANK
WATER LEVEL
LENGTH
HIGH
120mm
MIDDLE
140mm
LOW
205mm
SENSOR ASSY NO
83343
LOW LEVEL
Fig.14 - Correct wiring
A1224-LEVEL-SENSORS-HOTNCOLD.DRW
PAGE 1 OF 2
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 15 of 28
Thermal Overload Assembly
Thermal overload assembly
The thermal overload assembly is designed to isolate the element by disconnecting both poles preventing over boiling if
the hot sensor or PCBA 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 Miniboil.
Ensure that the vent pipe is cool to touch then depress the red reset button in the middle of the thermal 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
Fig.15 - Location of overload
Removal of the thermal overload
1.
2.
3.
See page 12 for appliance entry.
Remove the two securing screws holding the overload in place.
Ensure you note down which way the wires are connected then remove the quick connectors from the thermal
overload. (See figure 19 on page 18)
Continuity test of overload

Fig.16 - Continuity test of overload - pass
X
Fig.17 - Continuity test of overload - fail
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 16 of 28
Thermal Overload Assembly
Re-installation of the thermal overload assembly
1.
2.
3.
4.
Perform the removal procedure in reverse.
Perform an earthing continuity test. (see page 12)
Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap.
Re-connect and turn on the water and power supplies to the HydroTap Miniboil.
Important Note: When fitting new overload.
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 below when upgrading
to the new overload.
Do not mechanically adjust spade connectors on the overload. Excessive lateral force and deflection may result in deformation of tthe copper rivets.
Old Overload
New Overload
From PCBA heater
From PCBA heater
Contact pair 1
To element
2
1
2
Contact pair 2
1
Contact pair 1
Contact pair 2
To element
Fig.18 - Old and new overload
NOTE: Numbering of the pairs
on the black plastic housing.
Page 17 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Heating Element
The element is used to heat the water. The element is designed to only be used while submerged in water.
To test the element, isolate the mains power and water supplies to the Miniboil. Disconnect both element wires then using
a multimeter, select ohms and test the resistance between both element wires.
Element
Fig.19 - Location of heating element
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%
**The Miniboil only comes with a 2000 Watt element. The resistance reading will be 28.9 (approx.)
**Element size for units manufactured from 04/2011 till 07/2012 is 2000watts. Units made from 08/2012 till current have
a 1500watt element.
Fig.20 - Continuity test of element
Fig.21 - Blown Element
Removal of element:
1.
Isolate the water supply to the Miniboil.
2.
Use the Miniboil Tap to drain the boiling water tank.
3.
See page 12 for appliance entry.
4.
Remove the insulation lid from the boiling water tank.
5.
Disconnect the earth lead from the main chassis.
6.
Disconnect the wiring from the PCBA to level sensors and temperature sensor.
7.
Disconnect the wiring from the thermal overload to the element.
8.
Unscrew the two (2) screws that fasten the lid to the boiling water tank and remove the tank lid and element
assembly.
9.
Remove the earth connection from the tank lid this will release the element.
10.
Remove the element.
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 18 of 28
Heating Elements
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.
Perform an earthing continuity test. (see page 12 )
5.
Replace the outer case and connect the supply tubes from
the under-sink unit to the Miniboil tap.
6.
Turn on the power supply to the Miniboil.
Fig.22 - Live test of voltage to overload and element. **caution high voltage will be present**
Temperature Sensor Probe
There is one (1) temperature sensor probe in the HydroTap Miniboil. The red or hot sensor probe provides a temperature
reading of the water in the boiling tank allowing the PCBA to regulate the element as required. The set temperature for the
boiling water can be changed using the bridging connector on the PCBA (see fig 33 on page 23).
Signs the sensor may need replacing
Sensor is physically broken.
There is no continuity (resistance) through the sensor.
The sensor is brittle to touch.
The resistance to temperature reading is incorrect. (See resistance to temperature chart.)
Fig.23 - Resistance to temperature chart
Page 19 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Temperature Sensor Probe
Continuity verses temperature reading test

Fig.24 - Continuity and temprature
test on flow sensor - Pass
X
Fig.25 - Continuity and temprature
test on flow sensor - Fail
Fig.26 - Continuity test
Temperature Sensor probe removal (Picture of sensor probe in pocket on top of tank)
1.
2.
3.
4.
See page 12 appliance entry.
Remove the top insulation panel from the boiling water tank.
Remove the hot (red) sensor probe from pocket on lid of the boiling tank.
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).
Fig.27 - Top of hot tank. Location of level
sensors, element and hot sensor probe.
Hot Sensor in Pocket
Temperature sensor probe replacement
1.
2.
3.
4.
5.
6.
Perform the removal procedure in reverse.
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 (Show photo).
Turn on the water supply and check for any leaks.
Perform an earthing continuity test (see page 12).
Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap.
Turn on the power supply to the HydroTap Miniboil.
Page 20 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Boiling Water Module & Pump
Boiling water pump operation
The Zip HydroTap Miniboil dispenses boiling water via a 12 Volt pump featuring a “soft start” to prevent water splashing
out of your cup, the speed then increases to achieve a smooth steady flow. The pump also features a maximum run time
of fifteen (15) seconds at one time.
This pump is controlled by the PCBA and the operational program includes a self priming feature to ensure that air does
not get trapped in the pump. Every 5 minutes the PCBA will prime the pump by activating it for 0.06 seconds.
Caution: If the pump has failed you will not be able to drain the boiling water tank prior to its removal. 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.
Boiling water module & pump removal
1.
2.
3.
4.
5.
6.
7.
8.
9.
See page 12 for appliance entry.
Remove the insulation panel from the top of the boiling water tank.
Disconnect the water inlet (copper tube) from the silicone elbow on the lid.
Disconnect the pump wiring, 2 earth connections, temperature sensor, heater connections and level sensor
wiring from the PCBA and chassis.
Remove all cable ties.
Release the clip from the top packing strap that holds the tank assembly to the chassis.
Slide the boiling water outlet and vent pipe outlet fitting from the chassis and carefully remove the tank
assembly. TIP – Ensure you do not let the outlet pipe drop below the top (height) of the tank as water will drain
from it. Once the tank has been removed from the unit, remove the four screws holding the lid of the boiling
water tank and remove it, together attached wiring, from the tank. Carefully drain the tank (completely) into a
sink or other water receptacle.
Remove and slide the quick release clip from the pumps inlet hose and remove the cable tie on the outlet of the
pump.
Remove the pump.
Hot pump replacement
1.
2.
3.
4.
5.
6.
Perform the removal procedure in reverse.
Make sure all wiring is fixed in place with cable ties.
Turn on the water supply and check for any leaks.
Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap.
Perform an earthing continuity test. (see page 12)
Turn on the power supply to the HydroTap Miniboil.
Fig.28 - Outlet Fitting
Fig.29 - Hot Tank Removed
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Fig.30 - Hot Pump
Page 21 of 28
Leak Detector
There is a “Flood Detector” located within the sealed safe tray of the HydroTap Miniboil under-sink unit. This allows the
PCBA 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 wiring and corroded terminals.
Leak Detector removal
1.
See page 12 appliance entry.
2.
Remove the retaining screw holding the detector in place.
3.
Disconnect the wiring loom from the PCBA.
Fig.31 - Flood sensor location
Leak detector 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 Miniboil tap.
5.
Perform an earthing continuity test. (see page 12)
6.
Turn on the power supply to the HydroTap Miniboil.
Internal Leak
TIP: If you have had an internal leak follow (leak detector removal steps 1 - 5) 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-connect the Miniboil under-sink unit to the
Miniboil 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 aging o-rings that are used as a seal in the John Guest fittings.
Fitting
John Guest Fitting Tips
Fig.32 - 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.
Page 22 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
PCBA
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 PCBA
1.
See page 12 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 replacement
1.
Perform the removal procedure in reverse.
2.
Ensure you wire the PCBA as per the wiring diagram.
3.
Perform an earthing continuity test (see page 12).
4.
Replace the outer case and connect the supply tubes from the under-sink unit to the Miniboil tap.
5.
Re-connect and turn on the water and power supply to the HydroTap Miniboil.
Miniboil PCBA Altitude Adjustment
To adjust for the correct altitude, select your preferred setting with the bridging connector.
Failure to set the temperature to the correct altutude setting will result in HydroTap over boiling.
Altitude Setting Guideline
Temperature
Altitude
98°C
Sea level - 600m
95°C
600m - 1400m
92°C
> 1400m
*Factory set to 98°C.
Fig.33 - Temperature settings on PCBA
Miniboil PCBA Fuses
There are two (2) fuses located on the PCBA the 1Amp fuse protects the PCBA and the 10Amp fuse protects the element.
TIP: Overfilling Tank
Please be aware that there is no additional earth strap on the Miniboil PCBA. The PCBA is earthed via the retaining nut and
bolt that secures the PCBA heat sink in place. If this nut is loose it may cause the boiling water tank to overfill.
Please emsure
this nut is tight
Fig.34 - Miniboil PCBA Fuses
Fig.35 - Miniboil PCBA heatsink earth connection
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 23 of 28
Miniboil Parts Diagram
26
ELITE TAP
23
CLASSIC TAP
28
25
24
27
9
13
12
16
2
1
4
17
3
6
11
5
8
7
21
14
10
30
20
15
22
19
18
Page 24 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Miniboil Parts List
Item
Part
1
93120UK GASKET ELBOWS KIT MINIBOIL
1
2
90618UK ELEMENT KIT 1500W
1
3
93114UK SAFETY SOLENOID KIT
1
4
93115UK ADAPTOR 1/2BSPx1/4 JG CI3208 KIT
1
5
93116UK DOUBLE SOLENOID BARBED KIT
1
6
93117UK NUT ASSY FEMALE 3/4BSP x 1/4JG KIT
1
7
93119UK OVERLOAD 2 POLE KIT
1
8
91271UK BULKHEAD 1/4’ JG KIT
1
9
90190UK LOOM PCB TO TAP W GLAND
1
10
93121UK HYDROTAP 12VDC PUMP KIT
1
11
93126UK LEVEL SENSOR ASSY KIT
1
12
93122UK PCB KIT
1
13
93123UK LEAK DETECTOR KIT MINIBOIL
1
14
90186UK LOOM PCB TO OVERLOAD KIT
1
15
93124UK SOLENOIDS TO PCB LOOM KIT
1
16
93125UK LEVEL SENSOR LOOM H-TANK KIT
1
17
93127UK SENSOR PROBE HOT TANK KIT HTAP
1
18
90833UK KIT APEX MULTI-VALVE 350Kpa
1
19
99048UK SINGLE FILTER HEAD ASSY
1
20
21
22
Description
/
SUB-MICRON - TRIPLE ACTION
90978UK HOT TANK KIT COPPER WELDED
/
HydroTap MINIBOIL FILTER KIT
Qty
1
1
1
23
90985UK MINIBOIL CLASIC TAP ASSY
1
24
93129UK CAP ASSY KIT _ MINIBOIL CLASSIC
1
25
90046UK FONT KIT STANDARD
1
26
90984UK MINIBOILELITE TAP ASSY
1
27
93128UK CAP ASSY KIT-MINIBOIL ELITE
1
28
90915UK FONT KIT-MINIBOIL ELITE
1
29
93118UK Stem Elbow Assy JG 1/4” Kit
1
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 25 of 28
HydroTap Miniboil Wiring Diagram
HYDROTAP MINIBOIL
Wiring diagram
BLUE
HIGH L.
RED
MIDDLE L.
BLACK
LOW L.
BLACK
OVERLOAD
SAFETY
SOLENOID
BLACK
RED
HOT TANK
YELLOW
ELEMENT
DOUBLE
SOLENOID
TAP
J10
MAINS
POWER
GREY
10A FUSE
J2
HOT SENSOR
RED
BLUE
RED
BLACK
BLACK
RED
HOT TANK
FILLER
BLUE
J11
J3 J7 J8
J5
AMBIENT
OUTLET
RED
1A FUSE
0.5A
J12
YELLOW
89653
HOT PUMP
FLOOD DETECTOR
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
Page 26 of 28
Notes
Page 27 of 28
Zip HydroTap Miniboil- Service Manual - 800557UK - September 2012 v1.00
Head Office
Zip Heaters (UK) Ltd
14 Bertie Ward Way
Dereham
Norfolk NR19 1TE
Page 28 of 28
Website: www.zipheaters.co.uk
sales@zipheaters.co.uk
Telephone: 0845 602 4533
Facsimile: 01362 692 448.
Zip HydroTap Miniboil - Service Manual - 800557UK - September 2012 v1.00
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