ZURN AquaSense AV ZER Series User manual

AquaSense Battery
Powered Flush
Valves/Retrofit Kits
AquaSense®AV
ZER Series
Automatic, Sensor-Operated
Battery-Powered Flushometer
Installation, Operation,
Maintenance, and Parts Manual
Patented and Patents Pending
LIMITED WARRANTY
All goods sold hereunder are warranted to be free from defects in material and factory workmanship for a period of three years from the date of purchase.
Decorative finishes warranted for one year. We will replace at no cost goods that prove defective provided we are notified in writing of such defect and
the goods are returned to us prepaid at Sanford, NC, with evidence that they have been properly maintained and used in accordance with instructions.
We shall not be responsible for any labor charges or any loss, injury or damages whatsoever, including incidental or consequential damages. The sole and
exclusive remedy shall be limited to the replacement of the defective goods. Before installation and use, the purchaser shall determine the suitability
of the product for his intended use and the purchaser assumes all risk and liability whatever in connection therewith.Where permitted by law, the implied
warranty of merchantability is expressly excluded. If the products sold hereunder are “consumer products,” the implied warranty of merchantability is
limited to a period of three years and shall be limited solely to the replacement of the defective goods. All weights stated in our catalogs and lists are
approximate and are not guaranteed.
Sensor-Operated, Battery-Powered
Closet/Urinal Systems
Note: This manual covers all ZER Sensor,
Battery Closet/Urinal Systems with
-CPM (Chrome-Plated Metal Cover) and
-CP (Chrome Plastic Cover) Units.
ZER6000AV-CP
ZER6000AV-CPM
ZER6003AV-CP
ZER6003AV-CPM

ADA

ADA
FV237 Page 1

AquaSense Battery
Powered Flush
Valves/Retrofit Kits
E
A
BA
C
D
D
PRIOR TO INSTALLATION
Prior to installing the ZER Flushometer, install the items listed below:
• Closet or urinal fixture
• Drain line
• Water supply line
B
31
2
F
5Hand tighten spud nut and vacuum breaker tube nut to fixture and flush
valve. Adjust the valve assembly for plumb. Tighten fixture spud nut,
vacuum breaker tube nut and lock nut with a wrench. Do not turn
water on until batteries are inserted – see 6.
4
1Install stop valve assembly using proper size supply escutcheon
and sweat solder adapter kit if applicable. Thread sealing compounds
should be used on male NPT threads only.
4Determine the length of vacuum breaker tube required to join the
flush valve and fixture spud. Cut the vacuum breaker tube, if required,
to this length. Assemble the vacuum breaker tube assembly and spud
nut assembly to the flush valve and fixture spud.
F
2Prior to inserting the flush valve tailpiece into stop valve, be certain
that the O-ring seal is located in O-ring seal groove at the end of
the tailpiece, and the locking nut and locking snap ring are
located as shown. Care should be taken not to damage the O-ring
when inserting the tailpiece into the stop valve. If lubrication is needed,
wetting the O-ring with water will be sufficient.
IMPORTANT:
• ALL PLUMBING IS TO BE INSTALLED IN ACCORDANCE WITH APPLICABLE
CODES AND REGULATIONS.
• WATER SUPPLY LINES MUST BE SIZED TO PROVIDE AN ADEQUATE VOLUME
OF WATER FOR EACH FIXTURE.
• FLUSH ALL WATER LINES PRIOR TO OPERATION (SEE STEP 9).
• DIRT AND DEBRIS CAN CAUSE FLUSH VALVE TO RUN CONTINUOUSLY.
The ZER is designed to operate with 20 to 80 psi (138 to 552 kPa) of water pressure. THE MINIMUM PRESSURE REQUIRED TO THE VALVE IS DETERMINED
BY THE TYPE OF FIXTURE SELECTED. Consult fixture manufacturer for pressure requirements.
Protect the chrome or special finish of this flushometer. DO NOT USE TOOTHED TOOLS TO INSTALL OR SERVICE THE VALVE.
3Insert the flush valve tailpiece into the stop valve and hand
tighten the lock nut to the stop valve. Plumb the entire unit.
AB
D
A
B
D
C
E
Page 2 FV237

AquaSense Battery
Powered Flush
Valves/Retrofit Kits
7VISUAL INDICATOR GUIDE
6ACTIVATION
Using supplied battery compartment wrench,
remove battery compartment from the
E-Z Flush™unit.
Load batteries into compartment tray
(note position of batteries in tray), and
reinstall battery tray into the E-Z Flush unit.
Secure tray with battery compartment wrench. The last three turns of
the wrench will activate the E-Z Flush unit. The E-Z Flush System is
now operational.
Your E-Z Flush unit comes preset from the factory. If special circumstances
require adjustment of the activation distance, see Item 11 – “Adjusting
Your E-Z Flush.”
The E-Z Flush unit has a 10-minute start-up sequence in which the sensor
will flash the User-In-View yellow L.E.D. continuously as long as a user is
in view. After the start-up sequence is completed and when the sensor
has a user in view, the User-In-View yellow L.E.D. will flash only 3 times
after a 5-second delay. This delay prevents needless flushes when
someone walks by.
Sensor units should not be located across from each other or in close
proximity to highly reflective surfaces.
SENSOR
COURTESY MANUAL FLUSH BUTTON Allows manual activation of flush
when needed.
6
BATTERY L.E.D. Red light flashes indicating it is time to replace batteries
with 4 new “C” batteries.
USER-IN-VIEW L.E.D. Yellow light flashes 3 times – after 5-second
delay – when a user is in view. The yellow light flashes constantly
when a user is in view during the 10-minute start-up sequence.
8Before the supply water is turned on, be sure all stop valves to the
flush valves are closed off tight. The stop valves can be opened and
closed by using the adjusting screw located at the center of the stop
valve cap , behind the adjusting screw cover if already installed.
Stop valve adjustments can only be made by using the adjusting screw.
It is not necessary to remove the stop valve cap when making
adjustments. If for any reason it becomes necessary to remove
the stop valve cap, be certain the water is shut off at the main
supply valve.
8
T
T
7
FV237 Page 3

AquaSense Battery
Powered Flush
Valves/Retrofit Kits
Use the following procedure to flush out the supply piping:
A. Remove the main valve body cover and internal plastic cap .
B. Remove the trip mechanism from the flush valve and set aside
(shown in 9).
C. Replace the plastic cover and main body cover without rein-
stalling the trip mechanism .
D. Open the stop valve by using the stop adjusting screw and flush out
all debris from pipe and connections.
E. Once pipe and connection are flushed, shut off stop, open cover,
reinstall the trip mechanism , replace both covers ( and )
and tighten.
This procedure should also be repeated when the system is drained for
seasonal use, as occurs in athletic fields, recreation parks, etc.
O
9
10
10 The ZER flush valves are preset for fixture volume as marked on the
valve cartons. The valve does not require regulation for variation in
water pressure within its operating range. To set the flush valve for
proper operation, gradually adjust the stop valve open, using the adjusting
screw, while actuating the valve until the rate of water flow into the
fixture is not excessive, yet is sufficient to adequately evacuate the
waste. The final setting for urinals should be such that the fixture will
not overflow when the valve is actuated in succession. The stop cap
screw cover should be replaced after final adjustments have been made.
Working Parts
Q
P
O
New RetroFlush
Diaphragm Kit
9When all flush valves are connected to the fixtures and water pressure
is available, it is recommended that the supply piping be flushed to remove
dirt, pipe chips, etc., from system.
TROUBLESHOOTING GUIDE
PROBLEM CAUSE SOLUTION
Yellow L.E.D. light flashes 3 times Front of sensor is covered or sensor is set too far Remove item covering sensor or adjust sensor activation
when there are no users. out, registering the opposite wall or door as a user. distance. (See 11 – “Adjusting the E-Z Flush.”)
Yellow L.E.D. light flashes E-Z Flush unit is in 10-minute start-up mode Yellow L.E.D. light will flash only 3 times, acknowledging
continuously when sensor (when first activated). a user is in view after the 10-minute start-up mode.
is activated by a user.
Red L.E.D. light flashes. Batteries need replacing. Replace batteries.
Not enough water to fixture Diaphragm damaged or valve control stop Replace diaphragm and/or adjust valve control stop.
or too much water to fixture. improperly adjusted.
Valve will not operate. Sensor range set too close to E-Z Flush, batteries Adjust sensor, replace batteries, or turn water on. If the
are dead, or water supply is turned off. E-Z Flush does not begin to function, call Customer Service
at 1-800-997-3876.
Valve does not shut off. Dirt or debris preventing diaphragm from Remove dirt or debris, check by-pass hole in diaphragm.
functioning properly.
Valve does not flush even after Batteries are dead. Replace batteries. If the E-Z Flush does not begin to function,
sensor has been adjusted. call Customer Service at 1-800-997-3876.
P
PO
Q
Q
Q O P
Page 4 FV237

AquaSense Battery
Powered Flush
Valves/Retrofit Kits
WIRING DIAGRAM
STEP A Use battery compartment wrench to
remove battery compartment tray.
STEP B Pull cover off by rotating battery side
forward and out.
STEP C Sensor Adjustor Tool comes in a built-
in storage pocket. Replace after use.
11 ADJUSTING YOUR E-Z FLUSH
TO CHANGE ACTIVATION DISTANCE FOR THE SENSOR
1. Remove battery compartment tray as shown in Step 11.
2. Remove cover and sensor adjustor tool as shown in Step 11.
3. Replace battery compartment without cover in E-Z Flush to activate unit (the yellow L.E.D. will flash continuously when it has an object in view for the
10-minute reset period). See Step 6, “Activation.”
4. Have an individual stand at desired activation distance.
5. Use sensor adjustor tool and turn Sensor Range Adjustment Screw all the way down and then turn slowly up until yellow L.E.D. begins to flash.
6. Ensure sensor is not detecting stall door or wall by closing door, stepping out of sensor path and making sure yellow L.E.D. is not flashing. If sensor
locks onto door or wall, unit will not flush properly. Shorten activation distance.
7. Remove battery compartment, replace sensor adjustor tool and cover. Replace battery compartment tray to reactivate E-Z Flush unit.
8. After 10-minute start-up sequence, the yellow L.E.D. will flash only 3 times when a user is in view (after a 5-second delay).
FV237 Page 5

AquaSense Battery
Powered Flush
Valves/Retrofit Kits
ZURN INDUSTRIES, INC. COMMERCIAL BRASS OPERATION
5900 ELWIN BUCHANAN DRIVE, SANFORD, NC, U.S.A. 27330, PHONE: [phone], FAX: [phone], WEBSITE: www.zurn.com
IN CANADA: ZURN INDUSTRIES LIMITED 3544 NASHUA DRIVE, MISSISSAUGA, ONTARIO L4V 1L2, PHONE: [phone], FAX: [phone]
© 2004 Zurn Industries, Inc. Printed in the U.S.A. Form No. FV237, 6/04
Parts Identification
1.* Seal
2.* Collar Gasket
3. Sensor Module
4.* Manual Override Push Button
5. Replacement Sensor Lens
6. Chrome Plastic Cover
7. Chrome Metal Cover
8. Battery Drawer
9.* O-Ring
10. Valve Body Cover
11. Plastic Cover
12. Trip Mechanism
13. Diaphragm Repair Kit
14. Valve Body
15. Vacuum Breaker Friction Washer
16. Vacuum Breaker Insert
17. Vacuum Breaker Duckbill
18. Vacuum Breaker Tube
19. Vacuum Breaker Tube Nut
20. Spud Nut
21. Spud Friction Washer
22. Spud Sleeve
23. Spud Escutcheon
24. Tailpiece
25. Snap Ring
26. Tailpiece O-Ring
27. Locking Nut
28. Setscrew for Cast Wall Flange
29. Cast Wall Escutcheon
30. Supply Cover Tube
31. Sweat Solder Adaptor
32. Stop Body
33. Piston Seal
34. Piston
35. Stop Spring
36. Guide O-Ring
37. Piston Guide
38. Guide Holder
39. Adjusting Screw
40. Stop Cap
Covers and Repair Kits Product No.
Outside Cover - CP – Item 10 P6000-LL-CP
Inside Cover – Item 11 P6000-L
Low Consumption Closet Kit – 1.6 gal. flush P6000-ECA-WS1
Water Saving Closet Kit – 3.5 gal. flush P6000-ECA-WS
Full Flow Closet Kit – 4.5 gal. flush P6000-ECA-FF
Low Consumption Urinal Kit – 1.0 gal. flush P6000-EUA-WS1
Water Saving Urinal Kit – 1.5 gal. flush P6000-EUA-WS
Full Flush Urinal Kit – 3.0 gal. flush P6000-EUA-FF
Control Stop Repair Kit and Parts Product No.
Control Stop Repair Kit for 1" and 3⁄4", P6000-D-SD
Includes Items 33-39
Seal Seat for 1" and 3⁄4", Includes Item 33 P6000-D42
VP Control Stop Repair Kit for 1" and 3⁄4", P6000-D-VP
Includes Items 33-39
Sweat Solder Connection with Cast Wall Flange, P6000-YBYC
Includes Items 29-31
Adjustable Tailpieces Product No.
Adjustable Tailpiece for Standard Flush Valve, P6000-J1
Includes Items 24-26
Tailpiece Coupling Assembly, Includes Items 25-27 P6000-K
Tailpiece Locking Ring, Includes Item 25 P6000-C30
Tailpiece O-Ring, Includes Item 26 P6000-C31
Coupling Nut, Includes Item 27 P6000-C32
Flush Connections and Spud Coupling Kits Product No.
Flush Tube Assembly for Flush Valves, Includes Items 15-19.
Specify diameter and length. P6000-A
Vacuum Breaker Repair Kit, Includes Items 15-17 P6000-B
Spud Coupling Assembly, Includes Items 20-23.
Specify size. P6000-H
Repair Parts – Inside Parts Product No.
Urinal Relief Valve – Item 12 P6000-EU13
Closet Relief Valve – Item 12 P6000-EC13
AquaVantage Rebuild Kits Product No.
Closet and Urinal Rebuild Kits Include P6000-ECA-WS-RK
Items 12, 13, 15-17, 26 P6000-ECA-WS1-RK
P6000-EUA-WS-RK
P6000-EUA-WS1-RK
Handle Assembly and Repair Kits Product No.
Chrome Plastic Cover – Item 6 PERK6000-L-CPCR
Chrome Metal Cover – Item 7 PERK6000-L-CPMCR
Replacement Sensor Lens – Item 5 PERK6000-SCR
Battery Drawer – Item 8 PERK6000-BD
*Repair Kit Includes Item 1, Item 2, Item 4 and Item 9 PERK6000-RK
Sensor Module PERK6000-SR
AquaVantage®Exposed E-Z Flush Repair Kits
41. Snap Cap Screw Cover
42. Vandal-Resistant Control Stop Cover
43. Setscrew for Control Stop Cover
44. Handle Nut Wrench
45. Allen Wrench