ZURN Z6140 User manual

Aquaflush
Flush Valves
Aquaflush®
Z6100 Series
Aquaflush Concealed 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.
Aquaflush Concealed
Closet/Urinal Systems
Z6140
Z6142
Z6143
Z6144
Z6150
Z6152
Z6154
Z6155
Z6190
Z6195
Z6196
Z6140
Z6195
FV251 Page 1

Aquaflush
Flush Valves
ENGINEERING SPECIFICATION: ZURN Aquaflush Concealed
Closet Flush Valve – Concealed, quiet diaphragm-type, rough brass
flushometer valve with chloramine resistant, dual seal diaphragm
with a clog resistant by-pass. Complete with a non-hold-open
and no leak handle feature, high back pressure vacuum breaker,
flush tube, elbow flush connections, wall escutcheon, fixture spud
escutcheon, and fixture spud securing nut. Control stop has internal
siphon-guard protection. Internal seals are made of chloramine
resistant materials.
MODELS
Z6140 – 1-1/2" Water Closet valve with top spud connection
Z6152 – 1-1/2" Water Closet valve with back spud connection
Z6190 – 1-1/4" Urinal Valve with top spud connection
Z6195 – 3/4" Urinal Valve with top spud connection
FLOWS
-WS1 Low Consumption
1.0 Gal. for Urinal, 1.6 Gal. for Water Closet
-WS Water Saver
1.5 Gal. for Urinal, 3.5 Gal. for Water Closet
(Standard Flow)
-FF Full Flow
3.0 Gal. for Urinal, 4.5 Gal. for Water Closet
OPTIONS
-BG BioCare ADA Handle
-J Metal Oscillating ADA Handle
-L 1" [25] Metal Push Button
-L3 3" [76] Metal Push Button
-YB Sweat Solder Kit
Other
Models: Z6152
-WS1 (water saver) 1.6 Gal. Low Consumption
Models: Z6140
-WS1 (water saver) 1.6 Gal. Low Consumption
Models: Z6195 (3/4" urinal flush valve) shown,
Z6190 (1-1/4" urinal flush valve)
-WS1 (water saver) 1.0 Gal. Low Consumption
Aquaflush Rough-In, Product Specification, Models and Options
Page 2 FV251

Aquaflush
Flush Valves
Aquaflush Installation Instructions
3. Remove the actuator end, coupling and mounting nut from the
actuator sleeve and insert the sleeve through the 1-1/2" hole
from the fixture side. Reinstall the mounting nut (hand tight),
coupling and actuator end to the sleeve.
3
1. Install the Zurn Control Stop to the supply line with the water
outlet positioned as needed. If using a sweat solder adaptor,
sweat the adaptor to copper tubing before installing control stop.
2. Attach vacuum breaker tube and elbows to fixture with spud
nut. Note: When cutting scored pipe to fit, leave a minimum
of 1-1/4" of scoring to ensure proper engagement with
compression coupling.
Important:
• All plumbing is to be installed according to state and local codes
and regulations.
• Water supply lines need to allow proper water flow for each
fixture.
• Flush all lines of any debris before making connections.
• Do not use pipe sealant or plumbing grease on any fitting other
than the control stop inlet.
The Aquaflush valve is designed to operate under various water
pressures with a recommended range between 10 and 100 psi
(69 to 689 kPa). Each Zurn valve is tested for proper performance
at the factory before being shipped. Consult the product pages of
the catalog for available flow options.
Most low consumption valves (1.6 gallon) require a minimum of 25
psi running pressure through the valve to obtain proper evacuation.
When installing your quality Zurn valve, it is recommended that a
smooth jawed wrench be used. This will prevent gouges and
scratches on your valve.
Before starting the installation process, bore a 1-1/2" hole in
wall for actuator, and a 2" hole for piping if required.
4. Insert the adjustable tail piece into the control stop while installing
the valve. Note: The adjustable tail piece allows for +/- 1/2" from
the standard 4-3/4" centerline to centerline rough in. Lubricate
O-ring on adjustable tail piece with water if needed for installation.
Secure the valve by hand tightening the actuation coupling nut
and tail piece coupling nut. Position valve over flush tube and
secure with the flush tube coupling nut. After aligning the valve
securely tighten the actuator assembly, control stop and the flush
tube with a wrench. A smooth jaw wrench is recommended to
protect special finishes.
4
5. Shut off the control stop, remove the valve cover and remove
the internal diaphragm kit. Reinstall the valve cover and open
control stop to flush lines of debris. After the lines are clear,
remove the cover and reinstall the diaphragm kit. Tighten the
cover back on and adjust flush flow using the control stop.
The stop cap screw cover should be replaced after final
adjustments have been made.
5
2
1
Control Stop
Sweat Solder Adaptor
with Copper Tubing
1-1/4" Min.
4-3/4"
± 1/2"
FV251 Page 3

Aquaflush
Flush Valves
Engineering Specification: Zurn Z6199 Access Panel and Frame for Manual-Operated Concealed Flush Valves –
The access panel and frame provide quick and simple access to in-wall concealed flush valves when a mechanical chase of
adequate size is not available. The panel is #14 gage stainless steel and the frame is #18 gage stainless steel. Both have a satin
finish. The assembly comes complete with (4) 1" [25 mm] vandal-proof screws. Specify Z6199-BX12 for 12" x 12", Z6199-BX15
for 15" x 15", or Z6199-BX17 for 13" x 17".
Z6199-BX12
SUFFIX OPTIONS
(Check/specify appropriate options.)
-SP Solid Panel
-2VPS 2" [51mm] Long
Vandal-Proof Screws
Z6199-BX15 Z6199-BX17
Step 1: Determine the applicable column by locating the valve’s 4-digit model number.
Step 2: Determine the applicable row by locating the correct wall thickness.
NOTE: For wall thicknesses not listed, locate and use the next largest size.
Step 3: Order the applicable suffix shown at the intersection of the row and column.
Example: For closet valve model number Z6152 and a wall thickness of 6", order: Z6152-LDIM9.
Combination
Closets Urinals Fixtures
6140 6152 6602
6142 6154 6602
Wall 6143 6155 6609 6601
Thickness 6144 6605 6190 6613 6603
“W” 6150 6611 6681 6195 6615 6616
1/4" LDIM4 LDIM7 LDIM4 LDIM5
1" LDIM4 LDIM7 LDIM4 LDIM5
2" LDIM5 LDIM8 LDIM5 LDIM6
3" LDIM6 LDIM9 LDIM6 LDIM7
4" LDIM7 LDIM10 LDIM7 LDIM8
5" LDIM8 LDIM11 LDIM8 LDIM9
6" LDIM9 LDIM12 LDIM9 LDIM10
7" LDIM10 LDIM13 LDIM10 LDIM11
8" LDIM11 LDIM14 LDIM11 LDIM12
9" LDIM12 LDIM15 LDIM12 LDIM13
10" LDIM13 LDIM16 LDIM13 LDIM14
Z6199
Product No. Size A B C D E F
Z6199-BX12 12 x 12 [305x305] 12 [305] 12 [305] 13-1/2 [343] 13-1/2 [343] 5-1/2 [140] 5-1/2 [140]
Z6199-BX15 15 x 15 [381x381] 15 [381] 15 [381] 16-1/2 [419] 16-1/2 [419] 7 [178] 7 [178]
Z6199-BX17 13 x 17 [330x432] 17 [432] 13 [330] 14-1/2 [368] 18-1/2 [470] 6 [152] 8 [203]
Specifying “L” Dimension for Concealed Manual-Operated Flush Valves
Z6199 Model Access Panel and Frame
for Manual-Operated Concealed Flush Valves
Page 4 FV251

Aquaflush
Flush Valves
Parts Identification
1. Optional 1" Metal Push Button
2. Optional 3" Metal Push Button
3. Handle
4. Actuator Rod
5. Handle O-Ring
6. Handle Spring
7. Handle Seal Retainer
8. Handle Seal
9. Gasket
10. Valve Body Cover
11. Plastic Cover
12. Trip Mechanism
13. Retainer Disk
14. Diaphragm
15. Flow Ring
16. Guide Ring
17. Cylinder Slide
18. Valve Body
19. Vacuum Breaker Friction Washer
20. Vacuum Breaker Insert
21. Vacuum Breaker Duckbill
22. Vacuum Breaker Tube
23. Vacuum Breaker Tube Nut
24. Coupling Nut
25. Spud Friction Washer
26. Spud Rubber Gasket
27. 90° Elbow
28. Tailpiece
29. Snap Ring
30. Tailpiece O-Ring
31. Locking Nut
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
41. Wheel Handle
42. Wheel Handle Screw
Covers and Repair Kits Product No.
Outside Cover - RB – Item 10 P6000-LL-RB
Inside Cover – Item 11 P6000-L
Low Consumption Closet Kit – 1.6 gal. flush P6000-ECR-WS1
Water Saving Closet Kit – 3.5 gal. flush P6000-ECR-WS
Full Flow Closet Kit – 4.5 gal. flush P6000-ECR-FF
Low Consumption Urinal Kit – 1.0 gal. flush P6000-EUR-WS1
Water Saving Urinal Kit – 1.5 gal. flush P6000-EUR-WS
Full Flush Urinal Kit – 3.0 gal. flush P6000-EUR-FF
Control Stop Repair Kit and Parts Product No.
Control Stop Repair Kit for 1" and 3⁄4",
Includes Items 33-39 P6000-D-SD
Seal Seat for 1" and 3⁄4", Includes Item 33 P6000-D42
Sweat Solder Connection P6000-YBA
Adjustable Tailpieces Product No.
Adjustable Tailpiece for Standard Flush Valve,
Includes Items 28-31 P6000-J1-RB
Tailpiece Locking Ring, Includes Item 29 P6000-C30
Tailpiece O-Ring, Includes Item 30 P6000-C31
Coupling Nut, Includes Item 31 P6000-C32-RB
Flush Connections and Spud Coupling Kits Product No.
Flush Tube Assembly for Concealed Flush Valves
Refer to Section Q in Aquaparts Guide. P6000-Q _ _-
Specify ‘L’ Dim. and valve used.
Vacuum Breaker Repair Kit, Includes Items 19-21 P6000-B
Spud Coupling Assembly, Includes Items 56-58
Specify size. P6000-HN
Repair Parts – Inside Parts Product No.
Urinal Relief Valve – Item 12 P6000-EU13
Closet Relief Valve – Item 12 P6000-EC13
Handle Assembly and Repair Kits Product No.
Concealed Valve Actuator P6000-N-
(Spec. Type and ‘L’ Dim.) P6000-NL-
P6000-NL3-
Handle Repair Kit (Side), Includes Items 4-9 P6000-NK
Handle Seal, Includes Item 8 P6000-M9
Handle Gasket, Includes Item 9 P6000-M10
Aquaflush Rebuild Kits Product No.
P6000-ECR-WS-RK
Closet and Urinal Rebuild Kits, P6000-ECR-WS1-RK
Includes Items 4-9, 12-17, 19-21, 30 P6000-EUR-WS-RK
P6000-EUR-WS1-RK
Aquaflush Repair Kits
43. Solid Gasket
44. Solid Handle Nut
45. Flanged/Scored Horizontal Tube
46. P30 Flat Gasket
47. Wall Escutcheon
48. Sleeve/Socket
49. Adjusting Nut
50. Optional Bell Nut
51. Handle Nut
52. Push Rod/Filler Rod
53. Spud Nut
54. 3/4" 90° Elbow
55. 3/4" Horizontal Tube
56. 3/4" Spud Nut
57. Spud Friction Washer
58. Spud Rubber Gasket
FV251 Page 5

Aquaflush
Flush Valves
Care of Chrome-Plated Surfaces
The suggested cleaning of chrome-plated surfaces is simply to clean them with mild soap and water, then dry. Commercial cleaning compounds are never recommended.
Seasonal Use
Valves used in installations subject to shut down because of cold and freezing conditions should be maintained in the following manner. After the main supply has
been shut off and the water drained from the system, remove the stop valve cap and stop valve internals to allow the water to drain from the flush valve itself.
*See previous page for numerical references.
Problem Cause* Corrective Action*
Valve will not operate. 1.) Stop valve is closed. 1.) Open stop valve.
2.) Supply valve is closed. 2.) Open supply valve.
Insufficient volume of water 1.) Stop valve is not open enough. 1.) Open stop valve for desired volume of water.
to adequately siphon fixture. 2.) Urinal trip mechanism installed in wrong kit, 2.) Replace urinal part with proper closet valve part.
urinal or closet.
3.) Insufficient volume or pressure at supply. 3.) If gauges are not available to measure supply pressure or volume
of water at the valve, completely remove the working parts and
open the stop valve to allow water to pass through the empty valve.
If the supply is adequate to siphon the fixture, the guide ring (#16)
may be removed from the guide assembly to provide additional
flow. Should this prove unsatisfactory, steps should be taken to
increase the pressure and/or supply.
Flush valve shuts off too quickly. 1.) Damaged or punctured diaphragm. 1.) Install new P6000-EUR replacement kit to remedy the problem.
(#12 thru #17)
2.) Enlarged by-pass orifice. 2.) Install new P6000-ECR, P6000-EUR replacement kit to remedy the
problem. (#12 thru #17)
Valve is short flushing. 1.) Cylinder guide assembly and diaphragm assembly 1.) Screw the two assemblies hand tight.
are not tight.
2.) Enlarged by-pass orifice. 2.) Install new P6000-ECR, P6000-EUR replacement kit to remedy
the problem. (#12 thru #17)
3.) Urinal trip mechanism (black #12) in closet 3.) Install closet trip mechanism (white #12).
flush valves.
Valve is flushing too long or 1.) Trip mechanism not seating properly due to foreign 1.) Disassemble parts and rinse thoroughly.
not shutting off. material between trip mechanism and retainer disc.
2.) By-pass orifice is plugged or partially plugged. 2.) Examine by-pass orifice and clean if necessary being certain
not to enlarge orifice opening.
3.) Line pressure is not adequate to force 3.) Pressure is inadequate or has dropped below minimum operating
trip mechanism to seal. range. Steps should be taken to increase the line pressure.
4.) Cracked cover. 3.) Replace cover with new one (#11).
Water splashes out of fixture. 1.) Supply volume is more than is necessary. 1.) Adjust downward on control stop.
2.) Lime accumulation on vortex or spreader holes 2.) Remove the lime build up.
of fixture.
Flush is not considered quiet. 1.) Control stop may not be adjusted for quiet 1.) Adjust the control stop for quiet operation keeping in mind the
operation. fixture evacuation requirements.
2.) Fixture may be contributing to noise. 2.) Check noise created by fixture by placing a cover over the bowl
opening to separate valve noise from bowl noise. If it is determined
the fixture is too noisy consult with fixture manufacturer.
3.) Piping system may be source of noise. 3.) High pressure in the system can sometimes be controlled by the
stop valve. Other sources of noise may be the absence of air
chambers and shock arrestors, loose pipes, improper size pipes,
etc. In these cases the building engineer should be consulted.
Chattering noise in flush valve. 1.) Segment diaphragm (#14) has been installed 1.) Reposition segment diaphragm as instructed by the markings on
upside down. the diaphragm (”this side down”).
2.) The inside cover has been distorted by freezing 2.) Replace both inside plastic cover and outside brass cover.
or abuse.
Handle assembly leaking. 1.) Handle assembly is not tight. 1.) Tighten handle assembly.
Aquaflush Trouble Shooting Guide
© 2004 Zurn Industries, Inc. Printed in the U.S.A. Form No. FV251, 8/01
ZURN INDUSTRIES, INC. COMMERCIAL BRASS OPERATION, 5900 ELWIN BUCHANAN DRIVE, SANFORD, NC, U.S.A. 27330
PHONE: [phone] FAX: [phone] WEBSITE: www.zurn.com
ZURN INDUSTRIES LIMITED 3544 NASHUA DRIVE, MISSISSAUGA, ONTARIO L4V 1L2 PHONE: [phone] FAX: [phone]