ZURN AquaSense AV ZR Series User manual

ZR6003AV
ZR6000AV
Sensor-Operated, Battery-Powered
Closet/Urinal Systems
ZR6000AV
ZR6000AV-WS
ZR6000AV-WS1
ZR6001AV
ZR6001AV-WS
ZR6001AV-WS1
ZR6003AV-WS
ZR6003AV-WS1
AquaSense®AVTM
ZR Series
Sensor-Operated, Battery-Powered
Flushometer.
Installation,
Operation, Maintenance
and Parts Manual
Patented and Patents Pending
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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.

FV62 Rev. D 11/14/18
Page 2
PRIOR TO INSTALLATION
Prior to installing theAquaSense “AV” Flushometer, install the items
listed below:
•Closet or urinal fixture
•Drain line
•Water supply line
IMPORTANT:
•ALLPLUMBING IS TO BE INSTALLED INACCORDANCE WITH
APPLICABLE CODESAND REGULATIONS.
• WATER SUPPLY LINES MUST BE SIZEDTO PROVIDEAN
ADEQUATE VOLUME OF WATER FOR EACH FIXTURE.
• FLUSHALLWATER LINES PRIOR TO OPERATION (See Step 9).
The AquaSense “AV” is designed to operate with 20 to 80 psi (138 to
552kPa)ofwaterpressure.THEMINIMUMPRESSUREREQUIREDTO
THEVALVEISDETERMINEDBYTHETYPEOFFIXTURE 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.
4. Determine 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.
5. Hand 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 8.
2. Prior 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.
1. Install 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. Flush supply line by opening the
control stop. Turn on water supply to flush line of any debris or sediment.
Then close control stop.
1
6. Loosen handle nut, aim sensor at desired tilt angle (horizontal, tilt up, or
tilt down), hold in place and tighten handle nut
4
Adjust sensor
angle to pick
up user
Tilt Down
Horizontal
Tilt Up
6
7
7. Remove electronics access cover with vandal-resistant hex wrench
provided. Insert preassembled battery holder into electronics
compartment. Connect battery cable connector to electronics cable
connector. (Important: Insert non-connector end of battery holder
first, as shown. Ensure foam spacer is in place)
2
3. Insert the flush valve tailpiece into the stop valve and hand tighten the
lock nut to the stop valve. Plumb the entire unit.
3

FV62 Rev. D 11/14/18
Page 3
8. Adjust feature settings as desired. The sensor range is factory set.
If adjustment is necessary, use a Phillips head screwdriver and turn
GENTLY. SEE SENSOR RANGE ADJUSTMENT. Replace electronics
access cover and tighten securely with vandal-resistant hex wrench.
Before 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
usingtheadjustingscrewlocated at thecenter of thestop 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.
9. When 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., fromsystem. Thisprocedure shouldalso berepeated
when the system is drained for seasonal use, as occurs in athletic fields,
recreation parks, etc.
10. The AquaSense “A” 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, open the stop valve completely by using the
adjusting screw and flush theAquaSense “AV” several times. Gradually
adjust the stop valve closed, using the adjusting screw, so that the
rate of water flow into the fixture is not excessive, yet is sufficient to
adequately evacuate the waste. The final setting for closets should
provide a rate of water flow sufficient enough to evacuate thirty sheets
of toilet paper from the fixture. The final setting for urinals should be
such that the fixture will not overflow when the valve is actuated twenty
times in succession. The stop cap screw cover should be replaced after
final adjustments have been made.
Sensor Range Adjustment
The range is factory set for urinal or closet applications. If necessary, the
sensor range can be adjusted. Pressing the reset button will initiate a
ten minute set-up period. During these ten minutes a red light will flash
through the sensor lens when an object is in view of the sensor. Use this
featureto properly setthe sensor range.Slowly rotate therange adjustment
clockwise to increase range and counterclockwise to decrease range. The
range adjustment will stop at minimum and maximum settings. Do not turn
beyond these stops. For an additional ten minutes of blinking, push reset
button. Stand in front of sensor (minimum 10 seconds) and move forward
and backward to determine range.
9
A. Remove the main valve
body cover.
D. Place tube cap over
riser tube.
B. Remove the plastic
cover.
C. Remove the diaphragm
kit assembly from the
flush valve
E. Replace the plas-
tic cover and main
body cover without
reinstalling the dia-
phragm kit assembly.
F. Open the stop valve by
using the stop adjusting
screw and flush out all
debrisfrom pipe andcon-
nections.
G. Shut stop, open cover, remove tube cap, replace the
diaphragmkit assembly,replaceandtighten bothcovers.
Option Setting
Switch 1 -Automatic Flush - The unit will automatically flush 24 hours after
the last user. On position = activate, Off position = deactivate.
Switch 2 - Courtesy Flush - When an object has been detected for two
seconds, the unit flushes then goes into normal mode. On position
= activate, Off position = deactivate. (Always press reset button after
changing switches.)
Switch 3 - Flush Time - Factory setting.
Switch 4 - Urinal Water Saver - Reduces flush volume by 40% during
periods of continuous use. (Note: Always press reset button after
changing switches.)
ON-OFF SWITCHES RESET BUTTON
RANGE ADJUSTMENT
810
Sensor
Control Panel

FV62 Rev. D 11/14/18
Page 4
•Main Flush
The sensor will provide a main flush after a user is in range
for eight or more seconds. The eight-second delay prevents
actuation of the flush valve by a person walking past the
sensor.
•Automatic 24-Hour Flush
The sensor will provide an automatic flush 24 hours after
the last flush. The automatic flush feature can be manually
switched on or off in the field, depending on owner
preference. The option is controlled by switch number one.
•Courtesy Flush
The sensor will provide a courtesy flush within two seconds
after a person is first detected. The courtesy flush freshens
thebowl andremovesany residue fromthefixture.The main
flush will occur when the user steps away from the fixture.
The courtesy flush feature can be manually switched on or
off in the field, depending on owner preference. The option
is controlled by switch number two.
•Maintenance Override
One may initiate an immediate flush by placing a magnet
in front of the sensor window for one-half to three seconds.
This feature is typically used by the cleaning staff who do
not wish to stand in front of the sensor to cause actuation.
One may prevent operation of the flush valve by placing a
magnet in front of the sensor window for longer than three
seconds. This feature is typically used by maintenance or
cleaning staff who wish to prevent automatic actuation of
the valve. This feature is automatically defeated after ten
minutes.
If one wishes to defeat the feature prior to the ten-minute
time out, simply place a magnet in front of the sensor
window for one-half to three seconds.
Zurn RetroFlush System Features
•Indicator Light
The sensor unit includes a red indicator light having three
functions:
1. Range Adjustment: For the first ten minutes of operation,
the red light will flash when an object is detected.
2. Low Battery Indication: When the batteries have reached
the caution level, the red light will flash when an object is
detected.
3. Abnormal Reflection Indicator: When a reflective surface
ispresent forlongerthan 30minutes,the redlightwill flash
indicating that an object is being continuously detected.
•Adjustable Range
The detection distance is field adjustable from 12 to 60
inches. Slowly rotate the range adjustment clockwise to
increase range and counterclockwise to decrease range.
The range adjustment will stop at minimum and maximum
settings. Do not turn beyond these stops. For ten minutes
after battery installation, a blinking red light in the sensor
window will appear when an object is in view. For an
additional ten minutes of blinking, push the reset button.
Standinfrontofthesensorandmoveforwardandbackward
to determine range.
•Urinal Water Saver
This feature is intended for a high-use application, such as
a stadium or civic arena, where a continuous line of users
wait to use a urinal. When a sensor-operated urinal is
used continuously, water consumption can be significantly
reduced. Water is conserved by flushing a partial volume of
water after two consecutive users have been sensed and a
new user enters the range of the sensor within five seconds
of the previous user leaving. This partial flush clears the
urinal and allows for the next repetitive flush to continue to
move the waste water through the drain line. This feature is
automatically defeated if a user does not enter the sensor
range within five seconds of the previous user leaving. The
urinal water saver feature can also be manually switched
on or off in the field, depending on owner preference. The
option is controlled by switch number four.
ON-OFF SWITCHES RESET BUTTON
RANGE ADJUSTMENT
Sensor Control Panel
Maintenance Override Feature

FV62 Rev. D 11/14/18
Page 5
Removing The Old Solenoid
1. Turn off water supply to flush valve at shut off (S.O.).
2. Cycle the valve once – flush it to relieve pressure holding the
valve closed.
3. Remove the main valve body cap (Item #1) from the flush
valve (Item #6) using a wrench.
4. Remove the plastic diaphragm cover (Item #2) from the top of
the diaphragm assembly.
5. Remove the diaphragm assembly (Item #3) from the flush
valve (Item #6).
6. Using a screwdriver, remove the riser tube (Item #5)from the
solenoid (Item #7).
7. Remove the RetroFlush sensor assembly (Item #9) from the
flush valve handle port using a wrench on the handle nut
(Item #11).
8. Remove the solenoid retaining clip (Item #8) and gently pull
the solenoid (Item #7) out of the housing. Note: Pay special
attention to the position of the retaining clip ends to
ensure proper reassembly into the proper slots.
9. Disconnect the sensor cable connector from the solenoid.
Note: If the white connector is not fully accessible, then
see the special instructions on page 6.
ZR Flush Valve/ZRK Retrofit Kit
Solenoid Replacement Instructions
Installing The New Solenoid
1. Connect the cable connector on the solenoid (Item #7) to
the sensor cable connector.
2. Lightly lubricate the solenoid O-ring seal with silicon
grease provided to prevent damage while reassembling
the unit. Insert the solenoid (Item #7) into the housing
and install the solenoid retaining clip (Item #8). When
installed properly, the end of the solenoid housing is free
to rotate. Note: Be careful not to crimp the battery
wires while inserting the solenoid into the housing.
3. Reinstall the RetroFlush sensor assembly (Item #9) onto
the flush valve using a wrench. Be sure the solenoid
inlet (threaded hole) is facing upward when installed in
the flush valve. If not, remove Item #9 and rotate the
solenoid for proper position.
4. Remove old O-ring (Item #4) from the upper part of the
riser tube (Item #5). Install new quad ring (Item #4) onto
the riser tube (Item #5) making sure the quad ring is not
twisted. Lightly lubricate the quad ring with the silicone
grease provided.
5. Reinstall the riser tube (Item #5) onto the solenoid (Item
#7). Tighten snug with screwdriver, do not over tighten.
6. Reinstall the original diaphragm assembly (Item #3) onto
the flush valve (Item #6).
7. Reinstall the original plastic diaphragm cover (Item #2)
on top of the diaphragm assembly (Item #3).
8. Reinstall the main valve body cap (Item #1) onto the
flush valve (Item #6) using a wrench. Tighten properly.
9.Removebatterycover(Item#10) from RetroFlush sensor
assembly (Item #9) with the hex key wrench provided
and press reset button located on the sensor module
case. Reinstall cover (Item #10).
10. Turn on water supply and cycle flush valve for normal
operation. Adjust stop valve for optimal flow to the
fixture.

FV62 Rev. D 11/14/18
Page 6
1. If the white connector is not fully accessible then the
sensor module must be removed from the case in order
to reassemble the solenoid connector to the sensor
connector.
2. Remove the battery cover (Item #10) from the RetroFlush
sensor assembly (Item #9).
3. Remove the battery case (Item #15) and disconnect from
the sensor.
4. Remove the sensor module (Item #12) held in place by
two screws (Item #13) and rubber plug (Item #14).
5. Lightly lubricate the solenoid O-ring seal with silicone
grease provided to prevent damage while reassembling
the unit. Insert the solenoid (Item #7) into the housing
and install the solenoid retaining clip (Item #8). When
installed properly, the end of the solenoid is free to rotate.
Notes: Be careful not to crimp the battery wires while
inserting the solenoid into the housing. Also, be sure
the blue and gray wires of the solenoid valve extend
into the sensor module cavity of the housing (Item #9).
6. Connect the sensor module blue and gray wires to the
solenoid valve blue and gray wires and reinstall the
sensor module. Note: Be very careful not to crimp the
wires when reinstalling the sensor module. Replace
the two screws (do not over tighten) and rubber plug
holding the sensor module in place.
7. Replace the battery pack and reconnect to the sensor.
8. Continue with Step 3 and beyond under “Installing The
New Solenoid” on reverse side of this page.
ZR Flush Valve/ZRK Retrofit Kit
Solenoid Replacement Instructions
Special Note On #9 – Removing Old Solenoid Valve

FV62 Rev. D 11/14/18
Page 7
Covers Product No.
Outside Cover – Chrome Plated(1) P6000-LL-CP
Inside Cover(2) P6000-L
Replacement Kits Product No.
Closet Replacement Kit(4) PR6000-EC
Water-Saving Closet Replacement Kit(4) PR6000-EC-WS
Low-Consumption Closet Replacement Kit(4) PR6000-EC-WS1
Urinal Replacement Kit(4) PR6000-EU
Water-Saving Urinal Replacement Kit(4) PR6000-EU-WS
Low-Consumption Urinal Replacement Kit(4) PR6000-EU-WS1
Replacement Parts – Inside Components Product No.
Riser Tube(5) PR6000-E13F
Closet Volume Control - 4.5 GpF(3) PR6000-EC25
Water-Saving Closet Volume Control - 3.5 GpF(3) PR6000-EC25-WS
Low-Consumption Closet Volume Control - 1.6 GpF(3) PR6000-EC25-WS1
Urinal Volume Control - 4.5 GpF(3) PR6000-EU25
Water-Saving Urinal Volume Control - 3.5 GpF(3) PR6000-EU25-WS
Low-Consumption Urinal Volume Control - 1.6 GpF(3) PR6000-EU25-WS1
Diaphragm PR6000-E15A
Sensor Module Replacement Kits Product No.
Solenoid Valve Replacement Kit(8, 9, 10) PR6000-M
Sensor Lens Kit(12)
PR6000-SC
High Volume Sensor(13) PR6000-SH
Low Volume Sensor(13) PR6000-SL
Battery Holder with Connecting Cable(15, 16) PR6000-MB
Metal Housing(11) PR6000-MH
Vandal-Resistant Cover Wrench(20) PR6000-W
Cover with Screw and Seal for RetroFlush(17-19) PR6000-MC
Parts Replacement Guide
1 Main Valve Body Cover
2 Plastic Cover
3 Volume Control
(Yellow or Red)
4 Diaphragm
5 Riser Tube
6 Main Valve Body
(with Tailpiece)
7 O-Ring
8 Gasket
9 Solenoid Valve
10 Solenoid Valve Retainer Clip
11 Metal Housing
12 Sensor Electronics
13 Sensor Lens Kit for Dual
Flush
14 Sensor Screws - 2
15 Battery Holder and Battery
16 Connecting Cable
17 O-Ring Seal
18 Metal Housing Cover
19 Cover Screw & O-ring
20 Cover Screw Wrench

Product Specifications
Sensor Range: 12” to 60” (adjustable)
Battery Type : AA Duracell Alkaline – Model MN-1500
Battery Life: 3 years at 4,000 flushes per month
Flush Volume: ZR-6000 – 4.5 gallons per flush
ZR-6000-WS – 3.5 gallons per flush
ZR-6000-WS1 – 1.6 gallons per flush
ZR-6001 – 3.0 gallons per flush
ZR-6003-WS – 1.5 gallons per flush
ZR-6003-WS1 – 1.0 gallons per flush
Voltage: 6 VDC
Operating Water
Pressure: 45 psi min running; 80 psi max static.
Note: Installations with running pressure below
recommended value may void warranty.
Automatic Flush: Flush 24 hours after the last use (switchable)
Maintenance
Override: Magnetic flush triggering or inhibiting switch (see
page 2)
Indicator Light: Range Adjustment (first ten minutes)
Low Battery Indication (see page 2)
Reflective surface in view for greater than 30 minutes
(see page 2)
Reset Button: To restart ten-minute range adjustment cycle
To enter option changes in the electronics after
repositioning switches (see page 2)
Operating
Temperature: 35°F to 104°F (2°C to 40°C)
Outside Case
and Cover: Chrome-Plated Die Casting
Operation
1. Invisible light rays are continually emitted from the RetroFlush sensor.
2. When the user comes into range of the sensor’s detection zone (range
12 to 60 inches), the beam is reflected back to the sensor’s receiver
and converted to a low voltage electrical signal that activates an
eight-second time delay circuit. This time delay prevents the unit from
incidental activation in the restroom. Once this circuit is completed, the
output circuit is signaled and continues in a “hold” mode for as long as
the user remains within range of the sensor. User must be in sensor
range for at least 10 seconds.
3.Aftertheuser moves awayfrom thesensor,theabsenceof reflectedlight
starts an electrical “one-time” signal that operates the solenoid operator
(6 VDC) and activates the flushing cycle to flush the fixture. The circuit
then automatically resets for the next user.
IMPORTANT NOTE: The Zurn AquaVantage is engineered for quiet
operation. Excessive water flow creates noise, while too little water
flow may not satisfy the needs of the fixture. Proper adjustment of stop
valve is made when:
1.The plumbingfixture iscleansed after eachflush withoutsplashingwater
out from the lip.
2.Aquiet flushing cycle is achieved.After adjustment of the stop adjusting
screw: replace the Zurn stop cap screw cover.
Care and Cleaning Instructions
DO NOT use abrasive or chemical cleaners to clean flush valve as they
will dull the luster and attack the chrome or special decorative finishes.
Use only mild soap and water, then wipe dry with a clean cloth or towel.
While cleaning the bathroom tile and floor, the flush valve and electronics
should be protected from splattering of water, cleaner, acids and cleaning
fluids that can damage the sensor flush valve.
Problem Cause Solution
Valve will not operate Water supply shut off Turn on water supply, check control stop and supply
Sensor range adjustment set too short Increase sensor range adjustment
Expired batteries Replace batteries
Difficulty with electronic control module Check batteries. If problem continues, consult factory.
Solenoid problem Replace solenoid
Red light flashes when
user is not present Obstruction in front of the sensor Remove the obstruction
Sensor range set too long
Sensor is detecting opposite wall Shorten sensor range
Red light flashes when
user comes into view Batteries about to expire Replace batteries
Unit is in start-up mode Light will stop in 10 minutes
Range adjustment reset button was
pressed. Light will stop in 10 minutes
Valve does not shut off Dirt in diaphragm bypass hole Clean bypass hole
Dirt or debris at valve seat or sealing area Clean valve seat and clean diaphragm kit
Riser tube filter plugged Clean filtered riser tub
Solenoid problem Replace solenoid
Not enough water to
fixture Wrong RetroFlush unit installed Check fixture requirements. Install proper RetroFlush unit.
Control stop improperly adjusted Adjust control stop
Diaphragm damaged Replace diaphragm
Low running pressure Adjust water supply to ensure 45 psi running pressure
at each valve. Move switch #1 to the off position and
press the RESET button for more water per flush.
Solenoid problem Replace solenoid
Too much water for
fixture Wrong RetroFlush unit installed Check fixture requirements. Install proper RetroFlush unit.
Control stop improperly adjusted Adjust control stop
Dirt in diaphragm bypass hole Clean bypass hole
Customer wishes to realize maximum water
savings Change out yellow volume control to red volume control included with kit.
Water drips from
chrome cap The plastic cover has been cracked by freezing or abuse Replace plastic cover
The chrome cap is not tight Tighten chrome cap
TROUBLESHOOTING GUIDE
ZURN INDUSTRIES, LLC 5900 Elwin Buchanan Drive, Sanford, NC U.S.A. 27330, Ph. 1-800-997-3876, Fax [phone]
In Canada: ZURN INDUSTRIES LIMITED 7900 Goreway Drive, Unit 10, Brampton, Ontario L6T 5W6, Ph. 905-405-8272, Fax [phone]
Rev. D Date: 11/14/2018 C.N. No. SAN008311 Prod. | Dwg. No. FV62