ZURN AquaSense ZER-TM Series User manual

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Power Options:
Lithium Metal Battery (Standard)
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 nishes warranted for one year. We will replace at no costs goods that prove defective provided we are notied 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.
NOTICE: READ ENTIRE MANUAL PRIOR TO INSTALLING PRODUCT
AquaSense®
ZER-TM Series
Automatic Sensor-Operated Gear
Driven Type Flushometer Retrot Kit
Installation,
Operation, Maintenance
and Parts Manual
Universal Kit
Water Closet Kit:
ZERK-C-ONE-TM 1.1 gpf
ZERK-C-HET-TM 1.28 gpf
ZERK-C-WS1-TM 1.6 gpf
ZERK-C-DF-TM 1.1/1.6 gpf
Urinal Kit:
ZERK-U-ULF-TM 0.125 gpf
ZERK-U-EWS-TM 0.5 gpf
ZERK-U-WS1-TM 1.0 gpf
Sloan Kit
Water Closet Kit:
ZERK-C-ONE-TM-S 1.1 gpf
ZERK-C-HET-TM-S 1.28 gpf
ZERK-C-WS1-TM-S 1.6 gpf
ZERK-C-DF-TM-S 1.1/1.6 gpf
Urinal Kit:
ZERK-U-ULF-TM-S 0.125 gpf
ZERK-U-EWS-TM-S 0.5 gpf
ZERK-U-WS1-TM-S 1.0 gpf

FV687 Rev. A 12/16/2019
Page 1
Required Additional Tools
ZER-TM Series Retrot Kit Package Contents
Flat Head
Screwdriver
Smooth Jawed
Wrench
Strap Wrench
Valve Head
Magic
Magnet Batteries
Handle Cap Seal
Handle Nut
Diaphragm Kit
Alternative
Locking Ring
3/32”, 5/64”
Allen Wrench

FV687 Rev. A 12/16/2019
Page 2
Prior to Installation:
• The ZER-TM ushometer is designed to operate optimally between 25 psi (running) to 80 psi (static) water pressure (172 to 552
kPa). Higher running pressure may be required for some xtures. Consult xture manufacturer for details.
• When installing a ushometer, it is important that the ush volume matches the requirements of the plumbing xture.
• To protect chrome nish, do not use toothed tools to install or service the ushometer.
• Before installing your Zurn® Gear Flush valve Retrot kit, the items listed below should already be installed on site:
- Closet or urinal xture
- Fixture carrier
- Flush valve
- Drain line
- Water supply line
Overview:
Zurn Aqua-Sense® ZER-TM Series Retrot kit o󰀨ers in a variety of ow rates. The ZER-TM design is a chrome plated brass
body with an automatic sensor-operated gear driven valve. The retrot kit incorporates a diaphragm kit with ltered bypass and
valve head with an electronic override pushbutton (MOB) for alternative ushing method. All internal and external gaskets and
seals are chloramine resistant.
NOTE: The information in this manual is subject to change at any time without notice. Installations may
be performed at di󰀨erent times of construction by di󰀨erent individuals. For this reason, these instructions
should be left on-site with the facility or maintenance manager.
Specications:
Voltage: 6 VDC Series [4 “AA” 1.5V Lithium Cells] or 6 VDC Series [4 “AA” 1.5V Alkaline Cells]
Sensor Range: Factory set for user at end of elongated bowl or eld adjustable by installer
Important Safety Information:
• Installer is responsible for ensuring the product is installed and conforms to all plumbing codes and ordinances.
• Do not convert or modify this Zurn product yourself. All warranties will be voided.
• Water supply lines must be sized according to building designer in order to provide adequate water supply for each xture.
• Flush all water lines prior to making connections.

FV687 Rev. A 12/16/2019
Page 3
Retrot Valve Head - STEP 1
STEP 1.5
Install valve head on to diaphragm kit loosely by turning locking
clockwise by hand. While locking ring is installed loosely, adjust
valve sensor to face user location. Once sensor angle is set
correctly, turn locking ring to a full stop clockwise by hand, then
tighten it down using strap wrench for at least a third of a turn
more.
STEP 1.6
If retrot from another ZER-TM Series Flush Valve, Skip to Step
3 for battery installation instruction. Else, follow Step 2 to install
handle nut.
NOTE: Before installation, turn o󰀨 water supplies to existing xture and remove ushometer if replacing an existing device.
STEP 1.1
Remove vandal-resistant cover with allen wrench from control
stop (if present) and turn control stop clockwise to turn o󰀨 the
water supply.
STEP 1.3
Uninstall existing valve cap/valve head with supplied strap
wrench by turing counter-clock wise, then remove the diaphragm
within by sliding it straight up carefully.
STEP 1.2
Press and hold the handle for 3 seconds for manual ush valve
or press manual override button for Automatic ush valve to
release any residual pressure.
STEP 1.4a
Test t Alternative Sloan Locking Ring on valve Body. If it ts,
follow instruction on page 5 to replace locking ring on valve head,
then continue to step 1.4b. Otherwise, follow step 1.4b.
STEP 1.4b
Remove valve head and diaphragm kit from packing and carefully
slide diaphragm kit into valve body with orice placed on the
opposite side of the tailpiece
Figure 1 Figure 2
Figure 3 Figure 4
Figure 5
Tail piece
Orice

FV687 Rev. A 12/16/2019
Page 4
STEP 2.1
Uninstall existing handle on manual ush valve or actuator on
automatic ush valve by turning the handle nut counter-clockwise
with a smooth jawed wrench (not supplied).
STEP 2.2
Place handle cap seal in handle nut. Then turn handle nut clockwise
by hand to a full stop, then tighten it for at least a third
of a turn clockwise with a smooth jawed wrench (not supplied).
Replacing Handle Nut - STEP 2 (If applicable)
Figure 6
Battery Installation - STEP 3
Figure 7
Handle
Cap Seal
Handle Nut
STEP 3.1
Use the 3/32” Allen Wrench to loosen the internal set screw
counter-clockwise until it stops. Screw will retract into the shell.
STEP 3.2
Remove the valve head by turning it counter-clockwise and lifting
gently. Disconnect the wire harness before fully removing valve
head.
Figure 8 Figure 9
STEP 3.3
Flip the valve head upside down on a at, soft surface. Loosen
the knurled screw by hand to remove the battery cap. Use at
head screwdriver to loosen knurled screw if necessary.
STEP 3.4
Remove the battery cap from the battery housing.
Figure 10 Figure 11

FV687 Rev. A 12/16/2019
Page 5
Battery Installation - STEP 3
STEP 3.5
Insert four batteries (supplied) into battery housing and ensure the
batteries are inserted in the correct orientation. Use AA Lithium
Batteries or AA Alkaline batteries, but do not mix Lithium with Alkaline.
STEP 3.6
See notes below and reverse steps 3.1 - 3.4 to reinstall battery
cap and valve head onto valve body. Then, turn control stop back
on by turning counter-clockwise using a at head screw driver.
Figure 12
Note: Knurled screw on
battery cap should only
tighten by hand.
Note: During reassemble,
connectors between valve
head and valve body should
be placed in the empty
place as shown below.
Figure 13B
318613-001
Figure 13A
Figure 14
Figure 15
Locking Ring Replacement (when necessary)
STEP 2
Remove the three phillip head screws on the ring insert to
seperate ring insert from the manifold assembly.
STEP 1
Follow battery installation step 3.1 & 3.2 to sepreate shell
assembly from manifold assembly.
STEP 3
Switch out standard locking ring with alternative Sloan locking
ring. Note that standard locking ring should read “318613-001”
on indicated location (See Figure 14) while alternative Sloan
locking ring should read “318613-002”.
STEP 4
Reinstall ring insert back on to manifold assembly using the same
three phillip head screws.
STEP 5
Ensure the cables are placed inside the cable routing features
on both motor bracket and ring insert. Also, the connector
should be placed in the empty place indicated in Figure 15 before
reassambling the shell assembly.
STEP 6
Reverse step 3.1 & 3.2 in battery installation section to
reassemble shell assembly.
318613-001
Ring
Insert
Locking
Ring
Phillip
Screws Cable Routing
Motor
Bracket
Cable
Routing

FV687 Rev. A 12/16/2019
Page 6
Sensor Angle Adjustment (when necessary)
STEP 2
Mark down Locking ring original position relative to valve body
with tape or marker. Loosen locking ring (See Figure 16) on
valve head using strap wrench (supplied) turning counter-
clockwise.
STEP 1
Turn o󰀨 control stop using a at head screw driver turning
clockwise (See Figure 16). Then, use the electronic override
button to ush the water out of the ush valve.
STEP 3
Rotate ush valve head to adjust sensor angle.
STEP 4
Tighten locking ring back to original position with strap wrench
(supplied) by turning clockwise.
STEP 4
Place valve head back onto diaphragm kit. Tighten locking ring
back to original position with strap wrench (supplied) by turning
clockwise.
STEP 5
Turn control stop back on by turning counter-clockwise using a
at head screw driver.
STEP 5
Turn control stop back on by turning counter-clockwise using a
at head screw driver.
Locking Ring
Orice
Diaphragm Kit
Manifold Stem
Control Stop
Electronic
Override
Button
Diaphragm Replacement and Cleaning (when necessary)
STEP 1
Turn o󰀨 control stop using a at head screw driver turning
clockwise (See Figure 16 above). Then, use the electronic
override button to ush the water out of the ush valve.
STEP 2
Mark down Locking ring original position relative to valve body
with tape or marker. Uninstall valve head by loosening locking
ring (See Figure 16 above) using strap wrench (supplied) turning
counter-clockwise.
STEP 3B - Replace Diaphragm Kit
Slide out existing diaphragm kit under valve head and replace
with new diaphragm kit back into the valve body with the orice
on the opposite side from the tail piece. Inspect o-rings and
replace with supplied o-rings if damage is seen.
STEP 3A - Cleaning Diaphragm Kit
Slide out existing diaphragm kit under valve head. Wash
diaphragm and orice throughly with water. Slide cleaned
diaphragm kit back into the valve body with the orice on the
opposite side from the tail piece. If cleaning diaphragm and
orice do not resolve issue, follow step 3B.
Do not to damage or enlarge orice. Doing so will result in
incorrect ush rate.
Figure 16
Figure 17

FV687 Rev. A 12/16/2019
Page 7
Courtesy Flush Settings (when necessary)
A courtesy ush can be enabled for the ZER-TM ushometer where the valve will automatically ush at a specied interval based on
customer preference.
STEP 1
Reference Step 4 Battery installation section on page 6 to
remove battery cap.
STEP 2
Remove 4 small screws on two sides and 1 long screw in the
center (See gure 19) with cross head screwdriver.
STEP 3
Detach electronic housing cover slowly without disconnect
connector within electronic housing.
STEP 4
Manipulate Dipswitches #2 and #3 (See table below) located
inside the electronic housing to change the courtesy ush
interval.
On
O󰀨
Courtesy Flush Interval Dipswitch #2 Dipswitch #3
Disabled (Default Setting) OFF OFF
24 hours OFF ON
48 hours ON OFF
72 hours ON ON
Test new calibrated sensor range using targets of various
material types/textures to ensure calibration accuracy. Verify
that sensor range does not detect stall doors or other reective
surfaces.
Sensor Range Adjustment (when necessary)
STEP 3
After 10 LED ashes followed by a double ash the new
detection range will be calibrated and set. If the Magnet was
not removed at the end of the 5 second ash above, then the
valve may enter Calibrate Mode again if the magnet is not
removed immediately after the double ash.
STEP 1
Place a piece of cardboard or a light-colored target at desired
detection range away from sensor.
Note: When placing the target for a water closet consider that
when standing at the front of the bowl the sensor is focused on
the right upper thigh area.
STEP 2
Place the Zurn MagicMagnet® (supplied) on top at surface (see
Figure 18). Once magnet is in place, the red LED illuminate
continuously on for 5 seconds. The LED will quickly ash and
then begin ashing once a second. The valve will then have
entered Calibrate Mode and the magnet can be removed.
Note: The target must be in position no later than the end of the
2nd ash after the quick ash. The last 8 ashes will determine
the new detection range.
Figure 18
Figure 19 Figure 20

FV687 Rev. A 12/16/2019
Page 8
Problem Indicator Cause Corrective Action
Flush valve does not ush.
No water ushed. Stop valve is closed Open stop valve
No lights on sensor board Batteries not making contact
Remove and reinstall batteries correctly.
See step 4 on page 5 for reference.
Sensor ashes every 10
seconds
Low battery voltage indication
Sensor ashes every 30
seconds
Continuous user detection of object
within sensor range
Inspect and clean lens
Identify and remove any user from
sensor eld
Reduce sensor range distance (see
page 6 for Sensor Range Adjustment
instructions)
Sensor detects user but fails
to ush upon exiting sensor
range
Battery power level too low to activate
ush valve (Sensor rmware prevents
valve from opening when there is not
enough energy to fully close)
Replace batteries. See step 4 on page
5 for reference.
Dirty sensor lens Clean sensor lens with warm water and
mild soap until free of debris
Loose or damaged wire harness Inspect wire harness and connection
between electronics and motor
User not detected.
Sensor range may need to be adjusted Increase sensor range distance (see
page 8 for Sensor Range Adjustment
instructions)
Flush valve is aimed at an angle. Rotate ush valve head to be
perpendicular to wall. See page 6 for
adjusting the ush valve head.
Manual override button does
not initiate a ush.
Battery power level too low to activate
ush (computer prevents valve from
opening when there is not enough
energy to also fully close)
Replace batteries. See step 4 for
reference.
Trouble Shooting Guide
Dual Flush User Guide (For ZER6000AV-DF-TM Only)
• The Dual Flush model supplies ush volumes of 1.1 and 1.6 gallons per ush. When a user is present for less than 60
seconds, the valve will ush with 1.1 gallons of water. When a user is present for over 60 seconds, the valve consumes 1.6
gallons of water. If the manual override button is pressed, the valve will always ush 1.6 gallons of water. A user must be
present for a minimum of 8 seconds in order to trigger a ush.
• The Dual Flush model must be paired with a xture with a ush volume range that includes 1.1 to 1.6 gallons per ush. For a
list of recommended bowls, please refer to our website, www.zurn.com, or speak with your local Zurn rep.
• Do not use any abrasive or chemical cleaners to clean the ushometer.
• 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.
• Upon cleaning other areas of the restroom, be sure the sensor lenses are protected from other cleaning chemicals/solvents to
prevent potential damages to the sensor and/or electronics.
• 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 o󰀨 and the water drained from the system, remove the stop valve cap and stop
valve internals to allow the water to drain from the ush valve itself.
Care and Cleaning Instruction

FV687 Rev. A 12/16/2019
Page 9
For further assistance with troubleshooting, visit http://www.zurn.com/
Problem Indicator Cause Corrective Action
Valve does not evacuate
xture
Insu󰀩cient volume of water to
adequately siphon xture.
Stop valve is not open enough. Open stop valve for desired volume of
water.
Insu󰀩cient volume or pressure at
supply.
Increase incoming water supply
pressure to minimum 25psi.
Valve shuts o󰀨 too quickly or
short ushes.
Damaged or punctured diaphragm. Install new diaphragm replacement kit.
(See page 6 for replacement instruction)
Enlarged by-pass orice. Install new diaphragm replacement.
(See page 6 for replacement instruction)
Diaphragm kit is not matched to the
xture.
Install new diaphragm replacement kit.
(See page 6 for replacement instruction)
Valve is ushing too long or
not shutting o󰀨.
High water delivery or
continuous ow.
By-pass orice is plugged or partially
plugged.
Examine by-pass orice and clean if
necessary being certain not to enlarge
orice opening. (See page 6 for cleaning
instruction)
Water splashes out of xture. Water splashes onto oor
during ush cycle.
Supply volume is too high. Slowly close the control stop to lower
water pressure.
Mineral accumulation on vortex or
spreader holes of xture.
Remove the mineral build up.
Flush is not considered quiet. Flush is loud.
Control stop may not be adjusted for
quiet operation.
Adjust the control stop for quiet opera-
tion keeping in mind the xture evacua-
tion requirements.
Fixture may be contributing to noise. Check noise created by xture by
placing a cover over the bowl opening to
separate valve noise from bowl noise. If
it is determined the xture is too noisy,
consult with xture manufacturer.
Piping system may be source of noise. 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.
Valve leaking near valve head. Water droplets seen between
valve head and valve body.
Locking ring not tight. Tighten locking ring. See Sensor Angle
Adjustment section for reference.
Valve ushed with no user
present
Valve ushed with no user
present
Highly reective environment
Re-calibrate sensor range - see Sensor
Range Adjustment section (page 7)
Sensor range set too far; picking up
other objects
Flush valve may be congured to
exchange the water in the trap-way at
every [24 / 48 / 72] hours after no usage
(default is OFF).
See page 7 for instructions on changing
dipswitch settings to achieve desired
trap exchange timing.
Trouble Shooting Guide

FV687 Rev. A 12/16/2019
Page 10
Control Stop Repair Kit and Parts Product No.
Control Stop Repair Kit for 1” and 3⁄4”,
Items 18-24 P6000-D-SD
Seal Seat for 1” and 3/4”, Item 18 P6000-D42
VP Control Stop Repair Kit for 1” and 3/4”,
Items 18-24 P6000-D-VP
Sweat Solder Connection with Cast Wall Flange,
Items 14-16 P6000-YBYC
Part Identication
1. Valve Body
2. Vacuum Breaker Duckbill
3. Vacuum Breaker Tube
4. Vacuum Breaker Tube Nut
5. Spud Nut
6. Spud Friction Washer
7. Spud Sleeve
8. Spud Escutcheon
9. Tailpiece
10. Snap Ring
11. Tailpiece O-Ring
12. Locking Nut
13. Stop Body
14. Sweat Solder Adapter
15. Supply Cover Tube
16. Cast Wall Escutcheon
17. Setscrew for Cast Wall Flange
18. Piston Seal
19. Piston
20. Stop Spring
21. Guide O-Ring
22. Piston Guide
23. Guide Holder
24. Adjusting Screw
25. Stop Cap
26. Snap Cap Screw Cover
27. Vandal Resistant Control Stop Cover
28. Setscrew for Control Stop Cover
29. Handle Cap Seal
30. Handle Nut
31. Diaphragm Kit
32. Volume Control Ring
33. Manifold Stem O-Ring
34. ZER-TM Valve Head
35. Locking Ring
36. Sloan Locking Ring
ZER-TM Series Repair Kits
8
6
5
5
7
7
4
31
32
33
36
4
3
3
13
2
16
15
14
20
18
22
21
19
23
25
27
24
26
28
34
29
30
1
9
10
11
12
17
6
8
35
Adjustable Tailpieces Product No.
Adjustable Tailpiece for Standard Flush Valve,
Items 9-11 P6000-J1
Tailpiece Coupling Assembly, Items 10-12 P6000-K
Tailpiece Locking Ring, Item 10 P6000-C30
Tailpiece O-Ring, Item 11 P6000-C31
Coupling Nut, Item 12 P6000-C32
Flush Connections and Spud Coupling Kits Product No.
Vacuum Breaker Repair Kit, Item 2 P6000-B
Spud Coupling Assembly for Water Closet,
Items 5-8. Specify size. P6000-H
Spud Coupling Assembly for Urinal,
Items 5-8. Specify size. P6003-H
ZER-TM Valve Head Repair Kit and Parts Product No.
Locking Ring, Item 35 PER6000-M-RING
Sloan Locking Ring, Item 36 PER6000-M-RING-S
Valve Head, (1.1 gpf), Item 34 PERK6000-L-1.1
Valve Head, (1.28 gpf), Item 34 PERK6000-L-1.28
Valve Head, (1.6 gpf), Item 34 PERK6000-L-1.6
Valve Head, (1.6/1.1 gpf), Item 34 PERK6000-L-1.6/1.1
Valve Head, (0.125gpf), Item 34 PERK6003-L-0.125
Valve Head, (0.5 gpf), Item 34 PERK6003-L-0.5
Valve Head, (1.0 gpf), Item 34 PERK6003-L-1.0
Valve Head for Sloan, (1.1 gpf), Item 34 PERK6000-L-1.1-S
Valve Head for Sloan, (1.28 gpf), Item 34 PERK6000-L-1.28-S
Valve Head for Sloan, (1.6 gpf), Item 34 PERK6000-L-1.6-S
Valve Head for Sloan, (1.6/1.1 gpf), Item 34 PERK6000-L-1.6/1.1-S
Valve Head for Sloan, (0.125 gpf), Item 34 PERK6003-L-0.125-S
Valve Head for Sloan, (0.5 gpf), Item 34 PERK6003-L-0.5-S
Valve Head for Sloan, (1.0 gpf), Item 34 PERK6003-L-1.0-S
ZER-TM Diaphragm Repair Kit Product No.
Closet Repair Kit - (1.1, 1.28, 1.6, 1.6/1.1 gpf),
Item 31-33 PER6000-EC
Urinal Repair Kit - (0.125 gpf), Item 31-33 PER6003-EU-ULF
Urinal Repair Kit - (0.5, 1.0 gpf), Item 31-33 PER6003-EU

US 1.855.ONE.ZURN CANADA 1.905.405.8272
ZURN INDUSTRIES, LLC 511 W. Freshwater Way, Milwaukee, WI U.S.A. 53204 · Ph. 1-855-ONE-ZURN, Fax [phone]
In Canada: ZURN INDUSTRIES LIMITED 7900 Goreway Drive, Unit 10, Brampton, Ontario L6T 5W6, Ph. 905-405-8272, Fax [phone]
Rev. A Date: 12/16/2019 C.N. No. 142246 Prod. | Dwg. No. FV687
ZURN.COM