proper repair and maintenance of flush valve systemsproper repair and maintenance of flush valve...

Proper Repair and Maintenance of

Flush Valve Systems

for

Presented by

Bill Ballantyne

Vice President of Operations

LEED GA

Flushometer

Troubleshooting in

Section 4 of your Best

Catalog

Topic Learning

ObjectivesUpon successful completion of this topic you will be able

to understand:

1. The purpose of a Flushometer.

2. How a Flushometer operates.

3. Troubleshooting.

4. Repair Parts ID and Options.

What is a

Flushometer?Definition: A valve attached to a pressurized water supply pipe and

so designed that when actuated, it opens the line for direct flow into the fixture at a rate and predeterminedvolume to properly operate the fixture and then gradually close in order to avoid water hammer.

A precision metering device.

It is NOT a Flush Valve!

Flushometer

Applications Sanitary fixtures:

Water Closets

Urinals

Service Sinks

Other

Water Pressure

10 to 100 psi For Valve

ASSE 1037 Standard - 125 psi Max

Requires ~ 10 psi For Shut Off

Minimum Pressure Is A Requirement Of Fixture

Fixture Requirements 25 to 80 psi

HET 35 psi minimum

All pressures are Flowing - not Static

Flow Restrictions

Water Meter

Back Flow Preventers

Age

Mineral Build Up

Elbows & Fittings

Gravity / Elevation

Minimum sized reduction remains throughout thereafter

Length of supply run

Valve Operation

Pressure Upper & Lower Chambers

Trip Relief Valve Relieve Pressure

Diaphragm/Piston Lift

Reseal Refill Top Chamber

Shut Off

Ready

to

Go

Flush by

hitting the

handle

Water is now

going into the

fixture

Reset and

ready to flush

again

Flushometer Performance

• Proper Match Of Valve AND Fixture

Water Use - How

Much? Water Closet

Traditional: 4.5 - 5 gpf (17 Lpf)

Water Saver: 3.5 gpf (13.2 Lpf)

Low Consumption: 1.6 gpf (6.0 Lpf)

High Efficiency (HET): 1.28 gpf (4.5 Lpf)

Foreign: 2.4 gpf (9 Lpf)

Water Use - How

Much ? Urinals

Old Blow Outs: 3.5 gpf (13.3 Lpf)

Water Saver: 1.5 gpf (5.7 Lpf)

Low Consumption: 1.0 gpf (3.8 Lpf)

New Wash Downs - 1/2 to 1 gallon (1.9 Lpf)

High Efficiency (HEU)

1/4 gpf – 1 quart

1/8 gpf – 1 pint

Why Low

Consumption Federal Energy Policy Act Of 1992 (EPACT)

1.6 gpf Toilets (Low Consumption), Water Closet Residential - Jan. 1, 1994

Commercial -Jan. 1, 1996

Urinals - 1.0 gpf - Jan. 1, 1994

Shower Heads & Faucets 2.2 gpm

State & Local Requirements California - New York - Texas - Others

Mismatch? 1.6 gallon Valve On Older

3.5/4.5 gpf Bowls Not Enough Water For A Complete

Flush SHORT FLUSH

3.5 Gallon Valve On New 1.6 gpf Bowl Long flush – wasting water Water spilling out vent holes of vacuum

breaker

How To Identify - GPF

Label

Cover Marking

“LC” Indicates Low Consumption

Bowl Marking

Low Consumption Only

Look At the Parts

Flushometer Labels

Required per federal law Permanent (Meets UL

Requirements) Exposed

Placed Underside of body

Concealed On Cover

Valuable Information Valve Type – Closet or

Urinal Flush Volume (gpf & lpf) Date Code (Week & Year) CHECK THE PARTS!

Traditional Kit

Components

By Operating

Kit

(Drop-in Kit)

Regal Segment Diaphragm

Traditional Heart Of The Regal Valve A-156-A

Natural Rubber

Brass Inserts

Reliable

Resilient

Long lasting

Single Metering Orifice

Brass

Controls

Flush Timing

Royal vs. Regal

Similarities Castings

High Copper

Same Valve Body

Parts Are Interchangeable

Royal Features Dual Filter Diaphragm

Superior Diaphragm Material

ADA Compliant Handle

High Back Pressure Vacuum Breaker w/ Bottom Hex Coupling

Triple Seal Handle Packing

Vandal-Resistant Stop Cap

Dual-Filtered

Diaphragm Kit Sold Complete or in

Performance Kit

Closet: 3.5 gpf, 1.6 gpf & 2.4 gpf

Urinal: 1.0 gpf, 1.5 gpf & 0.5 gpf

Optima Plus

Bypass Ring On Top Side Of

Diaphragm

Contains Molded Bypass

Locks into Diaphragm

3 offset barbs

Secondary Filtering on

Bypass Ring “Dual Towers”

Two Posts

Each With 5 Grooves

5:1 Area Ratio

Stabilizes Diaphragm

By Operating Kit

(Drop-in Kit)

Testing

Internal

Willy Wonker - Sloan’s testing machine

70,000 to 150,000 Cycles - dual diaphragm

A-156-A - 50 Cycles - segmented

In the Field

Tested Where Others Have Failed

Indiana Site – Gravel

Testimonial Letters

Americans with Disabilities Act ADA

Requirements

• Handle

– < 5 Pound Force

– Wide Side Of The Stall

– 44” Maximum Height

• Grab Bars

• Opportunities For Hydraulic & OPTIMA

Handle Components

Royal

B-51-A w/ Triple Handle Seal

Regal

B-50-A w/ B-29 Seal

White Bushing

Triple Seal Handle Packing

50% increase in sealing capability

Factory Lubricated

Keeps foreign matter from sealing area

Permex material

Holds up against chloramines

Vacuum Breaker Prevents Back Siphon Into

Water Supply

Required By Plumbing Code

Atmospheric -

ASSE 1001 Critical Line -

6” Above Fixture Often Changed For Wrong

Reason

Vacuum Breaker

Sack Features Energized Lip

Senses fixture back pressure and compensates

Permex

Increased GPM

H-700-A Common Stop

**Identical inside parts for 3/4” & 1”

Better flow adjustment

Less repair parts

Stainless Steel Spring

Permex Seat

A-71 Inside Cover Inside Cover ensures consistent volume in

upper chamber Prevents threads from contact with

water!! Used with Royal, Royal II, Regal, & Sloan Problems & Repair

Chatter Leakage Run On Hammer

A-11 Inside Cover For Royal Valves With ‘Bell Shaped’

Cover Replaces old brass inside cover A11

Inside cover

Inside Cover

Royal & Regal Creates Consistent Upper

Chamber

A-11 For old valves with ‘bell’

cover

Problems & Repair

Chatter

Leakage

Run On

Some Troubleshooting

1. PROBLEM: Flushometer does not function.

CAUSE:

(a). Control Stop or Main Valve is closed.

(b). Handle Assembly is worn.

(c). Relief valve is worn.

SOLUTION:

(a). Open Control Stop or Main Valve.

(b). Install Sloan Handle Repair Kit ( # 44413

B-50-A) or replace handle.

(c). Replace Inside Parts Kit.

Some Troubleshooting

2. PROBLEM: Insufficient volume of water to adequately siphon

fixture.

CAUSE:

(a). Control Stop not open enough.

(b). Urinal Parts inside a Closet Flushometer.

(c). Low Consumption Flushometer installed on a non-Low

Consumption fixture.

(d). Water Saver Kit installed in old, non-Water Saver bowl.

(e). Inadequate volume or pressure at supply.

SOLUTION:

(a). Adjust Control Stop for desired delivery of water.

(b). Replace Inside Urinal Parts with proper Closet Parts.

(c.) Replace # 44423, A-41-A inside parts kit with

# 43228 A- 38-A Water Saver Kit.

. PROBLEM: Flushometer closes off immediately.

CAUSE:

(a). Damaged Diaphragm.

(b). Enlarge By-pass orifice from corrosion or damage.

SOLUTION: Install Inside Parts Kit to correct above problems

and update Flushometer. Ort at least replace the diaphragm.

Troubleshooting

TroubleshootingPROBLEM: Length of flush is too short (Short Flushing).

CAUSE:

(a). Diaphragm Assembly and Guide Assembly are not hand-tight.

(b). Enlarged By pass orifice from corrosion or damage.

(c.) #44404, A-19-AU (black urinal relief valve in closet

flushometer.

(d). # 44423, A-41-A Low Consumption Kit installed in non

Low Consumption fixture.

(e). Handle Assembly is worn.

SOLUTION:

(a). Screw the two assemblies hand-tight.

(b). Install NEW Inside Parts Kit to correct problem

and update Flushometer.

(c). Replace Relief Valve with # 44403, A-19-AC

(White) Closet Relief Valve.

(d). Replace with proper Inside Parts Kit.

(e). Install Handle Repair Kit #. 44413 B-50-A

or the Handle.

Troubleshooting. PROBLEM: Length of flush is too long (Long Flushing) or fails to close off.

CAUSE:

(a). Relief Valve is not seating properly or By-pass orifice is clogged

because of foreign material, or By-pass is closed by an invisible gelatinous film

from”over-treated” water.

(b). Line pressure has dropped and is not sufficient to

force Relief Valve to seat.

(c.) # 44403 A-19-AC (white) Closet Relief Valve has been used in a 1 or 1.5 gpf

Urinal.

(d). Inside Cover is cracked or damaged.

SOLUTION: (a). Size of the orifice in the by-pass is of

Utmost Importance for the proper metering of water into

the upper chamber of the flushometer. Do Not enlarge or

damage this orifice. Replace inside Kit.

(b). Shut off all control stops until pressure has been

restored, then open them again.

(c). Replace with # 44404, A-19-AU (black) Relief Valve.

(d). Replace the Inside Cover # 45504, A-71).

Troubleshooting

PROBLEM: Chattering noise in Flushometer.

CAUSE:

(a.) The #44405, A-156-A Segment Diaphragm has been installed

upside-down.

(b.) The Inside Cover has become distorted from wear, freezing or

abuse.

SOLUTION:

(a.) Replace the Segment Diaphragm to the proper position

as instructed by markings on the Diaphragm.

(b.) Replace Inside Cover.

Troubleshooting

PROBLEM: Leaking at handle assembly.

CAUSE: (a.) The #46607, B-39 seal is worn or deteriorated.

(b.) Handle gasket has been omitted.

(c.) Valve handle bushing is worn.

SOLUTION: (a.) Install new #. 46607, B-39 Seal. NOTE:

The # 46607, B-39 Seal will easily slide right onto the B-40

Bushing if it is wet.

(b.) Install # 46608, A-31 handle gasket or Sloan

handle repair kit (# 44413 B-50-A)

(c.) Install Sloan handle repair kit ( # 44413 B-50-A)

Zurn has developed

two

diaphragm repair

kits

AquaVantage

and

Aquaflush

AQUAFLUSH DIAPHRAGM KITS

Linear Filtered By-pass

Chemical Resistant

Thermoplastic Material

Light Blue in Color

Standard Repair Kit

AQUAVANTAGE® KITS

Triple Filtered By-pass

Chemical Resistant

Theroplastic Material

Dark Blue in Color

Premium Repair Kit

Delany

Flushboy

Delany Flushboy

Delany Handle Parts

Most popular replacement parts -

Delany Flushboy

Flex Tube Diaphragm

-Installation Guidelines -

• With the diaphragm kit now fully assembled to the Optima product, place the assembly into

the valve body.

• Tighten With Strap Wrench

The G2 and Sloan

Optima Plus• Easy Access Design

• New Optics

• Non-Isolated Solenoid

• Batteries Factory Installed

• New look

Outside Cover G2 Optima Plus

EBV-142-A

SLOAN Optima Plus

Obsolete EBV-11

Urinal

EBV-38-A

Closet w/ Override

EBV-11

EBV-138-A

Obsolete

Metal Cover - ‘Hard Hat’

Die Cast

Metal Override Button

Tempered Glass Window

Impact Resistant

Replaceable

Zurn Requires Unit Replacement

Counters Zurn

Sensor Flushometer

ComponentsElectronic Module

Optima Plus G2 Optima Plus

Obsolete

Solenoid Operator

• Available with old cable connector for our

existing products, and our new

connection for G-2 Optima Plus

• How to id a solenoid.

• 03/33-04/22 – Green Triangle they’re

going to be. ∆

• 04/23-06/39 – Blue Triangle – might not

be bad.∆

• 06/04 –Current – Double Blue Triangles

∆∆

•G-2 & Sloan Optima Plus

–Blue Sensor Module

•EBV-129-A

–Uses 49935

•Older Optima Plus

–Black Sensor Module

•EBV-25-A - Obsolete

–Uses #99065117

Optima Plus

Diaphragms• Dual Filter Dual Filter with Flex Tube

Obsolete

OPTIMA PLUS DIAPHRAGM KIT

VOLUME

REGULATOR

GUIDE

DISC

FLEX TUBE ASSEMBLY

ROYAL DUAL-FILTER

DIAPHRAGM

REFILL HEAD

FLOW CONTROL

RING

OPTIMA PLUS UNIVERSAL CLOSET KIT

REMOVING VOLUME REGULATOR

GREEN 1.6 GPF

BLUE 2.4 GPF

WHITE 3.5 GPF

CUT FLOW RING FOR 4.5 GPF,

USE WHITE REGULATOR

GRAY REFILL

HEAD

OPTIMA PLUS

DIAPHRAGM STROKE

ALLOWED BY VOLUME

REGULATOR

Diagnostic Techniques

• (1) Run on Flushometers.

– This includes manual Royal Regal Pro Regal, hydraulic, ES-S.

Debris in the valve. Clean out. Lack of Water pressure. Usually caused by undersized water lines. They can install pressure tanks in this case.


• (2) G-2 Optima Plus Dead.

This may be caused by the magnet dropping out of the magnet holder in the button. They can verify this by removing the button to see if the unit comes back to life. If the unit starts blinking right away, then the override button is the problem. Simply replace the button.


• (3) Optima Plus G-2 Dead.

This also could be caused by a faulty solenoid operator. The unit should be reset by holding the override button in for 40 seconds. Let it go and the lights should blink when detecting. (Reset). Then trigger the valve and listen for any clicks. If a faint clicking is heard, replace solenoid operator. This is a faulty solenoid. The fluid may have leaked out.

Side Mount Operator

• Limited Parts Available

• Lens –Glass Only

• Wrenches

• Washers

• Buttons

• Cover

• Adapters

Sloan Dual Flush Side Mount with Manual Override

What is SMOOTH?

Side Mount

Operator

Over The

Handle

Features

Works on Sloan Royal & Regal Valves

Also Zurn valves

Fits over handle

One Tool installation Installs with screwdriver

Automatic Range Adjustment Adaptive Sensing

4 ‘C’ Size batteries 2 year life @ 4000 flushes/month

Easy Installation

• Installs right over handle

• Ideal for retrofit

• Batteries already installed– Asleep in the

box

Review and Summary

• Why is it important to make sure the batteries

are installed correctly?

• Why might the Lens Deflector be used?

• What are some of the features of the new G2

Controller and Solenoid?

BESTPlumbing Specialties

Go Green With

Your One Stop

WATER:

It covers 70 percent of the earth's

surface.

At least 97 percent of the world's water

is salty and undrinkable.

Another two percent is polluted, polar

ice, or otherwise inaccessible and

undrinkable.

That leaves approximately 1% for

humans to use.

Products to keep

your facility

“green”

Flushometers

Electronic or manual,

we have products that

can help reduce water

consumption, sewer

costs, and

maintenance. New

install or retrofit,

products from Sloan,

Zurn, Delany, Toto and

other OEM’s are

available to fit your

“green” program.

bestplumbingonline.com

Visit us at

Solar Powered

Electronic Faucets

Each faucet works with ambient light, like a

solar-powered calculator. The faucet with its

integrated storage cell, transforms light from

any source into electrical energy.

&


Visit us at

Aerators

Slotted, laminar flow, vandal resistant &

regular…all with water saving features. We

have aerators for your faucets that offer 2.5

gpm, 2.2 gpm, 1.0 gpm, 0.5 gpm and even

.33 gpm!


Visit us at

Drinking Fountains

Bottle Fillers

Being able to offer some of the most

innovative products from leading

manufacturers means water savings to you.

We have bubbler heads that operate at 0.4

gpm and metering drinking faucets that

eliminate water run-on.


Visit us at

Shower Heads

we provide shower heads with water

reduction ranging from 2.5 to 1.0 gpm.

These gpm ratings mean thousands of

gallons of water saved from earlier

conventional model shower heads.

Commercial or residential style,


Visit us at

Commercial Kitchens

EPAct2005 mandates that all commercial pre-

rinse spray valves have a flow rate no greater

than 1.6 gpm at 60 psi, when used with

commercial dishwashing and ware washing

equipment.

We offer products from the leading OEM’s that

can offer the same cleaning efficiency at 1.48

gpm and even 1.2 gpm!


Visit us at

Pressure Assisted Tanks

Can be installed to use 1.6 or 1.0 gallons per

flush. These products can save 20-45% more

water than your typical tank and bowl

configurations. The stronger flushing action

reduces double flushing, and cleans better

than gravity style units.


Visit us at

By installing waterless

urinals, especially in high

usage areas, you can save

up to 45,000 gallons per year,

per urinal! And since there is

no need to run water supply

pipes, the installation is less

costly. Retrofit costs are

easily recovered in the water

reduction savings.

Waterless Urinals


Visit us at

Hand Dryers

Sensor-operated hand dryers

and 90% savings vs.. paper

towel costs!

use 80% less energy


Visit us at

Daily indoor per capita water use in a typical

single family home is 69.3 gallons (260 litres).

Overall use falls into the following categories:BODY CLEANLINESS:

▪ Toilets - 26.7%

▪ Baths - 1.7%

▪ Showers - 16.8%

WASHING:

▪ Clothes Washers - 21.7%

▪ Dishwashers - 1.4%

▪ Faucets - 15.7%

▪ Leaks - 12.7%▪ Other Domestic Uses - 2.2%

How much is that drip costing you?

Customized Assortments

All the water savings products in the world won’t help if

your fixture or valve experiences leaks.

Our customized assortments, which YOU design, keep your

building operating efficiently, allowing properly maintained

conservation and water management efforts.

BEST

Plumbing Specialties

Go Green With

Your One Stop

proper repair and maintenance of flush valve systemsproper repair and maintenance of flush valve...

Documents