Proper Repair and Maintenance of Flush Valve Systems

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
Objectives
Upon 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 predetermined
volume 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.
Troubleshooting
. 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
PROBLEM: 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
 Obsolete
 EBV-11
 Urinal
 EBV-38-A
 Closet w/ Override
EBV-138-A
Metal Cover - ‘Hard Hat’



Die Cast
Metal Override Button
Tempered Glass Window
 Impact Resistant
 Replaceable
 Zurn Requires Unit
Replacement
 Counters Zurn
Sensor Flushometer
Components
Electronic Module
Optima Plus
Obsolete
G2 Optima Plus
Solenoid
Operator
•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
•
•
•
•
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
∆∆
Optima Plus
Diaphragms
•
Dual Filter
Obsolete
Dual Filter with Flex Tube
OPTIMA PLUS DIAPHRAGM KIT
VOLUME
REGULATOR
DISC
REFILL HEAD
FLOW CONTROL
RING
FLEX TUBE ASSEMBLY
ROYAL DUAL-FILTER
DIAPHRAGM
GUIDE
OPTIMA PLUS UNIVERSAL CLOSET KIT
REMOVING VOLUME REGULATOR
GRAY REFILL
HEAD
GREEN 1.6 GPF
BLUE 2.4 GPF
WHITE 3.5 GPF
CUT FLOW RING FOR 4.5 GPF,
USE WHITE REGULATOR
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.
Diagnostic Techniques
• (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.
Diagnostic Techniques
• (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?
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It covers 70 percent of the earth's
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Flushometers
Electronic or manual,
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EPAct2005 mandates that all commercial prerinse spray valves have a flow rate no greater
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We offer products from the leading OEM’s that
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Pressure Assisted Tanks
Can be installed to use 1.6 or 1.0 gallons per
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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?
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All the water savings products in the world won’t help if
your fixture or valve experiences leaks.
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