proper repair and maintenance of flush valve systemsproper repair and maintenance of flush valve...
TRANSCRIPT
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Proper Repair and Maintenance of
Flush Valve Systems
for
Presented by
Bill Ballantyne
Vice President of Operations
LEED GA
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Flushometer
Troubleshooting in
Section 4 of your Best
Catalog
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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.
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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!
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Flushometer
Applications Sanitary fixtures:
Water Closets
Urinals
Service Sinks
Other
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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
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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
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Valve Operation
Pressure Upper & Lower Chambers
Trip Relief Valve Relieve Pressure
Diaphragm/Piston Lift
Reseal Refill Top Chamber
Shut Off
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Ready
to
Go
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Flush by
hitting the
handle
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Water is now
going into the
fixture
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Reset and
ready to flush
again
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Flushometer Performance
• Proper Match Of Valve AND Fixture
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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)
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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
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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
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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
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How To Identify - GPF
Label
Cover Marking
“LC” Indicates Low Consumption
Bowl Marking
Low Consumption Only
Look At the Parts
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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!
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Traditional Kit
Components
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By Operating
Kit
(Drop-in Kit)
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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
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Royal vs. Regal
Similarities Castings
High Copper
Same Valve Body
Parts Are Interchangeable
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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
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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
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Bypass Ring On Top Side Of
Diaphragm
Contains Molded Bypass
Locks into Diaphragm
3 offset barbs
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Secondary Filtering on
Bypass Ring “Dual Towers”
Two Posts
Each With 5 Grooves
5:1 Area Ratio
Stabilizes Diaphragm
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By Operating Kit
(Drop-in Kit)
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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
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Americans with Disabilities Act ADA
Requirements
• Handle
– < 5 Pound Force
– Wide Side Of The Stall
– 44” Maximum Height
• Grab Bars
• Opportunities For Hydraulic & OPTIMA
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Handle Components
Royal
B-51-A w/ Triple Handle Seal
Regal
B-50-A w/ B-29 Seal
White Bushing
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Triple Seal Handle Packing
50% increase in sealing capability
Factory Lubricated
Keeps foreign matter from sealing area
Permex material
Holds up against chloramines
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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
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Vacuum Breaker
Sack Features Energized Lip
Senses fixture back pressure and compensates
Permex
Increased GPM
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H-700-A Common Stop
**Identical inside parts for 3/4” & 1”
Better flow adjustment
Less repair parts
Stainless Steel Spring
Permex Seat
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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
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Inside Cover
Royal & Regal Creates Consistent Upper
Chamber
A-11 For old valves with ‘bell’
cover
Problems & Repair
Chatter
Leakage
Run On
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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.
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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.
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. 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
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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.
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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).
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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.
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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)
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Zurn has developed
two
diaphragm repair
kits
AquaVantage
and
Aquaflush
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AQUAFLUSH DIAPHRAGM KITS
Linear Filtered By-pass
Chemical Resistant
Thermoplastic Material
Light Blue in Color
Standard Repair Kit
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AQUAVANTAGE® KITS
Triple Filtered By-pass
Chemical Resistant
Theroplastic Material
Dark Blue in Color
Premium Repair Kit
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Delany
Flushboy
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Delany Flushboy
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Delany Handle Parts
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Most popular replacement parts -
Delany Flushboy
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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
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The G2 and Sloan
Optima Plus• Easy Access Design
• New Optics
• Non-Isolated Solenoid
• Batteries Factory Installed
• New look
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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
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Metal Cover - ‘Hard Hat’
Die Cast
Metal Override Button
Tempered Glass Window
Impact Resistant
Replaceable
Zurn Requires Unit Replacement
Counters Zurn
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Sensor Flushometer
ComponentsElectronic Module
Optima Plus G2 Optima Plus
Obsolete
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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
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Optima Plus
Diaphragms• Dual Filter Dual Filter with Flex Tube
Obsolete
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OPTIMA PLUS DIAPHRAGM KIT
VOLUME
REGULATOR
GUIDE
DISC
FLEX TUBE ASSEMBLY
ROYAL DUAL-FILTER
DIAPHRAGM
REFILL HEAD
FLOW CONTROL
RING
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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
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OPTIMA PLUS
DIAPHRAGM STROKE
ALLOWED BY VOLUME
REGULATOR
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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.
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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.
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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.
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Side Mount Operator
• Limited Parts Available
• Lens –Glass Only
• Wrenches
• Washers
• Buttons
• Cover
• Adapters
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Sloan Dual Flush Side Mount with Manual Override
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What is SMOOTH?
Side Mount
Operator
Over The
Handle
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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
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Easy Installation
• Installs right over handle
• Ideal for retrofit
• Batteries already installed– Asleep in the
box
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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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BESTPlumbing Specialties
Go Green With
Your One Stop
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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.
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Products to keep
your facility
“green”
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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
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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.
&
bestplumbingonline.com
Visit us at
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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!
bestplumbingonline.com
Visit us at
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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.
bestplumbingonline.com
Visit us at
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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,
bestplumbingonline.com
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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!
bestplumbingonline.com
Visit us at
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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.
bestplumbingonline.com
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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
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Hand Dryers
Sensor-operated hand dryers
and 90% savings vs.. paper
towel costs!
use 80% less energy
bestplumbingonline.com
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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%
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How much is that drip costing you?
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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.
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BEST
Plumbing Specialties
Go Green With
Your One Stop