hydrovantagetm zgen series - zurn products · zgen series automatic sensor-operated, hydrogenerator...

HydroVantageTM

ZGEN SeriesAutomatic Sensor-Operated,HydroGenerator FlushometerInstallation, Operation, Maintenance, andParts ManualPatented and Patents Pending

Models:ZGEN6203EV-ULF 0.125 gpfZGEN6203EV-QRT 0.25 gpfZGEN6203EV-EWS 0.5 gpfZGEN6203EV-WS1 1.0 gpfZGEN6200EV 1.28 gpfZGEN6200EV-WS1 1.6 gpf

HydroGeneratorSensor-Operated Flush Valve

LIMITED WARRANTYAll goods sold hereunder are warranted to be free from defects in material and factory workmanship for a period of five years from thedate of purchase. Decorative finishes warranted for one year. We will replace at no costs goods that prove defective provided we arenotified in writing of such defect and the goods are returned to us prepaid at Sanford, NC, with evidence that they have been properlymaintained and used in accordance with instructions. We shall not be responsible for any labor charges or any loss, injury or damageswhatsoever, including incidental or consequential damages. The sole and exclusive remedy shall be limited to the replacement of thedefective goods. Before installation and use, the purchaser shall determine the suitability of the product for his intended use and thepurchaser assumes all risk and liability whatever in connection therewith. Where permitted by law, the implied warranty of merchantabilityis expressly excluded. If the products sold hereunder are “consumer products,” the implied warranty of merchantability is limited to aperiod of three years and shall be limited solely to the replacement of the defective goods. All weights stated in our catalogs and lists areapproximate and are not guaranteed.

Customer service Phone Number: 1-800-997-3876

FV520 Rev. C 6/27/11

1. Install stop valve assembly using sweat solder adapterkit if applicable. Thread sealing compounds shouldbe used on male NPT threads only.

E

CD

B2.) Before the supply water is turned on, be sure all stop valves

are closed off tight. The stop valves can be opened andclosed by using the adjusting screw located at the center ofthe stop valve cap. Stop valve adjustments can only bemade by using the adjusting screw. It is not necessary toremove the stop valve cap when making adjustments. Iffor any reason it becomes necessary to remove the stopvalve cap, be certain the water is shut off at the mainsupply valve.

3.) Prior to inserting the flush valve tailpiece (B) into stop valve(A), be certain that the O-ring seal (C) is located in O-ringseal groove at the end of the tailpiece and that the lockingnut (D) and locking snap ring (E) are located as shown.Care should be taken not to damage the O-ring when in-serting the tailpiece into the stop valve. If lubrication isneeded, wetting the O-ring with water will be sufficient.

When all stops are connected to the water supply andwater pressure is available, it is recommended that thesupply piping be flushed to remove dirt, metal chips, etc.,from system.

A

2

A. Before the valve is installed, open each stop fully for abrief time and catch the water in a two gallon or largerbucket. For multiple installations, start with the stopvalve closest tothe water supplyand work towardthe most remotevalve.

B. Due to the smallpassages andorifices, it is notpossible toflush the pipingthrough the lowvolume valve.

C. Once the linesare flushed, thevalve can beinstalled.

PRIOR TO INSTALLATIONPrior to installing the HydroVantageTM flushometer valve,install the items listed below:• Closet or urinal fixture• Drain line• Water supply line

IMPORTANT:• All Plumbing is to be installed in accordance with applicable

codes and regulations.• Water supply lines must be sized to provide an adequate

volume of water for each fixture.• Flush all water lines prior to operation (See Step 2).• Dirt and debris can cause flush valve to run continuously.• Sensor units should not be located across from each other

or in close proximity to highly reflective surfaces.

The HydroVantageTM design is optimized to operate between 35 and 80 psi (241 to 552 kPa) of water pressure(running). Theminimum pressure required for the valve to work properly is determined by the fixture selected. Please consult fixture manufacurerfor pressure requirements. The sensor is designed to operate at light levels as low as 1 lux but for optimum performance aminimum of 20 lux is recommended. Protect the chrome or special finish of this flushometer. Do not use toothed tools to installor service the valve.

Important: Do not remove sensor sticker until reading instructions 8a-8d

FV520 Rev. C 6/27/11

7

4.) Insert the flush valve tailpiece (B) into the stop valve (A) andhand tighten the lock nut (D) to the stop valve. Plumb theentire unit.

5.) Determine the length of vacuum breaker tube (F) requiredto join the flush valve and fixture spud. Cut the vacuumbreaker tube, if required, to this length. Assemble thevacuum breaker tube assembly and spud nut assembly tothe flush valve and fixture spud.

4 5

F

7.) Determine all flush valve connections are tight and pro-ceed to fully open the control stop. Use the Manual Over-ride Button to check for leaks. Proceed to step 8 and readthe important instructions thoroughly.

Important: If stall partitions are to be installed at a laterdate here DO NOT proceed to step 8 Activation.

B D

A

D

H

G

VacuumBreaker

Tube Nut

Spud Nut

Slip GasketRubberGasket

SpudEscutcheon

6.) Hand tighten spud nut (G) and vacuum breaker tube nut (H)to fixture and flush valve. Adjust the valve assembly for plumb.Tighten fixture spud nut (G), vacuum breaker tube nut (H)and lock nut (D) with a wrench.

6

FV520 Rev. C 6/27/11

Important: Step 8 Valve Activation should only be conducted after allpartitions, paper dispensers, hand rails and other accessories are inplace.

IMPORTANT: READ THOROUGHLY BEFORE REMOVING STICKER.

8) Valve is ready for activation and calibration.

8a) OPEN CONTROL STOP- If the water begins to flow through the valve when the control stop is openedit is likely that the solenoid opened during shipment. The solenoid will be closedat the beginning of the valve calibration.- For urinal installations it is important that the flow rate into the urinal does notexceed the flow rate out of the urinal. Test this by holding down the ManualOverride Button for 30 seconds. If necessary reduce the flow rate by closingthe control stop just to the point where the urinal will not overflow.

8b) ACTIVATIONRemove Sticker

Note: If the sticker was removed prior to the completion of the installation, calibra-tion attempts will be made every 5 minutes.

8c) DETECTION:All 4 LEDs will flash 3 times within 1 minute indicating that the valve hassensed bright lights. Calibration will begin in one minute (Fig 8b)

8d) MOVE AWAY FROM THE FRONT OF THE VALVE (step outside of the stallwith the door in the natural position) Fig 8c.

CHARGING:Flush valve will attempt to charge its power supply (rechargeable cell).

There will be 1-5 flushes initiated depending on the initial power supply stateand running pressure in the facility. At the end of each flush, the LEDs willdisplay the current level of charge (bottom blue led= 0-25% charge, bottomblue and green = 26-50% charge, three bottom LEDs (blue, green, green) =51%-75% charge, all 4 = 76%-100% charge

If for some reason the valve can not achieve a full charge during the firstflush, it will immediately attempt to charge its power supply with another 1-5 flushes. If it fails a second time, the valve will not attempt to recharge foranother 5 minutes. Every minute the LEDs will display the generator failurepattern. (green top and blue bottom led) It will repeat an attempt every 5minutes to charge the power supply until successful. The completion of asuccessful charging sequence is signified by the flashing of all 4 led’s fromtop to bottom. Once the rechargeable cell is fully charged (100%), the valvewill proceed to calibration of the sensor.

8e) CALIBRATION:Once the power supply is charged, the valve will attempt to calibrate thesensor after a one minute delay. It is very important that the installerdoes not block the ambient light in the room and does not walk infront of the sensor during calibration. User should be outside ofstall with the door in the natural position. (Fig 8c)

The valve takes 20 sensor readings. During each reading, it flashes all 4LEDs from the top to the bottom. (Fig 8d)

AUTOMATIC LIGHTING: If bathroom is equipped with occupancy sensors, be certain the

lights remain on throughout the entire calibration process.

READY TO GO:If the sensor calibration passes, the LEDs will turn off, the valve will flush,and then the valve is ready to go.

If it fails due to the ambient light levels being too low or the valve sensedsomeone in front of the valve, it will immediately attempt to re-calibrate thesensor. Another 20 LED flashes from top to bottom will be seen. The valvewill attempt 3 sensor calibrations. After the third failure, the valve will notattempt to re-calibrate for another minute. The majority of valves willcalibrate in 5 minutes but depending on lighting conditions it could take upto 15 minutes. The end of calibration and the valve being ready for use issignified by two consecutive flushes.

8b

8c

8d

8a

FV520 Rev. C 6/27/11

Installation Notes: For closet applications the sensor may activate if the toilet seat and/or toilet lid are

left in the upright position. See Trouble Shooting Guide at the end of this document for assistance.

For ADA installations it is recommended to mount the grab bar at the maximum

height of 36” (914mm) or use split grab bars on either side of the flush valve. The tailpiece length for the HydroVantage Valve to fit a given rough in dimension

dif fers from other Zurn products. The chart below shows the various tailpiece lengths available and the corresponding rough in dimensions.

Rough In HydroVantage Other Zurn Valves

Min (in.) Max (in.)

Tailpiece Length -Suffix Tailpiece

Length -Suffix

3.000 3.875 2.125 -J1 - - 3.625 4.500 2.750 -J2 - - 4.250 5.250 3.375 Standard 2.125 Standard 5.000 5.750 4.000 -J4 2.750 -J2 5.500 6.250 4.620 -J5 3.375 -J3 6.000 7.000 5.250 -J6 4.000 -J4 6.750 7.500 5.875 -J7 4.620 -J5 7.250 8.250 - - 5.250 -J6 7.875 8.875 - - 5.875 -J7

Testing Functionality (Sensor Verification)

o The valve is looking for the fluctuations in ambient light and infrared ref lection patterns associated with someone using the product for its intended purpose

o The valve will not respond to waving your hand in front of the sensor o To test the valve follow the steps below: Approach the valve (Urinal) or walk into the stall and stand at the edge of the

bowl or sit facing the valve (Closet) so you can observe the LED activity Look for the following LED sequence

Single Blue LED (Change in ambient light detected) 5-7 seconds (Closet), 3-4 seconds (Urinal) later a series of 4-5 Blue LED

flashes (User Confirmation) Green LED flashing (Valve is waiting for occupant to leave in order to

flush)

Optional Interface Software o The optional interface software can be loaded onto a laptop PC and used to

communicate with the valve to retrieve activation statist ics, estimated water usage, adjust f low rate, adjust sensor settings, and general trouble shooting.

o If interested in the interface software and communication cable, please call Zurn Customer Service at 1-800-997-3876 and ask about service part number PGEN6200-CA-CD

FV520 Rev. C 6/27/11

Service/Disassembly Notes: To change a valve from a Right Hand to a Left Hand installation:

1. Remove 2 security screws from either side of valve cap with provided security Allen wrench.

2. Gently pull up on the cap to separate the valve cap from the rest of the valve body.

3. Turn the valve cap 180°. 4. Lower the valve cap back onto the valve body being careful not to pinch any

wires. 5. Gently push the valve cap down until it is fully seated. Excessive force should

not be used any may indicate an interference or a pinched wire which may damage the electronics.

6. Replace the 2 security screws. Removing Valve Cap:

1. Remove 2 security screws from either side of valve cap with provided security Allen wrench.

2. Gently pull up on the cap to separate the valve cap from the rest of the valve body.

3. Disconnect the 3 electrical connections between the valve cap and the valve body.

a. RS232 Communication (3 pin Red/White/Black - Wire to Wire) b. Solenoid (2 pin Red/Blue – Wire to Main PCB) c. Generator (3 pin Red/Green/Black – Wire to Main PCB)

NOTE: All connections are locking waterproof connectors. The locking tab must be depressed during disconnection to avoid damage to the connectors. A thin flat blade screwdriver can be slipped into the connectors on the Main PCB to gently depress the locking tab to ease disassembly.

Cleaning the Valve Water and a mild detergent may be used to clean the outside of the HydroVantage. Harsh chemicals such as chlorine bleach or cleaning agents that contain ammonium chloride, acid or alkali can damage the surface of the lens. Abrasive cleansers, polishing powders, and coarse surfaces that come in contact with the valve can damage the lens as well as the chrome finish.

FV520 Rev. C 6/27/11

ZURN INDUSTRIES, LLC. COMMERCIAL BRASS OPERATION 5900 ELWIN BUCHANAN DRIVE SANFORD NC 27330Phone: 1-800-997-3876 Fax: 919-775-3541 World Wide Web: www.zurn.com

In Canada: ZURN INDUSTRIES LIMITED 3544 Nashua Drive Mississauga, Ontario L4V1L2 Phone: 905-405-8272 Fax: 905-405-1292

ZGEN6200EV HydroVantage ValveParts Identification 1. Cast Wall Escutcheon 2. Setscrew for Cast Wall Escutcheon 3. Supply Cover Tube 4. Sweat Solder Adapter 5. Stop Body 6. Piston Seal 7. Piston 8. Stop Spring 9. Guide O-Ring10. Piston Guide11. Guide Holder12. Adjusting Screw13. Stop Cap14. Snap Cap Screw Cover15. Vandal-Resistant Control Stop Cover16. Setscrew for Control Stop Cover17. Locking Nut18. Filter19. Tailpiece O-Ring20. Snap Ring21. Tailpiece22. Valve Cap/Sensor Assembly(For detailed breakdown see page 7)23. Valve Cap Screw24. Solenoid Repair Kit25. Flange O-Ring (Primary Valve Housing)26. Flange O-Ring (Piston Kit)27. Piston Kit28. Shell Screw29. Primary Shell30. Secondary Shell31. RS232 Cable Assembly32. RS232 Plug33. 2.5mm Security Wrench34. Manual Override Button Assembly35. Valve Body with Generator36. Vacuum Breaker37. Vacuum Breaker Tube38. Vacuum Breaker Tube Nut39. Spud Nut40. Spud Friction Washer41. Spud Sleeve42. Spud Escutcheon43. 5/64 Allen Wrench

Sole noid and Valve Kits Product No.Solenoid Replacement Kit, Items 24-26 PGEN6200-M Solenoid O-Rings, Includes Items 25-26 PGEN6200-M-RING Piston Replacement Kit, Item 27 See Next Sheet

Control Stop Repair Kit and Parts Product No.Control Stop Repair Kit for 1” and 3/4”, Includes Items 6-12

P6000-D-SD

Seal Seat for 1” and 3/4”, Includes Item 6 P6000-D42Sw eat Solder Adapter, Includes Item 4 P6000-YBA

Repair Parts Product No.Filter Replacement, Item 18 See Next SheetHydroVantage Replacement Screw s, Items 23, 28, 44, & 49

PGEN6200-S-KIT

Vandal Resistant Valve Cap Screw s, Items 23 & 33

PGEN6200-L-S

Interface Cable, 31 & 32 PGEN6200-IC

Covers and Repair Kits Product No.Hydro Generator Replacement Kit, Items 17-21 & 35

See Next Sheet

Valve Cap, Items 23, 33 & 51 PGEN6200-L Low er Body Housing Replacement Kit, Items 23,28-33

PGEN6200-HSA

Push Button Replacement Kit, Item 34 PGEN6200-MOB Vacuum Breaker Tube Nut for HydroVantage, Item 38

PGEN6200-AA-CP

FV520 Rev. C 6/27/11

WARNING!Replacement parts must be matched to the original flow volume of the valve. The flow volume of thevalve is designated on the label located on the underside of the tailpiece (connection to control stop).Mismatching of components will cause SEVERE PERMANENT DAMAGE to the valve and will voidthe warranty

1.6 and 1.28 (Closet) 1.0 and 0.5 (Urinal) 0.25 and 0.125 (Urinal)PGEN6200-EC (Item 27) PGEN6203-EU (Item 27) PGEN6203-EU-LF (Item 27)

White Body White Body Black Body

KIT

White Nut Black Nut Blue Nut

PGEN6200-FA (Item 18) PGEN6203-FA (Item 18) PGEN6203-FA-LF (Item 18)

Clear Black BlackFILTER with Integral

FlowRegulator

Hydro Generator Replacement Kit (1.6 and 1.28 GPF) Items 17-21 & 35 PGEN6200-GEN Hydro Generator Replacement Kit (1.0 and 0.5 GPF) Items 17-21 & 35 PGEN6203-GENHydro Generator Replacement Kit (0.25 & 0.125 GPF) Items 17-21 & 35 PGEN6203-GEN-LF

Sensor Assembly (1.6 and 1.28 GPF) Item 50 PGEN6200-SR Sensor Assembly (Urinal) Item 50 PGEN6203-SR

FV520 Rev. C 6/27/11

ZGEN6200EV HydroVantage Electronics



Parts Identification44. Battery Door Screws45. Battery Door46. Battery Door O-ring47. Battery Pack (Return envelope &recycling included.)48. Electronics Assembly49. Screw50. Sensor Assembly51. Valve Cap

Warning!Replacement parts must be matched to the original flow volume of the valve. The flow volume of the valve is designated onthe label located on the underside of the tailpiece (connection to control stop.) Mismatching of components will causeSEVERE PERMANENT DAMAGE to the valve and will void the warranty.

Sensor Replacement Parts Product No.Sensor Assembly, Item 50 See Previous Sheet

1.6 gpf Cap, Electronics and Sensor Assembly, Item 22

PGEN6200-LL-1.6


PGEN6200-LL-1.28


PGEN6203-LL-1.0


PGEN6203-LL-0.5


PGEN6203-LL-0.25


PGEN6203-LL-0.125

Electronics Replacement Parts Product No.1.6 gpf Electronics Assembly, Item 48 PGEN6200-EL-1.28 1.28 gpf Electronics Assembly, Item 48 PGEN6200-EL-1.6 1.0 gpf Electronics Assembly, Item 48 PGEN6203-EL-1.0 0.5 gpf Electronics Assembly, Item 48 PGEN6203-EL-0.5 0.25 gpf Electronics Assembly, Item 48 PGEN6203-EL-0.25 0.125 gpf Electronics Assembly, Item 48 PGEN6203-EL-0.125 Battery Drawer Repair Kit, Items 44-46 PGEN6200-BD-KIT Replacement Battery, Item 47 PGEN6200-BAT

FV520 Rev. C 6/27/11

Trouble Shooting Guide

Problem Possible Cause Diagnosis SolutionTop Blue LED flashes The sensor is detecting an

objectNormal operation After the 8-10 second user

confirmation cycle the blue LED will stop flashing and the top green LED will begin to flash

Top Green LED flashes The sensor is detecting an object and waiting to flush

Normal operation The top green LED indicates that the sensor is detecting an object and waiting for it to leave the sensor area to initiate a flush

Valve flushes multiple times immediately following installation

This is a normal and expected part of the automatic calibration sequence

Normal operation Wait 5 minutes for the valve to complete calibration

After a flush LEDs light up from bottom to top

This is the power cell charge indicator

Normal operation Lowest blue LED = 0-25% chargeLowest 2 LEDs = 26-50% chargeLower 3 LEDs = 51-75% chargeAll 4 LEDs = 76-100% charge

Lens could be dirty or damaged Visual inspection of lens. Clean or replace if obstructed or damaged

Sticker removed from sensor before installation or without water turned on

Valve does not show normal sensor detection LEDs and displays generator error LED pattern (top green and bottom blue LED) once every minute

Close stop. Wait 5 minutes and open stop very slowly to allow valve to shut. The valve will attempt generator calibration every five minutes, once it does so with the stop open, it will proceed to sensor calibration.

Sensor calibration not yet complete

Valve does not show normal sensor detection LEDs

Make sure there are no obstructions infront of the valve, the lights are on in the bathroom and there is no movement in front of the stall when the valve is calibrating. Leave the stall and let door lay in its "natural" position. The valve will attempt sensor calibration every few minutes until successful.

Sensor assembly or electronics malfunction

Perform sensor verification process from Page 5

If there is no LED activity - Check connection between sensor assembly and main circuit board - Call Zurn Customer Revice for further troubleshooting

With an object in the sensor range, no sensor lens LEDs are visible. Valve does not flush when object is removed.

FV520 Rev. C 6/27/11

Valve flushes on its own Trap seal/courtesy flush occurs 24 hours after last activation

This feature is to help keep valve charged and for sanitary purposes

This feature can be turned off with the Field Adjustment Software

Incorrect door position during calibration

Valve flushes without an occupant in stall

Adjust sensor range or recalibrate sensor with Field Adjust Software

Change in enviorment within stall causing sensor to initiate flush

Valve flushes without an occupant in stall

Adjust sensor range or recalibrate sensor with Field Adjust Software

Toilet seat in the up position is within sensor detection zone

Valve flushes without an occupant in stall with seat up

Reposition valve further into stop move sensor away from seat.

Water not turned on Check for water flow Find source valve and turn onPlugged filter Close stop, disconnect valve,

remove and inspect tailpiece filterClean or replace tailpiece filter (PGEN6200-FA, PGEN6203-FA, or PGEN6203-FA-LF)

Stop valve closed Turn screw counter clockwise Open stop valveWiring fault Check solenoid wires and insertion

of solenoid plugReinsert plug

Solenoid malfunction Activate valve with sensor and listen for audible "click" from solenoid

If "click" is not heard upon activation, replace solenoid and flange (PGEN6200-M)

Excessive water pressure causing solenoid to not function.

Consult with plumbing contractor to check static pressure. Pressure above 125psi may cause solenoid to not fuction.

Reduce pressure into valve

Incorrectly installed Check for leak location Remove and reinstall. Pay close attention to the alignment of inlet tube and outlet boss with mating pieces.

Damaged O-ring on inlet tube Check for damage Replace O-ringDamaged internal O-ring Remove outer shells and check for

leak locationSee parts list for applicable O-ring and component replacement.

Solenoid is open upon installation of valve

Shipment of valve can cause solenoid to open

Remove sticker from sensor, solenoid will shut within 30 seconds.

Manual Override Button (MOB) not functioning properly

Check if button is loose, missing, or jammed.

Replace MOB (PGEN6200-MOB)

Damaged or clogged piston kit orifice hole

Check piston kit Clean or replace piston kit (PGEN6200-EC, PGEN6203-EU, or PGEN6203-EU-LF)

Debris in piston kit face seal or damaged face seal

Check piston kit face seal Clean or replace piston kit (PGEN6200-EC, PGEN6203-EU, or PGEN6203-EU-LF)

Solenoid malfunction Close stop and remove cap. Inspect outside of solenoid. Activate valve with sensor and listen for audible "click" from solenoid

If water is present around solenoid or if "click" is not heard upon activation, replace solenoid and flange (PGEN6200-M)

LEDs follow normal sequence but valve does not flush

Valve has a long flush or does not shut off (continuous flow)

Valve leaks

FV520 Rev. C 6/27/11



Insufficient water pressure Consult with plumbing contractor to check running pressure of water into valve

Adjust pressure into valve to meet minimum required for fixture

Stop valve is not completely open Turn control stop screw counter clockwise

Adjust control stop screw until bowl evacuates properly without splashing

Plugged filter Close stop, disconnect valve, remove and inspect tailpiece filter

Clean or replace tailpiece filter (PGEN6200-FA)

Excessive water pressure Consult with plumbing contractor to check running pressure of water into valve

Adjust pressure into valve to achieve proper flow rate

Control stop open too far Turn control stop screw clockwise Adjust control stop screw until bowl evacuates properly without splashing

Top green and blue LEDs flash at the same time. This indicates the backup battery is low on power

Valve is in calibration mode for an extended period of time

Low backup battery power Replace backup battery (PGEN6200-BAT)

Bottom Green and Blue LEDs flash at the same time. This indicates a solenoid malfunction.

Debris in valve or within solenoid The valve had to increase the power to the solenoid to stop the flow of water

Clean or replace solenoid and flange (PGEN6200-M) or piston kit (PGEN6200-EC, PGEN6203-EU, PGEN6203-EU-LF)

Top green and bottom blue LEDs flash at the same time every few seconds. This indicates a generator malfunction.

Water is not turned on or low flow within valve

The generator output has fallen below the minimum required to recharge the cell

Open stop to highest flow rate allowable with fixture. Valve will continue to function drawing power from the back-up battery for up to 4 years depending on prior usage. If LEDs still flash with stop open replace valve body (PGEN6200-GEN, PGEN6203-GEN, or PGEN6203-GEN-LF)

Top green and bottom green and blue LEDs flash at the same time every few seconds. This indicates a sensor assembly malfunction.

Damage to sensor or loss of communication from sensor

Sensor is no longer functional Disconnect and reconnect sensor cables. If this does not resolve issue, replace sensor (PGEN6200-SR)

Flush is too powerful (flow rate too high)

Flush is weak (flow rate too low)

hydrovantagetm zgen series - zurn products · zgen series automatic sensor-operated, hydrogenerator...

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