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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 - Sloans 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
Grab Bars
< 5 Pound Force
Wide Side Of The Stall
Opportunities For
Hydraulic & OPTIMA
44 Maximum Height
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
fromover-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
Obsolete
SLOAN Optima Plus 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 G2 Optima Plus

Obsolete
Solenoid
Operator
G-2 & Sloan Optima Plus
Blue Sensor Module Available with old cable connector for our
EBV-129-A existing products, and our new
Uses 49935 connection for G-2 Optima Plus
How to id a solenoid.
Older Optima Plus 03/33-04/22 Green Triangle theyre
Black Sensor Module going to be.
EBV-25-A - Obsolete
04/23-06/39 Blue Triangle might not
Uses #99065117 be bad.
06/04 Current Double Blue Triangles

Optima Plus
Diaphragms
Dual Filter Dual Filter with Flex Tube

Obsolete
OPTIMA PLUS DIAPHRAGM KIT
VOLUME
REGULATOR

DISC

REFILL HEAD

FLOW CONTROL ROYAL DUAL-FILTER


RING DIAPHRAGM

FLEX TUBE ASSEMBLY


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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Plumbing Specialties

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Flushometers
Electronic or manual,
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EPAct2005 mandates that all commercial pre-


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Can be installed to use 1.6 or 1.0 gallons per


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By installing waterless
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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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