ZURN ZPWC1 Trim Kit Instruction Manual

ZURN ZPWC1 Trim Kit

Product Information

The ZPWC1 Trim Kit is a carrier system designed for the installation of water closets. It ensures proper support and stability for the water closet and allows for adjustment of the rough-in height. The kit includes a faceplate, mounting bolts, threaded rods, locknuts, and necessary installation accessories.

Note : The dimensional data provided in inches and [mm] are subject to manufacturing tolerances and may change without notice.
Disclaimer : These instructions cover the installation of the carrier system. Local codes may require additional pressure testing.

Product Usage Instructions

Step 1: Adjust Rough-in Height

1. If using an adjustment tool to set the rough-in height, refer to the ZPWC1 Adjustment Tool Installation Instructions (Form C75).
   Step 2: Install Faceplate

2. Place the faceplate in the clearance opening between the double structural wall studs mentioned in the Wall Assembly section above.

3. Take into account the thickness of the finished flooring and set the faceplate to the desired rough-in height of 4-8 [102203]. Ensure that the faceplate is centered in the clearance opening and parallel to the wall studs.\

4. Temporarily clamp the faceplate to the wall studs to prevent movement. Confirm that both faceplate flanged faces fully contact the wall studs. (Refer to Figure 4)

5. Drill out six mounting holes using a 1/2 [13] bit, using the faceplate as a drilling template. Ensure that the faceplate does not shift during drilling. Remove any large burrs.

6. Note: Improperly placed holes should not overlap or be oversized, as this may result in premature failure under load.
   Step 3: Mounting

7. Insert the provided 6 bolts for mounting through the back of the faceplate.

8. Torque the provided flanged head nylon-insert lock nut to 25-35 lb-ft [33.9-47.5 N-m]. Use the notch in the faceplate for easy access with a wrench for the middle bolts. Remove temporary clamps.

9. Insert the provided threaded rods through corresponding holes in the finished wall.

10. Assemble locknuts on threaded rods on the rear of the faceplate (Refer to Figure 5).

11. Set the rod distance as follows:

For Wall Mount Water Closet:

• Use (4) 5/8 threaded rods and ensure they extend no more than 5/8 [16] past the closet bowl flange.
• The holes in the finished wall should be sized appropriately to accommodate backing nut and washer adjustment, approximately 1-3/4 [44.5].
• Torque the 4 locknuts to 70-75 lb-ft [94.9-101.7 N-m].

For Floor Mount Back Outlet Water Closet:

• Use (2) 3/8 threaded rods and ensure they extend no more than 5/8 [16] past the closet bowl flange.
• The holes in the finished wall should be sized appropriately to accommodate backing nut and washer adjustment, approximately 1 [25.4].
• Torque the 2 locknuts to 12-17 lb-ft [16.3-23.1 N-m].

For additional information and support, please refer to the ZPWC1 Trim Kit Installation Instructions provided by Zurn Industries.

Design and Dimensional Data (inches and [ mm ]) are Subject to Manufacturing Tolerances and Change Without Notice
Disclaimer : These instructions pertain to the installation of the carrier system. All pressure testing necessary by local codes is still required.

Wall Assembly

1. Assemble a pair of (2) 18 gage, 3-5/8” x 1-5/8” x 1/2” lip structural steel wall  studs (Figure 1) that conform to AISI S240 and/or ASTM C955 back-to-back and screw together with (2) minimum #8 screws approved by the wall stud manufacturer. The starting pair of screws should be within 2” [50.8] of the bottom of the stud and the spacing between screws should be a maximum of 12” [304.8] (Figure 2). Mount the pair of double structural wall studs to the top and bottom structural track with 2 screws (minimum #8) per individual wall stud with a clearance opening of 11-5/8” +/- 1/8” [295.3 +/- 3.0]. Ensure the wall studs are 90 degrees to the track and plumb. If installing sole plate to flooring, ensure hardware is centered in clearance opening.
   The total finished wall thickness from wall stud to finished face is required to be between ½” to 1-1/4” [12.7 to 31.75] (Figure 3).
   Note : Excessive deflection will occur and leakage may be a result of improper installation.

Carrier Assembly

1. If using adjustment tool to set rough in height, reference ZPWC1 Adjustment Tool Installation Instructions (Form C75).

2. Place faceplate in clearance opening between the double structural wall studs mentioned in the “Wall Assembly” section above. Accounting for finished flooring thickness, set the faceplate to the desired rough in height of 4”-8” [102- 203], ensuring faceplate is centered in clearance opening and parallel to wall studs. Temporarily clamp faceplate to wall studs to prevent movement, confirming both faceplate flanged faces fully contact the wall studs. (Figure 4)

3. Drill out six mounting holes with a 1/2” [13] bit using the Figure 4 faceplate as a drilling template, ensuring the faceplate does not shift during drilling. Remove any large burrs. Note: If holes are improperly placed, do not overlap or oversize holes. Failure to comply with this may result in premature failure under load

4. Insert the provided 6 bolts for mounting through the back of the faceplate, and torque the provided flanged head nylon-insert lock nut to 25-35 lb-ft [33.9-47.5 N- m]. The notch in the faceplate is for ease of wrench access for the middle bolts. Remove temporary clamps.

5. Insert the provided threaded rods through corresponding holes in finished wall and assemble locknuts on threaded rods on rear of faceplate (Figure 5). Set the rod distance by referencing steps 5a and 5b below.
   NOTE : If the studs are too long they will bottom out in the finishing cap nut preventing proper gasket compression which may result in leakage.
   a. Wall mount water closet will use (4) 5/8” threaded rods and rods should extend no more than 5/8” [16] past the closet bowl flange. The holes in the finished wall should be sized appropriately to accommodate backing nut and washer adjustment, approximately 1-3/4” [44.5]. The 4 locknuts to be torqued to 70- 75lb-ft [94.9-101.7 N-m].
   b. Floor mount back outlet water closet will use (2) 3/8” threaded rods and rods should extend no more than 5/8” [16] past the closet bowl flange. The holes in the finished wall should be sized appropriately to accommodate backing nut and washer adjustment, approximately 1” [25.4]. The 2 locknuts to be torqued to 12-17lb-ft [16.3-23.1 N-m].

6. Ensure the hole in the finished wall is large enough to accommodate the flange of the coupling, approximately 4-3/4” to 5” [120.7 to 127] diameter. Referencing the instruction on the O-ring bag, lubricate O-ring and coupling threads with provided lubricant. Insert O-ring into grove in faceplate and thread coupling into faceplate. Ensure coupling flange extends 5/16” [8] past finished wall. (Figure 7)

7.  Install backing nuts and washers onto threaded rods. Follow steps 7a and 7b below per water closet type.
   a. For wall mount water closet, thread a 5/8” bearing nut and slide a bearing washer onto each of the (4) threaded rods. Adjust hardware so that there is a 1/16” [2] gap between the front of finished wall and back of fixture ensuring all bearing washers make contact with the fixture.(Figure 7) Warning: Failure to do so may result in increased risk of cracking.
   b. For floor mount back outlet water closet, thread a 3/8” bearing nut and slide a bearing washer onto each of the (2) threaded rods. Adjust hardware so that there is a 1/16” [2] gap between the front of finished wall and back of fixture ensuring both bearing washers make contact with the fixture. Warning: Failure to do so may result in increased risk of cracking.

8. Peel off the removable backing from one-side of the Neo-Seal gasket and seat into the groove of the water closet outlet horn. (Figure 8)

9. Peel off removable backing liner from the opposite side of the Neo-Seal gasket and hang the water closet onto the threaded rods. Ensure Neo-Seal gasket seals to the coupling.

10. Assemble a fiber washer and cap nut onto each threaded rod and hand tighten in a progressive pattern. Secure closet with an additional half-turn using a wrench on each nut to complete the installation, achieving a torque of 96-120 in-lbs [130.2-162.7 N-m]. (Figure 9)
    Note : The water closet should not contact the finished wall.

11. For Fitting Installation Instructions, reference ZPWC1 Fitting Installation Instructions (Form C74).
    Disclaimer : Zurn is not responsible for damaged fittings if installed at the manufacturer. Fittings to be shipped to jobsite then installed.

12.  After final installation, double check bolt torques ensuring everything is to the required specification.

Note : Complete all steps in ZPWC1 Trim Kit Installation Instructions (Form C73) before proceeding with fitting installation.
Disclaimer : Zurn is not responsible for damaged fittings if installed at the manufacturer. Fittings to be shipped to jobsite then installed.

Horizontal Fitting and Fitting Adapters Installation

Disclaimer: Horizontal fittings are only to be used in the horizontal orientation with the vent connection facing upward. In addition, threaded rods may need cut to clear horzontal fitting, especially for floor mount back outlet installations.

1. Gently place gasket onto fitting flange, ensuring a snug fit with both ears wrapping around flange. Check for slot alignment and concentricity of opening, adjust as needed while not stretching the gasket.
   Note : Gasket orientation for horizontal fittings will be vertical. (Figure 1a)
   Note : Gasket orientation for vertical fitting will be horizontal. (Figure 1b)
   Note : Gasket orientation for fitting adapters will be vertical. (Figure 1a)

2. Place fitting over coupling, aligning the slots of the fitting over the countersunk threaded holes on the faceplate. Insert hardware and hand tighten. (Figure 2) Note: If coupling is in the way of the installation, reference ZPWC1 Coupling Cut Guide Installation Instructions (Form C76).

3. Adjust slope of fitting with integrated slots. Once slope is set, tighten hardware in a star pattern, torque to 13-17 lbs-ft [17.6-23.1 N-m]. (Figure 3)
   Note : For 3” PVC/Cast Iron fitting adapters, ensure adapter is in proper orientation and the text “TOP” is facing the top of the carrier. If installed improperly there is an increased risk of poor line carry, clogging, and may result in leakage. (Figure 4).

4. Connect fittings to building plumbing with proper venting per local code requirements. PVC fittings are designed in accordance with solvent welding and cast iron fittings are designed in accordance with No-Hub connections.

Vertical Fitting Installation

Disclaimer : The vertical fitting is only to be used in the vertical orientation with the extended barrel protruding through the floor. In addition, threaded rods may need cut to clear horzontal fitting, especially for floor mount back outlet installations.

1. To install the vertical fitting, a minimum core drill hole of 6” [152.4] diameter must be located 3 1/2” [88.9] from back of sole plate to center of hole. For floor mount back outlet installation, cut threaded rods flush with back of locknut for fitting clearance when being inserted into the core hole. (Figure 5)

2. Gently place gasket onto fitting flange, ensuring a snug fit with both ears wrapping around flange. Check for slot alignment and concentricity of opening, adjust as needed while not stretching the gasket.

3. Vertically align barrel over core drill hole, and slowly lower into place. If the barrel needs cut to length, no more than 12” [304.8] may be removed. The cut must be square to the barrel and deburred, ensuring sufficient length for connecting to building plumbing. Ensure gasket stays aligned to flange and does not get damaged. (Figure 5)

4. Place fitting over coupling, aligning the slots of the fitting over the countersunk threaded holes on the faceplate. Insert the (4) bolts and hand tighten. Confirm fitting does not interfere with core
   hole.
   Note : If coupling is in the way of the installation, reference ZPWC1 Coupling Cut Guide Installation Instructions (Form C76).

5. Tighten the (4) bolts in a star pattern and torque to 22-28 in-lbs [2.5-3.2 N-m]. (Figure 6)

6. Connect fittings to building plumbing with proper venting per local code requirements. Cast iron fittings are designed in accordance with No-Hub connections.

ZPWC1 ADJUSTMENT TOOL INSTALLATION INSTRUCTIONS

1. Set adjustment tool on back of faceplate and loosely hand tighten the 4 bolts provided to the faceplate. Note: All (4) bolts must be used to ensure proper rough in height adjustment and sufficient faceplate support for installation.

2. Align the center of the bottom bolts with the numbered locating feature to achieve the intended rough in height.
   Note : Rough in height adjustment tool does not account for finish flooring thickness.

3. Torque to 24-36 in-lbs [2.7-4.1 N-m].

4. Set adjustment tool into sole plate and tip assembly into the wall.

5. Reference ZPWC1 Trim Kit Installation Instructions (Form C73) steps 3 and 4 for faceplate to wall installation.

6. Once faceplate is secure, remove the adjustment tool and keep the hardware with the tool for future use. Proceed with the ZPWC1 Trim Kit Installation Instructions (Form C73) starting at step 5.
   Note : The 1-1/4” length hardware provided with the adjustment tool is only to be used with the adjustment tool. Risk of leaking may occur if used with other components.

ZPWC1 COUPLING CUT GUIDE INSTALLATION INSTRUCTIONS

1. Complete all steps in ZPWC1 Trim Kit Installation Instructions (Form C73).

2. If using a floor mount back outlet water closet, cut extra threaded rod off flush with lock nut.
   Note : After cutting, the rods can no longer be adjusted forward.

3.  Place coupling cut guide over coupling. Using the provided 1-1/2” [38.1] fitting hardware, insert and hand tighten at least 2 bolts located diagonally on the back of the faceplate. If interfering with threaded rods for floor mount back outlet, the rods must be cut shorter.
   Cut coupling flush with cut guide and remove all burrs.

4. Remove the cut guide and set aside for future use.

5. Reference ZPWC1 Fitting Installation Instructions (Form C74) proceeding at step 3 for horizontal fitting installation or step 5 for verticle fitting installation.

WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov
Zurn Industries, LLC | Specification Drainage Operation 1801 Pittsburgh Avenue, Erie, PA 16502, Ph. 855.663.9876
In Canada | Zurn Industries Limited
7900 Goreway Drive, Unit 10, Brampton, Ontario L6T 5W6, Ph. 877.892.5216
www.zurn.com
Date: 06/02/2023
C.N. No. 145358
Patent zurn.com/patents
Form No. C7

References

• P65Warnings.ca
• P65Warnings.ca.gov
• Patents | Zurn Industries LLC's products

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