ZURN ZER-HYD Series Automatic Sensor Operated Gear Driven Type Flushometer Instruction Manual

ZER-HYD Series Automatic Sensor Operated Gear Driven Type Flushometer

AquaSense®

ZER-HYD Series
Automatic Sensor-Operated Gear
Driven Type Flushometer for Water
Closets and Urinals
Installation, Operation, Maintenance
and Parts Manual

Water Closet Battery Models:

• ZER6000AV-ONE-HYD 1.1 gpf
• ZER6000AV-HET-HYD 1.28 gpf
• ZER6000AV-WS1-HYD 1.6 gpf
• ZER6000AV-DF-HYD 1.1/1.6 gpf

Compliance:

• ADA Compliant 
• ASSE 1037/ASME A112.1037/CSA B125.37
• cUPC
• Texas Accessibility Standard (TAS)
• WaterSense Compliant

Urinal Battery Models:

• ZER6003AV-ULF-HYD 0.125 gpf
• ZER6003AV-EWS-HYD 0.5 gpf
• ZER6003AV-WS1-HYD 1.0 gpf  

WARNING : Cancer and Reproductive Harm – www.P65Warnings.ca.gov

LIMITED WARRANTY

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

NOTICE: READ ENTIRE MANUAL PRIOR TO INSTALLING PRODUCT

Specifications

Sensor Range: 12” to 60” (adjustable)
Voltage: 3.2 VDC Rechargable (LiFePO) Battery with 3.0 VDC Backup batteries [ 2 “AA” 1.5V Alkaline Cells Parallel] Operating Water Pressure: 25 psi [172 kPa] (Running); 80 Psi [552 kPa] Max (Static)
Operating Temperature: 35°F to 104°F [2°C to 40°C]

Important Safety Information

• Do not convert or modify this Zurn product. All warranties will be voided.
• 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 making connections.
• Do not use pipe sealant or plumbing grease on any fitting other than the control stop inlet.
• Sensor units should not be located across from each other or in close proximity to highly reflective surfaces.
• Control stop should never be opened to allow flow greater than fixture is capable of evacuating. In the event of valve failure, fixture
  must be able to handle a continuous flow.

Prior to Installation

• Before installing your flush valve, the items listed below should already be installed on-site:
  – Water closet or urinal fixture
  – Fixture carrier
  – Drain line
  – Water supply line

NOTE: The information in this manual is subject to change at any time without notice. Installations may
be performed at different times of construction by different individuals. For this reason, these instructions
should be left on-site with the facility or maintenance manager.

Package Contents

Required Tools Optional Accessories

Sweat Solder Adapter Installation Instructions

NOTE: Before installation, turn off water supplies to existing fixture and remove flushometer if replacing an existing device.

1. Measure distance from finished wall to the center line of the fixture
spud. If necessary, cut water supply pipe 1-1/4” shorter than this
measurement. Deburr by chamfering O.D. and I.D of end of water
supply pipe

2. Slide threaded sweat solder adapter onto water supply pipe until
shoulder stops on end of pipe. Then sweat-solder the adapter to
water supply pipe.

3. Measure distance from finished wall to first thread of sweat solder
adapter. If necessary, cut chrome cover tube this length.

4. Slide wall escutcheon over chrome cover tube and slide both
items over water supply pipe. Press wall escutcheon flush against
finished wall and tighten set screw with hex wrench (supplied) to
secure it in place

Control Stop Installation Instructions

1. Install control stop assembly by threading it onto water supply
pipe and tightening with a smooth jawed wrench. Apply thread
sealing compound or pipe tape to male NPT thread on sweat
solder adapter only.

2. When all stop valves are properly connected to the water supply
line and water pressure is available open the control stop using a
flathead screwdriver and turning the stop valve adjustment screw
counterclockwise.
Prior to turning on main water supply line ensure all stop valves
are closed off tight by using a flathead screwdriver and turning
the stop valve adjustment screw clockwise.
Allow the water supply line to flush any debris or sediment that
may be present in the line. Close the control stop once the lines
are completely flushed.

Flush Valve Installation Installation

Prior to attaching flush valve tailpiece to control stop, inspect and
verify that the O-ring seal is located within the O-ring groove at
the tailpiece. Ensure that the locking nut and locking snap ring
are also present on the tailpiece.
Lubricate O-ring with water if necessary and insert flush valve
tailpiece into the control stop valve. Tighten locking nut using a
smooth jawed wrench

Vacuum Breaker & Flush Connection Installation

Lossen the set screws through two small holes on the shroud
escutcheon by turning counter-clockwise. Uninstall shroud
escutcheon from the valve body by turning it counter-clockwise
and lower it from the shroud.
Determine the length of vacuum breaker tube required to join the
flush valve and fixture spud, and cut if necessary.

Slide the tube nut, spud nut, slip gasket, rubber gasket, spud
escutcheon and shroud escutcheon over the vacuum breaker
tube and insert tube into fixture spud. Hand tighten tube nut to
valve body and hand tighten spud nut onto fixture spud. Adjust
the valve assembly for plumb. Tighten fixture spud nut, vacuum
breaker tube nut and locking nut with a wrench.

Adjust and plumb the valve assembly. Tighten all connections with smooth jawed wrench and turn on water supply at the control stop.
Lasty, reinstall the shroud escutcheon back onto the shroud by turing it clockwise and tighten both set screws clockwise to secure
escutcheon in place .
DO NOT cut vacuum breaker tube shorter than 6” below the -C-L- indicator mark, as vacuum breaker must be 6” above the fixture.
Consult plumbing Codes & Regulations for specific details.

Battery Installation

1. Turn both set screw through the small holes on the side of the
valve head counterclockwise with the 3/32” Allen Wrench until
they are back into the valve head. Then, remove the valve head
by lifting it up.

2. As shown, insert 2 AA Alkaline batteries (supplied) into the battery
tray as backup batteries.

Wire Harness Connection

1. Connect the connector from the valve head to the connector from  the valve body carefully.

2.Bundle the connected cable harness up neatly and place in the  area above backup battery tray and slowly lower valve head back  on to valve body. Reinstall the valve head back onto valve body  by reversing step 1 in battery installation instruction.

Alternate Left Hand Installation Instruction

Follow right hand installation instruction to install flush valve with the sensor lens facing the back wall up to Harness Connection step.

1. Connect the connector from the valve head to the connector from the valve body carefully.
2. Rotate the valve head to have the sensor lens facing the front.

3. Bundle the wire harness neatly and flat across the rechargable
battery and position the connectors in the vacant area shown.
Next, slowly lower valve head back onto valve body. Reinstall the
valve head back onto valve body by reversing step 1 in battery
installation instruction.

Diaphragm Replacement and Cleaning (when necessary)

1. Turn off control stop using a flat head screwdriver turning
clockwise. Afterward, utilize the manual override button to flush
water out of the flush valve.

2. Lossen the set screws through two small holes on the shroud
escutcheon by turning counter-clockwise. Uninstall shroud
escutcheon from the valve body by turning it counter-clockwise
and lower it from the shroud.

3. Lift the valve head slightly to release the two shrouds. Move the
shrouds away from each other at the same time to remove them
from the valve body.
Use tape or a marker to mark the original position of the locking
ring in relation to the valve body.

4. Ensure both the strap wrench and locking ring are completely dry
for optimial grip.
Using the supplied strap wrench to counter-clockwise loosen the
valve head’s locking ring. If the strap wrench is slipping, you may
use a large wrench on the flats of the locking ring to loosen it.

5. Remove the existing diaphragm kit from the manifold stem.
Thoroughly wash the diaphragm and orifice using water.
Install the cleaned diaphragm back into the valve body, ensure that
the orifice is facing the correct orientation. For the correct orifice
orientation, Refer to the retrofit installation instruction section.
If the issue persists after cleaning, proceed to step 5B.
Do not to damage or enlarge orifice. Doing so will result in
incorrect flush rate.

6. Place the valve head with the diaphragm kit back onto the valve
body. Ensure that both the strap wrench and locking ring are dry
for a better grip. Tighten the locking ring to its original position
using the supplied strap wrench by turning it clockwise.
5B. Remove the existing diaphragm kit from the manifold stem. If
the o-rings show signs of wear or damage, replace them with
the new ones provided in the diaphragm repair kit.
Install a new diaphragm kit (with matching flow rate) into the
valve body, ensure that the both orifices are positioned inline
with the control stop. Take care to align it properly.
Note that unless the Volume Control Ring is missing or broken,
there is no need to replace it.
5. Remove the existing diaphragm kit from the manifold stem.
Thoroughly wash the diaphragm and orifice using water.
Install the cleaned diaphragm back into the valve body, ensure that
the orifice is facing the correct orientation. For the correct orifice
orientation, Refer to the retrofit installation instruction section.
If the issue persists after cleaning, proceed to step 5B.
Do not to damage or enlarge orifice. Doing so will result in
incorrect flush rate.
7. Reverse step 2 & 3 to reinstall both shrouds and shroud
escutcheon. Turn the control stop back on by turning counterclockwise
using a flat head screwdriver.

Sensor Range Adjustment (when necessary)

ensure optimal performance in various restroom environments,
each ZER-HYD is initially calibrated at the factory. However, in
situations where there is low light or high reflectivity, it might be
necessary to make adjustments to the calibration distance of the
unit. This can be done using a Magic Magnet (P6900-AT-MAG).
Follow the steps outlined below to re-calibrate the ZER-HYD using
a Magic Magnet (P6900-AT-MAG):
1. Stand at the desired calibration distance:
– ~28” from the sensor in a water closet application.
– ~22” from the sensor in a urinal application.
2. Place Magic Magnet to the right of the ZER-HYD’s lens within
indicated area. Hold the Magic Magnet in that position until the
user LED lights up.
3. Maintain the position of the Magic Magnet until the user
LED starts blinking. Once the blinking begins, remove the
Magic Magnet and allow the user LED to blink 10 times while
remaining in the same position. A quick double-blink of the user
LED indicates that the calibration process is complete.
4. To verify the new calibration distance, step away from the unit
for 5 seconds. Then return to the exact position at which it was
calibrated and observe the user LED. If the user LED blinks,
it indicates that the calibration distance has been successfully
calibrated.

Note: To ensure proper functionality, make sure the calibration distance in water closet applications prevents the sensor from detecting
the stall door. Verify this by closing the door for 10 seconds, then opening it. If the flush valve doesn’t activate, the calibration distance is
suitable. Otherwise, recalibrate to a closer distance using the magnet.

Dual Flush User Guide (For ZER6000AV-DFv Only)

• The Dual Flush model supplies flush volumes of 1.1 and 1.6 gallons per flush. When a user is present for less than 60
  seconds, the valve will flush with 1.1 gallons of water. When a user is present for over 60 seconds, the valve consumes 1.6
  gallons of water. A user must be present for a minimum of 8 seconds in order to trigger a flush.

• The Dual Flush model must be paired with a fixture with a flush volume range that includes 1.1 to 1.6 gallons per flush. For a
  list of recommended bowls, please refer to our website, www.zurn.com, or speak with your local Zurn rep.

Care and Cleaning Instruction

• Do not use any abrasive or chemical cleaners to clean the flushometer.

• The suggested cleaning of chrome plated surfaces is simply to clean them with mild soap and water, then dry. Commercial
  cleaning compounds are never recommended.

• Upon cleaning other areas of the restroom, be sure the sensor lenses are protected from other cleaning chemicals/solvents to
  prevent potential damages to the sensor and/or electronics.

• Valves used in installations subject to shut down because of cold and freezing conditions should be maintained in the following
  manner. After the main supply has been shut off and the water drained from the system, remove the stop valve cap and stop
  valve internals to allow the water to drain from the flush valve itself.

Trouble Shooting Guide

Problem

|

Indicator

|

Cause

|

Corrective Action

---|---|---|---

Flush valve does not flush.

|

No water flushed.

|

Stop valve is closed

|

Open stop valve

Sensor flashes 5 times in quick succession

|

Flush cycle did not complete

|

Contact Customer Service for further  instruction

No sensor light

|

Batteries not making contact

|

Remove and reinstall batteries correctly, or replace batteries See Battery installation for reference.

Critically low battery voltage

Sensor flashes once every 5 seconds

|

Low battery voltage indication

Sensor flashes every 30

seconds

|

Continuous user detection of object  within sensor range

|

Recalibrate. See Sensor Range  adjustment section for reference.

Sensor flashes rapidly

|

Battery Powered:

Batteries installed incorrectly.

|

Remove and reinstall batteries correctly.  See Battery installation for reference.

Hardwired:

Backup batteries installed incorrectly

|

Remove and reinstall batteries correctly.  See Battery installation for reference.

Hardwired:

Backup Battery not detected.

|

ryInstall backup batteries, or reference

courtesy flush & battery detection settings section to turn off backup battery detection.

Sensor detects user, three slow flashes & two quick

flashs, but fail to flush upon exiting sensor range

|

inaUser/object still in sensor field

|

Identify and remove any user from sensor field

Reduce sensor range distance (see  Sensor Range Adjustment instructions)

Battery power level too low to activate  flush valve

|

Replace batteries. See Battery Installa tion for reference.

Dirty sensor lens

|

Clean sensor lens with warm water and  mild soap until free of debris

Loose or damaged wire harness

|

Inspect wire harness and connection between electronics and motor

eliUser not detected; no LED  flashes.

|

Sensor range may need to be adjusted

|

Increase sensor range distance (see  Sensor Range Adjustment instructions)

mFlush valve is aimed at an angle.

|

Rotate flush valve head to be

perpendicular to wall. See Sensor  Angle Adjustment section for adjusting  the flush valve head.

Manual override button does  not initiate a flush.

|

Stop valve is closed / turned off.

|

Turn on stop valve.

MOB does not depress

|

Contact Customer Service.

PValve does not evacuate  fixture

|

rInsufficient volume of water to adequately siphon fixture.

|

Stop valve is not open enough.

|

Open stop valve for desired volume of  water.

Insufficient volume or pressure at supply.

|

Increase incoming water supply

pressure to minimum 25psi.

Insufficient volume for installed fixture

|

Contact Customer Service.

Valve shuts off too quickly or short flushes.

|

Damaged or punctured diaphragm.

|

Install new diaphragm replacement kit. (See Diaphragm Replacement  and Cleaning Section for replacement  instruction)

Enlarged by-pass orifice.

|

Install new diaphragm replacement. (See Diaphragm Replacement and  Cleaning Section for replacement  instruction)

Diaphragm kit is not matched to the  fixture.

|

Install new diaphragm replacement kit. (See Diaphragm Replacement  and Cleaning Section for replacement  instruction)

FV845 Rev. A 1/31/2024

Page 10

Trouble Shooting Guide

Problem

|

Indicator

|

Cause

|

Corrective Action

---|---|---|---

Valve is flushing too long or not shutting off.

|

High water delivery or

continuous flow.

|

By-pass orifice is plugged or partially plugged.

|

Examine by-pass orifice and clean if necessary being certain not to en large orifice opening. (See Diaphragm Replacement and Cleaning Section for  cleaning instruction)

Water splashes out of fixture.

|

Water splashes onto floor during flush cycle.

|

Supply volume is too high.

|

Slowly close the control stop to lower  water pressure.

Mineral accumulation on vortex or  spreader holes of fixture.

|

Remove the mineral build up.

Flush is not considered quiet.

|

Flush is loud.

|

Control stop may not be adjusted for  quiet operation.

|

Adjust the control stop for quiet opera tion keeping in mind the fixture evacua tion requirements.

Fixture may be contributing to noise.

|

y Check noise created by fixture by

placing a cover over the bowl opening to  separate valve noise from bowl noise. If it is determined the fixture is too noisy, consult with fixture manufacturer.

naPiping system may be source of noise.

|

rHigh pressure in the system can

sometimes be controlled by the stop  valve. Other sources of noise may be  the absence of air chambers and shock  arrestors, loose pipes, improper size pipes, etc. In these cases, the building engineer should be consulted.

Valve leaking near valve head.

|

Water droplets seen between  valve head and valve body.

|

iLocking ring not tight.

|

Tighten locking ring. See Sensor Angle  Adjustment section for reference.

Valve flushed with no user present

|

iValve flushed with no user present

|

Highly reflective environment

|

Re-calibrate sensor range – see Sensor  Range Adjustment section

Sensor range set too far; picking up other objects

mFlush valve may be configured to

exchange the water in the trap-way at  every [24 / 48 / 72] hours after no usage  (default is OFF).

|

See Courtesy Flush Battery Detection  Settings for instructions on changing dipswitch settings to achieve desired  trap exchange timing.

PrelFor further assistance with troubleshooting, visit http://www.zurn.com/

FV845 Rev. A 1/31/2024 Page 11

ZER-HYD Series Repair Kits

Part Identification

Preliminary

1. Valve Body

2. Vacuum Breaker Duckbill 3. Vacuum Breaker Tube 4. Vacuum Breaker Tube Nut 5. Spud Nut

6. Spud Friction Washer 7. Spud Sleeve

8. Spud Escutcheon

9. Tailpiece

10. Snap Ring

11. Tailpiece O-Ring

12. Locking Nut

13. Stop Body

14. Sweat Solder Adapter 15. Supply Cover Tube

16. Cast Wall Escutcheon

17. Setscrew for Cast Wall Flange 18. Piston Seal

19. Piston

20. Stop Spring

21. Guide O-Ring

22. Piston Guide

23. Guide Holder

24. Adjusting Screw

25. Stop Cap

26. Snap Cap Screw Cover

27. Vandal Resistant Control Stop Cover 28. Setscrew for Control Stop Cover 29. Handle Cap Seal

30. Handle Nut

31. Diaphragm Kit

32. Volume Control Ring 33. Manifold Stem O-Ring 34. ZER-HYD Valve Head 35. Locking Ring

36. Sloan© Locking Ring 37. Filter

38. Flow Restrictor

FV845 Rev. A 1/31/2024 Page 12

Service Parts

Control Stop Repair Kit and Parts

|

Product No.

---|---

Control Stop Repair Kit for 1” and 3⁄4”,

Items 18-24

|

P6000-D-SD

Seal Seat for 1” and 3/4”, Item 18

|

P6000-D42

VP Control Stop Repair Kit for 1” and 3/4”, Items 18-24

|

P6000-D-VP

Sweat Solder Connection with Cast Wall Flange, Items 14-16

|

P6000-YBYC

Adjustable Tailpieces

|

Product No.

---|---

Adjustable Tailpiece for Standard Flush Valve, Items 9-11

|

P6000-J1

Tailpiece CouplingAssembly, Items 10-12

|

P6000-K

Tailpiece Locking Ring, Item 10

|

P6000-C30

Tailpiece O-Ring, Item 11

|

P6000-C31

Coupling Nut, Item 12

|

P6000-C32

Filter, (Full Valve Only), Item 37

|

P6000-FA

Flow Restrictor, (Universal ULF PERK6203-FAKit Only), Item 38

|

PERK6203-FA

Flush Connections and Spud Coupling Kits

|

Product No.

---|---

Vacuum Breaker Repair Kit, Item 2

|

P6000-B

Spud Coupling Assembly for Water Closet, Items 5-8. Specify size.

|

P6000-H

Spud Coupling Assembly for Urinal,

Items 5-8. Specify size.

|

P6003-H

ZER-HYD Valve Head Repair Kit and Parts

|

Product No.

---|---

Locking Ring, Item 35

|

PER6000-M-RING

Sloan© Locking Ring, Item 36

|

PER6000-M-RING-S

Valve Head, (1.1 gpf), Item 34

|

PERK6000-L-1.1

Valve Head, (1.28 gpf), Item 34

|

PERK6000-L-1.28

Valve Head, (1.6 gpf), Item 34

|

PERK6000-L-1.6

Valve Head, (1.6/1.1 gpf), Item 34

|

PERK6000-L-1.6/1.1

Valve Head, (0.125gpf), Item 34

|

PERK6003-L-0.125

Valve Head, (0.5 gpf), Item 34

|

PERK6003-L-0.5

Valve Head, (1.0 gpf), Item 34

|

PERK6003-L-1.0

Valve Head for Sloan©, (1.1 gpf), Item 34

|

PERK6000-L-1.1-S

Valve Head for Sloan©, (1.28 gpf), Item 34

|

PERK6000-L-1.28-S

ryValve Head for Sloan©, (1.6 gpf), Item 34

|

PERK6000-L-1.6-S

Valve Head for Sloan©, (1.6/1.1 gpf), Item 34

|

PERK6000-L-1.6/1.1-S

Valve Head for Sloan©, (0.125 gpf), Item 34

|

PERK6003-L-0.125-S

Valve Head for Sloan©, (0.5 gpf), Item 34

|

PERK6003-L-0.5-S

Valve Head for Sloan©, (1.0 gpf), Item 34

|

PERK6003-L-1.0-S

ZER-HYD Diaphragm Repair Kit

|

Product No.

---|---

aCloset Repair Kit – (1.1, 1.28, 1.6, 1.6/1.1 gpf), Item 31-33

|

PER6000-EC

Urinal Repair Kit – (0.125 gpf), Item 31-33

|

PER6003-EU-ULF

Urinal Repair Kit – (0.5, 1.0 gpf), Item 31-33

|

PER6003-EU

FV845 Rev. A 1/31/2024 Page 13

Rev. A | Date: 1/31/2024 | C.N. No. 145585 | Prod./Dwg. No. FV845

Patent zurn.com/patents

US 1.855.ONE.ZURN CANADA 1.877.892.5216 ZURN.COM

References

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

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