ZURN ZTR Series ZTR6200-W2 AquaSense Exposed Sensor Battery Water Closet Flush Valve Instruction Manual

: June 5, 2024
: ZURN

Table of Contents

ZURN ZTR Series ZTR6200-W2 AquaSense Exposed Sensor Battery Water Closet
ZTR Series Flush Valve Package Contents
TROUBLE SHOOTING GUIDE
2 Identify and remove any target from sensor field
3 Reduce sensor range distance (see page 10 for Sensor Range Adjustment
2 Remove valve from stop and fixture #3 Inspect/clean filter (see parts
ZTR6200 Series Parts Breakdown (Plastic Cap)
- Parts Identification
ZTR6200 Series Parts Breakdown (Metal Cap)
- Parts Identification
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

ZURN ZTR Series ZTR6200-W2 AquaSense Exposed Sensor Battery Water Closet

Flush Valve

ZURN-ZTR Series-ZTR6200-W2-AquaSense-Exposed-Sensor-Battery-Water-Closet-
Flush-Valve-product-image

Water Closet Models:

ZTR6200-ONE 1.1 gpf
ZTR6200EV 1.28 gpf
ZTR6200-WS1 1.6 gpf
ZTR6200-WS1-DF 1.6/1.1 gpf

Urinal Models:
ZTR6203-ULF 0.125 gpf
ZTR6203-QRT 0.25 gpf
ZTR6203-EWS 0.5 gpf
ZTR6203-WS1 1.0 gpf

Power Options:
Battery (Standard)

LL (Long Life Battery)
HW (Hardwired using 7.6 VDC Power Supply Input)

Compliance:

ADA Compliant – Operational Controls
WaterSense Compliant

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

ZTR Series Flush Valve Package Contents

Required Tools

Optional Accessories

Overview:

Zurn Aqua-Sense® ZTR Series Flushometer offers two models (closet/urinal) in a variety of flow rates. The ZTR design is a chrome plated brass body with an automatic sensor-operated piston-type valve. The flushometer incorporates a filtered bypass, high back pressure vacuum breaker, adjustable tailpiece, spud coupling, flange for top spud connection and a mechanical override pushbutton (MOB) for alternative flushing methods. The control stop has internal siphon- guard protection, vandal resistant stop cap, sweat solder kit, and cast wall flange with set screw. All internal and external gaskets and seals are chloramine resistant.

Specifications:

Voltage: 6 VDC Series [4 “AA” (Alkaline or Lithium) and/or external power option] Sensor Range: Factory set for user at end of elongated bowl or field adjustable by installer

Important Safety Information:

Installer is responsible for ensuring the product is installed and conforms to all plumbing codes and ordinances.
Do not convert or modify this Zurn product yourself. All warranties will be voided.
Water supply lines must be sized according to building designer in order to provide adequate water supply for each fixture.
Flush all water lines prior to making connections.

Prior to Installation:

The ZTR flushometer is designed to operate optimally between 25 psi (running) to 80 psi (static) water pressure (172 to 552 kPa). Higher running pressure may be required for some fixtures. Consult fixture manufacturer for details.
When installing a flushometer, it is important that the flush volume matches the requirements of the plumbing fixture.
To protect chrome finish, do not use toothed tools to install or service the flushometer.
Before installing your Zurn® Aqua-FIT® Faucet: the items listed below should already be installed on site.
- Closet
- 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.

Sweat Solder Adapter Installation Instructions – STEP 1

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

STEP 1.1
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.

STEP 1.2
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.

STEP 1.3
Measure distance from finished wall to first thread of sweat solder adapter. If necessary, cut chrome cover tube this length.

STEP 1.4
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 – STEP 2

STEP 2.1
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.

STEP 2.2
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.
Apply sealing compound here

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.
Using a flathead screwdriver, turning counterclockwise, flush supply line by opening the control stop. Turning clockwise will close control stop.

Flush Valve Installation – STEP 3

STEP 3.1
Prior to attaching flush valve to control stop(A) inspect and verify that the O-ring (C) is located within the O-ring groove at the tailpiece. Ensure the locking nut (D) and locking snap ring (E) are also present on the tailpiece. See Figure 3.

STEP 3.2
Lubricate O-ring with water if necessary and carefully insert flush valve tailpiece into the control stop valve to ensure O-ring remains seated. Tighten locking nut using a smooth jawed wrench. See Figure 4.

STEP 3.3
Determine the length of vacuum breaker tube required to join the flush valve and fixture spud, and cut if necessary. See Figure 5.

DO NOT use pipe sealant or plumbing grease on any valve component or coupling with the exception of the Control Stop Inlet! Ensure Vacuum Breaker does not twist or warp when tightening Vacuum Breaker Tube Nut.

STEP 3.4
Assemble and secure the vacuum breaker tube assembly and spud nut assembly to the flush valve and fixture spud by hand tightening the spud nut and vacuum breaker tube nut.
Adjust and plumb the valve assembly. Tighten all connections with smooth jawed wrench and turn on water supply at the control stop. See Figure 5.
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.

Remove Sensor Cap (Applies to all versions) – STEP 4

STEP 4.1
Use the 3/32″ Allen Wrench to loosen the internal set screw until it stops. Screw will retract into the base to eliminate loss.

STEP 4.2
Rotate cap clockwise and pull cap up to remove.

STEP 4.3
Disconnect black solenoid plug before accessing batteries.

Battery Installation (Applies to battery and -LL versions only) – STEP

5A

STEP 5A.1
Remove sealed battery housing from sensor cap and remove top of sealed battery housing by loosening the knurled screw by hand or with a flat head screwdriver. Insert four batteries (supplied) into sealed battery housing and ensure the batteries are inserted in the correct orientation. Reattach top to the sealed battery housing.

STEP 5A.2
Connect sealed battery housing to sensor lens via RED connectors by aligning arrows and pressing together.
Insert sealed battery housing into sensor cap. Ensure sticker on top of sealed battery housing is oriented properly with the WHITE arrow pointing toward the sensor lens. See Figure 8.1.

Utilize open space within the sensor cap to store the connected RED power connectors and BLACK solenoid connectors. See Figure 8.2.

Only use one battery type for installation. DO NOT mix and match Standard (Alkaline) and Long Life (Lithium) Batteries.

STEP 5A.3
Reattach the sensor cap and tighten cap screws.
Hardwire Installation (Applies to -HW versions only) – STEP 5B

STEP 5B.1
Route 10′ power supply cable (supplied) through the wall escutcheon (supplied), wire supply tube (supplied) and the opening on the back of sensor cap.
Connect power supply cable to sensor lens via RED connectors by aligning arrows and pressing together.

Hand-tighten wire supply tube into the back of the sensor cap. Slide wall escutcheon along wire supply tube until it is against the sensor cap.
Reattach the sensor cap to the flushometer valve body while ensuring wire supply tube is properly inserted into thru-hole in wall.

Tighten the set screw using 3/32″ Allen wrench to secure sensor cap. Slide wall escutcheon flush with wall and secure using set screw and Allen wrench (supplied).

Connect ZTR-HW directly to HW6 Power Converter.

STEP 5B.2
Cut RED power connector from end of power supply cable not connected to the Sensor Cap and strip back the wire insulation by minimum of 1/4″.
(Recommended if one to two ZTR flush valves are powered by one HW6.)

STEP 5B.3
Secure RED wire to Positive (+) and BLACK wire to Negative (-) screw terminals on HW6.
Optional Junction Box (recommended when three or more ZTR flush valves utilize one HW6)

Metal Sensor Cap Retrofit Installation Instructions

STEP 6.1
Remove vandal-resistant cover with Allen wrench from control stop (if present) and turn control stop clockwise to turn off the water supply.

STEP 6.2
Press and hold the manual override button for 3 seconds to release any residual pressure.

STEP 6.3
(For Hardwired Only) Loosen set screw in wall escutcheon and slide escutcheon against the sensor cap

STEP 6.4
Use a 5/64″ Allen wrench to remove the two cap screws from the sensor cap and remove the sensor cap. See Figure 17. Disconnect black solenoid plug.

STEP 6.5
(For Hardwired Only) Disconnect the red sensor plug and loosen the wire supply tube. Remove both the wire supply tube and escutcheon. Keep for metal sensor cap installation.
STEP 6.6
Remove the 4 sockets screws shown in Figure 18 using a M3 Allen wrench and discard the screws

STEP 6.7
Note socket screw pockets in the ring insert and place over remaining 2 socket screws See Figure 19.

STEP 6.8
Ensure ring insert set screws align with valve body holes shown in Figure 20. Hand start the 4 new sockets screws(included) into the ring insert. Tighten screws in the torque sequence shown on Figure 21.

STEP 6.9
Remove sealed battery housing from sensor cap and remove top of sealed battery housing by loosening the knurled screw by hand or with a flat head screwdriver. Insert four batteries (supplied) into sealed battery housing and ensure the batteries are inserted in the correct orientation. Reattach top to the sealed battery blousing.

STEP 6.10
Connect sealed battery housing to sensor lens via RED connectors by aligning arrows and pressing together.
Insert sealed battery housing into sensor cap. Ensure sticker on top of sealed battery housing is oriented properly with the WHITE arrow pointing toward the sensor lens. See Figure 23.
Utilize open space within the sensor cap to store the connected RED power connectors and BLACK solenoid connectors per the sticker on the battery housing. See Figure 24.

STEP 6.11
(For Hardwired Only) Route 10′ power supply cable through the wall escutcheon, wire supply tube, and the opening on the back of the metal sensor cap.
Connect the power supply cable to the sensor lens via the RED connectors by aligning the arrows and pressing together.
Hand-tighten wire supply tube into the back of the sensor cap. Slide wall escutcheon along wire supply tube until it is against the sensor cap.

STEP 6.12
Align set screw hole in sensor cap with key way in ring insert and place sensor cap on valve body.
Rotate sensor cap counter clockwise until the set screw is visible in the sensor cap hole and the sensor is facing forward. Using the 3/32″ Allen wrench(provided) rotate the set screw clockwise to secure the cap.

Dip Switch Settings (when necessary)

Courtesy Flush
A courtesy flush can be enabled for the ZTR flushometer where the valve will automatically flush at a specified interval based on customer preference. Simply manipulate Dips witches #2 and #3 located on the Sensor Lens found on the inside of the Sensor Cap to change the courtesy flush interval.

Courtesy Flush Interval	Dipswitch #2	Dipswitch #3
Disabled (Default Setting)	ON	ON
24 hours	ON	OFF
48 hours	OFF	ON
72 hours	OFF	OFF

Dual Flush Option (If Equipped) The dual flush option can be enabled by turning switch #1 to the ON position.
Note: The ZTR Dual Flush must be originally ordered with the dual flush option. Regular single flush valves will not function in dual flush mode .

Sensor Range Adjustment (when necessary)

STEP 1.1
Place the Zurn Magic Magnet (optional accessory: P6900-ATMAG) against the cap at the lower right corner of the Zurn logo under the sensor lens. Hold in place until the valve automatically flushes and the red LED light flashes two (2) times. Remove Magic Magnet from flush valve. The valve has entered calibrate mode.

STEP 1.2
Place light-colored target at desired detection range away from sensor. After 10 more LED flashes followed by a double flash and/or flush the new detection range will be calibrated and set.
Test new calibrated sensor range using targets of various material types/textures to ensure calibration accuracy. Verify that sensor range does not detect stall doors or other reflective surfaces.

Care and Cleaning Instruction

Do not use any abrasive or chemical cleaners to clean the flushometer.
ONLY use mildly warm soapy water, and then wipe the device dry with a clean/soft towel or cloth.
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.

Accessing Piston Kit

Turn off water supply and press manual override button to relieve all water pressure.
Remove valve cap to expose ring insert. Using the M3 Allen Wrench remove the 4 screws and the ring insert.
Remove the remaining 2 screws and the solenoid flange.
Remove the piston kit from the valve body and inspect for damage to the seals or debris in the orifice. Excessive build up of debris may occur on filter screen.

TROUBLE SHOOTING GUIDE

PROBLEM	INDICATOR	POTENTIAL CAUSE	SOLUTION

**** Valve does not flush

| No lights on sensor board| Batteries not making contact| Remove and reinstall batteries correctly

– See step 5A for reference

Batteries reversed polarity
Sensor flashes (red) every 10 seconds| Low battery voltage indication| Replace batteries – see Step 5A for reference
Sensor flashes (red) every 30 seconds| Continuous target detection of object within sensor range| #1 Inspect and clean lens

2 Identify and remove any target from sensor field

3 Reduce sensor range distance (see page 10 for Sensor Range Adjustment

instructions.
Sensor detects user but fails to flush upon exiting sensor range| Batter power level too low to activate full flush – sensor board automatically shuts down to avoid open flush| Replace batteries See Step 5A for reference
Dirty sensor lens| Clean lens until free of debris
Loose or damaged solenoid connection| Inspect connection between solenoid and sensor for proper insertion – step 4
No target detected| Install environment may require adjustment of the sensor range from the factory settings| Re-calibrate sensor range – see Sensor Range Adjustment (Figure 28) page 10
Valve does not shut off water (continuous flow)| Normal target detection| Water pressure either too high or too low| Adjust water pressure to recommended range:

35 to 80 psi running water pressure

Piston and / or solenoid plugged or damaged| Remove Piston and / or Solenoid to examine for damage or plugging. Clean piston / solenoid orifice if plugged.

Replace solenoid kit if solenoid di phragma is damaged.

Low or no power allowing solenoid to move to open position but not enough power to return to closed position.| Replace batteries or restore power if hardwired.
MOB (mechanical override button) sticking in open position| ****

Replace MOB.

Valve flows low (short flushing)| Valve does not evacuate fixture| Tailpiece filter is clogged with debris| #1 Turn stop off

2 Remove valve from stop and fixture #3 Inspect/clean filter (see parts

break- down – Part number 10)

Piston orifice is enlarged| Replace piston
Flush valve rating does not match fixture flush rating| Replace flush valve to match fixture flush rating
Ghost flushing| Flush valve activates without target present.| Highly reflective environment| Re-calibrate sensor range – see Sensor Range Adjustment
Sensor range set too far, picking up other objects.
Continuous flushing| Valve flushes every 30 seconds.| Magnet stored in sensor cap.| Remove magnet from sensor cap. Do not store magnet in flush valve.
Electronic Control Board| Cannot adjust sensor range| Processor latched| Reset electronics module by removing cap, disconnect power connector and shorting terminals together. Reconnect power, allowing 30 seconds to complete power up sequence.
DIP switch settings| Configuration changes to DIP switches| ****

Remove cap from valve and disconnect power. Move DIP switch to desired position. Reconnect power, allowing 30 seconds to complete power up sequence.

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