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									Commercial Brass

           FLUSH LOGIC
           The Working of a Flush Valve
Flush valves in themselves are very
reliable. They have been used over the
last 60 to 70 years as the means for waste
evacuation of commercial fixtures. The
following is a simple explanation of the
working of a flush valve.
Flush Valves Require Two Important
    Factors For Their Operation
• Adequate water line pressure.
      (minimum 15 psi)
• Adequate pipe size to maintain a volume
  of water to sustain the water line
In professionally engineered commercial
  projects the plumbing engineer is
  responsible for these two factors.
              Typical Pipe Sizing
            Commercial / Institutional
                Saint Frank Lastowski Hospital and
                       Golfer’s Rehab Center

6th Floor

5th Floor

4th Floor

3rd Floor

2nd Floor

1st Floor
                          What’s in the Flush Valve
     The Flush Valve Diaphragm Kit and its components.
             The things that make it all happen.

                                     Trip Mechanism/Relief Valve
                                         P6000-EC13 Closet
       Inside Plastic Cover
                                         P6000-EU13 Urinal            Molded Disc

 Diaphragm Orifice
 or By-pass Hole

                                                   Diaphragm Kit (Shown in Full Assembly)


                                      Guide Ring

                                 Cylinder Guide
          Before The Valve is Activated
Diaphragm Orifice
                                   Flush valve at rest
or By-pass Hole        Diaphragm
                                   Before a flush, the water
                                   pressure above and below
Trip Mechanism
                                   the diaphragm are equal due
                                   to the diaphragm orifice or
                                   by-pass hole passage
                                   between them.
                                   The trip mechanism and
                                   diaphragm are sealed and at
                                   rest. No water is flushing.
                 Activation of the Valve
                         Molded Disc
                                  Once the handle is pushed, the
Trip Mechanism                    trip mechanism is tipped and
                                  breaks its seal with the molded
                                  Water from the area above the
                                  diaphragm is dumped into the
                                  outlet bore of the valve through
                                  the cylinder guide. This lowers
                                  the pressure above the
        Action After Valve is Activated
                                                The higher water
                                                pressure under the
Molded Disc                                     diaphragm pushes the
                                                diaphragm kit upward off
                                                the outlet bore of the
Valve Outlet Bore
Trip Mechanism                     Water Flow   The outlet bore is now
                                                open and the flush
                                                After the trip mechanism
                                                clears the actuator rod, it
                    Actuator Rod
                                                seats with the molded
                                                disk and seals the top
                                                diaphragm area.
                     As the Valve Flushes
                                          Water in the body and inlet
                                          rush down the open outlet
Diaphragm Orifice
or By-pass Hole
                                  Inlet   The higher water pressure
 Valve Outlet Bore                        below the diaphragm
          Body                            forces water through the
                                          orifice or by-pass hole into
                                          the area above the
                                          diaphragm and begins the
                                          process of building
                                          pressure above the
                    The Flush Terminating
                                          As the pressure above the
                                          diaphragm builds, it forces
                                          the diaphragm down back
Diaphragm                                 toward the outlet bore.
Valve Outlet Bore
                                          Water rushing down the
 Guide Ring                               outlet bore hits the guide
                                          ring and also helps push the
                                          diaphragm kit downward.
                          As the diaphragm approaches the bore, a
                          seal starts to be made and the flush begins
                          to terminate. The flush valve shuts off
                          quietly and is ready for the next activation
                          and returns back to the rested position.
       Determine the Flush
The thickness and shape of the flow ring,    Trip Mechanism
the orifice size, the length of the trip
mechanism and the guide ring determine
the flush duration and volume.              Molded Disc

Different Flows:
    Water Closets:                           Diaphragm
        4.5 GPF
        3.5 GPF                             Flow Ring
        1.6 GPF
   Urinals:                                 Guide Ring
        3.0 GPF
        1.5 GPF                             Cylinder Guide
        1.0 GPF
AquaVantage and Aquaflush
    Kit Configurations

The next three slides will show the kit
 configurations for the flows that are
 desired. Note the Color of the Trip
   Mechanism and Flow Ring that
produces the proper GPF for each kit.
            Valve Trouble Shooting
•   Valve not shutting off
          • Cause - Debris lodged in the diaphragm orifice, debris under the trip mechanism, debris
            or buildup of chemicals from hard water on the molded disc.
          • Fix - Clean or replace affected parts.
•   Non Functional Handle - Handle will not activate valve and appears to be in
    flush position.
          • Cause - Broken retainer or spring
          • Fix - replace broken part and add Silicone grease
•   Leaking around the valve cap at top of valve
          • Cause - Cracked inner cover (P6000-L) or a loose outer cover
          • Fix - Replace inner cover (P6000-L) or tighten outer cover to torque 25”#
•   Leaking at the stop nut
          • Cause - Bad O’ring on tailpiece (P6000-C31)
          • Fix - Replace the O’ring (P6000-C31)
•   Leaking at the Handle
          • Cause - Bad handle seal, ripped or missing handle gasket or handle nut not tightened
          • Fix - replace handle seal, replace or put on a handle gasket, tighten handle nut
     Valve Trouble Shooting con’t
•   Leaking at top of Vacuum Breaker Tube
          • Cause - Bad vacuum breaker
          • Fix - Replace with new vacuum breaker repair kit (P6000-B)
•   Flush Valve will not flush
          • Cause - Broken trip, trip mechanism lodged in up position, no water available
          • Fix - Replace broken trip (P6000-EC13 (closet) or P6000-EU13 (urinal)), clean trip
            mechanism so that the lower part will flop up and down freely, make sure that the stop
            valve is in the on position or make sure that the main water supply is turned on
•   Run-on Flush
          • Cause - possible debris on the valve internals or the orifice may be plugged
          • Fix - Clean the internal parts of the valve and/or make sure the orifice is clear
•   Short flush
          • Cause - Molded retainer is unscrewed, the flush kit is undersized for fixture being used,
            running pressure too low
          • Fix - the molded retainer should be torqued to 15”#, upgrade to a new kit to flush
            according to the fixture rate, re-size the water system
Flush Valve Parts
        Zurn Flush Logic
This presentation was compiled by the following:
      Tim O’Connor - Sanford Engineering
  Jody Randall - Supervisor Customer Service
                 February 2004

                 Zurn Industries, Inc.
              Commercial Brass Products
              5900 Elwin Buchanan Drive
                  Sanford, NC 27330

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