Geberit Manufacturing, Inc Boone Drive, Michigan City, IN Phone: (800) Fax: (219)

Transcription

1 INSTALLA ALLATION INSTRUCTIONS TABLE OF CONTENTS Product Overview...2 Features...2 In Compliance With...2 Available Options...2 How to Order...2 Technical Support...2 Product Specifications...2 Installation Requirements...2 Safety Information...3 Dimensions Component Identification...5 Tank & Carrier Installation Wall Hung Bowl Installation Access Panel-Flush Actuator Installation Theory of Operation...11 Troubleshooting Guide...12 Warranty...12 ADA Compliant Trademarks The PF/2 Pressure Assist Tank is licensed by one or more of the following U.S. patents: , , , RE37921 and other patents pending. PF/2 is a registered trademark of Geberit. Copyrights 2004 Geberit. All rights reserved. The information in this manual is subject to change without notice. Notice to Installers Please leave this manual with the facility manager after completing the Pressure Assist Toilet installation. This document contains information necessary for routine maintenance and servicing. Geberit Manufacturing, Inc Boone Drive, Michigan City, IN Phone: (800) Fax: (219) Effective May 2004

2 PRODUCT OVERVIEW Geberit's Pressure Assist Toilet System, using PF/2 energized flushing system, is a revolutionary concealed tank, carrier and wall-hung toilet system. It takes the pressure assist technology and moves it into the wall for a quieter flush cycle than floor-mounted pressure assist toilets. Geberit's pressure assist toilet system redefines low consumption plumbing. It can save up to 25% more water than conventional 1.6 GPF technologies since double flushing is eliminated. Maintenance personnel especially appreciate this pressure assist toilet because the 3" discharge pipe helps prevent clogs, the drain line carry exceeds the ASME standard and the large water surface in the bowl reduces stains, odor and provides a more sanitary environment. The Geberit system consists of: Tank & Carrier Model Wall Hung Bowl Model DY.1 Access Panel-Flush Actuator Model Open Front Toilet Seat Model DY.1 FEATURES PF/2 #160 pressure vessel Steel, powder-coated carrier Die-cast actuator dimension: - 9-5/8" (245 mm) wide - 6-1/2" (165 mm) high 3" DWV discharge elbow 90 with lowflex shielded coupling. Bowl passway 2-1/4" (57 mm) Carrier height adjustable range 15" - 19" ( mm) bowl seat height Water consumption 1.6 GPF (6 LPF) Large water spot 10-1/2" x 12" (265 x 305 mm) Easy sanitation of surrounding areas IN COMPLIANCE WITH ASME A ASME A M-1998 ASME A ADA ; ; ; ; AVAILABLE OPTIONS ASSE 1037 CSA -B125 Polished Chrome Actuator Plate Matte Chrome Actuator Plate Discharge Elbows 3" DWV SCH-40 Straight extension pipe Horizontal left side discharge elbow Horizontal right side discharge elbow Back-to-back discharge connector-3" Back-to-back discharge connector-4" Cast-iron 90 discharge elbow White Elongated Toilet Seat, Closed Front \ w/lid DY.1 Open Front w/self-sustaining Check HInges DY.1 Discharge Extension Kit Geberit In-Wall Pressure Assist Toilet System 2 HOW TO ORDER Contact your local Geberit dealer or visit our website at TECHNICAL SUPPORT For additional technical assistance call , or visit our website at PRODUCT SPECIFICATIONS The bowl complies with ASME A Vitreous China fixture standard, with 4 bolts, 1/2" UNC onto the carrier. The carrier has an adjustable height to accommodate 15"-19" ( mm) seat height, per ADA. The unit flushes on 1.6 GPF (6 L). Actuator panels are die-cast zinc and plated to preserve the materials integrity. INSTALLATION REQUIREMENTS Tank and carrier system shall be placed within standard 2 x 6 wall studs (wood or metal) placed 16" (406 mm) on center or with an opening clearance of 14-1/4" (36.83 cm). NOTE: If metal studs are used, wood reinforcement must be placed within the stud u-channel. 3" diameter waste discharge tube. Water supply shall be 1/2" copper, minimum water pressure 35 PSI. Finished wall thickness should not exceed 2" (60.96 cm). NOTE: Any wall depth over 6" or extension behind the wall (10"-12" maximum) will require the accessory Discharge Extension Kit # (sold separately). Multiple Installation and/or an above floor waste line that is behind the wall will require the accessory Discharge Extension Kit # (sold separately). Back-to-back installation may require a back-to-back discharge connector (sold separately). There are two types one for 3" waste pipe and one for 4" waste pipe. Framing construction must conform to ASME A Framing Affixed Supports for Off-The-Floor Water Closets with concealed tanks. All installations must conform to local and national plumbing, building and fire codes. The In-Wall Pressure Assist System is packaged and shipped according to your construction installation process. This eliminates product damage and provides the products when needed. Rough-In: The completely assembled Tank and Carrier System is shipped. Finished Wall: Wall Hung Bowl Installation Access Panel - Flush Actuator Installation

3 SAFETY INFORMATION Read this entire instruction sheet to ensure proper installation. Compliance and conformity to local codes and ordinances is the responsibility of the installer. Compliance and conformity to local fire codes and ordinances is the responsibility of the installer. Purge all the water supply lines before making connections. 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. DIMENSIONS FRONT VIEW 16 " [406mm] 14-1/4" [360mm] WATER INLET SIDE VIEW 8-9/16 " [217mm] 5-1/4 " [133mm] 3" [75mm] 5-1/4 " [137mm] 9" [230mm] 28-3/4 " [730mm] 4" [102mm] 8-1/2 " [216mm] 7-1/2 " [190mm] 7-1/2"-22" [190mm-559mm] ADJUSTABLE 3-3/4"-9" [95mm-229mm] ELBOW LENGTH 4" MINIMUM [100mm] INSTALLATION OPTIONS RIGHT OR LEFT OF CENTER 3-1/2 " [90mm] STUD FRONT CENTER HOLE DIMENSIONS IN INCHES AND [MILLIMETERS]. NOTES: 1. FINISHED WALL THICKNESS NOT TO EXCEED 2". 2. RECOMMENDED MATERIAL FOR WALL SURFACE CONSTRUCTION: - GYPSUM - GREEN BOARD - CEMENT BOARD - TILE BACKER BOARD - CERAMIC TILE SURFACE 3. LOWFLEX SHIELDED COUPLING SUPPLIED. ADA COMPLIANT 3

4 DIMENSIONS FINISHED WALL 22" [558mm] 7-1/2" [190mm] FINISHED SEAT HEIGHT (FSH) 9" [230mm] 4

5 COMPONENT IDENTIFICATION Care should be taken when unpacking shipping carton to avoid damage to unit and the following components enclosed. If any parts are missing or damaged, contact your local Chicago Faucets dealer. Ref Description 1 Braided Hose, 3/8" x 14" 2 Screen Filter 3 Push Lever Assembly w/screws 4 Actuator Rod 5 Drop Ear Elbow, 1/2" NPT 6 Shutoff Valve, 1/2" NPT 7 Actuator Box Guard & Cover 8 Actuator Lock Pins 9 Actuator Retaining Frame 10 Actuator Panel 11 Screws, Vandal Resistant Ref Description 12 Toilet Seat, White 13 Toilet Bowl 14 Installation Hardware Kit, Toilet Bowl 15 Hinge Hardware & Wrench (included w/seat) 16 Threaded Rods & Locking Nuts, 1/2 x 6" 17 Carrier Installation Hardware 18 Carrier Frame Assembly 19 Bowl Outlet Gasket 20 Discharge Adapter 21 Shielded Coupling 22 Discharge Elbow, 3" 23 3" Discharge Pipe Clamp 24 Flush Pipe Assembly 25 Bowl Inlet Adapter 26 Bowl Inlet Gasket 27 PF/2 Model 160 Tank 28 Retaining Pin 29 Flush Valve Assembly 30 Cap Assembly

6 TANK & CARRIER INSTALLATION 1 IMPORTANT! The Finished Seat Height for the bowl must be determined prior to installing the carrier. Please take into account the seat height for final height dimensions. NOTE: When determining X, include the dimension for the finished floor covering (up to.5"). Distance between top of the bowl rim surface and discharge outlet centerline 5¼" (133 mm) Finished Seat Height Distance between discharge outlet centerline and raw floor X T + FSH - 5¼ = X T 2 The 2 x 6 framework must be secured firmly to the floor and ceiling for proper installation. Locate the supporting studs and reinforce with additional nails or screws. Make sure rough opening(s) are properly plumbed and square. Reinforce with additional nails or screws 3 1. Place the tank & carrier assembly into the desired location. The carrier metal frame must be flush with the front of the mounting studs to provide maximum support for the wall surface (applied later). 2. Mark the 6 anchor hole locations in the base and the 4 side mounting hole locations (2 each side) on the studs. 3. If the discharge is to be installed vertically in ground, mark the discharge elbow location on the base support. 4. Remove the tank & carrier assembly from the studs. 5. Drill six 3/16" holes in the base support; drill four 5/16" holes on the side studs where marked. 6. For vertical discharge only, bore a 4" hole into the base plate where marked. 7. Install tank & carrier into framework and secure with hardware provided. 8. Install 3" shielded coupling (provided) to connect discharge elbow to waste pipe. Side Mounting Hole Locations 5/16" (2 each side) 6 Base Anchor Holes (3/16") Horizontal Above Ground Installation Vertical In Ground Installation 6

7 4 1. Install a 1/2" water supply line into the 1/2" NPT drop ear elbow. NOTE: If soldering copper line, allow sufficient cooling time before proceeding. 2. Turn off the supply shutoff valve. 3. Attach a separate drain hose to the top of the shutoff valve and place the other end into a bucket or drain. 4. Turn on the main water supply, then turn the shutoff valve to the ON position and purge the main water line into a container. This will avoid clogging the filter. 5. When the water line is clear, turn shutoff valve OFF. 7. Remove drain hose from shutoff valve. 1/2" Main Water LIne Shutoff Valve with Drain Hose Connected 5 Connect the braided hose to the shutoff valve. NOTE: The braided line has a filter that may become clogged and cause slow water flow, especially in new construction. To clean filter, turn shutoff valve to OFF, disconnect braided hose, remove filter and clean. Reinstall filter and connect braided line. Braided Hose Filter Location 6 1. Install four 1/2 x 6" threaded rods (supplied) into the tank & carrier assembly. 2. Estimate the total wall thickness and add 3" for the approximate fixture rod exposed length (A). 3. Install protective clear plastic sleeves onto fixture rods. NOTE: The fixture rods are secured with locknuts. Do not install locknuts at this time Remove retaining ring (28) and push lever (3). 2. Slide guard box into the tank & carrier assembly. 3. Secure guard box to frame using two screws provided. 4. Snap cover into place on the box. 2 Mounting Screws 7

8 WALL HUNG BOWL INSTALLATION 1 1. Remove the plugs from the fill and discharge openings of tank & carrier assembly. 2. Install the bowl inlet adapter and discharge adapter fully into their respective holes. 3. Assemble the gaskets onto the inlet adapter and discharge adapter. 3. Place a straightedge flush against the wall and across the fill pipe and mark dimension A. Repeat for discharge adapter. 4. Remove inlet and discharge adapters from tank & carrier assembly A Fill Discharge 2 1. Install the inlet and discharge adapters, with gaskets, fully into the bowl. 2. Measure and mark dimension B on both pipes. 3. Remove pipes from bowl. B Measure from edge of bowl 3 1. Add dimensions A and B, then subtract 1/8" to get dimension C. 2. Using this dimension, mark a line on each pipe, measuring from the gasket side. 3. Cut off the excess on the spigot side of each pipe. Gasket Side B A Spigot Side 1/8" Spigot Side C (A + B - 1/8") 4 Bevel the rough and sharp edges as shown to ensure a smooth insertion into the pipe spigots on the wall. 45 S S/2 8

9 5 1. Lubricate gaskets with appropriate rubber seal lubricant. Do not use plumbers putty or silicone sealant. 2. Install both adapters into the spigots on the wall. 3. Remove protective clear plastic sleeves from threaded rods Rods should protrude 3" from face of wall. Adjust rods if necessary. 2. Secure rods to tank & carrier assembly using locknuts provided Place the bowl fully onto the four threaded rods. 2. Install cap retainers (1), washers (2) and nuts (3). Do not tighten nuts yet.. NOTE: Cap retainers (1) should be installed with the larger end facing up. 3. Level the bowl then tighten nuts snug. DO NOT OVERTIGHTEN NUTS. 4. Snap caps (4) over cap retainers (1). 5. Caulk around the bowl with waterproof sealant. UP

10 ACCESS PANEL-FLUSH ACTUATOR INSTALLATION 1 1. Remove box guard cover. 2. Trim off excess material from box. 3. Discard cover and excess material. 2 Measure wall thickness for dimension X. x 3 Cut the lock pins to equal dimension X (from step 2) + 1/2". 4 Install lock pins into box guard. Adjust the length of the pins so the ends are flush with the wall surface. X + 1/2" If not done previously, purge the supply line. 2. Disconnect the braided line from the top of the shutoff valve. 3. Connect a separate drain hose to the shutoff valve and place the other end of the hose into a container or drain. 4. Allow supply water to flow until clear. 5. Disconnect the drain hose and reconnect the braided hose to the shutoff valve. 6 To install actuator push rod: 1. Measure dimension Y, from wall surface to front of bushing. 2. Cut the actuator push rod to dimension Y + 1". Actuator Push Rod Y+1" Measure from wall surface to front of bushing 10

11 7 1, Install the actuator push rod into the bushing so it extends only 3/8" (9.5mm) in front of actuator frame surface as shown. 2. Install rod and turn clockwise to lock it into the bushing. 3/8" 8 1. Place actuator frame onto front of box with spring at the bottom facing outward. 2. Secure frame to lock pins with two self-tapping screws provided Attach the actuator panel to the lower spring, then push up and snap it over the upper edge. Test actuator for functionality. 2. Install vandal resistant screws into cement board and tiling. 3. Remove protective film. Step 1 Step 2 Step 3 Push HOW THE IN-WALL PRESSURE ASSIST TANK WORKS 3 Stages of the Flush Cycle Flush Stage: The flush begins when the actuator valve is depressed, and ends when the tank has discharged all of its water through the bowl. Air Intake/Bowl Refill Stage: As water rushes through the empty tank past the fill tube to refill the bowl,it causes a Venturi effect, which draws air into the tank. The small amount of water in the air inducer cap disappears, and a suction sound occurs for seconds. Pressurization Stage: After the flush valve seats the tank begins to fill with water. The ball in the air inducer floats against the seat in the cap and air intake stops. A small amount of water fills the cap. Water continues to fill the tank, compressing the air inside, until the force of the regulator spring is overcome and the supply is shut off. 11

12 TROUBLESHOOTING GUIDE Problem Cause Corrective Action No pressurization (no flush action on actuation). Vessel pressurizes but flow never shuts off. Vessel pressurizes but toilet has poor flush. Actuator push rod is too long. actuator valve broken. Inadequate water flow. Flush valve seals damaged. Unknown. Slow leak somewhere in pressure zone. Unknown. Air is not being pulled through the air inducer cap. Bowl or sewer line is clogged. Tank drain valve door is obstructed. Lift off the actuator plate to release the force on the actuator push rod. If unit pressurizes, the push rod was holding the actuator open. Adjust push rod to shorter length. Cut if necessary. Lift off the actuator plate to release force on the actuator push rod. Actuator stem will pop out if broken. Replace cap assembly (# ) Turn off water supply valve. Flush toilet then unscrew the braided hose supply line from the cap inlet. Remove and clean the screen filter. Open supply valve and rinse supply line. Direct flowing water into tank shroud. Turn off water supply valve and flush toilet. Pull the cap assembly retaining pin, remove the cap assembly, and remove the flush valve piston. Inspect both seals on the flush valve piston, and replace piston if damage or wear is visible (# ). When cause is unknown and none of the above corrective actions solves the problem, call Geberit Technical Support at Ensure retaining pin is fully inserted, and securely holding down cap assembly. Listen and look for leaks. Check gaskets on cap assembly and the small check valve. If worn/damaged, replace cap assembly (# ). When cause is unknown and none of the above corrective actions solves the problem, call Geberit Technical Support at Check air intake after flush. If device does not take in air, then allow unit to pressurize. Turn off supply line and flush toilet (holding in actuator for 3 seconds). Listen for gurgling sound after flush. If gurgling sound is present, replace cap assembly (# ). If bowl trap is clogged, plunge toilet. If no result, snake if necessary. Geberit toilet bowl will hold 5 gallons of water or withstand 3 flushes without overflowing. Since the unit is installed in the wall and the tank is protected by a plastic shroud, the drain valve (flapper) will not be visible. Disconnect the water supply hose from the cap assembly and flow water for approximately 15 seconds into the tank shroud. This should flush out any small obstructions/debris holding the flapper open. Geberit Technical Support: Please have In-Wall Pressure Assist Serial Number available (see tank label). CHICAGO FAUCETS WARRANTY / GEBERIT BRAND PRODUCT PRESSURE ASSIST TOILET SYSTEM Chicago Faucets offers a limited lifetime warranty on the carrier. The pressure tank (vessel) has a 5-year warranty from the date of installation plus a one-year warranty on the toilet bowl and flush actuator plate. Chicago Faucets will either replace or repair the defective equipment or refund the purchase price, at its option, if inspection by Chicago Faucets or its authorized representative discloses any manufacturing defects in material or workmanship during this period. Chicago Faucets will not be liable for any labor or other expenses not specifically stated above and disclaim any responsibility for incidental or consequential damages. Warranties implied by law, including that of merchantability are expressly limited to the period of this warranty. This limitation and exclusion does not apply in those states that do not allow limitations on the duration of implied warranties. Or the exclusion may not apply to you. This warranty gives you specific legal rights and you may have other rights, which vary, from state to state. 12