SF 16X24 Sand Handler Pop-Up Flush Valve (835-00-081) Installation Instructions

General Guidelines

For proper operation, the “Superflush” system depends on careful installation of the major components with close attention to the elevations and grades.  For proper flushing when using sand as bedding, the grade across the flush lane should be level for the entire length of the lane.  The slope down the lane in the direction of the flush should be uniform and a minimum of 2.5 percent and maximum of 6 percent grade.  Reservoir height (head) should be a maximum of 30′ (40′ if splashing is not a concern) above top of valve with a minimum supply pipe size of 15″.  These recommendations and accompanying drawings are advisory in nature intended to show typical fixture placement and pipe routing.  There are many types of pipe, pipe materials, and fittings that can be used for systems of this type.  The standard flange connection on the fixtures allows connection to most type of pipe available in the U. S.   It is recommended to use gasketed fittings and pipe connections as much as possible.  The pipe system will be attached to the fixtures with a standard flange and gasket.  The flange should be a two piece Vanstone type with a full face gasket.  Caution: do not use raised face flanges with ring gaskets.  Desired sealing around bolts will not occur.  The remainder of the pipe system will be installed in accordance with instructions and specifications from the supplier of the actual pipe and pipe fittings selected.  Be careful to utilize appropriate cleaning and bonding agents for pipe and fixture connections per pipe and fitting supplier specifications.  Other Factors To Consider: Local Conditions – Local seismic conditions, frost penetration, soils compaction, or other factors may require pipe expansion joints, isolation fixtures, cable tie downs, thrust blocks, or other measures to protest the pipe system, fixtures and adjacent concrete structures.  Water Hammer – Large pipe systems are subject to damage from water hammer, pipe collapse, and related vibration whenever fast acting valves are installed.  The air operated valves help protect the system from damage of this nature.  If other valves or shutoff devices are used in the operating systems, they are to be installed and operated in accordance with procedures to avoid damage from water hammer and related factors.  It is the responsibility of the owner and his plumbing subcontractor to install the pipe system and fittings leading to the flush valves, and other fixtures in accordance with the pipe manufacturer’s instructions with provisions for local weather, soils, and seismic conditions.  Failure to do so may limit or negate warranties.  All piping must be carefully set on a uniform grade with good connections at each valve, elbow, tee and other fixtures.  It is recommended the main piping system be tested for leaks before covering.  Verify procedure with pipe supplier or plumbing contractor.  Use extra care setting all below grade joints.  Do not subject system to greater than 22 psi pressure during operation.  Agpro, Inc.  recommends the inclusion of a quality air dryer in all Pneumatic Systems.  Moisture present in all compressed air systems can create problems for components unless removed on a continuous basis.  Consult your local refrigeration company on recommendations for your specific system and climatic conditions.  Safety: Keep children and small animals away from the Superflush System.  Do not install or leave ladders up the outside of the reservoirs.  Be sure any electrical controls within the structure to be flushed are properly installed and grounded and control boxes are kept closed.  When performing service work on any part of the system, be certain the pumps and other automatic components are shut off by turning off power supply at the safety disconnect switch(es).

1. Dirt Work

Flush Dirt WorkPrepare pipe trench(es) for laying of pipe.  The full trench width should be bedded with two inches of fill sand to bed and level the pipe.  Layout the flush water supply pipe above the trench and dry join all pieces and connections so that all components will be prepared for assembly.  Prepare the one inch drain line pipe in the same manner.  Installing one inch drain line from each flush valve draining via a 1 1/2 inch primary to the collection ditch. And route another 1 inch conduit from the planned location(s) for the flush control stations to the side of each flush valve.  Each flush valve should have one individual conduit running from the control stations to the flush valve.  This one inch conduit will house the airline running from the air supply solenoid valve or shut off to the flush valve air supply.

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2. Installing the Cable for Stabilization

Install835-00-067 (47)ing the Cable for Stabilization: The cable (not included) runs underneath the pipe, is looped back up on both sides of the riser and taped to the top of the riser until the flush valve is installed.  To reduce the friction to the bottom of the pipe where the cable runs across it, place a peace of sheet metal between the pipe and the cable.  Once the flush valve is installed, the cable ends can be attached to the turnbuckle in front of the flush valve and the tab at the back of the flush valve and the turnbuckle tightened. This gives the valve extra stability to reduce the effects of water hammer or potential of frost heaving.

3. Install Piping

Install the piping with tees and risers in appropriate positions to accepTees and Riser 2t the “Superflush” Valves.  After pipe is placed and bedded, the valves are installed.  When floor slope exceeds 2%, it is recommended to slightly slope the riser so the flange will ultimately follow floor slope.  A standard 16 inch 150 rated flange should now be dry fitted onto the 16 inch riser.  Slip the flange onto the riser until the top face of the flanged sealing surface is exactly 14 5/8 inches below finished floor level (- 1/8 inch to + 3/8 inch tolerance).  Mark the riser for reference. (Use peipe wrap to insure level measurement.)   Cut the riser at the measured height.  Bevel top of riser 1/4” for easier glue application.  Apply glue and install the flange making sure to bring back to marked elevation on riser.  Install rubber gasket on flange surface.  Caulk liberally using high quality silicone sealant on both sides of gasket.  Place complete “Superflush” valve assembly onto flange.  Care should be taken to insure “flow” direction is placed in the right position for proper flushing down the prospective lane.

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4. HARDWARE FOR THE FLANGE sold separately (12 inch FLANGE HARDWARE KIT is 835-01-003)

Using the hardware supplied with the FLANGE HARDWARE KIT  (sold separately), bolt the valve body to the flange.  Each bolt requires 2 flat washers, 1 rubber washer, one lock washer and one nut.  The rubber washer is placed under the flat washer next to the rubbert gasket inside valve body.  DO NOT use pneumatic tools as this may damage the flange.  From inside valve, position rubber sealing washers and flat metal washers then calk liberally under and around bolt heads prior to securing valve flange using 1 inch x 3 1/2 inch hex bolts and nuts.
Bolt Tightening Procedure:– Hand tighten according to sequence beginning with (1)- Final torque to be obtained in small increments, following sequence, to recommended torque. Recommended torque: 53-75- Bolt threads should be well-lubricated- Nut and bolt threads should be free-running during assembly- Always use full size flat washers with bolts and nuts.

5. Install 1 inch Air Supply

airsupplytube2    airsupplytube    airsupplytube3    airsupplytube4

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SaveInstall 1” air supply conduit (not supplied by Agpro, Inc.) to Each flush valve with the fittings supplied. Wrap Teflon tape around both the air elbow fitting and adapter before placing in receptacle on air pillow.  Tighten until fitting faces toward air line outlet side.  Install female adapter from outside valve body.  Install lock ring on female adapter inside, then PVC bushing, and Cord grip (all inside flushvalve).  Bring airline through cord grip, through guide nuts welded on channel to air elbow fitting.  Place air elbow nut on air line and tighten nut.  Tighten cord grip and calk with silicone caulk where air line exits cord grip.  Each flush control station will require a regulated air supply (120 psi maximum). For solenoid controlled valves an electrical service for solenoid operation connection will also be required. (It should be noted controllers are not included with the valve.  They are sold separately.) Air Supply Tube (not supplied by Agpro, Inc.) Air Supply Tube is housed in 1 inch conduit running from the controller to the flush valve (not supplied by Agpro, Inc.)

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6. Install and Connect the Drain Line

Drain LineInstall and connect the drain line and any remaining water supply line and test.  CAUTION: Do not assemble long sections of supply line without stabilizing the movement of the Superflush valves.   Check to see that the supply line, conduit and drain lines are all connected properly and laid in place.  Backfill trench with sand or fill dirt and compact.

7. Flush Valve Lid Installation

finger tabFlush Valve Lid Installation: Place the lid on the body using blocks to hold the lid in up position.  Install lid tabs (lid fingers) to lid (inside mount).  Make sure the lid tabs are in the correct position.  The narrow part of the lid tab is facing outward and down before installing bolts.No. 16 – Inside mount – finger tab facing down

8. Block out a 6 foot X 6 foot area around the valve (minimum)

Block out 5X5 2 Block out 5X5 3 Block out 5X5 4 block out 5X5After valve placement, floors will be poured in area around valves.  Note:  Block out a 6 ft X 6 ft minimum area around valve  for valve and conduit operation.  Pour and finish other areas of the floor first.  The block out will keep the valve from moving with the floor in case of frost heave or settlement.Install the expansion joint material.  There should be no rebar connecting this area to the main floor.  Build forms for concrete work and place in wire mesh for concrete slab.  Be sure all valves come to the exact elevation in reference to the proposed floor elevation.

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9. Soil around valve must be compacted (minimum)

compactSoil around the valve must be compacted to avoid excessive settlement.Pour concrete slab to the top of the valve cover.

10. Installation Diagram

11. Installation Diagram