Zip FlushMaster 40090

Questions and Answers

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Brenda HallAug 12, 2025
Why is my Zip Accessories sensor not activating?
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  Krystal JosephAug 12, 2025
  If the Zip Accessories sensor isn't activating, several issues could be the cause. First, replace the battery or check the power pack and turn on the power. If that doesn't work, replace the fuse on the circuit board. Ensure the lens slots are clean and that the sensor is positioned correctly. If none of these steps work, the sensor may be faulty and need replacing.
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jeffreygillAug 15, 2025
How to fix Zip FlushMaster 40090 Accessories cistern that does not fill?
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  david95Aug 16, 2025
  If the Zip Accessories cistern isn't filling or the direct inject isn't flushing, start by checking the water supply and ensuring the tap is on. Then, back off the regulator screw. Make sure the latching valve is correctly reinstalled. Verify the cable connection to the sensor circuit board. If issues persist, consider replacing the latching valve or checking the sensor.
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powellericaAug 20, 2025
Why does my Zip FlushMaster 40090 cistern continue to fill after flushing?
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  James ArnoldAug 20, 2025
  If the Zip Accessories cistern continues to fill during and after flushing, it's likely a sensor timing issue. Try resetting the sensor timer switches. If that doesn't resolve the problem, empty the cistern and then restart the timing.
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Mary BarnesAug 23, 2025
What to do if Zip Accessories cistern under fills?
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  Logan ClarkAug 23, 2025
  If the Zip Accessories cistern under fills or the direct inject flushes for too long, the sensor duration time is likely set incorrectly. Reset the sensor timer switches to correct this.
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veronica31Aug 27, 2025
Why does my Zip Accessories cistern over fill?
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  James SheaAug 27, 2025
  If the Zip Accessories cistern overfills, or the direct inject only flushes for 5 seconds, the sensor duration time is probably set incorrectly. Reset the sensor timer switches.
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lancebrooksAug 31, 2025
What causes Zip Accessories cistern to fill continually?
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  Cynthia MezaAug 31, 2025
  If the Zip Accessories cistern fills or the direct inject flushes continually except for the set duration, the sensor cable wires are likely crossed. Uncross the latching wire connection.
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jonesjeremySep 4, 2025
Why does Zip Accessories cistern fill for only 35 seconds?
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  Jennifer MaloneSep 4, 2025
  If the Zip Accessories cistern fills or the direct inject flushes for only 35 seconds, the sensor timers are likely set to test mode and the latching valve cable wires are crossed. Reset the sensor timer switches and uncross the latching valve wire connection.
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David WilsonSep 7, 2025
Why does Zip Accessories cistern fill for only 5 seconds?
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  jacksonemilySep 7, 2025
  If the Zip Accessories cistern fills or the direct inject flushes for only 5 seconds, the sensor timers are set to test mode. Reset the sensor timer switches.

Summary

Installation Steps

Set Up Water Discharge

Details typical installation methods for cistern and direct injection systems.

Latching Valve Installation

Instructions for fitting the latching valve, including flow direction and isolation.

Restrictor and Autosyphon Installation

Guidance on installing Restrictaflow and connecting to cisterns via autosyphon.

Airbreak Installation

Procedure for fitting the air break in a vertical position for direct injection systems.

Install Sensor

Details on positioning the surface-mounted sensor for optimal coverage.

Sensor Placement Guidelines

Guidance on sensor positioning for single, double, and triple stall urinals.

Environmental Considerations for Sensor

Advice on avoiding heat sources and direct sunlight for sensor placement.

Mounting the Sensor Housing

Instructions for fastening the sensor housing to the ceiling.

Connect Latching Valve to Sensor

Detailed instructions for connecting the latching valve cable to the sensor circuit board.

System Initialization (Test Mode)

Information on activating test mode and using the reset button after power connection.

Connect Power Pack

Instructions for connecting the optional 220-240V AC power pack.

Set Timing Using Switches

Guide to setting delay and valve open times using DIP switches.

Set Fill Timing Using Fill Time Button

Procedure for setting valve open (flush/fill) time using the Fill Time button.

Complete Installation

Final step involving fitting the cover and tightening fixing screws.

Maintenance

Cleaning the Sensor

Instructions for cleaning the sensor housing and face slots.

Battery Replacement

Procedure for removing and replacing the lithium battery in the sensor.

Valve Diaphragm Replacement

Steps for isolating water and replacing the diaphragm in the latching valve.

Troubleshooting

Cistern or Injector Issues

Diagnosing and resolving problems with cistern filling or direct injection.

Flushing Duration Problems

Addressing issues with flushes being too long, too short, or continuous.

Sensor Activation Issues

Troubleshooting common causes for the sensor not activating or false activations.

End of Life Disposal

Guidance on correctly disposing of the product at its end of life.

The Zip FlushMaster (Product Code 40090) is a surface-mounted, water-saver urinal flushing system designed for efficient and hygienic operation in commercial and public restrooms. It utilizes an infrared sensor to detect user presence and activate a flush cycle, promoting water conservation and improved hygiene.

Function Description:

The Zip FlushMaster system consists of a surface-mounted sensor, a latching valve, and either a battery or an optional power pack for operation. The sensor detects when a urinal has been used and triggers the latching valve to open, allowing water to flow into the urinal for a set duration. This system is designed to replace traditional manual flushing mechanisms, offering an automated and water-saving solution. It can be configured for use with cisterns or direct injection airbreak systems, accommodating various plumbing setups. The FlushMaster is capable of managing multiple urinal stalls or troughs, with specific installation guidelines for single, twin, and triple stall configurations. The system's intelligence allows for adjustable delay times (valve closed) and valve open durations (flush/fill times), which can be customized to optimize water usage based on the specific urinal setup and local water pressure.

Important Technical Specifications:

Sensor Type: Surface-mounted infrared sensor.
Power Source: Battery-operated (6V battery included) for simple installation, with an optional power pack for 220-240 V AC power connection. The recommended battery type is a lithium cell CRP2 / 223A (Zip product code 90098).
Operating Pressure: 350 - 700 kPa.
Flush Cycle: Variable, allowing for precise adjustment to meet specific needs.
Delay Time (Valve Closed): Adjustable from a minimum of 45 seconds (all switches OFF) to a maximum of 15 minutes (all switches ON).
Valve Open Duration (Flush/Fill Time): Adjustable from 5 seconds (all switches OFF) to 15.75 minutes (all switches ON).
Sensor Coverage: Approximately 2400 x 3600 mm from a 2700 mm ceiling.
Latching Valve: 15mm OD, ensuring correct flow direction.
Restrictor: Restrictaflow restrictor (1.9mm) is normally required for operating pressures greater than 700kPa, designed to save water and reduce flow, especially in single stall installations. It can be drilled out in 0.5mm increments or removed if higher flow is needed for multiple stalls or if water pressure is insufficient.
Fuse: F1.6A fuse (Buss).
Compliance: All plumbing connections must be made in accordance with AS/NZS3500, and installation with AS/NZS3500.2. Designed for indoor use only.

Usage Features:

Automated Flushing: Infrared sensor detects user presence, eliminating the need for manual flushing and improving hygiene.
Water Conservation: Variable flush cycle and adjustable timing settings allow for precise control of water usage, making it an effective water-saver system.
Flexible Installation: Choice of surface-mounted or ceiling-recessed sensors (though this manual focuses on surface-mounted). Battery operation simplifies installation, while the optional power pack offers a permanent power solution.
Configurable for Different Setups: Compatible with both cistern-based and direct injection airbreak urinal systems.
Multi-Stall Management: Can be installed to manage single, twin, or triple urinal stalls, or troughs, with guidelines for optimal sensor placement. Additional sensors can be used for more than three stalls.
Adjustable Timing: Flush delay and valve open times can be set using DIP switches or a "Fill Time Button" for fine-tuning.
- Test Mode: When all switches are OFF, the sensor defaults to a test mode with approximately 35 seconds delay and 5 seconds flush, which can be adjusted.
- Fill Time Button: Allows for intuitive setting of the valve open (flush/fill) time, particularly useful for cistern installations to ensure adequate filling and syphon activation.
Backflow Prevention: An air gap must always remain between the cistern water level and the inlet water pipe level to prevent backflow.
Vandalism Prevention: Secure fixing of piping to the wall as per AS/NZS3500 is recommended to prevent tampering.

Maintenance Features:

Cleaning: The sensor's slot openings should be kept clear of dirt. The case should be wiped with a soft cloth, warm water, and dishwashing liquid; strong or abrasive cleaners should be avoided. Hosing or spraying any part of the system is not recommended.
Battery Replacement: For battery-powered units, the lithium battery (CRP2 / 223A) should be replaced annually, or approximately every three years depending on activation frequency, to avoid system malfunction. The process involves removing the protective cover, locating the battery holder, and replacing the battery.
Valve Diaphragm Replacement: It is recommended to replace the latching valve diaphragm annually, especially in conjunction with battery replacement. The procedure involves isolating the water supply, removing the fixing clip and coil from the latching valve, carefully disassembling the valve housing, replacing the rubber diaphragm, and reassembling. A replacement diaphragm kit (Zip part number 90279) is available.
Power Pack Maintenance: If an optional power pack is fitted, the power must be turned off at the power point before any maintenance is attempted.
Troubleshooting Guide: The manual includes a comprehensive troubleshooting section to diagnose and resolve common issues such as the cistern not filling, incorrect flush durations, or the sensor not activating. This includes recommended actions like checking water supply, resetting timer switches, replacing components, or cleaning the sensor.