Bradley Smoker Dryer Accessories EXD 2N User Manual

Installation  
Instructions  
EXD-2N  
Express® Deck Lavatory  
System EXD-Series  
(Standard and Wall-Hung Pedestals)  
Express® Decks are ADA  
and TAS compliant.  
Table of Contents  
Dimensions . . . . . . . . . . . . . . . . . . . . . . .2–3  
Rough-Ins . . . . . . . . . . . . . . . . . . . . . . . . 4–5  
Installation Instructions . . . . . . . . . . . . . .6–9  
Cleaning and Maintenance . . . . . . . . . . . .10  
Assembly of Components . . . . . . . . . . . . .11  
Vernatherm™ Valve Troubleshooting . . . .12  
Vernatherm™ Valve Repair Parts . . . . . . .13  
IMPORTANT  
Read this entire installation manual to ensure proper installation, then file these  
instructions with the owner or maintenance department.  
Flush all the water supply lines before making connections. Debris in supply  
lines will cause the valves to malfunction.  
Turn OFF electrical power to the outlet when installing the Express® Deck.  
Wall anchors used must have a minimum pull-out rating of 1,000 lbs.  
Product warranties may be found under "Product Information" on our web site at  
P.O. Box 309, Menomonee Falls, WI 53052-0309  
TEL. 1-800-BRADLEY FAX 262-251-5817  
215-1542 Rev. E; EN 06-915  
© 2007 Bradley Corporation  
Page 1 of 13 2/9/07  
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Express® Deck Lavatory System Dimensions continued . . .  
21-1/8"  
(537mm)  
11-1/2"  
(292mm)  
STANDARD HEIGHT  
34"  
(864mm)  
8-5/8"  
30"  
(219mm)  
(762mm)  
3" (76mm)  
13-1/4"  
(337mm)  
SCUFF BASE  
STANDARD  
HEIGHT ONLY  
21-1/8"  
21-1/8"  
(537mm)  
(537mm)  
WALL-HUNG  
MOUNTED AT  
11-1/2"  
(292mm)  
11-1/2"  
(292mm)  
WALL-HUNG  
MOUNTED AT  
STANDARD HEIGHT  
JUVENILE HEIGHT  
AGES 6 THROUGH 12  
31"  
(787mm)  
34"  
(864mm)  
8-5/8"  
(219mm)  
8-5/8"  
(219mm)  
27"  
686mm)  
30"  
(762mm)  
10-1/4"  
(260mm)  
13-1/4"  
(337mm)  
21-1/8"  
(537mm)  
21-1/8"  
WALL-HUNG  
WALL-HUNG  
MOUNTED AT  
TAS HEIGHT  
(537mm)  
MOUNTED AT  
TAS HEIGHT  
11-1/2"  
(292mm)  
11-1/2"  
(292mm)  
GRADES 6  
GRADES PRE-K  
THROUGH 5 OR 6  
THROUGH 8 OR 9  
30"  
(762mm)  
32"  
(813mm)  
26"  
(660mm)  
8-5/8"  
(219mm)  
8-5/8"  
(219mm)  
28"  
(711mm)  
9-1/4"  
235mm)  
TAS  
11-1/4"  
(286mm)  
TAS  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
2/9/07  
3
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Installation Instructions  
Supplies required for installation:  
• (6) 3/8" wall anchors, bolts and 1" min. O.D. washers to mount main frame and bowl to wall  
(minimum pull-out rating of 1,000 lbs.)  
• STD. HEIGHT ONLY: (2) 3/8" wall anchors, bolts and 1" min. O.D. washers to mount scuff  
base to wall  
• 1/2" NPT hot and cold supply piping  
• 1-1/2" NPT drain piping  
• 110 volt electrical outlet for optional 110/24 VAC plug-in transformer, if required  
• (2) #10 wall anchors and fasteners for optional Vernatherm™ valve mounting  
• 240/208-volt or 277-volt electrical box for optional electric tankless water heater  
Step 1: Rough in  
IMPORTANT: Dimensions shown in Figure 1 on page 5 are for a Standard and Wall-  
Hung Pedestal Express® Deck only. Make sure to follow appropriate  
dimensions based on configuration and required rim height. See  
Charts 1 and 2 on page 5 before beginning rough-ins.  
1. Rough in 1/2" NPT hot and cold supply lines through wall at dimensions shown.  
2. Rough in 1-1/2" NPT drain waste connection through wall at dimensions shown.  
3. FOR OPTIONAL ELECTRIC FAUCETS: Install the 110 volt GFCI electrical outlet per local  
code at the location shown in Figure 1.  
4. Install four to six 3/8" wall anchors with a minimum pull-out rating of 1,000 lbs. (supplied by  
installer) at the locations shown in Figure 1.  
5. On the back of the bowl, measure the distance between the 3/4" bowl mounting holes. Divide  
this measurement in half. Measure and mark this dimension on the wall to the left of the  
centerline and to the right of the centerline. Install two 3/8" wall anchors with a minimum pull-  
out rating of 1,000 lbs. (supplied by installer) at the locations marked (ref. location “A” shown in  
Figure 1).  
NOTE: Wall anchors at location “C” (standard frame only) do not require a minimum pull-out  
rating of 1,000 lbs.  
NOTE: The anchors will be used to mount the Express® Deck bowl and frame to the wall.  
4
2/9/07  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
EXD-2N Express® Deck Lavatory System Dimensions  
C
L
23-1/2"  
(597mm)  
23-1/2"  
(597mm)  
13-1/4"  
(337mm)  
OPTION #1*  
9-3/8"  
(238mm)  
9-3/8"  
(238mm)  
A
A
3"  
(76mm)  
4"  
(102mm)  
HOT SUPPLY  
OPTION #2**  
B
B
D
D
E
4"  
(102mm)  
F
COLD OR  
TEMPERED  
SUPPLY  
G
G
OPTION  
32"  
(813mm)  
28-3/4"  
(730mm)  
1-3/8"  
(35mm)  
B
B
25-3/4"  
(654mm)  
2" (51mm)  
13"  
(330mm)  
22"  
(559mm)  
21"  
(533mm)  
20"  
(508mm)  
15"  
(381mm)  
19"  
(483mm)  
C
C
FLOOR  
3-1/2"  
(89mm)  
* OPTION 1 - RECOMMENDED 240V/208V OR 277V  
ELECTRICAL BOX LOCATION (4"L x 4"W x 8"H)  
or  
** OPTION 2 - RECOMMENDED 240V/208V OR 277V  
ELECTRICAL BOX LOCATION (4"L x 4"W x 4"H)  
Figure 1  
CHART 1  
VERTICAL HEIGHT ADJUSTMENTS  
“A” THROUGH “F”  
RIM HEIGHT  
FIXTURE STYLE  
34"  
34"  
32"  
31"  
30"  
NONE  
STANDARD HEIGHT  
WALL HUNG  
NONE  
SUBTRACT 2"  
SUBTRACT 3"  
SUBTRACT 4"  
TAS, GRADES 6 THRU 8/9  
JUVENILE HEIGHT  
TAS, PRE-K THROUGH 5/6  
CHART 2  
CODE  
DESCRIPTION  
QTY.  
“A” 3/8" BOWL WALL ANCHORS WITH A MINIMUM PULL-OUT FORCE OF 1,000 LBS.  
“B” 3/8" MAIN FRAME WALL ANCHORS WITH A MINIMUM PULL-OUT FORCE OF 1,000 LBS.  
“C” 3/8" BASE FRAME WALL ANCHORS, STANDARD FRAME OPTION ONLY.  
“D” 1/2" NPT HOT/COLD SUPPLIES, STUB OUT 2" FROM WALL  
2
6
2
2
1
1
2
“E”  
“F”  
1-1/2" NPT DRAIN, STUB OUT 2" FROM WALL  
110V GFCI PROTECTED ELECTRIC OUTLET (FOR OPTIONAL ELECTRONIC FAUCETS)  
“G” #10 WALL ANCHORS/FASTENERS FOR OPTIONAL VERNATHERM™ VALVE MOUNTING  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
2/9/07  
5
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Installation Instructions continued . . .  
Step 2: Mounting frame to wall  
1. Using a T20 Torx key, remove the six #10-24 flat head Torx screws and #10 finish washers  
securing the access panel to the main frame, and remove the panel (Figure 2).  
2. Position the frame against the wall, ensuring that it is level.  
IMPORTANT: Anchoring the frame to a wall that is not flat may cause the frame to  
bend, making it difficult to reinstall the access panels.  
3. Ensure that the back of the frame is flat against the wall.  
4. Once you have positioned the  
frame such that it is level (and  
MAIN FRAME  
resting on the floor, standard height  
frame only) and flat against the  
wall, use the 3/8" bolts and 1" min.  
ACCESS PANEL  
O.D. washers to mount the frame  
to the wall (Figure 3).  
#10-24 PANEL FASTENERS  
AND WASHERS  
5. When mounting the standard  
height frame, mount the scuff base  
(6) PLACES  
to the wall at the same time using  
the two additional 3/8" bolts and  
washers mentioned in Step 1,  
SCUFF PANEL  
STANDARD HEIGHT  
FRAME ONLY  
procedure #3 on page 4 (Figure 3).  
SCUFF PANEL FASTENERS  
AND WASHERS  
(4) PLACES  
Figure 2  
3/8" WALL ANCHORS  
(4) PLACES  
*
*
MAIN FRAME  
*
*
SCUFF BASE FRAME  
STANDARD HEIGHT  
FRAME ONLY  
3/8" WALL ANCHORS  
*
(2) PLACES  
STANDARD HEIGHT  
*
FRAME ONLY  
Figure 3  
6
2/9/07  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Installation Instructions continued . . .  
Step 3: Installing bowl  
WARNING: To prevent serious injury and/or damage to the bowl, move and  
position the bowl with the assistance of another person and always  
use appropriate lifting procedures.  
NOTE: Refer to Figure 4 below when installing the bowl.  
1. With someone to assist you, place the bowl squarely onto the frame.  
2. Attach the front underside of the bowl to the frame using the two 1/4"-20 x 1/2" pan-head screws  
and washers provided. Do not tighten bolts at this time.  
IMPORTANT: When bolting the bowl to the frame and wall, do not overtighten  
bolts. Overtightening bolts can damage the Terreon® material.  
3. After the bowl is attached to the frame, use 3/8" bolts and 1" min. O.D. washers (supplied by the  
installer) to bolt the bowl to the wall anchors, two places.  
4. Tighten the screws installed in procedure #2 above to secure the bowl to the frame. Do not  
overtighten.  
Figure 4  
BOWL  
1/4-20 SCREWS AND WASHERS  
(2) PLACES BOWL/FRAME  
MOUNTING  
MAIN FRAME  
SCUFF BASE FRAME  
3/8" BOLT AND WASHER  
(2) PLACES FOR  
AND DRAIN ASSEMBLY  
NOT SHOWN FOR CLARITY  
BOWL MOUNTING  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
2/9/07  
7
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Installation Instructions continued . . .  
Step 4: Connecting supply and drain  
1. Connect the Vernatherm™ Thermostatic Mixing Valve as shown in Figure 5a.  
2. Install the drain plug in the drain hole in the bowl (see Figure 5b).  
3. Beneath the bowl, install the 1/8" rubber washer and the threaded tailpiece onto the drain plug.  
4. Assemble the P-trap by connecting the 1-1/2" tubular pipe to the tailpiece and to the 1-1/2" drain  
pipe stubbed out of the wall (see Figure 5c).  
5. Install the strainer on the drain plug opening inside the bowl using the #8 screw.  
HOT SUPPLY  
COLD SUPPLY  
1/2" NPT  
CHECK/STOP  
VALVE  
H
1/2" FLEXIBLE  
HOSE  
C
VERNATHERM™  
VALVE  
VERNATHERM™  
BRACKET  
Figure 5a  
#10 SCREW  
#8 SCREW  
BOWL  
STRAINER  
P-TRAP  
1/8"  
RUBBER  
WASHER  
STRAINER  
TAILPIECE  
DRAIN  
PLUG  
45˚  
TAILPIECE  
Figure 5b  
Figure 5c  
FRAME (FRONT)  
8
2/9/07  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Installation Instructions continued . . .  
Step 5: Optional hot water heater  
WARNING: To avoid personal injury or damage to the unit when installing the water  
heater, make all plumbing connections first, then proceed with the  
electrical connections.  
NOTE: 240/208 or 277 voltage is required  
for hot water heater. Refer to the  
installation manual provided with the hot  
#8 NUT  
BRACKET  
#8 WASHER  
water heater for further installation  
information.  
1. Remove the cover from the water  
heater. Attach the bracket to the cover  
with the two screws, nuts and  
washers, then reattach the cover (see  
Figure 6a).  
#8-32 x 3/4"  
ROUND HEAD  
MACHINE SCREW  
2. Hang the water heater on the right  
side frame member (see Figure 6b).  
WATER  
HEATER  
BASE  
3. Connect the 1/2" flexible hose from  
the cold water supply stub-out to the  
hot water heater inlet.  
WATER  
HEATER  
COVER  
Figure 6a  
4. Connect the 1/2" flexible hose from  
the hot water heater outlet to the  
supply inlet on the solenoid valve  
assembly.  
PREPACKS:  
EX95TMLB (S45-2186)  
EX100TMLB (S45-2187)  
Step 6: Completing installation  
1. Install the faucets according to the  
installation instructions that came  
with your faucets.  
OPTIONAL 90˚ ELBOW  
CHECK/STOP  
VALVE  
2. Turn on the water supply to the  
Express® Deck and check for  
leaks.  
3. FOR DECKS WITH INFRARED  
FAUCETS ONLY: Turn on the  
electrical power to the electrical  
outlet and pass your hand in front  
of each faucet’s sensor until all  
the air is purged from the lines  
and water is flowing smoothly.  
4. After testing is complete, reinstall  
panel to frame. Fasten panel with  
eight Torx-head screws provided  
(see Figure 2 on page 6).  
WATER  
HEATER  
INLET  
OUTLET TO  
FAUCETS  
COLD WATER  
SUPPLY  
Figure 6b  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
2/9/07  
9
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Cleaning and Maintenance Instructions  
IMPORTANT: Strong alkaline or acid-based chemicals and cleansers should not be  
used to clean Terreon®. If these chemicals come in contact with the  
Terreon® surface, wipe off the surface immediately and flush with  
soapy water.  
Terreon® and panel maintenance  
The bowl is constructed of Terreon®, a densified solid surface material composed of an acrylic  
modified polyester resin. Terreon® is resistant to chemicals, stains, burns and impact. Surface  
damage can be easily repaired with everyday cleaners or fine grit abrasives. The panel is made of an  
acrylic/ABS laminate, and will not chip, peel or flake. With regular cleaning, your Terreon® fixture  
will provide years of dependable service.  
Cleaning  
• Daily Cleaning: Wipe the surface with a damp cloth and wipe dry.  
• Weekly Cleaning: Wipe the surface with a damp cloth and a household liquid detergent.  
Stubborn stains can be removed as follows:  
1. Using a #7448 Scotch-Brite® pad, scrub with an abrasive cleanser such as Ajax®,  
Comet® or Soft Scrub® and water.  
2. Clean thoroughly with soapy water and allow to dry.  
• Scorch Marks: Although Terreon® will not burn, a lit cigarette in contact with Terreon® could  
leave a scorch mark. Scorch marks can be removed by buffing with a #7448 Scotch-Brite pad or  
with an abrasive cleaner.  
Repair kit: In the unlikely event your Terreon® surface becomes damaged, it can easily be  
repaired. Contact your Bradley representative to order a repair kit and be sure to specify color  
when ordering.  
Panel cleaning  
IMPORTANT: Do not use abrasive cleansers to clean the panel. Abrasive cleaners  
can mar the surface.  
Graffiti/Vandalism: If vandals create markings on the panel, Bradley recommends using  
Motsenbocker’s LIFT OFF® to remove ink and spray paint. Remover #3 is for ink and markers,  
and Remover #4 is for spray paint. Motsenbocker’s LIFT OFF® can be ordered through Sanitary  
Maintenance Service Inc. (call 1-800-451-5523 x 425 or visit  
OFF®, give the panel a final thorough cleaning with a liquid tub and tile cleaner to remove soil  
and maintain the glossy finish.  
NOTE: Use of brand names is intended only to indicate a type of cleaner. This does not constitute an  
endorsement, nor does the omission of any brand name cleaner imply its inadequacy. Many products  
named are regional in distribution and can be found in local supermarkets, department and hardware  
stores or through your cleaning service. It is emphasized that all products should be used in strict  
accordance with package instructions.  
10  
2/9/07  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Assembly of Components  
BOWL  
PREPACK  
(S45-2166)  
PANEL  
FASTENERS  
(160-450)  
90˚ ELBOW  
(169-639)  
MAIN  
FRAME  
WASHERS  
(142-002CA)  
(S17-325)  
(6) PLACES  
ACCESS PANEL  
GRAY (186-1646)  
PUTTY (186-1646A)  
COAL (186-1646B)  
CHECK STOP  
(S27-102)  
HOSE  
(269-1735)  
SCUFF FRAME  
(S17-326)  
USED WITH  
SCUFF BASE PANEL  
GRAY (185-034)  
PUTTY (185-034A)  
COAL (185-034B)  
STANDARD HEIGHT  
FRAME ONLY  
SCUFF PANEL  
FASTENERS (160-450)  
WASHERS (142-002CA)  
(4) PLACES  
BOWL MOUNTING  
HARDWARE  
#8-32 SCREW  
1/4"-20 x 1/2"  
PAN HEAD  
SCREW (qty. 2)  
(160-389)  
1/4"-20  
WASHER  
(qty. 2)  
DRAIN  
ASSEMBLY  
(160-319)  
STRAINER  
(P16-075)  
(142-002DB)  
DRAIN PLUG  
(P16-072)  
1/8" RUBBER  
WASHER  
(125-001DP)  
VERNATHERM™ VALVE ASSEMBLY  
CHECK/STOP VALVE  
(S27-102)  
TAILPIECE  
(129-056)  
1/2" FLEXIBLE  
HOSE  
(269-1735)  
#10 SCREW  
(P18-054)  
1/2" FLEXIBLE  
HOSE  
(269-653)  
VERNATHERM™  
VALVE  
(S01-524)  
P-TRAP (POLYPROPYLENE)  
(269-1697)  
OPTIONAL P-TRAP  
(CHROME-PLATED BRASS)  
(S29-094)  
VERNATHERM™ BRACKET  
(140-934)  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
2/9/07  
11  
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Thermostatic Mixing Valve Maintenance and Troubleshooting  
NOTE: Before attempting to troubleshoot the valve or disassemble the components, check for the  
following conditions:  
• If stop/check valves are used, make sure that they are fully open.  
• Make sure that the hot and cold inlet pipes are connected properly, and that there are no cross-  
connections or leaking stop/check valves.  
• Check the hot water heater output to make sure that it is at least 20° F above the set  
temperature.  
Be sure to close the appropriate shut-off valves prior to disassembly of the valve and reopen the  
valves after inspection and repair is complete.  
Problem: Limited water flow  
Cause: Dirt and debris have built up in the valve or strainer.  
1. Remove and clean strainer. If strainer needs to be replaced, order Bradley part no. 173-028.  
2. Check the piston for smooth movement.  
To check the valve's piston for free and smooth movement, follow the procedures outlined below:  
1. Remove the valve's cap and thermostat (see Figure 7 on Page 13).  
2. Push down on the piston with your finger (the piston should move freely). If the movement is  
not as it should be, the piston needs to be cleaned. Follow the method outlined below for  
cleaning the piston and valve body:  
• Remove the thermostat.  
• Lift the piston out with a needle-nose pliers and remove the spring.  
• Any cleaner suitable for brass and stainless steel may be used (if cleaning with suitable cleaner  
is not sufficient to remove debris, a 400-grit sandpaper may be used to polish and hone the  
piston and valve body).  
• Snap spring into piston (will detent) and reassemble into the valve body. Retest the piston.  
3. If, after a thorough cleaning, the piston does not move freely, the piston must be replaced.  
Contact your Bradley representative and ask for Repair Kit (part number S65-259).  
Problem: External leaks in the system  
Cause: O-rings have been damaged.  
Solution: Replace O-rings where necessary. For replacement of the O-rings, contact your  
Bradley representative and ask for Repair Kit (part number S65-259).  
Problem: Improper water temperature or temperature fluctuation  
Cause: Thermostat is slowly failing or not working at all.  
Solution: Check the thermostat for proper operation.  
1. At room temperature (80° F or less) remove cap and thermostat.  
2. Place thermostat into container with 115° F water. The pushrod should pop out of the  
thermostat approximately 1/10".  
3. If thermostat pushrod does not pop out, the thermostat must be replaced. Contact your Bradley  
representative and ask for Repair Kit (part number S65-259).  
Cause: Valve temperature is not properly set.  
Solution: Adjust the temperature. Using a blade screwdriver, turn the adjustment stem  
counterclockwise to increase the temperature or clockwise to decrease the temperature.  
12  
2/9/07  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
 
Express® Deck Lavatory System EXD-Series  
EXD-2N  
Installation Instructions  
Vernatherm™ Thermostatic Mixing Valve S01-524  
Repair Kit S65-259  
10  
Nut 3/8-24 Hex Jam  
Cap  
Item Qty  
Description  
5
7
8
1
1
1
Thermostat  
O-Ring  
O-Ring  
9
8
7
O-Ring  
O-Ring  
6
5
Stem  
Thermostat  
Piston  
4
3
2
Spring  
Seal Cup  
1
Valve Body  
Strainer  
11  
(173-028)  
Figure 7  
Bradley Corporation • 215-1542 Rev. E; EN 06-915  
2/9/07  
13  
 

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