Kohler Discovery manual

1 These instructions are to be left with the user Installation and User Guide SHOWER VALVE BUILT IN DUAL CONTROL[...]

2 CONTENTS Introduction ............................................................................................. 3 Safety : Warnings .................................................................................... 3 Pack Contents ......................................................................................... 4 Dimensions ........[...]

3 This Discovery Thermostatic Shower Control is precision engineered and should give continued safe and controlled performance, provided: 1. It is installed, commissioned, operated and maintained in accordance with manufacturers recommendations. 2. Periodic attention is given, when necessary, to maintain the product in good functional order. The fu[...]

4  1 x Control Assembly  Tick the appropriate boxes to familiarize yourself with the Discovery Thermostatic Shower Control part names and to confirm that the parts are included.  PACK CONTENTS  1 x Shower Valve fitted to the Building-in Shroud  3 x Compression Nuts  3 x Olives   x Flow Regulator (12 litres per minute)  1 [...]

5 DIMENSIONS Note! All Dimensions are Nominal Pipe Centres 186 mm 47 mm 64 - 82 mm 108 mm 231 mm 27 mm[...]

6 SPECIFICATIONS Pressures Maximum Static Pressure: 10 Bar . Minimum Maintained Pressure (Gas Water Heater): 1.0 Bar . (for optimum performance initial supplies should be nominally equal). Minimum Maintained Pressure (Gravity System): 0.1 Bar . (0.1 bar = 1 Metre head from base of cold tank to the outlet of the shower handset). Maximum Maintained P[...]

7 Connections Standard connections are: Hot-Left, Cold-Right, Top-Outlet, if reversed inlets are required refer to sections: ‘Installation’ and ‘Reversed Supplies’ . Inlets: 15 mm Compression. Outlet: 15 mm Compression. Thermostatic Shut-down Thermostat will shut off Hot Supply Within 2 Seconds if Cold Supply Fails. (Achieved only if the ho[...]

8 Flow Regulator Recommended INSTALLATION REQUIREMENTS Isolating valve Mixing Valve Twin Impeller Pump Tempering Valve Pressure Reducing Valve Single Impeller Pump Overflow Indicator Mini Expansion Vessel Gas heated system The shower MUST be installed with a gas water heater or combination boiler of a fully modulating design. Note! Flow regulator r[...]

9 Flow Regulator Recommended Flow Regulator Recommended Unvented mains pressure system The shower can be installed with a unvented, stored hot water cylinder. Pumped system The shower can be installed with an inlet pump (twin impeller). The pump must be installed on the floor next to the hot water cylinder. Note! Flow regulator recommended to be in[...]

10 INSTALLATION General Installation must be carried out in accordance with these instructions, and must be conducted by designated, qualified and competent personnel. The installation must comply with the “Water Supply Regulations 1999 (Water Fittings)” or any particular regulations and practices, specified by the local water company or water [...]

11 Installation Methods The Discovery Thermostatic Shower Control can be installed using Rear Fixing Points on the Body, or by using the Securing Brackets (supplied) on the Front Face of a Solid Wall or Stud Partition, or on the Rear Face of a Laminated Panel. For installation from the front face into a Solid Wall or Stud Partition using the Securi[...]

12 1. Solid Wall or Stud Partition (Using Securing Brackets - Mounting off Front Face) 1.1 Remove the three securing screws and remove the shower valve from the building-in shroud (retain the screws for later use). 1.2 Mark the position of the shower valve, a cut out 150 x 170 mm (Max) is required. Note! Use a spirit level to make sure that the hol[...]

13 1.7 Fit the three securing brackets to the shower valve. Important! Make sure that the correct holes are used, otherwise the backplate will not fit (refer to illustration). Note! The brackets can be rotated for suitable fixing points. 1.8 Mark the positions of the countersunk fixing holes on the wall. Note! Make sure that they do not interfere w[...]

14 1.14 Re-fit the building-in shroud to the shower valve using the three fixing screws. 1.15 Using the building-in shroud as a guide for the finished wall thickness, finish the wall. Caution! Make sure that the finished wall is within the minimum and maximum limits otherwise the control components will not fit correctly. 1.16 Remove the building-i[...]

15 2. Solid Wall or Stud Partition (Using Rear Fixing Points on Shower Control) 2.1 Refer to section: ‘1. Solid Wall or Stud Partition Installation (Using Securing Brackets - Mounting off Front Face)’ and follow instructions 1 to 4. 2.2 Cut away the plasterboard or brick work to the required depth. Important! This depth ‘X’ will depend on t[...]

16 2.3 Mark the positions of the fixing screw holes on the wall. 2.4 For solid walls drill two 6 mm holes for the wall plugs. 2.5 Fit the wall plugs (supplied) and fix the shower valve to the wall with the securing screws (supplied). Note! For stud partition installations alternative fixings may be required (not supplied) to fix the shower valve to[...]

17 Note! For laminated panels the shower valve must be positioned from the rear of the panel. Panel thickness must be between 4 and 22 mm (if a thicker panel is used it will be necessary to recess the securing brackets into the rear of the panel). Important! Make sure that there is a minimum clearance of 64 mm behind the laminated panel to house th[...]

18 3.6 To assist in marking the positions of the fixing holes, reverse the shower valve and fit the building in shroud through the cutout in the front of the panel. Mark the positions of the M5 fixing holes in the two top brackets only . Important! Make sure that the correct holes are used (refer to illustration). Warning! Do not drill any holes fo[...]

19 Control Assembly 1. Pull off the temperature knob. 2. Carefully separate the concealing plate from the backplate. Note! Use a screwdriver in the cutout to assist separation. 3 . Fit the backplate to the shower control and secure with the three securing screws (removed from the building-in shroud). Make sure that the seal is fully compressed on t[...]

20 Push up and Latch over the Top of the Backplate Align Flow Lever as Shown ‘Click’ into Position 5. Align the flow control lever so that the lever is pointing up (refer to illustration). 6. Slide the flow control lever and concealing plate over the flow control hub. 7. Latch the top of the concealing plate over the top of the backplate. Note![...]

21 Reversed Supplies The Discovery Dual Control is supplied with inlet connections Hot-Left , Cold-Right and Top-Outlet as standard. If the hot and cold water supply pipes have been reversed during installation the following procedure must be performed. Note! Refer to illustrations in section: ‘ Installation, Control Assembly’. ‘O’ Key 1. I[...]

22 COMMISSIONING Maximum Temperature Setting The Thermostatic Shower Controls are preset at approximately 43 °C at the factory. If adjustment is required, set the maximum temperature as follows: Note! Make sure that the hot water temperature is at least 10 °C above the required maximum showering temperature. 1. Pull-off the temperature knob. 2. U[...]

23 OPERATION Note! If excessive flow rate is experienced from the Shower Control, install the supplied Flow Regulator, refer to the Discovery Fittings Installation and User Guide. OFF ON COLD HOT Flow Control Lever Temperature Knob[...]

24 FAULT DIAGNOSIS SYMPTOM 1. Only hot or cold water from the control outlet. 2. Fluctuating or reduced flow rate. 3. No flow rate from the control outlet. 4. Blend temperature drift. 5. Maximum blend temperature setting too hot or too cold. 6. Water leaking from the shower control fitting. 7. Flow rate too low or too high. CAUSE/RECTIFICATION a. I[...]

25 ‘O’ Key Supply Filter MAINTENANCE General This Product is precision engineered and should give continued safe and controlled performance, provided: 1. It is installed, commissioned, operated and maintained in accordance with manufacturers recommendations. 2. Periodic attention is given, when necessary, to maintain the product in good functio[...]

26 SPARE PARTS 1609.040 (A) Thermostatic Cartridge Assembly 1609.041 (B) Elbow Pack (2 off) 1609.042 (C) Flow Control Assembly 1609.043 (D) Flow Control Housing 1609.044 (E) Non-Return Valve (2 off) 1609.045 (F) Screw Pack (not illustrated) 1609.046 (G) Filter Pack (2 off) 1609.047 (H) Seal Pack (not illustrated) 1609.048 (I) Component Pack 1609.04[...]

27 J A B C C, K, J D D D E G I L K, J[...]

28 7 - # 5 1058366-W2-A (1609) © Kohler Mira Limited, February 2006 CUSTOMER SERVICE[...]