Kohler K-528-K1 Montageanleitung

Installation and Care Guide

Digital Thermostatic Valve for DTV+

K-528-K1, K-557-K1

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1240338-2-A

IMPORTANT INSTRUCTIONS

WARNING: When using electrical products, basic precautions should always be followed,

including the following:

WARNING: Risk of electric shock. A qualiﬁed electrician should route all electrical wiring.

WARNING: Risk of electric shock. Disconnect power before servicing.

WARNING: Unauthorized modiﬁcation may cause poor performance of the valve. Do not make

modiﬁcations to the valve as this could adversely affect the performance of the valve and void the

warranty. Kohler Co. shall not be liable under its warranty or otherwise for personal injury or

damage caused by any such unauthorized modiﬁcation.

DANGER: Risk of injury or property damage. If the power cord gets damaged, it must be

replaced by the manufacturer, its authorized service agent or qualiﬁed personnel to avoid danger.

WARNING: Risk of injury. This device is not intended for use by persons (including children)

with different or reduced physical, sensory, or mental abilities, or who lack experience or

knowledge, unless they are under the supervision of or receive training for the use of the device by

a person responsible for their safety. Children should be under supervision to ensure that they do

not use devices as toys.

WARNING: Risk of injury or property damage. Please read all instructions thoroughly before

beginning installation.

NOTICE: Follow all plumbing, electrical, and building codes.

NOTICE: Some electrical codes require a circuit protected by a Ground-Fault Circuit-Interrupter (GFCI)*.

NOTICE: For K-557-K1: If a GFCI outlet is required, connect only one valve per outlet.

NOTICE: Provide unrestricted service access to the valve.

NOTICE: The valve manufacturer’s minimum ﬂow rate is 1.6 gal/min (6 l/min).

*Outside North America, this device may be known as a Residual Current Device (RCD).

___________________________________________________________________________________________________

Operation with DTV+

To connect the valve to the DTV+ system, the K-99695 system controller is required.

The provided data cable is used to connect the valve to the system controller.

Refer to the ″DTV+ System Layout″section in this guide.

Before Operating the System For the First Time:

Download and install the latest software for connected components. This may take an hour or more to

complete based on system conﬁguration and internet connection speed. Do not disconnect the power from

any components during software download and installation.

Speciﬁcations

Pressures

Maximum Static Pressure 125 psi, 862 kPa, 8.6 bar

Supply Pressure Differential* Max 5 psi, 34.5 kPa, 0.34 bar (Equal pressures recommended.)

1240338-2-A 2 Kohler Co.

Speciﬁcations (cont.)

Pressures

Minimum Flow Rate 1.6 gal/min (Less than 72 psi dynamic pressure.)

6 l/min (Less than 500 kPa maintaining pressure.)

2.1 gal/min (Greater than 72 psi dynamic pressure.)

8 l/min (Greater than 500 kPa maintaining pressure.)

Temperatures

Programmable Temperature Max 120°F (49°C) Min 86°F (30°C) Full cold may also be selected.

Default Temperature at Start-up 100°F (38°C)

Minimum Mixed Temperature Differential

from Hot Supply 3.6°F (2°C)

Temperature Stability at Recommended

Supply Conditions +/- 1.6°F (1°C)

Ambient Temperature Greater than 34°F (1°C), Max 104°F (40°C)

Maximum Relative Humidity 95% non-condensing

Electrical

Electrical Rating 120 V, 15 A, 60 Hz

Data Cable Length 25’ (7.6 m)

*In commercial applications where there is a large difference in hot and cold supply pressures or frequent

ﬂuctuation in either supply line is anticipated, it is strongly recommended that pressure regulators be

installed.

Tools and Materials

Before You Begin

NOTICE: Do not install the valve under a whirlpool surround or any location where the temperature may

exceed 104°F (40°C). The valve and its integrated power supply is rated to operate in temperatures up to

104°F (40°C).

NOTICE: Do not apply excessive heat near the valve or apply ﬂux or acids directly onto the valve. This

valve contains plastic and rubber components which will melt if heat is directly applied.

NOTICE: Do not apply petroleum-based lubricants to the valve components. Doing so will damage the

valve components.

NOTICE: Do not use oil-based, non-setting compounds, such as plumbers putty, on the threaded

connections.

Plus:

• (2) 1/2" Union Connectors

• Wood and Framing Materials

• PEX Tubing, Copper Tubing, or PVC

• (2) Water Hammer Arrestors (Recommended)

• (2) Supply Shut-Off Valves

Solder Propane

Torch

Hacksaw or Tube Cutter Sealant

Tape

Kohler Co. 3 1240338-2-A

Before You Begin (cont.)

NOTICE: Do not remove the check valves from the inlets as this can damage the product.

NOTICE: If the valve will be used for a bath/shower application, the bath ﬁll supply line must be routed

from the #1 outlet port.

Read these instructions and determine the locations of all required components before beginning

installation. For shower conﬁguration options, refer to the guide on the K-99695 controller product

page at www.us.kohler.com.

If possible, ﬂush all piping thoroughly before installing the valve. If the pipes are ﬂushed after the

valve is installed, clean the inlet screens before using the system.

A qualiﬁed electrician should install a 120 V electrical outlet, within the stud framing, in close

proximity to the valve. A GFCI outlet may be required in certain applications.

If possible, install the electrical outlet prior to installing the valve.

Multiple Valve Applications

Showering conﬁgurations using large water volumes require supply piping and drain systems that

will sufficiently accommodate the actual total ﬂow rate at any one time.

Hot water generation: Use a water heating system capable of handling large ﬂow rates. Tankless

(on-demand) water heaters and recirculating pumps may not be adequate for your showering

conﬁguration.

1240338-2-A 4 Kohler Co.

1. DTV+ System Layout

The K-99695 system controller powers the interface(s) and controls the digital valve(s) and other system

components. The controller is required to conﬁgure the valve(s).

NOTICE: If the valve will be used for a bath/shower application, the bath ﬁll supply line must be routed

from the #1 outlet port.

NOTICE: Custom shower conﬁgurations may not allow certain features to be enabled. For shower

conﬁguration options, refer to the guide on the K-99695 controller product page at www.us.kohler.com.

Determine the locations of all required components, including shower ﬁttings.

A data cable is provided to connect the valve to the controller. If the valve is not within 25’ (7.6 m)

of the controller, obtain a longer telephone-style cable or add an extension cable.

When routing piping, make sure each shower ﬁtting will connect to the appropriate valve outlet for

your conﬁguration.

Before Operating the System For the First Time:

Download and install the latest software for connected components. This may take an hour or more to

complete based on system conﬁguration and internet connection speed. Do not disconnect the power from

any components during software download and installation.

Digital

Valve

Router

AC Power

Controller

AC Power

25' (7.6 m)

Data Cable

Component Cable

Connections

Interface

(Up to Three)

Digital

Valve

Water InletsShower Fittings

Kohler Co. 5 1240338-2-A

2. Mounting Conﬁgurations

NOTICE: Do not mount the valve with the inlets pointing up or positioned above the outlet ports. Doing

so will damage this product.

The two-port valve is shown above. The same vertical or horizontal mounting conﬁgurations apply

for the three-port valve.

Mounting on a Horizontal SurfaceMounting on a Vertical Surface

Inlets

Cable

Sockets

Inlets

1240338-2-A 6 Kohler Co.

3. Prepare the Site

NOTICE: Do not install the valve under a whirlpool surround or any location where the temperature may

exceed 104°F (40°C).

NOTE: Horizontal installation within a stud cavity is shown. The valve can also be mounted vertically or

mounted to a horizontal surface. Refer to the ″Mounting Conﬁgurations″section.

K-528-K1: This product is designed to ﬁt within a minimum 14-1/2″(368 mm) 2x4 stud cavity.

K-557-K1: This product will not ﬁt within a standard stud cavity. Construct a minimum 18″(457

mm) wide 2x4 stud cavity.

Install adequate bracing for mounting the valve. Notch the bracing as needed to accommodate the

inlets and outlets.

Install a 120 V electrical outlet within the stud framing, in close proximity to the valve. Locate the

outlet above the valve. A GFCI outlet may be required in some applications.

Cross Brace MountBoard Mount

Notch bottom brace.

2-3/4"

(70 mm)

Min

9-1/2"

(241 mm) 12-1/2"

(318 mm)

11-5/8"

(295 mm)

Drip Loop

Place the outlet

higher than

the valve.

K-528-K1:

14-1/2" (368 mm) Min

K-557-K1:

18" (457 mm) Min

K-528-K1: 14-1/2"

(368 mm) Min

K-557-K1:

18" (457 mm) Min

Kohler Co. 7 1240338-2-A

4. Assemble the Adapters and Unions

NOTICE: Do not apply excessive heat near the valve or apply ﬂux or acids directly onto the valve. This

valve contains plastic and rubber components which will melt if heat is directly applied.

Disassemble the adapter. Ensure all rubber and plastic components are removed.

Slide the union nut onto the inlet/outlet tube.

Solder the inlet/outlet tube to the union. Allow to cool completely.

Assemble the union.

Slide the adapter nut onto the inlet/outlet tube.

Assemble the adapter lock onto the inlet/outet tube and slide the assembly into the adapter nut.

Slide the O-ring onto the inlet/outlet tube.

For inlet tubes only: Insert the screen into the end of the inlet tube.

Reinstall the adapter assembly to the valve.

Repeat for all inlet/outlet tubes as required.

1/2" Union

Inlet/Outlet Tube

Adapter Nut

Screen (Inlets Only)

O-Ring

Adapter Lock

Solder this connection.

1240338-2-A 8 Kohler Co.

5. Install the Valve

NOTICE: Do not apply excessive heat near the valve or apply ﬂux or acids directly onto the valve. This

valve contains plastic and rubber components which will melt if heat is directly applied.

IMPORTANT! If your water supply has high amounts of particulates, install wye strainers in the supply

lines.

Route the water supply lines. Use unions to install removable pipe segments to the valve inlets to

allow access for periodic cleaning of the inlet screens.

Install shut-off valves and water hammer arrestors in the supply lines prior to the valve.

Hold the valve up to the installation location. Verify ﬁt and mark the hole locations.

Pre-drill the holes.

Secure the valve with the washers and screws. Do not overtighten.

IMPORTANT! Make sure each shower ﬁtting is connected to the appropriate valve outlet for your shower

conﬁguration. For shower conﬁguration options, refer to the guide on the K-99695 controller product page

at www.us.kohler.com.

Route the piping from the valve outlets to the appropriate shower ﬁtting.

Connect the hot and cold supply lines to the appropriate valve inlets. Hot is red and marked with

″HOT,″cold is blue and marked with ″COLD.″

Secure all piping to the framing.

Shut-Off Valve

1/2" Union

Water Hammer Arrestor

Offset Foot

Cross Brace Mount

Board Mount

Kohler Co. 9 1240338-2-A

6. Installation Checkout

Test for Leaks

Turn on the water supply to the valve.

Connect the jumper to the valve.

Verify there is power to the 120 V electrical outlet, then plug the power cord into the outlet.

Wait 10 seconds for the valve to initialize; the outlets will activate.

Check all connections for leaks.

Disconnect the power, then remove the jumper.

Connect the Cables

NOTE: Make drip loops in all cables and cords.

Install the K-99695 system controller according to the instructions packed with the product.

Route the data cable in the wall between the controller and valve installation location.

Attach a split boot to the data cable, toward the end that will connect to the valve.

Connect the cable to the valve. Press the boot over the connection in the valve socket.

Insert a solid boot into the unused socket.

Conﬁgure the Valve (Requires an Installed Controller)

NOTE: Valves which have been recently installed, or have not been used for some time should be

exercised before running tests or setting the maximum temperature.

To conﬁgure valve setup, refer to the guide on the K-99695 controller product page at

www.us.kohler.com.

Before Operating the System For the First Time:

Download and install the latest software for connected components. This may take an hour or more to

complete based on system conﬁguration and internet connection speed. Do not disconnect the power from

any components during software download and installation.

Slide the split boot

onto the cable.

Split

Boot

Solid Boot

Jumper

Drip Loop

1240338-2-A 10 Kohler Co.

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