Precedence Bath Whirlpools: K-1355-H1 K-1356-H1

Transcription

1 Precedence Bath Whirlpools: K-1355-H1 K-1356-H CA (9608) Copyright 1996 Kohler Co.

2 IMPORTANT SAFETY INSTRUCTIONS ATTENTION INSTALLER: INSTRUCTIONS PERTAINING TO RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS WARNING: When using this unit, always follow basic precautions, including the following: WARNING: RISK OF ELECTRICAL SHOCK. The unit must be connected only to a circuit that is protected by a Ground-Fault Circuit-Interrupter (GFCI). Such a GFCI should be provided by the installer and should be tested on a routine basis. To test the GFCI, press the test button. The GFCI should interrupt power. Press the reset button. Power should be restored. If the GFCI fails to operate in this manner, there is a ground current flowing or the GFCI is defective. The possibility of an electric shock may exist. DO NOT use this unit. Disconnect the unit and have the problem corrected by a qualified licensed electrician. Grounding is required. The unit should be installed and grounded by a qualified service representative. A pressure wire connector is provided on the pump to permit connection of a solid copper bonding conductor between this unit and all other electrical equipment and exposed metal in the vicinity, as needed to comply with local requirements. DANGER: RISK OF INJURY. Hot whirlpool baths can put certain stresses on the body, as do any hot bath, shower, sauna, or steam bath. Prolonged immersions in hot water may induce hyperthermia. Hyperthermia occurs when the internal temperature of the body reaches a level several degrees above the normal body temperature of 98.6 F. The symptoms of hyperthermia include an increase in the internal body temperature, dizziness, lethargy, drowsiness, and fainting. The effects of hyperthermia include: (1) failure to perceive heat, (2) failure to recognize the need to exit the bath, (3) unawareness of impending hazard, (4) fetal damage in pregnant women, (5) physical inability to exit the bath, and (6) unconsciousness resulting in the danger of drowning. Warning: The use of alcohol, drugs, or other medication can greatly increase the risk of fatal hyperthermia. DO NOT operate this unit without the guard on the suction fitting. Never drop or insert any object into any opening. Use this unit only for its intended use as denoted in this manual. DO NOT use attachments not recommended by the Kohler Co. Install to permit access for servicing. DANGER: RISK OF INJURY. To reduce the risk of injury, do not permit children to use this unit unless they are closely supervised at all times CA (9608) 2

3 TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS INTRODUCTION ROUGHING-IN: K-1355-H1, K-1356-H Ordering Information Required Electrical Service Product Information Installation Notes PRODUCT NOTICES Installer Hazard Notification Factory-Assembled Features PRODUCT REQUIREMENTS Summary of Key Requirements Plumbing Specifications Product Inspection Connections and Service Access Electrical Requirements INSTALLATION REQUIREMENTS Tools Required Materials Required Clearance Requirements New Or Replacement Installation Requirements 6 SITE REQUIREMENTS Old Bath Removal Subfloor Preparation Remove Aprons and Inspect Unit Stud Pocket Preparation Plumbing Preparation BEFORE INSTALLING UNIT Recommended Installation Partially Install Bath Drain Protect Whirlpool Unit INSTALL WHIRLPOOL Whirlpool Set-In To Adjust Level Connect Drain Secure Whirlpool Pump Banding Strap Cut COMPONENT LOCATION ELECTRICAL CONNECTIONS Identify Electrical Requirements Field Wiring Compartment -H1 Models Connect Compressor Box -H1 Models INSTALL WHIRLPOOL TRIM KIT TEST DOOR SYSTEM Operating Sequence Troubleshoot Door System WATER TEST WHIRLPOOL & ELECTRONICS.. 13 INSTALL APRONS INSTALL FINISH WALL INSTALL KICK STRIP CLEAN-UP AFTER INSTALLATION CONFIRM PROPER OPERATION Start-Up Whirlpool Operating Sequence TROUBLESHOOTING PROCEDURES Flexjet Installation Troubleshoot Whirlpool System INTRODUCTION Please read these instructions carefully to familiarize yourself with the required tools, materials, and installation sequences. Follow the sections that pertain to your particular installation. This will help you avoid costly mistakes. In addition to proper installation, read all operating and safety instructions. All information in this manual is based upon the latest product information available at the time of publication. Kohler Co. reserves the right to make changes in product characteristics, packaging, or availability at any time without notice. The variety of installations possible with this bath may require framing procedures other than those described in this manual. Identify and record the model and serial numbers below (found at the pump end of the bath): Model No. Serial No. Date of Manufacture CA (9608)

4 1. ROUGHING-IN: K-1355-H1, K-1356-H1 A. ORDERING INFORMATION Applicable product: Left outlet K-1355-H1 not shown Right outlet K-1356-H1 shown Accessories/hardware: Jet trim kit K-9695 required Drain K-7167 recommended Wall-mount grab bars, anti-scald faucet, and high-flow bath filler are recommended for maximum accessibility. B. REQUIRED ELECTRICAL SERVICE Dedicated branch circuit required, protected with Class A Ground-Fault Circuit-Interrupter (GFCI): Pump/control 120 V, 20 A, 60 Hz C. PRODUCT INFORMATION Fixture*: basin area top area weight Bathing well 43 x x lbs. water depth capacity To overflow 19-1/4 80 gals. * Approximate measurements for comparison only. Pump: HP V Hz A 1-speed Included Components: Apron factory installed D. INSTALLATION NOTES Read the entire installation instruction before beginning the installation. Finished floor thickness 1/2 max. above bottom of pump base pan. For thicker flooring, provide additional subflooring under the bath. ROUGHING-IN NOTES Fixture dimensions are nominal and conform to tolerances in ANSI Standard Z No change in measurements if connected with drain illustrated. Minimum access: Pump/control 30 W x 15 H panel required 32 PUMP 25-1/2 23-1/8 37-3/4 1-1/2 PUMP ACCESS 3/4 AIR COMPRESSOR /2 2-1/ >132 2 I.P.S. 2 O.D. AIR COMPRESSOR SHOWN WITH APRON REMOVED 5/8 20-1/2 DOOR OPENING 3-1/ CA (9608) 4

5 2. PRODUCT NOTICES A. INSTALLER HAZARD NOTIFICATION DANGER: Risk of fire, electric shock, or injury to persons. Read important safety instructions on inside front cover of these instructions. WARNING: Risk of electrical shock. A licensed electrician should make all electrical connections. WARNING: Risk of electrical shock. Connect only to a circuit protected by a Ground-Fault Circuit-Interrupter (GFCI). WARNING: Risk of electrical shock. Disconnect power before servicing. WARNING: Risk of injury or property damage. Please read all instructions thoroughly before beginning installation, including the following Product Requirements. NOTICE: Follow all local plumbing and electrical codes. B. FACTORY-ASSEMBLED FEATURES K-1355-H1, K-1356-H1: Factory installed components include pump with integral heater, control, variable flow valve, and switch. No installation is needed. The whirlpool pump and piping are factory-assembled. WARNING: Unauthorized modification may cause unsafe operation and poor performance of the whirlpool. Do not relocate the whirlpool pump, or make other modifications to the whirlpool system, as this could adversely affect the performance and safe operation of the whirlpool. Kohler Co. shall not be liable under its warranty or otherwise for personal injury or damage caused by any such unauthorized modification. 3. PRODUCT REQUIREMENTS A. SUMMARY OF KEY REQUIREMENTS Install unit to a level subfloor. Provide properly dimensioned framing. Recess installation is recommended. C. PRODUCT INSPECTION Carefully uncrate and inspect your product for damage. Do not remove the spacer bar until the unit is secured to the stud pocket. Return whirlpool to carton during construction to prevent damage. B. PLUMBING SPECIFICATIONS Confirm adequate support for the faucet; large faucets that may be inadvertently used as a means of support are not appropriate or safe for this installation. D. CONNECTIONS AND SERVICE ACCESS Before installation, ensure proper access to the final connections. NOTICE: Provide unrestricted service access to the pump and controls. Removable front apron provides access to the pump and controls. NOTICE: Make sure both union connections to the pump are securely tightened. E. ELECTRICAL REQUIREMENTS The installation must have a Class A Ground-Fault Circuit-Interrupter (GFCI). The GFCI protects against line-to-ground shock hazard. Use a 120 V, 20 A, 60 Hz dedicated service for the whirlpool CA (9608)

6 4. INSTALLATION REQUIREMENTS A. TOOLS REQUIRED Conventional woodworking tools Arc pliers or 14 pipe wrench Rule Level Safety shoes Safety glasses Square Screwdriver Pliers Utility knife Tin snips B. MATERIALS REQUIRED Plumbers putty Wall coverings, as necessary Silicone sealant Construction adhesive (optional) 2x4 s Drop cloth Nails C. CLEARANCE REQUIREMENTS Check the roughing-in and room dimensions to provide adequate available space for the bath unit. D. NEW OR REPLACEMENT INSTALLATION REQUIREMENTS This whirlpool can be installed in new or existing bathrooms. For new installations: Position the plumbing according to the roughing-in on Page 4. Cap the supplies, and check for leaks. For replacement installations: Remove the old bath. Remove the old wall material, and remove any old floor covering from the area. Remove any old plumbing that does not conform to roughing-in requirements. 5. SITE REQUIREMENTS A. OLD BATH REMOVAL Disconnect the drain at the trap. Remove the old wall material. Slip boards under the old bath feet to protect the floor and slide the old bath out of the recess as illustrated. Old Bath Floor Protection Boards B. SUBFLOOR PREPARATION Check the flooring under the bath, and make repairs as needed. Make sure the subfloor is level CA (9608) 6

7 C. REMOVE APRONS, AND INSPECT UNIT Carefully uncrate and inspect the whirlpool for damage. Do not remove spacer bar until unit is secured to stud pocket. Loosen and remove the screws at the base of the two aprons. These screws secure the aprons to the pan base. Save these screws. Spacer Bar Small Apron Pull the bottom of the apron away from the whirlpool unit. Then pull the top down and out from the flange in the whirlpool rim. Inspect the whirlpool for damage. Reinstall the aprons if the unit is not immediately installed. Return the whirlpool to the carton during construction, to prevent damage. Large Apron Supplied Drywall Screws D. STUD POCKET PREPARATION Refer to the Roughing-In section beginning on Page 4. Measure the exact outside dimension of the bath from the two front edges of the nailing flange. This should be close to 60. Size the stud pocket accordingly. NOTE: The stud pocket must fit the width of the unit exactly. The bath is shipped with a spacer bar to prevent spreading or squeezing of the door opening. This would affect the proper function of the inflatable seal and door. Stud Pocket Header Nailing Flange Construct a recess designed for your particular installation. Install stud pocket headers. Construct the required access panel according to Roughing-In section beginning on Page 4. Design of the bath will allow for up to 1/2 of finish floor material if the bath is installed to the subfloor. For thicker flooring, raise bath with plywood underlayment to compensate. This is necessary to allow clearance for apron removal. 32 Min. NOTE: Nailing flange holes in unit are 24-3/4 from base of unit NOTE: Refer to instructions NOTE: Allow adequate clearance for plumbing. Centerline of drain is 23-1/8 from back of unit. E. PLUMBING PREPARATION Position the plumbing according to the roughing-in dimensions. Cap the supplies, and check for leaks CA (9608)

8 6. BEFORE INSTALLING UNIT A. RECOMMENDED INSTALLATION Illustrated is a recommended installation. Incorporate framing support for the vertical and horizontal grab bars, if used. In addition, incorporate framing support for the hand spray on vertical slide bar, if used. Route piping and adapt framing as necessary for the hand spray supply elbow, pressure-balanced mixer valve, and high-flow tub filler and valves. Recommended Location of Grab Bars, if Used B. PARTIALLY INSTALL BATH DRAIN Install the drain on the whirlpool according to the drain manufacturer s instructions. C. PROTECT WHIRLPOOL UNIT Position a drop cloth or similar material in the bottom of the unit. Be careful not to scratch the surface of the product. 7. INSTALL THE WHIRLPOOL A. WHIRLPOOL SET-IN The pump base pan is integral to the unit. If the subfloor is level, no adjustments are required. Set the whirlpool into place, align the drain tailpiece with the trap, and proceed to the next section. CAUTION: Risk of product damage. Do not use the piping or pump for structural support or positioning of the whirlpool. If the subfloor is not level, some leveling of the whirlpool area will be necessary. Do not support the weight of the whirlpool by the flange. Do not use drywall plaster as a means of support. Drain Hole Shims CA (9608) 8

9 B. TO ADJUST LEVEL Shim using minimum size 6 x 6 shims, and a maximum spacing of 24. Set the whirlpool into position, and align the drain tailpiece with the trap. Make sure the whirlpool is level. C. CONNECT DRAIN When the whirlpool is securely positioned, connect the drain to the trap as shown. Stud Drain Pocket Plumbing D. SECURE WHIRLPOOL Secure the nailing flange to the stud pocket header with the screws supplied with the unit. After the unit is secured to the header to prevent spreading or squeezing of the walls, remove the shipping spreader bar. Test the operation of the door to ensure there is no binding. Supplied Screws Spacer Bar E. PUMP BANDING STRAP CUT NOTICE: This step is necessary to make your Kohler whirlpool operate more quietly. 1. Use tin snips to cut the two banding straps. These banding straps secure the pump to the support pan during shipping. Suction Line Pump Subfloor Banding Straps Pump Base Support Pan CA (9608)

10 8. COMPONENT LOCATION Familiarize yourself with the location of all major components before proceeding to the wiring (as required), trim kit installation, testing, and troubleshooting. Jet Suction Button This unit uses a compressor assembly to inflate a seal in the door. The door has a backup gasket on the outside for added safety. A bolt-type latch secures the door. It is released by the button on top of the door. After the button is depressed, slight pressure inward should open the door. This unit is different from many other Kohler whirlpools in that the power for the whirlpool pump and controls is supplied through the compressor assembly control box. Control Switch Seat Pump Hose Air Compressor Inflatable Seal Door Backup Gasket 9. ELECTRICAL CONNECTIONS A. IDENTIFY ELECTRICAL REQUIREMENTS The model number is printed on a label at the pump end of the whirlpool. The label identifies electrical rating. B. FIELD WIRING COMPARTMENT 120 V, 60 HZ, -H1 (UL LISTED) MODELS WARNING: Risk of electrical shock. Make sure the power has been disconnected before performing the following procedures. Refer to Important Safety Instructions located on Page 2. CAUTION: Risk of electrical shock. All services must have a Class A Ground-Fault Circuit-Interrupter (GFCI) which will provide additional protection against line-to-ground shock hazard. A dedicated service is required for the whirlpool. The whirlpool controls and system have been prewired at the factory. A licensed electrician should make a routine service connection to the compressor box accessible through the apron. * For bonding in accordance with national and local codes. Pump Switch Bonding (Earthing) Lugs* Pump Compressor Box Control Box CA (9608) 10

11 C. CONNECT COMPRESSOR BOX, -H1 (UL LISTED) MODELS Connect service to the field wiring compartment of the compressor box. The compressor control contains black and white wires and a ground lug. The compressor control is prewired to the whirlpool pump. Black Wire (Line) Wire Nut White Wires (Neutral) Water-Level Sensor A 120 V, 20 A dedicated circuit is required. Provide a Class A Ground-Fault Circuit-Interrupter (GFCI). Provide a separate equipment grounding conductor for the inside grounding lug. Ground must not be connected to any current-carrying conductor. Bonding Lug Green Wire (Ground) Ground Lug To Pump 10. INSTALL WHIRLPOOL TRIM KIT Refer to the installation instructions packed with the trim kit when installing the jet or suction trim CA (9608)

12 11. TEST DOOR SYSTEM A. OPERATING SEQUENCE Tightly close the door. When swinging the door shut, a clicking sound assures the door is closed and secure. Check that the door latch engages the latch receptor. Close the drain, and begin filling the bath. Latch Button The door seal will inflate automatically after the two water-level sensors (inside the bath, and near the bottom of the door) are covered with water. Monitor the outside of the door for any signs of leakage, and continue to fill the bath to a level at least 2 above the top of the highest jet. Open the drain, and allow the bath to empty. Water Line 2 Min. The door seal will automatically deflate when the water level reaches below the water-level sensors. Press in the button on the top of the door, and open the door inward. B. TROUBLESHOOT DOOR SYSTEM Suction Whirlpool Jet This troubleshooting guide is for general aid only. A Kohler Authorized Service Representative or a qualified electrician should correct all electrical problems. For warranty service, contact your dealer or wholesale distributor. SYMPTOMS PROBABLE CAUSES RECOMMENDED ACTION 1. Door won t close. A. Seal is out of track. A. Re-insert seal. B. Seal remains inflated. B. Contact dealer/installer. C. Improper installation. C. Contact dealer/installer. 2. Door won t open. A. Bath is not empty. A. Wait for bath to empty. B. No power to unit. B. Reset breaker. C. Compressor controller. C. Contact dealer/installer. 3. Door leaks water. A. No power to unit. A. Reset breaker. 4. Compressor runs periodically. B. Incorrect field wiring. B. Contact dealer/installer. C. Seal is leaking. C. Contact dealer/installer. D. Compressor controller. D. Contact dealer/installer. A. Seal is leaking air. A. Contact dealer/installer. B. Faulty pressure switch. B. Contact dealer/installer CA (9608) 12

13 12. WATER TEST WHIRLPOOL AND ELECTRONICS Check all electrical connections. Make sure all pipe connections to the pump are securely tightened. Fill the whirlpool to a level at least 2 above the top of the highest jet. Operate the whirlpool for 5 minutes, and check all whirlpool harness (piping) connections for leaks. For additional information on whirlpool operation, see Start-Up Whirlpool instructions on Page INSTALL APRONS Locate the screws removed during the whirlpool inspection. This apron system is designed so the finish wall materials go over the apron columns. It is also designed so the finished floor materials butt up against the pan base. Slip the top of an apron up into the channel groove. Tilt the apron inward. Align the bottom of the apron with the pan base. The apron should align with both the bath rim and the edges of the apron columns, and with the pre-drilled holes in the pan base. Secure the apron to the pan base with screws. Repeat for the other apron. Large Apron Supplied Drywall Screw Small Apron Supplied Drywall Screws CA (9608)

14 14. INSTALL FINISH WALL NOTICE: Before covering the framing, perform the following procedure: Open the hot and cold water valves, and check all supply connections for leaks. Fill the whirlpool to the overflow, and check the overflow and drain connections for leaks. Operate the whirlpool for 5 minutes, and again check all connections for leakage. Protect the whirlpool surface. Cover the framing and walls with water-resistant wall material. Tape and mud the wall material. Seal the wall material and joints under the whirlpool rim. Install the finish wall material to the subwall. Use silicone sealant to seal the joints between the whirlpool rim and the finish wall. Stud Water-Resistant Wall Material Finish Wall Covering Silicone Sealant Whirlpool 15. INSTALL KICK STRIP NOTE: Install kick strip after the finished flooring is installed. With the paper backing still attached, position the kick strip along the outline of the whirlpool base. Begin at one end, and peel back a few inches of the paper backing from the kick strip. Align the end of the kick strip to the finish wall and the bottom of the whirlpool base. Lightly press the kick strip to the whirlpool base. Peeling back a few inches of paper backing at a time, continue aligning and pressing the kick strip to the whirlpool base. After the kick strip is completely applied, go over the entire length with firm pressure to secure the kick strip to whirlpool base. Kick strip CA (9608) 14

15 16. CLEAN-UP AFTER INSTALLATION When cleaning up after installation, do not use abrasive cleansers as they may scratch and dull the bath surface. Use warm water and a liquid detergent to clean the surface. Stubborn stains, paint, or tar can be removed with turpentine or paint thinner. Do not allow cleaners containing petroleum distillates to remain in contact with whirlpool surfaces for long periods of time. Plaster can be removed by scraping with a wood edge. Do not use metal scrapers, wire brushes, or other metal tools. A powder-type detergent may be used on a damp cloth to provide mild abrasive action to the residual plaster. Polystyrene FRP Polystyrene 17. CONFIRM PROPER OPERATION A. START-UP WHIRLPOOL Refer to Important Safety Instructions on Page 2. Please perform the following so the owner can safely receive the benefits of whirlpool bathing. 1. Rotate the jets so they are facing down toward the basin. 2. Fill the whirlpool to a water level at least 2 above the top of the highest jet. Water temperature in the bath should not exceed 104 F (40 C). Bath Wall 2 Minimum Jet Trim Water Line CA (9608)

16 B. OPERATING SEQUENCE Refer to the chart at right for the proper operating sequence. 1. Turn on the whirlpool jets. Adjust each jet for optimum air/water mixture. 2. A built-in timer automatically stops the motor after 20 minutes of operation. 3. A built-in heater automatically maintains the water temperature while whirlpool bathing. ALL 2-HP, VARIABLE FLOW MODELS: TO METHOD OBSERVE Turn on whirlpool massage and the heater. Decrease flow by pressing key; increase flow by pressing key. Up/ More Down/ Less To add air and water to whirlpool action, rotate the flange counterclockwise. To reduce air and water, rotate it clockwise. Shut off whirlpool. Reduce Air and Water Add Air and Water Restart whirlpool after 20 minute cycle is complete CA (9608) 16

17 18. TROUBLESHOOTING PROCEDURES A. FLEXJET INSTALLATION NOTE: The Flexjet O-ring must be correctly positioned, must be lubricated, and must be in good condition to permit easy rotation and proper operation. 1. Install the O-ring onto the first shoulder of the Flexjet. Lubricate the O-ring with silicone lubricant to prevent noisy operation of the Flexjet. 2. Insert the Flexjet into the housing, and lightly push and rotate the Flexjet until it snaps into position. Do not force the Flexjet. NOTE: When installed correctly, the Flexjet should turn smoothly both clockwise and counterclockwise. O-Ring (Must Be Lubricated) Flexjet Housing Slide O-Ring Flexjet CA (9608)

18 B. TROUBLESHOOT WHIRLPOOL SYSTEM This troubleshooting guide is for general aid only. A Kohler Authorized Service Representative or a qualified electrician should correct all electrical problems. For warranty service, contact your dealer or wholesale distributor. SYMPTOMS PROBABLE CAUSES RECOMMENDED ACTION 1. Whirlpool does not start/stop. 2. Motor starts, all jets are not functioning. A. No power to pump motor. A. Set/Reset GFCI breaker; check wiring. B. Faulty switch. B. Replace switch. C. Jets are blocked. C. Remove blockage. D. Faulty pump circuit board. D. Replace pump circuit board. E. Switch disconnected from panel. E. Reconnect wire at switch or at pump. F. Faulty motor/pump assembly. F. Replace motor and pump. A. Jet is closed. A. Rotate jets counterclockwise to open. B. Trim kit installed incorrectly. B. Reinstall trim kit, checking for damage to O-ring. C. Jets are blocked. C. Remove blockage. 3. Whirlpool stops A. GFCI trips. A. Identify source of fault and correct. automatically before 18 minutes. B. Suction blocked. B. Remove obstruction. C. Jets are blocked. C. Remove blockage. 4. Whirlpool does not automatically stop after 22 minutes. D. Motor overheated and protection device activated. D. Check for blockage at motor vents. Remove blockage and allow motor to cool. Check for suction blockage. Remove blockage and allow motor to cool. Check for jet blockage. Remove blockage and allow motor to cool. E. Faulty pump circuit board. E. Replace pump circuit board. A. Faulty pump circuit board. A. Replace pump circuit board. 5. Jet squeals/is noisy. A. O-ring unseated. A. Remove jet. Replace and lubricate O-ring onto jet valve body; reinstall jet. 6. Whirlpool is noisy. A. Shipping straps holding pump to bath have not been cut. 7. Water flow cannot be regulated. A. Cut straps so pump sits on subfloor. A. Faulty flow valve. A. Check for loose connections or wire(s) leading to pump. Replace flow valve or pump circuit board as necessary CA (9608) 18

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