215-t3/222-t3 SERIES

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1 5-t3/-t3 SERIES PRODUCT MANUAL IMPORTANT Installer: This Manual is the property of the customer and must be retained with the product for maintenance and operational purposes.

2 INDEX page INTRODUCTION 3 DESCRIPTION 3 SAFETY WARNINGS 5 SPECIFICATION 6 DIMENSIONS 0 INSTALLATION 3 COMMISSIONING OPERATION 4 FAULT DIAGNOSIS 5 MAINTENANCE 6 SPARE PARTS 33 RECOMMENDED SPARES MINIMUM STOCK LIST 40 CUSTOMER CARE Back Cover

3 INTRODUCTION Rada Thermoscopic mixing valves are specified to meet the highest standards of safety, comfort and economy as demanded by todays users. All Rada products are designed, manufactured and supported in accordance with accredited BS EN ISO 900:994 Quality Systems. This Manual covers all Rada 5/ series manufactured from October 994. DESCRIPTION A range of /" and 3/4" thermostatic mixing valves to suit a wide diversity of applications and installation formats. Incorporates the Radatherm cartridge, a unique sealed-for-life unit utilising proven durability high-technology materials for extended service-free reliability. This cartridge employs the advanced nd generation 'thermoscopic' temperature sensor to provide water at safe, accurate temperatures for ablutionary or process requirements. The mixing valve inlets incorporate strainers and checkvalves, housed within readily accessible cartridges for easy maintenance. Product range Rada 5-t3 oem - Rada 5-t3 c - Rada 5-t3 bc - Concealed model, duct/box installation, all chrome finish /" BSP external unions to accept flat faced connectors. Exposed model, surface mounted, all chrome finish, 5 mm compression//" BSP connections. Semi-concealed model, built-in mounting, chrome and polished stainless steel finish, /" BSP/also accepts 5 mm compression connections. Rada 5-t3 zc - Exposed model, pipework mounted, all chrome finish, inlets 3/4" BSP union (optional 3/4" x /" offset adaptors for variable centres and pipe concealing plates are available) outlet 5 mm compression//" BSP connection. Rada 5-t3 dk - Rada 5dk - (less fittings) Rada -t3 dk Rada dk - (less fittings) Concealed model, duct/cupboard mounting, nickel-plated finish with white trim, /" BSP external unions to accept flat-faced connectors. (Additionally elbows and straight union nickel-plated connector are supplied, terminating in 5 mm compression connections). Concealed model, duct/cupboard mounting, nickel-plated finish with white trim, /" BSP external unions to accept flat-faced connectors. Concealed model, duct/cupboard mounting, nickel-plated finish with white trim, 3/4" BSP external unions to accept flat-faced connectors. (Additionally elbows and straight union nickel-plated connector are supplied, terminating in mm compression connections). Concealed model, duct/cupboard mounting, nickel-plated finish with white trim, 3/4" BSP external unions to accept flat-faced connectors. 3

4 All models except 5-t3 dk, 5dk (less fittings), -t3 dk and dk (less fittings) are provided with adjustable temperature control which allows the user to select blend water temperatures up to a pre-set safe maximum level. Temperature knobs incorporate a short lever to assist those with reduced use of their hands. All models are supplied with optional temperature-locking facility (standard on dk models). Model range references: oem - c - b - d - k - concealed model, duct/box installation. all chrome finish Product Selector built-into wall recess or panel, temperature knob protrudes through stainless steel plate. duct or fully concealed mounting, no user access required. locked temperature control, requires wrench key to adjust. Format: 5-t3oem 5-t3c 5-t3bc 5-t3 zc 5-t3dk -t3dk 5dk dk less fittings less fittings Exposed Built-in Duct/concealed Finish: White trim/nickel All chrome (+st/st) Control: Adjustable temp. Locked temp. Connections: 5 mm mm /" 3/4" (outlet) (outlet) (inlets) (+st/st: concealing plate on built-in models is polished stainless steel). 4

5 SAFETY : WARNINGS Rada products are precision-engineered and should give continued superior and safe performance, provided:. They are installed, commissioned, operated and maintained in accordance with the recommendations given in this Manual.. Periodic attention is given, as necessary, to maintain the product in good functional order. Recommended guidelines are given in the MAINTENANCE section. The function of a thermostatic mixing valve is to deliver water consistently at a safe temperature. In keeping with every other mechanism, it cannot be considered as being functionally infallible and as such, cannot totally replace the vigilance of nursing/supervisory staff where that is necessary. Provided it is installed, commissioned, operated and maintained within these recommendations, the risk of failure, if not eliminated, is reduced to the minimum achievable. 5

6 Important Points: SPECIFICATION The installation, commissioning and maintenance of this product must be carried out in accordance with instructions given in this Manual, and must be conducted by designated, qualified and competent personnel.. Installations must comply with all Local/National Water Supply Authority Regulations/Byelaws, and Building and Plumbing Regulations. 3. Rada products are precision-engineered and should give continued superior and safe performance, provided:- - they are installed, commissioned, operated and maintained in accordance with these recommendations and - periodic attention is given as necessary to maintain the product in good functional order. Recommended guidelines are given in the MAINTENANCE section. 4. Warning: continued use of this product in conditions outside the limits listed in this section can severely affect the performance and reduce the effective service life, and can present potential risk to users. 5. Suitable for use with most fully modulating Instantaneous Gas Water Heaters. For information on Multipoint Electric Water Heaters, refer to Data Sheet P99. For information on other specific applications or suitability, refer to Kohler Mira Ltd, or Local Agent. 6. Disinfectants: In applications where system chemical disinfection is practised, chlorine can be used (calculated chlorine concentration of 50mg/l (ppm) maximum in water, per one hour dwell time, at service interval frequency). Such procedures must be conducted strictly in accordance with the information supplied with the disinfectant and with all relevant Guidelines/Approved Codes of Practice. If in any doubt as to the suitability of chemical solutions, refer to Kohler Mira Ltd, or Local Agent. Normal Operating Conditions are considered as: - inlet dynamic pressures nominally balanced to within 0% of each other during flow. - a differential of approximately 50 o C between the hot and cold inlet temperatures, and with differentials of 5-35 o C between the blend setting and either supply. - daily usage of - 6 hours. - installation and usage environment not subject to extremes of temperature, unauthorised tampering or wilful abuse. 6

7 Operating Parameters:- Pressures/Flow Rates For optimum performance, dynamic supply pressures should be nominally equal. Recommended Minimum Flow Rate: 3 l/min at mid-blend with equal dynamic supply pressures. Recommended Maximum Flow Rate: 5 models: 35 l/min at mid-blend (which equates to maximum pressure loss of.8 bar). models: 40 l/min at mid-blend (which equates to maximum pressure loss of. bar). Maximum Pressure Loss Ratio*: should not exceed 0:, in favour of either supply, during flow. Recommended Minimum Dynamic Supply Pressure: 0.5 bar. Recommended Maximum Dynamic Supply Pressure: 5 bar. Maximum Static Supply Pressure: 0 bar. Recommended maximum flow velocity in pipelines is metres/second. * Pressure Loss Ratio is determined by subtracting the resistance to flow of the outlet pipework and outlet fittings (generally known as "back pressure", and measured at the outlet of the mixing valve) from the dynamic pressures of the hot and cold water at each inlet of the mixing valve. This is at its extreme when the mixing valve is being used at its lowest flow-rate and when the maximum inequality occurs in the pressure of the hot and cold water supplies. Hydraulic Restriction: Flow Rate/Pressure Loss Graph (mixing valve only, equal dynamic supply pressures and mid-blend temperature setting) Rada Flow Rate Litres/Min Rada Pressure Loss - bar 7

8 Operating Parameters:- Temperatures Optimum performance is obtained when temperature differentials of 0 o C or more exist between blend and either supply. Blend control accuracy will begin to diminish at temperature differentials below o C. Blend Temperature Range: between ambient cold and approximately 60 o C, according to hot water supply temperature. Thermostatic Control Range: approximately 5-60 o C. Optimum Thermostatic Control Range: o C. Recommended Minimum Cold Water Temperature: o C. Recommended Maximum Hot Water Supply Temperature: 85 o C. Note! The mixing valve can accept temporary temperature excursions above 85 o C without damage, however operation of the mixing valve at such elevated supply temperatures is not recommended. For reasons of general safety, hot water storage temperatures should ideally be maintained at between o C where serving ablutionary applications. Flow Control: Rada 5/ series mixing valves do not have integral flow control; appropriate provision must be made for this in the outlet pipework. This can be in the form of basin/bath tap, stop-cock, mechanical timed-flow controller or solenoid. The device chosen must be non-concussive in operation. Connections Rada 5-t3 c Rada 5-t3 bc - Inlets and Outlet: /" BSP external union or 5 mm compression (nut and olive provided). - Inlets and Outlet: /" BSP external union or 5 mm compression (nut and olive not provided). Rada 5-t3 dk - Inlets and Outlet: /" flat-faced external union ( elbows and straight union connector are supplied, terminating in 5 mm compression connections). Rada 5-t3 oem - Inlets: /" flat-faced external union Outlets: /" BSP external union or 5 mm compression (nut and olive not provided). Rada 5-t3 zc - Inlets: 3/4" BSP internal captive nuts to accept offset unions (available separately on request, these allow for variable (8-78 mm) rear-fed supply pipework centres via parallel or taper sockets). Outlet: /" BSP external union or 5 mm compression (nut and olive provided). 8

9 Rada 5dk (less fittings) - Inlets and Outlet: /" flat-faced external union. Rada -t3dk - Inlets and Outlet: 3/4" flat-faced external union ( elbows and straight union connector are supplied, terminating in mm compression connections). Rada dk (less fittings) - Inlets and Outlet: 3/4" flat-faced external union. Inlet/Outlet Options: inlets:* outlet:* 5-t3 c top, bottom, rear-fed top, bottom 5-t3 bc top, bottom top, bottom 5-t3 dk any configuration any configuration 5-t3 oem any configuration any configuration 5-t3 zc rear-fed top, bottom -t3 dk any configuaration any configuration 5dk/dk any configuration any configuration (less fittings) *Products are supplied in the format shown in bold. Standard Connections are: hot - left (marked red) cold - right (marked blue) Note! Should the supplies be reversed then the mixing valve will not be able to control temperature. This can be corrected by reversing the position of the Radatherm cartridge within the valve body, as described in INSTALLATION, Reversed inlets. Outlet - top (can be altered to bottom outlet as required, refer to INSTALLATION, Outlet position). All models can operate in any plane, and may be inverted if necessary for pipework layout convenience, provided hot and cold pipework is connected to the appropriate inlets (hot - red, cold - blue). 9

10 Dimensions (All dimensions in mm) Rada 5-t3 c DIMENSIONS Rada 5-t3 bc Rada 5-t3 oem

11 Rada 5-t3 zc Rada 5-t3 dk Rada 5 dk (less fittings)

12 Rada -t3 dk Rada dk (less fittings)

13 General INSTALLATION Installation must be carried out in accordance with these instructions, and must be conducted by designated, qualified and competent personnel.. Before commencing, ensure that the installation conditions comply with the information given in SPECIFICATION.. Care must be taken during installation to prevent any risk of injury or damage. 3. The mixing valve should be positioned for easy access during use and maintenance. All routine maintenance procedures can be conducted with the mixing valve body in place (except for strainer and checkvalve access on 5dk/ 5-t3 dk, 5-t3 oem, 5-t3 zc and dk/-t3 dk). For all models, allow a minimum 80 mm clearance in front of the temperature control to enable removal of the Radatherm cartridge during maintenance. 4. Conveniently situated isolating valves must be provided for maintenance. 5. The use of supply-line or zone strainers will reduce the need to remove debris at each mixing valve point. The recommended maximum mesh aperture dimension for such strainers is 0.5 mm 6. Pipework must be rigidly supported. 7. Pipework dead-legs should be kept to a minimum. 8. Supply pipework layout should be arranged to minimise the effect of other outlet usage upon the dynamic pressures at the mixing valve inlets. 9. Inlet and outlet threaded joint connections should be made with PTFE tape or liquid sealant. Do not use oil-based, non-setting jointing compounds. 0. To eliminate pipe debris it is essential that supply pipes are thoroughly flushed through before connection to the mixing valve. Outlet position/reversed inlets Rada 5dk/5-t3 dk, 5-t3 oem and dk/-t3 dk models are readily adaptable for rising or falling pipework; the flat-faced union connectors provided allow the valve body to accept a variety of pipework configurations, and to be reversed or inverted as appropriate. All Rada 5 series mixing valves, except 5dk/5-t3 dk, are supplied with inlet connections configured hot - left, cold - right, and top outlet as standard. It is essential that inlet supplies correspond with the red and blue markings on the Radatherm cartridge. Should the existing hot and cold pipework make this configuration inconvenient, or a bottom outlet position be required, the valve inlets or outlet can be reversed, as detailed below. If both the outlet and inlet positions require reversing, it is easier to simply rotate the complete mixing valve by / turn, and then reposition the temperature knob or cap. 3

14 Outlet Reversal should be done prior to installation of the mixing valve body. Reversed connections can be altered before or after the mixing valve has been installed. The procedure for both operations is as follows:. If the mixing valve body has already been installed, isolate the supplies to the mixing valve, and open an outlet fitting to release pressure and to assist the draining of residual water.. Remove the temperature knob assembly (44 0) or locking cap (407 54), using 3 mm wrench key provided (refer to Figure 6). Do not remove the temperature hub. 3. (Built-in models). Carefully lever off the concealing plate (408 76) by inserting a medium slotted screwdriver blade under each corner, refer to Figure With removal clip still in place, unscrew the head nut using 35 mm A/F wrench; this will release the body shroud and also begin to draw the Radatherm cartridge out of the body (refer to Figure 8). Warning! Some residual water may be released. Pull the Radatherm cartridge free of the valve body. 5. Outlet Reversal: rotate the valve body / turn so that the outlet is in the opposite position. Do not rotate the Radatherm cartridge. Reversed Inlets: rotate the Radatherm cartridge / turn, which reverses the position of the cartridge hot and cold inlets. 6. Carefully push the Radatherm cartridge back into the valve body, checking that the cartridge inlet port seals remain in place, and locate cartridge lugs into body slots. Note! The red and blue markings on the cartridge will now not correspond with the body markings, so to avoid future confusion remove the red and blue stickers from the valve body. 7. Carefully align and then tighten the head nut; do not over-tighten (max torque.5 N/m -.85 lbf ft). 8. Complete the INSTALLATION, if appropriate. 9. If the mixing valve body has already been installed, restore hot and cold supplies and check for any leaks. 0. Align and refit the body shroud and temperature knob assembly/locking cap so that the markings will be visible to the user (built-in models: first re-fit the concealing plate).. The maximum temperature may now need re-setting; check, and if necessary refer to COMMISSIONING. 4

15 Installation: Rada 5-t3 c. When un-packed, the inlet elbows are positioned to accept falling supplies. Should the installation require rising or rear-fed supplies then the elbows will need adjusting: loosen each elbow grub screw (68 ) using.5 mm wrench key provided, pull the elbow away from the valve body and re-fit in the desired position, and retighten the grub screw.. Where rear-fed supplies are required, pipe concealing plates are provided which recess into the tiling for a neater finish. 3. Loosen backplate grub screws (68 ) using.5 mm wrench key provided and pull off backplate (408 73) For 5 mm compression pipework inlet or outlet connections: fit compression nuts and olives supplied. - For /" BSP union inlet or outlet connections: fit flat-faced inserts supplied, press in firmly (refer to Figure ). 5. Mount backplate securely to wall surface, with grub screws downwards, using wall screws/plugs provided if appropriate. 6. Important! Flush through the hot and cold supplies thoroughly before connection to mixing valve. 7. Re-fit valve onto backplate and tighten grub screws. 8. Connect inlet and outlet pipework, checking that the hot and cold supplies have been piped to the correct inlets, and check all connections are watertight. Refer to COMMISSIONING. 5 mm Inlet/outlet Connectors Supplied 5-t3 c, 5-t3 bc, 5-t3 zc (outlet only) Figure 5

16 Installation: Rada 5-t3 bc - wall recess The Rada 5-t3bc is suitable for building-in to solid, dry-lined, stud partition or dry partition wall structures. To allow for connection of pipework, the recess in the wall (un-finished) should be approximately 80 mm x 7 mm x 50 mm (refer to Figure ). The depth of concealment is critical, the minimum depth to accept the mounting bracket is 50 mm, with another 5 mm maximum on top of this for finishing coat thickness of plaster and tiles or other material. This last dimension determines how much of the temperature or locking knob will be visible through the concealing plate. A building-in shroud is supplied, which protects the mixing valve during plastering/ finishing and provides a reference for the building-in depth.. This mixing valve is supplied with outlet to top, should the installation require outlet to bottom, then refer to Outlet Position.. When un-packed, the inlet elbows are positioned to accept falling supplies. Should the installation require rising supplies, then the elbows will need adjusting; loosen each elbow grub screw (68 ) using.5 mm wrench key provided, pull the elbow away from the valve body and re-fit on opposite inlet port so that the check valve cartridges remain facing forwards, and re-tighten the grub screw. 3. Fit mounting bracket (407 88) to valve base using screws (65 39) supplied, and mount the valve into recess (refer to Figure ), using wall screws/plugs provided if appropriate. The mounting bracket must be horizontal. 50 mm 80 mm 7 mm 5-t3 bc - Wall Recess Mounting Figure 6

17 4. Important! Flush through the hot and cold supplies thoroughly before connection to mixing valve. 5. Connect inlet and outlet pipework, checking that the hot and cold supplies have been piped to the correct inlets, and check all connections are watertight. 6. Assemble building-in shroud (407 9) as shown below (refer to Figure 3) and fit over mixing valve in recess. Plaster and tile, or finish as appropriate, up to edge of shroud. Final wall surface must fall between lines on building-in shroud (refer to Figure 3). 7. When wall surface is finished, remove the building-in shroud and temperature knob. 8. When packed, the concealing plate bracket assembly (408 77) and concealing plate (408 76) are assembled together. To detach, carefully lever off the concealing plate by inserting a medium slotted screwdriver blade under each corner (refer to Figure 7). Building-in Shroud Finished Wall Surface 5-t3 bc - Wall Recess Finishing Figure 3 7

18 9. The concealing plate bracket assembly (408 77) is provided with a foam seal on its rear face, which mates with the wall surface and reduces the possibility of water penetration into the recess. Should the wall surface or tiling be uneven, this seal will not be fully effective and should be assisted/substituted by silicone sealant. Align and secure concealing plate bracket assembly to mounting bracket with each of 30 mm panhead stainless steel screws (66 5), washers (64 0) and nuts (66 6) provided. 0. Remove protective film from concealing plate (408 76), and align into position with bracket. Press firmly at each corner to secure. Re-fit temperature knob. Refer to COMMISSIONING. Installation: Rada 5-t3 bc - thin panel The Rada 5-t3 bc incorporates a mounting bracket, enabling the valve to be installed through a laminated panel or shower cubicle. The bracket must be mounted to the rear face of panels of - 5 mm finished thickness (see below for thicker panels). The rear clearance requirement is 50 mm.. Cut a hole in the panel measuring 80 x 7 mm.. Drill fixing holes of 4 mm diameter at mm centres in the positions shown on Figure 4 and Figure Follow previous instructions - for wall recess installation. 4. Fit mounting bracket (407 88) to valve base using screws (65 39) supplied. If access is available it may be preferable to make the initial valve/pipework connections prior to securing the mixing valve to the panel. 5. Mount the mixing valve securely onto rear of panel (refer to Figure 5), with each of 30 mm panhead stainless steel screws (66 5), washers (64 0) and nuts (66 6) provided. 6. Important! Flush through the hot and cold supplies thoroughly before connection to mixing valve. 7. Connect inlet and outlet pipework, checking that the hot and cold supplies have been piped to the correct inlets, and check all connections are watertight. 8. Follow previous instructions 7-0 for wall recess installation. Refer to COMMISSIONING. 8

19 7 mm -5 mm 80 mm Mounting 5-t3 bc to Panel ( - 5 mm) Figure 4 mm 80 mm - 5 mm 5 mm 50 mm Figure 5 Installation: Rada 5-t3 bc - Panels 6 mm+ Note! The mounting bracket can also be mounted to the front face of thicker panels which will receive a further finishing layer of - 7 mm thickness. If this further finishing layer is not to be provided, the ends of the mounting bracket must be recessed mm depth) into the panel face until flush.. Cut a hole in the panel measuring 80 x 7 mm. 9

20 . Drill fixing holes at centres of mm in positions marked on Figure 4. The fixing hole dimensions must be suitable for the selected securing method, appropriate for the particular panel material. 3. Follow previous instructions - for wall recess installation. Note! The inlets accept rising or falling supplies, on thicker panels this may require the inlet pipework to be configured with elbows or pipe bends immediately prior to the inlet connections. 4. Fit mounting bracket (407 88) to valve base using screws (65 39) supplied. If access is available it may be preferable to make the initial valve/pipework connections prior to securing the valve to the panel. 5. Mount valve securely into recess (refer to Figure 5), using drilled mm hole centres. 6. Important! Flush through the hot and cold supplies thoroughly before connection to mixing valve. 7. Connect inlet and outlet pipework, checking that the hot and cold supplies have been piped to the correct inlets, and check all connections are watertight. 8. Plaster and tile, or finish as appropriate, up to the panel hole perimeter only, and to a maximum thickness of 5 mm over the front face of the mounting bracket. Protect the mixing valve and pipe connections during this process. 9. Follow Rada 5-t3 bc instructions 7-0 for wall recess installation. Refer to COMMISSIONING. Installation: Rada 5-t3 zc Note: Rada Offset connectors (555 4) and offset pipe concealing plates (076 59) are not supplied with this mixing valve, but are available separately as optional accessories.. Check that the hot and cold supplies are piped to the correct inlet positions. Supplies (pipe centres between 8-78 mm) must terminate in /" BSP internal sockets to within 3 mm, above or below, the final wall surface. Note! It is essential that inlet supply sockets are parallel, and square with wall surface.. Join offset connectors (555 4) and screw into sockets so that faced edge is 34 mm proud of final wall surface (refer to Figure ). Shorten /" BSP external thread, if necessary. 3. Screw pipe concealing plates (076 59) onto offset connectors. 4. Important! Flush through the hot and cold supplies thoroughly before connection to mixing valve. 5. With nylon washers (636 ) in position, offer up mixing valve and tighten union nuts onto offset connectors. 0

21 6. Connect outlet pipework: - for 5 mm compression pipework outlet connection: fit compression nut and olive supplied (refer to Figure ). - for /" BSP union outlet connection: fit flat-faced insert supplied, press in firmly (refer to Figure ). 7. Check all connections are watertight. Refer to COMMISSIONING. 34 mm 3/4" Union Thread /" Thread (shorten if necessary) 5-t3 zc - Offset Connector Figure Installation: Rada 5dk/5-t3 dk, 5-t3 oem and dk/-t3 dk. The mixing valve is supported by its inlet and outlet pipework only, which must be suitably and securely fastened.. Inlets and outlet are external BSP union, intended to accept flat-faced connectors. It is recommended that such union connections are used, so that the mixing valve body can be readily removed from its pipework for maintenance purposes. (5-t3 dk and -t3 dk models:) Three additional connectors are supplied ( elbows, straight, terminating in compression connections), which are interchangeable to the inlets and outlet. Select the most appropriate configuration tor the intended installation, and, with nylon washers (636 0/) in place, secure to valve body. 3. Run inlet and outlet pipework to the mixing valve, checking that hot and cold supplies have been piped to the correct inlets. 4. Important! Flush through the hot and cold supplies thoroughly before connection to mixing valve.

22 5. Connect inlet and outlet pipework, checking that the hot and cold supplies have been piped to the correct inlets, and check all connections are watertight. Refer to COMMISSIONING. COMMISSIONING Commissioning must be carried out in accordance with these instructions, and must be conducted by designated, qualified and competent personnel. Maximum Temperature The maximum blend temperature obtainable by the user should be limited, to prevent accidental selection of a temperature that is too hot. All Rada Thermostatic mixing valves are fully performance tested and the maximum temperature is pre-set to approximately 43 o C under ideal installation conditions at the factory. Site conditions and personal preference may dictate that the maximum temperature has to be re-set following installation. This mixing valve is provided with two methods of temperature setting, an adjustable temperature control knob which allows the user to select the blend temperature between ambient cold up to a pre-set maximum, or if considered more appropriate, a locked cap can be fitted, allowing no user adjustment. Maximum Temperature Setting Check that an adequate supply of hot water is available at the hot inlet of the mixing valve. The minimum temperature of the hot water must be at least o C above the desired blend, however during resetting this should be close to the typical storage maximum to offset the possibility of any blend shift due to fluctuating supply temperatures. Check that both inlet isolating valves are fully open. Temperatures should always be recorded using a thermometer with proven accuracy. For Adjustable Temperature:. Remove the temperature knob assembly (44 0) or locking cap (407 54) using 3 mm wrench key provided (refer Figure 6).. Pull off the temperature hub (407 8/9). 3. Rotate the spindle until required maximum blend temperature is obtained at discharge point (clockwise = decrease temperature). When resistance is felt do not use force to turn any further, as this can damage the internal parts.

23 4. Once the desired maximum blend temperature has been achieved, refit the hub without disturbing the spindle, positioning the hub such that the lug is against the side of the stop on the cartridge face, thus preventing anticlockwise rotation which could damage the internal mechanism (see Figure 7). Check that blend temperature has not altered. 5. Refit temperature knob so that the indicator on the metal knob is aligned to the left of the red markings (approximately in the 9 O'clock position). Maximum Temperature Setting Stop Hub 3 mm Spindle Locked Temperature Setting Hub 3 mm Figure 6 For Locked Temperature: (Initial setting). Remove the temperature knob assembly (44 0, see Figure 6) using 3 mm wrench key provided, and lever off body shroud, and discard. Retain the locking screw (65 87). (Resetting). Remove locking screw (65 87) using 3 mm wrench key provided, and pull off locking cap.. Pull off the temperature hub (407 8). 3

24 3. Rotate the spindle until required maximum blend temperature is obtained at discharge point (clockwise = decrease temperature). When resistance is felt do not use force to turn any further, as this can damage the internal parts. 4. Once the desired maximum blend temperature has been achieved, refit the hub without disturbing the spindle, positioning the hub such that the lug is against the side of the stop on the cartridge face, thus preventing anticlockwise rotation which could damage the internal mechanism (see Figure 6). Check that blend temperature has not altered. 5. Fit locking cap, engaging cap guides into body slots, and secure with locking screw. Commissioning Checks (Temperatures should always be recorded with a thermometer with proven accuracy). Check inlet pipework temperatures for correct function of checkvalves. Operate the outlet flow control and check:. Flow rate is sufficient for purpose.. Temperature(s) obtainable are acceptable. 3. All connections and mixer body are water tight. It is advisable to establish a performance check at this time, which should be noted for future reference as part of a Planned Maintenance Programme (a Maintenance Record Card has been provided with this Manual). The procedure should be chosen to imitate both typical and difficult operating conditions, such as any supply pressure fluctuations that may be likely. An ideal method is to locate another outlet on the common cold water supply close to the mixing valve (operating this outlet should cause a drop in supply pressure), and note the subsequent effect on blend temperature (should be no more than o C change). OPERATION For models with standard temperature knob fitted, adjustment of blend temperature from preset maximum to cold is achieved by clockwise rotation of the knob. For models with locked temperature control, no user adjustment is intended. Control of flow is via separate outlet valve(s), refer to SPECIFICATION. 4

25 Symptom. Only hot or cold water from outlet.. Fluctuating or reduced flow rate. 3. No flow from mixing valve outlet. 4. Blend temperature drift. 5. Hot water in cold supply or vice versa. 6. Maximum blend temperature setting too hot or too cool. 7. Water leaking from valve body. FAULT DIAGNOSIS Cause/Rectification a. Inlet supplies reversed (i.e. hot supply to cold inlet). Check. b. No hot water reaching mixing valve. Check c. Check strainers and inlet/outlet fittings for blockage. d. Refer to symptom 5 below. e. Installation conditions continuously outside operating parameters: refer to SPECIFICATION and e below. Normal function of mixing valve when operating conditions are unsatisfactory. a. Check strainers and inlet/outlet fittings for flow restriction. b. Assure that minimum flow rate is sufficient for supply conditions. c. Assure that dynamic inlet pressures are nominally balanced. d. Assure that inlet temperature differentials are sufficient. e. (subsequent to rectification of supply conditions) Check thermostatic performance; renew Radatherm cartridge if necessary. a. Check strainers and inlet/outlet fittings for blockage. b. Hot or cold supply failure; thermostat holding correct shut-down function: rectify, and return to e above. Indicates operating conditions changed. a. Refer to symptom above. b. Hot supply temperature fluctuation. c. Supply pressure fluctuation. Indicates checkvalves require maintenance, refer to MAINTENANCE. a. Indicates incorrect maximum temperature setting; refer to COMMISSIONING. b. As symptom 4 above. c. As symptom 5 above. Seal(s) worn or damaged. Obtain Service Pack (408 9)/(408 87), and renew all seals(if leak persists from around temperature spindle). Renew Radatherm cartridge. 5

26 General MAINTENANCE Rada products are precision-engineered and should give continued superior and safe performance, provided:. They are installed, commissioned, operated and maintained in accordance with the recommendations stated in this Product Manual.. Periodic attention is given as necessary to maintain the product and its associated installation components in good functional order. Guidelines for frequency are given below. All the mixing valves in this series have all functional parts (except the temperature or locking knob) contained within service-free cartridges, so any maintenance requirement is reduced to temperature, performance and functional checks and inspection, with cartridge renewal when necessary. In larger installations with a number of mixing valves, it is good policy to maintain a small stock of spare cartridges so that no mixing valve or facility need be out of commission for more than the time it takes to exchange the cartridge, and also, eventually, a rolling programme of cartridge renewal can be undertaken as part of a planned maintenance procedure. The designed minimum service life of all cartridges used in our products is five years under normal operating conditions. However, when supply conditions and/or usage patterns do not conform to "normal operating conditions" the cartridge may need to be replaced more frequently (refer to page 6 for normal operating conditions). In all cases where users are deemed at risk, irrespective of supply or usage conditions or the evidence of any performance checks, the cartridge should be replaced at intervals of no more than three years. It is recommended that the user maintains a log of all periodic performance checks together with a record of any service work carried out and cartridge exchange details. The use of main supply-line or zone strainers (recommended maximum mesh aperture dimension is 0.5 mm) will reduce the need to remove debris at each mixing valve point. Rada Service Engineers/Agents will call by prior arrangement, if required. Service Contracts may be undertaken, subject to survey - details upon request. Planned Maintenance Programmes (Preventative/Precautionary Maintenance) The frequency and extent of attention required will vary according to prevailing site and operational conditions however, the following guideline schedule is suggested to cover average duty and site conditions: Six Monthly Blend Temperature: check for correct blend setting and/or maximum preset temperature. Re-set as necessary. 6

27 Performance: check blend stability against known datum (e.g. commissioning check) for an induced pressure or flow change. Renew Radatherm cartridge when necessary. Function: check inlet pipework temperature for correct function of checkvalves, and maintain/renew as necessary. Check and clean strainers as appropriate. Lubricate accessible seals when necessary using silicone-only based lubricant. Maintenance Procedures Maintenance must be carried out in accordance with these instructions, and must be conducted by designated, qualified and competent personnel. This mixing valve series is designed for minimal maintenance under conditions of normal use. External surfaces may be wiped clean with a soft cloth, and if necessary, a mild washing-up type detergent or soap solution can be used. Warning! Many household and industrial cleaning products contain mild abrasives and chemical concentrates, and should not be used on polished, chromed or plastic surfaces. Should an internal malfunction occur then this will probably require cartridge renewal. The Radatherm and checkvalve cartridges contain no user-serviceable parts, and must not be dismantled. Components are precision-made, so care must be taken while servicing to avoid damage. Component compatibility note: many Rada 5 series components are directly interchangeable with Rada Exact series; this should assist Maintenance Departments holding Spares stocks. Refer to Recommended Spares Minimum Stock List. When ordering spare parts, please state product type, i.e. Rada 5 or, and identify part name and number (refer to PARTS LIST). A Service pack is available, containing all the seals and strainer screens that may be necessary for renewal during maintenance or servicing (part no or 408 9). 5 bc Figure 7 7

28 Lubricants Important: Use silicone-only based lubricants on this product. Do not use oilbased or other lubricant types as these may cause rapid deterioration of seals. Standard silicone-only based lubricants may be used on all static seals, and threads, to assist re-fitting (e.g. Rocol MX). Maintenance Procedure - Radatherm cartridge Removal. Isolate the supplies to the mixing valve, and open an outlet fitting to release pressure and to assist the draining of residual water.. Remove the temperature knob assembly (44 0) or locking cap (407 54) using 3 mm wrench key provided (refer to Figure 6). Do not remove the temperature hub. 3. (Built-in models). Carefully lever off the concealing plate (408 76) by inserting a medium slotted screwdriver blade under each corner, refer to Figure With removal clip still in place, unscrew the head nut using 35 mm A/F wrench; this will release the body shroud and also begin to draw the Radatherm cartridge out of the body (refer to Figure 8). Warning! Some residual water may be released. Note which inlet aligns with the hot (marked H and red) lug on cartridge. Pull the Radatherm cartridge free of the valve body. Removal Clip (in place) Head Nut 35 mm Radatherm Cartridge Removal Figure 8 8

29 Cleaning/Renewal of Parts 5. The interior surface of the mixing valve body must be clean before re-fitting cartridge. If scale or deposition is present clean (without Radatherm and checkvalve cartridges fitted) using a mild proprietary inhibited scale solvent, e.g. domestic kettle descalent. After descaling, rinse valve interior thoroughly in clean water before refitting cartridges. Note! The body interior must be cleaned carefully and not damaged in any way. Do not use any abrasive material. 6. Cartridges may only be cleaned by flushing through under a jet of clean water to remove lodged particles. Do not descale. Cartridges are not serviceable, and must not be dismantled. Cartridges cannot be tested individually, service condition should be assessed as part of the performance check; refer to COMMISSIONING CHECKS. 7. When renewing Radatherm cartridge, retain removal clip (407 6) and head nut (407 64) off the displaced unit and re-fit. Note! The Radatherm cartridge differs for 5 and models; check that the colour-coded locking ring at the cartridge base is the same when renewing. The colour-coding is: 5 - black, - yellow. 8. Examine all accessible seals for signs of deformation or damage, and renew as necessary, taking care not to damage seal grooves (a Service Pack is available, containing all seals and strainer screens that may be necessary for renewal during maintenance or servicing, part no /87). 9. Lightly coat all seals with a silicone-only based lubricant to assist re-assembling (see Lubricants). Thermoscopic Unit Inlet Port Seals Body Seal Locking Ring (5 series - black dk - yellow) Hub (5 series - black dk - yellow) Location Lug () Radatherm Cartridge Figure 9 9

30 Re-assembly 0. Identify which is the hot inlet to the mixing valve body, and align the Radatherm cartridge accordingly. Carefully push the Radatherm cartridge back into the valve body, checking that the cartridge inlet port seals remain in place (refer to Figure 0), and locate cartridge lugs into body slots.. Carefully align and then tighten the head nut; do not over-tighten (max. torque.5 N/m =.85 lbf. ft). (Built-in models: re-fit the concealing plate).. Align and refit the body shroud and temperature knob assembly/locking cap so that the markings will be visible to the user. 3. Restore hot and cold supplies and check for any leaks. 4. The temperature will now need re-setting; refer to COMMISSIONING. Maintenance Procedure - Checkvalve cartridges Hot water entering the cold supply, or vice versa, indicates that immediate attention is necessary. This is carried out by removing and cleaning, or renewing as necessary, the two Checkvalve cartridges.. Isolate the supplies to mixing valve, and open an outlet fitting to release pressure and to assist the draining of residual water.. Location and removal of Checkvalve cartridges varies according to valve model: 5-t3 c 5-t3 bc 5-t3 zc 4 mm mm mm 5dk/5-t3 dk/5-t3 oem dk/-t3 dk mm 30 mm Checkvalve Cartridges Figure 0 30

31 5-t3 c; The Checkvalve cartridges are located in each elbow, to remove undo the Checkvalve cartridge head hexagon using 4 mm A/F wrench and pull free. 5-t3 bc; The Checkvalve cartridges are located in each elbow. To remove, first remove the temperature knob and carefully lever off the concealing plate (408 76) by inserting a medium slotted screwdriver blade under each corner refer to Figure 7. Then undo the Checkvalve cartridge head hexagon using mm A/F hexagon wrench and pull free. 5-t3 zc; The Checkvalve cartridges are located at the inlet of each elbow. To remove, first release the outlet connection, then release the mixing valve body from the offset connectors using 3 mm wrench and release the Checkvalve cartridges using mm A/F hexagon wrench. 5-t3 dk/5dk/5-t3 oem; The Checkvalve cartridges are located at the valve body inlets. To remove, first release the valve body from the inlet and outlet flatfaced connectors, then release the Checkvalve cartridges using mm A/F wrench. -t3 dk/dk; The Checkvalve cartridges are located at the valve body inlets. To remove, first release the valve body from the inlet and outlet flat-faced connectors, then release the Checkvalve cartridges using 30 mm A/F wrench. (Warning! Some water may be released at this point). 3. The Checkvalve cartridge assembly may be cleaned by removal of the inlet strainers (refer to Figure 0), and flushing through under a jet of water to remove lodged particles. The Checkvalve cartridge is not a serviceable item, so any apparent wear or damage will require its renewal. Lightly wipe external seals and thread with a silicone-only based lubricant to assist refitting. Re-assembly into the mixing valve is a reversal of the above procedures. Do not overtighten when re-inserting cartridges. Restore the water supplies and check for leaks. Maintenance Procedure - Inlet Strainers Blockage of the inlet strainer screens (08 90) can lead to poor flow performance and reduced temperature control. It is essential that the inlet strainer screens are cleaned or, if necessary, renewed as part of the six-monthly maintenance operations. A strainer pack is available for all 5 series models (408 9) containing strainer screens and all the seals (plus lubricant) and nylon washers which may need to be renewed during Strainer inspection (see component matrix). A similar range of components suitable for -t3 dk/dk is supplied in the Series Service and Strainer Pack (408 87). 3

32 . Isolate the supplies to mixing valve, and open an outlet fitting to release pressure and to assist the draining of residual water.. The strainer screens are located at the inlet of each Checkvalve cartridge. To access the inlet strainer screens: 5-t3 c, 5-t3 bc; remove the Checkvalve cartridges as described in the previous section. 5-t3 dk, 5dk, 5-t3 oem, 5-t3 zc, -t3 dk, dk; remove the mixing valve body from its pipework connections. 3. The strainer screens are dished outwards and are a push-fit into the housing. Remove carefully, using a sharp-pointed implement. 4. The strainer screens may be cleaned under a jet of water, or renewed. 5. Re-assembly into the mixing valve is a reversal of the above procedures. Do not over-tighten when re-inserting cartridges. 6. Restore the water supplies and check for leaks. Maintenance Procedure - Elbow/Body Seals Some models have inlet/outlet adaptor, elbow and elbow adaptor seals (ref and 630 4) which are static and should rarely require renewal. These seals are included in the Service Pack (408 9) and may be accessed if necessary:. Isolate the supplies to the mixing valve, and open an outlet fitting to release pressure and to assist the draining of residual water.. Release inlet and outlet connections. 5-t3 bc model: the mixing valve body will require removal from recess or panel mountings, refer Installation Procedures. 3. Remove elbows by loosening each elbow grub screw (68 ) using.5 mm wrench key provided. 4. Remove adaptors ( and/or ) using mm wrench key. 5. Lightly coat seals with a silicone-only based lubricant to assist re-assembly. 6. When re-inserting adaptors, do not over-tighten. 7. Refit and remake pipework connections, restore hot and cold supplies and check for any leaks. 3

33 D t3 c C, B C, B C C, B C C, B C C C C C D 33

34 5-t3 bc D E E E , C 63 6, C 63 6, C , C E , C 636 0, C 575 D 68, C C C , C , BC E (408 74) , C 34

35 5 dk/5-t3 dk dk/-t3 dk A, B, C A, B, C 63 3 A, B, C A, B, C C C

36 5-t3 oem A, B, C C C

37 5-t3 zc C C, B C, B C C, B 68 C , C C C C C D 37

38 Parts List Pipe concealing plate; 5-t3 zc () - Accessory Pipe concealing plate; 5-t3 c () Inlet strainer screen; 5 series Removal clip, black; 5 series Removal clip, yellow; series Hub, black; 5 series Hub, yellow; series Locking cap; 5dk Locking cap, dk Body; 5-t3 c Body; 5-t3 bc/oem Body; 5dk/5-t3 dk Body; 5-t3 zc Head nut; 5/ series Body; dk/-t3 dk Radatherm cartridge assembly, yellow; -t3 dk Radatherm cartridge assembly, black; 5 series Strainer screen, series () Elbow adaptor, 5-t3 c/bc, 5-t3 zc () Elbow RH; 5-t3 bc Elbow LH; 5-t3 bc Mounting bracket; 5-t3 bc Building-in shroud; 5-t3 bc Foam seal; 5-t3 bc Outlet plug: 5-t3 zc Locking cap; 5-t3 dk Locking cap, -t3 dk Elbow; 5-t3 c () Flat-faced insert, 5 mm; 5-t3 c/bc/oem (3), 5-t3 zc (outlet only) Checkvalve cartridge assembly; 5-t3 c () Backplate, 5-t3 c Comp pack; 5-t3 c, 5-t3 bc - components identified 'D' Checkvalve cartridge; 5-t3 bc () Concealing plate assembly; 5-t3 bc Concealing plate bracket assembly; 5-t3 bc Bracket component pack; 5-t3 bc - components identified 'E' Elbow; 5-t3 zc () Checkvalve cartridge - 5-t3 zc () Checkvalve cartridge - 5dk/5-t3 dk/5-t3 oem () Connector, elbow - 5mm; 5-t3 dk () Connector, straight - 5mm; 5-t3 dk () Checkvalve cartridge; series () Connector, elbow - mm, -t3 dk () Connector, straight - mm, -t3 dk () Service and strainer pack; series - components identified 'A' Inlet/outlet adaptor; 5c (3), 5-t3 bc, 5-t3 oem, 5-t3 zc (outlet only) Strainer pack; 5 series - components identified 'B' Service pack; 5 series - components identified 'C' Radatherm cartridge assembly, yellow, dk 44 0 Temperature knob assembly, chrome; 5-t3 c/bc/zc 38

39 54 0 Olive, 5mm; 5-t3 c (3), 5-t3 zc (outlet only) Offset connector; 5-t3 zc () - Accessory Wrench key, 3 mm 575 Wrench key,.5 mm 5-t3 c, 5-t3 bc/oem Screws() 5-t3 bc Locking screw, uses 3 mm wrench key 66 5 Screw 30mm; 5-t3 bc 68 Grub screw Compression nut, 5 mm, chrome; 5-t3 c (3), 5-t3 zc (outlet only) 64 9 Captive nut, chrome; 5-t3 zc () 66 6 Nut 30mm; 5-t3 bc O seal; 5-t3c, 5-t3 bc, 5-t3 zc O seal; 5-t3c, 5-t3 bc, 5-t3 zc 63 6 O seal 5-t3 dk/oem/c/bc, 5dk,dk, -t3 dk Nylon washer; 5-t3 c/bc/dk, 5dk (3), 5-t3 zc (outlet only) 636 Nylon washer; dk/-t3dk (3) 64 0 Washer; 5-t3 bc Washer; 5-t3 bc 93 9 Offset connector pack Lubricant sachet Kohler Mira has a policy of continual product development and parts illustrated may not be identical to those supplied. 39

40 Recommended Spares Minimum Stock List Component spares per quantity of mixing valves installed Radatherm cartridge - 5 series Radatherm cartridge - series Service pack - 5 series Strainer pack - 5 series Service and Strainer pack - dk/-t3 dk Locking screw, all models Checkvalve cartridge - 5-t3 c Checkvalve cartridge - 5-t3 bc Checkvalve cartridge - 5dk, 5-t3 dk, 5-t3 oem Checkvalve cartridge - dk/-t3 dk Rada 5 series: Strainer and Service Packs component matrix Part ref. Qty Part no. Component -t3 c -t3 zc -t3 bc -t3 oem -t3 dk dk Strainer Pack, 5 series x 4x 3x x x Strainer Screen Seal Nylon Washer 5mm Nylon Washer mm Lubricant Service Pack, 5 series x x x x x x 4x 5x 3x x x Strainer Screen Inlet Seal Seal Locking Screw Grubscrew Seal Seal Seal Nylon Washer 5mm Nylon Washer mm Lubricant 4 5 3* 3 * 4 3 3* 3* 3* 3* *Used for /" BSP inlet/outlet connections only Rada series: Service and Strainer Pack Component Matrix Part ref. Qty. Part no. Component Service and Strainer pack, dk/-t3 dk x x x x x 3x x 407 Seal Seal Strainer Screen Locking Screw 63 6 Seal 636 Nylon Washer Lubricant 40

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