Service Manual - support.kohler.com · This manual specifically covers the servicing of a Kohler digital thermostatic valve (DTV). The manual includes The manual includes general

1043877-X1-B ©2007 Kohler Co.

Service ManualSix-Port Thermostatic Valve

and Digital Interface

K-682

K-683, K-685

K-684, K-686

Service Manual

1043877-X1-B ©2007 Kohler Co.

Kohler Co. i 1043877-X1-B

Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1-1

Manual Scope - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 1-1Manual Arrangement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 1-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2-1Safety Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 2-1Hazard Classifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 2-1Safety Standards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 2-1Authorized Service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 2-2Obtaining Service Parts- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 2-2Special Tools Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 2-2Glossary of Terms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 2-3

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3-1Description- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 3-1

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4-1Digital Thermostatic Valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 4-1DTV Parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 4-2DTV Parts By Service Kit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 4-3DTV Parts By Service Kit Cont. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 4-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5-1Isolating the Problem - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 5-1User Interface Error Code Diagnosis - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 5-7

Access Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6-1Disassemble the Cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 6-1Disconnect the Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 6-1Disconnect the Wiring Looms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 6-2Disassemble the Valve Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 6-2

Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7-1Clean the Inlet Screens- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-1Check Valve / Inlet Clamp Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-2Outlet Adapter / Outlet Clamp Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-3Cable Cover Replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-4Case Insert Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-5Circuit Board Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-6Solenoid Wiring Loom Replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-7Solenoid Wiring Loom Replacement Cont. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-8Motor Wiring Loom Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-9Thermistor Wiring Loom Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-10Motor Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-11Internal Clamp Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-12Internal Clamp Replacement Cont.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-13Solenoid Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-14Solenoid Replacement Cont. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-15

Table of Contents

1043877-X1-B ii Kohler Co.

Inlet Clamp and Mixer Valve Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-16Inlet Clamp and Mixer Valve Replacement Cont. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-17Interface Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-18Interface Replacement/Reinstallation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-18Interface Cable Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 7-19

Wiring and Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8-1General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 8-1DTV Internal Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 8-1Solenoid Wiring Loom - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Page 8-2

Kohler Co. Page 1-1 1043877-X1-B

IntroductionMANUAL SCOPEThis manual specifically covers the servicing of a Kohler digital thermostatic valve (DTV). The manual includesgeneral information, operational theories, and troubleshooting service procedures.

MANUAL ARRANGEMENT The material in each section is divided into frames. Each frame includes a text column on the left side and anycorresponding illustrations on the right side. Each frame has a number that is referenced whenever the informationwithin that frame is needed in this manual.

The information in this manual is divided into eight sections, and is presented in the following order:

Section 1. Introduction

Section 2. General Information

Section 3. Theory of Operation

Section 4. Parts Identification

Section 5. Troubleshooting

Section 6. Access Procedures

Section 7. Service Procedures

Section 8. Wiring Schematic

Introduction

1043877-X1-B Page 1-2 Kohler Co.


General InformationSAFETY REQUIREMENTSPersonal safety should be your primary concern when maintenance or service operations are performed on a Kohlerdigital thermostatic valve (DTV). As such, these general safety requirements should be heeded at all times:

• All electrical work should be performed by a qualified electrician or Kohler Authorized Service Representative(ASR).

• When servicing electrical components or any portion of the system where high voltages may beencountered, be sure the power to the DTV is turned OFF. When the power must be turned on for voltagemeasurements, for example, use extreme caution.

• No unauthorized modifications or alterations should ever be made to a Kohler DTV.

WARNING: Electrical shock can cause severe injury or death to the user and/or service personnel.

• Kohler Co. will not assume responsibility for product performance or safety where replacement componentsor parts other than Genuine Kohler Replacement Parts or authorized alternates are used. Should anydeviation be noted that would indicate unauthorized modification, Kohler Co. recommends you contact theCustomer Service Department for clarification.

• The instructions, drawings, and diagrams contained in this manual present information available at the timeof printing. Although every attempt has been made to keep them up-to-date, Kohler Co. reserves the right toimplement product changes without further notice.

Frame 2-1

HAZARD CLASSIFICATIONSAdditional safety information is provided throughout this manual. A series of signal words is used to draw immediateattention to this important information. To ensure your protection, pay careful attention to all these safety notices. Thefollowing signal words will be found throughout this manual:

DANGER: Indicates the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored. This includes hazards which will cause external leaks.

WARNING: Indicates the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored. This includes hazards which can cause external leaks.

CAUTION: Indicates the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored. This includes hazards which may cause internal leaks.

IMPORTANT! Indicates maintenance or service information which is helpful but not hazard related.

Frame 2-2

SAFETY STANDARDSA Kohler digital thermostatic valve (DTV) is designed and manufactured to meet or exceed all current industry safetystandards. The electrical components for all DTVs are individually tested before leaving the factory. The DTV andinterface system(s) are UL and CSA listed. The DTV and interface system(s) comply with Part 15 of the FCC rules,ASSE 1016 CSA, B125.1, and ASME A112.18.1.

Frame 2-3

General Information


AUTHORIZED SERVICEService should be performed by a Kohler ASR. Should any deviation be noted that would indicate that unauthorizedmodifications or alterations have been made, Kohler recommends that you contact their Customer ServiceDepartment for clarification.

Kohler CompanyAttn: Customer Service DepartmentKohler, WI 53044 U.S.A.(920) 457-4441 or1-800-4-KOHLER.

Frame 2-4

OBTAINING SERVICE PARTSTo obtain service parts, refer to the service parts page for the product you are servicing. If you are unable to find theparts you need, or need additional information, contact:

Kohler CompanyAttn: Customer Service DepartmentKohler, Wisconsin 530441-800-4-KOHLERwww.serviceparts.kohler.com

If you need service parts pricing information or a quotation, please contact: the Kohler Company at 1-800-4-KOHLER.

Frame 2-5

SPECIAL TOOLS REQUIREDIn general, you will only need commonly used tools to service a Kohler DTV. You will also need T15 and T20 torxwrenches.

Frame 2-6


GLOSSARY OF TERMSACCESS PROCEDURES: Procedures generally limited to the removal and installation of parts or components forone of several reasons:

• to replace them with new items or assemblies• to permit further disassembly of the items• to gain access to another item or assembly

ADJUST: To alter, modify, or bring within required tolerances the components of an assembly to correct or improveperformance or fit.

ASSEMBLE: To restore a disassembled component to its assembled state; generally replacing worn or damagedparts in the process.

CONNECT: Join or plug wiring or tubing into a mating terminal, connector, or pipe.

DISASSEMBLE: To remove parts from an assembled component to repair that component.

DISCONNECT: Separate wiring or tubing from mating terminal, connector, or pipe.

ENVIRONMENTAL FACTORS: Non-system elements that affect the operation of the fixture.

REINSTALL: To install the same part that has been removed.

REPLACE: To install a new part in place of the one removed.

REMOVAL: To remove a part or component for one of several reasons:

• to replace it with a new item or assembly • to permit further disassembly of the item • to gain access to another item or assembly

SERVICE PROCEDURE: Component disassembly and reassembly instructions. Generally intended for repairing adamaged or defective component.

Frame 2-7

General Information



Theory of OperationDESCRIPTIONThe digital thermostatic valve (DTV) is controlled by either a master or auxiliary user interface (UI). Power is suppliedto both DTV and UI via a 12 V power supply. The power supply is plugged into a standard 120 V GFCI outlet. Hot andcold water enters the DTV through ¾" NPT inlets. The water is then mixed by a stepper motor that moves a shuttle toincrease or decrease the flow of hot or cold water. The microcontroller, located on the printed circuit board (PCB),controls the stepper motor shuttle. A thermistor monitors the outlet water temperature and provides information to themicrocontroller. The microcontroller then maintains the desired temperature and makes any adjustments neededbased on the thermistor feedback. The water outlets are regulated by six independent solenoid valves which arecontrolled by the UI.

Frame 3-1

Theory of Operation



Parts IdentificationDIGITAL THERMOSTATIC VALVE

Frame 4-1

Motor

Mixer Valve

Themistor Wiring Loom

Solenoid Wiring Loom

Motor Wiring Loom

Outlet Clamp

Circuit Board

Intenal Clamp

Solenoid

Inlet Clamp

Inlet Connection

Case Cover

Mini Circuit Board

Case Cover Screw

Grommets

Grommets Outlet Connection

Parts Identification


DTV PARTS

Frame 4-2

Power Supply

Clip

Internal Clamp

Cover

Circuit BoardCover Seal

Outlet Case Insert

Inlet Case Insert

Seal

Solenoid

Solenoid O-RingAdapter O-Ring

Check Valve O-Ring

O-Ring

Cap

Mixer Valve

Strainer

Adapter (1/2" NPT)

Cover Screw

Clamp Screw

Inlet Screw

Grommet

Grommet

Grommet

Thermistor Wiring Loom


Adapter (3/4" NPT)

Check Valve

Cartridge

Inlet Clamp Bottom

Outlet Clamp Bottom

Outlet Clamp Top

Inlet Clamp Top

Ferrite

Belt Motor

Outlet Screw

Motor Wiring Loom

Adapter O-Ring

8-Pin Cable Assembly

This page is for reference use only. Do not use this page for ordering parts.To obtain service parts refer to the homeowners guide packed with your product or visit the Kohler Service Parts Store online at www.kohlerserviceparts.kohler.com.


DTV PARTS BY SERVICE KIT

Frame 4-3

Cover

1052070Solenoid

1052072

1052071Circuit Board

1052073Solenoid Wiring Loom

1052074Motor

1052075Cable Cover

1052077Inlet Clamp

1052081Inlet Clamp and Adapters

1052076Motor Wiring Loom

Seal

Cap

Adapter O-Rings

Inlet Clamp Bottom

Inlet Clamp Top

Cover Screws

Cover Screws

Inlet Screws

Inlet Screws

Cover Screws

Cover Seal

Grommets Grommets Grommet


Adapter O-Rings Inlet Clamp Bottom

Inlet Clamp Top

Adapters (3/4" NPT)

Adapter O-Rings

Internal Clamps

Check Valves

Strainers

Cover and Clamp Screws

Circuit Board

Cover Screws

Inlet Screws

Cartridges

Solenoid O-Rings

Adapter O-Rings

Check Valve O-Rings

Cover Screws

Belt

Motor

Ferrite Motor Wiring Loom

Solenoid

Check Valves and Cartridges


Parts Identification


DTV PARTS BY SERVICE KIT CONT.

Frame 4-4

1052078Inlet Clamp and Mixer Valve

1052079

1052085Outlet Clamps

1052086Power Supply

Outlet Screw

Inlet Clamp Bottom

Inlet Clamp Top

Clip

Internal Clamps

Solenoid O-Ring

O-RingMixer Valve

Adapter O-Rings

1052082Outlet Adapters

Outlet Screw Adapter O-Rings

Adapters (1/2" NPT)

Outlet Clamp Bottom

Outlet Clamp Top

Outlet Clamp Bottom

Outlet Clamp Top

Inlet Screws Cover and Clamp Screws

Inlet Screws

Outlet Screws

Cover and Clamp ScrewsBelt

Adapter O-Rings

Solenoid O-RingsO-Ring

1052084Internal Clamps

Clamp ScrewInternal Clamps

Solenoid O-Ring

1052080Thermistor Wiring Loom

1052083Plates

Clip

O-Ring

Cover Screws

Thermistor Wiring Loom Outlet Case Insert

Inlet Case Insert

Seals and Screws

8-Pin Cable Assembly1045251



TroubleshootingISOLATING THE PROBLEMThere are two steps for resolving a digital thermostatic valve (DTV) malfunction:

Troubleshooting Tables

1. Use the Troubleshooting and Error Code Tables to isolate the malfunction.

Troubleshooting Procedures

2. Whenever you repair, replace, or adjust any components or assemblies of a DTV, always check that the problemhas been solved, and that no other problems exist. If the valve works correctly when reinstalled and retested,discontinue troubleshooting.

Frame 5-1

Troubleshooting


SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION REFERENCE

1. Control panel is not lit. A. Power supply is not plugged into the outlet.

A. Plug the power supply into the outlet.

A. None

B. Power supply connection to the valve may be loose or disconnected.

B. Check power supply connections to the valve and reconnect if needed.

B. None

C. Interface cable connections may be loose or disconnected.

C. Check all interface cable connections, connect if needed.

C. None

D. Circuit breaker has been tripped.

D. Reset the circuit breaker.

D. None

E. The valve memory may require resetting.

E. Disconnect and reconnect the power supply from the valve.

E. None

F. Interface cable is damaged.

F. Replace interface cables.

F. See Frame 7-20

G. Power supply is damaged.

G. Replace power supply. G. None

H. Circuit board is damaged.

H. Replace the circuit board.

H. See Frame 7-6

I. User interface is damaged.

I. Replace the user interface.

I. See Frame 7-18 See Frame 7-19

Frame 5-2

2. The control panel power indicator pulses but does not turn on.

A. Interface cable connections may be loose or disconnected.

A. Check all interface cable connections, connect if needed.

A. None

B. The valve memory may require resetting.

B. Disconnect and reconnect the power supply from the valve.

B. None

C. Interface cable is loose or damaged.

C. Replace interface cables.

C. See Frame 7-20

D. Circuit board is damaged.

D. Replace the circuit board.

D. See Frame 7-6

E. User interface is damaged.

E. Replace the user interface.

E. See Frame 7-18 See Frame 7-19

Frame 5-3


3. Primary interface is lit, but Auxiliary interface is not



A. None

B. The valve memory may need resetting.


B. None

C. Interfaces may be at different software revision levels.

C. Enter the “About” screen on present functional primary user interface and record version number. Unplug present primary user interface and replace with accessory user interface. Attempt to activate shower. If shower functions, enter the “About” screen and record version number. If the two version numbers do not match, or the shower does not function, replace accessory interface with an interface at same version level as primary interface.

C. See Frame 7-18 See Frame 7-19

D. Auxiliary interface cable is damaged.

D. Replace auxiliary interface cables.

D. See Frame 7-20

E. Primary user interface cable is damaged.

E. Replace primary user interface cable.

E. See Frame 7-20

F. Auxiliary interface is damaged.

F. Replace auxiliary interface.

F. See Frame 7-18 See Frame 7-19

G. Primary user interface is damaged.

G. Replace primary user interface.

G. See Frame 7-18 See Frame 7-19

H. Valve circuit board is damaged.

H. Replace the valve circuit board.

H. See Frame 7-6

Frame 5-4

4. Auxiliary interface power indicator pulses, but primary interface's does not.



A. See Frame 6-2

B. The valve memory may need resetting.


B. See Frame 6-2

C. Primary user interface cable is damaged.

C. Replace primary user interface cable.

C. See Frame 7-20

D. Primary user interface is damaged.

D. Replace primary user interface.

D. See Frame 7-18 See Frame 7-19


Troubleshooting


E. Valve circuit board is damaged.

E. Replace the valve circuit board.

E. See Frame 7-6

Frame 5-5

5. Primary and auxiliary interface are lit, but auxiliary interface does not appear to function.

A. Lock-Out function is enabled.

A. Disable in setup mode. A. Refer to the “User Interface Homeowners Guide.”

Frame 5-6

6. Display is difficult to read.

A. Contrast is not optimized.

A. Adjust contrast in the user interface setting menu.

A. Refer to the “User Interface Homeowners Guide.”

B. Brightness is not optimized.

B. Adjust the brightness in the user interface setting menu.

B. Refer to the “User Interface Homeowners Guide.”

Frame 5-7

7. The interface functions normally but no water flows from the outlets.

A. Inlet/outlet fittings may be blocked.

A. Check the inlets and outlets for blockage or debris.

A. See Frame 7-1

B. Hot and cold water supplies are not turned on.

B. Turn on the water supply to the valve.

B. None

C. Outlets not configured correctly in custom configuration.

C. Check to make sure the outlet is turned on.

C. Refer to the “User Interface Homeowners Guide.”

D. The valve memory may require resetting.

D. Disconnect and reconnect the power supply from the electrical outlet.

D. None

E. System error. E. Check the user interface for an error code.

E. Refer to the “User Interface Homeowners Guide.”

F. Solenoid wiring loom loose.

F. Check wiring loom connections.

F. See Frame 7-7See Frame 7-8

Frame 5-8

8. Only cold water from the outlets.

A. Hot water supply is either not turned on or not connected to the valve inlet.

A. Check if the hot water supply is turned on and connected to the valve inlet.

A. None

B. Hot water inlet is blocked.

B. Check the hot water inlet screen for blockage. Clean or replace the inlet screen.

B. See Frame 7-1See Frame 7-2

Frame 5-9



9. Fluctuating or reduced flow rate. Valve is functioning properly.

A. Inlet/outlet fittings may be blocked.

A. Check the inlets and outlets for blockage or debris. Clean the inlet screens.

A. See Frame 7-1

B. Water outlet pressure is low.

B. Check that the flow rate is at or above the minimum rate required.

B. Refer to the “Specifications” section in the valve homeguide.

C. Fluctuating flow. C. Verify that the dynamic inlet pressures are within specifications.

C. Refer to the “Specifications” section in the valve homeguide.

Frame 5-10

10. Blend temperature drift or temperature cycling.

A. Fluctuating water temperature.

A. Check the inlet temperature differentials and verify they are sufficient.

A. Refer to the “Specifications” section in the valve homeguide.

B. Hot water supply temperature fluctuation.

B. Check and make adjustments as needed.

B. None

C. Pressure difference greater than 5 psi (34.5 kPa) between the hot and cold supply lines.

C. Install pressure regulators to bring supply lines within 5 psi (34.5 kPa) of each other.

C. None

Frame 5-11

11. Maximum blend temperature too hot or too cold.

A. Incorrect maximum temperature setting.

A. Set the maximum temperature setting as desired using the user interface.


Frame 5-12

12. Continuous flow. A. Flow continues out of one or more outlets after switching power off.

A. Replace the malfunctioning solenoid pair.

A. See Frame 7-14

Frame 5-13

13. Water leaking from the valve. CAUTION: Risk of personal injury or product damage. Turn off the main power and water supply.

A. Connections not secure.

A. Check all connections. Make adjustments as needed.

A. None

B. Seals are worn or damaged.

B. Order a seal service pack and replace all seals.

B. See Frame 4-2 See Frame 4-4

C. Internal leak. C. Unit requires overhaul. Contact your authorized Kohler service representative.

C. None


Troubleshooting


Frame 5-14

14. Massage mode shuts down but water continues to run from the outlets.

A. Unequal flow rates between valve outlets.

A. Revise installation to have one bodyspray per valve outlet. Use bodysprays with the same flow rate.

A. Contact the installer.

B. Fluctuation of the inlet water pressure.

B. Install pressure regulators in the supply lines.

B. None

C. Pressure difference greater than 5 psi (34.5 kPa) between the hot and cold supplies.

C. Install pressure regulators to bring supply lines within 5 psi (34.5 kPa) of each other.

C. None

Frame 5-15

15. Hot water only, then the valve shuts down.

A. Hot and cold lines are reversed.

A. Switch hot and cold water supply connections. Verify the hot water supply is connected to the inlet marked “H” and the cold water supply is connected to the inlet marked “C.”

A. None

Frame 5-16

16. Massage and temperature therapy does not work.

A. Massage and temperature therapy functions are not enabled.

A. Enable the massage and temperature therapy functions using the User Interface.


Frame 5-17



USER INTERFACE ERROR CODE DIAGNOSIS

ERRORCODE

ERROR DESCRIPTION POSSIBLE CAUSE CORRECTIVE ACTION REFERENCE

003 Outlet temperature is too high or control thermistor fault.

A. The inlet/outlet fittings may be blocked.


A. See Frame 7-1

B. Cold water supply failure.

B. Reinstate the cold water supply.

B. None

C. Safety circuit may require resetting.

C. Press the OK switch when on the shower screen.

C. None

D. Thermistor is damaged.

D. Replace the thermistor.

D. See Frame 7-10



E. See Frame 7-6

Frame 5-18

004 Open circuit thermistor detected.

A. Thermistor is damaged.

A. Replace the thermistor.

A. See Frame 7-10

B. Valve circuit board is damaged.

B. Replace the valve circuit board.

B. See Frame 7-6

Frame 5-19

007 Outlet temperature is too high or outlet thermistor fault.

A. The inlet/outlet fittings may be blocked.


A. See Frame 7-1

B. Cold water supply failure.

B. Reinstate the cold water supply.

B. None

C. Safety circuit may require resetting.

C. Press the OK switch when in the shower screen.

C. None

D. Thermistor is damaged.

D. Replace the thermistor.

D. See Frame 7-10



E. See Frame 7-6

Frame 5-20

036 Safety relay fault or thermistor.

A. Safety circuit may require resetting.

A. Unplug the valve power supply from the electrical outlet, wait 10 seconds, and plug it back in.

A. None

B. Thermistor is damaged.

B. Replace the thermistor.

B. See Frame 7-10

C. Valve circuit board is damaged.

C. Replace the valve circuit board.

C. See Frame 7-6

Troubleshooting


Frame 5-21

060 The stepper motor is temporarily stuck.

A. Hot water supply temperature is too hot.

A. Reduce the temperature setting on your hot water heater to approximately 125°F (52°C).

A. None

B. The system needs to be reset.

B. To reset the error, press the OK switch when in the shower screen.

B. None

Frame 5-22

061 Motor stuck (attempted to clear) or mixer assembly is jammed

A. Hot water supply temperature is too hot.

A. Reduce the temperature setting on your hot water heater to approximately 125°F (52°C).

A. None

B. Belt is damaged. B. Examine condition of belt. Replace belt if damaged.

B. See Frame 7-11

C. Valve assembly may be damaged.

C. Manually turn valve pulley in both directions. If it does not turn easily, or resistance is felt, replace valve assembly.

C. See Frame 7-16 See Frame 7-17

D. Motor wiring loom is damaged.

D. Replace the stepper motor wiring loom.

D. See Frame 7-9

E. Stepper motor is damaged.

E. Replace the stepper motor.

E. See Frame 7-11

F. Valve circuit board is damaged.

F. Replace the valve circuit board.

F. See Frame 7-6

Frame 5-23

All Other Codes

A fault has occurred on the valve circuit board.

A. Memory requires resetting.

A. Unplug the valve power supply from the electrical outlet, wait 10 seconds, and plug it back in.

A. None

B. If the symptom has not been rectified by resetting the memory, the valve circuit board is damaged.

B. Replace the valve circuit board.

B. See Frame 7-6

Frame 5-24

ERRORCODE

ERROR DESCRIPTION POSSIBLE CAUSE CORRECTIVE ACTION REFERENCE


Access ProceduresDISASSEMBLE THE COVER

1. Unplug the power supply from the wall and turn off the water supply.

2. If needed, disconnect the inlet and outlet connections from the valve assembly using an adjustable wrench.

3. Using the torx driver, remove the five screws from the case cover.

Frame 6-1

DISCONNECT THE CABLES


2. To disconnect the cables from the valve, press and hold down the tab while gently pulling the connector free.

Frame 6-2

Cover Screw

Case Cover

Power Supply

Outlet Connection

Inlet Connection

Power Supply

TabAuxilliary interface

Primary Interface

Access Procedures


DISCONNECT THE WIRING LOOMS

1. Remove the case cover and inserts.

2. Disconnect the three wiring looms from the circuit board; press and hold down the tabs while gently pulling eachof the connectors free. Gently remove the grommets from the box.

Frame 6-3

DISASSEMBLE THE VALVE UNIT

1. Using the T15 torx driver, remove the four internal clamp screws.

2. Lift out the valve assembly from the case.

Frame 6-4

Case Inserts

Grommet

Circuit Board

Wiring Loom

Connector Tab

Internal Clamp Screws

Internal Clamp

Valve Assembly


Service ProceduresCLEAN THE INLET SCREENS

1. Disconnect the power and turn off the water supply.

2. Disconnect and remove the removable pipe segment.

3. Using a screwdriver, remove the inlet clamp screws.

4. Remove the inlet clamp.

5. Remove the adapters from the valve inlets.

6. Gently pull the check valves from the valve inlets.

7. Remove the screens from the check valves.

8. Clean the screens to remove any dirt or debris.

9. Rinse or replace the check valves and screens.

10. Reassemble the inlet connections.

Frame 7-1

O-Ring

Screw

ScreenCheck Valve

Adapter

Union Connection

Removable Pipe Segment

Inlet Clamp

Service Procedures


CHECK VALVE / INLET CLAMP REPLACEMENT


2. Disconnect the inlet connections from the valve assembly using an adjustable wrench.

3. Using the screwdriver, remove the inlet clamp screws.

4. Remove the inlet clamp.


6. Gently pull the check valves from the valve inlets and discard.

7. Remove and discard the valve inlet O-rings.

8. Install the new O-rings.

9. Gently push a new check valve assembly into each of the valve inlets.

10. Insert the O-rings into the end of the adapter. Verify the O-rings are seated.

11. Reassemble the inlet connections using the new inlet clamp and inlet adapters, if supplied.

12. Connect the power supply and turn on the water supply.

13. Check for leaks.

Frame 7-2

O-Ring

Screw

Adapter

Inlet Clamp

Valve Inlet

O-Ring

Inlet Connection

Check Valve Assembly


OUTLET ADAPTER / OUTLET CLAMP REPLACEMENT


2. Disconnect the outlet connections from the valve assembly.

3. Using the screwdriver, remove the outlet clamp screw.

4. Remove the outlet clamp.

5. Remove the adapters from the valve outlets.

6. Remove and discard the valve outlet O-rings.

7. Install the new O-rings.

8. Reassemble the outlet connections using the new outlet clamp and outlet adapters if supplied.



Frame 7-3

Adapter

Valve Outlet

O-Ring

Outlet Clamp

Outlet Connection

Screw

Service Procedures


CABLE COVER REPLACEMENT

1. Unplug the power supply from the wall.

2. Turn off the water supply and remove the cover.

• Disassemble the CoverSee Frame 6-1

3. Remove the case cover seal located inside the cover and replace with the new seal. Discard the old seal.

4. Unlatch the cable cover, lift out and discard.

5. Set the new cable cover into the slots and snap closed.

6. Install the grommets into all unoccupied slots upon which the case cover seal will connect.

7. Install the case cover using the new screws provided.

8. Reconnect the power supply.

Frame 7-4

Cable Cover

Cover Seal

Slot

Slot

Grommet


CASE INSERT REPLACEMENT

1. Unplug the power supply from the wall and remove the cover.

• Disassemble the CoverSee Frame 6-1

2. Remove and discard the case inserts.

3. Install the new case inserts.

4. Reinstall the case cover using the new screws provided.

5. Reconnect the power supply.

Frame 7-5

Case Inserts

Service Procedures


CIRCUIT BOARD REPLACEMENT

CAUTION: Use caution, electrostatic discharge can damage electronic components.


2. Disconnect all cables from the valve; press and hold down the tab while gently pulling each connector free.

• Disconnect the Cables:See Frame 6-2

3. Remove the case cover.

• Disassemble the Cover:See Frame 6-1

4. Read and record the three digit calibration code found on the valve assembly label.

5. Disconnect the motor, solenoid, and thermistor wiring looms from the circuit board by gently pressing theconnector tabs.

• Disconnect the Wiring Looms:See Frame 6-3

6. Press on each end of the circuit board near the clasps and push the circuit board towards the inside of the case.

7. Remove and discard the old circuit board.

8. Place the new circuit board between the two grooves at the bottom of the case and tilt towards the outside of thecase until the board snaps into the clasps.

9. Connect the three wiring looms to the new circuit board.

10. Verify all connectors and grommets are secured.

• Digital Thermostatic Valve:See Frame 4-1

IMPORTANT! Position the wiring looms so that they are not pinched when the cover is secured.

11. Install the case inserts and cover using the new screws provided.

12. Connect the power supply and any remaining cables to the valve.

13. Turn on the water supply and check for leaks.

14. Enter the calibration code into the user interface. Path: Settings > Valve > Service > Activation Code (1012)

Frame 7-6

Press here.Circuit Board

Calibration Code

Clasp

Press here.


SOLENOID WIRING LOOM REPLACEMENT




3. Disconnect the solenoid wiring loom from the solenoids.

4. Disconnect the solenoid wiring loom from the circuit board; press and hold down the tab while gently pulling theconnector free. Gently remove the grommet from the box.

5. Discard the old solenoid wiring loom.

Frame 7-7

Solenoids

Circuit Board

Grommet

Solenoid Wiring Loom Connector Tab

Service Procedures


SOLENOID WIRING LOOM REPLACEMENT CONT.

6. Connect the new wiring loom to the solenoids and circuit board according to the Wiring Diagram.






11. Verify correct operation of outlets during the massage cycle.

Frame 7-8

BlackOutlet 1 White

BlackBlack

Brown

Outlet 2

Outlet 3

Outlet 4

Outlet 5

Outlet 6

BlackBlack

Violet

GreenRed

Red

RedYellowRed

Wiring Diagram

Orange Red


MOTOR WIRING LOOM REPLACEMENT




3. Disconnect the motor wiring loom from the circuit board; press and hold down the tab while gently pulling theconnector free. Gently remove the grommet from the box.

4. Disconnect the wiring loom from the motor.

5. Using the T20 torx driver, remove the screw securing the mini circuit board to the mixing valve.

6. Discard the old wiring loom.

7. Using the T20 torx driver, secure the new wiring loom mini circuit board to the mixing valve assembly. Do notovertighten.

8. Connect the new wiring loom to the motor and circuit board.






13. Turn on the system and verify the system is functioning properly.

Frame 7-9

Grommet

Screw

Mini Circuit Board

Circuit Board

Motor

Motor Wiring Loom

Connector Tab

Mixing Valve

Service Procedures


THERMISTOR WIRING LOOM REPLACEMENT




CAUTION: Valve may have high internal pressure. Use caution when removing the thermistor.

3. Disconnect the thermistor wiring loom from the circuit board; press and hold down the tab while gently pulling theconnector free. Gently remove the grommet from the box.

4. Remove the locking clip and remove the thermistor from the mixer valve housing.

5. Discard the old wiring loom.

NOTE: Replace thermistor O-ring if worn or leaking. The O-ring may remain in the mixer valve housing when the thermistor is removed.

6. Insert the new thermistor into the mixer valve housing and reinsert the clip.

IMPORTANT! When fully inserted, the locking clip will snap around the thermistor. Verify that the clip is secure or water leakage will occur.

7. Connect the new wiring loom to the circuit board.






Frame 7-10

Grommet

Locking Clip

O-Ring

Circuit Board

Thermistor Wiring Loom

Connector Tab

Mixer Valve

Thermistor


MOTOR REPLACEMENT




3. Remove the case inserts and disconnect the three wiring looms from the circuit board; press and hold down thetabs while gently pulling the connectors free. Gently remove the grommets from the box.


4. Remove the valve assembly from the case.

• Disassemble the Valve Unit:See Frame 6-4

5. Disconnect the motor wiring loom from the motor.

6. Slide the belt off the valve assembly and discard.

7. Remove and retain the four nuts securing the motor.

8. Remove and discard the old motor.

9. Secure the new motor to the bracket with the four nuts. Do not overtighten.

10. Install the new belt over the motor spindle and valve assembly.

11. Connect the motor wiring loom to the motor.

12. Place the valve unit into the case and secure with the four torx screws.

13. Connect the three wiring looms to the circuit board and verify all connectors and grommets are secured.



15. Reconnect the inlet and outlet connections.

16. Connect the power supply, turn on the water supply, and check for leaks.


Frame 7-11

Motor Wiring Loom

Valve Assembly

Loom Connection

Nut

Bracket

Motor

Belt

Grommet

Service Procedures


INTERNAL CLAMP REPLACEMENT








5. Using the torx driver, remove the four internal clamp screws.

6. Lift out the valve unit from the case.

7. Remove and discard the internal clamp and the O-ring.

Frame 7-12

O-Ring

Solenoid

Internal Clamp Cap


Internal Clamp Screw


INTERNAL CLAMP REPLACEMENT CONT.

8. Install the new O-ring.

9. Connect the solenoid to the valve assembly using the new internal clamp, making sure the lower part of theclamp will position itself over the screw hole. The screw holes alternate from one side of the solenoid to the other.Make sure the latch is fully engaged when assembled.

NOTE: If the solenoid being replaced is at the end of the solenoid chain, install a new end cap.


11. Connect the solenoid wiring loom to the solenoids.

12. Connect the three wiring looms to the circuit board.








Frame 7-13

BlackOutlet 1 White

BlackBlack

Brown

Outlet 2

Outlet 3

Outlet 4

Outlet 5

Outlet 6

BlackBlack

Violet

GreenRed

Red

RedYellowRed

Wiring Diagram

Orange Red

Service Procedures


SOLENOID REPLACEMENT








5. Using the torx driver, remove the four internal clamp screws.


7. Using the screwdriver, remove the outlet clamp screw of the solenoid being replaced.

8. Remove the outlet clamp by gently prying against the latches.

9. Remove the adapters from the valve outlets.

10. Remove and discard the valve outlet O-rings.

11. Disconnect the solenoid wiring loom from the solenoid being replaced.

12. Remove both internal clamps connecting the solenoid to the rest of the valve assembly.

13. Discard the old solenoid.

Frame 7-14

Outlet Clamp

Adapter

Screw

O-Ring

O-Ring

Solenoid


Internal Clamp



SOLENOID REPLACEMENT CONT.

14. Install the four new O-rings to the inlet and outlets of the new solenoid.

NOTE: The two smaller O-rings are used for the external outlet valves.

15. Reassemble the external outlet connections.

16. Connect the solenoid to the valve assembly using the internal clamps, making sure the lower part of the clampwill position itself over the screw hole. The screw holes alternate from one side of the solenoid to the other. Makesure the latch snaps in place before securing with screws.

IMPORTANT! Verify that the internal clamps snap into place securely.

NOTE: If the solenoid being replaced is at the end of the solenoid chain, install a new end cap.


18. Connect the solenoid wiring loom to the new solenoid.

19. Connect the three wiring looms to the circuit board.








Frame 7-15

BlackOutlet 1 White

BlackBlack

Brown

Outlet 2

Outlet 3

Outlet 4

Outlet 5

Outlet 6

BlackBlack

Violet

GreenRed

Red

RedYellowRed

Wiring Diagram

Orange Red

Service Procedures


INLET CLAMP AND MIXER VALVE REPLACEMENT




3. Remove the case inserts


4. Disconnect the solenoid wiring loom from the circuit board; press and hold down the tab while gently pulling theconnector free. Gently remove the grommet from the box.

5. Remove the locking clip and disconnect the thermistor from the mixing valve housing.

6. Using the T20 torx driver, remove the screw securing the mini circuit board to the mixing valve.

7. Disconnect the motor wiring loom from the motor.

8. Using the T15 torx driver, remove the four internal clamp screws.


Frame 7-16

Screw

Mini Circuit Board

Circuit Board

Motor

Mixing Valve

Thermistor


Grommet

Locking Clip

Connector Tab

Motor Wiring Loom


INLET CLAMP AND MIXER VALVE REPLACEMENT CONT.

10. Using the screwdriver, remove the inlet clamp and discard.


12. Remove the internal clamp and O-ring connecting the mixer valve to the solenoid. Discard the old mixer valve.

13. Install the new O-ring onto the solenoid.

14. Connect the new mixer valve to the solenoid using the new internal clamps, making sure the lower part of theclamp will position itself over the screw hole. The screw holes alternate from one side of the solenoid to the other.

IMPORTANT! Verify that the internal clamps snap into place securely.

15. Read and record the three digit calibration code found on the mixer valve label.


17. Connect the solenoid wiring loom to circuit board.

18. Using the T20 torx driver, secure the mini circuit board to the mixing valve assembly. Do not overtighten.

19. Connect the motor wiring loom to the motor.

20. Install the new thermistor O-ring to the thermistor.

21. Insert the thermistor into the mixer valve housing and reinsert the clip.

IMPORTANT! When fully inserted, the locking clip will snap around the thermistor. Verify that the clip is secure or water leakage will occur.




24. Reinstall the inlet adapters using the new inlet clamp.


26. Connect the power supply, turn on the water supply, and check for leaks.


28. Enter the calibration code into the user interface. Path: Settings > Valve > Service > Activation Code (1012)

Frame 7-17


Screw

Inlet ClampAdapter

Valve Inlet

O-Ring

Internal Clamp

Solenoid

Mixer Valve

Calibration Code

Service Procedures


INTERFACE REMOVAL

1. Secure the suction cup to the smooth portion of the interface.

2. Firmly pull the suction cup removing the interface from the wall sleeve.

3. Disconnect the interface from the interface cable by pulling the cable collar in the opposite direction of the arrow.If replacing, discard the old interface.

Frame 7-18

INTERFACE REPLACEMENT/REINSTALLATION

1. Connect the new interface to the interface cable.

2. Carefully feed then through the hole in the wall sleeve and into the wall cavity. A drip loop will automatically beformed in the cable.

3. Slide the interface into the wall sleeve.

4. Firmly press on the interface with the palms of your hands until it snaps into place.

Frame 7-19

Interface

Wall Sleeve

Interface

Suction Cup

Pull the interface from the wall sleeve.

Disconnectthe cable.

Interface

Wall Sleeve

Reconnectthe cable.

Push the interface back into the wall sleeve.


INTERFACE CABLE REPLACEMENT

1. Remove the interface.

• Interface Removal

See Frame 7-18

2. Disconnect the interface cable from both the interface and valve by pulling the cable collar in the oppositedirection of the arrow.

3. Remove and discard the old interface cable.

4. Route the new interface cable.

5. Secure the cable to the interface sleeve a minimum of 18” (45.7 cm) from the end of the cable.

6. Connect the interface cable to the interface.

7. Carefully feed the connection through the hole in the wall sleeve and into the wall cavity. A drip loop willautomatically be formed in the cable.

8. Install the interface.

• Interface Replacement/Reinstallation

See Frame 7-19

Frame 7-20

Sleeve

Cable

Drip Loop

Interface

Secure cable.18" (45.7 cm) Min

Control Knob

Service Procedures



Wiring and Schematic DiagramsGENERALThis section contains wiring and schematic diagrams for the electrical and electronic elements.

Frame 8-1

DTV INTERNAL WIRING

Frame 8-2

Themistor Wiring loom


Motor Wiring Loom

Circuit Board

Mini Circuit Board

Thermistor Wiring Loom Connection

Motor Wiring Loom Connection

Wiring and Schematic Diagrams


SOLENOID WIRING LOOM

Frame 8-3

BlackOutlet 1 White

BlackBlack

Brown

Outlet 2

Outlet 3

Outlet 4

Outlet 5

Outlet 6

BlackBlack

Violet

GreenRed

Red

RedYellowRed

Wiring Diagram

Orange Red

© 2007 Kohler Co. 1043877-X1-B

1043877-X1-B © 2007 Kohler Co.

Service Manual - support.kohler.com · This manual specifically covers the servicing of a Kohler digital thermostatic valve (DTV). The manual includes The manual includes general

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