Kohler K1357GRA0 Installation Manual

Installation Guide

Bath with Airjets and Integral Apron

K-1112, K-1114, K-1160, K-1122, K-1124, K-1151, K-1244, K-1257, K-1357

M product numbers are for Mexico (i.e. K-12345M) Los números de productos seguidos de M corresponden a México (Ej. K-12345M) Français, page ″Français-1″ Español, página ″Español-1″

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Important Information

Read all instructions before using or installing this product.

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

DANGER: Risk of electric shock. Connect only to a circuit protected by a ground-fault

circuit-interrupter (GFCI) or residual current device (RCD). Grounding is required. The unit should be installed by a qualiﬁed service representative and grounded.

WARNING: Risk of electric shock. A licensed electrician must route all electrical wiring and connections for this product. Improper installation will create an electrical hazard and may not comply with local building and electrical codes.

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

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

beginning installation, including the following requirements.

WARNING: Risk of property damage. Building materials and wiring should be routed away from the blower motor body and other heat-producing components of the unit.

NOTICE: Follow all local plumbing and electrical codes.

NOTICE: An access panel is required to service the pump/control. The access panel size must be a

minimum of 20″ (50.8 cm) in width, and 15″ (38.1 cm) in height.

Save these instructions.

Product Information

Electrical Requirements

WARNING: Risk of burns, ﬁre, electric shock, or injury to persons. Do not operate the pump if the pump supply cord is damaged. For proper guidance to have this product repaired, please call: 1-800-4-KOHLER from within the USA, 1-800-964-5590 from within Canada, or 001-877-680-1310 from within Mexico.

The installation must have a Class A Ground-Fault Circuit-Interrupter (GFCI) or Residual Current Device (RCD). The GFCI or RCD protects against line-to-ground shock hazard. Use a 120 V, 15 A, 60 Hz dedicated service for the bath with airjets.

Product Notices

NOTICE: Keep the area around the blower motor clean and free of debris. Ensure that the area around the blower motor is free of sawdust, insulation, dirt, or other small loose debris. Such material could clog the blower motor air ducts and reduce the air ﬂow through the blower.

Factory-Assembled Features

Factory installed components include blower motor with power supply cord, check valve, air piping, user keypad, and keypad cable. Other than power wiring and plumbing, no assembly is needed.

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Product Information (cont.)

Connections and Service Access

NOTICE: Provide unrestricted service access to the blower motor and check valve. The access must be located immediately next to the blower motor. Study the roughing-in information packed with the bath.

Before installation, ensure that there is proper access to the blower motor and ﬁnal connections. If the blower motor is installed in an enclosed area, an access panel is required at the blower motor. This panel should be 18″ (45.7 cm) wide and 14″ (35.6 cm) high minimum.

Table of Contents

Important Information .............................................................. 2

Product Information ............................................................... 2

Electrical Requirements .......................................................... 2

Product Notices ................................................................ 2

Factory-Assembled Features ...................................................... 2

Connections and Service Access ................................................... 3

Tools and Materials ............................................................... 3

Before You Begin ................................................................. 4

Prepare the Site ................................................................. 5

Prepare the Site - Concrete Construction ............................................... 6

Prepare the Bath with Airjets ........................................................ 6

Secure the Unit .................................................................. 7

Option Using a Cement or Mortar Bed ............................................... 7

Option Using Construction Adhesive ................................................. 7

Secure the Whirlpool .............................................................. 8

Install the Plumbing ............................................................... 8

Make Electrical Connections ......................................................... 9

Test Run the Bath with Airjets ....................................................... 10

Complete the Finished Wall ........................................................ 11

Removing the Apron Panel ......................................................... 11

Clean-Up After Installation ......................................................... 11

Conﬁrm Proper Operation .......................................................... 12

Fill the Bath .................................................................. 12

Troubleshooting Procedure ......................................................... 14

Troubleshooting Guide .......................................................... 14

Tools and Materials

Plus:

• Conventional Woodworking Tools and Materials

Silicone Sealant Measuring Tape

Safety Glasses Level

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Pipe Wrench

Pencil

Claw Hammer

Blade Screwdriver

• Drop Cloth

•

Construction Adhesive (Optional)

• Cement or Mortar (Optional)

• #6 Large-Head Galvanized Nails

• 2x4's or 2x6's

Before You Begin

NOTICE: Do not lift the bath with airjets by the piping or blower motor, or use the piping or blower motor for structural support of the bath.

NOTICE: Do not lift the bath with airjets by the integral apron.

We recommend this bath with airjets for alcove installation.

Please read these instructions carefully to familiarize yourself with the required tools, material, and installation sequences. Follow the sections that pertain to your particular installation. This will help you avoid costly mistakes. In addition to installation instructions, read all operating and safety instructions.

Inspect the bath with airjets for damage before you begin installation. You must install this bath to an adequately supported, level subﬂoor. Conﬁrm adequate mounting and connection space for the faucet speciﬁed for your installation. An optional accessories kit is available for relocating the blower motor. Refer to the back cover for

contact information if this kit is desired but was not ordered. If relocating the blower motor, follow the instructions that came with the kit while performing this installation.

Kohler Co. reserves the right to make revisions in the design of products without notice, as speciﬁed in the Price Book.

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Showerhead

Blocking

Supply Valves

Spout

Header Over Opening

Remove bottom plate.

1. Prepare the Site

NOTICE: Do not support the bath by the rim.

NOTICE: Refer to the Roughing-in Guide packed with this product for proper minimum lbs/square foot

(kg/square meter) ﬂoor support loading.

NOTICE: Provide adequate ventilation and a minimum of 15 cubic feet (.4 cubic meters) in the installed location for cooling the motor and to supply sufficient air for the blower. Do not install the blower motor closer than 1″ (2.5 cm) from the wall or other objects.

Make sure the ﬂoor offers adequate support for your bath, and verify that the subﬂoor is ﬂat and level.

Construct 2x4 or 2x6 stud framing designed for your particular installation. Install an access panel to allow the blower motor to be serviced. Position the plumbing according to the roughing-in information packed. Cap the supplies, and

check for leaks.

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1/16" (2 mm)

Bath

Apron Side

Tile

Approved Tile Backing

Brick

Approved Tile Backing

Tile

Brick

2. Prepare the Site - Concrete Construction

NOTICE: Do not support the bath by the rim.

NOTICE: Refer to the Roughing-in Guide packed with this product for proper minimum lbs/square foot

(kg/square meter) ﬂoor support loading.

Make sure the ﬂooring offers adequate support for your bath, and verify that the subﬂoor is ﬂat and level.

Construct brick or concrete supports. Provide a 1/16″ (2 mm) gap between the bath rim and the concrete or brick framing. Frame the

ﬂoor, or construct a frame for a raised installation, in accordance with the roughing-in information packed with the bath.

Position the plumbing according to the roughing-in information packed. Cap the supplies, and check for leaks.

3. Prepare the Bath with Airjets

Install the drain to the bath according to the drain manufacturer’s instructions. Do not connect the trap at this time.

Position a clean drop cloth or similar material in the bottom of the bath to protect the ﬁnish. Be careful not to scratch the surface of the bath.

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Spread a 2" (5.1 cm) layer of cement or mortar bed material.

Clear spaces for support blocks.

Apply construction adhesive to the support blocks.

4. Secure the Unit

NOTICE: Do not lift the bath with airjets by the air channels or blower motor, or use the piping or blower motor for structural support of the bath.

NOTICE: Do not support the bath by the rim.

Choose the installation option that best applies to your particular installation. Follow the appropriate instructions.

If the subﬂoor is not level, shim the bath support blocks as necessary.

Option Using a Cement or Mortar Bed

NOTICE: Do not use gypsum cement or drywall compound for this application, as they will not provide an acceptable, durable bond.

Spread a 2″ (5.1 cm) thick layer of cement or mortar on the subﬂoor where the bath will be set. This will help secure, level, and support the unit. Clear all the material away from the support block locations.

Position a piece of plastic drop cloth material on top of the cement or mortar bed. With help, carefully lift the bath into place, and make sure the support blocks do not rest in the bed

material. Insert the drain tailpiece into the trap. Make sure the bath is level and resting on all support blocks. Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant

around the entire rim of the bath. Allow the sealant to cure according to the manufacturer’s instructions.

Option Using Construction Adhesive

Apply a generous amount of high-quality construction adhesive to the bottom of the support blocks. With help, carefully lift the bath into position. Insert the drain tailpiece into the trap. Make sure the bath is level and resting on all support blocks. Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant

around the entire rim of the bath. Allow the sealant to cure according to the manufacturer’s instructions.

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Nail 1/4" (6 mm) thick furring strips to the studs.

Stud

Use #6 large-head galvanized nails to secure the nailing-in flange to the studs.

Drill a small hole through the nailing-in flange at each stud.

5. Secure the Whirlpool

Wood Construction

Drill a small pilot hole through the nailing-in ﬂange at each stud. Add shims between the nailing-in ﬂange and the studs as needed to eliminate gaps.

Nail 1/4” (6 mm) thick furring strips to the studs to shim out to the edge of the nailing-in ﬂange. Use #6 large-head galvanized nails to secure the nailing-in ﬂange to the studs.

Concrete Construction

NOTE: We recommend that the ﬂange be secured to the wall for support.

Drill pilot holes through the nailing-in ﬂange so they are about 16” (40.6 cm) apart. Install concrete wall anchors to the wall at the pilot hole locations. Secure the nailing-in ﬂange to the wall anchors with screws.

6. Install the Plumbing

WARNING: Risk of property damage. Ensure a watertight seal on the bath drain.

Connect the drain to the trap according to the drain manufacturer’s instructions.

NOTICE: An access panel will simplify future maintenance.

Install the faucet valving according to the faucet manufacturer’s instructions. Do not install the faucet trim until instructed. Open the hot and cold water supplies, and check the supply connections for leakage.

Run water into the bath, and check the drain connections for leakage.

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GFCI-Protected Receptacle

Blower Motor

7. Make Electrical Connections

DANGER: Risk of electric shock. Connect the blower motor to a properly grounded, grounding-type receptacle protected by Ground-Fault Circuit-Interrupters (GFCI’s) or Residual Current Devices (RCD’s). Do not remove the plug grounding pins. Do not use grounding adapters.

NOTE: The bath with airjets model number is printed on a label near the blower motor. This label also identiﬁes the electrical rating.

Your Kohler bath with airjets is equipped with a cord and plug. The blower motor has been wired at the factory. A licensed electrician must install a dedicated GFCI-protected, 120 V, 15 A, grounded outlet. Locate the outlet behind the bath and within 24″ (61 cm) of the blower motor.

Plug the blower motor into this outlet. Clean the area of all dust and debris.

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Purge Mode

Increases Flow

On/Off

Decreases Flow

8. Test Run the Bath with Airjets

For information on unit operation, refer to the ″Conﬁrm Proper Operation″ section. Check all electrical connections, and make sure the electrical power to the bath with airjets is on. Make sure all piping connections in the air harness are secure. Verify that the blower motor is secure. Temporarily remove the plastic drop cloth or other protective sheeting from the bath. Fill the bath to a level at least 2″ (5.1 cm) above the top of the highest airjet. Check the drain piping for leaks. Repair any leaks. Operate the bath and check for air ﬂow through the airjets. Check the air piping for air leaks. Stop the bath and drain the water. Return the plastic drop cloth or other protective sheeting to the bath.

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Framing

Water-Resistant Wall Material

Finished Wall

Bath

Apply silicone sealant to the joint between the bath and the finished wall.

On models with an integral apron, access the pump by gently prying at the apron edge with a screwdriver or dull knife to remove.

9. Complete the Finished Wall

NOTE: Your bath with airjets has an integral apron. It is designed so the ﬁnished wall material [1-1/2” (3.8 cm) maximum] will overlap the apron columns. The ﬁnished ﬂoor material [2” (5 cm) maximum] should butt against the apron.

If you have not already done so, carefully remove the protective tape from the bath rim. If necessary allow for deck-mounted valves and spout. Cover the bath framing with water-resistant wall material. Seal the joints between the rim edge and

the water-resistant wall material with silicone sealant. Tape and mud the water-resistant wall material. Install the ﬁnished wall to the water-resistant wall

material. Seal the joints between the bath rim and the ﬁnished wall material with silicone sealant. Install the faucet trim according to the trim manufacturer’s instructions.

10. Removing the Apron Panel

To remove the apron panel, insert the edge of a ﬂat blade screwdriver or dull knife under the edge of the panel. Be careful not to scratch the visible surfaces. Gently pry up at one end. Carefully pull the apron panel off.

To reinstall, bow the apron panel slightly so both ends can be inserted at the same time. Gently press in the center of the panel to secure it in place.

11. Clean-Up After Installation

Clean the area around the blower motor of all dust and debris. Use warm water and a liquid detergent to clean the surface of the bath with airjets. Do not use

abrasive cleansers, as they may scratch and dull the surface. Do not use powdered cleaners unless the cleaner is fully dissolved in water. Solid substances could block the airjets. Do not use bleach or ammonia cleaning solutions. Chemically active cleaning solutions can damage the bath surface.

Refer to the homeowners guide for normal cleaning recommendations.

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Purge Mode

Increases Flow

On/Off

Decreases Flow

12. Conﬁrm Proper Operation

Fill the Bath

NOTICE: Ensure that the area around the blower motor is free of sawdust, insulation, dirt, or other small loose debris. Such material could clog the blower motor air ducts and reduce the air ﬂow through the blower motor.

NOTE: Please read these steps carefully before you operate your bath with airjets. Troubleshoot any problems using the ″Troubleshooting″ section.

Keypad Operation

On/Off - Turns the blower motor on and off. Pressing the switch once starts the blower motor at a midrange speed. Pressing the button again stops the blower motor. The blower motor automatically stops after about 20 minutes of operation. The blower motor can be restarted by pressing the On/Off button.

Purge Mode - Initiates the purge cycle manually. The purge cycle blows any residual water out of the air channels after the bath has been drained. Pressing the button once starts the blower motor at low-speed. The blower motor stops automatically after about two minutes. Pressing the button again before the cycle ends will stop the blower motor. Note that this product also has an automatic purge cycle, which initiates about 30 minutes after the blower has stopped.

Increases Flow - Increases the air ﬂow. Decreases Flow- Decreases the air ﬂow.

Preliminary Checks

Temporarily remove all access panels. Verify that the union connection at the check valve is securely hand tightened. Verify that the screws are installed in the PVC air piping at the blower motor and at the check

valve. Verify that cable ties support the air piping. Verify that the blower motor is secure. Verify that the keypad cable is securely connected at the user keypad and at the blower motor. Fill the bath to a level at least 2″ (5 cm) above the top of the highest airjet.

Conﬁrm Air System Operation

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Conﬁrm Proper Operation (cont.)

Press the power button on the user keypad. Observe that the blower motor starts at a midrange speed. Observe that air is blowing through all of the airjets. Press the up button on the user keypad. Verify that the air ﬂow increases. Press the down button on the user keypad. Verify that the air ﬂow decreases. Press the power button on the keypad to stop the blower motor.

Conﬁrm Manual Purge Operation

Drain the bath. When the bath has drained, press the purge button once. Observe that the blower motor starts at low speed and blows any residual water from the air

channels. Observe that air comes out of the airjets. Verify that pressing the purge button again stops the blower motor. Press the purge button to restart the manual purge. Observe that the blower motor stops automatically after about two minutes.

Conﬁrm Automatic Purge Operation

Press the power button. Press the power button again to turn off the blower. Note the time. If ﬁlled, drain the bath. Observe that the blower motor starts in the purge cycle after about 30 minutes. Observe that the blower motor stops automatically after about two minutes.

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Purge Mode

Increases Flow

On/Off

Decreases Flow

13. Troubleshooting Procedure

Troubleshooting Guide

This troubleshooting guide is for general aid only. A Kohler Authorized Service Representative or qualiﬁed electrician should correct any electrical problems. For warranty service, contact your dealer or wholesale distributor.

Symptoms Probable Causes Recommended Action

1. Bath with airjets does not

start.

2. Blower motor starts, but there are few or no bubbles.

3. Bath stops automatically before 18 minutes.

4. Bath does not stop automatically after 22 minutes.

5. Blower motor does not stop when power button on user keypad is pressed.

6. Blower motor operates but variable speed feature does not work.

A. No power to blower motor. A. Set/reset GFCI or ELCB breaker;

B. User keypad cable loose or

damaged.

C. User keypad does not work. C. Check wire connections. Replace

D. Blower motor does not work. D. Replace blower motor. A. Blower motor is disconnected. A. Connect blower motor to air

B. Blower motor air ﬂow is

restricted.

A. GFCI or ELCB trips. A. Identify source of fault and

B. Motor overheated and protection

device activated.

A. Blower motor does not work. A. Replace blower motor.

A. User keypad cable loose or

damaged.

B. User keypad does not work. B. Replace user keypad. A. User keypad cable loose or

damaged.

B. User keypad does not work. B. Replace user keypad. C. Blower motor does not work. C. Replace blower motor.

check wiring.

B. Check wire connections. If

necessary, replace user keypad cable.

user keypad.

harness.

B. Clean the area around the blower

motor. Ensure adequate ventilation.

correct.

B. Check for blockage at motor

vents. Remove blockage and allow motor to cool.

A. Check wire connections. If

necessary, replace user keypad cable.

A. Check wire connections. If

necessary, replace user keypad cable.

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Troubleshooting Procedure (cont.)

Symptoms Probable Causes Recommended Action

7. Automatic purge cycle

does not occur.

8. Manual purge cycle does not work.

A. Blower motor does not work. A. Replace blower motor.

A. User keypad cable loose or

damaged.

B. User keypad does not work. B. Replace user keypad. C. Blower motor does not work. C. Replace blower motor.

A. Check wire connections. If

necessary, replace user keypad cable.

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