KOHLER K-528 Installation Manual
Installation Guide
Two-Outlet Thermostatic Valve
K-528
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″
1145587-2-A
IMPORTANT INSTRUCTIONS
WARNING: When using electrical products, basic precautions should always be followed,
including the following:
DANGER: Risk of electric shock. Grounding is required. Connect only to circuits protected by a
Ground-Fault Circuit-Interrupter (GFCI) or Residual Current Device (RCD). The unit should be
installed and grounded by a qualified service representative.
WARNING: Risk of electric shock. A licensed electrician should route all electrical wiring.
WARNING: Risk of electric shock. Disconnect power to the valve before servicing.
WARNING: Unauthorized modification may cause poor performance of the valve. Do not make
modifications to the valve as this could adversely affect the performance of the valve and void the
warranty. Kohler Co. shall not be liable under its warranty or otherwise for personal injury or
damage caused by any such unauthorized modification.
WARNING: Risk of injury or property damage. Please read all instructions thoroughly before
beginning installation.
NOTICE: Follow all plumbing, electrical, and building codes.
NOTICE: Provide generous, unrestricted service access to the valve. Provide access for servicing the
valve and interface. This access must be located immediately next to the valve. Refer to the roughing-in
information.
1145587-2-A 2 Kohler Co.
Specifications
Pressures
Maximum Static Pressure 125 psi, 862 kPa, 8.6 bar
Supply Pressure Differential* Max 5 psi, 34.5 kPa, 0.34 bar (Equal pressures recommended.)
Minimum Flow Rate 1.6 gpm (Less than 72 psi dynamic pressure.)
Temperatures
Programmable Temperature Max 120°F (49°C) Min 86°F (30°C) Full cold may also be selected.
Default Temperature at Start-up 100°F (38°C)
Minimum Mixed Temperature
Differential from Hot Supply
Temperature Stability at Recommended
Supply Conditions
Ambient Temperature Greater than 34°F (1°C), Max 104°F (40°C)
Maximum Relative Humidity 95% non-condensing
Electrical
Electrical Service 120 V, 15 A, 60 Hz
User Interface Cable Length (supplied) 20 ft (6.1 m)
* In commercial applications where there is a large difference in hot and cold supply pressures or frequent
fluctuation in either supply line is anticipated, it is strongly recommended that pressure regulators be
installed.
6 lpm (Less than 500 kPa maintaining pressure.)
2.1 gpm (Greater than 72 psi dynamic pressure.)
8 lpm (Greater than 500 kPa maintaining pressure.)
3.6°F (2°C)
+/- 1.6°F (1°C)
Tools and Materials
Plus:
• (2) 1/2" Union Connectors
• Wood and Framing Materials
• PEX Tubing, Copper Tubing, or PVC
Adjustable
Wrench
Pencil Screwdrivers Pipe Wrench Hacksaw or Tube Cutter Wood Saw Sealant
Level Drill Solder Propane
Torch
• (2) Water Hammer Arrestors (Recommended)
• (2) Supply Shut-Off Valves
Hammer
Tape
Kohler Co. 3 1145587-2-A
1-9/16"
(4 cm)
9-7/16" (24 cm)
2-11/16"
(6.8 cm)
1-7/16"
(3.7 cm)
2-3/8"
(6 cm)
Roughing-In
Before You Begin
12-1/2"
(31.8 cm)
2"
(5.1 cm)
1-13/16"
(4.6 cm)
9-1/2"
(24.1 cm)
1"
(2.5 cm)
12-1/2"
(31.8 cm)
3-3/8"
(8.6 cm)
8-1/16"
(20.5 cm)
13/16"
(2.1 cm)
10-3/16"
(25.9 cm)
11-5/8"
(29.5 cm)
13-3/8"
(34 cm)
1-5/16"
(3.3 cm)
NOTICE: Do not install the valve under a whirlpool surround or any location where the temperature may
reach temperatures over 104°F (40°C). The valve and its integrated power supply is rated to operate in
temperatures up to 104°F (40°C).
NOTICE: Do not apply excessive heat near the valve or apply flux or acids directly onto the valve. This
valve contains plastic and rubber components which will melt if heat is directly applied.
NOTICE: Do not apply petroleum-based lubricants to the valve components. Doing so will damage the
valve components.
NOTICE: Do not use oil-based, non-setting compounds, such as plumbers putty, on the threaded
connections.
NOTICE: If the digital valve will be used for a bath/shower application, the bath fill supply line must be
routed from the #1 outlet port.
Observe all local plumbing, building, and electrical codes.
Read these instructions and determine all required components along with their installation
locations before beginning this installation.
Provide access for servicing.
For optimum performance, 1/2″ dedicated water supply lines are recommended.
When possible, install the valve prior to installing the interface(s).
1145587-2-A 4 Kohler Co.
Before You Begin (cont.)
If possible, flush all piping thoroughly before installing the valve to prevent clogging the inlet
filters. If the valve is installed when the pipes are flushed, clean the inlet screens before using the
system.
This valve is not intended for single-outlet use.
A qualified electrician should install a 120 V GFCI electrical outlet, within the stud framing, in close
proximity to the digital mixing valve.
If possible, install the electrical outlet prior to installing the valve.
This valve complies with UL1951, ASME A112.18.1, ASSE 1016, CSA B125, and CSA C222 No.
218.2-93. This valve is listed with ASSE, IAPMO/cUPC, and UL.
Kohler Co. reserves the right to make revisions in the design of faucets without notice, as specified
in the Price Book.
Kohler Co. 5 1145587-2-A
Mounting on a Horizontal SurfaceMounting on a Vertical Surface
1. Valve Mounting Configurations
NOTICE: Do not mount the valve with the inlets located at the top. Doing so will damage this product.
Vertical and horizontal mounting options are shown above. Do not mount the valve with the inlets
or cable sockets pointing up.
1145587-2-A 6 Kohler Co.
Interface
Outlet
Power Cord
Outlets
Supply Inlets
2. Preparation
Interface
Drip
Loop
Coupler
Drip Loop
20' (6.1 m) Cables
NOTE: Only one interface, installed inside the shower, is required.
An additional interface can be installed outside the shower.
NOTICE: If the digital valve will be used for a bath/shower application, the bath fill supply line must be
routed from the #1 outlet port.
NOTE: The two valve interfaces are identical. Either can be used for primary and secondary connections.
One is located outside the showering enclosure, while the other is located inside the showering enclosure.
Determine all required components along with their installation locations before beginning this
installation.
When routing piping, keep in mind the numbers marked at each valve outlet must correspond to
the appropriate showering component for the preprogrammed or custom showering experiences to
function properly.
Kohler Co. 7 1145587-2-A
2-3/4"
(7 cm)
Min
14-1/2" (36.8 cm) Min
Cross Brace MountBoard Mount
14-1/2" (36.8 cm) Min
11-5/8"
(29.5 cm)
9-1/2"
(24.1 cm)
16" (40.6 cm)
Centers
Notch bottom brace.
3. Prepare the Site
NOTE: Vertical wall installation shown. The valve can also be mounted to a horizontal surface. Refer to
the ″Valve Mounting Configurations″ section.
This product is designed to fit within a minimum 14-1/2″ (36.8 cm) 2x4 stud cavity. If necessary to
modify the stud cavity, apply adequate bracing for mounting the valve.
12-1/2"
(31.8 cm)
1145587-2-A 8 Kohler Co.
Place outlet higher
than valve.
Power Cord
Drip Loop
4. Install the Electrical Outlet
NOTICE: Do not install the valve under a whirlpool surround or in any location where the temperature
may reach temperatures over 104°F (40°C). The valve and its integrated power supply are rated to operate
in temperatures up to 104°F (40°C).
Install a 120 V GFCI electrical outlet, within the stud framing, in close proximity to the valve. Locate
the outlet above the valve allowing ample space to mount the valve in close proximity to the
outlet.
Kohler Co. 9 1145587-2-A
O-Ring
Screen (Inlets Only)
Inlet/Outlet Tube
Adapter Lock
Solder this connection.
Adapter Nut
1/2" Union
5. Assemble the Adapters and Unions
NOTICE: Do not apply excessive heat near the valve or apply flux or acids directly onto the valve. This
valve contains plastic and rubber components which will melt if heat is directly applied.
Disassemble the adapter. Ensure all rubber and plastic components are removed.
Slide the union nut onto the inlet/outlet tube.
Solder the inlet/outlet tube to the union. Allow to cool completely.
Assemble the union.
Slide the adapter nut onto the inlet/outlet tube.
Assemble the adapter lock onto the inlet/outet tube and slide the assembly into the adapter nut.
Slide the O-ring onto the inlet/outlet tube.
For inlet tubes only: Insert the screen into the end of the inlet tube.
Reinstall the adapter assembly to the valve.
Repeat for all inlet/outlet tubes as required.
1145587-2-A 10 Kohler Co.
Offset Foot
Board Mount
Cross Brace Mount
1/2" Union
Water Hammer Arrestor
Shut-Off Valve
6. Install the Valve
NOTICE: Do not apply excessive heat near the valve or apply flux or acids directly onto the valve. This
valve contains plastic and rubber components which will melt if heat is directly applied.
NOTICE: Do not use oil-based, non-setting compounds, such as plumbers putty, on the threaded
connections.
IMPORTANT! If your water supply has high amounts of particulates, install wye strainers in the supply
lines.
Route the 1/2″ dedicated water supply lines. To allow access to the inlet screens for periodic
cleaning, install a removable segment of piping to the valve inlets using unions.
Install supply shut-off valves and water hammer arrestors in the supply lines prior to the valve.
Hold the valve up to the installation location and verify fit.
Mark the hole locations.
Predrill the holes.
Secure the valve with the washers and screws. Do not overtighten.
IMPORTANT! Make sure the components are connected to the corresponding numbered outlet(s) on the
valve.
Route the piping from the valve outlets to the appropriate shower components based on your
chosen configuration.
Connect the supply lines to the valve inlets. Verify that the hot and cold supplies are connected to
the appropriate inlets. Hot is red and marked by an ″H,″ cold is blue and marked by a ″C.″
Secure all piping to the framing.
Kohler Co. 11 1145587-2-A
Slide the split boot onto the
interface cable.
Solid Boot
Split Boot
7. Complete the Installation
If an interface is not available, proceed to the ″Installation Checkout″ section, and ″Checking the Valve
Installation without an Installed Interface.″
NOTICE: Do not plug in the power cord until all interface cables are connected.
NOTE: Make drip loops in all cables and cords.
Route the interface cable(s) in the wall from the valve location to the interface installation locations.
If not already installed, install the interface(s) at this time according to the instructions packed with
the product.
Connect the interface cable(s) to the valve.
Verify there is power to the 120 V GFCI electrical outlet.
Plug the power cord into the outlet.
1145587-2-A 12 Kohler Co.
Jumper
8. Installation Checkout
Turn on the water supply to the valve.
Check all connections for leaks and make any adjustments as needed.
Checking the Valve Installation without an Installed Interface
Disconnect the power from the valve.
Insert the jumper into one of the valve sockets.
Reconnect the power to the valve.
Wait 10 seconds for the valve to initialize; outlets will activate.
Check all connections for leaks.
Disconnect the power, then remove the jumper.
Reconnect the power to the valve for normal usage.
Test for Proper Operation (Requires an Installed Interface)
Press the power icon on the user interface. The interface should turn on and the screen will be lit.
If not already completed, refer to the ″Digital Interface User Guide″ to set up the interface.
NOTE: For more information about using the user interface and its menus, refer to the user interface
Homeowners Guide.
Using the interface, turn on both water outlets.
Check for leaks and make any adjustments as needed.
Verify that the water flow is sufficient for your showering needs.
Exercising the Mixing Valve (Requires an Installed Interface)
NOTE: The maximum water temperature to the outlets is limited to 120°F (49°C). The valve will
automatically shut down if the temperature exceeds 120°F (49°C).
Kohler Co. 13 1145587-2-A
Installation Checkout (cont.)
NOTE: Mixing valves which have been in storage, installed recently, or not been used for some time,
should be exercised before running any tests or setting the maximum temperature. Follow the steps below
to exercise your valve.
Verify that both hot and cold water are connected to appropriate valve inlets.
Using the up and down arrow icons on the user interface, adjust the temperature from cold to hot
and back to cold several times, pausing for 30 seconds at each extreme.
1145587-2-A 14 Kohler Co.
Copper Tube
Check Valve
Boot
Split Boot
Nut
Screen
O-Ring
Seal
Clean the Inlet Screens
Disconnect the power and turn off the water supply.
Unthread the plastic nuts from the hot and cold inlets.
Remove the copper tubes. The O-ring and screen may be attached to the end of the tube.
If the screen remains in the check valve, use a small flat-blade screwdriver to gently pull the check
valve from the valve inlets.
Remove the screens from the copper tubes or check valves.
Clean the screens to remove any dirt or debris.
Rinse or replace the check valves and screens.
Reassemble the inlet connections.
9. Troubleshooting
CAUTION: Risk of personal injury. The valve may contain hot water; be careful when draining
any residual water.
WARNING: Risk of electric shock. Disconnect power before performing any maintenance. When
disconnected, the product will no longer be electrically live, which will eliminate the risk of electric
shock.
It is recommended that any valve maintenance should be performed by a KOHLER Authorized Service
Representative.
This troubleshooting guide is for general aid only. For service and installation issues or concerns, call
1-800-4KOHLER.
Troubleshooting Table
Symptoms Probable Cause Recommended Action
1. Control panel is not lit. A. Valve is not plugged into the
outlet.
Kohler Co. 15 1145587-2-A
A. Plug the valve into an outlet.
Troubleshooting (cont.)
Troubleshooting Table
Symptoms Probable Cause Recommended Action
B. Interface cable connections may
be loose or disconnected.
C. Circuit breaker has been
tripped.
D. The valve memory may require
resetting.
E. A ″straight-through″ cable or
coupler was used to connect the
interface to the valve.
F. If none of the recommended
actions for the above issues
correct the symptom, the valve
or interface requires servicing.
2. The interface power
indicator is lit, but the
system will not turn on.
3. The interface functions
normally but no water
flows from the
components.
4. Maximum blend
temperature too hot or
too cold.
5. Continuous flow. A. System will not switch off. A. Turn off the water and power
6. Only cold water flows
from the outlets.
A. Interface cable connections may
be loose.
B. If the above recommended
action does not correct the
symptom, the interface or valve
requires servicing.
A. Valve outlets may be blocked. A. Check the valve outlets for
B. Fittings/Spray faces may be
blocked.
C. Hot and cold water supplies are
not turned on.
D. The valve memory may require
resetting.
E. System error. E. Check the user interface for an
F. If none of the recommended
actions for the above issues
correct the symptom, the valve
requires servicing.
A. Incorrect maximum temperature
setting.
B. If the above recommended
action does not correct the
symptom, the interface or valve
requires servicing.
B. Flow rate exceeds 10 gpm (45.5
lpm) from one outlet.
A. Hot water supply is either not
turned on or not connected to
the valve inlet.
B. Check all interface cable
connections, connect if needed.
C. Reset the circuit breaker.
D. Disconnect and reconnect the valve
power cord from the electrical
outlet.
E. Connect the interface to the valve
using a ″cross-over″ cable and
coupler.
F. Contact your Kohler Co.
Authorized Service Representative.
A. Check all interface cable
connections, connect if needed.
B. Contact your Kohler Co.
Authorized Service Representative.
blockage or debris. Clean the outlet
screens. Refer to the ″Clean the
Outlet Screens″ section.
B. Clean the spray faces and any
screens in your fittings.
C. Turn on the water supply to the
valve.
D. Disconnect and reconnect the valve
power cord from the electrical
outlet.
error code. Refer to the ″Error Code
Diagnosis″ section in the Digital
Interface Homeowners or User
Guide.
Contact your Kohler Co.
F.
Authorized Service Representative.
A. Refer to the ″Set the Maximum
Temperature″ section in the Digital
Interface User Guide.
B. Contact your Kohler Co.
Authorized Service Representative.
supply and contact your Kohler Co.
Authorized Service Representative.
B. Ensure flow restrictors are installed
in both outlets.
A. Check if the hot water supply is
turned on and connected to the
valve inlet.
1145587-2-A 16 Kohler Co.
Troubleshooting (cont.)
Troubleshooting Table
Symptoms Probable Cause Recommended Action
7. Fluctuating or reduced
flow rate. Valve is
functioning properly.
8. Blend temperature drift or
temperature cycling.
9. Water leaking from the
valve.
CAUTION: Risk of
personal injury or
product damage. Turn off
the main power and
water supply.
10. Hot water only, the valve
shuts down.
B. Hot water inlet is blocked. B. Check the hot water inlet screen for
C. The hot water supply is
exhausted.
D. If none of the recommended
actions for the above issues
correct the symptom, the valve
requires servicing.
A. Valve inlets may be blocked. A. Check the valve inlets for blockage
B. Fittings/Spray faces may be
blocked.
C. Water outlet pressure is low. C. Check that the flow rate is at or
D. Fluctuating supply pressure. D. Verify that the dynamic inlet
E. Water supply temperatures are
not within the recommended
range.
A. Fluctuating water supply
temperature.
B. Pressure difference greater than
5 psi (34.5 kPa) between the hot
and cold supply lines.
C. If none of the recommended
actions for the above issues
correct the symptom, the valve
requires servicing.
A. Connections are not secure. A. Check all connections. Make
B. Seals are worn or damaged. B. Order a seal service pack and
C. Internal leak. C. Unit requires overhaul. Contact
A. Hot and cold lines are reversed. A. Switch hot and cold water supply
blockage. Clean or replace the inlet
screen.
C. Allow time for the water heater to
come up to temperature.
D. Contact your Kohler Co.
Authorized Service Representative.
or debris. Clean the inlet screens.
Refer to the ″Clean the Inlet
Screens″ section.
B. Clean the spray faces and any
screens in your fittings.
above the minimum rate required.
Refer to ″Specifications″ section.
pressures are within specifications.
Refer to ″Specifications″ section.
E. Check if inlet water temperatures
are within the recommended range.
A. Check the inlet temperature
differentials and verify they are
sufficient. Refer to ″Specifications″
section.
B. Install pressure regulators to bring
the supplies within 5 psi (34.5 kPa)
of each other.
C. Contact your Kohler Co.
Authorized Service Representative.
adjustments as needed.
replace all seals.
your Kohler Co. Authorized Service
Representative.
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.″
Kohler Co. 17 1145587-2-A
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