Aqualisa Dream DCV Series User manual

Dream
Thermostatic Dual control mixer
valve range
Installation guide
TM
DCV

Index
Introduction p.3
- Safety information p.3
- Product specification p.3
Connection to supplies p.4
- Pipe sizing p.4
- Flushing p.4
- Filters p.4
- Isolating valves p.4
- Pressures p.5
Boosted gravity system p.5
- Pump installation p.5
- Stored water capacities p.6
Combination boiler systems p.6
Balanced high pressure systems p.6
Typical water systems p.7
System components p.9
Valve installation instructions p.11
- Dream Dual Control Valve (DCV) p11
Shower head installation p.15
- Adjustable height Harmony head p.15
- Wall mount drencher head p.18
- Bath overflow filler p.19
- Waste pipe extension kit p.21
User guide p.21
- Shower valve p.21
- Adjustable height Harmony head p.22
- Wall mount drencher head p.22
Cleaning & maintenance p.22
Commissioning p.23
Cartridge replacement P.24
Trouble shooting guide p.26
Notes p.27
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Introduction
The Dream DCV concealed shower range is available as a single outlet
product with either an adjustable or wall drencher head or as a Divert shower
solution complete with adjustable head and wall drencher head or bath fill.
Dream DCV valves feature separate flow and temperature controls. Dream
DCV thermostatic valves provide close temperature stability and fail safe
protection on appropriate high pressure systems. Please refer to the product
specification section below.
If at any stage during installation you have any questions, please contact the
Aqualisa customer helpline on 01959 560010 for assistance.
Safety information
This product must be installed by a competent person in accordance with all
relevant current Water Supply Regulations.
THE SHOWER MUST NOT BE USED WITH A HOT WATER SUPPLY
TEMPERATURE OVER 65 C.
The Dream DCV range is designed for domestic use only.
Product specification
Dream DCV products are suitable for all boosted gravity, balanced high
pressure and combination boiler systems*. Pressure range 1bar – 5bar max
(static).
*The combination boiler MUST have a minimum rating of 24kW (80000 Btu)
and be of the type fitted with a fully modulating gas valve.
If in any doubt, please contact the appliance manufacturer before
installation commences.
When fitted to combination boiler systems, Dream DCV shower valves have
been designed to give optimum temperature control and stability from fully
modulating combination boilers and instantaneous gas water heaters.
Important information
º

Connections
Dream DCV products are designed for conventional supplies with HOT on the
left and COLD on the right as viewed from the front.
Dream DCV shower valves are supplied with ¾ inch BSP threads.
Supply lines must be flushed clear of any debris before installation of the
unit. Any debris accumulation in the shower valve and head may result in
damage and poor performance.
Pipe sizing
Long pipe runs, on both inlet and outlet, will reduce the flow rate at the
shower head. If long pipe runs are unavoidable, use copper pipe rather than
plastic. If plastic pipe is used, minimise the number of elbows as pipe inserts
are very restrictive. Consideration should be given to using 22mm plastic or
copper pipe especially if a diverter valve is to be fitted.
Flushing
Some modern fluxes can be extremely corrosive and, if left in contact, will
attack the working parts of the unit. All soldering must be completed and the
pipe work thoroughly flushed out in accordance with current Water Supply
Regulations prior to connection of the product.
Filters
To ensure ongoing optimum performance, Dream DCV products are
protected by inlet filter assemblies in the internal waterways. Debris
accumulation may result in reduced flow from the shower head and noisy
operation.
As this condition is not covered by our standard warranty terms, it is
suggested that the filters be removed and checked by a competent person.
In the event of any difficulties please contact the Aqualisa customer helpline
for assistance.
Isolating valves
Suitable full way isolation valves must be fitted to both supplies in
accordance with current Water Supply Regulations and our terms of warranty.
Due to their restrictive characteristics, stopcocks and ball type valves that
reduce the pipe bore size must not be used on gravity and boosted gravity
installations.
4

Pressures
The Dream DCV cartridge is designed to operate from the mains at a
maximum of 5bar. If the mains pressure is likely to exceed 5bar, a ‘drop
tight’ PRV must be fitted on the supply pipe after the main stopcock.
A setting of 3bar is recommended. It should be noted that daytime
pressures approaching 5bar can rise above the stated maximum overnight.
A suitable PRV is available from Aqualisa.
Dream DCV products are not suitable for mixed supply systems, e.g.
gravity hot and mains cold.
Boosted gravity fed hot and cold supplies
Services must be installed according to good plumbing practice having regard
to pipe sizing, long pipe runs and low head situations.
The cold supply for the valve assembly must be taken directly from the cold
water storage system. The hot supply may be taken from the vent/draw off
pipe of the hot water cylinder at a point below the cylinder connection or
alternatively from the underside of the horizontal draw off.
Rising pipe work must NOT be connected into the horizontal draw off from
the cylinder or to any point in the vent/draw off pipe above the cylinder
connection.
CYLINDER TEMPERATURE IN EXCESS OF 65°C MAY RESULT IN POOR
SHOWER PERFORMANCE
To minimise pressure loss we recommend that the hot and cold supplies are
run in 22mm to the mixing valve.
Pump installation
UNDER NO CIRCUMSTANCES MUST A PUMP BE FITTED DIRECTLY TO
THE WATER MAIN
A pump must only be used to boost the pressure from tank fed supplies.
A minimum 1 bar twin ended booster pump is recommended.
ENSURE THE MINIMUM GRAVITY FLOW RATE IS SUFFICIENT TO
OPERATE THE PUMP FLOW SWITCHES.
PLEASE REFER TO THE MANUFACTURERS PUMP INSTALLATION GUIDE
FOR PUMP INSTALLATION INFORMATION.
Please refer to the typical system layout on page 7.
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Stored water capacities
The minimum capacity of the cold storage cistern should be not less than
225 litres (50 gallons). The capacity of the hot cylinder must be capable of
meeting the anticipated demand.
Combination boiler/multipoint system
Dream DCV products are suitable for use with combination boiler systems.
The combination boiler MUST have a minimum rating of 24kW (80,000 Btu)
and be of the type fitted with a fully modulating gas valve. This is sufficient
to operate one outlet at a time.
If in any doubt, please contact the appliance manufacturer before
installation commences.
The cold supply can be taken from the nearest convenient mains supply and
the hot supply can be taken from the nearest hot water draw off point.
Account must be taken of the pressure drops that will occur when other draw
off points are used while the shower is in use.
Please refer to the typical system layout on page 7.
When fitted to combination boiler systems, Dream DCV shower valves have
been specifically designed to give optimum temperature control and stability
from fully modulating combination boilers and instantaneous gas water
heaters.
Balanced high pressure system
The cold water supply must be drawn from the same mains supply as that
to the hot water system (downstream of the cylinder manufacturer’s
pressure limiting valve, where supplied) and the hot supply from the nearest
convenient draw off point. Account must be taken of pressure drops that
may occur when other draw off points are used while the shower is in use.
Please refer to the typical system layout on page 8.

7
Typical system diagrams
Typical pumped system installation
Typical combination boiler system installation

Typical system diagrams continued
Typical thermal storage unit system installation
Typical UHW system installation
8

Components - Dream DCV with adjustable head
9
Components - Dream DCV with wall drencher head

Components - Dream DCV Divert with adjustable and wall drencher heads
Components - Dream DCV Divert with adjustable head and bath overflow filler
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11
!In addition to the guide below it is essential that the Important information section is read and
understood and that you have all the necessary components (shown on page 9 or 10) before
commencing installation. Failure to install the product in accordance with these instructions may
adversely affect the warranty terms and conditions. Do not undertake any part of this installation
unless you are competent to do so. Prior to starting, ensure that you are familiar with the necessary
plumbing regulations required to install the product correctly and safely.
Dream DCV valve installation
1If installing the product into a solid wall, chase out
a suitable recess in the wall to receive the valve and
pipework. If installing the valve in a concealed panel
mounted situation, in most cases it will be necessary
to first install a suitable sound fixing in the cavity
area before fixing the valve.
A hole of 117mm wide x 135mm high is required to
enable removal of the mortar guard and to allow
for any future maintenance of the valve.
The valve needs to be mounted to the depth shown
opposite. The distance between the ¾ inch inlet
pipe connections is 140mm.
2Remove the mortar guards from the valve assembly and set aside.
3Prepare suitable 22mm inlet pipe work ending in suitable ¾ inch BSP connections and construct a suitable
15mm outlet supply pipe to the desired location for the wall outlet, fixed head or bath overflow outlet.
4Place the valve into the required position within the wall and mark and prepare the
fixing points.
85mm max. to finished/tiled wall surface
70mm min from
back face of valve
to finished/tiled
wall surface
(10mm allowance
for tiles)
!For divert valves, the top outlet feeds to the fixed head and the side outlet feeds to the adjustable kit
wall outlet or bath overflow filler.

5Secure the valve to the wall using suitable fixing screws.
6Secure the pipe work to the valve inlets using a suitable tool.
!Pipework connections are not supplied, suitable ¾ inch BSP unions/connection fittings are required.
7The valve can now be checked for leaks by rotating the flow control knob, ensuring the flow can discharge
safely to waste. If all is sound, turn the valve off.
8Refit the mortar guards to the valve assembly and fill in the chase. Suitable non-
setting infill material such as paper, polystyrene etc. should be wrapped around
the components and a plaster finish applied. Once the infilling material has set,
carefully remove the mortar guards to expose the valve body.
!THE MORTAR GUARDS MUST BE USED
9Using a silicone based lubricant or liquid soap, lubricate the
wall plate seal within the round cut out of the wall plate.
Remove the double sided tape on the rear of the wall plate
and carefully push the wall plate into position flush with the
finished wall surface.
10 Screw the adapter sleeve into position on the top on/off flow
control spindle, ensuring the black O-ring is correctly aligned in
the groove on the back of the adapter.
!A small amount of petroleum jelly (Vaseline or similar) can
be used to hold the O-ring in place whilst screwing the
adapter into position.
11 Secure the brass spindle adapter into position using the brass
screw provided.
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12 Place the top on/off flow control knob into position and
tighten the grub screw using the hexagonal key provided.
13 Secure the lever grub screw to the on/off flow control knob using the hexagonal key
provided.
14 Secure the on/off flow control lever to the control knob.
15 Ensure the markings on the temperature brass spindle and the white plastic
temperature stop ring align at the 12 o’clock position.
16 Place the temperature control knob into position with the temperature stop button
at the 12 o’clock position.
17 Tighten the temperature control knob grub screw using the hexagonal key provided.
!The on/off flow control / Divert knobs can be fitted with or without the levers. If not using the levers,
the hexagonal fixing points can be concealed using the blanking caps provided. N.B. We recommend
these are placed on the underside of the control knobs.
If using the levers, please follow the instructions below.

18 If the lever is not to be fitted, place the temperature control screw cover into position
and carefully push into place.
19 If fitting the lever, secure the lever grub screw to the temperature control knob using
the hexagonal key provided.
20 Secure the temperature lever to the control knob.
Please refer to pages 15 to 20 for adjustable height head, wall mount fixed head or bath overflow filler
installation instructions.
14

Adjustable height head installation
Adjustable height head installation
1Prepare pipework from the shower valve to the required position for the hose outlet using a Ø15mm copper
pipe. Slide the wall spacer down the projecting pipe flush with the finished wall surface.
2Slide the 15mm gripper ring down the projecting pipe flush with the wall spacer
fitting.
3Trim the projecting pipe to a length of 15-22mm using a rotary type cutter. If a hacksaw is used, the pipe
end must be carefully de-burred and chamfered.
4Clean and lubricate the pipe using a suitable (silicone based) lubricant.
15
5Remove the locking screw, rotate the chrome outlet assembly and remove the outlet
from the wall mounting plate.
6Place the wall outlet mounting plate onto the pipe assembly and mark and prepare
the fixing points, using the fixings provided, if suitable.
7Ensuring the locking screw hole is positioned at the bottom; secure the wall mounting plate to the wall
using the screws provided, if suitable.

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8Ensuring the O-ring is in the correct position on the recess of the spigot section on the mounting plate, place
the wall outlet onto the mounting plate in the 5 o’clock position and rotate clockwise until a stop is
reached.
9Refit the locking screw taking care not to over tighten
10 Drill and prepare two fixing points between 520mm (minimum) and 830mm
(maximum) apart using the fixings provided, if suitable.
11 Pass the rail through the handset holder while keeping the slider levers depressed.
!The top rail end bracket can be adjusted to suit existing screw holes in the
finished wall by sliding the bracket up or down the rail to suit the required
position.
12 Carefully slide the gel hook onto the rail under the handset holder.
!Current Water Supply regulations state that the handset should not be allowed to pass a point 25mm
above the spill over level of the bath or shower tray. If this cannot be achieved, the hose must be
passed through the gel hook which has been designed to be utilised as a hose restraint.
13 Secure the top rail bracket into position using the screws provided, if suitable.
14 Attach the bottom rail end body onto the rail.

17
15 Slide the rail assembly up through the top rail end body.
16 Align the small hole in the rail with the bottom rail end fixing point. Secure the rail assembly to the wall,
using the fixings provided, if suitable, taking care to not over tighten.
17 Place the rail end caps into the rail ends and push firmly into position.
18 Pass the hose through the gel hanger.
19 Ensuring the hose washer is in the correct position, secure the handset to the hose by
pressing and holding the anti-swivel locking button on the handset whilst securing the
handset to the hose, then place the handset into the handset holder.
20 Ensuring the hose washer is in the correct position; attach the hose to the wall outlet.

Wall mount drencher head installation
1Prepare pipework from the shower valve to the required position for the fixed shower head using Ø15mm
copper pipe. Cut the outlet pipe to a finished length (55mm – 150mm measured from the finished wall
surface) using a rotary type cutter. If a hacksaw is used, the pipe end must be carefully de-burred and
chamfered.
2Slide the wall spacer down the projecting pipe flush with the finished wall surface.
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3Ensure the pipe is clean and free of dust and slide the fixing bush which incorporates
the 15mm gripper ring down the projecting pipe flush with the wall spacer.
4Carefully remove the fixed head arm and drill and prepare the fixings using the fixings provided, if suitable,
taking care to avoid pipework hidden in the wall.
5Ensuring the fixing bush is clean and free of dust, fit the 15mm O-ring against the
end of the fixing bush. Lubricate the O-ring using a suitable silicone based lubricant.
!The O-ring must be positioned on the 15mm pipe flush to the fixing bush, not
onto the fixing bush shaft.
6Refit the shower arm and secure it to the wall using the screws provided.

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7Run the shower for a few seconds to clear any debris that may be present.
8Slide the cover plate into position flush with the finished wall surface.
9Ensuring the rubber washer is in the correct position, attach the shower head to the
fixed arm and carefully secure using a suitable spanner, or a tool with smooth jaws,
sufficiently to lock the head into position.
Bath overflow filler
!The bath overflow filler is suitable for baths up to a maximum thickness of 24mm.
1Carefully unscrew and remove the overflow filler outlet from the body assembly and
set aside.
2Carefully unscrew and remove the bath waste clicker assembly from the waste body
and set aside.
3Offer the bath waste into position ensuring the rubber washer is correctly aligned
between the waste assembly and the bath base.

20
4Ensuring the rubber washer is correctly aligned, pass the bath waste clicker through
the bath and secure to the waste body assembly
6Offer the outlet body assembly into position at the rear of the bath ensuring the
rubber washer is correctly aligned between the outlet body assembly and bath wall.
7Ensuring the rubber washer is correctly aligned, pass the overflow filler outlet through
the bath and secure to the body assembly.
5Connect the bath waste to a suitable waste pipe.
8Remove the relevant inlet blanking plug and attach the flexible hose to the blended
inlet connection.
9Connect the flexible hose to the blended supply pipe ensuring suitable non-restrictive double check valves
are fitted in line with current Water Supply Regulations (not supplied).