rada DRV40 User manual

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DRV40 Digital Recirculation Valve
Important! This Manual is the property of the customer and must be
retained with the product for maintenance and operational purposes.
Product Manual

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CONTENTS
Safety - Warnings....................................................................................4
Advice.......................................................................................................4
Introduction .............................................................................................5
Description...............................................................................................5
Pack Contents .........................................................................................6
Dimensions..............................................................................................7
Specication ............................................................................................8
Default Settings.......................................................................................9
Installation .............................................................................................10
General...............................................................................................10
Recirculation Circuit - Plumbing Schematic .......................................12
Commissioning .....................................................................................15
Operation ...............................................................................................16
Temperature Adjust Using Laptop or PC............................................16
COM Port ...........................................................................................17
DRV Information.................................................................................19
Temperatures .....................................................................................20
Setpoints ............................................................................................21
Setpoints - Explained .........................................................................23
Alerts - Explained...............................................................................24
Preset Display Alerts..........................................................................26
Thermal Disinfection...........................................................................27
Disinfection Step by Step - 1..............................................................33
Disinfection Step by Step - 2..............................................................34
Options...............................................................................................35
Alert Messages......................................................................................36
Error Messages .....................................................................................36
Connectivity...........................................................................................37
Modbus...............................................................................................37
If you experience any difculty with the installation of your new mixing valve, then
pleaserefer tothe Fault Diagnosis section, before contacting Kohler Mira Limited.
Our telephone and fax numbers can be found on the back cover of this guide.

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System Performance.............................................................................38
Pump Capacity...................................................................................38
System Safety Measures ...................................................................38
Maintenance and Spare Parts..............................................................39
Batteries.............................................................................................39
Disassembly.......................................................................................40
Electronics Module.............................................................................41
PCB Connections...............................................................................44
DRV ...................................................................................................45
Valve Calibration ................................................................................53
Fault Diagnosis......................................................................................55
Customer Service..................................................................Back Cover
Patent
UK - 2 421 297 2 437 891
USA - 7669776 8043556
PCT - PCT/GB2006/000159
European - 06702758.1
India - 1231/MUMNP/2007
Australia 2006 207 367
Canada 2 595064
China ZL 2006 8000 5853.8
Japan 4933451

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The function of this DRV (Digital Recirculation Valve) is to deliver water consistently
at a safe temperature. This requires that:
1. It is installed, commissioned, operated and maintained in accordance with the
recommendations given in this Manual.
2. Periodic attention is given, as necessary, to maintain the product in good
functional order. Recommended guidelines are given in the 'Maintenance and
Spare Parts' section.
3. If this equipment is used in a manner not specied by Kohler Mira Ltd, the
protection provided by the equipment may become impaired.
4. The electrical installation must comply with BS 7671 (commonly referred to
as the IEE Wiring Regulations) and all relevant building regulations, or any
particular regulation or practice specied by the local electricity supply company.
This appliance is to be permanently connected to the xed electrical wiring
and must be earthed.
SAFETY: WARNINGS
ADVICE
The use of the word ‘failsafe’ to describe the function of any hot and cold water
mixingvalveisbothincorrectandmisleading.ThisDRV(Digital Recirculation Valve)
incorporates additional shut-off devices to improve the level of safety however, in
keeping with every other mechanism it cannot be considered as being functionally
infallible.
Provided that the valve is installed, commissioned, operated within the specication
limits and maintained according to this Manual, the risk of malfunction, if not limited,
is considerably reduced.
Malfunction of valves is almost always progressive in nature and will be detected by
the use of proper temperature checking and maintenance routines. Certain types of
systemcan result in excessive‘dead-legs’ofpipework.Others allow anauxiliarycold
water supply to be added to the mixed water from the mixing valve. Such systems
can disguise the onset of thermostatic mixing valve malfunction.
Ultimately, the user or attendant must exercise due diligence to ensure that the
delivery of warm water is at a stable, safe temperature. This is particularly important
in such healthcare procedures as supervised bathing of patients unable to respond
immediately to unsafe temperatures.
Where chloramine/chlorine disinfection is practiced, DO NOT exceed a chlorine

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INTRODUCTION
The Rada DRV40 Digital Recirculation Valve is specied to meet the highest
standards of safety, comfort and economy as demanded by todays users. The Rada
DRV40 is designed, manufactured and supported in accordance with accredited
BS EN ISO 9001:1994 Quality Systems.
DESCRIPTION
Product Range
A 1 1/2 BSP inlet / outlet thermostatic mixing valve employing digital temperature
sensors to provide water at safe, accurate temperature for ablutionary or process
requirements. Includes an Electronics Module with LCD display and an interface
connection for PC/Laptop device. The 'DRV Programming Software' is available
to monitor and alter the valve's operation (Microsoft Windows based).
Rada DRV40
Pipe mounted Digital Recirculation Valve requiring a permanent electrical power
connection.
Data Storage
Kohler Mira Limited shall not accept liability in contract, tort (including negligence
or otherwise) for any loss of prots, business or anticipated savings, or loss or
corruption of data, or any indirect or consequential loss arising out of the customer's
use of DRV40. The customer shall be solely responsible for the independent
backup of all data/information stored on DRV40. Notwithstanding the foregoing,
none of the exclusions and limitations stated above are intended to limit any rights
the customer may have under local law or other statutory rights which may not be
excluded.
Guarantee
We guarantee this product against any defect in materials or workmanship for a
period of one year from the date of purchase. For terms and conditions refer to the
back cover.
concentration of 50 mg/l (ppm) in water, per one hour dwell time. Such procedures
must be conducted strictly in accordance with the information supplied with the
disinfectant and with all relevant Guidelines/Approved Codes of Practice.

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PACK CONTENTS
Tick the appropriate boxes to familiarize yourself with the part names and to
conrm that the parts are included.

Rada DRV40
1 x DRV
Digital
Recirculation
Valve
1 x Circlip
1 x Electronics Module*
2 x Electronics Module
Screws
1 x PC USB Cable (for connecting
Laptop/PC to Electronics Module)
3 x Hexagonal Keys
(1 x 2.5mm)
(1 x 3mm)
(1 x 4mm)
*2 x CR - P2 6V Batteries not supplied.
1 x USB stick (contains USB cable driver
software, DRV Programming Software
and DRV40 product guides)

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All dimensions are nominal.
DIMENSIONS
3m
power cable
length
172 mm
144 mm 55 mm AF Hex
1-1/2 BSP
Internal
268 mm
240 mm
50 mm
minimum
recommended
clearance
140 mm
67 mm

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SPECIFICATION
General
Protection IP20
Connections 1 1/2 BSP Internal (female)
Installation Environment Suitable for indoor use only
Pressures
Maximum Static Pressure 1000 kPa (10 bar)
Maximum Operating Pressure Drop
across DRV 140 kPa (1.4 bar)
Supply Pressure Differential Equal pressure recommended - Inlet pressures must be stable for optimum
performance.
Temperatures
Cold Water Range 2 - 25°C
Hot Water Range 2°C above setpoint - 80°C
Optimum Setpoint Range 27 - 70°C
Ambient Temperature Greater than 2°C, max. 50°C
Maximum Relative Humidity 95% non-condensing
Recirculation Circuit
Minimum distance to First Outlet 7.6 m
Flow Rates
Minimum Flow Rate Per Outlet 6 l/min (<500kPa maintained pressure)
8 l/min (>500kPa maintained pressure)
Maximum recommended Flow Rate 155 l/min at 2.3 m/s
Minimum recirculation Flow Rate 19 l/min
Minimum system Draw-off 0 l/min during recirculation
2 l/min from 1 outlet
Electrical
Power Supply 230V ~ 50Hz 15W
Supply Fuse Switched type 3 Amp
Internal Fuse (Electronics Module) T2AH 250V
Battery 2 x CR - P2 6V
Duty cycle Continuously rated
Auxiliary Relay (see Alerts - Activate Relay on Alert)
Relay Type Single pole changeover relay contacts
Power Supply 230V AC / 24V DC
Supply Fuse 2 Amp
The Rada DRV40 conforms to the CE marking requirements.

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DEFAULT SETTINGS
The following table shows the factory default settings of the Rada DRV40. These
values can be altered using the 'DRV Programming Software' available to install
from the USB stick supplied.
Temperatures
Adjusted Setpoint 49 °C
Setpoints
Max 68 °C
Default 49 °C
Min 38 °C
Alerts & Valve Units
Valve Units °C
Above Setpoint 2 °C
Below Setpoint 2 °C
Error Temp 60 °C
Activate Relay on Alert On
Disinfection
Enable Disinfection Off
Disinfection Timeout 1 minute
Options
Valve Address null
Network Modbus Inactive
Modbus Address (when 'Active') 3

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INSTALLATION
General
Installation must be carried out in accordance with these instructions, and must be
conducted by designated, qualied and competent personnel.
Theinstallationmust comply with any particular regulations and practices, specied
by the local water supply regulations.
The installation must follow the 'Recirculation Circuit - Plumbing Schematic' in
this manual. All plumbing components are to be supplied by the installer. Failure to
include these components will compromise the DRV40 and system performance.
1. Before commencing, ensure that the installation conditions comply with the
information shown in 'Specication'.
2. Care must be taken during installation to prevent any risk of injury or damage.
3. The DRV40 must be installed in a dry area where it will not be able to freeze
(minimum ambient temperature of 2°C
4. Inlet isolating valves (full ow type) must be installed close to the DRV40 for
ease of maintenance. It is recommended that outlet isolating valves (full ow
type) are also installed.
5. The DRV40 must be positioned for easy access during use and maintenance
(this includes connecting to a PC/Laptop).All routine maintenance procedures
can be conducted with the valve body in place.
6. Theuseof supply-line or zone strainers will reducetheneedtoremovedebris at
eachmixing valvepoint.The recommendedmaximummesh aperturedimension
for such strainers is 0.5mm.
7. Inlet pressure tappings which allow measurement of the inlet pressures to the
DRV40 under operating conditions are particularly recommended for in-service
testing.
8. Pipework must be rigidly supported.
9. Supplypipeworklayoutshouldbe arranged to minimise the effectof other outlet
usage upon the dynamic pressures at the DRV40 inlets.
10. Inlet and outlet threaded joint connections should be made with PTFE tape or
liquid sealant. Do not use oil-based, non-setting jointing compounds.
11. To eliminate pipe debris it is essential that supply pipes are thoroughly
ushed through before connection to the DRV40.

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200 mm
50 mm
100 mm 100 mm 150 mm
50 mm
The DRV40 must be installed in this orientation only.
These clearance dimensions are recommended for maintenance purposes.
Batteries are not supplied with the DRV40, but must be tted prior to installation.
Do not t rechargeable batteries. (Also see 'Maintenance and Spare Parts'.)
CAUTION! RISK OF FIRE OR PRODUCT DAMAGE IF INCORRECT TYPE OF BATTERY IS FITTED.
DISPOSE OF USED BATTERIES ACCORDING TO THE BATTERY MANUFACTURER'S INSTRUCTIONS.
2 x CR - P2 6V

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Outlets
Mixed Return
Blend Circuit
Cold Water
Supply
Recirculation Circuit - Plumbing Schematic
Stop Valve
Full Bore Isolating Valve
Pressure Reducing Valve
Shower
Thermometer
Cold Water
Hot Water
Mixed Water
Check Valve
Recirculation Pump
Key
Strainer / Filter
Needle Valve
Flow indicator
Safety Valve
Water
Heater

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Hole markers inside the Electronics
Modulecase indicatewherecablescan be
tted for options such as an error relay.
1. Before tting to the pipework, it is
recommended that suitable unions
are fitted to the inlets and outlet.
This will enable the DRV tobe easily
removed, if required.
2. Flushpipework thoroughly(minimum
of 5 minutes).
3. Fit the DRV to the pipework.
4. Attach the Electronics Module and
secure using the circlip supplied.

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5. Connect and secure the 4 and 8 pin
plugs to the back of the Electronics
Module.
6. Connect the Power Cable to the
mains electricity.
A separate, permanently connected
supply must be taken from the ring
main to the appliance through a
3 Amp double pole switched fuse
spur providing a minimum 3mm
contact separation gap in each
pole. The fuse spur must be suitably
located, easily reached and identied
as to its purpose.
7. Close and secure the Electronics
Module with the 2 x 4mm hexagon
socket screws provided.
Note! The Electronics Module
must be closed for the DRV40 to
function.
8. Commission the DRV40 and
recirculation system using the
'Commissioning' instructions
contained in this manual.
Power Cable
4mm
HEX

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COMMISSIONING
Commissioningmust be carried out in accordance with these instructions, and must
be conducted by designated, qualied and competent personnel.
1. Makesure thatthesystemispowered andthedisplay ontheElectronics Module
is illuminated.
2. Flood the system in the following sequence:
• Open the cold water supply isolation valve(s).
• Open the outlet ow isolation valve(s).
• Open the hot water supply isolation valve(s).
3. Makesurethe hot and cold inlet suppliesare at theirdesignatedpressures and
temperatures.
4. Close all the mixed water outlets and turn on the circulating pump.
5. The LCD display will indicate the outlet water temperature and the outlet water
temperature setpoint. The setpoint is preprogrammed to 49ºC. This can be
altered using the 'DRV Programming Software' on the USB stick supplied.
Temp. 48˚C
Setpoint 49˚C
drv40
Rada
Temp. 48˚C
Setpoint 49˚C
Display as seen during normal operating mode
Current Outlet Temperature
Current Setpoint

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OPERATION
Temperature Adjust Using Laptop or PC
1. Operating System: Microsoft Windows XP, Vista or Windows 7.
Minimum Screen Resolution: 1024 x 768 (Recommended 1280 x 1024 or
higher.)
2. Install the USB Driver and 'DRV Programming Software' from USB stick
supplied.
3. Connect the Laptop/PC to the Electronics Module with the PC USB Cable
supplied. Connect the cable to any USB port on the laptop/PC and the serial
port on the Electronics Module of the DRV40.
4. Run the 'DRV Programming Software' by double clicking
the icon on the desktop or search for and run the file
'Titan Terminal CSharp.exe'.
Electronics Module

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COM Port
Locate the DRV40 by selecting the correct COM Port. The COM Port can be
conrmed using the Device Manager utility within the Windows OS.
Note! Make sure the USB Driver has been installed.
Example of Windows XP Device Manager

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The DRV40 is now connected to the PC/Laptop device and will receive data
automatically.
The control screens can be selected individually by clicking on each of the tabs.
The general status of the DRV40 is displayed on the right of the screen.
Valve Units - displays the temperature units.
Valve Status - displays the DRV40’s current operating status.
Valve Response - displays any conrmation of commands received or any error
messages.
Valve Control - Alters the DRV40’ state ON/OFF. This is required when making
specic adjustments to the DRV40’s settings (detailed further in these instructions).

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DRV Information
Once the DRV40 is connected, the DRV information screen is updated.
Serial Number - The serial number of the DRV40 assigned at manufacture.
Version - The version of Rada DRV40 control software.
Manufacturing Date - The date the DRV40 was built.
These data elds are read only and can only be changed by updating the DRV40
internal software (only to be performed by a qualied service engineer).

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Temperatures
Temperatures
The 'Cold', 'Hot' and 'Outlet' are read only values and can be used to monitor the
current settings. They are continuously updated every 2 seconds.
Adjusted Setpoint
1. Input 'Adjusted Setpoint' value
2. Click 'Set' to transfer the value to the DRV40
3. The 'Adjusted Setpoint' value is displayed on the DRV40 as 'Setpoint'.
4. To change the 'Adjusted Setpoint' back to the default value, click 'Reset to
Default'.
Temp 42˚C
Setpoint 43˚C