rada EXACT-3 User manual

1
IMPORTANT
Installer: This Manual is the property of the customer and
must be retained with the product for
maintenance and operational purposes.
PRODUCT MANUAL

2
INDEX
Page
SAFETY WARNINGS 3
ADVICE 3
INTRODUCTION 4
DESCRIPTION 4
PACK CONTENTS 5
DIMENSIONS 7
SPECIFICATION 8
INSTALLATION 12
COMMISSIONING 19
OPERATION 22
FAULT DIAGNOSIS 23
MAINTENANCE 25
SPARE PARTS 33
CUSTOMER CARE Back Cover
If you experience any difficulty with the installation or operation of your new
mixing valve, then please refer to the Fault Diagnosis section, before
contacting Kohler Mira Ltd. Our telephone and fax numbers can be found
on the back cover of this guide.

3
SAFETY: WARNINGS
The function of this thermostatic shower control 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. Type 3 valves are only used for applications covered by their approved
designations.
3. Periodic attention is given, as necessary, to maintain the product in good functional
order. Recommended guidelines are given in the MAINTENANCE section.
4. Continued use of this product in conditions outside the specification limits given
in this manual can present potential risk to users.
ADVICE
The use of the word 'failsafe' to describe the function of a thermostatic shower control
is both incorrect and misleading. In keeping with every other mechanism, it cannot
be considered as being functionally infallible.
Provided that the thermostatic shower control is installed, commissioned, operated
within the specification limits and maintained according to this manual, the risk of
malfunction, if not eliminated, is considerably reduced.
Malfunction of thermostatic shower controls are almost always progressive in nature
and will be detected by the use of proper temperature checking and maintenance
routines.
Certain types of system can result in the thermostatic shower control having excessive
'dead-legs' of pipework. Others allow an auxiliary cold water supply to be added to the
mixed water from the shower control. Such systems can disguise the onset of
thermostatic shower control malfunction.
Ultimately, the user or attendant must exercisedue 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.

4
INTRODUCTION
A range of 1/2" thermostatic shower controls to suit differing exposed installation
formats. Incorporates the Thermostatic cartridge, a unique sealed-for-life unit utilising
proven durability high-technology materials, for extended service-free reliability.
Also incorporates a sealed-for-life flow cartridge, utilising ceramic technology to provide
durable and positive control of flow.
The shower control inlets are fitted with strainers and checkvalves, housed within
readily-accessible cartridges for easy maintenance.
Product range
Rada Exact-3 - Exposed model, surface mounted, all chrome finish, 15 mm
compression / 1/2" BSP connections.
Rada Exact-3 z - Exposed model, pipework mounted, all chrome finish, inlets
3/4" BSP union (optional 3/4" x 1/2" offset adaptors for
variable centres and pipe concealing plates are available),
outlet 15 mm compression / 1/2" BSP connection.
Both models are provided with adjustable temperature control which allows the user
to select blend water temperatures up to a preset safe maximum level. Temperature
and flow knobs each incorporate a short lever, with approximately half a turn rotation,
to assist those with reduced use of their hands.
DESCRIPTION
The Rada Exact-3 Thermostatic shower control is specified to meet the highest
standards of safety, comfort and economy as demanded by today’s users. All Rada
Exact-3 Thermostatic shower controls are designed, manufactured and supported in
accordance with accredited BS EN ISO 9001:1994 Quality Systems.
The manual covers all Rada Exact-3 Thermostatic shower controls manufactured
from May 1995.
The suffix 3 indicates that the valve has been certified for use in UK healthcare
premises as a Type 3 mixing valve under the TMV3 scheme. Where this product is to
be used in such an installation, particular Application, Installation, Commissioning
and Maintenance requirements apply. These are given in the section 'TYPE 3 VALVES'.

5
PACK CONTENTS


 Tick the appropriate boxes to familiarize yourself with the part names and to
confirm that the parts are included.
Exact-3
1 x Exact-3 
1 x 2.5 mm A/F Hexagonal Wrench 
3 x Olives 
3 x Compression Nuts 
3 x Flat Faced Inserts 
2 x Wall Plugs 
2 x Screws 
2 x Pipe Concealing Plates 
ü

6


 Tick the appropriate boxes to familiarize yourself with the part names and to
confirm that the parts are included.
Exact-3 z
1 x Exact-3 
1 x Olive 
1 x Flat Faced Insert 
1 x 2.5 mm A/F Hexagonal Wrench 
1 x 3 mm A/F Hexagonal Wrench 
2 x Screws 
2 x Captive Nuts 
2 x Pipe Concealing
Plates 
2 x Checkvalve
Cartridges
2 x Offset Connectors 
ü

7
Rada Exact-3 z
DIMENSIONS
Rada Exact-3
153 mm
32 mm
28 mm
55 mm
33 mm
55 mm
80 mm
94 mm
55 mm
80 mm
94 mm
56 mm
55 mm
153 mm

8
SPECIFICATION
Normal Operating Conditions are considered as:
-inlet dynamic pressures nominally balanced to within 10% of each other during
flow
-a differential of approximately 50°C between the hot and cold inlet
temperatures, and with differentials of 15-35°C between the blend setting and
either supply
-daily usage of 1-6 hours
-installation and usage environment not subject to extremes of temperature,
unauthorised tampering or wilful abuse.
Other Applications
For information on other specific applications or suitability, refer to Kohler Mira Ltd,
or local agent.
Disinfection
In applications where system chemical disinfection is practised, chlorine can be
used (calculated chlorine concentration of 50 mg/l [ppm] maximum in water, per one
hour dwell time, at service interval frequency). Such procedures must be conducted
strictly in accordance with the information supplied with the disinfectant and with all
relevant Guidelines/Approved Codes of Practice.
If in any doubt as to the suitability of chemical solutions, refer to Kohler Mira Limited,
or Local Agent.
Operating Parameters
For Type 3 valves the supply conditions specified in Type 3 Valves - Application
take precedence over the operating parameters which follow.
Pressures/Flow Rates
For optimum performance, dynamic supply pressures should be nominally equal.
Recommended Minimum Flow Rate: 3 litres/minute at mid-blend with equal
dynamic supply pressures.
Recommended Maximum Flow Rate: 35 litres/min at mid-blend (which equates
to a maximum pressure loss of 1.9 bar).
Maximum Pressure Loss Ratio*: should not exceed 10:1, in favour of either supply,
during flow.
Recommended Minimum Dynamic Supply Pressure: 0.15 bar (0.2 bar
healthcare).

9
Recommended Maximum Dynamic Supply Pressure: 5 bar.
Maximum Static Supply Pressure: 10 bar.
Recommended maximum flow velocity in pipelines is 2 metre/second.
*PressureLossRatioisdeterminedbysubtractingtheresistancetoflowattheoutlet
(generally known as “back pressure”, and measured at the outlet of the mixing tap)
from the dynamic pressures of the hot and cold water at each inlet of the mixing tap.
This is at its extreme when the mixing tap is being used at its lowest flow rate and
whenthemaximuminequalityoccursinthepressureofthehotandcoldwatersupplies.
Hydraulic restriction: Flow Rate/Pressure Loss Graph - all models
(Shower control only, equal dynamic supply pressures, unrestricted outlet and
mid-blend temperature setting)
Pressure Loss - bar
Flow Rate
Litres/
Minute
0
10
20
30
40
50
0123
Operating Parameters: Temperatures
Optimum performance is obtained when temperature differentials of 20°Cor more
exist between blend and either supply. Blend control accuracy will begin to diminish at
temperature differentials below 12°C.
Blend Temperature Range: between ambient cold and approximately 60°C,
according to hot water supply temperature.
Thermostatic Control Range: approximately 25-60°C.
Optimum Thermostatic Control Range: 30-50°C.
Recommended Minimum Cold Water Supply Temperature: 1°C.
Recommended Maximum Hot Water Supply Temperature: 85°C.

10
Note! The shower control can accept temporary temperature excursions above 85°C
without damage, however operation at such elevated supply temperatures is not
recommended. For reasons of general safety, hot water storage temperatures should
ideally be maintained at between 60-65°C where serving ablutionary applications.
Flow Control:
Rada Exact-3 series shower controls have integral flow control; no other user-
operated flow controller should be used with this shower control.
Connections:
Rada Exact-3 -Inlets and Outlet: 1/2” BSP external union or 15 mm compression
(nut and olive provided).
Rada Exact-3 z - Inlets: 3/4” BSP internal captive nuts to accept offset unions
(available separately on request, these allow for variable (115-
165 mm) rear-fed supply pipework centres via parallel or taper
sockets). Outlet: 1/2” BSP external union or 15 mm compression
(nut and olive provided).
Standard Connections are;
hot - left (marked red)
cold - right (marked blue)
Note! Should the supplies be reversed then the shower control will not be able to
control temperature. This can be corrected by reversing the position of the Thermostatic
cartridge within the control body, as described in INSTALLATION.
Outlet - bottom (can be altered to top outlet if required,
refer to INSTALLATION)
All models can operate in any plane, and may be inverted if necessary for supply
pipework layout convenience, provided hot and cold pipework is connected to the
appropriate inlets (hot - red, cold - blue).
Outlet Fittings: The outlet connector is designed to accept:
Rada/standard flexible hose (1/2” BSP) unions and flat-faced/flanged unions
(maximum flange diameter 20 mm); use flat-faced insert (408 71)
15 mm pipework; use compression olive (542 10).
Inlet/ Outlet Options:
INLETS:* OUTLET:*
Exact-3 top, bottom, rear-fed bottom, top
Exact-3 z rear-fed bottom, top
*Products are supplied in the format shown in bold.

11
INSTALLATION
General
Installation must be carried out in accordance with these instructions, and must
be conducted by designated, qualified and competent personnel.
1. Before commencing, ensure that the installation conditions comply with the
information given in the SPECIFICATION section. For type 3 valves see also
Installation conditions in TYPE 3 VALVES.
2. Care must be taken during installation to prevent any risk of injury or damage.
3. Installations must comply with all Local/National Water Supply Authority
Regulations/Bye-Laws, and building and Plumbing Regulations.
4. The shower control should be positioned for easy access during use and
maintenance. All routine maintenance procedures can be conducted with the
shower control body in place (except for strainer and check valve access on the
Exact-3 z). For all models, allow a minimum 150 mm top and bottom clearance to
enable removal of the Thermostatic and Flow cartridges from the shower control
body during maintenance.
5. Conveniently situated isolating valves must be provided for maintenance.
6. The use of supply-line or zone strainers will reduce the need to remove debris at
each shower control point. The recommended minimum mesh aperture dimension
for such strainers is 0.5 mm.
7. Inlet pressure tappings which allow measurement of the inlet pressures to the
mixing valve under running conditions are particularly recommended for healthcare
applications with Type 3 valves.
8. Pipework must be rigidly supported. The mixed water outlet piping should not
exceed 2 m and the overall length from the hot water circuit to the discharge
point should not exceed 5 m.
9. Pipework dead-legs should be kept to a minimum.
10. Supply pipework layout should be arranged to minimise the effect of other outlet
usage upon the dynamic pressures at the shower control inlets.
11. Inlet threaded joint connections should be made with PTFE tape or liquid sealant.
Do not use oil-based, non-setting jointing compounds.
12. To eliminate pipe debris it is essential that supply pipes are thoroughly
flushed through before connection to the shower control.

12
Note! If both the outlet and inlet positions require reversing, it is easier to
simply rotate the complete shower control by 1/2 turn.
2. Standard (Refer to Figure 1)
- As supplied.
3. Top outlet (Refer to Figure 2)
(a) Remove the temperature knob assembly, using the 3 mm A/F hexagonal
wrench (supplied) (Refer to Figure 8). Do not remove the temperature hub.
(b) With removal clip still in place, unscrew the head nut using a 35 mm A/F
wrench; this will release the body shroud and also begin to draw the
Thermostatic cartridge out of the body (Refer to Figure 8).
(c) Pull the Thermostatic cartridge free of the shower control.
(d) Rotate the Thermostatic cartridge 1/2 a turn (this reverses the position of the
cartridge hot and cold inlets).
(e) Carefully push the Thermostatic cartridge back into the shower control body.
Make sure that the 2 cartridge inlet port seals remain in place, and locate the
cartridge lugs into the body slots.
Note! The red and blue markings on the cartridge will now not correspond with
the body markings, so to avoid future confusion remove the red and the blue
stickers from the cartridge.
(f) Carefully align and then tighten the headnut. Do not overtighten (maximum
torque 2.5 Nm (1.85 lbf ft)).
(g) Rotate the shower control 1/2 turn.
Note! The inlet elbows may need repositioning (Refer to Installation).
4. Reversed inlets (Refer to Figure 3)
(a) Remove the temperature knob assembly, using the 3 mm A/F hexagonal
wrench (supplied) (Refer to Figure 8). Do not remove the temperature hub.
(b) With removal clip still in place, unscrew the head nut using a 35 mm A/F
wrench; this will release the body shroud and also begin to draw the
Thermostatic cartridge out of the body (Refer to Figure 8).
Outlet Position/Reversed Inlets (Refer to Figures 1 to 4)
All Rada Exact-3 series shower controls are supplied with inlet connections configured
hot - left, cold - right, and bottom outlet as standard. It is essential that inlet
supplies correspond with the red and blue markings on the Thermostatic cartridge.
Should the existing hot and cold pipework make this configuration inconvenient, or a
top outlet position be required, the inlets or outlet can be reversed.
1. If the shower control body has already been installed, isolate the supplies to the
shower control, and open the flow control to release pressure and to assist the
draining of residual water.

13
(f) Carefully align and then tighten the headnut. Do not overtighten (maximum
torque 2.5 Nm (1.85 lbf ft)).
5. Reversed inlets and top outlet (Refer to Figure 4)
(a) Rotate the shower control 1/2 turn.
Note! The inlet elbows may need repositioning (Refer to Installation).
6. Complete INSTALLATION, if appropriate.
Reversed Inlets
Figure 3
Reversed Inlets and Top Outlet
Figure 4
CHCH
Top Outlet
Figure 2
Standard
Figure 1
C
H
C
H
Note! The red and blue markings on the cartridge will now not correspond with
the body markings, so to avoid future confusion remove the red and the blue
stickers from the cartridge.
(c) Pull the Thermostatic cartridge free of the shower control.
(d) Rotate the Thermostatic cartridge 1/2 a turn (this reverses the position of
the cartridge hot and cold inlets).
(e) Carefully push the Thermostatic cartridge back into the shower control body.
Make sure that the 2 cartridge inlet port seals remain in place, and locate
the cartridge lugs into the body slots.

14
Installation: Rada Exact-3 (Refer to Figure 5)
1. When unpacked, the inlet elbows are positioned to accept falling supplies.
Should the installation require rising or rear-fed supplies then the elbows will
need adjusting.
(a) Loosen each elbow grub screw using the 2.5 mm A/F hexagonal wrench
(supplied)
(b) Pull the elbow away from the body and refit in the desired position.
(c) Tighten the grub screw.
3. Mount the backplate securely to wall surface (with the grub screws pointing
downwards) using wall screws/plugs provided.
4. Install the supply pipework to the respective inlets.
Important! Flush through the hot and cold supplies thoroughly before connection to
shower control. Failure to do so may result in reduced performance and/or product
damage.
5. Refit body onto backplate and tighten the grub screws.
6. Connect inlet pipework, checking that the hot and cold supplies have been piped
to the correct inlets.
(a) For 15 mm compression pipework inlet (or outlet) connections: Use
compression nuts and olives supplied.
(b) For 1/2" BSP union inlet (or outlet) connections: Use flat-faced inserts
supplied, press in firmly.
7. Connect outlet shower hose or rigid outlet pipework. Check all connections are
watertight. Refer to COMMISSIONING.
2. Where rear-fed supplies are required, pipe concealing plates are provided which
recess into the tiling for a neater finish.
Installation: Rada Exact-3 z (Refer to Figure 6)
Note! Rada Offset connectors and offset Pipe concealing plates are not supplied with
this shower control, but are available separately as optional accessories. A backplate
is not required for this installation.
1. Check that hot and cold supplies are piped to the correct inlet positions.
7. If the shower control body has already been installed, restore the hot and cold
supplies and check for any leaks.
8. Align and refit the body shroud and temperature knob assembly so that the
markings will be visible to the user.
9. The maximum temperature may now need resetting; check, and if necessary refer
to COMMISSIONING.

15
Exact-3 - Installation
Figure 5
Flat Faced
Insert
Rada Exact-3
Olive
Compression Nut
13 mm
Pipe
Concealing
Plate
Fixing
Screws
2.5 mm A/F
Hexagonal
Wrench
Grub
Screw
Backplate
Assembly
Wall Plug
153 mm
3. Screw pipe concealing plates onto offset connectors.
Important! Flush through the hot and cold supplies thoroughly before connection to
shower control. Failure to do so may result in reduced performance and/or product
damage.
2. Joint offset connectors and screw into sockets so that faced edge is 34 mm
proud of final wall surface. If necessary, shorten 1/2" BSP external thread.
Note! It is essential that inlet supply sockets are parallel, and square with wall surface.
Supplies (pipe centres between 115-165 mm) must terminate in 1/2" BSP internal
sockets to within 3 mm, above or below, the final wall surface.

16
5. With the nylon washers in position, offer up the shower control and tighten the
union nuts onto the offset connectors.
6. Connect the shower hose or rigid outlet pipework:
(a) for 15 mm compression pipework outlet connection; fit compression nut and
olive supplied.
(b) for 1/2" BSP union outlet connection; fit flat-faced insert supplied, press in
firmly (Refer to Figure 6).
7. Check all connections are watertight. Refer to COMMISSIONING.
Exact-3 Z - Installation
Figure 6
153 mm
34 mm
Rada Exact-3
Captive Nut
Checkvalve Cartridge
Offset Connector
Pipe Concealing
Plate
Note! Ensure that the filters are fitted correctly into the checkvalve cartridge.

17
COMMISSIONING
Commissioning must be carried out in accordance with these instructions,
and must be conducted by designated, qualified and competent personnel.
Exercising the Thermostat
Thermostatic mixing valves are inclined to lose their responsiveness if not used.
Valves which have been in storage, installed but not commissioned, or simply not
used for some time should be exercised before setting the maximum temperature
or carrying out any tests.
A simple way to provide this exercise is:
(a) ensure that the hot and cold water are available at the valve inlets, and the
outlet is open.
(b) move the temperature control rapidly from cold to hot and hot back to cold
several times, pausing at each extreme.
Maximum Temperature
The maximum blend temperature obtainable by the user should be limited, to prevent
accidental selection of excessive hot temperatures.
All Rada thermostatic shower controls are fully performance tested, and the maximum
temperature is preset to approximately 43°C under ideal installation conditions at the
factory.
Site conditions and personal preference may dictate that the maximum temperature
has to be reset following installation. For Type 3 valves in healthcare installations the
maximum blend temperature is determined by the application - see table under
Application and Designation
This shower control is provided with a levered, adjustable temperature control knob,
which allows the user to select the blend temperature between ambient cold up to a
preset maximum.
Maximum Temperature Setting (Refer to Figure 7)
Check that an adequate supply of hot water is available at the hot inlet of the shower
control.
During resetting, the hot supply to the shower must be as close to the typical maximum
to offset the possibility of any blend shift due to fluctuating supply temperatures.
However, the minimum temperature of the hot water must be at least 12°C above the
desired blend for correct operation.
Temperatures should always be recorded using a thermometer with proven accuracy.

18
4. Once the desired maximum blend temperature is achieved, refit the hub without
disturbing the spindle, positioning it so that the lug is against the stop on cartridge
face, preventing further rotation. Check that blend temperature has not altered.
5. Refit the temperature knob so that the lever is aligned with the maximum hot
position shown on the body shroud.
6. Refit the cap and locking screw.
Commissioning Checks
(Temperatures should always be recorded using a thermometer with proven accuracy)
1. Check inlet pipework temperatures for correct function of checkvalves.
2. Operate the flow control and check:
- Flow-rate is sufficient for purpose.
- Temperatures obtainable are acceptable.
- All connections and control body are watertight.
- Supply pressures are within the range of operating pressures for the valve
3. It is advisable to establish a performance check at this time, which should be
noted for future reference as part of a Planned Maintenance Programme (a
Maintenance Record Card has been provided with this Manual).
The procedure should be chosen to imitate both typical and difficult operating
conditions, such as any supply pressure fluctuations that may be likely. An ideal
method is to locate another outlet on the common cold water supply close to the
shower control (operating this outlet should cause a drop in supply pressure),
and note the subsequent effect on blend temperature (should be no more than
2°C change).
Exercise the thermostat as described on page 17.
.
- If the outlet temperature is set correctly then refer to Commissioning Checks.
- If adjustment of the temperature is required, carry out the procedure shown
below and refer to Figure 7.
1. Remove the temperature knob, using the 3 mm A/F hexagonal wrench (supplied).
2. Pull off the temperature hub.
3. Rotate the spindle until the required maximum blend temperature is obtained at
the discharge point (clockwise = decrease temperature).
When resistance is felt do not use force to turn any further, as this can
damage the internal parts.
Check that both inlet isolating valves are fully open. Turn the temperature knob to
maximum and operate the flow control. Allow the temperature to stabilize and check
the outlet temperature.

19
Maximum Temperature Setting
Figure 7
3 mm A/F Hexagonal Wrench
Locking Screw
Temperature Knob
Hub
Spindle

20
OPERATION
Adjustment of blend temperature from preset maximum to cold is achieved by
clockwise rotation of the temperature knob.
The flow control knob operates through 180° rotation, with full flow when the lever
is fully to the right and flow closure when fully to the left for bottom outlet
applications (this configuration reverses for top outlet). The rate of flow can be
readily controlled within this rotation.