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58

Common Faults

Problem: 

“Blend temperature rises when system is in zero demand...”

DRV40 display errors

These are the most likely error 
messages to be displayed 
during this problem. For the 
most probable causes and 
solutions see 

'DRV40 Display 

Errors'

.

If any other error message is displayed see 

'DRV40 Display Errors'

.

Error PCB

Temp        49˚C

Error Motor

Temp        49˚C

Error Thermistor

Temp        49˚C

Temp High

Error Temp

49˚C

Summary of Contents for DRV40

Page 1: ...1 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 ...

Page 2: ... 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 difficulty with the installation of your new mixing valve then please refer to the Fault Diagnosis section before cont...

Page 3: ...sembly 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 ...

Page 4: ...e is both incorrect and misleading This DRV 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 specification limits and maintained according to this Manual the risk of malfunctio...

Page 5: ...orage Kohler Mira Limited shall not accept liability in contract tort including negligence or otherwise for any loss of profits 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 f...

Page 6: ... 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 ...

Page 7: ...7 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 ...

Page 8: ...midity 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...

Page 9: ...stall 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 ...

Page 10: ...e DRV40 for ease of maintenance It is recommended that outlet isolating valves full flow 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 The use of supply line or zone strainers will reduce the need to remove debris at each mix...

Page 11: ...maintenance purposes Batteries are not supplied with the DRV40 but must be fitted prior to installation Do not fit 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 ...

Page 12: ...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 ...

Page 13: ...elay 1 Before fitting to the pipework it is recommended that suitable unions are fitted to the inlets and outlet This will enable the DRV to be easily removed if required 2 Flush pipework thoroughly minimum of 5 minutes 3 Fit the DRV to the pipework 4 Attach the Electronics Module and secure using the circlip supplied ...

Page 14: ...switched fuse spur providing a minimum 3mm contact separation gap in each pole The fuse spur must be suitably located easily reached and identified 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 ins...

Page 15: ...e s Open the hot water supply isolation valve s 3 Make sure the hot and cold inlet supplies are at their designated pressures 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 S...

Page 16: ...iver 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 Modu...

Page 17: ...te the DRV40 by selecting the correct COM Port The COM Port can be confirmed using the Device Manager utility within the Windows OS Note Make sure the USB Driver has been installed Example of Windows XP Device Manager ...

Page 18: ... 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 confirmation of commands received or any error messages Valve Control Alters the DRV40 state ON OFF This is required when making specific adjustments to the DRV40 s settings detailed further in these instructions ...

Page 19: ...he 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 fields are read only and can only be changed by updating the DRV40 internal software only to be performed by a qualified service engineer ...

Page 20: ...gs 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 ...

Page 21: ... Alter the Max Min and Default values as required for the application 1 Switch Valve Control to OFF 2 Click Set to transfer the values to the DRV40 3 Switch Valve Control back ON 4 The Setpoint Default value is displayed on the DRV40 Units 1 Click the preferred Valve Units ºF or ºC ...

Page 22: ...lso see Alerts Explained and Preset Display Alerts 1 Input the Above Setpoint and Below Setpoint values 2 Input the Error Temp value 3 Click Activate Relay on Alerts if required 4 Switch Valve Control to OFF 5 Click Set to transfer the values to the DRV40 6 Click Refresh and confirm the updated values 7 Switch Valve Control back ON ...

Page 23: ...he setpoint itself The Default value is the temperature the DRV will return to should the power be lost and the DRV40 is reset The Default is adjustable but cannot be more than the Max maximum value or less than the Min minimum value Example 1 Temp 42 C Setpoint 43 C Temp 42 C Setpoint 39 C normal operation reset after power failure to change back to 43 C use Adjusted Setpoint ...

Page 24: ...terminal have continuity 1 Power failure 2 Start up sequence 3 Outlet temperature causing an alert signal can be disabled via the Setpoints tab of the DRV Programming Software 4 Outlet temperature causing an error signal 5 Internal fault on PCB 6 Battery failure 7 Thermistor failure DRV40 will also issue an alert if the preset Error Temp value located under the Setpoints tab is exceeded the defaul...

Page 25: ... Setpoint 41 C 2 C Below Setpoint 38 C 49 C 60 C Error Temp Min Setpoint 43 C Setpoint M I X E D T E M P E R A T U R E F L U C T U A T I O N ALERT SHUT DOWN TO FULL COLD ALERT Note The Adjusted Setpoint value does not need to be the same as the Default value Both Adjusted Setpoint and Default can be set within the Max and Min range only ...

Page 26: ...ull cold Max Hot Cold 45 C 2 C Above Setpoint 41 C 2 C Below Setpoint 38 C 49 C Error Temp Min Setpoint 43 C Setpoint Default M I X E D T E M P E R A T U R E F L U C T U A T I O N ALERT SHUT DOWN TO FULL COLD ALERT Temp Low 41 C Setpoint 49 C Temp High 45 C Setpoint 49 C Temp High 49 C Error Temp Important Error Temp can also indicate the need for maintenance See DRV40 Display Errors for further d...

Page 27: ...be thermally disinfected regularly as part of good bacterial infection control DO NOT USE THE THERMAL DISINFECTION FEATURE IF THE HOT WATER SUPPLY CAN EXCEED 80 C Warning Thermal disinfection is a potentially hazardous process to raise the water temperature to a level that will scald or even kill It is therefore the responsibility of the person supervising the process to make sure it is carried ou...

Page 28: ...its full cold position and allow the blend circuit to be reduced gradually to a safe temperature level Make sure the blend circuit temperature returns to normal operation within the Disinfection Timeout period see Disinfection Cycle 6 The Disinfection cycle is monitored constantly and the supervisor is able to stop the cycle using the Abort button in the Disinfection screen Without a draw off the ...

Page 29: ...ature alert and error displays are disabled to allow for disinfection and cool down of the blend circuit before switching back on automatically i e if Disinfection Timeout is set to 30 minutes then the DRV40 has that amount of time to complete the disinfection and cool down before entering an error condition and switching to full cold Please note the following Disinfection Timeout starts when Trig...

Page 30: ...ve Control to OFF 3 Click Set to transfer the values to the DRV40 4 Click Refresh and confirm the updated values Disinfection Cycle Warning Due to the scalding temperature the disinfection process must be supervised The DRV40 should be monitored whilst in disinfection mode and no one should be allowed to approach within 3 metres of any affected outlets 1 Click Arm when prepared for disinfection cy...

Page 31: ... DRV40 changes to confirm the cool down mode After cool down has been initiated the blend circuit takes time to return to normal temperature Drain the hot water using the last outlet of the blend circuit or use a dump valve fitted near to the end of the blend circuit Check with local water authorities with regard to water temperature limitations to drain The time required to cool the blend circuit...

Page 32: ...ction Timeline Trigger Disinfection Timeout start Full Hot Disinfection Timeout Period Draw Off Blend Circuit Cool Down return to Setpoint Disinfection Timeout finish Abort If Abort is used when the cycle is at full hot the DRV40 switches to full cold and displays Error Temp Cycle the power off on to reset the DRV40 make sure the blend circuit is at a safe temperature before allowing any outlets t...

Page 33: ...ck Off under Valve Control 4 Click Set 5 Click Refresh to confirm the settings 6 Click Arm 7 Click Trigger and start stopwatch or note the time of day 8 Monitor the temperature and time until a satisfactory disinfection of the blend circuit has been achieved 9 Click Cool Down 10 Draw off hot water from the blend circuit Use either the last outlet on the circuit or a dump valve fitted near to the e...

Page 34: ...ction of the blend circuit has been achieved 5 Click Cool Down 6 Draw off hot water from the blend circuit Use either the last outlet on the circuit or a dump valve fitted near to the end of the circuit 7 When DRV40 temperature is within normal operation stop the draw off 8 Allow the DRV40 to return to normal operation automatically MAKE SURE ALL OUTLETS ON BLEND CIRCUIT ARE NOT IN USE UNTIL CYCLE...

Page 35: ...controlled as a Modbus RTU also see Connectivity Valve Calibration Must be used when replacing the following parts Proportioning Assembly PCB Drive Housing Gear Drive Assembly see Maintenance and Spare Parts for further details Do not use Calibration Set for any other reason ...

Page 36: ...nt 49 C Temp Low 38 C Setpoint 49 C Outlet temperature exceeds the Above Setpoint value This condition causes a relay to be activated Outlet temperature is less than the Below Setpoint value This condition causes a relay to be activated See Troubleshooting ...

Page 37: ...reen for details on how to enable DRV40 for Modbus Modbus When configured for Modbus the DRV40 becomes a Remote Terminal Unit RTU When connected directly to a BMS using Modbus RTU the DRV40 will be assigned a unique network address which is programmed via the integral DB9 external port A separate Guide to Rada DRV Modbus Networking is available from our website www radacontrols com DRV40 ...

Page 38: ...off the DRV40 reverts to a zero demand The recirculation temperature is continuously monitored and adjusted appropriately by the DRV40 The circulating pump must operate continuously the DRV40 requires a minimum flow of 19 l m Pump Capacity The circulating pump is only required to keep water gently moving around the system The pump should be sized and selected to overcome the system resistance feet...

Page 39: ...ctronics Module to make sure the DRV switches to Full Cold in the event of a primary power supply failure they should not be considered to be a backup power supply Battery life is variable depending upon usage A battery error message appears on the DRV display when they require replacing Where primary power supply failure occurs regularly or the DRV is installed within a supply system where safety...

Page 40: ... Allow the hot water inlet to cool sufficiently to reduce the risk of injury through contact with the hot pipe or DRV 4mm HEX Step 1 Step 2 Failure to disconnect the incoming power supply before removing the plugs may result in product damage Any damage caused in this way is not covered by the warranty See back page for full details Step 3 Step 4 ...

Page 41: ...41 Electronics Module 1793 237 1793 221 1793 221 x6 1793 219 x4 x6 1793 220 x3 1793 221 DRV40 Electronics Module Spare Parts 1793 237 Electronics Module 1793 219 PCB 1793 220 LCD 1793 221 Front Cover ...

Page 42: ...ly remove if seal is to be renewed Step 1 Step 2 Step 3 Step 4 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 ...

Page 43: ...43 Step 5 Step 6 ...

Page 44: ...44 Motor Battery CN3 DB9 RS485 DRV40 Thermistors Power Supply Fuse Relay Fuse Power Supply high voltage Relay Remote Thermistors CN2 Modbus See separate guide www radacontrols com DRV40 PCB Connections ...

Page 45: ...bly 1793 211 Proportioning Assembly 1793 212 Drive Housing 1793 213 Gear Drive Assembly 1793 214 Drain Plug 1793 215 Seal Pack 1793 245 Screw Pack 1793 209 1793 214 1793 207 1793 208 x4 1793 245 x20 1793 211 1793 215 1793 215 1793 210 1793 215 x3 1793 245 1793 210 1793 215 1793 212 x2 x2 x3 x3 1793 215 1793 245 1793 213 x4 ...

Page 46: ...46 2 5mm HEX 3mm HEX 13mm HEX Step 1 Step 3 Step 4 Step 2 Seals shown 1 1 when printed at Full Scale ...

Page 47: ...47 3mm HEX Step 5 3mm HEX Step 6 ...

Page 48: ...48 3mm HEX Step 7 Step 7a Step 7b Seals shown 1 1 when printed at Full Scale ...

Page 49: ...49 3mm HEX CAUTION Cartridge will fall when loose Use one of the 3mm Hex screws to assist in removing the cartridge Step 8 Step 9 ...

Page 50: ...50 Only use silicone based lubricants on rubber seals A D E E E D B C 1793 215 Seal Pack Step 10 ...

Page 51: ...51 A D B E C x 2 x 3 Seals shown 1 1 when printed at Full Scale ...

Page 52: ...52 3mm HEX Use one of the 3mm Hex screws to assist in refitting the cartridge Remove the screw when the cartridge is inserted fully Step 11 Step 12 ...

Page 53: ...B Drive Housing Gear Drive Assembly 1 Turn power on to the reassembled DRV40 and connect to a Laptop PC device 2 Run the DRV Programming Software and go to the Options screen 3 Click Off under Valve Control 4 Click Calibration Set 5 Click Yes to proceed with the calibration and monitor the DRV40 display ...

Page 54: ...54 Calibrate HotEnd Valve Reset Temp 48 C Setpoint 49 C drv40 Rada 6 Wait for the DRV40 to reset ...

Page 55: ...re than 2 C 60 LCD Display shows any of the following 61 Constant difference between blend circuit temperature reading and DRV40 temperature display 63 Unable to adjust outlet temperature 64 No display 66 No display or no control 66 Cannot read the LCD display 67 High pitched noise from DRV40 68 Water leaking from DRV40 69 FAULT DIAGNOSIS ...

Page 56: ...t or debris in gear mechanism Dirt or debris around motor Motor is disconnected Magnetic rotor is not coupled to motor Proportioning assembly is sticking or has seized Motor is loose Gear drive assembly is loose If the error persists replace the motor cable loom If the error still persists then the positioning sensor on the PCB has failed Replace the PCB DRV40 Display Errors Emergency Mode Setpoin...

Page 57: ...the following Battery is connected to PCB Battery connections signs of wear or debris corrosion Batteries are at minimal power or flat Replace batteries see Maintenance and Spare Parts Do not use rechargeable batteries Brightness of LCD Adjust setting on PCB See Common Faults Cannot read the LCD display No power to DRV40 Check circuit breaker and electrical supply If problem persists replace PCB a...

Page 58: ...hese are the most likely error messages to be displayed during this problem For the most probable causes and solutions see DRV40 Display Errors If any other error message is displayed see DRV40 Display Errors Error PCB Temp 49 C Error Motor Temp 49 C Error Thermistor Temp 49 C Temp High Error Temp 49 C ...

Page 59: ...ss than 19 l m Reset circuit flow rate and check for the following Air locks Blocked strainers Closed valves Pump failure Water pressure Make sure supply pressures are balanced Make sure mixed return is flowing correctly to hot water supply inlet Checkvalves Check circuit to make sure checkvalves are correct positioned and operating normally See Recirculation Circuit Plumbing Schematic Check mixed...

Page 60: ...alve Water Heater Problem Outlet temperature fluctuates more than 2 C Check internal mechanism Mechanism is jamming or slow to control Clean and descale the following parts Proportioning Assembly Gear Drive Assembly Magnetic Rotor Renew separator seal and lubricate internal mechanism Water pressure Make sure supply pressures are balanced Check for the following Air locks Blocked strainers Closed v...

Page 61: ...nd lubricate internal mechanism using silicone based grease suitable for plumbing applications Reset DRV40 Turn power off for 10 seconds and restart Inlet water temperatures Check water supplies are connected to the correct inlet ports Check inlet supply temperature Outlet temperature exceeds the Above Setpoint value This condition causes an alert signal to be activated Outlet temperature is below...

Page 62: ... C Setpoint 49 C Temp Low 38 C Setpoint 49 C Temp High Error Temp 49 C Problem LCD Display shows any of the following Blend circuit DRV Programming Software Blend circuit does not fully return to normal temperature within the Disinfection Timeout period Check the following Disinfection Timeout value Cool Down start and finish times Early abort of disinfection cycle Use of a dump valve to speed up ...

Page 63: ...r Safety Valve Water Heater Problem Constant difference between blend circuit temperature reading and DRV40 temperature display Water Heater Readings are not equal after outlet temperature has stabilized Check outlet thermistor Turn power off for 10 seconds and restart If the error persists check the thermistor connections or replace the thermistors Blend circuit thermometer Check or replace ...

Page 64: ...t likely error messages to be displayed during this problem For the most probable causes and solutions see DRV40 Display Errors If any other error message is displayed see DRV40 Display Errors Error PCB Temp 49 C Error Motor Temp 49 C Error Thermistor Temp 49 C Temp High Error Temp 49 C ...

Page 65: ... rate and check for the following Air locks Blocked strainers Closed valves Pump failure Checkvalves Check circuit to make sure checkvalves are correct positioned and operating normally See Recirculation Circuit Plumbing Schematic Check mixed return temperature Minimum recirculation loop temperature loss 1 C Water pressure Make sure supply pressures are balanced Make sure mixed return is flowing c...

Page 66: ...able causes and solutions see DRV40 Display Errors Blank display For the most probable causes and solutions see DRV40 Display Errors If any other error message is displayed see DRV40 Display Errors If any other error message is displayed see DRV40 Display Errors Temp High Error Temp 49 C Problem No display Problem No display or no control ...

Page 67: ...the DRV40 before disconnecting and removing the Electronics Module Warning Mains Electrical connections are exposed when the cover is removed Brightness Setting If any other error message is displayed see DRV40 Display Errors Adjust the brightness setting on the PCB and reconnect the Electronics Module ...

Page 68: ... Filter Needle Valve Flow indicator Safety Valve Water Heater Problem High pitched noise from DRV40 Water pressure Make sure supply pressures are balanced Check for the following Air locks Blocked strainers Closed isolator valves Check inlet flow rates are within s p e c i f i e d p a r a m e t e r s S e e Specifications Check motor Motor may be worn replace ...

Page 69: ...nd outlet connections Check inlet and outlet thread joints Check a correct seal has been made with PTFE thread sealing tape or liquid sealant Oil based non setting joint compounds should not be used DRV body failure DRV40 replacement required Check all DRV seals Check all internal seals for wear and or damage Clean and refit seals If problem persists replace seals Only use silicone based lubricant...

Page 70: ...70 NOTES ...

Page 71: ...71 NOTES ...

Page 72: ...e Products purchased ex showroom display What to do if something goes wrong If your product does not work correctly refer to this manual for fault diagnosis and check that it is installed and commissioned in accordance with our instructions If this does not resolve the issue contact us for help and advice Technical Helpdesk Service Contact our Customer Services Team for product advice to purchase ...

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