Kohler K-1630 User manual

Installation Guide

Bath/Shower Whirlpool Module

Mproduct numbers are for Mexico (i.e. K-12345M)

Los números de productos seguidos de Mcorresponden a México

(Ej. K-12345M)

Français, page “Français-1”

Español, página “Español-1”

K-1630 K-1635

1015417-2-C

Important Information

WARNING: When using electrical products, basic precautions should always be followed, including

the following:

DANGER: Risk of electric shock. Connect only to a circuit protected by a Ground-Fault

Circuit-Interrupter (GFCI).

Building materials and wiring should be routed away from the pump body and other heat-producing

components of the unit.

Install to permit access for servicing.

Grounding is required. The unit should be installed by a qualiﬁed service representative, and grounded.

WARNING: Risk of electric shock. A licensed electrician should make all electrical connections.

WARNING: Risk of electric shock. Disconnect power before servicing.

WARNING: Risk of injury or property damage. Please read all instructions thoroughly before

beginning installation, including the following requirements.

NOTICE: Follow all local plumbing and electrical codes.

Product Information

Electrical Requirements

The installation must have a Class A Ground-Fault Circuit-Interrupter (GFCI). The GFCI protects against

line-to-ground shock hazard. Use a 120 V, 15 A, 60 Hz dedicated service for the whirlpool.

″H″models require a separate 120 V, 15 A, 60 Hz dedicated service for the in-line heater.

NOTE: If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or

similarly qualiﬁed persons in order to avoid a hazard.

Product Notices

WARNING: Unauthorized modiﬁcation may cause unsafe operation and poor performance of the

whirlpool. Do not relocate the whirlpool pump, or make other modiﬁcations to the whirlpool system,

as this could adversely affect the performance and safe operation of the whirlpool. Kohler Co. shall not

be liable under its warranty or otherwise for personal injury or damage caused by any such

unauthorized modiﬁcation.

Factory-Assembled Features

Factory installed components include pump with power supply cord and air switch transmitter. No

installation is needed.

″H″models are also supplied with a factory assembled, in-line heater.

An optional timer kit is available for this product.

The whirlpool pump and piping are factory-assembled.

Connections and Service Access

Before installation, ensure proper access to the ﬁnal connections.

1015417-2-C 2 Kohler Co.

Product Information (cont.)

NOTICE: Provide unrestricted service access to the pump. You must provide access for servicing the

pump and controls. The access must be located immediately next to the pump. Study the roughing-in

information packed with the whirlpool.

Table of Contents

Important Information .............................................................. 2

Product Information ............................................................... 2

Electrical Requirements .......................................................... 2

Product Notices ................................................................ 2

Factory-Assembled Features ...................................................... 2

Connections and Service Access ................................................... 2

Thank You For Choosing Kohler Company .............................................. 4

Tools and Materials ............................................................... 4

Before You Begin ................................................................. 4

Prepare the Site ................................................................. 5

Prepare the Whirlpool ............................................................. 5

Secure the Module to the Stud Framing ................................................ 6

Install the Plumbing ............................................................... 6

Make Electrical Connections ......................................................... 7

Pump Wiring .................................................................. 7

In-Line Heater Wiring ............................................................ 7

Test Run the Whirlpool ............................................................. 7

Complete the Finished Wall ......................................................... 9

Clean-Up After Installation ......................................................... 10

Conﬁrm Proper Operation .......................................................... 10

Fill the Whirlpool .............................................................. 10

Operating Sequence ........................................................... 10

Troubleshooting Procedure ......................................................... 11

Remove the Factory Installed Jets ................................................. 11

Reinstall the Jets .............................................................. 11

Troubleshooting Guide .......................................................... 11

Kohler Co. 3 1015417-2-C

Thank You For Choosing Kohler Company

We appreciate your commitment to Kohler quality. Please take a few minutes to review this manual before

you start your installation. If you encounter any installation or performance problems, please don’t hesitate

to contact us. Our phone numbers and website are listed on the back cover. Thanks again for choosing

Kohler Company.

Tools and Materials

Before You Begin

CAUTION: Risk of product damage. Do not lift the whirlpool by the piping or pump, or use the

piping or pump for structural support of the whirlpool.

We recommend this whirlpool for alcove installation.

Inspect the whirlpool for damage before you begin installation.

You must install this whirlpool to an adequately supported, level subﬂoor.

Conﬁrm adequate mounting and connection space for the faucet speciﬁed for your installation.

Provide sufficient clearance to move the module into the construction area.

Avoid ﬂexing the side walls to prevent damage to the module.

Insulate all exterior walls before installation.

When ﬁre-rated wall is speciﬁed, the stud opening dimensions are to the inside of the wallboard.

If the module will be installed adjacent to vertical ducts or chases, surround the unit with ﬁre-rated

gypsum wallboard.

The basin area requires no additional support when the subﬂoor is level and square with respect to

the stud framing. Consider using shims for additional support if the subﬂoor is uneven.

Refer to the instructions included with accessories and shower doors before beginning this

installation.

Provide access to all plumbing connections. This is a one-piece module, and you cannot make the

drain and overﬂow connections by reaching over the end of the module.

To enhance the ﬁnished appearance of the tile-wall module designs, pay special attention to

placement of the exposed plumbing ﬁttings. Position the valving and shower ﬁttings where they

will complement the tile-wall appearance of the module.

Sealant Pencil

Level

Pipe Wrench Drill

Tin Snips

Plus:

• Conventional woodworking tools

and materials

• Drop Cloth

• Hole saws

• #6 Large-head galvanized nails

• 2x4's

• Screws or lag bolts

Tape

Measure

Safety

Glasses

1015417-2-C 4 Kohler Co.

1. Prepare the Site

NOTICE: Unless otherwise speciﬁed, ﬂoor support under the whirlpool must provide for a minimum of

80 lbs./square foot (390 Kg./square meter) loading.

NOTICE: Do not support the whirlpool by the rim.

Make sure the ﬂooring offers adequate support for your whirlpool, and verify that the subﬂoor is

ﬂat and level.

The module should be installed in an alcove installation. Construct 2x4 stud framing designed for

your particular installation. Construct a frame in accordance with the roughing-in information

packed with the whirlpool. Make sure the headers are level and square. Refer to instructions

included with your shower door and accessories before beginning this installation, and add any

additional bridging or support required.

If necessary, leave one of the framing side walls loose until you move the module into position.

Then line the side wall up with the module, and secure the side wall permanently in place to the

stud framing.

Position the plumbing according to the roughing-in information packed. Cap the supplies, and

check for leaks.

2. Prepare the Whirlpool

Install the drain to the whirlpool according to the drain manufacturer’s instructions. Do not connect

the trap at this time.

NOTE: To enhance the ﬁnished appearance of the tile-wall module designs, pay special attention to

placement of the exposed plumbing ﬁttings. Position the valving and shower ﬁttings where they will

complement the tile-wall appearance of the module.

Position a clean drop cloth or similar material in the bottom of the whirlpool. Be careful not to

scratch the surface of the whirlpool.

Lay out and mark the location of the mixing valve, shower, and bath spout holes on the back

surface of the module wall. Drill 1/4″pilot holes at the marked locations.

From the inside of the module (ﬁnished surface), use a hole saw of the recommended diameter to

carefully drill the ﬁtting holes. Immediately clean the module to reduce the risk of surface damage.

Construct 2x4 stud

framing according to

the roughing-in

information.

If necessary, leave

one of the framing

side walls loose

until you move the

module into

position.

Position

the rough

plumbing.

Verify that the subfloor offers adequate

support, and is flat and level.

Kohler Co. 5 1015417-2-C

3. Secure the Module to the Stud Framing

CAUTION: Risk of product damage. Do not lift the whirlpool by the piping or pump, or use the

piping or pump for structural support of the whirlpool.

With help, carefully lift the module into position.

Insert the drain tailpiece into the trap. Make sure the whirlpool is level and resting on all support

blocks.

Plumb and level the module along the nailing-in ﬂanges, and use shims to level the module rim. Do

not support the module by the rim.

Place shims under the module body to add support when module is in use.

Drill small pilot holes 8″(20.3 cm) apart through the vertical nailing-in ﬂanges along the front of the

module. Then drill small pilot holes through the horizontal nailing-in ﬂange at each side and back

stud. Add shims between the nailing-in ﬂange and the studs as needed to eliminate gaps.

Nail 1/4″(6 mm) thick furring strips to the studs to shim out to the edge of the nailing-in ﬂange.

For metal stud construction, drill the fastener holes through the nailing-in ﬂange and the metal

studs, and secure with sheet metal screws.

Use #6 large-head galvanized nails to secure the nailing-in ﬂange to the studs.

4. Install the Plumbing

CAUTION: Risk of property damage. Ensure a watertight seal on the whirlpool drain.

Connect the drain to the trap according to the drain manufacturer’s instructions.

NOTICE: An access panel will simplify future maintenance.

Install the faucet valving according to the faucet manufacturer’s instructions. Do not install the

faucet trim until instructed. Open the hot and cold water supplies, and check the supply

connections for leakage.

Run water into the whirlpool, and check the drain connections for leakage.

Nail 1/4" (6 mm) thick furring strips

to shim out to the edge of the

nailing-in flange. Drill a small hole through the

back nailing-in flange at each

stud.

Place shims under the whirlpool

body to provide support when the

whirlpool is in use.

Drill small holes through the side

nailing-in flange 8" (20.3 cm) apart.

Use #6 large-head galvanized nails to secure

the side nailing-in flange to the studs.

Stud

Nailing-In Flange

1015417-2-C 6 Kohler Co.

5. Make Electrical Connections

WARNING: Risk of electric shock. To reduce the risk of electrical shock, connect the pump and in-line

heater (if heater option included) to properly grounded, grounding-type receptacles protected by

Ground-Fault Circuit-Interrupters (GFCI’s). Do not remove the plugs’ grounding pins. Do not use

grounding adapters.

Pump Wiring

NOTE: The whirlpool model number is printed on a label near the whirlpool pump. This label also

identiﬁes the electrical rating of the whirlpool.

Your Kohler whirlpool bath is equipped with a cord and plug. All wiring of the pump and control

has been completed at the factory. A licensed electrician must install a GFCI-protected, 120 V, 15 A,

grounded outlet. No other load should be on this circuit. Locate the outlet behind the whirlpool,

and within 24″(61 cm) of the pump.

Plug the pump into this outlet.

NOTE: Make sure the air actuator tubing is securely attached to the pump, and is not kinked or damaged.

If a K-1639 Timer Kit will be used, install it now according to the instructions packed.

In-Line Heater Wiring

″H″Models: The in-line heater is equipped with a cord and plug. All wiring of the heater has been

completed at the factory. A licensed electrician must install a GFCI-protected, 120 V, 15 A, grounded

outlet. No other load should be on this circuit. Locate the outlet behind the whirlpool, and within

24″(61 cm) of the heater.

Plug the in-line heater into this outlet.

6. Test Run the Whirlpool

Check all electrical connections, and make sure the electrical power to the whirlpool and in-line

heater (if equipped) is on.

Make sure all union connections to the pump and heater are securely hand tightened.

Verify that the pump banding straps have been cut (if applicable), and that the pump is resting

directly on the subﬂoor or whirlpool base.

Fill the whirlpool to a level at least 2″(5.1 cm) above the top of the highest jet.

Operate the whirlpool for 5 minutes, and check all whirlpool piping connections for leaks.

Install a GFCI-protected 120 V, 15 A grounded outlet.

Install a second GFCI-protected outlet for "H" models

for the in-line heater.

Plug pump and

in-line heater into

these outlets.

Make sure the air actuator tubing is

securely attached to the pump.

Bond in accordance with applicable codes.

Connect here.

Optional In-Line Heater

(models may vary)

either T-style (shown) or

water intake (not shown)

Kohler Co. 7 1015417-2-C

Test Run the Whirlpool (cont.)

For additional information on whirlpool operation, refer to ″Conﬁrm Proper Operation″.

1015417-2-C 8 Kohler Co.

7. Complete the Finished Wall

If you have not already done so, carefully remove the protective tape from the whirlpool rim.

Apply a continuous bead of silicone sealant to the nailing-in ﬂanges. Install water-resistant wall

material so the paperbound edge is at least 1/4″(6 mm) above the ﬁnished, concave surface of the

whirlpool.

Tape and mud the water-resistant wall material. Install the ﬁnished wall material.

Install the mixing valve, shower, and spout trim according to the instructions packed with the trim.

Install any extra grab bars or towel bars to the bridging previously installed. Follow the accessory

manufacturer’s instructions.

Install the shower door according to the manufacturer’s instructions.

Concave Surface

Stud

Apply a continuous

bead of silicone sealant

to the nailing-in flanges

Install water-resistant wall

material so the paperbound

edge is at least 1/4" (6 mm)

above the finished, concave

surface of the whirlpool

Kohler Co. 9 1015417-2-C

8. Clean-Up After Installation

When cleaning up after installation, do not use abrasive cleansers, as they may scratch and dull the

whirlpool surface. Use warm water and a liquid detergent to clean the surface.

Remove stubborn stains, paint, or tar with turpentine or paint thinner. Do not allow cleaners

containing petroleum distillates to remain in contact with any whirlpool surfaces for long periods

of time. Remove plaster by carefully scraping with a wood edge. Do not use metal scrapers, wire

brushes, or other metal tools. Use a powder-type detergent on a damp cloth to provide mild

abrasive action to any residual plaster.

9. Conﬁrm Proper Operation

Fill the Whirlpool

NOTE: Please read these steps carefully before you operate your whirlpool.

Position the jet nozzles so they face down toward the basin. Turn the jet trim rings fully

counterclockwise.

Fill the whirlpool to a water level at least 2″(5.1 cm) above the top of the highest jet.

NOTE: The water temperature in the whirlpool should not exceed 104° F (40° C).

Operating Sequence

Press the air actuator to turn on the whirlpool jets.

Adjust each jet for optimum air/water mixture. Turn the trim ring clockwise to reduce the air ﬂow,

and counterclockwise to increase the air ﬂow.

If equipped with an in-line heater, the heater will engage automatically when the pump is turned on

and will disengage when the pump is turned off. The heater will not turn on if the water

temperature exceeds 104° F (40° C).

Press the air actuator a second time to turn off the whirlpool.

NOTE: The optional K-1639 Timer Kit automatically stops the whirlpool after approximately 20 minutes of

operation.

Fill with water 2" (5 cm)

above the highest jet

Turn the jet trim

ring clockwise to

decrease the flow Position the jet

nozzles to direct

the water flow as

desired

Turn the jet trim ring

counterclockwise to

increase the flow

Press the air actuator to turn on and

off the whirlpool

1015417-2-C 10 Kohler Co.

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