AVR AVK Series User manual

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
Installation, Operation and Maintenance Manual
AVK Series 854 Ball Float Valve
The AVK 854 is a series of ball float valves designed to be fitted within a tank or in the
top of a reservoir to control the filling and maintain a pre-determined water level.
The system operates by a float that closes the valve when rising and opens it when
lowering.
The float is made of polypropylene or stainless steel, the internal valve parts are
copper alloy and the valve housing is epoxy coated ductile iron.
Level difference between fully open and fully closed is between 170 mm for DN 50 to
930 mm for DN 300.

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
1. AVK series 854 exploded view

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
2. AVK series 854 parts list
Item
Description
Material
1
Body
Ductile iron
2
Cylinder retainer flange
Ductile iron
3
Fulcrum bracket
Ductile iron
4
Cylinder
DZR Brass
5
Piston
Bronze
6
Bolt
Stainless steel
7
Float ball
Stainless steel / PP
8
Lever
Steel, stainless / hot dip galvanized
9
Hinge pin
Stainless steel
10
Fulcrum pin
Stainless steel
11
Bushing
Bronze
12
Links
Steel, hot dip galvanized
13
Split pin
Stainless steel / copper
14
Piston seal ring
EPDM rubber
15
Groove for piston seal ring
-
16
O-Ring gasket
EPDM rubber
17
Seat ring
Bronze
18
Main seal
EPDM rubber
19
Valve guide
Bronze
20
Nut and washer
Stainless steel
21
Bolt
Stainless steel
22
Filler cap
Stainless steel / PP
23
Bushing (only certain models)
Stainless steel

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
3. Table of contents
1. AVK series 854 exploded view..........................................................................................2
2. AVK series 854 parts list...................................................................................................3
3. Table of contents...............................................................................................................4
4. Principle of operation.........................................................................................................5
5. Health and safety at work..................................................................................................5
6. Receiving and storage.......................................................................................................6
7. Installation and commissioning..........................................................................................7
8. Application hazards...........................................................................................................7
9. Operation and maintenance..............................................................................................8
9.1. Operation.........................................................................................................................8
9.2. Maintenance....................................................................................................................8
9.3. Seal renewal....................................................................................................................9
10. Troubleshooting ..............................................................................................................10
11. Recommended spare parts.............................................................................................10

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
4. Principle of operation
Series 854 Ball Float Valve controls discharge of water into a tank or reservoir in response to
water level variations. The float mechanism holds the valve closed until the water levels drops,
the float then follows the water level matching inflow to outflow. If the outflow ceases, the water
level will rise and the float close the valve.
5. Health and safety at work
Make sure all relevant Health and Safety issues and regulations are adhered to prior to and
during installation or maintenance work carried out on this product. It is the end user's
responsibility to ensure that safe working practices are followed at all times.
Whenever AVK’s products are installed, operated or maintained the inherent dangers of
pressurised liquids and gasses must be addressed. Before work on a valve or other piping
component is undertaken, that may involve the release of internal pressure, the valve or line
must be fully isolated, depressurised and drained prior to commencing the work. FAILURE TO
COMPLY WITH THIS MAY RESULT IN SEVERE INJURY OR DEATH.

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
All workers handling the product must be aware of the weight of the components or assemblies
to be handled and manipulated during installation and maintenance.
It is essential that staff undertaking these operations are adequately trained and it is the
responsibility of the end user that only trained and competent staff undertake these duties.
This manual has been designed to assist, but it cannot replace quality training in the workplace.
However, the AVK technical staff is always available and ready to answer questions relating to
specific problems that may not be covered by this manual.
AVK’s products are designed to be fit for purpose and to a high reliability standard. This
provides a safe, low risk product when used correctly for the purpose for which it was designed.
However, this assumes that the equipment is used and maintained in accordance with this
manual, and the user is advised to study it and to make it available to all staff that may need to
refer to it.
AVK cannot be held responsible for incidents arising from incorrect installation, operation or
maintenance. The responsibility for this rests wholly with the end user.
6. Receiving and storage
The valve housing, float and lever are shipped in separate boxes.
Unloading must be carried out carefully. The load must be put gently to the ground without
dropping. Lift only by means of shackles in the flange bolt holes or slings around the body
casting.
Do not lift the assembled valve in fulcrum pins, fulcrum bracket or float lever.
If a forklift is used it shall have sufficient capacity to lift the required weight and have a valid
inspection certificate.
All workers involved in the unloading shall be able to perform their functions. They shall wear
safety boots, safety vest, safety goggles and hard hat.
All slings used for the lifting shall be of sufficient strength. A record shall document that they
have been stored under cool, dry conditions away from sunlight and chemical atmosphere, and
that they still perform according to their marked strength.
Immediately after unloading the item should be inspected for compliance with specifications and
damage in shipment.
Compliance with specification check shall as a minimum comprise size, pressure class, flange
type and float material.
Damage in shipment check shall as a minimum comprise: coating, seating surfaces, bent levers
or shafts, cracked parts, loose bolts, missing parts or accessories or any other evidence of
mishandling during shipment.
Each item should be operated through one complete open-close cycle in the position in which it
is to be installed.
Storage shall be under dry, cool conditions, away from direct sunlight and corrosive or
otherwise chemically active atmosphere.
Make sure the main seal rubber ring is not compressed during storage.

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
7. Installation and commissioning
The valve is sensible to dust and dirt on its upper parts where the piston slides in the cylinder,
so if installed outdoors or in a dusty or otherwise dirty environment it must be protected in a
suitable valve chamber with sufficient cover from objects and debris falling from above.
Do not install closer than 6 pipe diameters downstream of tees or elbows or other irregularities;
this can cause violent turbulence and cavitation inside the valve and reduce its performance
and durability.
WARNING: Prior to installation make sure that all pressurized lines involved in the installation
are isolated, depressurized and drained before starting any work. Failure to do so may result in
sudden pressure release and subsequent severe injury or death.
•Position the valve housing on the flange and fit the bolts
•Tighten the bolts diagonally in increments to make sure the flanges are kept parallel and
finally tighten to correct torque
•Assemble lever and float with the filler cap pointing upwards, install them on the valve
housing with the fulcrum and hinge pins and secure them with split pins
•Check for freedom of movement and alignment
•Make sure the valve sealing areas are clean and lubricated with a lubricant suitable for
the medium
•If necessary to touch up coating that has been damaged during installation, make sure
that no paint is applied to the bearings or sealing surfaces.
When the pipeline has been charged, inspect for leaks and adjust as necessary in accordance
with the maintenance instructions.
Operate the valve over a full stroke and check for free movement.
8. Application hazards
Unless properly isolated the valve should not be installed in applications where the ambient
temperature can reach values below the freezing point of the liquid.
The seals are exceptionally well suited for use with water but exposed to hydrocarbons they will
dissolve and render the valve leaking.
Do not use with flammable liquids.
Saltwater and brine will corrode the standard materials used in the valve, but alternative more
corrosion-resistant materials may be available; contact AVK for further information.
Operation at max. allowed pressure and very low flow for prolonged periods can cause
cavitation and damage to the valve seat.

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
9. Operation and maintenance
9.1. Operation
The complete assembly must be able to move freely and easily up and down between fully
open and fully closed. Make sure all pin joints and linkages are greased and checked for
freedom of movement.
By adding water into the float through the filler cap it is possible to finely adjust the regulated
height of the water surface level.
9.2. Maintenance
Once every month operate the valve a few times all the way between fully open and fully
closed. Check that it shuts completely off when closed.
Once every 6 months clean and lubricate cylinder, pin joints and linkages. Check for wear or
damage and for freedom of operation and movement.
WARNING: Prior to any maintenance work that requires disassembly make sure that the
pressurized line involved is isolated, depressurized and drained before starting any
disassembly. Failure to do so may result in sudden pressure release and subsequent severe
injury or death.
In case the valve does not operate easily check the internals of the valve:
1) Support float and lever so that the mechanical load is removed from fulcrum- and hinge
pins
2) Remove split pins from fulcrum- and hinge pins
3) Remove fulcrum- and hinge pins and lift off lever and float
4) Remove the fulcrum bracket
5) Remove piston assembly
6) Inspect piston O-ring/lip seal and valve main seal for wear, damage, cuts, etc.; replace
if necessary
7) Check links, fulcrum and hinge pins for wear and replace if necessary
8) Clean and lubricate seal groove and refit or replace seals
9) Inspect valve guide and seat ring for damage or scoring from grit, stones or other
debris. Small damages can be smoothed out with a file and emery cloth, but replace
part if cuts are deep
10) Re-assemble piston components; be careful not to damage the piston O-ring/lip seal
11) Make sure the piston can move freely up and down
12) Install piston assembly in the cylinder and fit fulcrum bracket
13) Install lever/float assembly with new split pins
14) Check float for leaks or damage

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
9.3. Seal renewal
1. Remove the piston assembly
2. Remove piston seal ring (14)
3. Clean and lubricate seal groove (15)
4. Check seal ring for cracks or damage, replace if necessary
5. Install seal ring
6. Remove bottom nut (20)
7. Take apart valve guide (19), piston (5) and main seal (18)
8. Check main seal for cracks or damage, replace if necessary
9. Refit seal and assemble the parts
10. Lubricate inner cylinder and piston seal ring with suitable lubricant
11. Reinstall piston assembly with new split pins

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Copyright © AVK Holding A/S, original version, rev. 10, 30-June-2020
10. Troubleshooting
Symptom:
Valve sticks
Cause:
Piston is stuck in the cylinder
Cure:
Disassemble, clean and lubricate the piston assembly. Replace worn or
damaged parts
Symptom:
Valve sticks
Cause:
Worn bushings and pins
Cure:
Replace worn parts
Symptom:
Water level is unstable
Cause:
Worn bushings and pins
Cure:
Replace worn parts
Symptom:
Valve leaks from main seal
Cause:
Worn or damaged main seal
Cure:
Replace main seal
Make sure the liquid is not chemically aggressive to the valve parts and that
the pressure/flow combination does not cause cavitation
Symptom:
Valve leaks from main seal
Cause:
Impurities between valve seat and main seal
Cure:
Clean the piston assembly and replace the seal if damaged.
Install a filter before the valve
Symptom:
Water drips down the valve from its upper side
Cause:
Defective piston seal
Cure:
Replace piston seal
Symptom:
Valve does not close
Cause:
Float leaky and filled with water
Cure:
Replace float
Check if corrosion is the reason in which case another float material should be
considered.
11. Recommended spare parts
Only genuine AVK spare parts should be used.
AVK accepts no responsibility for damage caused by failing non-AVK parts.
Following spare parts are recommended to purchase with a ser. 854 valve:
•Seals
•Gaskets
•Lubricants
•Touch up paint