KERAFLO AYLESBURY K User manual

AYLESBURY
K VALVE
INSTALLATION GUIDE
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FOR VALVE SIZES (DN):
2”(50)HF
2½”(65)SF
3”(80)RB
IMPORTANT
PLEASE KEEP FOR FUTURE REFERENCE.
PLEASE READ THESE INSTRUCTIONS
CAREFULLY AND REFER TO ANY DIAGRAMS
BEFORE INSTALLATION.
These instructions contain important
information which will help you install
your KERAFLO delayed action float
valve correctly and ensure safe use
and maintenance.
For further assistance please ring our
Customer Helpline: 0118 921 9920
P/KTFINSTALL A-02

KERAFLO Aylesbury delayed action float
valves contain a pair of maintenance free
ceramic discs.
There are rare occasions when it may be necessary to
partially disassemble the valve, for example, to clear a
blockage or to replace some parts.
If the problem you are experiencing cannot be solved by
using a spares kit, you made need to replace the entire
valve. Contact KERAFLO or your supplier for details.
KERAFLO AYLESBURY VALVES ARE UNLIKE
ANY OTHER FLOAT OPERATED VALVE, BALLCOCK
OR FLOAT VALVE.
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IMPORTANT
PLEASE READ THESE INSTRUCTIONS
CAREFULLY AND REFER TO ANY DIAGRAMS
BEFORE INSTALLATION.
INSTALLATION OF VALVES SHOULD BE IN
ACCORDANCE WITH THE WATER SUPPLY (WATER
FITTINGS) REGULATIONS 2010 AND BS 8558:2011.
TANKS AND PIPES SHOULD BE DISINFECTED USING
THE PROCEDURES IN BS EN 806-4:2010 SECTION
6: COMMISSIONING.
p2 AYLESBURY K VALVE
DOUBLE-R CLIP
FLOAT ADJUSTING CATCH
FLOAT ARM ASSEMBLY
SPIRIT LEVEL
DISCHARGE ASSEMBLY
FLOAT
LINK
BAR
VALVE
BODY
Once the valve has been installed and tested, complete and apply the tank label to
the tank and send a photograph of the label in place to warranties@keraflo.co.uk
in order to receive a full five years’ extended warranty for the valve. See warranty
sheets for full details.
YEAR
extended
warranty
5
T-OUTLET
VALVE
BODY

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PRE-INSTALLATION
CHECKS
RAISED VALVE Do not use a K Type valve with a raised valve chamber.
CHAMBERS: Use a KAX or KB Type valve for these tanks.
OPERATING SPACE: Check for sufficient clearance. The working dimensions are shown on the
attached drawings on page 7 & 8.
OVERFLOW/WARNING Check the position of the overflow and warning pipe, where fitted (see drawing on page 7).
PIPES:
TURBULENT Exceptionally turbulent waters, such as in cooling towers, should be avoided directly
WATER: beneath the float. Calming measures such as baffle plates, still ponds etc. should be
used in these installations.
FLANGED TANKS: The design of the valves, allows sufficient clearance between the float and most internal
tank flanges and ribs (see drawings on pages 7 & 8). The valve backnuts may be adjusted
to enable fitting to tanks with large flanges; provided a minimum of 20mm exists between
the float and tank wall throughout the arc of the float.
ROUND TANKS: Minimum tank diameters required.
NOTE: TO ENSURE SUFFICIENT OPERATING CLEARANCE IT MAY BE NECESSARY TO EXTEND THE
PIPEWORK TO POSITION THE VALVE ASSEMBLY IN THE CENTRE OF THE TANK CHAMBER.
SLOPING TANK The wall to which the Aylesbury K Valve is to be attached must be vertical. If the wall
WALL: around the fixing hole is sloped, tapered washers must be used. These should be
available from the tank supplier.
PIPEWORK KERAFLO Aylesbury valves create virtually no tank wall stress. It is therefore not necessary
SUPPORT: to provide additional support to the pipework as long as the Code of Practice for the
Support of Pipework in general is met.
ISOLATING An isolating valve must be fitted as near as is reasonably practicable to the
VALVE: KERAFLO valve.
VALVE 2”HF 2½”SF 3”RB
MIN TANK
DIAMETER (M) 0.6M 0.6M 0.6M
AYLESBURY K VALVE p3

DOUBLE-R CLIP
BACK NUT
DIAGRAM 1
INSTALLATION
INSTRUCTIONS
The valve is supplied with the float arm and
discharge assemblies detached. To avoid
damage it is recommended, where possible,
to fit both of these assemblies AFTER installing
the valve in the tank.
1Before fitting the valve, flush the supply
pipes to clear all debris.
2Remove and retain the double-R clips
from both valve bodies.
3Remove and discard the red protective
cap from the tail.
4Remove and retain one inlet backnut
from the T-outlet.
5Insert the valve tail through the hole in
the tank wall observing the side of the
T-outlet marked “TOP”.
6Replace the backnut with the flanged
side against the tank wall.
7Level the two valves on the T-outlet by
placing a spirit level across the T-outlet,
parallel to the tank wall on which it
is mounted and twisting the whole
assembly to bring the assembly level.
8Tighten the backnut sufficiently to
hold the assembly in position but note
that it may be necessary to move the
assembly later after the float clearances
have been measured.
9Fit the float arm assemblies, fixing them
in place with the parts retained at step 2
(Diagram 3).
BACKNUT HOLD WITH
WRENCH
HERE, ONLY
DIAGRAM 2
DIAGRAM 3
p4 AYLESBURY K VALVE
USE A SPIRIT LEVEL TO ENSURE
T-OUTLET IS HORIZONTAL
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TANK
WALL
ENSURE PIN ENGAGES
IN HOLE IN ACTUATOR

WARNING!
THE BUILT-IN SPIRIT LEVEL MUST BE USED TO
ALIGN THIS VALVE. FAILURE TO FOLLOW THE
PROCEDURE LISTED BELOW WILL PREVENT THE
VALVE OPERATING CORRECTLY.
INSTALLATION OF VALVES SHOULD BE IN
ACCORDANCE WITH THE WATER SUPPLY (WATER
FITTINGS) REGULATIONS 2010 AND BS 8558:2011.
TANKS AND PIPES SHOULD BE DISINFECTED USING
THE PROCEDURES IN BS EN 806-4:2010 SECTION
6: COMMISSIONING.
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10 The float arms should hang vertically
with the built-in spirit level bubbles
exactly between the black lines as
shown in diagram 4.
ENSURE THAT THE FLOAT ARM OPERATING
PINS ENGAGE IN THE HOLES IN THE ACTUATOR
WHEELS AND THAT THE FLOAT MARKED WITH
A RED DOT IS FITTED TO THE VALVE WHICH IS
ALSO MARKED WITH A RED DOT.
11 If the valves are not level, each individual
valve can be rotated at its screwed
connection into the T-outlet. This joint is
sealed by an “o”-ring so can be moved
without fear of a leak.
12 Loosen the locknuts on the valve body
and rotate each valve individually as
necessary so that the float arms are
ABSOLUTELY VERTICAL.
13 Align each valve, tighten the locknut
and re-check the alignment.
EACH BUBBLE MUST BE PRECISELY
BETWEEN THE BLACK LINES.
14 Check that the clearance between
the tank wall and the floats is at least
25mm, when the float arms are
vertical. If it is less than this move
the assembly further into the tank
by adjusting the valve backnuts and
repeating steps 6 to 8.
15 When the clearance and the levels are
correctly set, fully tighten the backnuts
holding the assembly to the tank wall.
16 Using the 4mm Allen key supplied,
remove the two M5x12 screws from the
ends of the float link bar.
17 Place the bar between the lowest holes of
the two Float Arms and attach it using the
M5x12 screws, as shown in Diagram 5.
DIAGRAM 4
SPIRIT LEVEL
AYLESBURY K VALVE p5
SPIRIT LEVEL
DIAGRAM 5
SPIRIT LEVEL
VALVE
BODY
LOCK
NUTS
FLOAT ARMS
FLOAT LINK BAR

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p6 AYLESBURY K VALVE
ALIGNMENT WARNING!
THE FLOAT ARMS MUST BE FITTED IN THE VERTICAL
POSITION WHEN THE VALVES ARE FULLY OPEN. THIS
IS CRITICAL TO THE OPERATION OF THE VALVES.
18 Tighten using the Allen key, ensuring
that the Float Arms remain parallel.
19 Connect the supply pipe after an isolating
valve and hand tighten the connection
backnut. To prevent the valve turning
when tightening the pipe fitting, use
either a wrench or a spanner on the valve
tail where indicated in Diagram 2. DO NOT
USE A WRENCH ON ANY OTHER PART OF THE
VALVE.
20 Remove and discard the protective
caps from the discharge assemblies
before adjusting the closing level and
commissioning the valve.
21 Using the 4mm Allen key supplied, fit
the discharge assemblies referring to
Diagram 6 for the direction.
DIAGRAM 6
ADJUSTING CLOSING
WATER LEVEL (TWL)
1Pull out the float adjusting catches.
2Move the floats to the desired position.
3Release catches and ensure the pins
locate in desired hole.
4ENSURE THAT BOTH FLOATS ARE SET TO
THE SAME LEVEL.
5The delayed action (level differential)
is the difference between the Opening
and the Closing Levels. This will be
between 50 and 100mm depending on
the float position and is not adjustable.
DIAGRAM 7
SLIDE FLOAT
INTO POSITION
FLOAT
ADJUSTING
CATCH
TESTING
Before leaving the installation, manually
move the valves to test their operation a
number of times, ensuring that they move
freely from the open to the closed position
and from the closed to the open position.
Where a valve has not been in operation for
one month it is also recommended that the
above procedure is carried out.

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AYLESBURY K VALVE p7
2”(50)HF
2½”(65)SF
3”(80)RB
SIZES (DN):
BASIC SPECIFICATION:
Maximum static pressure: 10bar
Maximum flow rate: 3m/s nominal pipe velocity (Flow Rate and
Pipe Velocity chart is available at www.keraflo.co.uk)
Temperature range: 1° – 60°C
Level differential: 50 - 100mm non-adjustable delayed action
See page 8 for side view.
FLOAT
LINK BAR
FLOAT
FLOAT
ADJUSTING
CATCH (PULL
TO RELEASE)
INSERT
WEIGHT
FLOAT ARM
SPIRIT
LEVEL
603
SPIGOT
VALVE
BODY
SLIDE
FLOAT TO
DESIRED
CLOSING
LEVEL
37
515
ATTACH
FLOAT
LINK BAR
USING 4MM
ALLEN KEY
PROVIDED
200
350
VALVE
BODY
DOUBLE
R CLIP
11
ADJUST ALIGNMENT
HERE

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p8 AYLESBURY K VALVE
WARNING
THE FLOAT ARM MUST BE FITTED ABSOLUTELY
VERTICALLY (IN THE OPEN POSITION) AS INDICATED
BY THE SPIRIT LEVEL (SEE BELOW).
MISALIGNMENT WILL PREVENT THE VALVE FROM
CLOSING.
ENSURE OVERFLOW LEVEL IS NOT LOWER THAN
225MM FROM THE CENTRE LINE OF
THE VALVE.
THE WARNING PIPE AND OVERFLOW OUTLET SHOULD
ALWAYS BE ABOVE THE HIGHEST WATER LEVEL
ACHIEVED BEFORE THE VALVE CLOSES.
2”(50)HF 2½”(65)SF 3”(80)RB
DELAYED ACTION
50MM APPROX
OPEN
POSITION
CLOSING LEVEL
(TWL)
OPENING LEVEL
(LWL)
CLOSED
POSITION
390
80
155 270
40º
SIZES (DN):
DN 50HF 65SF 80RB
SIZE 2” 2½” 3”
BMAX 95 100 99
ØE 6o 75.5 89
NOTES:
SCHD2, SECT 7, G16.5 Water Regs. Gaps should be more if water is turbulent –
especially if near valve discharge.
Typically twice inlet bore. SCHD 2, SECT 7, G16.10 Water Regs. Warning/overflow pipes
should be capable of taking any possible flow in the pipe arising from inlet valve failure.
See page 7 for front view.
A
B
LOWEST WATER
LEVEL SETTING
155 340
DELAYED
ACTION
100MM
APPROX
OPEN
POSITION
CLOSED
POSITION
CLOSING
LEVEL
(TWL)
OPENING
LEVEL
(LWL)
250
25
190
111
510
WARNING PIPE
PUSH GENTLY
TO LIMIT WHEN
CHECKING
ALIGNMENT
SPIRIT LEVEL
BUBBLE BETWEEN
BLACK LINES
225
MAX
200
MAX OVERFLOW
A
25MM
MIN
50HF ATTACH
WRENCH HERE
HIGHEST WATER
LEVEL SETTING
B MAX
ØE
B