KERAFLO AYLESBURY KAX User manual

AYLESBURY
KAX 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/KAXTFINSTALL A-02

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.
FLOAT
ASSEMBLY
SPIRIT LEVEL
DISCHARGE
ASSEMBLY
p2 AYLESBURY KAX VALVE
DROP ARM ASSEMBLY
T-OUTLET
DISCHARGE
ASSEMBLY
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
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 contact KERAFLO or your supplier.
DOUBLE-R CLIP
DOUBLE-R CLIP
VALVE
BODY
VALVE
BODY
FLOAT
LINK BAR

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PRE-INSTALLATION
CHECKS
RAISED VALVE Use a KAX or KB Type valve for tanks with raised chambers.
CHAMBERS: DO NOT USE A K TYPE VALVE FOR THESE TANKS.
OPERATING SPACE: Check for sufficient clearance. The working dimensions are shown on the
attached drawings on page 9 & 10.
OVERFLOW/WARNING Check the position of the overflow and warning pipe (where fitted).
PIPES: See drawing on page 9.
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. 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 KAX 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) 0.65M 0.65M 0.65M
AYLESBURY KAX VALVE p3

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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, washers and bushes from the
bottom of both drop arm assemblies.
3Remove and discard the red
protective cap from the tail.
4Remove and retain the backnut
closest to the end of the tail.
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.
ONLY USE A WRENCH ON THE VALVE
WHERE INDICATED IN DIAGRAM 2.
DOUBLE-R
CLIP
BACK NUT
DIAGRAM 2
DIAGRAM 1
p4 AYLESBURY KAX VALVE
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 AND WILL
INVALIDATE THE WARRANTY.
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.
HOLD WITH
WRENCH
HERE, ONLY.
TANK WALL
BACK NUT
WASHER
BUSH
DROP ARM
ASSEMBLY

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 valves
level.
8Tighten the backnut sufficiently to
hold the complete valve in position
but note that it may be necessary to
move the valve later after the float
clearances have been measured.
9Fit the float arm assemblies, fixing
them in place with the parts retained
at step 2, checking the correct
positioning of the bush with the
recessed side against the float
arm. ENSURE THAT THE FLOAT ARM
OPERATING PINS ENGAGE IN THE HOLES
IN THE DROP ARM ACTUATORS AND THAT
THE FLOAT MARKED WITH A RED DOT IS
FITTED TO THE VALVE WHICH IS ALSO
MARKED WITH A RED DOT.
10 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.
11 Loosen the valve locknuts on the
T-outlet and rotate each valve
individually as necessary so that the
float arms are ABSOLUTELY VERTICAL.
DIAGRAM 3
AYLESBURY KAX VALVE p5
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USE A SPIRIT LEVEL TO ENSURE
T-OUTLET IS HORIZONTAL
FLOAT ARM
ASSEMBLIES
DOUBLE-R
CLIP, WASHER
AND BUSH
ENSURE
THAT THE
FLOAT ARM
OPERATING
PINS ENGAGE
IN THE HOLES
IN THE
DROP ARM
ACTUATORS
VALVE LOCK
NUTS

12 Align each valve, tighten the locknuts,
and re-check the alignment. EACH
BUBBLE MUST BE PRECISELY BETWEEN
THE BLACK LINES ON THE SPIRIT LEVEL.
13 Check that the clearance between
the tank wall and the floats is at least
25mm. If it is less than this, move
the assembly further into the tank by
adjusting the tank wall backnuts and
repeating steps 7-8 and 10-12.
14 When the clearance and the levels
are correctly set, fully tighten the
backnuts holding the assembly to the
tank wall.
15 Using the supplied 4mm Allen key,
remove the two M5 x 12 screws from
the end of the float link bar.
16 Place the bar between the lowest
holes of the two Float Arms and
attach using the M5 x 12 screws as
shown in Diagram 5.
17 Tighten using the Allen key, ensuring
that the Float Arms remain parallel.
SPIRIT
LEVEL
DIAGRAM 4
DIAGRAM 5
p6 AYLESBURY KAX VALVE
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FLOAT
LINK BAR
FLOAT ARM
SPIRIT
LEVEL

HOLD WITH
WRENCH
HERE, ONLY.
18 Using the 4mm Allen key supplied, fit
the discharge assembly referring to
Diagram 6 for the direction.
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 6.
DO NOT USE A WRENCH ON ANY OTHER
PART OF THE VALVE
20 Remove and discard the protective
cap from the discharge assembly,
before adjusting closing level, testing
and using.
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.
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DIAGRAM 6
AYLESBURY KAX VALVE p7

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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
125 and 166mm and is not adjustable.
The delay will be ~125mm if the float is
at the top of the float arm and ~166mm
if the float is at the bottom of the arm.
TESTING
Before leaving the installation, manually move
the valves to test 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.
ONCE THE VALVES HAVE BEEN INSTALLED AND
TESTED, COMPLETE AND APPLY THE TANK LABEL
TO THE TANK AND SEND A PHOTOGRAPH OF THE
LABEL IN PLACE TO [e-mail] IN
ORDER TO RECEIVE A FULL FIVE YEARS’ EXTENDED
WARRANTY FOR THE VALVE. SEE WARRANTY
SHEETS FOR FULL DETAILS.
p8 AYLESBURY KAX VALVE
SLIDE FLOAT
INTO POSITION
FLOAT
ADJUSTING
CATCH
DIAGRAM 7
FLOAT
ADJUSTING
CATCH

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AYLESBURY KAX VALVE p9
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°C — 60°C
Level differential: 125 — 166mm
non-adjustable delayed action
Parallel male BSP (G)
connection.
See page 10 for side view
ATTACH FLOAT
LINK BAR USING
4MM ALLEN KEY
PROVIDED
FLOAT
FLOAT
LINK BAR
DOUBLE
R CLIP
SPIRIT
LEVEL
BUSH
570
INSERT
WEIGHT
FLOAT ADJUSTING
CATCH (PULL TO
RELEASE
VALVE
BODY
VALVE
BODY
376
DISCHARGE ASSEMBLY
ADJUST ALIGNMENT
HERE
WASHER
SPIGOT
FLOAT ARM
37
11
SLIDE FLOAT INTO
DESIRED CLOSING
LEVEL (TWL)
200

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p10 AYLESBURY KAX 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
470MM FROM THE CENTRE LINE OF THE VALVE; AND
HIGHER FOR TURBULENT WATER.
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
SIZES (DN):
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 9 for front view.
A
B
DN 50HF 65SF 80RB
SIZE 2”HF 2½”SF 3”RB
BMAX 95 100 99
ØE 60 75.5 89
HIGHEST WATER
LEVEL SETTING
DELAYED ACTION
125MM APPROX
OPEN
POSITION
CLOSING LEVEL
(TWL)
OPENING LEVEL
(LWL)
CLOSED
POSITION
211
152 263
40°
359
684
B MAX
ØE
152
273
DELAYED ACTION
166MM APPROX
OPEN
POSITION
CLOSED
POSITION CLOSING
LEVEL
(TWL)
OPENING
LEVEL
(LWL)
331
810
520
243
15°
52
WARNING PIPE
PUSH GENTLY TO LIMIT
WHEN CHECKING
ALIGNMENT
SPIRIT LEVEL BUBBLE
BETWEEN BLACK LINES
495
MAX
470
MAX
OVERFLOW B
A
25MM
MIN
ATTACH DISCHARGE USING
4MM ALLEN KEY PROVIDED
LOWEST WATER
LEVEL SETTING
190
111
358