KERAFLO AYLESBURY KB User manual

AYLESBURY
KB VALVE
INSTALLATION GUIDE
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FOR VALVE SIZES (DN):
¾”(20)
1”(25)
1¼”(32)
1½”(40)SF
1½”(40)HF
2”(50)SF
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/KBSFINSTALL 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.
p2 AYLESBURY KB VALVE
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
DISCHARGE ASSEMBLY
ACTUATOR ARM
CHAIN
FLOAT ASSEMBLY
SPIRIT LEVEL
VALVE
BODY
ACTUATOR
ARM LEVER
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.

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PRE-INSTALLATION
CHECKS
MINIMUM TANK A KB Type valve can be used in a tank that is at least 1.3m deep for KB40HF & KB50SF
DEPTH: and 1.0m for KB20, KB25, KB32, KB40SF.
RAISED VALVE Use a KAX or KB Type valve for tanks with raised valve 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.
OVERFLOW/WARNING Check the position of the overflow and warning pipe (where fitted).
PIPES: See drawing on page 7.
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 (dimension G shown on drawing on page 7). 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.
SLOPING TANK The wall to which the Aylesbury KB 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.
AYLESBURY KB VALVE p3
VALVE ¾” 1” 1¼” 1½”SF 1½”HF 2”S F
MIN TANK
DIAMETER (M) 0.5M 0.5M 0.6M 0.6M 0.8M 0.8M

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.
INSTALLATION
INSTRUCTIONS
The valve is supplied with the actuator 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 clip
and actuator lever from the valve body.
3Remove and discard the red protective
cap from the tail.
4Remove and retain one backnut.
5Insert the valve tail through the hole in
the tank wall, replace the backnut with
the flanged side against the
tank wall.
6Connect the supply pipe then hand
tighten the backnut to hold the valve in
place. 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.
7Fit the actuator arm over the spigot and
refit the actuator lever, ensuring that the
pin on the actuator lever engages with
the actuator disk in the valve body.
THE HANGER MUST BE ON THE RIGHT AS
SHOWN IN DIAGRAM 3.
8Refit the double-R clip on to the spigot,
retained at step 2, to hold the actuator
lever in place.
p4 AYLESBURY KB VALVE
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DOUBLE-R CLIP
BACK NUT
DIAGRAM 1
PROTECTIVE
CAP
ACTUATOR
LEVEL
HOLD WITH
WRENCH
HERE, ONLY.
DIAGRAM 2
BACK
NUT
DIAGRAM 3
TANK
WALL
DOUBLE-R
CLIP
ACTUATOR
LEVEL
HANGER
ACTUATOR
ARM
SPIGOT

9The actuator tube should be tilting down
to the left (brass end lowest). NOTE: the
chain is not connected at this stage.
10 Rotate the tail of the valve with a wrench
until the spirit level indicates that the
valve is ABSOLUTELY LEVEL. The actuator
tube is actually angled 26º from horizontal
at this point.
11 Tighten the backnuts then CHECK
ALIGNMENT AGAIN. THE BUBBLE MUST BE
PRECISELY BETWEEN THE BLACK LINES.
12 Using the 4mm Allen key supplied, fit the
discharge assembly (referring to Diagram
5 for the direction).
13 Remove and discard the protective cap
from the discharge assembly, before
adjusting closing level, testing and use.
14 Hang the chain on the hanger. DO NOT
CUT OR REMOVE ANY PART OF THE CHAIN;
IT IS CRITICAL TO THE CORRECT OPERATION
OF THE VALVE.
15 The length of this chain determines the
opening water level and the position of
the float on the chain determines the
closing level and the delay.
16 CLOSING WATER LEVEL (TWL) When the
actuator tube is held horizontal, the
closing water level is indicated by the
base of the closing float. Identify the
desired maximum water level & measure
the distance from the centre line of the
valve; this is X.
17 OPENING WATER LEVEL (LWL) When the
actuator tube is held horizontal, the
opening water level is indicated by a line
on the opening buoy. Identify the desired
minimum water level & measure the
distance from the centre line of the valve;
this is Y.
AYLESBURY KB VALVE p5
DIAGRAM 4
SPIRIT
LEVEL
DIAGRAM 5
PROTECTIVE
CAP
DISCHARGE
ASSEMBLY
DIAGRAM 6
CLOSING WATER LEVEL (TWL)
OPENING WATER LEVEL (LWL)
DELAYED
ACTION
FLOAT ADJUSTING PEG
HANGER
OPENING
BUOY
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CLOSING
FLOAT
X
Y

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p6 AYLESBURY KB VALVE
ALIGNMENT WARNING!
THE ACTUATOR ARM MUST BE FITTED WITH THE
BRASS END TILTED DOWN WHEN IN THE CLOSED
POSITION AND ENSURE THE BUBBLE IN THE SPIRIT
LEVEL IS BETWEEN THE LINES. THIS IS CRITICAL TO
THE OPERATION OF THE VALVE.
18 Adjust the length of the chain from
the buoy to the hanger to match the
following:
Chain length = Y - 190mm
(20,25,32 & 40SF)
Chain length = Y - 250mm
(40HF & 50HF)
Do not cut the chain, loop
any excess chain on to the hanger.
19 Unhook the Float Adjusting Peg and
move the float along the chain so the
distance from the Hanger to the Float
Peg is as follows: X - 163mm
20 The highest closing water level (JMIN
page 7) can be achieved by having no
spare chain links between the hanger
and the float adjusting peg. The lowest
closing water level (JMAX page 7) can be
achieved by having the float touching the
top of the opening buoy whilst using all of
the available chain (last link on hanger).
21 Applications where the top water level
(TWL) can rise after the valve has closed
will cause the chain to become slack.
A cable tie/ratchet strap should be fitted
over the float adjusting peg in such a
way as to prevent the chain from slipping
off. Ensure the chain cannot become
entangled with tank tie bars etc.
IT MAY BE EASIER TO ADJUST THE CHAIN LENGTH
BEFORE INSTALLATION.
22 DELAYED ACTION (LEVEL DIFFERENTIAL)
The delayed action is the distance the
water level will drop from before the
valve opens i.e. the difference between
opening and closing water levels. This is
adjustable between PMIN (Float touching
top of Opening Buoy) and PMAX (Float
Adjusting Peg almost touching Hanger
whilst using all of the available chain)
see page 7.
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.
DIAGRAM 6
SPIRIT
LEVEL

NOTES:
Longer chain available on request.
Opposite hand valves available as cost option (chain on left).
SCHD2, SECT 7, G16.5 Water Regs. Gaps should be more if water is turbulent – especially if near valve discharge. 40mm
minimum for valves 1½“ (DN 40mm) or larger – recommended by KERAFLO.
Typically twice inlet bore. SECT 7, SCHD 2G16.10 Water Regs. Warning/overflow pipes should be capable of taking any possible
flow in the pipe arising from inlet valve failure. See page 8 for side view.
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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 (B) IS NOT
LOWER THAN 200MM 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.
¾”(20)
1”(25)
1¼”(32)
1½”(40)SF
1½”(40)HF
2”(50)SF
SIZES (DN):
AYLESBURY KB VALVE p7
DN 20 25 32 40SF 40HF 50SF
SIZE ¾” 1” 1¼” 1½”SF 1½”HF 2”SF
JMIN 175 175 175 175 210 210
JMAX 1800 1800 1800 1800 1670 1670
K168 168 168 168 210 210
LMAX 200 200 200 200 237 237
M26o 26o 26o 26o 34o 34o
NMIN 160 160 160 160 180 180
NMAX 180 180 180 180 220 220
O70 70 70 70 115 115
PMIN 200 200 200 200 330 330
PMAX 1825 1825 1825 1825 1815 1815
Q65 65 65 65 120 120
RMIN 375 375 375 375 540 540
RMAX 2000 2000 2000 2000 2000 2000
SMAX 215 215 215 215 268 268
T26° 26° 26° 26° 34° 34°
WMIN 170 170 170 170 320 320
XMAX 245 245 245 245 305 305
YMIN 500 500 500 500 800 800
A
B
C
D
OPENING LEVEL (LWL)
XMAX
CLOSING LEVEL (TWL)
P DELAYED
ACTION
Y MIN
(TYPICALLY
REQUIRES
ADDITIONAL
500MM
DEPTH)
OVERFLOW
B
C
D
SMAX
Q
OPEN POSITION
OPENING
BUOY
E
MINIMUM
OPENING LEVEL
FROM BOTTOM
OF THE TANK
WMIN
CLOSING
FLOAT
Ø50
OPENING
BUOY
CLOSING
FLOAT
25MM
MIN
WARNING PIPE
O
LMAX B
CLOSED POSITION
K
N
J
A
M
SPIRIT LEVEL
WITH CHAIN
DISCONNECTED
BUBBLE MUST
BE BETWEEN
BLACK LINES
R
A
T
P DELAYED
ACTION

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SIZES (DN):
p8 AYLESBURY KB VALVE
A
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
Parallel male BSP (G) connection.
NOTES:
Suitable for spigot and fibre washer fittings on ¾” and
1” valves. See page 7 for front view
A
¾”(20)
1”(25)
1¼”(32)
1½”(40)SF
1½”(40)HF
2”(50)SF
DN 20 25 32 40SF 40HF 50SF
SIZE ¾” 1” 1¼” 1½”SF 1½”HF 2”SF
A 330 330 277 277 277 315
BMAX 44 44 55 55 55 92
C34 34 73 73 73 73
ØD 19.5 26.9 35.4 35.4 35.4 35.4
ØE 26.5 33 42 47.5 47.5 6o
ØF 142 142 142 142 186 186
GMIN 92 92 74 74 54 55
H83 83 111 111 111 111
37
DOUBLE
R CLIP
11
DISCHARGE
ASSEMBLY
SPIGOT
PIN B
VALVE
BODY
DISCHARGE
ASSEMBLY
TAIL
ACTUATOR
TUBE HANGER
ACTUATOR
LEVER
WEIGHT
CRITICAL
EXCESS CHAIN
LOOP INTO
HANGER DO NOT
CUT OR EXTEND
ØF
Ø50
CLOSING FLOAT
ASSEMBLY
OPENING
BUOY
OPENING LEVEL
INDICATOR MUST
BE AT LEAST
300MM ABOVE
OUTLET OR LOW
LEVEL ALARM
ØD
H
C
ØE
A
FLANGED
BACKNUTS
FLOAT ADJUSTING
PEG (MUST GO
THROUGH A LINK)
46AF (1¼”,
1½” & 2”SF
VALVES)
ATTACH
WRENCH
HERE
38AF (½”,
¾” & 1”
VALVES)
ATTACH
WRENCH
HERE