KERAFLO AYLESBURY KB User manual

AYLESBURY
KB 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/KBTFINSTALL 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
FLOAT ASSEMBLY
DISCHARGE ASSEMBLY
VALVE
BODY
BUOY ASSEMBLY
ACTUATOR ARM ASSEMBLY
T-OUTLET
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.

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PRE-INSTALLATION
CHECKS
MINIMUM TANK A KB Type valve can only be use in a tank that is at least 1.3m deep.
DEPTH:
RAISED VALVE A KB or KAX Type valve can be used in tanks with a raised valve chamber.
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 10.
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 actuator arm assembly
and most internal tank flanges and ribs (see drawing on page 10). The valve backnuts may
be adjusted to enable fitting to tanks with large flanges, provided a minimum of 20mm
exists between the actuator arm and buoy assembly and the tank wall throughout the arc
of the arm.
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 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 2”HF 2½”SF 3”RB
MIN TANK
DIAMETER (M) 1.8M 1.8M 1.8M

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, for most
installations, 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
and actuator levers from both bodies.
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”. The outlet
for fitting the discharge should be
uppermost.
6Replace the backnut with the flanged
side against the tank wall (Diagram 2).
7Connect the supply pipe, then hand
tighten the backnut to hold the valve in
place.
8To prevent the valve assemblies from
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. THE VALVE ASSEMBLY
MUST BE POSITIONED ABSOLUTELY
HORIZONTALLY.
p4 AYLESBURY KB VALVE
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DOUBLE-R CLIP
BACK NUT
DIAGRAM 1
TANK WALL
HOLD WITH
WRENCH
HERE, ONLY.
DIAGRAM 2
BACK
NUT
ACTUATOR
LEVER

9Level 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.
10 Fit the actuator arms over the spigots and
push their pins through their respective
brackets and into the hole in the actuator
located within the valve body (Diagram 3).
THE ACTUATOR TUBE WITH THE RED DOT
SHOULD BE FITTED TO THE VALVE WITH THE
RED DOT.
THE CAP SCREW HEADS ON THE ACTUATOR
ARM BRACKETS SHOULD FACE AWAY FROM
THE VALVE ASSEMBLY.
11 Refit the actuator levers and double-R
clips on the spigots (Diagram 3).
12 The actuator tube should be tilting down
towards the tank wall (brass end lowest)
as Diagram 3. NOTE: NEITHER THE LINK
TUBE ASSEMBLY NOR THE CHAIN SHOULD BE
CONNECTED AT THIS STAGE.
13 The spirit levels should indicate that the
valves are level. The bubble must be
EXACTLY between the black lines.
14 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.
15 Loosen the locknut at the T-outlet, as
indicated in Diagram 5, and rotate each
valve until the bubble in the spirit level is
precisely between the black lines.
AYLESBURY KB VALVE p5
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USE A SPIRIT LEVEL TO ENSURE
T-OUTLET IS HORIZONTAL
DIAGRAM 3
BRASS END
ACTUATOR ARM
CAP
SCREW
SPIGOT
DIAGRAM 4
SPIRIT
LEVEL
LOCK
NUT LOCK
NUT
DIAGRAM 5
BACK
NUT
ACTUATOR
LEVER
DOUBLE-R
CLIP

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p6 AYLESBURY KB VALVE
16 Align each valve, tighten the locknuts,
and re-check the alignment.
17 When the clearance and the levels are
correctly set, fully tighten the backnuts
holding the assembly to the tank wall.
18 One end of the link tube assembly is
already fitted to the stud of one actuator
tube.
19 Locate the other end of the link tube
assembly over the other actuator stud
before inserting and deforming the split
cotter pin, to hold link tube assembly in
place. NOTE: TO AVOID STRAINING THE LINK
TUBE ASSEMBLY DURING INSTALLATION,
PUSH THE END OF THE ACTUATOR TUBE
DOWN.
20 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.
21 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.
22 Using the 4mm Allen key supplied, fit the
discharge assembly referring to Diagram
7 for the direction.
23 Remove and discard the protective cap
from the discharge assembly, before
adjusting closing level, testing and
using.
24 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.
ACTUATOR TUBE
LINK TUBE
ASSEMBLY
DIAGRAM 6
FLOAT ADJUSTING PEG
CLOSING WATER LEVEL
OPENING WATER LEVEL
DELAY
ACTION
OPENING
BUOY
CLOSING
FLOAT
HANGER
DIAGRAM 7
Y
X

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AYLESBURY KB VALVE p7
25 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.
26 Adjust the length of the chain from
the buoy to the hanger to match the
following:
Chain length = Y - 274mm
Do not cut the chain, loop any excess
chain on to the hanger.
27 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 - 190mm
28 The highest closing water level (X = 210)
can be achieved by having no spare
chain links between the hanger and the
float adjusting peg. The lowest closing
water level (X = 1610) 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).
29 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.
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.

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p8 AYLESBURY KB VALVE
ALIGNMENT WARNING!
THE ACTUATOR ARMS MUST BE FITTED IN THE
TILTED POSITION WHEN THE VALVES ARE FULLY
CLOSED AND THE SPIRIT LEVEL ALIGNED. THIS IS
CRITICAL TO THE OPERATION OF THE VALVES.
30 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 390mm (Float
touching top of Opening Buoy) and
1815mm (Float Adjusting Peg almost
touching Hanger whilst using all of the
available chain); see page 10.
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

tel [phone] fax [phone] info@keraflo.co.uk www.keraflo.co.uk
2”(50)HF 2½”(65)SF 3”(80)RB
SIZES (DN):
AYLESBURY KB VALVE p9
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.
See page 10 for side view
OPENING
BUOY
CLOSING FLOAT
ASSEMBLY
DISCHARGE
ASSEMBLY
467
DOUBLE-R
CLIP
DISCHARGE
ASSEMBLY
ACTUATOR
LEVER
STUD
HANGER
PIN
ACTUATOR LEVER
DOUBLE-R
CLIP
SPLIT COTTER PIN -
INSTALL AFTER FITTING
BOTH ACTUATOR TUBES
TO VALVE BODIES AND
LINK TUBE ASSEMBLY
TO STUDS
LINK TUBE
ASSEMBLY
WEIGHT CRITICAL
EXCESS CHAIN LOOP
INTO HANGER - DO
NOT CUT OR EXTEND
OPENING LEVEL
INDICATOR MUST BE
AT LEAST 300MM
ABOVE OUTLET OR
LOW LEVEL ALARM
Ø75
Ø186
ACTUATOR TUBE ACTUATOR TUBE
FLOAT ADJUSTING
PEG (MUST GO
THROUGH A LINK)
REFER TO SIDE
VIEW FOR
CONNECTION
DETAILS
PIN
ADJUST
ALIGNMENT
HERE
VALVE
BODY
VALVE
BODY
SPLIT
COTTER PIN
SPIGOT 111
46
11
37

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p10 AYLESBURY KB VALVE
D
SIZES (DN):
2”(50)HF
2½”(65)HF
3”(80)RB
NOTES:
Longer chain available on request.
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.
When opening level – 575mm
See page 9 for front view
A
B
C
OPENING LEVEL (LWL)
CLOSING LEVEL (TWL)
MINIMUM
OPENING LEVEL
FROM BOTTOM
OF THE TANK
240
850 MIN
(TYPICALLY
REQUIRES
MIN DEPTH
OF 1350MM)
600 MIN -
2000 MAX
FLANGED
BACKNUTS
390 MIN -
1815 MAX
(DELAYED
ACTION)
210 MIN -
1610 MAX
210
185 MIN -
220 MAX
115
8 MAX
270 MAX 305 MAX
120
111
235 MAX
CLOSING
FLOAT
185
OVERFLOW
25MM MIN
SPIRIT LEVEL WITH CHAIN
DISCONNECTED BUBBLE MUST
BE BETWEEN BLACK LINES
50AF ATTACH
WRENCH HERE
Ø186
Ø75
OPENING
BUOY
OPENING
BUOY
WARNING PIPE
34°
OPEN POSITION
CLOSED POSITION
CLOSING
FLOAT
DN 50HF 65SF 80RB
SIZE 2”HF 2½”SF 3”RB
BMAX 95 100 99
ØE 60 75.5 89
WARNING!
THE WARNING PIPE AND OVERFLOW OUTLET
SHOULD BE AVAILABLE ABOVE THE HIGHEST WATER
LEVEL ACHIEVED BEFORE THE VALVE CLOSES.
AB
C
D