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INSTALLATION / OPERATION / MAINTENANCE
MODEL
100-46
(Full Internal Port)
316 Stainless Steel Hytrol Valve
Description
The Cla-Val Model 100-46 Hytrol 316SS Valve is a hydraulically operated, diaphragm actuated, globe pattern valve with all 316 Stainless
Steel metal parts. Specially designed 316 Stainless Steel removable
slip-on flanges provide 150 or 300 ANSI class flange connections that
meet ANSI and ISO standards. This valve is ideal for control valve
applications where fluid compatibility is often a problem. The standard
Electropolish finish on the 316 Stainless Steel parts offers extreme corrosion resistance to many industrial fluids such as seawater, high
alkyl or high acid concentrations or other aggressive or corrosive fluids.
The Model 100-46 Hytrol consists of these major components: body,
flanges, diaphragm assembly and cover. The diaphragm assembly is
the only moving part and is guided top and bottom by a precisionmachined stem. A non-wicking diaphragm of nylon fabric reinforced,
synthetic rubber creates the control chamber for the valve. A resilient,
synthetic rubber disc forms a drip-tight seal, with the renewable seat, when pressure is applied to the control chamber. The rugged
simplicity of design and packless construction assures a long life of dependable, trouble-free operation. Smooth flow passages
and fully guided diaphragm assembly assure optimum control, when used in piping systems requiring remote control, pressure regulation, solenoid operation, rate of flow control or check valve operation.
Installation
1. Before valve is installed, pipe lines should be flushed of
all chips, scale and foreign matter.
2. It is recommended that either gate or block valves be
installed on both ends of the 100-46 Hytrol Valve to facilitate
isoIating the valve for preventive maintenance and repairs.
3. Place the valve in the line with flow through the valve in
the direction indicated on the inlet nameplate. (See “Flow
Direction” Section)
4. Allow sufficient room around valve to make adjustments
and for disassembly.
5. CIa-VaI 100-46 Hytrol Valves operate with maximum eff iciency when mounted in horizontal piping with the cover
Principle of Operation
On-Off Control
UP, however, other positions are acceptable. Due to size and
weight of the cover and internal components of 8 inch and
larger valves, installation with the cover UP is advisable. This
makes internal parts readily accessible for periodic inspection.
6. If a pilot control system is installed on the 100-46 Hytrol
Valve, use care to prevent damage. If it is necessary to remove
fittings or components, be sure they are kept clean and replaced
exactly as they were.
7. After the valve is installed and the system is first pressurized,
vent air from the cover chamber and pilot system tubing by
loosening fittings at all high points.
On-Off Control
Modulating
Control
Full Open Operation
When pressure in the
ber is relieved to a zone of lower
pressure, the line pressure at the
valve inlet opens the valve, allowing full flow.
cover cham-
Tight Closing Operation
When pressure from the valve inlet
is applied to the cover chamber, the
valve closes drip-tight.
Modulating Action
The valve holds any intermediate
position when operating pressure
is equal above and below the
diaphragm. Using a Cla-Val
“Modulating” Control will allow the
valve to automatically compensate for line pressure changes.
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Flow Direction
The flow through the 100-46 Hytrol Valve can be in one of two
directions. When flow is “up-and-over the seat,” it is in “normal”
Recommended Tools
1. Three pressure gauges with ranges suitable to the installation to be put at Hytrol inlet, outlet and cover connections.
flow and the valve will fail in the open position. When flow is “overthe seat-and down,” it is in “reverse” flow and the valve will fail in
the closed position. There are no permanent flow arrow markings.
The valve must be installed according to nameplate data.
BRIDGEWALL INDlCATOR
(cast into side of valve body)
2. Cla-Val Model X101 Valve Position Indicator. This provides visual indication of valve position, during start-up and
while in service.
3. Other items are: suitable hand tools such as screw-
Normal Flow Reverse Flow
drivers, wrenches, etc. soft jawed (brass or aluminum) vise,
400 grit wet or dry sandpaper and water for cleaning.
Troubleshooting
The following troubleshooting information deals strictly with the
Model 100-46 Hytrol Valve. This assumes that all other components of the pilot control system have been checked out and are
in proper working condition. (See appropriate sections in
Technical Manual for complete valve).
SYMPTOM PROBABLE CAUSE REMEDY
Fails to Close
Fails to Open
Closed isolation valves in control system, or in main line.
Lack of cover chamber pressure.
Diaphragm damaged. (See Diaphragm Check.)
Diaphragm assembly inoperative.
Corrosion or excessive scale build up on valve stem.
(See Freedom of Movement Check)
Mechanical obstruction. Object lodged in valve.
(See Freedom of Movement Check)
Worn disc. (See Tight Sealing Check)
Badly scored seat. (See Tight Sealing Check)
Closed upstream and/or downstream isolation
valves in main line.
Insufficient line pressure.
All trouble shooting is possible without removing the valve from the
line or removing the cover. It is highly recommended to permanently
install a Model X101 Valve Position Indicator and three gauges in
unused Hytrol inlet, outlet and cover connections.
Open Isolation valves.
Check upstream pressure, pilot system, strainer, tubing, valves, or needle
valves for obstruction.
Replace diaphragm.
Clean and polish stem. Inspect and replace any damaged or badly eroded
part.
Remove obstruction.
Replace disc.
Replace seat.
Open isolation valves.
Check upstream pressure. (Minimum 5 psi flowing line pressure differential.)
Diaphragm assembly inoperative. Corrosion or excessive
buildup on valve stem. (See Freedom of Movement Check)
Diaphragm damaged. (For valves in "reverse flow" only)
Clean and polish stem. Inspect and replace any
damaged or badly eroded part.
Replace diaphragm.
After checking out probable causes and remedies, the following three checks can be used to diagnose the nature of the
problem before maintenance is started. They must be done in the order shown.
THIS VALVE CANNOT BE SERVICED UNDER PRESSURE.
Three Checks
The 100-46 Hytrol Valve has only one moving part (the diaphragm
and disc assembly). So, there are only three major types of problems to be considered.
First: Valve is stuck - that is, the diaphragm assembly is not free
to move through a full stroke either from open to close or vice
versa.
CAUTION:
Care should be taken when doing the troubleshooting checks on
the 100-46 Hytrol Valve. These checks may require the valve to
open fully. This will either allow a high flow rate through the
valve, or the downstream pressure will quickly increase to the
inlet pressure. In some cases, this can be very harmful. Where
this is the case, and there are no block valves in the system to
protect the downstream piping, it should be realized that the
Second: Valve is free to move and can’t close because of a
damage diaphragm.
valve cannot be serviced under pressure. Steps should be
taken to remedy this situation before proceeding any further.
Third: Valve leaks even though it is free to move and the
diaphragm isn’t leaking.
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Diaphragm Check (#1 )
1. Shut off pressure to the Hytrol Valve by slowly closing down-
stream and upstream isolation valves. SEE CAUTION.
2. Disconnect or close all pilot control lines to the valve cover and
leave only one fitting in highest point of cover open to atmosphere.
3.With the cover vented to atmosphere, slowly open upstream
isolation valve to allow some pressure into the Hytrol Valve body.
Observe the open cover tapping for signs of continuous flow. It is
not necessary to fully open isolating valve. Volume in cover chamber capacity chart will be displaced as valve moves to open position. Allow sufficient time for diaphragm assembly to shift positions. If there is no continuous flow, you can be quite certain the
diaphragm is sound and the diaphragm assembly is tight. If the
fluid appears to flow continuously this is a good reason to believe
the diaphragm is either damaged or it is loose on the stem. In
either case, this is sufficient cause to remove the valve cover and
investigate the leakage. (See “Maintenance” Section for procedure.)
Cover Capacity
Liquid Volume Displaced from Diaphragm Chamber
When Valve Opens or Closes
Valve Size Displacement
11⁄2" .020 gal
3” .080 gal
4" .169 gal
6" .531 gal
Freedom of Movement Check (#2)
4. Determining the Hytrol Valve’s freedom of movement can be
done by one of two methods.
5. For most valves it can be done after completing Diaphragm
Check (Steps 1, 2, and 3). SEE CAUTION. At the end of step 3
the valve should be fully open.
6. If the valve has a Cla-Val X101 Position Indicator, observe the
indicator to see that the valve opens wide. (Mark the point of maximum opening).
7. Re-connect enough of the control system to permit the application of inlet pressure to the cover. Open pilot system isolation
valves so pressure flows from the inlet into the cover.
8. While pressure is building up in the cover, the valve should
close smoothly. There is a hesitation in every Hytrol Valve closure,
which can be mistaken for a mechanical bind. The stem will
appear to stop moving very briefly before going to the closed position. This slight pause is caused by the diaphragm flexing at a
particular point in the valve’s travel and is not caused by a
mechanical bind.
9. When closed, a mark should be made on the X101 Valve position indicator corresponding to the “closed” position. The distance
between the two marks should be approximately the stem travel
shown in the stem travel chart.
STEM TRAVEL
(Fully Open to Fully Closed)
Valve Size (inches) Travel (inches)
Inches MM Inches MM
1 1⁄2 40 0.4 10
380 0.615
4 100 0.8 20
6 150 1.1 23
restricting the stroke of the valve at one end of its travel. If the flow
does not stop through the valve when in the indicated “closed”
position, the obstruction probably is between the disc and the
seat. If the flow does stop, then the obstruction is more likely in the
cover. In either case, the cover must be removed, and the obstruction located and removed. The stem should also be checked for
scale build-up. (See “Maintenance, section for procedure.)
11. For valves 6” and smaller, the Hytrol Valve’s freedom of movement check can also be done after all pressure is removed from
the valve. SEE CAUTION. After closing inlet and outlet isolation
valves and bleeding pressure from the valve, check that the cover
chamber and the body are temporarily vented to atmosphere.
Insert fabricated tool into threaded hole in top of valve stem, and
lift the diaphragm assembly manually. Note any roughness. The
diaphragm assembly should move smoothly throughout entire
valve stroke. The tool is fabricated from rod that is threaded on
one end to fit valve stem and has a “T” bar handle of some kind
on the other end for easy gripping. (See chart in Step 4 of
“Disassembly” Section.)
12. Place marks on this diaphragm assembly lifting tool when the
valve is closed and when manually positioned open. The distance
between the two marks should be approximately the stem travel
shown in stem travel chart. If the stroke is different than that
shown, there is a good reason to believe something is mechanically restricting the stroke of the valve. The cover must be
removed, and the obstruction located and removed. The stem
should also be checked for scale build-up. (See “Maintenance”
Section for procedure.)
Tight Sealing Check (#3)
13. Test for seat leakage after completing checks #1 & #2 (Steps
1 to 12). SEE CAUTION. Close the isolation valve downstream of
the Hytrol Valve. Apply inlet pressure to the cover of the valve, wait
until it closes. Install a pressure gauge between the two closed
valves using one of the two ports in the outlet side of the Hytrol.
Watch the pressure gauge. If the pressure begins to climb, then
either the downstream isolation valve is permitting pressure to
creep back, or the Hytrol is allowing pressure to go through it.
Usually the pressure at the Hytrol inlet will be higher than on the
isolation valve discharge, so if the pressure goes up to the inlet
pressure, you can be sure the Hytrol is leaking. Install another
gauge downstream of isolating valve. If the pressure between the
valves only goes up to the pressure on the isolation valve
discharge, the Hytrol Valve is holding tight, and it was just the isolation valve leaking.
10. If the stroke is different than that shown in stem travel chart
this is a good reason to believe something is mechanically
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Maintenance
Preventative Maintenance
The Cla-Val Co. Model 100-46 Hytrol Valve requires no lubrication
or packing and a minimum of maintenance. However, a periodic
inspection schedule should be established to determine how the
operating conditions of the system are affecting the valve. The
effect of these actions must be determined by inspection.
Disassembly
Inspection or maintenance can be accomplished without removing the valve from the line. Repair kits with new diaphragm and
disc are recommended to be on hand before work begins.
WARNING: Maintenance personnel can be injured and equipment damaged if disassembly is attempted with pressure in the
valve. SEE CAUTION.
1. Close upstream and downstream isolation valves and independent operating pressure when used to shut off all pressure
to the valve.
2. Loosen tube fittings in the pilot system to remove pressure from
valve body and cover chamber. After pressure has been released
from the valve, use care to remove the controls and tubing. Note
and sketch position of tubing and controls for re-assembly. The
schematic in front of the Technical Manual can be used as a guide
when reassembling pilot system.
3. Remove cover nuts and remove cover. If the valve has been in
service for any length of time, chances are the cover will have to
be loosened by driving upward along the edge of the cover with a
dull cold chisel.
VALVE STEM THREAD SIZE
Valve Size Thread Size (UNF Internal)
1 1⁄2" 10—32
3"—4" 1/4—28
6" 3/8—24
5. The next item to remove is the stem nut. Examine the stem
threads above the nut for signs of mineral deposits or corrosion.
If the threads are not clean, use a wire brush to remove as much
of the residue as possible. Attach a good fitting wrench to the nut
and give it a sharp “rap” rather than a steady pull. Usually several blows are sufficient to loosen the nut for further removal. On the
smaller valves, the entire diaphragm assembly can be held by the
stem in a vise equipped with soft brass jaws before removing
the stem nut.
The use of a pipe wrench or a vise without soft brass jaws scars
the fine finish on the stem. No amount of careful dressing can
restore the stem to its original condition. Damage to the finish of
the stem can cause the stem to bind in the bearings and the valve
will not open or close.
6. After the stem nut has been removed, the diaphragm assembly
breaks down into its component parts. Removal of the disc from
the disc retainer can be a problem if the valve has been in service for a long time. Using two screwdrivers inserted along the outside edge of the disc usually will accomplish its removal. Care
should be taken to preserve the spacer washers in water, particularly if no new ones are available for re-assembly.
7. The only part left in the valve body is the seat which ordinarily
does not require removal. Careful cleaning and polishing of inside
and outside surfaces with 400 wet/dry sandpaper will usually
restore the seat’s sharp edge. If, however, it is badly worn and
replacement is necessary, it can be easily removed.
Seats in valve sizes 1 1/4” through 6” are threaded into the valve
body. They can be removed with accessory X109 Seat Removing
Tool available from the factory. On 8” and larger valves, the seat
is held in place by flat head machine screws. Use a tight-fitting,
long shank screwdriver to prevent damage to seat screws. If upon
removal of the screws the seat cannot be lifted out, it will be necessary to use a piece of angle or channel iron with a hole drilled
On 6” and smaller valves block and tackle or a power hoist can be
used to lift valve cover by inserting proper size eye bolt in place
of the center cover plug. on 8” and larger valves there are 4 holes
(5/8” — 11 size) where jacking screws and/or eye bolts may be
in the center. Place it across the body so a long stud can be inserted through the center hole in the seat and the hole in the angle
iron. By tightening the nut a uniform upward force is exerted on
the seat for removal.
inserted for lifting purposes. Pull cover straight up to keep from
damaging the integral seat bearing and stem.
NOTE: Do not lift up on the end of the angle iron as this may force
the integral bearing out of alignment, causing the stem to bind.
COVER CENTER PLUG SIZE
Valve Size Thread Size (NPT)
1
1
⁄2"
3"
4"—6"
4. Remove the diaphragm and disc assembly from the valve body.
With smaller valves this can be accomplished by hand by pulling
1
⁄4"
1
⁄2"
3
⁄4"
DO NOT
LIFT
NUT
straight up on the stem so as not to damage the seat bearing.
On large valves, an eye bolt of proper size can be installed in the
stem and the diaphragm assembly can be then lifted with a block
and tackle or power hoist. Take care not to damage the stem or
bearings. The valve won't work if these are damaged.
VALVE SEAT
VALVE BODY
ANGLE OR CHANNEL IRON
LONG STUD OR BOLT
NUT OR BOLT HEAD
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Lime Deposits
Inspection of Parts
One of the easiest ways to remove lime deposits from the valve
stem or other metal parts is to dip them in a 5-percent muriatic
acid solution just long enough for the deposit to dissolve. This
will remove most of the common types of deposits. CAUTlON:
USE EXTREME CARE WHEN HANDLING ACID. Rinse parts in
water before handling. If the deposit is not removed by acid, then
a fine grit (400) wet or dry sandpaper can be used with water.
Reassembly
1. Reassembly is the reverse of the disassembly procedure. If a
new disc has been installed, it may require a different number of
spacer washers to obtain the right amount of “grip” on the disc.
When the diaphragm assembly has been tightened to a point
where the diaphragm cannot be twisted, the disc should be compressed very slightly by the disc guide. Excessive compression
should be avoided. Use just enough spacer washers to hold the
disc firmly without noticeable compression.
2. MAKE SURE THE STEM NUT IS VERY TIGHT. Attach a good
fitting wrench to the nut and give it a sharp “rap” rather than a
steady pull. Usually several blows are sufficient to tighten the
stem nut for final tightening. Failure to do so could allow the
diaphragm to pull loose and tear when subjected to pressure.
After the valve has been disassembled, each part should be
examined carefully for signs of wear, corrosion, or any other
abnormal condition. Usually, it is a good idea to replace the rubber parts (diaphragm and disc) unless they are free of signs of
wear. These are available in a repair kit. Any other parts which
appear doubtful should be replaced. WHEN ORDERlNG
PARTS, BE SURE TO GIVE COMPLETE NAMEPLATE DATA,
ITEM NUMBER AND DESCRlPTlON.
NOTE: If a new disc isn’t available, the existing disc can be
turned over, exposing the unused surface for contact with the
seat. The disc should be replaced as soon as practical.
3. Carefully install the diaphragm assembly by lowering the stem
through the seat bearing. Take care not to damage the stem or
bearing. Line up the diaphragm holes with the stud or bolt holes
on the body. on larger valves with studs, it may be necessary to
hold the diaphragm assembly up part way while putting the
diaphragm over the studs.
4. Put spring in place and replace cover. Make sure diaphragm
is Iying smooth under the cover.
5. Tighten cover nuts firmly using a cross-over pattern until all
nuts are tight.
6. Test Hytrol Valve before re-installing pilot valve system.
Test Procedure After Valve Assembly
There are a few simple tests which can be made in the field to
make sure the Hytrol Valve has been assembled properly. Do
these before installing pilot system and returning valve to
service. These are similar to the three troubleshooting tests.
1. Check the diaphragm assembly for freedom of movement
after all pressure is removed from the valve. SEE CAUTlON.
Insert fabricated tool into threaded hole in top of valve stem, and
lift the diaphragm assembly manually. Note any roughness,
sticking or grabbing. The diaphragm assembly should move
smoothly throughout entire valve stroke. The tool is fabricated
from rod that is threaded on one end to fit valve stem (See chart
in Step 4 of “Disassembly” section.) and has a “T” Bar handle of
some kind on the other end for easy gripping.
Place marks on this diaphragm assembly lifting tool when the
valve is closed and when manually positioned open. The distance between the two marks should be approximately the stem
travel shown in stem travel chart. (See “Freedom of Movement
Check” section.) If the stroke is different than that shown, there
is a good reason to believe something is mechanically restricting
the stroke of the valve. The cover must be removed, the obstruction located and removed. (See “Maintenance” Section for
procedure.)
Due to the weight of the diaphragm assembly this procedure is
not possible on valves 8” and larger. on these valves, the same
determination can be made by carefully introducing a low
pressure-less than five psi) into the valve body with the cover
vented. SEE CAUTION. Looking in cover center hole see the
diaphragm assembly lift easily without hesitation, and then
settle back easily when the pressure is removed.
2. To check the valve for drip-tight closure, a line should be
connected from the inlet to the cover, and pressure applied at the
inlet of the valve. If properly assembled, the valve should hold
tight with as low as ten PSI at the inlet. See “Tight Sealing
Check” section.)
3. With the line connected from the inlet to the cover, apply full
working pressure to the inlet. Check all around the cover for any
leaks. Re-tighten cover nuts if necessary to stop leaks past the
diaphragm.
4. Remove pressure, then re-install the pilot system and tubing
exactly as it was prior to removal. Bleed air from all high
points.
5. Follow steps under “Start-Up and Adjustment” Section in
Technical Manual for returning complete valve back to service
.
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Model 100-46
CLA-VAL
Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice.
P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Specifications
Sizes
Globe (inch):
1
⁄2", 3", 4", 6"
1
End Detail
Slip-on Two Piece Flange
Dimensions Per ANSI B16.5
Pressure Rating
ANSI Class 150:
Maximum 285 psi
ANSI Class 300:
Maximum 400 psi
Higher Pressure Available
Please Contact Factory
Operating Temperature
Fluids Compatible with Valve
Materials
-40º to 180º F (-40º to 82º C)
Materials
Body, Cover, Trim,
Diaphragm Assembly,
Flanges, and Fasteners
316 Series
Stainless Steel
Electropolished
Disc:
Buna-N
Diaphragm:
®
Rubber*
Nylon Fabric Reinforced
Synthetic Buna-N
®
*Contact Factory for Other
Disc or Diaphragm Materials
Rubber*
NAMEPLATE
Two Piece
FLANGE
(QTY 2)
D
Inlet Outlet
EE
E
A
C, CC
G, GG
F, FF
AA
B
Dimensions
Size (In) 11⁄2 346
(mm) 40 80 100 150
A 150 ANSI 7.87 12.01 15.00 20.00
AA 300 ANSI 7.87 12.01 15.00 20.00
B 5.70 9.25 11.61 15.75
C .89 .93 .93 1.02
CC 300 ANSI .88 1.00 1.00 1.10
D 5.90 8.20 10.12 13.32
E 2.56 3.74 4.53 5.61
EE 300 ANSI 3.05 4.13 5.02 6.30
F .63 .71 .71 .91
FF 300 ANSI .87 .87 .87 .87
G 3.88 6.00 7.50 9.50
GG 300 ANSI 4.50 6.62 7.88 10.62
Flange Bolts (150 Class) 4488
Flange Bolts (300 Class) 4 8 8 12
Approx. Ship Wt. Lbs. 25 75 160 290
Approx. Ship Wt. Kgs. 11.4 35 73 132
Reduced Port Functional Data
Size (Inches) Cv (gpm)* Cv (l/s)**
*Cv = gpm flow at 1 psi drop
**Cv = l/s flow at 1 bar drop
When Ordering Please
Specify:
1. Catalog No. 100-46
11⁄2 32 7.7
3 67 16
4 138 33
6 242 58
2. Valve Size
3. Fluid Being Handled
4. Fluid Temperature
5. Inlet Pressure Range
6. Outlet Pressure Range
7. Maximum and Minimum
Differential Pressure
8. Flow Rate Range
N-100-46 (R-3/2011)
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