Cla-Val 393-01-3693-01 User Manual

Download

Page 1

393-01/3693-01

Page 2

Page 3

Page 4

Page 5

Electronic Actuated Pressure Reducing

and Solenoid Shut Off

Typical Applications

Schematic Diagram

Item Description

1 Hytrol (Main Valve) 2 X58C Restriction Assembly 3 CRD-30 Electronic Pressure Reducing Control 4 100-01 Hytrol (Reverse Flow) 5 CS3 Solenoid Control 6 X105LC Limit Switch Assembly

Optional Features

Item Description

A X46A Flow Clean Strainer B CK2 (Isolation Valve) C CV Flow Control (Closing) D Check Valves with Isolation Valve

P X141 Pressure Gauge S CV Flow Control (Opening) V X101 Valve Position Indicator Y X43 "Y" Strainer

High Pressure Transmission Line

CLA-VAL

393-01/3690-01

Electronic Actuated

Pressure Reducing and

Solenoid Shutoff Valve

Lower Pressure Distribution

SCADA

Computer

Remote Set Point

Higher Upstream Pressure

Remote Telemetry Unit

(Customer Supplied)

Process Variable (Lower Downstream Pressure)

OUTLET

INLET

CS3

The valve is designed to be used with supervisory control systems having a isolated remote analog setpoint output and a process variable (downstream pressure) input and on-off signal from solenoid. An application for this valve is reducing high transmission line pressure to lower distribution system levels, while opening and closing on command. The solenoid control feature can be activated by an electrical signal from a timer or programmer. It is also an effective solution for lowering direct costs associated with “confined space” requirements by eliminating need for entry into valve structure for setpoint adjustment and system information. Additional Pilot Controls, hydraulic and/or electronic, can be easily added to perform multiple control functions to fit exact system requirements.

•

Simplified Interfacing with SCADA Systems

•

Accepts Local or Remote Setpoint

•

Integral Loop Power Supply

•

Accurate Pressure Control

•

Reliable Hydraulic Operation

•

Rugged Durable Design

The Cla-Val Model 393-01/3693-01 Electronic Actuated Pressure Reducing and Solenoid Shut Off Control Valve combines the precise control of field proven Cla-Val hydraulic pilots and the convenience and versatility of remote setpoint control. The 393-01/3693-01 is an accurate, pilot-operated regulator capable of holding downstream pressure to a pre-determined delivery pressure. When downstream pressure exceeds the pressure setting of the control pilot, the pilot valve and main valve close drip-tight. A solenoid control is provided to intercept the operation of the pressure reducing control and close the main valve. This valve is furnished either normally open (de-energized to open), or normally closed (energized to open). The pilot control, consisting of a hydraulic pilot and integral controller, accepts a setpoint and compares it with a pressure or internal potentiometer position signal and makes incremental adjustments to modulate the valve to a setpoint. The X105 limit switch prevents actuator travel when the solenoid closes the valve.

Adjustable solid state limit switches eliminate over ranging. In the event of a power or transmitter failure, the CRD-30 hydraulic pilot remains in valve control virtually assuring system stability under changing conditions. If the optional check feature (“D”) is added, and a pressure reversal occurs, the valve closes to prevent return flow.

393-01

MODEL

(Full Internal Port)

3693-01

(Reduced Internal Port)

Page 6

Model 393-01 (Uses Basic Valve Model 100-01)

Model 393-01 Dimensions (In Inches)

Note: The top two flange holes on valve size 36 are threaded to 1 1/2"-6 UNC.

Dimensions

(In inches)

GGGG

DDDD

Inlet

AAAA

100-01

Grooved

(MAX)

Inlet

Outlet

(Diameter)

GGG

Inlet

DDD

100-01

Threaded &

Flanged

(MAX)

Inlet

Outlet

AAA

(Diameter)

Valve Body & Cover

Pressure Class

Flanged Grooved Threaded

Grade Material

ANSI

Standards*

150

Class

300

Class

300

Class

End‡

Details

ASTM A536 Ductile Iron B16.42 250 400 400 400

ASTM A216-WCB Cast Steel B16.5 285 400 400 400

ASTM B62 Bronze B16.24 225 400 400 400

Note: * ANSI standards are for flange dimensions only.

Flanged valves are available faced but not drilled.

‡ End Details machined to ANSI B2.1 specifications.

Valves for higher pressure are available; consult factory for details

Pressure Ratings

(Recommended Maximum Pressure - psi)

Component Standard Material Combinations

Body & Cover Ductile Iron Cast Steel Bronze

Available Sizes 1" - 36" 1" - 16" 1" - 16"

Disc Retainer & Diaphragm Washer

Cast Iron Cast Steel Bronze

Trim: Disc Guide, Seat & Cover Bearing

Bronze is Standard

Stainless Steel is Optional

Disc Buna-N®Rubber

Diaphragm Nylon Reinforced Buna-N®Rubber

Stem, Nut & Spring Stainless Steel

For material options not listed, consult factory. Cla-Val manufactures valves in more than 50 different alloys.

Materials

Valve Size (Inches) 11 1/4 1 1/2 22 1/2 3 4 6 8 10 12 14 16 18 20 24 30 36 A Threaded

7.257.257.259.3811.0012.50————————————

AA 150 ANSI

—

8.50 9.38 11.00 12.00 15.00 20.00 25.38 29.75 34.00 39.00 41.38 46.00 52.00 61.50 63.00 76.00

AAA 300 ANSI

— — 9.00 10.00 11.62 13.25 15.62 21.00 26.38 31.12 35.50 40.50 43.50 47.64 53.62 63.24 64.50 76.00

AAAA Grooved End

——8.509.0011.0012.5015.0020.0025.38—————————

B Dia.

5.62 5.62 5.62 6.62 8.00 9.12 11.50 15.75 20.00 23.62 28.00 32.75 35.50 41.50 45.00 53.16 56.00 66.00

C Max.

5.50 5.50 5.50 6.50 7.56 8.19 10.62 13.38 16.00 17.12 20.88 24.19 25.00 39.06 41.90 43.93 54.60 61.50

CC Max. Grooved End

——4.755.756.887.259.3112.1214.62—————————

D Threaded

3.253.253.254.755.506.25————————————

DD 150 ANSI

— — 4.00 4.75 5.50 6.00 7.50 10.00 12.69 14.88 17.00 19.50 20.81 — — 30.75 — —

DDD 300 ANSI

— — 4.25 5.00 5.88 6.38 7.88 10.50 13.25 15.56 17.75 20.25 21.62 — — 31.62 — —

DDDD Grooved End

———4.75—6.007.50———————————

1.12 1.12 1.12 1.50 1.69 2.06 3.19 4.31 5.31 9.25 10.75 12.62 15.50 12.95 15.00 17.75 21.31 24.56

EE Grooved End

——2.002.502.883.124.256.007.56—————————

F 150 ANSI

—

2.50 3.00 3.50 3.75 4.50 5.50 6.75 8.00 9.50 10.50 11.75 15.00 16.50 19.25 22.50 25.60

FF 300 ANSI

— — 3.06 3.25 3.75 4.13 5.00 6.25 7.50 8.75 10.25 11.50 12.75 15.00 16.50 19.25 24.00 25.60

G Threaded

1.881.881.883.254.004.50————————————

GG 150 ANSI

— — 4.00 3.25 4.00 4.00 5.00 6.00 8.00 8.62 13.75 14.88 15.69 — — 22.06 — —

GGG 300 ANSI

— — 4.25 3.50 4.31 4.38 5.31 6.50 8.50 9.31 14.50 15.62 16.50 — — 22.90 — —

GGGG Grooved End

———3.25—4.255.00———————————

H NPT Body Tapping

.375.375.375.375.50.50.75.751111111122

J NPT Cover

Center Plug

.25 .25 .25 .50 .50 .50 .75 .75 1 1 1.25 1.5 2 1.5 1.5 1.5 2 2

K NPT Cover Tapping

.375.375.375.375.50.50.75.751111111122

Stem Travel

0.4 0.4

0.4 0.6 0.7 0.8 1.1 1.7 2.3 2.8 3.4 4.0 4.5 5.1 5.63 6.75 7.5 8.5

Approx. Ship Wt. Lbs.

15 15 15 35 50 70 140 285 500 780 1165 1600 2265 2982 3900 6200 7703 11720

X Pilot System 11 11 11 13 14 15 17 29 31 33 36 40 40 43 47 68 79 85 Y Pilot System 9 9 9 9 10 11 12 20 22 24 26 29 30 32 34 39 40 45 Z Pilot System 9 9 9 9 10 11 12 20 22 24 26 29 30 32 34 39 42 47

Page 7

393-01/3693-01 Purchase Specifications

The 393-01/3693-01 Electronic Actuated Pressure Reducing and Solenoid Shutoff Control Valve shall have an integral hydraulic and electronic controller contained in a NEMA 4 enclosure to provide the interface between remote telemetry and valve control. It will compare a selectable remote analog or local setpoint with a process variable signal or an internal position sensor signal and automatically adjust the hydraulic pilot control until the main control valve reaches desired setpoint. The electronic actuator will supply loop power for the process variable signal. Retransmission of the process variable shall be with an isolated nonpowered analog signal. The actuator speed will be infinitely adjustable between 1/3 and 5 RPM and will have an adjustable dead band. In the event of an erroneous communications signal, actuator output will be capable of being limited to a predetermined process variable value. If these signals (SP and /or PV) are lost, the valve shall remain under control of the pressure reducing hydraulic control. The actuator can also be programmed to drive the main valve to the open or closed position if these signals are lost. All setup and adjustments will be capable of being made prior to placing the valve into service using actuator test points for signal measurement and subsequent calibration. Actuator diagnostics will be displayed using LEDs. Manual operation of the hydraulic pilot will be fully adjustable using a non-rotating handwheel. The Electronic Actuated Pressure Reducing and Solenoid Shut-Off Control Valve shall be the Cla-Val Model 393-01/3693-01 as manufactured by Cla-Val, Newport Beach, CA.

Model 3693-01 Dimensions (In Inches)

Materials

Inlet

100-20

Flanged

(MAX)

Inlet

Outlet

(Diameter)

Dimensions

(In inches)

Component Standard Material Combinations

Body & Cover Ductile Iron Cast Steel Bronze

Available Sizes 3" - 48" 3" - 16" 3" - 16"

Disc Retainer & Diaphragm Washer

Cast Iron Cast Steel Bronze

Trim: Disc Guide, Seat & Cover Bearing

Bronze is Standard

Stainless Steel is Optional

Disc Buna-N®Rubber

Diaphragm Nylon Reinforced Buna-N®Rubber

Stem, Nut & Spring Stainless Steel

For material options not listed, consult factory. Cla-Val manufactures valves in more than 50 different alloys.

Pressure Ratings

(Recommended Maximum Pressure - psi)

Valve Body & Cover

Pressure Class

Flanged

Grade Material

ANSI

Standards*

150

Class

300

Class

ASTM A536 Ductile Iron B16.42 250 400

ASTM A216-WCB Cast Steel B16.5 285 400

ASTM B62 Bronze B16.24 225 400

Note: * ANSI standards are for flange dimensions only.

Flanged valves are available faced but not drilled.

Valves for higher pressure are available; consult factory for details

Note: The top two flange holes on valve sizes 36 thru 48 are threaded to 1 1/2"-6 UNC.

*Consult Factory

Valve Size (Inches)

34681012141618202430364248

A 150 ANSI

10.25 13.88 17.75 21.38 26.00 30.00 34.25 35.00 42.12 48.00 48.00 63.25 65.00 76.00 94.50

AA 300 ANSI

11.00 14.50 18.62 22.38 27.38 31.50 35.75 36.62 43.63 49.62 49.75 63.75 67.00 76.00 94.50

B Dia.

6.62 9.12 11.50 15.75 20.00 23.62 27.47 28.00 35.44 35.44 35.44 53.19 56.00 66.00 66.00

C Max.

7.00 8.62 11.62 15.00 17.88 21.00 20.88 25.75 25.00 31.00 31.00 43.94 54.60 61.50 61.50

D 150 ANSI

—6.948.8810.69CF*CF*CF*CF*CF*CF*CF*————

DD 300 ANSI

—7.259.3811.19CF*CF*CF*CF*CF*CF*CF*————

E 150 ANSI

—5.506.757.25CF*CF*CF*CF*CF*CF*CF*————

EE 300 ANSI

—5.817.257.75CF*CF*CF*CF*CF*CF*CF*————

F 150 ANSI

3.75 4.50 5.50 6.75 8.00 9.50 11.00 11.75 15.88 14.56 17.00 19.88 25.50 28.00 31.50

FF 300 ANSI

4.12 5.00 6.25 7.50 8.75 10.25 11.50 12.75 15.88 16.06 19.00 22.00 27.50 28.00 31.50

H NPT Body Tapping

.375.50.75.7511111111222

J NPT Cover Center Plug

.50.50.75.75111.251.252222222

K NPT Cover Tapping

.375.50.75.7511111111222

Stem Travel

0.6 0.8 1.1 1.7 2.3 2.8 3.4 3.4 3.4 4.5 4.5 6.5 7.5 8.5 8.5

Approx. Ship Wt. Lbs.

45 85 195 330 625 900 1250 1380 1500 2551 2733 6500 8545 12450 13100

X Pilot System 13 15 27 30 33 36 36 41 40 46 55 68 79 85 86 Y Pilot System 10 11 18 20 22 24 26 26 30 30 30 39 40 45 47 Z Pilot System 10 11 18 20 22 24 26 26 30 30 30 39 42 47 49

Page 8

CLA-VAL

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

Input Voltage: 120/240 Vac +/- 10%, 50/60 Hz

Operating Current: 2 Amperes at 120 Vac

Process Variable: Field Selectable between 4-20mA

transmitter (supplied by others) or internal potentiometer

Loop Power Supply: 0-24 VDC

Retransmission: Isolated non-powered 4-20mA

Input Signal Monitor: If process variable is lost actuator

holds in present position, opens or closes, field selectable

Setpoint: Field selectable between local

and remote 4-20 mA, 0-5 Volt, 0-10 Volt

Manual Adjustment: Non-rotating handwheel

Limit Switches: Electronic-Full range adjustable

Terminations: Terminal blocks accepting up to

#16 Awg solid or stranded wire

Operating Temperature: 0

F to 150 °F (-18 C to 65 C)

Environmental Rating: Enclosure rated NEMA type 4

indoor/outdoor, corrosion resistant aluminum

Adjustment Ranges

2 to 30 psi 15 to 75 psi 20 to 105 psi 30 to 300 psi

Temperature Range

Water: to 180°F

Materials

Standard Pilot System Materials

Pilot Control: Bronze ASTM B62

Trim: Stainless Steel Type 303

Rubber: Buna-N

Synthetic Rubber

Optional Pilot System Materials

Pilot Systems are available with optional Aluminum,

Stainless Steel or Monel materials.

Note: Available with remote sensing control. Consult Factory

Pilot System Specifications

Electronic Actuator - CRD-30 Pilot Control

Many factors should be considered in sizing pressure reducing valves including inlet pressure, outlet pressure and flow rates. For sizing questions or cavitation analysis, consult Cla-Val with system details.

We recommend providing adequate space around valve for maintenance work

E-393-01/3693-01 (R-7/2011)

When Ordering, Please Specify

1. Catalog No. 393-01 or 3693-01

2. Valve Size

3. Pattern - Globe or Angle

4. Pressure Class

5. Threaded or Flanged

6. Trim Material

7. Adjustment Range

8. Desired Options

9. When Vertically Installed

10. Energized or de-energized to open Main Valve

11. Solenoid Voltage

3693-01

Valve

Selection

100-20 Pattern: Globe (G), Angle (A), End Connections: Flanged (F) Indicate Available Sizes

Inches 3 4 6 8 10 12 14 16 18 20 24 30 36 42 48

mm 80 100 150 200 250 300 350 400 450 500 600 750 900 1000 1200

Basic Valve

100-20

Pattern

GG, AG, AG, AGGGG GGGGGGG

End DetailFFFFFFFF F FFFFFF

Suggested

Flow

(gpm)

Maximum

260 580 1025 2300 4100 6400 9230 9230 16500 16500 16500 28000 33500 33500 33500

Minimum

1 2 4 10 15 35 50 50 95 95 95 275 450 450 450

Suggested

Flow

(Liters/Sec)

Maximum

16 37 65 145 258 403 581 581 1040 1040 1040 1764 2115 2115 2115

Minimum

.06 .13 .25 .63 .95 2.2 3.2 3.2 6.0 6.0 6.0 17.4 28.4 41.0 41.0

100-20 Series is the reduced internal port size version of the 100-01 Series. For Lower Flows Consult Factory

393-01

Valve

Selection

100-01 Pattern: Globe (G), Angle (A), End Connections: Threaded (T), Grooved (GR), Flanged (F) Indicate Available Sizes

Inches 1 11⁄4 11⁄2 2 21⁄2 3 4 6 8 10 12 14 16 18 20 24 30 36

mm 25 32 40 50 65 80 100 150 200 250 300 350 400 450 500 600 750 900

Basic Valve

100-01

Pattern

G, A G, A G, A G, A G, A G, A G, A G, A G, A G, A G, A G, A G, A G G G, A G G

End Detail T T

T, F,

Gr*

T, F,GrT, F,

Gr*

T, F,GrF, GrF,

Gr*

FFFFFFFFF

Suggested

Flow

(gpm)

Maximum

55 93 125 210 300 460 800 1800 3100 4900 7000 8400 11000 14000 17000 25000 42000 50000

Maximum Intermittent

68 120 160 260 370 580 990 2250 3900 6150 8720 10540 13700 17500 21700 31300 48000 62500

Minimum

1111224101535507095120150275450650

Suggested

Flow

(Liters/Sec)

Maximum

3.5 6 8 13 19 29 50 113 195 309 442 530 694 883 1073 1577 2650 3150

Maximum Intermittent

4.3 7.6 10 16 23 37 62 142 246 387 549 664 863 1104 1369 1972 3028 3940

Minimum

.03 .03 .03 .06 .09 0.13 0.25 0.63 0.95 2.2 3.2 4.4 6.0 7.6 9.5 17.4 28.4 41.0

100-01 Series is the full internal port Hytrol. For Lower Flows Consult Factory *Globe Grooved Only

Page 9

Description

The CIa-VaI Model 100-01 Hytrol Valve is a main valve for CIa-VaI Automatic Control Valves. It is a hydraulically operated, diaphragm-actuated, globe or angle pattern valve.

This valve consists of three major components; body, diaphragm assembly, and cover. The diaphragm assembly is the only moving part. The diaphragm assembly uses a diaphragm of nylon fabric bonded with synthetic rubber. A synthetic rubber disc, contained on three and one half sides by a disc retainer and disc guide, forms a seal with the valve seat when pressure is applied above the diaphragm. The diaphragm assembly forms a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure.

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 100-01 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 100-01 Hytrol Valves operate with maximum eff iciency when mounted in horizontal piping with the cover 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. Caution must be taken in the installation of this valve to insure that galvanic and/or electrolytic action does not take place. The proper use of dielectric fittings and gaskets are required in all systems using dissimilar metals.

7. If a pilot control system is installed on the 100-01 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.

8. 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.

Tight Closing Operation

When pressure from the valve inlet (or an equivalent independent operating pressure) is applied to the diaphragm chamber the valve closes drip-tight.

Full Open Operation

When pressure in diaphragm chamber is relieved to a zone of lower pressure (usually atmosphere) the line pressure (5 psi Min.) at the valve inlet opens the valve.

Modulating Action

Valve modulates when diaphragm pressure is held at an intermediate point between inlet and discharge pressure. With the use of a Cla-Val. "modulating control," which reacts to line pressure changes, the pressure above the diaphragm is varied, allowing the valve to throttle and compensate for the change.

Principles of Operation

Three Way

Pilot Control

Three Way

Pilot Control

Restriction

Modulating

Control

100-01

Hytrol Valve

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Page 10

Flow Direction

The flow through the 100-01 Hytrol Valve can be in one of two directions. When flow is “up-and-over the seat,” it is in “normal” 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

Normal Flow Reverse Flow

Troubleshooting

The following troubleshooting information deals strictly with the Model 100-01 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).

Three Checks

The 100-01 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.

Second: Valve is free to move and can’t close because of a worn out diaphragm.

Third: Valve leaks even though it is free to move and the diaphragm isn’t leaking.

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.

Diaphragm assembly inoperative. Corrosion or excessive buildup on valve stem. (See Freedom of Movement Check)

Diaphragm damaged. (For valves in "reverse flow" only)

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.

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.)

Clean and polish stem. Inspect and replace any damaged or badly eroded part.

Replace diaphragm.

Fails to Close

Fails to Open

CAUTION: Care should be taken when doing the troubleshooting checks on the 100-01 Hytrol Valve. These checks do 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 valve cannot be serviced under pressure. Steps should be taken to remedy this situation before proceeding any further.

(cast into side of valve body)

SYMPTOM PROBABLE CAUSE REMEDY

Recommended Tools

1. Three pressure gauges with ranges suitable to the installation to be put at Hytrol inlet, outlet and cover connections.

2. Cla-Val Model X101 Valve Position Indicator. This provides visual indication of valve position without disassembly of valve.

3. Other items are: suitable hand tools such as screwdrivers, wrenches, etc. soft jawed (brass or aluminum) vise, 400 grit wet or dry sandpaper and water for cleaning.

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.

Page 11

Diaphragm Check (#1 )

1. Shut off pressure to the Hytrol Valve by slowly closing upstream and downstream 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.)

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 cock 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 chart.

10. If the stroke is different than that shown in stem travel chart this is a good reason to believe something is mechanically 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 buildup. (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.

STEM TRAVEL

(Fully Open to Fully Closed)

Valve Size (inches) Travel (inches)

Inches MM Inches MM

1 1/4 32 0.4 10 1 1/2 40 0.4 10 250 0.615 2 1/2 65 0.7 18 380 0.820 4 100 1.1 28 6 150 1.7 43 8 200 2.3 58 10 250 2.8 71 12 300 3.4 86 14 350 4.0 100 16 400 4.5 114 20 500 5.6 143 24 600 6.7 165 30 800 7.5 190 36 900 8.5 216

COVER CHAMBER CAPACITY

(Liquid Volume displaced when valve opens)

Valve size (inches) Displacement

Gallons Liters

1 1/4 .020 .07 1 1/2 .020 .07 2 .032 .12 2 1/2 .043 .16 3 .080 .30 4 .169 .64 6 .531 2.0 8 1.26 4.8 10 2.51 9.5 12 4.00 15.1 14 6.50 24.6 16 9.57 36.2 20 12.00 45.4 24 29.00 109.8 30 42.00 197.0 36 90.00 340.0

Page 12

Maintenance

Preventative Maintenance

The Cla-Val Co. Model 100-01 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 independ- ent 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.

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 inserted for lifting purposes. Pull cover straight up to keep from damaging the integral seat bearing and stem.

4. Remove the diaphragm and disc assembly from the valve body. With smaller valves this can be accomplished by hand by pulling

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.

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 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.

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.

VALVE STEM THREAD SIZE

Valve Size Thread Size (UNF Internal)

1 1/4"

—2 1/2" 10—32 3"—4" 1/4—28 6"—14" 3/8—24

16" 1/2—20

20 3/4-16 24" 3/4-16 30” 3/4-16 36” 3/4-16

COVER CENTER PLUG SIZE

Valve Size Thread Size (NPT)

1 1/4"

—1 1/2" 1/4" 2"—3" 1/2" 4"—6" 3/4" 8"—10" 1"

12" 1 1/4" 14" 1 1/2"

16" 2" 20” & 24" 2" 30” & 36” 2”

NUT

ANGLE OR CHANNEL IRON

LONG STUD OR BOLT

NUT OR BOLT HEAD

DO NOT

LIFT

VALVE SEAT

VALVE BODY

Page 13

Lime Deposits

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.

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.)

Inspection of Parts

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.

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

Page 14

OUTLE

INLET

GLOBE PATTERN

INLET

OUTLET

ANGLE PATTERN

TOP VIEW

8" - 24" SEAT DETAIL

1 1/4" - 6" SEAT DETAIL

16" COVER DETAIL

Item Description

1. Pipe Plug

2. Drive Screws (for nameplate)

3. Hex Nut (8” and larger)

4. Stud (8” and larger)

5. Cover Bearing

6. Cover

7. Stem Nut

8. Diaphragm Washer

9. Diaphragm

10. Spacer Washers

11. Disc Guide

12. Disc Retainer

13. Disc

14. Stem

15. Seat

16. Body

17. Spring

22. Flat Head Screws (8” and larger)

23. Seat O-Ring

24. Hex head Bolt (1 1/4” thru 4”)

25. Nameplate

26. Upper Spring Washer (Epoxy coated valves only)

27. Lower Spring Washer (Epoxy coated valves only)

28. Cover Bearing Housing (16” only)

29. Cover O-Ring (16’” only)

30. Hex Bolt (16” only)

31. Pipe Cap (16” only)

PARTS LIST

Page 15

100-01

Hytrol Valve Service Data

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Description 100-01 Hytrol Valve

The CIa-VaI Model 100-01 Hytrol Valve is a main valve for

CIa-VaI Automatic Control Valves. It is a hydraulically operated,

diaphragm-actuated, globe or angle pattern valve.

This valve consists of three major components; body, diaphragm

assembly, and cover. The diaphragm assembly is the only

moving part. The diaphragm assembly uses a diaphragm of nylon

fabric bonded with synthetic rubber. A synthetic rubber disc,

contained on three and one half sides by a disc retainer and disc

guide, forms a seal with the valve seat when pressure is applied

above the diaphragm. The diaphragm assembly forms a sealed

chamber in the upper portion of the valve, separating operating

pressure from line pressure.

Description 100-20 600 Series Hytrol Valve

The CIa-VaI Model 100-20 Hytrol Valve (600 Series main valve)

have only one part -the body- that is different from standard 100

Series Cla-Val main valve parts. The remaining parts of the 600

series main valve are standard Cla-Val main valve parts. All serv-

ice and maintenance information for the standard 100 Series

main valves also apply to the 600 series main valves.

The most important thing to remember when ordering main

valve repair kits and replacement parts, except for the body, all

other parts are going to be for a smaller size main valve. Cla-

Val identifies main valve parts with the flange size of the stan-

dard 100 Series main valve. Refer to the "Main Valve Sizes”

chart below.

HYTROL Service Data

HYTROL SIZE

Stem

Travel

Cover Capacity

Displacement

Valve Stem

Thread

UNF-Internal

Cover

Center

Plug

NPT

Cover Nut or Bolt

Cover

Lifting

Holes

UNC

Cover Plug Cover Torque

Stem Nut**

Stem Nut Torque

(ft. Lbs.)

100-01

100-20

Thread

(Bolt)

Socket

Qty Thread

Socket ft. Lbs. in. Lbs.

Thread

Socket

(Long)

inches mm inches mm inches mm

Gallons

Liters

Lubed DRY

25 0.3 8 1/4"

1/4" - 20 (B)

7/16" 8

48 3/8" - 24

1 1/4"

0.4

0.020

0.07

10 - 32

1/4" 5/16" - 18 (B) 1/2"

8 96 7/16" -20 6 10

1 1/2" 40 0.4 10 0.020 0.07

10 - 32

1/4" 5/16" - 18 (B) 1/2"

8 96 7/16" -20 6 10

2" 50 0.6 15 0.032

0.12 10 - 32

1/2" 3/8" - 16 (B) 9/16" 8 3/8" 7/16" 12

1/2" - 20

3/4" 10 15

2 1/2"

65 0.7 18

0.043 0.16

10 - 32

1/2" 7/16" - 14 (B) 5/8" 8 1/2" 9/16" 20

5/8" - 18 15/16" 21

3" 80 4" 100 0.8

0.080 0.30

1/4 - 28 1/2"

1/2" - 13 (B)

3/4" 8 1/2" 9/16" 30 5/8" - 18

15/16"

21 30

4" 100 6" 150 1.1 23

0.169 0.64

1/4 - 28 3/4"

3/4" - 10 (B)

1 1/8" 8 3/4" 5/8" 110 3/4" - 16

1 1/16"

6" 150 8" 200 1.7 43 0.531 2.00 3/8 - 24 3/4"

3/4" - 10 (B) 1 1/8"

12 3/4"

5/8" 11 0

7/8" - 14

1 5/16"

85 125

200 10"

250

2.3 58

1.26 4.80 3/8 - 24

3/4" - 10

1 1/4" 16 5/8" - 11

1" 13/16" 11 0

1 1/8" -12 1 13/16"

125

185

10" 250 12" 300 2.8 71 2.51 9.50

3/8 - 24

1" 7/8" - 9 1 7/16"

3/4" - 10

13/16" 160 1 1/2" -12 1 7/8" 252 375

12" 300 16" 400 3.4 86 4.0 15.10

3/8 - 24

1 1/4" 1 1/8" - 7 1 13/16"

3/4" - 10

1" 13/16" 390 1 1/2" -12 2 1/2" 270 400

14" 350 3.9

6.5

24.60

3/8 - 24 1 1/2" 1 1/4" - 7

2" 20

1" - 8

1" 13/16" 545 1 1/2" -12

2 1/2"

280 420

16"

400

20", 24"

600

4.5

114

9.6 36.20

1/2 - 20

2" 1 1/4" - 7

2" 20

1" - 8

1" 13/16" 545 2" - 16 3" 500 750

20" 500 5.63

143

12 45.40

3/4 - 16 1 1/2" 1 3/8" - 6

2 1/8" 24

1" - 8

1" 13/16" 670

2 1/4" - 16

3 1/2" 930

N/R

24" 600

30"

800 6.75 165

29.0

108.80 3/4 - 16*

3/4"

1 1/2" - 12 2 3/8" 24

1 1/8"- 7

1" 13/16"

800

3" - 12

Special

1350

N/R

* Adapter

p/n 2594101E

inside 1/4" - 28"

Grade 5 Bolts

"Heavy" Grade Nuts

Tighten cover nuts in a "star" cross-over pattern

** Must Use ONLY

Cla-Val Supplied part

Page 16

COVER

PIPE PLUG

COVER BEARING

SPRING

STEM NUT

DIAPHRAGM WASHER

DISC RETAINER

BODY

SPACER WASHERS

DISC GUIDE

SEAT

PIPE PLUG

STEM

SEAT O-RING

STUD

8" and Larger

DIAPHRAGM

DISC

Repair Parts

Seat Screw

8" and Larger

(Globe

Angle)

PIPE PLUG

HEX NUT

8" and Larger

Cover Bolt

6" and Smaller

DISC GUIDE

SEAT

KO Anti-Cavitation

Trim Option

N-100-01 (R-3/2011

CLA-VAL

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

BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS

BOLTS

Follow this procedure when reassembling MAIN Valve:

1. Tightens bolts/nuts in a “Star” or “Cross-Over” pattern following the

numbers shown above to insure that cover seats evenly on the diaphragm

material and body.

2. Torque the bolt/nuts in three stages with a "Star" or "Cross-Over" pattern

for each stage:

A. To approximately 10% of final torque.

B. To approximately 75% of final torque.

C. To final required torque.

3. Valves that are to be tested to 375 PSI or higher should be retorqued

after 24 hours.

100-01 Hytrol Main Valve Assembly

Page 17

UNDERSTANDING THE 600 SERIES VALVES

In 1987, Cla-Val introduced the Model 100-20 Hytrol as the basic main valve for the 600 Series of automatic control valves. To identify all new valves using the 100-20 Hytrol, an existing catalog number is modified. Making a 600 Series catalog number is simply done by using a "6" in front of the two digit catalog numbers or replacing the "2" with a "6" in three digit catalog numbers. Current schematics reflect both catalog numbers together separated by a slash ( i.e. - 90-01/690-01, 58-02/658-02, 21001/610-01, etc). Since these two valves 'share' the same catalog number and schematic, they provide the same function in a system. The only difference between the two valves is the relative capacity of the two main valve series.

The 100-01 Hytrol is the basic main valve for Cla-Val automatic control valves. This valve is the current version of the Clayton Hytrol valve design originated in 1936. The 100-01 Hytrol is designed as a full flow area valve. This means that the inlet, seat and outlet openings are the same size. Thus, the pressure drop is kept to a minimum for this globe style design.

The 100-20 Hytrol valve has all of the basic features and advantages of the original 100-01 Hytrol. Only one part has been changed - the body. It is designed with different size inlet, seat and outlet openings. The 100-20 Hytrol has inlet and outlet flanges one valve size larger than the seat opening size. This results in what is sometimes called a ''reduced port' main valve. For example, a 4" 100-20 valve has a 3" seat. Note: valve size is always determined by the flange size. The following chart compares the 100-01 and the 100-20 main valves.

600 Series Hytrol Valve

100-20

MODEL

INSTALLATION / OPERATION / MAINTENANCE

SERVICE AND MAINTENANCE OF 600 SERIES VALVES

The 600 series main valves have only one part -the body- that is different from standard 100 Series Cla-Val main valve parts. The remaining parts of the 600 series main valve are standard ClaVal main valve parts. All service and maintenance information for the standard 100 Series main valves in this manual also apply to the 600 series main valves.

The most important thing to remember when ordering main valve repair kits and replacement parts, except for the body, all other parts are going to be for a smaller size main valve. Cla-Val identifies main valve parts with the flange size of the standard 100 Series main valve. Refer to the "Main Valve Sizes Comparison" chart. For example, if you are servicing a 6" 100-20 Hytrol and needed a repair kit, you would order a repair kit for a 4" 100-01 Hytrol. This kit is also suitable for a 6" 100-20 Hytrol. Complete Technical Manuals include a repair kit data sheet N-RK that shows this relationship.

When you order repair parts, it is a good idea to include valve nameplate data (size, catalog number, and part number) and description of the parts desired. Do this to be sure parts will fit the valve you are working on and not be too big for it. Pilot controls and repair kits maintenance information remain the same for 100 or 600 Series valves.

Cla-Val Main Valves

Catalog Number

The 100-20 Hytrol is available only in ductile iron, 150 and 300 pressure class, and Bronze trim standard. Available extra cost main valve options include stainless steel trim, epoxy coating, Dura-Kleen stem, Delrin sleeved stem, and high temperature rubber parts. All four basic main valves have a 600 Series version available with all of the same benefits and size relationships. The following chart shows the relationship of Cla-Val main valve catalog numbers.

Catalog Name

Hytrol

Powertrol

Powercheck

Hycheck

Circa 1936

100 (Angle =2100)

100P & 100PA

100PC & 100PCA

181

100-Series

100-01

100-02

100-03

100-04

600 Series

100-20

100-21

100-22

100-23

(Reduced Internal Port)

Basic Main Valve Size Comparison

Globe Pattern Valves

Flange Size (inch)

Seat Size

100-01 (100 Series) 100-20 (600 Series) 3 3 2 4 4 3 6 6 4 8 8 6

10 10 8 12 12 10 14 14 ---16 16 12 18 ---- 16 20 20 16 24 24 16 30 30 24 36 36 30 42 ---- 36 48 ---- 36

Angle Pattern Valves

Flange Size (inch)

Seat Size

100-01 (100 Series) 100-20 (600 Series) 4 4 3 6 6 4 8 8 6

Page 18

CLA-VAL

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

N-100-20 (R-3/2011)

100-20

PARTS LIST

NO. DESCRIPTION

1 Pipe Plug

2 Drive Screws (for nameplate)

3 Hex Nut (8" and larger)

4 Stud (8" and larger)

5 Cover Bearing

6 Cover

7 Stem Nut

8 Diaphragm Washer

9 Diaphragm

10 Spacer Washers

11 Disc Guide

12 Disc Retainer

13 Disc

14 Stem

15 Seat

16 Body

17 Spring

22 Flat Head Screws (10" and larger)

23 Seat O-Ring

24 Hex Bolt (3 " Thru 6")

25 Nameplate (Mounted on inlet flange)

26 Upper Spring Washer (Epoxy coated valves only)

27 Lower Spring Washer (Epoxy coated valves only)

28 Cover Bearing Housing (20" & 24" & 30")

29 Cover Bearing Housing O-Ring (20"& 24" & 30")

30 Hex Bolt (20" & 24")

31 Pipe Cap (20" & 24 & 30"")

12434

5 17

10" — 24" SEAT DETAIL

20" — 24" COVER DETAIL

TOP VIEW

OUTLET

GLOBE

INLET

ANGLE

INLET

3" — 6" COVER DETAIL

WHEN ORDERING PARTS, BE SURE TO GIVE COMPLETE NAMEPLATE DATA, ITEM NUMBER AND DESCRIPTION.

Page 19

Page 20

Page 21

DIST.CODE 007A

X58C

RESTRICTION ASSEMBLIES

SHEET 1 OF 2

F:WORD/BUY/48834.TUB.DOC

DWG. 48834 REV.AR

REV. AR CHGD. TO WORD FORMAT AND ADDED 48834-07B; -08K ,ECO 23087( 06/06/12) OV

TUBE CONNECTOR

RESTRICTION PLUG

SIZE

MATERIAL

X58C

STOCK #.

ORIFICE

DIA.

MATERIAL

TUBE

NPT

1 / 4 1 / 8-27 NPT

BRASS

45º FLARED

*37814B

.031 (1/32)

S.STEEL

*80500C

.062 (1/16)

3 / 8

1 / 8-27 NPT

*67739D

.040

3 / 8

3 / 8-18 NPT

*64672K

.062 (1/16)

*99329-01D

.094 (3/32)

**48834-05F

.125 (1/8)

1 / 2

1 / 2 -14 NPT

**79730J

.125 (1/8)

1 / 4

1 / 8-27 NPT

*85484E

.031 (1/32)

DELRIN

*85486K

.040

**48834-03A

.125 (1/8)

*48834-04J

.093

3 / 8

1 / 8-27 NPT

*88409-01G

.031 (1/32)

*88409J

.052

*42346H

.062 (1/16)

**48834-01E

.125 (1/8)

3 / 8

1 / 4-18 NPT

*42775H

.062 (1/16)

**63604D

.156 (5/32)

3 / 8

3 / 8-18 NPT

*10253D

.031 (1/32)

*46946A

.062 (1/16)

**64673H

.125 (1/8)

*68565B

.094 (3/32)

**43302K

.188 (3/16)

Page 22

DIST.CODE 007A

X58C

RESTRICTION ASSEMBLIES

SHEET 2 OF 2

F:WORD/BUY/48834.TUB.DOC

DWG. 48834 REV.AR

REV. AR CHGD. TO WORD FORMAT AND ADDED 48834-07B; -08K ,ECO 23087( 06/06/12) OV

TUBE CONNECTOR

RESTRICTION PLUG

SIZE

MATERIAL

X58C

STOCK #.

ORIFICE

DIA.

MATERIAL TUBE

NPT

1 / 2

1 / 2 -14 NPT

BRASS

45º FLARED

**12900H

.125 (1/8)

DELRIN

**48834-02C

.188 (3/16)

**48834-06D

.250 (1/4)

3 / 8

3 / 8 -18 NPT

303

45º FLARED

**48834-07B

.125 (1/8)

**48834-08K

.062 (1/16)

3 / 8

3 / 8 -18 NPT

ALUMINUM 37º FLARED

**44734C

.125 (1/8)

S.STEEL

Page 23

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Configuration procedures . . . . . . . . . . . . . . . . . . .2

Main power supply selection . . . . . . . . . . . . . . . . .2

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . .2

Actuator speed . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Loss of signal conditions . . . . . . . . . . . . . . . . . . .3

Setpoint command signal . . . . . . . . . . . . . . . . . . .3

Set up procedures . . . . . . . . . . . . . . . . . . . . . . . .3

Remote automatic mode . . . . . . . . . . . . . . . . . . .2

Remote manual mode . . . . . . . . . . . . . . . . . . . . .2

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Wiring information . . . . . . . . . . . . . . . . . . . . . . . .5

Wiring diagrams . . . . . . . . . . . . . . . . . . . . . .6 - 12

MODEL

INSTALLATION / OPERATION / MAINTENANCE

N-130VC Electronic Actuator

130VC

Electronic Actuator

able of Contents

Page 24

130 Series Actuator Start Up Procedures

Introduction

It is recommended that this manual is read before applying power to the actuator and start up is attempted. It will take you step by step through:

• Modes of operation

• Factory configured default settings

• Configuration procedures

• Setup procedures

• Diagnostics

• Electrical components and wiring information For specific information on the pilot(s) and control

valve being actuated,consult the appropriate section of the Instruction Operation and Maintenance Manual (i.e. CRD-30, CRL-30, 90-01, etc.).

There are two separate methods of remote operation possible with the actuator. These are remote automatic and remote manual.

The remote automatic mode can use an external process variable or an internal potentiometer as the feedback signal.

Enable either one by changing the wiring on TB4 terminal strip (see pages 8,9 and 10).

Remote automatic mode. In this mode the actuator will typically position in the increasing direction when the setpoint (local or remote) is greater than the process variable (external PV or internal potentiometer). The actuator will continue to increase until the process variable is equal to the setpoint, the actuator maximum travel position (span) is reached or the process variable has reached a value equal to the maximum process variable limit.

The actuator will also decrease when the setpoint is lower than the process variable value.The actuator will continue to decrease until the process variable is equal to the setpoint, the actuator minimum position (zero) is reached or the process variable has reached a value equal to the minimum process variable range limit.

Remote manual mode. In this mode the actuator can be positioned between the minimum actuator position (zero) and the maximum actuator position (span) using dry contact closures supplied from an external source.

Factory default setting information.

The actuator, if new and factory installed on a hydraulic pilot, has been configured to specific default settings and preset at minimum actuator position. If these settings are appropriate for your application, then further configuration may not be required.

If new and not installed, these default settings will still be present, however some adjustment to the hydraulic control will be required. It will be necessary to turn the adjusting stem of the hydraulic control counter clockwise to the minimum spring setting before the actuator is installed.This will

insure that the minimum spring setting of the hydraulic pilot is equal to the minimum setting of the actuator.

If previously in service and settings are unknown, the unit should be completely reconfigured and the procedure for the hydraulic control adjusting stem, as described above, should be followed.

Default settings.

• Actuator power: 120 VAC

• Direction: Reverse acting (clockwise rotation when process variable is less than setpoint)

• Speed: 1/2 RPM

• Loss of remote setpoint or process variable: Actuator locks in place.

• setpoint type: 4-20 mA

• Zero (minimum) actuator position: Set at minimum CCW position

• Span (maximum) actuator position: Set at 8 turns CW from minimum CCW position

• Minimum process variable range limit:4.0 mA

• Maximum process variable range limit:20.0 mA

• Actuator set to minimum 4.0 mA position

1 Configuration procedures for remote automatic mode

This section contains the configuration and setup procedures for the remote automatic mode only. Use these steps to establish or change some or all of the default settings.

Remove cover using a 3/16 inch Allen wrench.

Main Power Supply Selection.

The AC input voltage must be selected prior to powering up the actuator.After cover removal, locate the main switch on the power supply board (see power supply terminal diagram). Slide the switch to the position corresponding to the correct input line voltage.

Right for 120 VAC. Left for 240 VAC.

Direction of Rotation.

The direction is determined by the position of switch #1. When this switch is in the down position indicating reverse acting, the actuator will rotate clockwise when an increasing command is given. When the switch is in the up position indicating direct acting, the actuator will rotate counter clockwise when an increasing command is given. Default

setting is reverse acting. Actuator speed.

Turning the speed potentiometer to the desired value will set actuator speed. Increase is CW and decrease is CCW.

Default setting is 1/2 RPM.

Page 25

Loss of Signal Conditions.

The actuator will respond differently during loss of signal conditions. It will lock in place, rotate fully to the lowest limit of actuator travel (zero position) or rotate fully to the highest limit of actuator travel (span position).A loss of signal condition occurs when the setpoint signal or the process variable is not present. Default setting is lock in place.

Setpoint Command Signal.

The setpoint command signal can accept a 4 – 20 mA current loop, 0 – 5 volt, 0 – 10 volt or a local setpoint.

Default setting is with 4 – 20 mA enabled.

SW - 2 SW- 3 LOS Function UP UP The actuator will lock in place during

LOS conditions.

DOWN UP The actuator will go to the minimum zero

CCW position during LOS conditions

UP DOWN The actuator will go to the maximum

span CW position during LOS condition

Switch number Enable Function SW1 – 5 DOWN Used to enable the 0 - 5 V setpoint (this

must be used in conjunction with SW1 – 7

which must be down) SW1 – 6 DOWN Used to enable the 4 to 20 ma setpoint SW1 – 7 DOWN Used to enable the 0 to 10 v setpoint (this

must be used in conjunction with SW1 – 5

which must be up) SW1 – 8 DOWN Used to enable the local setpoint. In this

mode the actuator will use a manually

adjusted setpoint.

Setup Mode.

The setup of the actuator consists of the setting the lowest limit of actuator travel (zero position), the highest limit of actuator travel (span position), the minimum process variable range limit and the maximum process variable range limit.

Placing switch #4 (setup mode) in the down position enables the setup mode.Actuator travel can then be increased using the blue push button and decreased using the yellow push button to any position.

While in this mode, all remote commands given to the actuator will be temporarily disabled.

Setting the minimum actuator position. External Process variable

Position the actuator using the increase or decrease push button to the desired minimum position. Press the red enable and the blue zero push b uttons at the same time.The LED light directly underneath the blue zero push button will illuminate confirming the setting. Default setting is min-

imum CCW position.

Setting the maximum actuator position. External Process variable mode

Position the actuator using the increase or decrease push button to the desired maximum position. Press the red enable and yellow span push buttons at the same time.The LED adjacent to the yellow span push button will illuminate confirming the setting. Default setting is 8 turns from

minimum CCW position.

Setting the 4 milliamp actuator position internal potentiometer mode (if used)

Position the actuator to the minimum system value using the increase or decrease push button. Press the red enable and the blue zero push buttons at the same time. This sets the value at 4 mA.

Setting the 20 milliamp actuator position Internal potentiometer mode (if used)

Position the actuator to the maximum system value using the increase or decrease push button. Press the red enable and the yellow span buttons at the same time. This sets the valve 20 mA.

It is highly recommended that a minimum of one pilot spring revolution be used between the 4 and 20 milliamps values.

Setting the minimum process variable limit. External process variable mode only

Method one: Using the system process variable. Set the minimum process variable limit by reducing the actual system dynamic (i.e. pressure, flow etc.) to the desired value.This can be done by pressing the actuator increase or decrease push button to attain the desired minimum process variable.When achieved, press the red enable and black LS1 push buttons at the same time .The LED adjacent to the black LS1 push button will illuminate confirming the setting. Default setting is 4 mA.

Method two: Applies only to external PV using a milliamp calibrator (if process variable cannot be changed or is not in service). Disconnect the actual process variable wires located on the logic board (including jumper on terminals 11 and 12 if used) and connect a milliamp calibrator to the process variable input terminals 10 (+) and 11 (-). Use a milliamp value corresponding to the desired minimum process variable limit (i.e. 25 psi = 8 mA, if transducer range is 0 -100 psi). This must be at least 4 mA. Press the red enable and black LS1 push buttons at the same time. The LED adjacent to the black LS1 push button will illuminate to confirm the setting.

Default setting is 4 mA.

Page 26

Setting the maximum process variable limit.

Method one: Using the system process variable. Set the maximum process variable limit by increasing the actual system dynamic (i.e. pressure, flow etc.) to the desired value. This can be done by pressing the actuator increase or decrease push button to attain the desired maximum process variable. When achieved, press the red enable and the white LS2 push buttons at the same time. The LED directly underneath will illuminate to confirm the setting. Default setting is 20 mA.

Method two: Applies only to external PV using a milliamp calibrator (if process variable cannot be changed or is not in service). Disconnect the actual process variable wires located on the logic board (including jumper on terminals 11 and 12 if used) and connect a milliamp calibrator to the process variable input terminals 10 (+) and 11 (-). Use a milliamp value corresponding to the desired maximum process variable limit (i.e. 75 psi = 16mA, if transducer range is 0-100 psi). This must be 20mA or less. Press the red enable and the white LS2 push buttons at the same time.The LED directly underneath will illuminate to confirm the setting. Default

setting is 20 mA. Setup Complete.

Once the setup of the actuator has been completed, the setup mode selector must be turned off. This can be accomplished by placing switch #4 into the up position.The actuator is now in remote automatic operation and actuator movement will begin immediately.

2 Configuration procedures for remote manual mode.

Remove cover using a 3/16 inch Allen wrench. In this mode, movement of the actuator is by dry contact

closures (supplied by others). Only the direction of rotation, speed of rotation and actuator minimum and maximum positions require setting. Use the following steps to establish or change some or all of the default settings.

Main Power Supply Selection.

The AC input voltage must be selected prior to pow ering up the actuator. After cover removal, locate the main switch located on the power supply board (see power supply terminal diagram). Slide the switch to the position co rresponding to the correct input line voltage. Default is

120VAC

Right for 120 VAC. Left for 240 VAC.

Direction of Rotation.

Default setting is reverse acting. Setting the actuator speed.

Turning the speed potentiometer to the desired value can set actuator speed. Increase is CW and decrease is CCW.

Default setting is 1/2 RPM. Setup Mode.

The setup consists of setting the lowest limit of actuator travel (zero position) and the highest limit of actuator travel (span position).Placing switch #4 (setup mode) in the down position enables the setup mode. Actuator travel can then be increased using the blue push button and decreased using the yellow push button to any position. While in this mode, all remote commands given to the actuator will be temporarily disabled.

Setting the minimum actuator position.

Position the actuator using the increase or decrease push button to the desired minimum position. Press the red enable and the blue zero push buttons at the same time. The LED light directly underneath the blue zero push button will illuminate confirming the setting. Default setting is

minimum CCW position. Setting the maximum actuator position.

imum CCW position. Setup Complete.

Once the setup of the actuator has been completed, the setup mode selector must be turned off. This can be accomplished by placing switch #4 into the up position.The actuator is now in remote manual mode and actuator movement will begin upon contact closure.

3 Diagnostics

The actuator contains two types of diagnostics.LED indication and voltage meter test ports.

Page 27

LED Function Microprocessor This LED is on when power is applied to the microprocessor, and running the microprocessor is running. If LED is not on, then verify power to the board,

as well as the SW1 setting on the top board Actuator Increasing This LED is on when the actuator is moving in the increasing direction Actuator Decreasing This LED is on when the actuator is mowing in the decreasing direction. Fault This LED will flash when a fault is present. The LED will flash at a

given rate. If the LED is flashing at 0.5 second inter vals, then a LOS

for the remote setpoint is present. If the LED is flashing at 1 second

intervals, then a LOS for the process variable is present. If the LED

is flashing a 2 second intervals, then the remote operation is disabled

because the zero and span positions have not been set. Red Enable Button This LED will be on when the enable button and one of the other four

setup push buttons have been pressed at the same time Minimum Position This LED will be on when the actuator is at or below its set minimum position. LS1 Position This LED will be on when the process variable is at or below its minimum value. LS2 Position This LED will be on when the process variable is at or above its maximum value. Maximum Position This LED will be on when the actuator is at or above its maximum position.

Test Point Function Range SPD Speed of the actuator. A value of 0 to 5 volts will be displayed.

See Figure #4 PSN The position of the actuator. A value of 4.49 to 1.57 volts will be displayed

4.49V is minimum and 1.57V is maximum position

CMD The setpoint command. I f 4 to 2 0ma current is selected, 0.8 volts to 4 will

be displayed.If 0 to 5 volts, 0 to 10 or local setpoint volts is selected, then 0 to 5 volts will be displayed.

PV The process variable. Input is 4 to 20ma only and a value 0.8 volts

to 4 volts will be displayed.

Tests using voltage meter.

There are four test points located on the logic board. The black test point labeled COM is used for the common connection. Connect a voltage meter to the COM and the appropriate test point. The values of the four red test points are shown in the following table:

Voltage at Test Point vs. Current (mA)

5.00

4.50

4.00

3.50

3.00

2.50

2.00

1.50

1.00

0.50

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

18.00

20.00

22.00

Curreent (mA)

Voltage at Test Point (V) vs Current (mA)

Voltage at Test Point (V)

LED indication.

LEDs are provided to display the status of the actuator.They are located on the logic board.Their functions are shown in the following table.

Page 28

Wiring of remote automatic and remote manual operation.

There are two modes of remote operation possible with the actuator.They are remote automatic mode and remote manual mode.The wiring diagrams for each are shown separately.

Remote Automatic Actuator Wiring (when using an external process variable)

Use the following procedures when interfacing this actuator with ancillary instrumentation components. This arrangement has been thoroughly tested and insures that problems associated with ground loops are avoided.

A.Wire the process variable transmitter directly to the actuator, using the actuator’s internal power supply. B.Retransmit the process variable signal using the terminals 9&10 on TB2 These outputs are isolated and

must be externally powered. C.Use isolator when remote setpoint is used. D.Use isolator when externally powering process variable. Avoid whenever possible the “sharing” or “breaking-into” the process-variable loop wiring unless an optical

isolator is used.

4 Wiring information

Page 29

TB4

567

910

TB2

Isolated 4-20 mA Tramsmitter Isolated 4-20 mA Tramsmitter +

1 2 3 4

6 7

TB3

TB1

Remote Setpoint

Loop Isolator

Power Supply

Load

Process Variable

240AC 120AC

120/240 AC Input

Isolated + 24 VDC

4 to 20 ma PV input +

4 to 20 ma PV input -

Isolated common

1. Remote setpoint must be isolated and powered from external source

2. PV retransmission requires an external power supply within 12 to 36 VDC . Maximum load = (Power supply VDC 8 VDC) / .020 A.

3. A switch may be placed between terminals 9 and 10 on TB3 to interrupt actuator travel. Contact between 9 and 10 will stop actuator movement.

DO NOT POWER.

Optional external switch to stop actuator rotation

G N

Ground to green screw in floor of housing

Remote Automatic Mode

Using external PV and internal power supply to power 4-20 mA loop

Page 30

Remote Automatic Mode

Using external PV and external power supply to power 4-20 mA loop

Power Supply

Process Variable

Loop Isolator (recommended)

420 mA Pv input +

Isolated +24 VDC

Ground to green screw in floor of housing

N L

TB1

1 2 3 4 5 6 7 8 9

TB3

Isolated 420 mA Transmitter -

Isolated 420 mA Transmitter +

Load

Power Supply

—

Remote Setpoint

—

Loop Isolator

Optional external switch to stop actuator rotation

1. Remote setpoint must be isolated and powered from ecternal source.

2. PV retransmission requires an external power supply within 12 to 36 VDC. Maximum load = (Power supply VDC - 8 VDC) / .020A.

240AC 120AC

TB2

120/240 AC Input

TB4

1234

89101112

Isolated Common

420 mA PV input —

+-+

3. A switch may be placed between terminals 9 and 10 on TB3 to interrupt actuator travel. Contact between 9 and 10 will stop actuator movement.

DO NOT POWER.

Page 31

Remote Automatic Mode

Using internal potentiometer as Process V ariable

1. Remote setpoint must be isolated and powered from ecternal source.

2. PV retransmission requires an external power supply within 12 to 36 VDC. Maximum load = (Power supply VDC-8 VDC) / 0,20 A.

1 2 3 4 5 6 7

8 9

TB3

TB1

Isolated 420 mA Transmitter -

Isolated 420 mA Transmitter +

TB4

1234

89101112

Remote Setpoint

Loop Isolator

G N

TB2

120/240 AC Input

Ground to green screw in floor of housing

Isolated Common

4-20 mA PV input —

—

240AC

120AC

420 mA Pv input +

Isolated +24 VDC

Page 32

Remote Manual Operation - Wiring Diagram Position actuator using contact closure

Ground to green screw in floor of housing

TB2

120/240 AC Input

240AC 120AC

Manual Increase

Manual Decrease

TB1

1 2 3 4 5 6 7

TB3

1. DO NOT POWER MANUAL INPUTS!

2. Use unpowered mechnaical or solid state relays.

1234

89101112

TB4

Enable Manual

Enable Manual common

3. Use external jumper across terminal 9 and 10.

Page 33

100-01

PARTS LIST

2.50

2.75

OPERATING PRESSURE 1/8 NPT

3/8 NPT

BOTH ENDS

1.50

1.25

INLET

SECTION

100-01 3/8" HYTROL VALVE

3/8"-1 Hytrol Valve

PARTS LIST

ITEM DESCRIPTION

1. Cover Screw (8 Required)

2. Cover

3. Spring

4. Diaphragm Washer

5. Diaphragm

6. Disc Retainer Assembly

7. Body Plug (3/8 NPT)

8. Body

* *

* Recommended Spare Parts

When Ordering parts, please specify

• All nameplate data

• Description

• Item Number

• Material

MODEL

Page 34

100-01

PARTS LIST

1/2"-3/4"-1” Hytrol Valve

CLA-VAL

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

PL-100-01 3/8” - 1” (R-7/2012)

MODEL

OPERATING PRESSURE

1/8

OUTLET

INLET

BODY WITH INTEGRAL SEAT

OPERATING PRESSURE

1/4

5.12

2.68

OUTLET

1.03

INLET

PARTS LIST

ITEM DESCRIPTION

1 COVER SCREW 2 COVER 3 SPRING 4 STEM NUT 5 DIAPHRAGM WASHER 6 DIAPHRAGM 7 DISC RETAINER ASSEMBLY 8 DISC GUIDE & STEM

9 BODY 10 SEAT 11 NAMEPLATE 12 BODY PLUG HEX HD. 13 O-RING SEAT

(FOR OLD STYLE BODY ONLY)

* *

* Recommended Spare Parts

When Ordering parts, please specify

• All nameplate data

• Description

• Item Number

• Material

1/2 3/4

1-7/16 3-1/2

2-3/8 2-3/8

25/32 29/32

A C (MAXIMUM) D

PARTS LIST

ITEM DESCRIPTION

1 COVER SCREW 2 NAMEPLATE

3 NAMEPLATE SCREW 10 COVER 11 SPRING 13 STEM NUT 14 DIAPHRAGM WASHER 15 DIAPHRAGM 16 DISC RETAINER ASSEMBLY 19 DISC GUIDE 22 SEAT 24 BODY PLUG 25 BODY 26 O-RING, SEAT

* Recommended Spare Parts

100-01 3/4" & 1/2" Hytrol Valve

100-01 1" Hytrol Valve

Page 35

NORMALLY OPEN PRESS AT 3 (C)

NORMALLY CLOSED PRESS AT 3 (C)

UNIVERSAL-PRESS AT ANY ORIFICE.

FORM

SOLENOID

DE-

ENERGIZED

SOLENOID

ENERGIZED

(C)

(B)(A)

(C)

(B)(A)

(C)

(B)(A)

(C)

(B)(A)

(C)

(B)(A)

(C)

(B)(A)

DESCRIPTION

MANUAL OPERATORS (OPTIONAL)

NOTE: Port Markings 1, 2, and 3 correspond directly to A, B and C.

Bulletin 8320 is a small 3-way solenoid operated valve with all three pipe connections located in the body. The bodies are of brass or stainless steel construction. Standard valves have General Purpose, Nema Type 1 Solenoid Enclosures. Valves that are equipped with a solenoid enclosure which is designed to meet Nema Type 4-Water tight, Nema Type 7 (C or D) Hazardous Locations - Class I, Group C or D, and Nema Type 9 (E, F or G) Hazardous Locations - Class II, Group E, F or G are shown on separate sheets of Installation and Maintenance Instructions, Form Numbers V-5391 and V-5381.

Check Nameplate for correct Catalog Number, pressure, voltage and service.

Valves with suffix "MO" or "MS" in catalog number are provided with a Manual Operator which allows manual operation when desired or during an interruption of electrical power.

INSTALLATION

Valve may be mounted in any position

POSITIONING

Connect piping to valve according to markings on valve body. Refer to Flow Diagram provided. Apply pipe compound sparingly to male pipe threads only; if applied to valve threads, it may enter valve and cause operational difficulty. Pipe strain should be avoided by proper support and alignment of piping. When tightening pipe, do not use valve as lever.

PIPING

Wiring must comply with local and National Electrical Codes. For valves equipped with an explosion-proof, watertight solenoid enclosure, the electrical fittings must be approved for use in the approved hazardous locations. Housings for all solenoids are made with connections for 1/2 inch conduit. The general purpose enclosure may be rotated to facilitate wiring by removing the retaining cap.

WIRING

OPERATION

Normally Closed: Applies pressure when solenoid is energized:

exhausts pressure when solenoid is de-energized Normally Open: Applies pressure when solenoid is de-energized; exhausts pressure when solenoid is energized. Universal: For normally closed or normally open operation, selection or diversion of pressure can be applied at port 1 (A), 2 (B), or 3 (C).

NOTE

SOLENOID TEMPERATURE

MAINTENANCE

COIL REPLACEMENT

(REF. FIG. 2)

Alternating Current (A-C) and Direct Current (D-C) solenoids are built differently. To convert from one to other, it is necessary to change the complete solenoid, including the core assembly.

Turn off electrical power, disconnect coil lead wires and proceed as follows:

Spare Parts Kits and Coils are available for ASCO valves. Parts marked with

Standard catalog valves are supplied with coils designed for continuous duty service. When the solenoid is energized for a long period, the solenoid enclosure becomes hot and can be touched with the bare hand for only an instant. This safe operating temperature. Any excessive heating will be indicated by the smoke and odor of burning coil insulation.

CLEANING

A periodic cleaning of all valves is desirable. The time between cleanings will vary, depending on the media and service conditions. In general, if the voltage to the coils is correct, sluggish valve operation or excessive leakage will indicate that cleaning is required.

IMPROPER OPERATION

Faulty Control Circuit: Check the electrical system by energiz-

ing the solenoid. A metallic click signifies the solenoid is operating. Absence of the click indicate loss of power supply. Check for loose or blown-out fuses, open-circuited or grounded coil, broken lead wires or splice. Burned-out Coil: Check for open-circuited coil. Replace coil, if necessary. Low Voltage: Check voltage across coil leads. Voltage must be at least 85% of nameplate ratings. Incorrect Pressure: Check valve pressure. Pressure to valve must be within the range specified on nameplate. Excessive Leakage: Disassemble valve and clean all parts. Replace parts that are worn or damaged with a complete Spare Parts Kit for best results.

Turn off electrical power supply and de-pressurize valve.

VALVE DISASSEMBLY AND REASSEMBLY (REF. FIG. 2)

WARNING: Turn off electrical power and line pressure to valve

before making repairs. It is not necessary to remove valve from pipe line for repairs.

Remove retaining cap, nameplate and cover. Slip yoke containing coil, sleeves and insulating washers off the solenoid base sub-assembly. Insulating washers are omitted when molded coil is used. In some D.C. Constructions, a single flux plate over the coil replaces yoke, sleeves and insulating washers. Reassemble in reverse order of disassembly.

Remove retaining cap and slip entire solenoid off solenoid base subassembly or plugnut/core tube sub-assembly. Unscrew bonnet or solenoid base sub-assembly. Remove core assembly, core spring and body gasket. Remove end cap, body gasket, disc spring, disc holder, disc or disc holder assembly. All parts are now accessible for cleaning or replacement. Replace worn or damaged parts with a complete Spare Parts Kit for best results. Reassemble in reverse order of disassembly paying careful attention to exploded view provided.

ORDERING INFORMATION FOR SPARE

PARTS KITS

When Ordering Spare Parts Kits or Coils

Specify Valve Catalog Number,

Serial Number and Voltage

INSTALLATION AND

MAINTENANCE INSTRUCTIONS

3-WAY SOLENOID VALVES, NORMALLY OPEN

NORMALLY CLOSED AND UNIVERSAL CONSTRUCTION

IMPORTANT: For protection of the solenoid valve, install a strainer

or filter suitable for the service involved in the inlet side as close to the valve as possible. Periodic cleaning is required depending on the service conditions.

BULLETIN

8320

ASCO

FORM NO. V5291R2

Page 36

NOTE:

1. FOR MOUNTING, A FLAT SURFACE MUST BE PROVIDED ACROSS THE ENTIRE LENGTH OF THE BRACKET. THE VALVE BODY BECOMES SECURE TO BRACKET, WHEN BRACKET IS TIGHTENED IN TO POSITION. IF THE VALVE HAS A MANUAL OPERATOR, A HOLE MUST BE MADE THROUGH THE MOUNTING SURFACE FOR THE OPERATOR STEM.

RETAINING CAP

NAMEPLATE

COVER

YOKE

HOUSING

FLUX PLATE (NOT PRESENT IN ALL CONSTRUCTIONS)

SOLENOID BASE SUB ASSEMBLY

(OPTIONAL)

MOUNTING BRACKET

(FOUR POSITIONS)

TWO SELF-TAPPING

SCREWS PROVIDED

CORE SPRING (WIDE END IN CORE FIRST, CLOSED END PROTRUDES FROM TOP OF CORE)

CORE ASSEMBLY

BODY GASKET

BODY

(BRASS)

DISC HOLDER ASSEMBLY

DISC SPRING

BODY GASKET

END CAP

BODY GASKET

DISC SPRING

DISC

DISC HOLDER

BODY

(ST. ST.)

BODY GASKET

CORE ASSEMEBLY

CORE SPRING (WIDE END IN CORE FIRST, CLOSED END PROTUDES FROM TOP OF CORE)

PLUGNUT/CORE TUBE SUB-ASSEMBLY

BONNET GASKET

BONNET

SOLENOID ENCLOSURE

RETAINING CAP

PARTS INCLUDED IN SPARE PARTS KITS

MANUAL OPERATOR

SCREW TYPE

(MS)

MANUAL OPERATOR

PUSH TYPE

(MO)

SLEEVE

INSULATING WASHER (OMITTED WHEN MOLDED COIL IS USED)

COIL

INSULATING WASHER (OMITTED WHEN MOLDED COIL IS USED)

SLEEVE

(OPTIONAL)

MOUNTING BRACKET

(SEE NOTE

CLA-VAL

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

N-V5291 (R-3/2011)

Page 37

INSTALLATION AND

MAINTENANCE INSTRUCTIONS

OPEN-FLAME, GENERAL PURPOSE,

WATERTIGHT/EXPLOSIONPROOF SOLENOIDS

BULLETIN

8016G

ASCO

FORM NO. V6583R5

-SERVICE NOTICE-

ASCO®solenoid valves with design change letter "G" in the catalog number (example: 8210G 1) have an epoxy encapsulated ASCO®Red Hat II. solenoid. This solenoid replaces some of the solenoids with metal enclosures and open-frame constructions. Follow these installation and maintenance instructions if your valve or operator uses this solenoid.

DESCRIPTION

Catalog numbers 8016G1 and 8016G2 are epoxy encapsulated pull-type solenoids. The green solenoid with lead wires and 1/2 " conduit connection is designed to meet Enclosure Type 1 -General Purpose,Type 2Dripproof,Types 3 and 3S-Raintight, and Types 4 and 4X-Watertight. The black solenoid on catalog numbers prefixed "EF" is designed to meet Enclosure Types 3 and 3S-Raintight, Types 4 and 4X-Watertight, Types 6 and 6P-Submersible, type 7 (A, B, C, & D) Explosionproof Class 1, Division 1, Groups A, B, C, & D and Type 9 (E, F, & G)-Dust-lgnitionproof Class 11, Division 1, Groups E, F, & G. The Class 11, Groups F & G Dust Locations designation is not applicable for solenoids or solenoid valves used for steam service or when a class "H" solenoid is used. See Temperature Limitations section for solenoid identification and nameplate/retainer for service. When installed just as a solenoid and not attached to an ASCO valve, the core has a 0.250-28 UNF-2B tapped hole,

0.38 minimum full thread.

Series 8016G solenoids are available in:

• Open-Frame Construction

The green solenoid may be supplied with 1/4 spade, screw, or DIN terminals (Refer to Figure 4).

• Panel Mounted Construction

These solenoids are specifically designed to be panel mounted by the customer through a panel having a .062 to .093 maximum wall thickness. (Refer to Figure 3 and section on Installation of Panel Mounted Solenoid).

Optional Features For Type 1—General Purpose Construction Only

• Junction Box

This junction box construction meets Enclosure Types 2,3,3S,4, and 4X. Only solenoids with 1/4" spade or screw terminals may have a junction box. The junction box provides a 1/2 conduit connection, grounding and spade or screw terminal Connections within the junction box (See Figure 5).

• DIN Plug Connector Kit No. K236 - 034

Use this kit only for solenoids with DIN terminals. The DIN plug connector kit provides a two pole with grounding contact DIN Type 43650 construction (See Figure 6).

OPERATION

When the solenoid is energized, the core is drawn into the solenoid base subassembly. IMPORTANT: When the solenoid is de-energized, the initial return force for the core, Whether developed by spring, pressure, or weight, must exert a minimum force to overcome residual magnetism created by the solenoid. Minimum return force for AC construction is 11 ounces, and 4 ounces for DC construction.

INSTALLATION

Check nameplate for correct catalog number, service, and wattage. Check front of solenoid for voltage and frequency.

WARNING: To prevent the possibility of electrical shock from the accessibility of live parts, install the open-frame solenoid in an enclosure.

FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLY

CAUTION: To prevent fire or explosion, do not install solenoid and/or valve

where ignition temperature is less than 165˚ C. On valves used for steam service or when a class "H" solenoid is used, do not install in hazardous atmosphere where ignition temperature is less than 180˚ C. See nameplate/retainer for service. NOTE: These solenoids have an internal non-resetable thermal fuse to limit solenoid temperature in the event that extraordinary conditions occur which could cause excessive temperatures. These conditions include high input voltage, a jammed core, excessive ambient temperature or shorted solenoid, etc. This unique feature is a standard feature is a standard feature only in solenoids with black explosionproof/dust-ignitionproof enclosures (types 7&9).

IMPORTANT: To protect the solenoid valve or operator, install a strainer or filter, suitable for the service involved in the inlet side as close to the valve or operator as possible. Clean periodically depending on service condition & See ASCO Series 8600, 8601, and 8602 for strainers.

Temperature Limitations

For maximum valve ambient temperatures, refer to chart. The temperature limitations listed, only indicate maximum application temperatures for field wiring rated at 90°C. Check catalog number prefix and watt rating on nameplate to determine maximum ambient temperature. See valve installation and maintenance instructions for maximum fluid temperature. NOTE: For steam service, refer to Wiring section, Junction Box for temperature rating of supply wires.

Minimum ambient temperature -40° F (-40° C). Positioning

Positioning

This solenoid is designed to perform properly when mounted in any position. However, for optimum life and performance, the solenoid should be mounted vertically and upright to reduce the possibility of foreign matter accumulating in the solenoid base sub-assembly area.

Wiring

Wiring must comply with local codes and the National Electrical Code. All solenoids supplied with lead wires are provided with a grounding wire which is green or green with yellow stripes and a 1/2" conduit connection. To facilitate wiring, the solenoid may be rotated 360˚. For the watertight and explosionproof solenoid, electrical fittings must be approved for use in the approved hazardous locations.

Additional Wiring Instructions For Optional Features:

• Open-Frame solenoid with 1/4" spade terminals

For solenoids supplied with screw terminal connections use #12-18 AWG stranded copper wire rated at 90°C or greater. Torque terminal block screws to 10 ± 2 in-lbs (1,0 + 1,2 Nm). A tapped hole is provided in the solenoid for grounding, use a #Y10-32 machine screw. Torque grounding screw to 15 -20

Temperature Limitations For Series 8016G Solenoids for use

Valves Rated at 6.1, 8.1,9.1,10.6 or 11.1 Watts

Watts

Rating

Catalog

Number Coil

prefix

Class of

Insulation

Maximum

ambient Temp.

˚F

6.1, 8.1, 9.1, & 11.1

None, FB, KF, KP,

SF, SP, SC, & SD

F 125

6.1, 8.1, 9.1, & 11.1

HB, HT, KB, KH,

SS, ST, SU, & ST

H 140

10.6

None, KF,

SF, & SC

F 104

10.6

HT, KH,

SU, & ST

H 104

Page 38

in-lbs (1,7 - 2,3 Nm). On solenoids with screw terminals, the socket head screw holding the terminal block to the solenoid is the grounding screw. Torque the screw to 15 - 20 in-lbs (1,7 - 2,3 Nm). with a 5/32" hex key wrench.

• Junction Box

The junction box is used with spade or screw terminal solenoids only and is provided with a grounding screw and a 1/2" conduit connection. Connect #12-18AWG standard copper wire only to the screw terminals. Within the junction box use field wire that is rated 90°C or greater for connections. For steam service use 105°C rated wire up to 50 psi or use 125°C rated wire above 50 psi. After electrical hookup, replace cover gasket, cover, and screws. Tighten screws evenly in a crisscross manner.

• DIN Plug Connector Kit No. KC236-034

1. The open—frame solenoid is provided with DIN terminals to accommodate the DIN plug connector kit.

2. Remove center screw from plug connector. Using a small screwdriver, pry terminal block from connector cover.

3. Use #12-18 AWG stranded copper wire rated at 90°C or greater for connections. Strip wire leads back approximately 1/4" for installation in socket terminals. The use of wire-end sleeves is also recommended for these socket terminals. Maximum length of wire-end sleeves to be approximately 1/4". Tinning of the ends of the lead wires is not recommended.

4. Thread wire through gland nut, gland gasket, washer, and connector

cover.

NOTE: Connector cover may be rotated in 90° increments from position shown for alternate positioning of cable entry.

5. Check DIN connector terminal block for electrical markings. Then make electrical hookup to terminal block according to markings on it. Snap terminal block into connector cover and install center screw.

6. Position connector gasket on solenoid and install plug connector. Torque center screw to 5 ± 1 in-lbs (0,6 ± 1,1 Nm).

NOTE: Alternating current (AC) and direct current (DC) solenoids are built differently. To convert from one to the other, it may be necessary to change the complete solenoid including the core and solenoid base subassembly, not just the solenoid. Consult ASCO.

Installation of Solenoid

Solenoids may be assembled as a complete unit. Tightening is accomplished by means of a hex flange at the base of the solenoid. The 3/4" bonnet construction (Figure 1) must be disassembled for installation and installed with a special wrench adapter.

Installation of Panel Mounted Solenoid (See Figure 3)

Disassemble solenoid following instruction under Solenoid Replacement then proceed

3/4" Valve Bonnet Construction

1. Install retainer(convex side to solenoid) in 1.312 diameter mounting hole in customer panel.

2. Then position spring washer over plugnut/core tube sub-assembly.

3. Install plugnut/core tube sub-assembly through retainer in customer panel. Then replace solenoid, nameplate/retainer and red cap.

15/16" Valve Bonnet Construction

1. Install solenoid base sub-assembly through 0.69 diameter mounting hole in customer panel.

2. Position spring washer on opposite side of panel over solenoid base sub-assembly then replace.

Solenoid Temperature

Standard solenoids are designed for continuous duty service. When the solenoid is energized for a long period, the solenoid becomes hot and can be touched by hand only for an instant. This is a safe operating temperature.

MAINTENANCE

WARNING: To prevent the possibility of personal injury or property damage, turn off electrical power, depressurize solenoid operator and/or valve, and vent fluid to a safe area before servicing.

Cleaning

All solenoid operators and valves should be cleaned periodically. The time between cleaning will vary depending on medium and service conditions. In general, if the voltage to the solenoid is correct, sluggish valve operation, excessive noise or leakage will indicate that cleaning is required. Clean strainer or filter when cleaning the valve,

Preventive Maintenance

• Keep the medium flowing through the solenoid operator or valve as free from dirt and foreign material as possible.

• While in service, the solenoid operator or valve should be operated at least once a month to insure proper opening and closing.

• Depending on the medium and service conditions, periodic inspection of internal valve parts for damage or excessive wear is recommended. Thoroughly clean all parts. Replace any worn or damaged parts.

Causes of Improper Operation

• Faulty Control Circuit: Check the electrical system by energizing the

solenoid. A metallic click signifies that the solenoid is operating. Absence of the click indicates loss of power supply. Check for loose or blown fuses, open-circuited or grounded solenoid, broken lead wires or splice connections.

• Burned-Out Solenoid: Check for open-circuited solenoid. Replace if necessary. Check supply voltage; it must be the same as specified on nameplate/retainer and marked on the solenoid. Check ambient temperature and check that the core is not jammed.

• Low Voltage: Check voltage across the solenoid leads. Voltage must be at least 85% of rated voltage.

Solenoid Replacement

1. On solenoids with lead wires disconnect conduit, coil leads, and grounding wire.

NOTE: Any optional parts attached to the old solenoid must be reinstalled on the new solenoid.

2. Disassemble solenoids with optional features as follows:

• Spade or Screw Terminals

Remove terminal connections, grounding screw, grounding wire, and terminal block (screw terminal type only).

NOTE: For screw terminals, the socket head screw holding the terminal block serves as a grounding screw.

• Junction Box Remove conduit and socket head screw (use 5132" hex key wrench) from center of junction box. Disconnect junction box from solenoid.

• DIN Plug Connector Remove center screw from DIN plug connector. Disconnect DIN plug connector from adapter. Remove socket head screw (use 5/32" hex key wrench), DIN terminal adapter, and gasket from solenoid.

3. Snap off red cap from top of solenoid base sub-assembly.

4. Push down on solenoid. Then using a suitable screwdriver, insert blade in slot provided between solenoid and nameplate/retainer. Pry up slightly and push to remove. Then remove solenoid from solenoid base sub-assembly.

5. Reassemble using exploded views for parts identification and placement

Disassembly and Reassembly of Solenoids

1. Remove solenoid, see Solenoid Replacement.

2. Remove finger washer or spring washer from solenoid base sub- assembly.

3. Unscrew solenoid base sub-assembly.

NOTE: Some solenoid constructions have a plugnut/core tube sub-assembly, bonnet gasket and bonnet in place of the solenoid base sub-assembly. To remove bonnet use special wrench adapter supplied in ASCO Rebuild Kit. For wrench adapter only, order ASCO Wrench Kit No.K218 - 948.

4. The core is now accessible for cleaning or replacement.

5. If the solenoid is part of a valve, refer to basic valve installation and maintenance instructions for further disassembly.

6. Reassemble using exploded views for identification and placement of parts.

ORDERING INFORMATION FOR ASCO SOLENOIDS

When Ordering Solenoids for ASCO Solenoid Operators or Valves, order the number stamped on the solenoid. Also specify voltage and frequency.

Page 39

wave washer

valve bonnet

bonnet gasket

core

plugnut/core tube sub-assembly

Remove red cap and

push solenoid down.

Then pry here to lift

nameplate/retainer

and push to remove.

solenoid with 1/2" NPT

For special wrench

adapter order kit

No. K218-948.

0.750-28 UN-2A thread

Tapped hole in core

0.250-28 UNF-2B

0.38 minimum full thread.

red cap

nameplate/ retainer

grounding wire green or green with yellow stripes

solenoid base sub-assembly

0.9375-26 UNS -2A thread

core (DC)

core (AC)

spring washer

3/4" Bonnet Construction 15/16" Bonnet Construction

Side View

collar to face

valve body

finger washer

Alternate

Construction

Remove red cap and

push solenoid down.

Then pry here to lift

nameplate/retainer

and push to remove.

See torque chart

for bonnet screws

red cap

nameplate/ retainer

spacer

solenoid

finger washer

valve bonnet

core tube

Bolted Bonnet

Construction

red cap

nameplate/retainer

solenoid with 1/2" NPT

1.312 diameter mounting hole

grounding wire green or green with yellow stripes

.062 to .093 maximum

thickness of panel

for mounting

plugnut/core tube sub-assembly

core

For special wrench adapter order kit No. K218-948

bonnet gasket

valve bonnet

spring washer

retainer

core

solenoid base sub-assembly

finger washer

0.69 diameter mounting hole

Remove red cap and push solenoid down.

Then pry here to lift

nameplate/retainer

and push to remove.

3/4" Bonnet Construction 15/16" Bonnet Construction

Part Name

solenoid base sub-assembly

valve bonnet (3/4" bonnet constructions)

bonnet screw (3/8" or 1/2" NPT pipe size)

bonnet screw (3/4" NPT pipe size)

Torque Value in inch-Pounds

175 ± 25

90 ± 10

25 40

Torque Value in Newton-Meters

19.8 ± 2.8

10.2 ± 1.1

2.8

4.5

Torque Chart

Figure 1. Series 8016G solenoids

Figure 2. Series 8016G solenoid Figure 3. Series 8016G panel mounted solenoids

Page 40

CLA-VAL

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

Torque Chart

Part Name

terminal block screws

socket head screw

center screw

Torque Value in inch-Pounds

10 ± 2

15 - 20

5 ± 1

Torque Value in Newton-Meters

1,1 ± 0,2

1,7 - 2,3

0,6 ± 0,1

Open Frame Solenoid

with 1/4" Spade Terminals

tapped hole for #10-32 grounding screw (not included)

See

torque chart

above

Open-Frame Solenoid

with Screw Terminals. Socket head screw is

used for grounding.

Screw terminal adapter

terminal block screw

socket head grounding screw (5/32" hex key wrench)

Open-Frame Solenoid

with DIN Terminals.

gasket

DIN terminal adapter

socket head screw (5/32" hex key wrench)

Junction box Solenoid

with 1/4" Spade Terminals

or Screw Terminals

screw terminal block

(see note)

junction box gasket

junction box with 1/2" conduit connection and grounding terminal

socket head screw (5/32" hex key wrench)

cover screw

cover

cover gasket

grounding screw and cup washer

See

torque chart

above

gasket

DIN terminal adapter

connector gasket

gland nut

gland gasket

washer

center screw

Open-Frame Solenoid

with DIN Terminal

Plug Connector

Note:

Junction box with screw terminals shown. With screw terminal block removed, remaining parts comprise the junction box for spade terminal construction.

See

torque chart

above

socket head screw (5/32" hex key wrench)

DIN connector terminal block

(see note 2)

connector cover

(see note 1)

Notes:

1. Connector cover may be rotated in 90˚ increments from position shown for alternate postion of cable entry.

2. Refer to markings on DIN connector for proper electrical connections.

Indicates that these parts are included in DIN plug connector Kit No. K236-034

Figure 4. Open - frame solenoids

Figure 5. Open - frame solenoids

N-V6583 (R-3/2010)

Page 41

Limit Switch Assemblies

Switches shown in unactivated position.

CLA-VAL

124-02/624-02

Float Valve

Annunciator Alarm

Stilling Well

Tank

Supply

Double Pole Double Throw Switch

Single Pole Double Throw Switch

Installation

Typical Application

Actuating Collar Adjustment

Minimum Setting

When adjusting actuating collar for proper switch action, a clearance of at least 1/16" (1/8” for 24” valve) must be provided between the collar and the bushing gland nut when valve is in the fully closed position.

Used for any electrical operation which can be performed by either opening or closing a switch; such as alarm systems, process control, pump control, motor starting or stopping, etc. Readily attached to most Cla-Val Valves.

1. Remove plug in top of valve cover.

2. Screw actuating stem into main valve stem.

3. Slip adapter down over stem and screw into place on valve cover.

4. Attach micro switch housing and bracket to adapter with jam nut.

5. Bring electrical supply circuit into unit through the 1/2" tapping in micro switch housing.

6. Adjust switch collars. (Set collar to trip switch after valve is positioned fully open or fully closed)

• UL Listed Switches

• Positive Action

• Rugged and Dependable

• Weather Proof or Explosion Proof

• Easy To Adjust

The Cla-Val Model X105L/X105L2 Limit Switch Assembly is a rugged, dependable and positive acting switch assembly actuated by the opening or closing of a Cla-Val control valve on which it is mounted. The single pole, double throw micro switch can be connected either to open or to close an electrical circuit when actuated. By loosening the allen screw on the actuating collar and raising or lowering the collar on the stem, the X105L is easily adjusted to signal that the valve has fully reached the desired position (open or closed).

X105L

X105L2

MODEL

COM

N.C.

N.O.

Circuit Diagram of Single Pole Double Throw Switch

Common Lug

Normally

Closed Normally Open

N.C.

N.O.

COM

Circut Diagram of Single Pole Double Throw Switch

Normally Closed

Normally Open

Common Lug

N.O.

Stem

Bushing Gland Nut

Jam Nut

Bracket

Switch Actuating Collar

Adapter

Min. 1/16"

Switch only

Annunciator Alarm

Page 42

X105 Series Dimensions

(In Inches)

1. Valve Size and Basic Valve Model Number

2. Catalog Number from Table Below

3. All Valve Name Plate Data

4. Select Single or Double Pole Switch

5. Explosion Proof or Weather Proof Type Enclosure

6. Amperes and Voltage, AC or DC

7. Actuating Position (Valve Open or Closed)

CATALOG ACTUATION SWITCH

NO. POSITION ENCLOSURE

X105LCW Valve Weather Proof

Closed

X105LCX Valve Explosion Proof

Closed

X105LOW Valve Weather Proof

Open

X105LOX Valve Explosion Proof

Open

X105L2W Dual Weather Proof

X105L2X Dual Explosion Proof

Specifications

Materials: Aluminum switch housing

Steel bracket and brass adapter Stainless steel stem

Electrical: 1/2" Conduit connection

Switch Type: SPDT UL, File No. E12252,

CSA Certified, File No. LR57325 Weather proof NEMA 1,3,4, and13

Switch Rating: UL/CSA rating: L96

15 amp. 125, 250, or 480 volts AC 1/2 amp. 125 volts DC 1/4 amp. 250 volts DC

Switch Options: DPDT switches available on request

UL/CSA Rating: L59, 10 amps

Explosion proof micro switches are NEMA 1,7, and 9 UL Listed, File No. E14274 and CSA Certified, File No. LR57324: Class I, Group C and D and Class II, Group E, F and G.

Fig. 1

Valve Size

1 1/4" Thru 8"

X105L2W

X105L2X

1/2-14 N.P.S.M. Thread (Conduit Connections)

.13

2.44

1.70

3.00

.86

3.13

2.00

C (Typical)

Fig. 2

Valve Size

1 1/4" Thru 24"

X105LCW

X105LCX

Fig. 4

Valve Size

10" Thru 24"

X105LOW

X105LOX

Fig. 3 Valve Size 1 1/4" Thru 8" X105LOW X105LOX

Fig. 5

Valve Size

10" Thru 24"

X105L2W

X105L2X

E-X105L/X105L2 (R-3/2011)

BasicValve 100-01 1 1⁄4 1 1⁄2 2 2 1⁄2 3 4 6 8 10 12 14 16 18 20 24 30 36* 42* 48*

Dimension "A" 10.19 10.19 7.16 7.16 7.34 7.00 6.69 6.91 9.88 9.59 9.16 10.78 10.78 CF* 11.30 CF* CF* CF* CF*

Dimension "B" 1.69 2.44 2.94 2.94 2.94 2.94 CF* 5.19 CF* CF* CF* CF*

C (NPT) 1/4 1/4 1/2 1/2 1/2 3/4 3/4 1 1 1 1/4 1 1/2 2 2 CF* 1CF*CF* CF* CF*

BasicValve 100-20 3 4 6 8 10 12 14 16 18 20 24 30 36* 42* 48*

Dimension "A" 7.16 7.34 7.00 6.69 6.91 9.88 9.59 9.59 10.78 10.78 10.78 11.30 CF* CF* CF*

Dimension "B" 1.69 2.44 2.94 2.94 2.94 2.94 2.94 5.19 CF* CF* CF*

C (NPT) 1/2 1/2 3/4 3/4 1 1 1 1/4 1 1/4 2 2 2 1 CF* CF* CF*

PO Box 1325 Newport Beach CA 92659-0325

Phone: 949-722-4800 Fax: 949-548-5441

LA-VAL

CLA-VAL CANADA CLA-VAL EUROPE

4687 Christie Drive Beamsville, Ontario Canada L0R 1B4 Phone: 905-563-4963 Fax: 905-563-4040

Chemin dés Mesanges 1 CH-1032 Romanel/ Lausanne, Switzerland Phone: 41-21-643-15-55 Fax: 41-21-643-15-50

Specifications subject to change without notice.

www.cla-val.com

Represented By:

When Ordering, Please Specify

*Consult Factory

Page 43

Limit Switch Assembly

VALV E

COVER

When ordering parts, please specify:

• Item Number

• Description

• Part Number

X105L

CLA-VAL

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

PL- X105L (R-3/2011)

PARTS LIST

COVER

Item

Part

Number

Description

Valves Sizes

Used On

1-2 20441701E Collar W/Set Screw All

3 67578-21B Screw, Machine (2) All

4 67584-23F Washer, Lock (2) All

5 34637K

Switch Assembly, Weather Proof

All

34633J

Switch Assembly, Explosion Proof

All

6 64310G

Bracket Switch Mounting

10" thru 16"

7 67815-06J Nut, Jam All

8 63674G Plate, Mounting All

2838201J 2838202G

Adapter Adapter

2" thru 3"

4" thru 16"

10 63398C

Bushing, Gland

All

11 00951E O-Ring (2) All

67644-17K 67644-18H 67644-19F 67644-91J

Bushing Bushing Bushing Bell Reducer

8" and 10"

12" 14" 16"

89701-01F 89701-02D 89701-03B 89701-04K 89701-05G

Stem, Actuating Stem, Actuating Stem, Actuating Stem, Actuating Stem, Actuating

2"-2 1/2"

3"-4" 6"-8"

10"-12"-14"

16"

15 6551201H Fiber Washer All

16 6824421K Screw 8-32 x 3/8 All

Page 44

The strainer is designed for use in conjunction with a Cla-Val Main Valve, but can be installed in any piping system where there is a moving fluid stream to keep it clean. When it is used with the Cla-Val Valve, it is threaded into the upstream body port provided for it on the side of the valve. It projects through the side of the Main Valve into the flow stream. All liquid shunted to the pilot control system and to the cover chamber of the Main Valve passes through the X46 Flow Clean Strainer.

Male

Pipe

SAE

Male Pipe

Width Across Flats

Female

Pipe

• Self Scrubbing Cleaning Action

• Straight Type or Angle Type

The Cla-Val Model X46 Strainer is designed to prevent passage of foreign particles larger than .015". It is especially effective against such contaminant as algae, mud, scale, wood pulp, moss, and root fibers. There is a model for every Cla-Val. valve.

The X46 Flow Clean strainer operates on a velocity principle utilizing the circular "air foil" section to make it self cleaning. Impingement of particles is on the "leading edge" only. The low pressure area on the downstream side of the screen prevents foreign particles from clogging the screen. There is also a scouring action, due to eddy currents, which keeps most of the screen area clean.

Dimensions

(In Inches)

INSTALLATION

X46 Angle Type B (In Inches)

(NPT)C(SAE)

DEH I

1/8 1/4 1-3/8 5/8 7/8 1/4

1/4 1/4 1-3/4 3/4 1 3/8

3/8 1/4 2 7/8 1 1/2

3/8 3/8 1-7/8 7/8 1 1/2

1/2 3/8 2-3/8 1 1-1/4 5/8

X46A Straight

X46B Angle

X46A Straight Type A (In Inches)

A B D E F G I

1/8 1/8 1-3/4 3/4 1/2 1/2 1/4

1/4 1/4 2-1/4 1 3/4 3/4 3/8

3/8 3/8 2-1/2 1 7/8 7/8 1/2

3/8 1/2 2-1/2 1-1/4 1/2 7/8 3/4

1/2 1/2 3 1-1/4 1 1-1/8 3/4

3/8 3/4 3-3/8 2 1/2 1 7/8

3/4 3/4 4 2 1 1-1/2 7/8

3/8 1 4-1/4 2-3/4 1/2 1-3/8 7/8

1 1 4-1/2 2-3/4 1-1/4 1-3/4 7/8

1/2 1 4-1/4 2-3/4 1/2 1-3/8 7/8

Flow Clean Strainer

X46

INSPECTION

Inspect internal and external threads for damage or evidence of cross-threading. Check inner and outer screens for clogging, embedded foreign particles, breaks, cracks, corrosion, fatigue, and other signs of damage.

CLEANING

After inspection, cleaning of the X46 can begin. Water service usually will produce mineral or lime deposits on metal parts in contact with water. These deposits can be cleaned by dipping X46 in a 5-percent muriatic acid solution just long enough for deposit to dissolve. This will remove most of the common types of deposits. Caution: use extreme care when handling acid. If the deposit is not removed by acid, then a fine grit (400) wet or dry sandpaper can be used with water. Rinse parts in water before handling. An appropriate solvent can clean parts used in fueling service. Dry with compressed air or a clean, lint-free cloth. Protect from damage and dust until reassembled.

REPLACEMENT

If there is any sign of damage, or if there is the slightest doubt that the Model X46 Flow Clean Strainer may not afford completely satisfactory operation, replace it. Use Inspection steps as a guide. Neither inner screen, outer screen, nor housing is furnished as a replacement part. Replace Model X46 Flow Clean Strainer as a complete unit.

When ordering replacement Flow-Clean Strainers, it is important to determine pipe size of the tapped hole into which the strainer will be inserted (refer to column A or F), and the size of the external connection (refer to column B or G).

When Ordering, Please Specify:

• Catalog Number X46

• Straight Type or Angle Type

• Size Inserted Into and Size Connection

• Materials

DISASSEMBLY

Do not attempt to remove the screens from the strainer housing.

MODEL

INSTALLATION / OPERATION / MAINTENANCE

CLA-VAL

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

N-X46 (R-3/2011)

(NPT) (NPT)

X46B

X46A

Page 45

CLA-VAL

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

PL-CK2 (R-3/2011)

Page 46

3/8 NPT

2.06

2.72

Strainer

X43

Standard 60 mesh pilot system strainer for fluid service.

CLA-VAL

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

PL- X43 (R-3/2011)

PARTS LIST

ITEM DESCRIPTION MATERIAL

Pipe Plug Steel

Strainer Plug Brass

Gasket Copper

Screen SST

Body Brass

No parts available. Rreplacement assembly only.

Size Stock Number

3/8 x 3/8 33450J

Page 47

CLA-VAL

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

INSTALLATION / OPERATION / MAINTENANCE

Flow Control

MODEL

N-CV (R-3/2011)

DESCRIPTION

The Cla-Val Model CV Flow Control is a simply-designed, spring-loaded check valve. Rate of flow is full flow in one direction and restricted in other direction. Flow is adjustable in the restricted direction. It is intended for use in conjunction with a pilot control system on a Cla-Val Automatic Control Valve.

OPERATION

The CV Flow Control permits full flow from port A to B, and restricted flow in the reverse direction. Flow from port A to B lifts the disc from seat, permitting full flow. Flow in the reverse direction seats the disc, causing fluid to pass through the clearance between the stem and the disc. This clearance can be increased, thereby increasing the restricted flow, by screwing the stem out, or counter-clockwise. Turning the stem in, or clockwise reduces the clearance between the stem and the disc, thereby reducing the restricted flow.’

INSTALLATION

Install the CV Flow Control as shown in the valve schematic All connections must be tight to prevent leakage.

DISASSEMBLY

Follow the sequence of the item numbers assigned to the parts in the cross sectional illustration for recommended order of disassembly.

Use a scriber, or similar sharp-pointed tool to remove O-ring from the stem.

INSPECTION

Inspect all threads for damage or evidence of cross- threading. Check mating surface of seat and valve disc for excessive scoring or embedded foreign particles. Check spring for visible distortion, cracks and breaks. Inspect all parts for damage, corrosion and cleanliness.

CLEANING

After disassembly and inspection, cleaning of the parts can begin. Water service usually will produce mineral or lime deposits on metal parts in contact with water. These deposits can be cleaned by dipping the parts in a 5-percent muriatic acid solution just long enough for deposits to dissolve. This will remove most of the common types of deposits. Caution: use extreme care when handling acid. If the deposit is not removed by acid, then a fine grit (400) wet or dry sandpaper can be used with water. Rinse parts in water before handling. An appropriate solvent can clean parts used in fueling service. Dry with compressed air or a clean, lint-free cloth. Protect from damage and dust until reassembled.

REPAIR AND REPLACEMENT

Minor nicks and scratches may be polished out using a fine grade of emery or crocus cloth; replace parts if scratches cannot be removed.

Replace O-ring packing and gasket each time CV Flow Control is overhauled.

Replace all parts which are defective. Replace any parts which create the slightest doubt that they will not afford completely satisfactory operation. Use Inspection steps as a guide.

REASSEMBLY

Reassembly is the reverse of disassembly; no special tools are required.

TEST PROCEDURE

No testing of the flow Control is required prior to reassembly to the pilot control system on Cla-Val Main Valve.

Page 48

3/8" Flow Control

2.12 MAX

STAMP PART NO. ON SMOOTH SURFACE

RESTRICTED

FLOW

3/8 - 18 NPT

1.84

ADJUSTING STEM (TURN CLOCKWISE TO INCREASE RESTRICTION)

.85

FREE FLOW

BAR STOCK

CONFIGURATION

When ordering parts,

please specify:

• Number Stamped on Side

• Description (CV Flow Control)

• Part Description

• Material

CLA-VAL

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

PL-CV (R-3/2011)

PARTS LIST

ITEM DESCRIPTION QTY

Cap (SS only)

Nut, Jam

Seat

Gasket

Disc

Spring

Ring, Retaining

Stem

O-Ring

Housing

Page 49

Page 50

3/8 NPT

2.06

2.72

Strainer

X43

Standard 60 mesh pilot system strainer for fluid service.

CLA-VAL

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

PL- X43 (R-3/2011)

PARTS LIST

ITEM DESCRIPTION MATERIAL

Pipe Plug Steel

Strainer Plug Brass

Gasket Copper

Screen SST

Body Brass

No parts available. Rreplacement assembly only.

Size Stock Number

3/8 x 3/8 33450J

Page 51

Cla-Val Product

Identification

Proper Identification

For ordering repair kits, replacement parts, or for inquiries concerning valve operation, it is important to properly identify Cla-Val products already in service by including all nameplate data with your inquiry. Pertinent product data includes valve function, size, material, pressure rating, end details, type of pilot controls used and control adjustment ranges.

Identification Plates

For product identification, cast-in body markings are supplemented by identification plates as illustrated on this page. The plates, depending on type and size of product, are mounted in the most practical position. It

is extremely important that these identification plates are not painted over, removed, or in any other way rendered illegible.

INLET EINTRITT ENTREE ENTRADA

SIZE & CAT NO.

STOCK NO.

CODE

MFD. BY CLA-VAL NEWPORT BEACH, CALIF, U.S.A.

RESERVOIR

END

SIZE & CAT NO.

STOCK NO.

FLOW

MFD. BY CLA-VAL NEWPORT BEACH, CALIF. U.S.A.

CODE

™

SIZE & CAT NO.

STOCK NO.

SPRING RANGE

MFD. BY CLA-VAL NEWPORT BEACH, CALIF. U.S.A.

SIZE & CAT NO.

STOCK NO.

CODE

MFD. BY CLA-VAL

NEWPORT BEACH, CALIF.

U.S.A.

™

DO NOT REMOVE

THIS VALVE HAS BEEN MODIFIED SINCE ORIGINAL SHIPMENT FROM FACTORY. WHEN ORDERING PARTS AND/ OR SERVICE SUPPLY DATA FROM THIS PLATE & ALL OTHER PLATES ON ORIGINAL VALVE.

REDUCED PRESSURE BACKFLOW PREVENTION DEVICE

STK. NO.

SER. NO.

CAT.

NO.

-4

CLA-VAL

NEWPORT BEACH, CA.

This brass plate appears on valves sized 21/2" and larger

and is located on the top of the inlet flange.

These two brass plates appear on 3/8", 1/2", and 3/4" size

valves and are located on the valve cover.

These two brass plates appear on threaded valves

1" through 3" size or flanged valves 1" through 2".

It is located on only one side of the valve body.

This brass plate appears on altitude valves only and is

found on top of the outlet flange.

This brass plate is used to identify pilot control valves.

The adjustment range is stamped into the plate.

This tag is affixed to the cover of the pilot control valve.

The adjustment range appears in the spring range section.

This aluminum plate is included in pilot system

modification kits and is to be wired to the new pilot

control system after installation.

This brass plate is used on our backflow prevention

assemblies. It is located on the side of the Number Two

check (2" through 10"). The serial number of the

assembly is also stamped on the top of the inlet flange of

the Number One check.

How to Order

Page 52

HOW TO ORDER

Because of the vast number of possible configurations and combinations available, many valves and controls are not shown in published product and price lists. For ordering information, price and availability on product that are not listed, please contact your local Cla-Val office or our factory office located at:

SPECIFY WHEN ORDERING

• Model Number • Valve Size

• Globe or Angle Pattern • Threaded or Flanged

• Adjustment Range • Body and Trim Materials (As Applicable) • Optional Features

• Pressure Class

UNLESS OTHERWISE SPECIFIED

• Globe or angle pattern are the same price

• Ductile iron body and bronze trim are standard

• X46 Flow Clean Strainer or X43 “Y” Strainer are included

• CK2 Isolation Valves are included in price on 4" and larger valve sizes (6" and larger on 600 Series)

P. O. Box 1325

Newport Beach, California 92659-0325

(949) 722-4800

FAX (949) 548-5441

LIMITED WARRANTY

Automatic valves and controls as manufactured by Cla-Val are warranted for three years from date of shipment against manufacturing defects in material and workmanship that develop in the service for which they are designed, provided the products are installed and used in accordance with all applicable instructions and limitations issued by Cla-Val. Electronic components manufactured by Cla-Val are warranted for one year from the date of shipment.

We will repair or replace defective material, free of charge, that is returned to our factory, transportation charges prepaid, if upon inspection, the material is found to have been defective at time of original shipment. This warranty is expressly conditioned on the purchaser’s providing written notification to Cla-Val immediate upon discovery of the defect.

Components used by Cla-Val but manufactured by others, are warranted only to the extent of that manufacturer’s guarantee.

This warranty shall not apply if the product has been altered or repaired by others, Cla-Val shall make no allowance or credit for such repairs or alterations unless authorized in writing by Cla-Val.

DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY

The foregoing warranty is exclusive and in lieu of all other warranties and representations, whether expressed, implied, oral or written, including but not limited to any implied warranties or merchantability or fitness for a particular purpose. All such other warranties and representations are hereby cancelled.

Cla-Val shall not be liable for any incidental or consequential loss, damage or expense arising directly or indirectly from the use of the product. Cla-Val shall not be liable for any damages or charges for labor or expense in making repairs or adjustments to the product. Cla-Val shall not be liable for any damages or charges sustained in the adaptation or use of its engineering data and services. No representative of Cla-Val may change any of the foregoing or assume any additional liability or responsibility in connection with the product. The liability of Cla-Val is limited to material replacements F.O.B. Newport Beach, California.

TERMS OF SALE

ACCEPTANCE OF ORDERS

All orders are subject to acceptance by our main office at Newport Beach, California.

CREDIT TERMS

Credit terms are net thirty (30) days from date of invoice.

PURCHASE ORDER FORMS

Orders submitted on customer’s own purchase order forms will be accepted only with the express understanding that no statements, clauses, or conditions contained in said order form will be binding on the Seller if they in any way modify the Seller’s own terms and conditions of sales.

PRODUCT CHANGES

The right is reserved to make changes in pattern, design or materials when deemed necessary, without prior notice.

PRICES

All prices are F.O.B. Newport Beach, California unless expressly stated otherwise on our acknowledgement of the order. Prices are subject to change without notice. The prices at which any order is accepted are subject to adjustment to the Seller’s price in effect at the time of shipment. Prices do not include sales, excise, municipal, state or any other Government taxes. Minimum order charge $100.00.

RESPONSIBILITY

We will not be responsible for delays resulting from strikes, accidents, negligence of carriers, or other causes beyond our control. Also, we will not be liable for any unauthorized product alterations or charges accruing there from.

RISK

All goods are shipped at the risk of the purchaser after they have been delivered by us to the carrier. Claims for error, shortages, etc., must be made upon receipt of goods.

EXPORT SHIPMENTS

Export shipments are subject to an additional charge for export packing.

RETURNED GOODS

1. Customers must obtain written approval from Cla-Val prior to returning any material.

2. Cla-Val reserves the right to refuse the return of any products.

3. Products more than six (6) months old cannot be returned for credit.

4. Specially produced, non-standard models cannot be returned for credit.

5. Rubber goods such as diaphragms, discs, o-rings, etc., cannot be returned for credit, unless as part of an unopened vacuum sealed repair kit which is less than six months old.

6. Goods authorized for return are subject to a 35% ($100 minimum) restocking charge and a service charge for inspection, reconditioning, replacement of rubber parts, retesting, repainting and repackaging as required.

7. Authorized returned goods must be packaged and shipped prepaid to Cla-Val, 1701 Placentia Avenue, Costa Mesa, California 92627.

PO Box 1325 Newport Beach CA 92659-0325

Phone: 949-722-4800 Fax: 949-548-5441

LA-VAL

CLA-VAL CANADA CLA-VAL EUROPE

4687 Christie Drive Beamsville, Ontario Canada L0R 1B4 Phone: 905-563-4963 Fax: 905-563-4040

Chemin dés Mesanges 1 CH-1032 Romanel/ Lausanne, Switzerland Phone: 41-21-643-15-55 Fax: 41-21-643-15-50

Specifications subject to change without notice.

www.cla-val.com

E-Product I.D. (R-3/2011)

Represented By:

Page 53

Complete Replacement Diaphragm Assemblies for 100-01 and 100-20 Hytrol Main Valves

For:

Hytrol Main Valves with Ductile Iron, Bronze Trim Materials—125/150 Pressure Class Only. FACTORY ASSEMBLED Includes: Stem, Disc Guide, Disc, Disc Retainer, Spacer Washers, Diaphragm, Diaphragm Washer and Stem Nut.

3/8"

1/2" - 3/4"

1 1/4"-1 1/2"

2 1/2"

3" 4"

(Also 81-01 ) (Also 81-01 )

N/A N/A N/A N/A N/A

N/A C2524B C2525J

8" 10" 12" 14" 16" 20" 24"

40456G 45276D

81752J

85533J 89067D 89068B

N/A N/A

33273E 40456G 45276D

81752J

N/A

85533J 89068B 89068B

Valve

Size

Valve

Size

49097K

C2518D

C2520K

C2522 F

C2524B

C2523D

C2525J 33273E

100-01 100-20

Diaphragm Assembly

Stock Number

100-01 100-20

Diaphragm Assembly

Stock Number

3/8"

1/2" - 3/4"

1 1/4" - 1 1/2"

2 1/2"

3" 4" 6"

8" 10" 12" 14" 16" 20" 24"

(Also 81-01 ) (Also 81-01 )

N/A N/A N/A N/A N/A

N/A 9169805A 9169812G 9169813E 9169815K 9817901D 9817902B

N/A 9817903K 9817905E 9817905E

3/8"

1/2" - 3/4"

1 1/4” - 1 1/2"

2 1/2"

3" 4" 6" 8"

9169806J

9169807G

9169808E

9169809C

9169810A 9169817F

9169818D

9169819B 9169820K 9169834A

N/A N/A N/A N/A N/A N/A

9169810A

9169818D

9169819B 9169820K

Valve

Size

Valve

Size

9169801K 9169802H 9169803F 9169804D 9169805A 9169811J 9169812G 9169813E 9169815K 9817901D 9817902B 9817903K 9817904H 9817905E

N/A

9817906C

100-01 100-20

Repair Kit

Stock Number

100-01 100-20

Repair Kit

Stock Number

Repair Kits for 100-01/100-20 Hytrol Valves

For:

Hytrol Main Valves—125/150 Pressure Class Only.

Includes: Diaphragm, Disc (or Disc Assembly) and spare Spacer Washers.

(Also 81-01 ) (Also 81-01 )

REPAIR KITS

When ordering, please give complete nameplate data of the valve and/or control being repaired.

MINIMUM ORDER CHARGE APPLIES.

Buna-N®Standard Material

Viton (For KB Valves)

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Page 54

Repair Kits for 100-04/100-23 Hy-Check Main Valves

For:

Hy-Check Main Valves—125/150 Pressure Class Only

Includes: Diaphragm, Disc and O-Rings and full set of spare Spacer Washers.

Larger Sizes: Consult Factory.

Repair Kits for 100-02/100-21 Powertrol and 100-03/100-22 Powercheck Main Valves

For:

Powertrol and Powercheck Main Valves—125/150 Pressure Class Only

Includes: Diaphragm, Disc (or Disc Assembly) and O-rings and full set of spare Spacer Washers.

Repair Kits for Pilot Control Valves (In Standard Materials Only)

Includes: Diaphragm, Disc (or Disc Assembly), O-Rings, Gaskets or spare Screws as appropriate.

Repair Assemblies (In Standard Materials Only)

CLA-VAL

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

N-RK (R-3/2011)

Valve

Size

Kit Stock Number

100-02

Valve

Size

Kit Stock Number

100-02 & 100-03 100-21 & 100-22

⁄8”

9169901H

⁄2”

9169910J N/A

⁄2” &3⁄4”

9169902F

3”

9169911G 9169905J

1” 9169903D

4”

9169912E 9169911G

⁄4” &11⁄2”

9169904B

6”

9169913C 9169912E

2” 9169905J

8”

99116G 9169913C

10”

9169939H 99116G

12"

9169937B 9169939H

Valve

Size

Kit Stock Number

Valve

Size

Kit Stock Number

100-04 100-23 100-04 100-23

4” 20210901B N/A 12” 20210905H 20210904J 6” 20210902A 20210901B 14” 20210906G N/A 8” 20210903K 20210902A 16” 20210907F 20210905H

10” 20210904J 20210903K 20” N/A 20210907F

24” N/A 20210907F

BUNA-N

(Standard Material)

VITON (For KB Controls)

Pilot

Control

Kit

Stock

Number

Pilot

Control

Kit

Stock

Number

Pilot

Control

Kit

Stock

Number

CDB 9170006C CFM-7 1263901K CDB-KB 9170012A CDB-30 9170023H CFM-7A 1263901K CRA-KB N/A CDB-31 9170024F CFM-9 12223E

CRD-KB (w/bucking spring)

9170008J

CDB-7 9170017K

CRA (w/bucking spring)

9170001D CRL-KB 9170013J

CDH-2 18225D

CRD (w/bucking spring)

9170002B CDHS-2BKB 9170010E

CDHS-2 44607A

CRD (no bucking spring)

9170003K CDHS-2FKB 9170011C CDHS-2B 9170004H CRD-18 20275401K CDHS-18KB (no bucking spring) 9170009G CDHS-2F 9170005E CRD-22 98923G

102C-KB

1726202D CDHS-3C-A2 24657K CRL (55F, 55L) 9170007A CDHS-8A 2666901A CRL-4A 43413E CDHS-18 9170003K CRL-5 (55B) 65755B CDS-4 9170014G CRL-5A (55G) 20666E CDS-5 14200A CRL-18 20309801C CDS-6 20119301A CV 9170019F

Buna-N

CDS-6A 20349401C X105L (O-ring) 00951E CFCM-M1 1222301C 102B-1 1502201F CRD Disc Ret. (Solid) C5256H CFM-2 12223E 102C-2 1726201F CRD Disc Ret. (Spring) C5255K

102C-3 1726201F

Control Description Stock Number

CF1-C1 Pilot Assembly Only 89541H CF1-Cl Complete Float Control less Ball and Rod 89016A CFC2-C1 Disc, Distributor and Seals 2674701E CSM 11-A2-2 Mechanical Parts Assembly 97544B CSM 11-A2-2 Pilot Assembly Only 18053K 33A 1" Complete Internal Assembly and Seal 2036030B 33A 2" Complete Internal Assembly and Seal 2040830J

When ordering, please give complete nameplate data of the valve and/or control being repaired. MINIMUM ORDER CHARGE APPLIES

Larger Sizes: Consult Factory.

Cla-Val 393-01-3693-01 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual