CLA-VAL 49-01 Installation, Operation And Maintenance Manual

INSTALLATION / OPERATION / MAINTENANCE

Distributed By: M&M Control Service, Inc.

http://www.mmcontrol.com/claval-index.php

800-876-0036 847-356-0566

Rate of Flow Controller & Pressure Reducing Valve

INTRODUCTION

This manual titled the 49-01 Series Combination Rate of Flow
Controller and Pressure Reducing Valve contains information for instal­lation, operation and maintenance of the valve and control system.

The Cla-Val 49-01 is an automatic valve designed to reduce a higher
inlet pressure to a steady lower downstream pressure regardless of
changing flow rate and/or varying inlet pressure, as long as the flow rate
is below a preset maximum. The automatic valve also prevents exces­sive flow by limiting flow to a preselected maximum rate.

The Cla-Val 49-01 is a single seated, hydraulically operated, pilot con­trolled diaphragm type globe or angle valve. The pilot system includes
a direct acting, spring loaded, pressure reducing pilot (CRA) and a rate
of flow differential control (CDHS-18).

INSTALLATION

1. Allow sufficient room around the valve to make adjustments and for
disassembly.

2. It is recommended that gate or line block valves be installed
upstream and downstream of the Cla-Val valve assembly to facilitate
isolating the valve for preventive maintenance.

MODEL

imum. Under these conditions of increased demand the downstream
pressure falls below the normal reduced pressure.

2. Prior to pressurizing the valve assembly, make sure the necessary
gauges are installed, to measure required pressure and flow, as desig­nated by the system engineer. A Cla-Val X101 Valve Position Indicator
may be installed in the center cover port to provide a visual indication
of the stem position during startup adjustment.

CAUTION: During startup and test procedures a large volume of water
may be discharged downstream. Check that the downstream venting is
adequate to prevent damage to personnel and equipment.

3. With the downstream block valve closed, slowly open upstream block
valve. If isolation valves are installed, as shown on the schematic, open
these valves slowly.

4. Carefully loosen the pipe plug at top of cover assembly. If a Valve
Position Indicator is installed, loosen the vent plug at top of Indicator.
Bleed air from cover and retighten plug.

5. Carefully loosen tube fittings at highest points and bleed air from sys­tem. Retighten fittings.

49-01

NOTE: BEFORE THE VALVE IS INSTALLED, PIPE LINES SHOULD
BE FLUSHED OF ALL CHIPS, SCALE AND FOREIGN MATTER.

3. Place valve in line with flow through the valve in the direction indi­cated on the inlet plate or by flow arrows. Check all fittings and hard­ware for proper makeup and that no apparent damage is evident. Be
sure main valve cover nuts/bolts are tight. Pressure in some applica­tions can be very high so be thorough in checking and inspecting for
proper installation and makeup.

4. For best control, it is recommended that the orifice plate restriction
be installed 1 to 5 pipe diameters downstream of the main valve. The
flow arrows should be pointing to the downstream side of the system.

5. A sensing line, supplied by other than Cla-Val, must be connected
between the orifice plate holder and the Differential Control. See dotted
lines on schematic drawing.

6. Cla-Val Valves operate with maximum efficiency when mounted in
horizontal piping with the cover UP; however, other positions are
acceptable. Due to size and weight of cover and internal components
of six inch valves and larger, installation with the cover up is advisable.
This makes periodic inspection of internal parts readily accessible.

OPERATION AND START-UP

1. Operation of the Cla-Val 49-01 Series Valve is fully automatic once the
flow rate and reduced pressure settings have been made. Modulation
in the main valve is brought about by the action of the pressure reduc­ing and differential pilot controls. Throttling of either of these controls in
response to changes in the flow rate or downstream pressure produces
a change in the flow rate through the control system. This, in turn, caus­es changes in the main valve cover chamber pressure.

It is the constant variations of main valve cover chamber pressure which
forces the main valve to seek new throttling positions in response to
slight changes in the flow rate or downstream pressure.

NOTE: Be sure the sensing line (dotted line shown on schematic), which
connects the orifice plate to the CDHS-18 and the CRA Control, is
installed. This sensing line is supplied by the contractor or others. The 49­01 system will not function unless this sensing line is installed. The line
should be routed without any high spots above the control connections.
Be sure to bleed air from line at the control fittings.

6. Turn the CRA Control adjusting screw clockwise until spring is fully
compressed. DO NOT FORCE. This puts the control in a full open
mode.

7. Slowly open downstream block valve and adjust the CDHS-18 Control,
turning the adjusting screw slowly counterclockwise until the main valve
closes. Adjust for rate of flow by turning adjusting screw slowly clock­wise.

8. Reduce flow rate to a value below the setting of CDHS-18 Control by
closing downstream block valve or other means, then turn the adjust­ment screw on the CRA Control counterclockwise until the main valve
begins to close. Adjust for outlet pressure requirements.

9. Check operation of controls by changing flow and pressure in the pip­ing system.

10. If opening and closing speed controls (Cla-Val CV) are installed on
the valve assembly, fine tune the opening and closing speed of the main
valve while performing step 9.

11. The rate of flow and pressure reducing feature is outlined in Cla-Val
engineering drawing 76573 included in this manual.

MAINTENANCE

1. Cla-Val Valves and Controls require no lubrication or packing and a
minimum of maintenance. However, a periodic inspection schedule
should be established to determine how the fluid handled is affecting the
efficiency of the valve assembly.

The controls are so arranged that the reducing control is in command
of the main valve only when the flow rate is below the setting of the dif­ferential control. The valve, therefore, holds a constant delivery pres­sure. If, however, the flow rate reaches the preset maximum the differ­ential control takes command and holds the flow rate at the desired max-

2. Repair and adjustment procedures of the main valve and control
components are included in separate sections of the manual.
Accessory components are listed for reference.

3. Refer to the Service Suggestions Chart to identify operation symptoms.

40-01/640-01 SCHEMATIC

Distributed By: M&M Control Service, Inc.

http://www.mmcontrol.com/claval-index.php

800-876-0036 847-356-0566

D1

Y

B1

C

B1

INLET OUTLET

1

BASIC COMPONENTS

1 100-01 Hytrol (Main Valve)

100-20 600 Series Hytrol (Main Valve)
2 X58C Restriction Fitting
3 CRA Pressure Reducing Control
4 X52A-1 Orifice Plate Assembly
4 CDHS18 Differential Control

1.

HYTROL MAIN VALVE

COVER

Cover Bolt

6" and Smaller

SPRING

2

A

PIPE PLUG

COVER BEARING

STEM NUT

DIAPHRAGM WASHER

3

S

OPTIONAL FEATURES

A X46A Flow Clean Strainer
B CK2 Valve (Isolation Valve)
C CV Flow Control (Closing)
D Check Valves with Isolation Valve
S CV Flow Control (Opening)
Y X43 “Y” Strainer

D2

5

D3

B2

4

X140-1

Security Cap

HEX NUT

8" and Larger

PIPE PLUG

Option

B1

SYMPTOM

Main valve
won't open.

Main valve
won't close.

SERVICE SUGGESTIONS

PROBABLE CAUSE

Controls not adjusted properly.

Orifice port and/or orifice
sensing line clogged.

Control line shutoff cock to
cover, main valve outlet,
and/or orifice sensing line
closed.

Either of the pilot valves stuck
closed. Mineral deposits or
foreign matter under disc
retainer assembly.

Main valve stuck closed.
Mineral buildup on stem. Stem
damaged.

Controls not adjusted properly.

CRA and/or CDHS-18 Control
has foreign matter or mineral
buildup on yoke assembly.

CDHS-18 Control has foreign
matter or mineral buildup
above diaphragm.

Diaphragm of either control
leaks or stuck. Diaphragm
nut loose.

Clogged restriction assembly.

Clogged Flow Clean Strainer.

Control line shutoff cock from
inlet to restrictor closed.

CV Flow Control closed or
clogged.

Pilot control (CRA or
CDHS-18) disc worn or
nicked. Fails to seat.

REMEDY

Readjust controls.

Remove line and clean
orifice port. Clean or
replace line.

Open shutoff cock.

Remove plug and disc
retainer assembly. Clean
or replace.

Disassemble valve, clean
parts and/or replace dam­aged parts.

Readjust controls.

Disassemble and clean
parts.

Disassemble and clean
parts.

Disassemble and clean
parts.

Remove and clean.

Remove and clean or
replace.

Open shutoff cock.

Readjust or disassemble
and clean.

Remove disc retainer
assembly and replace.

*

DIAPHRAGM

*

DISC

DISC GUIDE

SEAT

DISC RETAINER

*

SPACER WASHERS

STEM

Seat Screw

8" and Larger

SEAT O-RING

8" and Larger

STUD

X58C

2.

CDHS18

5.

CRA

X46A

A.

X52A-1

Flow

3.

CK2

B.

X43

BODY

(GlobeorAngle)

PIPE PLUG

*

Repair Parts

CV

C.

CDC-1

D.

For a more detailed IOM Manual go to www.cla-val.com or contact a Cla-Val Regional Sales Office.

Y.

4.

Distributed By: M&M Control Service, INC.

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: [phone] • Fax: [phone] • E-mail: [e-mail] • Website cla-val.com

©

Copyright Cla-Val 2005 Printed in USA Specifications subject to change without notice.

Phone: [phone] Fax: [phone] Email: [e-mail]

N-49-01 (R-5/05)