Cla-Val 50-20 User Manual

50-20/650-20

Seawater Service Pressure Relief Valve

F

2

4

3

S

C

H

REMOTE SENSING

INLET

OUTLET

DRAIN TO

ATMOSPHERE

1

50-20

Please note that if the Model 50-20 is to be used on a continuous duty
basis to maintain fire-system pressure, suitable back pressure must be
provided on the valve to prevent cavitation damage. Consult the
factory for details.

• Fast Opening to Maintain Steady Line Pressure

• Accommodates Wide Range of Flow Rates

• Closes Gradually for Surge-Free Operation

• Adjustable Pressure Settings, Not Affected by
Pressure At Valve Discharge

The Cla-Val Model 50-20 Seawater Service Pressure Relief
Valve is designed specifically to automatically relieve
excess pressure in fire protection pumping systems. Pilot
controlled, it maintains constant system pressure at the
pump discharge within very close limits as demands change.

50A-20 (Angle)

Schematic Diagram

Item Description

1 100S/2100S Hytrol (Main Valve)
2 CRL Pressure Relief Control
3 X44A Strainer & Orifice Assy
4 81-01 Check Valve

Optional Features

Item Description

B CK2 (Isolation Valves)
C CV Flow Control (Closing)
F Remote Pilot Sensing
H Drain to Atmosphere
S CV Flow Control (Opening)

MODEL

Specification

Sizes: Threaded Ends: 1 1/2" - 3" Materials:

Main valve body & cover

Adjustment 20 - 200 psi (150 class)

Globe Flanged: 2" - 36" Ductile Iron ASTM A-536* Ranges: 100 - 300 psi (300 class)
Angle Flanged: 2" - 16" Cast Steel ASTM A216-WCB*

Naval Bronze ASTM B61

*The 50G-20 (globe) and
50A-20 (angle) in cast
steel are supplied with
standard internal and
external epoxy coating

End Details: Cast Steel ANSI B16.5 Stainless Steel ASTM A743-CF-8M

Bronze ANSI B16.24 Ni. AL. Bronze ASTM B148
Stainless Steel ANSI B16.5 Super Duplex SST
Ductile Iron ANSI B16.42

Main valve trim:

Pressure 150 Class 250 psi Max. ASTM B61 Bronze Seat,

Ratings: 300 Class 400 psi Max. Monel Trim

Temperature

Pilot control system:

Range: Water 180°F Max.

Cast Bronze with Monel Trim
Monel, Super Duplex Stainless Steel optional
Stainless Steel 316 Tubing & Fittings

OUTLET

A

AA

AAA

E

INLET

H

J

B (DIAMETER)

K

FF

F

C

DDD

DD

INLET

OUTLET

C

H

B (DIAMETER)

K

GG

G

GG

G

D

J

The Fire Pump Pressure Relief Valve shall modulate to relieve excess pressure
in a fire protection system. It shall maintain constant pressure in the system
regardless of demand changes. It shall be pilot controlled and back pressure
shall not affect its set point. It shall be actuated by line pressure through a pilot
control system and open fast in order to maintain steady system pressure as
system demand decreases. It shall close gradually to control surges and shall
re-seat drip-tight within 5% of its pressure setting. The main valve shall be of
the hydraulically-operated, pilot-controlled, diaphragm-type, globe or angle
valve. It shall have a single, removable, teflon-coated seat. Internal and exter-

nal epoxy coating, a stem guided at both ends, and a resilient disc with a rec­tangular cross section, being contained on 3 1/2 sides. No external packing
glands shall be permitted and the diaphragm shall not be used as a seating sur­face. The pilot control shall be a direct-acting, adjustable, spring-loaded,
diaphragm-type valve designed for modulating service to permit flow when
controlling pressure exceeds spring setting. It shall be the MODEL 50G-20
(globe) or Model 50A-20 (angle) Pressure Relief Valve as manufactured by
Cla-Val, Newport Beach, California.

Purchase Specifications

Dimensions

We recommend providing
adequate space around
valve for maintenance work.

Valve Size (Inches) 11⁄2 2 2 1⁄2 3 4 6 8 10 12 14 16 24 36
A Threaded

7.25 9.38 11.00 12.50 — — — — — — — — —

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 61.50 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 63.24 78.00

B Dia.

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

C Max.

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

D Threaded

3.25 4.75 5.50 6.25 — — — — — — — — —

DD 150 ANSI

4.00* 4.75 5.50 6.00 7.50 10.00 12.75 14.88 17.00 19.50 20.81 — —

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 — —

E

1.12 1.50 1.69 2.56 3.19 4.31 5.31 9.25 10.75 12.62 15.50 17.75 24.56

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 19.25 28.00

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 — —

G Threaded

1.88 3.25 4.00 4.50 — — — — — — — — —

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 — —

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 — —

H NPT Body Tapping

3

⁄83⁄81⁄21⁄23⁄43⁄4

1 1 1 1 1 1 2

J NPT Cover Center Plug

1

⁄41⁄21⁄21⁄23⁄43⁄4

1 1

1

1

⁄4 11⁄2

2

1

1

⁄2

2

K NPT Cover Tapping

3

⁄83⁄81⁄21⁄23⁄43⁄4

1 1 1 1 1 1 2

Valve Stem Internal
Thread UNF

10-32 10-32 10-321⁄4-281⁄4-283⁄8-243⁄8-243⁄8-243⁄8-243⁄8-241⁄2-203⁄4-163⁄4-16

Stem Travel

0.4 0.6 0.7 0.8 1.1 1.7 2.3 2.8 3.4 4.0 4.5 6.75 10.12

Approx. Ship Wt. Lbs.

15 35 50 70 140 285 500 780 1165 1600 2265 6200 11470

X Pilot System 11.00 13.00 14.00 15.00 17.00 29.00 31.00 33.00 36.00 40.00 40.00 68.00 86.00
Y Pilot System 9.00 9.00 10.00 11.00 12.00 20.00 22.00 24.00 26.00 29.00 30.00 39.00 45.00
Z Pilot System 9.00 9.00 10.00 11.00 12.00 20.00 22.00 24.00 26.00 29.00 30.00 39.00 45.00

Valve Size (mm) 40 50 65 80 100 150 200 250 300 350 400 600 900
A Threaded

184 238 279 318 — — — — — — — — —

AA 150 ANSI

216* 238 279 305 381 508 645 756 864 991 1051 1562 1930

AAA 300 ANSI

229* 254 295 337 397 533 670 790 902 1029 1105 1606 1981

B Dia.

143 168 203 232 292 400 508 600 711 832 902 1350 1676

C Max.

140 165 192 208 270 340 406 435 530 614 635 1116 1562

CC Max.

104 127 — 165 223 281 — — — — — — —

D Threaded

83 121 140 159 — — — — — — — — —

DD 150 ANSI

102* 121 140 152 191 254 324 378 432 495 528 — —

DDD 300 ANSI

108* 127 149 162 200 267 337 395 451 514 549 — —

E

29 38 43 65 81 110 135 235 273 321 394 451 624

F 150 ANSI

64 76 89 95 114 140 171 203 241 267 298 489 711

FF 300 ANSI

78 83 95 105 127 159 191 222 260 292 324 — —

G Threaded

48 83 102 11 4 — — — — — — — — —

GG 150 ANSI

102* 83 102 102 127 152 203 219 349 378 399 — —

GGG 300 ANSI

102* 89 110 111 135 165 216 236 368 397 419 — —

H NPT Body Tapping

3

⁄83⁄81⁄21⁄23⁄43⁄4

1 1 1 1 1 1 2

J NPT Cover Center Plug

1

⁄41⁄21⁄21⁄23⁄43⁄4

1 1

1

1

⁄4 11⁄2

2

1

1

⁄2

2

K NPT Cover Tapping

3

⁄83⁄81⁄21⁄23⁄43⁄4

1 1 1 1 1 1 2

Valve Stem Internal
Thread UNF

10-32 10-32 10-321⁄4-281⁄4-283⁄8-243⁄8-243⁄8-243⁄8-243⁄8-241⁄2-203⁄4-163⁄4-16

Stem Travel

10 15 18 20 28 43 58 71 86 102 11 4 171 257

Approx. Ship Wt. Kgs.

7 16 23 32 64 129 227 354 528 726 1027 2812 5200

CLA-VAL

Copyright Cla-Val 2007 Printed in USA Specifications subject to change without notice.

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

©

E-50-20 (R-5/07)

Valve Size (inches) 1 1/2 2 2 1/2 3 4 6 8 10 12 14 18 24 36
Max. Continuous GMP 125 208 300 460 800 1800 3100 4900 7000 8500 11000 25000 50000
Max Surge GPM 280 470 670 1000 1800 4000 7000 11000 16000 19000 25000 56500 85000

Valve Capacity

• Drip - tight, positive seating

• Service without removal from line

• Screwed or flanged ends

• Globe or angle pattern

• Every valve factory-tested

The Cla-Val Model 100S/2100S Seawater Service Hytrol Valve
is a hydraulically operated, diaphragm actuated, globe or
angle pattern valve. It consists of three major components:
body, diaphragm assembly and cover. The diaphragm assem­bly is the only moving part.

The body (ductile iron or cast steel) is epoxy coated and contains
a removable seat insert. The diaphragm assembly is guided top
and bottom by a precision machined stem. It utilizes a non-wick­ing diaphragm of nylon fabric bonded with synthetic rubber. A
resilient synthetic rubber disc retained on three and one half sides
by a disc retainer forms a drip-tight seal with the renewable seat
when pressure is applied above the diaphragm.

The Model 100S/2100S Seawater Service Hytrol Valve is the
basic valve used for seawater applications. It is the valve of
choice for system applications requiring deluge, pressure regu­lation, pressure relief, solenoid operation, rate of flow control, liq­uid level control or check valve operation. The rugged simplicity
of design and packless construction assure a long life of
dependable, trouble-free operation. It is available in various
materials and in a full range of sizes, with either screwed or
flanged ends. Its applications are unlimited.

Modulating Action

The valve holds any intermediate position
when operating pressures are equal above
and below the diaphragm. A Cla-Val “modu­lating” pilot control will allow the
valve to automatically compen­sate for line pressure changes.

Principle of Operation

Full Open Operation

When pressure in the

cover chamber
is relieved to a zone of lower pres­sure, the line pressure at the valve
inlet opens the valve, allowing full flow.

Tight Closing Operation

When pressure from the valve inlet
is applied to the cover chamber, the
valve closes drip-tight.

Seawater Service Hytrol Valve

100S

2100S

MODEL

On-Off Control

Modulating

Control

On-Off Control

Specifications

When Ordering, Please Specify:

1. Model No. 100S or No. 2100S

2. Valve Size

3. Pattern - Globe or Angle

4. Pressure Class

5. Screwed or Flanged

6. Temperature and fluid to be handled.

7. Static and Flowing Line Pressure.

8. Body & Trim Material

9. Desired Options

10. When Vertically Installed

Purchase Specifications

The Model 100S/2100S shall be a hydraulically operated, diaphragm-actuated, globe or
angle pattern valve. It shall contain a resilient, synthetic rubber disc, having a rectangular
cross-section, contained on three and one-half sides by a disc retainer and disc guide,
forming a tight seal against a single removable seat insert. The diaphragm assembly, con­taining a valve stem, shall be fully guided at both ends by a bearing in the valve cover and
an integral bearing in the valve seat. This diaphragm assembly shall be the only moving
part and shall form a sealed chamber in the upper portion of the valve, separating operat­ing pressure from line pressure. The diaphragm shall consist of nylon fabric bonded with
synthetic rubber and shall not be used as a seating surface. Packing glands or stuffing
boxes are not permitted and there shall be no pistons operating the valve or its pilot con­trols. All necessary repairs shall be possible without removing the valve from the line. All
materials shall be compatible with seawater.
Valve shall be Model 100S/2100S manufactured by Cla-Val, Newport Beach, CA 92659-0325

For assistance in selecting appropriate valve options or valves manufactured with special design requirements, please contact our Regional Sales Office or Factory.

Available Sizes

Pattern Threaded Flanged Grooved End

Globe3⁄8" - 3" 11⁄2" - 36" 11⁄2"-2"- 3"- 4"- 6"

Angle 11⁄2" - 3" 2" - 16" 2" - 3" - 4"

Operating Temp. Range

Fluids

-40° to 180° F

Valve Body & Cover

Pressure Class

Flanged Threaded

Material

Material

Specifications

ANSI

Standards**

150 Lb. 300 Lb.

End***
Details

Ductile Iron* ASTM-A536 B16.42 250 400 400

Cast Steel* ASTM A216 B16.5 285 400 400

Naval Bronze ASTM B61 B16.24 225 400 400

Stainless Steel
Type 316

ASTM A743-CF-8M B16.5 285 400 400

NI.AL.Bronze ASTM B148 B.16.24 225 400 400

Super Duplex
Stainless Steel

B16.5 285 400 400

Note: *Fusion Bonded Epoxy Coated Internal and External.

**ANSI Standards are for flanged dimensions only.

Flanged Valves are available faced but not drilled

***End Details machined to ANSI B2.1 specifications

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

or

Angle)

PIPE PLUG

HEX NUT

8" and Larger

Cover Bolt

6" and Smaller

KO
DISC GUIDE

KO
SEAT

KO Anti-Cavitation
Trim Option

(Patent Pending)

KO Anti-Cavitation Trim
can be added to any
standard Hytrol Valve

Component Standard Material Combinations

Body & Cover Ductile Iron Cast Steel Bronze

Stainless Steel

Type 316

NI. AL. Bronze

Super Duplex

Stainless Steel

Available Sizes 11⁄4" - 36" 11⁄4" - 16" 11⁄4" -16" 11⁄4" -16" 11⁄4" -16" 11⁄4" -16"

Disc Retainer &
Diaphragm Washer

Cast Iron Cast Steel Bronze Bronze Monel

Super Duplex

Stainless Steel

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

Pressure Ratings

(Recommended Maximum Pressure - psi)

Model 100S/2100S Flow Chart (Based on normal flow through a wide open valve)

K =

894d

4

C

2

v

L =

K
12 f

K Factor (Resistance Coefficient)

The Value of K is calculated from the formula:
(U.S. system units)

Equivalent Length of Pipe

Equivalent lengths of pipe (L) are determined from the formula:
(U.S. system units)

Fluid Velocity

Fluid velocity can be calculated from the following formula:
(U.S. system units)

d

V =

.4085 Q

2

d

C

V

Factor

Formulas for computing C Factor, Flow (Q) and Pressure Drop

V

( P):

C

V

=

Q

P

C

V

=

Q

P

C

V

=

Q

P

2

V

Where:

U.S. (gpm) @ 1 psi differential at 60 F water

(l/s) @ 1 bar (14.5 PSIG) differential

or

at 15 C water

inside pipe diameter of Schedule 40 Steel Pipe (inches)

friction factor for clean, new Schedule 40 pipe

(dimensionless) (from Cameron Hydraulic Data,

18th Edition, P 3-119)

Resistance Coefficient (calculated)

Equivalent Length of Pipe (feet)

Flow Rate in U.S. (gpm) or (l/s)

Fluid Velocity (feet per second) or (meters per second)

Pressure Drop in (psi) or (bar)

=

=

=

=

=

=

=

=

=

P

V

Q

L

K

f

d

C

Functional Data Model 100S/2100S

*Estimated

Valve Size

Inches

3⁄81⁄23

⁄4 1 11⁄4 11⁄2 2 21⁄2 3 4 6 8 10 12 14 16 24 36

mm.

10 15 20 25 32 40 50 65 80 100 150 200 250 300 350 400 600 900

C

V

Factor

Globe

Pattern

Gal./Min. (gpm.)

1.8 6 8.5 13.3 30 32 54 85 115 200 440 770 1245 1725 2300 2940 7655 13320

Litres/Sec. (l/s.)

.43 1.44 2.04 3.2 7.2 7.7 13 20.4 27.6 48 105.6 184.8 299 414 552 706 1837 3200

Angle

Pattern

Gal./Min. (gpm.)

— — — — — 29 61 101 139 240 541 990 1575 2500* 3060* 4200* — —

Litres/Sec. (l/s.)

— — — — — 7 14.6 24.2 33.4 58 130 238 378 600 734.4 1008 — —

Equivalent

Length

of

Pipe

Globe

Pattern

Feet (ft.)

25 7 16 23 19 37 51 53 85 116 211 291 347 467 422 503 628 1866

Meters (m.)

7.6 2.2 4.8 7.1 5.7 11.4 15.5 16.0 25.9 35.3 64.2 88.6 105.8 142.4 128.6 153.6 191.6 569

Angle

Pattern

Feet (ft.)

— — — — — 46 40 37 58 80 139 176 217 222* 238* 247* — —

Meters (m.)

— — — — — 13.9 12.1 11.4 17.8 24.5 42.5 53.6 66.1 67.8 72.7 75.2 — —

K

Factor

Globe Pattern

16.3 3.7 5.7 6.1 3.6 5.9 5.6 4.6 6.0 5.9 6.2 6.1 5.8 6.1 5.0 5.2 4.0 7.1

Angle Pattern

— — — — — 7.1 4.4 3.3 4.1 4.1 4.1 3.7 3.6 2.9 2.8 2.6 — —

Liquid Displaced from

Cover Chamber When

Valve Opens

Fl. Oz

.12 .34 .34 .70 — — — — — — — — — — — — — —

U.S. Gal.

— — — — .02 .02 .03 .04 .08 .17 .53 1.26 2.51 4.0 6.5 9.6 29 42

ml

3.5 10.1 10.1 20.7 75.7 75.7 121 163 303 643 — — — — — — — —

Litres

— — — — — — — — — — 2.0 4.8 9.5 15.1 24.6 36.2 109.8 159

10 20 30 40 60 80 100 200 500 1000 2000 5000 10,000 20,000 50,000

1

2

3

4

6

8

10

20

30

40

60

80

100

5 3

Angle Valve Sizes (Inches)

Globe Valve Sizes (Inches)

1/2 1

2

3 4

6

8 10

12

12

24

3/4

11/2

21/2

11/2

2 3

4 6 8 10

14

16

16

1

1/4

21/2

Pressure Drop — psi

14

Flow Rate gpm (water)

1

36

100,000

OUTLET

A

AA

AAA

E

INLET

H

J

B (DIAMETER)

K

FF

F

C

DDD

DD

INLET

OUTLET

C

H

B (DIAMETER)

K

GG

GGG

G

D

J

(MAX)

100S (Globe) 2100S (Angle) 100S Grooved (Globe) 2100S Grooved (Angle)

Dimensions

Model 100S

CLA-VAL

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

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

©

E-100S/2100S (R-8/06)

Cla-Val Control Valves operate with maximum efficiency when mounted in horizontal piping with the main valve cover UP, however, other positions are acceptable. Due to
component size and weight of 8 inch and larger valves, installation with cover UP is advisable. We recommend isolation valves be installed on inlet and outlet for maintenance.
Adequate space above and around the valve for service personnel should be considered essential. A regular maintenance program should be established based on the specific
application data. However, we recommend a thorough inspection be done at least once a year. Consult factory for specific recommendations.

*11⁄2"Size Only

*40mm Size Only

Valve Size (Inches)

3⁄81

⁄2 - 3⁄4 1 11⁄4-11⁄2 2 21⁄2 3 4 6 8 10 12 14 16 24 36

A Threaded

2.75 3.50 5.12 7.25 9.38 11.00 12.50 — — — — — — — — —

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 61.50 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 63.24 78.00

AAAA Grooved End

— — — 8.50 9.00 11.00 12.50 15.00 20.00 25.38 — — — — — —

B Dia.

2.50 3.12 4.38 5.62 6.62 8.00 9.12 11.50 15.75 20.00 23.62 28.00 32.75 35.50 53.16 66.00

C Max.

2.00 3.00 2.75 5.50 6.50 7.56 8.19 10.62 13.38 16.00 17.12 20.88 24.19 25.00 43.93 61.50

CC Max. Grooved End

— — — 4.75 5.75 6.88 7.25 9.62 12.12 14.62 — — — — — —

D Threaded

— — — 3.25 4.75 5.50 6.25 — — — — — — — — —

DD 150 ANSI

— — — 4.00* 4.75 5.50 6.00 7.50 10.00 12.75 14.88 17.00 19.50 20.81 — —

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 — —

DDDD Grooved End

— — — — 4.75 — 6.00 7.50 — — — — — — — —

E

1.25 0.88 1.63 1.12 1.50 1.69 2.56 3.19 4.31 5.31 9.25 10.75 12.62 15.50 17.75 24.56

EE Grooved End

— — — 2.00 2.50 2.88 3.12 4.25 6.00 7.56 — — — — — —

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 19.25 28.00

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 — —

G Threaded

— — — 1.88 3.25 4.00 4.50 — — — — — — — — —

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 — —

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 — —

GGGG Grooved End

— — — — 3.25 — 4.25 5.00 — —

— — — — — —

H NPT Body Tapping

—

1

⁄8

1

⁄4

3

⁄8

3

⁄8

1

⁄2

1

⁄2

3

⁄4

3

⁄4

1 1 1 1 1 1 2

J NPT Cover Center Plug

1

⁄

8

1

⁄

8

1

⁄

4

1

⁄

4

1

⁄

2

1

⁄

2

1

⁄

2

3

⁄

4

3

⁄

4

1 1

1

1

⁄

4

1

1

⁄

2

2

1

1

⁄

2

2

K NPT Cover Tapping

—

1

⁄8

1

⁄4

3

⁄8

3

⁄8

1

⁄2

1

⁄2

3

⁄4

3

⁄4

1 1 1 1 1 1 2
Valve Stem Internal
Thread UNF

— — — 10-32 10-32 10-321⁄4-281⁄4-283⁄8-243⁄8-243⁄8-243⁄8-243⁄8-241⁄2-203⁄4-163⁄4-16

Stem Travel

— — —

0.4 0.6 0.7 0.8 1.1 1.7 2.3 2.8 3.4 4.0 4.5 6.75 10.12

Approx. Ship Wt. Lbs.

3 3 8 15 35 50 70 140 285 500 780 1165 1600 2265 6200 11470

Valve Size (mm) 10 15-20 25 32-40 50 65 80 100 150 200 250 300 350 400 600 900
A Threaded

70 89 130 184 238 279 318 — — — — — — — — —

AA 150 ANSI

— — — 216* 238 279 305 381 508 645 756 864 991 1051 1562 1930

AAA 300 ANSI

— — — 229* 254 295 337 397 533 670 790 902 1029 1105 1606 1981

AAAA Grooved End

— — — 216 228 279 318 381 508 645 — — — — — —

B Dia.

64 80 111 143 168 203 232 292 400 508 600 711 832 902 1350 1676

C Max.

51 76 70 140 165 192 208 270 340 406 435 530 614 635 1116 1562

CC Max. Grooved End

— — — 120 146 175 184 244 308 371 — — — — — —

D Threaded

— — — 83 121 140 159 — — — — — — — — —

DD 150 ANSI

— — — 102* 121 140 152 191 254 324 378 432 495 528 — —

DDD 300 ANSI

— — — 108* 127 149 162 200 267 337 395 451 514 549 — —

DDDD Grooved End

— — — — 121 — 152 191 — — — — — — — —

E

32 23 42 29 38 43 65 81 110 135 235 273 321 394 451 624

EE Grooved End

— — — 52 64 73 79 108 152 192 — — — — — —

F 150 ANSI

— — — 64 76 89 95 114 140 171 203 241 267 298 489 711

FF 300 ANSI

— — — 78 83 95 105 127 159 191 222 260 292 324 — —

G Threaded

— — — 48 83 102 114 — — — — — — — — —

GG 150 ANSI

— — — 102* 83 102 102 127 152 203 219 349 378 399 — —

GGG 300 ANSI

— — — 102* 89 110 111 135 165 216 236 368 397 419 — —

GGGG Grooved End

— — — — 83 — 108 127 — — — — — — — —

H NPT Body Tapping

—

1

⁄8

1

⁄4

3

⁄8

3

⁄8

1

⁄2

1

⁄2

3

⁄4

3

⁄4

1 1 1 1 1 1 2

J NPT Cover Center Plug

1

⁄8

1

⁄8

1

⁄4

1

⁄4

1

⁄2

1

⁄2

1

⁄2

3

⁄4

3

⁄4

1 1

1

1

⁄4 11⁄2

2

1

1

⁄2

2

K NPT Cover Tapping

—

1

⁄8

1

⁄4

3

⁄8

3

⁄8

1

⁄2

1

⁄2

3

⁄4

3

⁄4

1 1 1 1 1 1 2
Valve Stem Internal
Thread UNF

— — — 10-32 10-32 10-321⁄4-281⁄4-283⁄8-243⁄8-243⁄8-243⁄8-243⁄8-241⁄2-203⁄4-163⁄4-16

Stem Travel

— — —

10 15 18 20 28 43 58 71 86 102 114 171 257

Approx. Ship Wt. Kgs.

1.4 1.4 4 7 16 23 32 64 129 227 354 528 726 1027 2812 5200

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 efficiency
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 πlarger valves,
installation with the cover UP is advisable. This makes internal
parts readily accessible for periodic inspection.

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

7. After the valve is installed and the system is first pressurized,
vent air from the cover chamber and pilot system tubing by
loosening fittings at all high points.

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

2

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.

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
2 50 0.6 15
2 1/2 65 0.7 18
3 80 0.8 20
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
24 600 6.5 165
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
24 29.00 109.8
36 42.00 159.0

3

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
24" 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"
24" 2"
36” 2”

NUT

ANGLE OR CHANNEL IRON

LONG STUD OR BOLT

NUT OR BOLT HEAD

DO NOT

LIFT

VALVE SEAT

VALVE BODY

4

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

.

5

1

5

8

10

14

16

6

17

7

9

OUTLETINLET

GLOBE PATTERN

9

26

27

12

15

14

16

INLET

OUTLET

ANGLE PATTERN

22

23

13

12

14

10

11

15

15

TOP VIEW

8" - 24" SEAT DETAIL

1 1/4" - 6" SEAT DETAIL

16" COVER DETAIL

4

24

2

25

13

31

28

30

29

5

14

3

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

6

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.

1”

1 1/4”

1 1/2”2”2 1/2”

3”4”6”

8”

10”

12”

14”

16”

24”

2532405065

80

100

150

200

250

300

350

400

600

100-01

HYTROL SIZE Stem

Travel

Cover Capacity

Displacement

Valve Stem

Thread

UNF-Internal

Cover

Center

Plug NPT

4”6”8”

10”

12”

16”

20”,24”

100

150

200

250

300

400

600

0.3

0.4

0.4

0.6

0.7

0.8

1.1

1.7

2.3

2.8

3.4

3.9

4.5

6.5

8

1010151820234358718699

114

165

0.020

0.020

0.032

0.043

0.080

0.169

0.531

1.26

2.51

4.0

6.5

9.5

29.0

0.07

0.07

0.12

0.16

0.30

0.64

2.00

4.80

9.50

15.10

24.60

36.20

108.80

1/4”

1/4”

1/4”

1/2”

1/2”

1/2”

3/4”

3/4”

1”

1”

1 1/4”

1 1/2”

2”

3/4”

1/4” - 20 (B)

5/16” - 18 (B)

5/16” - 18 (B)

3/8” - 16 (B)

7/16” - 14 (B)

1/2” - 13 (B)

3/4” - 10 (B)

3/4” - 10 (B)

3/4” - 10

7/8” - 9

1-1/8” -7

1-1/4” -7

1-1/4” -7

1-1/2” -12

10-32

10-32

10-32

10-32

1/4 - 28

1/4 - 28

3/8 - 24

3/8 - 24

3/8 - 24

3/8 - 24

3/8 - 24

1/2 - 20

3/4 - 16 *

100-20

Thread

(Bolt)

7/16”

1/2”

1/2”

9/16”

5/8”

3/4”

1 1/8”

1 1/8”

1 1/4”

1 7/16

1 13/16

2”

2”

2 3/8”

Socket

5/8” - 11

3/4” - 10

3/4” - 10

1” - 8

1” - 8

1-1/8” 7

Cover

Lifting

Holes UNC

Liters

8888888

12162020202024

Qty

3/8”

1/2”

1/2”

3/4”

3/4”

1”1”1”1”1”

1”

Thread

3/8” - 24

7/16” 20

7/16” 20

1/2” - 20

5/8” - 18

5/8” - 18

3/4” - 16

7/8” - 14

1 1/8” - 12

1 1/2” - 12

1 1/2” - 12

1 1/2” - 12

2” - 16

3” - 12

Thread

3/4”

15/16”

15/16”

1 1/16”

1 5/16”

1 13/16”

1 7/8”

2 1/2”

2 1/2”

3”

Special

Socket

(Long)

7/16”

9/16”

9/16”

5/8”

5/8”

13/16”

13/16”

13/16”

13/16”

13/16”

13/16”

Socket

488

122030

110

110

110

160

390

545

545

800

ft. Lbs.

489696

in. Lbs.

466

1021214085

125

250

270

280

500

1350

Lubed

6

1010153030

60

125

185

375

400

420

750

N/R

DRY

Gallonsmmmm mm inchesinches inches

Cover Nut or Bolt Cover Plug Cover Torque Stem Nut ** Stem Nut Torque

(ft Lbs)

Grade 5 Bolts

“Heavy” Grade Nuts

Tighten cover nuts in a “star” cross-over pattern

* Adapter p/n 2594101E

inside 1/4” - 28

**Must Use ONLY

Cla-Val Supplied part

HYTROL Service Data

CLA-VAL

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

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

©

N-100-01 (R-5/05)

BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS

4

BOLTS

6

BOLTS

8

BOLTS

12

BOLTS

16

BOLTS

20

BOLTS

4

3

2

1

65

4

3

2

1

8

7

6

5

4

3

2

1

0

9

8

7

6

5

3

2

1

12

11

10

9

8

7

6

5

4

3

2

1

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

20

19

18

17

16

15

14

13

12

11

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:

A. To approximately 10% of final torque valve.

B. To approximately 75% of final torque valve.

C. To final required torque valve.

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

after 24 hours.

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

or

Angle)

PIPE PLUG

HEX NUT

8" and Larger

Cover Bolt

6" and Smaller

KO

DISC GUIDE

KO

SEAT

KO Anti-Cavitation

Trim Option

(Patent Pending)

KO Anti-Cavitation Trim

can be added to any

standard Hytrol Valve

100-01 Hytrol Main Valve Assembly

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.

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
20 16
24 24 16

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

600 Series Hytrol Valve

100-20

M O D E L

INSTALLATION / OPERATION / MAINTENANCE

Basic Main Valve Sizes Comparison

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)

N-100-20 (R-6/06)

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")

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

30 Hex Bolt (20" & 24")

31 Pipe Cap (20" & 24")

11

14

1 24 3 4

5
17

16

26

14

7

8

9

27

10

14

13

22

12

15

31

28

5

30

29

10" — 24" SEAT DETAIL 20" — 24" COVER DETAIL

TOP VIEW

12

13

15

OUTLET

GLOBE

INLET

ANGLE

INLET

6

8

9

2

25

3" — 6" COVER DETAIL

23

11

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

DESCRIPTION

The CRL Pressure Relief Control is a direct acting, spring loaded,
diaphragm type relief valve. It may be used as a self-contained valve or as
a pilot control for a Cla-Val Main valve. It opens and closes within very
close pressure limits.

INSTALLATION

The CRL Pressure Relief Control may be installed in any position. The
control body (7) has one inlet and one outlet port with a side pipe plug (24)
at each port. These plugs are used for control connections or gauge appli­cations. The inlet in the power unit body (6) is the sensing line port. A flow
arrow is marked on the body casting.

OPERATION

The CRL Pressure Relief Control is normally held closed by the force of the
compression spring above the diaphragm; control pressure is applied
under the diaphragm.

When the controlling pressure exceeds the spring setting, the disc is lifted
off its seat, permitting flow through the control.

When controlling pressure drops below spring setting, the spring returns
the control to its normally closed position.

ADJUSTMENT PROCEDURE

The CRL Pressure Relief Control can be adjusted to provide a relief setting
at any point within the range found on the nameplate.

Pressure adjustment is made by turning the adjustment screw (9) to vary
the spring pressure on the diaphragm. Turning the adjustment screw clock­wise increases the pressure required to open the valve. Counterclockwise
decreases the pressure required to open the valve.

When pressure adjustments are complete the jam nut (10) should be tight­ened and the protective cap (1) replaced. If there is a problem of tamper­ing, lock wire holes have been provided in cap and cover. Wire the cap to
cover and secure with lead seal.

DISASSEMBLY

The CRL Pressure Relief Control does not need to be removed from the
line for disassembly. Make sure that pressure shut down is accompanied
prior to disassembly. If the CRL is removed from the line for disassembly
be sure to use a soft jawed vise to hold body during work.

Refer to Parts List Drawing for Item Numbers.

1. Remove cap (1), loosen jam nut (10) and turn adjusting
screw counterclockwise until spring tension is relieved.

2. Remove the eight screws (4) holding the cover (3) and
powerunit body (6). Hold the cover and powerunit together
and place on a suitable work surface.

See NOTE under REASSEMBLY.

3. Remove the cover (3) from powerunit body (6). The spring
(12) and two spring guides (11).

4. Remove nut (13) from stem (19) and slide off the belleville washer
(14), the upper diaphragm washer (15) and the diaphragm (16).

5. Pull the stem (19) with the disc retainer assembly (21) through the
bottom of powerunit. The lower diaphragm washer (17) will slide off
of stem top.

6. Remove jam nut (23) and disc retainer assembly (21) from stem.
Use soft jawed pliers or vise to hold stem. The polished surface of

stem must not be scored or scratched.

7. The seat (22) need not be removed unless it is damaged. If removal
is necessary use proper size socket wrench and turn counterclockwise.
Note: Some models have an integral seat in the body (7).

INSPECTION

Inspect all parts for damage, or evidence of cross threading. Check
diaphragm and disc retainer assembly for tears, abrasions or other dam­age. Check all metal parts for damage, corrosion or excessive wear.

REPAIR AND REPLACEMENT

Minor nicks and scratches may be polished out using 400 grit wet or dry
sandpaper fine emery or crocus cloth. Replace all O-rings and any dam­aged parts.
When ordering replacement parts, be sure to specify parts list item num­ber and all nameplate data.

REASSEMBLY

In general, reassembly is the reverse of disassembly. However, the fol­lowing steps should be observed:

1. Lubricate the O-Ring (18) with a small amount of a good grade of
waterproof grease, (Dow Corning 44 medium grade or equal).
Use grease sparingly and install O-ring in powerunit body (6).

2. Install stem (19) in powerunit body (6). Use a rotating motion with
minimum pressure to let stem pass through O-ring.

Do Not Cut O-Ring.

3. Install O-ring (5) at top of stem (19). Place lower diaphragm
washer (17) on the stem with the serrated side up. Position
diaphragm (16), upper diaphragm washer (15), with serration down,
and belleville washer (14) with concave side down.

4. Position powerunit body (6) as shown on parts list drawing (top view).

5. Continue reassembly as outlined in disassembly steps 1 through 3.

Pressure Relief Control

CRL

Note: Item (4) Screw will have a quantity of 8 for the 0-75 and 20-200psi
design and a quantity of 4 for the 100-300psi design. Item (25) Screw is
used on the 100-300psi design only. Install item (25), before item (4) for
preload of item (12) spring.

SYMPTOM PROBABLE CAUSE REMEDY

Fails to open. Controlling pressure

too low.

Back off adjusting
screw until valve
opens.

Fails to open with
spring compression
removed.

Mechanical obstruc­tion, corrosion, scale
build-up on stem.

Disassemble,
locate,and remove
obstruction, scale.

Leakage from cover
vent hole when con­trolling pressure is
applied.

Diaphragm Damage Disassembly replace

damaged
diaphragm.

Fails to close with
spring compressed.

Mechanical obstruc­tion.

Disassemble, locate
and remove
obstruction.

Fails to close. No spring compres-

sion.

Re-set pressure
adjustment.

Loose diaphragm
assembly.

Tighten upper
diaphragm washer.

MODEL

INSTALLATION / OPERATION / MAINTENANCE

CLA-VAL

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

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

©

N-CRL (R-8/05)

1/2" & 3/4" PRESSURE RELIEF CONTROL

CRL

Ajusting Screw
(3/8" - 16UNF THREAD)

9

1

10

3

11

12

14

13

11

8

22

23

7

18

19

21

INLET

1/8 - 27 NPT
SENSING
CONNECTION
(TYP.)

7.44
MAX

.71

OUTLET

20

6

2

0 TO 75 AND

20 TO 200 PSI DESIGN

5

17

16

15

4

1A

9

10

3

11

12

11

7

2

100 To 300 psi Design

.71

ADJUSTING SCREW
(1/2" 20UNF THREAD)

10.44
MAX.

When ordering parts please specify:

1. All Nameplate Data

2. Item Part Number

3. Item Description

CRL

RANGE PSI

APPROX. INCREASE

FOR EACH CLOCK-

WISE TURN OF

ADJUSTING SCREW

0 to 75 8.5 PSI

20 to 200 28.0 PSI

100 to 300 18.0 PSI

25

25

24

4

45º

3.12

DIA.

TRUE LOCATION OF
SENSING
CONNECTION
(TYP.)

ADJUSTING SO
(3/8" - 16UNF )

SIZE

1/2"
1/2"
1/2"
3/4"
3/4"
3/4"

SPRING

RANGE

0-75 PSI

20-200 PSI

100-300 PSI

0-75 PSI

20-200 PSI

100-300 PSI

PART

NUMBER

79222-01E
79222-02C
82809-01D

79229-01K
79229-02H

86005-01E

For 100-450 PSI Contact Factory

Body with
integral Seat

1

1A

2

3
4*
5*

6

7

8*

9
10
11
12
13
14
15

16*

17

18*

19

20*
21*

22
23
24

25*

Cap
Cap 100 to 300 psi Design
Nameplate
Cover
Screw Fil.Hd.10-32 x 1.88
0-Ring
Body, Powerunit
1/2" Body
3/4" Body
0-Ring, Seat
Screw, Adjusting
Nut Hex (Locking)
Guide, Spring
Spring,
Nut, Stem, Upper
Washer, Belleville
Washer, Diaphragm (upper)
Diaphragm
Washer, Diaphragm (lower)
0-Ring, Stem
Stem
0-Ring, Body
Retainer Assembly, Disc
Seat
Nut, hex, Stem, Lower
Pipe Plug
Screw Fil.Hd, 10-32 x 2.25 (Qty 4 on 100-300 psi)

FACTORY SET POINT

REPAIR KIT*

Plastic
Plastic

Brass

Bronze
303 SS
Rubber

Bronze

Bronze

Bronze
Rubber

Brass
303 SS
303 SS

CHR/VAN

Bronze

Steel
303 SS
Rubber
303 SS
Rubber
303 SS
Rubber
303 SS
303 SS

Bronze
Bronze

303 SS

0-75

67628J

1257601D

--

C2544K

6757867E

00902H

7920504D

C7928K
C9083B

00718H

7188201D

6780106J

71881H
71884B
73034B

7055007E

71891G

C1505B

45871B

00746J

8982401F

00767E

C8964D

62187A
6779806G
6784701C
6757867E

50 PSI

9170007A

20-200

67628J

1257601D

--

C2544K

6757867E

00902H

7920504D

C7928K
C9083B

00718H

7188201D

6780106J

71881H
71885J
73034B

7055007E

71891G
C1505B

45871B
00746J

8982401F

00767E

C8964D

62187A
6779806G
6784701C

6757867E

60 PSI

9170007A

100-300

1257601D
1257601D

--

44587E

6757867E

00902H

7920504D

C7928K
C9083B

00718H

7188201D

6780106J
1630301J

1630201A

73034B

7055007E

71891G
C1505B

45871B
00746J

8982401F

00767E

C8964D

62187A

6779806G

6784701C
6757867E

100 PSI

9170007A

Item Material Part Number

Part Number

Part Number

Description

CLA-VAL

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

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

©

PL-CRL (R-12/05)

PARTS LIST

*This drawing is the property of CLA-VAL and same and copies made thereof, if any, shall be returned to it upon demand. Delivery and disclosure hereof are made solely
upon condition that the same shall not be used, copied ore reproduced, nor shall the subject here of be disclosed in any manner to anyone for any purpose, except as
herein authorized, without prior approval of CLA-VAL. Whether or not the equipment or information shown hereon is patented or otherwise protected, full title and copy­rights if any, in and to this drawing and/or information delivered or submitted are fully reserved by CLA-VAL.

Dwg#47117

Regulator Spring Color Coding Chart

THE FOLLOWING CONTROL & SPRING P/N#'S WERE REMOVED, 32656B, 31554K, 44591G, V65695B, & V5695B.
ADDED CRL-13, CRL-5A, CRA, CRA-10A, CHANGED SPRING RANGES TO MATCH CURRENT CONTROLS.

CLA-VAL

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

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

©

PL-47117 AD (R-11/06)

PARTS LIST

WIRE SIZE SPRING NUMBER COLOR WIRE MATERIAL CATALOG NUMBER PSI RANGE *PSI PER TURN

.080 DIA. C0492D BLUE S.S.

CDB-7

CRL-5A

0-7
0-7

.75
.75

.018 DIA. 82575C -- S.S.

CRD

CRD-10A

1.9-6.5

1.9-6.5

.61
.49

.116 DIA. 81594E -- S.S.

CRD

CRD-10A

2-30
2-30

3.0

2.4

.120 DIA. V5654J GREEN CHR VAN

CRL-5A

CRD

5-25

10-40

4.0

4.0

.162 DIA. 32447F NATURAL S.S.

CDB-7

CRL-5A

CRL-13

10-60
10-60
10-60

12.0

12.0

12.0

.162 DIA. V5695B YELLOW MUSIC WIRE

CDB-7

CRL-5A

CRL-13

20-80
20-80
20-80

14.5

14.5

14.5

.207 DIA. C1124B CAD PLT MUSIC WIRE

CDB-7

CRL-13

CRL-5A

50-150
50-150
50-150

29.5

29.5

29.5

.225 DIA. V6515A RED MUSIC WIRE

CDB-7

CRL-13

CRL-5A

65-180
65-180
65-180

44.0

44.0

44.0

.115 X .218 71884B RED CHR VAN

CRL

CRD

CRD-10A

0-75
15-75
15-75

8.5

9.0

7.2

.118 X .225 71886J GREEN CHR VAN

CRL

CRD

CRD-10A

20-200
30-300
30-300

28.0

27.0

22.4

.225 X .295 1630201A CAD PLT CHR VAN

CRL

CRL-5A

100-300
100-300

18.00

18.00

.440 X .219 48211H CAD PLT STEEL

CRA-18
CRD-22
CRL-4A

200-450
200-450
100-450

17.0

17.0

17.0

.187 20561901H BLACK STEEL CRD 20-105 12.0

WIRE SIZE SPRING NUMBER COLOR WIRE MATERIAL CATALOG NUMBER PSI RANGE *FEET PER TURN

.080 DIA. C0492D BLUE S.S.

CRA

CRD-2

4.5-15

4.5-15

.82
.82

.375 DIA.

87719B
1 SPRING
2 SPRING
3 SPRING
4 SPRING
5 SPRING

EPOXY

COATED

CHROME SILICON CDS-5

5-40

30-80

70-120

110-120

150-200

1.0

2.0

3.0

4.0

5.0

.072 DIA. V5097A -- 302SS CVC 1-17 .7

.375 DIA.

2933502H
1 SPRING
2 SPRING
3 SPRING
4 SPRING
5 SPRING

EPOXY

COATED

CHROME SILICON CDS-6

5-40

30-80

70-120

110-120

150-200

.75

1.50

2.20

3.00

3.70

*THESE FIGURES ARE ONLY APPROXIMATE. FINAL ADJUSTMENTS SHOULD BE MADE WITH A PRESSURE GAGE.

When ordering parts, please specify:

• All Nameplate Data

• Item Number

• Description

• Recommended Spare Parts

Strainer and Orifice Assembly

X44A

BRONZE BODY — S.S. ORIFICE

1/8 NPT

3/8 NPT

3/4

3/4

3 3/8

2

3

5

4

3/8 NPT

8

7

6

1

2 1/4 MAX.

7/8

Inlet

Outlet

X44A

STOCK NO.

71310-01

-02

-03

-04

-05

-06

* -07

-08

-09

-10

ORIFICE DIA.

.031

.046

.062

.078

.093

.109

.125

.140

.156

.187

ORIFICE PLUG

PART # (ITEM 5)

94132-01

-02

-03

-04

-05

-06

-07

-08

-09

-10

*Standard

3/8" x 3/8"

ITEM

1

2

3

4

5

6

7

8

DESCRIPTION

Body

Plug, Top

"O" Ring, Plug Top

Screen

Orifice Plug

Plug, Pipe

Strainer Plug

"O" Ring, Strainer Plug

MATERIAL

Red Brs.

Brass

Syn. Rub.

Monel

Delrin

Brass

S.S.

Syn. Rub.

QTY.

1

1

1

1

1

1

1

1

CLA-VAL

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

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

©

P-X44A (R-5/05)

PARTS LIST

A

2.50

A

2.75

SECTION

AA

3/8 N.P.T.

1.25

1.50

3/8 N.P.T.
BOTH ENDS

6

5

4

1

3

2

8

7

Outlet

Inlet

Flow

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 (Threaded)

ITEM DESCRIPTION

When ordering

parts, please

specify:

• All nameplate data

• Description

• Part Number

• Item Number

• Material

*Recommended Spare Parts

3/8" Check Valve

81-01

PARTS LIST

2

10

7

6

9

11

3
5

1
4

8

3.50

.56

2.56

FLOW

OUTLETINLET

3.12 DIA

ITEM DESCRIPTION

When ordering

parts, please

specify:

• All nameplate data

• Description

• Part Number

• Item Number

• Material

*Recommended Spare Parts

1/2" & 3/4 Check Valve

81-01

CLA-VAL

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

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

©

PL-81-01 (R-5/05)

PARTS LIST

1. Body 1

2. Cover 1

*3. Diaphragm 1

4. Guide Disc 1

*5. Disc Retainer Assembly 1

7. Nut Hex 3/8 - 24UNF 28 1

8. Plug Pipe Hex NPT 2

9. Screw, Fil HD 10 32UNF 2 x 2LG 8

10. Spring 1

11. Nameplate 1

CLA-VAL

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

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

PL-CK2 (R-5/05)

CLA-VAL

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

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

©

INSTALLATION / OPERATION / MAINTENANCE

Flow Control

CV

MODEL

N-CV (R-5/05)

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 cross­threading. 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.

3/8" Flow Control

CV

2.12
MAX

STAMP PART NO. ON
SMOOTH SURFACE

RESTRICTED

FLOW

3/8 - 18 NPT

1.84

ADJUSTING STEM
(TURN CLOCKWISE TO
INCREASE RESTRICTION)

1

7

2

10

9

8

6

5

4

3

.85

FREE FLOW

BAR STOCK

CONFIGURATION

When ordering parts,

please specify:

• Number Stamped on Side

• Description (CV Flow Control)

• Part Description

• Material

ITEM DESCRIPTION QTY

1 Cap (SS only) 1

2 Nut, Jam 1

3 Seat 1

4 Gasket 1

5 Disc 1

6 Spring 1

7 Ring, Retaining 1

8 Stem 1

9 O-Ring 1

10 Housing 1

CLA-VAL

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

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

©

PL-CV (R-5/05)

PARTS LIST

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

I

N

L

E

T

I

N

L

E

T

SIZE &
CAT NO.

STOCK
NO.

FLOW

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

CODE

C

¤

“

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.

C

¤

“

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.

RP

-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

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

[phone]

FAX [phone]

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.

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 $75.00.

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% ($75 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: [phone] Fax: [phone]

CLA-VAL

CLA-VAL CANADA CLA-VAL EUROPE

4687 Christie Drive
Beamsville, Ontario
Canada LOR 1B4
Phone: [phone]
Fax: [phone]

Chemin dés Mesanges 1
CH-1032 Romanel/
Lausanne, Switzerland
Phone: [phone]
Fax: [phone]

©COPYRIGHT CLA-VAL 2005 Printed in USA

Specifications subject to change without notice.

www.cla-val.com

E-Product I.D. (R-5/05)

Represented By:

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 1/4"-1 1/2"

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

6"

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 1/4" - 1 1/2"

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 1/4” - 1 1/2"

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

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

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

Repair Assemblies (In Standard Materials Only)

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.

CLA-VAL

Copyright Cla-Val 2007 Printed in USA Specifications subject to change without notice.

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

©

N-RK (R-5/07)

Larger Sizes: Consult Factory.

Valve

Size

Kit Stock Number

100-02

Valve

Size

Kit Stock Number

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

3

⁄

8”

9169901H

2

1

⁄2”

9169910J N/A

1

⁄2” &3⁄4”

9169902F

3”

9169911G 9169905J

1” 9169903D

4”

9169912E 9169911G

1

1

⁄4” &11⁄2”

9169904B

6”

9169913C 9169912E

2” 9169905J

8”

99116G 9169913C

10”

9169939H 99116G

12"

9169937B 9169939H

Larger Sizes: Consult Factory.

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 Control)

Pilot

Control

Kit

Stock

Number

Pilot

Control

Kit

Stock

Number

Pilot

Control

Kit

Stock

Number
CDB 9170006C CRM-7 1263901K CDB-KB 9170012A
CDB-3D 9170023H CFM-7A 1263901K CRA-KB N/A
CDB-3I 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 172601F CRD Disc Ret. (Spring) C5255K

102C-3 172601F

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