Cla-Val 94-01-694-01 User Manual

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Page 1

94-01/694-01

Page 2

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Combination Pressure Reducing and

Surge Control Valve

Typical Application

Schematic Diagram

Item Description

1 100-01Hytrol (Main Valve) 2 X58C Restriction Assembly 3 CRD Pressure Reducing Control 4 CRL Pressure Relief Control

Optional Features

Item Description

A X46A Flow Clean Strainer B CK2 (Isolation Valve) C CV Flow Control (Closing)* D Check Valves with Isolation Valve F Remote Pilot Sensing P X141 Pressure Gauge S CV Speed Control (Opening) V X101 Valve Position Indicator Y X43 "Y" Strainer

The closing speed control (optional) on this valve should

always be open at least three (3) turns off its seat.

High Pressure

Isolation Valve

Gauge

Zone A

Zone C

Zone B

On-Off Remote Control Valves

CLA-VAL 94-01BY/694-01BY

Combination Pressure Reducing and

Surge Control Valve

On-Off Remote Control Valves

Reduced Pressure

• Sensitive and Accurate Pressure Control

• Easy Adjustment and Maintenance

• Tamper Resistant

• Optional Check Feature

• Fully Supported Frictionless Diaphragm

The Cla-Val Model 94-01/694-01 Combination Pressure Reducing and Surge Control Valve automatically reduces a higher inlet pressure to a steady lower downstream pressure, regardless of changing flow rate and/or varying inlet pressure. This valve is an accurate, pilot-operated control valve capable of holding downstream pressure to a predetermined limit. When downstream pressure rapidly exceeds the pressure setting of the pressure reducing control pilot, the surge pilot (CRL) will open quickly to prevent a rapid pressure rise downstream. If a check feature is added, and a pressure reversal occurs, the downstream pressure is admitted in the main valve cover chamber closing the valve to prevent return flow.

Should the downstream pressure suddenly increase above the setting of the pressure reducing control due to onoff operation of two or more downstream systems, the Surge Control tracks rapidly enough to prevent high pressure surges from entering any of the downstream systems, when any one of the downstream systems is rapidly closed off. The typical combination pressure reducing and surge control valve station uses Model 94-01BY/694-01BY to control surges in downstream piping as remote control valves change from one downstream zone to another. Surge Control is set approximately 10 psi above Pressure Reducing Control to prevent high pressure surge entering other downstream zones.

94-01

MODEL

(Full Internal Port)

694-01

(Reduced Internal Port)

Page 6

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

Model 94-01 (Uses Basic Valve Model 100-01)

Dimensions

(In inches)

Model 94-01 Dimensions (In Inches)

Component Standard Material Combinations

Body & Cover Ductile Iron Cast Steel Bronze

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

Disc Retainer & Diaphragm Washer

Cast Iron Cast Steel Bronze

Trim: Disc Guide, Seat & Cover Bearing

Bronze is Standard

Stainless Steel is Optional

Disc Buna-N®Rubber

Diaphragm Nylon Reinforced Buna-N®Rubber

Stem, Nut & Spring Stainless Steel

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

Materials

GGGG

DDDD

Inlet

AAAA

100-01

Grooved

(MAX)

Inlet

Outlet

(Diameter)

GGG

Inlet

DDD

100-01

Threaded &

Flanged

(MAX)

Inlet

Outlet

AAA

(Diameter)

Valve Body & Cover

Pressure Class

Flanged Grooved Threaded

Grade Material

ANSI

Standards*

150

Class

300

Class

300

Class

End‡

Details

ASTM A536 Ductile Iron B16.42 250 400 400 400

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

ASTM B62 Bronze B16.24 225 400 400 400

Note: * ANSI standards are for flange dimensions only.

Flanged valves are available faced but not drilled.

‡ End Details machined to ANSI B2.1 specifications.

Valves for higher pressure are available; consult factory for details

Pressure Ratings

(Recommended Maximum Pressure - psi)

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

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

AA 150 ANSI

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

AAA 300 ANSI

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

AAAA Grooved End

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

B Dia.

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

C Max.

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

CC Max. Grooved End

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

D Threaded

3.253.253.254.755.506.25————————————

DD 150 ANSI

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

DDD 300 ANSI

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

DDDD Grooved End

———4.75—6.007.50———————————

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

EE Grooved End

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

F 150 ANSI

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

FF 300 ANSI

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

G Threaded

1.881.881.883.254.004.50————————————

GG 150 ANSI

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

GGG 300 ANSI

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

GGGG Grooved End

———3.25—4.255.00———————————

H NPT Body Tapping

.375.375.375.375.50.50.75.751111111122

J NPT Cover

Center Plug

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

K NPT Cover Tapping

.375.375.375.375.50.50.75.751111111122

Stem Travel

0.4 0.4

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

Approx. Ship Wt. Lbs.

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

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

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Dimensions

(In inches)

Model 694-01 (Uses Basic Valve Model 100-20)

Model 694-01 Dimensions (In Inches)

Inlet

100-20

Flanged

(MAX)

Inlet

Outlet

(Diameter)

Component Standard Material Combinations

Body & Cover Ductile Iron Cast Steel Bronze

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

Disc Retainer & Diaphragm Washer

Cast Iron Cast Steel Bronze

Trim: Disc Guide, Seat & Cover Bearing

Bronze is Standard

Stainless Steel is Optional

Disc Buna-N®Rubber

Diaphragm Nylon Reinforced Buna-N®Rubber

Stem, Nut & Spring Stainless Steel

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

Materials

Pressure Ratings

(Recommended Maximum Pressure - psi)

Valve Body & Cover

Pressure Class

Flanged

Grade Material

ANSI

Standards*

150

Class

300

Class

ASTM A536 Ductile Iron B16.42 250 400

ASTM A216-WCB Cast Steel B16.5 285 400

ASTM B62 Bronze B16.24 225 400

Note: * ANSI standards are for flange dimensions only.

Flanged valves are available faced but not drilled.

Valves for higher pressure are available; consult factory for details

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

*Consult Factory

Valve Size (Inches)

34681012141618202430364248

A 150 ANSI

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

AA 300 ANSI

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

B Dia.

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

C Max.

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

D 150 ANSI

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

DD 300 ANSI

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

E 150 ANSI

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

EE 300 ANSI

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

F 150 ANSI

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

FF 300 ANSI

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

H NPT Body Tapping

.375.50.75.7511111111222

J NPT Cover Center Plug

.50.50.75.75111.251.252222222

K NPT Cover Tapping

.375.50.75.7511111111222

Stem Travel

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

Approx. Ship Wt. Lbs.

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

X Pilot System 13 15 27 30 33 36 36 41 40 46 55 68 79 85 86

Y Pilot System 10 11 18 20 22 24 26 26 30 30 30 39 40 45 47

Z Pilot System 10 11 18 20 22 24 26 26 30 30 30 39 42 47 49

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Temperature Range

Water: to 180°F

Materials

Standard Pilot System Materials

Pilot Control: Bronze ASTM B62

Trim: Stainless Steel Type 303

Rubber: Buna-N

Synthetic Rubber

Optional Pilot System Materials

Pilot Systems are available with optional Aluminum, Stainless Steel, Monel or Cast Steel materials.

Note: Available with remote sensing control.

Adjustment Ranges

CRD CRL

2 to 30 psi 0 to 75 psi 15 to 75 psi 20 to 105 psi* 20 to 105 psi 20 to 200 psi 30 to 300 psi* 100 to 300 psi

*Supplied unless otherwise specified

Other ranges available, please consult factory.

Temperature Range

Water: to 180°F

When Ordering, Please Specify

1. Catalog No. 94-01 or No. 694-01

2. Valve Size

3. Pattern - Globe or Angle

4. Pressure Class

5. Threaded or Flanged

6. Trim Material

7. Adjustment Range

8. Desired Options

9. When Vertically Installed

Pilot System Specifications

E-94-01/694-01 (R-7/2011)

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

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

94-01

Valve

Selection

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

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

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

Basic Valve

100-01

Pattern

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

End Detail T T

T, F,

Gr*

T, F,GrT, F,

Gr*

T, F,GrF, GrF,

Gr*

FFFFFFFFF

Suggested

Flow

(gpm)

Maximum

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

Maximum Intermittent

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

Minimum

1111224101535507095120150275450650

Suggested

Flow

(Liters/Sec)

Maximum

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

Maximum Intermittent

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

Minimum

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

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

694-01

Valve

Selection

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

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

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

Basic Valve

100-20

Pattern

GG, AG, AG, AGGGG GGGGGGG

End DetailFFFFFFFFFFFFFFF

Suggested

Flow

(gpm)

Maximum

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

Minimum

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

Suggested

Flow

(Liters/Sec)

Maximum

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

Minimum

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

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

Page 9

Description

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

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

Installation

1. Before valve is installed, pipe lines should be flushed of all chips, scale and foreign matter.

2. It is recommended that either gate or block valves be installed on both ends of the 100-01 Hytrol Valve to facilitate isoIating the valve for preventive maintenance and repairs.

3. Place the valve in the line with flow through the valve in the direction indicated on the inlet nameplate. (See “Flow Direction” Section)

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

5. CIa-VaI 100-01 Hytrol Valves operate with maximum effici ency when mounted in horizontal piping with the cover UP, however, other positions are acceptable. Due to size and weight of the cover and internal components of 8 inch and larger valves,

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

6. Caution must be taken in the installation of this valve to insure that galvanic and/or electrolytic action does not take place. The proper use of dielectric fittings and gaskets are required in all systems using dissimilar metals.

7. If a pilot control system is installed on the 100-01 Hytrol Valve, use care to prevent damage. If it is necessary to remove fittings or components, be sure they are kept clean and replaced exactly as they were.

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

Tight Closing Operation

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

Full Open Operation

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

Modulating Action

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

Principles of Operation

Three Way

Pilot Control

Three Way

Pilot Control

Restriction

Modulating

Control

100-01

Hytrol Valve

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Page 10

Flow Direction

The flow through the 100-01 Hytrol Valve can be in one of two directions. When flow is “up-and-over the seat,” it is in “normal” flow and the valve will fail in the open position. When flow is “overthe seat-and down,” it is in “reverse” flow and the valve will fail in the closed position. There are no permanent flow arrow markings.

The valve must be installed according to nameplate data.

BRIDGEWALL INDlCATOR

Normal Flow Reverse Flow

Troubleshooting

The following troubleshooting information deals strictly with the Model 100-01 Hytrol Valve. This assumes that all other components of the pilot control system have been checked out and are in proper working condition. (See appropriate sections in Technical Manual for complete valve).

Three Checks

The 100-01 Hytrol Valve has only one moving part (the diaphragm and disc assembly). So, there are only three major types of problems to be considered.

First: Valve is stuck - that is, the diaphragm assembly is not free to move through a full stroke either from open to close or vice versa.

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

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

Closed isolation valves in control system, or in main line.

Lack of cover chamber pressure.

Diaphragm damaged. (See Diaphragm Check.)

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

Mechanical obstruction. Object lodged in valve. (See Freedom of Movement Check)

Worn disc. (See Tight Sealing Check)

Badly scored seat. (See Tight Sealing Check)

Closed upstream and/or downstream isolation valves in main line.

Insufficient line pressure.

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

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

After checking out probable causes and remedies, the following three checks can be used to diagnose the nature of the problem before maintenance is started. They must be done in the order shown.

Open Isolation valves.

Check upstream pressure, pilot system, strainer, tubing, valves, or needle valves for obstruction.

Replace diaphragm.

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

Remove obstruction.

Replace disc.

Replace seat.

Open isolation valves.

Check upstream pressure. (Minimum 5 psi flowing line pressure differential.)

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

Replace diaphragm.

Fails to Close

Fails to Open

CAUTION: Care should be taken when doing the troubleshooting checks on the 100-01 Hytrol Valve. These checks do require the valve to open fully. This will either allow a high flow rate through the valve, or the downstream pressure will quickly increase to the inlet pressure. In some cases, this can be very harmful. Where this is the case, and there are no block valves in the system to protect the downstream piping, it should be realized that the valve cannot be serviced under pressure. Steps should be taken to remedy this situation before proceeding any further.

(cast into side of valve body)

SYMPTOM PROBABLE CAUSE REMEDY

Recommended Tools

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

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

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

All trouble shooting is possible without removing the valve from the line or removing the cover. It is highly recommended to permanently install a Model X101 Valve Position Indicator and three gauges in unused Hytrol inlet, outlet and cover connections.

Page 11

Diaphragm Check (#1 )

1. Shut off pressure to the Hytrol Valve by slowly closing upstream and downstream isolation valves. SEE CAUTION.

2. Disconnect or close all pilot control lines to the valve cover and

leave only one fitting in highest point of cover open to atmosphere.

3.With the cover vented to atmosphere, slowly open upstream isolation valve to allow some pressure into the Hytrol Valve body. Observe the open cover tapping for signs of continuous flow. It is not necessary to fully open isolating valve. Volume in cover chamber capacity chart will be displaced as valve moves to open position. Allow sufficient time for diaphragm assembly to shift positions. If there is no continuous flow, you can be quite certain the diaphragm is sound and the diaphragm assembly is tight. If the fluid appears to flow continuously this is a good reason to believe the diaphragm is either damaged or it is loose on the stem. In either case, this is sufficient cause to remove the valve cover and investigate the leakage. (See “Maintenance” Section for procedure.)

Freedom of Movement Check (#2)

4. Determining the Hytrol Valve’s freedom of movement can be

done by one of two methods.

5. For most valves it can be done after completing Diaphragm Check (Steps 1, 2, and 3). SEE CAUTION. At the end of step 3 the valve should be fully open.

6. If the valve has a Cla-Val X101 Position Indicator, observe the indicator to see that the valve opens wide. Mark the point of maximum opening.

7. Re-connect enough of the control system to permit the application of inlet pressure to the cover. Open pilot system cock so pressure flows from the inlet into the cover.

8. While pressure is building up in the cover, the valve should close smoothly. There is a hesitation in every Hytrol Valve closure, which can be mistaken for a mechanical bind. The stem will appear to stop moving very briefly before going to the closed position. This slight pause is caused by the diaphragm flexing at a particular point in the valve’s travel and is not caused by a mechanical bind.

9. When closed, a mark should be made on the X101 Valve position indicator corresponding to the “closed” position. The distance between the two marks should be approximately the stem travel shown in chart.

10. If the stroke is different than that shown in stem travel chart this is a good reason to believe something is mechanically restricting the stroke of the valve at one end of its travel. If the flow does not stop through the valve when in the indicated “closed” position, the obstruction probably is between the disc and the seat. If the flow does stop, then the obstruction is more likely in the cover. In either case, the cover must be removed, and the obstruction located and removed. The stem should also be checked for scale buildup. (See “Maintenance, section for procedure.)

11. For valves 6” and smaller, the Hytrol Valve’s freedom of movement check can also be done after all pressure is removed from the valve. SEE CAUTION. After closing inlet and outlet isolation valves and bleeding pressure from the valve, check that the cover chamber and the body are temporarily vented to atmosphere. Insert fabricated tool into threaded hole in top of valve stem, and lift the diaphragm assembly manually. Note any roughness. The diaphragm assembly should move smoothly throughout entire valve stroke. The tool is fabricated from rod that is threaded on one end to fit valve stem and has a “T” bar handle of some kind on the other end for easy gripping. (See chart in Step 4 of “Disassembly” Section.)

12. Place marks on this diaphragm assembly lifting tool when the valve is closed and when manually positioned open. The distance between the two marks should be approximately the stem travel shown in stem travel chart. If the stroke is different than that shown, there is a good reason to believe something is mechanically restricting the stroke of the valve. The cover must be removed, and the obstruction located and removed. The stem should also be checked for scale build-up. (See “Maintenance” Section for procedure.)

Tight Sealing Check (#3)

13. Test for seat leakage after completing checks #1 & #2 (Steps

1 to 12). SEE CAUTION. Close the isolation valve downstream of the Hytrol Valve. Apply inlet pressure to the cover of the valve, wait until it closes. Install a pressure gauge between the two closed valves using one of the two ports in the outlet side of the Hytrol. Watch the pressure gauge. If the pressure begins to climb, then either the downstream isolation valve is permitting pressure to creep back, or the Hytrol is allowing pressure to go through it. Usually the pressure at the Hytrol inlet will be higher than on the isolation valve discharge, so if the pressure goes up to the inlet pressure, you can be sure the Hytrol is leaking. Install another gauge downstream of isolating valve. If the pressure between the valves only goes up to the pressure on the isolation valve discharge, the Hytrol Valve is holding tight, and it was just the isolation valve leaking.

STEM TRAVEL

(Fully Open to Fully Closed)

Valve Size (inches) Travel (inches)

Inches MM Inches MM

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

COVER CHAMBER CAPACITY

(Liquid Volume displaced when valve opens)

Valve size (inches) Displacement

Gallons Liters

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

Page 12

Maintenance

Preventative Maintenance

The Cla-Val Co. Model 100-01 Hytrol Valve requires no lubrication or packing and a minimum of maintenance. However, a periodic inspection schedule should be established to determine how the operating conditions of the system are affecting the valve. The effect of these actions must be determined by inspection.

Disassembly

Inspection or maintenance can be accomplished without removing the valve from the line. Repair kits with new diaphragm and disc are recommended to be on hand before work begins.

WARNING: Maintenance personnel can be injured and equipment damaged if disassembly is attempted with pressure in the valve. SEE

CAUTION.

1. Close upstream and downstream isolation valves and independ- ent operating pressure when used to shut off all pressure to the

valve.

2. Loosen tube fittings in the pilot system to remove pressure from valve body and cover chamber. After pressure has been released from the valve, use care to remove the controls and tubing. Note and sketch position of tubing and controls for re-assembly. The schematic in front of the Technical Manual can be used as a guide when reassembling pilot system.

3. Remove cover nuts and remove cover. If the valve has been in service for any length of time, chances are the cover will have to be loosened by driving upward along the edge of the cover with a dull cold chisel.

On 6” and smaller valves block and tackle or a power hoist can be used to lift valve cover by inserting proper size eye bolt in place of the center cover plug. on 8” and larger valves there are 4 holes (5/8” — 11 size) where jacking screws and/or eye bolts may be inserted for lifting purposes. Pull cover straight up to keep from damaging the integral seat bearing and stem.

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

straight up on the stem so as not to damage the seat bearing.

On large valves, an eye bolt of proper size can be installed in the stem and the diaphragm assembly can be then lifted with a block and tackle or power hoist. Take care not to damage the stem or bearings. The valve won't work if these are damaged.

5. The next item to remove is the stem nut. Examine the stem threads above the nut for signs of mineral deposits or corrosion. If the threads are not clean, use a wire brush to remove as much of the residue as possible. Attach a good fitting wrench to the nut and give it a sharp “rap” rather than a steady pull. Usually several blows are sufficient to loosen the nut for further removal. On the smaller valves, the entire diaphragm assembly can be held by the stem in a vise equipped with soft brass jaws before removing the stem nut.

The use of a pipe wrench or a vise without soft brass jaws scars the fine finish on the stem. No amount of careful dressing can restore the stem to its original condition. Damage to the finish of the stem can cause the stem to bind in the bearings and the valve will not open or close.

6. After the stem nut has been removed, the diaphragm assembly breaks down into its component parts. Removal of the disc from the disc retainer can be a problem if the valve has been in service for a long time. Using two screwdrivers inserted along the outside edge of the disc usually will accomplish its removal. Care should be taken to preserve the spacer washers in water, particularly if no new ones are available for re-assembly.

7. The only part left in the valve body is the seat which ordinarily does not require removal. Careful cleaning and polishing of inside and outside surfaces with 400 wet/dry sandpaper will usually restore the seat’s sharp edge. If, however, it is badly worn and replacement is necessary, it can be easily removed.

Seats in valve sizes 1 1/4” through 6” are threaded into the valve body. They can be removed with accessory X109 Seat Removing Tool available from the factory. On 8” and larger valves, the seat is held in place by flat head machine screws. Use a tight-fitting, long shank screwdriver to prevent damage to seat screws. If upon removal of the screws the seat cannot be lifted out, it will be necessary to use a piece of angle or channel iron with a hole drilled in the center. Place it across the body so a long stud can be inserted through the center hole in the seat and the hole in the angle iron. By tightening the nut a uniform upward force is exerted on the seat for removal.

NOTE: Do not lift up on the end of the angle iron as this may force the integral bearing out of alignment, causing the stem to bind.

VALVE STEM THREAD SIZE

Valve Size Thread Size (UNF Internal)

1 1/4"

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

16" 1/2—20

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

COVER CENTER PLUG SIZE

Valve Size Thread Size (NPT)

1 1/4"

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

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

16" 2" 20” & 24" 2" 30” & 36” 2”

NUT

ANGLE OR CHANNEL IRON

LONG STUD OR BOLT

NUT OR BOLT HEAD

DO NOT

LIFT

VALVE SEAT

VALVE BODY

Page 13

Lime Deposits

One of the easiest ways to remove lime deposits from the valve stem or other metal parts is to dip them in a 5-percent muriatic acid solution just long enough for the deposit to dissolve. This will remove most of the common types of deposits. CAUTlON: USE EXTREME CARE WHEN HANDLING ACID. Rinse parts in water before handling. If the deposit is not removed by acid, then a fine grit (400) wet or dry sandpaper can be used with water.

Reassembly

1. Reassembly is the reverse of the disassembly procedure. If a

new disc has been installed, it may require a different number of spacer washers to obtain the right amount of “grip” on the disc. When the diaphragm assembly has been tightened to a point where the diaphragm cannot be twisted, the disc should be compressed very slightly by the disc guide. Excessive compression should be avoided. Use just enough spacer washers to hold the disc firmly without noticeable compression.

2. MAKE SURE THE STEM NUT IS VERY TIGHT.Attach a good fitting wrench to the nut and give it a sharp “rap” rather than a steady pull. Usually several blows are sufficient to tighten the stem nut for final tightening. Failure to do so could allow the diaphragm to pull loose and tear when subjected to pressure.

Test Procedure After Valve Assembly

There are a few simple tests which can be made in the field to make sure the Hytrol Valve has been assembled properly. Do these before installing pilot system and returning valve to service. These are similar to the three troubleshooting tests.

1. Check the diaphragm assembly for freedom of movement after all pressure is removed from the valve. SEE CAUTlON. Insert fabricated tool into threaded hole in top of valve stem, and lift the diaphragm assembly manually. Note any roughness, sticking or grabbing. The diaphragm assembly should move smoothly throughout entire valve stroke. The tool is fabricated from rod that is threaded on one end to fit valve stem (See chart in Step 4 of “Disassembly” section.) and has a “T” Bar handle of some kind on the other end for easy gripping.

Place marks on this diaphragm assembly lifting tool when the valve is closed and when manually positioned open. The distance between the two marks should be approximately the stem travel shown in stem travel chart. (See “Freedom of Movement Check” section.) If the stroke is different than that shown, there is a good reason to believe something is mechanically restricting the stroke of the valve. The cover must be removed, the obstruction located and removed. (See “Maintenance” Section for procedure.)

Inspection of Parts

After the valve has been disassembled, each part should be examined carefully for signs of wear, corrosion, or any other abnormal condition. Usually, it is a good idea to replace the rubber parts (diaphragm and disc) unless they are free of signs of wear. These are available in a repair kit. Any other parts which appear doubtful should be replaced. WHEN ORDERlNG PARTS, BE SURE TO GIVE COMPLETE NAMEPLATE DATA, ITEM NUMBER AND DESCRlPTlON.

NOTE: If a new disc isn’t available, the existing disc can be turned over, exposing the unused surface for contact with the seat. The disc should be replaced as soon as practical.

3. Carefully install the diaphragm assembly by lowering the stem through the seat bearing. Take care not to damage the stem or bearing. Line up the diaphragm holes with the stud or bolt holes on the body. on larger valves with studs, it may be necessary to hold the diaphragm assembly up part way while putting the diaphragm over the studs.

4. Put spring in place and replace cover. Make sure diaphragm is Iying smooth under the cover.

5. Tighten cover nuts firmly using a cross-over pattern until all nuts are tight.

6. Test Hytrol Valve before re-installing pilot valve system.

Due to the weight of the diaphragm assembly this procedure is not possible on valves 8” and larger. on these valves, the same determination can be made by carefully introducing a low pressure-less than five psi) into the valve body with the cover vented. SEE CAUTION. Looking in cover center hole see the diaphragm assembly lift easily without hesitation, and then settle back easily when the pressure is removed.

2. To check the valve for drip-tight closure, a line should be connected from the inlet to the cover, and pressure applied at the inlet of the valve. If properly assembled, the valve should hold tight with as low as ten PSI at the inlet. See “Tight Sealing Check” section.)

3. With the line connected from the inlet to the cover, apply full working pressure to the inlet. Check all around the cover for any leaks. Re-tighten cover nuts if necessary to stop leaks past the diaphragm.

4. Remove pressure, then re-install the pilot system and tubing exactly as it was prior to removal. Bleed air from all high

points.

5. Follow steps under “Start-Up and Adjustment” Section in

Technical Manual for returning complete valve back to service

Page 14

OUTLE

INLET

GLOBE PATTERN

INLET

OUTLET

ANGLE PATTERN

TOP VIEW

8" - 24" SEAT DETAIL

1 1/4" - 6" SEAT DETAIL

16" COVER DETAIL

Item Description

1. Pipe Plug

2. Drive Screws (for nameplate)

3. Hex Nut (8” and larger)

4. Stud (8” and larger)

5. Cover Bearing

6. Cover

7. Stem Nut

8. Diaphragm Washer

9. Diaphragm

10. Spacer Washers

11. Disc Guide

12. Disc Retainer

13. Disc

14. Stem

15. Seat

16. Body

17. Spring

22. Flat Head Screws (8” and larger)

23. Seat O-Ring

24. Hex head Bolt (1 1/4” thru 4”)

25. Nameplate

26. Upper Spring Washer (Epoxy coated valves only)

27. Lower Spring Washer (Epoxy coated valves only)

28. Cover Bearing Housing (16” only)

29. Cover O-Ring (16’” only)

30. Hex Bolt (16” only)

31. Pipe Cap (16” only)

PARTS LIST

Page 15

100-01

Hytrol Valve Service Data

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Description 100-01 Hytrol Valve

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

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

diaphragm-actuated, globe or angle pattern valve.

This valve consists of three major components; body, diaphragm

assembly, and cover. The diaphragm assembly is the only

moving part. The diaphragm assembly uses a diaphragm of nylon

fabric bonded with synthetic rubber. A synthetic rubber disc,

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

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

above the diaphragm. The diaphragm assembly forms a sealed

chamber in the upper portion of the valve, separating operating

pressure from line pressure.

Description 100-20 600 Series Hytrol Valve

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

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

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

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

ice and maintenance information for the standard 100 Series

main valves also apply to the 600 series main valves.

The most important thing to remember when ordering main

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

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

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

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

chart below.

HYTROL Service Data

HYTROL SIZE

Stem

Travel

Cover Capacity

Displacement

Valve Stem

Thread

UNF-Internal

Cover

Center

Plug

NPT

Cover Nut or Bolt

Cover

Lifting

Holes

UNC

Cover Plug Cover Torque

Stem Nut**

Stem Nut Torque

(ft. Lbs.)

100-01

100-20

Thread

(Bolt)

Socket

Qty Thread

Socket ft. Lbs. in. Lbs.

Thread

Socket

(Long)

inches mm inches mm inches mm

Gallons

Liters

Lubed DRY

25 0.3 8 1/4"

1/4" - 20 (B)

7/16" 8

48 3/8" - 24

1 1/4"

0.4

0.020

0.07

10 - 32

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

8 96 7/16" -20 6 10

1 1/2" 40 0.4 10 0.020 0.07

10 - 32

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

8 96 7/16" -20 6 10

2" 50 0.6 15 0.032

0.12 10 - 32

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

1/2" - 20

3/4" 10 15

2 1/2"

65 0.7 18

0.043 0.16

10 - 32

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

5/8" - 18 15/16" 21

3" 80 4" 100 0.8

0.080 0.30

1/4 - 28 1/2"

1/2" - 13 (B)

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

15/16"

21 30

4" 100 6" 150 1.1 23

0.169 0.64

1/4 - 28 3/4"

3/4" - 10 (B)

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

1 1/16"

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

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

12 3/4"

5/8" 110

7/8" - 14

1 5/16"

85 125

200 10"

250

2.3 58

1.26 4.80 3/8 - 24

3/4" - 10

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

1" 13/16" 11 0

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

125

185

10" 250 12" 300 2.8 71 2.51 9.50

3/8 - 24

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

3/4" - 10

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

12" 300 16" 400 3.4 86 4.0 15.10

3/8 - 24

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

3/4" - 10

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

14" 350 3.9

6.5

24.60

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

2" 20

1" - 8

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

2 1/2"

280 420

16"

400

20", 24"

600

4.5

114

9.6 36.20

1/2 - 20

2" 1 1/4" - 7

2" 20

1" - 8

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

20" 500 5.63

143

12 45.40

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

2 1/8" 24

1" - 8

1" 13/16" 670

2 1/4" - 16

3 1/2" 930

N/R

24" 600

30"

800 6.75 165

29.0

108.80 3/4 - 16*

3/4"

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

1 1/8"- 7

1" 13/16"

800

3" - 12

Special

1350

N/R

* Adapter

p/n 2594101E

inside 1/4" - 28"

Grade 5 Bolts

"Heavy" Grade Nuts

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

** Must Use ONLY

Cla-Val Supplied part

Page 16

COVER

PIPE PLUG

COVER BEARING

SPRING

STEM NUT

DIAPHRAGM WASHER

DISC RETAINER

BODY

SPACER WASHERS

DISC GUIDE

SEAT

PIPE PLUG

STEM

SEAT O-RING

STUD

8" and Larger

DIAPHRAGM

DISC

Repair Parts

Seat Screw

8" and Larger

(Globe

Angle)

PIPE PLUG

HEX NUT

8" and Larger

Cover Bolt

6" and Smaller

DISC GUIDE

SEAT

KO Anti-Cavitation

Trim Option

N-100-01 (R-3/2011

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS

BOLTS

Follow this procedure when reassembling MAIN Valve:

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

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

material and body.

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

for each stage:

A. To approximately 10% of final torque.

B. To approximately 75% of final torque.

C. To final required torque.

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

after 24 hours.

100-01 Hytrol Main Valve Assembly

Page 17

UNDERSTANDING THE 600 SERIES VALVES

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

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

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

600 Series Hytrol Valve

100-20

MODEL

INSTALLATION / OPERATION / MAINTENANCE

SERVICE AND MAINTENANCE OF 600 SERIES VALVES

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

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

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

Cla-Val Main Valves

Catalog Number

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

Catalog Name

Hytrol

Powertrol

Powercheck

Hycheck

Circa 1936

100 (Angle =2100)

100P & 100PA

100PC & 100PCA

181

100-Series

100-01

100-02

100-03

100-04

600 Series

100-20

100-21

100-22

100-23

(Reduced Internal Port)

Basic Main Valve Size Comparison

Globe Pattern Valves

Flange Size (inch)

Seat Size

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

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

Angle Pattern Valves

Flange Size (inch)

Seat Size

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

Page 18

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

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

100-20

PARTS LIST

NO. DESCRIPTION

1 Pipe Plug

2 Drive Screws (for nameplate)

3 Hex Nut (8" and larger)

4 Stud (8" and larger)

5 Cover Bearing

6 Cover

7 Stem Nut

8 Diaphragm Washer

9 Diaphragm

10 Spacer Washers

11 Disc Guide

12 Disc Retainer

13 Disc

14 Stem

15 Seat

16 Body

17 Spring

22 Flat Head Screws (10" and larger)

23 Seat O-Ring

24 Hex Bolt (3 " Thru 6")

25 Nameplate (Mounted on inlet flange)

26 Upper Spring Washer (Epoxy coated valves only)

27 Lower Spring Washer (Epoxy coated valves only)

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

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

30 Hex Bolt (20" & 24")

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

12434

5 17

10" — 24" SEAT DETAIL

20" — 24" COVER DETAIL

TOP VIEW

OUTLET

GLOBE

INLET

ANGLE

INLET

3" — 6" COVER DETAIL

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

Page 19

DIST.CODE 007A

X58C

RESTRICTION ASSEMBLIES

SHEET 1 OF 2

F:WORD/BUY/48834.TUB.DOC

DWG. 48834 REV.AR

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

TUBE CONNECTOR

RESTRICTION PLUG

SIZE

MATERIAL

X58C

STOCK #.

ORIFICE

DIA.

MATERIAL

TUBE

NPT

1 / 4 1 / 8-27 NPT

BRASS

45º FLARED

*37814B

.031 (1/32)

S.STEEL

*80500C

.062 (1/16)

3 / 8

1 / 8-27 NPT

*67739D

.040

3 / 8

3 / 8-18 NPT

*64672K

.062 (1/16)

*99329-01D

.094 (3/32)

**48834-05F

.125 (1/8)

1 / 2

1 / 2 -14 NPT

**79730J

.125 (1/8)

1 / 4

1 / 8-27 NPT

*85484E

.031 (1/32)

DELRIN

*85486K

.040

**48834-03A

.125 (1/8)

*48834-04J

.093

3 / 8

1 / 8-27 NPT

*88409-01G

.031 (1/32)

*88409J

.052

*42346H

.062 (1/16)

**48834-01E

.125 (1/8)

3 / 8

1 / 4-18 NPT

*42775H

.062 (1/16)

**63604D

.156 (5/32)

3 / 8

3 / 8-18 NPT

*10253D

.031 (1/32)

*46946A

.062 (1/16)

**64673H

.125 (1/8)

*68565B

.094 (3/32)

**43302K

.188 (3/16)

Page 20

DIST.CODE 007A

X58C

RESTRICTION ASSEMBLIES

SHEET 2 OF 2

F:WORD/BUY/48834.TUB.DOC

DWG. 48834 REV.AR

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

TUBE CONNECTOR

RESTRICTION PLUG

SIZE

MATERIAL

X58C

STOCK #.

ORIFICE

DIA.

MATERIAL

TUBE

NPT

1 / 2

1 / 2 -14 NPT

BRASS

45º FLARED

**12900H

.125 (1/8)

DELRIN

**48834-02C

.188 (3/16)

**48834-06D

.250 (1/4)

3 / 8

3 / 8 -18 NPT

303

45º FLARED

**48834-07B

.125 (1/8)

**48834-08K

.062 (1/16)

3 / 8

3 / 8 -18 NPT

ALUMINUM 37º FLARED

**44734C

.125 (1/8)

S.STEEL

Page 21

DESCRIPTION

The Cla-Val Model CRD Pressure Reducing Control automatically reduces a higher inlet pressure to a lower outlet pressure. It is a direct acting, spring loaded, diaphragm type control that operates hydraulically or pneumatically. It may be used as a self-contained valve or as a pilot control for a Cla-Val main valve. It will hold a constant downstream pressure within very close pressure limits.

OPERATION

The CRD Pressure Reducing Control is normally held open by the force of the compression spring above the diaphragm; and delivery pressure acts on the underside of the diaphragm. Flow through the valve responds to changes in downstream demand to maintain a pressure.

INSTALLATION

The CRD Pressure Reducing Control may be installed in any position. There is one inlet port and two outlets, for either straight or angle installation. The second outlet port can be used for a gage connection. A flow arrow is marked on the body casting.

ADJUSTMENT PROCEDURE

The CRD Pressure Reducing Control can be adjusted to provide a delivery pressure range as specified on the nameplate.

Pressure adjustment is made by turning the adjustment screw to vary the spring pressure on the diaphragm. The greater the compression on the spring the higher the pressure setting.

1. Turn the adjustment screw in (clockwise) to increase delivery pressure.

2. Turn the adjustment screw out (counter-clockwise) to decrease the delivery pressure.

3. When pressure adjustment is completed tighten jam nut on adjusting screw and replace protective cap.

4. When this control is used, as a pilot control on a Cla-Val main valve, the adjustment should be made under flowing conditions. The flow rate is not critical, but generally should be somewhat lower than normal in order to provide an inlet pressure several psi higher than the desired setting

CRD

MAINTENANCE

Disassembly

To disassemble follow the sequence of the item numbers assigned to parts in the sectional illustration.

Reassembly

Reassembly is the reverse of disassembly. Caution must be taken to avoid having the yoke (17) drag on the inlet nozzle of the body (18). Follow this procedure:

1. Place yoke (17) in body and screw the disc retainer assembly (16) until it bottoms.

2. Install gasket (14) and spring (19) for 2-30 and 2-6.5 psi

range onto plug (13) and fasten into body. Disc retainer must enter guide hole in plug as it is assembled. Screw the plug in by hand. Use wrench to tighten only.

3. Place diaphragm (12) diaphragm washer (11) and belleville washer (20) on yoke. Screw on hex nut (10).

4. Hold the diaphragm so that the screw holes in the diaphragm and body align. Tighten diaphragm nut with a wrench. At the final tightening release the diaphragm and permit it to rotate 5° to 10°. The diaphragm holes should now be properly aligned with the body holes.

To check for proper alignment proceed as follows:

Rotate diaphragm clockwise and counterclockwise as far as possible. Diaphragm screw holes should rotate equal distance on either side of body screw holes ±1/8".

Repeat assembly procedure until diaphragm and yoke are properly aligned. There must be no contact between yoke and body nozzle during its normal movement. To simulate this movement hold body and diaphragm holes aligned. Move yoke to open and closed positions. There must be no evidence of contact or dragging.

5. Install spring (9) with spring guide (8).

6. Install cover (5), adjusting screw (2) and nut (3), then cap (1).

Pressure Reducing Control

The approximate minimum flow rates given in the table are for the main valve on which the CRD is installed.

Valve Size

Minimum Flow GPM

1 1/4" -3" 4"-8" 10"-16"

15-30 50-200 300-650

MODEL

INSTALLATION / OPERATION / MAINTENANCE

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

N-CRD (R-3/2011)

SYMPTOM PROBABLE CAUSE REMEDY

Fails to open

when deliver pres-

sure lowers

No spring compression Tighten adjusting screw

Damaged spring Disassemble and replace

Spring guide (8) is not in place Assemble properly

Yoke dragging on inlet nozzle

Disassemble and reassemble

properly (refer to Reassembly)

Fails to close when delivery

pressure rises

Spring compressed solid Back off adjusting screw

Mechanical obstruction

Disassemble and reassemble

properly (refer to Reassembly)

Worn disc

Disassemble remove and

replace disc retainer assembly

Yoke dragging on inlet nozzle

Disassemble and reassemble

properly (refer to Reassembly)

Leakage from

cover vent hole

Damaged diaphragm Disassemble and replace

Loose diaphragm nut Remove cover and tighten nut

Page 22

Pressure Reducing Control

(Bronze Body with 303SS Trim)

*SUGGESTED REPAIR PARTS

CRD

3 1/8

PRESSURE SETTING ADJUSTING SCREW (TURN CLOCKWISE TO INCREASE SETTING

SECTION A-A OPEN POSTION FOR HIGH PRESSURE CONTROL

5 3/8

1 13/16

inlet

cover vent

3/8" NPT

Body and Disc Retainer Detail

for Low Pressure

Control

SECTION B-B

CLOSED POSITION

When ordering parts specify:

• All nameplate data

• Item Description

• Item number

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

PL-CRD (R-8/2011)

PARTS LIST

Size

(inch)

Stock

Number

Adjustment Range

psi Ft of Water 3/8 7194307A 2 - 6.5 4.5 - 15 3/8 7194308J 2 - 30 4.5 - 69 3/8 7194303K 15 - 75 35 - 173 3/8 7194311C 20 - 105 46 - 242 3/8 7194304H 30 - 300 69 - 692

Factory Set Pressure

PSI per Turn*

2 - 6.5 set @ 3.5 psi .61

2 - 30 set @ 10 psi 3.0

15 - 75 set @ 20 psi 9.0 20 - 105 set @ 60 psi 12.0 30 - 300 set @ 60 psi 27.0

*Approximate-Final Adjustment should be

with a pressure gauge and with flow.

Item Description Material Part Number List Price

1 Cap PL 67628J

2 Adjusting Screw BRS 7188201D

3 Jam Nut (3/8-16) SS 6780106J

4* Machine Screw (Fil.Hd.) 8 Req'd 303 6757821B

5 Cover BRS C2544K

6 Nameplate Screw SS 67999D

7 Nameplate BRS C0022001G

8 Spring Guide 302 71881H

Spring Guide (20 - 105 psi) 303 205620F

9 Spring (15-75 psi) CHR/VAN 71884B

Spring (2 - 6.5 psi) SS 82575C

Spring (2 - 30 psi) SS 81594E

Spring (20 - 105 psi) 316 20632101E

Spring (30 - 300 psi) CHR/VAN 71885J

10 Hex Nut 303 71883D

11 Diaphragm Washer 302 71891G

12* Diaphragm NBR C6936D

13 Plug, Body BRS V5653A

14* Gasket Fiber 40174F

15 Plug BRS 6766003F

16* Disc Retainer Assy. (2 - 30 psi) SS/Rub C8348K

Disc Retainer Assy. (15 - 75 psi) SS/Rub 37133G

Disc Retainer Assy. (20 - 105 psi) SS/Rub 37133G

Disc Retainer Assy. (30 - 300 psi) SS/Rub 37133G

17 Yo ke VBZ V6951H

18 Body & 1/4" Seat Assy BR/SS 8339702G

19* Bucking Spring (2 - 6.5 psi)(2 - 30psi) 302 V0558G

20 Belleville Washer STL 7055007E

* Repair Kit (No Bucking Spring)

Buna®-N

9170003K

* Repair Kit (with Bucking Spring)

Buna®-N

9170002B

Page 23

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 counterclock

wise. 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

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

N-CRL (R-3/2011)

Page 24

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

(Bronze Body with 303SS Trim)

CRL

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

INLET

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

7.44 MAX

.71

OUTLET

0 TO 75 AND

20 TO 200 PSI

DESIGN

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

45º

3.12

DIA.

TRUE LOCATION OF SENSING CONNECTION (TYP.)

Body with integral Seat

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

PL-CRL (R-8/2011)

PARTS LIST

Item Description Material Part Number Part Number Part Number Part Number

0-75 20-105 20-200 100-300

1 Cap Plastic 67628J 67628J 67628J 1257601D 2 Nameplate Brass -- -- -- -3 Cover Bronze C2544K C2544K C2544K 44587E 4* Screw Fil. Hd. 10-32 x 1.88 (Qty 8) 303 SS 6757867E 6757867E 6757867E 6757867E 5* O-Ring Rubber 00902H 00902H 00902H 00902H 6 Body, Powerunit Bronze 7920504D 7920504D 7920504D 7920504D 7 1/2” Body Bronze C7928K C7928K C7928K C7928K

3/4” Body Bronze C9083B C9083B C9083B C9083B 8* O-Ring, Seat Rubber 00718H 00718H 00718H 00718H 9 Screw, Adjusting Brass 7188201D 7188201D 7188201D 82811B 10 Nut Hex (Locking) 303 SS 6780106J 6780106J 6780106J 6780606H 11 Guide, Spring 303 SS 71881H 71881H 71881H 1630301J 12 Spring CHR/VAN 71884B 20632101E 71885J 1630201A 13 Nut, Stem Upper Bronze 73034B 73034B 73034B 73034B 14 Washer, Belleville Steel 7055007E 7055007E 7055007E 7055007E 15 Washer, Diaphragm (upper) 303 SS 71891G 71891G 71891G 71891G 16* Diaphragm Rubber C1505B C1505B C1505B C1505B 17 Washer, Diaphragm (lower) 303 SS 45871B 45871B 45871B 45871B 18* O-Ring, Stem Rubber 00746J 00746J 00746J 00746J 19 Stem 303 SS 8982401F 8982401F 8982401F 8982401F 20* O-Ring, Body Rubber 00767E 00767E 00767E 00767E 21* Retainer Assembly, Disc 303 SS C9158B C9158B C9158B C9158B 22 Seat 303Rub 62187A 62187A 62187A 62187A 23 Nut, Hex, Stem, Lower Bronze 6779806G 6779806G 6779806G 6779806G 24 Pipe Plug Bronze 6784701C 6784701C 6784701C 6784701C

FACTORY SET POINT 50 PSI 60 PSI 60 PSI 100 PSI

REPAIR KIT* 9170007A 9170007A 9170007A 9170007A

CRL

Range PSI

APPROX. INCREASE

FOR EACH

CLOCKWISE TURN OF

ADJUSTING SCREW

0 to 75 8.5 PSI

20 to 105 12.5 PSI

20 to 200 28.0 PSI

100 to 300 18.0 PSI

SIZE SPRING

PART

NUMBER

1/2” 0-75 PSI 7922201E

1/2” 20-105 PSI 7922205F

1/2” 20-200 PSI 7922202C

1/2” 100-300 PSI 8280901D

3/4” 0-75 PSI 7922901K

3/4” 20-105 PSI 7922903F

3/4” 20-200 PSI 7922902H

3/4” 100-300 PSI 8600501E

For 250-600 PSI Contact Factory

Page 25

*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

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

PL-47117 AF (R-4/2010)

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

.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

.162 DIA. 32447F NATURAL S.S.

CDB-7

CRL-5A

CRL-13

10-60 10-60 10-60

12.0

.162 DIA. V5695B YELLOW MUSIC WIRE

CDB-7

CRL-5A

CRL-13

20-80 20-80 20-80

14.5

.207 DIA. C1124B CAD PLT MUSIC WIRE

CDB-7

CRL-13

CRL-5A

50-150 50-150 50-150

29.5

.225 DIA. V6515A RED MUSIC WIRE

CDB-7

CRL-13

CRL-5A

65-180 65-180 65-180

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 71885J 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

.440 X .219 48211H CAD PLT STEEL

CRA-18 CRD-22 CRL-4A

200-450 200-450 100-450

17.0

.187 20632101E BLACK 316 SST

CRD

CRL

20-105 20-105

13.0

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

.080 DIA. C0492D BLUE S.S.

CRA

CRD-2

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-6A

5-40

30-80

70-120 110-160 150-200

.75

1.50

2.20

3.00

3.70

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

Page 26

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

Male

Pipe

SAE

Male

Pipe

Width Across Flats

Female

Pipe

• Self Scrubbing Cleaning Action

• Straight Type or Angle Type

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

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

Dimensions

(In Inches)

INSTALLATION

X46 Angle Type B (In Inches)

(NPT)C(SAE)

DEH I

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

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

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

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

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

X46A Straight

X46B Angle

X46A Straight Type A (In Inches)

A B D E F G I

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

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

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

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

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

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

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

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

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

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

Flow Clean Strainer

X46

INSPECTION

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

CLEANING

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

REPLACEMENT

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

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

When Ordering, Please Specify:

• Catalog Number X46

• Straight Type or Angle Type

• Size Inserted Into and Size Connection

• Materials

DISASSEMBLY

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

MODEL

INSTALLATION / OPERATION / MAINTENANCE

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

N-X46 (R-3/2011)

(NPT) (NPT)

X46B

X46A

Page 27

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

PL-CK2 (R-3/2011)

Page 28

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

INSTALLATION / OPERATION / MAINTENANCE

Flow Control

MODEL

N-CV (R-3/2011)

DESCRIPTION

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

OPERATION

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

INSTALLATION

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

DISASSEMBLY

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

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

INSPECTION

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

CLEANING

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

REPAIR AND REPLACEMENT

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

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

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

REASSEMBLY

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

TEST PROCEDURE

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

Page 29

3/8" Flow Control

2.12 MAX

STAMP PART NO. ON SMOOTH SURFACE

RESTRICTED

FLOW

3/8 - 18 NPT

1.84

ADJUSTING STEM (TURN CLOCKWISE TO INCREASE RESTRICTION)

.85

FREE FLOW

BAR STOCK

CONFIGURATION

When ordering parts,

please specify:

• Number Stamped on Side

• Description (CV Flow Control)

• Part Description

• Material

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

PL-CV (R-3/2011)

PARTS LIST

ITEM DESCRIPTION QTY

Cap (SS only)

Nut, Jam

Seat

Gasket

Disc

Spring

Ring, Retaining

Stem

O-Ring

Housing

Page 30

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

Dimensions

Available only in replacement assembly.

PL-CDC-1 (R-6/2011)

NPT

Full Open Operation

NPT

Tight Closing Operation

NSF 61

Approved

Item Description Material

1 Body Brass

End

Connection

Brass

3 Disc Polytherimide

4 Seat NBR

5 Spring Stainless Steel

Size

(NPT)

Stock

Number

A B C I CVpsi Wt.

3/8" 9834501A 1.73 0.79 1.06 0.40 4.55 400 0.37

1/2" 9834502J 2.32 0.98 1.35 0.53 6.00 400 0.32

• NSF 61 Approved

• Meets low lead requirements

• Soft Seat for Bubble Tight Shutoff, Spring Loaded for

Fast Seating Action

• Compact Design

• Low Cracking Pressure 1/2 psi

• Flow Profile Designed to Minimize Head Loss

• Perfect Seating both at High and Low Pressure, Wide

Temperature Range: +10

° to 210°F

•

Polyethermide Disc to ensure the Best Resistance for

Corrosion and Abrasion

•

Patented Disc Guide to Prevent Any Side Loading

CDC-1

PARTS LIST

Check Valve (Sizes 3/8” and 1/2”)

MODEL

Page 31

3/8 NPT

2.06

2.72

Strainer

X43

Standard 60 mesh pilot system strainer for fluid service.

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

PL- X43 (R-3/2011)

PARTS LIST

ITEM DESCRIPTION MATERIAL

Pipe Plug Steel

Strainer Plug Brass

Gasket Copper

Screen SST

Body Brass

No parts available. Rreplacement assembly only.

Size Stock Number

3/8 x 3/8 33450J

Page 32

Cla-Val Product

Identification

Proper Identification

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

Identification Plates

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

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

INLET EINTRITT ENTREE ENTRADA

SIZE & CAT NO.

STOCK NO.

CODE

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

RESERVOIR

END

SIZE & CAT NO.

STOCK NO.

FLOW

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

CODE

™

SIZE & CAT NO.

STOCK NO.

SPRING RANGE

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

SIZE & CAT NO.

STOCK NO.

CODE

MFD. BY CLA-VAL

NEWPORT BEACH, CALIF.

U.S.A.

™

DO NOT REMOVE

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

REDUCED PRESSURE BACKFLOW PREVENTION DEVICE

STK. NO.

SER. NO.

CAT.

NO.

-4

CLA-VAL

NEWPORT BEACH, CA.

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

and is located on the top of the inlet flange.

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

valves and are located on the valve cover.

These two brass plates appear on threaded valves

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

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

This brass plate appears on altitude valves only and is

found on top of the outlet flange.

This brass plate is used to identify pilot control valves.

The adjustment range is stamped into the plate.

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

The adjustment range appears in the spring range section.

This aluminum plate is included in pilot system

modification kits and is to be wired to the new pilot

control system after installation.

This brass plate is used on our backflow prevention

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

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

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

the Number One check.

How to Order

Page 33

HOW TO ORDER

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

SPECIFY WHEN ORDERING

• Model Number • Valve Size

• Globe or Angle Pattern • Threaded or Flanged

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

• Pressure Class

UNLESS OTHERWISE SPECIFIED

• Globe or angle pattern are the same price

• Ductile iron body and bronze trim are standard

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

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

P. O. Box 1325

Newport Beach, California 92659-0325

(949) 722-4800

FAX (949) 548-5441

LIMITED WARRANTY

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

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

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

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

DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY

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

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

TERMS OF SALE

ACCEPTANCE OF ORDERS

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

CREDIT TERMS

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

PURCHASE ORDER FORMS

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

PRODUCT CHANGES

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

PRICES

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

RESPONSIBILITY

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

RISK

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

EXPORT SHIPMENTS

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

RETURNED GOODS

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

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

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

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

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

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

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

PO Box 1325 Newport Beach CA 92659-0325

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

LA-VAL

CLA-VAL CANADA CLA-VAL EUROPE

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

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

Specifications subject to change without notice.

www.cla-val.com

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

Represented By:

Page 34

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

For:

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

3/8"

1/2" - 3/4"

1 1/4"-1 1/2"

2 1/2"

3" 4"

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

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

N/A C2524B C2525J

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

40456G 45276D

81752J

85533J 89067D 89068B

N/A N/A

33273E 40456G 45276D 81752J

N/A 85533J 89068B 89068B

Valve

Size

Valve

Size

49097K

C2518D

C2520K

C2522 F

C2524B

C2523D

C2525J 33273E

100-01 100-20

Diaphragm Assembly

Stock Number

100-01 100-20

Diaphragm Assembly

Stock Number

3/8"

1/2" - 3/4"

1 1/4" - 1 1/2"

2 1/2"

3" 4" 6"

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

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

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

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

N/A 9817903K 9817905E 9817905E

3/8"

1/2" - 3/4"

1 1/4” - 1 1/2"

2 1/2"

3" 4" 6" 8"

9169806J 9169807G 9169808E 9169809C 9169810A

9169817F 9169818D 9169819B 9169820K 9169834A

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

9169810A

9169818D

9169819B 9169820K

Valve

Size

Valve

Size

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

N/A

9817906C

100-01 100-20

Repair Kit

Stock Number

100-01 100-20

Repair Kit

Stock Number

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

For:

Hytrol Main Valves—125/150 Pressure Class Only.

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

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

REPAIR KITS

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

MINIMUM ORDER CHARGE APPLIES.

Buna-N®Standard Material

Viton (For KB Valves)

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Page 35

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

For:

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

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

Larger Sizes: Consult Factory.

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

For:

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

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

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

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

Repair Assemblies (In Standard Materials Only)

CLA-VAL

P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com

N-RK (R-3/2011)

Valve

Size

Kit Stock Number

100-02

Valve

Size

Kit Stock Number

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

⁄8”

9169901H

⁄2”

9169910J N/A

⁄2” &3⁄4”

9169902F

3”

9169911G 9169905J

1” 9169903D

4”

9169912E 9169911G

⁄4” &11⁄2”

9169904B

6”

9169913C 9169912E

2” 9169905J

8”

99116G 9169913C

10”

9169939H 99116G

12"

9169937B 9169939H

Valve

Size

Kit Stock Number

Valve

Size

Kit Stock Number

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

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

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

24” N/A 20210907F

BUNA-N

(Standard Material)

VITON (For KB Controls)

Pilot

Control

Kit

Stock

Number

Pilot

Control

Kit

Stock

Number

Pilot

Control

Kit

Stock

Number

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

CRD-KB (w/bucking spring)

9170008J

CDB-7 9170017K

CRA (w/bucking spring)

9170001D CRL-KB 9170013J

CDH-2 18225D

CRD (w/bucking spring)

9170002B CDHS-2BKB 9170010E

CDHS-2 44607A

CRD (no bucking spring)

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

102C-KB

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

Buna-N

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

102C-3 1726201F

Control Description Stock Number

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

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

Larger Sizes: Consult Factory.

Cla-Val 94-01-694-01 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual