Claval PRV TM-90-01

90-01/690-01DescriptionTheCIa-VaIModel100-01HytrolValveisamainvalveforCIa-VaIAutomatic Control Valves. It is a hydraulically operated, diaphragm-actu-ated, globe or angle pattern valve.This valve consists of three major components; body, diaphragm assem-bly,andcover.Thediaphragmassemblyistheonlymovingpart.Thediaphragm assembly uses a diaphragm of nylon fabric bonded with syn-theticrubber. Asyntheticrubberdisc,containedonthreeandonehalfsides by a disc retainer and disc guide, forms a seal with the valve seatwhen pressure is applied above the diaphragm. The diaphragm assem-bly forms a sealed chamber in the upper portion of the valve, separatingoperating pressure from line pressure.Installation1. 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 onboth ends of the 100-01 Hytrol Valve to facilitate isoIating the valve forpreventive maintenance and repairs.3. Place the valve in the line with flow through the valve in the direc-tionindicatedontheinletnameplate.(SeeFlowDirectionSection)Note: Valve can be installed in the vertical or horizontal position.4. Allow sufficient room around valve to make adjustments and for dis-assembly.5. CIa-VaI 100-01 Hytrol Valves operate with maximum efficiency whenmounted in horizontal piping with the cover UP, however, other posi-tions are acceptable. Due to size and weight of the cover and internalcomponents of 8 inch and larger valves, installation with the cover UPis advisable. This makes internal parts readily accessible for periodicinspection.6.Cautionmustbetakenintheinstallationofthisvalvetoinsure that galvanic and/or electrolytic action does not takeplace.Theproperuseofdielectricfittingsandgasketsarerequired in all systems using dissimilar metals.7.Ifapilotcontrolsystemisinstalledonthe100-01HytrolValve,usecaretopreventdamage.Ifitisnecessarytoremove fittings or components, be sure they are kept cleanand replaced exactly as they were.8. After the valve is installed and the system is first pressur-ized, vent air from the cover chamber and pilot system tub-ing by loosening fittings at all high points.Tight Closing OperationWhenpressurefromthevalveinlet(oranequivalentindependentoperatingpressure)isappliedtothediaphragmchamber the valve closes drip-tight.Full Open OperationWhenpressureindiaphragmchamberisrelievedtoazoneoflowerpressure(usuallyatmosphere)thelinepressure(5 psi Min.) at the valve inlet opens thevalve.Modulating ActionValve modulates when diaphragm pres-sureisheldatanintermediatepointbetweeninletanddischargepressure.WiththeuseofaCla-Val."modulatingcontrol,"whichreactstolinepressurechanges,thepressureabovethediaphragm is varied, allowing the valvetothrottleandcompensateforthechange.Principles of OperationThree Way Pilot ControlThree Way Pilot ControlRestrictionModulatingControl100-01Hytrol Valve MODELINSTALLATION / OPERATION / MAINTENANCE2Flow DirectionTheflowthroughthe100-01HytrolValvecanbeinoneoftwodirections.Whenflowisup-and-overtheseat,itisinnormalflow and the valve will fail in the open position. When flow is over-the seat-and down, it is in reverse flow and the valve will fail inthe closed position. There are no permanent flow arrow markings.The valve must be installed according to nameplate data.BRIDGEWALL INDlCATORNormal Flow Reverse FlowTroubleshootingThefollowingtroubleshootinginformationdealsstrictlywiththeModel 100-01 Hytrol Valve. This assumes that all othercompo-nents of the pilot control system have been checked out and areinproperworkingcondition.(SeeappropriatesectionsinTechnical Manual for complete valve). Three ChecksThe 100-01 Hytrol Valve has only one moving part (the diaphragmand disc assembly). So, there are only three major types of prob-lems to be considered.First: Valve is stuck - that is, the diaphragm assembly is not freetomovethroughafullstrokeeitherfromopentocloseorviceversa.Second: Valve is free to move and cant close because of a wornout diaphragm.Third: Valveleakseventhoughitisfreetomoveandthediaphragm isnt 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.Insufficientline pressure.Diaphragm assembly inoperative.Corrosion or excessivebuildup 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 theproblem before maintenance is started. They must be done in the order shown.Open Isolation valves.Check upstream pressure, pilot system, strainer, tubing, valves, or needlevalves for obstruction.Replace diaphragm.Clean and polish stem. Inspect and replace any damaged or badly erodedpart.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 anydamaged or badly eroded part.Replace diaphragm.Fails to CloseFails to OpenCAUTION:Care should be taken when doing the troubleshooting checks onthe100-01HytrolValve.Thesechecksdorequirethevalvetoopenfully.Thiswilleitherallowahighflowratethroughthevalve,orthedownstreampressurewillquicklyincreasetotheinlet pressure. In some cases, this can be very harmful. Wherethis is the case, and there are no block valves in the system toprotectthedownstreampiping,itshouldberealizedthatthevalvecannotbeservicedunderpressure. Stepsshouldbetaken to remedy this situation before proceeding any further.(cast into side of valve body)SYMPTOM PROBABLE CAUSE REMEDYRecommended Tools1.Three pressure gauges with ranges suitable to the instal-lation to be put at Hytrol inlet, outlet and cover connections.2. Cla-Val Model X101 Valve Position Indicator.This pro-vides visual indication of valve position without disassemblyof valve.3.Other items are:suitable hand tools such as screw-drivers, wrenches, etc. soft jawed (brass or aluminum) vise,400 grit wet or dry sandpaper and water for cleaning.Alltroubleshootingispossiblewithoutremovingthevalvefromtheline or removing the cover. It is highly recommended to permanentlyinstallaModelX101ValvePositionIndicatorandthreegaugesinunused Hytrol inlet, outlet and cover connections.Diaphragm Check (#1 )1. Shut off pressure to the Hytrol Valve by slowly closing upstreamand downstream isolation valves. SEE CAUTION.2. Disconnect or close all pilot control lines to the valve cover andleave only one fitting in highest point of cover open to atmosphere.3.Withthecoverventedtoatmosphere,slowlyopenupstreamisolation valve to allow some pressure into the Hytrol Valve body.Observe the open cover tapping for signs of continuous flow.It isnot necessary to fully open isolating valve. Volume in cover cham-ber capacity chart will be displaced as valve moves to open posi-tion.Allowsufficienttimefordiaphragmassemblytoshiftposi-tions. If there is no continuous flow, you can be quite certain thediaphragmissoundandthediaphragmassemblyistight.Ifthefluid appears to flow continuously this is a good reason to believethediaphragmiseitherdamagedoritislooseonthestem.Ineither case, this is sufficient cause to remove the valve cover andinvestigate the leakage. (See Maintenance Section for procedure.)Freedom of Movement Check (#2)4. DeterminingtheHytrolValvesfreedomofmovementcanbedone by one of two methods.5. FormostvalvesitcanbedoneaftercompletingDiaphragmCheck (Steps 1, 2, and 3). SEE CAUTION. At the end of step 3the valve should be fully open.6. If the valve has a Cla-Val X101 Position Indicator, observe theindicator to see that the valve opens wide. Mark the point of max-imum opening.7.Re-connectenoughofthecontrolsystemtopermittheappli-cationofinletpressuretothecover.Openpilotsystemcocksopressure flows from the inlet into the cover.8.Whilepressureisbuildingupinthecover,thevalveshouldclose smoothly. There is a hesitation in every Hytrol Valve closure,whichcanbemistakenforamechanicalbind.Thestemwillappear to stop moving very briefly before going to the closed posi-tion.Thisslightpauseiscausedbythediaphragmflexingataparticularpointinthevalvestravelandisnotcausedbyamechanical bind.9. When closed, a mark should be made on the X101 Valve posi-tion indicator corresponding to the closed position. The distancebetween the two marks should be approximately the stem travelshown in chart.10. Ifthestrokeisdifferentthanthatshowninstemtravelchartthis is a good reason to believe something is mechanically restrict-ing the stroke of the valve at one end of itstravel. If the flow doesnot stop through the valve when in the indicated closed position,theobstructionprobablyisbetweenthediscandtheseat.Iftheflow does stop, then the obstruction is more likely in the cover. Ineither case, the cover must be removed, and the obstruction locat-ed and removed. The stem should also be checked for scale build-up. (See Maintenance, section forprocedure.)11. For valves 6 and smaller, the Hytrol Valves freedom of move-ment check can also be done after all pressure is removed fromthevalve.SEECAUTION. Afterclosinginletandoutletisolationvalves and bleeding pressure from the valve, check that the coverchamberandthebodyaretemporarilyventedtoatmosphere.Insert fabricated tool into threaded hole in top of valve stem, andliftthediaphragmassemblymanually.Noteanyroughness.Thediaphragmassemblyshouldmovesmoothlythroughoutentirevalvestroke.Thetoolisfabricatedfromrodthatisthreadedonone end to fit valve stem and has a T bar handle of some kindontheotherendforeasygripping.(SeechartinStep4ofDisassembly Section.)12. Place marks on this diaphragm assembly lifting tool when thevalve is closed and when manually positioned open. The distancebetweenthetwomarksshouldbeapproximatelythestemtravelshowninstemtravelchart.Ifthestrokeisdifferentthanthatshown, there is a good reason to believe something is mechani-callyrestrictingthestrokeofthevalve.Thecovermustberemoved,andtheobstructionlocatedandremoved.Thestemshouldalsobecheckedforscalebuild-up.(SeeMaintenanceSection for procedure.)Tight Sealing Check (#3)13. Test for seat leakage after completing checks #1 & #2 (Steps1 to 12). SEE CAUTION. Close the isolation valve downstream ofthe Hytrol Valve. Apply inlet pressure to the cover of the valve, waituntilitcloses.Installapressuregaugebetweenthetwoclosedvalves using one of the two ports in the outlet side of the Hytrol.Watchthepressuregauge.Ifthepressurebeginstoclimb,theneitherthedownstreamisolationvalveispermittingpressuretocreepback,ortheHytrolisallowingpressuretogothroughit.Usually the pressure at the Hytrol inlet will be higher than on theisolationvalvedischarge,soifthepressuregoesuptotheinletpressure,youcanbesuretheHytrolisleaking.Installanothergauge downstream of isolating valve. If the pressure between thevalvesonlygoesuptothepressureontheisolationvalvedischarge, the Hytrol Valve is holding tight, and it was just the iso-lation valve leaking.STEM TRAVEL(Fully Open to Fully Closed)Valve Size (inches) Travel (inches)Inches MM Inches MM1 1/4 32 0.4 101 1/2 40 0.4 102 50 0.6 152 1/2 65 0.7 183 80 0.8 204 100 1.1 286 150 1.7 438 200 2.3 5810 250 2.8 7112 300 3.4 8614 350 4.0 10016 400 4.5 11420 500 5.6 14324 600 6.7 16530 800 7.5 19036 900 8.5 216COVER CHAMBER CAPACITY(Liquid Volume displaced when valve opens)Valve size (inches) DisplacementGallons Liters1 1/4 .020 .071 1/2 .020 .072 .032 .122 1/2 .043 .163 .080 .304 .169 .646 .531 2.08 1.26 4.810 2.51 9.512 4.00 15.114 6.50 24.616 9.57 36.220 12.00 45.424 29.00 109.830 42.00 197.036 90.00 340.03Maintenance Preventative MaintenanceThe Cla-Val Co. Model 100-01 Hytrol Valve requires no lubrication orpacking and a minimum of maintenance. However, a periodic inspec-tion schedule should be established to determine how the operatingconditions of the system are affecting the valve. The effect of theseactions must be determined by inspection.DisassemblyInspectionormaintenancecanbeaccomplishedwithoutremovingthe valve from the line.Repair kits with new diaphragm and disc arerecommended to be on hand before work begins.WARNING:Maintenancepersonnelcanbeinjuredandequipmentdamaged if disassembly is attempted with pressure in the valve. SEECAUTION.1. Close upstream and downstream isolation valves and independ-entoperatingpressurewhenusedtoshutoffallpressuretothevalve.2. Loosentubefittingsinthepilotsystemtoremovepressurefromvalvebodyandcoverchamber.Afterpressurehasbeenreleasedfrom the valve, use care to remove the controls and tubing. Note andsketchposition of tubing and controls for re-assembly. The schemat-icinfrontoftheTechnicalManualcanbeusedasaguidewhenreassembling pilot system.3. Removecovernutsandremovecover.Ifthevalvehasbeeninservice for any length of time, chances are the cover will have to beloosened by driving upward along the edge of the cover with a dullcold chisel.On 6 and smaller valves block and tackle or a power hoist can beused to lift valve cover by inserting proper size eye bolt in place ofthe center cover plug. on 8 and larger valves there are 4 holes (5/8 11 size) where jacking screws and/or eye boltsmay be insertedfor lifting purposes. Pull cover straight up to keep from damagingtheintegral seat bearing and stem.4.Removethediaphragmanddiscassemblyfromthevalvebody.Withsmallervalvesthiscanbeaccomplishedbyhandbypullingstraight up on the stem so as not to damage the seat bearing.Onlargevalves,aneyeboltofpropersizecanbeinstalledinthestem and the diaphragm assembly can be then lifted with a block andtackle or power hoist. Take care not to damage the stem or bearings.The valve won't work if these are damaged.5. Thenextitemtoremoveisthestemnut.Examinethestemthreads above the nut for signs of mineral deposits or corrosion.If the threads are not clean, use a wire brush to remove as muchof the residue as possible. Attach a good fitting wrench to the nutandgiveitasharprapratherthanasteadypull.Usuallyseveral blows are sufficient to loosen the nut for further removal.On the smaller valves, the entire diaphragm assembly can be heldbythesteminaviseequippedwithsoftbrassjaws beforeremoving the stem nut.The use of a pipe wrench or a vise without soft brass jaws scarsthefinefinishonthestem.Noamountofcarefuldressingcanrestore the stem to its original condition. Damage to the finish ofthe stem can cause the stem to bind in the bearings and the valvewill not open or close.6. After the stem nut has been removed, the diaphragm assemblybreaks down into its component parts. Removal of the disc fromthe disc retainer can be a problem if the valve has been in serv-ice for a long time. Using two screwdrivers inserted along the out-sideedgeofthediscusuallywillaccomplishitsremoval.Careshould be taken to preserve the spacer washers in water, partic-ularly if no new ones are available for re-assembly.7. The only part left in the valve body is the seat which ordinarilydoes not require removal. Careful cleaning and polishing of insideandoutsidesurfaceswith400wet/drysandpaperwillusuallyrestoretheseatssharpedge.If,however,itisbadlywornandreplacement is necessary, it can be easily removed.Seats in valve sizes 1 1/4 through 6 are threaded into the valvebody.They can be removed with accessory X109 Seat RemovingTool available from the factory. On 8 and larger valves, the seatis held in place by flat head machine screws.Use a tight-fitting,long shank screwdriver to prevent damage to seat screws. If uponremoval of the screws the seat cannot be lifted out, it will be nec-essary to use a piece of angle or channel iron with a hole drilledin the center. Place it across the body so a long stud can be insert-ed through thecenter hole in the seat and the hole in the angleiron.Bytighteningthenutauniformupwardforceisexertedonthe seat for removal.NOTE: Do not lift up on the end of the angle iron as this may forcethe integral bearing out of alignment, causing the stem to bind.VALVE STEM THREAD SIZEValve SizeThread Size (UNF Internal)1 1/4"2 1/2" 10323"4" 1/4286"14" 3/82416" 1/22020 3/4-1624" 3/4-1630 3/4-1636 3/4-16COVER CENTER PLUG SIZEValve 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 2NUTANGLE OR CHANNEL IRONLONG STUD OR BOLTNUT OR BOLT HEADDO NOTLIFTVALVE SEATVALVE BODY4Lime DepositsOne of the easiest ways to remove lime deposits from the valvestem or other metal parts is to dip them in a 5-percent muriaticacidsolutionjustlongenoughforthedeposittodissolve.Thiswillremovemostofthecommontypesofdeposits.CAUTlON:USE EXTREME CARE WHEN HANDLING ACID. Rinse parts inwater before handling. If the deposit is not removed by acid, thena fine grit (400) wet or dry sandpaper can be used with water.Reassembly1. Reassembly is the reverse of the disassembly procedure. If anew disc has been installed, it may require a different number ofspacer washers to obtain the right amount of grip on the disc.Whenthediaphragmassemblyhasbeen tightenedtoapointwhere the diaphragm cannot be twisted, the disc should be com-pressed very slightly by the disc guide. Excessive compressionshould be avoided. Use just enough spacer washers to hold thedisc firmly without noticeable compression.2. MAKE SURE THE STEM NUT IS VERY TIGHT. Attach a goodfittingwrenchtothenutandgiveitasharpraprather thanasteadypull.Usuallyseveralblowsaresufficientto tightenthestemnutforfinaltightening.Failuretodoso couldallowthediaphragm to pull loose and tear when subjected to pressure.Test Procedure After Valve AssemblyThere are a few simple tests which can be made in the field tomakesuretheHytrolValvehasbeenassembledproperly. Dothesebeforeinstallingpilotsystemandreturningvalvetoservice.These are similar to the three troubleshooting tests.1. Checkthediaphragmassemblyforfreedomofmovementafterallpressureisremovedfromthevalve.SEECAUTlON.Insert fabricated tool into threaded hole in top of valve stem, andliftthediaphragmassemblymanually.Noteanyroughness,stickingorgrabbing.Thediaphragmassemblyshould movesmoothlythroughoutentirevalvestroke.Thetoolis fabricatedfrom rod that is threaded on one end to fit valve stem (See chartin Step 4 of Disassembly section.) and has a T Bar handle ofsome kind on the other end for easy gripping.Placemarksonthisdiaphragmassemblyliftingtoolwhen thevalveisclosedandwhenmanuallypositionedopen.The dis-tance between the two marks should be approximately the stemtravel shown in stem travel chart. (See Freedom of MovementCheck section.) If the stroke is different than that shown, thereis a good reason to believe something is mechanically restrictingthe stroke of the valve. The cover must be removed, the obstruc-tionlocatedandremoved. (SeeMaintenanceSectionforprocedure.)Inspection of PartsAfterthevalvehasbeendisassembled,eachpartshouldbeexaminedcarefullyforsignsofwear,corrosion,oranyotherabnormal condition. Usually, it is a good idea to replace the rub-ber parts (diaphragm and disc) unless they are free of signs ofwear. These are available in a repair kit. Any other parts whichappeardoubtfulshouldbereplaced. WHENORDERlNGPARTS,BESURETOGIVECOMPLETE NAMEPLATEDATA,ITEMNUMBER AND DESCRlPTlON.NOTE:Ifanewdiscisntavailable,theexistingdisccanbeturnedover,exposingtheunusedsurfaceforcontactwiththeseat. The disc should be replaced as soon as practical.3. Carefully install the diaphragm assembly by lowering the stemthrough the seat bearing. Take care not to damage the stem orbearing. Line up the diaphragm holes with the stud or bolt holeson the body. on larger valves with studs, it may be necessary toholdthediaphragmassemblyuppartway whileputtingthediaphragm over the studs.4. Put spring in place and replace cover. Make sure diaphragmis Iying smooth under the cover.5. Tightencovernutsfirmlyusingacross-overpatternuntil allnuts are tight.6. Test Hytrol Valve before re-installing pilot valve system.Due to the weight of the diaphragm assembly this procedure isnot possible on valves 8 and larger. on these valves, the samedeterminationcanbemadebycarefullyintroducinga lowpressure-lessthanfivepsi)intothevalvebodywiththe covervented.SEECAUTION.Lookingincovercenterholesee thediaphragmassemblylifteasilywithouthesitation,and thensettle back easily when the pressure is removed.2. Tocheckthevalvefordrip-tightclosure,alineshouldbeconnected from the inlet to the cover, and pressure applied at theinletofthevalve.Ifproperlyassembled,thevalveshould holdtightwithaslowastenPSIattheinlet.SeeTightSealingCheck section.)3. With the line connected from the inlet to the cover, apply fullworking pressure to the inlet. Check all around the cover for anyleaks. Re-tighten cover nuts if necessary to stop leaks past thediaphragm.4. Remove pressure, then re-install the pilot system and tubingexactlyasitwaspriortoremoval.Bleedairfromallhighpoints.5. FollowstepsunderStart-UpandAdjustmentSectioninTechnical Manual for returning complete valve back to service.51581014 1661779OUTLET INLETGLOBE PATTERN9262712151416INLETOUTLETANGLE PATTERN22 2313 12 14 10 11 15 23TOP VIEW8" - 24" SEAT DETAIL 1 1/4" - 6" SEAT DETAIL 16" COVER DETAIL4242251331283029 5143Item Description1. Pipe Plug2. Drive Screws (for nameplate)3. Hex Nut (8 and larger)4. Stud (8 and larger)5. Cover Bearing6. Cover7. Stem Nut8. Diaphragm Washer9. Diaphragm10. Spacer Washers11. Disc Guide12. Disc Retainer13. Disc14. Stem15. Seat16. Body17. Spring22. Flat Head Screws (8 and larger)23. Seat O-Ring24. Hex head Bolt (1 1/4 thru 4)25. Nameplate26. 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 LIST6100-01Hytrol Valve Service Data MODELINSTALLATION / OPERATION / MAINTENANCEDescription 100-01 Hytrol ValveThe CIa-VaI Model 100-01 Hytrol Valve is a main valve forCIa-VaI Automatic Control Valves. It is a hydraulically operated,diaphragm-actuated, globe or angle pattern valve.This valve consists of three major components; body, diaphragmassembly, and cover. The diaphragm assembly is the onlymoving part. The diaphragm assembly uses a diaphragm of nylonfabric bonded with synthetic rubber. A synthetic rubber disc,contained on three and one half sides by a disc retainer and discguide, forms a seal with the valve seat when pressure is appliedabove the diaphragm. The diaphragm assembly forms a sealedchamber in the upper portion of the valve, separating operatingpressure from line pressure.Description 100-20 600 Series Hytrol ValveThe CIa-VaI Model 100-20 Hytrol Valve (600 Series main valve)have only one part -the body- that is different from standard 100Series Cla-Val main valve parts. The remaining parts of the 600series main valve are standard Cla-Val main valve parts. All serv-ice and maintenance information for the standard 100 Seriesmain valves also apply to the 600 series main valves. The most important thing to remember when ordering mainvalve repair kits and replacement parts, except for the body, allother 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 Sizeschart below.HYTROL Service DataHYTROL SIZEStemTravelCover CapacityDisplacementValve StemThreadUNF-InternalCoverCenterPlugNPTCover Nut or BoltCoverLiftingHolesUNCCover PlugCover TorqueStem Nut**Stem Nut Torque(ft. Lbs.)100-01100-20Thread(Bolt)SocketQtyThreadSocketft. Lbs.in. Lbs.ThreadSocket(Long)inchesmminchesmminchesmmGallonsLitersLubedDRY1"250.381/4"1/4" - 20 (B)7/16"84483/8" - 24461 1/4"320.4100.0200.0710 - 321/4"5/16" - 18 (B)1/2"88967/16" -206101 1/2"400.4100.0200.0710 - 321/4"5/16" - 18 (B)1/2"88967/16" -206102"500.6150.0320.1210 - 321/2"3/8" - 16 (B)9/16"83/8"7/16"121/2" - 203/4"10152 1/2"650.7180.0430.1610 - 321/2"7/16" - 14 (B)5/8"81/2"9/16"205/8" - 1815/16"21303"804"1000.8200.0800.301/4 - 281/2"1/2" - 13 (B)3/4"81/2"9/16"305/8" - 1815/16"21304"1006"1501.1230.1690.641/4 - 283/4"3/4" - 10 (B)1 1/8"83/4"5/8"1103/4" - 161 1/16"40606"1508"2001.7430.5312.003/8 - 243/4"3/4" - 10 (B)1 1/8"123/4"5/8"1107/8" - 141 5/16"851258"20010"2502.3581.264.803/8 - 241"3/4" - 101 1/4"165/8" - 111"13/16"1101 1/8" -121 13/16"12518510"25012"3002.8712.519.503/8 - 241"7/8" - 91 7/16"203/4" - 101"13/16"1601 1/2" -121 7/8"25237512"30016"4003.4864.015.103/8 - 241 1/4"1 1/8" - 71 13/16"203/4" - 101"13/16"3901 1/2" -122 1/2"27040014"3503.9996.524.603/8 - 241 1/2"1 1/4" - 72"201" - 81"13/16"5451 1/2" -122 1/2"28042016"40020", 24"6004.51149.636.201/2 - 202"1 1/4" - 72"201" - 81"13/16"5452" - 163"50075020"5005.631431245.403/4 - 161 1/2"1 3/8" - 62 1/8"241" - 81"13/16"6702 1/4" - 163 1/2"930N/R24"60030"8006.7516529.0108.803/4 - 16*3/4"1 1/2" - 122 3/8"241 1/8"- 71"13/16"8003" - 12Special1350N/R* Adapterp/n 2594101Einside 1/4" - 28"Grade 5 Bolts"Heavy" Grade NutsTighten cover nuts in a "star" cross-over pattern** Must Use ONLYCla-Val Supplied partCLA-VAL Copyright Cla-Val 2014 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comCOVER 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 OptionN-100-01 (R-08/2014)BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS4BOLTS6BOLTS8BOLTS12BOLTS16BOLTS20BOLTS43216543218765432109876543211211109876543211615141312111098765432120191817161514131211Follow 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 diaphragmmaterial and body.2. Torque the bolt/nuts in three stages with a "Star" or "Cross-Over" patternfor 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 AssemblyUNDERSTANDING THE 600 SERIES VALVESIn 1987, Cla-Val introduced the Model 100-20 Hytrol as the basicmain valve for the 600 Series of automatic control valves.Toidentify all new valves using the 100-20 Hytrol, an existing cata-log number is modified.Making a 600 Series catalog number issimply done by using a "6" in front of the two digit catalog num-bers or replacing the "2" with a "6" in three digit catalog num-bers.Current schematics reflect both catalog numbers togetherseparated by a slash ( i.e. - 90-01/690-01, 58-02/658-02, 210-01/610-01, etc).Since these two valves 'share' the same catalognumber and schematic, they provide the same function in a sys-tem.The only difference between the two valves is the relativecapacity of the two main valve series.The 100-01 Hytrol is the basic main valve for Cla-Val automaticcontrol valves.This valve is the current version of the ClaytonHytrol valve design originated in 1936.The 100-01 Hytrol isdesigned as a full flow area valve.This means that the inlet,seat and outlet openings are the same size.Thus, the pressuredrop is kept to a minimum for this globe style design.The 100-20 Hytrol valve has all of the basic features and advan-tages of the original 100-01 Hytrol.Only one part has beenchanged - the body.It is designed with different size inlet, seatand outlet openings.The 100-20 Hytrol has inlet and outletflanges one valve size larger than the seat opening size.Thisresults in what is sometimes called a ''reduced port' main valve.For example, a 4" 100-20 valve has a 3" seat.Note: valve sizeis always determined by the flange size.The following chartcompares the 100-01 and the 100-20 main valves.600 Series Hytrol Valve100-20MODELINSTALLATION / OPERATION / MAINTENANCESERVICE AND MAINTENANCE OF 600 SERIESVALVESThe 600 series main valves have only one part -the body- that isdifferent from standard 100 Series Cla-Val main valve parts.Theremaining parts of the 600 series main valve are standard Cla-Val main valve parts.All service and maintenance informationfor the standard 100 Series main valves in this manual alsoapply to the 600 series main valves. The most important thing to remember when ordering main valverepair kits and replacement parts, except for the body, all otherparts are going to be for a smaller size main valve.Cla-Val iden-tifies main valve parts with the flange size of the standard 100Series main valve.Refer to the "Main Valve Sizes Comparison"chart.For example, if you are servicing a 6" 100-20 Hytrol andneeded a repair kit, you would order a repair kit for a 4" 100-01Hytrol. This kit is also suitable for a 6" 100-20 Hytrol.CompleteTechnical Manuals include a repair kit data sheet N-RK thatshows this relationship. When you order repair parts, it is a good idea to include valvenameplate data (size, catalog number, and part number) anddescription of the parts desired.Do this to be sure parts will fitthe valve you are working on and not be too big for it.Pilot con-trols and repair kits maintenance information remain the samefor 100 or 600 Series valves.Cla-Val Main ValvesCatalog NumberThe 100-20 Hytrol is available only in ductile iron, 150 and 300pressure class, and Bronze trim standard.Available extra costmain valve options include stainless steel trim, epoxy coating,Dura-Kleen stem, Delrin sleeved stem, and high temperature rub-ber parts.All four basic main valves have a 600 Series versionavailable with all of the same benefits and size relationships.The following chart shows the relationship of Cla-Val main valvecatalog numbers.Catalog NameHytrolPowertrolPowercheckHycheckCirca 1936 100 (Angle =2100)100P & 100PA100PC & 100PCA181100-Series100-01100-02100-03100-04600 Series100-20100-21100-22100-23(Reduced Internal Port)Basic Main Valve Size ComparisonGlobe Pattern ValvesFlange Size (inch)Seat Size100-01 (100 Series) 100-20 (600 Series)3 3 24 4 36 6 48 8 610 10 812 12 1014 14 ----16 16 1218 ---- 1620 20 1624 24 1630 30 2436 36 3042 ---- 3648 ---- 36Angle Pattern ValvesFlange Size (inch)Seat Size100-01 (100 Series) 100-20 (600 Series)4 4 36 6 48 8 6CLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comN-100-20(R-3/2011)100-20PARTS LISTNO. DESCRIPTION1 Pipe Plug2 Drive Screws (for nameplate)3 Hex Nut (8" and larger)4 Stud (8" and larger)5 Cover Bearing6 Cover7 Stem Nut8 Diaphragm Washer9 Diaphragm10 Spacer Washers11 Disc Guide12 Disc Retainer13 Disc14 Stem15 Seat16 Body17 Spring22 Flat Head Screws (10" and larger)23 Seat O-Ring24 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"")11141 24 3 451716261478927141322121531285302910" 24" SEAT DETAIL 20" 24" COVER DETAILTOP VIEW121315OUTLETGLOBEINLETANGLEINLET6892253" 6" COVER DETAIL2311WHEN ORDERING PARTS, BE SURE TO GIVE COMPLETENAMEPLATE DATA, ITEM NUMBER AND DESCRIPTION.10DESCRIPTIONThe Cla-Val Model CRD Pressure Reducing Control automatically reducesa higher inlet pressure to a lower outlet pressure. It is a direct acting,spring loaded, diaphragm type control that operates hydraulically or pneu-matically. It may be used as a self-contained valve or as a pilot control fora Cla-Val main valve. It will hold a constant downstream pressure withinvery close pressure limits.OPERATIONThe CRD Pressure Reducing Control is normally held open by the force ofthe compression spring above the diaphragm; and delivery pressure actson the underside of the diaphragm.Flow through the valve responds tochanges in downstream demand to maintain a pressure.INSTALLATIONThe CRD Pressure Reducing Control may be installed in any position.There is one inlet port and two outlets, for either straight or angle installa-tion.The second outlet port can be used for a gage connection.A flowarrow is marked on the body casting.ADJUSTMENT PROCEDUREThe CRD Pressure Reducing Control can be adjusted to provide a deliv-ery pressure range as specified on the nameplate.Pressure adjustment is made by turning the adjustment screw to vary thespring pressure on the diaphragm. The greater the compression on thespring the higher the pressure setting.1. Turn the adjustment screw in (clockwise) to increasedelivery 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 settingCRDMAINTENANCEDisassemblyTo disassemble follow the sequence of the item numbers assigned toparts in the sectional illustration.ReassemblyReassembly is the reverse of disassembly.Caution must be taken toavoid 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 ofbody screw holes 1/8".Repeat assembly procedure until diaphragm and yoke are properlyaligned.There must be no contact between yoke and body nozzleduring its normal movement.To simulate this movement hold bodyand diaphragm holes aligned.Move yoke to open and closed posi-tions.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), thencap (1).Pressure Reducing ControlThe approximate minimum flow rates given in the table are for the main valveon which the CRD is installed.Valve SizeMinimum Flow GPM1 1/4" -3"4"-8"10"-16"15-3050-200300-650MODELINSTALLATION / OPERATION / MAINTENANCECLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comN-CRD (R-3/2011)SYMPTOM PROBABLE CAUSE REMEDYFails to openwhen deliver pres-sure lowersNo spring compression Tighten adjusting screwDamaged spring Disassemble and replaceSpring guide (8) is not in place Assemble properlyYoke dragging on inlet nozzleDisassemble and reassembleproperly (refer to Reassembly)Fails to closewhen deliverypressure risesSpring compressed solid Back off adjusting screwMechanical obstructionDisassemble and reassembleproperly (refer to Reassembly)Worn discDisassemble remove andreplace disc retainer assemblyYoke dragging on inlet nozzleDisassemble and reassembleproperly (refer to Reassembly)Leakage fromcover vent holeDamaged diaphragm Disassemble and replaceLoose diaphragm nut Remove cover and tighten nutPressure Reducing Control(Bronze Body with 303SS Trim)*SUGGESTED REPAIR PARTSCRD3 1/8PRESSURE SETTINGADJUSTING SCREW(TURN CLOCKWISETO INCREASE SETTINGSECTION A-AOPEN POSTIONFOR HIGH PRESSURE CONTROL5 3/81 13/16inletB13 1416181712111098531 2cover ventB3/8" NPT1619Body and DiscRetainer Detailfor Low Pressure ControlSECTION B-BCLOSED POSITION201817154A A6 7When ordering parts specify: All nameplate data Item Description Item numberCLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comPL-CRD (R-8/2011)PARTS LISTSize(inch)StockNumberAdjustment Rangepsi Ft of Water3/8 7194307A 2 - 6.5 4.5 - 153/8 7194308J 2 - 30 4.5 - 693/8 7194303K 15 - 75 35 - 1733/8 7194311C 20 - 105 46 - 2423/8 7194304H 30 - 300 69 - 692Factory Set Pressure PSI per Turn*2 - 6.5 set @ 3.5 psi .612 - 30 set @ 10 psi 3.015 - 75 set @ 20 psi 9.020 - 105 set @ 60 psi 12.030 - 300 set @ 60 psi 27.0*Approximate-Final Adjustment should be with a pressure gauge and with flow.Item Description Material Part Number List Price1 Cap PL 67628J2 Adjusting Screw BRS 7188201D3 Jam Nut (3/8-16) SS 6780106J4* Machine Screw (Fil.Hd.) 8 Req'd 303 6757821B5 Cover BRS C2544K6 Nameplate Screw SS 67999D7 Nameplate BRS C0022001G8 Spring Guide 302 71881HSpring Guide(20 - 105 psi) 303 205620F9 Spring (15-75 psi) CHR/VAN 71884BSpring (2 - 6.5 psi) SS 82575CSpring (2 - 30 psi) SS 81594ESpring (20 - 105 psi) 316 20632101ESpring (30 - 300 psi) CHR/VAN 71885J10 Hex Nut 303 71883D11 Diaphragm Washer 302 71891G12* Diaphragm NBR C6936D13 Plug, Body BRS V5653A14* Gasket Fiber 40174F15 Plug BRS 6766003F16* Disc Retainer Assy. (2 - 30 psi) SS/Rub C8348KDisc Retainer Assy. (15 - 75 psi) SS/Rub 37133GDisc Retainer Assy. (20 - 105 psi) SS/Rub 37133GDisc Retainer Assy. (30 - 300 psi) SS/Rub 37133G17 Yoke VBZ V6951H18 Body & 1/4" Seat Assy BR/SS 8339702G19* Bucking Spring (2 - 6.5 psi)(2 - 30psi) 302 V0558G20 Belleville Washer STL 7055007E* Repair Kit (No Bucking Spring) Buna-N 9170003K* Repair Kit (with Bucking Spring) Buna-N 9170002BThestrainerisdesignedforuseinconjunctionwithaCla-ValMainValve,butcanbeinstalledinanypipingsystemwherethere is a moving fluid stream to keep it clean. When it is usedwith the Cla-Val Valve, it is threaded into the upstream body portprovidedforitonthesideofthevalve.Itprojectsthroughtheside of the Main Valve into the flow stream. All liquid shunted tothepilotcontrolsystemandtothecoverchamberoftheMainValve passes through the X46 Flow Clean Strainer.C Male PipeSAEHDEBIGMalePipeBIWidth Across FlatsFemalePipeADEF Self Scrubbing Cleaning Action Straight Type or Angle TypeThe Cla-Val Model X46 Strainer is designed to prevent passage offoreignparticleslargerthan.015".Itisespeciallyeffectiveagainstsuch contaminant as algae, mud, scale, wood pulp, moss, and rootfibers.There is a model for every Cla-Val. valve.The X46 Flow Clean strainer operates on a velocity principle utilizingthe circular "air foil" section to make it self cleaning. Impingement ofparticles is on the "leading edge" only. The low pressure area on thedownstream side of the screen prevents foreign particles from clog-gingthescreen. Thereisalsoascouringaction,duetoeddycur-rents, which keeps most of the screen area clean.Dimensions (In Inches)INSTALLATIONX46 Angle Type B (In Inches)B(NPT)C(SAE)D E H I1/8 1/4 1-3/8 5/8 7/8 1/41/4 1/4 1-3/4 3/4 1 3/83/8 1/4 2 7/8 1 1/23/8 3/8 1-7/8 7/8 1 1/21/2 3/8 2-3/8 1 1-1/4 5/8X46A StraightX46B AngleX46AStraight Type A (In Inches)AB D E F G I1/8 1/8 1-3/4 3/4 1/2 1/2 1/41/4 1/4 2-1/4 1 3/4 3/4 3/83/8 3/8 2-1/2 1 7/8 7/8 1/23/8 1/2 2-1/2 1-1/4 1/2 7/8 3/41/2 1/2 3 1-1/4 1 1-1/8 3/43/8 3/4 3-3/8 2 1/2 1 7/83/4 3/4 4 2 1 1-1/2 7/83/8 1 4-1/4 2-3/4 1/2 1-3/8 7/81 1 4-1/2 2-3/4 1-1/4 1-3/4 7/81/2 1 4-1/4 2-3/4 1/2 1-3/8 7/8Flow Clean StrainerX46INSPECTIONInspect internal and external threads for damage orevidenceof cross-threading. Check inner and outer screens for clogging,embeddedforeignparticles,breaks,cracks,corrosion,fatigue,and other signs of damage.CLEANINGAfter inspection, cleaning of the X46 can begin.Water service usually will producemineral or lime deposits on metal parts in contact with water.These deposits canbe cleaned by dipping X46 in a 5-percent muriatic acid solution just long enoughfor 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 removedby 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 usedin fueling service.Dry with compressed air or a clean, lint-free cloth.Protect from damage and dust until reassembled.REPLACEMENTIf there is any sign of damage, or if there is the slightest doubt that the Model X46Flow Clean Strainer may not afford completely satisfactory operation, replace it. UseInspection steps as a guide. Neither inner screen, outer screen, nor housing is fur-nished as a replacement part. Replace Model X46 Flow Clean Strainer as a com-plete unit.When ordering replacement Flow-Clean Strainers, it is important to determine pipesize of the tapped hole into which the strainer will be inserted (refer to columnA orF), 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 MaterialsDISASSEMBLYDo not attempt to remove the screens from the strainer housing.MODELINSTALLATION / OPERATION / MAINTENANCECLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comN-X46 (R-3/2011)(NPT) (NPT)X46BX46ACLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comPL-CK2 (R-3/2011)CLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comINSTALLATION / OPERATION / MAINTENANCEFlow ControlCVMODELN-CV (R-3/2011)DESCRIPTIONTheCla-ValModelCVFlowControlisasimply-designed,spring-loaded check valve. Rate of flow is full flow in one direc-tion and restricted in other direction.Flow is adjustable in therestricted direction. It is intended for use in conjunction with apilot control system on a Cla-Val Automatic Control Valve.OPERATIONTheCVFlowControlpermitsfullflowfromportAtoB,andrestrictedflowinthereversedirection.FlowfromportAtoBlifts the disc from seat, permitting full flow. Flow in the reversedirection seats the disc, causing fluid to pass through the clear-ancebetweenthestemandthedisc.Thisclearancecanbeincreased,therebyincreasingtherestrictedflow,byscrewingthestemout,orcounter-clockwise.Turningthestemin,orclockwisereducestheclearancebetweenthestemandthedisc, thereby reducing the restricted flow.INSTALLATIONInstall the CV Flow Control as shown in the valve schematicAllconnections must be tight to prevent leakage.DISASSEMBLYFollowthesequenceoftheitemnumbersassignedtothepartsinthecrosssectionalillustrationforrecommendedorder of disassembly.Use a scriber, or similar sharp-pointed tool to remove O-ringfrom the stem.INSPECTIONInspect all threads for damage or evidence of cross- thread-ing. Check mating surface of seat and valve disc for exces-sive scoring or embedded foreign particles. Check spring forvisibledistortion,cracksandbreaks.Inspectallpartsfordamage, corrosion and cleanliness.CLEANING After disassembly and inspection, cleaning of the parts canbegin.Waterserviceusuallywillproducemineralorlimedepositsonmetalpartsincontactwithwater.Thesedeposits can be cleaned by dipping the parts in a 5-percentmuriaticacidsolutionjustlongenoughfordepositstodis-solve.Thiswillremovemostofthecommontypesofdeposits.Caution: use extreme care when handling acid.Ifthedepositisnotremovedbyacid,thenafinegrit(400)wet or dry sandpaper can be used with water.Rinse partsin water before handling.An appropriate solvent can cleanparts used in fueling service.Dry with compressed air or aclean,lint-freecloth.Protectfromdamageanddustuntilreassembled.REPAIR AND REPLACEMENTMinor nicks and scratches may be polished out using a finegradeofemeryorcrocuscloth;replacepartsifscratchescannot be removed.ReplaceO-ringpackingandgasketeachtimeCVFlowControl is overhauled.Replaceallpartswhicharedefective.Replaceanypartswhich create the slightest doubt that they will not afford com-pletelysatisfactoryoperation.UseInspectionstepsasaguide.REASSEMBLYReassembly is the reverse of disassembly; no special toolsare required.TEST PROCEDURENo testing of the flow Control is required prior to reassemblyto the pilot control system on Cla-Val Main Valve.3/8" Flow ControlCV2.12MAXSTAMP PART NO. ONSMOOTH SURFACERESTRICTEDFLOW3/8 - 18 NPT1.84ADJUSTING STEM(TURN CLOCKWISE TOINCREASE RESTRICTION)17210986543.85FREE FLOWBAR STOCKCONFIGURATIONWhen ordering parts,please specify:Number Stamped on Side Description (CV Flow Control)Part DescriptionMaterialCLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comPL-CV (R-3/2011)PARTS LISTITEM DESCRIPTION QTY1 Cap (SS only) 12 Nut, Jam 13 Seat 14 Gasket 15 Disc 16 Spring 17 Ring, Retaining 18 Stem 19 O-Ring 110 Housing 1CLA-VAL Copyright Cla-Val 2011 Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comDimensionsAvailable only in replacement assembly.PL-CDC-1 (R-6/2011)NPT5 3 42 1IFull Open OperationNPT5 3 42 1ITight Closing OperationBCANSF 61ApprovedItem Description Material1 Body Brass2EndConnectionBrass3 Disc Polytherimide4 Seat NBR5 Spring Stainless SteelSize (NPT)StockNumberA B C I CVpsi Wt.3/8" 9834501A 1.73 0.79 1.06 0.40 4.55 400 0.371/2" 9834502J 2.32 0.98 1.35 0.53 6.00 400 0.32 NSF 61 ApprovedMeets 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 210F Polyethermide Disc to ensure the Best Resistance for Corrosion and Abrasion Patented Disc Guide to Prevent Any Side LoadingCDC-1PARTS LISTCheck Valve (Sizes 3/8 and 1/2)MODEL1 23 4 53/8 NPTStrainerX43Standard 60 mesh pilot system strainer for fluid service.CLA-VAL Copyright Cla-Val 2012Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comPL- X43 (R-9/2012)PARTS LISTITEM DESCRIPTION MATERIAL1 Pipe Plug Steel2 Strainer Plug Brass3 Gasket Copper4 Screen SST5 Body BrassNo parts available. Rreplacement assembly only.Size Stock Number3/8 x 3/8 33450JCla-Val ProductIdentificationProper IdentificationFororderingrepairkits,replacementparts,orforinquiries concerning valve operation, it is important toproperlyidentifyCla-Valproductsalreadyinservicebyincludingallnameplatedatawithyourinquiry.Pertinentproductdataincludesvalvefunction,size,material,pressurerating,enddetails,typeofpilotcontrols used and control adjustment ranges.Identification PlatesForproductidentification,cast-inbodymarkingsaresupplemented by identification plates as illustrated onthis page. The plates, depending on type and size ofproduct, are mounted in the most practical position. Itisextremelyimportantthattheseidentificationplatesarenotpaintedover,removed,orinanyother way rendered illegible.INLETEINTRITTENTREEENTRADASIZE &CAT NO.STOCKNO. CODEMFD. BY CLA-VALNEWPORT BEACH, CALIF, U.S.A.RESERVOIRENDINLETINLETSIZE &CAT NO.STOCKNO.FLOWMFD. BY CLA-VAL NEWPORT BEACH, CALIF. U.S.A.CODECSIZE &CAT NO.STOCKNO.SPRINGRANGEMFD. BY CLA-VAL NEWPORT BEACH, CALIF. U.S.A.SIZE &CAT NO.STOCKNO.CODEMFD. BY CLA-VALNEWPORT BEACH, CALIF.U.S.A.CDONOTREMOVETHI SVALVEHASBEENMODI FI EDSINCE ORIGINAL SHIPMENT FROMFACTORY.WHEN ORDERING PARTSAND/ OR SERVICE SUPPLY DATA FROMTHIS PLATE & ALL OTHER PLATES ON ORIGINAL VALVE.REDUCED PRESSURE BACKFLOW PREVENTION DEVICESTK.NO.SER.NO.CAT.NO.RP-4CLA-VAL NEWPORT BEACH, CA.This brass plate appears on valves sized 21/2" and largerand is located on the top of the inlet flange.These two brass plates appear on 3/8", 1/2", and 3/4" sizevalves and are located on the valve cover.These two brass plates appear on threaded valves1" 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 isfound 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 systemmodification kits and is to be wired to the new pilotcontrol system after installation.This brass plate is used on our backflow preventionassemblies.It is located on the side of the Number Twocheck (2" through 10"). The serial number of theassembly is also stamped on the top of the inlet flange ofthe Number One check.How to OrderHOW TO ORDERBecauseofthevastnumberofpossibleconfigurationsandcombinationsavailable,manyvalvesandcontrolsarenotshowninpublishedproductandpricelists.Fororderinginformation, price and availability on product that are not listed,pleasecontactyourlocalCla-Valofficeorourfactoryofficelocated 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 ClassUNLESS 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 1325Newport Beach, California 92659-0325(949) 722-4800FAX (949) 548-5441LIMITED WARRANTYAutomatic valves and controls as manufactured by Cla-Val are warrantedforthreeyearsfromdateofshipmentagainstmanufacturingdefectsinmaterialandworkmanshipthatdevelopintheserviceforwhichtheyaredesigned,providedtheproductsareinstalledandusedinaccordancewithallapplicableinstructionsandlimitationsissuedbyCla-Val.ElectroniccomponentsmanufacturedbyCla-Valarewarrantedforoneyear from the date of shipment.We will repair or replace defective material, free of charge, that is returnedtoourfactory,transportationchargesprepaid,ifuponinspection,thematerial is found to have been defective at time of original shipment. Thiswarrantyisexpresslyconditionedonthepurchasersprovidingwrittennotification to Cla-Valimmediate upon discovery of the defect.ComponentsusedbyCla-Valbutmanufacturedbyothers,arewarrantedonly to the extent of that manufacturers guarantee.This warranty shall not apply if the product has been altered or repaired byothers,Cla-Valshallmakenoallowanceorcreditforsuchrepairsoralterations unless authorized in writing by Cla-Val.DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITYTheforegoingwarrantyisexclusiveandinlieuofallotherwarranties and representations, whether expressed, implied, oral orwritten,includingbutnotlimitedtoanyimpliedwarrantiesormerchantabilityorfitnessforaparticularpurpose.Allsuchotherwarranties 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 theproduct. Cla-Val shall not be liable for any damages or charges forlabororexpenseinmakingrepairsoradjustmentstotheproduct.Cla-Val shall not be liable for any damages or charges sustained intheadaptationoruseofitsengineeringdataandservices.NorepresentativeofCla-Valmaychangeanyoftheforegoingorassumeanyadditionalliabilityorresponsibilityinconnectionwitht heproduct . Thel i abi l i t yof Cl a-Val i sl i mi t edt omat eri alreplacements F.O.B. Newport Beach, California.TERMS OF SALEACCEPTANCE OF ORDERSAll orders are subject to acceptance by our main office at Newport Beach, California.CREDIT TERMSCredit terms are net thirty (30) days from date of invoice.PURCHASE ORDER FORMSOrders submitted on customers own purchase order forms will be accepted onlywith the express understanding that no statements, clauses, or conditions containedin said order form will be binding on the Seller if they in any way modify the Sellersown terms and conditions of sales.PRODUCT CHANGESThe right is reserved to make changes in pattern, design or materials when deemednecessary, without prior notice.PRICESAll prices are F.O.B. Newport Beach, California unless expressly stated otherwise onour acknowledgement of the order. Prices are subject to change without notice. Theprices at which any order is accepted are subjectto adjustment to the Sellers pricein effect at the time of shipment. Prices do not include sales, excise, municipal, stateor any other Government taxes. Minimum order charge $100.00.RESPONSIBILITYWe will not be responsible for delays resulting from strikes, accidents, negligence ofcarriers, or other causes beyond our control. Also, we will not be liable for anyunauthorized product alterations or charges accruingthere from.RISKAll goods are shipped at the risk of the purchaser after they have been delivered byus to the carrier. Claims for error, shortages, etc., must be made upon receipt ofgoods.EXPORT SHIPMENTSExport shipments are subject to an additional charge for export packing.RETURNED GOODS1. Customers must obtain written approval from Cla-Val prior to returning anymaterial.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 forcredit, unless as part of an unopened vacuum sealed repair kit which is lessthan six months old.6. Goods authorized for return are subject to a 35% ($100 minimum) restockingcharge and a service charge for inspection, reconditioning, replacement ofrubber 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 CLA-VAL CLA-VAL CANADA CLA-VAL EUROPE 4687 Christie DriveBeamsville, OntarioCanada L0R 1B4Phone: 905-563-4963Fax: 905-563-4040 Chemin ds Mesanges 1 CH-1032 Romanel/ Lausanne, Switzerland Phone: 41-21-643-15-55 Fax: 41-21-643-15-50 COPYRIGHT CLA-VAL 2011 Printed in USASpecifications subject to change without notice. www.cla-val.com E-Product I.D. (R-3/2011)Represented By:Complete Replacement Diaphragm Assemblies for 100-01 and 100-20 Hytrol Main ValvesFor: Hytrol Main Valves with Ductile Iron, Bronze Trim Materials125/150 Pressure Class Only.FACTORY ASSEMBLEDIncludes: Stem, Disc Guide, Disc, Disc Retainer, Spacer Washers, Diaphragm, Diaphragm Washerand 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/AN/AN/AN/AN/AN/AC2524BC2525J6"8"10"12"14"16"20"24"40456G45276D81752J85533J89067D89068BN/AN/A33273E40456G45276D81752JN/A85533J89068B89068BValve SizeValve Size49097KC2518DC2520KC2522 FC2524BC2523DC2525J33273E100-01100-20Diaphragm AssemblyStock Number100-01 100-20Diaphragm AssemblyStock Number3/8"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/AN/AN/AN/AN/AN/A9169805A9169812G9169813E9169815K9817901D9817902BN/A9817903K9817905E9817905E3/8" 1/2" - 3/4"1"1 1/4 - 1 1/2"2"2 1/2"3"4"6"8"9169806J9169807G9169808E9169809C9169810A9169817F9169818D9169819B9169820K9169834AN/AN/AN/AN/AN/AN/A9169810A9169818D9169819B9169820KValve SizeValve Size9169801K 9169802H 9169803F 9169804D 9169805A 9169811J 9169812G 9169813E 9169815K 9817901D 9817902B 9817903K 9817904H 9817905EN/A 9817906C 100-01 100-20Repair KitStock Number100-01100-20Repair KitStock NumberRepair Kits for 100-01/100-20 Hytrol ValvesFor: Hytrol Main Valves125/150 Pressure Class Only.Includes: Diaphragm, Disc (or Disc Assembly) and spare Spacer Washers.(Also 81-01 )(Also 81-01 ) REPAIR KITSWhen ordering, please give complete nameplate data of the valve and/or control being repaired.MINIMUM ORDER CHARGE APPLIES.Buna-NStandard Material Viton (For KB Valves)MODELINSTALLATION / OPERATION / MAINTENANCERepair Kits for 100-04/100-23 Hy-Check Main ValvesFor: Hy-Check Main Valves125/150 Pressure Class OnlyIncludes: 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 ValvesFor: Powertrol and Powercheck Main Valves125/150 Pressure Class OnlyIncludes: 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 Copyright Cla-Val 2014Printed in USA Specifications subject to change without notice. P.O. Box 1325 Newport Beach, CA 92659-0325 Phone: 949-722-4800 Fax: 949-548-5441 E-mail: [email protected] Website cla-val.comN-RK (R-05/2014)ValveSizeKit Stock Number100-02ValveSizeKit Stock Number100-02 & 100-03 100-21 & 100-2238 9169901H 212 9169910J N/A12 &34 9169902F 3 9169911G 9169905J1 9169903D 4 9169912E 9169911G114 & 112 9169904B 6 9169913C 9169912E2 9169905J 8 99116G 9169913C10 9169939H 99116G12" 9169937B 9169939HValveSizeKit Stock Number ValveSizeKit Stock Number100-04 100-23 100-04 100-234 20210901B N/A 12 20210905H 20210904J6 20210902A 20210901B 14 20210906G N/A8 20210903K 20210902A 16 20210907F 20210905H10 20210904J 20210903K 20 N/A 20210907F24 N/A 20210907FBUNA-N(Standard Material)VITON (For KB Controls)PilotControlKitStockNumberPilotControlKitStockNumberPilotControlKitStockNumberCDB 9170006CCFM-7 1263901K CDB-KB 9170012ACDB-30 9170023H CFM-7A 1263901K CRA-KB N/ACDB-31 9170024F CFM-9 12223E CRD-KB (w/bucking spring) 9170008JCDB-7 9170017K CRA (w/bucking spring) 9170001D CRL-KB 9170013JCDH-2 18225D CRD (w/bucking spring) 9170002B CDHS-2BKB 9170010ECDHS-2 44607A CRD (no bucking spring) 9170003K CDHS-2FKB 9170011CCDHS-2B 9170004H CRD-18 20275401K CDHS-18KB (no bucking spring) 9170009GCDHS-2F 9170005E CRD-22 98923G 102C-KB 1726202DCDHS-3C-A2 24657K CRL(55F, 55L) 9170007ACDHS-8A 2666901ACRL/55L-60 9170033GCDHS-18 9170003K CRL-4A 43413ECDS-4 9170014G CRL-5(55B) 65755BCDS-5 14200A CRL-5A(55G) 20666ECDS-6 20119301A CRL-18 20309801CCDS-6A 20349401C CV 9170019FBuna-NX105L(O-ring) 00951ECFCM-M1 1222301C 102B-1 1502201F CRD Disc Ret. (Solid) C5256HCFM-2 12223E 102C-2 1726201F CRD Disc Ret. (Spring) C5255K102C-3 1726201FControl Description Stock NumberCF1-C1 Pilot Assembly Only 89541HCF1-Cl Complete Float Control less Ball and Rod 89016ACFC2-C1 Disc, Distributor and Seals 2674701ECSM 11-A2-2 Mechanical Parts Assembly 97544BCSM 11-A2-2 Pilot Assembly Only 18053K33A 1" Complete Internal Assembly and Seal 2036030B33A 2" Complete Internal Assembly and Seal 2040830JWhen ordering, please give complete nameplate data of the valve and/or control being repaired. MINIMUM ORDER CHARGE APPLIESLarger Sizes: Consult Factory.