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134-05

C V

Factor

Valve Size

Globe

Pattern

Angle

Pattern

Inches

mm.

Gal./Min. (gpm.)

Litres/Sec. (l/s.)

Gal./Min. (gpm.)

Litres/Sec. (l/s.)

3

80

115

27.6

139

33.4

4

100

200

48

240

58

6

150

440

105.6

541

130

8

200

770

184.8

990

238

10

250

1245

299

1575

378

Functional Data

Solenoid Operated Deluge Valve

Schematic Diagram

Item Description

1 100G/2100G UL Listed Hytrol Main Valve

2 CS3 Solenoid Control

3 100-01 Hytrol Pilot Valve

4 X58C Restriction Orifice

5 X46A Flow Clean Strainer

2

43

F

INDEPENDENTOPERATINGPRESSURE

51

INLET OUTLET

CS3

3 2

1

Cover Capacity

134-05

Specifications

SIZES Globe: 3” - 10” flanged

Angle: 3” - 10” flanged

END DETAILS Ductile Iron 150 ANSI B16.42 flanged

Cast Steel 150 ANSI B16.5 flanged

PRESSURE RATINGS 150 class, 175 psi maximum (Ductile Iron)150 class, 285 psi maximum (Cast Steel)

300 class, 400 psi maximum

TEMPERATURE RANGE Water: to 180° F. Max

MATERIALS Main valve body & cover:

Ductile Iron ASTM A-536*

Cast Steel ASTM A216-WCB*

Naval Bronze ASTM B61

Nickel Aluminum Bronze ASTM B148

Super Duplex Stainless Steel

Stainless Steel ASTM A743-CF-8M

Main valve trim:Bronze / Stainless Steel

Pilot control system:

Cast Bronze ASTM B61

UL Listed 3" - 10"

• U.L. Listed / U.L.C. Listed

• Fast Acting Solenoid Control

• Reliable Drip Tight Shut-off

• Simple Design, Proven Reliable

• Easy Installation & Maintenance

The Cla-Val Model 134-05 Solenoid Control Valve is an

on-off control valve which either opens or closes upon receiving

an electrical signal to the solenoid pilot control. This valve consists

of a 100G/2100G U.L. listed hytrol main valve, a three-way solenoid valve

and an auxiliary pilot valve. This pilot control system alternately applies

pressure to/or relieves pressure from the diaphragm chamber of the main

valve. It is furnished either normally open (de-energize solenoid to open)

or normally closed (energize solenoid to open).

Note: For seawater applications use 100GS/2100GS main valve

MODEL

Valve

Size

Displace-

ment

3” .080 gal

4” .169 gal

6” .531 gal

8” 1.26 gal

10” 2.51 gal

PO Box 1325 Newport Beach CA 92659-0325 Phone: 949-722-4800Fax: 949-548-5441 Web Site: cla-val.com E-mail: [email protected]

CLA-VAL

CLA-VAL CANADA CLA-VAL EUROPE4687 Christie Drive

Beamsville, Ontario

Canada LOR 1B4

Phone: 905-563-4963

Fax: 905-563-4040

E-Mail: [email protected]

Chemin des M ! sanges 1

CH-1032 Romanel/

Lausanne, Switzerland

Phone: 41-21-643-15-55

Fax: 41-21-643-15-50

E-Mail: [email protected]'COPYRIGHT CLA-VAL 2002 Printed in USA Specifications subject to change without notice.

CLA-VAL UKDainton House, Goods Station Road

GB - Tunbridge Wells

Kent TN1 2 DH England

Phone: 44-1892-514-400

Fax: 44-1892-543-423


Represented By:

134-05 (R-8/06)

Pilot System Specifications

Temperature Range

Water: to 180°F

Fluids

Air, water, light oils

Rubber Parts

Buna-N® Synthetic Rubber

Solenoid Control*Body:

Brass ASTM B283Enclosure:

NEMA Type 1, 2, 3, 3S, 4, 4X general purpose watertight

NEMA Type 6, 6P, 7, 9 watertight

Explosion Proof available at extra cost

Voltages:110, 220 -50Hz AC24, 120, 240, 480 - 60Hz AC6, 12, 24, 120, 240 - DC

Others available at extra cost

Max. operating pressure differential: 200 psi

Coil:

Insulation molded Class F

Watts AC 6

AC Volt Amps Inrush 30

AC Volt Amps Holding 16

Watts DC 10.6

Manual operator available at extra cost.

UL Listed: 3" - 10"

*Optional material available for Seawater Service

When Ordering,

Please Specify

1. Catalog No. 134-05

2. Valve Size

3. Pattern - Globe or Angle

4. Pressure Class

5. Threaded, Flanged or Grooved

6. Material Desired

7. Energized or De-energized to

Open Main Valve

8. Solenoid Enclosure,

Voltage & Hertz

9. When Vertically Installed

Valve Size (Inches) 3 4 6 8 10

A 150 ANSI 12.00 15.00 20.00 25.38 29.75

AA 300 ANSI 13.25 15.62 21.00 26.38 31.12

B Dia. 9.12 11.50 15.75 20.00 23.62

C Max. 8.19 10.62 13.38 16.00 17.12

D 2.56 3.19 4.31 5.16 8.50

E 150 ANSI 7.00 8.50 10.00 12.69 14.88

EE 300 ANSI -- 8.81 10.50 13.19 --

F 150 ANSI 4.00 4.97 6.00 8.00 8.62

FF 300 ANSI -- 5.28 6.50 8.50 --

G 4.75 5.94 7.25 8.50 10.50

H 2.69 2.81 3.88 5.31 6.56

J 2.56 2.81 3.81 4.81 5.81

K 7.00 4.03 6.75 17.00 15.50

L 2.56 2.81 3.81 4.81 8.50

M 1.75 2.41 2.75 4.00 4.24

N NPT 1/2"-14 3/4"-14 3/4"-14 1"-11 1/2 1"-11 1/2

P NPT 1/4"-11 1/2 2"-11 1/2"

R 150 ANSI 2.50 3.47 3.25 4.19 7.12

RR 300 ANSI 3.12 3.78 3.75 4.69 7.81

X Pilot System 15.00 17.00 29.00 31.00 33.00

Y Pilot System 11.00 12.00 20.00 22.00 24.00

Z Pilot System 11.00 12.00 20.00 22.00 24.00

Valve Size (mm) 80 100 150 200 250

A 150 ANSI 305 381 508 645 756

AA 300 ANSI 337 397 533 670 791

B Dia. 232 292 400 508 600

C Max. 208 270 340 406 435

D 65 81 110 131 216

E 150 ANSI 178 216 254 322 378

EE 300 ANSI -- 224 267 350 --

F 150 ANSI 102 126 152 203 219

FF 300 ANSI -- 134 165 216 --

G 121 151 184 216 267

H 68 71 99 135 167

J 65 71 97 122 148

K 178 102 171 432 394

L 65 71 97 122 216

M 45 61 70 102 108

N NPT 1/2"-14 3/4"-14 3/4"-14 1"-11 1/2 1"-11 1/2

P NPT 1/4"-11 1/2 2"-11 1/2"

R 150 ANSI 64 88 83 106 181

RR 300 ANSI 79 96 95 119 198

X Pilot System 381 432 737 787 838

Y Pilot System 279 305 508 559 610

Z Pilot System 279 305 508 559 610

100G2100G

• U.L. Listed / U.L.C. Listed• Globe or Angle Pattern• Proven Reliable Design

The Cla-Val Model 100G/2100G Deluge Valve is designed for use in controllingwater flow to Deluge, Pre-Action, or Foam-Water type fire protection sprinklersystems. This valve is U.L. Listed in "Special Systems Water Control ValvesClass I (VLFT)".The Model 100G-2100G is a hydraulically-operated, diaphragm-actuated, globeor angle pattern Deluge Valve. It consists of three major components: the body,the cover, and the diaphragm assembly. The only moving part is the diaphragmassembly. Packless construction and simplicity of design assures long servicelife and dependable low maintenance for this valve. All ferrous parts are fusionepoxy coated internally and externally for added corrosion resistance, alongwith a delrin sleeve stem and teflon coated removable seat.

Typical Application

Deluge Valve

The Model 100G/2100G is installed to control the water flow to thesprinklers in Deluge, Pre-Action, or Foam-Water type systems. Asimplified system is used to illustrate typical operation.

The Model 100G/2100G Deluge Valve (3) ismaintained in the closed position by means ofsystem water pressure controlled by a pilotcontrol (4). When the pilot control valvereceives a signal from the fire detection sys-tem, it allows the deluge valve to open.Firefighting water (1) then enters systempiping (5) and discharges fromsprinklers (6).

4

1

2 3

5

UL®

Globe: 3" – 10" Angle: 3" – 10" Ductile Iron 150 ANSI B16.42 flangedCast Steel 150 ANSI B16.5 flanged 150 class, 250 psi maximum (Ductile Iron)150 class, 285 psi maximum (Cast Steel)300 class, 400 psi maximumWater, to 180°F MAX.Main Valve Body & Cover:

Ductile Iron ASTM A-536* UL, ULCCast Steel ASTM A216-WCB* UL, ULCNickel Aluminum Bronze ASTM B148 UL, ULCNaval Bronze ASTM B61 UL, ULCSuper Duplex Stainless steel UNS32750 UL, ULCStainless Steel ASTM A743-CF-8M UL, ULC

Main Valve Internal Trim:Bronze ASTM B61Stainless Steel Type 303Monel QQ-N-281 Class B

Diaphragm and Disc:Buna-N® synthetic rubber

*Internally & Externally Epoxy Coated Standard

SizesEnd Details

Pressure Rating

Temperature RangeMaterials

Specifications

1. Catalog No. 100G or 2100G 2. Size3. Body and Cover Material 4. Globe or Angle Pattern5. Pressure Class 6. Internal Trim Material

When Ordering, Please Specify

Friction Loss For use in hydraulically calculated systems, friction loss equivalent to:

100G (Globe):3" Size=42 Ft. of 3" Pipe4" Size=92 Ft. of 4" Pipe6" Size=116 Ft. of 6" Pipe8" Size=123 Ft. of 8" Pipe

10" Size=201 Ft. of 10" Pipe

2100G (Angle):3" Size=33 Ft. of 3" Pipe4" Size=44 Ft. of 4" Pipe6" Size=79 Ft. of 6" Pipe8" Size=105 Ft. of 8" Pipe

10" Size=153 Ft. of 10" Pipe

(1) From System Water Supply(2) System Shut-off Valve (Visual Stem)(3) Cla-Val Model 100G or 2100G(4) Pilot Control System(5) Sprinkler System Piping(6) Sprinklers

MODEL

PO Box 1325 Newport Beach CA 92659-0325 Phone: 949-722-4800Fax: 949-548-5441 Web Site: cla-val.com E-mail: [email protected]

CLA-VAL

CLA-VAL CANADA CLA-VAL EUROPE

4687 Christie Drive

Beamsville, Ontario

Canada LOR 1B4

Phone: 905-563-4963

Fax: 905-563-4040


Chemin des Mésanges 1

CH-1032 Romanel/


Phone: 41-21-643-15-55

Fax: 41-21-643-15-50

E-Mail: [email protected] Copyright CLA-VAL 2008 Printed in USA Specifications subject to change without notice.

CLA-VAL UK

Dainton House, Goods Station Road

GB - Tunbridge Wells

Kent TN1 2 DH England

Phone: 44-1892-514-400

Fax: 44-1892-543-423

E-Mail: [email protected] ©

Represented By:

To calculate the maximum wet sprinkler pilot height above the valve, use the graph below.

E-100G (R-12/07)

Functional DataValve Size Inches 3 4 6 8 10

mm 80 100 150 200 250

CVFactor

GlobePattern

Gal./Min. (gpm) 115 200 440 770 1245Litres/Sec. (l/s) 27.6 48 105.6 184.8 299

AnglePattern

Gal./Min. (gpm) 139 240 541 990 1575Litres/Sec. (l/s) 33.4 58 130 238 378

Valve Size (Inches) 3 4 6 8 10A 150 ANSI 12.00 15.00 20.00 25.38 29.75AA 300 ANSI 13.25 15.62 21.00 26.38 31.12B Dia. 9.12 11.50 15.75 20.00 23.62C Max. 8.19 10.62 13.38 16.00 17.12D 2.56 3.19 4.31 5.16 8.50E 150 ANSI 7.00 8.50 10.00 12.69 14.88EE 300 ANSI -- 8.81 10.50 13.19 --F 150 ANSI 4.00 4.97 6.00 8.00 8.62FF 300 ANSI -- 5.28 6.50 8.50 --G 4.75 5.94 7.25 8.50 10.50H 2.69 2.81 3.88 5.31 6.56J 2.56 2.81 3.81 4.81 5.81K 7.00 4.03 6.75 17.00 15.50L 2.56 2.81 3.81 4.81 8.50M 1.75 2.41 2.75 4.00 4.24N NPT 1/2"-14 3/4"-14 3/4"-14 1"-11 1/2 1"-11 1/2P NPT 1/4"-11 1/2 2"-11 1/2"R 150 ANSI 2.50 3.47 3.25 4.19 7.12RR 300 ANSI 3.12 3.78 3.75 4.69 7.81X Pilot System 15.00 17.00 29.00 31.00 33.00Y Pilot System 11.00 12.00 20.00 22.00 24.00Z Pilot System 11.00 12.00 20.00 22.00 24.00

Valve Size (mm) 80 100 150 200 250A 150 ANSI 305 381 508 645 756AA 300 ANSI 337 397 533 670 791B Dia. 232 292 400 508 600C Max. 208 270 340 406 435D 65 81 110 131 216E 150 ANSI 178 216 254 322 378EE 300 ANSI -- 224 267 350 --F 150 ANSI 102 126 152 203 219FF 300 ANSI -- 134 165 216 --G 121 151 184 216 267H 68 71 99 135 167J 65 71 97 122 148K 178 102 171 432 394L 65 71 97 122 216M 45 61 70 102 108N NPT 1/2"-14 3/4"-14 3/4"-14 1"-11 1/2 1"-11 1/2P NPT 1/4"-11 1/2 2"-11 1/2"R 150 ANSI 64 88 83 106 181RR 300 ANSI 79 96 95 119 198X Pilot System 381 432 737 787 838Y Pilot System 279 305 508 559 610Z Pilot System 279 305 508 559 610

DescriptionThe 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.

Installation1. Before valve is installed, pipe lines should be flushed of allchips, scale and foreign matter.2. It is recommended that either gate or block valves beinstalled on both ends of the 100-01 Hytrol Valve to facilitateisoIating the valve for preventive maintenance and repairs.3. Place the valve in the line with flow through the valve in thedirection indicated on the inlet nameplate. (See “Flow Direction”Section)4. Allow sufficient room around valve to make adjustments andfor disassembly.5. CIa-VaI 100-01 Hytrol Valves operate with maximum efficiencywhen mounted in horizontal piping with the cover UP, however,other positions are acceptable. Due to size and weight of thecover and internal components of 8 inch and larger valves,

installation with the cover UP is advisable. This makes internalparts readily accessible for periodic inspection.6. Caution must be taken in the installation of this valve to insurethat galvanic and/or electrolytic action does not take place. Theproper use of dielectric fittings and gaskets are required in allsystems 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 fittingsor components, be sure they are kept clean and replacedexactly 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 byloosening fittings at all high points.

Tight Closing OperationWhen pressure from the valve inlet (oran equivalent independent operatingpressure) is applied to the diaphragmchamber the valve closes drip-tight.

Full Open OperationWhen pressure in diaphragm chamberis relieved to a zone of lower pressure(usually atmosphere) the line pressure(5 psi Min.) at the valve inlet opens thevalve.

Modulating ActionValve modulates when diaphragm pres-sure is held at an intermediate pointbetween inlet and discharge pressure.With the use of a Cla-Val. "modulatingcontrol," which reacts to line pressurechanges, the pressure above thediaphragm is varied, allowing the valveto throttle and compensate for thechange.

Principles of OperationThree Way Pilot Control

Three Way Pilot Control

RestrictionModulatingControl

100-01Hytrol Valve

MODEL

INSTALLATION / OPERATION / MAINTENANCE

2

Flow DirectionThe flow through the 100-01 Hytrol Valve can be in one of twodirections. 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 “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 INDlCATOR

Normal Flow Reverse Flow

TroubleshootingThe following troubleshooting information deals strictly with theModel 100-01 Hytrol Valve. This assumes that all other compo-nents of the pilot control system have been checked out and arein proper working condition. (See appropriate sections inTechnical 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 freeto move through a full stroke either from open to close or viceversa.Second: Valve is free to move and can’t close because of a wornout diaphragm.Third: Valve leaks even though it is free to move and thediaphragm 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 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 Close

Fails to Open

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

(cast into side of valve body)

SYMPTOM PROBABLE CAUSE REMEDY

Recommended 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.

All trouble shooting is possible without removing the valve from theline or removing the cover. It is highly recommended to permanentlyinstall a Model X101 Valve Position Indicator and three gauges inunused 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.With the cover vented to atmosphere, slowly open upstreamisolation 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. Allow sufficient time for diaphragm assembly to shift posi-tions. If there is no continuous flow, you can be quite certain thediaphragm is sound and the diaphragm assembly is tight. If thefluid appears to flow continuously this is a good reason to believethe diaphragm is either damaged or it is loose on the stem. 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. Determining the Hytrol Valve’s freedom of movement can bedone by one of two methods.5. For most valves it can be done after completing DiaphragmCheck (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-connect enough of the control system to permit the appli-cation of inlet pressure to the cover. Open pilot system cock sopressure flows from the inlet into the cover.8. While pressure is building up in the cover, the valve shouldclose smoothly. There is a hesitation in every Hytrol Valve closure,which can be mistaken for a mechanical bind. The stem willappear to stop moving very briefly before going to the closed posi-tion. This slight pause is caused by the diaphragm flexing at aparticular point in the valve’s travel and is not caused by amechanical 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. If the stroke is different than that shown in stem travel chartthis is a good reason to believe something is mechanically restrict-ing the stroke of the valve at one end of its travel. If the flow doesnot stop through the valve when in the indicated “closed” position,the obstruction probably is between the disc and the seat. If theflow 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 for procedure.)11. For valves 6” and smaller, the Hytrol Valve’s freedom of move-ment check can also be done after all pressure is removed fromthe valve. SEE CAUTION. After closing inlet and outlet isolationvalves and bleeding pressure from the valve, check that the coverchamber and the body are temporarily vented to atmosphere.Insert fabricated tool into threaded hole in top of valve stem, andlift the diaphragm assembly manually. Note any roughness. Thediaphragm assembly should move smoothly throughout entirevalve stroke. The tool is fabricated from rod that is threaded onone end to fit valve stem and has a “T” bar handle of some kindon the other end for easy gripping. (See chart in Step 4 of“Disassembly” Section.)12. Place marks on this diaphragm assembly lifting tool when thevalve is closed and when manually positioned open. The distancebetween the two marks should be approximately the stem travelshown in stem travel chart. If the stroke is different than thatshown, there is a good reason to believe something is mechani-cally restricting the stroke of the valve. The cover must beremoved, and the obstruction located and removed. The stemshould 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 (Steps1 to 12). SEE CAUTION. Close the isolation valve downstream ofthe Hytrol Valve. Apply inlet pressure to the cover of the valve, waituntil it closes. Install a pressure gauge between the two closedvalves using one of the two ports in the outlet side of the Hytrol.Watch the pressure gauge. If the pressure begins to climb, theneither the downstream isolation valve is permitting pressure tocreep back, or the Hytrol is allowing pressure to go through it.Usually the pressure at the Hytrol inlet will be higher than on theisolation valve discharge, so if the pressure goes up to the inletpressure, you can be sure the Hytrol is leaking. Install anothergauge downstream of isolating valve. If the pressure between thevalves only goes up to the pressure on the isolation valvedischarge, 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 11424 600 6.5 16530 800 7.5 19036 900 8.5 216

COVER CHAMBER CAPACITY(Liquid Volume displaced when valve opens)

Valve size (inches) DisplacementGallons Liters

1 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 36.224 29.00 109.830 42.00 197.036 90.00 340.0

3

Maintenance 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.

DisassemblyInspection or maintenance can be accomplished without removingthe valve from the line. Repair kits with new diaphragm and disc arerecommended to be on hand before work begins.WARNING: Maintenance personnel can be injured and equipmentdamaged if disassembly is attempted with pressure in the valve. SEECAUTION.1. Close upstream and downstream isolation valves and independ-ent operating pressure when used to shut off all pressure to thevalve.2. Loosen tube fittings in the pilot system to remove pressure fromvalve body and cover chamber. After pressure has been releasedfrom the valve, use care to remove the controls and tubing. Note andsketch position of tubing and controls for re-assembly. The schemat-ic in front of the Technical Manual can be used as a guide whenreassembling pilot system.3. Remove cover nuts and remove cover. If the valve has been inservice 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 bolts may be insertedfor lifting purposes. Pull cover straight up to keep from damagingthe 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 pullingstraight 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 thestem 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. The next item to remove is the stem nut. Examine the stemthreads 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 nutand give it a sharp “rap” rather than a steady pull. Usuallyseveral blows are sufficient to loosen the nut for further removal.On the smaller valves, the entire diaphragm assembly can be heldby the stem in a vise equipped with soft brass jaws beforeremoving the stem nut.The use of a pipe wrench or a vise without soft brass jaws scarsthe fine finish on the stem. No amount of careful dressing canrestore 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-side edge of the disc usually will accomplish its removal. 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 insideand outside surfaces with 400 wet/dry sandpaper will usuallyrestore the seat’s sharp edge. If, however, it is badly worn andreplacement 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 the center hole in the seat and the hole in the angleiron. By tightening the nut a uniform upward force is exerted onthe 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 Size Thread Size (UNF Internal)

1 1/4"—2 1/2" 10—323"—4" 1/4—286"—14" 3/8—24

16" 1/2—2024" 3/4-1630” 3/4-1636” 3/4-16

COVER 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"24" 2"

30” & 36” 2”

NUTANGLE OR CHANNEL IRON

LONG STUD OR BOLT

NUT OR BOLT HEAD

DO NOTLIFT

VALVE SEAT

VALVE BODY

4

Lime DepositsOne of the easiest ways to remove lime deposits from the valvestem or other metal parts is to dip them in a 5-percent muriaticacid solution just long enough for the deposit to dissolve. Thiswill remove most of the common types of deposits. 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.When the diaphragm assembly has been tightened to a pointwhere 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 goodfitting wrench to the nut and give it a sharp “rap” rather than asteady pull. Usually several blows are sufficient to tighten thestem nut for final tightening. Failure to do so could allow thediaphragm 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 tomake sure the Hytrol Valve has been assembled properly. Dothese before installing pilot system and returning valve toservice. These are similar to the three troubleshooting tests.1. Check the diaphragm assembly for freedom of movementafter all pressure is removed from the valve. SEE CAUTlON.Insert fabricated tool into threaded hole in top of valve stem, andlift the diaphragm assembly manually. Note any roughness,sticking or grabbing. The diaphragm assembly should movesmoothly throughout entire valve stroke. The tool is 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.Place marks on this diaphragm assembly lifting tool when thevalve is closed and when manually positioned open. 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-tion located and removed. (See “Maintenance” Section forprocedure.)

Inspection of PartsAfter the valve has been disassembled, each part should beexamined carefully for signs of wear, corrosion, or any otherabnormal 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 whichappear doubtful should be replaced. WHEN ORDERlNGPARTS, BE SURE TO GIVE COMPLETE NAMEPLATE DATA,ITEM NUMBER AND DESCRlPTlON.NOTE: If a new disc isn’t available, the existing disc can beturned over, exposing the unused surface for contact with theseat. 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 tohold the diaphragm assembly up part way while putting thediaphragm over the studs.4. Put spring in place and replace cover. Make sure diaphragmis Iying smooth under the cover.5. Tighten cover nuts firmly using a cross-over pattern until 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 samedetermination can be made by carefully introducing a lowpressure-less than five psi) into the valve body with the covervented. SEE CAUTION. Looking in cover center hole see thediaphragm assembly lift easily without hesitation, and thensettle back easily when the pressure is removed.2. To check the valve for drip-tight closure, a line should beconnected from the inlet to the cover, and pressure applied at theinlet of the valve. If properly assembled, the valve should holdtight with as low as ten PSI at the inlet. See “Tight SealingCheck” 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 tubingexactly as it was prior to removal. Bleed air from all highpoints.5. Follow steps under “Start-Up and Adjustment” Section inTechnical Manual for returning complete valve back to service.

5

1

58

10

14 16

617

79

OUTLETINLET

GLOBE PATTERN

926

27

12

1514

16

INLET

OUTLET

ANGLE PATTERN

22

23

13

12

14

10

11 15

23

TOP VIEW

8" - 24" SEAT DETAIL1 1/4" - 6" SEAT DETAIL 16" COVER DETAIL

4

24225

1331

28

30

295

14

3

Item 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. Diaphragm

10. Spacer Washers11. Disc Guide12. Disc Retainer13. Disc

14. 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 LIST

6

100-01Hytrol Valve Service Data

MODEL


Description 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 service and maintenance information for the standard 100Series main 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 Sizes”chart below.

1”1 1/4”1 1/2”2”

2 1/2”3”4”6”8”10”12”14”16”24”

253240506580100150200250300350400600

100-01HYTROL SIZE Stem

TravelCover CapacityDisplacement

Valve StemThread

UNF-InternalCoverCenterPlug NPT

4”6”8”10”12”16”

20”,24”

100150200250300400600

0.30.40.40.60.70.81.11.72.32.83.43.94.56.5

81010151820234358718699114165

0.0200.0200.0320.0430.0800.1690.5311.262.514.06.59.529.0

0.070.070.120.160.300.642.004.809.5015.1024.6036.20108.80

1/4”1/4”1/4”1/2”1/2”1/2”3/4”3/4”1”1”

1 1/4”1 1/2”2”3/4”

1/4” - 20 (B)5/16” - 18 (B)5/16” - 18 (B)3/8” - 16 (B)7/16” - 14 (B)1/2” - 13 (B)3/4” - 10 (B)3/4” - 10 (B)3/4” - 107/8” - 91-1/8” -71-1/4” -71-1/4” -71-1/2” -12

10-3210-3210-3210-321/4 - 281/4 - 283/8 - 243/8 - 243/8 - 243/8 - 243/8 - 241/2 - 203/4 - 16 *

100-20 Thread(Bolt)

7/16”1/2”1/2”9/16”5/8”3/4”1 1/8”1 1/8”1 1/4”1 7/161 13/162”2”

2 3/8”

Socket

5/8” - 113/4” - 103/4” - 101” - 81” - 81-1/8” 7

CoverLifting

Holes UNCLiters888888812162020202024

Qty

3/8”1/2”1/2”3/4”3/4”1”1”1”1”1”1”

Thread3/8” - 247/16” 207/16” 201/2” - 205/8” - 185/8” - 183/4” - 167/8” - 141 1/8” - 121 1/2” - 121 1/2” - 121 1/2” - 122” - 163” - 12

Thread

3/4”15/16”15/16”1 1/16”1 5/16”1 13/16”1 7/8”2 1/2”2 1/2”3”

Special

Socket(Long)

7/16”9/16”9/16”5/8”5/8”13/16”13/16”13/16”13/16”13/16”13/16”

Socket488122030110110110160390545545800

ft. Lbs.489696

in. Lbs.46610212140851252502702805001350

Lubed6101015303060125185375400420750N/R

DRYGallonsmmmm mm inchesinches inches

Cover Nut or Bolt Cover Plug Cover Torque Stem Nut ** Stem Nut Torque(ft Lbs)

Grade 5 Bolts“Heavy” Grade NutsTighten cover nuts in a “star” cross-over pattern

* Adapter p/n 2594101Einside 1/4” - 28

**Must Use ONLYCla-Val Supplied part

HYTROL Service Data

CLA-VAL Copyright Cla-Val 2008 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.com

© N-100-01 (R-12/07)

BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS

4BOLTS

6BOLTS

8BOLTS

12BOLTS

16BOLTS

20BOLTS

4

3

2

1

65

4

3

2

1

8

7

6

5

4

3

2

1

0

9

8

7

6

5

4

3

2

112

1110

9

8

76

5

43

2

116

1514

1312

11

10

9

8

7

6

5

43

2

120

1918

17

16

15

14

1312

11

Follow this procedure when reassembling MAIN Valve:1. Tightens bolts/nuts in a “Star” or “Cross-Over” Pattern following the numbers shown above to insure that cover seats evenly on the diaphragmmaterial and body.2. Torque the bolt/nuts in three stages:

A. To approximately 10% of final torque valve.B. To approximately 75% of final torque valve.C. To final required torque valve.

3. Valves that are to be tested to 375 PSI or higher should be retorqued after 24 hours.

COVER

PIPE PLUG

COVER BEARING

SPRING

STEM NUT

DIAPHRAGM WASHER

DISC RETAINER

BODY

*SPACER WASHERS

DISC GUIDE

SEAT

PIPE PLUG

STEM

SEAT O-RING

STUD

8" and Larger

*DIAPHRAGM

*DISC

*Repair Parts

Seat Screw 8" and Larger

(Globe or Angle)

PIPE PLUG

HEX NUT 8" and Larger

Cover Bolt 6" and Smaller

KO

DISC GUIDE

KO

SEAT

KO Anti-Cavitation

Trim Option

100-01 Hytrol Main Valve Assembly

100-01PARTS LIST

2.50

A

2.75

OPERATING PRESSURE1/8 NPT

231456

8

3/8 NPT

3/8 NPTBOTH ENDS

1.50

1.25

INLET

A

SECTION AA100-01 3/8" HYTROL VALVE

7

3/8"-1 Hytrol Valve

PARTS LISTITEM DESCRIPTION

1. Cover Screw (8 Required)2. Cover3. Spring4. Diaphragm Washer5. Diaphragm6. Disc Retainer Assembly7. Body Plug (3/8 NPT)8. Body

**

* Recommended Spare Parts

When Ordering parts,please specify• All nameplate data• Description• Item Number• Material

MODEL

100-01PARTS LIST

1/2"-3/4"-1” Hytrol Valve


© PL-100-01 3/8” - 1” (R-1/08)

MODEL

10

13

312

6

7

8

A

4

5

9

13

OPERATING PRESSURE1/8

COUTLETINLET

BODY WITH INTEGRAL SEAT

111014115

1622

192625

OPERATING PRESSURE1/4

5.12

2.68

OUTLET

1.03INLET


1 COVER SCREW2 COVER3 SPRING4 STEM NUT5 DIAPHRAGM WASHER6 DIAPHRAGM7 DISC RETAINER ASSEMBLY8 DISC GUIDE & STEM9 BODY

10 SEAT11 NAMEPLATE12 BODY PLUG HEX HD.13 O-RING SEAT (FOR OLD STYLE BODY ONLY)

**


When Ordering parts,please specify• All nameplate data• Description• Item Number• Material

1/2 3/41-7/16 3-1/22-3/8 2-3/825/32 29/32

AC (MAXIMUM)D


1 COVER SCREW2 NAMEPLATE3 NAMEPLATE SCREW

10 COVER11 SPRING13 STEM NUT14 DIAPHRAGM WASHER15 DIAPHRAGM16 DISC RETAINER ASSEMBLY19 DISC GUIDE22 SEAT24 BODY PLUG25 BODY26 O-RING, SEAT


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

100-01 1" Hytrol Valve

NORMALLY OPEN!PRESS AT 3 (C)

NORMALLY CLOSED!PRESS AT 3 (C)

UNIVERSAL-PRESS!AT ANY ORIFICE. FORM

SOLENOID!DE-!

ENERGIZED

SOLENOID!!

ENERGIZED

3

I

(C)

2(B)(A)

3

I

(C)

2(B)(A)

3

I

(C)

2(B)(A)

3

I

(C)

2(B)(A)

3

I

(C)

2(B)(A)

3

I

(C)

2(B)(A)

DESCRIPTION

MANUAL OPERATORS (OPTIONAL)

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

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

Check Nameplate for correct Catalog Number, pressure, voltage andservice.

Valves with suffix "MO" or "MS" in catalog number are provided with aManual Operator which allows manual operation when desired or dur-ing an interruption of electrical power.

INSTALLATION

Valve may be mounted in any positionPOSITIONING

Connect piping to valve according to markings on valve body. Refer toFlow Diagram provided. Apply pipe compound sparingly to male pipethreads only; if applied to valve threads, it may enter valve and causeoperational difficulty. Pipe strain should be avoided by proper supportand alignment of piping. When tightening pipe, do not use valve aslever.

PIPING

Wiring must comply with local and National Electrical Codes. Forvalves equipped with an explosion-proof, watertight solenoid enclo-sure, the electrical fittings must be approved for use in the approvedhazardous locations. Housings for all solenoids are made with connec-tions for 1/2 inch conduit. The general purpose enclosure may be rotat-ed to facilitate wiring by removing the retaining cap.

WIRING

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

NOTE

SOLENOID TEMPERATURE

MAINTENANCE

COIL REPLACEMENT (REF. FIG. 2)

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

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

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

Standard catalog valves are supplied with coils designed for contin-uous duty service. When the solenoid is energized for a long period,the solenoid enclosure becomes hot and can be touched with thebare hand for only an instant. This safe operating temperature. Anyexcessive heating will be indicated by the smoke and odor of burn-ing coil insulation.

CLEANINGA periodic cleaning of all valves is desirable. The time betweencleanings will vary, depending on the media and service conditions.In general, if the voltage to the coils is correct, sluggish valve oper-ation or excessive leakage will indicate that cleaning is required.IMPROPER OPERATIONFaulty Control Circuit: Check the electrical system by energiz-ing the solenoid. A metallic click signifies the solenoid is operat-ing. Absence of the click indicate loss of power supply. Check forloose or blown-out fuses, open-circuited or grounded coil, brokenlead wires or splice.Burned-out Coil: Check for open-circuited coil. Replace coil, ifnecessary.Low Voltage: Check voltage across coil leads. Voltage must beat least 85% of nameplate ratings.Incorrect Pressure: Check valve pressure. Pressure to valvemust be within the range specified on nameplate.Excessive Leakage: Disassemble valve and clean all parts.Replace parts that are worn or damaged with a complete SpareParts Kit for best results.

Turn off electrical power supply and de-pressurize valve.VALVE DISASSEMBLY AND REASSEMBLY (REF. FIG. 2)

WARNING: Turn off electrical power and line pressure to valvebefore making repairs. It is not necessary to remove valve frompipe line for repairs.

1.

2.3.4.5.

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

1.2.

3.

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

1.2.

3.4.

5.

ORDERING INFORMATION FOR SPAREPARTS KITS

When Ordering Spare Parts Kits or CoilsSpecify Valve Catalog Number,

Serial Number and Voltage

INSTALLATION ANDMAINTENANCE INSTRUCTIONS3-WAY SOLENOID VALVES, NORMALLY OPEN

NORMALLY CLOSED AND UNIVERSAL CONSTRUCTION

IMPORTANT: For protection of the solenoid valve, install a straineror filter suitable for the service involved in the inlet side as close tothe valve as possible. Periodic cleaning is required depending on theservice conditions.

BULLETIN8320ASCO

FORM NO. V5291R2

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

RETAINING CAP

NAMEPLATE

COVER

YOKE

HOUSING

FLUX PLATE! (NOT PRESENT IN!ALL CONSTRUCTIONS)

SOLENOID BASE!SUB ASSEMBLY

(OPTIONAL)!!

MOUNTING BRACKET!(FOUR POSITIONS)!TWO SELF-TAPPING!SCREWS PROVIDED

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

CORE ASSEMBLY

BODY GASKET

BODY!(BRASS)

DISC HOLDER!ASSEMBLY

DISC SPRING

BODY GASKET

END CAPEND CAP

BODY GASKET

DISC SPRING

DISC

DISC HOLDER

BODY!(ST. ST.)

BODY GASKET

CORE ASSEMEBLY

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

PLUGNUT/CORE TUBE!SUB-ASSEMBLY

BONNET GASKET

BONNET

SOLENOID ENCLOSURE

RETAINING CAP

PARTS INCLUDED IN!SPARE PARTS KITS

MANUAL OPERATOR!SCREW TYPE!

(MS)MANUAL OPERATOR!

PUSH TYPE!(MO)

*

SLEEVE!

INSULATING WASHER!(OMITTED WHEN MOLDED!COIL IS USED)

COIL

INSULATING WASHER!(OMITTED WHEN MOLDED!COIL IS USED)

SLEEVE

**

**

*

**

*

*

**

** **

(OPTIONAL)!MOUNTING BRACKET!

(SEE NOTE


© N-V5291 (R-1/08)

INSTALLATION ANDMAINTENANCE INSTRUCTIONS

OPEN-FLAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS

BULLETIN8016GASCO

FORM NO. V6583R5-SERVICE NOTICE-

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

DESCRIPTIONCatalog numbers 8016G1 and 8016G2 are epoxy encapsulated pull-typesolenoids. The green solenoid with lead wires and 1/2 " conduit connec-tion is designed to meet Enclosure Type 1 -General Purpose,Type 2-Dripproof,Types 3 and 3S-Raintight, and Types 4 and 4X-Watertight. Theblack solenoid on catalog numbers prefixed "EF" is designed to meetEnclosure Types 3 and 3S-Raintight, Types 4 and 4X-Watertight, Types 6and 6P-Submersible, type 7 (A, B, C, & D) Explosionproof Class 1,Division 1, Groups A, B, C, & D and Type 9 (E, F, & G)-Dust-lgnitionproofClass 11, Division 1, Groups E, F, & G. The Class 11, Groups F & G DustLocations designation is not applicable for solenoids or solenoid valvesused for steam service or when a class "H" solenoid is used. SeeTemperature Limitations section for solenoid identification and name-plate/retainer for service. When installed just as a solenoid and notattached to an ASCO valve, the core has a 0.250-28 UNF-2B tapped hole,0.38 minimum full thread.Series 8016G solenoids are available in:• Open-Frame Construction

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

• Panel Mounted ConstructionThese solenoids are specifically designed to be panel mounted by thecustomer through a panel having a .062 to .093 maximum wall thickness.(Refer to Figure 3 and section on Installation of Panel Mounted

Solenoid).

Optional Features For Type 1—General PurposeConstruction Only• Junction Box

This junction box construction meets Enclosure Types 2,3,3S,4, and4X. Only solenoids with 1/4" spade or screw terminals may have ajunction box. The junction box provides a 1/2 conduit connection,grounding and spade or screw terminal Connections within the junction box (See Figure 5).

• DIN Plug Connector Kit No. K236 - 034Use this kit only for solenoids with DIN terminals. The DIN plug connector kitprovides a two pole with grounding contact DIN Type 43650 construction(See Figure 6).

OPERATIONWhen the solenoid is energized, the core is drawn into the solenoid base sub-assembly. IMPORTANT: When the solenoid is de-energized, the initialreturn force for the core, Whether developed by spring, pressure, orweight, must exert a minimum force to overcome residual magnetism cre-ated by the solenoid. Minimum return force for AC construction is 11 ounces,and 4 ounces for DC construction.

INSTALLATION Check nameplate for correct catalog number, service, and wattage. Check frontof solenoid for voltage and frequency.WARNING: To prevent the possibility of electrical shock fromthe accessibility of live parts, install the open-frame solenoid

in an enclosure.FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLYCAUTION: To prevent fire or explosion, do not install solenoid and/or valvewhere ignition temperature is less than 165˚ C. On valves used for steamservice or when a class "H" solenoid is used, do not install in hazardous atmos-phere where ignition temperature is less than 180̊ C. See nameplate/retainer for service.NOTE: These solenoids have an internal non-resetable thermal fuse to limitsolenoid temperature in the event that extraordinary conditions occur which couldcause excessive temperatures. These conditions include high input voltage,a jammed core, excessive ambient temperature or shorted solenoid, etc.This unique feature is a standard feature is a standard feature only insolenoids with black explosionproof/dust-ignitionproof enclosures(types 7&9).IMPORTANT: To protect the solenoid valve or operator, install a strain-er or filter, suitable for the service involved in the inlet side as close to thevalve or operator as possible. Clean periodically depending on service con-dition & See ASCO Series 8600, 8601, and 8602 for strainers.Temperature LimitationsFor maximum valve ambient temperatures, refer to chart. The temperature limi-tations listed, only indicate maximum application temperatures for field wiringrated at 90°C. Check catalog number prefix and watt rating on nameplate todetermine maximum ambient temperature. See valve installation and mainte-nance instructions for maximum fluid temperature. NOTE: For steam service,refer to Wiring section, Junction Box for temperature rating of supply wires.

Minimum ambient temperature -40° F (-40° C). PositioningPositioningThis solenoid is designed to perform properly when mounted in any position.However, for optimum life and performance, the solenoid should be mounted ver-tically and upright to reduce the possibility of foreign matter accumulating in thesolenoid base sub-assembly area.WiringWiring must comply with local codes and the National Electrical Code. All sole-noids supplied with lead wires are provided with a grounding wire which is greenor green with yellow stripes and a 1/2" conduit connection. To facilitate wiring, thesolenoid may be rotated 360 .̊ For the watertight and explosionproof solenoid,electrical fittings must be approved for use in the approved hazardous locations.Additional Wiring Instructions For Optional Features: • Open-Frame solenoid with 1/4" spade terminalsFor solenoids supplied with screw terminal connections use #12-18 AWG strand-ed copper wire rated at 90°C or greater. Torque terminal block screws to 10 ± 2in-lbs (1,0 + 1,2 Nm). A tapped hole is provided in the solenoid for grounding, usea #Y10-32 machine screw. Torque grounding screw to 15 -20

Temperature Limitations For Series 8016G Solenoids for useValves Rated at 6.1, 8.1,9.1,10.6 or 11.1 Watts

WattsRating

CatalogNumber Coil

prefixClass of

InsulationMaximum

ambient Temp.˚F

6.1, 8.1, 9.1,& 11.1

None, FB, KF, KP,SF, SP, SC, & SD F 125

6.1, 8.1, 9.1,& 11.1

HB, HT, KB, KH,SS, ST, SU, & ST H 140

10.6 None, KF,SF, & SC F 104

10.6 HT, KH,SU, & ST H 104

in-lbs (1,7 - 2,3 Nm). On solenoids with screw terminals, the socket headscrew holding the terminal block to the solenoid is the grounding screw.Torque the screw to 15 - 20 in-lbs (1,7 - 2,3 Nm). with a 5/32" hex key wrench.• Junction BoxThe junction box is used with spade or screw terminal solenoids onlyand is provided with a grounding screw and a 1/2" conduit connection.Connect #12-18AWG standard copper wire only to the screw terminals. Within the junction box use field wire that is rated 90°C or greater for connections. For steam service use 105°C rated wire up to 50 psi oruse 125°C rated wire above 50 psi. After electrical hookup, replace cover gasket, cover, and screws. Tighten screws evenly in a crisscross man-

ner.• DIN Plug Connector Kit No. KC236-0341. The open—frame solenoid is provided with DIN terminals to accommodatethe DIN plug connector kit.

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

3. Use #12-18 AWG stranded copper wire rated at 90°C or greater forconnections. Strip wire leads back approximately 1/4" for installation in socket terminals. The use of wire-end sleeves is also recommended

for these socket terminals. Maximum length of wire-end sleeves to beapproximately 1/4". Tinning of the ends of the lead wires is not recommended.

4. Thread wire through gland nut, gland gasket, washer, and connectorcover.NOTE: Connector cover may be rotated in 90° increments from positionshown for alternate positioning of cable entry.5. Check DIN connector terminal block for electrical markings. Then make electrical hookup to terminal block according to markings on it. Snap terminal block into connector cover and install center screw.

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

NOTE:Alternating current (AC) and direct current (DC) solenoids are builtdifferently. To convert from one to the other, it may be necessary tochange the complete solenoid including the core and solenoid base sub-assembly, not just the solenoid. Consult ASCO.Installation of SolenoidSolenoids may be assembled as a complete unit. Tightening is accomplishedby means of a hex flange at the base of the solenoid. The 3/4" bonnetconstruction (Figure 1) must be disassembled for installation and installedwith a special wrench adapter.Installation of Panel Mounted Solenoid (See Figure 3)Disassemble solenoid following instruction under Solenoid Replacementthen proceed 3/4" Valve Bonnet Construction1. Install retainer(convex side to solenoid) in 1.312 diameter mounting holein customer panel.

2. Then position spring washer over plugnut/core tube sub-assembly.3. Install plugnut/core tube sub-assembly through retainer in customerpanel. Then replace solenoid, nameplate/retainer and red cap.

15/16" Valve Bonnet Construction1. Install solenoid base sub-assembly through 0.69 diameter mountinghole in customer panel.

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

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

MAINTENANCEWARNING: To prevent the possibility of personal injury or property dam-age, turn off electrical power, depressurize solenoid operator and/orvalve, and vent fluid to a safe area before servicing.

CleaningAll solenoid operators and valves should be cleaned periodically. Thetimebetween cleaning will vary depending on medium and service conditions.In general, if the voltage to the solenoid is correct, sluggish valve operation,excessive noise or leakage will indicate that cleaning is required. Cleanstrainer or filter when cleaning the valve,Preventive Maintenance• Keep the medium flowing through the solenoid operator or valve asfree from dirt and foreign material as possible.

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

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

Causes of Improper Operation• Faulty Control Circuit: Check the electrical system by energizing thesolenoid. A metallic click signifies that the solenoid is operating. Absence of the click indicates loss of power supply. Check for loose orblown fuses, open-circuited or grounded solenoid, broken lead wires or

splice connections.• Burned-Out Solenoid: Check for open-circuited solenoid. Replaceif necessary. Check supply voltage; it must be the same as specified onnameplate/retainer and marked on the solenoid. Check ambient temperatureand check that the core is not jammed.

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

Solenoid Replacement1. On solenoids with lead wires disconnect conduit, coil leads, andgrounding wire.

NOTE: Any optional parts attached to the old solenoid must be reinstalledon the new solenoid.2. Disassemble solenoids with optional features as follows:• Spade or Screw TerminalsRemove terminal connections, grounding screw, grounding wire, andterminal block (screw terminal type only).

NOTE: For screw terminals, the socket head screw holding the terminalblock serves as a grounding screw.• Junction BoxRemove conduit and socket head screw (use 5132" hex key wrench)from center of junction box. Disconnect junction box from sole-

noid.• DIN Plug ConnectorRemove center screw from DIN plug connector. Disconnect DIN plug connector from adapter. Remove socket head screw (use 5/32" hex

key wrench), DIN terminal adapter, and gasket from solenoid.3. Snap off red cap from top of solenoid base sub-assembly.4. Push down on solenoid. Then using a suitable screwdriver, insert bladein slot provided between solenoid and nameplate/retainer. Pry upslightly and push to remove. Then remove solenoid from solenoid basesub-assembly.

5. Reassemble using exploded views for parts identification and placementDisassembly and Reassembly of Solenoids1. Remove solenoid, see Solenoid Replacement.2. Remove finger washer or spring washer from solenoid base sub-assembly.3. Unscrew solenoid base sub-assembly.NOTE: Some solenoid constructions have a plugnut/core tubesub-assembly, bonnet gasket and bonnet in place of the solenoid basesub-assembly. To remove bonnet use special wrench adapter supplied inASCO Rebuild Kit. For wrench adapter only, order ASCO Wrench KitNo.K218 - 948.4. The core is now accessible for cleaning or replacement.5. If the solenoid is part of a valve, refer to basic valve installation andmaintenance instructions for further disassembly.

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

ORDERING INFORMATION FOR ASCO SOLENOIDSWhen Ordering Solenoids for ASCO Solenoid Operators or Valves, orderthe number stamped on the solenoid. Also specify voltage and frequency.

wave!washer

valve!bonnet

bonnet!gasket

core

plugnut/core tube!sub-assembly

Remove red cap and!push solenoid down.!Then pry here to lift!nameplate/retainer!

and push to remove.solenoid!with 1/2" NPT

For special wrench!adapter order kit!No. K218-948.

0.750-28 UN-2A!thread

Tapped hole in core!0.250-28 UNF-2B!

0.38 minimum full thread.

red cap

nameplate/!retainer

grounding wire -!green or green with!yellow stripes

solenoid base!sub-assembly0.9375-26 UNS -2A! thread

core!(DC)

core!(AC)

spring washer

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

Side View

collar to face!valve body

finger!washer

Alternate!Construction


and push to remove.

See torque chart!for bonnet screws

red capnameplate/!retainerspacer

solenoid

finger!washervalve!bonnet

core!tube

Bolted Bonnet!Construction

red capnameplate/retainer

solenoid with 1/2" NPT

1.312 diameter!mounting hole

grounding wire -!green or green with!yellow stripes

.062 to .093 maximum!thickness of panel!

for mounting

plugnut/core tube!sub-assembly

core

For special wrench!adapter order kit!No. K218-948bonnet!

gasket

valve!bonnet

spring!washer

retainer

core

solenoid base!sub-assembly

finger washer

0.69 diameter!mounting hole


and push to remove.

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

Part Namesolenoid base sub-assembly

valve bonnet (3/4" bonnet constructions)bonnet screw (3/8" or 1/2" NPT pipe size)

bonnet screw (3/4" NPT pipe size)

Torque Value in inch-Pounds175 ± 2590 ± 10

2540

Torque Value in Newton-Meters19.8 ± 2.810.2 ± 1.1

2.84.5

Torque Chart

Figure 1. Series 8016G solenoids

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


©

Torque ChartPart Name

terminal block screwssocket head screw

center screw

Torque Value in inch-Pounds10 ± 215 - 205 ± 1

Torque Value in Newton-Meters1,1 ± 0,21,7 - 2,30,6 ± 0,1

Open Frame Solenoid!with 1/4" Spade Terminals

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

See!torque chart!

above

Open-Frame Solenoid!with Screw Terminals.!Socket head screw is !used for grounding.

Screw terminal !adapter

terminal!block!screwsocket head!

grounding screw!(5/32" hex key wrench)

Open-Frame Solenoid!with DIN Terminals.

gasket DIN terminal!adapter

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

Junction box Solenoid!with 1/4" Spade Terminals!

or Screw Terminals

screw terminal block!(see note)

junction box gasket

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


cover screwcovercover gasket

grounding screw!and cup washer

See !torque chart!

above

gasketDIN terminal!adapter

connector!gasket

gland nut

gland gasket

washer

center screw

Open-Frame Solenoid!with DIN Terminal!Plug Connector

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

See !torque chart!

above


DIN connector!terminal block!(see note 2)

connector cover!(see note 1)

Notes:!!1. Connector cover may be! rotated in 90˚ increments from! position shown for alternate! postion of cable entry.!!2. Refer to markings on DIN! connector for proper! electrical connections.

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

** **

**

Figure 4. Open - frame solenoids

Figure 5. Open - frame solenoids

N-V6583 (R-1/08)

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

C Male

Pipe

SAE

H

D

E

B

I

G

MalePipe

B

I

Width Across Flats

FemalePipe

A

D

EF

• Self Scrubbing Cleaning Action• Straight Type or Angle Type

The Cla-Val Model X46 Strainer is designed to prevent passage offoreign particles larger than .015". It is especially effective againstsuch 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 utiliz-ing the circular "air foil" section to make it self cleaning. Impingementof particles is on the "leading edge" only. The low pressure area onthe downstream side of the screen prevents foreign particles fromclogging the screen. There is also a scouring action, due to eddycurrents, which keeps most of the screen area clean.

Dimensions (In Inches)

INSTALLATION

X46 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 5/8

X46A Straight

X46B Angle

X46A Straight Type A (In Inches)A B 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 7/8

Flow Clean Strainer

X46

INSPECTIONInspect internal and external threads for damage or evidenceof cross-threading. Check inner and outer screens for clogging,embedded foreign particles, 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.Use Inspection steps as a guide. Neither inner screen, outer screen, nor housing isfurnished 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 column A 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• Materials

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

MODEL



© N-X46 (R-1/08)

(NPT) (NPT)

X46B

X46A


©


Flow Control

CVMODEL

N-CV (R-1/08)

DESCRIPTIONThe Cla-Val Model CV Flow Control is a simply-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.

OPERATIONThe CV Flow Control permits full flow from port A to B, andrestricted flow in the reverse direction. Flow from port A to Blifts the disc from seat, permitting full flow. Flow in the reversedirection seats the disc, causing fluid to pass through the clear-ance between the stem and the disc. This clearance can beincreased, thereby increasing the restricted flow, by screwingthe stem out, or counter-clockwise. Turning the stem in, orclockwise reduces the clearance between the stem and thedisc, thereby reducing the restricted flow.’

INSTALLATIONInstall the CV Flow Control as shown in the valve schematicAll connections must be tight to prevent leakage.

DISASSEMBLYFollow the sequence of the item numbers assigned to theparts in the cross sectional illustration for recommendedorder 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-threading. Check mating surface of seat and valve disc forexcessive scoring or embedded foreign particles. Checkspring for visible distortion, cracks and breaks. Inspect allparts for damage, corrosion and cleanliness.

CLEANING After disassembly and inspection, cleaning of the parts canbegin. Water service usually will produce mineral or limedeposits on metal parts in contact with water. Thesedeposits can be cleaned by dipping the parts in a 5-percentmuriatic acid solution just long enough for deposits to dis-solve. This will remove most of the common types ofdeposits. Caution: use extreme care when handlingacid. If the deposit is not removed by acid, then a fine grit(400) wet or dry sandpaper can be used with water. Rinseparts in water before handling. An appropriate solvent canclean parts used in fueling service. Dry with compressed airor a clean, lint-free cloth. Protect from damage and dustuntil reassembled.

REPAIR AND REPLACEMENTMinor nicks and scratches may be polished out using a finegrade of emery or crocus cloth; replace parts if scratchescannot be removed.Replace O-ring packing and gasket each time CV FlowControl is overhauled.Replace all parts which are defective. Replace any partswhich create the slightest doubt that they will not afford com-pletely satisfactory operation. Use Inspection steps as aguide.

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 Control

CV

2.12MAX

STAMP PART NO. ONSMOOTH SURFACE

RESTRICTEDFLOW

3/8 - 18 NPT1.84

ADJUSTING STEM(TURN CLOCKWISE TOINCREASE RESTRICTION)

17

2

10

9

8

6

5

4

3

.85

FREE FLOW

BAR STOCKCONFIGURATION

When ordering parts,please specify:

• Number Stamped on Side • Description (CV Flow Control)• Part Description• Material

ITEM 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 1


© PL-CV (R-1/08)

PARTS LIST

*This drawing is the property of CLA-VAL and same and copies made thereof, if any, shall be returned to it upon demand. Delivery and disclosure hereof are made solelyupon 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 asherein authorized, without prior approval of CLA-VAL. Whether or not the equipment or information shown hereon is patented or otherwise protected, full title and copy-rights 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.


© PL-47117 AF (R-1/08)

PARTS LIST

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

.080 DIA. C0492D BLUE S.S. CDB-7CRL-5A

0-70-7

.75

.75.018 DIA. 82575C -- S.S. CRD

CRD-10A1.9-6.51.9-6.5

.61

.49.116 DIA. 81594E -- S.S. CRD

CRD-10A2-302-30

3.02.4

.120 DIA. V5654J GREEN CHR VAN CRL-5ACRD

5-2510-40

4.04.0

.162 DIA. 32447F NATURAL S.S.CDB-7CRL-5ACRL-13

10-6010-6010-60

12.012.012.0

.162 DIA. V5695B YELLOW MUSIC WIRECDB-7CRL-5ACRL-13

20-8020-8020-80

14.514.514.5

.207 DIA. C1124B CAD PLT MUSIC WIRECDB-7CRL-13CRL-5A

50-15050-15050-150

29.529.529.5

.225 DIA. V6515A RED MUSIC WIRECDB-7CRL-13CRL-5A

65-18065-18065-180

44.044.044.0

.115 X .218 71884B RED CHR VANCRLCRD

CRD-10A0-7515-7515-75

8.59.07.2

.118 X .225 71885J GREEN CHR VANCRLCRD

CRD-10A20-20030-30030-300

28.027.022.4

.225 X .295 1630201A CAD PLT CHR VAN CRLCRL-5A

100-300100-300

18.0018.00

.440 X .219 48211H CAD PLT STEELCRA-18CRD-22CRL-4A

200-450200-450100-450

17.017.017.0

.187 20632101E BLACK 316 SST CRDCRL

20-10520-105

13.013.0

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

.080 DIA. C0492D BLUE S.S. CRACRD-2

4.5-154.5-15

.82

.82

.375 DIA.

87719B1 SPRING2 SPRING3 SPRING4 SPRING5 SPRING

EPOXYCOATED

CHROME SILICON CDS-55-4030-8070-120110-120150-200

1.02.03.04.05.0

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

.375 DIA.

2933502H1 SPRING2 SPRING3 SPRING4 SPRING5 SPRING

EPOXYCOATED

CHROME SILICON CDS-6A5-4030-8070-120110-160150-200

.751.502.203.003.70

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

Cla-Val Product

Identification

Proper IdentificationFor ordering repair kits, replacement parts, or forinquiries concerning valve operation, it is important toproperly identify Cla-Val products already in serviceby including all nameplate data with your inquiry.Pertinent product data includes valve function, size,material, pressure rating, end details, type of pilotcontrols used and control adjustment ranges.Identification PlatesFor product identification, cast-in body markings aresupplemented by identification plates as illustrated onthis page. The plates, depending on type and size ofproduct, are mounted in the most practical position. Itis extremely important that these identificationplates are not painted over, removed, or in anyother way rendered illegible.

INLETEINTRITTENTREEENTRADA

SIZE &CAT NO.STOCKNO. CODE

MFD. BY CLA-VALNEWPORT BEACH, CALIF, U.S.A.

RESERVOIREND

INLET

INLET

SIZE &CAT NO.STOCKNO.

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

CODE

C®

™


SPRINGRANGE

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


CODE

MFD. BY CLA-VALNEWPORT BEACH, CALIF.

U.S.A.

C ®

™

DO NOT REMOVE

THIS VALVE HAS BEEN MODIFIEDSINCE 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-4

CLA-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 pilot

control system after installation.

This brass plate is used on our backflow preventionassemblies. It is located on the side of the Number Two

check (2" through 10"). The serial number of theassembly is also stamped on the top of the inlet flange of

the Number One check.

How to Order

HOW TO ORDERBecause of the vast number of possible configurations andcombinations available, many valves and controls are notshown in published product and price lists. For orderinginformation, price and availability on product that are not listed,please contact your local Cla-Val office or our factory officelocated 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) 548-5441

LIMITED WARRANTYAutomatic valves and controls as manufactured by Cla-Val are warrantedfor three years from date of shipment against manufacturing defects inmaterial and workmanship that develop in the service for which they aredesigned, provided the products are installed and used in accordancewith all applicable instructions and limitations issued by Cla-Val.Electronic components manufactured by Cla-Val are warranted for oneyear from the date of shipment.We will repair or replace defective material, free of charge, that is returnedto our factory, transportation charges prepaid, if upon inspection, thematerial is found to have been defective at time of original shipment. Thiswarranty is expressly conditioned on the purchaser’s providing writtennotification to Cla-Val immediate upon discovery of the defect.Components used by Cla-Val but manufactured by others, are warrantedonly to the extent of that manufacturer’s guarantee.This warranty shall not apply if the product has been altered or repaired byothers, Cla-Val shall make no allowance or credit for such repairs oralterations unless authorized in writing by Cla-Val.

DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITYThe foregoing warranty is exclusive and in lieu of all otherwarranties and representations, whether expressed, implied, oral orwritten, including but not limited to any implied warranties ormerchantability or fitness for a particular purpose. All such otherwarranties 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 forlabor or expense in making repairs or adjustments to the product.Cla-Val shall not be liable for any damages or charges sustained inthe adaptation or use of its engineering data and services. Norepresentative of Cla-Val may change any of the foregoing orassume any additional liability or responsibility in connection withthe product. The l iabil i ty of Cla-Val is l imited to materialreplacements 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 customer’s 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 Seller’sown 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 subject to adjustment to the Seller’s pricein effect at the time of shipment. Prices do not include sales, excise, municipal, stateor any other Government taxes. Minimum order charge $75.00.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 accruing there 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 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 lessthan six months old.

6. Goods authorized for return are subject to a 35% ($75 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 Drive

Beamsville, Ontario

Canada LOR 1B4

Phone: 905-563-4963

Fax: 905-563-4040

Chemin dés Mesanges 1

CH-1032 Romanel/


Phone: 41-21-643-15-55

Fax: 41-21-643-15-50 ©COPYRIGHT CLA-VAL 2007 Printed in USA

Specifications subject to change without notice. www.cla-val.com E-Product I.D. (R-12//07)

Represented By:

Complete Replacement Diaphragm Assemblies for 100-01 and 100-20 Hytrol Main ValvesFor: Hytrol Main Valves with Ductile Iron, Bronze Trim Materials—125/150 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/A

C2524BC2525J

6"8"10"12"14"16"20"24"

40456G45276D81752J85533J89067D89068BN/AN/A

33273E40456G45276D81752JN/A85533J89068B89068B

Valve Size

Valve Size

49097KC2518DC2520KC2522 FC2524BC2523DC2525J33273E

100-01 100-20

Diaphragm AssemblyStock Number

100-01 100-20

Diaphragm AssemblyStock Number

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

1" 1 1/4" - 1 1/2"

2"2 1/2"3"4"6"8"10"12"14"16"20"24"

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

N/AN/AN/AN/AN/AN/A

9169805A9169812G9169813E9169815K9817901D9817902BN/A

9817903K9817905E9817905E

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

1"1 1/4” - 1 1/2"

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

9169806J9169807G9169808E9169809C9169810A9169817F9169818D9169819B9169820K9169834A

N/AN/AN/AN/AN/AN/A

9169810A9169818D9169819B9169820K

Valve Size

Valve Size

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

9817906C

100-01 100-20

Repair KitStock Number

100-01 100-20

Repair KitStock Number

Repair Kits for 100-01/100-20 Hytrol ValvesFor: 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


Repair Kits for 100-04/100-23 Hy-Check Main ValvesFor: Hy-Check Main Valves—125/150 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 Valves—125/150 Pressure Class OnlyIncludes: Diaphragm, Disc (or Disc Assembly) and O-rings and full set of spare Spacer Washers.

Repair Kits for Pilot Control ValvesIncludes: Diaphragm, Disc (or Disc Assembly), O-Rings, Gaskets or spare Screws as appropriate.

Repair Assemblies (In Standard Materials Only)


© N-RK (R-1/08)

ValveSize

Kit Stock Number100-02

ValveSize

Kit Stock Number100-02 & 100-03 100-21 & 100-22

3⁄8” 9169901H 21⁄2” 9169910J N/A1⁄2” & 3⁄4” 9169902F 3” 9169911G 9169905J

1” 9169903D 4” 9169912E 9169911G11⁄4” & 11⁄2” 9169904B 6” 9169913C 9169912E

2” 9169905J 8” 99116G 9169913C10” 9169939H 99116G12" 9169937B 9169939H

ValveSize

Kit Stock Number ValveSize

Kit Stock Number100-04 100-23 100-04 100-23

4” 20210901B N/A 12” 20210905H 20210904J6” 20210902A 20210901B 14” 20210906G N/A8” 20210903K 20210902A 16” 20210907F 20210905H10” 20210904J 20210903K 20” N/A 20210907F

24” N/A 20210907F

BUNA-N® (Standard Material) VITON (For KB Control)Pilot

ControlKit

StockNumber

PilotControl

KitStockNumber

PilotControl

KitStockNumber

CDB 9170006C CRM-7 1263901K CDB-KB 9170012ACDB-3D 9170023H CFM-7A 1263901K CRA-KB N/ACDB-3I 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 2666901A CRL-4A 43413ECDHS-18 9170003K CRL-5 (55B) 65755BCDS-4 9170014G CRL-5A (55G) 20666ECDS-5 14200A CRL-18 20309801CCDS-6 20119301A CV 9170019F

Buna-N®CDS-6A 20349401C X105L (O-ring) 00951ECFCM-M1 1222301C 102B-1 1502201F CRD Disc Ret. (Solid) C5256HCFM-2 12223E 102C-2 172601F CRD Disc Ret. (Spring) C5255K

102C-3 172601F

Control 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 2040830J

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

Larger Sizes: Consult Factory.

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