124-01/624-01

Float ValveDescriptionThe Cla-Val 124-01/624-01 is an automatic valve designed to open widewhen liquid level reaches a predetermined low point and to shut drip tightwhen a predetermined high point is reached. It is a hydraulically operated,pilot controlled valve. The Pilot Valve is actuated by a float ball to limit thehigh and low liquid levels in the tank or reservoir by closing or opening themain valve. High and low liquid levels are adjustable. The float control canbe remotely located only if the flowing line pressure at the valve inlet (inpsi) is equal to or greater than the elevation (in feet) from the main valveto the float pilot control.

Installation1. Allow sufficient room around the valve assembly for adjustments andmaintenance.NOTE: BEFORE VALVE IS INSTALLED, THE PIPELINE SHOULD BEFLUSHED OF ALL CHIPS, SCALE AND FOREIGN MATTER.2. It is recommended that a gate or line block valve be installed upstreamof the 124-01/624-01 Float Valve to facilitate isolating the valve for mainte-nance. If the discharge from the Float Valve is to atmosphere, an outletshutoff valve may not be required.3. Place the 124-01/624-01 Float Valve in the line with flow through thevalve in the direction of flow arrows or by the inlet nameplate. Check allfittings and hardware for proper makeup or apparent damage. Be sure mainvalve cover bolts or cap screws are tight.4. Cla-Val Valves operate with maximum efficiency when mounted in horizontalpiping with with the cover UP; however, other positions are acceptable.Installation with the cover up is advisable to make internal parts readilyaccessible for periodic inspection.5. When the valve is installed over water in the tank or reservoir mount thevalve to position the float rod and ball assembly (CF1-C1 item 3 ) vertically downfrom the valve.6. If the surface of the water in the tank is subject to waves by wind or byvalve discharge, a stilling well must be installed around the float ballassembly. 8'' I.D. PVC pipe is suggested.7. INITIAL ADJUSTMENT. See CF1-C1 on reverse side for proper assemblyof the float rod, ball and stop collars and threading into the Link Assembly.Temporarily remove float. Adjust counterweight on the rod to balance theweight of the link assembly and float rod assembly, less the float. Replacefloat.8. Move float rod to the "up" position. Adjust the upper stop collar on thefloat rod assembly approximately three inches above the high water leveldesired in the tank. Move float rod to “down” position. Adjust the lower stopcollar on the float rod assembly approximately three inches below the desiredlow water level. Tighten stop collar screws on the CF1-C1.

124-01624-01

Operation and Start-up1. Prior to pressuring the valve assembly make sure the necessarygauges to measure pressure in the system are installed as required bythe system engineer. A Cla-Val X101 Valve Position Indicator may beinstalled in the center cover port to provide visual indication of thevalve stem during start-up.CAUTION: During start-up and test procedures a large volume of watermay be discharged downstream. Check that the downstream venting is ade-quate to prevent damage to personnel and equipment.2. If the Pilot System shutoff valves (B) are installed, open valves.(see schematic).3. Very slowly open the upstream block valve.4. While the tank is filling, the float rod and link assembly (CF1-C1 item 19)can be moved slowly to the up position to manually close the main valve.This operation tests the closure of the Float Valve and also will purge air

SYMPTOM PROBABLE CAUSE REMEDY

Continuous flow Damaged valve diaphragm Replace diaphragmfrom float pilot system dischargeport Loose main valve (1) stem nut Tighten stem nut

Damaged float pilot control (2) Replace pilot valve assembly (See P-CFI-CI)

Main Valve fails Too low pressure differential Restrict valve opening withto close across valve (Need 5 psi d Min Cla-Val X102A flow limiting

under flowing conditions) assembly (Contact Cla-Val)

Isolation valve in control tubing Open isolation valve. clean closed or clogged X46 strainer strainer

Float and float rod fails to move Free float mechanismwith liquid level change (stays indown position)

Main Valve Float and float rod fails to move Free float mechanismfails to open with liquid level change (stays in

up position)

Inlet gate or block valve closed Open valve

Main Valve Air in cover Bleed all air with float Vibrates when in the up positionclosing

from the control lines and cover chamber. Carefully loosen tube fittings athighest points and bleed air from system. Carefully loosen the plug at topof main valve cover. If an indicator is installed, carefully loosen thevent at top of indicator. If the valve is installed on its side loosen thetop 4 cover bolts to bleed air trapped in the cover. Bleed air from coverand tighten plug. Tighten tube fittings.

Maintenance1. Cla-Val Valves and Controls require no lubrication or packing and a minimum of maintenance. However, a periodic inspection schedule shouldbe established to determine how the fluid handled is affecting the efficiencyof the valve assembly. Minimum of once per year.2. Repair and maintenance procedures of the Cla-Val Hytrol main Valveand the control components are included in a more detailed IOM manu-al. It can be downloaded from our web site (www.cla-val.com) or obtainedby contacting a Cla-Val Regional Sales Office.3. When ordering parts always refer to the catalog number and stocknumber on the valve nameplate.

MODEL

INSTALLATION / OPERATION / MAINTENANCE

COVERHEX NUT

PIPE PLUG

PIPE PLUG

COVER BEARING

SPRING

STEM NUT

DIAPHRAGM WASHER

DIAPHRAGM

DISC RETAINER

BODY

SPACER WASHER

DISC GUIDE

SEAT

STUD

PIPE PLUG

STEM

DISC

SEAT-O-RING

(GlobeShown)

**

*

1

13 18

12

11

1516 17

14

9

10

8

7

5

4

2

1

19

79

10

8

63

FLOATRODASSEMBLY

PILOT &BRACKETASSEMBLY

4

5

22

S

D

Y

BF

A 1

C

B

1

INLET OUTLET

INDEPENDENT OPERATING PRESSURE

S

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

CLA-VAL 'copyright Cla-Val 2002 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: claval@cla-val.com • Website cla-val.com

N-124-01/624-01 (R-10/02)

124-01/624-01 SCHEMATIC

CF1-C1

HYTROL MAIN VALVE

BASIC COMPONENTS1 100-01 Hytrol (Main Valve)

100-20 600 Series Hytrol (Main Valve)2 CF1-C1 Float Control

OPTIONAL FEATURESA X46A Flow Clean StrainerB CK2 Cock (Isolation Valve)C Closing Speed ControlF Independent Operating PressureS Opening Speed ControlY X43 “Y” Strainer

2

ITEM DESCRIPTION

1 Link Assembly 2 Cotter Pins (2 req'd) 3 Float Rod Assembly (2 ft. )

FLOAT ROD ASSY. BREAKDOWN ITEMS 4 - 9

4 Upper Float Rod (1 ft.) Upper Float Rod (2 ft.)

5 Stud (Req. for connecting upper andlower rods

and one for each extension rod) 6 Extension Float Rod (1 ft.)

Extension Float Rod (2 ft.)7 Stop Collar (2 req'd) 8 Set Screw (1 ea. stop collar) 9 Lower Float Rod (1 ft.)

Lower Float Rod (2 ft.)10 Float Ball 11 Base and Mounting Plate 12 Pilot Valve Assembly CF1-Cl13 Machine Screw 6/32 x 1 1/2"

(6 req'd.)14 Hex Nut 6/32 (6 req)15 Counter Balance Bracket Assy.16 Machine Screw 10/32 x 9/16" (4 req'd.)17 Hex Nut 10/32 (4 req'd.)18 Counterweight (varies with rod

length, includes set screws)19 Pilot & Bracket Assembly CF1-Cl

COUNTERWEIGHT NOT INCLUDED

X46A

CK2

CV

X43

A

B

C

Y

2

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.

Installation

1. 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 πlarger valves,installation with the cover UP is advisable. This makes internalparts readily accessible for periodic inspection.6. If a pilot control system is installed on the 100-01 Hytrol Valve,use care to prevent damage. If it is necessary to remove fittingsor components, be sure they are kept clean and replacedexactly as they were.7. After the valve is installed and the system is first pressurized,vent air from the cover chamber and pilot system tubing 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 Operation

Three Way Pilot Control

Three Way Pilot Control

RestrictionModulating

Control

100-01Hytrol Valve

MODEL

INSTALLATION / OPERATION / MAINTENANCE

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 cocks 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 Cocks.

Check upstream pressure, pilot system, strainer, tubing, cocks, 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 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 sys-tem to protect the downstream piping, it should be realized thatthe valve cannot be serviced under pressure. Steps shouldbe taken 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.

2

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 obstructionlocated and removed. The stem should also be checked for scalebuild-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 MM

1 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 610 6.5 165

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 29.00 109.8

3

Maintenance

Preventative MaintenanceThe Cla-Val Co. Model 100-01 Hytrol Valve requires no lubricationor packing and a minimum of maintenance. However, a periodicinspection schedule should be established to determine how theoperating conditions of the system are affecting the valve. Theeffect of these actions must be determined by inspection.

DisassemblyInspection or maintenance can be accomplished without remov-ing the valve from the line. Repair kits with new diaphragm anddisc are recommended to be on hand before work begins.

WARNING: Maintenance personnel can be injured and equip-ment damaged if disassembly is attempted with pressure in thevalve. SEE CAUTION.

1. Close upstream and downstream isolation valves and inde-pendent operating pressure when used to shut off all pressureto the valve.

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. Noteand sketch position of tubing and controls for re-assembly. Theschematic in front of the Technical Manual can be used as a guidewhen reassembling 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 tobe loosened by driving upward along the edge of the cover with adull cold 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 placeof the center cover plug. on 8” and larger valves there are 4 holes(5/8” — 11 size) where jacking screws and/or eye bolts may beinserted for lifting purposes. Pull cover straight up to keep fromdamaging the integral seat bearing and stem.

4. Remove the diaphragm and disc assembly from the valve body.With smaller valves this can be accomplished by hand by 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 blockand tackle or power hoist. Take care not to damage the stem orbearings. 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" 3-12

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" 4 1/4"

VALVE COVER

DULL COLD CHISEL�(ANGLE UPWARD AS MUCH�AS POSSIBLE)

�

HAMMER

NUT

ANGLE OR CHANNEL IRON

LONG STUD OR BOLT

NUT OR BOLT HEAD

DO NOTLIFT

VALVE SEAT

VALVE BODY

4

Lime Deposits

One 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.

Reassembly

1. 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 Assembly

There 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 Parts

After 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

5

810

14 16

6

17

7

9

OUTLETINLET

GLOBE PATTERN

9

26

27

12

15

14

16

INLET

OUTLET

ANGLE PATTERN

12

22

23

11

TOP VIEW

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

4

242

25

13

31

28

30

295

14

3

CLA-VAL ©copyright Cla-Val 2002 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: claval@cla-val.com • Website cla-val.com

N-100-01 (R-04/02)

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

MODEL

• Reduced Cavitation Design• Drip-tight, Positive Seating Action• Service Without Removal From Line• Globe or Angle Pattern• Every Valve Factory-Tested

The Cla-Val Model 100-20 Hytrol Valve is a hydraulically operated,diaphragm actuated, globe or angle pattern valve. It consists ofthree major components: body, diaphragm assembly and cover.The diaphragm assembly is the only moving part.

The diaphragm assembly is guided top and bottom by a precisionmachined stem which utilizes a non-wicking diaphragm of nylonfabric bonded with synthetic rubber. A resilient synthetic rubberdisc, retained on three and one-half sides by a disc retainer, formsa drip-tight seal with the renewable seat when pressure is appliedabove the diaphragm.

The reduced cavitation characteristics of the 100-20 Hytrol Valve isthe basis for the Cla-Val 600 Series. The rugged simplicity ofdesign and packless construction assure a long life of dependable,trouble-free operation. It's smooth flow passages and fully guideddisc and diaphragm assembly assure optimum control when usedin piping systems requiring remote control, pressure regulation,solenoid operation, rate of flow control or check valve operation.

Available in various materials and in a wide range of sizes. It'sapplications are unlimited.

100-20600 Series

Hytrol Valve

Principle of Operation

Full Open OperationWhen pressure in the cover chamberis relieved to a zone of lowerpressure, the line pressure at thevalve inlet opens the valve, allowingfull flow.

Modulating ActionThe valve holds any intermediateposition when operating pressure isequal above and below thediaphragm. Using a Cla-Val“Modulating” Control will allow thevalve to automatically compensatefor line pressure changes.

Tight Closing OperationWhen pressure from the valve inletis applied to the cover chamber, thevalve closes drip-tight.

On-Off Control

→

On-Off Control

→ ModulatingControl

→

Pattern Flanged

Globe 3”,4”,6”,8”,10”,12”,14”,16”,18”,20”,24”,30”

Angle 4”,6”,8”

Operating Temp. RangeAvailable Sizes

Options

Specifications

Fluids

-40° to 180° F

Epoxy Coating - suffix KCAn FDA approved fusion bonded epoxycoating for use with cast iron, ductile iron orsteel valves. This coating is resistant tovarious water conditions, certain acids,chemicals, solvents and alkalies. Epoxycoatings are applied in accordance withAWWA coating specifications C550-90. Donot use with temperatures above 175° F.

Dura-Kleen ® Stem - suffix KDThis stem is designed for applicationswhere water supplies containing dissolvedminerals create deposits that build-up on astandard stem and hamper valveoperation. A patented self-cleaning designon the stem allows all valve sizes tooperate freely in the harshest conditions.

Delrin ® Sleeved Stem - suffix KGThe Delrin® sleeved stem is designed forapplications where water supplies contain

dissolved minerals which can formdeposits that build up on the valve stemand hamper valve operation. Scale build-up will not adhere to the Delrin® sleevestem. Delrin® sleeved stems are notrecommended for valves in continuousoperation where differential pressures arein excess of 80 psi (2" and larger Hytrol valves).

Water Treatment Clearance - suffix KWThis additional clearance is beneficial inapplications where water treatmentcompounds can interfere with the closingof the valve. The smaller outside diameterdisc guide provides more clearancebetween the disc guide and the valve seat.This option is best suited for valves usedin on-off (non-modulating) service.

Viton ® Rubber Parts - suffix KBOptional diaphragm, disc and o-ringfabricated with Viton® synthetic rubber.Viton® is well suited for use with mineral

acids, salt solutions, chlorinatedhydrocarbons, and petroleum oils; and isprimarily used in high temperatureapplications up to 250° F. Do not use withepoxy coatings above 175° F.

Heavy Spring - suffix KHThe heavy spring option is used inapplications where there is low differentialpressure across the valve, and theadditional spring force is needed to helpthe valve close. This option is best suitedfor valves used in on-off (non-modulating)service.

For assistance in selecting appropriatevalve options or valves manufacturedwith special design requirements,please contact our Regional SalesOffice or Factory.

ANSIGrade Material Standards* 150 lb. 300 lb.

ASTM A536 Ductile Iron B16.42 250 400

ASTM A216-WCB Cast Steel B16.5 285 400

ASTM B62 Bronze B16.24 225 400

ASTM A743 Stainless Steel B16.5 285 400

356-T6 Aluminum B16.1 275 —

Note: *ANSI standards are for flange dimensions only.Flanged valves are available faced but not drilled.

Pressure Ratings (Recommended Maximum Pressure - psi)

Pressure Class

FlangedValve Body & Cover

Component Material Options

Body & Cover Ductile Cast Bronze Stainless AluminumIron Steel Steel

Available Sizes 3" - 30" 3" - 30" 3" - 16" 3" - 16" 3" - 16"

Disc Retainer & Cast Cast Bronze Stainless AluminumDiaphragm Washer Iron Steel Steel

Trim: Disc Guide, Bronze is standard.Seat & Cover Bearing Stainless Steel is optional. Stainless Steel is standard.

Disc Buna-N® Rubber

Diaphragm Nylon Reinforced Buna-N® Rubber

Stem, Nut & Spring Stainless Steel

Materials

Model 100 -20

6" Globe, Flanged

3" Globe, Flanged

6" Angle, Flanged

Model 100-20 Flow Chart (Based on normal flow through a wide open valve)

20 24

10 20 30 40 60 80 100 200 500 1000 2000 5000 10,000 20,000 50,000 1

2

3

4

6

8

10

20

30

40

60

80

100

53

Angle Valve Sizes (Inches)

Globe Valve Sizes (Inches) 3 4 6 8 10 12

6 8

16

Pres

sure

Dro

p —

psi

4

18 3014

Flow Rate gpm (water)

K = 894d4

C 2v

L = K 12 f

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

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

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

d

V = .4085 Q2d

Where:

C = U.S. (gpm) @ 1 psi differential at 60 F water O OOO or

=O (l/s) @ 1 bar (14.5 PSIG) differentialO at 15 C water

d = inside pipe diameter of Schedule 40 Steel Pipe (inches)

f = friction factor for clean, new Schedule 40 pipe

O (dimensionless) (from Cameron Hydraulic Data,

O 18th Edition)

K = Resistance Coefficient (calculated)

L = Equivalent Length of Pipe (feet)

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

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

P = Pressure Drop in (psi) or (bar)

CV Factor

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

CV= QP

CV=Q P CV=

QP

2V

Functional Data Model 100 - 20

3

80

62

15

—

—

293

89.3

—

—

20.6

—

—

.032

—

.12

4

100

136

32.5

135

32

251

76.4

254

77.6

12.7

12.9

—

.08

—

.30

6

150

229

55

233

56

777

237.1

751

229

23.1

22.3

—

.17

—

.64

8

200

480

115

545

132

748

228.1

580

176.9

15.7

12.2

—

.53

—

2.0

10

250

930

223

—

—

621

189.5

—

—

10.4

—

—

1.26

—

4.8

12

300

1458

350

—

—

654

199.4

—

—

8.5

—

—

2.51

—

9.5

14

350

1725

414

—

—

750

228.7

—

—

8.9

—

—

4

—

15.1

16

400

2110

506

—

—

977

298.1

—

—

10.2

—

—

4

—

15.1

18

460

2940

705

—

—

983

299.9

—

—

8.4

—

—

9.6

—

36.2

20

510

3400*

816

—

—

1125

343.2

—

—

8.8

—

—

9.6

—

36.2

24

610

3500*

840

—

—

3005

916.6

—

—

19.1

—

—

9.6

—

36.2

30

760

7900*

1895

—

—

2130

649.6

—

—

10.5

—

—

29.0

—

110

GlobePattern

AnglePattern

GlobePattern

AnglePattern

EquivalentLength

ofPipe

CVFactor

*Estimated

Valve Size

Liquid Displacedfrom DiaphragmChamber When

Valve Opens

K Factor

mm.

Gal./Min. (gpm)

Litres/Sec. (l/s)

Gal./Min. (gpm)

Litres/Sec. (l/s)

Feet (ft)

Meters (m)

Feet (ft)

Meters (m)

Fl. Oz

U.S. Gal.

ml

Litres

Inches

Globe Pattern

Angle Pattern

100-20 (R-11/01)

Represented By:

VALVE SIZE (Inches) 3 4 6 8 10 12 14 16 18 20 24 30A 150 ANSI 10.25 13.88 17.75 21.38 26.00 30.00 34.25 35.00 42.12 48.00 48.00 63.25AA 300 ANSI 11.00 14.50 18.62 22.38 27.38 31.50 — 36.62 43.63 49.62 49.75 —B DIA. 6.62 9.12 11.50 15.75 20.00 23.62 28.00 28.00 35.44 35.44 35.44 53.19C MAX. 7.00 8.62 11.62 15.00 17.88 21.00 20.88 25.75 25.00 31.00 31.00 43.94D 150 ANSI — 6.94 8.88 10.69 — — — — — — — —DD 300 ANSI — 7.25 9.38 11.19 — — — — — — — —E 150 ANSI — 5.50 6.75 7.25 — — — — — — — —EE 300 ANSI — 5.81 7.25 7.75 — — — — — — — —F 150 ANSI 3.75 4.50 5.50 6.75 8.00 9.50 11.00 11.75 15.88 14.56 17.00 19.88FF 300 ANSI 4.12 5.00 6.25 7.50 8.75 10.25 — 12.75 15.88 16.06 19.00 —G NPT Body Tapping 3⁄8 1⁄2 3⁄4 3⁄4 1 1 1 1 1 1 1 1H NPT Cover Center Plug 1⁄2 1⁄2 3⁄4 3⁄4 1 1 11⁄4 11⁄4 2 2 2 2J NPT Cover Tapping 3⁄8 1⁄2 3⁄4 3⁄4 1 1 1 1 1 1 1 1Valve Stem InternalThread UNF 10-32 1⁄4 -28 1⁄4 -28 3⁄8 -24 3⁄8 -24 3⁄8 -24 3⁄8 -24 3⁄8 -24 1⁄2 -20 1⁄2 -20 1⁄2 -20 3⁄4 -16Stem Travel 0.6 0.8 1.1 1.7 2.3 2.8 3.4 3.4 4.5 4.5 4.5 6.5Approx Ship Wt. Lbs. 45 85 195 330 625 900 1250 1380 1500 2551 2750 6500

100-20 (Angle)100-20 (Globe)

Dimensions Model 100 -20

Service and InstallationCla-Val Control Valves operate with maximum efficiency when mounted in horizontal piping with the main valve cover UP, however, otherpositions are acceptable. Due to component size and weight of 10 inch and larger valves, installation with cover UP is advisable. We recommendisolation valves be installed on inlet and outlet for maintenance. Adequate space above and around the valve for service personnel should beconsidered essential. A regular maintenance program should be established based on the specific application data. However, we recommend athorough inspection be done at least once a year. Consult factory for specific recommendations.

VALVE SIZE (mm) 80 100 150 200 250 300 350 400 450 500 600 750A 150 ANSI 260 353 451 543 660 762 870 889 1070 1219 1219 1607AA 300 ANSI 279 368 473 568 695 800 — 930 1108 1260 1263 —B DIA. 168 232 292 400 508 600 711 711 900 900 900 1351C MAX. 178 219 295 381 454 533 530 654 635 787 787 1116D 150 ANSI — 176 226 272 — — — — — — — —DD 300 ANSI — 184 238 284 — — — — — — — —E 150 ANSI — 140 171 184 — — — — — — — —EE 300 ANSI — 148 184 197 — — — — — — — —F 150 ANSI 95 114 140 171 203 241 279 298 403 370 432 505FF 300 ANSI 105 127 159 191 222 260 — 324 403 408 483 —G NPT Body Tapping 3⁄8 1⁄2 3⁄4 3⁄4 1 1 1 1 1 1 1 1H NPT Cover Center Plug 1⁄2 1⁄2 3⁄4 3⁄4 1 1 11⁄4 11⁄4 2 2 2 2J NPT Cover Tapping 3⁄8 1⁄2 3⁄4 3⁄4 1 1 1 1 1 1 1 1Valve Stem InternalThread UNF 10-32 1⁄4-28 1⁄4-28 3⁄8 -24 3⁄8-24 3⁄8-24 3⁄8-24 3⁄8-24 1⁄2 -20 1⁄2 -20 1⁄2-20 1⁄2-20Stem Travel 15 20 28 43 58 71 86 86 86 114 114 165Approx. Ship Wt. Kgs. 20 39 89 150 284 409 568 627 681 1157 1249 2951

IF ROD IS INSERTED THRU TOP OF TANK USE2" HOLE ALLOWANCE FOR LATERAL ROD MOVEMENT.

MAX. LATERALMOVEMENT

2 3/81 15/164 3/16

2 3/16

1 3/8.

25/32DIA.

DRAIN

6 1/4

2

1 3/16

8"MIN.

FLOATUP

LOWER

LIQUID LEVEL

5 3/8 DIA

3 3/430 1/2"FLOATDOWN

1" TO 19"ADJ.

RANGE

27" MAX

FLOATDOWN

1/2" DIA.

1/8" NPTTYP

LIQUID LEVEL

UPPER

1/2

9/16

3 5/8

2 5/8 MAX.FLOAT UP

6 5/16

1 3/8

1/211/16

7/16 TYP.

CF1-C1

Float Control For Open Tanks

SpecificationsPipingConnections 1/8" NPT

Pressure Rating 300 psi max.

TemperatureRating Water: to 160°F.

Materials In contact with operating fluid:Nylon Reinforced delrin, Stainless Steel, Monel, with Buna-N® SealsFloat linkage and float rod:

Brass and PVCBase plate: Treated steelFloat: PolypropyleneOther materials available:

Stainless steel floatStainless steel rod and stopsBrass rodsBrass base plate

Float 5 3/8" diameter. If maximum temperature exceeds 160°F. specify a stainless steel float. Available at extra cost.

Float Rod Standard: Two 12" sections of PVC rod, with12" extension increments at extra cost.

Larger counterweight required if float rod length exceeds 5'.

Optional: 24" stainless steel rod, with 24" extension increments at extra cost.

Larger counterweight required if float rod length exceeds 2".

Level Differential 1" min to 18" max. with PVC rod1" min to 40" max. with stainless steel rod

Operating Fluids Clean liquids or gases compatible withspecified materials.

Shipping Weight 12 Lbs.

• Accurate Liquid Level Control• Fully Hydraulic Operation• Simple Design, Easy Maintenance• No Lubrication Necessary• No Gears, No Mechanical Linkage Between

Valve and Control

The Cla-Val Model CF1-C1 Float Control is a float-actuatedmultiport pilot control which provides non-modulating, two-position,on-off operation. It is used primarily to operate remotely locatedCla-Val valves requiring three-way or four-way pilot valveoperation. Designed for used in open tanks, this control operateson a minimum level change of approximately 1". Maximum levelchange is 19". This level adjustment can be located up to 111⁄2 feetfrom the control by adding float rod extensions.

The float moves freely on the float rod. On rising liquid level, thefloat contacts the upper stop and lifts the float linkage to the "UP"position. As the liquid level lowers, the control stays in the "UP"position until the float contacts the lower stop. The control thenshifts to the "DOWN" position.

Dimensions (In Inches)

MOUNT BRACKET A MINIMUM OF 1-1/2" FROM TANK WALL FOR FLOATCLEARANCE.

TM

TM

MODEL

Installation Data

For Controlling Hytrol Valve

The float control is mounted above the highwater level in the tank. The valve is installedin the l ine leading to the tank and isconnected to the float control pilot by tubing.(Min. 3/8" tubing)

When line pressure is used to operate thevalve, tubing connections are made from thefloat control pilot to the valve cover, and alsoto the inlet side of the valve. An X46 FlowClean Strainer must be installed in the inletside of the valve. The control may beinstalled at any elevation above the valve,providing that the flowing line pressure in psi

is equal to, or greater than, the verticaldistance in feet between the valve and thefloat control.

An independent source of air or water may beused to operate the valve. The pressure fromthis independent source must constantly beequal to or greater than pressure at the valveinlet. The independent source is connected tothe float control pilot in place of the supplyline connected to the inlet side of the valve. Ifthe Model 100-01 under the control of theCF1-C1 is 8" or larger, auxiliary Hytrols maybe required. Consult factory for details.

For ControllingPowertrol Valves

Float Up Float UpCloses Valve Opens Valve

When Ordering, Please Specify

1. Catalog No. CF1-C1

2. Size and type of Valve to be controlled.

3. Material if different from standard

4. Float rod length if larger than 2 ft.

NOTE:

A stilling well (Min. 8" I.D.) must beprovided around the float if the liquidsurface is subject to turbulence,ripples or wind.

Float Up Closes ValveFloat Down Closes Valve

Float Position Valve 1 Valve 2UP CLOSED OPEN

DOWN OPEN CLOSED

Operation

StillingWell

Flow

CF1-C1

X43 or X46Strainer

Supply(Operating Pressure)

Port 2

Port 1(Plugged)

Drain

Supply(Operating Pressure)

Port 2

Port 1

Drain

Port 2

Supply(Operating Pressure)

Drain

Port 1

Supply(Operating Pressure)

Port 2Port 1

Drain

Valve 1 Valve 2

Supply (Operating Pressure)

Port 2

Port 1

Drain

Valve 1 Valve 2

Supply(Operating Pressure)

Port 2(Plugged)

Drain

Port 1

For ControllingTwo Valves Simultaneously

Note: We recommend protecting Float Control tubing and valve from freezing temperatures.

CLA-VALPO Box 1325 Newport Beach CA 92659-0325

Phone: 949-722-4800 • Fax: 949-548-5441CLA-VAL CANADA CLA-VAL EUROPE4687 Christie DriveBeamsville, OntarioCanada LOR 1B4Phone: 905-563-4963Fax: 905-563-4040

Chemin des Mésanges 1CH-1032 Romanel/Lausanne, SwitzerlandPhone: 41-21-643-15-55Fax: 41-21-643-15-50

'COPYRIGHT CLA-VAL 2002 Printed in USASpecifications subject to change without notice. www.cla-val.com

E-CF1-C1 (R-1/03)

TM

Represented By:

When ordering parts,please specify:• All nameplate data • Description• Item Number

ITEM DESCRIPTION MATERIAL

1 Link Assembly Brass 2 Cotter Pins (2 req'd) Brass 3 Float Rod Assembly (2 ft. ) PVC, Brass or Stainless Steel

FLOAT ROD ASSY. BREAKDOWN ITEMS 4 - 9 4 Upper Float Rod (1 ft.) PVC, Brass or Stainless Steel

Upper Float Rod (2 ft.) Brass or Stainless Steel 5 Stud (Req. for connecting upper and lower rods

and one for each extension rod) PVC, Brass or Stainless Steel 6 Extension Float Rod (1 ft.) PVC, Brass or Stainless Steel

Extension Float Rod (2 ft.) Brass or Stainless Steel 7 Stop Collar (2 req'd) PCV, Brass or Stainless Steel 8 Set Screw (1 ea. stop collar) Brass or Stainless Steel 9 Lower Float Rod (1 ft.) PVC, Brass or, Stainless Steel

Lower Float Rod (2 ft.) Brass or Stainless Steel 10 Float Ball 10 SS Float Ball (Stainless Steel) Plastic, Copper or Stainless Steel11 Base and Mounting Plate Steel 12 Pilot Valve Assembly CF1-Cl Brass and Monel w/Stainless Steel 13 Machine Screw 6/32 x 1 1/2" (6 req'd.) Stainless Steel14 Hex Nut 6/32 (6 req) Stainless Steel15 Counter Balance Bracket Assy. Brass16 Machine Screw 10/32 x 9/16" (4 req'd.) Stainless Steel17 Hex Nut 10/32 (4 req'd.) Stainless Steel18 Counterweight (varies with rod

length, includes set screws) Cad Plated Steel19 Pilot & Bracket Assembly CF1-Cl Brass, Steel with Stainless Steel

COUNTERWEIGHT NOT INCLUDED

OPERATION

FLOAT POSITION PORT 1 PORT 2Up Pressure Drain

Down Drain Pressure

Float ControlCF1-C1

Optional Stainless Steel Float

PL- CF1-C1 (R-11/01)

PARTS LIST

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.

I

C Male Pipe

SAE

H

D

E

B

G

MalePipe

BWidth 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 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-ging the screen. There is also a scouring action, due to eddy cur-rents, 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 I

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

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

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

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

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

X46A Straight

X46B Angle

X46A Straight Type A (In Inches)A B D E F G I

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

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

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

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

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

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

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

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

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

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

Flow Clean StrainerX46

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 enough fordeposit to dissolve. This will remove most of the common types of deposits.Caution: use extreme care when handling acid. If the deposit is not removed byacid, then a fine grit (400) wet or dry sandpaper can be used with water. Rinse partsin water before handling. An appropriate solvent can clean parts used in fueling ser-vice. Dry with compressed air or a clean, lint-free cloth. Protect from damage anddust 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 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

INSTALLATION / OPERATION / MAINTENANCE

CLA-VAL 'copyright Cla-Val 2002 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: claval@cla-val.com ¥ Website cla-val.com

N-X46 (R-11/02)

(NPT) (NPT)

X46B

X46A

INSTALLATION / OPERATION / MAINTENANCE

Flow ControlCVMODEL

N-CV (R-11/01)

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 ControlCV

2.12MAX

STAMP PART NO. ONSMOOTH SURFACE

RESTRICTEDFLOW

3/8 - 18 NPT1.84

ADJUSTING STEM(TURN CLOCKWISE TOINCREASE RESTRICTION)

1

7

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 QUAN.

1 Cap (SS only) 1

2 Nut, Jam 1

3 Seat 1

4 Gasket 1

5 Disc 1

6 Spring 1

7 Ring, Retaining 1

8 Stem 1

9 O-Ring 1

10 Housing 1

PL-CV (R-11/01)

PARTS LIST

ITEM DESCRIPTION MATERIAL

1 Pipe Plug Steel

2 Strainer Plug Brass

3 Gasket Copper

4* Screen Monel

5 Body Brass

SIZE STOCK NUMBER

3/8 x 3/8 33450J

StrainerX43

*Replacement screen stock number 68373A.All other parts available only in replacement assembly.

Standard 60 mesh pilot system strainer for fluid service.

PL- X43 (R-6/00)

PARTS LIST

Cla-Val ProductIdentification

Proper Identification

For ordering repair kits, replacement parts, or forinquiries concerning valve operation it is important toproperly identify Cla-Val products already in service.Include all nameplate data with your inquiry. Pertinentproduct data includes valve function, size, material,pressure rating, end details, type of pilot controlsused and control adjustment ranges.

Identification Plates

For 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.

C

®

™

C

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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 1" through 3" size

screwed valves or 1" through 2" flanged valves . It islocated 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 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 ORDER

There are many valves and controls manufactured by Cla-Valthat are not listed due to the sheer volume. For information notlisted, please contact your local Cla-Val office or our factoryoffice located at:

SPECIFY WHEN ORDERING• Model Number • Valve Size• Globe or Angle Pattern • Screwed or Flanged• Adjustment Range • Body and Trim Materials

(As Applicable) • Optional Features• Pressure Class

UNLESS OTHERWISE SPECIFIED• Globe or angle pattern are the same price• Ductile iron body and bronze trim are standard• X46 Flow Clean Strainer or X43 “Y” Strainer are included• CK2 Isolation Valves are included in price on 4” and larger

valve sizes (6” and larger on 600 Series)

P. O. Box 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 which 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.

We will repair or replace defective material, free of charge, which isreturned to our factory, transportation charges prepaid, provided that, afterinspection, the material is found to have been defective at time ofshipment. This warranty is expressly conditioned on the purchaser’s givingCla-Val immediate written notice 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, and 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 SALE

ACCEPTANCE OF ORDERS

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

CREDIT TERMS

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

PURCHASE ORDER FORMS

Orders submitted on customer’s own purchase order forms will be accepted 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 CHANGES

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

PRICES

All 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.

RESPONSIBILITY

We 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.

RISK

All 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 SHIPMENTS

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

RETURNED GOODS

1. Customers must obtain written approval from Cla-Val prior to returning 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% ($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.

E-Product I.D. (R-11/01)

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"

40456G45276D81752J85533J89067D89068B

N/AN/A

33273E40456G45276D81752J

N/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

9169805A9169812G9169813E9169815K9817901D9817902B

N/A9817903K9817905E9817905E

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

1"1 1/4” - 1 1/2"

2"2 1/2"

3"4"6"8"

9169806J9169807G9169808E9169809C9169810A9169817F9169818D9169819B9169820K

N/A

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

9169810A9169818D9169819B9169820K

Valve Size

Valve Size

9169801K 9169802H 9169803F 9169804D 9169805A9169811J 9169812G 9169813E 9169815K 9817901D 9817902B 9817903K 9817904H 9817905E

N/AN/A

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.Supplied Shrink Wrapped (4" and smaller) or Bagged (6" and larger)Includes: Diaphragm, Disc (or Disc Assembly) and spare Spacer Washers.

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

REPAIR KITS

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

Buna-N ® Standard Material Viton (For KB Valves)

MODEL

INSTALLATION / OPERATION / MAINTENANCE

Repair Kits for 100-02/100-21 Powertrol and 100-03/100-22 Powercheck Main ValvesFor: Powertrol and Powercheck Main Valves—125/150 Pressure Class OnlySupplied Shrink Wrapped (4" and Smaller) or Bagged (6" and larger)Includes: Diaphragm, Disc (or Disc Assembly) and spare Spacer Washers.

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

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

1"1 1/4" & 1 1/2"

2"

9169901H 9169902F 9169903D 9169904B9169905J

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

10"

9169910J9169911G9169912E9169913C

99116GN/A

N/A9169905J9169911G9169912E9169913C

99116G

CDBCDB-7CDH-2CDHS-2CDHS-2BCDHS-2FCDHS-3C-A2CDHS-8ACDHS-18CDS-4CDS-5CDS-6CFM-2, CFM-9, CFCM-M1

9170006C 9170017K 18225D 44607A9170004H 9170005E 24657K 2666901A9170003K 9170014G 14200A20119301A12223E

CFM-7 & 7-ACRA (w/bucking spring)

CRD (w/bucking spring)

CRD (no bucking spring)

CRD-22CRL (55F, 55L)CRL-4ACRL-5 (55B)CRL-5A (55G)CVX105L (O-ring)102B-1102C-2 & -3

1263901K9170001D9170002B9170003K 98923G9170007A43413E65755B20666E9170019F00951E1502201F1726201F

CDB-KB CRA-KB CRD-KB (w/bucking spring)

CRL-KB CDHS-2BKB CDHS-2FKB CDHS-18KB (no bucking spring)

102C-KB Buna-N®

9170012A9170018H9170008J9170013J9170010E9170011C 9170009G1726202D

PilotControl

KitStock

NumberPilot

Control

KitStock

NumberPilot

Control

KitStock

Number

BUNA-N ® (Standard Material) VITON (For KB Controls)

CF1-C1CF1-ClCFC2-C1CSM 11-A2-2CSM 11-A2-233A 1"33A 2"

Pilot Assembly OnlyComplete Float Control less Ball & RodDisc, Distributor & SealsMechanical Parts Assy.Pilot Assembly OnlyComplete Internal Assembly & SealComplete Internal Assembly & Seal

89541H89016A2674701E97544B18053K2036030B2040830J

Control Description Stock Number

Repair Assemblies (In Standard Materials Only)

Valve Size

ValveSize

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

Larger Sizes: Consult Factory.

CRD DISC RET. (SOLID)

CRD DISC RET. (SPRING)

C5256HC5255K

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

Repair Kits for 100-04/100-23 Hy-Check Main ValvesFor: Hy-Check Main Valves—125/150 Pressure Class OnlySupplied Shrink Wrapped (4" and Smaller) or Bagged (6" and larger)Includes: Diaphragm, Disc and O-Rings and full set of spare Spacer Washers.

4”6”8”

10”

20210901B20210902A20210903K20210904J

N/A20210901B20210902A20210903K

12”14”16”

20”, 24”

20210905H20210906G20210907F

N/A

20210904JN/A

20210905H20210907F

ValveSize

Valve Size

Kit Stock Number100-04 100-23

Kit Stock Number100-04 100-23

Larger Sizes: Consult Factory.

CLA-VAL ©copyright Cla-Val 2001 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: claval@cla-val.com ¥ Webiste cla-val.com

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