CLA-VAL 50B-4KG1 Installation and operating instructions

50B-4KG1/2050B-4KG1
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OPTIONAL FEATURESNOT FURNISHED BY CLA-VAL CO.
REV.
DRAWING NO.
DESIGN
DRAW
CHK'D
APV'D
CATALOG NO.
TYPE OF VALVE AND MAIN FEATURES
DESCRIPTION
CAD REVISION RECORD - DO NOT REVISE MANUALLY BY DATE
LTR
ADDED TO CATALOG NUMBER
NO. QTY
ITEM BASIC COMPONENTS
OPTIONAL FEATURE SUFFIX
INLET
1
2
3
1
1
1
1
1
1
*100-06 HYTROL (MAIN VALVE)
A-M SEE REVISION FILE
80984 T
MGR 8-18-80
**PRESSURE RELIEF CONTROL
5
1
3
CH 8-20-80
HWE 8-20-80
10-17-91TLCN
2
4
6
X44A STRAINER & ORIFICE ASSEMBLY
X46A FLOW CLEAN STRAINER 16
5PRESSURE GAGE
81-01 CHECK VALVE
4 1
1
NOT BE USED, COPIED OR REPRODUCED, NOR SHALL THE SUBJECT HEREOF BE DISCLOSED IN ANY MANNER TO ANYONE FOR ANY PURPOSE, EXCEPT AS HEREIN AUTHORIZED, WITHOUT PRIOR WRITTEN APPROVAL OF CLA-VAL CO. THIS
INFORMATION SHOWN HEREON IS PATENTED OR OTHERWISE PROTECTED, FULL TITLE AND COPYRIGHTS, IF ANY, IN AND TO THIS DRAWING AND/OR INFORMATION DELIVERED OR SUBMITTED ARE FULLY RESERVED CLA-VAL CO."
"THIS DRAWING IS THE PROPERTY OF CLA-VAL CO. AND SAME AND COPIES MADE THEREOF, IF ANY, SHALL BE RETURNED TO IT UPON DEMAND. DELIVERY AND DISCLOSURE HEREOF ARE SOLELY UPON CONDITION THAT THE SAME SHALL
SHEET 1 OF 2
DIST. CODE 050CVCL 1 2 3 4
50B-4KG1 (GLOBE)
2050B-4KG1 (ANGLE)
4-21-93TLCP
** UL LISTING
20-200 PSI &100-300 PSI
** FM APPROVED
CRL & CRL60 SPRING RANGES;
CRL SPRING RANGES;
* FORMERLY 100HKG
JB 2-27-97R
NOTE: FACTORY MUTUAL APPROVED
TO FM STANDARD 1361 PER PROJECT NO'S.
0Y2A4.AH & 3045403
PRESSURE RELIEF VALVE
FACTORY MUTUAL APPROVED FOR VALVE SIZES 3", 4", 6" & 8"
UL LISTED FOR VALVE SIZES 3", 4", 6" & 8" (GLOBE); 3", 4", 6" & 8" (ANGLE)
20-200 PSI &100-300 PSI
BF 10-18-12S MS 9-11-13
ADDED 8" GLOBE SIZE TO TITLE BLOCK (ECO 23755)
T
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SEE SHEET 1
LTR DATEBY
CAD REVISION RECORD - DO NOT REVISE MANUALLY
DESCRIPTION
TYPE OF VALVE AND MAIN FEATURES
OPERATING DATA
II. PRESSURE RELIEF FEATURE
PRESSURE RELIEF CONTROL (2) IS A SPRING LOADED, NORMALLY CLOSED PILOT CONTROL THAT
MODULATES (OPENS AND CLOSES) MAINTAINING A RELATIVELY CONSTANT PRESSURE AT THE
MAIN VALVE (1) INLET. A BRIEF EXPLANATION OF THE OPENING AND CLOSING CYCLE IS AS
(c) WHEN FLOW OUT OF MAIN VALVE COVER CHAMBER THROUGH CONTROL (2)
EXCEEDS FLOW INTO THE MAIN VALVE COVER CHAMBER THROUGH STRAINER &
ORIFICE (3), PRESSURE IN THE MAIN VALVE COVER CHAMBER IS REDUCED.
2-29-72
JM 2-29-72
JM 8-3-71
JM
T
80984
50B-4KG1 (GLOBE)
CATALOG NO.
APV'D
CHK'D
DRAW
DESIGN
DRAWING NO. REV.
SHEET 2 OF 2
DIST. CODE 050CVCL 1 2 3 4
(d) WITH REDUCED PRESSURE IN THE MAIN VALVE COVER CHAMBER AND FULL INLET PRESSURE
UNDER THE MAIN VALVE DISC, THE MAIN VALVE (1) OPENS.
2050B-4KG1 (ANGLE)
WITHIN THE RANGE SHOWN ON THE PRESSURE RELIEF CONTROL (2) NAMEPLATE.
PRESSURE AT THE MAIN VALVE INLET. THE PRESSURE RELIEF SET POINT IS EASILY ADJUSTED
ACTUATED PILOT CONTROLLED VALVES DESIGNED TO MAINTAIN A RELATIVELY CONSTANT
THE CLA-VAL 50B-4KG1 AND 2050B-4KG1 PRESSURE RELIEF VALVES ARE DIAPHRAGM
I. DESCRIPTION
RESPONDS TO SLIGHT PRESSURE CHANGES AT MAIN VALVE INLET. AN INCREASE IN INLET
PRESSURE TENDS TO OPEN CONTROL (2) AND A DECREASE IN INLET PRESSURE TENDS TO CLOSE
CONTROL (2). THIS CAUSES MAIN VALVE COVER PRESSURE TO VARY AND THE MAIN VALVE (1)
FOLLOWS:
THE FORCE OF THE SPRING IN CONTROL (2), CONTROL (2) OPENS.
(b) WHEN FORCE CREATED BY INLET PRESSURE UNDER DIAPHRAGM OF CONTROL (2) EXCEEDS
DIAPHRAGM OF CONTROL (2).
(a) INLET PRESSURE IS DIRECTED THROUGH THE SENSING LINE TO THE ACTUATING
OPENING CYCLE:
CLOSING CYCLE:
(a) WHEN FORCE CREATED BY INLET PRESSURE UNDER DIAPHRAGM OF CONTROL (2) IS LESS
THAN THE FORCE OF THE SPRING IN CONTROL (2), CONTROL (2) CLOSES.
STRAINER & ORIFICE (3) AND THE MAIN VALVE (1) CLOSES.
(b) AS A RESULT, THE MAIN VALVE (1) COVER CHAMBER IS SLOWLY PRESSURIZED THROUGH THE
III. PRESSURE RELIEF CONTROL (2) ADJUSTMENT
(a) REMOVE PLASTIC CAP (TURN COUNTERCLOCKWISE).
(b) LOOSEN ADJUSTING SCREW JAM NUT (TURN COUNTERCLOCKWISE).
(c) TURN ADJUSTING SCREW CLOCKWISE TO INCREASE PRESSURE RELIEF SET POINT
(OR COUNTERCLOCKWISE TO DECREASE SET POINT).
(e) REPLACE PLASTIC CAP.
(d) RE-TIGHTEN JAM NUT.
1. PERIODIC CLEANING OF STRAINER SCREEN IN ITEM (3) & (6) IS RECOMMENDED.
NOTES:
MAIN VALVE (1) CLOSED.
MAINTAINS THE HIGHER PRESSURE IN THE MAIN VALVE (1) COVER CHAMBER KEEPING THE
WHEN COVER PRESSURE IS HIGHER THAN INLET PRESSURE, CHECK VALVE (4) CLOSES. THIS
IV. CHECK VALVE FEATURE:
2. RELIEF VALVE (2) SHOULD BE TESTED AFTER INSTALLATION TO VERIFY SETTING.
NOT BE USED, COPIED OR REPRODUCED, NOR SHALL THE SUBJECT HEREOF BE DISCLOSED IN ANY MANNER TO ANYONE FOR ANY PURPOSE, EXCEPT AS HEREIN AUTHORIZED, WITHOUT PRIOR WRITTEN APPROVAL OF CLA-VAL CO. THIS
INFORMATION SHOWN HEREON IS PATENTED OR OTHERWISE PROTECTED, FULL TITLE AND COPYRIGHTS, IF ANY, IN AND TO THIS DRAWING AND/OR INFORMATION DELIVERED OR SUBMITTED ARE FULLY RESERVED CLA-VAL CO."
"THIS DRAWING IS THE PROPERTY OF CLA-VAL CO. AND SAME AND COPIES MADE THEREOF, IF ANY, SHALL BE RETURNED TO IT UPON DEMAND. DELIVERY AND DISCLOSURE HEREOF ARE SOLELY UPON CONDITION THAT THE SAME SHALL
PRESSURE RELIEF VALVE
FACTORY MUTUAL APPROVED FOR VALVE SIZES 3", 4", 6" & 8"
UL LISTED FOR VALVE SIZES 3", 4", 6" & 8" (GLOBE); 3", 4", 6" & 8" (ANGLE)
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The Cla-Val Model 50B4KG-1 Globe /2050B-4KG Angle Pressure
Relief Valve is designed specifically to automatically relieve
excess pressure in fire protection pumping systems. Pilot con-
trolled, it maintains constant system pressure at the pump dis-
charge within very close limits as demands change.
The Fire Pump Pressure Relief Valve shall modulate to relieve
excess pressure in a fire protection system. It shall maintain con-
stant pressure in the system regardless of demand changes. It
shall be pilot controlled and back pressure shall not affect its set
point. It shall be actuated by line pressure through a pilot control
system and open fast in order to maintain steady system pressure
as system demand decreases. It shall close gradually to control
surges and shall re-seat drip-tight within 5% of its pressure setting.
INSTALLATION
1. Allow sufficient room around the valve assembly to make
adjustments and for servicing.
2. lt is recommended that gate or block valves be installed to
facilitate isolating valve for preventative maintenance. When used
as a surge control or pressure relief valve where valve outlet dis-
charge is to atmosphere, then a gate or block valve is needed at
valve inlet. When used as a back pressure sustaining control
valve where valve outlet is connected to pressurized downstream
system, then gate or block valves are needed at valve inlet and
outlet.
NOTE: BEFORE THE VALVE IS INSTALLED, PIPE LINES
SHOULD BE FLUSHED OF ALL FOREIGN MATTER.
3. Place valve in line with flow through valve in direction indicated
on inlet plate or flow arrows. Check all fittings and hardware for
proper makeup and verify that no apparent damage is evident.
4. Cla-Val Valves operate with maximum efficiency when mounted
in horizontal piping with the cover UP; however, other positions are
acceptable. Due to size and weight of cover and internal components
on six inch and larger valves, installation with the cover up is
advisable. This makes periodic inspection of internal parts readily
accessible.
5. Caution must be taken in the installation of this valve to insure that
galvanic and/or electrolytic action does not take place. The proper use
of dielectric fittings and gaskets are required in all systems using dis-
similar metals.
OPERATION AND START-UP
1. Prior to pressurizing the valve assembly make sure the nec-
essary gauges to measure pressure in the system, are installed
as required by the system engineer.
CAUTION: During start-up and test a large volume of water
may be discharged downstream. Check that the downstream
venting is adequate to prevent damage to personnel and equip-
ment. All pilot adjustments should be made slowly in small
increments. If the main valve closes too rapidly it may cause
surging in upstream piping.
2. Remove cap from CRL then loosen adjusting screw counter-
clockwise. This will allow the valve to open at low pressure reliev-
ing the full flow of the fire pump. Bleed all air from the valve at this
time by carefully loosening the cover plug and tube fittings at the
high points. Slowly turn the adjusting screw clockwise on the CRL
while watching the gauge between the valve and the pump until
you reach the desired set-point. Tighten the jam nut on the CRL
and replace the cap. DO NOT USE THE GAUGE PROVIDED ON
THE VALVE TO SET THE VALVE. IT IS ONLY THERE TO INDI-
CATE PRESSURE IN THE COVER.
MAINTENANCE
1. Cla-Val Valves and Controls require no lubrication or packing
and a minimum of maintenance. However, a periodic inspection
schedule should be established to determine how the fluid is
affecting the efficiency of the valve assembly. Minimum of once
per year.
2. Repair and maintenance procedures of the Hytrol Main Valve
and control components are included in a more detailed IOM
manual. It can be downloaded from our web site (www.cla-val.com)
or obtained by contacting a Cla-Val Regional Sales Office.
3. When ordering parts always refer to the catalog number
and stock number on the valve nameplate.
Pressure Relief Valve
50B-4KG1/2050B-4KG1
MODEL
INSTALLATION / OPERATION / MAINTENANCE
SYMPTOM PROBABLE CAUSE REMEDY
Main valve Inlet pressure below setting of Reset pilot valve. If change
won't open pilot valve in setting is from tampering,
seal cap with wire and
lead seal
Pilot valve stuck closed Mineral Disassemble control and clean
deposit or foreign material between
disc retainer and power unit body
Pilot valve diaphragm ruptured or Disassemble and replace
diaphragm nut loose. Water coming diaphragm Tighten nut
out of the vent hole in cover
Main valve stuck closed Disassemble main valve,
clean
Mineral buildup on stem parts and/or replace damaged
Stem damaged part. Check downstream
Main valve Inlet pressure above setting of Reset pilot valve
won't close pilot valve
Clogged needle valve or strainer Disassemble and clean
Pilot valve stuck open. Mineral Disassemble and clean
deposit or foreign material under
disc retainer or under diaphragm
assembly
Main valve stuck open. Mineral Disassemble and clean
buildup on stem. Foreign material
between seat and disc assembly
Main valve diaphragm worn Disassemble and replace
Valve leaks Pilot valve disc worn out Disassemble and replace
Continuously Main valve disc worn or small Disassemble and replace
pin hole in main valve diaphragm
Set point too close to inlet pressure Reset CRL Pilot
UL
®
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4
2
3
5
6
1
INLET OUTLET
For a more detailed IOM Manual go to www.cla-val.com or contact a
Cla-Val Regional Sales Office.
N-50B4KG1/2050B4KG1 (R-1/2013)
50B-4KG-1 SCHEMATIC CRL
COVER PIPE PLU
G
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
BASIC COMPONENTS
1 100-06 Hytrol (Main Valve)
2 CRL Pressure Relief Control
3 X44A Strainer & Orifice Strainer
4 81-01 Check Valve
5 Pressure Gauge
6 X46A Flow Clean Strainer
X44A
X46A
HYTROL MAIN VALVE
INLET
1/8 - 27 NPT
SENSING
CONNECTION
OUTLET
Cap
Screw, Adjusting
Nut Hex(Locking)
Cover
Guide, Spring
Spring
Washer, Belleville
Washer, Diaphragm
(Upper)
Screw Fil. Hd.*
Diaphragm*
Washer, Diaphragm
(Lower)
O-Ring, Stem*
Nameplate
Body, Powerunit
O-Ring, Body*
Body
Nut, Stem, Lower
Seat
O-Ring, Seat*
Guide, Spring
Nut, Stem, Upper
*O-Ring, Stem
Stem
*Disc Retainer Assy.
1/2"or 3/4"NPT
(2 places)
2.
1.
3.
6.
Pressure Gauge
5.
* approximate. Use gauge at valve inlet to set
CRL
2.
X140-1
Security Cap
Option
CRL adjust range (psi) Spring Color psi change per turn
0 - 75 Red 8.5
20 - 200 Green 28
100 - 300 Yellow 18
CRL (20 - 200 psi) configuration shown
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Description
The CIa-VaI Model 100-01 Hytrol Valve is a main valve for
CIa-VaI Automatic Control Valves. It is a hydraulically operated,
diaphragm-actuated, globe or angle pattern valve.
This valve consists of three major components; body, diaphragm
assembly, and cover. The diaphragm assembly is the only
moving part. The diaphragm assembly uses a diaphragm of nylon
fabric bonded with synthetic rubber. A synthetic rubber disc,
contained on three and one half sides by a disc retainer and disc
guide, forms a seal with the valve seat when pressure is applied
above the diaphragm. The diaphragm assembly forms a sealed
chamber in the upper portion of the valve, separating operating
pressure from line pressure.
Installation
1. Before valve is installed, pipe lines should be flushed of all
chips, scale and foreign matter.
2. It is recommended that either gate or block valves be
installed on both ends of the 100-01 Hytrol Valve to facilitate
isoIating the valve for preventive maintenance and repairs.
3. Place the valve in the line with flow through the valve in the
direction indicated on the inlet nameplate. (See “Flow Direction”
Section)
4. Allow sufficient room around valve to make adjustments and
for disassembly.
5. CIa-VaI 100-01 Hytrol Valves operate with maximum efficiency
when mounted in horizontal piping with the cover UP, however,
other positions are acceptable. Due to size and weight of the
cover and internal components of 8 inch and larger valves,
installation with the cover UP is advisable. This makes internal
parts readily accessible for periodic inspection.
6. Caution must be taken in the installation of this valve to insure
that galvanic and/or electrolytic action does not take place. The
proper use of dielectric fittings and gaskets are required in all
systems using dissimilar metals.
7. If a pilot control system is installed on the 100-01 Hytrol Valve,
use care to prevent damage. If it is necessary to remove fittings
or components, be sure they are kept clean and replaced
exactly as they were.
8. After the valve is installed and the system is first pressurized,
vent air from the cover chamber and pilot system tubing by
loosening fittings at all high points.
Tight Closing Operation
When pressure from the valve inlet (or
an equivalent independent operating
pressure) is applied to the diaphragm
chamber the valve closes drip-tight.
Full Open Operation
When pressure in diaphragm chamber
is relieved to a zone of lower pressure
(usually atmosphere) the line pressure
(5 psi Min.) at the valve inlet opens the
valve.
Modulating Action
Valve modulates when diaphragm pres-
sure is held at an intermediate point
between inlet and discharge pressure.
With the use of a Cla-Val. "modulating
control," which reacts to line pressure
changes, the pressure above the
diaphragm is varied, allowing the valve
to throttle and compensate for the
change.
Principles of Operation
Three Way
Pilot Control
Three Way
Pilot Control
Restriction
Modulating
Control
100-01
Hytrol Valve
MODEL
INSTALLATION / OPERATION / MAINTENANCE
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2
Flow Direction
The flow through the 100-01 Hytrol Valve can be in one of two
directions. When flow is “up-and-over the seat,” it is in “normal”
flow and the valve will fail in the open position. When flow is “over-
the seat-and down,” it is in “reverse” flow and the valve will fail in
the closed position. There are no permanent flow arrow markings.
The valve must be installed according to nameplate data.
BRIDGEWALL INDlCATOR
Normal Flow Reverse Flow
Troubleshooting
The following troubleshooting information deals strictly with the
Model 100-01 Hytrol Valve. This assumes that all other compo-
nents of the pilot control system have been checked out and are
in proper working condition. (See appropriate sections in
Technical Manual for complete valve).
Three Checks
The 100-01 Hytrol Valve has only one moving part (the diaphragm
and disc assembly). So, there are only three major types of prob-
lems to be considered.
First: Valve is stuck - that is, the diaphragm assembly is not free
to move through a full stroke either from open to close or vice
versa.
Second: Valve is free to move and can’t close because of a worn
out diaphragm.
Third: Valve leaks even though it is free to move and the
diaphragm isn’t leaking.
Closed isolation valves in control system, or in main line.
Lack of cover chamber pressure.
Diaphragm damaged. (See Diaphragm Check.)
Diaphragm assembly inoperative.
Corrosion or excessive scale build up on valve stem.
(See Freedom of Movement Check)
Mechanical obstruction. Object lodged in valve.
(See Freedom of Movement Check)
Worn disc. (See Tight Sealing Check)
Badly scored seat. (See Tight Sealing Check)
Closed upstream and/or downstream isolation
valves in main line.
Insufficient line pressure.
Diaphragm assembly inoperative. Corrosion or excessive
buildup on valve stem. (See Freedom of Movement Check)
Diaphragm damaged. (For valves in "reverse flow" only)
After checking out probable causes and remedies, the following three checks can be used to diagnose the nature of the
problem before maintenance is started. They must be done in the order shown.
Open Isolation valves.
Check upstream pressure, pilot system, strainer, tubing, valves, or needle
valves for obstruction.
Replace diaphragm.
Clean and polish stem. Inspect and replace any damaged or badly eroded
part.
Remove obstruction.
Replace disc.
Replace seat.
Open isolation valves.
Check upstream pressure. (Minimum 5 psi flowing line pressure differential.)
Clean and polish stem. Inspect and replace any
damaged or badly eroded part.
Replace diaphragm.
Fails to Close
Fails to Open
CAUTION:
Care should be taken when doing the troubleshooting checks on
the 100-01 Hytrol Valve. These checks do require the valve to
open fully. This will either allow a high flow rate through the
valve, or the downstream pressure will quickly increase to the
inlet pressure. In some cases, this can be very harmful. Where
this is the case, and there are no block valves in the system to
protect the downstream piping, it should be realized that the
valve cannot be serviced under pressure. Steps should be
taken to remedy this situation before proceeding any further.
(cast into side of valve body)
SYMPTOM PROBABLE CAUSE REMEDY
Recommended Tools
1. Three pressure gauges with ranges suitable to the 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 disassembly
of 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 the
line or removing the cover. It is highly recommended to permanently
install a Model X101 Valve Position Indicator and three gauges in
unused Hytrol inlet, outlet and cover connections.
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Diaphragm Check (#1 )
1. Shut off pressure to the Hytrol Valve by slowly closing upstream
and downstream isolation valves. SEE CAUTION.
2. Disconnect or close all pilot control lines to the valve cover and
leave only one fitting in highest point of cover open to atmosphere.
3.With the cover vented to atmosphere, slowly open upstream
isolation valve to allow some pressure into the Hytrol Valve body.
Observe the open cover tapping for signs of continuous flow. It is
not necessary to fully open isolating valve. Volume in cover 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 the
diaphragm is sound and the diaphragm assembly is tight. If the
fluid appears to flow continuously this is a good reason to believe
the diaphragm is either damaged or it is loose on the stem. In
either case, this is sufficient cause to remove the valve cover and
investigate the leakage. (See “Maintenance” Section for procedure.)
Freedom of Movement Check (#2)
4. Determining the Hytrol Valve’s freedom of movement can be
done by one of two methods.
5. For most valves it can be done after completing Diaphragm
Check (Steps 1, 2, and 3). SEE CAUTION. At the end of step 3
the valve should be fully open.
6. If the valve has a Cla-Val X101 Position Indicator, observe the
indicator to see that the valve opens wide. Mark the point of 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 so
pressure flows from the inlet into the cover.
8. While pressure is building up in the cover, the valve should
close smoothly. There is a hesitation in every Hytrol Valve closure,
which can be mistaken for a mechanical bind. The stem will
appear to stop moving very briefly before going to the closed posi-
tion. This slight pause is caused by the diaphragm flexing at a
particular point in the valve’s travel and is not caused by a
mechanical bind.
9. When closed, a mark should be made on the X101 Valve posi-
tion indicator corresponding to the “closed” position. The distance
between the two marks should be approximately the stem travel
shown in chart.
10. If the stroke is different than that shown in stem travel chart
this is a good reason to believe something is mechanically restrict-
ing the stroke of the valve at one end of its travel. If the flow does
not stop through the valve when in the indicated “closed” position,
the obstruction probably is between the disc and the seat. If the
flow does stop, then the obstruction is more likely in the cover. In
either case, the cover must be removed, and the obstruction 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 from
the valve. SEE CAUTION. After closing inlet and outlet isolation
valves and bleeding pressure from the valve, check that the cover
chamber and the body are temporarily vented to atmosphere.
Insert fabricated tool into threaded hole in top of valve stem, and
lift the diaphragm assembly manually. Note any roughness. The
diaphragm assembly should move smoothly throughout entire
valve stroke. The tool is fabricated from rod that is threaded on
one end to fit valve stem and has a “T” bar handle of some kind
on the other end for easy gripping. (See chart in Step 4 of
“Disassembly” Section.)
12. Place marks on this diaphragm assembly lifting tool when the
valve is closed and when manually positioned open. The distance
between the two marks should be approximately the stem travel
shown in stem travel chart. If the stroke is different than that
shown, there is a good reason to believe something is mechani-
cally restricting the stroke of the valve. The cover must be
removed, and the obstruction located and removed. The stem
should also be checked for scale build-up. (See “Maintenance”
Section for procedure.)
Tight Sealing Check (#3)
13. Test for seat leakage after completing checks #1 & #2 (Steps
1 to 12). SEE CAUTION. Close the isolation valve downstream of
the Hytrol Valve. Apply inlet pressure to the cover of the valve, wait
until it closes. Install a pressure gauge between the two closed
valves using one of the two ports in the outlet side of the Hytrol.
Watch the pressure gauge. If the pressure begins to climb, then
either the downstream isolation valve is permitting pressure to
creep back, or the Hytrol is allowing pressure to go through it.
Usually the pressure at the Hytrol inlet will be higher than on the
isolation valve discharge, so if the pressure goes up to the inlet
pressure, you can be sure the Hytrol is leaking. Install another
gauge downstream of isolating valve. If the pressure between the
valves only goes up to the pressure on the isolation valve
discharge, the Hytrol Valve is holding tight, and it was just the 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 10
1 1/2 40 0.4 10
250 0.615
2 1/2 65 0.7 18
380 0.820
4 100 1.1 28
6 150 1.7 43
8 200 2.3 58
10 250 2.8 71
12 300 3.4 86
14 350 4.0 100
16 400 4.5 114
20 500 5.6 143
24 600 6.7 165
30 800 7.5 190
36 900 8.5 216
COVER CHAMBER CAPACITY
(Liquid Volume displaced when valve opens)
Valve size (inches) Displacement
Gallons Liters
1 1/4 .020 .07
1 1/2 .020 .07
2 .032 .12
2 1/2 .043 .16
3 .080 .30
4 .169 .64
6 .531 2.0
8 1.26 4.8
10 2.51 9.5
12 4.00 15.1
14 6.50 24.6
16 9.57 36.2
20 12.00 45.4
24 29.00 109.8
30 42.00 197.0
36 90.00 340.0
3
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Maintenance
Preventative Maintenance
The Cla-Val Co. Model 100-01 Hytrol Valve requires no lubrication or
packing and a minimum of maintenance. However, a periodic inspec-
tion schedule should be established to determine how the operating
conditions of the system are affecting the valve. The effect of these
actions must be determined by inspection.
Disassembly
Inspection or maintenance can be accomplished without removing
the valve from the line. Repair kits with new diaphragm and disc are
recommended to be on hand before work begins.
WARNING: Maintenance personnel can be injured and equipment
damaged if disassembly is attempted with pressure in the valve. SEE
CAUTION.
1. Close upstream and downstream isolation valves and independ-
ent operating pressure when used to shut off all pressure to the
valve.
2. Loosen tube fittings in the pilot system to remove pressure from
valve body and cover chamber. After pressure has been released
from the valve, use care to remove the controls and tubing. Note and
sketch position of tubing and controls for re-assembly. The schemat-
ic in front of the Technical Manual can be used as a guide when
reassembling pilot system.
3. Remove cover nuts and remove cover. If the valve has been in
service for any length of time, chances are the cover will have to be
loosened by driving upward along the edge of the cover with a dull
cold chisel.
On 6” and smaller valves block and tackle or a power hoist can be
used to lift valve cover by inserting proper size eye bolt in place of
the center cover plug. on 8” and larger valves there are 4 holes (5/8”
— 11 size) where jacking screws and/or eye bolts may be inserted
for lifting purposes. Pull cover straight up to keep from damaging
the integral seat bearing and stem.
4. Remove the diaphragm and disc assembly from the valve body.
With smaller valves this can be accomplished by hand by pulling
straight up on the stem so as not to damage the seat bearing.
On large valves, an eye bolt of proper size can be installed in the
stem and the diaphragm assembly can be then lifted with a block and
tackle or power hoist. Take care not to damage the stem or bearings.
The valve won't work if these are damaged.
5. The next item to remove is the stem nut. Examine the stem
threads above the nut for signs of mineral deposits or corrosion.
If the threads are not clean, use a wire brush to remove as much
of the residue as possible. Attach a good fitting wrench to the nut
and give it a sharp “rap” rather than a steady pull. Usually
several blows are sufficient to loosen the nut for further removal.
On the smaller valves, the entire diaphragm assembly can be held
by the stem in a vise equipped with soft brass jaws before
removing the stem nut.
The use of a pipe wrench or a vise without soft brass jaws scars
the fine finish on the stem. No amount of careful dressing can
restore the stem to its original condition. Damage to the finish of
the stem can cause the stem to bind in the bearings and the valve
will not open or close.
6. After the stem nut has been removed, the diaphragm assembly
breaks down into its component parts. Removal of the disc from
the disc retainer can be a problem if the valve has been in serv-
ice for a long time. Using two screwdrivers inserted along the out-
side edge of the disc usually will accomplish its removal. Care
should 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 ordinarily
does not require removal. Careful cleaning and polishing of inside
and outside surfaces with 400 wet/dry sandpaper will usually
restore the seat’s sharp edge. If, however, it is badly worn and
replacement is necessary, it can be easily removed.
Seats in valve sizes 1 1/4” through 6” are threaded into the valve
body. They can be removed with accessory X109 Seat Removing
Tool available from the factory. On 8” and larger valves, the seat
is held in place by flat head machine screws. Use a tight-fitting,
long shank screwdriver to prevent damage to seat screws. If upon
removal of the screws the seat cannot be lifted out, it will be nec-
essary to use a piece of angle or channel iron with a hole drilled
in the center. Place it across the body so a long stud can be insert-
ed through the center hole in the seat and the hole in the angle
iron. By tightening the nut a uniform upward force is exerted on
the seat for removal.
NOTE: Do not lift up on the end of the angle iron as this may force
the integral bearing out of alignment, causing the stem to bind.
VALVE STEM THREAD SIZE
Valve Size Thread Size (UNF Internal)
1 1/4"—2 1/2" 10—32
3"—4" 1/4—28
6"—14" 3/8—24
16" 1/2—20
20 3/4-16
24" 3/4-16
30” 3/4-16
36” 3/4-16
COVER CENTER PLUG SIZE
Valve Size Thread Size (NPT)
1 1/4"—1 1/2" 1/4"
2"—3" 1/2"
4"—6" 3/4"
8"—10" 1"
12" 1 1/4"
14" 1 1/2"
16" 2"
20” & 24" 2"
30” & 36” 2”
NUT ANGLE OR CHANNEL IRON
LONG STUD OR BOLT
NUT OR BOLT HEAD
DO NOT
LIFT
VALVE SEAT
VALVE BODY
4
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Lime Deposits
One of the easiest ways to remove lime deposits from the valve
stem or other metal parts is to dip them in a 5-percent muriatic
acid solution just long enough for the deposit to dissolve. This
will remove most of the common types of deposits. CAUTlON:
USE EXTREME CARE WHEN HANDLING ACID. Rinse parts in
water before handling. If the deposit is not removed by acid, then
a fine grit (400) wet or dry sandpaper can be used with water.
Reassembly
1. Reassembly is the reverse of the disassembly procedure. If a
new disc has been installed, it may require a different number of
spacer washers to obtain the right amount of “grip” on the disc.
When the diaphragm assembly has been tightened to a point
where the diaphragm cannot be twisted, the disc should be com-
pressed very slightly by the disc guide. Excessive compression
should be avoided. Use just enough spacer washers to hold the
disc firmly without noticeable compression.
2. MAKE SURE THE STEM NUT IS VERY TIGHT. Attach a good
fitting wrench to the nut and give it a sharp “rap” rather than a
steady pull. Usually several blows are sufficient to tighten the
stem nut for final tightening. Failure to do so could allow the
diaphragm to pull loose and tear when subjected to pressure.
Test Procedure After Valve Assembly
There are a few simple tests which can be made in the field to
make sure the Hytrol Valve has been assembled properly. Do
these before installing pilot system and returning valve to
service. These are similar to the three troubleshooting tests.
1. Check the diaphragm assembly for freedom of movement
after all pressure is removed from the valve. SEE CAUTlON.
Insert fabricated tool into threaded hole in top of valve stem, and
lift the diaphragm assembly manually. Note any roughness,
sticking or grabbing. The diaphragm assembly should move
smoothly throughout entire valve stroke. The tool is fabricated
from rod that is threaded on one end to fit valve stem (See chart
in Step 4 of “Disassembly” section.) and has a “T” Bar handle of
some kind on the other end for easy gripping.
Place marks on this diaphragm assembly lifting tool when the
valve is closed and when manually positioned open. The dis-
tance between the two marks should be approximately the stem
travel shown in stem travel chart. (See “Freedom of Movement
Check” section.) If the stroke is different than that shown, there
is a good reason to believe something is mechanically restricting
the stroke of the valve. The cover must be removed, the obstruc-
tion located and removed. (See “Maintenance” Section for
procedure.)
Inspection of Parts
After the valve has been disassembled, each part should be
examined carefully for signs of wear, corrosion, or any other
abnormal condition. Usually, it is a good idea to replace the rub-
ber parts (diaphragm and disc) unless they are free of signs of
wear. These are available in a repair kit. Any other parts which
appear doubtful should be replaced. WHEN ORDERlNG
PARTS, BE SURE TO GIVE COMPLETE NAMEPLATE DATA,
ITEM NUMBER AND DESCRlPTlON.
NOTE: If a new disc isn’t available, the existing disc can be
turned over, exposing the unused surface for contact with the
seat. The disc should be replaced as soon as practical.
3. Carefully install the diaphragm assembly by lowering the stem
through the seat bearing. Take care not to damage the stem or
bearing. Line up the diaphragm holes with the stud or bolt holes
on the body. on larger valves with studs, it may be necessary to
hold the diaphragm assembly up part way while putting the
diaphragm over the studs.
4. Put spring in place and replace cover. Make sure diaphragm
is Iying smooth under the cover.
5. Tighten cover nuts firmly using a cross-over pattern until all
nuts are tight.
6. Test Hytrol Valve before re-installing pilot valve system.
Due to the weight of the diaphragm assembly this procedure is
not possible on valves 8” and larger. on these valves, the same
determination can be made by carefully introducing a low
pressure-less than five psi) into the valve body with the cover
vented. SEE CAUTION. Looking in cover center hole see the
diaphragm assembly lift easily without hesitation, and then
settle back easily when the pressure is removed.
2. To check the valve for drip-tight closure, a line should be
connected from the inlet to the cover, and pressure applied at the
inlet of the valve. If properly assembled, the valve should hold
tight with as low as ten PSI at the inlet. See “Tight Sealing
Check” section.)
3. With the line connected from the inlet to the cover, apply full
working pressure to the inlet. Check all around the cover for any
leaks. Re-tighten cover nuts if necessary to stop leaks past the
diaphragm.
4. Remove pressure, then re-install the pilot system and tubing
exactly as it was prior to removal. Bleed air from all high
points.
5. Follow steps under “Start-Up and Adjustment” Section in
Technical Manual for returning complete valve back to service.
5
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1
5
8
10
14 16
6177
9
OUTLE
T
INLET
GLOBE PATTERN
9
26
27
12
15
14
16
INLET
OUTLET
ANGLE PATTERN
22
23
13
12
14
10
11 15
23
TOP VIEW
8" - 24" SEAT DETAIL
1 1/4" - 6" SEAT DETAIL 16" COVER DETAIL
4
24
2
25
13
31
28
30
29
5
14
3
Item Description
1. Pipe Plug
2. Drive Screws (for nameplate)
3. Hex Nut (8” and larger)
4. Stud (8” and larger)
5. Cover Bearing
6. Cover
7. Stem Nut
8. Diaphragm Washer
9. Diaphragm
10. Spacer Washers
11. Disc Guide
12. Disc Retainer
13. Disc
14. Stem
15. Seat
16. Body
17. Spring
22. Flat Head Screws (8” and larger)
23. Seat O-Ring
24. Hex head Bolt (1 1/4” thru 4”)
25. Nameplate
26. Upper Spring Washer (Epoxy coated valves only)
27. Lower Spring Washer (Epoxy coated valves only)
28. Cover Bearing Housing (16” only)
29. Cover O-Ring (16’” only)
30. Hex Bolt (16” only)
31. Pipe Cap (16” only)
PARTS LIST
6
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100-01
Hytrol Valve Service Data
MODEL
INSTALLATION / OPERATION / MAINTENANCE
Description 100-01 Hytrol Valve The CIa-VaI Model 100-01 Hytrol Valve is a main valve for CIa-VaI Automatic Control Valves. It is a hydraulically operated, diaphragm-actuated, globe or angle pattern valve. This valve consists of three major components; body, diaphragm assembly, and cover. The diaphragm assembly is the only moving part. The diaphragm assembly uses a diaphragm of nylon fabric bonded with synthetic rubber. A synthetic rubber disc, contained on three and one half sides by a disc retainer and disc guide, forms a seal with the valve seat when pressure is applied above the diaphragm. The diaphragm assembly forms a sealed chamber in the upper portion of the valve, separating operating pressure from line pressure.
Description 100-20 600 Series Hytrol Valve The CIa-VaI Model 100-20 Hytrol Valve (600 Series main valve) have only one part -the body- that is different from standard 100 Series Cla-Val main valve parts. The remaining parts of the 600 series main valve are standard Cla-Val main valve parts. All serv- ice and maintenance information for the standard 100 Series main valves also apply to the 600 series main valves. The most important thing to remember when ordering main valve repair kits and replacement parts, except for the body, all other parts are going to be for a smaller size main valve. Cla- Val identifies main valve parts with the flange size of the stan- dard 100 Series main valve. Refer to the "Main Valve Sizes” chart below.
HYTROL Service Data
HYTROL SIZE Stem
Travel
Cover Capacity
Displacement Valve Stem
Thread
UNF-Internal
Cover
Center
Plug
NPT
Cover Nut or Bolt Cover
Lifting
Holes
UNC
Cover Plug Cover Torque Stem Nut** Stem Nut Torque
(ft. Lbs.)
100-01 100-20 Thread
(Bolt) Socket Qty Thread Socket ft. Lbs. in. Lbs. Thread Socket
(Long)
inches mm inches mm inches mm Gallons Liters Lubed DRY
1" 25 0.3 81/4" 1/4" - 20 (B) 7/16" 8448 3/8" - 24 46
1 1/4" 32 0.4 10 0.020 0.07 10 - 32 1/4" 5/16" - 18 (B) 1/2" 8896 7/16" -20 610 1 1/2" 40 0.4 10 0.020 0.07 10 - 32 1/4" 5/16" - 18 (B) 1/2" 8896 7/16" -20 610
2" 50 0.6 15 0.032 0.12 10 - 32 1/2" 3/8" - 16 (B) 9/16" 83/8" 7/16" 12 1/2" - 20 3/4" 10 15
2 1/2" 65 0.7 18 0.043 0.16 10 - 32 1/2" 7/16" - 14 (B) 5/8" 81/2" 9/16" 20 5/8" - 18 15/16" 21 30
3" 80 4" 100 0.8 20 0.080 0.30 1/4 - 28 1/2" 1/2" - 13 (B) 3/4" 81/2" 9/16" 30 5/8" - 18 15/16" 21 30
4" 100 6" 150 1.1 23 0.169 0.64 1/4 - 28 3/4" 3/4" - 10 (B) 1 1/8" 83/4" 5/8" 110 3/4" - 16 1 1/16" 40 60
6" 150 8" 200 1.7 43 0.531 2.00 3/8 - 24 3/4" 3/4" - 10 (B) 1 1/8" 12 3/4" 5/8" 110 7/8" - 14 1 5/16" 85 125 8" 200 10" 250 2.3 58 1.26 4.80 3/8 - 24 1" 3/4" - 10 1 1/4" 16 5/8" - 11 1" 13/16" 110 1 1/8" -12 1 13/16" 125 185
10" 250 12" 300 2.8 71 2.51 9.50 3/8 - 24 1" 7/8" - 9 1 7/16" 20 3/4" - 10 1" 13/16" 160 1 1/2" -12 1 7/8" 252 375 12" 300 16" 400 3.4 86 4.0 15.10 3/8 - 24 1 1/4" 1 1/8" - 7 1 13/16" 20 3/4" - 10 1" 13/16" 390 1 1/2" -12 2 1/2" 270 400
14" 350 3.9 99 6.5 24.60 3/8 - 24 1 1/2" 1 1/4" - 7 2" 20 1" - 8 1" 13/16" 545 1 1/2" -12 2 1/2" 280 420
16" 400 20", 24" 600 4.5 114 9.6 36.20 1/2 - 20 2" 1 1/4" - 7 2" 20 1" - 8 1" 13/16" 545 2" - 16 3" 500 750
20" 500 5.63 143 12 45.40 3/4 - 16 1 1/2" 1 3/8" - 6 2 1/8" 24 1" - 8 1" 13/16" 670 2 1/4" - 16 3 1/2" 930 N/R
24" 600 30" 800 6.75 165 29.0 108.80 3/4 - 16* 3/4" 1 1/2" - 12 2 3/8" 24 1 1/8"- 7 1" 13/16" 800 3" - 12 Special 1350 N/R
* Adapter
p/n 2594101E
inside 1/4" - 28"
Grade 5 Bolts
"Heavy" Grade Nuts
Tighten cover nuts in a "star" cross-over pattern
** Must Use ONLY
Cla-Val Supplied part
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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
N-100-01 (R-3/2011
BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS
4
BOLTS
6
BOLTS
8
BOLTS
12
BOLTS
16
BOLTS
20
BOLTS
4
3
2
1
65
4
3
2
1
8
7
6
5
4
3
2
1
0
9
8
7
6
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
20
19
18
17
16
15
14
13
12
11
Follow this procedure when reassembling MAIN Valve: 1. Tightens bolts/nuts in a “Star” or “Cross-Over” pattern following the numbers shown above to insure that cover seats evenly on the diaphragm material and body. 2. Torque the bolt/nuts in three stages with a "Star" or "Cross-Over" pattern
for each stage:
A. To approximately 10% of final torque. B. To approximately 75% of final torque. C. To final required torque.
3. Valves that are to be tested to 375 PSI or higher should be retorqued
after 24 hours.
100-01 Hytrol Main Valve Assembly
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Listed/Approved Fire Protection Pressure Relief Valve
50B-4KG1 Globe
2050B-4KG1 Angle
• U.L. Listed / U.L.C. Listed
• Factory Mutual Approved
• Fast Opening to Maintain Steady Line Pressure
• Accommodates Wide Range of Flow Rates
• Closes Gradually for Surge-Free Operation
• Adjustable Pressure Settings, Not Affected by
Pressure At Valve Discharge
The Cla-Val Model 50B-4KG1 Globe / 2050B-4KG1 Angle
Pressure Relief Valve is designed specifically to automati-
cally relieve excess pressure in fire protection pumping sys-
tems. Pilot controlled, it maintains constant system pres-
sure at the pump discharge within very close limits as
demands change. The 50B-4KG1 and 2050B-4KG1 can be
supplied with optional internal and external epoxy coating of
the main valve wetted surfaces.
At pump start, Cla-Val Relief Valve modulates to relieve
excess pump capacity, maintaining positive system pres-
sure at the pump discharge.
When fire demand slows or ceases, Cla-Val Model
50B-4KG1 opens, diverting entire pump output to dis-
charge, allowing fire pump to be stopped without causing
surging in the lines.
(Please note that if the Model 50B-4KG1 is to be used on
a continuous duty basis to maintain fire-system pressure,
suitable back pressure must be provided on the valve to
prevent cavitation damage. Consult the factory for details.)
Operation Sequence
Typical Application KOModel 2050B-4KG1
Pressure Relief Valve
(Angle Pattern)
Fire Pump
Check Valve
"Fluid Control at It's Best"
2050B-4KG1 (Angle)
To Fire
Protection System
U.L. Listed...............Sizes 3" thru 8"
F.M. Approved.........Sizes 3" thru 8"
U.L.C. Listed............Sizes 2” thru 10”
L
A
B
L
L
E
D
B
Y
U
N
D
E
R
W
R
I
T
E
R
S
L
A
B
O
R
A
T
O
R
I
E
S
O
F
C
A
N
A
D
A
U
L
C
MODEL
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Represented By:
E-50B-4KG1/2050B-4KGL1 (R-10/2013)
Model 2050B-4KG1 Angle
Model 50B-4KG1 Globe
We recommend providing adequate space around valve for maintenance work.
Specifications
Globe: 2" - 10” flanged
Angle: 2" - 10" flanged
150 and 300 ANSI B16.42
class - 175 psi Max.
class - 300 psi Max
Water, to 180°F Max.
Main Valve Body & Cover
Ductile Iron ASTM A-536
Naval Bronze ASTM B61
Other Material Available
Standard Main Valve Trim:
Bronze Seat, Teflon Coated
Stainless Steel Stem,
Dura-Kleen Stem
Standard Pilot Control System:
Cast Bronze with
Stainless Steel trim
Available in the following relief
pressure ranges:
20-200 psi (150 Class)
100-300 psi (300 Class)
Protective epoxy resin coating
of wetted surfaces of main
valve cast iron components
(UL listed HNFX EX2855)
Dimensions
B
G
C
F
HE
C
D
A
The Fire Pump Pressure Relief Valve shall modulate to relieve excess
pressure in a fire protection system. It shall maintain constant pressure
in the system regardless of demand changes. It shall be pilot controlled
and back pressure shall not affect its set point. It shall be actuated by
line pressure through a pilot control system and open fast in order to
maintain steady system pressure as system demand decreases. It shall
close gradually to control surges and shall re-seat drip-tight within 5% of
its pressure setting. The main valve shall be of the hydraulically-operat-
ed, pilot-controlled, diaphragm-type, globe or angle valve. It shall have
a single, removable, teflon-coated seat, a grooved stem guided at both
ends, and a resilient disc with a rectangular cross section, being con-
tained on 3 1/2 sides. No external packing glands shall be permitted and
the diaphragm shall not be used as a seating surface. The pilot control
shall be a direct-acting, adjustable, spring-loaded, diaphragm-type valve
designed for modulating service to permit flow when controlling pressure
exceeds spring setting. This valve shall be UL Listed and Factory Mutual
approved. It shall be the Model 50B-4KG1 (globe) or Model 2050B-
4KG1 (angle) Pressure Relief Valve as manufactured by Cla-Val Newport
Beach, California.
*Special Note:
The Model 50B-4KG1 Pressure Relief Valve is available with 300# ANSI
inlet flange and 150# ANSI outlet flange. This valve is used on higher
pressure systems where 300# flange connections are required, and
allows for adapting of a discharge cone (generally supplied with 150#
flange) to accommodate "atmospheric break" at relief valve discharge.
This relief valve, with 300# / 150# flanges is available on special order,
and is UNDERWRITERS LABORATORIES LISTED AND FACTORY
MUTUAL APPROVED.
Purchase Specifications
Sizes
End Details
Pressure Ratings
Materials
Adjustment Range
Optional
Valve Capacity
Valve Sizes in Inches: 2" 2 1/2" 3" 4" 6" 8" 10"
NFPA 20 Maximum
Recommended GPM 208 300 500 1000 2500 5000 11000
= U.L., F.M. and
ULC sizes
Valve Size (inches) 2” 2-1/2” 3” 4” 6” 8” 10”
Threaded Ends 9.38 11.00 12.50 - - - - - - - - - - - -
A 150 Flanged 9.38 11.00 12.00 15.00 20.00 25.38 29.75
300 Flanged 10.00 11.62 13.25 15.62 21.00 26.38 31.12
300 X 150 12.88 15.31 20.56 25.88 30.44
B3.31 4.00 4.56 5.75 7.88 10.00 11.81
C12.00 12.25 12.50 13.00 14.31 16.31 18.00
D1.50 1.69 2.66 3.19 4.31 5.31 9.25
Threaded Ends 4.75 5.50 6.25 - - - - - - - - - - - -
E 150 Flanged 4.75 5.50 6.00 7.50 10.00 12.75 14.88
300 Flanged 5.00 5.88 6.38 7.88 10.50 13.25 15.56
Threaded Ends 3.25 4.00 4.50 - - - - - - - - - - - -
F 150 Flanged 3.25 4.00 4.00 5.00 6.00 8.00 8.62
300 Flanged 3.50 4.31 4.38 5.31 6.50 8.50 9.31
G & H 6.00 6.69 7.75 7.88 8.50 9.75 13.25
Valve Size (mm) 50 65 80 100 150 200 250
Threaded Ends 238 279 318 - - - - - - - - - - - -
A 150 Flanged 234 279 305 381 508 645 756
300 Flanged 254 295 337 397 533 670 790
300 X 150 - - - - - - 327 389 522 657 773
B84 102 116 146 200 254 300
C305 311 1318 330 363 414 457
D38 43 65 81 109 135 235
Threaded Ends 121 140 159 - - - - - - - - - - - -
E 150 Flanged 121 140 152 191 254 324 378
300 Flanged 127 149 162 200 267 337 395
Threaded Ends 83 102 114 - - - - - - - - - - - -
F 150 Flanged 83 102 102 127 152 203 219
300 Flanged 89 109 111 135 165 216 236
G & H 152 170 197 200 216 248 337
= ULC sizes only
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DESCRIPTION
The CRL Pressure Relief Control is a direct acting, spring loaded,
diaphragm type relief valve. It may be used as a self-contained valve or
as a pilot control for a Cla-Val Main valve. It opens and closes within
very close pressure limits.
INSTALLATION
The CRL Pressure Relief Control may be installed in any position. The
control body (7) has one inlet and one outlet port with a side pipe plug
(24) at each port. These plugs are used for control connections or gauge
applications. The inlet in the power unit body (6) is the sensing line port.
A flow arrow is marked on the body casting.
OPERATION
The CRL Pressure Relief Control is normally held closed by the force of
the compression spring above the diaphragm; control pressure is applied
under the diaphragm.
When the controlling pressure exceeds the spring setting, the disc is lifted
off its seat, permitting flow through the control.
When controlling pressure drops below spring setting, the spring returns
the control to its normally closed position.
ADJUSTMENT PROCEDURE
The CRL Pressure Relief Control can be adjusted to provide a relief set-
ting at any point within the range found on the nameplate.
Pressure adjustment is made by turning the adjustment screw (9) to vary
the spring pressure on the diaphragm. Turning the adjustment screw
clockwise increases the pressure required to open the valve.
Counterclockwise decreases the pressure required to open the valve.
When pressure adjustments are complete the jam nut (10) should be
tightened and the protective cap (1) replaced. If there is a problem of
tampering, lock wire holes have been provided in cap and cover. Wire
the cap to cover and secure with lead seal.
DISASSEMBLY
The CRL Pressure Relief Control does not need to be removed from the
line for disassembly. Make sure that pressure shut down is accompanied
prior to disassembly. If the CRL is removed from the line for disassembly
be sure to use a soft jawed vise to hold body during work.
Refer to Parts List Drawing for Item Numbers.
1. Remove cap (1), loosen jam nut (10) and turn adjusting
screw counterclockwise until spring tension is relieved.
2. Remove the eight screws (4) holding the cover (3) and
powerunit body (6). Hold the cover and powerunit together
and place on a suitable work surface.
See NOTE under REASSEMBLY.
3. Remove the cover (3) from powerunit body (6). The spring
(12) and two spring guides (11).
4. Remove nut (13) from stem (19) and slide off the belleville washer
(14), the upper diaphragm washer (15) and the diaphragm (16).
5. Pull the stem (19) with the disc retainer assembly (21) through the
bottom of powerunit. The lower diaphragm washer (17) will slide off
of stem top.
6. Remove jam nut (23) and disc retainer assembly (21) from stem.
Use soft jawed pliers or vise to hold stem. The polished surface of
stem must not be scored or scratched.
7. The seat (22) need not be removed unless it is damaged. If removal
is necessary use proper size socket wrench and turn counterclock
wise.
Note: Some models have an integral seat in the body (7).
INSPECTION
Inspect all parts for damage, or evidence of cross threading. Check
diaphragm and disc retainer assembly for tears, abrasions or other dam-
age. Check all metal parts for damage, corrosion or excessive wear.
REPAIR AND REPLACEMENT
Minor nicks and scratches may be polished out using 400 grit wet or dry
sandpaper fine emery or crocus cloth. Replace all O-rings and any dam-
aged parts.
When ordering replacement parts, be sure to specify parts list item num-
ber and all nameplate data.
REASSEMBLY
In general, reassembly is the reverse of disassembly. However, the fol-
lowing steps should be observed:
1. Lubricate the O-Ring (18) with a small amount of a good grade of
waterproof grease, (Dow Corning 44 medium grade or equal).
Use grease sparingly and install O-ring in powerunit body (6).
2. Install stem (19) in powerunit body (6). Use a rotating motion with
minimum pressure to let stem pass through O-ring.
Do Not Cut O-Ring.
3. Install O-ring (5) at top of stem (19). Place lower diaphragm
washer (17) on the stem with the serrated side up. Position
diaphragm (16), upper diaphragm washer (15), with serration down,
and belleville washer (14) with concave side down.
4. Position powerunit body (6) as shown on parts list drawing (top view).
5. Continue reassembly as outlined in disassembly steps 1 through 3.
Pressure Relief Control
CRL
Note: Item (4) Screw will have a quantity of 8 for the 0-75 and 20-200psi
design and a quantity of 4 for the 100-300psi design. Item (25) Screw is
used on the 100-300psi design only. Install item (25), before item (4) for
preload of item (12) spring.
SYMPTOM PROBABLE CAUSE REMEDY
Fails to open. Controlling pressure
too low.
Back off adjusting
screw until valve
opens.
Fails to open with
spring compression
removed.
Mechanical obstruc-
tion, corrosion, scale
build-up on stem.
Disassemble,
locate,and remove
obstruction, scale.
Leakage from cover
vent hole when con-
trolling pressure is
applied.
Diaphragm Damage Disassembly replace
damaged
diaphragm.
Fails to close with
spring compressed.
Mechanical obstruc-
tion.
Disassemble, locate
and remove
obstruction.
Fails to close. No spring compres-
sion.
Re-set pressure
adjustment.
Loose diaphragm
assembly.
Tighten upper
diaphragm washer.
MODEL
INSTALLATION / OPERATION / MAINTENANCE
N-CRL (R-3/2011)
Distributed By: M&M Control Service, Inc.
www.mmcontrol.com/claval-index.php
800-876-0036 847-356-0566

1/2" & 3/4" PRESSURE RELIEF CONTROL
(Bronze Body with 303SS Trim)
CRL
Ajusting Screw
(3/8" - 16UNF THREAD)
9
1
10
3
11
12
14
13 11
822 23 7
18
19
21
INLET
1/8 - 27 NPT
SENSING
CONNECTION
(TYP.)
7.44
MAX
.71
OUTLET
20
6
2
0 TO 75 AND
20 TO 200 PSI
DESIGN
5
17
16
15
4
1
9
10
3
11
12
18
7
2
100 To 300 psi Design
.71
ADJUSTING SCREW
(1/2" 20UNF THREAD)
10.44
MAX.
When ordering parts please specify:
1. All Nameplate Data
2. Item Part Number
3. Item Description
24
4
45º
3.12
DIA.
TRUE LOCATION OF
SENSING
CONNECTION
(TYP.)
Body with
integral Seat
PL-CRL (R-8/2011)
PARTS LIST
Item Description Material Part Number Part Number Part Number Part Number
0-75 20-105 20-200 100-300
1Cap Plastic 67628J 67628J 67628J 1257601D
2Nameplate Brass -- -- -- --
3Cover Bronze C2544K C2544K C2544K 44587E
4* Screw Fil. Hd. 10-32 x 1.88 (Qty 8) 303 SS 6757867E 6757867E 6757867E 6757867E
5* O-Ring Rubber 00902H 00902H 00902H 00902H
6Body, Powerunit Bronze 7920504D 7920504D 7920504D 7920504D
71/2” Body Bronze C7928K C7928K C7928K C7928K
3/4” Body Bronze C9083B C9083B C9083B C9083B
8* O-Ring, Seat Rubber 00718H 00718H 00718H 00718H
9Screw, Adjusting Brass 7188201D 7188201D 7188201D 82811B
10 Nut Hex (Locking) 303 SS 6780106J 6780106J 6780106J 6780606H
11 Guide, Spring 303 SS 71881H 71881H 71881H 1630301J
12 Spring CHR/VAN 71884B 20632101E 71885J 1630201A
13 Nut, Stem Upper Bronze 73034B 73034B 73034B 73034B
14 Washer, Belleville Steel 7055007E 7055007E 7055007E 7055007E
15 Washer, Diaphragm (upper) 303 SS 71891G 71891G 71891G 71891G
16* Diaphragm Rubber C1505B C1505B C1505B C1505B
17 Washer, Diaphragm (lower) 303 SS 45871B 45871B 45871B 45871B
18* O-Ring, Stem Rubber 00746J 00746J 00746J 00746J
19 Stem 303 SS 8982401F 8982401F 8982401F 8982401F
20* O-Ring, Body Rubber 00767E 00767E 00767E 00767E
21* Retainer Assembly, Disc 303 SS C9158B C9158B C9158B C9158B
22 Seat 303Rub 62187A 62187A 62187A 62187A
23 Nut, Hex, Stem, Lower Bronze 6779806G 6779806G 6779806G 6779806G
24 Pipe Plug Bronze 6784701C 6784701C 6784701C 6784701C
FACTORY SET POINT 50 PSI 60 PSI 60 PSI 100 PSI
REPAIR KIT* 9170007A 9170007A 9170007A 9170007A
CRL
Range PSI
APPROX. INCREASE
FOR EACH
CLOCKWISE TURN OF
ADJUSTING SCREW
0 to 75 8.5 PSI
20 to 105 12.5 PSI
20 to 200 28.0 PSI
100 to 300 18.0 PSI
SIZE SPRING PART
NUMBER
1/2” 0-75 PSI 7922201E
1/2” 20-105 PSI 7922205F
1/2” 20-200 PSI 7922202C
1/2” 100-300 PSI 8280901D
3/4” 0-75 PSI 7922901K
3/4” 20-105 PSI 7922903F
3/4” 20-200 PSI 7922902H
3/4” 100-300 PSI 8600501E
For 250-600 PSI Contact Factory
Distributed By: M&M Control Service, Inc.
www.mmcontrol.com/claval-index.php
800-876-0036 847-356-0566