CLA-VAL 92-01 Owner's manual

INTRODUCTION
The Cla-Val 92-01/692-01 is an automatic valve designed to maintain a
constant downstream pressure regardless of fluctuating demand and sus-
tain the upstream pressure to a predetermined minimum. The control sys-
tem consists of a reducing control sensing downstream pressure changes
and a pressure sustaining control that is sensing the main valve inlet. The
pressure reducing control responds to slight downstream variations in
pressure and immediately controls the main valve to maintain the desired
downstream pressure. The pressure sustaining control is normally held
open by the upstream pressure but closes if this pressure drops to the
control set point. This in turn closes the main valve to sustain the desired
upstream pressure.
INSTALLATION
1. Allow sufficient room around the valve assembly to make adjustments
and for disassembly.
2. It is recommended that gate or block valves be installed on both ends
of the 92-01/692-01 valve assembly to facilitate isolating the valve for
maintenance.
NOTE: BEFORE THE VALVE IS INSTALLED, PIPE LINES SHOULD BE
FLUSHED OF ALL CHIPS, SCALE, AND FOREIGN MATTER.
3. Place valve assembly in pipe line with flow through valve in direction
indicated on inlet plate or by flow arrows. Check all fittings and hardware
for proper makeup and that no apparent damage is evident.
4. Cla-Val Valves operate with maximum efficiency when mounted in hor-
izontal piping with the cover UP; however, other positions are acceptable.
Due to size and weight of cover and internal components of six inch and
larger valves installation with the cover up is advisable. This makes peri-
odic 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
dissimilar metals.
OPERATION AND START-UP
1. Prior to pressurizing the valve make sure necessary gauges to mea-
sure pressure in the system are installed as required by the system engi-
neer. A Cla-Val X101 Valve Position Indicator may be installed in the cen-
ter cover port to provide a visual indication of the valve stem position dur-
ing start-up adjustments.
CAUTION: During start-up and test a large volume of water may be dis-
charged downstream. Check that the downstream venting is adequate to
prevent damage to personnel and equipment. All adjustments in pressure
should be made slowly. If the main valve closes too fast it may cause
surging in upstream piping.
2. If isolation valves (B) are installed in pilot system open these valves
(see schematic).
3. Remove cap on the CRL Pressure Relief Control (4). Loosen jam nut
and turn adjusting screw counter clockwise. This puts the CRL in an open
position.
4. Cla-Val CV Flow Control (5 & C) provide adjustable regulation of flow
in and out of the main valve chamber which minimizes pulsations that
sometimes occur at very low flow rates. Loosen jam nuts and turn adjust-
ment screws counterclockwise from closed position 3.5 turns for an initial
setting.
5. Open the upstream gate or block valve just slightly to allow the valve
assembly and pilot system to fill with liquid.
6. Carefully loosen tube fittings at highest points and bleed air from sys-
tem. Carefully loosen the plug at top of main valve cover. If X101 indica-
tor is installed, carefully open vent valve at top of Indicator. Bleed air from
cover and tighten plug. Tighten tube fittings.
7. Open the upstream gate or block valve fully.
8. Slowly open the downstream gate or block valve. Flow should occur
and pressure should remain constant.
9. Adjust the CRD Control (3) to desired outlet pressure. To change pres-
sure setting, turn the adjusting screw clockwise to increase pressure,
counterclockwise to decrease pressure: There should be flow through the
valve when adjusting pressure. When the desired setting has been made,
tighten jam nut and replace cover. An increase in pressure at the outlet will
tend to close the CRD Control and main valve. This action causes the
main valve with CV control (5 or C) to modulate (open and close) main-
taining a relatively constant outlet pressure.
10. Adjust the CRL Control (4) to maintain the desired minimum inlet or
upstream pressure. To change pressure setting, turn the adjusting screw
clockwise to increase the inlet pressure, counterclockwise to decrease
pressure. When the desired setting has been made, tighten jam nut and
replace cover. A decrease in inlet pressure below the set pressure of the
CRL closes the control and main valve. The main valve will modulate to
maintain the upstream pressure at the set point of CRL.
11. To check the operation of the pressure reducing and pressure sus-
taining features of the valve assembly, induce pressure changes at the
valve inlet and outlet.
12. Fine-tune the opening and closing speed of the main valve with CV
control (5 or C) while performing steps 9 and 10.
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 handled is affecting the
efficiency of the valve assembly. Minimum of once per year.
2. Repair and maintenance procedures of the Cla-Val Hytrol Main Valve
and pilot control components are included in a more detailed IOM manu-
al. 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.
92-01/692-01
MODEL
INSTALLATION / OPERATION / MAINTENANCE
Combination Pressure Reducing and
Pressure Sustaining Valve
SYMPTOM
Main valve
fails to open
Main valve
fails to close
PROBABLE CAUSE
No pressure at valve inlet
Main valve diaphragm assembly
inoperative
CRD Pressure Reducing Control
not opening:
1. No spring compression
2. Damaged spring
3. Spring guide not in place
4. Yoke dragging on inlet nozzle
CRL Control not opening:
1. Adjusting screw turned in too
far (setting too high)
2. Fails to open with spring
compression removed
3. Diaphragm damage (leakage
from cover vent hole)
4. Loose upper diaphragm washer
Foreign matter between disc &
seat of main valve, damaged disc,
scale on stem or disc guide,
diaphragm damaged
X44A Strainer & orifice clogged.
CK2 Shutoff Valve (B2) in control
line closed
CRD Pressure Reducing Control
remains open or sluggish:
1. Spring compressed solid
2. Worn or damaged disc
3. Yoke dragging on inlet nozzle
4. CRD diaphragm damaged or
loose diaphragm nut (leakage
from vent hole in cover)
CRL Pressure Relief Control fails
to close due to lack of spring com-
pression
A mechanical obstruction holding
control open
REMEDY
Check inlet pressure
Adjust CRL Disassemble,
clean and polish stem, disc
guide, replace defective or
worn parts
1. Tighten adjusting screw
2. Disassemble and replace
3. Assemble properly
4. Assemble properly
1. Back off adjusting screw
reset
2. Disassemble, remove
scale, obstruction
3. Disassemble, replace
damaged diaphragm
4. Tighten upper diaphragm
Disassemble main valve,
remove foreign matter,
clean or replace damaged
parts
Remove strainer plug and
Clean screen and orifice
Open CK2 Valve
1. Back off adjusting screw
2. Disassemble, remove
and replace disc retainer
assembly
3. Assemble properly
4. Disassemble, tighten
diaphragm nut replace
diaphragm
Turn adjusting screw in
clockwise
Reset control
Disassemble, locate and
remove obstruction
Distributed By: M&M Control Service, Inc.
www.mmcontrol.com/claval-index.php
800-876-0036 847-356-0566

CLA-VAL
Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice.
P.O. Box 1325 •Newport Beach, CA 92659-0325 •Phone: [phone] •Fax: [phone] •E-mail: [email protected] •Website cla-val.com
©
N-92-01/692-01 (R-9/08)
4
F
3
D1
B
2C
5
BD2
D3
1
B
INLET OUTLET
REMOTE SENSING
92-01/692-01 SCHEMATIC CRD
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
BASIC COMPONENTS
1 100-01 Hytrol (Main Valve)
100-20 600 Series Hytrol (Main Valve)
2 X44A Strainer & Orifice
3 CRD Pressure Reducing Control
4 CRL Pressure Relief Control
5 CV Flow Control - Opening
OPTIONAL FEATURES
B CK2 (Isolation Valves)
C CV Flow Control - Closing
D Check Valves with Isolation Valves
F Remote Sensing
CRD
X44A
CRL
CV
CK2
HYTROL MAIN VALVE
inlet
Cover vent
(3/8" NPT)
Cap
Adjusting Screw
Jam Nut
Cover
Spring
Hex Nut
Belleville Washer
Diaphragm Washer
Diaphragm*
Yoke
Body and Seat Assy
Disc Retainer Assy
Gasket*
Plug, Body
*Machine Screw
(Fil.Hd) 8 Req'd
Spring Guide
Pressure Setting
Adjusting Screw
(Turn Clockwise to
Increase Setting)
2.
3.
CRL
4.
1.
3.
4.
5.
B.
D.
For a more detailed IOM Manual go to www.cla-val.com or contact a Cla-Val Regional Sales Office.
CDC-1
Ajusting Screw
(3/8" - 16UNF THREAD)
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, Hex,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)
*SUGGESTED REPAIR PARTS
X140-1
Security Cap
Option
Distributed By: M&M Control Service, Inc.
www.mmcontrol.com/claval-index.php
800-876-0036 847-356-0566