DOOLEY TACKABERRY SYSTEMS

Remotely Actuated / Operated Firewater

Monitor and Tower Structure

71157883-PO-37502

Tag No.

FZ-7691, FZ-7692

DOOLEY TACKABERRY
Houston Corporate Headquarters — P.O. Box 9700 — Deer Park, Texas 77536
Voice: 281.479.9700 — Fax: 281.478-4527 — Internet: www.dtihome.com

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 TABLE OF CONTENTS
SECTION 1. INTRODUCTION

SECTION 2. SAFETY REQUIREMENTS

SECTION 3. BILL OF MATERIAL

SECTION 4. INSTALLATION

A. MONITOR TOWER SUPPORT COLUMN

B. LADDERS AND PLATFORMS

C. 8” WATERWAY AND MONITOR PIPING

D. RHMB FIRE WATER MONITOR CONNECTION

E. FIRE WATER MONITOR PNEUMATIC CONTROL TUBING AND TUBING SUPPORTS

F. RHMB FIRE WATER MONITOR AND CONTROL STATION

G. CLA-VAL MODEL 100GS DELUGE VALVE ASSEMBLY

SECTION 5. SEISMIC CALCULATION PACKAGE

SECTION 6. DRAWINGS

A. 71157883-JPO-37502-MB1-025 MONITOR TOWER GENERAL ARRANGEMENT

B. 71157883-JPO-37502-MB1-026 LOWER COLUMN GENERAL ARRANGEMENT

C. 71157883-JPO-37502-MB1-027 UPPER COLUMN GENERAL ARRANGEMENT

D. 71157883-JPO-37502-MB1-028 LOWER PLATFORM GENERAL ARRANGEMENT

E. 71157883-JPO-37502-MB1-029 MID PLATFORM GENERAL ARRANGEMENT

F. 71157883-JPO-37502-MB1-030 UPPER PLATFORM GENERAL ARRANGEMENT

G. 71157883-JPO-37502-MB1-031 LOWER LADDER GENERAL ARRANGEMENT

H. 71157883-JPO-37502-MB1-032 MID LADDER GENERAL ARRANGEMENT

I. 71157883-JPO-37502-MB1-033 UPPER LADDER GENERAL ARRANGEMENT

J. 71157883-JPO-37502-MB1-034 DELUGE VALVE GENERAL ARRANGEMENT

K. 71157883-JPO-37502-MB1-036 REMOTE OPERATING STATION GENERAL ARRANGEMENT

L. 71157883-JPO-37502-MB1-037 REMOTE FIRE WATER MONITOR GENERAL ARRANGEMENT

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SECTION 1 - INTRODUCTION

Dooley Tackaberry, Inc. assumes no liability in regard to the design and installation of any
foundations. A qualified engineer should design the foundation of the elevated monitor tower.
Seismic and Tower-loading calculations have been provided (Section 6) to aid in the design of the
foundation.

SECTION 2 - SAFETY REQUIREMENTS

• Before climbing the Monitor Tower ladder, ensure that all personnel are provided proper
fall protection and have been trained in the use of such equipment.

• Wear proper protective equipment during assembly.

• We recommend the use of a crane when lifting the tower components. Special lifting
shackles have been provided for each tower section. See section 4 below for more
erection details.

• Do not stack more than one tower section at a time.

Important:
• Before installing and operating this equipment, read & study this manual thoroughly.
Proper installation is essential to safe operation. In addition, the following points should
be adhered to in order to ensure the safety of equipment and personnel:

• All personnel who may be expected to use this equipment must be thoroughly trained in
its safe and proper use.

• Before opening the deluge valve, check that all personnel (fire service and civilian) are
out of the stream path. Verify stream direction will not cause avoidable property damage.

• Become thoroughly familiar with the hydraulic characteristics of this equipment, and the
pumping system used to supply it. To produce effective firewater streams, operating
personnel must be properly trained.

• After each use, and on a scheduled basis, inspect equipment to ensure it is in good
working order.

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SECTION 3 – BILL OF MATERIAL

Tower 1 Remote actuated / operated firewater Tower 2 Remote Actuated / Operated Firewater
monitor) FZ-7691 Monitor FZ-7692

Quantity Item Quantity Item

1 Ea Lower Tower Support Structure 1 Ea Lower Tower Support Structure
1 Ea Upper Tower Support Structure 1 Ea Upper Tower Support Structure

1 Ea Lower Ladder Assembly 1 Ea Lower Ladder Assembly

1 Ea Mid Ladder Assembly 1 Ea Mid Ladder Assembly
1 Ea Upper Ladder Assembly 1 Ea Upper Ladder Assembly

1 Ea Lower Platform Assembly 1 Ea Lower Platform Assembly

1 Ea Mid Platform Assembly 1 Ea Mid Platform Assembly
1 Ea Upper Platform Assembly 1 Ea Upper Platform Assembly

1 Ea Lower 8" Fire Water Supply Pipe 1 Ea Lower 8" Fire Water Supply Pipe
1 Ea Mid 8" Fire Water Supply Pipe 1 Ea Mid 8" Fire Water Supply Pipe
1 Ea Upper 8" Fire Water Supply Pipe 1 Ea Upper 8" Fire Water Supply Pipe

26 Ea Hydraulic Tubing, 316 Stainless Steel, Seamless 26 Ea Hydraulic Tubing, 316 Stainless Steel, Seamless
Tubing, .625X.035, 20' Pipe Length Tubing, .625X.035, 20' Pipe Length
4 Ea Hydraulic Tubing Support Assembly 4 Ea Hydraulic Tubing Support Assembly

1 Ea Model 100GS 8" Deluge and Model 2508 Gate 1 Ea Model 100GS 8" Deluge and Model 2508 Gate
Valve Assembly Valve Assembly

Tower Structure Connection Hardware Tower Structure Connection Hardware

72 Ea 5/8" Galvanized Flat Washers 72 Ea 5/8" Galvanized Flat Washers
32 Ea 3/4" Nuts and Bolts for Platforms 32 Ea 3/4" Nuts and Bolts for Platforms
64 Ea 3/4" Flat washer for Platforms 64 Ea 3/4" Flat washer for Platforms
36 Ea 5/8" Nuts & Bolts for Ladders 36 Ea 5/8" Nuts & Bolts for Ladders
72 Ea 1-1/8" x 5 1/2" Connection Bolts 72 Ea 1-1/8" x 5 1/2" Connection Bolts
24 Ea SS-1010-6 -Union 5/8" 24 Ea SS-1010-6 -Union 5/8"
1 Ea 4" 150lb FF Garlock Gasket 1 Ea 4" 150lb FF Garlock Gasket
4 Ea 8" Ring Gaskets 316SS 4 Ea 8" Ring Gaskets 316SS

Tower Remote Monitor and Control Station

1 Ea Remote Monitor (Tower 1)
1 Ea Remote Monitor (Tower 2)

1 Ea Dual Monitor Control Station

2 Ea Manual Shutoff Hydraulic Connection Port

2 Ea Manual Shutoff Hydraulic Connection Port Clip
12 Ea Remote Monitor Hydraulic Hose Assembly

Tower Touch Up Paint

1 Ea 5 Gallon Pail of Touch up Paint
1 Ea 1 Gallon of Hardener

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SECTION 4 – INSTALLATION AND OPERATION
A. MONITOR TOWERSUPPORT COLUMN

The main support structure of the elevated monitor tower is comprised of two column
sections Drawing Attachment 71157883-PO-37502-MB1-025, 026 and 027). To assist
in the transport and movement of the column sections; lifting shackles have been
affixed to the connection flanges, base flange and to an exterior lifting eye located at
the top of the upper column (See Figure 1). In addition to the lifting shackles; interior
sling supports are located on each column section for the vertical movement and
positioning of the columns (See Figure 1).

Figure 1

The support plate and anchor bolt support chairs (See Figure 2) located at the base of
the lower tower column have been fabricated to accept a total of 12 each; 2” J-Type
anchor bolts. The lower column section is to be securely anchored, leveled and
grouted to the foundation prior to further assembly of the tower structure.

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Figure 2

IMPORTANT:
THE TOWER IS AN OPEN STRUCTURE. TO ENSURE ADEQUATE DRAINAGE OF THE
STRUCTURE; DRAINS MUST BE ADDED TO THE FOUNDATION GROUTING.

Once the lower support structure has been properly anchored the upper column can
be lifted into place and attached to the 60” class 75 flange connection on the lower
section. The 60” connection flange requires a total of 72 ea. 1” structural steel bolts
(See Figure 3).

Figure 3

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 B. LADDER AND PLATFORMS

Three sections of ladder and platforms are provided with each tower and are
designated as follows: lower, middle and upper. The ladder and platform sections
should be installed highest platform section first ending with the lowest ladder section.
The ladder and platforms are attached to the tower structure by both 5/8” and 3/4” bolt
assemblies. Each bolt assembly consists of a bolt, a nut and two washers.

The upper platform is secured to the top of the tower structure at eight connection
points (Drawing Attachment 71157883-PO-37502-MB1-025, 027 and 030). Each
connection point requires two 3/4” bolt assemblies. Once the upper platform has been
secured to the tower structure the upper ladder section can be secured to the
structure.

The upper ladder section is secured to the side of the tower structure at eight
connection points (Drawing Attachment 71157883-PO-37502-MB1-025, 027, and 033)
and requires a total of ten 5/8” bolt assemblies. Once secured to the tower structure
the ladder should be attached to the upper platform handrail at the ladder entryway;
the connection requires two 5/8 bolt assemblies (Drawing Attachment 71157883-PO-
37502-MB1-030).

The middle platform is secured to the tower structure at two connection points
(Drawing Attachment 71157883-PO-37502-MB1-025, 027 and 029). Each connection
point requires four 3/4” bolt assemblies. Once the middle platform has been secured
to the tower structure the middle ladder section can be secured to the structure.

The middle ladder section is secured to the tower structure at eight connection points
(Drawing Attachment 71157883-PO-37502-MB1-025, 026, 027 and 032) and requires
a total of ten 5/8” bolt assemblies. Once secured to the tower structure the ladder
should be attached to the middle platform handrail at the ladder entryway and will
require a single 5/8” bolt assembly.

The lower platform is secured to the tower structure at two connection points (Drawing
Attachment 71157883-PO-37502-MB1-026 and 031). Each connection point requires
four 3/4” bolt assemblies. Once the platform has been secured to the tower structure
the lower ladder section can be secured to the structure.

The lower ladder section is secured to the tower structure at eight connection points
(Drawing Attachment 71157883-PO-37502-MB1-027 and 031) and requires a total of
ten 5/8” bolt assemblies. Once the lower ladder has been secured to the tower
structure; the lower platform can be affixed to the structure. ; The handrail should be
connected to the ladder at the ladder entryway and requires a single 5/8” bolt
assembly.

The upper and middle ladder cages have been fitted with lower safety cage
extensions. The cage extensions should be field trimmed and welded to the upper and
middle platform handrails (See Figure 4). Once the welding is complete; all welds
should be coated to protect against rust. Cold galvanizing is recommended.

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Figure 4

C. 8” WATERWAY AND MONITOR PIPING

The waterway is comprised of three sections of 8” galvanized pipe connected at two

150lb raised face flange connection points. The base of the waterway is connected to
the main water supply via a 300 lb raised face flange connection. The upper section of
the waterway is fitted with a 4” 150 lb flat face flange to accommodate the remote fire
water monitor. The tower structure has been fitted with a total of four main pipe
supports to which the fire water supply piping and pneumatic tubing shall be attached
(Drawing Attachment 71157883-PO-37502-MB1-025, 026 and 027).

The lower and middle section of piping is connected to the tower at three points each
requiring two 5/8” bolt assemblies. The middle section can be installed first or pre
assembled to the lower section in the horizontal position and installed as one complete
unit. The 150lb raised face connection linking the two sections requires a single
316SS ring gasket and eight 3/4” x 4 1/2” stud assemblies.

Connection points for the upper section of piping are located on the floor of the upper
platform (Drawing Attachment 71157883-PO-37502-MB1-030). This section of piping
should be raised above and lowered through the floor of the upper platform. The pipe
is connected at three points each requiring two sets of 5/8” bolt assemblies. Once
lowered into place the upper section of pipe can be fitted to the middle section of the
waterway. The two sections are connected by 150lb RF flanges and require a single
316SS ring gasket and eight 3/4” x 4 1/2” stud assemblies.

D. RHMB FIRE WATER MONITOR CONNECTION

Once the upper section of piping has been attached; the fire water monitor can be
lifted and installed into place. The monitor is connected to the waterway via a 4” 150lb
flat face flange connection and requires a single 4” Garlock 3000 gasket and eight 5/8”
x 4 1/4” stud assemblies. The remote monitor is supplied with a manual by-pass

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 manifold which should be attached underneath the bottom flange with two of the eight
5/8” x 4 1/4” stud assemblies (See Figure 5).

Figure 5

E. FIRE WATER MONITOR PNEUMATIC CONTROL TUBING AND TUBING

SUPPORTS

The fire water monitor is linked to the remote control station via six pneumatic tubing
lines. A total of 26 sections of 5/8” stainless steel tubing, 24 union fittings and 4
Hydraulic Tubing Support Assemblies have been supplied for the pneumatic control
lines spanning the vertical length of the tower. The 5/8” stainless steel tubing has
been supplied in standard 20’ sections and each of the six runs of control tubing will
require approximately five sections of tube and four 5/8” unions. Connection points for
the tubing support assemblies have been predrilled and are located on the side of the
main pipe supports (See Figure 6).

Figure 6

The pneumatic tube supports have been preassembled; once attached to the tower
structure the tubing should be installed as per the manufactures instructions (See
Figure 7).

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Figure 7

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 F. RHMB FIRE WATER MONITOR AND CONTROL STATION

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 This manual has been written-up as a guide to the installation, operation and
maintenance of the TIGER TCO-360º model monitor. It is strongly recommended
that the operation and maintenance of this monitor system be carried out by
qualified and trained personnel.

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 HYDRAULIC POWER PACK
DUAL MONITOR CONTROL STATION

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 It is of the utmost importance that only genuine spare parts supplied by Angus Fire are
used, otherwise the guarantee will be null and void.

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 G. Cla-Val Model 100GS Deluge Valve Assembly

The fire water supply line is controlled by a manually activated Cla-Val model 100GS
deluge valve assembly. A single manual release lever (See Figure 8) is incorporated
into the trim work at the deluge valve assembly (Drawing Attachment 71157883-PO-
37502-MB1-026 and 031); a second release is located at the remote monitor control
station (Drawing Attachment 71157883-PO-37502-MB1-034 and 036).

Figure 8

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 100G Deluge Valve Operations Manual

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 100G 2100G

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 MODEL
100G
2100G
Deluge Valve
• U.L. Listed / U.L.C. Listed
• Globe or Angle Pattern
• Proven Reliable Design

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

Typical Application
The Model 100G/2100G is installed to control the water flow to the
sprinklers in Deluge, Pre-Action, or Foam-Water type systems. A (1) From System Water Supply
simplified system is used to illustrate typical operation. (2) System Shut-off Valve (Visual Stem)
The Model 100G/2100G Deluge Valve (3) is (3) Cla-Val Model 100G or 2100G
maintained in the closed position by means of
system water pressure controlled by a pilot (4) Pilot Control System
control (4). When the pilot control valve (5) Sprinkler System Piping
receives a signal from the fire detection sys- (6) Sprinklers
tem, it allows the deluge valve to open.
Firefighting water (1) then enters system
piping (5) and discharges from
sprinklers (6).

Specifications Friction Loss For use in hydraulically calculated

Sizes Globe: 3" – 10" systems, friction loss equivalent to:
Angle: 3" – 10"
End Details Ductile Iron 150 ANSI B16.42 flanged 100G (Globe): 2100G (Angle):
Cast Steel 150 ANSI B16.5 flanged
Pressure Rating 150 class, 175 psi maximum (Ductile Iron) 3" Size=42 Ft. of 3" Pipe 3" Size=33 Ft. of 3" Pipe
150 class, 285 psi maximum (Cast Steel) 4" Size=92 Ft. of 4" Pipe 4" Size=44 Ft. of 4" Pipe
300 class, 400 psi maximum
Temperature Range Water, to 180°F MAX.
6" Size=116 Ft. of 6" Pipe 6" Size=79 Ft. of 6" Pipe
Materials Main Valve Body & Cover: 8" Size=123 Ft. of 8" Pipe 8" Size=105 Ft. of 8" Pipe
Ductile Iron ASTM A-536* UL, ULC 10" Size=201 Ft. of 10" Pipe 10" Size=153 Ft. of 10" Pipe
Cast Steel ASTM A216-WCB* U L, ULC
Nickel Aluminum Bronze ASTM B148 UL, ULC
Naval Bronze ASTM B61 UL, ULC When Ordering, Please Specify
Super Duplex Stainless steal UNS32750 UL, ULC
Stainless Steel ASTM A743-CF-8M U L, ULC
1. Catalog No. 100G or 2100G 2. Size
Main Valve Internal Tr i m :
3. Body and Cover Material 4. Globe or Angle Pattern
Bronze ASTM B61 5. Pressure Class 6. Internal Trim Material
Stainless Steel Type 303
Monel QQ-N-281 Class B
Diaphragm and Disc:
Buna-N® synthetic rubber
*Internally & Externally Epoxy Coated Standard

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

Functional Data
Inches 3 4 6 8 10
Valve Size
mm 80 100 150 200 250
Globe Gal./Min. (gpm) 115 200 440 770 1245
CV Pattern Litres/Sec. (l/s) 27.6 48 105.6 184.8 299
Factor Angle Gal./Min. (gpm) 139 240 541 990 1575
Pattern Litres/Sec. (l/s) 33.4 58 130 238 378

Valve Size (Inches) 3 4 6 8 10 Valve Size (mm) 80 100 150 200 250
A 150 ANSI 12.00 15.00 20.00 25.38 29.75 A 150 ANSI 305 381 508 645 756
AA 300 ANSI 13.25 15.62 21.00 26.38 31.12 AA 300 ANSI 337 397 533 670 791
B Dia. 9.12 11.50 15.75 20.00 23.62 B Dia. 232 292 400 508 600
C Max. 8.19 10.62 13.38 16.00 17.12 C Max. 208 270 340 406 435
D 2.56 3.19 4.31 5.16 8.50 D 65 81 110 131 216
E 150 ANSI 7.00 8.50 10.00 12.69 14.88 E 150 ANSI 178 216 254 322 378
EE 300 ANSI -- 8.81 10.50 13.19 -- EE 300 ANSI -- 224 267 350 --
F 150 ANSI 4.00 4.97 6.00 8.00 8.62 F 150 ANSI 102 126 152 203 219
FF 300 ANSI -- 5.28 6.50 8.50 -- FF 300 ANSI -- 134 165 216 --
G 4.75 5.94 7.25 8.50 10.50 G 121 151 184 216 267
H 2.69 2.81 3.88 5.31 6.56 H 68 71 99 135 167
J 2.56 2.81 3.81 4.81 5.81 J 65 71 97 122 148
K 7.00 4.03 6.75 17.00 15.50 K 178 102 171 432 394
L 2.56 2.81 3.81 4.81 8.50 L 65 71 97 122 216
M 1.75 2.41 2.75 4.00 4.24 M 45 61 70 102 108
N NPT 1/2"-14 3/4"-14 3/4"-14 1"-11 1/2 1"-11 1/2 N NPT 1/2"-14 3/4"-14 3/4"-14 1"-11 1/2 1"-11 1/2
P NPT 1/4"-11 1/2 2"-11 1/2" P NPT 1/4"-11 1/2 2"-11 1/2"
R 150 ANSI 2.50 3.47 3.25 4.19 7.12 R 150 ANSI 64 88 83 106 181
RR 300 ANSI 3.12 3.78 3.75 4.69 7.81 RR 300 ANSI 79 96 95 119 198
X Pilot System 15.00 17.00 29.00 31.00 33.00 X Pilot System 381 432 737 787 838
Y Pilot System 11.00 12.00 20.00 22.00 24.00 Y Pilot System 279 305 508 559 610
Z Pilot System 11.00 12.00 20.00 22.00 24.00 Z Pilot System 279 305 508 559 610

Represented By:

E-100G (R-6/06)

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 INSTALLATION / OPERATION / MAINTENANCE

MODEL
100-01
Hytrol Valve
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 πlarger valves,
installation with the cover UP is advisable. This makes internal
parts 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 fittings
or components, be sure they are kept clean and replaced
exactly 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 by
loosening fittings at all high points.

Principles of Operation Modulating

Restriction Control
Three Way Three Way
Pilot Control Pilot Control

Tight Closing Operation Full Open Operation Modulating Action

When pressure from the valve inlet (or
an equivalent independent operating
pressure) is applied to the diaphragm
chamber the valve closes drip-tight.
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.
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.

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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
(cast into side of valve body)
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).
SYMPTOM PROBABLE CAUSE
Closed isolation valves in control system, or in main line.
Fails to Close
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
Fails to Open 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.
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.
2
71157883-PO-37502-N02-006
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.
REMEDY
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.
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.
Page 36 of 100 02/03/2009
 STEM TRAVEL
Diaphragm Check (#1 ) (Fully Open to Fully Closed)
1. Shut off pressure to the Hytrol Valve by slowly closing upstream Valve Size (inches) Travel (inches)
and downstream isolation valves. SEE CAUTION. Inches MM Inches MM
1 1/4 32 0.4 10
2. Disconnect or close all pilot control lines to the valve cover and 1 1/2 40 0.4 10
leave only one fitting in highest point of cover open to atmosphere.
2 50 0.6 15
3.With the cover vented to atmosphere, slowly open upstream 2 1/2 65 0.7 18
isolation valve to allow some pressure into the Hytrol Valve body. 3 80 0.8 20
Observe the open cover tapping for signs of continuous flow. It is 4 100 1.1 28
not necessary to fully open isolating valve. Volume in cover cham- 6 150 1.7 43
ber capacity chart will be displaced as valve moves to open posi- 8 200 2.3 58
tion. Allow sufficient time for diaphragm assembly to shift posi- 10 250 2.8 71
tions. If there is no continuous flow, you can be quite certain the 12 300 3.4 86
diaphragm is sound and the diaphragm assembly is tight. If the
14 350 4.0 100
fluid appears to flow continuously this is a good reason to believe
16 400 4.5 114
the diaphragm is either damaged or it is loose on the stem. In
24 600 6.5 165
either case, this is sufficient cause to remove the valve cover and
investigate the leakage. (See “Maintenance” Section for procedure.) 36 900 8.5 216

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
COVER CHAMBER CAPACITY flow does stop, then the obstruction is more likely in the cover. In
(Liquid Volume displaced when valve opens) either case, the cover must be removed, and the obstruction locat-
ed and removed. The stem should also be checked for scale build-
Valve size (inches) Displacement up. (See “Maintenance, section for procedure.)
Gallons Liters
1 1/4 .020 .07 11. For valves 6” and smaller, the Hytrol Valve’s freedom of move-
1 1/2 .020 .07 ment check can also be done after all pressure is removed from
2 .032 .12 the valve. SEE CAUTION. After closing inlet and outlet isolation
2 1/2 .043 .16 valves and bleeding pressure from the valve, check that the cover
3 .080 .30 chamber and the body are temporarily vented to atmosphere.
4 .169 .64 Insert fabricated tool into threaded hole in top of valve stem, and
6 .531 2.0 lift the diaphragm assembly manually. Note any roughness. The
8 1.26 4.8 diaphragm assembly should move smoothly throughout entire
10 2.51 9.5
valve stroke. The tool is fabricated from rod that is threaded on
12 4.00 15.1
one end to fit valve stem and has a “T” bar handle of some kind
14 6.50 24.6
16 9.57 36.2
on the other end for easy gripping. (See chart in Step 4 of
24 29.00 109.8 “Disassembly” Section.)
36 42.00 159.0 12. Place marks on this diaphragm assembly lifting tool when the
valve is closed and when manually positioned open. The distance
Freedom of Movement Check (#2) between the two marks should be approximately the stem travel
shown in stem travel chart. If the stroke is different than that
4. Determining the Hytrol Valve’s freedom of movement can be shown, there is a good reason to believe something is mechani-
done by one of two methods. cally restricting the stroke of the valve. The cover must be
removed, and the obstruction located and removed. The stem
5. For most valves it can be done after completing Diaphragm
should also be checked for scale build-up. (See “Maintenance”
Check (Steps 1, 2, and 3). SEE CAUTION. At the end of step 3
Section for procedure.)
the valve should be fully open.
6. If the valve has a Cla-Val X101 Position Indicator, observe the Tight Sealing Check (#3)
indicator to see that the valve opens wide. Mark the point of max-
imum opening. 13. Test for seat leakage after completing checks #1 & #2 (Steps
1 to 12). SEE CAUTION. Close the isolation valve downstream of
7. Re-connect enough of the control system to permit the appli-
the Hytrol Valve. Apply inlet pressure to the cover of the valve, wait
cation of inlet pressure to the cover. Open pilot system cock so
until it closes. Install a pressure gauge between the two closed
pressure flows from the inlet into the cover.
valves using one of the two ports in the outlet side of the Hytrol.
8. While pressure is building up in the cover, the valve should Watch the pressure gauge. If the pressure begins to climb, then
close smoothly. There is a hesitation in every Hytrol Valve closure, either the downstream isolation valve is permitting pressure to
which can be mistaken for a mechanical bind. The stem will creep back, or the Hytrol is allowing pressure to go through it.
appear to stop moving very briefly before going to the closed posi-
Usually the pressure at the Hytrol inlet will be higher than on the
tion. This slight pause is caused by the diaphragm flexing at a
isolation valve discharge, so if the pressure goes up to the inlet
particular point in the valve’s travel and is not caused by a
mechanical bind. pressure, you can be sure the Hytrol is leaking. Install another
gauge downstream of isolating valve. If the pressure between the
9. When closed, a mark should be made on the X101 Valve posi- valves only goes up to the pressure on the isolation valve
tion indicator corresponding to the “closed” position. The distance discharge, the Hytrol Valve is holding tight, and it was just the iso-
between the two marks should be approximately the stem travel
lation valve leaking.
shown in chart.

3
Page 37 of 100 02/03/2009
71157883-PO-37502-N02-006
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.
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"
24" 2"
36” 2”
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.
4
71157883-PO-37502-N02-006
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
24" 3/4-16
36” 3/4-16
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.
ANGLE OR CHANNEL IRON
NUT
LONG STUD OR BOLT
DO NOT
LIFT
NUT OR BOLT HEAD
VALVE SEAT
VALVE BODY
Page 38 of 100 02/03/2009
Lime Deposits Inspection of Parts

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.
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.

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.
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.

Test Procedure After Valve Assembly

Due to the weight of the diaphragm assembly this procedure is
There are a few simple tests which can be made in the field to
not possible on valves 8” and larger. on these valves, the same
make sure the Hytrol Valve has been assembled properly. Do
determination can be made by carefully introducing a low
these before installing pilot system and returning valve to
pressure-less than five psi) into the valve body with the cover
service. These are similar to the three troubleshooting tests.
vented. SEE CAUTION. Looking in cover center hole see the
diaphragm assembly lift easily without hesitation, and then
1. Check the diaphragm assembly for freedom of movement
settle back easily when the pressure is removed.
after all pressure is removed from the valve. SEE CAUTlON.
Insert fabricated tool into threaded hole in top of valve stem, and
2. To check the valve for drip-tight closure, a line should be
lift the diaphragm assembly manually. Note any roughness,
connected from the inlet to the cover, and pressure applied at the
sticking or grabbing. The diaphragm assembly should move
inlet of the valve. If properly assembled, the valve should hold
smoothly throughout entire valve stroke. The tool is fabricated
tight with as low as ten PSI at the inlet. See “Tight Sealing
from rod that is threaded on one end to fit valve stem (See chart
Check” section.)
in Step 4 of “Disassembly” section.) and has a “T” Bar handle of
some kind on the other end for easy gripping.
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
Place marks on this diaphragm assembly lifting tool when the
leaks. Re-tighten cover nuts if necessary to stop leaks past the
valve is closed and when manually positioned open. The dis-
diaphragm.
tance between the two marks should be approximately the stem
travel shown in stem travel chart. (See “Freedom of Movement
4. Remove pressure, then re-install the pilot system and tubing
Check” section.) If the stroke is different than that shown, there
exactly as it was prior to removal. Bleed air from all high
is a good reason to believe something is mechanically restricting
points.
the stroke of the valve. The cover must be removed, the obstruc-
tion located and removed. (See “Maintenance” Section for
5. Follow steps under “Start-Up and Adjustment” Section in
procedure.)
Technical Manual for returning complete valve back to service.

5
Page 39 of 100 02/03/2009
71157883-PO-37502-N02-006
 1 6
25 17
5 7
2
24 8 9
10

INLET OUTLET
3

4
TOP VIEW
14 16
GLOBE PATTERN
PARTS LIST
Item Description
1. Pipe Plug
2. Drive Screws (for nameplate)
3. Hex Nut (8” and larger)
4. Stud (8” and larger) 26
5. Cover Bearing 27
6. Cover 9
7. Stem Nut
8. Diaphragm Washer
9. Diaphragm
10. Spacer Washers
11. Disc Guide 12
12. Disc Retainer
13. Disc
14. Stem 15
15. Seat OUTLET
14
16. Body
17. Spring
22. Flat Head Screws (8” and larger)
23. Seat O-Ring
24. Hex head Bolt (1 1/4” thru 4”) 16
25. Nameplate
26. Upper Spring Washer (Epoxy coated valves only)
27. Lower Spring Washer (Epoxy coated valves only) INLET
28. Cover Bearing Housing (16” only) ANGLE PATTERN
29. Cover O-Ring (16’” only)
30. Hex Bolt (16” only)
31. Pipe Cap (16” only)
31
13

12 28
13 22
10
11
30
15 14
15

14

23

5 29

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

6
Page 40 of 100 02/03/2009
71157883-PO-37502-N02-006
 INSTALLATION / OPERATION / MAINTENANCE

MODEL
100-01
Hytrol Valve Service Data
Description 100-01 Hytrol Valve Description 100-20 600 Series Hytrol Valve
The CIa-VaI Model 100-01 Hytrol Valve is a main valve for The CIa-VaI Model 100-20 Hytrol Valve (600 Series main valve)
CIa-VaI Automatic Control Valves. It is a hydraulically operated, have only one part -the body- that is different from standard 100

71157883-PO-37502-N02-006
diaphragm-actuated, globe or angle pattern valve. Series Cla-Val main valve parts. The remaining parts of the 600
series main valve are standard Cla-Val main valve parts. All serv-
This valve consists of three major components; body, diaphragm ice and maintenance information for the standard 100 Series
assembly, and cover. The diaphragm assembly is the only main valves also apply to the 600 series main valves.
moving part. The diaphragm assembly uses a diaphragm of nylon The most important thing to remember when ordering main
fabric bonded with synthetic rubber. A synthetic rubber disc, valve repair kits and replacement parts, except for the body, all
contained on three and one half sides by a disc retainer and disc other parts are going to be for a smaller size main valve. Cla-
guide, forms a seal with the valve seat when pressure is applied Val identifies main valve parts with the flange size of the stan-
above the diaphragm. The diaphragm assembly forms a sealed dard 100 Series main valve. Refer to the "Main Valve Sizes”
chamber in the upper portion of the valve, separating operating chart below.
pressure from line pressure.

HYTROL Service Data

HYTROL SIZE Stem Cover Capacity Valve Stem Cover Cover Nut or Bolt Cover Cover Plug Cover Torque Stem Nut ** Stem Nut Torque
100-01 100-20 Travel Displacement Thread Center Thread Socket Qty Lifting (ft Lbs)
UNF-Internal Plug NPT Holes UNC Thread Socket ft. Lbs. in. Lbs. Thread Socket
inches mm inches mm inches mm Gallons Liters (Bolt) (Long) Lubed DRY
1” 25 0.3 8 1/4” 1/4” - 20 (B) 7/16” 8 4 48 3/8” - 24 4 6
1 1/4” 32 0.4 10 0.020 0.07 10-32 1/4” 5/16” - 18 (B) 1/2” 8 8 96 7/16” 20 6 10
1 1/2” 40 0.4 10 0.020 0.07 10-32 1/4” 5/16” - 18 (B) 1/2” 8 8 96 7/16” 20 6 10
2” 50 0.6 15 0.032 0.12 10-32 1/2” 3/8” - 16 (B) 9/16” 8 3/8” 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” 8 1/2” 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” 8 1/2” 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” 8 3/4” 5/8” 110 3/4” - 16 1 1/16” 40 60

Page 41 of 100
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” 250 375
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 9.5 36.20 1/2 - 20 2” 1-1/4” -7 2” 20 1” - 8 1” 13/16” 545 2” - 16 3” 500 750
24” 600 6.5 165 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

02/03/2009
Grade 5 Bolts
“Heavy” Grade Nuts **Must Use ONLY
* Adapter p/n 2594101E Cla-Val Supplied part
inside 1/4” - 28 Tighten cover nuts in a “star” cross-over pattern
 100-01 Hytrol Main Valve Assembly BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS
PIPE PLUG
COVER HEX NUT 1 6

02/03/2009
8" and Larger 1 3
1 3
PIPE PLUG
8 3
Cover Bolt
6" and Smaller
4 5 6 6 8
COVER BEARING
BOLTS BOLTS BOLTS

Page 42 of 100
SPRING
4 7
STEM NUT
4 2
DIAPHRAGM WASHER 4 2 5 2
*DIAPHRAGM 1 5 1 9 1 15
16 5 17 9
12 7 20 7
8 13
5 13
DISC RETAINER 0 3 12 3 12 3
12 16 20
*SPACER WASHERS BOLTS 4 BOLTS 11 4 BOLTS 11
4 9
KO Anti-Cavitation *DISC 14 6
Trim Option 14 7
(Patent Pending)
8 11 8 19
6 15 10 16
KO
DISC GUIDE
6 2 10 2 2 18
DISC GUIDE
STEM
Follow this procedure when reassembling MAIN Valve:
KO Seat Screw 1. Tightens bolts/nuts in a “Star” or “Cross-Over” Pattern following the

71157883-PO-37502-N02-006
SEAT 8" and Larger
SEAT
numbers shown above to insure that cover seats evenly on the diaphragm
material and body.
KO Anti-Cavitation Trim SEAT O-RING
can be added to any 2. Torque the bolt/nuts in three stages:
STUD
standard Hytrol Valve
8" and Larger
A. To approximately 10% of final torque valve.
B. To approximately 75% of final torque valve.
BODY
PIPE PLUG C. To final required torque valve.
(Globe or Angle)
3. Valves that are to be tested to 375 PSI or higher should be retorqued
*Repair Parts after 24 hours.
CLA-VAL 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
©Copyright Cla-Val 2005 Printed in USA Specifications subject to change without notice. N-100-01 (R-5-05)
 Cla-Val Product
Identification
How to Order
Proper Identification
For ordering repair kits, replacement parts, or for
INLET SIZE &
inquiries concerning valve operation, it is important to CAT NO.

properly identify Cla-Val products already in service

EINTRITT STOCK
NO. CODE

by including all nameplate data with your inquiry. ENTREE

MFD. BY CLA-VAL
Pertinent product data includes valve function, size, ENTRADA NEWPORT BEACH, CALIF, U.S.A.

material, pressure rating, end details, type of pilot

This brass plate appears on valves sized 21/2" and larger
controls used and control adjustment ranges.
and is located on the top of the inlet flange.
Identification Plates
For product identification, cast-in body markings are
supplemented by identification plates as illustrated on
this page. The plates, depending on type and size of IN L E T
product, are mounted in the most practical position. It
is extremely important that these identification
plates are not painted over, removed, or in any
IN L E T
other way rendered illegible.

These two brass plates appear on 3/8", 1/2", and 3/4" size
valves and are located on the valve cover.

SIZE &

RESERVOIR
CAT NO.
STOCK
NO.
CODE

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

These two brass plates appear on threaded valves

This brass plate appears on altitude valves only and is
found on top of the outlet flange. 1" through 3" size or flanged valves 1" through 2".
It is located on only one side of the valve body.

¤
SIZE & SIZE & CODE
CAT NO. CAT NO.
C STOCK
STOCK
“ NO.
NO.
MFD. BY CLA-VAL
SPRING NEWPORT BEACH, CALIF.
RANGE U.S.A.

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

DO NOT REMOVE
REDUCED PRESSURE BACKFLOW PREVENTION DEVICE

THIS VALVE HAS BEEN MODIFIED -4

RP
STK.
CAT. NO.
SINCE ORIGINAL SHIPMENT FROM
FACTORY. WHEN ORDERING PARTS SER.
NO. NO.
AND/ OR SERVICE SUPPLY DATA FROM
THIS PLATE & ALL OTHER PLATES ON CLA-VAL NEWPORT BEACH, CA.

ORIGINAL VALVE.
This brass plate is used on our backflow prevention
¤ assemblies. It is located on the side of the Number Two
check (2" through 10"). The serial number of the
C assembly is also stamped on the top of the inlet flange of
“

the Number One check.

This aluminum plate is included in pilot system
modification kits and is to be wired to the new pilot
control system after installation.

Page 43 of 100 02/03/2009

71157883-PO-37502-N02-006
 HOW TO ORDER SPECIFY WHEN ORDERING
• Model Number • Valve Size
Because of the vast number of possible configurations and • Globe or Angle Pattern • Threaded or Flanged
combinations available, many valves and controls are not • Adjustment Range • Body and Trim Materials
shown in published product and price lists. For ordering (As Applicable) • Optional Features
information, price and availability on product that are not listed, • Pressure Class
please contact your local Cla-Val office or our factory office
located at: UNLESS OTHERWISE SPECIFIED
• Globe or angle pattern are the same price
P. O. Box 1325 • Ductile iron body and bronze trim are standard
Newport Beach, California 92659-0325 • X46 Flow Clean Strainer or X43 “Y” Strainer are included
(949) 722-4800 • CK2 Isolation Valves are included in price on 4" and larger
FAX (949) 548-5441 valve sizes (6" and larger on 600 Series)

LIMITED WARRANTY DISCLAIMER OF WARRANTIES AND

Automatic valves and controls as manufactured by Cla-Val are warranted
for three years from date of shipment against manufacturing defects in
material and workmanship that develop in the service for which they are
designed, provided the products are installed and used in accordance
with all applicable instructions and limitations issued by Cla-Val.
We will repair or replace defective material, free of charge, that is returned
to our factory, transportation charges prepaid, if upon inspection, the
material is found to have been defective at time of original shipment. This
warranty is expressly conditioned on the purchaser’s providing written
notification to Cla-Val immediate upon discovery of the defect.
Components used by Cla-Val but manufactured by others, are warranted
only to the extent of that manufacturer’s guarantee.
This warranty shall not apply if the product has been altered or repaired by
others, Cla-Val shall make no allowance or credit for such repairs or
alterations unless authorized in writing by Cla-Val.
LIMITATIONS OF LIABILITY
The foregoing warranty is exclusive and in lieu of all other
warranties and representations, whether expressed, implied, oral or
written, including but not limited to any implied warranties or
merchantability or fitness for a particular purpose. All such other
warranties 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 the
product. Cla-Val shall not be liable for any damages or charges for
labor or expense in making repairs or adjustments to the product.
Cla-Val shall not be liable for any damages or charges sustained in
the adaptation or use of its engineering data and services. No
representative of Cla-Val may change any of the foregoing or
assume any additional liability or responsibility in connection with
the product. The liability of Cla-Val is limited to material
replacements 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 only
with the express understanding that no statements, clauses, or conditions contained
in said order form will be binding on the Seller if they in any way modify the Seller’s
own terms and conditions of sales.
PRODUCT CHANGES
The right is reserved to make changes in pattern, design or materials when deemed
necessary, without prior notice.
PRICES
All prices are F.O.B. Newport Beach, California unless expressly stated otherwise on
our acknowledgement of the order. Prices are subject to change without notice. The
prices at which any order is accepted are subject to adjustment to the Seller’s price
in effect at the time of shipment. Prices do not include sales, excise, municipal, state
or any other Government taxes. Minimum order charge $75.00.
RESPONSIBILITY
We will not be responsible for delays resulting from strikes, accidents, negligence of
carriers, or other causes beyond our control. Also, we will not be liable for any
unauthorized product alterations or charges accruing there from.
RISK
All goods are shipped at the risk of the purchaser after they have been delivered by
us to the carrier. Claims for error, shortages, etc., must be made upon receipt of
goods.
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 any
material.
2. Cla-Val reserves the right to refuse the return of any products.
3. Products more than six (6) months old cannot be returned for credit.
4. Specially produced, non-standard models cannot be returned for credit.
5. Rubber goods such as diaphragms, discs, o-rings, etc., cannot be returned for
credit, unless as part of an unopened vacuum sealed repair kit which is less
than six months old.
6. Goods authorized for return are subject to a 35% ($75 minimum) restocking
charge and a service charge for inspection, reconditioning, replacement of
rubber 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.

CLA-VAL Represented By:

PO Box 1325 Newport Beach CA 92659-0325
Phone: 949-722-4800 Fax: 949-548-5441
CLA-VAL CANADA CLA-VAL EUROPE
4687 Christie Drive Chemin dés Mesanges 1
Beamsville, Ontario CH-1032 Romanel/
Canada LOR 1B4 Lausanne, Switzerland
Phone: 905-563-4963 Phone: 41-21-643-15-55
Fax: 905-563-4040 Fax: 41-21-643-15-50
©COPYRIGHT CLA-VAL 2005 Printed in USA
E-Product I.D. (R-5/05) Specifications subject to change without notice. www.cla-val.com
Page 44 of 100 02/03/2009
71157883-PO-37502-N02-006
 INSTALLATION / OPERATION / MAINTENANCE

MODEL
REPAIR KITS
Complete Replacement Diaphragm Assemblies for 100-01 and 100-20 Hytrol Main Valves
For: Hytrol Main Valves with Ductile Iron, Bronze Trim Materials—125/150 Pressure Class Only.
FACTORY ASSEMBLED
Includes: Stem, Disc Guide, Disc, Disc Retainer, Spacer Washers, Diaphragm, Diaphragm Washer
and Stem Nut.

Valve Diaphragm Assembly Valve Diaphragm Assembly

Size Stock Number Size Stock Number
100-01 100-20 100-01 100-20
3/8" (Also 81-01 ) 49097K N/A 6" 40456G 33273E
1/2" - 3/4" (Also 81-01 ) C2518D N/A 8" 45276D 40456G
1" C2520K N/A 10" 81752J 45276D
1 1/4"-1 1/2" C2522 F N/A 12" 85533J 81752J
2" C2524B N/A 14" 89067D N/A
2 1/2" C2523D N/A 16" 89068B 85533J
3" C2525J C2524B 20" N/A 89068B
4" 33273E C2525J 24" N/A 89068B

Repair Kits for 100-01/100-20 Hytrol Valves

For: 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.
Buna-N® Standard Material Viton (For KB Valves)
Valve Repair Kit Valve Repair Kit
Size Stock Number Size Stock Number
100-01 100-20 100-01 100-20
3/8" (Also 81-01 ) 9169801K N/A 3/8" (Also 81-01 ) 9169806J N/A
1/2" - 3/4" (Also 81-01 ) 9169802H N/A 1/2" - 3/4" (Also 81-01 ) 9169807G N/A
1" 9169803F N/A 1" 9169808E N/A
1 1/4" - 1 1/2" 9169804D N/A 1 1/4” - 1 1/2" 9169809C N/A
2" 9169805A N/A 2" 9169810A N/A
2 1/2" 9169811J N/A 2 1/2" 9169817F N/A
3" 9169812G 9169805A 3" 9169818D 9169810A
4" 9169813E 9169812G 4" 9169819B 9169818D
6" 9169815K 9169813E 6" 9169820K 9169819B
8" 9817901D 9169815K 8" N/A 9169820K
10" 9817902B 9817901D
12" 9817903K 9817902B
14" 9817904H N/A
16" 9817905E 9817903K
20" N/A 9817905E
24" N/A 9817905E

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

Page 45 of 100 02/03/2009

71157883-PO-37502-N02-006
Repair Kits for 100-02/100-21 Powertrol and 100-03/100-22 Powercheck Main Valves
For: Powertrol and Powercheck 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.
Valve Kit Stock Number Valve Kit Stock Number
Size 100-02 Size 100-02 &100-03 100-21 &100-22
3/8" 9169901H 2 1/2" 9169910J N/A
1/2" - 3/4" 9169902F 3" 9169911G 9169905J
1" 9169903D 4" 9169912E 9169911G
1 1/4" & 1 1/2" 9169904B 6" 9169913C 9169912E
2" 9169905J 8" 99116G 9169913C
10" N/A 99116G
Larger Sizes: Consult Factory.
Repair Kits for 100-04/100-23 Hy-Check Main Valves
For: Hy-Check Main Valves—125/150 Pressure Class Only
Supplied Shrink Wrapped (4" and Smaller) or Bagged (6" and larger)
Includes: Diaphragm, Disc and O-Rings and full set of spare Spacer Washers.
Valve Kit Stock Number Valve Kit Stock Number
Size 100-04 100-23 Size 100-04 100-23

4” 20210901B N/A 12” 20210905H 20210904J

6” 20210902A 20210901B 14” 20210906G N/A
8” 20210903K 20210902A 16” 20210907F 20210905H
10” 20210904J 20210903K 20”, 24” N/A 20210907F
Larger Sizes: Consult Factory.

Repair Kits for Pilot Control Valves

Supplied Shrink Wrapped Includes: Diaphragm, Disc (or Disc Assembly), O-Rings, Gaskets or spare Screws as appropriate.

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

Kit Kit Kit
Pilot Stock Pilot Stock Pilot Stock
Control Number Control Number Control Number
CDB 9170006C CFM-7 & 7-A 1263901K CDB-KB 9170012A
CDB-7 9170017K CRA (w/bucking spring) 9170001D CRA-KB 9170018H
CDH-2 18225D CRD (w/bucking spring) 9170002B CRD-KB (w/bucking spring) 9170008J
CDHS-2 44607A CRD (no bucking spring) 9170003K CRL-KB 9170013J
CDHS-2B 9170004H CRD-22 98923G CDHS-2BKB 9170010E
CDHS-2F 9170005E CRL (55F, 55L) 9170007A CDHS-2FKB 9170011C
CDHS-3C-A2 24657K CRL-4A 43413E CDHS-18KB (no bucking spring) 9170009G
CDHS-8A 2666901A CRL-5 (55B) 65755B 102C-KB 1726202D
CDHS-18 9170003K CRL-5A (55G) 20666E Buna-N®
CDS-4 9170014G CV 9170019F
CDS-5 14200A X105L (O-ring) 00951E CRD DISC RET. (SOLID) C5256H
CDS-6 20119301A 102B-1 1502201F CRD DISC RET. (SPRING) C5255K
CFM-2, CFM-9, CFCM-M1 12223E 102C-2 & -3 1726201F

Repair Assemblies (In Standard Materials Only)

Control Description Stock Number
CF1-C1 Pilot Assembly Only 89541H
CF1-Cl Complete Float Control less Ball & Rod 89016A
CFC2-C1 Disc, Distributor & Seals 2674701E
CSM 11-A2-2 Mechanical Parts Assy. 97544B
CSM 11-A2-2 Pilot Assembly Only 18053K
33A 1" Complete Internal Assembly & Seal 2036030B
33A 2" Complete Internal Assembly & Seal 2040830J

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

CLA-VAL 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
'
copyright Cla-Val 2003 Printed in USA Specifications subject to change without notice. N-RK (R-9/03)

Page 46 of 100 02/03/2009

71157883-PO-37502-N02-006
 Hytrol Pilot Valve Operations Manual

Page 47 of 100 02/03/2009

71157883-PO-37502-N02-006

Seawater Service Hytrol Valve
Principle of Operation
On-Off Control
Full Open Operation
When pressure in the cover chamber
is relieved to a zone of lower pres-
sure, the line pressure at the valve
inlet opens the valve, allowing full flow.
71157883-PO-37502-N02-006
MODEL
100S
2100S
• Drip - tight, positive seating
• Service without removal from line
• Screwed or flanged ends
• Globe or angle pattern
• Every valve factory-tested
The Cla-Val Model 100S/2100S Seawater Service Hytrol Valve
is a hydraulically operated, diaphragm actuated, globe or
angle pattern valve. It consists of three major components:
body, diaphragm assembly and cover. The diaphragm assem-
bly is the only moving part.
The body (ductile iron or cast steel) is epoxy coated and contains
a removable seat insert. The diaphragm assembly is guided top
and bottom by a precision machined stem. It utilizes a non-wick-
ing diaphragm of nylon fabric bonded with synthetic rubber. A
resilient synthetic rubber disc retained on three and one half sides
by a disc retainer forms a drip-tight seal with the renewable seat
when pressure is applied above the diaphragm.
The Model 100S/2100S Seawater Service Hytrol Valve is the
basic valve used for seawater applications. It is the valve of
choice for system applications requiring deluge, pressure regu-
lation, pressure relief, solenoid operation, rate of flow control, liq-
uid level control or check valve operation. The rugged simplicity
of design and packless construction assure a long life of
dependable, trouble-free operation. It is available in various
materials and in a full range of sizes, with either screwed or
flanged ends. Its applications are unlimited.
Modulating
On-Off Control Control
Tight Closing Operation Modulating Action
When pressure from the valve inlet The valve holds any intermediate position
is applied to the cover chamber, the when operating pressures are equal above
valve closes drip-tight. and below the diaphragm. A Cla-Val “modu-
lating” pilot control will allow the
valve to automatically compen-
sate for line pressure changes.
Page 48 of 100 02/03/2009
Specifications

Available Sizes Operating Temp. Range

Pattern Threaded Flanged Grooved End Fluids
Globe 3
⁄8" - 3" 11⁄2" - 36" 11⁄2"-2"- 3"- 4"- 6" -40° to 180° F
Angle 11⁄4" - 3" 2" - 16" 2" - 3" - 4"

Pressure Ratings (Recommended Maximum Pressure - psi)

Pressure Class
Valve Body & Cover
Flanged Threaded
Material ANSI End***
Material 150 Lb. 300 Lb.
Specifications Standards** Details

Ductile Iron* ASTM-A536 B16.42 250 400 400

Cast Steel* ASTM A216 B16.5 285 400 400 2" Globe,100S

Naval Bronze ASTM B61 B16.24 225 400 400

Stainless Steel
ASTM A743-CF-8M B16.5 285 400 400
Type 316

NI.AL.Bronze ASTM B148 B.16.24 225 400 400

Super Duplex
B16.5 285 400 400
Stainless Steel
Note: *Fusion Bonded Epoxy Coated Internal and External.
**ANSI Standards are for flanged dimensions only.
Flanged Valves are available faced but not drilled
***End Details machined to ANSI B2.1 specifications

4" Angle, 2100S

For assistance in selecting appropriate valve

options or valves manufactured with special
design requirements, please contact our
Regional Sales Office or Factory.
4" Globe,100S

Purchase Specifications When Ordering, Please Specify:

The Model 100S/2100S shall be a hydraulically operated, diaphragm-actuated, globe or
angle pattern valve. It shall contain a resilient, synthetic rubber disc, having a rectangular 1. Model No. 100S or No. 2100S
cross-section, contained on three and one-half sides by a disc retainer and disc guide, 2. Valve Size
forming a tight seal against a single removable seat insert. The diaphragm assembly, con- 3. Pattern - Globe or Angle
taining a valve stem, shall be fully guided at both ends by a bearing in the valve cover and 4. Pressure Class
an integral bearing in the valve seat. This diaphragm assembly shall be the only moving 5. Screwed or Flanged
part and shall form a sealed chamber in the upper portion of the valve, separating operat- 6. Temperature and fluid to be handled.
ing pressure from line pressure. The diaphragm shall consist of nylon fabric bonded with
synthetic rubber and shall not be used as a seating surface. Packing glands or stuffing 7. Static and Flowing Line Pressure.
boxes are not permitted and there shall be no pistons operating the valve or its pilot con- 8. Body & Trim Material
trols. All necessary repairs shall be possible without removing the valve from the line. All 9. Desired Options
materials shall be compatible with seawater.
10. When Vertically Installed
Valve shall be Model 100S/2100S manufactured by Cla-Val, Newport Beach, CA 92659-0325

Page 49 of 100 02/03/2009

71157883-PO-37502-N02-006
Functional Data Model 100S/2100S
Inches ⁄8
3
⁄2
1
⁄4
3
1 11⁄4 11⁄2 2 21⁄2 3 4 6 8 10 12 14 16 24 36
Valve Size
mm. 10 15 20 25 32 40 50 65 80 100 150 200 250 300 350 400 600 900
Globe Gal./Min. (gpm.) 1.8 6 8.5 13.3 30 32 54 85 115 200 440 770 1245 1725 2300 2940 7655 13320
CV Pattern Litres/Sec. (l/s.) .43 1.44 2.04 3.2 7.2 7.7 13 20.4 27.6 48 105.6 184.8 299 414 552 706 1837 3200
Factor Angle Gal./Min. (gpm.) — — — — 27 29 61 101 139 240 541 990 1575 2500* 3060* 4200* — —
Pattern Litres/Sec. (l/s.) — — — — 6.5 7 14.6 24.2 33.4 58 130 238 378 600 734.4 1008 — —
Equivalent Globe Feet (ft.) 25 7 16 23 19 37 51 53 85 116 211 291 347 467 422 503 628 1866
Length Pattern Meters (m.) 7.6 2.2 4.8 7.1 5.7 11.4 15.5 16.0 25.9 35.3 64.2 88.6 105.8 142.4 128.6 153.6 191.6 569
of Angle Feet (ft.) — — — — 28 46 40 37 58 80 139 176 217 222* 238* 247* — —
Pipe Pattern Meters (m.) — — — — 8.7 13.9 12.1 11.4 17.8 24.5 42.5 53.6 66.1 67.8 72.7 75.2 — —
K Globe Pattern 16.3 3.7 5.7 6.1 3.6 5.9 5.6 4.6 6.0 5.9 6.2 6.1 5.8 6.1 5.0 5.2 4.0 7.1
Factor Angle Pattern — — — — 4.4 7.1 4.4 3.3 4.1 4.1 4.1 3.7 3.6 2.9 2.8 2.6 — —
Fl. Oz .12 .34 .34 .70 — — — — — — — — — — — — — —
Liquid Displaced from U.S. Gal. — — — — .02 .02 .03 .04 .08 .17 .53 1.26 2.51 4.0 6.5 9.6 29 42
Cover Chamber When
Valve Opens ml 3.5 10.1 10.1 20.7 75.7 75.7 121 163 303 643 — — — — — — — —
Litres — — — — — — — — — — 2.0 4.8 9.5 15.1 24.6 36.2 109.8 159
*Estimated

C V Factor Where:
Formulas for computing CV Factor, Flow (Q) and Pressure Drop ( P): C V = U.S. (gpm) @ 1 psi differential at 60 F water
2 or
Q Q = (l/s) @ 1 bar (14.5 PSIG) differential
CV = Q = CV P P= C at 15 C water
P V
d = inside pipe diameter of Schedule 40 Steel Pipe (inches)
K Factor (Resistance Coefficient) 4
The Value of K is calculated from the formula: K = 894d f = friction factor for clean, new Schedule 40 pipe
(U.S. system units) 2 Cv (dimensionless) (from Cameron Hydraulic Data,

Equivalent Length of Pipe 18th Edition, P 3-119)

Equivalent lengths of pipe (L) are determined from the formula: L = Kd K = Resistance Coefficient (calculated)
(U.S. system units) 12 f
L = Equivalent Length of Pipe (feet)

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

.4085 Q
Fluid velocity can be calculated from the following formula: V= V = Fluid Velocity (feet per second) or (meters per second)
(U.S. system units) d2 = Pressure Drop in (psi) or (bar)
P

Model 100S/2100S Flow Chart (Based on normal flow through a wide open valve)

Angle Valve Sizes (Inches) 11/4 11/2 2 21/2 3 4 6 8 10 12 14 16

11/4
Globe Valve Sizes (Inches) 1/2 3/4 1 11/2 2 21/2 3 4 6 8 10 12 14 16 20 24 30 36
100
80
60

40
Pressure Drop — psi

30

20

10
8
6

4
3

1
1 3 5 10 20 30 40 60 80 100 200 500 1000 2000 5000 10,000 20,000 50,000 100,000

Flow Rate gpm (water)

Page 50 of 100 02/03/2009

71157883-PO-37502-N02-006
Dimensions J Model 100S

(MAX)

OUTLET

GGGG

INLET
DDDD

100S (Globe) 2100S (Angle) 100S Grooved (Globe) 2100S Grooved (Angle)
Valve Size (Inches) 3
⁄8 ⁄2 - 3⁄4
1
1 11⁄4-11⁄2 2 21⁄2 3 4 6 8 10 12 14 16 24 36
A Threaded 2.75 3.50 5.12 7.25 9.38 11.00 12.50 — — — — — — — — —
AA 150 ANSI — — — 8.50* 9.38 11.00 12.00 15.00 20.00 25.38 29.75 34.00 39.00 41.38 61.50 76.00
AAA 300 ANSI — — — 9.00* 10.00 11.62 13.25 15.62 21.00 26.38 31.12 35.50 40.50 43.50 63.24 78.00
AAAA Grooved End — — — 8.50 9.00 11.00 12.50 15.00 20.00 25.38 — — — — — —
B Dia. 2.50 3.12 4.38 5.62 6.62 8.00 9.12 11.50 15.75 20.00 23.62 28.00 32.75 35.50 53.16 66.00
C Max. 2.00 3.00 2.75 5.50 6.50 7.56 8.19 10.62 13.38 16.00 17.12 20.88 24.19 25.00 43.93 61.50
CC Max. Grooved End — — — 4.75 5.75 6.88 7.25 9.62 12.12 14.62 — — — — — —
D Threaded — — — 3.25 4.75 5.50 6.25 — — — — — — — — —
DD 150 ANSI — — — 4.00* 4.75 5.50 6.00 7.50 10.00 12.75 14.88 17.00 19.50 20.81 — —
DDD 300 ANSI — — — 4.25* 5.00 5.88 6.38 7.88 10.50 13.25 15.56 17.75 20.25 21.62 — —
DDDD Grooved End — — — — 4.75 — 6.00 7.50 — — — — — — — —
E 1.25 0.88 1.63 1.12 1.50 1.69 2.56 3.19 4.31 5.31 9.25 10.75 12.62 15.50 17.75 24.56
EE Grooved End — — — 2.00 2.50 2.88 3.12 4.25 6.00 7.56 — — — — — —
F 150 ANSI — — — 2.50 3.00 3.50 3.75 4.50 5.50 6.75 8.00 9.50 10.50 11.75 19.25 28.00
FF 300 ANSI — — — 3.06 3.25 3.75 4.13 5.00 6.25 7.50 8.75 10.25 11.50 12.75 — —
G Threaded — — — 1.88 3.25 4.00 4.50 — — — — — — — — —
GG 150 ANSI — — — 4.00* 3.25 4.00 4.00 5.00 6.00 8.00 8.62 13.75 14.88 15.69 — —
GGG 300 ANSI — — — 4.25* 3.50 4.31 4.38 5.31 6.50 8.50 9.31 14.50 15.62 16.50 — —
GGGG Grooved End — — — — 3.25 — 4.25 5.00 — — — — — — — —
H NPT Body Tapping — 1
⁄8 1
⁄4 3
⁄8 3
⁄8 1
⁄2 1
⁄2 3
⁄4 3
⁄4 1 1 1 1 1 1 2
J NPT Cover Center Plug 1
⁄8 1
⁄8 1
⁄4 ⁄4
1 1
⁄2 1
⁄2 1
⁄2 3
⁄4 3
⁄4 1 1 11⁄4 11⁄2 2 11⁄2 2
K NPT Cover Tapping — 1
⁄8 1
⁄4 3
⁄8 3
⁄8 1
⁄2 1
⁄2 3
⁄4 3
⁄4 1 1 1 1 1 1 2
Valve Stem Internal
Thread UNF — — — 10-32 10-32 10-32 ⁄4-28
1
⁄4-28
1
⁄8-24
3
⁄8-24
3
⁄8-24
3 3
⁄8-24 ⁄8-24
3
⁄2-20
1
⁄4-16
3 3
⁄4-16
Stem Travel — — — 0.4 0.6 0.7 0.8 1.1 1.7 2.3 2.8 3.4 4.0 4.5 6.75 10.12
Approx. Ship Wt. Lbs. 3 3 8 15 35 50 70 140 285 500 780 1165 1600 2265 6200 11470
*40mm Size Only *11⁄2" Size Only

Valve Size (mm) 10 15-20 25 32-40 50 65 80 100 150 200 250 300 350 400 600 900
A Threaded 70 89 130 184 238 279 318 — — — — — — — — —
AA 150 ANSI — — — 216* 238 279 305 381 508 645 756 864 991 1051 1562 1930
AAA 300 ANSI — — — 229* 254 295 337 397 533 670 790 902 1029 1105 1606 1981
AAAA Grooved End — — — 216 228 279 318 381 508 645 — — — — — —
B Dia. 64 80 111 143 168 203 232 292 400 508 600 711 832 902 1350 1676
C Max. 51 76 70 140 165 192 208 270 340 406 435 530 614 635 1116 1562
CC Max. Grooved End — — — 120 146 175 184 244 308 371 — — — — — —
D Threaded — — — 83 121 140 159 — — — — — — — — —
DD 150 ANSI — — — 102* 121 140 152 191 254 324 378 432 495 528 — —
DDD 300 ANSI — — — 108* 127 149 162 200 267 337 395 451 514 549 — —
DDDD Grooved End — — — — 121 — 152 191 — — — — — — — —
E 32 23 42 29 38 43 65 81 110 135 235 273 321 394 451 624
EE Grooved End — — — 52 64 73 79 108 152 192 — — — — — —
F 150 ANSI — — — 64 76 89 95 114 140 171 203 241 267 298 489 711
FF 300 ANSI — — — 78 83 95 105 127 159 191 222 260 292 324 — —
G Threaded — — — 48 83 102 114 — — — — — — — — —
GG 150 ANSI — — — 102* 83 102 102 127 152 203 219 349 378 399 — —
GGG 300 ANSI — — — 102* 89 110 111 135 165 216 236 368 397 419 — —
GGGG Grooved End — — — — 83 — 108 127 — — — — — — — —
H NPT Body Tapping — 1
⁄8 1
⁄4 3
⁄8 3
⁄8 1
⁄2 1
⁄2 3
⁄4 3
⁄4 1 1 1 1 1 1 2
J NPT Cover Center Plug 1
⁄8 1
⁄8 1
⁄4 1
⁄4 1
⁄2 1
⁄2 1
⁄2 3
⁄4 3
⁄4 1 1 11⁄4 11⁄2 2 11⁄2 2
K NPT Cover Tapping — 1
⁄8 1
⁄4 3
⁄8 3
⁄8 1
⁄2 1
⁄2 3
⁄4 3
⁄4 1 1 1 1 1 1 2
Valve Stem Internal
Thread UNF — — — 10-32 10-32 10-32 1
⁄4-28 1
⁄4-28 3
⁄8-24 ⁄8-24
3
⁄8-24
3
⁄8-24
3
⁄8-24
3 1
⁄2-20 3
⁄4-16 ⁄4-16
3

Stem Travel — — — 10 15 18 20 28 43 58 71 86 102 114 171 257

Approx. Ship Wt. Kgs. 1.4 1.4 4 7 16 23 32 64 129 227 354 528 726 1027 2812 5200
Cla-Val Control Valves operate with maximum efficiency when mounted in horizontal piping with the main valve cover UP, however, other positions are acceptable. Due to
component size and weight of 8 inch and larger valves, installation with cover UP is advisable. We recommend isolation valves be installed on inlet and outlet for maintenance.
Adequate space above and around the valve for service personnel should be considered essential. A regular maintenance program should be established based on the specific
application data. However, we recommend a thorough inspection be done at least once a year. Consult factory for specific recommendations.

CLA-VAL 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
© Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice. E-100S/2100S (R-11/06)

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 Model 2508 Gate Valve Operations Manual

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 AMERICAN FLOW CONTROL

SERIES 2500 RESILIENT

WEDGE GATE VALVE
INTRODUCTION AND HISTORY

The Series 2500 Ductile Iron Resilient Wedge Gate

Valve has a rated working pressure of 250 p.s.i.g. and is
designed for use in drinking water, sewage, fire protec‐
tion systems as well as irrigation and backflow control
systems.
The Series 2500 Resilient Wedge Gate Valve can be fur‐
nished in configurations that are Listed by Underwrit‐
ers Laboratories, Inc. and Approved by Factory Mutual
Research.

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 FEATURES AND BENEFITS
FEATURES
American Flow Control's Series 2500 Ductile Iron Resil‐
ient Wedge Gate Valves are suitable for use in drinking
water, sewage and fire protection systems. These
valves have a rated working pressure of 250 p.s.i.g. The
valve seals 100% leak tight. The waterway is clear, un‐
obstructed and free from pockets.
ADVANTAGES WHEN COMPARED TO BUTTERFLY
VALVES
• No disc in waterway to restrict flow or to increase
pumping costs.
• Allows passage of pigging devices.
• Internal parts can be serviced without cutting valve
out of pipeline.
• 250 p.s.i.g. rating allows working pressure to be in‐
creased above the 150 p.s.i.g. pressure rating found
on most butterfly valves.
ADVANTAGES WHEN COMPARED TO DOUBLE DISC
GATE VALVES
• 100% bottle tight seal. No more time consuming test‐
ing to determine allowable leakage rate.
• No pocket in bottom of valve to collect sediment or
trap debris.
• Lower torque requirements to operate valve.
• 250 p.s.i.g. pressure rating compared to the 200
p.s.i.g. rating found on most double disc gate valves.
• Fusion bonded epoxy coated inside and out.
• Lower total valve weight.
SERIES 2500 RESILIENT WEDGE GATE VALVE STAN‐
DARD FEATURES:
• 250 p.s.i.g. rated working pressure.
• Ductile iron body, bonnet, wedge, operating nut and
stuffing box.
• Triple O-ring stem seals.
• Thrust washers.
• Fusion bonded epoxy coating.
• 100% bottle tight closure.
• Rubber encapsulated wedge.
• Flat features on valve body so valve stands upright
for storage or during installation.
• Optional geared actuators.
• 4” thru 48” valves are certified to ANSI/NSF Standard
61.
• Fusion bonded epoxy coating material used on
2” thru 48” valves is certified to ANSI/NSF Stan‐
dard 61.
AMERICAN FLOW CONTROL
71157883-PO-37502-N02-006
BENEFITS
DUCTILE IRON CONSTRUCTION
The ductile iron body and bonnet provide superior
strength and allow a pressure rating of 250 p.s.i.g.
The strength of ductile iron is double that provided
by gray iron. This added strength and higher pres‐
sure rating is provided in a compact, lighter design.
FUSION BONDED EPOXY COATING
The Series 2500 valve is epoxy coated both on the
interior as well as the exterior of the valve. The fu‐
sion bonded coating is applied after the valve body
is shot blasted clean. The coating is applied to all fer‐
rous surfaces so that even the bolt holes and body-‐
to-bonnet flange surfaces are epoxy coated.
THRUST WASHERS
Thrust washers are located above and below the
FEATURES AND BENEFITS
stem collar ensuring trouble-free operation of the
valve.
DUCTILE IRON LIFTING LUGS
The stuffing box is constructed of high strength duc‐
tile iron with integral lifting lugs on most sizes. Lifting
lugs allow the valve to be lifted safely, without risk of
the valve falling or damaging the valve by lifting from
the operating nut.
TRIPLE O-RING STEM SEALS
This valve features triple O-ring stem seals. Two O-‐
rings are located above the thrust collar and one O-‐
ring is located below the thrust collar. The O-ring di‐
rectly above and below the stem collar provide a
permanently sealed lubrication chamber. This fea‐
ture assures the ease of operation for long periods
of time without the need for constant maintenance
required for other designs. The upper O-ring acts as
a shield, sealing the stem from dirt and grit that might
otherwise enter the stuffing box in buried and sew‐
age service applications.
NO FLAT GASKETS
The stuffing box gasket and bonnet gasket are pres‐
sure energized rubber O-rings. This assures bottle
tight seals without the need for excessive bolt load‐
ing as is required of flat gaskets. The O-ring seals
are reusable which eliminates the need for time con‐
suming cleaning, scrapping and cutting of new gas‐
kets.
UL-FM RATED VALVES ARE AVAILABLE
The Series 2500 valve can be furnished in configu‐
rations that are listed by Underwriters Laboratories,
Inc. and Approved by Factory Mutual Research.
Configurations not available as UL/FM:
• NRS with handwheel
• Open right (NRS or OS & Y)
• NRS with gearing
• 2” NRS
3A- 3
SERIES 2500 RESILIENT WEDGE VALVE
Page 54 of 100 02/03/2009
 SERIES 2500 - OS & Y DIMENSIONS, 2”-12” SIZES
S E R I E S 2 5 0 0 - O S & Y D I M E N S I O N S, 2” - 1 2” S I Z E S

Valve Size
Dimension Series 2500 Series 2500-1
2” 2-1/2” 3” 4” 6” 8” 10” 12”
A (Valve Open) +/- 1/4 13.62 16.78 18.12 23.47 30.97 38.16 48.41 53.66
B (Valve Closed) +/- 1/4 11.50 14.12 14.94 19.12 24.59 29.91 38.16 41.78
Handwheel Diameter 8.00 8.00 8.00 10.00 12.00 14.00 16.00 16.00
End to End - FL/FL (Class 125) 7.00 7.50 8.00 9.00 10.50 11.50 13.00 14.00
No. of Turns to Open 9 11 13 14 20 25 31 38
End to End - FL/FL (Class 250) N/A N/A 11.19 12.00 15.88 16.50 18.00 19.75

NOTES:
1. 3” thru 12” valves meet or exceed requirements of ANSI/AWWA C515.
2. Valve may be ordered in configurations which are UL Listed and FM Approved.
3. 250 p.s.i.g. rated working pressure.
4. Fusion bonded epoxy coating meets or exceeds requirements of ANSI/AWWA C550.
5. Class 125 flanged ends are in accordance with ASME B16.1, Class 125 for cast iron flanges and ANSI/AWWA
C110/A21.10.
6. Class 250 flanged ends are in accordance with ASME B16.1, Class 250 for cast iron flanges.
7. 4” thru 12” valves are certified to ANSI/NSF Standard 61.

3A- 8 SERIES 2500 RESILIENT WEDGE VALVE AMERICAN FLOW CONTROL

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 SERIES 2500 - CLASS 250 FLANGE DIMENSIONS

S E R I E S 2 5 0 0 - C LAS S 2 5 0 F LAN G E D I M E N S I O N S
A B C D E F
Valve Raised
Model Bolt Bolt Holes No. of Hex Face
Size Diameter Flange Bolt Size
Circle Nuts Dia.
of Flange Thickness No. Size See Note 2
Diameter Required
Series 2500 3” 8.25 1.12 6.62 8 .88 3/4-10 x 3-1/2 8 5.69
4” 10.00 1.25 7.88 8 .88 3/4-10 x 4 8 6.94
6” 12.50 1.44 10.62 12 .88 3/4-10 x 4 12 9.69
Series
8” 15.00 1.62 13.00 12 1.00 7/8-9 x 4-1/2 12 11.94
2500-1
10” 17.50 1.88 15.25 16 1.12 1”-8 x 5-1/2 16 14.06
12” 20.50 2.00 17.75 16 1.25 1-1/8-7 x 5-1/2 16 16.44
14” 23.00 2.12 20.25 20 1.25 1-1/8-7 x 6 20 18.94
16” 25.50 2.25 22.50 20 1.38 1-1/4-7 x 6-1/2 20 21.06
18” 28.00 2.38 24.75 24 1.38 1-1/4-7 x 6-1/2 24 23.31
20” 30.50 2.50 27.00 24 1.38 1-1/4-7 x 7 24 25.56
24” 36.00 2.75 32.00 24 1.62 1-1/2-6 x 7-1/2 24 30.31
30”
Series 2500
36”
42”
48” Not Available with Class 250 Raised Face Flanged Ends
54”
60”
66”

NOTES:
1. Flange dimensions shown are per ASME B16.1, Class 250 for cast iron flanges.
2. Bolt lengths shown are for standard cast iron flange thicknesses with thru holes. Steel or ductile iron flanges
with reduced thickness or valves or fittings with tapped holes may require shorter bolts.

3A- 11
AMERICAN FLOW CONTROL SERIES 2500 RESILIENT WEDGE VALVE

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 SERIES 2500 - OPTIONAL TAPS ON CLASS 125 & CLASS 250
FLANGE X FLANGE BODIES
S E R I E S 2 5 0 0 - T A P S, C L A S S 1 2 5 & 2 5 0 F L A N G X F L A N G E B O D I E S

Available Tap Sizes for Boss

Model Valve Size Locations
A, B, C, D, E & F
2” 1/2, 3/4 NPT
Series 2500 2-1/2” 1/2, 3/4 NPT
3” 1/2, 3/4 NPT
4” 1/2, 3/4, 1” NPT
6” 1/2, 3/4, 1” NPT
Series 2500-1 8” 1/2, 3/4, 1” NPT
10” 1/2, 3/4, 1” NPT
12” 1/2, 3/4, 1” NPT

NOTES:
1. Valve body tap locations are in accordance with MSS SP-45.
2. Taps are available on any valve with flanged ends, whether it is an NRS or OS & Y type valve.

3A- 12 SERIES 2500 RESILIENT WEDGE VALVE AMERICAN FLOW CONTROL

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 SERIES 2500 - MECHANICAL JOINT ACCESSORIES

SERIES 2500 - MECHANICAL JOINT ACCESSORIES

Gland Gasket T-Head Bolt
Pipe C Diameter E F Dia G H
Model or
Valve A B Pit- ‐
Dia Dia Std. D Standard Transition Standard Transition Standard Transition Qty Size Length
Size Cast Qty Size
Gland Gasket Gasket Gasket Gasket Gasket Gasket
Gland

Series 2” 6.25 4.75 2.61 N/A .62 2 .75 2.48 2.33 .48 .56 1.05 1.11 2 5/8-1 1 3”
2500 3” 7.69 6.19 4.06 N/A .62 4 .75 3.86 3.45 .48 .70 1.05 1.11 4 5/8-1 1 3”
4” 9.12 7.50 4.90 5.13 .75 4 .88 4.68 4.43 .62 .77 1.22 1.26 4 3/4-10 3-1/2”
6” 11.12 9.50 7.00 7.24 .88 6 .88 6.73 6.53 .62 .76 1.22 1.25 6 3/4-10 3-1/2”
Series 8” 13.37 11.75 9.15 9.46 1.00 6 .88 8.85 8.50 .62 .82 1.22 1.27 6 3/4-10 4”
2500-1
10” 15.62 14.00 11.20 11.53 1.00 8 .88 10.87 10.59 .62 .79 1.22 1.26 8 3/4-10 4”
12” 17.88 16.25 13.30 13.63 1.00 8 .88 12.95 12.56 .62 .84 1.22 1.28 8 3/4-10 4”
14” 20.25 18.75 15.44 N/A 1.25 10 .88 14.99 N/A .62 N/A 1.22 N/A 10 3/4-10 4-1/2”
16” 22.50 21.00 17.54 N/A 1.31 12 .88 17.07 N/A .62 N/A 1.22 N/A 12 3/4-10 4-1/2”
18” 24.75 23.25 19.64 N/A 1.38 12 .88 19.13 N/A .62 N/A 1.22 N/A 12 3/4-10 4-1/2”
20” 27.00 25.50 21.74 N/A 1.44 14 .88 21.20 N/A .62 N/A 1.22 N/A 14 3/4-10 4-1/2”
Series 24” 31.50 30.00 25.94 N/A 1.56 16 .88 25.34 N/A .62 N/A 1.22 N/A 16 3/4-10 5”
2500
30” 39.12 36.88 32.17 N/A 2.00 20 1.12 31.47 N/A .73 N/A 1.54 N/A 20 1”-8 6”
36” 46.00 43.75 38.47 N/A 2.00 24 1.12 37.67 N/A .73 N/A 1.54 N/A 24 1”-8 6”
42” 53.12 50.62 44.67 N/A 2.00 28 1.38 43.78 N/A .73 N/A 1.54 N/A 28 1-1/4-7 6-1/2”
48” 60.00 57.50 50.97 N/A 2.00 32 1.38 49.98 N/A .73 N/A 1.54 N/A 32 1-1/4-7 6-1/2”

NOTES:
1. Dimensions shown for standard glands and gaskets in 2” thru 48” sizes are in accordance with ANSI/AWWA
C111/A21.11 and ANSI/AWWA C153/A21.53.
2. Dimensions shown are nominal.
3. T-head bolts and nuts are high-strength, low-alloy steel.
4. Glands are ductile iron.

3A- 13
AMERICAN FLOW CONTROL SERIES 2500 RESILIENT WEDGE VALVE

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 SERIES 2500 - OS & Y PARTS LIST, 4” - 8” SIZES
S E R I E S 2 5 0 0 - O S & Y P A R T S L I S T, 4” - 8” S I Z E S

Qty
Ref No. Description Material Series 2500-1
4” 6” 8”
2 Stem Nut Bronze 2 2 2
3 O-ring Nitrile Rubber 1 1 1
4 Handwheel Washer Brass 1 1 1
5 Stuffing Box Gasket Nitrile Rubber 1 1 1
8 Bonnet Ductile Iron 1 1 1
9 Hex Head Bolt, 5/8-11 x 2” Stainless Steel 6 2 2
10 Bonnet Gasket EPDM Rubber 1 1 1
11 Body Ductile Iron 1 1 1
12 Stem Free Cutting Brass 1 1 1
13 Wedge Nut Ductile Iron 1 1 1
14 Resilient Wedge Ductile iron, Encapsulated with EPDM Rubber 1 1 1
15 Hex Nut, 5/8-11 Stainless Steel 6 8 10
16 Hex Nut, 5/8-11 Brass 2 2 2
17 Handwheel Ductile Iron 1 1 1
18 Groove Pin Stainless Steel 1 1 1
19 Hex Head Bolt, 5/8-11 x 2-1/4” Stainless Steel - 6 -
20 Gland Follower Ductile Iron 1 1 1
21 Hex Head Bolt, 5/8-11 x 2-1/2” Stainless Steel - - 8
22 Hex Head Bolt, 5/8-11 x 2-3/4” Stainless Steel 2 2 2
23 Gland Sintered Bronze, Oil Impregnated 1 1 1
24 Packing Ring Tallow Impregnated Flax 5 5 5
25 Yoke Ductile Iron 1 1 1
40 UL/FM Label Pressure Sensitive Acrylic Film 1 1 1
69 Wedge Cover Acetal 2 2 2

3A- 28 SERIES 2500 RESILIENT WEDGE VALVE AMERICAN FLOW CONTROL

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 SERIES 2500 - WEIGHTS
NRS Valve - Series 2500

Valve Size
End
Series 2500
Connections
2” 2-1/2 ” 3” 14” 16” 18” 20” 24” 30” 36” 42” 48” 54” 60” 66”
MJ x MJ 42 - 44 670 820 1100 1520 2300 4100 7450 11210 15870 - - -
FL x MJ (Class 125) - - - 680 840 1110 1525 2300 4100 7450 11210 15870 - - -
FL x FL (Class 125) 38 46 52 690 870 1120 1530 2300 4100 7450 11210 15870 16970 29490 31200
FL x FL (Class 250) - - 68 875 1080 1370 1880 2300 - - - - - - -
TY x TY - - - - - - - - - - - - - - -
FL x TY (Class 125) - - - - - - - - - - - - - - -
PO x PO - - - 650 830 - - - - - - - - - -
PVC x PVC 35 41 47 - - - - - - - - - - - -
Threaded x Threaded
30 36 41 - - - - - - - - - - - -
(Screw x Screw)
FL x MJ (Tapping) - - - 680 845 1110 1525 2300 4100 7450 11210 15870 - - -
FX x FX (Flex-Ring) - - - - - - - 2300 4100 7450 11210 15870 - - -

SERIES 2500 - WEIGHTS

NRS Valve - Series 2500-1

Valve Size
End
Series 2500-1
Connections
4” 6” 8” 10” 12”
MJ x MJ 57 96 149 228 331
FL x MJ (Class 125) 63 102 162 246 364
FL x FL (Class 125) 71 108 177 268 400
FL x FL (Class 250) 93 162 251 378 549
TY x TY 70 110 177 263 370
FL x TY (Class 125) 70 109 176 264 384
PO x PO - - - - -
PVC x PVC 58 110 158 - -
Threaded x Threaded
- - - - -
(Screw x Screw)
FL x MJ (Tapping) 64 102 162 246 365
FX x FX (Flex-Ring) - - - - -

OS & Y Valve - Series 2500 and 2500-1

Valve Size
End Connections Series 2500 Series 2500-1
2” 2-1/2” 3” 4” 6” 8” 10” 12”
FL x FL (Class 125) 49 47 53 88 131 205 313 446
FL x FL (Class 250) - - 69 110 185 279 423 595

NOTE: All weights are in pounds.

3A- 31
AMERICAN FLOW CONTROL SERIES 2500 RESILIENT WEDGE VALVE

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 SERIES 2500 - INSTALLATION & TESTING

Storage Reference Material

Valves are palletized when shipped which provides These reference materials are available and
suitable protection from weather and sunlight during should be helpful in the installation and testing of
storage. If palletizing is disbanded and valves re‐ gate valve products.
moved, remaining valves should be suitably covered
AWWA C515 Reduced-wall, Resilient-Seated
or stored elsewhere with the valve stem vertical. Gate Valves
• Always store valves fully closed.
AWWA C500 Metal-Seated Gate Valves - 3 thru
• When possible, keep valves out of the weather. 48 inch
• In cold climates, keep the inside of the valve
AWWA C600 Installation of Ductile-Iron Water

drained of any water to prevent freezing.
• Whenever possible, cover valves with a water‐
proof covering.
• Protect all parts of the valve at all times.
Inspection Before Installation
• Check to make sure that the valve end connec‐
tions are clean and that the valve is not dam‐
aged.
• Check opening direction and other details
against specification.
• Open and close the valve to make sure it works
properly.
• Clean the inside of the valve to remove all con‐
taminants that may affect water system purity.
• Keep the valve closed when placing in trench.
Installation
1. Handle the valve carefully.
S E R I E S 2 5 0 0 - I N S TALLAT I O N & T E S T I N G
Mains
AWWA M23 PVC Pipe - Design and Installation
All installation, operation and maintenance in‐
structions issued by the manufacturer of the pipe
and the valves.
Valve user guides as published by MSS.
NFPA-24 Private Fire Service Mains and
Their Appurtenances
These industry practices have been listed to
help you make a safe and acceptable installation
of a gate valve.
Testing Procedure
1. Do not backfill around valves before hydro‐
static system test. Leave the valves and end
joints exposed while the pipeline is being pres‐
surized.

2. Check all bolts for tightness. Gaskets may 2. Check to see that all valve joints and pressure
shrink during storage and might leak if the bolts containing bolting are tight.
are not re-tightened. 3. Valves can be tested (but not operated) at up
to two times the rated pressure of the valve.
3. Prepare pipe ends in accordance with pipe
manufacturer's instructions. 4. After testing, steps should be taken to relieve
any trapped pressure in the body of the valve.
4. Install the valve as per appropriate instructions
for the specified joint (flanged, mechanical joint,
PVC, asbestos cement, etc.)
NOTE: Use 1/8” thick rubber “ring” type gas‐
kets or TorusealR full face gaskets. Do not
use composition or flat full face gaskets.
5. Be sure that the water main is properly sup‐
ported to avoid line stress on the valve.
6. In buried applications, make sure that the valve
box does not transmit traffic loads or other
stress to the valve.
7. Do not use valves to force a pipeline into posi‐
tion. Do not deflect any valve/pipe joint.

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AMERICAN FLOW CONTROL SERIES 2500 RESILIENT WEDGE VALVE

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 SERIES 2500 - OPERATION & MAINTENANCE

Operation Typical Operating Torque At

Rated Working Pressure
1. Direction of opening is indicated by an arrow cast on
the handwheel or wrench nut of the valve.
Valve Closing Opening
2. Operate gate valves from full closed to full open Size Torque Ft-lbs Torque Ft-lbs
position and back before applying pressure. 2” 15-20 15-20
3. Close gate valve slowly against pressure to avoid 2-1/2” 15-20 15-20
damage from surge or water hammer. 3” 30-40 30-40

SERIES 2 5 0 0 - OPERATION & MAINTENANCE

4. Valves installed on liquid service subject to freezing 4” 30-40 30-40
conditions should be protected to prevent trapping 6” 50-60 50-80
of liquid in the bonnet cavity, expansion on freezing
8” 70-80 60-90
and subsequent damage. The same is true of
valves which are subject to considerable tempera‐ 10” 90-100 125-150
ture increases. Trapped pressure should be vented 12” 100-125 140-175
back to the upstream side to prevent buildup of 14” Contact Factory
pressure in the valve bonnet due to high tempera‐
16” Contact Factory
ture expansion.
18” Contact Factory
5. Valves should be opened and closed without the
20” Contact Factory
use of excessive torque applied to the handwheel or
wrench nut. Excessive torque may damage the 24” Contact Factory
valve. 30” Contact Factory
36” Contact Factory
Maintenance 42” Contact Factory
48” Contact Factory
1. Operate gate valves from full open to full close at
regular intervals. The length of time between opera‐ 54” Contact Factory
tions depends upon the time of installation and the 60” Contact Factory
service conditions. 66” Contact Factory
2. Use MystikR FG-2 Food Machinery Grease for the
stem threads and thrust collar.
3. Chipped spots in the epoxy coating should be re‐
paired with a liquid two part epoxy.

! WARNING
To prevent possible personal injury, do not re‐
move bonnet bolts with valve under pressure.

Spare Parts
Under most conditions, the only spare parts needed for
the valve would be upper and lower stem O-rings. Un‐
der rigorous service, stems, wedges, upper and lower
stem O-rings and thrust washers should be carried as
spare parts.
Use parts list drawings as a guide for disassembly and
ordering repair parts. Also refer to disassembly/reas‐
sembly instructions.

3A- 35
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 SERIES 2500 - OS & Y REPAIRS, 4” - 8” SIZES
Disassembly
! WARNING
The valve waterway should not be under pressure.
1. Turn the handwheel to fully close the valve.
2. Mark the two stem nuts in line with each other, one
mark on the top of the upper stem nut and one mark
on the same side of the lower stem nut flange.
3. Remove the two hex-head bolts from the yoke.
4. Loosen the gland-follower nuts.
Reassembly
Reassembly is the reverse of disassembly with the fol‐
lowing notes:
1. Carefully inspect and replace any damaged compo‐
nents. Lubricate all O-rings with MystikR FG-2
Food Machinery Grease.
2. Make sure the wedge nut is fully seated into the slot
in the wedge.
3. Make sure the bonnet gasket is properly positioned
on the valve body flange when the bonnet is as‐
sembled onto the valve body.
4. After installing the wedge assembly and bonnet,
place one packing ring in the bonnet then position
the stuffing box gasket in the bonnet recess.
5. Place the yoke part-way onto the stem tipping the
top of the yoke to the side. Raise the yoke off of the
top of the stem and place the gland and gland-fol‐
lower onto the stem. Raise the yoke again and
thread the lower stem nut partially onto the stem.
Note the position of the alignment mark and place
the yoke onto the lower stem nut.
AMERICAN FLOW CONTROL
71157883-PO-37502-N02-006
5. Turn the handwheel in the closing direction to
unscrew the pair of stem-nuts from the stem.
The handwheel, yoke and handwheel wash‐
er will also be removed as they are trapped
between the stem-nuts. When the upper
S E R I E S 2 5 0 0 - O S & Y R E P A I R S, 4” - 8” S I Z E S
stem nut is fully unthreaded from the stem,
the handwheel can be removed. When the
lower stem nut is unthreaded from the stem,
the yoke, gland and gland-follower can be
removed.
6. Remove the bonnet bolts and grasping the
stem, withdraw the bonnet and wedge as‐
sembly from the valve.
7. Withdraw the stem and wedge assembly
from the bonnet and remove the wedge from
the stem by sliding the wedge nut out the side
of the wedge slot.
8. Drive the groove pin out of the wedge nut and
unscrew the stem from the wedge nut.
6. Place the handwheel washer on the top of the
yoke.
7. Note the location of the alignment mark on
the upper stem nut and place the nut in the
handwheel. Place the handwheel and upper
stem nut onto the yoke, engaging the teeth of
the stem nuts so that the marks are aligned.
8. Turn the handwheel and yoke as a unit onto
the stem until the yoke is nearly touching the
bonnet.
9. Using two hex head bolts, fasten the yoke to
the bonnet.
10. Raise the gland and gland-follower and re‐
place the packing rings so that joints in the
rings are not aligned. Use the same total
number of packing rings as were removed.
11. Replace and tighten the gland-follower nuts.
3A- 45
SERIES 2500 RESILIENT WEDGE VALVE
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 SERIES 2500 - OS & Y REPAIRS, 4” - 8” SIZES
S E R I E S 2 5 0 0 - O S & Y R E P A I R S, 4” - 8” S I Z E S

3A- 46 SERIES 2500 RESILIENT WEDGE VALVE AMERICAN FLOW CONTROL

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SECTION 5 – Seismic Calculation Package

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SECTION 6 – Drawing Files

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 7 -

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7

2.0

1.0
0.9
0.8
0.7
0.6

0.5

FRICTION LOSS - bar

0.4

0.3

2000
3000
4000
5000
6000
7000
FLOW RATE - l/min

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