Designer and operator manual dorot

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Version 200508

Automatic Control Valves USER MANUAL��

DESIGNER & OPERATOR

MANUAL

TABLE OF CONTENTS ��

Automatic Control Valves OPERATION MANUAL Section1��

Section 1, Basic Valves……………………………………………………. 3 Section 2, Automatic control valves……………………………………..... 32 Section 3, Operating instructions / trouble shooting guide………………72

BASIC VALVES ��

Automatic Control Valves OPERATION MANUAL Section 1 �

Basic valves operation….…………………………………………………...4 Basic Metal Valves – Size and Diaphragm Selection Guide…………….8 Plastic Valves………………………………………………………………..11 Plastic Valves – S-75.……………………………………………………....13 Plastic Valves – S-95, S-96…................................................................16 Plastic Valves – PVC Valves installation………………………………….18 Plastic Valves – S- 80……………………………………………………….20 Backflushing Control Valves………………………………………………..23

BASIC VALVES OPERATION ��


Closed valve

DIRECT-SEALING DIAPHRAGM The direct-sealing diaphragm valves are operated by pipeline pressure or by air pressure (which is equal to or larger than the pipeline pressure). The reinforced rubber diaphragm seals the water passage when the line pressure reaches the valve’s control chamber. Relieving the pressure from the control chamber causes the valve to open.

REINFORCED RUBBER DIAPHRAGM The valves only moving part is its diaphragm. A spring located above the diaphragm ensures “valve closure” regardless of pressure level and flow conditions.

Upstream pressure applied to twice the diaphragm area. Valve closes.

Opening port releases pressure from inside Bonnet. Valve opens.

Open valve

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HYDRAULIC Properties of water used in practical designs

Density: 1 gr/cm3 (0.036 lb/in3) Kinematic viscosity: 10-6 m2/s (10.76 ft2/sec) Static pressure : The column of water sorted in a tank with relation to a

relative surface, or the potential energy in a pipe line. Dynamic pressure: The energy gradient caused by flow of water. Flow rate: The amount of water passing through a nozzle at a period of time.

Open discharge flow equation Units US Metric

Equation 445.22 xDxVQ � 4.28272 �� DVQ Q = GPM

V = ft/sec D = Diameter (ID) inch 2.445 = Unit Conversion factor

Q = m3/h V = m/sec D = Diameter (m) 2827.4 = Unit Conversion factor

Valve pressure loss: The pressure differential across a valve caused by friction.

Pressure loss equation Units US Metric

Equation 2

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CvQ

P 2

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KvQ

P

Q = GPM Cv = Flow coefficient [GPM @ 1 psi pressure loss]

Q = m3/h KV = Flow coefficient [m3/h @ 1 bar pressure loss]

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WHAT IS A CONTROL VALVE Control (regulating) valves are semi-automatic directional devices, which control flow and/or pressure in a water supply network. The valves are pre-set by the operator to the required operating parameters.

OPERATING PRESSURES FOR VALVES The standard valves are divided into three pressure categories:

Medium pressure metallic models (up to 230 psi) High Pressure metallic models (up to 360 psi) Plastic valves (up to 150 psi)

OPENING PRESSURES OF VALVES The sealing diaphragm or plug of the hydraulic control valve is pushed to open by the pressure in the line. This pressure should be high enough to ensure the minimal required opening force. Verify that the upstream pressure is not below the minimal opening pressure of the valve, as defined in the technical data supplied.

Note: Non-standard, low-pressure diaphragms can be used with Direct Sealing Diaphragm valves (Gal) to allow lower opening pressures. These diaphragms should not be used with regulating valves and should be preferred for on\off use only.

OPERATING VELOCITIES FOR VALVES Direct Sealing Diaphragm valves (Gal valves) may be used at very high flow velocities due to the shape of the valve body, which allows smooth and wide flow passage. The valves may be operated in the fully open position at 8 m/sec [15 ft/sec] velocity without noise, shuddering or cavitation damage for short durations and at 5.5 m/sec [18 ft/sec] for continuous operation.

MEDIA CONTROLLED BY VALVES The valve is suitable for controlling slurries, untreated sewage water, water with high sand content as well as the potable water. This is due to the design of the valve, which has no shaft, bearings, seals or discs within the water passage. The control pressure should be the line pressure filtered to a degree of 40 mesh min. or use a clean external pressure source such as filtered fresh water or compressed natural gas\air. Note: In-line self-flushing filters, ensuring clog-free operation of the control devices when operating with potable or raw irrigation water, are a standard feature on all control valves.

CONTROL MEDIA FOR VALVES The valve can be controlled by an external source such as air or clean water in cases where the media is very dirty or aggressive.

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PRESSURE DIFFERENTIAL High pressure differential across the regulating valve may cause severe aberration and cavitation damage. One should avoid operating the valve for long durations at pressure ratio exceeding 3:1 (Upstream:Downstream pressures). Special attention should be given to maintain the operating pressures within the specified limits. In case such regulating conditions exist, the recommended solutions may be:

Installing two valves in sequence (inline), were each valve is operating with just half of the total pressure differential.

Installing A fixed orifice within the pipe to reduce the regulation ratio of the valve to the recommended 3:1 ratio. This solution is only possible when the flow is at a constant value most of the time.

PRESSURE LOSSES WITH VALVES As the water passes through the Gal valves is smooth and causes only minimal obstruction, the resulting pressure-losses are typically low. Consequently, the automatic control valve has a very high Kv [Cv] coefficient. This allows using a valve smaller than the pipeline nominal diameter. This is not detrimental to the system and is more economical. Note: Kv [Cv] data refers to a fully open valve (controlled by a 3 Way Control System were the control chamber's pressure is atmospheric). The pressure losses in a valve controlled by a 2 Way Control System (minimal control chamber's pressure is the downstream pressure) may be considerably higher.

CAVITATION POTENTIAL WITH VALVES The valves unique structure makes them very resistant to cavitation. However, it is not recommended to exceed a 3:1 ratio of Upstream/ Downstream pressures. When higher regulation ratios are required (up to 5:1), it is recommended to use cast bronze or non-metal (nylon/PVC) valves. Note: Pressure Relief valves and Modulating Float controlled valves whose downstream pressure is very low are subjected to destructive cavitation levels. Therefore, the use of bronze valves or a proper orifice plate is essential for prolonging their life span. Please consult DOROT VALVES technical department for further information.

MANUAL OVERRIDE Manual override feature (using 3-position selector ball valves) can be added to any control application.

GENERAL INFORMATION ABOUT VALVES DOROT VALVES broad range of specialized hydraulic control solutions, allows us to design a solution to any control system, no matter how complicated. Please note, we have not included our complete line of valves in this manual. If the required control system needed does not appear here, please contact your distributor or DOROT VALVES Technical Support department. We will design a tailor made control valve for your system if a standard one is not currently available.

BASIC METAL VALVES ��


Table 1

Table 2

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Notes: 1. Pressure range- referring to upstream pressure and not to downstream regulating set-pressure.

2. Standard and High Pressure diaphragms are suitable for regulating applications. 3. Low pressure diaphragms are suitable for on/ off applications.

Pressure rating:

� 100 series (GAL) valves pressure rating as marked on the valve I.D. plate refers to body & bonnet strength and diaphragm type. It is the customer's responsibility to define the adequate connection standard. Please consult Dorot Technical Support department in case you require assistance in selecting the right connection type\standard.

� Pressure rating of valve body for standard models: 16 bar /230 psi � Pressure rating of valve body for high pressure models: 25 bar / 360 psi � Connection standard is marked on valves identification plate. � Diaphragm standard is specified in the above table.

Non standard bonnets: Available on demand

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Automatic Control Valves OPERATION MANUAL Section 1

Hydraulic performance

Table 4.

PLASTIC VALVES ��


Background

Dorot is one of the first valve companies world-wide to bring automatic hydraulic control plastic valves to the market. It is the first company to present large diameter plastic valves and is currently holding an exceptionally wide range of composite and plastic material valves that allows the user to select the most appropriate valve for the specific system's requirement.

ADVANTAGES � Reliable control of corrosive liquids � Lightweight, cost-saving � Minimum maintenance - maximum dependability � Simple to install

APPLICATIONS

� Irrigation System � Industrial usage with corrosive fluids � Sewage systems � Landscape and Greenhouse applications

Reinforced nylon throttling 2-w electric

PVC 3-w electric

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6" PVC manual

80 Series 2-w electric

PLASTIC VALVES ��


3 way control The control devise (solenoid valve, pilot valves, relay valves, manual selector valves or combination of thereof) can admit pressure into the control chamber, causing valve closure, or relive pressure from control chamber to the atmosphere, enabling valve opening.

2 way electric control A permanent, constant resistance connection exists, from upstream (inlet) to the control chamber. A solenoid operator is installed on a second passage from the control chamber to the downstream (outlet) side of the valve. When the solenoid is de-energized (or in closed position in latching solenoid operators), it plugs the control chamber outlet, thus pressure entering through the upstream passage can not escape and the valve closes. Energizing a continuous current operated solenoid or pulsing a latching operator to open, opens the outlet to downstream and relives control chamber pressure which will enable the valve to open.

PLASTIC VALVES S-75

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DESCRIPTION

� Direct-sealing diaphragm valves that are operated by line pressure or by an external filtered water\air pressure (which is equal to or higher than the line pressure).

� The reinforced rubber diaphragm seals the water passage when line pressure reaches the valve’s control chamber.

� Relieving the pressure from the control chamber, to the atmosphere or to downstream, enables the valve to open.

� The valve’s only moving component is its diaphragm; no shaft, seals, or bearings are located within the water passage.

� The valves are made of robust, high-quality composite & plastic materials. It is produced in a number of structurally different versions (throttling, built-in solenoid operator, etc.), with a wide range of control and regulation functions (manual activation, remote pressure control, pressure reducing, etc.).

ADVANTAGES � Exceptional structural simplicity � Superb hydraulic performance � Reliable control of unfiltered irrigation water and corrosive

liquids � Lightweight, cost-saving � Minimum maintenance - maximum dependability � Simple to install

APPLICATIONS

� Irrigation System � Industrial usage with corrosive fluids � Sewage systems � Landscape and Greenhouse applications

Reinforced nylon throttling 2-w electric

75 series 3-w electric

75 series 3-w electric Pressure reducing

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S-75, Hydraulic Performance

Valve Size ¾"\20mm 1"\25mm 1½"\40mm

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2"\50mm � �

2½"/65mm��

323\80L � �

KV 7.5 �� Head loss (3-w models) CV � 17.5 ��

m3/hr 5 �� Max. recommended flow GPM 22 � � ��

m3/hr <1 Minimal flow

GPM <5 C0

�� Max. water temp.

F0 ��

C0 �� Max. ambient temp

F0 ��

3-way m 9-80 10-100 Pressure range 2-way m 5-80 8-100

Head loses for 2-way and 3-way valves

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2-way valves

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�-way valves

�-way valves 1" and 3/4"

PLASTIC VALVES S-95, S-96

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DESCRIPTION

� The uPVC valves, series 95 and 96 are direct sealing diaphragm valves at diameters of 3", 4" and 6". (90mm,110mm and 160mm)

� The uPVC valves are threaded (95 model) or solvent-welded straight to the pipe. (96 model)

� The uPVC valves are designed for high flow irrigation plots and offer excellent hydraulic performance.

� The uPVC valves offer high resistance to corrosive fluids and can be used for aggressive media conduction.

� The valves are designed for underground and above ground installation.

ADVANTAGES � Exceptional structural simplicity. � Superb hydraulic performance at high flow rates. � Reliable control of unfiltered irrigation water and

concentrated corrosive liquids. � Lightweight, cost-saving. � Minimum maintenance - maximum dependability. � Simple to install with slip or threaded PVC connections. � Suitable for subsurface installations - requires less fittings,

offers lower head losses and reduces mechanical and weather damage hazards.

APPLICATIONS

� Irrigation Systems. � Underground installation with controls at the surface. � Industrial usage with corrosive fluids. � Sewage systems.

95 series 3-way electric pressure

reducing��

95 series 3-way electric ��

96 series 3-way manual ��

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S-95, S-96 Hydraulic Performance

Head loses for 2-way and 3-way valves

Valve Size 3" \ 90mm � �

4" \ 110mm � �

6" \ 160mm � �

KV 150� � �� Head loss (3-w models) CV �� 557� �

m3/hr �� Max. recommended flow GPM ��

m3/hr <1� �Minimal flow

GPM <5 C0

�� Max. water temp.

F0 ��

C0 �� Max. ambient temp

F0 ��

Pressure range� � m� � �-�� -��

PLASTIC VALVES uPVC Valves Assembly and Installation

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THREADED VALVE Use a Teflon tape or Teflon sealer compound on the adapter and tighten by hand. Use a ��wrench to tighten the adapter another half revolution. Note: Over tightening may cause damage to ��the valve body. SOCKET OR “SLIP” VALVE WITH PVC PIPE Use the same procedure as when applying cementing PVC pipes. Mark the pipe first, then apply glue to the socket of the valve and the PVC pipe. Insert the pipe until reaching the mark and rotate a quarter-turn forward and aft. Hold the joint in place until the cement hardens.

INSTALLATION ABOVE GROUND When installed in a manifold above ground: keep the manifold short, no support will be needed. For longer spans, a firm support under the horizontal pipes is recommended for 3” and 4” valves. Install the valve with the bonnet exposed to the sun. For 6” valves install the valve with bonnet horizontally, command chambers side by side. INSTALLATION UNDERGROUND � For underground installations, use trust blocks where needed, allow sufficient space and keep the area around the valve free from rough objects and stones. Cover the valve with clean soil. A 0.6m (24”) cover is recommended to protect the valve from heavy equipment. �The controls for the valve, such as the pilot, 3-way valve, can be installed above ground. Mark the control tubing by color or number and place a protective poly or PVC tubing around the control tubing.

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PRESSURE TESTING � Partially fill the trench around the valve. � Charge the system and check for leaks.

Note: Do not exceed the pressure rating of the valve. (10 bars / 150 psi).

DIAPHRAGM REPLACEMENT � Loosen bolts, remove old diaphragm and insert new one. � Tighten the bolts, applying even pressure in the diagonal pattern, until the diaphragm is firmly pressed between the body and the bonnet. Do not over tighten. � If there is a leakage between the bonnet and the valve body, tighten the nuts a little more.

MODELS: � 3" Threaded � 3" solvent welded � 4" solvent welded � 6" solvent welded

Basic valve structure S- 95, 96��

PLASTIC VALVES 80 Series

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The 80 series valves are GRP rigid seal, diaphragm actuated type valves, designed especially for green-house irrigation and is also widely used for turf and crop irrigation. The valves are available in angel or globe pattern and offer unique features and benefits such as large passage inlet labyrinth device for the 2-way electric valve that reduces the risk for clogging under low water quality conditions, 3-position manual override for the 2-way electric valve, which allows overriding the electric control at any control mode, built in EasycleanR filter and more. Available sizes: 3/4", 1" – Turf irrigation valve 11/2", 2" – globe & angel irrigation valves Main Features � Simple, reliable and economical. � Unique clog-free inlet labyrinth used as the water inlet

restriction at the 2-way version. � 3-position manual override at 2-way version. � Operation from near- zero flow to max. flow. � All control system's devices are assembled on the

valve's bonnet; no tubes are connected to the valve's body.

� Optional throttling handle � Integral stainless-steel EasycleanR filter. � Stainless-steel bolts & nuts. Nuts are held in

housing, preventing it from dropping during assembly\ disassembly.

2-way electric S-80 valve parts

Wide water passage in restriction

labyrinth

Self-Flushing filter

3-position Override

Solenoid valve

Flow direction

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S-80, Hydraulic Performance 1½" – 2" Globe & Angel Valves

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Automatic Control Valves OPERATION MANUAL Section 1 ��

S-80, Hydraulic Performance ¾" – 1" Turf Irrigation Valve

BACKFLUSHING CONTROL VALVES

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Flush mode Irrigation mode

Operation principals By models



58 P 58

51, 52 57

62, 63

DESCRIPTION Backflush valves are 3-way hydraulically operated diaphragm valves used in filtration applications with media and disc filters. The PLASLITE is a non-corrosive valve using an innovative design eliminating maintenance.��The bronze backflush valve can also be easily maintained by virtue of its design. �� The selector valve is activated by pipeline pressure. The valve can be set in one of two positions: � Irrigation mode allows flow from the inlet manifold into the filter. � Flushing mode closes the filter inlet and opens the flush outlet, resulting in flow reversal in the filter. The valve is activated by a large rubber diaphragm, requiring minimal activation pressure. The valve can be operated automatically (using solenoid valve activation) or manually (Using 3-way selector valve).

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ADVANTAGES � Structural simplicity � Superb hydraulic performance � Frictionless position changeover (58, 58P, 57) � High reliability � Corrosion-resistant materials (plastic, brass) � Easy maintenance

MATERIALS

HYDRAULIC PERFOMANCE

Model 51 52 62 63 57 58 58 P

Body cast bronze Cast iron Reinforced polyamide

Bonnet Reinforced polyamide Cast iron Reinforced

polyamide Shaft Stainless steel

Spring Stainless steel Nuts and bolts Stainless steel Sealing disks Brass plastic brass plastic

O Rings NBR EPDM Seal NR

Diaphragm Reinforced NR

58 57 52 51 MODEL 3X2 4X3 3 X 2 2X 2 2X 2 SIZE 90 160 90 40 40 m3/h

396 704 396 176 176 gpm

Max. recommended flow at filtering

40 90 40 40 40 m3/h

176 396 176 176 176 gpm

Max. recommended flow at flushing

7-100 mwc 10-147 psi

Pressure range

130 160 130 52 43 Kv (metric) 150 185 150 60 50 Cv (US)

Flow rate factor at filtering

58 70 58 37 37 Kv (metric) 67 81 67 43 43 Cv (US)

Flow rate factor at flushing

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*Optional- High Pressure valve- up to 160 m'

MODEL 58 58 P SIZE 4X3 3X3 2X3 4X4 3X4

m3/h 160 90 90 160 160 Max. recommended flow at filtering gpm 704 396 396 704 704

m3/h 90 90 40 160 90 Max. recommended flow at flushing gpm 396 396 176 704 396

mwc 7-100 2-60 (5-80 in High pressure model) Pressure range

psi 10-150 3-90 (7-120 in High pressure model)

Kv (metric) 160 130 130 160 160 Flow rate factor at filtering Cv (US) 185 150 150 185 185

Kv (metric) 70 65 57 83 70 Flow rate factor at flushing Cv (US) 81 75 66 96 81

MODEL 62 63 SIZE 2X4 3X4 4X4 3X3 2X3 3X3 4X4

m3/h 160 160 160 90 160 Max. recommended flow at filtering gpm 704 704 704 396 704

m3/h 40 60 160 90 40 90 160 Max recommended flow at flushing gpm 176 265 704 90 176 90 704

mwc 3 - 120 Pressure range

psi 4 - 175 Kv (metric) 160 160 160 100 100 145 205 Flow rate factor

at filtering Cv (US) 185 185 185 115 115 170 237 Kv (metric) 110 140 205 145 80 100 160 Flow rate factor

at flushing Cv (US) 128 163 238 168 93 115 185

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Pressure losses on Single chamber valves

Pressure losses on double chamber valves

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STRUCTURE AND COMPONENTS OF BACKFLUSH VALVES Model: 57, 58 Size: 4x3

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Model: 57, 58 SK version Size: 3x2

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Model: 51, 52 Size: 2x2

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Model: 62, 63 Size: 3x2, 3x3

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Model: 62, 63 Size: 4x3, 4x4

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AUTOMATIC CONTROL VALVES

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32 Automatic Control Valves OPERATION MANUAL Section 2

Automatic Control Valves…………………………………………………………...33 Control System Characteristics…………………………………………………….34 Pilot Valves…………………………………………………………………………...38 Automatic Control Functions………………………………………………………..52 Valve and Pilot Selecting……………………………………………………………56 Solenoid Valves ………………………………………………………………..……57 Electric Valves – Wiring Sizing………………..……………………………………58 GEMSOL solenoid Components and Electrical Hook- Up……………………….61 Hydraulic Remote control – Principals and Assembly Schematics…………….62 Pressure Reducing Valves – Valve Design in Different Field Conditions……...67 Valves – Pressure Sustaining, Pressure Relief Sustaining, Sustaining Relief, Sustaining Quick Reacting, Surge Anticipating………………………………………………………...69 Pump Control Valves – Operating sequence …………………………………….71

AUTOMATIC CONTROL VALVES

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6" 3-way pressure sustaining��

3" electric��

4" 3-way pressure reducing��

2" remote control & Pressure reducing

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DESCRIPTION An automatic control valve is combined of:�� A basic valve � One or more pilot valves � A solenoid pilot valve (on electrically actuated valves) � Control tubes and fittings � A filter for the actuation pressure source�� Other accessories (relays valves, check valves, needle valves, etc.)

Each one of the listed control valves is designed to perform a special hydraulic control function. The pilot valve and other devices are selected to serve this function. These valves are self-contained and include all the components needed for accurate, dependable, long-life operation. Unlisted combinations of control functions are supplied on request.

TWO CONTROL MODES ARE SUPPLIED THREE-WAY MODE (“3-WAY”) The pilot valve is a selector, activated manually, electrically, or hydraulically. It vents the main valve control chamber to the atmosphere, permitting full opening.

TWO-WAY MODE (“2-WAY”) The pilot valve is a modulating, hydraulically-operated type, venting the main valve control chamber to downstream, allowing only partial opening. This control model is selected when permanent pressure loss is tolerated.

Please refer to next pages for more details.

CONTROL SYSTEMS��CHARECTARISTICS��The two control concepts��

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PILOT VALVES CONTROL TRIM OPERATION: Low pressure in sensing chamber (4): The spring (1) is compressed by the adjustment bolt (2), forcing diaphragm down. The shaft (5) is moving with the diaphragm, actuating the main valve by opening or closing pilot valve's internal water passages. Pilot valve set-point � The pilot valve's position is determined by the forces equilibrium

of hydraulic pressure and spring resistance. � Spring resistance is adjusted by the adjustment bolt (2). � Compressing the spring (turning the bolt in clock-wise direction)

increases the regulated parameter. For example- In Pressure Reducing valves- tightening the bolt (turning in clock-wise direction) will increase the maximal downstream pressure. In Pressure Sustaining valves- tightening the bolt will increase the minimal upstream pressure. In Flow Control valves- tightening the bolt will increase the maximal flow rate.

� A specific spring has specific pressure range in which it can regulate. Springs are marked by different colors that represent different pressure ranges, and correct spring selection is critical for the Pilot valve function.

� Colored rings located on the adjustment bolt specify the internal spring color. � The spring selection is usually done by "DOROT" according to the client's

data and demands but spring replacement can be easily done by the client if conditions demand.

High pressure in sensing chamber (4): The pressure in the sensing chamber (4) is overcoming spring (1) resistance, forcing the diaphragm (3) up.

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Required regulated pressure: Pilot valve is preventing flow at all passages. Main valve maintains fixed position.��

Low regulated pressure: Pilot valve is connecting the valve's control chamber to the atmosphere. Main valve is opening.

High regulated pressure: Pilot valve is connecting the valve's control chamber to the upstream. Main valve is closing.

THREE-WAY CONTROL (POSITIONING) SYSTEMS The three-way control device is a selector pilot (activated electrically, manually or by the pipeline pressure) which admits the control media into the control chamber to close the valve, relieves the media from the control chamber to open the main valve, or locks the volume in the control chamber to keep the valve throttled at a fixed regulating position. This control principle allows for full opening of the main valve when operating conditions require the valve to be fully open. Three-Way Control is used for:

� On-Off Control valves. � Regulating valves which need to

operate with low pressure differential. � Dirty water as raw irrigation water and

sewage water. � Where usage of external control media

(such as pressurized air) is required. TYPICAL DESIGN AND OPERATION PRINCIPLE OF 3-WAY PILOT VALVES A 3-way pilot valve's position is determined by the position of its internal diaphragm. The diaphragm is attached to a shaft which slides up or down according to the diaphragm's position. The shaft opens or closes the internal water passages in the pilot valve. 3- Way pilot valve operation principle: (Referring to a valve that opens at low regulated pressure and closes at high regulated pressure (such as PR)).

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Low regulated pressure

High regulated pressure

TWO-WAY CONTROL SYSTEMS In a two-way control system, the upstream side of the valve is connected by a control tube to the control chamber and to the downstream side of the valve. Two flow restrictors, one (orifice or needle valve) assembled upstream of the control chamber and the other (a pilot valve) assembled on the downstream side; modulates in response to the pipeline pressure. The relative opening of both restrictors dictates the position of the main valve. This type of control principal provides very accurate and sensitive regulation but creates considerable pressure loss even if no regulation is needed. Two-Way Control is used when:

� Minimal pressure differential at all operating conditions allow it.

� Sensitive (fast response) regulation is required. Note: Two-Way Control should not be used if the network

media is very dirty or abrasive. TYPICAL DESIGN AND OPERATION PRINCIPLE OF 2-WAY PILOT VALVES 2-way pilot operation principal: (Referring to a valve that closes at low regulated pressure and opens at high regulated pressure (such as PS)). Low regulated pressure: The flow into the main valve control chamber is restricted by the restrictor orifice (a). As regulated pressure (beneath the diaphragm) is lower then the pilot's set-point, the diaphragm and the shaft are descending, sealing water passage downstream and closing the main valve. High regulated pressure: As regulated pressure exceeds the pre- determined set point, the diaphragm is forced up and the shaft opens the water passage from the control chamber to the downstream tube, causing opening of the main valve.

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Required regulated pressure

Required downstream pressure: As regulated pressure reaches the pre- determined set-point, the forces above and beneath the diaphragm are in equilibrium. The diaphragm stabilizes at an intermediate position, allowing similar flow through the pilot valve and the restrictor orifice (a), resulting in constant water volume in the control chamber and the main valve maintains fixed position. Note: the flow through the first restricting element (a needle valve or an orifice) will determine the valve's closing rate. The flow ratios between the first restricting element and the pilot (in its fully opened position) will affect the valve's head loss when no regulation is needed.

PILOT VALVES ��


3- WAY PILOT VALVES FOR CONTROL APPLICATIONS OF HYDRAULIC VALVES UP TO 4" 29-100 29-300 29-200

29-100 / 29-200 – Pressure reducing applications

29-200 – Pressure sustaining / relief applications 29-300 – Flow control and pressure differential

regulation applications Table 5. SPRING PRESSURE REGULATING RANGES

Operation conditions recommendation: � Max. proof pressure (upstream): 10 bar (145psi) � Spring selection should be so that the required set

pressure is in the middle of the springs range.

Spring no. Spring color Regulation range (m) Regulation range (psi) 54 Green 45 – 10 66-15

72 Yellow 25 -5 36-8 65 Red 60 – 20 90-30

82 (29-300) 5 – 2 8-3

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Pilot valve model : 29-100

Spring No. 65 (yellow) Cat.No.0022065000 Spring No. 72 (Red) Cat.No.0022072000 Spring No. 54 (Green) Cat.No.0022054000

Diaphragm assembly kit

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Spring No. 65 (yellow) Cat.No.0022065000 Spring No. 72 (Red) Cat.No.0022072000 Spring No. 54 (Green) Cat.No.0022054000


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Spring No. 82 (Differential) Cat.No.00220��000 Spring No. 65 (yellow) Cat.No.0022065000 Spring No. 72 (Red) Cat.No.0022072000 Spring No. 54 (Green) Cat.No.0022054000


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3- WAY RELAY VALVES FOR ON / OFF APPLICATIONS OF HYDRAULIC VALVES

25-300 – Quick reacting hydraulic relay for on / off applications.

25-100 – Adjustable hydraulic relay for on / off applications. GALIT - Hydraulic relay for on / off applications.

Operation conditions recommendation: � Max. proof pressure (upstream): 10 bar (145psi) � GALIT – max. elevation difference – 22 m. PRESSURE RANGES:

Relay Pressure range

25-300 10-100 (m) / 15-150 (psi)

Minimal command pressure/ line pressure Ratio : 1/3

25-100 7 – 100 (m) / 10-150 (psi)

GALIT 5 – 100 (m) / 8-150 (psi)

GALIT 25-300��

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Relay valve model: 25-300

Parts kit Cat.No. 6652530008

Parts kit Cat.No. 6606253000

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2- WAY PILOT VALVES FOR CONTROL APPLICATIONS OF HYDRAULIC VALVES UP TO 6"

68-500 68-410

68-410 - Pressure Reducing applications. 68-500 - Pressure Sustaining / Relief.

Operation conditions recommendation: � Max. proof pressure (upstream): 25 bar (360 psi) Table 6. SPRING PRESSURE RANGES – 68-500

Table 7. SPRING PRESSURE RANGES – 68-410

Spring no. Spring color Regulation range

58 (standard) Green 10-90 (m) / 15-130 (psi)

86 Yellow 5-20 (m) / 8-30 (psi)

63 Red 80-140 (m) / 120-205 (psi)

Spring no. Spring color Regulation range

66 (standard) Green 10-110 (m) / 15-160 (psi)

78 Yellow 5-30 (m) / 8-45 (psi)

67 Red 20-200 (m) / 30-300 (psi)

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Pilot valve model: 68-410

Diaphragm kit Cat. No. 6671868410

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Spares kit Cat. No. 6606841001

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Diaphragm kit Cat. No.6671868500

Spares kit Cat. No. 606850000

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2- WAY AND 3-WAY PILOT VALVES FOR CONTROL APPLICATIONS OF HYDRAULIC VALVES OF LARGE DIAMETER (3" – 24") CX-PR CX-PS 66-310 31-310

66-310 – 2–w/ 3-w Pressure Reducing/ Sustaining

/Quick Relief applications. 31-310 – Pressure Reducing / Sustaining applications. CX-PR – 2-w Pressure Reducing applications. CX-PS - 2-w Pressure Sustaining applications. Operation conditions recommendation: � Max. proof pressure (upstream): 66-310 -12 bar (20 psi) high pressure version- 25 bar (360 psi)

CXPS, CXPR, 31-310 - 25 bar (360 psi) Table 8.

66-310 range 31-310 range (m) CX – PR / PS range Spring no. Spring color (m) (psi) (m) (psi) (m) (psi) 47 (st.) Green 10-60 15-90 10-60 15-90

42 Yellow 5-30 8-45 5-30 8- 45 50 / 56 Red 20-90 30- 135 20-86 30-125

76 black 70-140 105-210 70 2-5 3-8 69 6-8 9-12

53 (st.) 10 - 200 15-300 Double

Spring 53+54 10 - 250 15-375

SPRING PRESSURE RANGES ��

Note: Pilot Valves specified in this section are not the full verities of DOROT pilot valves. If the pilot valves specified do not answer your needs, please connect DOROT technical department.

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Spring No. 65 (yellow) Cat.No.0022065000 Spring No. 72 (Red) Cat.No.0022072000 Spring No. 54 (Green) Cat.No.0022054000 Diaphragm assembly kit - Cat.No.6671866310

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Spare parts kit - Cat. No. 6606631000

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Spring # 47 (Green) Cat. No. 0022047000 Spring # 50 (Red) Cat. No. 0022050000 Spring # 42 (yellow) Cat. No. 0022042000 Spring # 70 (no color) Cat. No. 0022070000

Diaphragm kit Cat. No.6671831310

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Pilot valve model: CX-PR Spring # 53 (Standard) Cat. No. 0022053000 Spring # 07 (Differential) Cat. No. 0022007000

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Pilot valve model: CX-PS Spring # 53 (Standard) Cat. No. 0022053000 Spring # 07 (Differential) Cat. No. 0022007000 Spring # 07 (High pres.) Cat. No. 0022054000

Diaphragm kit Cat. No. 66718CXS00

AUTOMATIC CONTROL FUNCTIONS ��


MANUAL ON-OFF VALVE (M) Equipped with a 3-way manual selector valve, permits the selection of the “open” or “closed” position of the main valve. Control Devices: 3-way valve Available: On all 3-way controlled valves ELECTRIC CONTROL VALVES (EL) A 3-way solenoid valve, activated by an electric current or electric pulse, opening or closing the main valve. “Normally closed” position of the main valve is standard. “Normally open” position is optional. Electric activation can be added to most control valves on request. Control Devices: Sizes 3/4” - 6” - Solenoid Valve.

Sizes 8” - 24” - Solenoid Valve + Accelerator Relay

Available: On all models PRESSURE REDUCING VALVE (PR) The valve maintains a preset downstream pressure, regardless of upstream pressure or flow rate fluctuation. The main valve is controlled by a 3-way pilot valve (permitting full opening when downstream pressure drops below the set-point) or by a 2-way pilot valve (creating a pressure differential in any condition).

Control Devices: 29-100, 31-310 Pilot Valves (3-Way)

CX-PR, 68-410, Pilot Valves (2-Way)��

Available: On all models PRESSURE SUSTAINING / RELIEF VALVE (PS) The valve maintains upstream (inlet) pressure, regardless of flow rate variations. The valve will be in the “closed” position if the inlet pressure drops below the set-point. It fully opens when upstream pressure exceeds the set-point. Control Devices: 29-200, 31-310, 66-310 Pilot Valves (3-Way) 68-500, CX-PS Pilot Valves (2-Way)

Available: On all models

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QUICK RELIEF SAFETY VALVE (QR) The valve opens instantly when the pressure in the pipeline exceeds the safe level, thus relieving excess pressure in the network. When pressure returns to normal, the valve closes slowly, at an adjustable pace. Control Devices: 31-310, 66-310 Pilot Valves (3-Way)

CX-PS, 68-500 (2-Way) Large diameters – GALIL valve accelerator

Available: On models: Cast Iron, Cast Bronze 2”- 24” HYDRAULIC REMOTE CONTROL VALVE (RC) An hydraulic relay opens or closes the valve (on which it is assembled), in response to a pressure command, carried by a control tube from a remote control center. The relay permits: � Quick response to the “open” and “close” command. � The conversion of a valve form “normally-open” to “normally closed”. � Overcoming elevation differences (25-100 relay) Control Devices: “Galit” Relays, 66-210 Relay, 25-100 relay. Available: On all models, excluding electric valves FLOW RATE CONTROL VALVE (FR) The valve limits the flow rate in the network to a preset level, regardless of inlet pressure variations. The valve fully opens when the flow rate drops below the set-point. Control Devices: 29-300, 76-200, CX-SD Differential Pilot

Valves. Available: On All models 2”- 24” EXCESSIVE FLOW SHUT-OFF VALVE (FE) - A VARIATION OF THE FLOW RATE CONTROL The valve closes drip-tight when the flow rate exceeds the preset maximum (due, for example, to pipe rupture). Control Devices: 29-300, 76-200 CX-SD Differential Pilot

Valves. Available: On All models 2”- 24” MODULATING FLOAT CONTROL VALVE (FL) The main valve is controlled by a 1/2" control valve, located in the tank or reservoir at the required max. water level. The valve maintains a constant max. level. Control Devises: 70-300 (plastic),

70-400 (metal) float pilots. Available: On all models.

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DIFFERENTIAL FLOAT CONTROL VALVE (DI/FL) A float valve controls the main valve, closing it when the water reaches the maximum level, and opening it when the water drops to its preset minimum level. The differential between maximum and minimum levels is adjustable. Control Devices: 70-550, 70-610 Differential Float Valves Available: On all models ALTITUDE CONTROL VALVE (AL) The main valve is controlled by a highly-sensitive pilot located outside the tank. The pilot opens or closes the valve in response to the static pressure of the water. The difference between maximum and minimum levels may be adjusted on the pilot. Control Devices: 70-110 Pilot Valve (3- Way)

70-600 Pilot Valve (2- Way) Available: On all models PUMP CONTROL VALVE (BC) The valve eliminates damaging surges caused by pump “start-up” and “shut-off”. The electrically activated valve opens gradually on pump “start-up”, and closes slowly before the pump is switched off. The valve can operate as a check valve, preventing reverse flow. Control Devices: Solenoid Valve, 66-210 Relay,

Limit Switch, solenoid valve Available: On models: Cast Iron, ductile iron TWO-STAGE OPENING VALVE (TO) The valve prevents surges, caused by the fast filling of drained pipelines. It restricts the flow rate until the network is full. The valve fully opens when downstream pressure reaches the duty point. Control Devices: 68-500, 66-310, 29-200 Pilot Valves Available: On all models

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DEEP WELL CONTROL VALVE (DW) The valve eliminates surges caused by “start-up” and “shut-off” of vertical or submersible pumps. It is a relief valve, assembled on the T-junction of the main pipeline. When the pump starts, the valve closes slowly, increasing the network pressure gradually. Before pump “shut-off” the valve opens slowly, reducing network pressure gradually. Control Devices: Solenoid Valve, 66-210 Relay, Limit Switch Available: On models: Cast Iron, Cast Bronze SURGE-ANTICIPATING VALVE (RE) The valve protects the pumping system from water hammer, caused by sudden pump halting (due, for example, to power failure). The valve is a relief valve, assembled on the T-junction of the main pipeline. The valve opens instantly when the pump stops, relieving the returning high pressure wave. The valve closes slowly, once the pressure returns to static level. The valve functions also as a quick-relief safety valve. Control Devices: 66-310, CX-PS Pilot Valves Available: On models: Cast Iron, Cast Bronze 3” - 24” HYDRAULIC HYDRANT VALVE (HY) A quick-activation fire extinguishing valve. A two-position manual selector allows for quick, effortless operation of the valve. A remote controlled valve is optional.

Control Devices: Manual Selector

Available: On models: Cast Iron �� DELUGE VALVE (DE) A control valve for “Dry” sprinkler lines in fire-extinguishing systems. The valve opens on electric command or pressure drop in pressurized sensor line. (Hydraulic or pneumatic) Control Devices: 66310 Pilot Valve, Solenoid Valve Available: On models: Ductile Iron ELECTRONICALLY CONTROLLED VALVE (EC) The main valve is controlled by PLC controller (DOROT "CONDOR") through 2 solenoid valve controlling command chamber inlet and outlet. The controller enables selection from a vast range of pre-programmed control functions and their combinations. Control devises: Solenoid valve, PLC controller Available on: on all models

VALVE and PILOT

SELECTING ��


EXMAPLES OF CHOOSING THE VALVE, DIAPHRAGM AND PILOT ACCORDING TO FIELD CONDITIONS: A. Function: Pressure Reducing Flow rate: 100 m3/h (440 gpm) Max. upstream pressure: 4 bar (60 psi) Required downstream pressure: 2 bar (50 psi) Making the selection: Valve size: consideration: Flow rate

- refer to table 4. (Page 10) – Continues flow 100 m3/h ---selecting 4" valve. Diaphragm: consideration: Upstream pressure

- refer to table 3. (Page 9) – The given pressure is within 12-160m (1.2-16 bar) range -- selecting standard diaphragm.

Pilot : consideration: Function, line pressure and valve size (see page 38) – PR for 4" valve – 29-100 pilot valve is suitable.

Pilot spring: consideration: Required downstream pressure – refer to table 5. (Page 31) required pressure is within the green spring pressure range.

B. Function: pressure sustaining Flow rate: 70 m3/h (310gpm) Max. upstream pressure: 18 bar (260 psi) Sustained upstream pressure: 16 bar (230 psi) Making the selection: Valve size: consideration: Flow rate

- refer to table 4. – Continues flow 60 m3/h --- selecting 3" valve. Diaphragm: consideration: Upstream pressure - refer to table 3.

– The given pressure is over the standard diaphragm limit (12-160m) and within the High Pressure diaphragm range (10-259 m) – selecting High Pressure diaphragm.

Pilot: consideration: Function, line pressure and valve size (see page 44) – PS for 3" valve, 18 bar upstream – 68-500 pilot valve is suitable.

Pilot spring: consideration: Required upstream pressure – refer to table 8. (page 35) - required pressure is within the red spring pressure range.

C. Function: On / Off Flow rate: 300 m3/h (1320 gpm) Upstream pressure: 1 – 1.5 bar (15 - 22 psi) Making the selection: Valve size: consideration: Flow rate

-refer to table 4. – Continues flow 300 m3/h ---selecting 6" valve. Diaphragm: consideration: Upstream pressure

- refer to table 3. – The given pressure is lower then standard diaphragm range (15-160 m) and is within Low Pressure diaphragm range (5 – 100 m) -- selecting Low Pressure diaphragm.

Pilot : consideration: Function, line pressure and valve size (see page 47) – PR for 6" valve – 66-310 3-way pilot valve is suitable. (3– Way pilot valves allow lower pressure loss in the main valve. relevant in cases of low pressure).

Pilot spring: consideration: line pressure – refer to table 8. – Line pressure is within the yellow spring pressure range. (30 – 5m)

SOLENOID VALVES

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Solenoid valves convert an electric signal to hydraulic command Solenoid valves are operated by a coil. When an electric signal is received, the magnetic field created, pulls a plunger up. This allows water to flow through the orifices in the solenoid.

NORMALLY OPEN/ NORMALLY CLOSED POSITION The solenoid is called normally open (N.O.) when the water passage from the pressure port to the common port (connected to the control chamber of the valve), is open with the solenoid de-energized. This is the case for field or zone valves; they are kept closed and when the solenoid is energized the valves open. The opposite is true for a ‘normally closed’ solenoid. The solenoid is called normally closed (N.C.) when common port is connected to the vent port with the solenoid de- energized. In most cases a Normally Open (N.O.).solenoid corresponds with a normally closed valve and vice versa. 2-WAY/ 3-WAY SOLENOIDS Solenoids are available in 2-way and 3-way configurations. The 3-way solenoid has 3 ports – common, pressure and vent, and is selecting between connecting control chamber to pressure or to vent. The 2-way solenoid is designed with 2 ports- common and vent and can only allow or stop water passage through it. It is not recommended to use a 2-way solenoid in dirty water conditions; the continuous flow through it makes it more sensitive to clogging than 3- way solenoid. SOLENOIDS – PRODUCT SELECTION, CONSIDERATIONS and APPLICATIONS Address the following subjects for a 3 -way solenoid: � Material � Electrical characteristics: inrush current, voltage, etc. � Mechanical, orifice size and pressure rating

ELECTRIC VALVES – WIRE SIZING FOR AC/ DC SOLENOIDS ONLY (Exclude latching)

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GEM – SOL DIRECT OPERATED 3- WAY SOLENOID VALVE Voltage: AC: 24, 120, 240, 480 V, 60 HZ (or 110,220 V, 50 HZ)��

DC: 6, 12, 24, 120, 240 V.��

Tolerance: ± 10% Body: mazak/ brass/ stainless steel. Max. pressure differential

DOROT DIRECT OPERATED 3- WAY / 3-WAY SOLENOID VALVES Voltage: 24 VAC / 50 HZ (others on demand)

Tolerance: ± 10% Body: nylon Orifice: 1.8 mm Pressure range: 0- 10 bar Inrush current: 0.29 A Holding current: 0.14 A

Orifice (mm) 2.4 2.0 1.6 1.2 0.8

N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. Units

Coil current/ power

8 8 10 11 15 15 20 20 23 25 bar 120 120 150 170 230 230 300 300 350 370 psi ADC

10 10 14 12 17 17 30 22 35 30 bar 150 150 210 180 250 250 450 330 530 450 psi

AC/8W DC/10W

8 8 10 11 15 15 20 20 23 25 bar 120 120 150 160 230 230 300 300 340 370 psi

AC/5.5W DC/5.5W

5 6 9 8 10 12 16 18 20 20 bar 80 90 140 120 150 180 240 265 300 300 psi

AC/2.5W DC/3.5W

3.5 3.0 2.5 2.2 1.7 1.4 1.1 1 0.6 0.6 l/min Kv factor

ELECTRIC VALVES – WIRE SIZING FOR AC/ DC SOLENOIDS ONLY (Exclude latching)

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The following formula is used to calculate the wire size:

Iinr*2*L1000*AVL

Ra �

Ra = max. allowable resistance of the wire in Ohms. AVL= Allowable Voltage loss (V) L = length from controller to the valves (meters or feet) I inr = inrush current of the solenoid (A)

The allowable voltage loss for the solenoids can be found in the table below: +/- 10 % of the nominal voltage as long as the operation pressure is within the specifications of the solenoid. The voltage output of the controller is usually 26 Volt depending on how many valves are operated at the same time. A typical AVL 26.4 V output is +/- 10% of 24V, or 4.8V. Note: The inrush current depends on the power consumption or wattage of the solenoid. Calculating example:

Solenoid Power Inrush Holding Orifice Max pressure DOROT 3W AC .2 W� 0.29A 0.14A 1.8 mm 100 mwc (150 psi)

GEM-SOL 3W AC 5.5W 0.72A 0.42A 2.0 mm 100 mwc (150 psi) GEM-SOL 3W AC 8.0 W 1.08A 0.60A 1.6 mm 170 mwc (250 psi)

Solenoid in use: GEM-SOL 3 Way 5.5 W. Inrush: 0.72 A. Controller to valve distance: 500 m. (1666 ft.) The allowable voltage loss is 4.8 V (AVL)

Calculating: Ohm66.60.72*2*500

1000*4.8Ra ��

The resistance of the wire chosen from the above table must be equal or lower than the calculated value. The wire gauge should be # 14with 8.28 Ohms/km. for the actual distance (0.5 km) the resistance is 4.14 Ohm. It is possible to use a different gauge for the hot and common wire; the resistance will be the average of the two wires used. The inrush current has to be multiplied by the number of valves operated at the same time. Each segment must be calculated considering Distances and operating valves. The controller has a maximum Amperage output that should not be exceeded.

� � � � 14 � 18 AWG # 0.25 0.40 0.63 1.00 1.59 2.52 4.02 6.40 Ohms per 1000 ft. 0.81 1.29 2.06 3.27 5.21 8.28 13.70 20.95 Ohms per km.

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CROSS SECTION WIRE SELECTION FOR DISTANCE INSTELATION OF GEM-SOL SOLENOID VALVES

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GEM-SOL SOLENOID COMPONENTS And electric hook-up

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1. Loosen bolt (1). 2. Pull hub assembly off. 3. Push (3) out with screwdriver through access port (remove 4). 4 .Connect wires to (1) and (2). 5. Reassemble, the hub can be turned 90 degrees to let port (4) face

sideways. 6. If no conduit tubing is used, seal opening (4) with silicone, to avoid

dirt or moisture from entering. When using conduit, remove the adapter to connect 1/2” conduit.

Note: Brass solenoids use (3/8”) adapter. 7. The base of the stainless steel solenoid has a manual override; a

screwdriver is used to activate the solenoid. Off position: the little mark on the slot points down. 8. The brass solenoid base has a knob with a mark. The solenoid is

deactivated when the mark or dot points down. Turning the knob or screw 90 degrees activates the solenoid.

Part list

1. Bolt 2. Junction box 3. Junction 4. Adapter 3/8" w/ seal 5. Rubber 6. Coil, sleeve nut 7. Coil hub (wire lead) 8. Sleeve 9. Seal 10. Spring 11.Plunger 12.Body of base

HYDRAULIC REMOTE CONTROL Principles and assembly schemes

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1. GENERAL The hydraulic remote control of "GAL" type valve is made in order to enable operating all the valves in the Irrigation system from a central control point, mostly (not necessarily) from the pump site. The control is executed by manual or automatic (electronic) means located in the control center that sends "open" or "close" commands to the valves. This publication will not be discussed Control means, but rather consider the command as pressure applied to or relieved from the control tube, regardless of the causing it.

2. REMOTE CONTROL VALVE Hydraulic relay should be added to the basic hydraulic valve, in order to enable opening or closure of the valve by the local pressure. The relay is activated by increasing or decreasing the control tube pressure which is done much faster than transporting the entire valve's control chamber water to or from the control center by small diameter tubes. DOROT valves can be remotely controlled by 25-100 adjustable relay, "GALIT" relay or 25-300 Quick Reaction relay, commonly used for large diameter valves and filtration system valves.

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CONTROL CENTER

CONTROL CENTER

The manual center consists of: a. 3– Way selector. b. Pressure source. c. Connecting tubes divided by Shifts. (A group of valves operating simultaneously)

3.1. 3- WAY VALVE Each 3- way valve is connected at one of its ports to the main line pressure. The common port (bottom) is connected to a 6 mm tube leading to the relevant group of valves. The 3- way valve port allows selection between the pressure port and the venting port. The third port remains unused, reserved for optional connection of automatic control device. The 3-way selector valves should be assembled on a common bracket, each one marked clearly by its shift number.

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3.2. AUTOMATIC CENTER The device selecting between pressurized control tube and relieved tube is activated by electric command. The device can be a solenoid valve or the “Galsol” relay. The latter has larger passages than the normally used solenoids so it is less sensitive to clogging, and creates faster response of the controlled valves. Any type of solenoid, selected for this function, must be equipped with a manual override to enable operating the system in case of electric malfunction.

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4. CONNECTING FIELD VALVES TO THE CENTER 4.1 A 6mm tube should connect all valves

operating simultaneously to one control device (manual or automatic). There is no advantage to larger diameter, unless the valves are located fairly near to the center, the relay is deleted so the control water volume must be transported to the valve from the center. Using 8mm tube in relay control increases the cost unnecessarily and delays valve response.

.4.2 It is recommended to connect all valves operating in the same shift and located in short distance from each other by “chain connection” as described in the drawing. The first valve’s relay is connected to the center. The command port of the valve outlet is connected to the relay of the next valve and so on.

Definition: On “open” command, first valve is open. The next one will open only when the network of the first valve has been filled and its pressure rises. The sequence of events is reversed at “close” command - the first valve closes, then the second, etc. This procedure prevents drop of pressure due to increased flow through the initial stage of network filling. It makes the changeover between shifts smoother, with less pressure fluctuation. It is possible, however, to connect all the relays directly to the tube leading to the center. If this option is selected, all the valves may get the command at the same time.

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5. ELEVATION DIFFERENCE BETWEEN CONTROL

CENTER AND FIELD VALVES 5.1 Center higher than the valves: a spring should be added to the GALIT

relay, in order to compensate for the static pressure existing in the control tube at the valve site, while it is relieved at the control center. Use a spring selection table of the GALIT relay in order to determine the proper spring. In case of very large elevation difference (more than 25m) it is advisable to use the 25-100 relay or 29-100 mini-pilot as a relay. (See Remote Control valve drawing).

5.2 Center lower than the valves: Draining of the control tubes and entry of air into them will Cause excessive delay of valve response. It is possible to avoid it by connecting a short tube to the venting port of the control device. The other end of this tube is inserted into a water bottle. Air entry is prevented.

6. DESIGN OF HYDRAULIC CONTROL 6.1 Define the groups of valves connected together in the same shift. 6.2 Draw the shortest route of the control tube leading to the valves and

groups of valves, considering the physical obstacles (roads, pipelines, etc.).

6.3 Check elevations and select springs. Mark the selected spring (green, white, etc.) on the map, at the specific valve location.

6.4 Calculate total quantity of tubes; add some 15% as safety margin. 6.5 Define type of central control (Manual / Automatic). 7. INSTALLATION OF CONTROL TUBES 7.1 Underground installation is preferred.

In case the remote control is designed at the initial stages of the project design, laying the command tubes in the main pipe trenches is advisable. Otherwise, bury the tubes in a depth, which prevents damage by tractor implements, heavy machinery crossing, etc. It is recommended to lay the tubes beside roads, windbreakers, etc. even if it increases the total length. Prevent stretching, stress of tubes, kinking, stone damage. At a specific point, beside controlled valve or even at other points along the tube route, create a “check point” where the tube is extended above ground for pressure test in case of possible malfunction in the future. This practice may prevent the need of replacement of total length of tube as it enables finding of the damaged section. Such checkpoints must be marked clearly to prevent accidental damage by machinery.

7.2 Above ground installation. Do not lay the tubes uncovered on the ground as it calls for inevitable damage, sooner or later. Hang the tubes on a wire, suspended on poles at proper height, so they will not be in a way of passing workers, and trucks.

7.3 Mark both ends of an installed tube by a tag with the name or number of the controlled valve / group. Large number of controlled valves requires many tubes assembled at the same route, and the marking may prevent a lot of hassle and mistaken connections. It is recommended to purchase “coded tubes”, marked by various colored lines, which help considerably in proper connections.

PRESSURE REDUCING VALVES VALVE DESIGN IN DIFFERENT CONDITIONS

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1. APPLICATION EXAMPLE - VINEYARD Conditions: Regular conditions with stable upstream pressure. Vineyard drip system with set pressure conditions that remain fairly constant.160 acre block with a pressure reducing valve for every 20 acres: Flow (Q) = 50 m3/h (200 gpm) Inlet pressure = 1.5-2.5 bar (25-40) A. DESIGN CONSIDERATIONS � Valve requirement- PR � Required downstream pressure: 1.3 bar (20 psi) B. SELECTION CONSIDERATIONS � Material – iron, bronze, plastic � Size and diaphragm choice (see page 41 ) � Pilot and spring selection (see page 41 ) C. SELECTION

The pressure allows using plastic/ PVC valves and plastic pilots. The flow requires 3" valves. Standard diaphragm is suitable. Yellow spring is suitable for the required pressure.

2. APPLICATION EXAMPLE - ROW CROP Conditions: a high pressure reducing ratio and cavitation conditions. Cavitation: when the water pressure drops below the vapor pressure, bubbles form in the restriction area. Downstream, when the pressure recuperates, the bubbles collapse, causing damage to the valve body. Exceeding reducing ratio of 3:1 may cause cavitaion. Row crop application: 0 acre block with 5-20 acre zones. Each 10-acre is controlled by a valve. Valves can be operated in pairs (20 acres) or individually. (10 acres). System flow (Q) = 140-70 m3/h (600-300 gpm) Inlet pressure = 2-3.5 bar (30-50 psi.) . A. DESIGN CONSIDERATIONS � Valve requirement PREL. � Required downstream pressure: 0.7 bar. (10 psi) B. PRODUCT SELECTIONS � Material – iron, bronze, plastic � Size and diaphragm choice (see page 41 ) � Pilot and spring selection (see page 41 ) � Solenoid selection (see pages 42-43) C. SELECTION A 70 m3/h flow requires a 3” size valve. The pressure range makes the PVC valve a logical choice unless an angle configuration is preferred. Pressure range allows using plastic pilot and the regulating pressure requires yellow spring. The above example presents one problem: when only one valve operates, the inlet pressure increases to 3.5 bar (50 psi). This creates a 5:1 reducing ratio which causes cavitation. How often will this condition occur? Solution: Use a PVC valve with plastic pilot, both offer high resistance to destructive cavitation.

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3. APPLICATION EXAMPLE - 3” VALVE WITH SPRINKLER AND DRIP IRRIGATION Discuss similar configuration as the example 1, but the same valves are used for: � Drip irrigation, requiring 1 bar (15 psi) downstream

pressure. � Sprinklers irrigation during germination of crop,

requiring 4 bar (60 psi) downstream pressure. The inlet pressure is always 4 bars (60 psi) Solution: Add another pressure reducing valve, (marked in red) located on the main line. The field valves (marked black) are the same as selected in example 1. (Plastic valves 3"). The main PR valve (red) will reduce pressure to 2 bar (30psi) when selector points to 'auto' and will be fully open when pointing to 'open'. The field valves will reduce pressure to 1 bar when selector point to 'auto' , will be closed when it point to 'closed' or fully open when it points to 'open'. At sprinkler irrigation- main valve is fully open - field valves are fully open. At drip irrigation - main valve is reducing pressure to 2 bar, the field valves are reducing pressure to 1bar. . 4. APPLICATION EXAMPLE – HUNTING OF PILOT VALVES This configuration presents two PR valves in series. Water supply is a pressurized pipeline with varying upstream pressures during the season. There are also pressure reducing valves in the field. Considerations: ‘Hunting’ and solutions to this problem. Hunting is the continuous readjusting of the valves to find the right pressure setting. It may appear in configurations such as described above due to mutual influence of the pilots. The use of two 3-way controlled valves and short distances between the valves aggravates the problem. Restricting the discharge out of the vent port of the pilot may help. Connecting a dripper to the vent port or connecting the vent port to downstream usually solves the problem. Longer distances between the valves and using a 2-way PR valve on the mainline valve will prevent the hunting phenomenon.

VALVES Pressure sustaining, sustaining relief, Sustaining quick-reacting relief, surge anticipating��

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PRESSURE SUSTAINING VALVES PS valves maintain a preset pressure level upstream of the valve. It is located in the main line. The size has to fit the maximum flow rate in the system. Application: Pump control valve, dictates the pump's duty point in a desired range to prevent overload. If the pump curve is flatter, other solutions can be found. A flow rate control valve can be chosen. SUSTAINING RELIEF VALVE Installed in a T-configuration off the mainline to sustain a certain level of pressure in the mainline. The water is returned to the well or reservoir. For this application it is important to consider the following design criteria: � The valve should be sized according to

the estimated by-pass flow rate. � It can be operated for considerable length

of time. (not a quick-reacting relief) � The drop of pressure through the valve

may exceed the recommended reduction ratio.

Reducing the cavitation risk: � Consider installing an orifice or a gate

valve on the discharge side and/ or keep the discharge line relatively small to create friction (back pressure).

� Put valve at end of discharge line: There is no cavitation when the downstream pressure cannot build up.

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SUSTAINING QUICK-REACTING RELIEF VALVE QR valve are designed to protect the system components from destructive pressure rises. � Opens quickly, closes slowly and operates for

short duration of time. � Designed for high flow rate: up to 16 m/s. � Use bronze when possible. � Discharge line should be large enough to allow

unrestricted flow. � Pilot has two positions: Open or close (not

regulating) and has a 5% tolerance. For example - 7.5 mwc (11 psi) tolerance at.150 mwc (220 psi).

SURGE ANTICIPATING VALVE . Installed in a T-configuration off the mainline, the RE valve is used to protect the mainline against water hammer created due to sudden pump stoppage (power failure). As pump stops, the pressure near it drops significantly and then rises drastically as the high pressure wave returns. The valve is equipped with a pilot which opens it when an exceptional low pressure is sensed. The returning high pressure wave can then be released. Valve closes slowly. The system contains another pilot which opens the valve as high pressure is sensed and protects the line from pressure surges created by sudden flow reduction etc.

PUMP CONTROL VALVES

Concept & operating sequence ��


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System risks at pump start-up and shut-off: Excessive flow rate at the system filling phase may cause pump overload, cavitation and high water surges as the line is filled and velocity dramatically changes. Surges are likely to appear also at pump's shut-off or power failure due to sudden flow stoppage. OPERATION SEQUENCE 1. Pump starts first. 2. Solenoid on valve is energized e.g. 2 minutes later. 3. The solenoid is connected to a relay, which allows a

bigger passage to bleed the water from the bonnet. 4. A needle valve can be used to regulate the opening

speed. 5. When system stops, the solenoid of the valve is first

de-energized.

6. A position indicating rod on the valve with a limit switch signal, the pump when the valve is closed and pump shuts off.

� Some turbine pumps cannot operate against a

closed valve, it may damage the impellers! � As Pump shuts off due to power faiure, a reverse

flow is stopped by a check valve feature on the valve.

� To protect the mainline against this sudden closure (water hammer); a surge anticipating valve is installed in T-configuration to the mainline.

� Two-stage opening application is used to fill the mainline slowly, only when pressurized, valve opens fully. This feature also prevents the electric motor from overloading and can be added to the standard Pump Control valve.

OPERATING INSTRUCTIONS/ TROUBLESHOOTING GUIDE

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Electric Valve Normally Closed................................. ………………………………………….73 Electric Valve with Relay Normally Closed................... ………………………………………..75 Manual Electric Valve Normally Closed................................................................................77 Remote Control Valve...........................................................................................................79 Pressure Reducing Valve 3-Way..........................................................................................82 Pressure Reducing Sustaining Valve 3-Way....................................................................... 87 Pressure Reducing Valve 3-Way Quick-Reacting................................................................89 Pressure Reducing Remote Control Valve...........................................................................91 Pressure Sustaining Valve 3-Way........................................................................................94 Pressure Sustaining Valve Normally Open...........................................................................98 Two-Stage Opening Valve...................................................................................................104 Quick Pressure Relief Valve................................................................................................106 Surge Anticipating & Quick Relief Valve..............................................................................112 Pressure Reducing Valve 2-Way.........................................................................................118 Pressure Reducing Sustaining Valve 2-Way.......................................................................122 Pressure Sustaining Valve 2-Way.......................................................................................126 Booster Pump Control Valve................................................................................................130 Booster Pump Control & Flow Rate Control Valve......................................................................................................132

ELECTRIC VALVE Normaly Closed Operating Instructions for 1" – 4" valves

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Components Part Numbers

a. Solenoid 30 - NO b. Filter 81-1/4"-24

INSTALLATION � The arrow on the bonnet should match the flow

direction. � Filter (b) is installed at the upstream side of the

valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Use primer and heavy duty solvent for the socket

style PVC valves. � Bolts of flanged valves should be tightened in a

diagonal sequence. ADJUSTMENTS � The common port of the solenoid (a) base, (c), is

connected to the bonnet of the valve. Port (p) is upstream pressure connection and the port marked (2) at the base is the vent port.

Note: A Normally Open valve uses a Normally Closed (N.C.) solenoid (a). The connections to the vent (2) and pressure port will be reversed! � Start the pump or open the main valve. If the

solenoid (a) is not energized, the valve closes. (N.C. Valve)

� When the solenoid (a) is energized the water in the control chamber will vent through the solenoid (a) and the valve opens.

� The manual override of the solenoid (a) should be in the auto position.

MAINTENANCE Keep the valve clear from weeds and dirt. WINTERIZING Drain the valve by disconnecting the tube at the upstream port of the valve and at any other location where water can be trapped.

TROUBLESHOOTING A solenoid converts an electric signal to a hydraulic command Diaphragm I.D. number can be found on the tip of the diaphragm

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Problem Cause Check Remedy

Pressure is too low. Compare with design data. Thickness of diaphragm.

Increase upstream pressure. Change to low pressure diaphragm.

Solenoid (a), incorrect voltage.

Measure ±10% of nominal voltage. Check wire sizing.

Correct.

No current Damaged wires. Repair.

Valve does not open

Solenoid (a), faulty coil. Voltage okay, but no click. Change coil.

Punctured diaphragm. Solenoid (a) continuously discharges water when valve is open.

Replace diaphragm. Refer to I.D. number.

Foreign substance on sealing seat.

Reduced water flow, noisy.

Dismantle, clean and reassemble.

Solenoid (a), incorrect position of the manual override.

Slot to be horizontal with arrow pointing down. Change position.

Solenoid (a), plugged. Disassemble from valve. No water from port (c). Take apart and clean.

Valve does not close

Clogged filter (b). Disconnect tube upstream. No firm stream. Clean or replace.

ELECTRIC VALVE Normaly Closed Operating Instructions for 6" – 16" valves

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INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS � The common port of the solenoid base, (2) is connected to the sensing port (1) of relay (a). � When the solenoid (c) is energized it causes the plunger in the

relay (a) to switch position and port (3) is connected with port (4), allowing the valve to open.

� The opening and closing pace of the valve is adjusted with needle valves (f2) and (f1). A long mainline requires a longer opening and closing time and a two stage opening may be necessary.

� With a Normally Open (N.O.) valve, the connections to port # 4 and # 2 of the relay (a) are reversed.

� The manual override of the solenoid (c) should be in the Auto position, the little arrow pointing down.

. � Connection of the wires to the solenoid (c) with 1/2" hub is

described on the attached diagram.

SOLENOID ELECTRICAL WIRE HOOK-UP � Loosen bolt (1). Pull hub assembly off. � Remove (4) and push terminal (3) out with a

screwdriver through access port. � Connect wires to A and B of the terminal block (3). For DCL solenoids connect negative (black) to A. If no

conduit is used, first put the wires through the 1/2” x 1/4” reducer. � Re-assemble the hub and seal for the access port (4).

MAINTENANCE Keep the valve clear from weeds and dirt.

WINTERIZING Drain the valve by disconnecting the tube at the upstream port of the valve and at any other location where water can be trapped. Open the needle valves (f1, f2).


a. Relay 66-210 b. Filter 81-1/2"-2 c. NC Solenoid 30-NC d. Ball Valves 34-1/2" f. Needle Valves

TROUBLESHOOTING A solenoid converts an electric signal to a hydraulic command. The relay Allows fast reaction of large valves and is not susceptible to clogging. Diaphragm I.D. number can be found on the tip of the diaphragm

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Pressure is too low.

Compare with design data. Thickness of diaphragm.

Increase upstream pressure. Change to low pressure diaphragm.

Needle valve (f2) closed. Open fully. Readjust.

Solenoid (c), incorrect voltage.


Correct.


Solenoid (c), faulty coil. Voltage okay, but no click. Change coil.

Valve does not open

Relay (a) does not close. Pressure too low, need 20 psi. Increase pressure.

Punctured diaphragm. Water keeps flowing from port #4 of the relay (a), when valve is open.

Replace diaphragm. Refer to I.D. #.




Solenoid (c), is clogged. Disconnect tube at #1 of relay (a). No water comes from port (c).

Clean.

Solenoid (c), incorrect position of the manual override.

Slot to be horizontal with arrow pointing down.

Change position.

Clogged filter (b). Disconnect tube upstream. No firm stream.

Clean or replace.


Needle valve (f1). Closed or dirty. Open fully, readjust. Clean or replace.

MANUAL ELECTRIC VALVE Normaly Closed Operating Instructions for 1" –6" valves

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diagonal sequence.

ADJUSTMENTS The 3-way selector (a) must be in the A-position. The O-port is used to manually open and the C-port to manually close the valve. A neutral position, not facing any of the ports, locks the water in the bonnet and can keep the valve in a throttled position.

FOR ELECTRIC OPTION The common port (2) of the solenoid base (c), is connected to the A-port of the 3-way selector (a) The top port (p) is the pressure port for Normally Open (N.O.) solenoids on Normally Closed (N.C.) valves. The port marked (1) at the base is the vent port. Note: A Normally Open valve uses a Normally Closed solenoid. For N.O. valves, the connections to the vent (1) and pressure (p) ports will be reversed! � Start the pump or open the main valve. The valve will close. � When the solenoid (c) is energized, the water in the bonnet will vent through the solenoid and the valve opens. The manual override of the solenoid (c) should be in the off position. MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the downstream pressure periodically with a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tube at the upstream port of the valve and at any other location where water can be trapped


a. 3-way Selector 35 1/4" / 1/8" b. Inline filter 81-1/4"-58

c. NO Solenoid 71-NO

TROUBLESHOOTING A solenoid converts an electric signal to a hydraulic command Diaphragm I.D. number can be found on the tip of the diaphragm

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The 3-way selector (a) is in the C position. Verify knob position. Turn to A position.

Ports are clogged. Turn 3-way selector (a) to O or A, no water.

Dismantle and clean.

Pressure is too low.

Compare with design data. Check thickness of diaphragm.

Increase upstream pressure. Change to LP diaphragm.



Correct.


Valve does not open

Solenoid (c), faulty coil.

Voltage okay, but no click. Change coil.

Punctured diaphragm. Turn 3-way selector (a) to port O, water flows constantly.





Clogged solenoid (c). Disconnect at A port, no water from tube. Clean solenoid (c).

Solenoid (c), incorrect position of manual override.

Slot to be horizontal with arrow or dot pointing down.

Change position.



Clean or replace.

REMOTE CONTROL VALVE Operating instructions for 1"-4" valves

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INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Use primer and heavy duty solvent for the socket style

PVC valves. � Bolts of flanged valves should be tightened in a diagonal

sequence.

ADJUSTMENTS � The manual override on the Galit must be in the Auto

position. � The Galit (c) requires a Normally Closed (N.C.) solenoid

at the control panel. � Connect the remote control line, 8 mm to the (1) port of

the Galit (c) after bleeding all the air. � When the solenoid (e) is energized, water in the

hydraulic tube pressurizes and closes the Galit (c), draining the water from the bonnet through the vent port (4) and the valve opens.

� Depressurizing the hydraulic tubing connects the (3) port with the (2) port and the bonnet, closing the valve.

� The signal line at the Galit (c), when depressurized, should not have more than 3 mwc (4 psi) of static pressure. The Galit (c) should not be lower than 3m (9 ft) in elevation compared to the solenoid (e) at the control panel. If at a lower level, see the spring selection chart.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the upstream pressure periodically, use a quality liquid filled gauge and shrader valve adapter.

WINTERIZING Drain the valve by disconnecting the tube at the access port of the valve and at (1) port of the Galit (c).


b. Filter 81-1/4"-58

c. GALIT

e. Solenoid 30 NC / 71 NC

Spring Color N.O. Valve N.C. Valve

Yellow 5m – 11m 5m – 11m

Green 11m-15m 11m-16m

White 3m-18m 16m-21m

Red 18m-24m 21m-27m

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�

�

�

��

�

Remote control using 25-100 –

The 25-100 relay enables accurate adjustments a pilot valve and is recommended for use where topography dictates significant altitude differences between solenoid and main valve. Adjustment: � The 25-100 requires a N.C. solenoid at the

control panel. � For N.C. main valve: Connect the remote control line,

(8mm) to port (1) of the relay (c) after bleeding all the air. Connect port (3) to control chamber, port (2) to upstream, port (4) remains open to atmosphere. For N.O. main valve: switch connections of (2) and (4) ports.

N.C. main valve operation: When solenoid (e) is energized, pressure rises In the hydraulic tube (port (1)) and connects ports (3) and (4) – valve opens. When solenoid is de-energized, pressure in port (1) drops and connects ports (3) and (2) – valve closes. Spring adjustment: (solenoid de-energized) � Turn adjusting bolt in clockwise direction (tighten) all the way. � Turn the bolt slowly in counter clockwise direction (release) until

water starts bleeding from the vent port of the relay. � Tighten the bolt until bleeding stops and 1/4 turn more.


b. Filter 81-1/4"-58

c. 25-100

e. Solenoid 30 NC / 71 NC Spring Color Pressure ranges

Yellow 7m – 27m

Green 22m-36m

Red 35m-69m

TROUBLESHOOTING A 25-100 or GALIT relay activated by remote hydraulic command by N.C. solenoid. Diaphragm I.D. number can be found on the tip of the diaphragm

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The Galit manual override is in the Closed position.

Verify knob position. Turn to Auto position.

Ports are clogged. Turn Galit manual override to Open or Auto, no water.


Compare with design data.

Increase upstream pressure. Pressure is too low.

Thickness of diaphragm.

Change to LP diaphragm.

Solenoid (e), incorrect voltage.


Correct.


Solenoid (e), faulty coil.


Check N.C. solenoid. Increase pressure.

Verify connections on ports. Correct or clean. No signal or low

pressure at port (1) of Galit (c). If green spring was

used. 25-100 – if bolt is released

Change to yellow spring. 25-100- release bolt

Broken or damaged control tubing. Leaks in the tubing. Repair and bleed air.

Valve does not open

Faulty Galit (c). Dirt inside. Take apart and clean.

Punctured diaphragm.

Turn Galit manual override to port Open or Auto, water flows constantly.





Signal line not draining due to static pressure.

Disconnect tube at (1) port measure pressure.

Dirt inside. Take apart and clean.


Galit (c) not returning to open position.

Yellow spring is too weak.

Replace or change to green spring, or use 25-100

PRESSURE REDUCING VALVE 3-Way Operating instructions 1" to 6" valves

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a. 3-way Selector 35 -1/4" 1/2" - 3

b. Filter 81 – 1/4" - 58

c. Pilot-29-100

d. Shrader Valve

e. Solenoid (option) 71-NO





diagonal sequence. ADJUSTMENTS The 3-way selector (a) must be in the A-position. The O-port is used to manually open and the C-port to close the valve. A neutral position, not facing any of the ports, locks the water in the bonnet, used in case the pilot (c) malfunctions. Note: The O-port is plugged when the pilot (c) has a yellow spring, to avoid accidental opening causing high pressure downstream. The pilot (c) has a colored ring on the top identifying the spring inside. � Loosen the lock nut and the adjustment bolt on pilot (c). � Start the pump or main valve. Valve opens and

downstream pressure is kept at a low level. � Tighten the bolt of pilot (c) slowly until downstream

pressure reaches the desired level. � Wait until pressure stabilizes, make final adjustments

and tighten the lock nut on the pilot (c). FOR ELECTRIC OPTION � Turn the manual override of the solenoid (e) 90 degrees and follow the above steps. � After making the adjustments, turn the override to the original position. MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the downstream pressure periodically with a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tubes at the access ports of the valve and at any other location where water can be trapped.


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Ports are clogged. Turn 3-way selector (a) to O or A, no water. Dismantle and clean.


Increase upstream pressure.

Pressure is too low. Check thickness of diaphragm.




Correct.


Faulty coil. Voltage okay, but no click. Change coil.

Valve does not open

Faulty pilot (c). Disconnect tube at port A. Water keeps flowing out. Repair or replace.






Solenoid (e) is clogged. Disconnect tube at A port, no water comes out. Clean solenoid (e).


Solenoid (e) incorrect position of manual override.


Change position.

Incorrect connections. Compare with schematic. Change accordingly.

Wrong spring in pilot (c). Check data, yellow spring 5-25 mwc (7-35 psi) downstream.

Change to green spring10-45 mwc (14-70 psi).

Inlet pressure too low. Measure, check design. Increase pressure.

Clogged filter (b). Disconnect tube upstream, no firm stream. Clean or replace.

Valve does not regulate

Faulty pilot (c). Disconnect tube at port 2, no water coming out. Clean pilot or replace.

Valve has low pressure diaphragm.

Noisy, chattering, high pressure differential. Check diaphragm I.D.

Use high pressure diaphragm.

Unstable performance

Low flow or high pressure differential. Valve is surging.

Install dripper or needle valve at vent port (3) and/or port A.


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a. 3-way Selector 35-1/4" – 3 / 6 b. Filter 81-1/2"- 2 c. Pilot-Brass 31-310 d. Ball Valves 34 –/ 1/2" e. Solenoid (option) 30- NC f. Pressure gauge


direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Use primer and heavy duty solvent for the socket style PVC valves. � Bolts of flanged valves should be tightened in a

diagonal sequence.

ADJUSTMENTS The 3-way selector (a) must be in the A-position. The O-port is used to manually open and the C-port to close the valve. A neutral position, not facing any of the ports locks the water in the bonnet, used in case the pilot (c) malfunctions. The isolation ball valves (d) at the access ports of the valve must be open. � Loosen the lock nut and the adjustment bolt on

pilot (c). � Start the pump or main valve. Valve opens and

downstream pressure is kept at a low level. � Tighten the bolt of pilot (c) slowly until downstream

pressure reaches the desired level. � Wait until pressure stabilizes, make final adjustments

and tighten the lock nut on the pilot (c). FOR ELECTRIC OPTION � Turn the manual override of the solenoid (f) 90

degrees and follow the above steps.

� After making the adjustments, turn the override to the original position.

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SOLENOID ELECTRICAL WIRE HOOK-UP • Loosen bolt (1). Pull hub assembly off. • Remove (4) and push terminal (3) out with a

screwdriver through access port. • Connect wires to A and B of the terminal block (3).

For DCL solenoids, connect negative (black) to A. If no conduit is used, first put the wires through the1/2” x 1/4” reducer.

• Re-assemble the hub and seal for the access port (4).

MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the downstream pressure periodically with a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tube at the upstream port of the valve and at any other location where water can be trapped.

TROUBLESHOOTING Pressure reducing valve reduces inlet pressure to steady pre-determined downstream pressure. A solenoid converts an electric signal to a hydraulic command. Diaphragm I.D. number can be found on the tip of the diaphragm��




Selector ports are clogged.

Turn 3-way selector (a) to O or A, no water. Dismantle and clean.



Check thickness of diaphragm.




Correct.


Faulty coil. Voltage okay, but no click. Change coil.

Valve does not open

Faulty pilot (c). Disconnect tube at port A. Water keeps flowing out.

Repair or replace.






Solenoid (e) is clogged. Disconnect tube at A port, no water comes out.

Clean solenoid (e).




Change position.


Wrong spring in pilot (c).

Check data, yellow spring 5-30 mwc (7-35 psi) downstream.

Change to green spring 10-60 mwc (14-70) psi.


Clogged filter (b). Disconnect tube upstream, no firm stream.

Clean or replace.


Faulty pilot (c). Disconnect tube at port 3, no water coming out. Clean pilot or replace.

Valve has low pressure diaphragm.

Noisy, chattering, high pressure differential. Check diaphragm I.D.

Use high pressure diaphragm.



Install dripper or needle valve at vent port (2) and/or port A.

PRESSURE REDUCING SUSTAINING VALVE 3-WAY

Operating instructions 6" to 12" valves ��



a. 3-way Selector 35-1/4" 3 / 6

b. Filter 81-1/2" - 58 c. Reducing Pilot 31-310 d. Ball Valve 34- /1/2" g. Sustaining Pilot 31-300

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (c) is installed at the upstream side of the valve. � The valve can be installed in any position. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS The 3-way selector (a) must be in the A-position. The O-port is used to manually open and the C-port to close the valve. A neutral position, not facing any of the ports, locks the water in the bonnet, used in case the pilots (c, g) malfunction. Note: The pilots (c, g) have a colored ring on the top identifying the spring inside. � Loosen the lock nut and tighten the adjustment bolt of both

pilots (c) and (g). � Start the pump or open main valve. Valve remains closed

or opens slightly maintaining a high upstream pressure. � Loosen the bolt of pilot (g) slowly until upstream Pressure reaches the desired level. � Loosen the bolt of pilot (c) slowly until the

downstream reaches the required pressure level. � Wait until pressure stabilizes, make final adjustments

and tighten the lock nut on both pilots (c, g). MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the correct setting of the pilots (c, g) periodically with a quality liquid filled gauge and shrader valve adapter, by measuring the up and downstream pressure. WINTERIZING Drain the valve by disconnecting the tubes at the access ports of the valve and any other location where water can be trapped.

TROUBLESHOOTING Pressure reducing pilot reduces inlet pressure to steady pre-determined downstream pressure. Pressure sustaining pilot maintains a minimum upstream pressure. A solenoid converts an electric signal to a hydraulic command. Diaphragm I.D. number can be found on the tip of the diaphragm ��



The 3-way selector (a) is in the C position.

Verify knob position. Turn to A position.

Ports are clogged. Turn 3-way selector (a) to O or A, no water flowing.


Pressure is too low. Compare with design data.


Valve does not open

Faulty pilot (c). Disconnect tube (c3). Tube keeps venting water.

Repair or replace.


Replace diaphragm. Refer to I.D. number. Valve does not

close Foreign substance on sealing seat.




Wrong spring in pilot (c).

Check data, yellow spring 5-25 mwc (7-35 psi) downstream.

Change to green spring 10-47 mwc (14-70 psi).



Clean or replace.


Faulty pilot (c). Disconnect tube at port (c3), no water coming out.

Clean pilot (c) or replace.

Pilot set points are too close together, causing interference.

Set points of pilots (c, g) to be a minimum of 10 psi apart.

Change accordingly.



Install needle valve between (c3) and A port of 3-way selector (a).

PRESSURE REDUCING VALVE 3-WAY QUICK REACTING

Operating instructions 6" to 12" valves ��



a. Pilot Quick-Reacting 66-310 b. Pilot-Brass 31-310 c. Filter 81-1/2"-58 d. Ball Valves 34- 1/2"

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (c) is installed at the upstream side of the valve. � The valve can be installed in any position. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENT � The isolation ball valves (d) at the access ports of valve

must be open. � Loosen the lock nut and the adjustment bolt on pilot (a). � Tighten the bolt on pilot (b). � Start the pump or main valve. Valve opens and

downstream pressure is kept at a low level. � Tighten the bolt of pilot (a) slowly until downstream

pressure reaches the desired level at which the valve will react quickly.

� Wait until pressure stabilizes, make final adjustments and loosen the lock nut on the pilot (b).

� Loosen the bolt on pilot (b) until the downstream pressure reaches the required level for normal regulation and tighten the bolt about two turns. The set point of the bolt on pilot (a) should be at least 7 mwc (10 psi) higher than the one on pilot (b).

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the downstream pressure periodically with a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tube at the access ports of the valve and at other locations where water can be trapped.

TROUBLESHOOTING Pressure reducing valve reduces inlet pressure to steady pre-determined downstream pressure. Quick reacting pilot closes the valve fast as pressure exceeds it set point.. Diaphragm I.D. number can be found on the tip of the diaphragm ��


Problem Cause� � Check Remedy Valve does not

open Incorrect pilot (b) connections.

Compare to diagram. Make corrections.


Pilots (a, b) do not regulate.

Replace diaphragm Refer to I.D. #. Valve does not

close Foreign substance on sealing seat.



Incorrect connections.

Compare with schematic. Change accordingly.

Wrong spring in pilot (b).

Check data, yellow spring 5-20 mwc (7-30psi) downstream.

Change to green spring 10-70 mwc (14-100 psi) or red spring 20-130 mwc (30-190 psi).

Inlet pressure too low.

Measure, check design. Increase pressure.

Clogged filter (c). Disconnect tube upstream. No firm stream.

Clean or replace.

Valve does not regulate� �

Faulty pilot (b).

Disconnect tube at port-3, of pilot (b), no water coming out.

Clean pilot (b) or replace.

PRESSURE REDUCING REMOTE CONTROL VALVE Operating instructions 1" to 12" valves ��



a. Pilot (sizes 1" to 4") 29-100 Pilot (sizes 6" to12") 31-310 b. GALIT GALIT

c. Filter 81- 1/4" 1/2" -58

Red port numbers refer to Pilot valve 31-310 installation

INSTALLATION � The valve can be installed in any position, but flow direction

should match the engraved arrow on the bonnet. � Connect port (1) of the GALIT relay (b) to the control center by a

PE command tube, 6 mm size is preferred. � Drain the air from the command tube - air in the tube will cause

delay in activation of the relay. ADJUSTMENTS � Turn the adjusting bolt (1) of the Pilot (a) in a counterclockwise

direction all the way.(loosening) � Start the pump or open the main valve of the network. � Turn the adjusting bolt (1) of the Pilot (a) in a clockwise direction

until the downstream pressure reaches the required set point. � Elevation difference between the controller and the valve may

require inserting a spring in the Galit (b) to overcome the static pressure in the control tube.

MAINTENANCE For Normally Closed Valves - Turn the handle of the relay to the "C", closed position for manual opening. The valve will perform as a Pressure reducer at this position. For Normally Open Valves - Turn the handle of the relay to the "O", open position for manual opening. The valve will perform as a Pressure Reducer at this position. Return the handle to the "A", auto position for normal remote control of the valve. WINTERIZING Check and clean the in-line filter as water quality dictates. Unless the water is very dirty, this service should not be done more than once in a few months. Watch the valve performance by checking the downstream pressure gauge periodically

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Pilot (sizes 1" to 4") 29-100 a. Pilot (sizes 6" to

12") 31-310

b. 25-100 relay 25-100

c. Filter 81- 1/4" -58

Red port numbers refer to Pilot valve 31-310 installation

REMOTE CONTROL USING 25-100 RELAY:

ADJUSTMENTS: � The 25-100 requires a N.C. solenoid at the

control panel. � For N.C. main valve: Connect the remote control

line, (6 mm) to port (1) of the relay (b) after bleeding all the air. Connect port (3) to control chamber, port (2) to upstream, port (4) remains open to atmosphere.

� For N.O. main valve: switch connections of (2) and (4) ports.

N.C. main valve operation: When solenoid (e) is energized, pressure rises in the hydraulic tube (port (1)) and connects ports (3) and (4) – valve opens. When solenoid is de-energized, pressure in port (1) drops and connects ports (3) and (2) – valve closes.

25-100 adjustment: � Disconnect tube of port 4 of relay (b). � Tighten bolt of relay (b) clock-wise all the way. � As solenoid is de-energized, loosen the bolt of

relay (b) until water start draining from port (4). � Tighten the bolt until water stops dripping and

about 1/2 revolution more. � Tighten locking nut and reconnect tube. � Reducing pilot adjustment: tighten bolt of

reducing pilot all the way. � Energize solenoid or manually open the valve,

the valve will maintain low downstream pressure.

� Loosen the adjusting bolt until downstream pressure rises to required level.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the downstream pressure periodically with a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tube at the access ports of the valve and at other locations where water can be trapped.

TROUBLESHOOTING The GALIT and 25-100 are relays activated by remote hydraulic signal from control panel, using N.C. solenoid. Diaphragm I.D. number can be found on the tip of the diaphragm. ��



The GALIT manual override is in the Closed position.

Verify knob position. Turn to Auto position.

Ports are clogged. Turn GALIT manual override to Open or Auto, no water.


Pressure is too low. Compare with design data. Thickness of diaphragm.

Increase upstream pressure. Change to LP diaphragm.



Correct.

Damaged wires. Repair.

Solenoid (e), faulty coil. Voltage okay, but no click. Change coil.

Need N.C. solenoid. Increase pressure.

Verify connections on ports. Correct or clean.

No signal or low pressure at (1) port of relay (b).

If green spring was used. Change to yellow spring 25-100: adjust bolt

Broken or damaged control tubing. Leaks in the tubing. Repair and bleed air.

Valve does not open

Faulty relay (b). Dirt inside. Take apart and clean.


Turn GALIT manual override to port open or Auto, water flows constantly.





Signal line holds too high static pressure.

Disconnect tube at (1) port measure pressure.

Dirt inside. Take apart and clean.


Relay (b) not returning to open position.

Yellow spring is too weak.

Replace or change to green spring. 25-100: adjust bolt


Wrong spring in pilot (c). Check data, yellow spring 5-25 mwc (7-35 psi) downstream.

Change to green spring 10-47 mwc (14-70 psi).



Clean or replace.


Faulty pilot (c). Disconnect tube at port 2 (29-100) or 3 (31-310), no water coming out.

Clean pilot or replace.


Valve has low pressure diaphragm. Low flow or high pressure differential.

Noisy, chattering, high pressure differential. Check diaphragm I.D. Valve is surging.

Use high pressure diaphragm. Install dripper or needle valve at vent port (3).

PRESSURE SUSTAINING

VALVE 3-Way Operating instructions 1" to 4" valves ��



a. 3-way Selector 35- 1/4" -3 b. Filter 81- 1/4" -58 c. Pilot 29-200 e. Solenoid (option) 71-NC

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. If below ground

level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Use primer and heavy duty solvent for the socket style


sequence. ADJUSTMENTS � The 3-way selector (a) must be in the A-position. The

O-port is used to manually open the valve and the C-port to close the valve. A neutral position, not facing any of the ports locks the water in the bonnet, used in case the pilot (c) malfunctions.

� Loosen the lock nut and tighten the adjustment bolt on pilot (c).

� Start the pump or open the main valve. The valve remains closed or opens slightly while the upstream pressure maintains a high level.

� Loosen the bolt on pilot (c) until the upstream pressure reaches the minimum required level.

� Wait until pressure stabilizes, make final adjustments and tighten the lock nut on the pilot (c).

THE ELECTRIC OPTION Turn the manual override of the solenoid (e) 90-degrees and follow the above steps. MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the upstream pressure periodically with a quality liquid filled gauge and a shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tubing from the access ports of the valve and at other locations where water can be trapped.

TROUBLESHOOTING A sustaining valve maintains a preset pressure at the upstream side of the valve. Diaphragm I.D. number can be found on the tip of the diaphragm. ��




Ports are clogged. Turn 3-way selector (a) to O or A, no water. Dismantle and clean.

Low upstream pressure

design data, pump curve


Solenoid (e), incorrect connections Verify port connections Correct.

Solenoid plugged Disconnect tube, check flow clean

Solenoid (e) no current Check voltage and coil. Correct voltage, Change coil.

Valve does not open

Faulty pilot (c). Disconnect tube at port A. Water keeps flowing from the pilot

Repair or replace.






Solenoid (e) is stuck. Disconnect tube at solenoid port 2, water flow out.

Clean solenoid (e).



Change position.


3-way selector (a) on 'O' position verify knob position Turn to A


Valve with low pressure diaphragm Noisy, chattering. Replace with high

pressure diaphragm


Clean or replace.

Faulty pilot (c).

No flow from port (3), extreme bolt adjustments needed to modify pressure

Clean pilot or replace.

Unstable regulation

Low flow or high pressure differential Valve is surging

Install needle valve between port A and port (3) of pilot

PRESSURE SUSTAINING

VALVE 3-Way Operating instructions 6" to 10" valves ��



a. 3-way Selector 35-1/4" 3 / 6

b. Filter 81- 1/2" -2 c. Pilot 31-310 d. Ball Valve 34-1/2" e. Pressure gauge f. Solenoid (option) 30 - NC


direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. If below

ground level, use a valve box to protect it � Bolts of flanged valves should be tightened in a

diagonal sequence ADJUSTMENTS

The 3-way selector (a) must be in the A-position. The O-port is used to manually open the valve and the C-port to close the valve. A neutral position, not facing any of the ports locks the water in the bonnet, used in case the pilot (c) malfunctions.



� Loosen the bolt on pilot (c) until the upstream pressure reaches the minimum required level.


THE ELECTRIC OPTION Turn the manual override of the solenoid (e) 90-degrees and follow the above steps. MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the upstream pressure periodically with a quality liquid filled gauge and a shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tubing from the access ports of the valve and at other locations where water can be trapped.

TROUBLESHOOTING A sustaining valve maintains a preset pressure at the upstream side of the valve. Diaphragm I.D. number can be found on the tip of the diaphragm. ��







Low upstream pressure.

Design data, pump curve.


Incorrect solenoid (f), connection.

Verify port connections, top is drain port.

Correct.

Plugged. Disconnect tube, check flow. Clean.

Solenoid (f), no current.

Check voltage and coil.

Correct, change coil.

Valve does not open

Faulty pilot (c).

Pressure is too high. Disconnect tube at pilot port 3, water flows out.

Make necessary adjustments. Repair or replace pilot (c).

Punctured diaphragm. Turn 3-way selector (a) to O, water flows continuously.

Change diaphragm, check I.D. #.


Water leaking from outlet or noise can be heard.

Remove bonnet, clean seat and re-assemble.

3-way selector (a) set on 'O'.

Verify knob position. Turn to A.


Solenoid (f) override in wrong position.


Turn to correct position.

Valve has low pressure diaphragm. Noisy, chattering.

Replace with high pressure diaphragm.

Incorrect pilot (c) connections.

Compare with schematic.

Correct accordingly.

Clogged or faulty pilot (c).

No water flow from port (3).

Clean or replace pilot (c). Adjust bolts to modify pressure.



Install needle valve between A port and port 3 of pilot (c).

PRESSURE SUSTAINING

VALVE 3-Way Normally Open Operating instructions 1" to 4" valves ��



a. 3-way Selector 35-1/4"-3

b. Filter 81- 1/4"- 58 c. Pilot 29-200 e. Solenoid 30 - NC

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. If below ground

level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Use primer and heavy duty solvent for the socket style PVC

valves. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS The 3-way selector (a) must be in the A-position. The O-port is used to manually open the valve and the C-port to close the valve. A neutral position, not facing any of the ports locks the water in the bonnet, used in case the pilot (c) malfunctions Note: The valve is normally open and sustains pressure only when the filters backflush. The solenoid (e) is connected to the master valve of the backflush controller. � Loosen the lock nut and tighten the adjustment bolt

on pilot (c). � Start the pump or open the main valve and perform

a backflush cycle with the controller. � The valve remains closed or opens slightly while the

upstream pressure maintains a high level. � Loosen the bolt on pilot (c) until the upstream

pressure reaches the minimum required level to backwash the filter.


� If the manual override screw on the solenoid (e) was used, turn it to the original position.

MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the upstream pressure periodically, using a quality liquid filled Gauge. WINTERIZING Drain the valve by disconnecting the tubing from the access ports of the valve and at any other location where water can be trapped.

TROUBLESHOOTING A normally open sustaining valve maintains a preset pressure at the upstream side of the valve during the backflush cycle of the filters. Diaphragm I.D. number can be found on the tip of the diaphragm. ��







Low upstream pressure. Design data, pump curve.


Solenoid (e), incorrect connection.


Change accordingly.

Valve does not open

Solenoid is plugged. Check flow at the solenoid vent port. Clean.



3-way selector (a) on 'O'. Verify knob position. Turn to A position.

Solenoid (e) override in wrong position.


Turn to right position.

Solenoid (e), no current. Measure output at controller.

Consult controller manual.

Solenoid (e), faulty coil. Check at coil, no click. Replace.

Solenoid (e) is clogged. Disconnect tube at A, no water flow from solenoid (e)

Clean solenoid (e).




Valve does not sustain pressure



Clean or replace pilot (c). Adjust bolt to change pressure.

PRESSURE SUSTAINING

VALVE 3-Way Normally Open Operating instructions 6" valves ��



a. 3-way Selector 35-1/4" -3

b. Filter 81-1/4-24 c. Pilot 29-200

d. 3/2 1/2" valve

e. Solenoid 30 NC

f. Quick reacting relay 25-300

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. If below

ground level, use a valve box to protect it. � Use primer and heavy duty solvent for the socket style


sequence. ADJUSTMENTS

The 3-way selector (a) must be in the A-position. The O-port is used to manually open the valve and the C-port to close the valve. A neutral position, not facing any of the ports locks the water in the bonnet, used in case the pilot (c) malfunctions.

Note: The valve is normally open and only sustains pressure when the filters backflush. The solenoid (e) is connected to the master valve of the backflush controller. � Loosen the lock nut and tighten the adjustment bolt on

pilot (c). � Start the pump or open the main valve and perform a

backflush cycle with the controller. � The valve remains closed or opens slightly while the

upstream pressure maintains a high level. � Loosen the bolt on pilot (c) until the upstream pressure

reaches the minimum required level to backwash the filter.

� Wait until pressure stabilizes, make final adjustments and tighten the lock nut on the pilot (c). If the manual override screw on the solenoid (e) was used, turn it to the original position.

MAINTENANCE Keep the valve clear from weeds and dirt. Turn the handle of the 3-way selector (a) periodically to prevent sticking. Verify the upstream pressure periodically, use a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tubing from the access ports of the valve and at any other location where water can be trapped.




The 3-way selector (a) or 2 way valve (d) are in the C position. .




Low upstream pressure. Design data, pump curve.


Solenoid (e), incorrect connection.


Change accordingly.

Valve does not open

25-300 (f) Plugged. Check flow at the vent port. Clean.



3-way selector (a) on 'O'. Verify knob position. Turn to A position.

Solenoid (e) override in wrong position.


Turn to right position.

Solenoid (e), no current. Measure output at controller.


Solenoid (e), faulty coil. Check at coil, no click. Replace.

Solenoid (e) is clogged.

Disconnect tube at port A of valve (a), no water flow from solenoid (e)

Clean solenoid (e).




Valve does not sustain pressure



Clean or replace pilot (c). Adjust bolt to change pressure.

PRESSURE SUSTAINING

VALVE 3-Way Normally Open Operating instructions 8" to 12" valves ��



a. Pilot 66-310 b. Relay 25-300 c. Solenoid 30 NC d. Filter 81-1/2-2 e. Ball Valves 34-1/2" f. Check valve

g. Needle valve 34-1/4" NE



valve. � The valve can be installed in any position. If below

ground level, use a valve box to protect it. � Use primer and heavy duty solvent for the socket


diagonal sequence. OPERATION Note: The valve is normally open (N.O.) and only sustains pressure when the filters backflush. The solenoid N.C. is hooked up to the master valve of the backflush controller. Control pressure tubes connected to solenoid (c) and relay valve (b) are to be connected upstream of filters. � Loosen the lock nut and tighten the adjustment

bolt on pilot (a). Tighten needle valve (g) all the way and release 2 turns.

� Start the pump or open the main valve and perform a backflush cycle with the controller.

� The valve remains closed or opens slightly while the upstream pressure maintains a high level.

� Loosen the bolt on pilot (a) until the upstream pressure reaches about 35 mwc (50 psi).

� Tighten the lock nut on the pilot (a). If the manual override screw on the solenoid (c) was used, turn it to the original position.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the upstream pressure periodically with a quality liquid filled gauge and shrader value adapter. WINTERIZING Drain the valve by disconnecting the tubing from the access port of the valve and any other locations where water can be trapped.





Design data, pump curve.

Increase upstream pressure. Valve does not

open fully Solenoid (c) override in wrong position.


Turn to correct position.


Water keeps flowing from vent port of relay (b).


Solenoid (c) no current.

Measure output at controller.



Check at coil, no click. Replace.

Solenoid clogged. Disconnect tube at port 2 of solenoid (c), no water flow.

Clean.

Incorrect pilot (a) connections.

Compare with schematic. Correct accordingly.

Relay (b).

Needs minimum of 10 mwc (15 psi) upstream pressure to operate.

Increase upstream pressure

Valve does not sustain

pressure

Needle valve too closed Needle valve position Release and re-

adjust

TWO-STAGE OPENING VALVE Operating instructions 2" to 4" valves ��



a. 3-way Selector 35- 1/4"

b. Filter 81- 1/4" -58 c. Pilot 29-200


direction. � The filter (b) is installed at the upstream side of the

valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Use primer and a heavy duty solvent to install the

socket style nPVC valves. � Bolts of flanged valves should be tightened in a

diagonal sequence. ADJUSTMENTS

The 3-way selector (a) must be in the A-position. The O-port is used to manually open the valve and the C-port to close the valve. A neutral position, not facing any of the ports locks the water in the bonnet.



� Loosen the bolt on pilot (c) until the upstream pressure reaches a pressure level that produces the desired flow rate to fill the pipeline. The pilot (c) should be set at about 2/3 of the operating pressure.

� The pilot (c) measures the pressure in the bonnet which is approximately the average of the upstream and downstream pressure.

A higher pressure setting increases the filling time.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the proper filling time of the pipeline and adjust the pilot(c) setting if necessary. Turn the handle of the 3-way selector (a) periodically to prevent sticking. WINTERIZING Drain the valve by disconnecting the tubing from filter (b).

TROUBLESHOOTING A two-stage maintains a preset pressure in the bonnet until the mainline is full and downstream pressure builds up. ��



3-way selector (a) is in the C position.





Design data, pump curve. Increase pressure.

Check connections. Correct.

Valve does not open

Faulty pilot (c). Clogged or dirty. Take apart, clean.


Turn 3-way selector (a) to O water flows continuously.

Change diaphragm. Check I.D. # on lip.


Water leaking from outlet or noise can be heard.

Remove bonnet, clean seat and reassemble.


3-way selector (a) is in the O position


QUICK PRESSURE RELIEF VALVE Operating instructions 2" valves ��



a. Pilot (Quick Reacting) 68-500

b. Filter 81-1/4"-24

INSTALLATION � The valve is installed on a Tee-junction in the pipe

network. � The discharge side of the valve is usually kept in a

horizontal position. � A gate valve can be installed upstream of the

valve to isolate the valve from the network. � Do not connect a pipe downstream of this valve

unless sized correctly (70% of normal flow). � Filter (b) is installed at the upstream side of the

valve. � Use five layers of teflon tape. ADJUSTMENTS � Tighten the adjustment bolt of the pilot (a). � Operate the system at the maximum expected

pressure. � Loosen the adjustment bolt of the pilot (a) until the

valve starts to open, then tighten the bolt about 2 turns. The pilot (a) is now set about 3-7mwc (5-10 psi) higher than the maximum operating pressure. Tighten the lock nut.

. MAINTENANCE The valve should be activated once a year to ensure proper functioning and to clean the upstream side of possible dirt build up. The proper pressure setting should be checked. Filter (b) should be cleaned once a year. WINTERIZING Drain the valve by disconnecting the tube at the upstream side or drain the mainline.

TROUBLESHOOTING A quick relief valve opens instantly and fully to relieve excess pressure from the network. The quick reacting pilot opens the valve when pressure exceeds its set point and protects system components ��


Problem Cause Check Remedy Valve does not open Wrong adjustment. Verify upstream

pressure. Loosen adjustment bolt on pilot (a).

Pilot (a) incorrectly adjusted.

Verify upstream pressure.

Tighten bolt on pilot (a).


Continuous flow at discharge. Replace diaphragm

Foreign substance on the sealing seat.

Dismantle bonnet and inspect.

Remove, clean or replace.

Valve does not close or leaks

Needle bolt (in the pilot) clogged. Valve stays open. Clean, re-install and

tighten completely.

QUICK PRESSURE RELIEF VALVE Operating instructions for 3" and 4" valves ��



a. Pilot (Quick Reacting) CX-PS

b. Filter 81- 1/2 - 2 c. Ball Valves 34 - 1/2" d. Pressure gauge


network. � A gate valve can be installed upstream of the valve to

isolate the valve from the network. � Do not connect a pipe downstream of this valve unless

sized correctly (70% of normal flow). � The arrow on the bonnet should match the flow

direction. � Filter (b) is installed at the upstream side of the valve. � Bolts of flanged valves should be tightened in a

diagonal sequence. ADJUSTMENTS � Tighten adjustment bolt [a1]. � Open valves[c], close needle valve [a2] all the way and

then open it one full turn.�� While the network operates at its maximal pressure,

open the isolating valve. � Turn adjustment bolt [a1] slowly in counter-clockwise

direction until the valve starts to leak. Then return the adjustment bolt until the leakage stops.

� Increase system pressure to a point that is higher than the normal operation value. The valve should open.

� Reduce system pressure to below maximum. The valve should close.

� Adjust closure pace of the valve by the needle valve [a2]. Opening accelerates valve closure.

Note: too fast closure may cause pressure surge Long mains dictate longer closure time. MAINTENANCE Keep the valve clear from weeds and dirt. The valve should be activated once a year to ensure proper functioning.Clean the filter (b) once a year. WINTERIZING Drain the valve by disconnecting the tube at the upstream side or drain the mainline.

TROUBLESHOOTING A quick relief valve opens instantly and fully to relieve excess pressure from the network. The quick reacting pilot opens the valve when pressure exceeds its set point and protects system components ��


.


Wrong adjustment.


Loosen adjustment bolt on pilot (a). Valve does not

open

Ball valves (c) closed.

Verify position.

Open ball valves

(c). Pilot (a) adjusted incorrectly.

Verify upstream pressure. Tighten bolt on pilot (a).


Continuous flow at discharge. Replace diaphragm.



Dismantle bonnet and inspect.


QUICK PRESSURE RELIEF VALVE Operating instructions for 6" to 24" valves ��



a. Pilot (Quick Reacting) CX-PS

b. Filter 81- 1/2 -2 c. Ball Valves 34 – 1/2 d. Needle Valve

e. Pressure gauge

f. 2" Relay valve GALIL 09- HA- NO


network. � A manual valve should be installed upstream of the valve

to isolate the valve from the network. � Do not connect a pipe downstream of this valve unless

sized correctly (70% of normal flow). � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS � Tighten adjustment bolt [a1]. � Open valve [c1], close needle valve [d] all the way and

then open it one full turns. � While the network operates at its maximal pressure, open

the isolating valve. � Open valve [c2]. � Turn adjustment bolt [a1] slowly in counter-clockwise

direction until the QR valve starts to open. Then re-tighten the adjustment bolt 1-2 full turns.

� Adjust opening of needle valve [d] to 1/2-1 full turns � Adjust closure pace of the valve by the needle valve [d].

Opening accelerates valve closure. Note: too fast closure may cause pressure surge. Long mains dictate longer closure time. MAINTENANCE Keep the valve clear from weeds and dirt. Activate the valve periodically and readjust the pilot (a) if necessary. Open the needle valve (d) fully and readjust. Clean the filter (b) once a year. WINTERIZING Drain the valve by disconnecting the tube at the upstream side or drain the mainline.

TROUBLESHOOTING A quick relief valve opens instantly and fully to relieve excess pressure from the network. The quick reacting pilot opens the valve when pressure exceeds its set point and protects system components. ��



Wrong adjustment. Verify upstream pressure.

Loosen bolt on pilot (a1). Valve does not

open Ball valve (c2) closed. Verify position. Open ball valve (c2).

Valve opens partially

Needle valve (d) wide open. Close (d) fully. Open 1-2 turns.




Punctured diaphragm. Continuous flow at discharge.

Replace diaphragm, check I.D. # on the lip.


Dismantle bonnet, inspect.



or leaks

Needle valve (d) plugged or closed.

Water discharges continuously.

Open (d) fully and readjust, if needed dismantle and clean

SURGE ANTICIPATING & QUICK RELIEF VALVE Operating instructions for 3" to 4" valves ��



a. Pilot QR High Pressure CX-PS

b. Pilot QR Low Pressure 66-310

c. Ball Valves 34-1/2" d. Filter 81- 1/2 - 2 e. Needle Valve 34-1/4" NE f. Pressure gauge

g. Check valve 21- 1/2"

�

��

�

�

�

��

�

�

�

��

��

� ��

�

INSTALLATION � The valve is installed on a Tee-junction in the mainline. � A gate valve should be installed upstream of the valve

to isolate the valve from the network. � Do not connect a pipe downstream of this valve unless


direction. � Filter (d) is installed at the upstream side of the valve,

in the main line. � Bolts of flanged valves should be tightened in a

diagonal sequence. ADJUSTMENTS REMARK: Most valves are preset at the factory according to Surge Analysis. In such case, skip first stage. 1. Turn bolt [a1] clockwise, bolt [b1] clockwise all the

way. 2. Close valves [c4, c5] and start the pump. 3. When normal operating pressure is reached, open

valve [c4] and turn bolt [a1] in counter-clockwise direction until water starts dripping from valve [c4]. Return until dripping stops, and add 1 turn. High- pressure opening is now set. Generally, high pressure point should be approximately 10m (15 psi) higher than normal pumps pressure.

4. Open valve [c5] 5. execute the "Low pressure simulation" procedure:

Close Isolating valve [c3]. Open slightly needle valve [e]. Check pressure gauge (f). The pressure

decreases. Allow pressure drop to the point where water

starts leaking from valve [c5] on pilot [b]. This is the set point of the pilot.

Close needle valve [e] and open isolating valve [c3]. The RE valve is now in automatic mode, ready for power failure occurrence. � If set point does not comply with the required opening

pressure (according to the initial design and the commissioning), readjust the pilot [b]: Opening point too high- turn adjustment bolt in

counter-clockwise half a turn. Opening point too low- turn the bolt clockwise, half

a turn. Repeat the above steps. � Generally, opening pressure should be approx. 2/3 of static

pressure. � Stop the pump. The RE valve will open on low-pressure

wave

��


When high-pressure wave arrives, main pipe pressure should exceed the "low pressure opening" point by 5-10m (7-15 psi). Raise set-point of pilot [a] (turn clock-wise) if the pressure does not rise to it. 1. Use Needle valve [a2] to adjust closure pace. MAINTENANCE Keep the valve clear from weeds and dirt. Check the proper setting of the pilots and adjust (a, b) if necessary. Open the needle valve (e) completely close and open about 2 turns. WINTERIZING Drain the valve by opening all the ball valves (c) and the needle valve (e).

TROUBLESHOOTING Surge anticipating valve protects system components from power failure generated water hammer. A quick reacting pilot opens as pressure drops below its set-point. The pressure relief pilot opens as pressure exceed its set-point. ��



Wrong adjustment.


Tighten bolt on pilot (b). Valve does not

open at LOW pressure

Ball valves closed Verify position. Open valves at

(c1,3,5)





Continuous flow at discharge.

Replace diaphragm. Check I.D.# on lip.

Operate valve. Dirt flushes out. Foreign substance on sealing seat. Dismantle bonnet

and inspect. Remove, clean or replace.


Filter (d) clogged. Disconnect tube at ball valve (c3), no firm stream.

Clean filter (d) with system off.

SURGE ANTICIPATING &QUICK RELIEF VALVE Operating instructions for 6" to 24" valves ��



a. Pilot QR High Pressure CX-PS

b. Pilot QR Low Pressure 66-310

c. Ball Valves 34-1/2" d. Filter 81- 1/2 - 2 e. Needle Valve 1/4" f. Pressure gauge g. Check valve 21- 1/2"

h. Relay valve GALIL 09 HA-2 NO

��

INSTALLATION � The valve is installed on a Tee-junction in the main

line. � A manual valve should be installed upstream of the

valve to isolate the valve from the network. � Do not connect a pipe downstream of this valve unless


direction. � Filter (d) is installed at the upstream side of the valve,

in the main line. � Bolts of flanged valves should be tightened in a

diagonal sequence. .

ADJUSTMENTS REMARK: Most valves are preset at the factory according to Surge Analysis. In such case, skip stage 1.

1. Turn bolt [b1] counter-clockwise, bolt [a1] clockwise all

the way. 2. Close valves [c4, c5] and start the pump. 3. When normal operating pressure is reached, open

valve [c4] and turn bolt [a1] in counter-clockwise direction until water starts dripping from valve [c4]. Return until dripping stops, and add 1 turn. High- pressure opening is now set. Generally, high pressure point should be approximately 10m (15 psi) higher than normal pumps pressure.

4. Open valve [c5] 5. execute the "Low pressure simulation" procedure: Close Isolating valve [c3]. Open slightly needle valve [e]. Check pressure gauge (f). The pressure decreases. Allow pressure drop to the point where water starts

leaking from valve [c5] on pilot [b]. This is the set point of the pilot.

Close needle valve [e] and open isolating valve [c3]. The RE valve is now in automatic mode, ready for power failure occurrence. � If set point does not comply with the required opening

pressure (according to the initial design and the commissioning), readjust the pilot [b]: Opening point too high- turn adjustment bolt in

counter-clockwise, half a turn. Opening point too low- Turn the bolt clockwise, half

a turn. Repeat the above steps. � Generally, opening pressure should be approx. 2/3 of

static pressure.


� Stop the pump. The RE valve will open on low-pressure wave. � When high-pressure wave arrives, main pipe pressure should

exceed the "low pressure opening" point by 5-10m (7-15 psi). Reduce set-point of pilot [a] if the pressure does not rise to it.

� Use Needle valve [a2] to adjust closure pace. MAINTENANCE Keep the valve clear from weeds and dirt. Check the proper setting of the pilots and adjust (a, b) if necessary. Open the needle valve (e) completely close and open about 2 turns. WINTERIZING Drain the valve by opening all the ball valves (c) and the needle valve (e).

TROUBLESHOOTING surge anticipating valve protects system components from power failure generated water hammer. A quick reacting pilot opens as pressure drops below its set-point. The other pilot opens as pressure exceed its set-point. ��



Wrong adjustment. Verify upstream pressure

Tighten bolt on pilot (b). Valve does not

open at LOW pressure Ball valve closed at

(c5) or (c3) Verify position. Open valves

Valve opens partially

Needle restrictor of pilot (a) (a2) wide open.

Close fully. Open 1-2 turns.


Continuous flow at discharge.

Replace diaphragm. Check I.D.# on lip.

Operate valve. Dirt flushes out. Foreign substance on the sealing seat. Dismantle bonnet

and inspect. Remove, clean or replace.

Needle restrictor of pilot (a) (a2) plugged closed.

No water flow from port (c) of pilot (a)..

Open (a2) fully and readjust 1-2 turns open.

Filter (d) clogged.

Close (c3), disconnect tube between (c3)-(d), weak flow.

Clean filter (d) when system is off.


or leaks

Relay (h) leaks. Dirt on the sealing seat.

Activate valve or clean.

PRESSURE REDUCING VALVE 2- Way Operating instructions for 2" to 6" valves



a. Pilot 2-way ��-� b. Filter �-/4 - 58

c. Solenoid (option) 30 NO

d. Ball Valves 34 – 1/2"

e. 2 way Relay 28-200 f. Restrictor orifice



valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Bolts of flanged valves should be tightened in a

diagonal sequence.

ADJUSTMENTS � The pilot has a colored ring on the top, identifying

the spring inside. � Turn adjusting bolt of the pilot [a] in counter-

clockwise direction, all the way. � Open isolating ball valves [d 1-3]. � Start the pump or open main valve of the network. � Apply electric signal to the solenoid � Turn the adjusting bolt in clockwise direction until

downstream pressure reaches required value.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the downstream pressure periodically, with a quality liquid filled gauge. WINTERIZING Drain the valve by disconnecting the tubes at ball valves (d) and opening both.

TROUBLESHOOTING Pressure reducing valve reduces inlet pressure to steady pre-determined downstream pressure. A solenoid converts an electric signal to a hydraulic command.

��



Ball valves (d3) or (b2) are closed. Verify position. Open valves (d3)

and (b2).




Measure ±10% nominal voltage. Correct.


Valve does not open




Close downstream ball valve (d3), valve remains open.

Replace diaphragm. Refer to I.D.#.




Solenoid (c) incorrect position of the manual override.

Slot on the base to be in a horizontal position with arrow pointing down.

Change position.

Pilot (a) faulty, no flow conditions.

Unscrew pilots (a) bottom seat, dismantle seal and check it.

Replace seal.


Ball valve (d1) upstream is closed. Check position. Open (d1)


Inlet pressure too low.

Disconnect tube upstream. No firm stream.

Clean or replace.

PRESSURE REDUCING VALVE 2- Way Operating instructions for �" to �" valves

��



a. Pilot 2-way CX-PR

b. Filter 81-1/2-2


d. Ball Valves 34-1/2"

f. Needle Valve 34-1/4" NE

g. Relay 28-200

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Bolts of flanged valves should be tightened in a diagonal

sequence.

ADJUSTMENTS � The ball valves (d) must be open. Closure of the

downstream�valve (d) closes the valve manually. � The pilot (a) uses a spring with a range from 10-200

mwc (15-300 psi) downstream pressure setting. � Loosen the lock nut and the adjustment bolt on pilot (a). � Start the pump or main valve. The valve opens and

downstream pressure is kept at a low level. � Tighten the bolt of pilot (a) slowly until downstream

pressure reaches the desired level. � The valve’s response time is adjusted with the restricting

needle bolt (a1). Closing (a1) will slow it down and opening (a1) will speed up the valve’s response.

� Wait until pressure stabilizes, make final adjustments and tighten the lock nut on the pilot (a).

FOR ELECTRIC OPTION � Turn the manual override of the solenoid (c) 90 degrees

and follow the above steps. � After making the adjustments turn the override to the

original position. The wire connection to the solenoid (c) with 1/2" hub is described on the attached diagram.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the downstream pressure periodically, with a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tubes at ball valves (d1, d2) and open both.

TROUBLESHOOTING Pressure reducing valve reduces inlet pressure to steady pre-determined downstream pressure. A solenoid converts an electric signal to a hydraulic command.

��



Ball valves (d2) or (d3) are closed. Verify position. Open valves (d2, d3).




Measure ±10% of nominal voltage. Correct.


Valve does not open




Close downstream ball valve (d), valve remains open.






Slot on the base to be in a horizontal position with arrow pointing down.

Change position.

Pilot (a) faulty, no flow conditions,


Replace seal.


Upstream ball valve (d1) is closed. Check position. Open fully.

Restricting needle bolt(a1) is too closed or opened.

Change position Open or close slightly. Unstable

performance Inlet pressure too low.

Disconnect tube upstream. No firm stream.

Clean or replace.

PRESSURE REDUCING SUSTAINING VALVE 2- Way Operating instructions for 1.5" to 4" valves

��



a. Pilot PS-2way 68-500

b. Pilot PR-2way 68-410

c. Filter 81-1/4-24 (1.5"-2") 81-1/2- 2 (3"-4")

d. Solenoid (option) 30 NO

e. Ball Valves 34-1/2"

f. Needle restrictor bolt

g. Pressure gauge

h. Relay 28-200

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (c) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS � The ball valves (e) must be open. Closure of the

downstream valve (e2) closes the valve manually.

� The pilots (a, b) have a colored ring at the top identifying the spring inside.

� Open the needle bolt (f) 1- 2 turns. � Loosen the lock nut and tighten the bolts on both

pilots (a) and (b). � Start the pump. Valve stays closed or opens

slightly maintaining a high upstream pressure. Loosen the bolt of pilot (a) slowly until upstream pressure reaches the desired level.

� Loosen the bolt of pilot (b) until the required downstream pressure is reached.

� The valve’s closing time is adjusted with the needle bolt (f).

Closing will slow valve closure down and opening (f) will speed up the valve’s response.

� Wait until pressure stabilizes; make final adjustments and tighten the lock nuts on the pilots.

FOR ELECTRIC OPTION � Turn the manual override of the solenoid (d) 90

degrees and follow the above steps. � After making the adjustments, turn the override

to the original position. Connection of the wires to the solenoid (d) with 1/2"hub is described on the attached diagram.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the up and downstream pressure periodically with a quality liquid filled gauge and shrader valve adapter. Components WINTERIZING Drain the valve by disconnecting the tubes at ball valves (e) and open both.

TROUBLESHOOTING Pressure reducing pilot reduces inlet pressure to steady pre-determined downstream pressure. Pressure sustaining pilot maintains a minimum upstream pressure. A solenoid converts an electric signal to a hydraulic command. Diaphragm I.D. number can be found on the tip of the diaphragm

��



Downstream ball valve (e2) is closed. Verify position. Open ball valve (e2).



Solenoid (d), incorrect voltage.



Solenoid (d), faulty coil.


Valve does not open

Pilot (a) set point too high. Verify design data. Loosen bolt.


Close downstream valve (e2). Valve remains open.

Replace diaphragm. Refer to I.D.#




Solenoid (d), incorrect position of the manual override.

Slot in a horizontal position with arrow pointing down.

Change position.

Pilot (b) faulty, no flow conditions.

Unscrew pilot’s (b) bottom seat, dismantle seal and check it.

Replace seal.


Upstream ball valve (e1) is closed. Check position. Open valve (e1)

Needle valve (f) is too closed.

Tighten or loosen and check for stabilization

Open or close slightly. Unstable

performance Inlet pressure too low.

Disconnect tube upstream no firm stream.

Clean or replace.

PRESSURE REDUCING SUSTAINING VALVE 2- Way Operating instructions for �" to �" valves

��



a. Pilot PS-2way CX-SD (differential)

b. Pilot PR-2way CX-PR c. Filter 81-1/2-2 d. Solenoid (option) 30 NO e. Ball Valves 34- 1/2" f. Pressure gauge

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (c) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS � The ball valves (e) must be open. Closure of the

downstream valve (e2) closes the valve manually. � Loosen the lock nut and tighten the bolts on both pilots

(a) and (b). � Start the pump. Valve stays closed or opens slightly

maintaining a high upstream pressure. � Loosen the bolt of pilot (a) slowly until upstream

pressure reaches the desired level. � Loosen the bolt of pilot (b) until the required downstream

pressure is reached. The valve’s response time can be adjusted by the restrictor needle bolt (a1). Closing (a1) will slow down and opening (a1) will increase the valve’s closing speed.

� Wait until pressure stabilizes, make final adjustments and tighten the lock nuts on the pilots (a, b).

FOR ELECTRIC OPTION � Turn the manual override of the solenoid (d) 90 degrees

and follow the above steps. � After making the adjustments, turn the override to the

original position. Connection of the wires to the solenoid (d) with 1/2" hub is described on the attached diagram.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the up and downstream pressure periodically with a quality liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tubes at ball valves (e) and open both.

TROUBLESHOOTING Pressure reducing pilot reduces inlet pressure to steady pre-determined downstream pressure. Pressure sustaining pilot maintains a minimum upstream pressure. A solenoid converts an electric signal to a hydraulic command. Diaphragm I.D. number can be found on the tip of the diaphragm

��



Ball valves (e2) or (e3) are closed. Verify position. Open ball valves

(e2), (e3).








Valve does not open

Pilot (a) set point too high. Verify design data. Loosen bolt.


Close downstream valve (e2). Valve remains open.






Slot should be in a horizontal position with arrow pointing down.

Change position if arrow is not pointing down.

Pilot (a) faulty, no flow conditions.


Replace seal.


Upstream ball valve (e1) is closed. Check position. Open valve (e1)

Needle valve (a1, b1) is closed.

Tighten or loosen and check for stabilization


performance Clogged filter.

Disconnect upstream tube, no firm stream.

Clean or replace filter.

PRESSURE SUSTAINING VALVE 2- Way Operating instructions for 1.5" to 4" valves

��


��


a. Pilot 2-way 68-500 b. Filter 81-1/4-24


d. Ball Valves 34-1/4"

e. Pressure gauge f. Relay 28-200

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS � The ball valves (d) must be open. Closure of the

downstream ball valve (d2) closes the valve manually. � The pilot (a) has a colored ring on the top identifying the

spring inside. � Open the needle valve (a1) 1-2 turns. � Loosen the lock nut and tighten the adjustment bolt on

pilot (a). � Start the pump. The valve stays closed or opens slightly


pressure reaches the desired level. The valve’s response time is adjusted with the restrictor needle bolt (a1). Closing needle bolt (a1) will slow it down and opening (a1) will Speed up the valve’s response.




original position. Connection of the wires to the solenoid (c) with 1/2" hub is described on the attached diagram.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the upstream pressure periodically with a quality liquid filled gauge and shrader valve adapter.

WINTERIZING Drain the valve by disconnecting the tubes at ball valves (d) and open both. Operate the solenoid (c) periodically in the off season to prevent sticking.

TROUBLESHOOTING A sustaining valve maintains a preset pressure at the upstream side of the valve. Diaphragm I.D. number can be found on the tip of the diaphragm.

��


Problem

Cause Check Remedy

Downstream ball valve (d2) is closed. Verify position. Open valve (d2).




Measure ±10% of nominal voltage. Repair.



Valve does not open

Pilot (a), set point too high. Verify design data. Loosen bolt on top.


Close downstream valve (d). Valve remains open.




Dismantle, clean and re-assemble.



Change position.

Upstream ball valve (d1) closed. Verify position. Open valve (d).


Needle valve (a1) is totally closed. Check position. Open 1-2 turns.

Incorrect needle valve (a1) setting.

Regular setting open 1-2 turns.


performance Clogged filter (b).

Disconnect tube upstream No firm stream.

Clean or replace.

PRESSURE SUSTAINING VALVE 2- Way Operating instructions for �" to �" valves

��



a. Pilot 2-way CX-SD b. Filter 81-1/2- 2

c. Solenoid (option) 30 NO d. Ball Valves 34- 1/2"

g. Pressure gauge 61PIL66400

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Bolts of flanged valves should be tightened in a diagonal

sequence. ADJUSTMENTS � The ball valves (d) must be open. Closure of the

downstream ball valve (d2) closes the valve manually. � Loosen the lock nut and tighten the adjustment bolt on

pilot (a). � Start the pump. The valve stays closed or opens slightly


pressure reaches the desired level. � The valve’s response time is adjusted with the restrictor

needle bolt (a1). Closing needle bolt (a1) will slow it down and opening (a1) will speed up the valve’s response.




original position. Connection of the wires to the solenoid (c) with 1/2" hub is described on the attached diagram.

MAINTENANCE Keep the valve clear from weeds and dirt. Verify the downstream pressure periodically with a quality

liquid filled gauge and shrader valve adapter. WINTERIZING Drain the valve by disconnecting the tubes at ball valves

(d) and open both.

TROUBLESHOOTING A sustaining valve maintains a preset pressure at the upstream side of the valve. Diaphragm I.D. number can be found on the tip of the diaphragm.

��



Downstream ball valve (d2) is closed.

Verify position. Open downstream ball valve (d2).




Measure ±10% of nominal voltage. Repair.

No current Damaged wires. Replace.



Valve does not open

Pilot (a) set point too high. Verify design data. Loosen bolt on pilot

(a).


Close downstream ball valve (d2) valve remains open.






Slot to be in a horizontal position with arrow pointing down.

Change position.

Pilot restrictor needle (a1) is clogged

Unscrew pilot’s needle bolt (a1). Check for water passage.

Clean and reassemble.


Upstream ball valve (d1) is closed.

Check position. Open fully.


Pilot restrictor needle (a1) is partially clogged

Unscrew pilot’s needle bolt (a1). Check for water passage.

Clean and reassemble.

BOOSTER PUMP CONTROL VALVE Operating instructions for 2" to �" valves

��


Part Numbers Components

40-LS Limit Switch a.

81-1/4- 24 Filter b. 30 NO Solenoid g.

34- 1/2" Ball Valves d.

34-1/4 NE Needle Valves e.

21-1/2" Check valve f.

DCV Mechanical check valve g.

INSTALLATION � The arrow on the bonnet should match the flow direction. � The valve can be installed in any position at the

discharge side of the pump. � Use five layers of teflon tape for threaded valves. � Bolts on flanged valves need to be tightened in a

diagonal sequence. � Connect the limit switch (a) and the solenoid (c) to the

control panel. Connection of limit switch (a) should be open with the switch pressed by the position indicator. (See electric schematic on reverse side.)

ADJUSTMENTS � Check that ball valve (d) is open. � Manual override of the solenoid (c) is in the AUTO

position. � Needle valves (e1, e2) are open 1- 2 turns. � Start the pump. The valve will open. Opening rate can

be adjusted by needle valve (e1). � Shut off pump. The pump will run until valve closes and

limit switch is pressed. Closing rate can be adjusted by needle valve (e2).

� As limit is pressed the pump should shut off. � Connect the solenoid (c) wires according to the electric

schematic (de-energized when pump is off). � Adjust the opening speed (e1) and closing speed of the

valve (e2) according to the length of mainline. Note: a mechanical check valve reacts faster the CV application on the valve, and is many times

preferred. MAINTENANCE Keep the valve clear from weeds and dirt. Check the opening of needle valves (e1, e2) and also the location of the position indicator periodically. WINTERIZING Drain the mainline and/or valve by disconnecting the tubes at ball valves (d). Open the needle valves (e1 and e2).

TROUBLESHOOTING A booster pump valve prevents pressure surges caused by electric booster pumps start-ups and shut-off. Check valve feature is optional. Diaphragm I.D. number can be found on the tip of the diaphragm.

��





Needle valve (e1) doesn't drain. Closed or dirty. Open fully, re-adjust.




Valve does not open




Water keeps flowing from needle valve (e1) when valve is in OPEN position.

Replace diaphragm. Refer to I.D. #.

Solenoid (c) is clogged.

Disconnect solenoid at port 1. No water flow.

Clean.


Slot should be horizontal with arrow or dot pointing down.

Change position.


Clean or replace.

Needle valves (e2). Closed or dirty. Open fully, readjust.

Faulty check valves (g) or (f).

Verify proper function. Clean or replace.


Faulty connections Electric scheme correct

Position indicator or limit switch. Wrong position. Adjust. Pump does not

shut off Wrong wire hook-up.

Check electric schematic.

Correct in pump panel.

FLOW RATE CONTROL VALVE Operating instructions for 1.5" to 4" valves

��



a. 3-way Selector 35- 1/4" - 3

b. Filter 81-1/4"-24 c. Differential Pilot 29-300

d. Solenoid (option) 30 NC

e. Ball valves 34 -1/4"

f. Orifice Plate

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the valve. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Use five layers of teflon tape for all threaded valves. � Drill and tap a 1/4" hole on the pipe or PVC fitting

upstream of the orifice plate and install a 6mm tube from that port to port #1of pilot (c) and to the selector valve (a).

ADJUSTMENTS � The 3-way selector (a) must be in the A-position. � The O-port is used to manually open and the C-port to

close the valve. A neutral position, not facing any of the ports, locks the water in the bonnet, used in case the pilot (c) malfunctions.

� The headloss through the orifice for a certain flow rate is based on about 2.5 mwc (4 psi). The pilot’s (c) spring range is 2-5 mwc (3-8 psi) and allows 40% increase and 15 % reduction of the specified flow rate.

� Start the pump or main valve. � Unscrew the cap on top of the pilot (c). Tightening the

bolt will increase the flow rate and loosening will decrease the flow rate. Make adjustments turning the bolt 1/2 a turn at a time.

� Tighten the lock nut and also the cap on top of the pilot (c).

� For flow control of the backflush of a media filter, we recommend that the upstream water connection (b) is located at the filter of the hydraulic assembly, so that the pilot (c) is not contaminated.

FOR ELECTRIC OPTION � Turn the manual override of the solenoid (d) 90 degrees and

follow the above steps. � After making the adjustments turn the override to the original

position. Connection of the wires to the solenoid (d) with 1/2" hub is described on the attached diagram.

MAINTENANCE Keep the valve clear from weeds and dirt. Check the flow rate or pressure differential periodically and adjust the setting of the pilot (c) if necessary. Turn the handle of the 3-way selector (a) periodically to prevent sticking.

WINTERIZING Drain the valve by disconnecting the tubes at the access ports of the valve and at other locations where water can be trapped.

TROUBLESHOOTING Flow rate control valve delivers a constant flow by maintaining a preset pressure difference across an orifice. The solenoid converts electric signal to hydraulic command. Diaphragm I.D. number can be found on the tip of the diaphragm.

��













Correct.


Valve does not open



Punctured diaphragm. Turn 3-way selector (a) to port O water flows constantly.


Pilot (c), incorrect connection.

Check if connections on port (1) and (5) are reversed.

Correct.







Change position.

Pilot (d) incorrectly adjusted.

Check bolt on pilot (c). Readjust.

Clogged filter Check filter (b). Clean. Incorrect flow

Faulty pilot (c). Verify if dirty. Clean.


Valve opens or closes too much. Surging.

Install dripper or needle valve at port (2) of pilot (c).

FLOW RATE��

CONTROL VALVE Operating instructions for �" to �" valves

��



a. 3-way Selector 35- 1/4" - 6

b. Filter 81-1/2"-2 c. Differential Pilot 76- 200

d. Solenoid (option) 30 NC

e. Ball valves 34- 1/2"

f. Orifice Plate

INSTALLATION � The arrow on the bonnet should match the flow direction. � Filter (b) is installed at the upstream side of the orifice

plate. � The valve can be installed in any position. � If below ground level, use a valve box to protect it. � Drill and tap a 1/2" hole on the pipe or PVC fitting

upstream of the orifice plate and install an 8mm tube from that port to port #1of pilot (c) and to the selector valve (a).

ADJUSTMENTS � The 3-way selector (a) must be in the A-position. The O-

port is used to manually open and the C-port to close the valve. A neutral position, not facing any of the ports, locks the water in the bonnet, used in case the pilot (c) malfunctions.

� The headloss through the orifice for a certain flow rate is based on about 2.5 mwc (4 psi). The pilot’s (c) spring range is 2-5 mwc (3-8 psi) and allows 40% increase and 15 % reduction of the specified flow rate.

� Start the pump or main valve. � Unscrew the cap on top of the pilot (c). Tightening the

bolt will increase the flow rate and loosening will decrease the flow rate. Make adjustments turning the bolt 1/2 a turn at a time.

� Tighten the lock nut and also the cap on top of the pilot (c). � For flow control of the backflush of a media filter,

We recommend that the upstream water connection (b) will be located at the filter of the hydraulic assembly, so that the pilot (c) is not contaminated.

MAINTENANCE Keep the valve clear from weeds and dirt. Check the flow rate or pressure differential periodically and adjust the setting of the pilot (c) if necessary. Turn the handle of the 3-way selector (a) periodically to prevent sticking. WINTERIZING Drain the valve by disconnecting the tubes at the access ports of the valve and at other locations where water can be trapped. FOR ELECTRIC OPTION � Turn the manual override of the solenoid (d) 90 degrees and

follow the above steps. � After making the adjustments turn the override to the original

position. Connection of the wires to the solenoid (d) with 1/2" hub is described on the attached diagram.

TROUBLESHOOTING Flow rate control valve delivers a constant flow by maintaining a preset pressure difference across an orifice. The solenoid converts electric signal to hydraulic command. Diaphragm I.D. number can be found on the tip of the diaphragm.

��




Verify knob position.

Turn to A position.









Correct.


Valve does not open

Solenoid (d), faulty coil. Voltage okay, but no click. Change coil.


Turn 3-way selector (a) to port O, water flows constantly.


Pilot (c), incorrect connection.

Check if connections on port (1) and (5) are reversed.

Correct.







Change position.

Pilot (d) incorrectly adjusted.

Check bolt on pilot (c). Readjust.

Clogged filter Check filter (b). Clean. Incorrect flow

Faulty pilot (c). Verify if dirty. Clean.


Valve opens or closes too much. Surging.

Install dripper or needle valve at port (2) of pilot (c).

Engineering

Designer and operator manual dorot