Cashco 1000 HP Basic User Manual

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INSTALLATION, OPERATION & MAINTENANCE MANUAL

IOM-1000HP-

MODEL 1000HP - BASIC

PRESSURE REDUCING REGULATOR

SECTION I

I. DESCRIPTION AND SCOPE

The Model 1000HP is a pressure reducing regulator used to control downstream (outlet or P2) pressure to levels between 10 and 300 psig (0.7-20.6 Barg). Sizes are 1/2", 3/4", 1", 1-1/4", 1-1/2" and 2" (DN15, 20, 25, 32, 40 and

50).

The unit is designed for liquid, gaseous or steam service with proper trim utilization, and proper jet selection. Refer to Technical Bulletin 1000HP-TB for sizing, application and selection recommendations. Installation, operation and maintenance manuals (IOM's) also exist for the following other Model 1000 products:

1000LP-Basic 1000HP-Differential 1000HP-Cryogenic

SECTION II

Basic

12-13

CAUTION

For welded installations, all internal trim parts, seals and diaphragm(s) must be removed from regulator body prior to welding into pipeline. The heat of fusion welding will damage non-metallic parts if not removed. NOTE: This does not apply to units equipped with extended pipe nipples.

II. INSTALLATION

1. An inlet block valve should always be installed. An outlet block valve is recommended.

2. If service application is continuous such that shut down is not readily accomplished, it is rec om mended that an inlet block valve and a man u al bypass valve be installed.

3. Pipe unions must be installed to allow removal from piping. Trim can only be changed by unit removal from pipeline. If ﬂ anges are utilized, a lap joint ﬂ ange is required on the inlet end of the regulator to help align bolt holes as the cylinder screws into place.

4. An outlet pressure gauge should be located ap prox i mate ly ten pipe diameters down stream, and with in sight.

5. All installations should include a downstream relief de vice if the inlet pressure could exceed the pressure rating of any downstream equip ment or the maximum outlet pressure rating of the unit.

CAUTION

Installation of adequate overpressure protection is recommended to protect the regulator from overpressure and all downstream equipment from damage in the event of regulator failure.

Recommended Piping Schematic

For Pressure Reducing Station

CAUTION

The maximum outlet pressure listed on the name plate is the “upper operative limit” for the sens ing di a phragm. High er pres sures could damage the di a phragm. (Field hy dro static tests fre quent ly de stroy dia phragms. DO NOT HY DRO STAT IC TEST THRU AN IN STALLED UNIT; ISO LATE FROM TEST.)

6. Clean the pip ing of all foreign material in clud ing chips, welding scale, oil, grease and dirt before installing the regulator. Strainers are rec om mended.

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7. In placing thread sealant on pipe ends prior to en gage ment, ensure that excess material is re moved and not allowed to enter the regulator upon startup.

vertical pipe line. Rec om mend ed po si tion is with spring cham ber ver ti cal upwards. Orient to pre vent the spring cham ber vent hole from col lect ing rain wa ter or debris.

8. Flow Direction: Install so the ﬂ ow direction match es the arrow cast on the body.

9. For best performance, install in well drained hor i zon tal pipe, properly trapped if a steam ser vice application.

10. Basic regulator may be rotated around the pipe axis 360°

, and may be installed in a horizontal or

III. PRINCIPLE OF OPERATION

1. The Model 1000 is available in two variations: 1000LP (larger diaphragm) for downstream pressure control from 1-30 psig (0.07-2.06 Barg); 1000HP (small er diaphragm) for down stream pressure control from 10-300 psig (0.7-20.6 Barg), body size dependent.

2. Movement occurs as pressure variations reg ister on the diaphragm. The registering pres sure is the outlet, P range spring opposes di a phragm move ment. As out let pressure drops, the range spring push es the diaph ragm down, opening the port; as outlet pressure increases, the dia phragm pushes up and the port closes.

3. The Model 1000 includes a rocker arm in its op er a tion al mechanism. The rocker arm allows the regulator to operate ﬂ ow-to-open (FTO), rather than conventional ﬂ ow-to-close (FTC), which increases rangeability.

, or downstream pressure. The

11. Regulators are not to be direct buried under-

12. For insulated piping systems, recommen dation is

13. Cashco does not recommend ﬁ eld welding on the

SECTION III

5. The FTO design also is limited by a minimum

6. The Model 1000 includes an aspiration jet ef-

ground.

to not insulate regulator.

cyl in der (inlet) end of the body due to the pos si bil i ty of warpage.

setting is capable for a given inlet P

pressure.

This is a function of the ratio of the port area to diaphragm area. It is possible for there to be too high of an inlet pressure for the regulator to close off against. (Refer to 1000-TB, Tables 9 through 12 for limits.) Reduced ports, Option 1000-12, allow lower down stream (P

or outlet) pressure

settings for a given up stream (P1 or inlet) pres sure level.

pres sure drop. If the pressure drop is below 5 psid, an Option 1000-17 piston spring should be utilized to assist open ing the piston.

fect, due to the clearance of the piston from the body near the outlet. These clear ances vary as to whether the ﬂ uid is a gas (including steam), a liquid, or a viscous liquid (requires Option 1000-

27). Jets must be se lec ted to match one of these three general ﬂ uids. An improper jet selection will reduce perfor mance.

4. Due to the FTO design, there is a limit as to how low of a downstream (P

or outlet) pressure level

7. A complete diaphragm failure will cause the regulator to fail open.

SECTION IV

IV. STARTUP

1. Start with the block valves closed. A bypass valve may be used to maintain outlet pressure in the downstream system without changing the fol low ing steps.

2. Relax the range spring by turning the adjusting screw counterclockwise (CCW) a min i mum of three (3) full revolutions. This re duces the outlet (down stream) pres sure set point.

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3. If it is a “hot” piping system, and equipped with a bypass valve, slowly open the bypass valve to pre-heat the system piping and to allow slow expansion of the piping. Ensure proper steam trap operation if installed. Closely monitor out let (downstream) pressure via gauge to ensure not over-pressurizing. NOTE: If no bypass valve is

installed, extra caution should be used in start ing up a cold system; i.e. do everything slowly.

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4. Crack open the outlet (downstream) block valve.

5. Slowly open the inlet (upstream) block valve ob serv ing the outlet (downstream) pressure gauge. Determine if the regulator is ﬂ owing. If not, slowly rotate the regulator adjusting screw clockwise (CW) until ﬂ ow begins.

8. When ﬂ ow is established steady enough that the outlet (downstream) block valve is fully open, begin to slowly close the bypass valve if in stalled.

9. Develop system ﬂ ow to a level near its expected normal rate, and reset the regulator set point by turning the adjusting screw CW to increase outlet pressure, or CCW to reduce outlet pres sure.

6. Continue to slowly open the inlet (upstream) block valve until fully open.

7. Continue to slowly open the outlet (down stream) block valve, especially when the down stream piping system isn't pres surized. If the outlet (downstream) pressure exceeds the de sired pres sure, close the block valve and go to Step 2, then return to Step 4.

SECTION V

V. SHUTDOWN

1. On systems with a bypass valve, and where sys tem pressure is to be maintained as the regulator is shut down, slowly open the bypass valve while closing the inlet (up stream) block valve. Fully close the inlet (up stream) block valve. (When on bypass, the system pressure must be constantly observed and manually reg u lat ed.) Close the outlet (downstream) block valve.

SECTION VI

VI. MAINTENANCE

WARNING

SYSTEM UNDER PRESSURE. Prior to per form ing any maintenance, isolate the regulator from the system and relieve all pressure. Failure to do so could result in personal injury.

A. General:

1. Maintenance pro ce dures hereinafter are

based upon removal of the unit from the pipeline where in stalled.

10. Reduce system ﬂ ow to a minimum level and ob serve set point. Outlet pressure will rise from the set point of Step 9. The maximum rise in outlet pressure on de creas ing ﬂ ow should not exceed the stated upper limit of the range spring by greater than 30%; i.e. 10–40 psig (0.7-2.75 Barg) range spring, at low ﬂ ow the outlet pres sure should not exceed 52 psig (3.6 Barg). If it does, consult factory.

CAUTION

Do not walk away and leave a by passed regulator un at tend ed.

2. If the regulator and system are to both be shut down, slowly close the inlet (upstream) block valve. Close the outlet (downstream) valve only if reg u la tor removal is required.

4. Regulators originally supplied as “oxygen cleaned” (Options 1000-55) are assembled using special gasket sealant, Fluorolube GR-362 1, or equivalent. Cashco, Inc. rec om mends following factory cleaning speciﬁ cation #S-1134, or equiv a lent. Con tact factory for details.

B. Diaphragm Replacement:

1. Securely install the body (1) in a vise with the spring chamber (2) directed up wards.

WARNING

2. Owner should refer to owner's proce dures for removal, handling and cleaning of re us able parts, and disposal of nonreusable parts, i.e. gaskets, suitable sol vents, etc.

3. If desired, the gaskets may be lubricated with a light oil pro vid ed it is com pat i ble with the ﬂ uid.

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SYSTEM UNDER COMPRESSION. Prior to re mov ing ﬂ ange bolts, relieve spring com pres sion by backing out the adjusting screw. Failure to do so may result in ﬂ ying parts that could cause personal injury.

2. Remove closing cap (31) if provided. Relax range spring (27) by turning adjusting screw (6) CCW until removed from spring chamber (2).

Product of Fisher Scientiﬁ c Company

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3. Paint or embed a match mark between body casting (1) and spring chamber casting (2) along ﬂ anged area.

4. Remove all diaphragm nuts (9) and bolts (8). Remove nameplate (28).

5. Remove spring chamber (2), range spring (27) and spring button (4).

NOTE: The text hereafter will refer to “pusher

plate and stud" (13)" as a single part, for 1/2" – 1-1/4" sizes (DN15-DN32), and as two sep a rate parts, the “pusher plate (5)” and a “push er plate stud" (13)” for sizes 1-1/2" and 2" (DN40 & DN50).

6. Pry up the diaphragm(s) (20) and diaphragm gasket (19) around the perimeter of the body (1) diaphragm ﬂ ange to ensure that the diaphragm(s) (20) are not “sticking”. (Dia phragm gasket (19) is not used with a com po si tion (soft) diaphragm.)

7. Remove the diaphragm sub-assembly by slid ing the pusher plate and stud (13) and nut (11) in the direction of the regulator's inlet, ap prox i mate ly 1/2"-3/4" (12-20 mm). The push er plate and stud (13), stud nut (10), and stud collar (16) should disengage with the rocker arm (14) slot. Lift vertically for the diaphragm sub-assembly re mov al.

8. Place the pusher plate stud (13) in a sepa rate vise, gripping the stud (13) on the hex ago nal cast-in-place edges located on the un der neath side of the pusher plate stud. NOTE:

Do not remove the stud nut (10), stud collar (16) and the location locking cotter pin (15).

Loosen and remove nut (11).

9. Remove pressure plate (3) by lifting.

10. Pry loose pusher plate and stud (13) from diaphragm(s) (20) or from pusher plate gas ket (12). (Pusher plate gasket (12) is not used with a composition (soft) diaph ragm.) Remove the diaphragm(s) (20).

Diaphragm sub-assembly consists of items (10), (11), (12), (13), (15), (16) and (20). (Metal diaphragm de sign).

14. Install new diaphragm(s) (20) over pusher

plate and stud (13). NOTE: Refer to the quan-

tity of diaphragms (20) incorporated per the bill of materials listing. Depending on outlet pressure level, various quantities of metal diaphragms will be “stacked”.

15. Inspect pressure plate (3) to ensure no de for ma tion due to over-pressurization. If de formed, bent, or otherwise distorted, re place.

16. Ensuring that the curved outer rim of the pres sure plate (3) rests against the dia phragm (20) directly, place the pressure plate (3) over the pusher plate and stud (13). Place nut (11) onto the stud (13) and tighten. Rec om

mend ed

torques are as follows:

Body

Size

1/2"

3/4" – 1-1/4"

1-1/2" & 2"

DN15 DN20-DN32 DN40-DN50

Brass Trim

Metal/Comp

Diaphragm

25-30 ft-lbs 35-45 ft-lbs 50-60 ft-lbs

34-41 N-m 47-61 N-m 68-81 N-m

Stainless Trim

Metal

Diaphragm

45-50 ft-lbs. 45-50 ft-lbs. 80-90 ft-lbs.

61-68 N-m 61-68 N-m

108-122 N-m

Comp.

Diaphragm

25-30 ft-lbs. 35-45 ft-lbs. 50-60 ft-lbs.

34-41 N-m 47-61 N-m 68-81 N-m

11. Remove pusher plate gasket (12) from push er plate and stud (13).

12. Clean gasket sealing surface of pusher plate and stud (13) thoroughly.

13. Install new pusher plate gasket (12), if re quired, over pusher plate and stud (13).

(DO NOT USE FIN GERS TO HOLD DI A PHRAGMS (20) DURING TIGHT EN ING OF NUT (11).) Use two ﬂ ange bolts (8) to keep multiple di a phragms (20) bolt holes prop er ly aligned while tight en ing the stud nut (10).

CAUTION

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17. Remove cotter pin (15) securing stud nut (10) to lower end of pusher plate and stud (13), and replace with a new pin (15). (Do not allow

the stud nut (10) to move when the cotter pin (15) is removed.)

as those originally supplied. Sub sti tu tion may cause improper gasket com pres sion. It may

also adversely change the di a phragm setting, which will affect the unit's per for mance, i.e. Option 1000-45, non-as bes tos construction utilizes special gaskets.

18. Remove rocker arm shaft (17) and rocker arm (14). Measure inside of rocker arm (14) “prongs” as indicated below:

DIM MAT'L

A BRZ 7/8" (22mm) 1-5/32" (29mm) 1-7/16" (37mm)

B BRZ 5/8" (16mm) 25/32" (20mm) 3/4" (20mm)

A SST 13/16" (21mm) 1-1/16" (27mm) 1-7/16" (37mm)

B SST 9/16" (14mm) 23/32" (18mm) 3/4" (20mm)

DIM MAT'L 1-1/4" (DN32) 1-1/2" (DN40) 2" (DN50)

A BRZ 1-13/16" (46mm) 1-25/32" (45mm) 2-3/16" (56mm)

B BRZ 29/32" (23mm) 7/8" (22mm) 29/32" (23mm)

A SST 1-1/2" (38mm) 1-25/32" (45mm) 2-5/32" (55mm)

B SST 11/16" (17mm) 7/8" (22mm) 29/32" (23mm)

1/2" (DN15) 3/4" (DN20) 1" (DN25)

Valve Size

If any of the above dimensions are ex ceeded

by 1/8" (3 mm), re place rocker arm (14).

21. Using small gauge wire approximately 18" (500 mm) long, form a hook and place the hook over one prong of the rocker arm (14), and rotate the rocker arm (14) up until slack is removed in the mechanism. Secure the wire through a body (1) ﬂ ange bolt hole on the outlet side of the regulator.

22. Take the diaphragm sub-assembly (Step 16) and lower it down into the body (1) cavity off-center approximately 3/4"-1" (20-25 mm) and to wards the inlet side of the regulator. When fully low ered, slide the diaphragm subas sem bly horizontally to wards the regulator's out let. The wire of Step 21 should hold the rocker arm (14) up to allow engaging of the pusher plate and stud (13) (with stud nut (10) and stud collar (16)), so the rocker arm (14) prongs rest directly on the stud collar (16).

(Do not allow the rocker arm (14) prongs to get between the stud nut (10) and the stud collar (16).) Pull ﬁ rmly to remove wire

hold ing rocker arm (14) up.

23. Align diaphragm (20) bolt holes with body (1) ﬂ ange bolt holes. Set range spring (27) onto pressure plate (3), place spring button (4) on top of range spring (27). Place multi-pur pose, high temperature grease into de pres sion of spring button (4).

19. Check rocker arm shaft (17) for wear and straightness. Replace if damaged. Rein stall in body (1) through rocker arm (14). Apply thread sealant to the rocker arm shaft (17) threads prior to tightening. Make sure that the rocker arm shaft (17) enters the support slot opposite the threaded open ing, and does

24. Aligning the matchmarks, place spring cham ber (2) over the above stacked parts. Install all bolts (8), nuts (9) and nameplate (28) by hand tight en ing. Tighten bolting (8 and 9) in a cross pattern that allows spring chamber (2) to be pulled down evenly. Rec om mend ed torques are as follows:

not align crooked and re strained from full thread engagement of the rocker arm shaft (17). Make sure that the rocker arm (14) prongs that straddle the piston (24) hold the piston collar (23) against the piston (24); do not allow the rocker arm (14) prongs to push directly on the piston (24).

20. Clean the body (1) diaphragm ﬂ ange. Install a new diaphragm gasket (19). Composition (soft) diaphragms require no diaphragm gas ket. NOTE: Use only gaskets man u fac tured

by Cashco, Inc., that are of the same ma te ri al

* Minimum recommended torque regardless of gas ket ma te -

ri als. Some gasket materials may require higher bolt torques to obtain adequate seal.

Gasket ma te ri al may take a “set” with time; a re check of

torques should be made if the unit has been stored on the shelf for over 30 days.

Body Size Bolt Size All Diaphs.*-Torque

1/2" (DN15) 3/4" (DN20) 1" (DN25)

1-1/4" (DN32) 1-1/2" (DN40) 2" (DN50)

3/8"

7/16"

1/2"

9/16"

5/8"

25 ft-lbs. (34 N-m) 35 ft-lbs. (47 N-m) 45 ft-lbs. (61 N-m)

45 ft-lbs. (61 N-m) 80 ft-lbs. (108 N-m) 80 ft-lbs. (108 N-m)

5 IOM-1000HP-Basic

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NOTE: Never replace bolting (8 and 9) with just any bolting if lost. Bolt heads and nuts are marked with spec i ﬁ ca tion iden ti- ﬁ ca tion num bers. Use only proper grades as re placements.

25. Reinstall adjusting screw (6) with locknut (7); install closing cap (31) if provided.

26. Soap solution test around bolting (8 and 9), body (1), spring chamber (2) ﬂ anges, and cyl in der (21)-to-body (1) joint for leak age. Ensure that an outlet pressure is main tained during this leak test of at least mid-range spring level; i.e. 10-40 psig (0.7-2.75 Barg) range spring, 25 psig (1.75 Barg) test pres sure min i mum. Use 100 psig (7.0 Barg) min i mum inlet pres sure to leak test. Actual service con ditions should be used if in ex cess of the minimum con di tions.

C. Special Instructions for Diaphragm

Removal.

1. If Option 1000-3, Handwheel or Tee-bar, is uti lized, the adjusting screw (6) and locknut (7) are replaced re spec tive ly by handwheel/ tee-bar adjusting screw (6) and locking le ver (7).

2. Use only gaskets of the same material as those originally utilized. Cashco's Option 1000-45, non-asbestos construction, uti liz es spe cial gas kets.

D. Diaphragm Setting Adjustment:

1. In the previous “Sub-Section B. Diaph ragm Replace ment”, care was taken to prevent re mov al of the stud collar (16) and stud nut

(10). Location of the stud nut (10) is a critical ad just ment for a Model 1000 regulator.

2. Not removing the stud nut (10) will provide per for mance equal to original factory per form ance when a diaphragm(s) (20) is re placed with a like diaphragm(s) (20). How ever, if the stud nut (10) is removed, or a switch is made from metal to composition diaphragm (20), or vice versa, the dia phragm setting should be checked.

3. Follow procedure “Sub-Section B. Dia phragm Re place ment” to the point of re mov ing diaphragm(s) (20), Step 14. Remove di a phragm gasket (19) and pusher plate stud gas ket (12). Obtain a ﬂ at 12" x 1-1/2" x 1/4" (300 mm x 40 mm x 6 mm) plate bar with a 3/4" (20 mm) hole drilled in the center. Hook the pusher plate stud (13) into the rocker arm (14) prongs prop er ly. Pull ﬁ rmly up on the pusher plate stud (13) to ensure that all slack is re moved from the mech a nism and that the piston (24) is seat ed ﬁ rmly. Relax the pulling and place the ﬂ at bar over the pusher plate stud (13) with the stud (13) passing through the hole of the bar. Again, pull ﬁ rmly up to remove mech a nism slack. One of three positions will be reached:

a. Diaphragm setting too high. Pusher plate

stud (13) will lift the ﬂ at bar over 0.020" (0.50 mm).

b. Diaphragm setting acceptable. Bar lift ed

be tween 0.010"-0.020" (0.25-0.50 mm).

c. Diaphragm setting too low. Bar lifted less

than 0.010" (0.25 mm), or failed to be lifted.

4. The castle style stud nut (10) has six lo ca tions per revolution to align the stud nut (10) slots with the drilled hole through the pusher plate stud (13). Each stud nut (10) slot represents a movement up/down of 0.010" (0.25 mm).

NOTE: The ideal diaphragm set ting is 0.015" (0.38 mm) high, and better per for mance is usu al ly obtained when the di a phragm is slight ly higher rather than low er. As the measuring of thousandths of an inch is dif ﬁ cult with such a procedure, it is rec om mended that the “null” position be found where the di a phragm (20) is ﬂ ush with the body (1) ﬂ ange (bar ap- prox i mate ly at 0.000" (0.00 mm)). Remove

the push er plate stud (13), rotate the stud nut (10) one or two slots CCW to bring the setting to 0.010"-0.020" (0.25-0.50 mm) high.

Checking diaphragm setting.

6 IOM-1000HP-Basic

Page 7

5. Place cotter pin (15) through the slot/hole, bend over ends.

6. Continue reassembly per Sub-Section B. Di a phragm Replacement, Step 14.

E. Trim Removal and Replacement

1. Install body (1) horizontally in a vise with the spring chamber (2) directed upwards, and the body (1) held at the outlet end.

2. Use a box end wrench or socket, with a lever length of at least 24 inches (600 mm), and place it over the hex surfaces of the cylinder (21). The wrench should be rapped with a ham mer to loosen.

CAUTION

Take precaution to not allow the piston (24) to fall from within the cylinder (21); tip cylinder with hex end down.

3. Continue to unscrew cylinder (21) until re moved. The piston (24) and piston collar (23) should come out by gravity with the cylinder (21) removal.

4. If an Option 1000-17 piston spring (30) is utilized, it also should be removed and re placed at trim replacement.

5. Inspect inside surface of cylinder (21) at four points:

a. Valve seat (21.2). Check for ero sion/

wear on seat ing surfaces. If wear is ex ces sive, con sider utilizing Option 100015, stel lited seat sur faces.

b. Seat (21.2). Check for wire drawing

be tween cyl in der (21.1) and valve seat (21.2) where pressed in. If wear exists here, an Option 1000-14, integral seat, should be utilized as a re place ment.

c. Flow induced wear at expansion zone

where ﬂ uid turns to enter the piston (24) center.

d. Where the piston (24) ribbed guides bear

(guide zone).

If wear is signiﬁ cant at any of these points,

both cylinder sub-assembly (21) and piston sub-assembly (24 or 24, 25 and 26) should

CYLINDER SUB-ASSEMBLY (21) WITH

PISTON (24) — METAL SEATED

CONSTRUCTION

be replaced. (Cashco, Inc., does not rec om mend attempting to replace the valve seat (21.2) by pressing out and then re-pressing in. Cashco, Inc., also recom mends that a cyl in der (21) and piston (24 or 24, 25 and 26) be replaced as a set. Composition seat discs (25) may be re placed individually.)

6. If a composition (soft) seat trim design is uti lized, use the following sub-steps:

a. Tighten the “ﬂ ats” of the seat disc screw

(26) within a vise. Firmly hand-grip the piston (24) and turn CCW to loosen the seat disc screw (26). If too tight, place a screwdriver or similar rod within the pis ton (24) port holes and rotate. Remove the piston (24), and inspect for raised burrs around the port holes if a device is used to loosen; deburr as re quired. NOTE: Do

not grip the piston (24) with a wrench.

b. Remove the seat disc (25) and clean the

re cessed piston (24) area where the seat disc (25) is placed. If the edges which form the recess of the piston (24) are worn, also replace piston (24) and seat disc screw (26).

c. Place seat disc (25) into recessed end of

piston (24).

d. Place thread sealant on threaded por tion

of seat disc screw (26), and manu ally ro tate piston (24) into seat disc screw (26) (still ﬁ xed in vise) to secure seat disc (25). Tight en seat disc screw (26) ﬁ rmly. Do not over-tighten to the point of em bed ding

7 IOM-1000HP-Basic

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the seat disc screw (26) into the seat disc (25); the seat disc (25) should lay ﬂ at with no rounded sur face. A mech anical aid is nor mal ly not required; hand-tightening is nor mal ly suf ﬁ cient.

7. If utilized, place piston spring (30) over small er end of cylinder (21).

8. Insert piston assembly (24 metal seat; 24, 25 and 26 comp. seat) into end of cylinder (21).

9. Place piston collar (23) over end of piston (24), ensuring that the spherical surface of the piston (24) and the piston collar (23) bear against each other.

10. Clean the body (1) cavity through the open ings. Clean the “jet area” just inside the body (1) outlet end through which the piston (24) projects. Clean all parts to be reused. NOTE:

On valves originally sup plied with Option 1000-55, “ox y gen clean”, main te nance must in clude a level of clean li ness equal to Cashco, Inc's., cleaning standard #S-1134. Contact factory for details.

12. Lubricate the cylinder (21) threads lightly with thread sealant. Insert the entire trim stack into the body (1) opening and screw until tightly seated. Using the ham mer and wrench handle, impact the cylinder (21) into the body (1). NOTES: 1. Take special pre cau tion to

keep piston collar from getting “cocked” at an angle when inserted. 2. On 2" brass bodies (1) with brass trim, a TFE body O-ring (43) is utilized to seal between the body (1) and the cylinder (21) sub-as sem bly.

13. Inspect the body (1) outlet end to ensure that the piston (24) is located nearly concentric to the body (1) bore in the jet area with clear ance. Under no conditions should the piston (24) be touching the body (1). Use two pencils or similar shafts to place in inlet and outlet ends of regulator and alternately push on each end of the piston (24) to ensure free movement. (Total move ment is ap prox i mate ly 1/8" (3 mm).)

14. Bench test unit for suitable operation and seat leakage. NOTE: Regulators are not nor mal ly

tight shutoff devices. Pressure must build above setpoint for best shutoff.

11. Use special care cleaning the ﬂ at mating sur fac es of the body (1) and cylinder (21) shoulder, as this pressurized joint is metalto-metal with no gasket.

15. Soap solution test around cylinder (21)-tobody (1) con nec tion for leakage. Test pres sure should be a minimum of 100 psig (7.0 Barg) at the inlet, or actual service con di tions if high er.

SECTION VII

VII. TROUBLE SHOOTING GUIDE

1. Erratic operation, chattering.

Possible Causes Remedies

A. Oversized regulator; inadequate rangeability. A1. Check actual ﬂ ow conditions, resize for minimum and maximum ﬂ ow.

B. Worn piston/cylinder; inadequate guiding. B. Replace trim.

C. Flow induced instability. C1. Get straight runs of piping (5 diameters upstream, 10 downstream)

D. Improper (oversized) jet. D. Replace existing piston with new piston with proper jet.

E. Plugged trim. E. Remove trim and check for plugged holes in piston, or debris in guide

A2. Increase ﬂ ow rate. A3. Decrease pressure drop; decrease inlet pressure by placing a throttling oriﬁ ce in inlet piping union. A4. Replace full oriﬁ ce with reduced oriﬁ ce; i.e. new cylinder required.

to and from regulator. C2. Ensure outlet velocity is not excessive; use pipe reducer close to regulator outlet. C3. Add next higher range spring. Contact factory. C4. If composition diaphragm, switch to metal diaphragm.

zone or jet zone.

8 IOM-1000HP-Basic

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2. Regulator outlet (downstream) pressure too low.

Possible Causes Remedies

A. Setpoint too low. A. Turn adjusting screw down (CW) to increase setpoint.

B. Regulator undersized. B1. Conﬁ rm by opening bypass valve together with regulator.

B2. Check actual ﬂ ow conditions, resize; if regulator has inadequate capacity, replace with larger unit.

C. Plugged inlet strainer. C. Remove strainer screen and clean; consider leaving screen out.

D. Plugged trim. D. Remove trim and check for plugged holes in piston, or debris in guide

zone or jet zone.

E. Incorrect range spring (turning adjusting

E. Replace range spring with proper higher range. Contact factory. screw CW does not allow bringing pressure level up to proper level).

F. Too much droop. F1. Review droop expected. (See 2.B1 above.)

F2. Diaphragm setting too low; check setting and raise as required.

F3. Consider composition diaphragm over metal.

F4. Improper jet; make sure jet matches actual ﬂ uid.

G. Restricted diaphragm movement (pressure plate hitting upstops)

G1. Diaphragm setting too high; check and lower as required.

G2. Ensure no moisture in spring chamber at temperatures below freeze point.

Ensure no dust or debris entering vent opening. If rainwater or debris can

enter, reorient spring chamber.

H. Restricted diaphragm movement (overstretched diaphragm).

H1. Diaphragm setting too low; check and increase as required.

H2. Ensure no moisture in spring chamber at temperatures below freeze point.

Ensure no dust or debris entering vent opening. If rainwater or debris can

enter, reorient spring chamber.

3. Leakage through the spring chamber vent hole.

Possible Causes Remedies

A. Normal-life diaphragm failure. A. Replace diaphragm.

B. Abnormal short-life diaphragm failure. B1. Can be caused by excessive chattering. See No. 1 to remedy chatter.

B2. Can be caused by corrosive action. Consider alternate diaphragm material.

B3. For composition diaphragms, ensure not subjecting to over-temperature conditions.

B4. Downstream (outlet) pressure buildup occurring that overstresses diaphragms.

C. Pusher plate gasket leaking. C. Replace gasket.

D. Improper (oversized) jet. D. Replace existing piston with new piston with proper jet.

E. Plugged trim. E. Remove trim and check for plugged holes in piston, or debris in guide

zone or jet zone.

4. Excessive pressure downstream.

Possible Causes Remedies

A. Regulator not closing tightly. A1. Overly compressed range spring; i.e. approaching solid height. Use next

higher range spring. A2. Inspect the seating. Clean and lap metal seat surfaces; replace if lapping does not remedy. If composition seats are depressed, nicked or embedded with debris, replace seat disc. A3. Diaphragm setting too high; check setting. A4. Inlet pressure too high for oriﬁ ce size; check permissible inlet (P level for a given outlet. Change to reduced port if required.

) pressure

A5. Leakage past pressed in valve seat ring; consider integral seat. A6. When diaphragm sub-assembly was put into place, the rocker arm got between the stud collar and the stud nut rather than on top of the stud collar.

B. Downstream block. B. Check system; isolate (block) ﬂ ow at regulator inlet, not outlet. Relocate

regulator if necessary.

C. No pressure relief protection. C. Install safety relief valve, or rupture disc.

D. Restricted diaphragm movement. D1. Diaphragm setting too high; check and lower as required.

D2. Ensure no moisture in spring chamber at temperatures below freeze point. Ensure no dust or debris entering vent opening. If rainwater or debris can enter, reorient spring chamber.

9 IOM-1000HP-Basic

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5. Sluggish operation.

Possible Causes Remedies

A. Plugged spring chamber vent. A. Clean vent opening.

B. Plugged piston or jet zone. B. Remove trim and clean.

C. Fluid too viscous. C. Heat ﬂ uid.

D. Improper (undersized) jet. D. Replace existing piston with new piston for viscous service; i.e. Option 1000-27.

6. Frequent resetting of setpoint.

Possible Causes Remedies

A. Over-pressurization downstream resulting in:

1. Bent metal diaphragm(s).

2. Sprung rocker arm.

3. Range spring overstressed/fatigued.

A1. Replace diaphragms. Correct potential source of downstream overpressure.

A2. Check measurements of rocker arm. Replace if necessary.

A3. Replace range spring; consider next higher range spring.

SECTION VIII

VIII. ORDERING INFORMATION NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR

To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on the metal name plate and attached to the unit. This information can also be found on the Bill of Material (“BOM”), a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code typical format as follows: (last digit is alpha character that reﬂ ects revision level for the product).

–

NEW REPLACEMENT UNIT:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. With this information they can provide a quotation for a new unit including a complete description, price and availability.

CAUTION

Do not attempt to alter the original construction of any unit without assistance and approval from the factory. All purposed changes will require a new name plate with appropriate ratings and new product code to accommodate the recommended part(s) changes.

–

PARTS "KIT" for FIELD REPAIR:

Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. Identify the parts and the quantity required to repair the unit from the “BOM” sheet that was provided when unit was originally shipped.

NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” reﬂ ect minimum parts required for inspection and rebuild, - "Soft Goods Kit". Those in column “B” include minimum trim replacement parts needed plus those "Soft Goods" parts from column "A".

If the "BOM" is not available, refer to the crosssectional drawings included in this manual for part identiﬁ cation and selection.

A Local Sales Representative will provide quotation for appropriate Kit Number, Price and Availability.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or speciﬁ cations of such product at any time without notice. Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Cashco, Inc. product remains solely with the purchaser.

10 IOM-1000HP-Basic

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11 IOM-1000HP-Basic

Page 12

ITEM NO. DESCRIPTION

1. BODY & BODY ASSY

2. SPRING CHAMBER

3. PRESSURE PLATE

4. SPRING BUTTON

5. PUSHER PLATE

6. ADJUSTING SCREW

6. HANDWHEEL ASSY (-3 OPT)

6. TEE-BAR ASSY (-3 OPT)

7. ADJUSTING SCREW LOCK NUT

7. LOCKING LEVER (-3 OPT) 7 SEALING LOCK NUT (-1 OPT)

8. FLANGE BOLT

9. FLANGE NUT

10. STUD NUT

11. PRESSURE PLATE NUT

12. PUSHER PLATE GASKET

13. PUSHER PLATE STUD

14. ROCKER ARM

15. COTTER PIN

ITEM NO. DESCRIPTION

16. STUD COLLAR

17. ROCKER ARM SHAFT

18. BODY PLUG

19. DIAPHRAGM GASKET

20. DIAPHRAGM(S)

21. CYLINDER ASSEMBLY

21.1 CYLINDER

21.2 VALVE SEAT

23. PISTON COLLAR

24. PISTON

25. SEAT DISC

26. SEAT DISC SCREW

27. RANGE SPRING

28. NAME PLATE

29. SEAT CONE (-15 OPT)

30. PISTON SPRING (-17 OPT)

31. CLOSING CAP (-1 OPT)

32. CLOSING CAP GASKET (-1 OPT)

33. SPRING CHAMBER PIPE PLUG (-1 OPT)

Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: [email protected]

Printed in U.S.A. IOM-1000HP-BASIC

Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No. +49 3342 4243136 www.cashco.com Email: [email protected]

Cashco do Brasil, Ltda. Al.Venus, 340 Indaiatuba - Sao Paulo, Brazil PH +55 11 99677 7177 Fax. No. www.cashco.com Email: [email protected]