INSTALLATION, OPERATION & MAINTENANCE MANUAL
PI
SRV
Outlet
@ P
2
Supply
@ P
1
(Shaded portion for steam/condensate systems)
Model 1000HP-1+6
Diffe rential
Bypass
Blowdown-Drain Blowdown-Drain
PI
IOM-1000HP-
Differential
MODEL 1000HP - DIFFERENTIAL
SECTION I
I. DESCRIPTION AND SCOPE
The Model 1000HP-1+6 and 1000HP-1+8 are dif fer en tial pressure reducing regulators used to control dif fer en tial
pressure between downstream (outlet or P
are 1/2" , 3/4", 1", 1-1/4", 1-1/2" and 2" (DN15, 20, 25, 32, 40 and 50). With proper trim uti li za tion and jet selection,
this unit is suitable for liquid, gaseous, or steam service. Refer to Technical Bulletin 1000HP-DIFF-TB for sizing,
application and selection rec om men da tions.
II. INSTALLATION
1. An inlet block valve should always be installed.
An outlet block valve is desirable.
2. A manual bypass valve is recommended for “hot
piping” systems to assist in piping warm-up at
startup.
) pressure and a loading (P
2
SECTION II
) pressure to the spring chamber. Sizes
Load
12-13
3. An isolation valve on the loading line is not rec om -
4. Pipe unions must be installed to allow removal
DO NOT HYDROSTATIC TEST THROUGH AN IN STALLED UNIT; ISOLATE FROM TEST. DO NOT
HY DRO STAT IC TEST THE LOADING PRESSURE
WITH OUT PRESSURE IN THE MAIN REGULATOR.
The name plate indicated outlet pressure rating, if
reached, may cause internal damage. Refer to Tech ni cal
Bulletin Model 1000HP-DIFF-TB, Table 3 for “emer gen cy
overpressure level” that will not do irrepairable internals
damage. In addition, note on the name plate that the
Inlet and Outlet pressure and tem per a ture ratings are
at different levels.
mend ed. The annular body ring of the 1000HP-1+8
may be piped to a safe drainage point, but no valve
should be installed in the drain line.
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. NOTE: Cashco does not rec-
om mend fi eld welding on the cylinder (inlet) end
of the valve due to the possibility of warpage.
CAUTION
Recommended Piping Schematic for
Differential Pressure Reducing Station
5. An outlet pressure gauge should be located ap prox i mate ly ten pipe diameters downstream, and
within sight. A loading pressure (or differential
pressure) gauge is rec om mend ed.
6. All installations should include a downstream re lief device if the inlet pressure could exceed the
pressure rating of any downstream equipment or
the maximum outlet pressure rating of the unit.
7. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt before
in stall ing the regulator. Strainers are rec om mend ed.
8. 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.
9. Flow Direction: Install so the fl ow direction match es
the arrow cast on the body.
10. For best performance, install in well drained hor i zon tal pipe, properly trapped if a steam ser vice
ap pli ca tion.
diaphragm design): Regulator may be rotated
around the pipe axis 360° and may be installed
in a horizontal or vertical pipeline.
11. Differential Regulator – (Refer to Dwg. Opt-1+6
for single diaphragm or Dwg. Opt-1+8 for double
III. PRINCIPLE OF OPERATION
1. The differential Model 1000HP is also available
in two options: 1000HP-1+6 is single diaphragm
con struc tion; 1000HP-1+8 is double diaphragm
con struc tion. The dou ble diaphragm construction
prevents the loading fl uid from direct mixing with
the system fl uid in case of di a phragm failure.
2. Movement occurs as pressure variations register
on the diaphragm. One pressure is the outlet (p
or down stream pressure, which registers on the
“un der neath” side of the diaphragm. The second
pressure reg is tered is the loading (P
in the spring chamber “above” the di a phragm. The
range spring determines the differential pres sure
level (P
). As outlet (P2) pressure drops, the
Set
range spring pushes the diaphragm down, open ing the port; as outlet (P2) pressure in creas es,
the diaphragm pushes up and the port closes.
As the loading (P
) pressure varies, the outlet
Load
(P2) pressure tends to follow. An increase in P
(∆P
an equal amount (∆P
P
) will increase outlet P2 pressure by near ly
Load
will have a similar effect on outlet P2 pres-
Load
= ∆P2); a decrease in
Load
sure.
) pres sure
Load
12. Regulators are not to be direct buried un der -
SECTION III
)
2
∆P
P2 > P
P2 = P
∆P
Load
ground.
5. The Model 1000 includes an aspiration jet effect,
due to the clearance of the piston from the body
near the outlet. These clearances vary as to
whether the fl uid is a gas (including steam), a liquid,
or a viscous liquid (required Opt-27). Jets must
be selected to match one of these three general
fl uids. An improper jet will reduce per for mance.
NOTE: The regulator requires minimum output
pressure level or the regulator will not close.
= P1 - P
Sizing
Load
Load
Differential
2
+ P
Set
= P2 - P
Load
1000HP-1+6
DIFFERENTIAL SCHEMATIC
RANGE SPRING:
SETTING @ P
Set
LOADING
FLUID @ P
Diaphragm
Load
OUTLET
@ P
2
& T
2
3. The Model 1000 includes a rocker arm in its operation mechanism. The rocker arm allows the
regulator to op er ate fl ow-to-open (FTO), rather
than conventional fl ow-to-close (FTC), which
in creas es rangeability.
4. Due to the FTO design, there is a limit as to how
low of a downstream (P
setting is capable for a given inlet P
or outlet) pressure level
2
pressure.
1
This is a function of the ratio of the port area to the
diaphragm area. It is possible for there to be too
high of an inlet pressure for the regulator to close
off against. (Refer to 1000HP-DIFF-TB, Ta bles 9,
10, 11 and 12 for limits.) Reduced port, Opt-12,
allows lower down stream (P
settings for a given upstream (P
or outlet) pres sure
2
or inlet) pressure
1
level.
2
6. For a 1000HP-1+6 (single diaphragm) design, a
com plete diaphragm failure will cause the fl uids
to mix in the spring chamber or loading pressure
piping system.
7. For a 1000HP-1+8 (double diaphragm) design, a
complete diaphragm failure will cause the reg u la tor
to fail open, leaking fl uid through the annular ring
vent hole.
NOTE: Composition (soft) diaphragms may be
utilized only on -1+6 single diaphragm con struc tion.
8. For viscous fl uids normally heated (heavy fuel
oil), it may be desirable to include a fl ow-through
spring cham ber, the -65 Option.
IOM-1000HP-Dif fer en tial
SECTION IV
IV. STARTUP
1. Start with the block valves closed. A by pass valve
may be used to maintain outlet pressure in the
down stream system without changing the fol low ing steps.
2. Remove closing cap and relax the range spring
by turning the adjusting screw counterclockwise
(CCW) a minimum of three (3) full revolutions.
This reduces the outlet (downstream) pressure
set point.
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 outlet
(down stream) pressure, via gauge, to en sure not
over-pressurizing. NOTE: If no bypass valve is
in stalled, extra caution should be used in starting
up a cold system; i.e. do everything slow ly.
CAUTION
Do not walk away and leave a bypassed reg u la-
tor unattended!
rotate the regulator adjusting screw clockwise
(CW) until fl ow be gins.
6. Continue to slowly open the inlet (upstream) block
valve until fully open.
7. Continue to slowly open the outlet (downstream)
block valve, especially when the downstream piping sys tem isn’t pressurized. If the outlet (down stream) pressure exceeds the desired pressure,
close the block valve and go to Step 2, then return
to Step 4.
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 installed.
9. Set the regulator set point (P
ad just ing screw clockwise (CW) to increase outlet pres sure or CCW to reduce outlet pressure.
The outlet (P
will approximate the desired dif fer en tial pressure
when loaded with P
10. Pressurize the source of loading (P
and allow to fi ll the spring chamber cavity. Slightly
open the bleeder valve to vent any air as the spring
chamber is fi lling.
) pressure under these conditions
2
.
Load
) by turning the
set
) pres sure
Load
4. Crack open the outlet (downstream) block
valve.
5. Slowly open the inlet (upstream) block valve ob serv ing the outlet (downstream) pressure gauge.
De ter mine if the regulator is fl owing. If not, slowly
SECTION V
V. SHUTDOWN
CAUTION
Loading Pressure must be shut off before shut ting
down the system pressure.
1. To prevent force imbalances and possible di a phragm failure, the loading pressure (P
always be shutdown fi rst from its source of pres sure.
Systems se quenc ing must ensure this oc curs.
Load
) should
11. Develop system fl ow and pressure and readjust
set point as required to obtain desired response.
Per for mance should be analyzed at minimum and
maximum fl ow levels.
12. Install closing cap.
2. It is recommended that manual operation not be attempted by a bypass valve during a shutdown.
3. When the loading pressure (P
down, the regulator outlet pressure (P2) should
decrease substantially. When this is observed,
the inlet (upstream) block valve may be closed.
) has been shut-
Load
3
IOM-1000HP-Dif fer en tial
VI. MAINTENANCE
SECTION VI
(19) is not used with a composition (soft)
diaphragm.)
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 procedures hereinafter are based
upon removal of the unit from the pipeline
where installed.
2. Owner should refer to owner’s procedures for
re mov al, handling and cleaning of reusable
parts, and dis pos al of non-reusable parts, i.e.
gaskets.
3. If desired, the gaskets may be lubricated with
a light oil provided it is com pat i ble with the
fl uid.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vice with the
spring chamber (2) directed upwards.
NOTE: The text hereafter will refer to:
a. The -1+8 double di a phragm op tion al
con struc tion (-1+6 single di a phragm
con struc tion is sim i lar. Text regarding
com po si tion diaphragm(s) (20) applies
only to -1+6 op tion). Text portions deal ing with body spacer (42), diaphragm
spacer (41) and sep a ra tion of total di a phragm (20) quantity into two “stacks”
applies only to -1+8 option.
b. The “pusher plate and stud” (13) as a
single part for 1/2" – 1-1/4" sizes and
as two separate parts, a “pusher plate”
(5) and a “pusher stud” (13) , for 1-1/2"
and 2" sizes.
7. Pry up the diaphragm(s) (20) and diaphragm
gas ket (19) around the perimeter of the body (1)
di a phragm fl ange to ensure the diaphragm(s)
(20) are not “stick ing”. (Di a phragm gasket
(19) is not used with a com po si tion (soft)
diaphragm.)
8. Remove diaphragm subassembly by sliding
the push er plate and stud (13), body spacer
WARNING
SPRING UNDER COMPRESSION. Prior to re mov ing fl ange bolts, relieve spring compression by
back ing out the adjusting screw. Failure to do
so may result in fl ying parts that could cause
personal injury.
2. Remove closing cap (31). Relax range spring
(27) by turning adjusting screw (6) CCW until
re moved from spring chamber (2).
3. Paint or embed a match mark between body
casting (1), spring chamber casting (2), and
body spacer (42) along fl anged area.
4. Remove all diaphragm fl ange nuts (9) and
bolts (8). Remove nameplate (28).
5. Remove spring chamber (2), spring button (4)
and range spring (27).
6. Pry up the diaphragm(s) (20) and diaphragm
gasket (19) around the perimeter of the spring
chamber (2) fl ange to ensure the diaphragm(s)
(20) are not “sticking”. (Di a phragm gasket
Diaphragm subassembly consists of items (10), (11),
(12), (13), (15), (16), (20), (41), (42) and (50). (Metal
di a phragm design.)
(42) and nut (11) in the direction of the reg u la tor inlet, approximately 1/2"–3/4" (15-20
mm) The pusher plate and stud (13), stud nut
(10), and stud collar (16) should dis en gage
with the rocker arm (14) slot. Lift ver ti cal ly
for di a phragm subassembly re mov al, carefully hold ing the assembly at its outer edge
to prevent the body spacer (42) from falling
from be tween the diaphragm(s) (20).
4
IOM-1000HP-Dif fer en tial
9. Place the pusher plate stud (13) in a separate
vise, gripping the stud (13) on the hexagonal
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).
10. Loosen and remove nut (11).
plate (3) over the pusher plate and stud (13).
Place nut (11) onto the stud (13) and tighten.
Recommended torques are as follows:
Body Size Metal Diaphragm Comp. Diaphragm
3/8" – 1/2" 45–50 ft. lbs. 25–30 ft. lbs.
3/4" – 1" 45–50 ft. lbs. 30–45 ft. lbs.
1-1/4" – 2" 80–90 ft. lbs. 50–60 ft. lbs.
11. Lift and remove pressure plate (3) and O-ring
(50).
12. Remove upper diaphragm(s) (20), diaphragm
spacer (41) and body spacer (42).
13. Pry loose pusher plate and stud (13) from lower
diaphragm(s) (20) or from lower pusher plate
gasket (12). (Pusher plate gasket (12) is not
utilized with composition (soft) di a phragm.)
Remove the diaphragm(s) (20).
14. Remove pusher plate gasket (12) from push er
plate and stud (13).
15. Clean gasket sealing surfaces of pusher plate
and stud (13), spring chamber (2), body (1),
and pres sure plate (3) thoroughly.
16. Install new pusher plate gasket (12) over
pusher plate and stud (13).
17. Install one-half of total quantity of new
diaphragm(s) (20) over pusher plate and stud
(13). NOTE: Refer to quantity of diaphragms
(20) incorporated in the bill of materials listing. Depending on outlet pressure level,
var i ous quantities of metal diaphragms will be
“stacked”. They should always be in multiples
of two for -1+8 option.
Use two fl ange bolts (8) to keep mul ti ple
di a phragms’ (20) bolt holes prop er ly aligned
while tight en ing the nut (11).
CAUTION
Do not use your fi ngers to hold diaphragms (20)
during tightening of nut (11)!
23. 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.)
24. Remove rocker arm shaft (17) and rock er
arm (14). Measure inside of rocker arm (14)
“prongs” as in di cat ed in the following di a gram.
If either of the below di men sions are exceeded
by 1/8" (3mm), re place rocker arm (14).
18. Place diaphragm spacer (41) over pusher
plate and stud. Place body spacer (42) over
outer perimeter of diaphragm(s) (20).
19. Install remaining quan ti ty of diaphragm(s) (20)
over pusher plate and stud (13).
20. Place O-ring (50) over push er plate and stud
(13).
21. Inspect pressure plate (3) to ensure no de for ma tion due to over-pressurization. If de formed,
bent, or otherwise distorted, replace.
22. Ensuring that the curved outer rim side of the
pressure plate (3) is down, place the pressure
DIM MAT'L 1/2" (DN15) 3/4" (DN20) 1" (DN25)
A BRZ 7/8" 22 mm 1-5/32" 29 mm 1-7/16" 37 mm
B BRZ 5/8" 16 mm 25/32" 20 mm 3/4" 20 mm
A SST 13/16" 21 mm 1-1/16" 27 mm 1-7/16" 37 mm
B SST 9/16" 14 mm 23/32" 18 mm 3/4" 20 mm
DIM MAT'L 1-1/4" (DN32) 1-1/2" (DN40) 2" (DN 50)
A BRZ 1-13/16" 46 mm 1-25/32" 45 mm 2-3/16" 56 mm
B BRZ 29/32" 23 mm 7/8" 22 mm 29/32" 23 mm
A SST 1-1/2" 38 mm 1-25/32" 45 mm 2-5/32' 55 mm
B SST 11/16" 17 mm 7/8" 22 mm 29/32" 23 mm
5
Valve Size
IOM-1000HP-Dif fer en tial
25. Check rocker arm shaft (17) for wear and
straightness. Replace if damaged. Reinstall
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 opening, and does not
align crook ed 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).
26. Install a new di a phragm gas ket (19). Com po si tion (soft) diaphragms require no di a phragm
gasket. NOTE: Use only gaskets man u fac-
tured by Cashco, Inc., that are of the same
material as those originally supplied. Sub sti tu tion may cause im prop er gas ket 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.
30. Aligning the matchmarks, place spring cham ber (2) over the above stacked parts. Install
all bolts (8), nuts (9) and nameplate (28) by
hand tightening. Tighten bolting (8 and 9) in
a cross pattern that allows spring chamber
(2) to be pulled down evenly. Recommended
torques are as follows.
Body Size Bolt Size Metal Diaph 1 Comp Diaph
1/2" 3/8"-24 25 ft-lb 25 ft-lb
3/4" 7/16"-20 30 ft-lb 30 ft-lb
1"–1-1/4" 1/2"-20 35 ft-lb 35 ft-lb
1-1/2" 9/16"-18 45 ft-lb 45 ft-lb
2" 5/8"-18 45 ft-lb 45 ft-lb
1
Minimum recommended torque regardless of gasket
ma te ri als. Some gasket materials may re quire higher
bolt torques to obtain adequate seal.
2
Gasket material may “set” with time; a recheck of
torques should be made if the unit has been stored
on the shelf for over 30 days.
NOTE: Never replace bolting (8 and 9) with just
any bolting. Bolt heads and nuts are marked
with spec i fi ca tion identifi cation mark ings. Use
only proper grades as re place ments.
2
27. Using small gauge wire approximately 18"
(457 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.
28. Firmly holding the outer perimeter, take the
di a phragm subassembly (Step 8) and lower
it down into the body (1) cavity off-center ap prox i mate ly 3/4"–1" (20–25 mm) and towards
the inlet side of the regulator. When fully
low ered, slide the diaphragm subassembly
hor i zon tal ly towards the regulator outlet. The
wire of Step 27. should hold the rocker (14) up
to allow en gag ing 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. NOTE: DO NOT ALLOW
THE ROCKER ARM (14) PRONGS TO GET
BE TWEEN THE STUD NUT (10) AND THE
STUD COL LAR (16). Pull fi rmly to remove
wire holding rocker arm (14) up.
29. Align diaphragm(s) (20) bolt holes with body
(1) fl ange bolt holes. Install new diaphragm
gasket (19) on top of diaphragm(s) (20).
Vi su al ly center range spring (27) on to pressure plate (3), place spring button (4) on top
of range spring (27).
31. Reinstall adjusting screw (6) with sealing
lock nut (7); install new closing cap gasket
(32); install closing cap (31).
32. Pressurizing the body (1) and spring chamber
(2) to the same level, soap solution test around
bolting (8 and 9), body (1), spring chamber (2)
fl anges, closing cap (31) and cylinder (21) - to
body (1) joint for leakage. Use 100 psig min i mum inlet pressure to leak test. Actual service
con di tions should be used if in excess of the
minimum condition. (NOTE: Do not pres sur-
ize spring chamber without equal or greater
pressure in body registering on diaphragm(s)
(20) underneath side.)
C. Diaphragm Setting Adjustment:
1. In the previous “Sub-Section B., Diaphragm
Re place ment”, care was taken to prevent
removal of the stud collar (16) and stud nut
(10). Location of the stud nut (10) is a critical
adjustment for a Model 1000 regulator.
2. Not removing the stud nut (10) will provide
per for mance equal to original factory per for mance when diaphragm(s) (20) is replaced
with like diaphragm(s) (20); however, if the stud
nut (10) is removed, or a switch is made from
metal to composition (soft) diaphragm(s) (20),
or vice versa, the diaphragm setting should
be checked.
6
IOM-1000HP-Dif fer en tial
ob tained when the diaphragm is at this value,
rather than a lower level. As the measuring of
a thou sandths of an inch is diffi cult with such
a pro ce dure, it is rec om mend ed that the “null”
position be found where the diaphragm(s) (20)
is fl ush with the body (1) fl ange (bar approxi-
mately at 0.000"). Remove the pusher plate
stud (13), rotate the stud nut (10) one or two
slots CCW to bring the setting to 0.010–0.020"
(.25–.51 mm) high.
5. Place cotter pin (15) through the slot, bend
over ends.
6. Continue reassembly per Sub-Section B,
Di a phragm Replacement, Step 16.
E. Trim Removal and Replacement:
3. Follow procedure “Sub-Section B., Di a phragm
Re place ment” to the point of removing
diaphragm(s) (20), Step 13. Remove di a phragm gasket (19) and pusher plate stud
gasket (12). Obtain a fl at 12" x 1-1/2" x 1/4"
(15 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 properly. Pull fi rmly up on the
pusher plate stud (13) to ensure that all slack
is removed from the mechanism and that the
piston (24) is seated 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 po si tions will be reached:
a. Diaphragm setting too high. Pusher plate
stud (13) will lift the fl at bar over 0.020"
(.51 mm).
b. Diaphragm setting acceptable. Bar lifted
between 0.010"–0.020" (.25–.51 mm).
c. Diaphragm setting too low. Bar lifted
less than 0.010" (.25 mm), or failed to be
lifted.
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 (610 mm), and
place over the hex surfaces of the cylinder
(21). The wrench should be rapped with a
hammer to loosen.
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.
CAUTION
Take precautions not to allow the piston (24)
to fall from within the cylinder (21); tip cylinder
with hex end down.
4. If an Option 1000-17 piston spring (30) is utilized, it also should be removed and re placed
at trim re place ment.
5. Inspect inside surface of cylinder (21) at four
points:
4. The castle style stud nut (10) has six locations
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" (.25 mm).
NOTE: The ideal diaphragm setting is 0.015"
(.4 mm) high. Better performance is usually
7
a. Seat (21.2) ring. Check for erosion/wear
on seat ing surfaces. If wear is ex ces sive,
consider utilizing Option 1000-15, stellited
seat surface.
b. Seat (21.2). Check for wire drawing
be tween cylinder (21.1) and seat (21.2)
where pressed in. If wear exists here, an
Option 1000-14, integral seat, should be
utilized as a replacement.
IOM-1000HP-Dif fer en tial
d. Place thread sealant on threaded portion
of seat disc screw (26), and manually rotate piston (24) into seat disc screw (26)
(still fi xed in vise) to secure seat disc (25).
Tighten seat disc screw (26) fi rmly. Do not
over-tighten to the point of embedding the
seat disc screw (26) into the seat disc
(25); the seat disc (25) should lay fl at with
no rounded surface. A mechanical aid is
normally not re quired; hand tightening is
normally suffi cient.
7. Insert piston assembly (24 - metal seat) (24,
25 and 26 composition (soft) seat) into end
of cylinder (21).
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 subassembly (21) and piston
sub as sem bly (24 or 24, 25, and 26) should
be replaced. (Cashco does not rec om mend
at tempt ing to replace the seat (21.2) by press ing out and then repressing in. Cashco also
recommends that a cylinder (21) and piston
(24 or 24, 25 and 26) be replaced as a set.
Composition seat discs (25) may be replaced
individually.
6. If a composition (soft) seat trim design is
utilized, 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; de-burr as required. NOTE: Do
not grip the piston (24) with a wrench.
b. Remove the seat disc (25) and clean the
recessed 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).
8. Place piston collar (23) over the end of piston
(24), ensuring that the spherical surface of
the piston (24) and the piston collar (23) bear
against each other.
9. 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.
10. Use special care cleaning the fl at mating sur-
faces of the body (1) and cylinder (21) shoulder,
as this pres sur ized joint is metal-to-metal with
no gasket. (See NOTE next step.)
11. 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 hammer and wrench han dle,
impact the cylinder (21) into the body (1).
NOTES: 1. Take special precaution to keep
pis ton 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 be tween the
body (1) and the cylinder (21) subassembly.
This O-ring is not indicated on drawings.
12. 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 con di tion 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" (3mm).
c. Place seat disc (25) into recessed end of
piston (24).
8
IOM-1000HP-Dif fer en tial
13. Bench test unit for suitable operation and
seat leak age. NOTE: Regulators are not
normally tight shutoff devices. Pressure
must build above setpoint for best shutoff.
14. Soap solution test around cylinder (21)-to-
body (1) connection for leakage. Test pres sure should be a min i mum of 100 psig at the
inlet or actual service con di tions if higher.
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 regulator for
minimum and maximum fl ow.
A2. Increase fl ow rate.
A3. Decrease regulator 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.
B. Worn piston/cylinder; inadequate guiding. B. Replace trim.
C. Flow induced instability. C1. Get straight runs of piping (5 diameters upstream,
10 downstream) 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.
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.
F. Unstable loading pressure. F1. Stabilize loading pressure; i.e. pump, control
valve, etc.
F2. Air in loading piping. Vent spring chamber.
9
IOM-1000HP-Dif fer en tial
2. Regulator differential pressure too low.
Possible Causes Remedies
A. Setpoint too low. A. Turn adjusting screw down (CW) to increase
setpoint.
B. Regulator undersized; outlet pressure B1. Confi rm by opening bypass valve together with
(P
(P
) droops below loading pressure regulator.
2
). B2. Check actual fl ow conditions, resize reg u la tor;
Load
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.
screw CW does not allow bringing pressure Contact factory.
level up to proper level).
F. Too much proportional band (droop); F1. Re view P.B. (droop) expected. (See 2.B1 above.)
outlet pressure (P
pressure (P
Load
) droops below loading F2. Diaphragm setting too low; check setting and
2
). raise as required.
F3. Consider composition diaphragm over metal.
F4. Improper jet; make sure jet matches actual fl uid.
G. Restricted diaphragm movement. (Pressure G. Diaphragm setting too low; check and raise
plate hitting downstops.) as required.
3. Leakage through the body spacer vent hole, or mixing of fl uids.
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 valve chatter.
B2. Can be caused by corrosive action. Consider
alternate diaphragm material.
B3. For composition diaphragms, ensure not subject ing to over-temperature conditions.
B4. Downstream (outlet) pressure buildup occuring
that overstresses diaphragms.
B5. Shutoff of valve inlet pressure while loading
pressure is still on.
C. Pusher plate gasket or O-Ring leaking. C. Replace gasket and O-ring.
10
IOM-1000HP-Dif fer en tial
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 disk.
A3. Diaphragm setting too high; check setting.
A4. Inlet pressure too high for orifi ce size; check
permissible inlet (P
) pressure level for a given
1
outlet. Change to reduced port if required.
A5. Leakage past pressed in seat ring; consider
integral seat.
A6. When diaphragm subassembly 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 spacer ring at temperatures
below freeze point. Ensure no dust or debris
entering vent opening. If rainwater or debris can
enter, reorient spring chamber. (Not possible on
-1+6.)
5. Sluggish operation.
Possible Causes Remedies
A. Plugged piston or jet zone. A. Remove trim and clean.
B. Fluid too viscous. B. Heat fl uid.
C. Improper (undersized) jet. C. Replace existing piston with new piston for
viscous service; i.e. Opt-27.
6. Frequent resetting of setpoint.
Possible Causes Remedies
A. Overpressurization downstream resulting in: A1. Replace diaphragms. Correct potential source of
1. Bent metal diaphragm(s) downstream overpressure.
2. Sprung rocker arm A2. Check measurements of rocker arm. Replace if
3. Range spring overstressed/fatigued. necessary.
A3. Replace range spring; consider next higher range
spring.
11
IOM-1000HP-Dif fer en tial
7. Not able to maintain setpoint.
Possible Causes Remedies
A. Diaphragm may be bent due to pressure A. Make sure to prevent system reversal.
reversal.
8. Excess leakage:
Possible Causes Remedies
A. Faulty seating surfaces. A1. Seat has been nicked by welding splatters.
A2. Composition seat is damaged.
A3. Composition seat driven into metal seat surface
due to overpressure.
B. Outlet pressure setting too low for inlet B. Refer to Technical Bulletin.
pressure.
12
IOM-1000HP-Dif fer en tial
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.
–
7
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.
13
IOM-1000HP-Dif fer en tial
MODEL 1000HP-1+6
DIFFERENTIAL PRESSURE REDUCING REGULATOR
Item No. Description
1 Body & Body Assembly
2 Spring Chamber
(or Loading Chamber)
3 Pressure Plate
4 Spring Button
6 Adjusting Screw
7 Adjusting Screw Lock Nut
9 Flange Nut
10 Stud Nut
11 Pressure Plate Nut
12 Pusher Plate Gasket
13 Pusher Plate Stud
14 Rocker Arm
15 Cotter Pin
16 Stud Collar
17 Rocker Arm Shaft
19 Diaphragm Gasket
20 Diaphragm
14
Item No. Description
21 Cylinder Subassembly consisting of:
21.1 Cylinder
21.2 Seat
23 Piston Collar
24 Piston
25 Seat Disc
26 Seat Disc Screw
27 Range Spring
28 Nameplate
29 Seat Cone
31 Closing Cap
32 Closing Cap Gasket
34 Bleeder Valve Assembly
40 Thread Seal Washer
50 O-ring
Items Not
Shown
5 Pusher Plate
18 Body Plug/Drain Tap
30 Piston Spring
33 Spring Chamber Pipe Plug
36 Identifi cation Plate
(Supplied upon request)
43 Body O-ring
IOM-1000HP-Dif fer en tial
MODEL 1000HP-1+8
DIFFERENTIAL PRESSURE REDUCING REGULATOR
Item No. Description
1 Body & Body Assembly
2 Spring Chamber
(or Loading Chamber)
3 Pressure Plate
4 Spring Button
6 Adjusting Screw
7 Adjusting Screw Lock Nut
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
16 Stud Collar
17 Rocker Arm Shaft
15
Item No. Description
19 Diaphragm Gasket
20 Diaphragm
21 Cylinder Subassembly consisting of:
21.1 Cylinder
21.2 Seat
23 Piston Collar
24 Piston
27 Range Spring
28 Nameplate
29 Seat Cone
31 Closing Cap
32 Closing Cap Gasket
34 Bleeder Valve Assembly
40 Thread Seal Washer
41 Diaphragm Spacer
42 Body Spacer
50 O-ring
Items Not
Shown
5 Pusher Plate
18 Body Plug/Drain Tap
30 Piston Spring
33 Spring Chamber Pipe Plug
36 Identifi cation Plate
(Supplied upon request)
43 Body O-ring
IOM-1000HP-Dif fer en tial
Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH (785) 472-4461
Fax. # (785) 472-3539
www.cashco.com
email: sales@cashco.com
Printed in U.S.A. IOM-1000HP-Diff
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH +49 3342 4243135
Fax. No. +49 3342 4243136
www.cashco.com
Email: germany@cashco.com
Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH +55 11 99677 7177
Fax. No.
www.cashco.com
Email: brazil@cashco.com
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