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
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