Page 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL
Model 1000LP
Reducing Regulator
Blowdown-Drain
Blowdown-Drain
Bypass
SRV
Outlet
@ P2
Supply
@ P1
TR
TR
PI
IOM-1000LP-Basic
MODEL 1000LP - BASIC
PRESSURE REDUCING REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The Model 1000LP is a pressure reducing regulator used to control downstream (outlet or P2) pressure to
levels between 1 and 30 psig (0.07-2.06 Barg). Sizes are 1/2", 3/4", and 1" (DN15, 20, and 25).
The unit is designed for liquid, gaseous or steam service with proper trim utilization, and proper jet selection.
Refer to Technical Bulletin 1000LP-TB for sizing, application and selection recommendations.
Installation, operation and maintenance manuals (IOM's) exist for the following other Model 1000 products:
1000HP-Basic 1000HP-Differential 1000HP-Cryogenic
12-13
SECTION II
II. INSTALLATION
CAUTION A
For welded installations, all internal trim parts,
seals and diaphragm(s) must be removed from
reg u la tor body prior to welding into pipeline. The
heat of fusion welding will dam age non-metallic
parts if not re moved. NOTE: This does not apply
to units equipped with extended pipe nip ples.
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 B
Installation of adequate overpressure pro tec tion
is recommended to pro tect the reg u la tor from
overpressure and all down stream equip ment
from damage in the event of regulator failure.
Recommended Piping Schematic
For Pressure Reducing Station
Page 2
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.
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.
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. Ensure regulator is properly
trapped if used in a steam ser vice application.
CAUTION C
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.)
11. Regulators are not to be direct buried underground.
10. Basic regulator may be rotated around the pipe
axis 360° , and may be installed in a horizontal
or 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.
III. PRINCIPLE OF OPERATION
1. The Model 1000 is available in two variations:
1000LP (larger diaphragm) for downstream
pres sure control from 1-30 psig (.07-2.1 Barg);
1000HP (small er diaphragm) for down stream
pressure control from 10-300 psig (.69-20.7
Barg), body size dependent.
2. Movement occurs as pressure variations register on the diaphragm. The registering pres sure
is the outlet, P2, or downstream pressure. The
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.
12. For insulated piping systems, recommen dation
is to not insulate regulator.
13. Cashco does not recommend fi eld welding on
the cyl in der (inlet) end of the body due to the
pos si bil i ty of warpage.
SECTION III
5. The FTO design also is limited by a minimum
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.
6. The Model 1000 includes an aspiration jet ef 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 will reduce
perfor mance.
7. A complete diaphragm failure will cause the
regulator to fail open.
4. Due to the FTO design, there is a limit as to how
low of a downstream (P2 or outlet) pressure level
setting is capable for a given inlet P1 pres sure.
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 (P2 or outlet)
pressure settings for a given up stream (P1 or
inlet) pres sure level.
2
IOM-1000LP-Basic
Page 3
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.
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.
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.
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.
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.
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. 15-30 psig (1.0-2.1
Barg) range spring, at low fl ow the outlet pres-
sure should not exceed 39 psig (2.7 Barg). If it
does, consult factory.
V. SHUTDOWN
1. On systems with a bypass valve, and where sys tem pressure is to be maintained as the reg u la tor
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
A. General:
WARNING 1
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.
SECTION V
CAUTION D
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.
1. Maintenance pro ce dures hereinafter are
based upon removal of the unit from the
pipeline where in stalled.
2. Owner should refer to owner's proce dures
for removal, handling and cleaning of re useable parts, and disposal of non reuseable
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.
IOM-1000LP-Basic
3
Page 4
4. Regulators originally supplied as “oxygen
cleaned” (Option-55 ) are assembled using
special gasket sealant, Fluorolube GR-362
1
, or equivalent. Cashco, Inc. rec om mends
following factory cleaning spec ifi cation #S-
1134, or equiv a lent. Con tact factory for
details.
1
Product of Fisher Scientifi c Com pa ny
WARNING 2
SYSTEM UNDER COMPRESSION.
Prior to removing fl ange bolts, relieve spring
compression by backing out the adjusting screw.
Failure to do so may result in fl ying parts that
could cause personal injury.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vise with
the spring chamber (2) directed up wards.
2. Remove closing cap (31) if provided. Relax
range spring (27) by turning adjusting screw
(6) CCW until removed from spring chamber
(2).
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).
6. Pry up the diaphragm(s) (20) and diaph ragm
gasket (19) around the perimeter of the body
(1) diaphragm fl ange to ensure that the
diaphragm(s) (20) are not “sticking”. NOTE:
Diaphragm 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
from the rock er arm (14) slot. Lift vertically
for the diaphragm sub-assembly re mov al.
8. Place the pusher plate and 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), or cotter pin (15). Loosen
and remove pressure plate nut (11).
9. Remove pressure plate (3) by lifting.
Diaphragm sub-assembly consists of items (10), (11),
(12), (13), (15), (16) and (20). (Metal diaphragm de sign).
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).
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).
14. Install new diaphragm(s) (20) over pusher
plate and stud (13). NOTE: Refer to the
quantity 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 fl at side of the pressure
plate (3) rests against the dia phragm (20).
Place the pressure plate (3) over the pusher
plate and stud (13). Install pressure plate
nut (11) onto the stud (13) and tighten. Rec om mend ed torque val ues are as follows:
CAUTION E
DO NOT USE FIN GERS TO HOLD DIAPHRAGMS
(20) DURING TIGHT EN ING OF NUT (11). Use two
fl ange bolts (8) to keep multiple di a phragms' (20)
properly aligned with bolt holes while tight en ing the
stud nut (10).
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IOM-1000LP-Basic
Page 5
Body Size Metal Diaphragm Comp. Diaphragm
1/2" 35-40 ft. lbs. 25-30 ft. lbs.
3/4"-1" 45-50 ft. lbs. 35-40 ft. lbs.
DN 15 47-54 N-m. 34-41 N-m.
DN20-DN25 61-68 N-m 47-54 N-m
17. Remove cotter pin (15) se cur ing 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 rotate when
the cotter pin (15) is re moved.)
18. Remove rocker arm shaft (17) and rocker
arm (14). Measure inside of rocker arm (14)
“prongs” as indicated below:
"B"
90°
pres sion. It may also adversely change the
di a phragm setting, which will affect the unit's
per for mance, i.e. Option-45, non-as bes tos
construction utilizes special gaskets.
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).
Rotate the rocker arm (14) up until slack is
removed in the mechanism. Hold the wire
above the body (1) fl ange on the outlet side
of the valve.
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)
towards the inlet side of the valve. When
fully low ered, slide the di a phragm sub-as sem bly horizontally to wards the valve's
out let. The wire of Step 21 should hold the
rocker arm (14) up to allow the pusher plate
(5) and stud (13) (with stud nut (10) and stud
collar (16)), to slide underneath the rocker
arm (14) prongs. The rocker arm (14) prongs
must rest di rect ly on the stud collar (16). (Do
not allow the rocker arm (14) prongs to rest
between the stud nut (10) and the stud collar
(16).) Pull fi rmly to remove wire.
"A"
DIM MAT'L
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
If any of the above dimensions are exceeded by 1/8" (3 mm), replace rocker
arm (14)
1/2" DN15 3/4" DN20 1" DN25
Valve Size
19. Check rocker arm shaft (17) for wear and
straightness. Replace if damaged. Reinstall in body (1) thru 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 op po site the threaded open ing and
does not align crooked or re strained from
full thread en gage ment with the body (1).
Make sure the rocker arm (14) prongs that
strad dle 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 as those originally supplied. Sub sti tu tion may cause improper gasket com-
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).
24. Aligning the matchmarks, place spring
cham ber (2) over the above stacked parts.
Install all bolts (8), nuts (9) and name plate
(28). Tight en bolt ing (8 and 9) in a cross
pattern that allows the spring cham ber (2)
to be pulled down even ly. Rec om mend ed
torque values* are as follows: All sizes
and di a phragms: 35 Ft-lbs (47 N-m)
25. Reinstall ad just ing screw (6) with lock nut
(7). Install closing cap (31) if pro vid ed.
26. Spray liquid leak detector to test for leak age
around bolt ing (8 and 9), body (1) and spring
cham ber (2) fl anges, and cyl in der (21) to
body (1) joint. Ensure that an outlet pressure
is main tained during this leak test of at least
mid-range spring level; i.e. 15-30 psig (1.0-
2.1 Barg) range spring, 23 psig (1.6 Barg)
test pres sure min i mum. Use 100 psig (7.0
* Minimum recommended torque values 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 torque values 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 if lost. Bolt heads and nuts are
marked with specifi cation iden ti fi ca tion num bers.
Use only proper grades as re placements.
IOM-1000LP-Basic
5
Page 6
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-3, Handwheel, is uti lized, the
ad just ing screw (6) and locknut (7) are
re placed by a handwheel (6.3)/adjusting
screw (6) assembly and locking le ver (7).
2. Use only gaskets of the same material as
original equipment. Cashco's Option-45,
non-as bes tos con struc tion, 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 for-
over 0.020" (0.50 mm).
b. Diaphragm setting acceptable. Bar
lifts 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 thru the pusher
plate and 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 thou sandths 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 and 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.
5. Place cotter pin (15) thru the slot/hole, bend
over ends.
Checking diaphragm setting.
m 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 and stud (13)
into the rocker arm (14) prongs prop er ly.
Pull fi rmly up on the pusher plate and 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 and stud
(13) with the stud (13) passing thru 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 and stud (13) will lift the fl at bar
6. Continue re-assembly 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. Loosen and remove the cylinder (21) by
turning CCW. NOTE: The piston (24) and
piston collar (23) should come out with the
cylinder (21) re mov al.
CAUTION F
Do not allow the pis ton (24) to fall from within the
cylinder (21); tip cylinder with hex end down.
3. If an Option-17 piston spring (30) is utilized,
it also should be removed and re placed at
trim replacement.
4. 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 uti liz ing Op tion
1000-15, 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-14, integral seat, should
be uti lized as a re place ment.
6
IOM-1000LP-Basic
Page 7
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
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.)
(21.2) Pressed In Seat Ring (E.5 b)
21.1
1
Expansion Zone (E.15 c)
Guide Zone (E.5 d)
4
Jet Zone (E.10)
5. 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. Re move
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 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.
6. If utilized, place piston spring (30) over
small er end of cylinder (21).
Cylinder Sub-Assembly (21) with Piston (24) Metal
Seat Construction
Clean the “jet area” just inside the body (1)
outlet end thru 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.
10. 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.
11. Lubricate the cylinder (21) threads lightly
with thread sealant. Insert the entire trim
stack into the body (1) opening and thread
until tightly seated. NOTE: Take special
pre cau tion to keep piston collar from getting
“cocked” at an angle when inserted. Impact
until the cylinder (21) shoulder is metal-tometal with the body (1).
12. Inspect the body (1) outlet end to ensure that
the piston (24) is concentric to the body (1)
bore in the jet area and has clearance on
all sides. Under no conditions should the
piston (24) be touch ing the body (1). Use
two pencils or similar shafts to place in inlet
and outlet ends of valve and alternately push
on each end of the piston (24) to ensure
free movement. NOTE: Total move ment is
ap prox i mate ly 1/8" (3.2 mm).
13. 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.
7. Insert piston assembly (24 metal seat; 24,
25 and 26 comp. seat) into end of cylinder
(21).
8. 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.
9. Clean the body (1) cavity thru the openings.
IOM-1000LP-Basic
14. Spray liquid leak detector around cyl in der
(21)-to-body (1) connection and check for
leak age. Test pres sure should be a min i mum of 100 psig (6.9 Barg) at the inlet, or
actual service con di tions if high er.
7
Page 8
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.
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.
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.
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 screw E. Replace range spring with proper higher range. Contact factory.
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 G1. Diaphragm setting too high; check and lower as required.
plate hitting upstops). 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, re-orient spring chamber.
H. Restricted diaphragm movement (overstretched H1. Diaphragm setting too low; check and increase as required.
diaphragm). 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, re-orient 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 occuring that overstresses
diaphragms.
C. Pusher plate gasket leaking. C. Replace gasket.
8
IOM-1000LP-Basic
Page 9
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
pressure level for a given outlet. Change to reduced port if required.
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, re-orient spring chamber.
)
1
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-27.
6. Frequent resetting of setpoint.
Possible Causes Remedies
A. Over-pressurization downstream resulting in: A1. Replace diaphragms. Correct potential source of downstream over-
1. Bent metal diaphragm(s). pressure.
2. Sprung rocker arm. A2. Check measurements of rocker arm. Replace if necessary.
3. Range spring overstressed/fatigued. A3. Replace range spring; consider next higher range spring.
IOM-1000LP-Basic
9
Page 10
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.
10
IOM-1000LP-Basic
Page 11
6.3
7
4
2
27
8
9
5
16
‡‡
15
‡‡
21.1
‡‡
21.2
1
18
Option-26
Body Drain
Tap/Plug
‡‡
21.1
‡‡
21
‡‡
21.2
‡‡
21.1
‡‡
21
‡‡
21.2
IOM-1000LP-Basic
MODEL “1000LP”
Pressure Reducing Regulator
Metal Seat, Brass Trim Con-
struction
Option-17
Piston Spring
26
25
‡‡
‡– ‡‡
Composition Seat
‡‡
29
Metal Seat with
Option-15 Stellited Seat
‡‡
30
‡‡
23
‡‡ ‡‡
23
‡‡
24
24
6
2
13
11
7.3
‡– ‡‡
12
19
20
17
14
10
24
23
3
‡– ‡‡
‡– ‡‡
‡– ‡‡
‡‡
‡‡
Option-3 Handwheel
& Locking Lever
6
32
33
2
Option-1
31
7.1
4
27
‡– ‡‡
Closing Cap
1
1/4" (DN8) NPT Vent–
Options -1 & -25
Repair Parts
Item No. Description Kit A Kit B
1. Body
2. Spring Chamber
3. Pressure Plate
4. Spring Button
5. Pusher Plate
6. Adjusting Screw
6.3 Handwheel
7. Adjusting Screw Lock Nut
7.1 Sealing Lock Nut (Opt -1) ‡ ‡‡
7.3 Locking Lever (Opt -3)
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
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 (Opt-15) ‡‡
30. Piston Spring (Opt -17) ‡‡
31. Closing Cap (Opt -1)
32. Closing Cap Gasket (Opt-1) ‡ ‡‡
33. Pipe Plug (Opt-1)
43. Body O-Ring (Not Shown)
11
Page 12
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-1000LP-Basic
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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