cashco CLEAN STEAM, C-CS Installation, Operation & Maintenance Manual

INSTALLATION, OPERATION, & MAINTENANCE MANUAL

IOM-C-CS

12-16

ISO Registered Company

MODEL C-CS

“CLEAN STEAM”

PRESSURE REDUCING REGULATOR

SECTION l

I. DESCRIPTION AND SCOPE

Model C-CS is a pressure reducing regulator used to control down stream (outlet or P2) pressure. Inlet and outlet
sizes are 3/4" (DN20), 1" (DN25), 1-1/2" (DN40), 2" (DN50) and 3" (DN80) with Tri-Clamp® fitting connections. This
regulator is primarily designed for steam service at tem per a tures equal to or less than 366°F (185°C); this cor re sponds
to 150 psig (10.3 Barg) sat u rat ed steam; however, the unit may also be used for clean gaseous or liquid applications.

CAUTION

The Model C-CS should never be used as a shut-off device.

SECTION II

II. INSTALLATION

Outlet
@ P2

1. An inlet block valve should always be in stalled.

2. If service application is continuous such that
shutdown is not readily accomplished, it is
recommended that inlet and outlet block valves
and a manual bypass valve be in stalled.

3. An outlet pressure gauge should be lo cat ed
ap prox i mate ly ten pipe diameters down stream
and within sight.

Inlet

@ P1

Blowdown Drain

SRV

Bypass

Model C-CS

Reducing Regulator

Blowdown Drain

4. All installations should include a down stream
re lief device if the inlet pressure could exceed
the pressure rating of any down stream
equip ment.

5. Flow Direction: Install so the flow enters
through the bottom connection and exits the
side connection.

6. Install in a well drained pipe, properly trapped,
with spring chamber (2) in the vertical position
to allow for proper drain ing.

III. PRINCIPLE OF OPERATION

1. Movement occurs as pressure variations
reg is ter on the diaphragm. The registering
pres sure is the outlet, P2 or down stream
pressure. The range spring opposes di a phragm
move ment. As the outlet pressure drops, the
range spring pushes the diaphragm down,

(Recommended Piping Schematic for Pressure Reducing Station)

7. For insulated piping systems, the regulator
should not be insulated.

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.

SECTION III

CAUTION

Do not apply spring load or operate regulator with
hitch pin (21) removed from top of guide post (27 ).
Pre ma ture di a phragm failure will re sult.

opening the port; as outlet pressure in creas es,
the diaphragm pushes up and the port closes.

IV. START-UP

NOTE: The regulator set point must be set

under normal flowing conditions.

1. CCW = Counter Clockwise,
CW = Clockwise.

2. Inspect the unit's nameplate to confirm that
the proper range spring is installed in the
reg u la tor. Apply setpoint pres sures that are
only within the stated range.

2. A complete diaphragm failure will cause the
reg u la tor to fail open.

SECTION IV

7. Slowly open the inlet (upstream) block valve
ob serv ing the outlet (downstream) pressure
gauge. De ter mine if the regulator is flowing
(see NOTE above step 1). If no flow, rotate the
reg u la tor handle (6) CW (viewed from above)
until flow begins. De ter mine if downstream
equip ment is in operation.

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

3. Start with the block valves closed. A bypass
valve may be used to maintain outlet pressure
in the down stream system while performing
the following steps.

4. Relax compression of range spring (7) by
turning handle (6) counter-clockwise (CCW)
until rotation stops. Rotate handle (6) clockwise
(CW) three (3) full revolutions to maintain
spring (7) to di a phragm(17) contact. This
reduces the outlet pres sure setpoint.

5. If piping system includes a bypass valve,
slowly open the bypass valve to preheat the
system piping and to allow slow expansion of
the piping. Ensure proper steam trap op er a tion,
if installed. To prevent overpressurization,
closely mon i tor out let (down stream) pressure
with a gauge. NOTE: If no bypass valve is

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

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

9. Continue to slowly open the outlet (down stream)
block valve. When flow is es tab lished steady
enough that the outlet (down stream) block
valve is fully open, begin to slowly close the
bypass valve, if installed, until fully closed.

10. Develop system flow to a level near its
ex pect ed normal rate and reset the regulator
setpoint by turning the handle (6) CW (viewed
from above) to increase outlet pres sure or
CCW to reduce outlet pressure.

11. Reduce system flow to a minimum level and
observe setpoint. Outlet pressure will rise from
the setpoint of Step 10. The max i mum rise
in outlet pressure on de creas ing flow should
not exceed the stated upper limit of the range
spring by greater than 30%; i.e. 10-30 psig
(.69-2.1 Barg) range spring – at low flow the
outlet pres sure should not ex ceed 39 psig (2.7
Barg). If it does, consult factory.

V. SHUTDOWN

1. On systems with a bypass valve, and where
system pressure is to be main tained as the
reg u la tor is shutdown, slow ly open the by pass
valve while closing the inlet block valve. Fully
close the inlet block valve. When on bypass, the
system pres sure must be con stant ly ob served
and man u al ly reg u lat ed.

2 IOM-C-CS

SECTION V

2. If the regulator and system are to both be
shut down, slowly close the inlet block valve.
Close the outlet valve only if reg u la tor re mov al
is required.

CAUTION

DO NOT DEAD-END FLOW DOWN STREAM of
the Mod el C-CS as over pressurizing reg u la tor
may damage internals.

SECTION VI

VI. MAINTENANCE

WARNING

SYSTEM UNDER PRES SURE. Prior to per form ing
any maintenance, isolate the reg u la tor from the
sys tem and relieve all pressure. Failure to do so
could result in personal injury.

A. General:

1. Maintenance procedures here in af ter are
based upon removal of the regulator unit from
the pipeline where installed.

2. Refer to Figures 2 & 3 for basic regulator item
num ber reference ( ) and description.

B. Diaphragm – Trim Replacement:

1. Securely install the regulator in a soft-jawed
vise with the spring chamber (2) di rect ed
upwards. Ensure that the body (1) is not held
in the vise by the Tri-clamp® fitting con nec tions.
The regulator may be held in the vise with
flats on the plug (14). If this method is used,
ensure that the plug (14) is in contact with the
seating area of the body (1) and the face of
the inlet flange of the body (1) is resting on
the vise.

WARNING

SPRING UNDER COMPRESSION. Relieve all
spring (7) compression prior to removing clamp
(13). Failure to do so may result in flying parts that
could result in personal injury.

4. Pull hitch pin (21) and lift up on handle (6) to
remove.

5. Loosen and remove clamp nuts (13B), wash ers
(13D), bolts (13C) and clamps (13A). See

Figure 1.

6. Place matchmarks between body (1) and
spring chamber (2) to assist in final ori en ta tion
when re as sem bled. Lift spring chamber (2)
vertically up and off of body (1) and above
guide post (27) to remove. Note alignment of

spring button (4) tabs (ears) with respect to
slot guides inside spring chamber (2).

7. Remove bearing (26). Lift up and remove
ad just ing screw cap (25.7) and dowel pin (25.8)
as sem bly. NOTE: May need to tap lightly on

O.D. of adjusting screw (25.6) to free Dowel
pin (25.8) from adjusting screw (25.6).

NOTE: The two guide seals (25.9) may/may

not be extracted with as sem bly (25.7,25.8).

Re move guide seals (25.9).

8. Lift up the ad just ing screw (25.6 ) and spring
but ton (4) as an as sem bly to remove. NOTE:

Do not rotate or re move spring button (4) from
ad just ing screw (25.6). Re move spring (7) and

lay aside.

For Metal Seat: Secure the pres sure plate

9.
assembly (27,28 and 29) at the “flats” near
the base of pressure plate (28). Grasp the
lower portion of the plug (14) by the “flats”,
which protrudes from the body (1) inlet,
with soft-jawed pliers or soft-jawed vise and
pro ceed to turn CCW (viewed from above)
for dis as sem bly. NOTE: Main tain firm grasp

of plug (14). After dis en gage ment, plug (14)
could fall out of body (1) and damage seating
surface area. Remove plug (14).

2. Relax range spring (7) by turning handle (6)
CCW (viewed from above) until rotation stops.
Count and record the number of rev o lu tions
in the box below:

Number of revolutions required to relax
range spring: ________

CAUTION

Do not apply spring load or operate regulator with
hitch pin (21) removed from top of guide post (27 ).
Pre ma ture di a phragm failure will re sult.

3. Remove socket head set screw (30) CCW
from end of guide post (27).

IOM-C-CS 3

For Composition Seat: The tail piece (14.3)

may disengage at the plug stem (14.1) joint,
instead of at pressure plate joint(28). If it does,
lift plug stem and pressure plate assembly out
of the body cavity.

Remove seat disc (14.2) from tail piece.

Secure "winged" end of stem (14.1)in a soft­jawed vise. Use the "flats" on the pressure
plate to rotate CCW to remove pressure plate

assembly.

10. Lay pressure plate assembly (27,28 and 29)

and aside. NOTE: The travel of the guide post

(27) has been factory set. Do not loosen
or adjust the hex nut (29) on pres sure plate
assembly (27,28,29).

11a. For Model C-CS :

Remove diaphragm (17), O-ring (16),

diaphragm gas ket (15) and body (1).

11b. For Model C-CS with Opt.-11:

Remove diaphragm (17), diaphragm gaskets

(15), O-ring (18), seal (19), push er plate (20),
O-ring (16) and body (1).

12. Inspect plug (14) and seating surface of body
(1) for excessive wear. For composition
seat -install new soft seat (14.2) in tail piece
(14.3).

13. Inspect gasket (15) and O-ring (16) retaining
surfaces of body (1) and spring chamber (2).

14. Clean all parts in accordance with Own er’s
cleaning procedures. Secure plug (14) or
tail piece (14.3) back into vise. Set body

(1) over top of plug. Ensure that the plug
or seat of tail piece is in contact with the
seating area of the body (1) and the face of
the inlet flange of the body (1) is resting on
the vise.

For Composition Seat: Place a small

amount of medium strength, Food Grade
threadlocker on threaded end of stem (14.1).
Insert threaded end of stem into tail piece.

15. Place new diaphragm gasket (15) on body
(1) flange.

16. Install O-ring (16) on plug (14). For Opt.-11
re po si tion push er plate (20) on threaded
end of plug and install O-ring (18) and seal

(19). Refer to Figure 4.

17. Place diaphragm (17) over threaded end of
plug (14). NOTE: The word ‘TOP’ is etched

on one side of the diaphragm and should be
visible when looking down on the diaphragm.

18. Place a small amount of medium strength,
Food Grade threadlocker on threaded end
of plug (14). Reassemble pressure plate
assembly (27,28 and 29) to plug (14). Refer
to NOTE: in Step 10. Grasp the parts and
rotate pres sure plate assembly (27,28,29)
CW until wrench tight (met al-to-metal
con tact); Torque values not to ex ceed the
following:

Body Size

in (DN)

3/4"-1 1/2" (20-40) 100 (11)

2" - 3" (50-80) 270 (31)

Torque

in-lbs (N-m)

19. Center/align the above pressure plate/
diaphragm assembly on the di a phragm (17)
flange sur face in the body (1) cavity.

20. Position spring (7) on to hub of pressure
plate (28). Place adjusting screw (25.6)

- with spring button (4) - over end of guide
post (27) and into spring (7) cav i ty. NOTE:

Apply a small amount of Emhart Bostik White
Food Grade “Never-Seez” or equiv a lent to
threads of ad just ing screw (25.6) Do Not

rotate adjusting screw (25.6) or spring
button (4).

21. Install new guide seals (25.9) in adjusting
screw cap (25.7). NOTE: There are two

sizes of u-cup seals - install the seal with
the bigger diameter spring first, open face
into the cap recess. Install the second u-cap
seal, open face exposed to face of adjusting
screw (25.6). Slide adjusting screw cap

(25.7) over end of guide post (27). Align
dowel pin (25.8) with hole in adjusting screw
(25.6) and press together by hand. NOTE:

Top of dowel pin (25.8) should be flush with
top surface of adjusting screw cap (25.7).

22. Install new bearing (26) on top of upper
guide assembly (25).

23. Align slot guides inside spring chamber
(2) with spring button (4) tabs (ears) and
position on to body (1). Align with match
marks of step 6. previous.

24. Place handle (6) over end of guide post
(27) coming to rest on adjusting screw cap

(25.7). Insert hitch pin (21) into hole through
end of guide post (27). Apply Food Grade
threadlocker to threads of set screw (30)
install into top of guide post (27) and tighten
securely.

25. Reposition clamps (13A) around body (1)
and spring chamber (2) flanges. Insert clamp
bolts (13C), washers (13D) and tighten
clamp nuts (13B) in alternating pattern.

NOTE: Gap be tween clamp (13A) halves
should be equal in size. Gap and torque

re quire ments are as follows:

Figure 1: Clamp Arrangement.

Gap Torque

Equal Distance 225-250 in-lbs (25-28 N-m)

4 IOM-C-CS

26. Reapply compression to the range spring
(7) by rotating handle (6) CW as per the
num ber of revolutions re cord ed in VI.B.2.

27. Return to Section II for Installation and
Sec tion IV for Start-up.

SECTION VII

VII. 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 reflects
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.

–

7

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” reflect 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
identification 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.

IOM-C-CS 5

Figure 2

Barstock body

Metal Seat

Guide Seals

Composition Seat

Repair Parts
Item No. Description Kit A Kit B
1 Body
2 Spring Chamber
4 Spring Button
6 Handle
7 Range Spring
13 Clamp
14 Plug *

14.1 Stem *

14.2 Seat *

14.3 Tail Piece
15 Gasket (Diaphragm)
16 O-ring (Plug)
17 Diaphragm
18 O-ring
19 Seal
20 Pusher Plate
21 Hitch Pin

1

Refer to Figure 1 for Clamp and related item

1

*

numbers.

6 IOM-C-CS

* *

* *
* *
* *
* *

Item No. Description Kit A Kit B
25 Upper Guide Assembly

25.6 Adjusting Screw

25.7 Adjusting Screw Cap

25.8 Dowel Pin

25.9 Guide Seals (2 Req'd) * *
26 Bearing
27 Guide Post
28 Pressure Plate
29 Nut Hex Jam
30 Set Screw

Not Shown:
Item No. Description
11 Name Plate

12 Drive Screw

* Recommended Spare Part

See the previous page for Item Number and Descriptions

Investment Cast body

IOM-C-CS 7

Figure 3

Figure 4: Option-11, Diaphragm Restraint

(Barstock Body Only)

ATEX 94/9/EC: Explosive Atmospheres and Cashco Inc. Regulators

NOTICE

Only for Product Codes wherein hazard
category ATEX has been selected.

These valves satisfy the safety conditions according to EN 13463-1 and EN 13463-5 for equipment group IIG 2 c.

Caution: Because the actual maximum temperature depends not on the equipment itself, but upon the fluid temperature, a
single temperature class or temperature cannot be marked by the manufacturer.

Specific Precaution to Installer: Electrical grounding of valve must occur to minimize risk of effective electrical discharges.

Specific Precaution to Installer: Atmosphere vent holes should be plugged to further minimize the risk of explosion.

Specific Precaution to Maintenance: The Valve Body/ Housing must be regularly cleaned to prevent buildup of dust deposits.

Specific Precaution to Maintenance: Conduct periodic Continuity Check between Valve Body/ Housing and Tank to minimize
risk of electrical discharges.

Attention: When repairing or altering explosion-protected equipment, national regulations must be adhered to. For maintenance
and repairs involving parts, use only manufacturer's original parts.

ATEX requires that all components and equipment be evaluated. Cashco pressure regulators are considered components.
Based on the ATEX Directive, Cashco considers the location where the pressure regulators are installed to be classified
Equipment-group II, Category 3 because flammable gases would only be present for a short period of time in the event of a leak.
It is possible that the location could be classified Equipment-group II, Category 2 if a leak is likely to occur. Please note that the
system owner, not Cashco, is responsible for determining the classification of a particular installation.

Product Assessment

Cashco performed a conformity assessment and risk analysis of its pressure regulator and control valve models and their
common options, with respect to the Essential Health and Safety Requirements in Annex II of the ATEX directive. The details
of the assessment in terms of the individual Essential Health and Safety Requirements, are listed in Table 1. Table 2 lists all of
the models and options that were evaluated and along with their evaluation.

Models and options not listed in Table 2 should be assumed to not have been evaluated and therefore should not be selected
for use in a potentially explosive environment until they have been evaluated.

Standard default options for each listed model were evaluated even if they were not explicitly listed as a separate option in the
table. Not all options listed in the tables are available to all models listed in the tables. Individual TB’s must be referenced for
actual options.

When specifying a regulator that is to be used in a potentially explosive environment one must review the evaluations in Table 1
and 2 for the specific model and each and every option that is being specified, in order to determine the complete assessment
for the unit.

A summary of the models and options found to have an impact on ATEX assessment due to potential ignition sources or other
concerns from the ATEX Essential Health and Safety Requirements, are listed below.

1. The plastic knob used as standard on some models, (P1, P2, P3, P4, P5, P7, 3381, 4381, 1171, and 2171) is a
potential ignition source due to static electricity. To demonstrate otherwise, the knob must be tested to determine
if a transferred charge is below the acceptable values in IEC 60079-0 Section 26.14 (See items 25, 27, and 28 in
Appendix A). Until the plastic knob has been shown to be acceptable, then either the metal knob option, or a preset
outlet pressure option is required to eliminate this ignition source (See items 45 and 64 in Tables).

2. The pressure gauges offered as options on a few of the regulator models (DA’s, P1-7, D, 764, 521), use a plastic
polycarbonate window that is a potential ignition source due to static electricity. To demonstrate that the gauges are
not a potential source of ignition, the gauges would need to be tested to determine if a transferred charge is below

8 IOM-C-CS

indicating the gauge is compliant with the ATEX Directive (See items 26, 27, and 28 in Appendix A). Until compliance
is determined, regulators should not be ordered with pressure gauges for use in potentially explosive environments.

3. Tied diaphragm regulators with outlet ranges greater than 100 psig should be preset to minimize the risk that improper
operation might lead to an outboard leak and a potentially explosive atmosphere (See item 6 in Table 1).

4. Regulators must be ordered with the non-relieving option (instead of the self-relieving option) if the process gas they are
to be used with is hazardous (flammable, toxic, etc.). The self-relieving option vents process gas through the regulator
cap directly into the atmosphere while the non-relieving option does not. Using regulator with the self- relieving option
in a flammable gas system could create an explosive atmosphere in the vicinity of the regulator.

5. Regulators with customer supplied parts are to be assumed to not have been evaluated with regard to ATEX and thus
are not to be used in a potentially explosive environment unless a documented evaluation for the specific customer
supplied parts in question has been made. Refer to Table 1 for all models and options that have been evaluated.

Product Usage

A summary of ATEX related usage issues that were found in the assessment are listed below.

1. Pressure regulators and control valves must be grounded (earthed) to prevent static charge build-up due to the flowing
media. The regulator can be grounded through any mounting holes on the body with metal to metal contact or the
system piping can be grounded and electrical continuity verified through the body metal seal connections. Grounding
of the regulator should follow the same requirements for the piping system. Also see item 30 in Table 1.

2. The system designer and users must take precautions to prevent rapid system pressurization which may raise surface
temperatures of system components and tubing due to adiabatic compression of the system gas.

3. Heating systems installed by the user could possibly increase the surface temperature and must be evaluated by the
user for compliance with the ATEX Directive. User installation of heating systems applied to the regulator body or
system piping that affects the surface temperature of the pressure regulator is outside the scope of this declaration and
is the responsibility of the user.

4. The Joule-Thomson effect may cause process gases to rise in temperature as they expand going through a regulator.
This could raise the external surface temperature of the regulator body and downstream piping creating a potential
source of ignition. Whether the Joule-Thomson effect leads to heating or cooling of the process gas depends on
the process gas and the inlet and outlet pressures. The system designer is responsible for determining whether the
process gas temperature may rise under any operating conditions. If a process gas temperature rise is possible under
operating conditions, then the system designer must investigate whether the regulator body and downstream piping
may increase in temperature enough to create a potential source of ignition.

The process gas expansion is typically modeled as a constant enthalpy throttling process for determining the temperature change.
A Mollier diagram (Pressure – Enthalpy diagram with constant temperature, density, & entropy contours) or a Temperature –
Entropy diagram with constant enthalpy lines, for the process gas, can be used to determine the temperature change. Helium
and hydrogen are two gases that typically increase in temperature when expanding across a regulator. Other gases may
increase in temperature at sufficiently high pressures.

Product Declaration

If the above issues are addressed by selecting options that do not have potential sources of ignition, avoiding options that
have not been assessed, and by taking the proper usage issue precautions, then Cashco regulators can be considered to be a
mechanical device that does not have its own source of ignition and thus falls outside the scope of the ATEX directive.

Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [email protected]

Printed in U.S.A. IOM-C-CS

Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]

IOM-C-CS 9

Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]