INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-P7
MODEL P7
PISTON SENSING SINGLE STAGE
PRESSURE REDUCING REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The Model P7 is a 1/2" (DN15) or 3/4" (DN20) pressure reducing regulator used to control downstream (outlet or P2 )
pressure. The unit is suitable for gaseous or liquid services. Refer to Technical Bulletin P7-TB for design conditions
and selection recommendations.
SECTION II
11/13
II. INSTALLATION
CAUTION A
Installation of adequate overpressure pro tec tion
is recommended to pro tect the reg u la tor from
over pres sure and all down stream equip ment
from dam age in the event of regulator failure.
1. An inlet block valve should always be installed.
2. If service application is continuous such that
shut down is not readily accomplished, it is recommended that an inlet block valve, outlet block
valve, and a manual bypass valve be installed.
3. Pipe unions should be installed to allow removal
from piping.
4. An outlet pressure gauge should be located ap proxi mately ten pipe diameters downstream, and within
sight.
5. All installations should include a downstream re lief
de vice if the inlet pressure could exceed the pres sure rating of any downstream equip ment or the
maximum outlet pressure rating of the unit.
6. Clean the pip ing of all foreign material including
chips, welding scale, oil, grease and dirt before
installing the reg u la tor. Strainers are rec om mend ed.
Model P7
7. In plac ing thread seal ant on pipe ends pri or 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 inlet stamp on the main regulator body (1).
9. For best performance, install in well drained hori zon tal pipe.
10. Regulator may be rotated around the pipe axis 360°.
Recommended position is with spring loaded knob
(38) or loading dome (2) or ratio loading upper case
(44) in ver ti cal upwards position.
11. Regulators are not to be buried un der ground.
12. For insulated piping systems, recommendation is
to not insulate regulator.
III. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations register on the piston (5). The registering pressure
is the outlet, P
range spring (28) or loading pressure (for dome
loaded or ratio loaded designs) opposes piston
, or downstream pressure. The
2
SECTION III
(5) move ment. As outlet pressure drops, the
range spring (28) or loading pressure push es the
piston (5) down, opening the port; as outlet pres sure in creas es, the piston (5) push es up and the
port opening clos es.
2. A complete piston (5) failure will cause the reg u la tor to fail open.
SECTION IV
IV. STARTUP
CAUTION B
For Spring Loaded Design the maximum outlet pressure is indicated on the body as the upper range
spring pres sure level, and is the rec om mend ed “upper
operative limit” for the sens ing piston (see Sec tion IV.
Startup, Step 7).
For Dome & Ratio Loaded Design the max outlet pressure is 1500 psig (103.4 barg).
Max loading pressure for Ratio Loaded Design is 105
psig (7.2 barg).
DO NOT HYDRO STATIC TEST THRU AN IN STALLED
UNIT; ISO LATE FROM TEST.
1. Start with the block valves closed. A by pass
valve may be used to maintain out let pres sure
in the down stream sys tem without changing the
fol low ing steps.
2. Relax range spring (28) by turning the knob (38)
counter clockwise (CCW) until ro ta tion comes to
a complete stop; or remove the loading pressure
for dome loaded or ratio loaded designs.
3. If it is a “hot” piping system, and equipped with
a bypass valve, slowly open the bypass valve
to preheat the system piping and to allow slow
ex pan sion of the piping. Closely monitor outlet
(down stream) pres sure via gauge to ensure 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 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.
De ter mine if the regulator is fl owing. If not, slowly
rotate the regulator knob (38) clock wise (CW) or
increase the loading pressure until fl ow begins.
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 pip ing system isn't pressurized. If the outlet (down stream) pressure exceeds the desired 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, be gin to slowly close the bypass valve if installed.
9. Develop system fl ow to a level near its expected
normal rate, reset the regulator set point by turning
the knob (38) (CW) to increase outlet pressure or
(CCW) to reduce outlet pressure. Adust the loading pressure for dome or ratio loaded designs.
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 decreasing fl ow should not exceed
the stated up per limit of the range spring (28) by
greater than 10%; i.e. 2-100 psig (.14-6.9 Barg)
range spring (28).
V. SHUTDOWN
1. On systems with a bypass valve, and where sys tem pressure is to be main tained 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 sys tem pres sure must be con stant ly
observed and man u al ly reg u lat ed. Close the
outlet (down stream) block valve.
SECTION V
2. If the regulator and system are to both be shut
Do not walk away and leave a bypassed
regulator unattended.
down, slowly close the inlet (upstream) block
valve. Close the outlet (downstream) valve only
if reg u la tor re mov al is required.
CAUTION C
IOM-P72
SECTION VI
VI. MAINTENANCE
WARNING 1
SYSTEM UN DER PRES SURE. Prior to per form ing
any maintenance, isolate the reg u la tor from the sys tem and relieve all pres sure. Failure to do so could
result in personal injury.
A. General:
1. Maintenance procedures hereinafter are based
upon re mov al of the regulator unit from the
pipeline where in stalled.
2. Owner should refer to owner's procedures for
removal, handling, cleaning and disposal of
non -reuseable parts, i.e. gaskets, etc.
3. Apply a thin coat of Christo Lube to all o-rings.
4. Refer to Figure 1, Figure 2 or Figure 3 for pertinent design.
CAUTION D
To prevent damage to body, use soft jaws when
placing body in a vise. Position so that vise closes
over the fl ats on lower end of body.
5
WARNING 2
SPRING UNDER COMPRESSION. Prior to re mov ing
spring chamber, relieve range spring com pres sion
by turn ing the knob counter clock wise (CCW) until
ro ta tion comes to a com plete stop. For DOME or
RATIO Loaded remove all loading pressure. Fail ure
to so may result in fl ying parts that could cause
personal injury.
B. Poppet Seat & Piston Replacement - Spring
Loaded Vented Design:
1. Securely install the body (1) in a vise with the
spring knob (38) directed upwards.
2. Relax range spring (28) by turning the knob (38)
counter clockwise (CCW) until rotation comes
to a complete stop. NOTE: It is not necessary
to remove the knob (38) before removing the
spring chamber(2)-(upper assembly) from the
body (1). Remove upper assembly by turning-
spring chamber (2) (CCW). Lift upper assembly
off of range spring (28).
3. Remove spring (28), pin (40) and spring follower
(26).
4. Grab vent cap (25) by fl ats and pull up to remove
piston (5) and sleeve (3) from body (1). Remove
and replace o-ring (4).
5. With thumb, press down on top of vent cap (25)
to separate piston (5) from sleeve (3). Remove
and replace o-ring (6).
6. Secure piston (5) in a vise using the fl ats on
the sides of piston. Remove vent cap (25) by
turning (CCW).
7. Use a pair of needle nose pliers to grasp top of
poppet (23). Pull upwards to remove poppet,
poppet seat (24) and poppet spring (22).
8. Reinstall poppet spring (22) and poppet (23) in
piston (5). Slide new poppet seat / disc (24)
over poppet. Install vent cap (25) on piston (5),
use (CW) rotation to tighten metal to metal.
9. Insert smallest o.d. of piston (5) into largest i.d.
of sleeve (3). Press tighly together for metal to
metal contact. Press this assembly into body
(1); vent cap (25) oriented upwards.
10. Place spring follower (26) with smallest o.d.
next to piston. Install spring (28).
11. Place upper spring chamber assembly on body
(1). Turn spring chamber (2) (CW) to secure
tight to body. Remove knob cover (39).
12. Rotate vent screw (36) CCW to remove screw
and spring (35). Record number of revolutions.
for removal of screw. _________
13. Lower pin (40) through top / center of adjusting
screw (34), pin should rest on top of poppet (23).
NOTE: insert a small diameter tool through
center of adjusting screw and carefully press
downward on pin (40) to confi rm recoil of the
poppet spring (22).
14. Install spring (35) and vent screw (36) - recalling
the number of revolutions counted for removal
from above. Reinstall knob cover.
C. Piston Replacement - Spring Loaded
Non-Vented Design:
1. Instructions are similar to Vented with exception: Assembly does not include pin (40), per
B. 3, the poppet, (23) and poppet spring (22).
per B.7 & B.8. The poppet seat (24) is replaced
by a solid disc.
IOM-P7
3
WARNING 3
For DOME or RATIO Loaded remove all loading pressure. Fail ure to so may result in fl ying parts that could
cause personal injury.
D. Piston Replacement - Dome Loaded Design:
1. Securely install the body (1) in a vise with the
loading dome (2) directed upwards.
5
6. Insert smallest o.d. of piston (5) into largest i.d.
of sleeve (3). Press tighly together for metal to
metal contact. Press this assembly into body
(1).
7. To re-attach body assembly to upper & lower
case assembly, position body (1) on bonnet (2)
and rotate body (CW) to secure tight metal to
metal seal. NOTE: Align post (42) with recees
in piston (5).
2. Remove dome (2) by grasping the fl ats and
turning (CCW).
3. Grab piston (5), lift up to remove piston & sleeve
(3) from body (1). Remove and replace o-rings
(4 & 41).
4. With thumb, press down on top of piston (5) to
separate piston from sleeve (3). Remove and
replace o-ring (6).
5. Insert smallest o.d. of piston (5) into largest i.d.
of sleeve (3). Press tighly together for metal to
metal contact. Press this assembly into body.
6. Place dome (2) on body- turning (CW) to secure
body (1) and dome (2) fi rmly together.
7. Refer to Section IV for start up.
E. Piston Replacement - Ratio Loaded Design:
1. Securely install the upper & lower case assembly (43) (44) in a vise with the body(1) directed
upwards.
2. Remove body (1) from upper & lower case assembly (43)(44) and bonnet (2) by grasping the
fl ats on the body (1) and turning CCW. NOTE: It
is not necessary to dis-assemble upper & lower
case assembly. Do not remove post (42) from
upper & lower case assembly to maintain alignment of post (42) with pressure plate (46).
3. Rotate body assembly end to end 180 degrees
and securely install in a vise with piston (5)
upwards.
4. Grab piston (5), lift up to remove piston & sleeve
(3) from body (1). Remove and replace o-ring
(4).
F. Trim Inspection & Replacement: (All designs)
1. Remove pin (10) and baffl e plate assembly (7)
(8)(9). NOTE: spring pin (9) is pressed into
baffl e plate (7) fl ush to top surface. Pitot (8) is
threaded tight into bottom side of baffl e plate
(7).
2. With body securely clamped in vise remove
seat (11) turning (CCW). Remove and replace
o-ring (27). At re-assembly, tighten seat (11)
metal to metal into body (1).
3. Remove body from vise and rotate end to end
180 degrees to reclamp body in vise with body
cap (16) upwards.
4. Turn body cap (CCW) to remove and replace
o-ring (17). At re-assembly tighten body cap
(16) metal to metal to body (1).
5. With a pick type tool, locate leading edge of
spiral retaining ring (21) in the body cap (16)
and lift upwards slightly. Grab the elevated
end with needle-nose pliers and rotate (CCW)
to remove. At re-assembly replace with new
retaining ring (21).
6. Remove retainer (20). Remove and replace
o-ring (19) and backup ring (18).
7. Grasp end of plug (12) and pull upwards to
remove. Slide return spring (15) off of plug
(12).
8. Secure plug (12) in a vise with vent screw (14)
directed upwards. Turn vent screw (CCW) to
remove and replace seat disc ((13). NOTE:
chamfer on seat disc (13) faces away from the
plug. At re-assembly tighten vented screw (14)
into plug per following torque values:
5. With thumb, press down on top of piston (5) to
separate piston from sleeve (3). Remove and
replace o-ring (6).
For Cv Size Torque to in/oz.
0.8 65
2.0 96
IOM-P74
9. Clean body (1) and all reusable parts according
to owner's procedures. NOTE: On regulators
originally supplied as “oxygen clean”, Option-M,
maintenance must include a level of cleanliness
equal to Cashco's cleaning standard #S-1134.
Contact factory for details.
10. Inspect and replace any necessary parts.
NOTE: Use only parts manufactured and sup-
plied by Cashco, Inc. for these products.
11. Insert plug (12) and spring (15) into body (1).
12. Place backup ring (18) into body cap (16), fol-
lowed by o-ring (19) and guide bushing (20) - fl at
side up.
13. Insert spiral retaining ring (21) into groove be-
hind guide busing (20) to lock parts in place.
14. Thread body cap (16) into the body (1) metal
to metal, compressing o-ring (17) into chamfer
of body.
15. Remove body from vise and rotate end to end
180 degrees to reclamp body in vise with body
cap (16) downwards.
16. Thread seat (11) with 0-ring (27) (CW) into body
(1) tighten metal to metal.
17. Position baffl e plate assembly (7) pin side down
into body (1); align spring pin (9) in proper hole
in body so pitot (8) is visible in center of outlet
treaded connection.
18. Install pin (10) through center of baffl e plate (7).
19. Refer to Section VI to re-assemble piston and
top works to a specifi c design.
G. Diaphragm Replacement - Ratio Loaded Design:
1. Securely install the body (1) in a vise with
upper & lower case assembly (43) (44)
directed upwards.
2. Remove all bolts (48) and nuts (49) from
upper & lower case assembly.
3. Remove upper case (44).
4. Remove & replace diaphragm (45).
NOTE: Ensure that pressure plate (46) is
aligned correctly on post (42),
5. Align bolt holes in upper case (44) with
holes in diaphragm (45) & lower case (43).
Insert bolts (48) through holes and thread nuts
(49) on bolts. Torque boling and nusts to 35 ft.
lbs.
SECTION VII
VII. CALIBARTION OF POPPET VENT - SPRING LOADED MODEL
Refer to Section IV - Startup - to establish system regulating pressure and fl ow conditions. Pop knob cover off of the
knob (38). Rotate vent adjustment screw (36) CW, until a hissing sound is heard - then stop. Then slowly turn the vent
adjustment screw CCW until the hissing sound stops. From this point, rotate the vent adjustment screw CCW one more
revolution and stop. The vent relieving function of this model is calibrated.
SECTION VIII
VIII. TROUBLE SHOOTING GUIDE
1. Erratic operation; chattering.
Possible Causes Remedies
A. Oversized regulator; inadequate rangeability. A1. Check actual fl ow conditions, re-size regulator for minimum and maximum fl ow.
B. Worn poppet; inadequate guiding. Vented Design B. Replace trim (possible body replacement).
C. Weakened/broken poppet spring. Vented Design C. Replace poppet spring. Determine if corrosion is causing the failure.
A2. Increase fl ow rate.
A3. Decrease regulator pressure drop; decrease inlet pressure by placing a throttling orifi ce in
inlet piping union.
A5. Before replacing regulator, contact factory.
IOM-P7
5
2. Regulator can not pass suffi cient fl ow.
Possible Causes Remedies
A. Regulator undersized. A1. Confi rm by opening bypass valve together with regulator.
B. Too much droop. B1. Review droop expected.
A2. Check actual fl ow conditions, re-size regulator; if regulator has inadequate capacity,
replace with larger unit.
B2. Contact factory.
3. Sluggish operation.
Possible Causes Remedies
A. Fluid too viscous. A. Heat fl uid. Contact factory.
4. Excessive pressure downstream.
Possible Causes Remedies
A. Regulator not closing tightly. A. Inspect the seating. Clean and lap metal seat surfaces; replace if lapping does not remedy.
B. Downstream block.. B. Check system; isolate (block) fl ow at regulator inlet - not outlet. Relocate regulator if
C. No pressure relief protection. C. Install safety relief valve, or rupture disc.
D. Restricted piston movement. D. Ensure no moisture in spring chamber at temperatures below freeze point.
If composition seats are depressed, nicked or embedded with debris, replace trim.
necessary.
SECTION IX
IX. 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.
–
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” 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.
IOM-P76
SPRING LOADED
Repair Parts
Item No. Description
1 Body
2 Spring Chamber
3 Sleeve
4 O-Ring........................................++
5 Piston
6 O-Ring........................................++
7 Baffl e Plate
8 Pitot
9 Spring Pin
10 Body Pin
11 Seat Orifi ce................................++
12 Plug............................................++
13 Valve Seat Disc..........................++
14 Vent Screw(Valve Seat).............++
15 Return Spring
16 Body Cap
17 O-Ring........................................++
18 Backup Ring...............................++
19 O-ring..........................................++
20 Retainer
21 Spiral Retaining Ring...................++
Kit B
FIGURE 1
Repair Parts
Item No. Description
22 Vent Poppet Spring
23 Vent Poppet
24 Seat............................................++
25 Vent Cap
26 Spring Follower
27 O-ring..........................................++
28 Range Spring
29 Spring Button
30 Set Screw (Spring Button)
31 Thrust Washer
32 Thrust Bearing
33 Thrust Washer
34 Adjusting Screw
35 Adjusting Screw Spring
36 Vent Adjustment Screw
37 Retaining Ring (Snap Ring)
38 Knob
39 Knob Cover
40 Pin
50 Nut
Kit B
IOM-P7
7
Repair Parts
Item No. Description
1 Body
2 Dome
3 Sleeve
4 O-Ring........................................++
5 Piston
6 O-Ring........................................++
7 Baffl e Plate
8 Pitot
9 Spring Pin
10 Body Pin
11 Seat Orifi ce..................................++
12 Plug..............................................++
13 Valve Seat Disc............................++
14 Vent Screw...................................++
15 Return Spring
16 Body Cap
17 O-Ring.........................................++
18 Backup Ring................................++
19 O-Ring.........................................++
20 Retainer
21 Spirial Retaining Ring..................++
27 O-Ring.........................................++
41 O-Ring.........................................++
Kit B
FIGURE 2
DOME LOADED
Repair Parts
Item No. Description
42 Post
43 Lower Case
44 Upper Case
45 Diaphragm..................................++
46 Diaphragm Pressure Plate
47 Cap Screw
48 Cap Screws
49 Nut
Kit B
FIGURE 3
RATIO LOADED
IOM-P78
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.
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. P7-IOM
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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