cashco PA1, PL1 Installation, Operation & Maintenance Manual

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INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-PA1-PL1
05-17
ISO Registered Company
MODELS PA1 & PL1
PRESSURE REDUCING SANITARY REGULATORS
SECTION I
I. DESCRIPTION AND SCOPE
Models PA1 and PL1 are pressure reducing regulators used to control downstream (outlet or P2) pressure. Inlet and outlet size 1/2" (DN15) and 3/4" (DN 20) with Tri-Clamp® connections. Each model incorporates electro-polished stainless steel construction. Refer to Tech ni cal Bulletin PA1/PL1-TB for specific design conditions and selection recommendations.
SECTION II
II. INSTALLATION
CAUTION
Installation of adequate overpressure pro tec tion is recommended to pro tect the reg u la tor and all downstream equip ment from dam age in the event of reg u la tor failure.
1. An inlet block valve should al ways be installed upstream of the regulator.
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.
CAUTION
The maximum outlet pressure is list ed on the name plate as the upper range spring pres sure level, and is the rec om mend ed “upper operative limit” for the sens ing diaphragm (see Sec tion IV. Startup, Step 7). Higher press ures could dam age the di a phragm. (Field hydro static tests fre quent ly destroy dia phragms. DO NOT HYDRO STATIC TEST THROUGH AN IN STALLED UNIT; ISO LATE FROM TEST.)
SRV
Outlet @ P
2
P
1
Supply
@ P
1
Bypass
Model
PL1
Recommended Piping Schematic
For Pressure Reducing Station
Blowdown-Drain
Blowdown-Drain
3. An outlet pressure gauge should be located ap proxi mately ten pipe diameters downstream, and with in sight.
4. All installations should include a downstream re lief device if the inlet pressure could exceed the pres sure rating of any downstream equip ment or the maximum outlet pressure rating of the unit.
5. Flow Direction: Install so the flow direction match es the arrow stamped on the regulator body.
6. Install unit with spring chamber (2) in the vertical position to allow for proper draining.
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SECTION III
III. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations register on the diaphragm. The registering pressure is the outlet, P2, or downstream pressure. The range spring op pos es diaphragm movement. As
IV. STARTUP
1. For Model PA1: ensure that lock-open pin (19) is not inserted into the hole in the side of the spring chamber. See Sec tion VII.
2. Start with the block valves closed. A bypass valve may be used to maintain outlet pressure in the down stream system without changing the fol low ing steps.
3. Relax the range spring by turning the adjusting knob (3) counter clockwise (CCW) a min i mum of three full revolutions. This re duc es the outlet (down stream) pressure set point.
4. 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 ex pan sion of the piping. Closely monitor outlet (down stream) pres sure via gauge to assure 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.
5. Crack open the outlet (downstream) block valve.
6. Slowly open the inlet (upstream) block valve ob serv ing the outlet (downstream) pressure gauge. De ter mine if the regulator is flowing. If not, slowly rotate the regulator's adjusting knob clock wise (CW) until flow begins.
outlet pressure drops, the range spring pushes the di a phragm down, opening the port; as outlet pres sure in creas es, the diaphragm pushes up and the port opening closes.
2. A complete diaphragm failure will cause the reg u la tor to fail open.
SECTION IV
7. Continue to slowly open the inlet (upstream) block valve until fully open.
8. 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 3, then return to Step 5.
9. When flow is established steady enough that the outlet (downstream) block valve is fully open, be gin to slowly close the bypass valve if installed.
10. Develop system flow to a level near its expected normal rate, and reset the regulator set point by turning the adjusting knob CW to in crease outlet pressure, or CCW to reduce outlet pres sure.
11. Reduce system flow to a minimum level and ob serve set point. Outlet pressure will rise from the set point of Step 10. The maximum rise in outlet pressure on decreasing flow should not exceed the stated upper limit of the range spring by greater than 10%; i.e. 20-50 psig (1.4-3.4 Barg) range spring, at low flow the outlet pressure should not exceed 55 psig (3.8 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 (upstream) block valve. (When on bypass, the system pressure must be constantly observed and manually regulated. Close the outlet (down stream) block valve.
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SECTION V
CAUTION
Do not walk away and leave a bypassed regulator unattended.
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 re mov al is re quired.
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SECTION VI
VI. MAINTENANCE
WARNING
SYSTEM UN DER PRES SURE. Prior to performing any maintenance, isolate the reg u la tor from the system and relieve all pres sure. Failure to do so could result in personal injury.
A. General:
1. Maintenance procedures here in af ter are based upon removal of the reg u la tor unit from the pipeline where installed.
FIGURE 1: Diaphragm & Plug Sub as sem bly
2. Owner should refer to owner's pro ce dures for re mov al, handling, cleaning and disposal of nonreusable parts.
3. Refer to Figures 2 and 3 for basic regulator, item number reference ( ).
B. Maintenance :
WARNING
SPRING UNDER COMPRESSION. Prior to re mov ing spring chamber, relieve spring com pres sion by back ing out the adjusting knob. Failure to do so may result in flying parts that could cause personal injury.
1. Secure the body (1) in a soft-jaw vise using the flats on the sides of the body. Orient the knob (3) up wards.
2. Relax compression on spring (8) by turning knob (3) CCW until removed from spring chamber. Not necessary to rotate nut (5). Remove name plate.
3. Loosen spring chamber (2) by placing wrench on flats of spring chamber and rotating CCW making sure not to use flats on either side of vent hole.
4. Remove spring chamber, ball (6), spring button (7) and range spring.
5. With a wrench, secure the flats on the plug (10). Using a 7/16” wrench rotate nut (11) CCW to remove nut and lock washer (12). Do Not rotate the plug. See Figure 1. Remove pressure plate (14). NOTE: For Model PA1:
when nut is removed the plug (10) may slide out through the bottom, inlet connection. Do not let plug fall and damage seat surface.
IOM-PA1-PL1
6. Remove stabilizing o-ring with backup ring (13) from groove in O.D. of the pressure plate.
7. Remove travel stop (15), diaphragm (16), o-ring (18) and pusher plate (17).
8. For Model PL1: orient the body in a soft-jaw vise with the body cap (23) upwards. Rotate body cap CCW and remove. Remove o-ring (22). From below, push plug (10) upwards to remove.
9. For Composition Seat Construction: Secure the flats on the small diameter end of the plug in a soft-jaw vise. Use a wrench on the flats of the tail piece and rotate CCW to remove. Remove seat disc (24).
10. Clean body cavity and all reusable parts.
NOTE: Maintenance must in clude a level of clean li ness equal to Cash co clean ing stan dard #S-1576. Con tact fac to ry for details.
11. For Composition Seat Construction: Secure the flats on the small diameter end of the plug in a soft-jaw vise. Assemble the seat disc (24) and tail piece (9) on plug. Tighten to approximately 80 in.- oz.
12. For Model PL1: secure the body (1) in a soft-jaw vise using the flats on the side of the body. Orient with smaller, threaded I.D. facing upwards. For Model PA1: the inlet connection is upwards.
13. Insert the plug or plug assembly threaded end first through the body cap opening for Model PL1 or through inlet port for Model PA1.
14. For Model PL1: place o-ring (22) onto the landing above the threads of the body cap
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(23). Lightly apply “Food Grade Anti-Seez” to the body cap threads and install into the body. Tighten to 25-30 ft.-lbs.
23. Using a small adjustable wrench, hold the plug in place by the flats at the top. Use a 7/16” wrench to tighten hex nut to approx. 50 in.- lbs.
15. Re-orient the body in soft jaw vise to where the large body opening faces upward. For Model PA1: hold on to threaded end of plug so it does not fall out of the inlet, bottom connection.
16. Use appropriate end connection and loading source to pressurize the inlet of the body between 50 and 100 psig. (Inlet pressure will help hold the plug in place during the assembly and assure best plug position for regulation.
17. Continue to hold the plug (10) while placing the pusher plate (17) over the threaded end of the plug. Be sure to correctly orient the pusher plate so the o-ring groove faces up.
18. Slide the o-ring (18) over the threaded end of the plug and into the groove of the pusher plate
19. While still holding the plug, place the diaphragm (16) over the plug down on top of the pusher plate (17). Make sure the diaphragm is lying flat and is centered inside the body.
20. Place travel stop (15) over the diaphragm, ensure that the grooved side faces the diaphragm.
21. Lubricate stabilizing o-ring (13) with “Food Grade Anti-Seez” and slide it over the top edge of the pressure plate and into the groove. Position the backup ring (13) above the stabilizing o-ring in the pressure plate groove. Place the pressure plate over the threaded end of the plug.
22. Place the lock washer (12) over the threaded end of the plug and then thread nut (11) onto the same end of plug.
24. Release all pressure that was applied to inlet of the regulator.
25. Place the range spring (8) on top of the pressure plate. Then place the spring button (7) and ball (6) on top of range spring. Apply a small amount of “Food Grade Anti-Seez” to top of ball.
26. Lubricate the outside threads and flat bottom surface of spring chamber (2) and threads of adjusting screw (4) with “Food Grade Anti­Seez”.
27. Thread the spring chamber into the body and tighten to 75-100 ft. lbs.
28. Place the nameplate below the jam nut (5) and thread adjusting screw into the spring chamber until nut (5) makes contact with top of spring chamber.
29. Use appropriate end connections and test per Cashco Spec #S-1526 for Pressure Reducing Regulators.
NOTE: Regulators are not tight shutoff
de vic es. Even if pressure builds up be yond set point, a reg u la tor may or may not develop bubble tight shutoff. In general, tighter shutoff
can be ex pect ed with com po si tion seat.
30. For Model PL1: pressurize body with air and spray liquid leak de tec tor to test around body cap (6) and body (1) for leakage. Test pres sure should be a mini mum of 100 psig (6.9 Barg) at the inlet.
31. Return to Section IV for start up.
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SECTION VII
VII. CLEANING PROCEDURE for MODEL PA1:
A. Pre-Sanitation:
1. Owner should refer to owner’s op er at ing pro ce dures for system shutdown to include re liev ing all system pres sure.
CAUTION
Owner’s cleaning solution must be com pat i ble with regulator’s trim materials.
2. System internal pressure must be at/near 0 psig (0 Barg). This will ensure plug (17) is fully open. NOTE: Do not change range spring
(8) setting by rotating knob (3).
3. Insert the lock-open pin (19) into hole in the spring cham ber (2). See Figure 2.
B. Sanitation:
1. Flush, drain and sanitize system in ac cor dance to owner’s spec i fi ca tions.
NOTE: CIP is limited to 50 psig (3.45 Barg) maximum cleaning solution pres sure at 300°F (149°C). SIP is recommended to 20 psig (1.38 Barg) sat u rat ed steam pressure; can withstand 30 psig (2.07 Barg), but may reduce elastomer life expectancy.
C. Post-Sanitation:
1. Prior to system start-up, remove the lock-open pin (19) from the spring chamber (2). Unit is again operative at the setpoint established prior to cleaning.
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SECTION VIII
VIII. TROUBLE SHOOTING GUIDE
1. Erratic operation; chattering.
Possible Causes Remedies
A. Oversized regulator; inadequate rangeability. A1. Check actual flow conditions, re-size regulator for minimum and maximum
flow. A2. Increase flow rate. A3. Decrease regulator pressure drop; decrease inlet pressure by placing a
throttling orifice in inlet piping union. A4. Install next step higher range spring. Contact factory. A5. Before replacing regulator, contact factory.
B. Worn o-ring; inadequate guiding. B. Replace stabilizing o-ring (13).
2. Regulator can't pass sufficient flow.
Possible Causes Remedies
A. Regulator undersized. A1. Confirm by opening bypass valve together with regulator.
A2. Check actual flow conditions, re-size regulator; if regulator has inadequate
capacity, consult factory.
B. Incorrect range spring (screwing in CW of adjusting
screw does not allow bringing pressure level up to proper level).
C. Too much droop. C1. Review droop expected.
B. Replace range spring with proper higher range. Contact factory.
C2. Contact factory.
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, assure not subjecting to over-temperature
conditions.
B4. Downstream (outlet) pressure buildup occurring that overstresses
diaphragms. Relocate regulator or protect with safety relief valve.
C. O-ring failure. C. Replace O-ring (18), apply appropriate torque.
4. Sluggish operation.
Possible Causes Remedies
A. Fluid too viscous. A. Heat fluid. Contact factory.
5. Excessive pressure downstream.
Possible Causes Remedies
A. Regulator not closing tightly. A. Inspect the seating. Clean and lap metal seat surfaces; replace if lapping
B. Downstream block. B. Check system; isolate (block) flow at regulator inlet - not outlet. Relocate
does not remedy. If composition seats are depressed, nicked or embedded with debris, replace trim.
regulator if necessary.
C. No pressure relief protection. C. Install safety relief valve, or rupture disc.
D. Restricted diaphragm movement. D. Assure no moisture in spring chamber at temperatures below freeze point.
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Assure no dust or debris entering vent opening. If rainwater or debris can enter, re-orient regulator.
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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.
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.
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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.
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FIGURE 2: Basic Model PA1 - showing Metal Seat
Lanyard Drive Screw location Model PA1 ONLY.
Insert lock open pin here for CIP and SIP Feature, Model PA1 ONLY.
Item No. Description 1 Body
2 Spring Chamber 3 Knob 4 Adjusting Screw 5 Jam Nut 6 Ball 7 Spring Button 8 Range Spring 9 * Plug Tail Piece 10 Plug 11 Hex Nut (Plug) 12 * Lock Washer (Plug) 13 * Stabilizing O-Ring w/ Backup Ring 14 Pressure Plate 15 Travel Stop 16 * Diaphragm 17 Pusher Plate 18 * O-Ring (Pusher Plate) 19 Pin & Lanyard Assembly (Angle Style Only - Not Shown) 20 Lanyard Drive Screw (Angle Style Only - Not Shown) 21 Name Plate (Not Shown) 22 * O-Ring (Body Cap) (Inline Style Only) 23 Body Cap (Inline Style Only) 24 * Seat Disc
*Recommended replacement part
FIGURE 3: Basic Model PL1 - showing Soft Seat
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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
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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 (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: sales@cashco.com
Printed in U.S.A. IOM-PA1-PL1
Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 30968 0 Fax. No. +49 3342 30968 29 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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