cashco PA1, PL1 Installation, Operation & Maintenance Manual
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.
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.
2
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.
IOM-PA1-PL1
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
3
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