INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-POSR-2
12-13
MODEL POSR-2
PILOT OPERATED PRESSURE RE DUC ING REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The POSR-2 is a pilot operated pressure reducing reg u la tor used to control downstream (P2) pressure. Sizes are
1", 1-1/2", 2", 3" and 4" (DN25, 40, 50, 80, 100). The unit is suitable for steam service only. Refer to Technical Bulletin POSR-2-TB for design conditions and selection recommendations. NOT RECOMMENDED FOR DEAD END
SERVICE.
SECTION II
II. INSTALLATION
A. General:
WARNING
Do not dead end (no fl ow demand) downstream of POSR-2
if P1 - Inlet Pressure is greater than max i mum allowable
outlet design pressure.
Max. Allowable
Spring Range Outlet Pressure
5-15 psig (0.34–1.03 Barg) 100 psig (6.9 Barg)
10–40 psig (0.69–2.8 Barg) 200 psig (13.8 Barg)
30–80 psig (2.1–5.5 Barg) 200 psig (13.8 Barg)
70–150 psig (4.8–10.3 Barg) 200 psig (13.8 Barg)
B. Piping the Valve:
1. An inlet block valve should always be in stalled.
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 are recommended for NPT
screwed in stal la tions to allow removal from
piping.
4. An outlet pressure gauge should be located ap prox i mate ly ten pipe diameters down stream,
and within sight.
FIGURE 1
Recommended Piping Schematic for POSR-2
CAUTION
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.
CAUTION
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.
5. All installations should include a downstream
re lief device if the inlet pressure could exceed the pressure rating of any downstream
equip ment or the maximum allowable outlet
pres sure rating of the unit.
6. Clean the piping of all foreign material in clud ing chips, welding scale, oil, grease and
dirt before installing the regulator. Strainers
are recommended.
CAUTION
DO NOT HYDROSTATIC TEST THROUGH AN IN STALLED
UNIT, INCLUDING PILOT; ISOLATE BOTH PILOT AND MAIN
VALVE FROM TEST. The upper range spring pressure
level listed on the nameplate is the rec om mend ed “upper
operative limit” for the sens ing diaphragm(s) in the pilot.
Higher pres sures could cause internal damage. In addition,
note on the name plate that the Inlet and Outlet pressure
and tem per a ture ratings are at different levels.
7. In placing thread sealant on pipe ends prior
to en gage ment, assure that excess material
is removed and not allowed to enter the reg u la tor upon start-up.
8. Flow Direction. Install so the fl ow direction
match es the fl ow arrow on the body.
9. The POSR-2 comes factory piped between
the pilot supply and pilot loading. Install an
external sensing line from the 1/4" NPT con nec tion opposite the factory piped pilot load ing
port to a point downstream at gauge location;
use 1/4" OD metal tubing for dis tanc es 4 ft
(1.2 m) or less, and 3/8" OD metal tubing (requires 1/4" x 3/8" tubing adapter) for distances
greater than 4 ft. (1.2 m). The sensing line
should always be sloped down ward so that
condensation will drain away from the pilot.
If regulator pipe line is ex pand ing to a larger
pipe line, always connect sens ing line to the
larger pipe line.
10. See Figure 2 for installation ori en ta tion for
hor i zon tal or vertical piping. For best per for mance Cashco rec om mends in stall ing in a well
drained horizontal pipe, prop er ly trapped.
Position “H”: Horizontal Pipe. Re quires user
to in stall sensing line on down stream pip ing.
Position “VD”: Vertical pipe with down wards
fl ow direction. Requires user to install
sensing line on down stream pip ing.
Position “VU”: Vertical pipe with up wards
fl ow di rec tion. Pilot valve and main valve
shipped as separate units. Re quires user
to install pilot valve at down stream pipe tap
with a pipe nipple (not provided), provide
and install tub ing (4 tube fi ttings and two 4
ft (1.2 m) lengths of 1/4" OD copper tubing
supplied) to load ing cham ber tap and to
body tap from pilot valve.
P
1
11. Recommended installation is with pilot valve
spring chamber vertical upwards. Orient such
that the spring chamber vent hole does not
collect rainwater or debris.
12. Regulators are not to be buried underground.
13. For insulated piping systems, rec om men da tion
is to not insulate regulator.
III. PRINCIPLE OF OPERATION
A. General:
1. The POSR-2 pilot obtains its operating me di um
from the main valve body inlet. Down stream
pressure (P2) registers on the un der side of
the main valve’s piston and the pilot valve’s
diaphragm(s).
2. The loading pressure on the top side of the
main valve’s piston is an intermediate pres sure
higher than the downstream (P2) pres sure by
the sum of the pressures required to overcome
the main valve’s plug unbalance force and the
piston spring’s force.
3. The pilot has a bleed orifi ce that continu-
ously bleeds part of the loading medium
down stream. In op er a tion, the pilot valve’s
plug can fl ow more medium than is bleed-
SECTION III
ing down stream. This increases the loading
pres sure on the main valve’s plug and opens
valve. Partially closing the pilot valve’s plug will
reduce its fl ow to less than the amount bleed ing
downstream, and allows the loading pres sure
on the main valve’s piston to decay, allowing
partial closing of the main valve’s plug. This
continues until steady-state is de vel oped.
4. The pilot valve’s diaphragm(s) senses the
down stream (P2) pressure and compares
the force generated to the force developed
by the pilot’s range spring.
5. If, during operation, the downstream (P2)
pres sure falls below the pilot valve’s setpoint,
the main valve’s piston senses the reduced
pres sure on its underside and instantly moves
down, increasing the fl ow through the main
valve. At the same time, the pilot valve senses
the reduced pressure and the pilot valve’s plug
IOM-POSR-22
Pipe or tubing installed by customer / installer.
Pipe or tubing installed by Cashco.
POSITION “H”
Pilot valve and main
valve shipped as two
units. Installer to connect
between pilot valve and
main valve for “loading”
and “supply” tubes.
POSITION “VU”
FIGURE 2
Orientation/Arrangement
IOM-POSR-2 3
POSITION “VD”
increases its opening, elevating the loading
pressure on the upper side of the main valve’s
piston. The combined actions increase fl ow
enough to restore the down stream (P
sure to the setpoint.
6. If the downstream (P
) pressure rises above
2
the setpoint, the force developed by the
in creased pressure on the underside of the
piston instantly moves it upward and partially
closes the main valve’s plug. Simultaneously,
the pilot valve’s plug partially closes and al lows the loading pressure to decay through
) pres-
2
SECTION IV
the bleed orifi ce. The reduced loading pres-
sure on the upper side of the piston closes
the main valve’s plug enough to restore the
down stream (P
) pressure to the setpoint.
2
7. Pressure setpoint is adjusted by changing the
com pres sion of the pilot’s range spring by turning the adjusting screw either clockwise (CW)
or counter-clock wise (CCW). Turning the
adjusting screw clockwise (CW) will in crease
the downstream (P
) pressure. Turn ing the
2
adjusting screw counter-clockwise (CCW) will
decrease the down stream (P2) pressure.
IV. START-UP
A. General
1. Start with the block valves closed.
2. Ensure that the needle valve(s) on the
sensing line is opened and downstream (P2)
pressure is in di cat ing on pressure gauge.
3. Relax the pilot valve range spring by turning the adjusting screw counter clockwise
(CCW) (viewed from above) a minimum of
three (3) full revolutions. This reduces the
outlet (downstream) pressure setpoint.
4. Slowly open the bypass valve to preheat the
system piping and to allow slow expansion of
the piping. Assure proper steam trap op er a tion.
Closely monitor outlet (down stream) pressure
via gauge to assure not over-pres sur iz ing.
NOTE: If no bypass valve is in stalled, extra
caution should be used in start ing up a cold
system; i.e. do everything slowly.
If not, slightly close bypass valve, and then
slowly rotate the pilot valve adjusting screw
clockwise (CW) (viewed from above) until fl ow
begins.
7. Continue to alternate slowly closing the by pass valve and then slowly opening the inlet
(upstream) block valve, especially when the
downstream piping sys tem isn’t pres sur ized.
If the outlet (downstream) pressure exceeds
the desired pressure, close the by pass valve
until fully closed. If outlet pressure still re mains above desired level, rotate pilot’s ad just ing screw CCW (viewed from above) in
1/2 revolution increments until outlet pressure reaches desired level. If outlet pressure
is below desired level, rotate pilot’s adjusting
screw CW (viewed from above) until desired
level is reached.
8. When fl ow is established steady enough that
the inlet (upstream) block valve is fully open,
begin to slowly close the bypass valve and
continue until fully closed.
CAUTION
Do not walk away and leave a bypassed regulator unattended when on manual bypass!
5. Slowly open the outlet (downstream) block
valve until fully open. Slightly close the by pass
valve at same time.
6. Slowly open the inlet (upstream) block valve
ob serv ing the outlet (downstream) pressure
gauge. De ter mine if the regulator is fl owing.
9. Develop system fl ow to a level near its ex-
pect ed normal rate, and reset the regulator
setpoint by turning the pilot valve adjusting
screw CW (viewed from above) to increase
outlet pressure, or CCW to reduce outlet pres sure.
10. Reduce system fl ow to a minimum level and
observe setpoint. Outlet pressure will rise from
the set point of Step 9. There should be no
more than a 10% variation in outlet pres sure
over the maximum to minimum fl ow range.
IOM-POSR-24
V. SHUTDOWN
A. General
1. On systems with a bypass valve, and where
system pressure is to be maintained as the
POSR-2 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 pres sure
must be constantly observed and man u al ly
regulated.) Close the outlet (down stream)
block valve. Close the nee dle valve on the
pilot valve’s sensing line.
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 regulator removal is required.
Close the needle valve on the pilot valve’s
sensing line.
SECTION Vl
VI. MAINTENANCE
CAUTION
SYSTEM UNDER PRESSURE. Prior to performing any
maintenance, isolate the regulator from the sys tem and
relieve all pressure. Failure to do so could result in personal injury.
A. General:
1. Maintenance procedures hereinafter are
based upon removal of the regulator unit from
the pipeline where installed, and main te nance
performed in a workshop.
2. Owner should refer to owner’s procedures for
re mov al, handling, cleaning and disposal of
non-reuseable parts, i.e. gaskets, etc. Cash co
recommends not reusing any gaskets, but
replacing with only new and factory supplied
gaskets.
3. This regulator is supplied from the factory
using a gasket sealing aid, Federal Process
Company, PLS 2, or equal. Such compatible
sealing aids may be utilized by the Owner, if
desired.
4. All indicated item numbers that are with re spect
to the Pilot Valve will be in parenthesis and
underscored, i.e. (14), (PV). All item numbers
that are with respect to the Main Valve will
NOT be underscored, i.e. (1), (MV).
5. Refer to Figures 6 through 12 for item num ber
callouts.
6. Most pilot-operated valve operation problems
center around the pilot valve (PV). Cashco
always rec om mends full maintenance on any
POSR-2 pilot valve (PV) once a POSR-2 is
removed from the pipeline.
B. Separation:
1. Observe orientation of pilot valve (PV) with
re spect to main valve (MV) position “VD”,
“H”, or “VU”, Figures 6, 7 or 8, be fore dis as sem bling.
2. Place main valve body (1) into a vise, oriented
to allow rotation of pilot valve (PV) together
with in ter con nect ing pipe nipple (19).
3. Remove loading tubing (21) at both end fi t tings
(20) by rotating nut CCW (viewed from tubeend). Disengage union (28) where ap pli ca ble
and remove pilot valve (PV).
4. Place pipe wrench on pipe nipple (19) and
rotate CCW (viewed from pilot valve (PV)
end) to removal. Remove main valve (MV)
from vise and set aside.
5. Place pilot valve body (1) in vise. Remove
pipe nipple (19) or other pipe fi ttings (20, 27,
30) as is applicable.
6. Inspect the inside of the pipe and fi ttings for
corrosion, scaling, debris, or fi lming. Prob-
lems here will be an indication of im prop er
condensate cor ro sion control which can
affect the overall operation of the
POSR-2. Install an upstream strainer if scale
or debris ap pears at this point.
IOM-POSR-2 5
7. Remove pilot valve (PV) from vise and set
aside.
C. Pilot Valve (PV):
1. Securely install the pilot valve body (1) in
a vise with the spring chamber (2) directed
upwards.
8. Using a 7/8" deep well socket, remove bel lows
(11) by rotating CCW (viewed from above).
Count and record the number of revolutions
required to remove the bellows (11) in the box
below:
Number of revolutions required to remove
bellows (11):________________.
WARNING
SPRING UNDER COMPRESSION. Prior to re mov ing body
fl ange bolts, relieve spring com pres sion by backing out
the adjusting screw. Failure to do so may result in fl ying
parts that could cause personal injury.
2. Loosen locknut (20) by rotating CCW (viewed
from above) ONLY two revolutions. Relax
range spring (15) by turning adjusting screw
(19) CCW (viewed from above) until removed
from spring chamber (2). Set ad just ing screw
(19) with locknut (20) aside.
3. Draw or embed a match mark between body
casting (1) and spring chamber casting (2)
along fl anged area.
4. Remove all diaphragm fl ange nuts (18) and
bolts (17).
5. Remove spring chamber (2) by lifting up wards.
Re move range spring (15) and spring button
(16).
6. Remove pressure plate(14). Inspect to
en sure that the pressure plate (14) has not
been deformed by overpressure by placing a
thin, straight bar or ruler across the side that
touch es the diaphragm (12). If the pressure
plate (14) does not touch the bar at its center
(i.e. a depression in center), the pressure plate
(14) is deformed and must be replaced.
7. NOTE: Pilot valves (PV) supplied with a 5–15
psig (0.34–1.03 Barg) range spring (15) have
only one di a phragm (12) supplied; all other
spring ranges use two diaphragms (12).
Using a putty knife or similar tool, remove
diaphragm(s) (12) and diaphragm gasket
(13). Inspect diaphragm(s) (12) for cracks or
de for ma tion. Radial creases and cracks indicate over pressure. Cracks circumferentially
in di cate high cycles, and may be due to normal
cycling, or pulsing or chattering if premature.
Discard both diaphragm(s) (12) and gasket
(13).
Inspect the bellows (11) for a crack or joint
failure where leakage is occurring. Replace
bellows (11) if leaking.
9. Remove protruding stem extension (10).
10. Using a fl at, sharp-edged tool, clean body (1)
fl ange where diaphragm gasket (13) seals.
11. Using a wire gauge tool, clean the 0.068"
(1.73 mm) diameter bleed orifi ce located in
the body cavity (smaller of two holes) of any
fi lm or other buildup material that might be
restricting fl ow.
NOTE: Any signifi cant blockage of the bleed
or i fi ce will downgrade a POSR-2’s per for-
mance. If a buildup is form ing, attempt to determine the cause and remove the source.
12. Remove body (1) from vise and reorient with
body cap (9) on top; resecure body (1) in
vise.
13. Remove body cap (9) by rotating CCW (viewed
from above) with hex-end wrench. Hammerrapping the wrench may be necessary, as the
body cap (9) has a metal-to-metal shoulder
joint with the body (1). NOTE: Plug (4.2) and
plug spring (7) may come out with body cap
(9) removal.
14. Remove plug spring (7) and plug (4.2) from
body (1) recess.
15. Using needle nose pliers, carefully remove
the screen (6) from the body (1) recess.
16. Inspect body cap (9), screen (6), plug spring
(7), and plug (4.2) for buildup or fi lming. If
parts are “sticking” together, then improper
condensate corrosion treatment is likely. If
scale or other debris is present, then an up stream strainer is recommended.
17. Using a 5/8" deepwell socket, rotate valve seat
(4.1) CCW (viewed from above) to re mov al.
IOM-POSR-26
18. Remove seat gasket (8) using a tool with a
bent sharp end. Discard the seat gasket (8).
19. Using a sharp edged tool, clean all gasket
sur fac es, and metal-to-metal contact sur fac es
of body (1), valve seat (4.1) and body cap
(9).
with stem extension (10) into body (1) recess.
Allow stem extension (10) to “fall” into thread ed
opening for bellows (11). Align threaded por tion of bellows (11); rotate CW (viewed from
above) the same number of engaged rev o lu tions recorded in article 8. previous, this
sub sec tion.
20. Lap plug (4.2) with valve seat (4.1) using a
suitable lapping compound. Do for new re place ment plug (4.2) and seat (4.1) also.
21. Solvent clean all loose internal parts of pilot
valve (PV). Inspect the valve seat (4.1) and
plug (4.2) for wear. Replace the valve seat
(4.1) and plug (4.2) together, even if only one
piece shows signifi cant wear. Solvent clean
body (1).
22. Place body (1) into vise with body cap (9)
opening upwards.
23. Place seat gasket (8) into recess.
24. Put thread lubricant onto valve seat (4.1), and
rotate valve seat (4.1) into threaded recess
by rotating CW (viewed from above) until seat
(4.1) shoulders against body (1).
25. NOTE: Replace screen (6) only if neces-
sary. Using a 3/4" (19 mm) round bar, form
and interlock the fl at screen (6) similar to the
removed screen (6) being re placed. Slide
formed screen (6) off of bar. Insert the screen
into the body recess and over the hex points
of the valve seat (4.1). Ensure concentricity
of positioned screen (6).
26. Place plug spring (7) into recess of plug (4.2),
and position plug’s (4.2) stem-end through the
valve seat (4.1).
30. Place diaphragm gasket (13) onto body’s (1)
fl ange aligning cutouts of gasket (13) with bolt
hole open ings.
31. Place diaphragm(s) (12) onto body (1) po si tioned concentrically. NOTE: Reassemble
pilot valve (PV) ONLY with the number of
di a phragms (12) disassembled with; the 5–15
psig (0.34–1.03 Barg) spring range uses only
one diaphragm (12).
32. Concentrically position pressure plate (14)
onto diaphragm(s) (12).
33. Set range spring (15) over hub of pressure
plate (14).
34. Place multi-purpose, high temperature grease
into recess of spring button (16) where ad just ing screw (19) bears. Place spring button
(16) over top-end of range spring (15) with
greased recess on top side.
35. Clean threads of diaphragm bolting (17) (18).
Place thread lubricant on bolts (17). Engage
two sets of bolting (17) (18) for ease in ro ta tion;
disengage.
36. Place the two bolts (17) of above ap prox i mate ly
180° across through body (1) di a phragm
fl ange from un der neath side. Hold bolts (17)
with fi ngers of one hand to keep from falling
downwards.
27. Place thread lubricant on threads of body cap
(9). Capture protruding plug (4.2) end and plug
spring (7) with body cap (9) recess. Rotate
body cap (9) CW (viewed from above) until
shouldering on body (1). Hammer rap wrench
handle to ensure tightness.
28. Remove body (1) from vise and reposition
with di a phragm fl ange oriented on top.
29. Place thread sealant/lubricant onto threads
of bellows (11). Insert fl at-end of stem exten-
sion (10) into the center of the bellows (11);
cham fered end of stem ex ten sion (10) should
be protruding bellows (11). Invert bellows (11)
IOM-POSR-2 7
37. Set spring chamber (2) down over the two
pro trud ing bolts (17), aligning the matchmarks
of article 3. pre vi ous, this subsection.
38. Place the two nuts (18) onto bolts (17) of
above, and fi nger-tighten.
39. Place remaining bolts (17) through spring
cham ber (2) bolt hole openings. Engage all
nuts (18) onto bolts (17) along underneath
side of body (1) fl ange and fi nger-tighten.
40. Remove the two upside-down bolts (17) and
nuts (18) and rotate to position of other bolts
(17). Place nameplate tag (21) over one of
the bolts (17) before replacing into bolt hole.
Fin ger-tighten nuts (18).
41. Observe through opening in top of spring
cham ber (2) to ensure the concentricity of the
recess in the spring button (16) with the top
opening. It may be necessary to use an awl
or similar tool to realign the spring button (16)
as much as possible. The spring chamber (2)
is not tightened down, and may be temporarily “shifted” to help ensure alignment for the
adjusting screw (19) en gage ment.
42. Place lubricant onto the upper exposed threads
of the spring chamber’s (2) adjusting screw
(19) opening. Place lubricant onto the ad just ing
screw (19) lower-end threads. Engage adjusting screw (19) back into spring cham ber (2)
by rotating CW (viewed from above). Engage
only until resistance is made with the range
spring (15) via the spring button (16).
43. Realign the spring chamber (2) fl ange with the
body (1) fl ange, and wrench-tighten bolting
(17, 18) in an al ter nat ing, crossing pattern.
Final tightening should be done with a torque
wrench to 15 ft.-lbs. (20 N-M).
WARNING
subassembly (IS) will not “fall from within the
cylinder (3)” when the cylinder (3) is oriented
vertically, when gravity overcomes seal (12)
friction.
WARNING
Follow procedures given herein in handling main valve
topworks! Failure to heed may result in internals sliding
out of cylinder and falling down wards to im pact on foot!
For the 1" through 2" main valve (MV) body
sizes, the actuator/topworks is not so heavy
that an overhead hoist is re quired. However,
if an overhead hoist is not used, im prop er
handling of the removed cylinder (3) and
internals subassembly (IS) can still result in
the internals sub as sem bly (IS) “falling from
within the cyl in der (3)” by gravity, so the above
“warning statement” is still valid.
2. Using an overhead hoist, rig the main valve
(MV). Lift and securely place the main body
(1) in a vise with the cylinder head (4) directed
upwards.
3. Draw or embed a match mark between the
cyl in der head (4), cylinder (3), bonnet (2) and
body (1).
Never replace bolting (17, 18) with just any bolting if lost.
Bolt heads and nuts are marked with spec i fi ca tion iden-
tifi cation markings. Use only proper grades as replace-
ments.
44. Continue CW rotation (viewed from above) of
ad just ing screw (19) until locknut (20) touches
spring chamber (2). Back adjusting screw (19)
out by rotating CCW (viewed from above) two
revolutions. This position will ap prox i mate the
pressure setpoint prior to dis as sem bly if the
locknut (20) is only loosened two revolutions
as directed in article 2. previous, this subsection.
45. Reconnect pilot valve (PV) to main valve (MV).
See Figures 6, 7 and 8 for correct orientation.
Pressure leak test the complete assembly per
Section VII.D.
D. Main Valve (MV):
1. General Note: The actuator/topworks section
of the main valve (MV) is suffi ciently “heavy”
for the 3" and 4" (DN80 and 100) body sizes
that the procedures following are written to include overhead hoisting. Additionally, fol low ing
the procedure will ensure that the internals
4. Loosen elongated cylinder bolting (16, 17) by
rotating each nut (17) CW (viewed from above)
until fully removed. Withdraw each of the four
elongated bolts (16). NOTE: Sizes 3" and 4"
(DN80 and 100) have the body’s (1) bonnet
fl ange drilled and tapped so that no bottom
nut (17) is required.
5. While holding the cylinder (3) by hand, use
a wooden block to lightly rap the underneath
side of the cylinder head (4) to release the
head-to-cylinder joint. Once loosened, re move
the cylinder head (4).
6. Place locking pliers on stem nut (15). Keep
the pliers within the cylinder’s (3) interior away
from the cylinder (3) wall.
7. While placing downward force on the locking
pliers of the previous article, grasp the cyl in der
(3) by hand and simultaneously lift up wards
and wiggle sideways at the top until the joints
at the lower end of the cylinder (3), bonnet (2)
and body (1) loosen. If necessary, use a fl at,
sharp-edged tool to get under the bonnet (2)
at the joint between the bonnet (2) and the
body (1) while gently pushing the cylinder’s
(8) upper edge sideways back-and-forth; do
IOM-POSR-28
not apply excessive sideways force to the
cylinder (3). Move the fl at tool fully around
the bonnet-to-body joint to ensure being fully
loosened.
8. Install the temporary eyenut (supplied with
Parts Kits “A” or “B” for 2"–4" sizes) onto the
threaded end of the plug-stem assembly (7).
Eyenut size is:
Main Body Size Nominal Eyenut Size - Inch
2" 1/2" – 13 UNC
3" 1/2" – 13 UNC
4" 5/8" – 11 UNC
NOTE: For the 1" and 1-1/2" main valve (MV)
body sizes, fabricate a hanger bracket with
sheet metal similar to Figure 3 below.
Fabricated Sheet Metal
Hanger Bracket
16 Ga. Min.
that the outer diameter edge of the bonnet
(2) can be secured in the vise, and the plugstem assembly (7) oriented horizontally. When
se cured, slacken overhead hoist cable, rope,
etc., to allow removal.
11. Remove temporary eyenut from end of plugstem assembly (7).
12. Place a support strap around the cylinder (3)
and attach to overhead hoist. Place the strap
into “tension” with the hoist by removing “slack”
in strap.
13. Insert a “round” tool (rod, Allen key wrench,
Phillips-end screwdriver, etc.) through the hole
located in the stem portion of the plug-stem
assembly (7), just above the plug por tion.
NOTE: It may be necessary to place a wrench
on the stem nut (15) to rotate the plug-stem
assembly (7) enough to allow access for the
round tool through the “cage window” of the
bonnet (2) and through the stem (7) hole.
14. Loosen stem nut (15) by rotating CCW (viewed
from nut end), allowing tool of previous article
to secure the plug-stem assembly (7) from
rotating. Fully remove stem nut (15). NOTE:
There will be noticeable friction in removal of
nut (15) as piston spring (14) relaxes (elon gates). The spring (14) will be fully relaxed
before the stem nut (15) is fully removed.
FIGURE 3
Hanger Bracket
9. Using an overhead hoist with the cable, rope,
etc., fastened through the temporary eyenut,
pull the internals subassembly (IS) and cyl in der (3) upwards and out of the body (1).
The internals subassembly (IS) consist of the
fol low ing parts:
(2) bonnet
(5) seat ring
(7) plug-stem assembly
(8) piston
(12) piston seal
(13) one-ring gasket
(14) piston spring
(15) stem nut
10. Position the hoisted internals subassembly
(IS) and cylinder (3) above a second vise with
leaded jaws. Lower the suspended parts such
15. Pull cylinder (3) horizontally outwards to re mov al, moving overhead hoist as necessary.
Set cylinder (3) aside.
16. Using a needle-nose pliers, grasp outside lip
of seal (12), lift seal (12) up and pull out of
recess over end of piston (12). NOTE: Seal (12)
should be replaced with every dis as sem bly.
17. Remove piston (8) and piston spring (14).
18. While holding seat ring (5) with fi ngers, with-
draw plug-stem assembly (7). Seat ring (5)
will be released from capture.
19. Remove all three of the TFE gaskets (13) and
discard. These gaskets may be stuck to the
cylinder head (4), cylinder (3), bonnet (2) or
body (1). If any of these gaskets (13) were
leaking, determine by inspection the possible
reason for the leakage.
20. Remove seat ring gasket (6) from body (1)
cavity and discard.
IOM-POSR-2 9
21. Using a sharp, fl at-edged tool, clean the gas-
ket fac ings and all surfaces where a metalto-metal joint occurs on the body (1), bonnet
(2), cylinder (3) and cylinder head (4).
22. Remove body (1) and bonnet (2) from vises
and solvent clean. Solvent clean all loose parts
to be reused.
32. Place cylinder (3) into a strap support and lift
with an overhead hoist. Swing cylinder (3) over
threaded end of plug-stem assembly (7) and
lower into the shoulder of bonnet (2), taking
care to protect ring gasket (13) of previous
article 30., above. Align match marks and
apply duct tape to hold cylinder (3) to bon net
(2).
23. Inspect all surfaces for wear. Replace all parts
that have excessive wear. Replace seat ring
(5) and plug-stem assembly (7) as a set. Hone
cylinder (3) if slightly grooved.
24. Lap plug-stem assembly (7) together with seat
ring (5) using a suitable lapping com pound. Do
for new re place ment parts as well as reused
parts (5, 7). Clean parts of lapping compound
with suitable solvent and let dry.
25. Place cleaned body (1) back into vise.
26. Place new seat ring gasket (6) into body (1)
cavity.
27. Insert the plug-stem assembly (7) through
the bonnet (2) and check clearance between
stem (7) and hardened bushing (18) with a
wire gauge. Normal clearance is .001–.002"
(.025–.050 mm). If excess clearance is due to
wear in stem (7), replace plug-stem assembly
(7). If clearance is due to bushing wear, place
bon net (2) under a hydraulic press and “press
out” the bushing (18); “press in” a replacement
bushing. If new bushing seems “loose” after
pressing in, place four small tack welds along
the bushing (18) OD on top of bonnet (2)-tobushing (18) joint, taking care to not overheat
the bushing (18) and distort.
33. Place piston (8) with recess for piston spring
(14) face down on fl at surface.
34. Position a small section of the seal (12) cir cum fer ence around the top recess of the piston
(8). Apply an equal amount of thumb pressure
on opposing sides of the seal (12) as the seal
(12) is pressed around and over the top of the
piston (8) into the recess. NOTE: Install seal
(12) with opening of U-Cup facing upwards.
35. Place piston spring (14) into recess of piston
(8).
36. Rotate stem (7) until the tool of previous article
13., this subsection, can be inserted through
hole of stem (7). Leave the tool in the hole.
37. Carefully slide piston (8) with captured
piston spring (14) into cylinder (3). Insert a
rod or similar tool into the center hole of the
piston (8), and simultaneously lift and move
into the cylinder (3) deeper. Using fi ngers of
one hand, push the plug-stem assembly (7)
together from the plug (7) end. Lift piston (8)
onto threaded portion of plug-stem assembly
(7) as far as possible, removing tool when
nec es sary. Place hand into cylinder (3) and
push the piston (8) until the piston spring (14)
begins to compress.
28. Place bonnet (2) back into the second vise
held as previous.
29. Determine correct orientation of seat ring (5)
from Figure 9 herein. (DO NOT INSTALL
SEAT RING (5) UPSIDE DOWN.) Insert plugstem assembly (7) threaded end through seat
ring (5) and bonnet (2) bushing (18). Push seat
ring (5) into the “cage” portion of the bonnet
(2).
30. Place TFE ring gasket (13) onto upper side
of bonnet (2) and onto shoulder.
31. Place a thin fi lm of lubricant onto the cylinder
(3) inside wall at the wear points of the piston
seal (12). Wipe excess lubricant away with a
clean, dry cloth.
38. Place temporary eyenut onto threaded end of
plug-stem assembly (7). Finger-tighten eyenut
until piston spring (14) is slightly under com pres sion.
39. Place a rope, cable, etc., through the eyenut
and rig for overhead lifting. Simultaneously,
loos en the grip of the vise on the bonnet (2),
lift the cylinder (3) with its hoist, and lift the
partial internals subassembly (IS) with its hoist.
Con tin ue the lifting slowly until the internals
sub as sem bly (IS) is vertical. Release the strap
support from the cylinder (3). Fully release the
vise’s grip.
40. Place a round wooden peg about 2" (50 mm)
tall with fl at ends, and small enough to fi t within
the seat ring (5) onto a fl at work surface. Swing
IOM-POSR-210
partial assembly of previous article above until
centered over the peg. Lower partial assembly
down onto peg until weight is resting on peg.
Place spacers near outside diameter of bonnet
(2) 180° across to stabilize partial assembly
from tipping over. See Fig ure 4.
48. Remove temporary eyenut.
49. Place wrench back onto stem nut (15). While
grasping anti-stem rotation tool, hammer rap
nut (15) tightly. Re move anti-rotation tool.
50. Place temporary eyenut back onto threaded
end of plug-stem assembly (7). Re-rig to
over head hoist.
51. Lift the internals subassembly (IS) and cyl in der
(3). Place a suitable thread sealant in three or
four places along the bottom shoulder of the
bonnet (2) where the bonnet (2)-to-body (1)
ring gasket (13) is located. Push the ring gasket
(13) into the sealant expecting the sealant to
hold the gasket (13) for fi nal as sem bly and
alignment; apply additional sealant if necessary.
52. Swing lifted internals subassembly (IS) and
cyl in der (3) over the body (1) in its vise. Align
match marks and lower the internals sub as sem bly (IS) down wards into the body (1) cavity,
tak ing care to not damage the bonnet (2)-tobody (1) ring gas ket (13). Remove over head
rig ging and tem po rary eyenut.
FIGURE 4
Wooden Pegs and Spacers
41. Remove overhead support from eyenut. Re move eyenut.
42. Engage stem nut (15) with stem (7) end and
rotate nut (15) CW (viewed from above) about
two revolutions while restraining with tool to
prevent stem (7) rotation.
43. Remove the duct tape applied in previous article 32., this subsection. Grasp the cyl in der
(3) near its upper edge, and gently wiggle the
stacked internals sub as sem bly (IS) parts from
several directions.
44. Continue to wrench-tighten stem nut (15).
45. Place duct tape 360° around the cylinder (3)to-bonnet (2) joint.
46. Install temporary eyenut onto protruding
threads of plug-stem assembly (7). Install
cable, rope, etc., to over head hoist.
53. Prepare cylinder head (4) for its ring gas ket
(13) similar to ring gasket (13) for bonnet (2)
of previous article 33. , this subsection.
54. Align match marks and lower cylinder head (4)
down onto cyl in der (3) upper shoulder, taking
care to not damage cylinder (3)-to-cyl in der
head (4) ring gasket (13). Align the fl at edges
of the cylinder head (4) to be in the same plane
as the fl ange of the body (1) below by rotating
the head (4) as necessary.
55. Insert the four elongated cylinder bolts (16)
through the bolt hole of the cylinder head (4)
and downwards through the bolt hole of the
body (1) fl ange. Install nuts (17) on the bolts
(16) by rotating nuts (17) CCW (viewed from
above). Finger tighten all nuts (17).
WARNING
Never replace bolting (17, 18) with just any bolting if lost.
Bolt heads and nuts are marked with spec i fi ca tion iden-
tifi cation markings. Use only proper grades as replace-
ments.
47. Raise internals subassembly (IS) with cyl in der
(3) above wooden peg. Remove peg. Lower
internals sub as sem bly (IS) and cyl in der (3)
down onto the fl at work surface.
56. Using a torque wrench, tighten the bolting
(16, 17) to the levels indicated in the following table in an al ter nat ing, crossing pat tern in
1/4 revolution in cre ments.
IOM-POSR-2 11
Main Valve
Body Size
in (DN) ft-lbs (N-M)
1" (25) 25–30 (33-40)
1-1/2" (40) 25–30 (33-40)
2" (50) 70–75 (94-101)
3" (65) 100–110 (135-149)
4" (100) 150–160 (203-216)
Torque
57. Rig the reassembled main valve (MV) for
over head hoisting. Re move temporary duct
tape. Lift and remove from vise.
E. Joining:
2. Place thread sealant on threaded ends of pipe
nipples (19, 29 and 30) and on street elbow
(27). Ensure that excess material is removed
and not allowed to enter the regulator upon
start-up.
3. Reconnect pilot valve (PV) to main valve (MV)
using appropriate pipe nipple(s) and fi ttings
(19, 26, 27, 28, 29 & 30). Using a pipe wrench,
ensure that all connections are tight and in
proper orientation.
4. Reinstall interconnecting tubing (21) be tween
main valve (MV) cylinder head (4) and pilot
valve (PV) body (1).
1. Place main valve body (1) into vise, oriented
to allow correct positioning of pilot valve (PV)
and interconnecting piping. See Figures 6, 7
& 8.
VII. LEAK TESTING
A. General:
1. A POSR-2 is a metal-to-metal seated de sign
with standard hardened trim in main valve
(MV) and pilot valve (PV).
2. Both pilot valve (PV) and main valve (MV)
are of a fl ow-to-close design, and can be seat
leakage tested without extensive setup.
3. There are two design pressures for a
POSR-2; one for the higher inlet pressure
zone, and another for the lower outlet pres sure zone.
Recommended Test Pressures –
Inlet: 100 psig (7.0 Barg).
Outlet: 15 psig (1.03 Barg) for Pilot with
5–15 psig (0.34–1.03 Barg) spring
range.
Outlet: 40 psig (2.7 Barg) for Pilots with
(Cont.) 15–150 psig (1.03–10.3 Barg) spring
ranges.
B. Seat Leakage – Pilot Valve (PV):
1. Separate pilot valve (PV) from main valve
(MV), see Section VI, subsection B.
2. Install a temporary 1/4" - NPT pipe plug into
the (P
) connection.
Int
5. Leak test the combined unit per Section
VII.D.
SECTION VII
3. Install a hose fi tting and hose into the 1/2"
FNPT connection port of the pilot valve (PV)
body (1). Place other “open” end of the hose
at the bottom of a glass container having
approximately 1/8" (3 mm) of water depth.
NOTE: Pilot valve (PV) and glass container
should be at about the same elevation.
4. Relax the range spring (15) by rotating the
ad just ing screw (19) CCW (viewed from above
ad just ing screw) until fully loose. Keep track of
the num ber of rev o lu tions in the box below:
No. of Revolutions adjusting screw ro tat ed:
__________________
5. Connect temporary air supply with in-line ad just able airset regulator to P2 outlet of pilot.
Slow ly pres sur ize the pilot valve (PV) while
ob serv ing the jar with water. Bring pres sure
to 50 psig (3.4 Barg). Wait a min i mum of fi ve
min utes. Ob serve for leak age of bubbles in the
water jar. If the number of bub bles is greater
than one (1) per minute, the leakage is at the
point where trim re place ment is rec om mend ed.
(Rec om mend pres sure in teg ri ty test per subsection D. herein.)
6. Remove leak test apparatus. Reconnect pilot
valve (PV) to main valve (MV) using ap pro pri ate pipe nipples, tubing and fi ttings (19, 20,
26, 27, 28, 29 & 30). Ensure all connections
are tight and in proper orientation.
IOM-POSR-212
C. Seat Leakage – Main Valve (MV):
NOTE: The main valve’s (MV) plug (7)-to-seat (5)
leak age and cylinder (3)-to-seal ring (12)
leak age should both be tested.
1. Separate pilot valve (PV) from main valve
(MV). See Section VI, subsection B.
2. Insert tapped pipe plugs with hose fi ttings into
both the inlet and outlet connections. Place
open end of outlet hose in jar of water per B.3.
above.
3. Install temporary hoses with tight shutoff in stru ment needle valves at three con nec tions;
cylinder head-inlet, vent, and inlet of main
valve. See Figure 5.
4. Close valves #2, and #3. Open valve #1.
Slowly pressurize the inlet up to 50 psig (3.4
Barg). Wait a min i mum of 10 min utes. Ob serve
for leak age of bubbles in the water jar. If the
number of bubbles is greater than the limit
indicated below in Table 1, trim re place ment
or extra lap ping is rec om mend ed.
TABLE 1
Body Size
in. (DN)
1" (25)
1-1/2" (40)
2" (50)
3" (80)
4" (100)
Plug-to-Seat Ring Cyl in der-to-Seal Ring
Maximum Leak Rate
SCFH Bubbles Per Minute
2<1
4<1
71
13 1–3
17 3–6
5. Remove hose from open end of jar. Open valve
#2. Close valve #1. Place hose end back into
jar. Follow a similar pro ce dure as in article
4. previous, to leak test the Cylinder (3)-toSeal Ring (12) seal. (If a new seal ring (12)
was installed, stroke the piston (8) about 50
cycles by alternately opening/closing valves
#2 and #3 in se quence, at tempt ing to “seat”
the seal ring (12) before beginning the leak
test.) (Rec om mend pres sure in teg ri ty test per
sub sec tion D. herein.)
6. Remove leak test apparatus. Reconnect pilot
valve (PV) to main valve (MV) using ap pro pri ate pipe nipples, tubing and fi ttings (19, 20,
26, 27, 28, 29 & 30). Ensure all connections
are tight and in proper orientation.
FIGURE 5:
D. Pressure Integrity Leak Test:
1. Test pilot valve (PV) and main valve (MV)
assembled together with all interconnecting
pipe (19), tubing (21) and fi ttings (20).
2. Insert tapped pipe plugs with hose fi ttings to
both inlet and outlet body (1) connections.
3. Install temporary hoses with tight shutoff in stru ment needle valves at outlet connection of
main valve (MV) and of the pilot valve (PV).
4. Connect temporary air supply with in-line ad just able airset regulator to inlet connection of
main valve (MV).
5. Close needle valve at outlet connection of main
valve (MV). Crack open the needle valve at
the pilot valve (PV) outlet.
6. Rotate adjusting screw (19) of pilot valve (PV)
CW (viewed from above adjusting screw) until
a point of high resistance occurs; this should
correspond to the diaphragm (12) pushing
against the body's (1) down trav el stops. Record the number of rev o lu tions the ad just ing
screw was rotated in the box below:
No. of revolutions the adjusting screw was
ro tat ed ______________.
IOM-POSR-2 13
7. Slowly pressurize the inlet of the main valve
(MV) and pilot valve (PV) to 100 psig (6.9 Barg).
NOTE: If the pilot valve (PV) has any other
range spring (15) above 5–15 psig (.34–1.03
Barg), the test pressure can be raised to 200
psig (13.8 Barg).
8. Using a solution of leak detection fl uid and
water, apply a liberal amount of the solution to
cover each external joint, including the thread ed fi ttings (20), tub ing (21) and the intercon-
necting pipe nipple (19) threaded con nec tions.
Wait a minimum of fi ve min utes to allow suf-
fi cient time for a leak to form bub bles. Repeat
this procedure with a second fi ve minute wait.
9. Identify and mark any observed leakage.
Dis as sem ble down to the point of leakage
and determine the cause of the leak. Repair
and reassemble per instructions in Section
VI. Retest per Section VII.
10. Shut off pressure to inlet connection of main
valve (MV) and remove all leak testing equip ment. Reset the adjusting screw (19) back to
its normal setpoint by rotating the screw (19)
CCW (viewed from above) the same num ber
of revolutions recorded in Ar ti cle 6. pre vi ous,
this subsection.
SECTION VIII
VIII. TROUBLE SHOOTING GUIDE
1. Erratic or Noisy Operation.
Possible Cause Remedy
a. Wet steam or condensate at the inlet. a. Install a steam trap on the inlet side of theregulator.
b. Clogged pilot valve screen. b. Clean or replace. Blowdown inlet drip leg. Install up-
stream strainer, if severe.
c. Regulator oversized for fl ow conditions. c. Install correct size.
d. Insuffi ciently sloped line. d. Move tap from top of pipe to side; or, increase sensing
tube to 3/8" OD.
2. Regulator won't maintain downstream set pressure.
Possible Cause Remedy
a. Valve undersized. a. Resize based on actual service conditions.
b. Incorrect range spring. b. Replace range spring.
c. Failed bellows. c. Replace bellows assembly.
d. Failed piston seal ring. d. Replace seal ring.
e. Pressure drop less than required 15 or 20 psid
(1–1.4 Bard).
f. Insuffi ciently sloped line. f. Move tap from top of pipe to side; or, increase sensing
3. Leakage through the pilot spring chamber vent hole.
Possible Cause Remedy
a. Defective diaphragm. a. Replace diaphragm.
4. Excessive pressure downstream.
Possible Cause Remedy
a. Main valve or pilot plug not closing. a. Inspect the seating of the main valve and then the
e. Contact your Cashco Representative.
tube to 3/8" OD.
pilot plug seating. Clean or replace. Check seat
gaskets; replace.
IOM-POSR-214
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 un-
der "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 cross-sectional
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.
IOM-POSR-2 15
NOTES
IOM-POSR-216
NOTES
IOM-POSR-2 17
FIGURE 6
ITEM NO. DESCRIPTION
19 Pipe Nipple
20 Tube Fitting
21 Tubing
26 90° Elbow
27 90° Street Elbow
28 Union
29 Pipe Nipple
30 Pipe Nipple
FIGURE 8
FIGURE 7
IOM-POSR-218
FIGURE 10
POSR-2 Flanged End Con nec tion
FIGURE 9
MV – MAIN VALVE
ITEM NO. DESCRIPTION
1 Body
2 Bonnet
3 Cylinder
4 Cylinder Head
5 Seat Ring
6 Seat Ring Gasket
7 Valve Plug & Stem Assy.
8 Piston
12 Seal
13 Bonnet & Cylinder Gasket
14 Piston Spring
15 Hex. Nut
16 Hex. Head Bolt
17 Hex. Nut
18 Bushing
24 Flange
25 Flange Split Ring
31 Machine Screw
Not Shown on Drawing
22 Nameplate
23 Drive Screw
43 Drive Screw
44 Flow-Arrow
IOM-POSR-2 19
P
Int.
FIGURE 11
PV – PILOT VALVE
FIGURE 12
HANDWHEEL &
LOCK ING LEVER
P
2
ITEM NO. DESCRIPTION
1 Body
2 Spring Chamber
4 Plug & Seat Assembly
4.1 Valve Seat
4.2 Valve Plug
6 Screen
7 Spring
8 Valve Seat Gasket
9 Body Cap
10 Stem
11 Bellows Subassembly
12 Diaphragm
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-POSR-2
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH +49 3342 4243135
Fax. No. +49 3342 4243136
www.cashco.com
Email: germany@cashco.com
ITEM NO. DESCRIPTION
13 Diaphragm Gasket
14 Pressure Plate
15 Range Spring
16 Spring Button
17 Cap Screw
18 Hex. Nut
19 Adjusting Screw
20 Adjusting Screw Lock Nut
21 Nameplate
22 Handwheel
23 Locking Lever
24 Spring Pin
25 Bleed Orifi ce
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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