Cashco SA1 User Manual
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-CA1/SA1
MODEL CA1/SA1
CA1 and SA1 - ULTRA HIGH PURITY, SPRING LOADED
PRESSURE REDUCING REGULATORS
SECTION I
I. DESCRIPTION AND SCOPE
Models CA1/SA1 are pressure reducing regulators used to control downstream (outlet or P2) pressure. Sizes are
3/4" (DN20), 1" (DN25), 1-1/2" (DN40), and 2" (DN50). With proper trim uti li za tion, the unit is suitable for liquid or
gaseous service. (NOTE: This product was formerly identifi ed as a Model C1 or S1; a Model CA1/SA1 and C1/S1
are one and the same product.)
SECTION II
II. REFERENCES
Refer to Technical Bulletin CA1/SA1-TB for tech ni-
cal specifi cations of a Model CA1/SA1 reg u la tor.
CCW – Counter Clockwise
CW – Clockwise
ITA – Inner Trim Assembly
ABBREVIATIONS
11-13
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.
III. INSTALLATION
1. Install per direction of fl ow arrow indicated on
body, or "IN" and "OUT" markings.
2. Regulator may be rotated around pipe axis 360
degrees. For ease of maintenance, the rec om mend ed orientation is with the spring chamber
(4) upwards.
3. Provide space below, above, and around reg u la tor
for removal of parts during maintenance.
4. Install block valves and pressure gauges to pro vide means for adjustment, operation, bypass, or
removal of the regulator. A UHP fi lter is rec om-
mend ed before inlet to remove typical pipe line
debris from entering valve and damaging internal
“soft goods”, primarily the dynamic seal and valve
seat.
SECTION III
CAUTION
DO NOT HYDROSTATIC TEST THROUGH AN
IN STALLED UNIT; ISOLATE REGULATOR FROM
TEST. The upper range spring pres sure level
on the nameplate is the rec om mend ed “upper
op er at ing limit” for the sens ing di a phragm.
Higher pres sures could cause internal dam age.
In ad di tion, note on the nameplate that the Inlet
and Outlet pres sure and temperature ratings are
at different levels.
IV. PRINCIPLE OF OPERATION
SECTION IV
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 di a phragm movement. As outlet
pressure drops, the range spring pushes the di a phragm down, opening the port; as outlet pres sure
V. STARTUP
1 Start with the block valves closed.
2. Relax the range spring by turning the ad just ing
screw (1) CCW (viewed from above) a minimum
of three (3) full rev o lu tions. This reduces the outlet
(down stream) pres sure set point.
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) pressure via gauge to ensure not
over-pressurizing. 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.
CAUTION
Do not walk away and leave a bypassed reg u la tor unattended!
4. Crack open the outlet (downstream) block valve.
5. Slowly open the inlet (upstream) block valve to
about 25% open, observing the outlet (down stream) pres sure gauge. Determine if the reg u la tor is fl owing. If not, slowly rotate the regulator
ad just ing screw (1) CW (viewed from above) until
fl ow be gins.
increases, the diaphragm pushes up and the port
opening closes.
2. A complete diaphragm failure will cause the reg u la tor to fail open and fl uid will discharge from the
spring chamber vent hole.
SECTION V
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 piping system isn’t pressurized. If the outlet (down stream) pressure exceeds the desired pres sure,
close the inlet block valve and go to Step 2. Close
bypass valve approximately 25%, and re peat pro ce dure.
8. When fl ow is established steady enough that the
outlet (downstream) block valve is fully open, begin
to slowly close the bypass valve if installed.
9. Develop system fl ow to a level near its expected
normal rate, and reset the regulator set point by
turning the adjusting screw (1) CW to increase
outlet pressure, or CCW to reduce outlet pres sure.
10. Reduce system fl ow to a minimum level and ob-
serve pressure 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 upper limit of the range spring
by greater than 10%. If it does, consult factory.
VI. SHUTDOWN
1. Shutoff inlet block valve.
2. Allow suffi cient time for the line pressure down-
stream of the inlet block valve to bleed down.
3. Shutoff the outlet block valve.
2
SECTION VI
4. Relieve the trapped upstream and down stream
pres sure.
5. The regulator may now be disassembled for
inspection and pre ven ta tive main te nance while
in-line.
IOM-CA1/SA1
VII. MAINTENANCE
A. General:
1. The regulator may be serviced without re mov ing the regulator from pipeline. The reg u la tor
is designed with quick-change trim to simplify
maintenance.
SECTION VII
ing screw (1) CCW (viewed from above) until
removed from spring cham ber (4).
3. Loosen the diaphragm fl ange bolts (12) and
nuts (11) uniformly. Remove all bolting.
4. Place matchmarks on body (23) and spring
chamber (4) fl anges. Remove the spring
cham ber (4) by lifting vertically.
2. Record the nameplate information to req ui si tion spare parts for the regulator. The in for ma tion should include: Size, Product Code,
and Serial Number.
3. Refer to Section IX for recommended spare
parts. Only use original equipment parts sup plied by Cashco/KM for re build ing or re pair ing
regulators.
4. Owner should refer to owner's procedures for
removal, handling, cleaning and disposal of
nonreuseable parts, i.e. seals, etc.
5. The Inner Trim is re moved and replaced in the
body (23) as an assemblage of parts. The
Inner Trim Assembly, here in af ter called ITA,
consists of the fol low ing parts:
Item Dynamic
No. Seal Type Part Description
13 ..................... All ..........................Piston-Guide Bearing
15 .....................All ................................ Cage O-ring Seal
16..................... UC.................................................Shim
19 ..................... All ................................................... Cage
20 ..................... All ...........................................Valve Plug
21 ..................... All ............................................ Seat Ring
27 .....................All ............................. Dynamic Side Seal
27.1 .............. CP............................................. Cap Seal
27.2 .............. CP..........................O-ring Energizer/Seal
27.3 .............. UC .......... U-Cup Seal w/Metal Energizer
5. Remove the ball (14), spring follower (5) and
range spring (6).
6. Remove upper diaphragm pressure plate (8).
7. Remove diaphragm(s) (9) and examine to
de ter mine if failed. If diaphragms failed, de ter mine if op er at ing con di tions are ex ceed ing
designed pressure or tem per a ture limits.
8. Evenly loosen the three cage cap screws (18)
in single revolution increments. The reg u la tor
con tains a lower return spring (22); the ITA
should rise as the cage cap screws (18) are
backed out evenly. A downward holding force
should be ap plied to the top of the piston-guide
bearing (13) to pre vent the ITA from pop ping
up as the last threads of the cage cap screws
(18) are disengaged. Remove washers (17).
13
19
15
*
27.3
*
16
20
6. A detailed view of the dynamic side seal parts
is shown in Figure 1; an assembled ITA in
Figure 2; and a cross-sectional drawing of
the entire regulator is shown in Figure 3.
WARNING
SYSTEM UNDER PRESSURE. Prior to per form ing
any maintenance, isolate the reg u la tor from the
sys tem and relieve all pressure. Failure to do so
could result in personal injury.
B. Main Regulator Disassembly:
1. Shut down the system in accordance with
Section VI.
2. Loosen adjusting screw lock nut (2) and relax
range spring (6) pressure by turning ad just-
IOM-CA1/SA1
Type UC - U-Cup
Dynamic Seal
27
*
13
19
15
*
27.1
*
27.2
*
16
20
Type CP - Cap
Dynamic Seal
Figure 1: Dynamic Side Seals
3
9. Remove the ITA by pull ing up on the pistonguide bearing (13). Set ITA aside.
10. Remove the lower return spring (22) from
within the body (23).
11. Remove the cage o-ring seal (15).
12. Remove metal C-ring seal (28) from body (23)
di a phragm fl ange groove.
13. Clean all metal parts to be reused according to
owner's procedures. NOTE: Regulators are
originally supplied with a level of clean li ness
equal to Cashco cleaning standard #S-1662.
Contact factory for details.
C. Disassembly of the ITA:
1. To Disassemble the ITA (See Figure 2):
a. Hold the lower part of the valve plug (20)
in a bench vise; grasp in "smooth jaws"
directly under plug's (20) seating disc portion on hub "fl ats" provided. Do not hold
on the ma chined sur face in the plug's (20)
spin dle area.
e. Remove dynamic side seal (27) com po-
nents and discard. Special care should be
taken when using “tools” to remove the
components to ensure that no scratches
are made to any portion of the piston- guide
bearing (13) groove.
f. Remove the shim (16) from within the
cage (19).
g. Remove seat ring (21); examine for signs
of leakage. If seat ring (21) shows signs of
signifi cant leakage, determine if op er at ing
con di tions - pres sure, pressure drop, or
temperature ex ceed ddesign lim its.
2. Clean all metal parts to be reused according
to owner's procedures. NOTE: Regulators are
originally supplied with a level of clean li ness
equal to Cashco cleaning standard #S-1662.
Contact factory for details.
D. Inspection of Parts:
1. Remove and dis card the fol low ing parts:
o-ring (15), diaphragm(s) (9), seals (27, 28),
and seat ring (21). These parts MUST be
re placed with fac to ry supplied new parts.
16
Figure 2: Assembled ITA, with
"UC" Dynamic Side Seal
b. Using a special double-posted spanner
wrench fi tting (to order see NOTE in
Section IX, Parts Ordering Information),
turn the pis ton-guide bear ing (13) CCW
to loosen. The piston-guide bear ing (13)
may be re moved by hand after loos en
ing.
c. Remove ITA from vise. Pull the valve plug
(20) down and out through the cage's (19)
bottom opening.
d. Examine the com po nents (27.1, 27.2,
27.3) of the dy nam ic side seal (27)
mech a nism to de ter mine if sig nifi cant
leakage was oc cur ring. If the dy nam ic
side seal shows signs of sig nifi cant leak-
age, de ter mine if op er at ing con di tions
are ex ceed ing pres sure, pres sure drop,
or tem per a ture lim its.
2. Inspect the metal parts that will be reused. The
parts should be free of surface con tam i nants,
burrs, oxides, and scale. Rework and clean
the parts as necessary. Surface con di tions
that affect the regulator performance are stated
below; re place parts that can not be re worked
or cleaned.
3. QC Requirements:
a. Valve plug (20);
1. 16 rms fi nish on its seating surface
for tight shutoff.
2. No major defects on bottom guide
spin dle.
b. Cage (19);
1. 16 rms fi nish on cylinder bore. No
“ledg es” formed due to wear from
moving dynamic side seal (27) or plug
(20).
E. Reassembly of the ITA:
1. Installation of dynamic side seal (27) (See
Figure 1):
a. Type CP:
1. Stretch o-ring energizer/seal (27.2)
over low er cir cum fer ence of pistonguide bear ing (13), tak ing care not
to “cut” o-ring energizer/seal. Us ing
thumbs, work the o-ring en er giz er/
4
IOM-CA1/SA1
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