Cashco SA5 User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-CA5/SA5

MODEL CA5/SA5

CA5 and SA5 - ULTRA HIGH PURITY, SPRING LOADED

BACK PRESSURE REGULATORS

SECTION I

I. DESCRIPTION AND SCOPE

Models CA5/SA5 are spring operated back pressure regulators used to control upstream (inlet or P1) pressure. Sizes are
3/4" (DN20) and 1" (DN25). 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 C5 or S5; a Model CA5/SA5 and C5/S5 are one and the same product.)

II. REFERENCES

SECTION II

11-13

Refer to Technical Bulletin CA5/SA5-TB for tech ni-

cal specifi cations of a Model CA5/SA5 reg u la tor.

SECTION III

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.

ABBREVIATIONS
CCW – Counter Clockwise
CW – Clockwise
ITA – Inner Trim Assembly

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.

Recommended Piping Schematic

For Back Pressure/Relief Station

IV. PRINCIPLE OF OPERATION

SECTION IV

1. Movement occurs as pressure variations register
on the diaphragm. The registering pressure is the
inlet, P1, or upstream pressure. The range spring
op pos es di a phragm movement. As inlet pressure
drops, the range spring pushes the di a phragm

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 inlet
(upstream) pres sure set point.

3. Crack open manual bypass valve to initially pres­surize the system while simultaneously controlling
P1 pressure through manual actuation of bypass
valve.

CAUTION

Do not walk away and leave a bypassed reg u ­la tor unattended!

4. Closely monitor inlet (up 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.

down, closing the port; as inlet pres sure increases,
the diaphragm pushes up and the port opens.

2. A complete diaphragm failure will cause the reg u­ la tor to fail close and fl uid will discharge from the
spring chamber vent hole.

SECTION V

5. Open the outlet (downstream) block valve.

6. Slowly open the inlet (upstream) block valve to
about 25% open, observing the inlet (up 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) CCW (viewed from above) until fl ow
be gins.

7. When fl ow is established steady enough that the
inlet (upstream) block valve can be fully opened,
begin to slowly close the bypass valve if installed.

8. 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
inlet pressure, or CCW to reduce inlet pres sure.

9. Reduce system fl ow to a minimum level and
observe pressure set point. Inlet pressure will
increase from the set point of Step 7. The maxi­mum build in inlet pressure on increasing fl ow
should not exceed the stated upper limit of the
range spring by greater than 30%. If it does,
consult factory.

VI. SHUTDOWN

1. On systems with a bypass valve, and where sys­tem 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 con stant ly
observed and manually regulated.)

CAUTION

Do not walk away and leave a bypassed reg u la­ tor unattended!

2

SECTION VI

2. Remove range spring compression by turning
the adjusting screw (1) CCW to reduce the inlet
pressure.

3. Close the outlet (downstream) block valve.

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-CA5/SA5

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.

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:

SECTION VII

2. Loosen adjusting screw lock nut (2) and relax
range spring (6) pressure by turning ad just­ ing screw (1) CCW (viewed from above) until
removed from spring cham ber (4).

3. Loosen the diaphragm fl ange bolts (11) and
nuts (12) uniformly. Remove bolting (11,12).

4. Place matchmarks on body (23) and spring
chamber (4) fl anges. Remove the spring
cham ber (4) by lifting vertically.

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 (9) 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. Remove metal C-ring seal (28) from body (23)
di a phragm fl ange groove.

9. Evenly loosen the three cage cap screws (18)
in single revolution increments and remove
screws and washers (17).

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

31 .................... All .............................................Seat Disc

32 .................... All ........................................Disc Washer

34 .................... All ...........................................Cap Screw

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.

Type CP - Cap

Dynamic Seal

Type UC - U-Cup

Dynamic Seal

B. Main Regulator Disassembly:

1. Shut down the system in accordance with
Section VI.

IOM-CA5/SA5

Figure 1: Dynamic Side Seals

3

10. Remove the ITA from the cage pull ing up on
the piston-guide bearing (13). Set ITA aside.

11. Remove cage (19), o-ring seals (15) and (21).

e. Remove plug assembly and 3/8" bar stock

pieces from vise and rotate end for end
and secure in vise again.

12. 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. Fit 2 pieces of 3/8" wide x 3" long square

steel bar stock into the fl ats on either
side of the plug and secure snug in the
vise with the lower part (seat end) of the
valve plug (20) down. Do not clamp on
any ma chined, cylindical sur face on the
plug.

f. Using an allen wrench, rotate screw (34)

CCW and remove screw, disc washer (32)
and seat disc (31).

g. Clean all metal parts to be reused ac-

cording 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:
diaphragm(s) (9), o-ring (15), seals (21, 27,

28). These parts MUST be re placed with
fac to ry supplied new parts.

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.

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 shim (16).
d. Remove and examine the dynamic seal

(27.1, 27.2, 27.3) to de ter mine if sig nifi -

cant leakage was oc cur ring. If the seal

(27) shows signs of leakage, de ter mine

if op er at ing con di tions ex ceed pres sure,

pres sure drop, or tem per a ture lim its.
NOTE:

when using “tools” to remove the plug

and seal to ensure that no scratches

are made to any portion of the plug (20)

groove or plug itself.

Special care should be taken

3. QC Requirements:
a. Valve plug (20);

1. 16 rms fi nish on its seating surface
for tight shutoff.

b. Cage (19);

1. 16 rms fi nish on cage bore. No “ledg-
es” formed due to wear from moving
dynamic side seal (27) or plug (20).

E. Reassembly of the ITA:

1. Secure plug (20) in a vise with seat end up
using the steel bar stock pieces from C. 1.
previous.

2. Place new seat disc (31) and washer (32) over
end of plug (20).

3. Thread screw (34) into plug and torque to
20 - 35 ft-lbs (27 - 47 Nm).

4. Remove plug assembly and 3/8" bar stock
pieces from vise and rotate end for end and
secure in vise, again using the bar stock pieces.

4

IOM-CA5/SA5

5. Installation of dynamic side seal (27) (See
Figures 1 & 2):
a. Type CP:

1. Stretch o-ring energizer/seal (27.2)
over end of plug (20), tak ing care not
to “cut” o-ring energizer/seal (27.2).
Us ing thumbs, work the o-ring en er­ giz er/seal (27.2) into the groove of
the plug (20).

NOTE: Use NO lubricants!

2. Position cap seal (27.1) ring with
rect an gu lar cross-section at end of
plug (20). Stretch cap seal over the
plug, us e thumbs to work the cap seal
onto the plug. DO NOT USE A TOOL
OR LUBRICANT FOR THIS STEP.
Con tin ue pressing cap seal towards
the groove until the cap seal “snaps”
into the groove.

3. Insert shim (16) onto end of plug (20).

4. Thread piston-guide bearing (13) into
end of plug (20) and use the spanner
wrench to tighten to 60 to 70 ft-lbs (81
to 95 Nm).

b. Type UC:

1. Position u-cup seal (27.3) over end
of plug (20). Ensure the u-cup seal
is oriented with the center-open­upwards as shown in Fig ure 1, as the
u-cup seal de pends upon the P1-Inlet
pressure to activate prop er seal ing
ac tion. DO NOT USE A TOOL OR
LUBRICANT FOR THIS STEP.

2. Insert shim (16) onto plug (20).

3. Thread piston-guide bearing (13) into
end of plug (20) and use the spanner
wrench to tighten to 60 to 70 ft-lbs (81
to 95 Nm).

6. Remove plug assembly from vise.

7. Place properly oriented seal (21) onto the
shoul der at the lower end of cage (23).

8. Insert valve plug (20) down through top of
cage (19).

F. Main Regulator Reassembly:

1. Fit cage o-ring seal (15) into the body (23)
groove.

2. With the ITA and cage held manually in the
closed po si tion, insert ITA into body (23).

3. Properly align all three cage bolt (18) holes
as there is only one proper alignment pos-

sible. Ap ply a down ward force to the top of
the cage (19) to hold the ITA in place. Place
cage washers (17) on bolts (18) and engage
the bolts into the body (23). Tighten the bolts
in al ter nat ing one-half rev o lu tion in cre ments
to pull down the ITA evenly.

ENSURE THE ITA DOES NOT BECOME

WEDGED AS IT IS SLID INTO THE BODY.
Tight en cage bolts to a torque of 13-15 Ft-lbs
(17.5-20.5 Nm).

4. Units with CTFE or VTFE seat disc (31): Due to
the relative "hardness" of the CTFE and VTFE
material, to obtain the best possible shutoff
it is nec es sary to generate a "coined" seating
chamfer.

5. To coin the seat disc, use a soft-headed mallet
(rubber, leath er), sharply rap the top center of
the piston-guide bear ing (13) a couple of times
to press the plug (20) down into the bottom of
the cage, leav ing a "coined" seating chamfer
on the seat disc (31).

6. To Install Diaphragm(s):
a. Install a new metal C-ring seal (28) into

the body (23) diaphragm fl ange groove.

b. Center diaphragm(s) (9) onto body's (23)

diaphragm fl ange.

c. Position upper diaphragm pressure plate

(8) centered on top of diaphragm(s) (9)
with "cup" upwards.

7. Place a small amount of light lithium grease
onto the adjusting screw (1) threads. Insert
the ad just ing screw (1) (with lock nut (2))
into the spring chamber (4). Allow the end of
adjusting screw to protrude into the interior
approximately 1/2 inch (12 mm).

8. Place range spring (6) centered on upper
di a phragm plate (8).

9. Place a small amount of light lithium grease
into the recess of the spring follower (5). Install
ball (14) on spring follower. Place the spring
follower (5) on top of range spring (6).

10. Aligning matchmarks and bolt holes, place
spring chamber (4) over range spring (6).
If spring chamber fl ange rests on body (23)
fl ange without a gap, remove spring chamber
and rotate ad just ing screw (1) deeper into
spring cham ber cavity another 1/4 inch (6
mm). Repeat this pro ce dure until the adjust­ing screw keeps the two fl anges faces from
touching by ap prox i mate ly 1/8 inch (3 mm).

IOM-CA5/SA5

5

NOTE: If fl ang es do not come to geth er equal ly,

the upper di a phragm pres sure plate (8) may
be off-center. Remove spring cham ber (4) and

reposition upper di a phragm pres sure plate
(8) until the spring chamber (4) comes down
evenly on all sides.

11. Install all fl ange bolts (12) and nuts (11) with
nameplate (99) located under one bolt head.
Hand-tighten nuts (11).

12. Evenly tighten body bolting (11,12) using an
alternating cross pattern in one revolution
increments. Tighten all bolts to 30-35 Ft-lbs
(41-47 Nm).

6

IOM-CA5/SA5

SECTION VIII

VIII. TROUBLE SHOOTING GUIDE

When trouble shooting this regulator there are many possibilities as to what may be causing problems. Many
times, the regulator itself is not defective, but one or more of the accessories may be. Sometimes the pro cess
may be causing diffi culties.

The key to effi cient trouble shooting is information and communication. The customer should try to be as precise
as possible in their explanation of the problem, as well as their understanding of the application and operating
con di tions.

It is imperative the following information be provided by the customer:

Fluid (with fl uid properties)
Range of fl ow rate
Range of inlet pressure
Range of outlet pressure
Range of fl uid temperature
Range of ambient temperature

Pressure readings should be taken at every location that pressure plays a role - i.e., regulator inlet (as close as
possible to inlet port), regulator outlet (as close as possible to outlet port), etc.

Below are some of the more common complaints along with possible causes and remedies.

1. Erratic regulation, instability or hunting.

Possible Causes Remedies

A. Sticking of internal parts A. Remove internals, clean, and if necessary, replace.

B. Oversized regulator B. Check actual fl ow conditions; resize regulator for min i mum

and maximum fl ow; if necessary, replace with smaller
regulator.

2. Upstream pressure to high.

Possible Causes Remedies

A. Debris in trim preventing movement A. Clean unit of debris

B. Undersized regulator. B. Check actual fl ow conditions; resize regulator for minimum

and maximum fl ow; if necessary, replace with larger regulator.

3. Diaphragm continually breaks.

Possible Causes Remedies

A. Differential pressure across dia­ phragm may have exceeded limits.
(See Tech Bulletin).

A. Reference limits as recoreded in technical bulletin as well as
where the various pressures are acting.

IOM-CA5/SA5

7

4. Leakage at diaphragm fl ange.

Possible Causes Remedies

A. Body bolts not torqued properly. A1. Torque to proper value (see Section VII, F.12).

5. Leakage across seat.

Possible Causes Remedies

A. Contamination (debris) in regulator. A1. Remove internals, clean and if necessary, replace regulator.

A2. Install UHP fi lter at inlet.

B. Oversized regulator; plug operates
directly next to seat.

B. Check actual fl ow conditions; resize regulator for minimum and
maximum fl ow; if necessary, replace with smaller regulator.

8

IOM-CA5/SA5

SECTION IX

IX. ORDERING INFORMATION
NEW REPLACEMENT UNIT VS PARTS "KIT" FOR FIELD RE

To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on
the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"),
a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code
typical format as follows: (last digit is alpha character that refl ects revision level for the product).

–

NEW REPLACEMENT UNIT:

Contact your local Cashco, Inc., Sales Rep re sen­ ta tive with the Serial Number and Product code.
With this information they can provide a quotation
for a new unit including a complete description,
price and availability.

CAUTION

Do not attempt to alter the original construction
of any unit without assistance and approval from
the factory. All purposed changes will require a
new name plate with appropriate ratings and new
product code to accommodate the recommended
part(s) changes.

–

7

PARTS "KIT" for FIELD REPAIR:

Contact your local Cashco, Inc., Sales Rep re sen­ ta tive with the Serial Number and Product code.
Identify the parts and the quantity required to repair
the unit from the "BOM" sheet that was provided
when unit was originally shipped.

NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” refl ect minimum
parts required for inspection and rebuild, - "Soft
Goods Kit". Those in column “B” include minimum
trim replacement parts needed plus those "Soft
Goods" parts from column "A".

If the "BOM" is not available, refer to the cross­sectional drawings included in this manual for part
identifi cation and selection.

A Local Sales Representative will provide quotation
for appropriate Kit Number, Price and Availability.

NOTE: In addition to ordering repair parts, it is recommended that a special double-posted spanner wrench

fi tting be ordered for use in the main te nance of the ITA.

Double-Posted Spanner Wrench Fitting

Body Size Part Number

All A96-75-0-P0459-00

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-CA5/SA5

9

NOTES

10

IOM-CA5/SA5

NOTES

IOM-CA5/SA5

11

Opt-1 - Closing Cap

Figure 3:

Model CA5/SA5

Item No. Description

1 Adjusting Screw
2 Adjusting Screw Lock Nut
3 Closing Cap
4 Spring Chamber
5 Spring Follower
6 Range Spring
7 Nut Seal
8 Upper Diaphragm Plate
9

Diaphragm

*

10 Closing Cap Seal
11 Flange Bolt Nuts
12 Flange Bolt

‡

13

Piston-Guide Bearing
14 Ball
15

Cage O-ring Seal

*

16 Shim

Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [e-mail]

Printed in U.S.A. CA5/SA5-IOM

Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
Email: [e-mail]

Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
Email: [e-mail]

Item No. Description

17 Cage Washer
18 Cage Cap Screw
19 Cage
20 Valve Plug
21

Seal

*

23 Body
25 / 26 Plug / Vent
27 * Dynamic Side Seal

27.1 * Cap Seal

27.2 * O-ring Energizer

27.3 * U-Cup Seal w/ energizer
28 * Diaphragm Seal
30 Cage Collar
31 Seat Disc
32 Disc Washer
33 Pin
34 Cap Screw

Recommended Repair Parts

*

‡

It is recommended that a special double-posted spanner

wrench fi tting be ordered for use in the main te nance of
the ITA. To order, see NOTE in Section IX, Parts Order­ing Information.