cashco 1164 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-1164
11-16
MODEL 1164
BACK PRESSURE / RELIEF REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The Model 1164 is a modulating back pressure relief regulator used to control upstream (inlet) pressure. Sizes are
3/4", 1", 1-1/2" and 2" (DN 20, 25, 40 and 50) for side (inlet, flow-through,) and bottom (discharge) connections.
With proper trim utilization the unit is suitable for liquid, gaseous, or steam service. Refer to Technical Bulletin
1164-TB for design conditions and selection recommendations.
SECTION II
II. INSTALLATION
1. An inlet block valve should always be installed.
2. If service application is continuous such that
shutdown 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 should be installed to allow removal
from piping.
4. An inlet pressure gauge should be located
approximately ten pipe diameters upstream and
within sight. An outlet pressure gauge is optional.
5. All installations should include an upstream relief
device if the inlet pressure could exceed the
pressure rating of any equipment or the maximum
inlet pressure rating of the unit.
7. In placing thread sealant on pipe ends prior to
engagement, ensure that excess material is
removed and not allowed to enter the regulator
upon startup.
8. Flow Direction: Install so the flow direction matches
the arrow cast on the body. Connect the inlet
pressure to the body side connection(s). Fluid will
relieve out of the bottom connection. The double
inlet connections are for in-line installation (plug
one side connection if in-line installation is not
required).
CAUTION
This is not a safety device and must not be substituted for a code approved pressure safety relief valve or a rupture disc.
WARNING
The maximum inlet pressure is equal to 1.5 times
the larger number of the stated range spring on the
nameplate, and is the recommended “upper operative
limit” for the sensing diaphragm. Higher pressures could
damage the diaphragm. (Field hydrostatic tests frequently
destroy diaphragms. DO NOT HYDROSTATIC TEST THRU
AN INSTALLED UNIT; ISOLATE FROM TEST.)
6. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt
before installing the regulator. Strainers are
recommended.
CAUTION
Installation of adequate overpressure protection is
recommended to protect the regulator from overpressure
and all downstream equipment from damage in the event
of regulator failure.
ISO Registered Company

IOM-1164
2
9. Regulator may be installed in a vertical or horizontal
pipe. If it is a steam system, assure the piping is
properly trapped and oriented.
10. Regulator may be rotated around the pipe axis
360°. Recommended positions are with spring
chamber vertical upwards, or horizontal. Orient
such that the spring chamber vent hole does not
collect rainwater or debris.
11. Regulators are not to be direct buried underground.
12. For insulated piping systems, recommendation is
to not insulate regulator.
13. Spring Chamber Vent Tap - Option 1164-25: 1/4"
NPT Vent. Leave connection vented to atmosphere
or pipe to outside or sump (the later if fluid through
valve is toxic or could present a hazard) depending
on the application and the controlled fluid.
1. Movement occurs as pressure variations register
on the diaphragm. The registering pressure is the
inlet, P1or upstream pressure. The range spring
opposes diaphragm movement. As inlet pressure
drops, the range spring pushes the diaphragm
down, closing the port; as inlet pressure increases,
the diaphragm pushes up and the port opens.
SECTION IV
IV. STARTUP
SECTION III
III. PRINCIPLE OF OPERATION
1. Start with the block valves closed. A bypass valve
may be used to maintain system pressure without
changing the following steps.
2. Relax the range spring by turning the adjusting
screw counterclockwise (CCW) a minimum of
three (3) full revolutions. This reduces the inlet
(upstream) pressure set point.
3. 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
expansion of the piping. Assure proper steam
trap operation if installed. Closely monitor inlet
(upstream) pressure, via gauge, to assure not
over-pressurizing. NOTE: If no bypass valve is
installed, extra caution should be used in starting
up a cold system; i.e. do everything slowly.
4. Crack open the inlet (upstream) block valve.
5. Slowly open the outlet (downstream) block
valve observing the inlet (upstream) pressure
gauge. Determine if the regulator is flowing. If
not, slowly rotate the regulator adjusting screw
counterclockwise (CCW) until flow begins.
6. Continue to slowly open the outlet (downstream)
block valve until fully open.
7. Observing the inlet (upstream) pressure gauge,
rotate the adjusting screw clockwise (CW) slowly
until the inlet pressure begins to rise. Rotate CW
until the desired setpoint is reached.
8. Continue to slowly open the inlet (upstream) block
valve. If the inlet (upstream) pressure exceeds
the desired setpoint pressure, rotate the adjusting
screw CCW until the pressure decreases.
9. When flow is established steady enough that both
the outlet and inlet block valves are fully open,
begin to slowly close the bypass valve if installed.
10. Develop system flow to a level near its expected
normal rate, and reset the regulator setpoint by
turning the adjusting screw CW to increase inlet
pressure, or CCW to reduce inlet pressure.
11. Reduce system flow to a minimum level and
observe setpoint. Inlet pressure will rise from the
setpoint of Step 9. (Ensure that this rise does not
exceed the stated upper limit of the range spring by
greater than 50%; i.e. 30-80 psig (2.07-5.52 Barg)
range spring, at maximum flow the inlet pressure
should not exceed 1.5 x 80 psig (5.6 Barg), or 120
psig (8.3 Barg). If it does, consult factory.)
12. Increase flow to maximum level if possible. Inlet
(upstream or P1) pressure should fall off. Readjust
setpoint as necessary at the normal flow rate.
2. A complete diaphragm failure may cause the valve
to fail closed. A cracked metal diaphragm will leak
fluid through the vent hole of the spring chamber,
but will continue to operate.
CAUTION
For welded installations, all internal trim parts, seals and
diaphragm(s) must be removed from regulator body prior
to welding into pipeline. The heat of fusion welding will
damagenon-metallicpartsifnotremoved. NOTE:Thisdoes
not apply to units equipped with extended pipe nipples.

IOM-1164 3
V. SHUTDOWN
1. On systems with a bypass valve, and where system
pressure is to be maintained as the regulator is
shut down, slowly open the bypass valve while
closing the inlet (upstream) 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
(downstream) block valve.
SECTION V
SECTION VI
2. If the regulator and system are both to be shutdown,
slowly close the inlet (upstream) block valve. Close
the outlet (downstream) valve only if regulator
removal is required.
A. General:
1. Maintenance procedures hereinafter are based
upon removal of the regulator from the pipeline
where installed.
2. Owner should refer to owner’s procedures for
removal, handling, cleaning and disposal of
non-reusable parts, i.e. asbestos gaskets, etc.
3. Refer to Figure 1 for basic regulator
construction. For a blow-up of the TFE seat
trim, see Figure 2.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vise with the
spring chamber (2) directed upwards.
2. Relax range spring (3) by turning adjusting
screw (17) CCW until removed from spring
chamber (2).
3. Draw or embed a match mark between body
casting (1) and spring chamber casting (2)
along flanged area.
4. Remove all diaphragm flange nuts (14) and
bolts (13).
5. Remove spring chamber (2), range spring (3)
and spring button (4).
6. Remove pressure plate (5) and inspect
to ensure no deformation due to over-
pressurization. If deformed, replace.
7. Remove diaphragm (9), diaphragm gasket
(10), and O-ring (11).
8. Clean body (1) and diaphragm flange. NOTE:
On valves originally supplied as “special
cleaned”, option 1164-55, maintenance must
include a level of cleanliness equal to Cashco’s
cleaning standard #S-1134. Contact factory
for details.
9. Install new O-ring (11), diaphragm gasket (10),
and diaphragm. Apply a light coat of gasket
sealant.
VI. MAINTENANCE
10. Center pressure plate (5) on diaphragm (9).
Place the range spring (3) on to the retainer
hub of the pressure plate (5).
11. Place multi-purpose, high temperature grease
into depression of spring button (4) where
adjusting screw bears. Set spring button (4)
onto range spring (3); ensure spring button
(4) is laying flat.
12. Aligning the match marks, place spring
chamber (2) over the above stacked parts.
Apply pressure (manually) to the spring
chamber (2) from opposite sides to compress
the spring (7), so bolting can be started from
opposite sides. Install all bolts (13) and nuts
(14) by hand tightening. Mechanically tighten
CAUTION
Do not walk away and leave a bypassed regulator
unattended.
WARNING
SYSTEM UNDER PRESSURE. Prior to performing any
maintenance, isolate the regulator from the system
and relieve all pressure. Failure to do so could result in
personal injury.
WARNING
SPRING UNDER COMPRESSION. Prior to removing
spring chamber, relieve spring compression by backing
out the adjusting screw. Failure to do so may result in
flying parts that could cause personal injury.
CAUTION
When reassembling, the spring (7) will be under
compression. Center all internal parts before placing the
spring chamber.

IOM-1164
4
bolting (13 & 14) in a cross pattern that allows
spring chamber (2) to be pulled down evenly.
Recommended torques are as follows:
NOTE: Never replace bolting (13 & 14) with
just any bolting if lost. Bolt heads and nuts
are marked with specification identification
numbers. Use only proper grades as
replacements.
13. Reinstall adjusting screw (17) with locknut (8).
14. Soap solution test around bolting (13 & 14)
and body (1) and spring chamber (2) flanges
for leakage. Ensure that an inlet pressure is
maintained during this leak test of at least
mid-range level; i.e. 30-80 psig (2.07-5.52
Barg) range spring, 60 psig (4.14 Barg) test
pressure minimum.
C. Trim Replacement (For Metal Seated Units):
1. Trim removal requires that the diaphragm be
removed. Refer to previous procedure Section
VI., Sub-section B, Steps 1 through 8.
2. Remove valve guide (12), valve plug (16) and
spring (7).
3. Inspect seating surface of integral seat ring
(15). If seat ring shows erosion or wear, the
regulator should be replaced.
4. Inspect guide (12), plug (16), O-ring (11) and
spring (7). Inspect parts for excessive wear.
Replace if worn, nicked or depressed.
5. Clean the body (1) cavity. Clean all parts to
be reused. NOTE: On regulators originally
supplied with Option 1164-55, “special
cleaned”, maintenance must include a level of
cleanlinessequaltoCashco’scleaningstandard
#S-1134. Contact factory for details.
6. Reinstall the spring (7). Then place the O-ring
(11) on the plug (16) and the plug (16) into
the valve guide (12).
7. Now place the valve guide (12) (along with
the O-ring (11) and plug (16)) on to the spring
(7).
8. Reinstall diaphragm (9) per Section VI., Sub-
section B., Steps 9 through 14.
9. Bench test unit for suitable operation. NOTE:
Regulators are not tight shutoff devices. Even
if pressure falls below setpoint, a regulator
may or may not develop bubble tight shutoff.
In general, tighter shutoff can be expected
with composition seat.
10. Soap solution test around body (1) flange
for leakage. Test pressure should be the
maximum allowed.
D. Trim Replacement (For TFE Seated Units):
1. Follow same steps as listed under “Trim
Replacement - Metal Seated Units” except
for the following guidelines:
2. When inspecting parts for excessive wear
(VI.C.4), ensure there are no foreign particles
embedded or nicks in the TFE seat which is
an integral part of the plug assembly. Replace
plug assembly (16) if any of these conditions
are noted.
Regulator Size Bolt Size Metal Dia-
phragm
3/4" - 1" (DN20,25) 3/8" - 24 30 ft/lbs.
1-1/2" (DN40) 7/16" - 20 45 ft/lbs.
2" (DN50) 1/2" - 20 70 ft/lbs.

IOM-1164 5
SECTION VII
VII. TROUBLE SHOOTING GUIDE
Possible Causes Remedies
A. Oversized regulator. A1.
A2.
A3.
A4.
A5.
Check actual flow conditions, resize regulator for mini-
mum and maximum flow.
Tighten flange bolting.
Increase flow rate.
Decrease regulator pressure drop; decrease inlet pres-
sure by placing a throttling orifice in inlet piping union.
Install next step higher range spring.
Before replacing regulator, contact factory.
B. Inadequate Rangeability. B1.
B2.
B3.
Increase flow rate.
Decrease regulator pressure drop.
Install next step higher range spring. Contact factory.
1. Erratic Operation; chattering.
Possible Causes Remedies
A. Regulator undersized. A1.
A2.
Confirm by opening bypass valve together with regulator.
Check actual flow conditions, resize regulator; if regulator
has inadequate capacity, replace with larger unit.
B. Incorrect range spring (screwing out CCW of adjusting
screw does not allow bringing pressure level to a stable
and proper level).
B.1
B.2
Replace range spring with proper lower range.
Contact factory.
C. Too much build. C1.
C2.
Review build expected.
Contact factory.
D. Restricted diaphragm movement. D. Ensure no moisture in spring chamber at temperatures
below freeze point. Ensure no dust or debris entering
vent opening. If rainwater or debris can enter, reorient
spring chamber.
2. Regulator inlet (upstream) pressure too high.
Possible Causes Remedies
A. Foreign matter on the seating surface, erosion of the seat-
ing surface or foreign matter on plug balancing O-ring.
A. Clean or replace plug assembly (TFE seat). For metal
replace regulator if integral seat is damaged. Replace
plug and O-ring.
3. Excessive seat leakage.
Possible Causes Remedies
A. Normal-life diaphragm failure. A. Replace diaphragm.
B. Abnormal short-life diaphragm failure. B1.
B2.
B3.
Can be caused by excessive chattering. See No. 1. to
remedy chatter.
Can be caused by corrosive action. Consider alternate
diaphragm material.
Upstream (inlet) pressure build-up occurring that over-
stresses diaphragms. Relocate regulator or protect with
safety relief valve.
4. Leakage through the spring chamber vent hole.
Possible Causes Remedies
A. Plugged spring chamber vent. A. Clean vent opening.
B. Fluid too viscous. B. Heat fluid. Contact factory.
C. Broken spring. C. Replace spring.
5. Sluggish operation.

IOM-1164
6
SECTION VIII
NEW REPLACEMENT UNIT:
Contact your local Cashco, Inc., Sales Represen-
tative 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.
–7–
VIII. 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 reflects revision level for the product).
PARTS "KIT" for FIELD REPAIR:
Contact your local Cashco, Inc., Sales Represen-
tative with the Serial Number and Product code.
Identify the part s 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” reflect 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
identification and selection.
A Local Sales Representative will provide quotation
for appropriate Kit Number, 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 accomodate
the recommended part(s) changes.
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 specifications 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-1164 7
Figure 1
Basic Model 1164
Metal Seat Construction
Figure 2
Composition Seat
IItem No. Description
1 Body
2 Spring Chamber
3 Range Spring
4 Spring Button
5 Pressure Plate
6 Name Plate
7 Spring
8 Adjusting Screw Lock Nut
9 Diaphragm
10 Diaphragm Gasket
11 O-Ring
12 Valve Guide
13 Cap Screw (Flange Bolting)
14 Nut (Flange Bolting)
15 Valve Seat
16 Valve Plug or Valve Plug Subassembly
17 Adjusting Screw

IOM-1164
8
ATEX 94/9/EC: Explosive Atmospheres and Cashco Inc. Regulators
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
the acceptable values in IEC 60079-0 Section 26.14 or the pressure gauge supplier must provide documentation
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.
NOTICE
Only for Product Codes wherein hazard
category ATEX has been selected.

IOM-1164 9
Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [email protected]
Printed in U.S.A. IOM-1164
Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]
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.