cashco 964 Owner's manual

ISO Registered Company
INSTALLATION, OPERATION, & MAINTENANCE MANUAL (IOM)
MODEL 964
GLOBE-STYLE
PNEUMATIC CONTROL VALVE UNIT
BODY IOM
SECTION l
I. DESCRIPTION AND SCOPE
The Model 964 is a pneumatically actuated, sliding
stem globe-style control valve. Sizes are 1/2",3/4",
1", 1-1/2", & 2". Available in Cast Iron and Cast Steel
body materials.
Failure position is determined by actuator for:
"D" = Direct action; on increasing air loading pressure,
the actuator stem extends. Fail-safe position is with
the stem retracted.
"R" = Reverse action; on increasing air loading pressure,
the actuator stem retracts. Fail-safe position is with
the stem extended.
The valve is designed primarily for general service
or utility applications such as steam, air, oil, gas and
water.
II. REFERENCES
Refer to Technical Bulletin 964-TB for complete
technical specifications of a Model 964 coupled with
either Cashco Actuator Model C27 or C53.
www.cashco.com/techbulletins/964.pdf
Refer to following Installation, Operation &
Maintenance Manuals (IOM’s) for either actuator
and/or devices that maybe mounted to a Model 964:
Actuators: www.cashco.com/iom/C27-C53.pdf
IOM-964
12-16
ABBREVIATIONS
ATC–FO – Air–to–Close, Fail Open
ATO–FC – Air–to–Open, Fail Close
CCW – Counter Clockwise
CW – Clockwise
D or DIR – Direct Acting
IAS – Instrument Air Supply
LOAD – Positioner Output Air Pressure
R or REV – Reverse Acting
SIG – Output Signal from Instrument
V – Vent
SECTION II
Model 964
with ATO - FC Actuator

IOM-9642
Figure 1: Typical Control Valve Station
Figure 2: Body Insulation
SECTION III
2. Outdoors, all installations may be oriented any
angle from horizontal-to-vertical.
3. Valves are not recommended for installation
with the actuator oriented downwards..
B. Piping System:
1. It is recommended that the control valve unit
be installed with a double-block and bypass
as indicated in Figure 1. This arrangement is
recommended especially where maintenance
will be done on the valve body while still in-
stalled in the pipeline.
2. Pipe unions are recommended for NPT
screwed or socket welded installations to allow
complete removal from system. If removal
for maintenance is by cutting torch for socket
welded valves, leave sufficient pipe nipple
space between the 964 body and the next
piping component up or downstream to allow
socket weld couplings for re-installation.
3. If pipe reducers are located before and/or after
the valve body, keep the reducers as close as
practical to the valve body; this is especially
important where the reducers are more than
one line size larger than the valve body size,
which is common in gaseous service.
4. Clean the piping of all foreign debris, including
chips, weld scale, weld spatter, oil, grease,
sand or dirt prior to installing the control valve.
This is an absolute requirement for valves
supplied with composition soft seats. System
start-up strainers, for removal shortly after
initial start-up, are recommended.
5. Field hydrostatic testing the completed piping
system to 1-1/2 x CWP in psig indicated on the
nameplate, including the 964, is acceptable.
If hydro test pressure exceeds the 1-1/2 x
CWP limit, the 964 must be removed for such
testing. Before pressurization, the valve plug
should be lifted from the seat if of ATO-FC
action. Tighten packing as required.
6. In placing thread sealant on pipe ends prior
to engagement, ensure that excess material
is removed and not allowed to enter the valve
upon start-up.
7. Flow Direction: Install so the flow direction
matches the arrow marked on the valve body.
8. For best performance, install in well drained
horizontal pipe, properly trapped if a steam
service application.
9. Valves are not to be direct buried underground.
10. Insulation may be applied as indicated in Figure
2. Drainage away from the packing area must
be ensured when fully installed, sealed and
lagged for outdoors installation.
III. INSTALLATION
A. Orientation:
1. Recommended orientation when installed in
a horizontal pipeline with the stem vertical.
Valves may also be installed in vertical
pipelines with stems horizontal.
CAUTION
For welded installations, all internal trim parts and
seals, must be removed from body prior to welding
into pipeline. The heat of fusion welding will damage
non-metallic parts if not removed. NOTE: This does
not apply to units equipped with extended pipe nipples.
Limit of
Bonnet
Insulation

IOM-964 3
11. Undue piping stress/strain or bending
torques may not be transmitted through the
valve body. One pipe (inlet or outlet) should
be anchored rigidly for piping that is “hot” or
“cold” with respect to ambient temperature;
the remaining pipe (inlet or outlet) should
be supported and guided to ensure
unidirectional expansion/contraction.
C. Air Supply:
1. Use a desiccant dried, instrument quality
air supply. Such a supply is recommended
for outdoor installations, and is required in
areas of freezing weather conditions.
SECTION IV
IV. START-UP
A. General:
1. Ensure that the Model 964 unit has been
properly adjusted and calibrated, including
the positioner, if installed.
2. Recommend startup to be in a “manual”
mode. This procedure assumes double
block (isolation) and bypass valves for the
“control valve station”. See Figure 1.
3. Start with either of the two block valves
closed, with the other open. The bypass
valve should be closed. Pressurize system,
if possible/practical.
4. Back out the airset’s adjusting screw until
loose.
5. Turn on air supply pressure.
6. Adjust the air supply airset (filter-regulator)
to the proper level as indicated as follows:
8. Confirm that action of controller and
positioner - direct or reverse - are producing
the desired response in the control unit.
Confirm that the control valve “fail” position
is as required.
9. Hereafter, the procedure assumes that actual
fluid flow may be established. This may not
be practical / possible in all cases; if so, vary
procedure as required.
Always “heat” or “cool” down the system
piping SLOWLY by opening the control valve
station bypass valve in small increments.
10. With one of the control valve station block
valves still closed, and the loop controller
still in “manual” mode, open bypass valve
and vary flow rate manually to observe the
response of the controller and control valve
unit together.
11. Attempt to develop manual control of the
loop by opening/closing the manual bypass
as required, or by manually controlling
mainstream flow as required.
12. When the control valve is partially open, crack
open slowly the closed block valve while
simultaneously closing the bypass valve.
Continue this procedure until the bypass is
closed and the block valves are both fully
open. The system is still under “manual”
Bench Setting Airset Output
psig (Barg) psig (Barg)
5–15 (.34–1.0) 20 (1.4)
15–60 (1.0–4.1) 75 (5.2)
2. If air supply contains moisture and /or
lubricating oil, the air should be filtered
with a coalescing type of filter prior to use
in stroking the actuator.
3. Failure to remove moisture will cause
corrosion to the internals of the actuator
casings.
4. Connections for the air supply are 1/4" female
NPT. Use a suitable pipe thread sealant
when installing the pipe or tube fitting. DO
NOT allow sealant to enter the tube/pipe.
7. Place loop controller into “manual” mode.
Vary setting from minimum - mid-range -
maximum SIG output. Observe response of
control valve unit to these changes of input
SIG. The valve should fully stroke at the
variation from minimum SIG to maximum
SIG; the mid-range SIG should have the
valve stem travel at/near 1/2 open.
CAUTION
DO NOT WALK AWAY AND LEAVE A MANUALLY
CONTROLLED CONTROL VALVE UNATTENDED!

IOM-9644
mode control, but all flow is passing through
the control valve.
13. Vary controller “manual” SIG output until
matching the “automatic” SIG output, then
V. MAINTENANCE
A. General:
1. Maintenance procedures hereinafter are
based upon removal of the valve/actuator
unit from the pipeline where installed.
2. OwnershouldrefertoOwner’sproceduresfor
removal, handling and cleaning of non-reus-
able parts,i.e.gaskets,suitable solvents, etc.
3. Valves supplied from the factory use a
gasket sealant, Federal Process Company,
PLS2, or equal. Owner may use such aids
provided the aids are compatible with the
Owner’s fluid.
4. All indicated Item Numbers that are with
respect to the actuator assembly (AA) are
in parenthesis and underscored; i.e (20).
All Item Numbers that are with respect to
the body assembly (BA) of a Model 964
are not underscored; i.e. (32). Reference
with respect to the positioner is in double
parentheses; i.e. ((AP)).
5. Special care must be exhibited when
rotating the stem (3) of the valve to
not mar that portion of the surface of
the stem (3) where it contacts with the
packing (6). To rotate the stem (3), use
the jam nuts (18) or grasp stem with soft-
jawed pliers. NOTE: When using the jam
nuts (18) to rotate the stem (3), use the
upper jam nut to rotate the stem CW, and
the lower jam nut to rotate the stem CCW,
when viewed from above valve stem.
SECTION V
WARNING
SYSTEM UNDER PRESSURE. Prior to performing any
maintenance, isolate the valve/actuator from the system
and relieve all pressure. Failure to do so could result in
personal injury.
6. Hereafter, whenever text has the following
notation, “(Note PA.)”, the following text is
to be applied;
“For ATO-FC reverse action units,
connect a temporary air source to the
actuator and pressurize to a level suf-
ficient to initiate travel to approximately
mid-stroke.
7. Hereafter, whenever text has the following
notation, “(Note RP.)”, the following text is
to be applied:
“For ATO-FC reverse action units, re-
lease all temporary air pressure.
B. Actuator Removal:
1. Secure the body (1) in a vise with the actuator
assembly (AA) oriented vertically. Place
matchmarks between the body (1) bonnet
flange, the bonnet (2) flange, and the yoke
(3) to assist in final orientation when the
body is disassembled and/or the actuator
removed. If actuator has handwheel - see
Actuator IOM for removal instructions.
2. (Note PA.) Using blunt end tool, hammer
rap the tool to loosen yoke nut (29) turning
CCW (viewed from above) approximately 2
revolutions. Secure the actuator stem (6).
Loosen the stem jam nuts (18) by rotating
CW (viewed from above) one-at-a-time to
base of stem (3) threads.
3. Fully loosen any accessory devices that
are connected to the stem (6) or (3) such
as accessory plate ((AP)) for positioner.
4. Loosen packing (6) by rotating nuts (15)
CCW 2-3 revolutions. (Note RP.).
change the mode of the controller over to
“automatic”, and the loop will experience a
minimum of upset conditions, and will be in
automatic control.

IOM-964 5
NOTE: To fully disengage the actuator stem (6)
from the plug/stem (3) is a two-step procedure.
Be aware of the valve’s stroke length as indicated
on the nameplate (40) before beginning disen-
gagement. During the disengagement, measure
the distance extended, and stay at least 1/8" (3
mm) away from the full stroke length. Count and
record the number of revolutions for each step in
the box below:
6. For ATC-FO Direct Action Units:
a. Step A. Rotate plug/stem(3) CW (viewed
from above) to disengage the actuator
stem (6). Do not rotate the plug (3)
into the seat (11). Record the number
of plug/stem (3) revolutions for Step
A above. When the disengagement
reaches about 75% of full stroke travel,
Step A. is completed.
b. Step B. Support the actuator assembly
(AA) from above. Fully loosen yoke nut
(29)andremove. Lifttheactuator assem-
bly (AA) upwards approximately 1/4" -
3/8" (6-8 mm). Again, rotate plug/stem
(3) CW (viewed from above) to disen-
gage the actuator stem (6) from the plug/
stem (3), while holding the actuator stem
(6). Record the number of plug/stem
revolutions for Step B. This should al-
low the stems (6) (3) to fully disengage.
NOTE: Take notice of the parts “dangling
loosely” about the stem (3), the order of their
location and their proper orientation.
c. Fully raise actuator assembly (AA) from
the valve body assembly (BA). Remove
cautiously to prevent dangling parts – po-
sition indicating washer (26), accessory
plate ((AP)), yoke nut (29) - from falling.
C. Actuator Replacement:
1. Secure body assembly (BA) in a vise with
the plug/stem (3) oriented vertically. Push
plug/stem (3) down until the plug touches
the seating surface in the body.
2. Secure the actuator assembly (AA) from
above. Use matchmarks from B.1. previous
to assist with (BA) and (AA) alignment.
3. This procedure assumes that the bonnet (2)
has been bolted to the body (1), with stem
jam nuts (18) threaded on the plug/stem (3).
4. Lower actuator assembly (AA) until the plug/
stem (3) penetrates the opening in the yoke
(3). Reposition the “dangling parts” - yoke
nut (29), accessory plate ((AP)) or indicating
washer (26) - over threaded end of plug/
stem (3). Continue to lower the actuator
assembly (AA) until there is approximately
1/4" (6 mm) space between the two stems
(6) (3).
For Steps 5 and 6: Count the number of revolutions
to disengage plug/stem from actuator stem:
Step A. Step B.
TOTAL:
5. For ATO-FC Reverse Action Units:
a. (Note PA.)
b. Step A. Rotate plug/stem (3) CW (viewed
from above) to disengage the actuator
stem (6) from the plug/stem (3), while
holding the actuator stem (6). Record
the number of plug/stem revolutions for
Step A above. When the disengagement
reaches about 50% of full stroke travel
Step A is completed. (Note RP).
c. Step B. Support the actuator assem-
bly (AA) from above. Fully loosen
yoke nut (29). Lift the actuator as-
sembly (AA) upwards approximately
1/4"-3/8" (6-8 mm). Again, rotate plug/
stem (3) CW (viewed from above) to
disengage the actuator stem (6) from the
plug/stem (3) while holding the actuator
stem (6). Record the number of plug/
stem (3) revolutions for Step B above.
This should allow the stems (6) (3) to
fully disengage.
NOTE: Take notice of the parts “dangling
loosely” about the plug/stem (3), the order
of their location and their proper orientation.
d. Fully raise the actuator assembly (AA)
from the valve body assembly (BA).
Remove cautiously to prevent dangling
parts - position indicating washer (26),
accessory plate ((AP)), yoke nut (29) -
from falling.

IOM-9646
5. For ATC-FO: Connect a temporary air supply
hose that has an adjustable airset with gauge
to the actuator inlet to allow pressurization.
Slowly pressurize actuator to bring the actuator
stem (6) to within 1/8" (3 mm) of reaching the
plug/stem (3).
6. With hand lift plug/stem (3) up to touch actuator
stem (6). Rotate plug/stem (3) CCW (viewed
from above) to engage with actuator stem (6).
Use the total number of revs engagement
recorded in Step V.B. as the guide to control
engagement of the stems (6) (3). While en-
gaging, rotate yoke nut (29) as able to help
stabilize topworks, continue to pressurize the
actuator in 2-3 psi (.15-.20 Bar) increments
in an alternating sequence with the distance
engaged until the total number of revs engaged
is reached.
7. Hand-tighten yoke nut (29) until fully positioned
with the yoke (3) sitting on the bonnet (2).
8. Secure “dangling parts” - accessory plate
((AP)) and indicating washer (26) - to actuator
stem (6) with stem jam nuts (18).
9. Hammer rap yoke nut (29) until tight. (Release
temporary air source.)
D. Trim Removal and Replacement:
1. Secure body (1) assembly (BA) in a vise with
actuator assembly (AA) directed upwards.
Place match marks between the body (1) and
the bonnet (2).
2. Secure the actuator assembly (AA) with an
overhead support capable of vertical lift.
3. (Note PA.) Loosen all bonnet stud nuts (17)
(four nuts for 1/2" through 1-1/2" sizes; six
nuts for 2" size).
4. Ensure actuator support is “taut”; i.e. holding
weight of actuator.
5. Remove all bonnet bolting nuts (17).
6. Lift the actuator assembly (AA), together with
bonnet (2) and stem assembly (3) vertically
out of the valve body (1). Lay the topworks
assembly down onto a work bench horizontally.
For 1/2" - 1-1/2" sizes, remove the cage (10)
and seat ring (11) from the body (1) cavity.
7. From the topworks assembly, loosen the stem
jam nuts (18) by rotating CCW (viewed from
plug end) while securing the actuator stem
(6) with soft-jawed pliers.
8. Loosen stem packing (6) by turning nuts (15)
CCW to a point just short of disengagement
from the threads.
9. While securing the actuator stem (6) by soft-
jawed pliers, rotate the valve stem assembly
(3) CCW (viewed from plug end). Record the
number of revolutions of disengagement in
the box below:
Number of revolutions to disengage plug/stem as-
sembly from actuator stem.
CAUTION
Take extreme care to not mar internal wall surface of the
bonnet (2).
10. Remove packing flange nuts (15) with CCW
rotation.
11. Partially withdraw plug/stem assembly (3).
Remove position indicating washer (26), both
jam nuts (18), packing flange (4), packing
follower (5), and accessory plate ((AP)), if
installed.
12. Fully withdraw stem/plug assembly (3). For
1/2" through 1-1/2" sizes, cage (10) may have
come loose see Step 6 above.
13. Using a sharp, hooked-end, pick-type tool,
hook and pull the packing rings (6) up and out
of the bonnet’s (2) packing bore individually.
Discard old packing (6).
14. Using a sharp pointed tool, remove packing
washer (23) and packing spring (24).
15. Solvent clean all loose parts with suitable
solvent and let dry.
16. For SIZES 1/2” through 1-1/2", inspect
guide bushing (8) in-place, as the bushing
(8) is press fit into the bonnet (2). If worn
badly or “scored”:
a. Remove bonnet (2) by removing yoke
nut (29).
b. Hydraulically press guide bushing (8)
“out” of bonnet (2); press “in” new
guide bushing (8).
c. Reinstall bonnet (2) back through yoke
(3), and secure with yoke nut (29).

IOM-964 7
17. For SIZE 2", inspect guide bushing (8) in-
place, as the bushing (8) is press fit into the
bonnet (2). If worn or “scored:
a. Remove bonnet (2) by removing yoke nut
(29).
b. Remove retaining ring (9).
c. Hydraulically press guide bushing (8)
“out”; press “in” new guide bushing (8)
into bonnet (2).
d. Replace retaining ring (9).
e. Reinstall bonnet (2) back together with ac-
tuator yoke (3), securing with yoke nut (29).
18. Examine cage (10), seat ring (11), plug/stem
(3) seat insert (27), seat retainer (28) and
gasket (13) for wear. Replace all worn parts.
Refer to Figure 3 for correct orientation of
composition seat parts.
19. Examine stem (3) in critical finish zone where
contact is made with the packing (6). It is de-
sirable to restore the surface of the stem (3)
to a #8 Ra μ-in surface finish; metal removal
should not exceed 0.001-inch material. A
deeply scratched or pitted stem (3) should
be replaced.
20. Plug head of stem (3) assembly for metal
seated design may be hand lapped using
suitable lapping compound. If hand lapping
will not restore surface finish to an acceptable
degree, replacement of stem (3) assembly
and seat ring (11) is recommended.
21. Examine the inner surface of the bonnet’s
(2) packing bore. It is desirable to restore
the surface of stuffing box to a #16 Ra μ-in
surface finish; metal removal should not ex-
ceed 0.001-inch material. If inner surface is
deeply scratched or pitted, bonnet (2) should
be replaced.
22. Examine packing follower (5) for corrosion.
Replace if significantly corroded. Remove
follower bushing (25) from inside of packing
follower (5) and replace with new.
23. Remove gasket (12) (13), clean gasket facing
surfaces and replace with new gasket (12) (13).
24. Place seat ring (11) [and cage (10) - for sizes
1/2" - 1-1/2"] into the body (1) cavity. Insert
the threaded end of stem (3) through bonnet
(2) until it appears through the top side. Place
bonnet on body. (NOTE: The cage for 2"
size is integral with bonnet (2).)
25. For SIZES 1/2" - 1-1/2", lower packing spring
(24) into bonnet (2) packing bore.
For SIZE 2", first slide packing stop (7) into
bonnet (2) packing bore followed by the pack-
ing spring (24).
26. Lower packing washer (23) into bonnet (2)
packing bore. Ensure that washer (23) is
resting flat on the packing spring (24).
27. Carefully place lower adapter (6.3) of pack-
ing ring set (6) over stem’s (3) threaded end,
properly oriented. Using the packing follower
(5), push the lower adapter into the bonnet’s
(2) packing bore.
Packing Orientation
28. Carefully place a packing ring (6.2) properly
oriented over the stem’s (3) end and push
into the packing bore similar to the adapter
(6.3). Repeat process for balance of rings.
29. Carefully place upper adapter (6.1) over
threaded end of stem (3).
30. Slide packing follower (5) with new follower
bushing (25) over threaded end of stem.
31. Place packing flange (4) over end of stem
(3) and over packing studs (14). Install both
jam nuts (18) on stem and rotate to bottom
of stem threads.
32. Slide indicating washer(26) and accessory
plate ((AP)), if installed, over threaded end
of stem (3).
33. Engage plug/stem (3) into actuator stem
(6) per the same number of revolutions
recorded per D. Step 9.
34. Rotate both jam nuts (18) up tight against
position indicating washer (26).

IOM-9648
35. Tighten packing nuts (15) evenly in ½ revolu-
tion increments, until the packing flange (4)
is resting evenly on the upper edge of the
bonnet (2) at the packing box. Snug both
nuts (15) tightly.
36. Raise actuator assembly (AA). (Note RP.)
Lower into body (1) over bonnet studs/bolts
(16). Align with match marks.
37. For ATO-FC action units, wiggle the actuator
assembly (AA) to assist in alignment.
38. For ATC-FO action units, pressurize actuator
to the “higher” number of the bench set range
indicated on nameplate (12) plus 2 psig (.14
Barg); for 5-15 psig (.34-1.03 Barg) bench
setting, pressurize to 17 psig (1.17 Barg).
VI. CALIBRATION
A. General:
1. This section only covers calibration of the
control valve with Actuator Models C27/C53.
2. Positioner, if installed, requires reference to
the specific positioner model IOM for proper
calibration procedure.
3. All indicated items numbers that are with re-
spect to IOM-C27-C53 will be in parenthesis
and underscored; i.e. (20); those that reference
the positioner IOM will be in double parenthe-
ses; i.e. ((AP)). All item numbers that are with
respect to this IOM-964 are not underscored;
i.e. (3).
B. Procedure - Reverse Action, ATO-FC:
1. Reference the nameplate (40) attached to
the actuator yoke (3). Determine the bench
setting of the installed range springs (10) from
the nameplate (40); i.e. 5-15 psig (.34 -1.0
Barg), or 15-60 psig (1-4.1 Barg).
2. Connect a temporary air supply with an in-line
adjustable airset regulator and gauge to the
lower actuator connection. See Section IV. A.
6. for appropriate supply pressure. DO NOT
LOAD with any air pressure at this point.
3. To determine when stem/plug (3) begins to
lift out of the seat, touch the stem above the
packing studs with one finger. (Stem will begin
This should “lift” the bonnet (2) and “seat”
the plug (3) firmly into the seat ring (11) for
alignment purposes. Wiggle the actuator
assembly (AA) to assist in alignment.
39. Wrench-tighten the bonnet bolting (16) (17) in
an alternating cross-pattern in 1/4 revolution
increments. Torque bonnet bolting to 30-35
ft/lbs (40-47 N-M) for sizes 1/2" - 1-1/2" , and
50-55 ft/lbs (66-73 N-M) for size 2"
40. For ATC-FO action units, release actuator
pressure.
41. Hammer rap yoke nut (29) tight.
42. Calibrate unit per Section VI.
to move when actuator pressure exceeds
the spring load.)
4. Slowly pressurize the actuator to a pressure
equal to the lower pressure level of the bench
setting; i.e. for a 5-15 psig (.34 -1.0 Barg)
range, set pressure at 5 psig (.34 Barg). Take
note of pressure reading when the stem first
begins to move.
5. If the loading pressure for the start of stem
movement is below the lower end of the
desired bench setting, then the combined
stem (3, 6) length is too short.
a. Rotate both jam nuts (18) down to base of
threads on stem (3) and tighten together.
b. Increase pressure in the actuator to
approximately mid range of the bench
setting.
c. Rotate upper jam nut CW to increase
the combined stem length. DO NOT
allow actuator stem (6) to rotate in the
actuator.
d. Rotate upper jam nut CCW to hold indi-
cating washer (26) up against stem (6).
e. Release all pressure from the actuator
and repeat Step 4 previous.
6. If the loading pressure for the start of stem
movement is above the lower end of the
desired bench setting, then the combined
stem (3, 6) length is too long.
a. Rotate both jam nuts (18) down to base of
threads on stem (3) and tighten together.
SECTION VI

IOM-964 9
b. Increase pressure in the actuator to ap-
proximately mid range of the bench setting.
c. Rotate lower jam nut CCW to shorten the
combined stem length. DO NOT allow
actuator stem (6) to rotate in the actuator.
d. Rotate upper jam nut CCW to hold indicat-
ing washer (26) up against stem (6).
e. Release all pressure from the actuator
and repeat Step 4 previous.
7. After the opening set point pressure has been
established, rotate lower jam nut (18) CCW
up tight under the upper jam nut.
8. Release all pressure from the actuator.
9. Examine the location of the indicating washer
(26) to the "C" mark on the indicator plate
(23), making sure to use the “top edge” of the
indicating washer (26) as the reference point.
Adjust indicator plate as needed.
10. Increase pressure in the actuator until the
indicating washer (26) is in alignment with the
"O" mark on the indicator plate.
11. To limit the up travel at the desired stroke
length, rotate the travel stop nut (52) CW and
secure to bottom of the attachment hub (4).
NOTE: Secure the actuator stem (6) by the
flats when rotating the travel stop nut.
NOTE: “Stroke” length is indicated on the
nameplate (40), and is the distance between
the “C” and “O” marks of the indicator plate
(23).
NOTE: The proper calibration of the actuator/
valve unit will occur when at the lower pressure
level of bench setting, the valve plug (3) will
just begin to travel from the "C" position. At the
upper level of the bench setting, the actuator
pressure should be within ± 8% of the upper
bench setting for the designed stroke length.
12. Release all pressure from actuator.
C. Procedure - Direct Action, ATC-FO:
1. Reference the nameplate (40) attached to
the actuator yoke (3). Determine the bench
setting of the installed range springs (10) from
the nameplate (40); i.e. 5-15 psig (.34 -1.0
Barg), or 15-60 psig (1-4.1 Barg).
2. Connect a temporary air supply with an in-line
adjustable airset regulator and gauge to the
upper actuator connection. See Section IV. A.
6. for appropriate supply pressure. DO NOT
LOAD with any air pressure at this point.
3. To determine when stem/plug (3) makes
contact with the seat and travel stops, touch
the stem above the packing studs with one
finger. (Stem movement will stop when the
plug engages the seat.)
4. Slowly pressurize the actuator to a pressure
equal to the upper pressure level of the bench
setting; i.e. for a 5-15 psig (.34 -1.0 Barg)
range, set pressure at 15 psig (1.0 Barg).
Take note of the pressure reading when stem
travel actually stops.
5. If the loading pressure, when the stem move-
ment stops, is below the upper end of the
desired bench setting, then the combined
stem (3, 6) length is too long.
a. Rotate both jam nuts (18) down to base of
threads on stem (3) and tighten together.
b. Decrease pressure in the actuator to
approximately mid range of the bench
setting.
c. Rotate lower jam nut CCW to shorten the
combined stem length. DO NOT allow
actuator stem (6) to rotate in the actuator.
d. Rotate upper jam nut CW to hold indicat-
ing washer (26) up against stem (6).
e. Release all pressure from the actuator
and repeat Step 4 previous.
6. If the loading pressure when the stem move-
ment stops is above the upper end of the
desired bench setting, then the combined
stem (3, 6) length is too short.
a. Rotate both jam nuts (18) down to base of
threads on stem (3) and tighten together.
b. Decrease pressure in the actuator to
approximately mid range of the bench
setting.
c. Rotate upper jam nut CW to increase the
combined stem length. DO NOT allow
actuator stem (6) to rotate in the actuator.
d. Rotate upper jam nut CCW to hold indicat-
ing washer (26) up against stem (6).
e. Release all pressure from the actuator
and repeat Step 4 previous.
7. After the closed set point pressure has been
established, rotate lower jam nut (18) CCW
up tight under the upper jam nut.
8. Increase pressure in the actuator to the upper
pressure level of the bench setting.
9. Observe the location of the indicating washer
(26) to the "C" mark on the indicator plate
(23), making sure to use the “top edge” of

IOM-96410
VII. TROUBLE - SHOOTING GUIDE
SECTION VII
Possible Causes Remedies
A. Excess packing friction. A1.
A2.
A3.
A4.
Realign body - stem - actuator.
Packing follower too tight for optional packing designs.
Install positioner.
Increase bench set by changing to stiffer actuator
range spring. Will require positioner if not installed.
May require different airset.
B. Installed backwards. B. Install per flow arrow.
1. Valve is “jumpy” in stroking.
Possible Causes Remedies
A. Excess pressure drop. A. Bring pressure drop within design limits.
B. Guide bushing wear. B. Replace guide bushing.
C. Misalignment. C. Realign body-stem-actuator.
2. Valve makes “screeching” noise.
Possible Causes Remedies
A. Excess pressure drop. A. Bring pressure drop within design limits.
B. Guide bushing wear. B. Replace guide bushing.
C. Excessive cavitation in liquid service. C1.
C2.
Change operation parameters to relieve causes of
cavitation.
Replace valve with valve equipped for cavitational control.
D. High outlet velocity. D1.
D2.
D3.
Reduce flow rate and/or pressure drop.
Use multiple valves in series or parallel.
Increase outlet pipe size.
3. Valve exhibits “excess” vibration.
the indicating washer (26) as the reference
point. Adjust indicator plate as needed.
10. Slowly release air pressure in the actuator
until the indicating washer (26) is in alignment
with the "O" mark on the indicator plate.
11. To limit the up travel at the desired stroke
length, rotate travel stop nut (52) CW and
secure to bottom of the attachment hub (4).
NOTE: Secure the actuator stem (6) by the
flats when rotating the travel stop nut.
NOTE: “Stroke” length is indicated on the
nameplate (40), and is the distance between
the “C” and “O” marks of the indicator plate
(23).
NOTE: The proper calibration of the actuator/
valve unit will occur when at the upper pres-
sure level of bench setting, the valve plug (3)
will be in the "C" position. At the lower level
of bench set the actuator pressure should
be within ± 8% of the lower bench setting
for the designed stroke length.
12. Release all pressure from actuator.

IOM-964 11
Possible Causes Remedies
A. Excess pressure drop. A. Reduce pressure drop conditions.
B. Improper actuator bench setting. B1.
B2.
Calibrate actuator-to-valve.
Assure proper engagement of actuator stem-to-valve
stem. Adjust as calibration dictates.
C. Metal seat design instead of composition seat
design.
C. Convert valve to composition seat design.
D. Excess wear. D1.
D2.
D3.
D4.
D5.
Oversized valve operating too close to seat; go to re-
duced trim.
Incorporate stellite trim.
Remove particulate.
Possible excess cavitation in liquid service. Change
operation parameters.
Re-lap plug-seat surface.
E. Misalignment. E. Realign body - stem - actuator.
F. Composition seat failure. F1.
F2.
Replace soft seat.
Remove "dirty" portion of fluid causing failure.
G. Seat ring gasket failure. G. Replace seat ring gasket.
4. Valve exhibits “excess” seat leakage.
Possible Causes Remedies
A. Over-temperature. A1.
A2.
Bring process temperature to 450°F (232°C) or less.
Remove insulation along bonnet; allow direct contact
with ambient air.
B. Misalignment. B. Realign body - stem - actuator.
C. Wear. C1.
C2.
Remove dirt/grit from fluid.
Reduce cyclic travel.
D. Improper design for applied service. D1. Install alternate packing design.
5. Premature packing leakage.
Possible Causes Remedies
A. Improper bonnet bolting draw down. A1. Replace gasket and draw down bolting evenly in a
cross-pattern.
6. Bonnet gasket leaking.
Possible Causes Remedies
A. Over-tightening flange bolting. A1.
A2.
Loosen bolting, replace gasket, reinstall new flange
bolting.
Replace warped flanges.
B. Improper pipe supports and anchors. B. Provide piping anchors and guides at control valve sta-
tion. Restrain bending movements.
7. Body flange leakage.

IOM-96412
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 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” 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
accommodate 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-964 13
1/2"–1-1/2" Sizes MODEL 964
Figure 3: Composition Seat Arrangement

IOM-96414
2" Size MODEL 964
Item No. Description
1 Body
2 Bonnet
3 Plug & Stem Subassembly ‡
4 Packing Flange
5 Packing Follower
6 Packing ‡
7 Packing Stop (2" Size only)
8 Guide Bushing
9 Retaining Ring (2" Size only)
10 Cage
11 Seat Ring
12 Gasket - Body ‡
13 Gasket - Seat Ring ‡
Item No. Description
14 Packing Flange Stud
15 Packing Flange Nut
16 Studs - Body
17 Stud Nuts
18 Jam Nuts
23 Packing Washer
24 Packing Spring
25 Packing Follower (Bushing)
26 Indicating Washer
27 Seat Insert ‡
28 Seat Retainer
29 Yoke Nut
‡ Recommended replacement parts.

IOM-964 15
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.

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. 964-IOM
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.