cashco 987 User manual

INSTALLATION, OPERATION, AND MAINTENANCE MANUAL IOM-987
12-16
I. DESCRIPTION AND SCOPE
The Model 987 is a pneumatically actuated, sliding
stem globe-style control valve. Available sizes 1/2"
- 1" (DN15 - 25). Internal design is a “push down to
close” arrangement.
Failure position is determined by actuator.
"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.
This valve is designed to control moderate to severe
corrosive applications but may be applied in general
service applications also.
SECTION II
MODEL 987
GLOBE-STYLE
PNEUMATIC CONTROL VALVE
BODY IOM
SECTION I
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
Model 987
with ATO - FC Actuator
II. REFERENCE
Refer to Technical Bulletin 987-TB for complete
technical specifications of a Model 987 coupled with
either Cashco Actuator Model C27 or C53.
www.cashco.com/techbulletin/987.pdf
Refer to following Installation, Operation & Maintenance
Manuals (IOM’s) for either actuator and/or devices that
maybe mounted to a Model 987:
Actuators: www.cashco.com/iom/C27-C53.pdf
ISO Registered Company

2IOM-987
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
installed in the pipeline.
2. Pipe unions are recommended for NPT
screwed installations to allow complete
removal from system.
3. If pipe reducers are located before and/or after
the valve body, keep the reducers as close as
Figure 1: Typical Control Valve Station
1. Recommended orientation when installed in
a horizontal pipeline is with the stem vertical.
Valves may also be installed in vertical
pipelines with stems horizontal.
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.
SECTION III
III. INSTALLATION
A. Orientation:
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. For flangeless installation, body (1) must be
machined with serrations on each end of body.
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.
WARNING
DO NOT attempt to install a body machined for NPT end
connections as a flangeless installation. Failure to heed
could cause fluid leakage.
Model 987 bodies with flangeless end
connections may be installed as below:
TABLE 1
PIPING FLANGES & FLANGELESS
VALVE CONNECTIONS
Basic Flange
Size
Flange Pressure Class
150# 300# 600#
1/2" N/A N/A N/A
3/4" N/A √√
1" √√√
1" x 1/2" Reducing √√√
1" x 3/4" Reducing √√√
√Available
5. Opt-32 Extended Pipe Nipples should be used
for socket welding or butt welding. Standard
end preparation is for socket welding. If butt
welding is desired, weld end preparations must
be done in field with suitable tools.
6. 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.
7. Field hydrostatic testing the completed piping
system to 1-1/2 x CWP in psig indicated on the
nameplate, including the 987, is acceptable.
If hydro test pressure exceeds the 1-1/2 x
CWP limit, the 987 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.
8. 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.
Drain
Drain

3
IOM-987
Figure 2: Body Insulation
Limit of
Bonnet
Insulation
9. Flow Direction: Install so the flow direction
matches the arrow marked on the body.
10. For best performance, install in well drained
horizontal pipe, properly trapped if a steam
service application.
11. Valves are not to be direct buried underground.
12. 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.
13. Undue piping stress/strain or bending torques
may not be transmitted through the control
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.
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.
SECTION IV
IV. STARTUP
A. General:
1. Ensure that the Model 987 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:
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)
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!

4IOM-987
V. MAINTENANCE
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.
A. General:
1. Maintenance procedures hereinafter are
based upon removal of the valve/actuator
unit from the pipeline where installed.
2. Owner should refer to Owner’s procedures for
removal, handling and cleaning of nonreusable
parts, i.e. gaskets, suitable solvents, etc.
3. General service valves supplied from the
factory do not require use of any gasket
sealant.(See below for “oxygen cleaned”
valves.)
4. Valves originally supplied in accordance
with Option-55 require special cleaning
procedures. Refer to Cashco Specification No.
S-1134 for details. When in compliance
with Spec. #S-1134, the valve is suitable for
oxygen service. Sealants and lubricants used
in reassembly of a valve unit for use in oxygen
service MUST be suitable for O2service.
5. 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) are not underscored; i.e. (32).
Reference with respect to the positioner is in
double parentheses; i.e. ((AP)).
6. Special care must be exhibited when
rotating the plug stem (4) in the body to
not mar that portion of the surface of the
stem (4) where it contacts with the packing
(10). To rotate the stem (4) use the jam nuts
or grasp stem with soft-jawed pliers. NOTE:
When using the jam nuts (17) to rotate the
stem (4), use the upper jam nut to rotate the
stem CW, and the lower jam nut to rotate
the stem CCW, when viewed from above the
valve stem.
7. Hereafter, whenever text has the following
notation, "(Note PA.)", the following text is
to be applied:
"For ATO-FC units ONLY, connect a
temporary air source to the actuator and
pressurize to a level sufficient to initiate
travel to approximately mid-stroke."
8. Hereafter, whenever text has the following
notation, "(Note RP.)", the following text is
to be applied:
SECTION V
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” mode
control, but all flow is passing thru the control
valve.
13. Vary controller “manual” SIG output until
matching the “automatic” SIG output, then
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.
8. Confirm the 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.

5
IOM-987
No. of revolutions to disengage valve stem from
actuator stem:
Step A. ____________ Step B. ___________
TOTAL: ____________
"For ATO-FC units ONLY, release all
temporary air pressure."
B. Actuator Removal:
1. Secure the body assembly (BA) in a vise with
the actuator assembly (AA) oriented vertically.
Place matchmarks between the body (1),
bonnet flange (7) and the yoke (3) to assist in
final orientation when the body is disassembled
and/or the actuator removed.
2. (Note PA.) Using a blunt end tool, hammer
rap the tool to loosen yoke nut (15) turning
CCW (viewed from above) approximately
2 revolution. Secure the actuator stem (6).
Loosen the stem jam nuts (17) by rotating
CW (viewed from above) one-at-a-time until
rotation stops.
3. Fully loosen any accessory devices that are
connected to the stem (6) or (4), such as
accessory plate ((AP)) for positioner.
4. Loosen stem packing (10) by removing packing
stud nuts (21) CCW. (Note RP.).
NOTE: To fully disengage the actuator stem (6)
from the valve stem (4) is a two-step procedure. Be
aware of the valve’s stroke length as indicated on the
nameplate (40) before beginning disengagement.
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:
loosen yoke nut (15). Lift the actuator
assembly (AA) upwards approximately
1/4"-3/8" (6-8 mm). Again, rotate valve stem
(4) CW (viewed from above) to disengage
the actuator stem (6) from the valve stem
(4) while holding the actuator stem (6).
Count and record the number of valve stem
revolutions for Step B above. This should
allow the stems (6) (4) to fully disengage.
NOTE: Take notice of the parts “dangling
loosely” about the stem (4), 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 the dangling parts
- packing flange (23), position indicating
washer (16), accessory plate ((AP)), yoke
nut (15) - from falling.
6. For ATC-FO Direct Action Units:
a. Step A. Rotate valve stem (4) CW (viewed
from above) to disengage the actuator stem
(6). Do not rotate the stem (4) down into
the seating surface. Count and record the
number of valve stem (4) 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 (15). Lift the actuator assembly
(AA) upwards approximately 1/4" -
3/8" (6-8 mm). Again, rotate valve stem
(4) CW (viewed from above) to disengage
the actuator stem (6) from the valve stem
(4), while holding the actuator stem (6).
Count and record the number of valve stem
revolutions for Step B. This should allow
the stems (6) (4) to fully disengage.
NOTE: Take notice of the parts “dangling
loosely” about the stem (4), the order of their
location, and their proper orientation.
c. Fully raise the actuator assembly (AA) from
the valve body assembly (BA). Remove
cau
tiously to prevent the dangling parts
– packing flange (23), position indicating
washer (16), accessory plate ((AP)), yoke
nut (15) - from falling.
5. For ATO-FC Reverse Action Units:
a. (Note PA.)
b. Step A. Rotate valve stem (4) CW
(viewed from above) to disengage the
actuator stem (6) from the valve stem
(4), while holding the actuator stem (6).
Count and record the number of valve
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
assembly (AA) from above. Fully

6IOM-987
C. Actuator Replacement:
1. Secure body assembly (BA) in a vice with
the valve stem (4) oriented vertically. Push
plug/stem (4) down until the plug touches the
seating surface in the body (1).
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 installed to the body (1), with stem
jam nuts (17) on the valve stem (4).
4. Lower actuator assembly (AA) until the valve
stem (4) penetrates the opening in the yoke
(3). Reposition the “dangling parts” - packing
flange (23), yoke nut (15), accessory plate
((AP)) and indicating washer (16) - over the
body stem (4). Continue to lower the actuator
assembly (AA) until there is approximately
1/4" (6 mm) space between the two stems
(6) (4).
5. For ATC-FO: Connect a temporary air supply
hose that has an adjustable airset and gauge
to the actuator inlet to allow pressurization.
Slowly pressurize actuator to bring the
actuator stem (6) to be within 1/8" (3 mm) of
contacting the valve stem (4).
6. With hand, lift stem (4) up to touch actuator
stem (6). Rotate valve stem (4) CCW (viewed
from above) to engage w/ actuator stem (6).
Use the total number of revs engagement
recorded in Step V.B.4. as the guide to control
engagement of the stems (6) (4). While
engaging the stems, rotate yoke nut (15) 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 (15) until fully positioned
with the yoke (3) sitting on the bonnet (2).
8. Secure “dangling parts” - accessory plate
((AP)) and indicator washer (16) - to actuator
stem (6) with stem jam nuts (17).
9. Hammer rap yoke nut (15) until tight. (Release
temporary air source.)
10. Install nuts (21) on studs (20). Use torque
wrench to tighten to 25-30 in-lbs.
CAUTION
It sometimes occurs that the stem (4) will “stick” within the
bonnet (2) and pull out with parts of this step above. DO NOT
ALLOW THE STEM (4) TO DROP and do personal injury or
damage stem (4)!
D. Trim/Packing Removal and Replacement:
NOTE: This Subsection assumes that the actuator
assembly (AA) has been already removed
per Sub-section B. previous.
1. Secure (BA) in a vise with the valve stem (4)
pointing upwards.
2. Pull stem (4) upwards. Hold stem (4) up if
necessary using soft-jawed locking pliers.
Loosen four bonnet flange nuts (9) and
remove.
3. Carefully wiggle stem (4) side-to-side to break
loose bonnet (2) from body (1). Lift the bonnet
(2) directly upwards along with stem (4),bonnet
flange (7) and all the packing components
(10,11). Lay the group of parts on a flat work
surface. Ensure that the bonnet (2) will not
"roll".
4. Remove bonnet flange (7) from bonnet (2).
5. Remove packing follower (11) over threaded
end of stem (4).
6. Push stem (4) threaded-end into bonnet (2)
as far as possible using fingers while holding
bonnet (2) with other hand. Grasp plug-end
of plug/stem subassembly (4) and withdraw
from the bonnet (2) and thru the packing rings
(10). Set plug/stem subassembly (4) aside.
7. Place bonnet (2) into a leaded-jaw vise with
packing-end upwards. Using a pick-type tool,
remove the five packing rings (10). Inspect
rings (10) for signs of damage and then discard.
8. Place all bonnet-area removed parts (2,4,7,11)
into a suitable cleaning solvent.
9. Remove bonnet O-ring seal (6) from body (1).
Inspect O-ring (6) for signs of failure to seal,
then discard.
10. If body (1) includes a screwed-in seat ring (3),
use a sufficiently wide piece of 1/4" thick steel
bar to remove the seat ring (3) by rotating seat
ring (3) CCW (viewed from above) to removal.

7
IOM-987
11. Remove seat ring O-ring seal (5) from seat
ring (3). Inspect O-ring (5) for signs of failure
to seal, then discard.
12. Remove body (1) from vise and place body
(1) and seat ring (3) into a suitable cleaning
solvent.
13. For valves equipped with Opt-27 Viscous
Service Bonnet, ensure that the two equalizing
passageways located in bonnet (2) are fully
open.
14. For valves equipped with a composition seat
as a part of the plug/stem subassembly (4), the
parts are mechanically pressed together such
that the composition seat is non-replaceable.
A new plug/stem subassembly (4) must be
supplied in order to replace the composition
seat.
15. After soaking, remove all parts (1,2,3,4,7,11)
and inspect for any signs of wear or corrosion;
replace all worn parts with new parts. Bonnet
(2) packing box and stem (4) sealing zones
must be finished to a 16Rasurface or better.
16. Place body (1) into a vise with bonnet-zone
on topside.
17. Place a new O-ring seal (5) onto the seat ring
(3). Reinstall the seat ring (3) into the body (1)
by rotating the seat ring (3) CW (viewed from
above). Using the steel bar tool, firmly tighten
the seat ring (3). NOTE: Do not over-tighten
the seat ring (3) to prevent galling of threads.
18. Place a new O-ring seal (6) into the bonnet's
(2) recess in the body (1).
19. Place TFE sealant tape over threaded-end of
stem (4), covering all the peaks.
20. Place plug/stem subassembly (4) with the plug-
end into the seat ring (3), and the threaded-end
directed upwards. Place lower end of bonnet
(2) over threaded end of stem (4) and fully
lower bonnet (2) until properly aligned in body
(1) recess.
21. Place bonnet flange (7) over bonnet (2) and
down over the bonnet studs (8), align match
marks.
22. Install bonnet flange nuts (9) and finger-tighten.
23. See Figure 5. Place a lower adapter packing
ring (10.1) over the stem-end (4) and press
it into the bonnet (2) packing box using the
packing follower (11). Repeat for the three
middle packing v-rings (10.2). Press upper
adapter ring (10.3) into the box; leave the
packing follower (11) in position.
Packing Orientation
24. Wiggle stem (4) around to align parts
(2,3,4,7,10) as much as possible. Wrench-
tighten bonnet flange nuts (9) equally with a 1/4
turn revolution each, in alternating, cross-
pattern. Using a torque wrench, tighten the
nuts (9) to 25 - 30 ft-lbs (33.8 - 40.6 N•m).
25. Using hand pressure, push plug/stem (4)
assembly down into the body (1) until the
plug touches the seating surface in the body.
Remove TFE tape from threaded end of
stem (4).
26. Raise Model C27or C53 actuator (AA) above
the threaded end of the stem assembly. Use
matchmarks from B.1. previous to assist with
(BA) and (AA) alignment.
27. Lower actuator assembly (AA) until the valve
stem (4) penetrates the opening in the yoke
(3). Reposition the “dangling parts” - packing
flange (23), yoke nut (15), accessory plate
((AP)) and indicating washer (16) - over the
body stem (4). Continue to lower the actuator
assembly (AA) until there is approximately
1/4" (6 mm) space between the two stems
(6) (4).
28. 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 be within 1/8" (3 mm) of
contacting the valve stem (4).
29. With hand lift stem (4) up to touch actuator
stem (6). Rotate valve stem (4) CCW (viewed
from above) to engage w/ actuator stem (6).

8IOM-987
Use the total number of revs engagement
recorded in Step V.B.4. as the guide to control
engagement of the stems (6) (4). While
engaging the stems, rotate yoke nut (15) 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.
30. Hand-tighten yoke nut (15) until fully positioned
with the yoke (3) sitting on the bonnet (2).
31. Secure “dangling parts” - accessory plate ((AP))
and indicator washer (16) - to actuator stem (6)
with stem jam nuts (17).
32. Hammer rap yoke nut (15) until tight. (Release
temporary air source.)
33. Install nuts (21) on studs (20). Use torque wrench
to tighten to 25-30 in-lbs.
SECTION VI
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
respect to IOM-C27-C53 will be in parenthesis
and underscored; i.e. (20); those that
reference the positioner IOM will be in double
parentheses; i.e. ((AP)). All item numbers
that are with respect to this IOM-987 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 (4) begins to lift
out of the seat, touch the stem below the jam
nuts with one finger. (Stem will 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 the 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
(4, 6) length is too short.
a. Rotate both jam nuts (17) down to base of
threads on stem (4) 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
indicating washer (16) 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
(4, 6) length is too long.
a. Rotate both jam nuts (17) down to base of
threads on stem (4) and tighten together.
b. Increase pressure in the actuator to
approximately mid range of the bench set.
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
indicating washer (16) 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 (17) CCW up
tight under the upper jam nut.
8. Release all pressure from the actuator.
9. Observe the location of the indicating washer

9
IOM-987
(16) to the "C" mark on the indicator plate
(23), making sure to use the “top edge” of
the indicating washer (16) as the reference
point. Adjust indicator plate as needed.
10. Increase pressure in the actuator until the
indicating washer (16) 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 (4) will just begin to travel from the "C"
position. At the upper level of the bench set,
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 (4) 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 stops.
5. If the loading pressure, when the stem
movement stops, is below the upper end of
the desired bench setting, then the combined
stem (4, 6) length is too long.
a. Rotate both jam nuts (17) down to base of
threads on stem (4) and tighten together.
b. Decrease pressure in 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 indicating
washer (16) up against stem (6).
e. Release all pressure from the actuator
and repeat Step 4 previous.
6. If the loading pressure when the stem
movement stops is above the upper
end of the desired bench setting, then
the combined stem (4, 6) length is too
short.
a. Rotate both jam nuts (17) down to
base of threads on stem (4) 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
indicating washer (16) 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 (17) 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
(16) to the "C" mark on the indicator plate
(23), making sure to use the “top edge” of
the indicating washer (16) as the reference
point. Adjust indicator plate as needed.
10. Decrease pressure in the actuator until the
indicating washer (16) 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 attachment hub (4).

10 IOM-987
SECTION VII
Possible Cause Remedy
A. Excess packing friction.
A1. Realign body–stem–actuator.
A2. Packing follower too tight.
A3. Install Positioner.
A4. Increase bench.
B. Installed backwards. B. Install per flow arrow.
Possible Cause Remedy
A. Excess pressure drop. A. Bring pressure drop within design limits.
B. Bushing wear. B. Replace bushing and stem.
C. Misalignment. C. Realign body-stem-actuator.
Possible Cause Remedy
A. Excess pressure drop. A. Bring pressure drop within design limits.
B. Bushing wear. B. Replace bushing and stem.
C. Excessive cavitation in liquid service.
C1. Change operation parameters to relieve causes
of cavitation.
C2. Replace valve with valve equipped for cavitation control.
D. High outlet velocity.
D1. Reduce flow rate and/or pressure drop.
D2. Use multiple valves in series or in parallel.
D3. Increase outlet pipe size.
2. Valve makes "screeching" noise.
3. Valve exhibits "excess" vibration.
1. Valve is "jumpy" in stroking
VII. TROUBLE-SHOOTING GUIDE
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.
NOTE: The proper calibration of the actuator/
valve unit will occur when at the upper pressure
level of bench setting, the valve plug (4) 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.

11
IOM-987
Possible Cause Remedy
A. Excess pressure drop. A1. Reduce pressure drop conditions.
A2. Convert to reduced trim.
B. Improper actuator bench setting. B1. Calibrate actuator-to-valve.
B2. Assure proper engagement of act.stem to valve stem.
C. Metal seat design instead of composition seat design. C. Convert valve to composition seat.
4. Valve exhibits "excess" seat leakage.
Possible Cause Remedy
A. Over-temperature.
A1. Bring process temperature to 450°F (232°C) or less.
A2. Remove insulation along bonnet; allow direct contact
with ambient air.
B. Misalignment. B. Realign body-stem-actuator.
C. Wear. C1. Remove dirt/grit from fluid.
C2. Reduce cyclic travel.
D. Improper design for applied service. D. Install alternate packing design.
E. Corrosion of stem. E. Consider use of Model 988 or 989 or 2296.
Possible Cause Remedy
A. Improper bonnet bolting draw down. A. Replace bonnet o-ring and draw down bolting evenly.
B. Corrosion. B. Consider use of Model 988 or 989 or 2296.
C. Over-temperature. C. Bring process temperature to 450°F (232°C) or less.
D. Excess wear.
D1. Oversized valve operating too close to seat, convert to
reduced trim.
D2. Remove particulate.
D3. Possible excess cavitation in liquid service, change
operation parameters.
D4. Re-lap plug-seat surface.
E. Misalignment. E. Realign body-stem-actuator.
F. Composition seat failure. F1. Replace soft seat.
F2. Remove "dirty" portion of fluid causing failure.
G. Seat ring gasket failure. G. Replace seat ring o-ring.
5. Premature packing leakage.
6. Bonnet gasket leaking.

12 IOM-987
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 ap-
propriate 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 con-
strued 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.

13
IOM-987
Item No. Description
1 Body
2 Bonnet
3 Seat Ring
4 Plug & Stem Subassembly
5 Seat Ring O-Ring ‡
6 Bonnet O-Ring ‡
7 Bonnet Flange
8 Bonnet Stud
9 Flange Nut
10 Packing ‡
11 Packing Follower
13 Nut
14 Stud
15 Yoke Nut
16 Indicating Washer
17 Stem Jam Nut
20 Packing Stud
21 Packing Stud Nut
23 Packing Flange
‡ Recommended replacement parts.
Figure 4
Composition Seat Design
Figure 5
Packing Design
Figure 3
Representative of 1/2" – 1" Sizes
Metal Seat Design. Critical
Finish
Zone

14 IOM-987
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. 987-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.