cashco 1000HP Guide

INSTALLATION, OPERATION & MAINTENANCE MANUAL
MODEL 1000HP - CRYOGENIC
PRESSURE REDUCING REGULATOR
SECTION I
IOM-1000HP-
Cryogenic
12-16
I. DESCRIPTION AND SCOPE
The Model 1000HP-5 and 1000HP-36 are cryogenic pressure reducing regulators used to control downstream
(outlet or P2) pressure to levels above 10 psig, and up to 300 psig (size dependent). Sizes are 1/2", 3/4", 1",
1-1/2" and 2".
The unit is designed for liquid or gaseous service with proper trim utilization, and proper jet selection.
Refer to Technical Bulletin 1000HP-CRYO-TB for sizing, application and selection recommendations.
Installation, operation and maintenance manuals (IOM's) exist for the following other Model 1000 products:
1000HP-Basic 1000LP-Basic 1000HP-Differential
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, and a
manual bypass valve be installed.
3. Pipe unions must be installed to allow removal
from piping. Trim can only be changed by unit
removal from pipeline. If flanges are utilized, a lap
joint flange is required on the inlet end of the valve
to help align bolt holes as the cylinder screws into
place.
4. An outlet pressure gauge should be located
approximately ten pipe diameters downstream,
and within sight.
5. All installations should include a downstream
relief device if the inlet pressure could exceed the
pressure rating of any downstream equipment or
the maximum outlet pressure rating of the unit.
6. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt before
installing the valve. 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.
WARNING
The maximum outlet pressure listed on the nameplate is
the "upper operative limit" for the sensing diaphragm.
Higher pressures could damage the diaphragm. (Field
hydrostatic tests frequently destroy diaphragms. DO NOT
HYDROSTATIC TEST THROUGH AN INSTALLED UNIT;
ISOLATE FROM TEST.)
ISO Registered Company

2 IOM-1000HP-Cryogenic
can drip melted condensate as required. A purge
gas is recommended for the spring chamber.
10. Regulators are not to be direct buried under-
ground.
11. For insulated piping systems, recommendation is
to not insulate regulator.
12. Cashco does not recommend field welding on
the cylinder (inlet) end of the regulator, due to the
possibility of warpage.
SECTION III
III. PRINCIPLE OF OPERATION
1. The Model 1000 is available in two variations:
1000LP (larger diaphragm) for downstream pres-
sure control from 1-30 psig; 1000HP (smaller
diaphragm) for downstream pressure control from
10-300 psig, body size dependent.
2. Movement occurs as pressure variations reg-
ister on the diaphragm. The registering pressure
is the outlet, P2, or downstream pressure. The
range spring opposes diaphragm movement. As
outlet pressure drops, the range spring pushes
the diaphragm up, opening the port; as outlet
pressure increases, the diaphragm pushes down
and the port closes.
3. The Model 1000 includes a rocker arm in its
operational mechanism. The rocker arm allows
the regulator to operate flow-to-open (FTO),
rather than conventional flow-to-close (FTC),
which increases rangeability.
4. Due to the FTO design, there is a limit as to how
low of a downstream (P2or outlet) pressure level
setting is capable for a given inlet P1pressure.
This is a function of the ratio of the port area to
diaphragm area. It is possible for there to be too
high of an inlet pressure for the regulator to close
off against. (Refer to Technical Bulletin, Tables 6
and 7 for limits.) Reduced port, Option -12 allows
lower downstream (P2or outlet) pressure settings
for a given upstream (P1or inlet) pressure level.
5. The FTO design also is limited by a minimum
pressure drop. If the regulator pressure drop is
below 5 psi, an Option 1000-17 Piston Spring
should be utilized to assist opening the valve
piston. (Standard with 1000-5; must be specified
with 1000-36.)
6. The Model 1000 includes an aspiration jet effect,
due to the clearance of the piston from the body
near the regulator's outlet. These clearances vary
as to whether the fluid is a gas or a liquid. Jets must
be selected to match one of these two general
fluids. An improper jet selection will reduce perfor-
mance.
7. A complete diaphragm failure will cause the
regulator to fail open.
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.
9. For best performance, install in well drained
horizontal pipe. Recommended position is with
spring chamber vertically downwards. Orient
to prevent the spring chamber vent hole from
collecting rainwater or debris, and so drain hole

IOM-1000HP-Cryogenic 3
SECTION IV
VI. MAINTENANCE
A. General:
1. Maintenance procedures hereinafter are
based upon removal of the regulator unit
from the pipeline where installed.
2. Owner should refer to owner's procedures for
removal, handling and cleaning of reusable
parts, and disposal of nonreusable parts, i.e.
asbestos gaskets, suitable solvents, etc.
IV. STARTUP
1. Purge the system, including the spring chamber,
to remove air, moisture, carbon dioxide, etc.
2. Start with the block valves closed. A bypass
valve may be used to maintain outlet pressure
in the downstream system without changing the
following steps.
3. Relax the range spring by turning the adjusting
screw counterclockwise (CCW) a minimum of
three (3) full revolutions. This reduces the outlet
(downstream) pressure set point. NOTE: Rotation
CW or CCW is as viewed from the adjusting screw
end, i.e. bottom of valve looking up.
4. If equipped with a bypass valve, slowly open
the bypass valve to cool the system piping and
to allow slow contraction of the piping. Closely
monitor outlet (downstream) pressure via gauge
to ensure not over-pressurizing. NOTE: If no
bypass valve is installed, extra caution should
be used in starting up an ambient temperature
system; i.e. do everything slowly.
5. Crack open the outlet (downstream) block valve.
6. Slowly open the inlet (upstream) block valve
observing the outlet (downstream) pressure
gauge. Determine if the regulator is flowing. If
SECTION V
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.
2. If the regulator and system are to both be
shutdown, slowly close the inlet (upstream) block
valve. Close the outlet (downstream) valve only if
regulator removal is required.
SECTION VI
not, slowly rotate the regulator adjusting screw
clockwise (CW) until flow begins.
7. Continue to slowly open the inlet (upstream) block
valve until fully open.
8. Continue to slowly open the outlet (downstream)
block valve, especially when the downstream
piping system isn't pressurized. If the outlet
(downstream) pressure exceeds the desired
pressure, close the block valve and go to Step 2,
then return to Step 4.
9. When flow is established steady enough that the
outlet (downstream) block valve is 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 set point by
turning the adjusting screw CW to increase outlet
pressure, or CCW to reduce outlet pressure.
11. Reduce system flow to a minimum level and
observe set point. Outlet pressure will rise from
the set point of Step 9. The maximum rise in
outlet pressure on decreasing flow should not
exceed the stated upper limit of the range spring
by greater than 30%; i.e. 10-40 psig range spring,
at low flow the outlet pressure should not exceed
52 psig. If it does, consult factory.
CAUTION
Do not walk away and leave a bypassed regulator unat-
tended.

4 IOM-1000HP-Cryogenic
8. Place the pusher plate stud (13) in a
separate vise, gripping the stud (13) on the
hexagonal cast-in-place edges located on
the underneath side of the pusher plate stud.
NOTE: Do not remove the stud nut (10), stud
collar (16) and the location locking cotter pin
(15). Loosen and remove nut (11).
9. Remove pressure plate (3) by lifting.
10. Pry loose pusher plate and stud (13) from
diaphragm(s) (20) or from pusher plate gasket
(12). Remove the diaphragm(s) (20).
11. Remove pusher plate gasket (12) from pusher
plate and stud (13).
12. Clean gasket sealing surface of pusher plate
and stud (13) thoroughly.
13. Install new pusher plate gasket (12), if
required, over pusher plate and stud (13).
14. Install new diaphragm(s) (20) over pusher
plate and stud (13). NOTE: Refer to the
quantity of diaphragms (20) incorporated
per the bill of materials listing. Depending on
outlet pressure level, various quantities of
metal diaphragms will be "stacked".
3. If desired, gaskets may be oiled, or coated with
gasket sealant or thread sealing compound,
provided the sealant is compatible with
the fluid. (See below for "oxygen cleaned"
valves.)
4. Valves originally supplied as "oxygen
cleaned" (Options 1000-55, 1000-5 or 1000-
36) are assembled using special gasket
sealant, Fluorolube GR-3621, or equivalent.
Cashco, Inc. recommends following factory
cleaning specification #S-1134, or equivalent.
Contact factory for details.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vise with the
spring chamber (2) directed upwards.
2. Relax range spring (27) by turning adjusting
screw (6) CCW until removed from spring
chamber (2).
3. Paint or embed a match mark between body
casting (1) and spring chamber casting (2)
along flanged area.
4. Remove all diaphragm nuts (9) and bolts (8).
Remove nameplate (28).
5. Remove spring chamber (2), range spring
(27) and spring button (4).
NOTE: The text hereafter will refer to "pusher plate and
stud (13)" as a single part, which it is for SST trim.
Brass trim uses a separate "pusher plate (5)" and a
"pusher plate stud (13)", both of which are peened
together at initial assembly.
6. Pry up the diaphragm(s) (20) and diaph-
ragm gasket (19) around the perimeter of the
body (1) diaphragm flange to ensure that the
diaphragm(s) (20) are not "sticking".
7. Remove the diaphragm sub-assembly by
sliding the pusher plate and stud (13) and
nut (11) in the direction of the regulator's
inlet, approximately 1/2"-3/4". The pusher
plate and stud (13), stud nut (10), and stud
collar (16) should disengage with the rocker
arm (14) slot. Lift vertically for the diaphragm
sub-assembly removal.
Diaphragm sub-assembly consists of items (10), (11), (12),
(13), (15), (16) and (20).

IOM-1000HP-Cryogenic 5
Dim. Mat'l
Valve Size
1/2" 3/4" 1" 1-1/4" 1-1/2" 2"
A BR 7/8" 1-5/32" 1-7/16" 1-13/16" 1-25/32" 2-3/16"
B BR 5/8" 25/32" 3/4" 29/32" 7/8" 29/32"
A SST 13/16" 1-1/16" 1-7/16" 1-1/2" 1-25/32" 2-5/32"
B SST 9/16" 23/32" 3/4" 11/16" 7/8" 29/32"
If either of the above dimensions are
exceeded by 1/8", replace rocker arm
(14).
19. Check rocker arm shaft (17) for wear and
straightness. Replace if damaged. Reinstall
in body (1) through rocker arm (14). Apply
thread sealant to the rocker arm shaft (17)
threads prior to tightening. Make sure that the
rocker arm shaft (17) enters the support slot
opposite the threaded opening, and does not
align crooked and restrained from full thread
engagement of the rocker arm shaft (17).
Make sure that the rocker arm (14) prongs that
straddle the piston (24) hold the piston collar
(23) against the piston (24); do not allow the
rocker arm (14) prongs to push directly on the
piston (24).
20. Clean the body (1) diaphragm flange. Sealant
may be applied to the body (1) flange prior
to diaphragm (20) placement. Install a new
diaphragm gasket (19).
21. Using small gauge wire approximately 18"
long, form a hook, and place the hook over
one prong of the rocker arm (14), and rotate
the rocker arm (14) up until slack is removed
in the mechanism. Secure the wire through a
body (1) flange bolt hole on the outlet side of
the regulator.
22. Take the diaphragm sub-assembly (Step 16)
and lower it down into the body (1) cavity
off-center approximately 3/4"-1" and towards
the inlet side of the regulator. When fully
lowered, slide the diaphragm sub-assembly
horizontally towards the regulator's outlet.
The wire of Step 21 should hold the rocker
arm (14) up to allow engaging of the pusher
plate and stud (13) (with stud nut (10) and stud
collar (16)), so the rocker arm (14) prongs rest
directly on the stud collar (16). (Do not allow
the rocker arm (14) prongs to get between
the stud nut (10) and the stud collar (16).)
Pull firmly to remove wire holding rocker arm
(14) up.
23. Align diaphragm (20) bolt holes with body (1)
flange bolt holes. Set range spring (27) onto
pressure plate (3), place spring button (4) on
top of range spring (27). Place cryogenic,
multi-purpose temperature lubricant into
depression of spring button (4).
15. Inspect pressure plate (3) to ensure no
deformation due to over-pressurization.
If deformed, bent, or otherwise distorted,
replace.
16. Ensuring that the curved outer rim side
of the pressure plate (3) rests against the
diaphragm (20) directly, place the pressure
plate (3) over the pusher plate and stud (13).
Place nut (11) onto the stud (13) and tighten
to 35 ft.-lbs. torque for metal diaphragm.
Use two flange bolts (8) to keep multiple
diaphragms' (20) bolt holes properly aligned
while tightening the stud nut (10). (DO NOT
USE FINGERS TO HOLD DIAPHRAGMS
(20) DURING TIGHTENING OF NUT (11).)
17. Remove cotter pin (15) securing stud nut (10)
to lower end of pusher plate and stud (13), and
replace with a new pin (15). (Do not allow the
stud nut (10) to move when the cotter pin (15)
is removed.)
18. Remove rocker arm shaft (17) and rocker
arm (14). Measure inside of rocker arm (14)
"prongs" as indicated below:

6 IOM-1000HP-Cryogenic
25. Reinstall adjusting screw (6) with locknut (7).
26. Soap solution test around bolting (8 and 9),
body (1), spring chamber (2) flanges, and
cylinder (21)-to-body (1) joint for leakage.
Ensure that an outlet pressure is maintained
during this leak test of at least mid-range
spring level; i.e. 10-40 psig range spring, 25
psig test pressure minimum. Use 100 psig
minimum inlet pressure to leak test. Actual
service conditions should be used if in excess
of the minimum conditions.
C. Special Instructions for Diaphragm Removal:
1. If Option1000-9, TFE diaphragm cover, (35)
is included, the diaphragm cover (35) should
be placed on the wetted side of the lower
diaphragm (20).
2. Never replace bolting (8 and 9) with just any
bolting if lost. Bolt heads and nuts are marked
with specification identification numbers. Use
only proper grades as replacements. Bolting
is stainless steel.
3. Use only factory provided gaskets; do not
use "homemade" gaskets. Substitution may
cause improper gasket compression. It may
also adversely change diaphragm setting,
which will affect unit's performance.
4. Use only gaskets of the same material as
those originally utilized.
24. Aligning the matchmarks, place spring
chamber (2) over the above stacked parts.
Install all bolts (8), nuts (9) and nameplate (28)
by hand tightening. Tighten bolting (8 and 9)
in a cross pattern that allows spring chamber
(2) to be pulled down evenly. Recommended
torques are as follows:
D. Diaphragm Setting Adjustment:
1. In the previous "Sub-Section B. Diaphragm
Replacement", care was taken to prevent
removal of the stud collar (16) and stud nut
(10). Location of the stud nut (10) is a critical
adjustment for a Model 1000 regulator.
2. Not removing the stud nut (10) will provide
performance equal to original factory
performance when a diaphragm(s) (20)
is replaced with a like diaphragm(s) (20).
However, if the stud nut (10) is removed, or
a switch is made from metal to composition
diaphragm (20), or vice versa, the diaphragm
setting should be checked.
3. Follow procedure "Sub-Section B. Diaphragm
Replacement" at the point of removing
diaphragm(s) (20), Step 14. Remove
diaphragm gasket (19) and pusher plate
stud gasket (12). Obtain a flat 12" x
1-1/2" x 1/4" plate bar with a 3/4" hole drilled
in the center. Hook the pusher plate stud
(13) into the rocker arm (14) prongs properly.
Pull firmly up on the pusher plate stud (13)
to ensure that all slack is removed from the
mechanism and that the piston (24) is seated
firmly. Relax the pulling and place the flat
bar over the pusher plate stud (13) with the
stud (13) passing through the hole of the bar.
Again, pull firmly up to remove mechanism
slack. One of three positions will be reached:
Checking diaphragm setting.
Model 1000HP-5 or -36
Body Size Bolt Size Metal Diaph.
1/2" 3/8" Bolt 25 Ft/Lb
3/4" 7/16" Bolt 30 Ft/Lb
1"-1-1/4" 1/2" Bolt 35 Ft/Lb
1-1/2" 9/16" Bolt 45 Ft/Lb
2" 5/8" Bolt 45 Ft/Lb

IOM-1000HP-Cryogenic 7
CYLINDER SUB-ASSEMBLY (21) WITH
PISTON (24) – METAL SEATED
CONSTRUCTION
4. If an Option 1000 -17 piston spring (30)
is utilized, it also should be removed and
replaced at trim replacement.
5. Inspect inside surface of cylinder (21) at four
points:
a. Valve seat (21.2) ring erosion/wear on
seating surfaces. If wear is excessive,
consider utilizing Option1000-15, stellited
seat surfaces.
b. Valve seat (21.2) wire drawing between
cylinder (21.1) and valve seat (21.2)
where pressed in. If wear exists here, an
Option 1000-14, integral seat, should be
utilized as a replacement.
c. Flow induced wear at expansion zone
where fluid turns to enter the piston (24)
center.
d. Where the piston (24) ribbed guides bear
(guide zone).
If wear is significant at any of these points,
both cylinder sub-assembly (21) and piston
sub-assembly (24 or 24, 25 and 26) should be
replaced. (Cashco, Inc., does not recommend
attempting to replace the valve seat (21.2) by
pressing out and then re-pressing in. Cashco,
Inc., also recommends that a cylinder (21)
and piston (24 or 24, 25 and 26) be replaced
as a set. Composition seat discs (25) may be
replaced individually.)
a. Diaphragm setting too high. Pusher plate
stud (13) will lift the flat bar over 0.020".
b. Diaphragm setting acceptable. Bar lifted
between 0.010"-0.020".
c. Diaphragm setting too low. Bar lifted less
than 0.010", or failed to be lifted.
4. The castle style stud nut (10) has six locations
per revolution to align the stud nut (10) slots
with the drilled hole through the pusher plate
stud (13). Each stud nut (10) slot represents
a movement up/down of 0.010". NOTE: The
ideal diaphragm setting is 0.015" high, and
better performance is usually obtained when
the diaphragm is slightly higher rather than
lower. As the measuring of thousandths of
an inch is difficult with such a procedure, it
is recommended that the "null" position be
found where the diaphragm (20) is flush with
the body (1) flange (bar approximately at
0.000"). Remove the pusher plate stud (13),
rotate the stud nut (10) one or two slots CCW
to bring the setting to 0.015"-0.020" high.
5. Place cotter pin (15) through the slot/hole,
bend over ends.
6. Continue re-assembly per Sub-Section B.
Diaphragm Replacement, Step 14.
E. Trim Removal and Replacement:
1. Install body (1) horizontally in a vise with the
spring chamber (2) directed upwards, and the
body (1) held at the outlet end.
2. Use a box end wrench or socket, with a lever
length of at least 24 inches, and place it over
the hex surfaces of the cylinder (21). The
wrench should be rapped with a hammer to
loosen.
3. Continue to unscrew cylinder (21) until
removed. The piston (24) and piston collar
(23) should come out by gravity with the
cylinder (21) removal.
CAUTION
Take precaution to not allow the piston (24) to fall from
within the cylinder (21); tip cylinder with hex end down.
NOTE: The Option 1000-17 piston spring and Option
1000-14 integral seat ring are standard with the
Option 1000-5 construction.

8 IOM-1000HP-Cryogenic
6. If a composition (soft) seat trim design is
utilized, use the following sub-steps:
a. Tighten the "flats" of the seat disc screw
(26) within a vise. Firmly hand-grip the
piston (24) and turn CCW to loosen the
seat disc screw (26). If too tight, place a
screwdriver or similar rod within the piston
(24) port holes and rotate. Remove the
piston (24), and inspect for raised burrs
around the port holes if a device is used
to loosen; deburr as required. NOTE: Do
not grip the piston (24) with a wrench.
b. Remove the seat disc (25) and clean the
recessed piston (24) area where the seat
disc (25) is placed. If the edges which
form the recess of the piston (24) are
worn, also replace piston (24) and seat
disc screw (26).
c. Place seat disc (25) into recessed end of
piston (24).
d. Place thread sealant on threaded portion
of seat disc screw (26), and manually
rotate piston (24) into seat disc screw (26)
(still fixed in vise) to secure seat disc (25).
Tighten seat disc screw (26) firmly. Do not
over-tighten to the point of embedding the
seat disc screw (26) into the seat disc
(25); the seat disc (25) should lay flat with
no rounded surface. A mechanical aid is
normally not required; hand-tightening is
normally sufficient.
7. If utilized, place piston spring (30) over
smaller end of cylinder (21).
8. Insert piston assembly (24 metal seat; 24, 25
and 26 comp. seat) into end of cylinder (21).
9. Place piston collar (23) over end of piston
(24), ensuring that the spherical surface of
the piston (24) and the piston collar (23) bear
against each other.
10. Clean the body (1) cavity through the
openings. Clean the "jet area" just inside
the body (1) outlet end through which the
piston (24) projects. Clean all parts to be
reused. NOTE: On regulators originally
supplied with Option 1000-55, "oxygen
clean", maintenance must include a level of
cleanliness equal to Cashco, Inc's., cleaning
standard #S-1134. Contact factory for details.
11. Use special care cleaning the flat mating
surfaces of the body (1) and cylinder (21)
shoulder, as this pressurized joint is metal-
to-metal with no gasket.
12. Lubricate the cylinder (21) threads lightly with
thread sealant. Insert the entire trim stack
into the body (1) opening and screw until
tightly seated. Using the hammer and wrench
handle, impact the cylinder (21) into the body
(1). NOTES: 1. Take special precaution to
keep piston collar from getting "cocked" at an
angle when inserted. 2. On 2" brass bodies
(1) with brass trim, a TFE body O-ring (43) is
utilized to seal between the body (1) and the
cylinder (21) sub-assembly. This O-ring is not
indicated on the drawing.
13. Inspect the body (1) outlet end to ensure that
the piston (24) is located nearly concentric to
the body (1) bore in the jet area with clearance.
Under no conditions should the piston (24) be
touching the body (1). Use two pencils or
similar shafts to place in inlet and outlet ends
of valve and alternately push on each end
of the piston (24) to ensure free movement.
(Total movement is approximately 1/8".)
14. Bench test unit for suitable operation and seat
leakage. NOTE: Regulators are not normally
tight shutoff devices. Pressure must build
above setpoint for best shutoff.
15. Soap solution test around cylinder (21)-to-
body (1) connection for leakage. Test
pressure should be a minimum of 100 psig at
the inlet, or actual service conditions if higher.

IOM-1000HP-Cryogenic 9
SECTION VII
VII. TROUBLE SHOOTING GUIDE
Possible Causes Remedies
A. Oversized regulator; inadequate rangeability. A1.
A2.
A3.
A4.
Check actual flow conditions, resize regulator for minimum and
maximum flow.
Increase flow rate.
Decrease regulator pressure drop; decrease inlet pressure by
placing a throttling orifice in inlet piping union.
Replace full orifice with reduced orifice; i.e. new cylinder required.
B. Worn piston/cylinder; inadequate guiding. B. Replace trim.
C. Flow induced instability. C1.
C2.
C3.
Get straight runs of piping (5 diameters upstream, 10 downstream)
to and from valve.
Ensure outlet velocity is not excessive; use pipe reducer close to
valve outlet.
Add next higher range spring.
D. Improper (oversized) jet. D. Replace existing piston with new piston with proper jet.
E. Plugged trim. E. Remove trim and check for plugged holes in piston, or debris in
guide zone or jet zone.
1. Erratic operation; chattering.
Possible Causes Remedies
A. Setpoint too low. A. Turn adjusting screw down (CW) to increase setpoint.
B. Regulator undersized. B1.
B2
Confirm by opening bypass valve together with regulator.
Check actual flow conditions, resize and if regulator has inadequate
capacity, replace with larger unit.
C. Plugged inlet strainer. C. Remove strainer screen and clean; consider leaving screen out.
D. Plugged trim. D. Remove trim and check for plugged holes in piston, or debris in
guide zone or jet zone.
E. Incorrect range spring (turning adjusting screw
CW does not allow bringing pressure level up to
proper level).
E. Replace range spring with proper higher range.
F. Too much proportional band (droop). F1.
F2.
F3.
Review P.B. (droop) expected. (See 2.B1 above.)
Diaphragm setting too low; check and raise as required.
Improper jet; make sure jet matches actual fluid.
G. Restricted diaphragm movement. (pressure plate
hitting upstops)
G1.
G2.
Diaphragm setting too high; check and lower as required.
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, re-orient spring chamber.
H. Restricted diaphragm movement. (over-stretched
diaphragm)
H1.
H2.
H3.
Diaphragm setting too low; check and increase as required.
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, re-orient spring chamber.
Ensure drain opening is clear of blockage.
2. Regulator outlet (downstream) pressure too low.
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 valve
chatter.
Can be caused by corrosive action. Consider alternate diaphragm
material, or Option 1000-9, TFE diaphragm cover.
Downstream (outlet) pressure buildup occurring that overstresses
diaphragms.
C. Pusher plate gasket leaking. C. Replace gasket.
3. Leakage through the spring chamber vent hole.

10 IOM-1000HP-Cryogenic
Possible Causes Remedies
A. Regulator not closing tightly. A1.
A2.
A3.
A4.
A5.
A6.
Overly compressed range spring; i.e. approaching solid height. Use
next higher range spring. Contact factory.
Inspect the seating. Clean and lap metal seat surfaces; replace if
lapping does not remedy. If composition seats are depressed, nicked
or embedded with debris, replace seat disc.
Diaphragm setting too high; check setting.
Inlet pressure too high for orifice size; check permissible inlet (P1)
pressure level for a given outlet. Change to reduced port if required.
Leakage past pressed in valve seat ring; consider integral seat.
When diaphragm sub-assembly was put into place, the rocker arm
got between the stud collar and the stud nut rather than on top of
the stud collar.
B. Downstream block. B. Check system; isolate (block) flow at regulator inlet, not outlet. Re-
locate regulator if necessary.
C. No pressure relief protection. C. Install safety relief valve, or rupture disc.
D. Restricted diaphragm movement. D1.
D2.
Diaphragm setting too high; check and lower as required.
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, re-orient spring chamber.
4. Excessive pressure downstream.
Possible Causes Remedies
A. Plugged spring chamber vent. A. Clean vent opening.
B. Plugged piston or jet zone. B. Remove trim and clean.
C. Plugged drain and vent opening. C. Clear opening & purge.
5. Sluggish operation.
Possible Causes Remedies
A. Over-pressurization downstream resulting in:
1. Bent metal diaphragm(s).
2. Sprung rocker arm.
3. Range spring overstressed/fatigued.
A1.
A2.
A3.
Replace diaphragms. Correct potential source of downstream over-
pressure.
Check measurements of rocker arm. Replace if necessary.
Replace range spring; consider next higher range spring.
6. Frequent resetting of setpoint.

IOM-1000HP-Cryogenic 11
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
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.

12 IOM-1000HP-Cryogenic
ITEM NO. DESCRIPTION
REPAIR PARTS
KIT A KIT B
1. BODY & BODY ASSY
2. SPRING CHAMBER
3. PRESSURE PLATE
4. SPRING BUTTON
5. PUSHER PLATE
6. ADJUSTING SCREW
7. ADJUSTING SCREW LOCK NUT
8. FLANGE BOLT
9. FLANGE NUT
10. STUD NUT
11. PRESSURE PLATE NUT
12. PUSHER PLATE GASKET ***
13. PUSHER PLATE STUD
14. ROCKER ARM
15. COTTER PIN **
16. STUD COLLAR
17. ROCKER ARM SHAFT
18. BODY PLUG (-26 OPT.)
19. DIAPHRAGM GASKET ***
20. DIAPHRAGM(S) ***
21. CYLINDER ASSEMBLY **
21.1 CYLINDER
21.2 VALVE SEAT
23. PISTON COLLAR **
24. PISTON **
25. SEAT DISC ***
26. SEAT DISC SCREW **
27. RANGE SPRING
28. NAME PLATE
30. PISTON SPRING
35. DIAPHRAGM COVER (-9 OPT)
36. BODY O-RING (not shown)

IOM-1000HP-Cryogenic 13
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
NOTICE
Only for Product Codes wherein hazard
category ATEX has been selected.

14 IOM-1000HP-Cryogenic
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-1000HP-Cryo
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]
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.
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.