cashco 1164 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-1164
07-04
MODEL 1164
BACK PRESSURE / RELIEF REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The Model 1164 is a modulating back pressure relief regulator used to control upstream (inlet) pressure. Sizes are
3/4", 1", 1-1/2" and 2" (DN 20, 25, 40 and 50) for side (inlet, flow-thru,) and bottom (discharge) connections. With
proper trim utilization the unit is suitable for liquid, gaseous, or steam service. Refer to Technical Bulletin 1164-TB
for design conditions and selection recommendations.
SECTION II
II. INSTALLATION
1. An inlet block valve should always be installed.
2. If service application is continuous such that
shutdown is not readily accomplished, it is rec-
ommended that an inlet block valve, outlet block
valve, and a manual bypass valve be installed.
3. Pipe unions should be installed to allow removal
from piping.
4. An inlet pressure gauge should be located approxi-
mately ten pipe diameters upstream and within
sight. An outlet pressure gauge is optional.
5. All installations should include an upstream relief
device if the inlet pressure could exceed the pres-
sure rating of any equipment or the maximum inlet
pressure rating of the unit.
7. In placing thread sealant on pipe ends prior to
engagement, ensure that excess material is re-
moved and not allowed to enter the regulator upon
startup.
8. Flow Direction: Install so the flow direction match-
es the arrow cast on the body. Connect the inlet
pressure to the body side connection(s). Fluid will
relieve out of the bottom connection. The double
inlet connections are for in-line installation (plug
one side connection if in-line installation is not
required).
CAUTION
This is not a safety device and must not be substituted for a code approved pressure safety relief valve or a rupture disc.
WARNING
The maximum inlet pressure is equal to 1.5 times the
larger number of the stated range spring on the name-
plate, and is the recommended “upper operative limit” for
the sensing diaphragm. Higher pressures could damage
the diaphragm. (Field hydrostatic tests frequently destroy
diaphragms. DO NOT HYDROSTATIC TEST THRU AN IN-
STALLED UNIT; ISOLATE FROM TEST.) CAUTION
Installation of adequate overpressure protection is recom-
mended to protect the regulator from overpressure and
all downstream equipment from damage in the event of
regulator failure.
6. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt before
installing the regulator. Strainers are recom-
mended.

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

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

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

IOM-1164 5
SECTION VII
VII. TROUBLE SHOOTING GUIDE
Possible Causes Remedies
A. Oversized regulator. A1.
A2.
A3.
A4.
A5.
Check actual flow conditions, resize regulator for mini-
mum and maximum flow.
Tighten flange bolting.
Increase flow rate.
Decrease regulator pressure drop; decrease inlet pres-
sure by placing a throttling orifice in inlet piping union.
Install next step higher range spring.
Before replacing regulator, contact factory.
B. Inadequate Rangeability. B1.
B2.
B3.
Increase flow rate.
Decrease regulator pressure drop.
Install next step higher range spring.
1. Erratic Operation; chattering.
Possible Causes Remedies
A. Regulator undersized. A1.
A2.
Confirm by opening bypass valve together with regulator.
Check actual flow conditions, resize regulator; if regulator
has inadequate capacity, replace with larger unit.
B. Plugged inlet strainer. B. Remove strainer screen and clean; consider leaving
screen out.
C. Incorrect range spring (screwing out CCW of adjusting
screw does not allow bringing pressure level to a stable
and proper level).
C. Replace range spring with proper lower range.
D. Too much build. D1.
D2.
Review build expected.
Contact factory.
E. Restricted diaphragm movement. E. Ensure no moisture in spring chamber at temperatures
below freeze point. Ensure no dust or debris entering
vent opening. If rainwater or debris can enter, reorient
spring chamber.
2. Regulator inlet (upstream) pressure too high.
Possible Causes Remedies
A. Foreign matter on the seating surface, erosion of the seat-
ing surface or foreign matter on plug balancing O-ring.
A. Clean or replace plug assembly (TFE seat). For metal
replace regulator if integral seat is damaged. Replace
plug and O-ring.
3. Excessive seat leakage.
Possible Causes Remedies
A. Normal-life diaphragm failure. A. Replace diaphragm.
B. Abnormal short-life diaphragm failure. B1.
B2.
B3.
Can be caused by excessive chattering. See No. 1. to
remedy chatter.
Can be caused by corrosive action. Consider alternate
diaphragm material.
Upstream (inlet) pressure build-up occuring that over-
stresses diaphragms. Relocate regulator or protect with
safety relief valve.
4. Leakage through the spring chamber vent hole.
Possible Causes Remedies
A. Plugged spring chamber vent. A. Clean vent opening.
B. Fluid too viscous. B. Heat fluid. Contact factory.
C. Broken spring. C. Replace spring.
5. Sluggish operation.

IOM-1164
6
Trim Designation
No.
Kit
Abbreviation
Size
3/4" & 1" 1-1/2" & 2"
S1 & S2 A AB5-AS1K-A AB8-AS1K-B
S1 B AB5-BS1K-A AB8-BS1K-B
S2 B AB5-BS2K-A AB8-BS2K-B
SECTION VIII
METHOD A - USE OF PRODUCT CODE.
Step 1. If available, obtain the 18 character product
code number from:
a. The Bill of Materials sheet attached herein.
b. The metal tag attached to the regulator.
PARTS KIT NUMBERS
(KIT NOS. SHADED)
The shaded parts kit numbers below represent an abbreviated identification number for a basic regulator (no options).
Step 2. Identify which kits or parts are desired from
the following:
a. The Bill of Materials sheet attached herein,
or refer to the cross-sectional drawings.
b. Standard maintenance parts for a basic
regulator (no options) are included in the
Parts Kit Number table below. Kit “A” con-
tains seal(s) diaphragm(s) and gasket(s).
Kit “B” contains trim replacement parts
plus seal(s), diaphragm(s) and gasket(s).
Step 3. Contact your local Cashco, Inc., Sales Rep-
resentative and specify the product code
number along with a description of any parts
not included in the kits below. Costs of re-
quired parts (and kits) can be given by the
Sales Representative.
VIII. PARTS ORDERING INFORMATION
There are three methods to obtain parts ordering information/numbers. These methods are listed below, in order
of ease of entering. The least expensive method is to utilize parts in kits where possible.
METHOD B - NO PRODUCT CODE AVAILABLE- DIS-
ASSEMBLED REGULATOR.
Step 1. Determine all available information from
regulator's metal tag.
a. Serial number (5-digit).
b. Regulator “Type” or “Model” number.
c. Size (may have to observe body con-
nection).
d. Spring range.
e. Trim designation number (if available).
Step 2. Determine construction of trim:
a. Metal or composition (soft) seat?
Step 3. With the information from Steps 1 and 2 pre-
vious, contact your local Cashco, Inc., Sales
Representative for the proper identification
numbers to use, and the parts costs.
METHOD C - NO PRODUCT CODE AVAILABLE- AS-
SEMBLED REGULATOR IN-SERVICE.
Step 1. Determine all available information from regu-
lator tag using Step 1, Method B.
Step 2. Contact your local Cashco, Inc., Sales Rep
with the above information.
Step 3. Sales Representative will contact the factory
to determine the original internal construction.
Factory will relay information to the Sales Rep-
resentative.
Step 4. Await the Sales Representative's return con-
tact with the proper part numbers and cost.
7 --

IOM-1164 7
Epoxy Coated Steel Springs
Range Spring
psig
Regulator Size
3/4" – 1" 1-1/2" – 2"
5–15 830-69-5-00147-99
Red
830-69-5-00114-99
Blue
10–40 830-69-5-00109-99
Blue
830-69-5-00117-99
Dark Green
30–80 830-69-5-01161-99
Dark Green
830-69-5-01163-99
Light Blue
70–150 830-L2-5-01164-99
White
830-L2-5-01166-99
White
MODEL 1164
*COLOR-CODED SPRING CHART
Figure 1
Basic Model 1164
Metal Seat Construction
Figure 2
Composition Seat
IItem No. Description
1 Body
2 Spring Chamber
3 Range Spring
4 Spring Button
5 Pressure Plate
6 Name Plate
7 Spring
8 Adjusting Screw Lock Nut
9 Diaphragm
10 Diaphragm Gasket
11 O-Ring
12 Valve Guide
13 Cap Screw (Flange Bolting)
14 Nut (Flange Bolting)
15 Valve Seat
16 Valve Plug or Valve Plug Subassembly
17 Adjusting Screw
* NOTE: If it becomes necessary to change a regulator's range spring and install a new spring for a different pressure
range, a NEW CASHCO, INC., NAMEPLATE MUST BE AFFIXED TO THE REGULATOR. Contact your local Cashco,
Inc. Sales Representative, specify the new pressure range and the serial number off the existing nameplate. They
will contact the factory who will review the unit's orginial internal construction and determine new operating pressure
limits. Await the Sales Representative's return contact with the proper part numbers and cost.

Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
FAX [phone]
E-mail: [email protected]
[email protected]
Printed in U.S.A. IOM-1164