cashco CA1 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
IOM-CA1/SA1
12-16
I. DESCRIPTION AND SCOPE
Models CA1/SA1 are pressure reducing regulators used to control downstream (outlet or P2) pressure. Sizes are
3/4" (DN20), 1" (DN25), 1-1/2" (DN40), and 2" (DN50). With proper trim utilization, the unit is suitable for liquid or
gaseous service. (NOTE: This product was formerly identified as a Model C1 or S1; a Model CA1/SA1 and C1/S1
are one and the same product.)
MODEL CA1/SA1
CA1 and SA1 - ULTRA HIGH PURITY, SPRING LOADED
PRESSURE REDUCING REGULATORS
SECTION I
II. REFERENCES
Refer to Technical Bulletin CA1/SA1-TB for techni-
cal specifications of a Model CA1/SA1 regulator.
ABBREVIATIONS
CCW – Counter Clockwise
CW – Clockwise
ITA – Inner Trim Assembly
SECTION III
SECTION II
III. INSTALLATION
1. Install per direction of flow arrow indicated on
body, or "IN" and "OUT" markings.
2. Regulator may be rotated around pipe axis 360
degrees. For ease of maintenance, the recom-
mended orientation is with the spring chamber
(4) upwards.
3. Provide space below, above, and around regulator
for removal of parts during maintenance.
4. Install block valves and pressure gauges to pro-
vide means for adjustment, operation, bypass, or
removal of the regulator. A UHP filter is recom-
mended before inlet to remove typical pipeline
debris from entering valve and damaging internal
“soft goods”, primarily the dynamic seal and valve
seat.
CAUTION
Installation of adequate overpressure protection
is recommended to protect the regulator and all
downstream equipment from damage in the event
of regulator failure.
CAUTION
DO NOT HYDROSTATIC TEST THROUGH AN
INSTALLED UNIT; ISOLATE REGULATOR FROM
TEST. The upper range spring pressure level
on the nameplate is the recommended “upper
operating limit” for the sensing diaphragm.
Higher pressures could cause internal damage.
In addition, note on the nameplate that the Inlet
and Outlet pressure and temperature ratings are
at different levels.
ISO Registered Company

IOM-CA1/SA1
2
IV. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations register
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 dia-
phragm down, opening the port; as outlet pressure
V. STARTUP
1 Start with the block valves closed.
2. Relax the range spring by turning the adjusting
screw (1) CCW (viewed from above) a minimum
of three (3) full revolutions. This reduces the outlet
(downstream) pressure set point.
3. If it is a “hot” piping system, and equipped with
a bypass valve, slowly open the bypass valve
to preheat the system piping and to allow slow
expansion 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 a cold system; i.e. do everything slowly.
SECTION VI
6. Continue to slowly open the inlet (upstream) block
valve until fully open.
7. Continue to slowly open the outlet (downstream)
block valve, especially when the downstream pip-
ing system isn’t pressurized. If the outlet (down-
stream) pressure exceeds the desired pressure,
close the inlet block valve and go to Step 2. Close
bypass valve approximately 25%, and repeat
procedure.
8. When flow is established steady enough that the
outlet (downstream) block valve is fully open, begin
to slowly close the bypass valve if installed.
9. Develop system flow to a level near its expected
normal rate, and reset the regulator set point by
turning the adjusting screw (1) CW to increase
outlet pressure, or CCW to reduce outlet pressure.
10. Reduce system flow to a minimum level and ob-
serve pressure 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 10%. If it does, consult factory.
SECTION IV
SECTION V
increases, the diaphragm pushes up and the port
opening closes.
2. A complete diaphragm failure will cause the regu-
lator to fail open and fluid will discharge from the
spring chamber vent hole.
4. Crack open the outlet (downstream) block valve.
5. Slowly open the inlet (upstream) block valve to
about 25% open, observing the outlet (down-
stream) pressure gauge. Determine if the regu-
lator is flowing. If not, slowly rotate the regulator
adjusting screw (1) CW (viewed from above) until
flow begins.
VI. SHUTDOWN
1. Shutoff inlet block valve.
2. Allow sufficient time for the line pressure down-
stream of the inlet block valve to bleed down.
3. Shutoff the outlet block valve.
4. Relieve the trapped upstream and downstream
pressure.
5. The regulator may now be disassembled for
inspection and preventative maintenance while
in-line.
CAUTION
Do not walk away and leave a bypassed regulator
unattended!

IOM-CA1/SA1 3
VII. MAINTENANCE
A. General:
1. The regulator may be serviced without remov-
ing the regulator from pipeline. The regulator
is designed with quick-change trim to simplify
maintenance.
2. Record the nameplate information to requisi-
tion spare parts for the regulator. The infor-
mation should include: Size, Product Code,
and Serial Number.
3. Refer to Section IX for recommended spare
parts. Only use original equipment parts
supplied by Cashco for rebuilding or repairing
regulators.
4. Owner should refer to owner's procedures for
removal, handling, cleaning and disposal of
nonreusable parts, i.e. seals, etc.
5. The Inner Trim is removed and replaced in the
body (23) as an assemblage of parts. The
Inner Trim Assembly, hereinafter called ITA,
consists of the following parts:
SECTION VII
Item Dynamic
No. Seal Type Part Description
13 ..................... All ..........................Piston-Guide Bearing
15 ..................... All ................................ Cage O-ring Seal
16..................... UC.................................................Shim
19 ..................... All ................................................... Cage
20 ..................... All ...........................................Valve Plug
21 ..................... All ............................................ Seat Ring
27 ..................... All ............................. Dynamic Side Seal
27.1 .............. CP............................................. Cap Seal
27.2 .............. CP..........................O-ring Energizer/Seal
27.3 .............. UC .......... U-Cup Seal w/Metal Energizer
6. A detailed view of the dynamic side seal parts
is shown in Figure 1; an assembled ITA in
Figure 2; and a cross-sectional drawing of
the entire regulator is shown in Figure 3.
Figure 1: Dynamic Side Seals
ing screw (1) CCW (viewed from above) until
removed from spring chamber (4).
3. Loosen the diaphragm flange bolts (12) and
nuts (11) uniformly. Remove all bolting.
4. Place matchmarks on body (23) and spring
chamber (4) flanges. Remove the spring
chamber (4) by lifting vertically.
5. Remove the washers (14), spring follower (5)
and range spring (6).
6. Remove upper diaphragm pressure plate (8).
7. Remove diaphragm(s) (9) and examine to
determine if failed. If diaphragms failed, de-
termine if operating conditions are exceeding
designed pressure or temperature limits.
8. Evenly loosen the three cage cap screws (18)
in single revolution increments. The regulator
contains a lower return spring (22); the ITA
should rise as the cage cap screws (18) are
backed out evenly. A downward holding force
should be applied to the top of the piston-guide
bearing (13) to prevent the ITA from popping
up as the last threads of the cage cap screws
(18) are disengaged. Remove washers (17).
Type UC - U-Cup
Dynamic Seal
Type CP - Cap
Dynamic Seal
27
13
13
19
19
20
20
27.3
27.1
27.2
15
15
*
*
*
*
*
*
16
16
WARNING
SYSTEM UNDER PRESSURE. Prior to performing
any maintenance, isolate the regulator from the
system and relieve all pressure. Failure to do so
could result in personal injury.
B. Main Regulator Disassembly:
1. Shut down the system in accordance with
Section VI.
2. Loosen adjusting screw lock nut (2) and relax
range spring (6) pressure by turning adjust-

IOM-CA1/SA1
4
e. Remove dynamic side seal (27) compo-
nents and discard. Special care should be
taken when using “tools” to remove the
components to ensure that no scratches
are made to any portion of the piston- guide
bearing (13) groove.
f. Remove the shim (16) from within the
cage (19).
g. Remove seat ring (21); examine for signs
of leakage. If seat ring (21) shows signs of
significant leakage, determine if operating
conditions - pressure, pressure drop, or
temperature exceed design limits.
2. Clean all metal parts to be reused according
to owner's procedures. NOTE: Regulators are
originally supplied with a level of cleanliness
equal to Cashco cleaning standard #S-1662.
Contact factory for details.
D. Inspection of Parts:
1. Remove and discard the following parts:
o-ring (15), diaphragm(s) (9), seals (27, 28),
and seat ring (21). These parts MUST be
replaced with factory supplied new parts.
2. Inspect the metal parts that will be reused. The
parts should be free of surface contaminants,
burrs, oxides, and scale. Rework and clean
the parts as necessary. Surface conditions
that affect the regulator performance are stated
below; replace parts that can not be reworked
or cleaned.
3. QC Requirements:
a. Valve plug (20);
1. 16 rms finish on its seating surface
for tight shutoff.
2. No major defects on bottom guide
spindle.
b. Cage (19);
1. 16 rms finish on cylinder bore. No
“ledges” formed due to wear from
moving dynamic side seal (27) or plug
(20).
E. Reassembly of the ITA:
1. Installation of dynamic side seal (27) (See
Figure 1):
a. Type CP:
1. Stretch o-ring energizer/seal (27.2)
over lower circumference of piston-
guide bearing (13), taking care not
to “cut” o-ring energizer/seal. Using
thumbs, work the o-ring energizer/
b. Using a special double-posted spanner
wrench fitting (to order see NOTE in
Section IX, Parts Ordering Information),
turn the piston-guide bearing (13) CCW
to loosen. The piston-guide bearing (13)
may be removed by hand after loosening.
c. Remove ITA from vise. Pull the valve plug
(20) down and out through the cage's (19)
bottom opening.
d. Examine the components (27.1, 27.2,
27.3) of the dynam
ic side seal (27)
mechanism to determine if significant
leakage was occurring. If the dynamic
side seal shows signs of significant leak-
age, determine if operating conditions
are exceeding pressure, pressure drop,
or temperature limits.
Figure 2: Assembled ITA, with
"UC" Dynamic Side Seal
9. Remove the ITA by pulling up on the piston-
guide bearing (13). Set ITA aside.
10. Remove the lower return spring (22) from
within the body (23).
11. Remove the cage o-ring seal (15).
12. Remove metal C-ring seal (28) from body (23)
diaphragm flange groove.
13. Clean all metal parts to be reused according to
owner's procedures. NOTE: Regulators are
originally supplied with a level of cleanliness
equal to Cashco cleaning standard #S-1662.
Contact factory for details.
C. Disassembly of the ITA:
1. To Disassemble the ITA (See Figure 2):
a. Hold the lower part of the valve plug (20)
in a bench vise; grasp in "smooth jaws"
directly under plug's (20) seating disc por-
tion on hub "flats" provided. Do not hold
on the machined surface in the plug's (20)
spindle area.
16

IOM-CA1/SA1 5
seal (27.2) into the groove of the
piston-guide bearing (13).
NOTE: Use NO lubricants!
2. Position cap seal (27.1) ring with
rectangular cross-section at end of
piston-guide bearing (13). Stretch cap
seal over lower end of piston-guide
bearing (13) using thumbs to work the
cap seal onto the piston-guide bear-
ing. DO NOT USE A TOOL FOR THIS
STEP. Continue pressing cap seal
(27.1) upwards towards the groove
until the cap seal “snaps” into the
groove of the piston-guide bearing.
3. Insert shim (16) into cage (19) and
allow to rest inside the cage.
4. Position piston-guide bearing (13)
over and into upper end of cage (19)
until the cap seal (27.1) edge touches
the upper lip of the cage. While gently
applying force to press the piston-
guide bearing (13) into the cage (19),
simultaneously use fingers to lightly
press the cap seal (27.1) inwards into
the groove of the piston-guide bearing
until the cap seal “slips into” the cage
(19). DO NOT use tools or lubricant
to engage the cap seal (27.1) into the
cage (19). DO NOT press downward
on piston-guide bearing (13) too hard
or fast - the cap seal (27.1) may slide
out of its groove and become dam-
aged.
b. Type UC:
1. Position u-cup seal (27.3) over lower
circumference of piston-guide bearing
(13). Ensure the u-cup seal is oriented
with the center-open-downwards as
shown in Figure 1, as the u-cup seal
depends upon the P1-Inlet pressure
to activate proper sealing action.
2. Insert shim (16) into cage (19) and
allow to rest inside the cage.
3. Position piston-guide bearing (13)
over and into upper end of cage (19)
until the cap seal (27.1) edge touches
the upper lip of the cage. Gently apply
downward force to press the piston-
guide bearing (13) into the cage (19).
DO NOT use tools, lubricant, or heavy
force to engage the u-cup seal (27.3)
into the cage.
2. Place properly oriented seat ring (21) onto its
shoulder at the lower end of cage (19).
3. Completion of ITA Reassembly.
a. Insert valve plug (20) upwards through
lower end of cage (19) and through the
center hole of shim (16).
b. Engage valve plug (20) with piston-guide
bearing (13) threads and finger tighten.
c. Place ITA into a vise with smooth jaws
and grasp at hub "flats" location on the
valve plug (20) that is not in the “spindle”
zone. (See Figure 2.)
d. Using a special double-posted spanner
wrench fitting (to order see NOTE in
Section IX, Parts Ordering Information),
tighten the piston-guide bearing (13) to
the valve plug (20) with the following
torque values. Do NOT allow valve plug
(20) to rotate against seat ring (21) during
tightening.
e. This completes ITA reassembly.
Body Size Ft-lbs. (Nm)
3/4"-1" 40–50 (54–68)
1-1/2"–2" 70–80 (95–108)
F. Main Regulator Reassembly:
1. Insert the return spring (22) into the body (23).
2. Fit cage O-ring seal (15) into the body (23)
groove.
3. With the ITA held manually in the closed posi-
tion, insert ITA and cage (19) into body (23).
4. Properly align all three cage bolt (18) holes as
there is only one proper alignment possible.
Apply a downward force to the top of the
cage (19) until the ITA is lowered sufficiently
to engage the cage bolts (18) with washers
(17) into the body (23). Engage all of the cage
bolts , then tighten the cage bolts in alternating
one-half revolution increments to pull down the
ITA evenly. ENSURE THE ITA DOES NOT
BECOME WEDGED AS IT IS SLID INTO
THE BODY. Tighten the cage bolts (18) to a
torque value of 13-15 Ft-lbs (17.5-20.5 Nm).
5. Units with CTFE or VTFE seat ring (21): Due to
the relative "hardness" of the CTFE and VTFE
material, to obtain the best possible shutoff
it is necessary to generate a "coined" seating
chamfer.
6. To coin the seat ring:
a. Close-off the outlet connection.
b. The level of seat leakage can be quanti-
fied at the internal sensing passage.

IOM-CA1/SA1
6
flanges do not come together equally, the
upper diaphragm pressure plate (8) may be
off-center. Remove spring chamber (4) and
reposition upper diaphragm pressure plate (8)
until the spring chamber comes down evenly
on all sides.
12. Install all flange bolts (12) and nuts (11) with
nameplate (99) located under one bolt head.
Hand-tighten nuts (11).
13. Evenly tighten body bolting (11,12) using an
alternating cross pattern in one revolution
increments. Tighten to the following torque
value: All body sizes: 30-35 Ft-lbs (41-47 Nm).
G. Pressure Testing:
1. If a high static pressure test is performed,
pressure must be applied to all three of spring
chamber, inlet and outlet of body at the same
level.
DO NOT HIGH STATIC PRESSURE TEST
THE BODY WITHOUT SPRING CHAMBER
PRESSURIZED. NOT ADHERING WILL DO
PHYSICAL DAMAGE TO INTERNALS THAT
COULD RENDER THE UNIT INOPERABLE.
MAXPRESSUREIS_______psig(_______Barg).
2. Seat Leakage Test.
a. Release all range spring (6) force by
backing out adjusting screw (1) fully.
b. Pressurize inlet to 50 psig (3.5 Barg) with
UHP grade GN2.
c. Tube outlet to a beaker of water to ob-
serve number of escaping gas bubbles.
A steady flow of gas bubbles (e.g., 20
bubbles / minute or greater) is excessive
leakage.
3. Excessive leakage will require disassembly,
examination of sealing elements, correction of
problem, reassembly and retesting. Leakage
path may be via plug/seat or dynamic side
seal.
NOTE: If disassembly and re-testing is
required, the metal C-ring seal (28) MUST
be replaced for each disassembly/reas-
sembly.
c. Pressurize the regulator's inlet with
50–100 psig (3.5–6.9 Barg) of UHP grade
GN2.
d. Place a thin, flexible membrane that more
than covers the diaphragm flange cavity
of the body (23).
e. Using a soft-headed mallet (rubber,
leather), sharply rap the thin membrane
over the top,center end of the piston-guide
bearing (13). (Note: Gas will escape as
the plug (20) is momentarily forced off
the seat ring (21). Allow sufficient time
for leakage pressure on outlet side to
bleed-off.) The hammer rap should be
strong enough to "bounce" the plug (20)
into the seat ring (21), leaving a "coined"
seating chamfer. Repeat a minimum of
2 times. Check after each rap to see if
required shut off is obtained.
f. After "coining" is complete, remove UHP
grade GN2 pressure source, membrane
and open outlet.
7. To Install Diaphragm(s):
a. Install a new metal C-ring seal (28) into
the body (23) diaphragm flange groove.
b. Center diaphragm(s) (9) onto body's (23)
diaphragm flange.
c. Position upper diaphragm pressure plate
(8) centered on top of diaphragm(s) (9)
with cup upwards.
8. Place a small amount of light lithium grease
onto the adjusting screw (1). Insert both the
adjusting screw (1) and its lock nut (2) into the
spring chamber (4). Allow the end of adjusting
screw to protrude into interior approximately
1/2 inch (12 mm).
9. Place range spring (6) centered on upper
diaphragm pressure plate (8).
10. Place a small amount of light lithium grease
into the recess of the spring follower (5). In-
stall washers (14) on spring follower. Place
the spring follower (5) on upper end of range
spring (6).
11. Aligning matchmarks and bolt holes, place
spring chamber (4) over range spring (6).
If spring chamber flange rests on body (23)
flange without a gap, remove spring chamber
and rotate adjusting screw (1) deeper into
spring chamber cavity another 1/4 inch (6
mm). Repeat this procedure until the adjusting
screw (1) keeps the two flanges from touching
by approximately 1/8 inch (3 mm). NOTE: If

IOM-CA1/SA1 7
SECTION VIII
VIII. TROUBLE SHOOTING GUIDE
When trouble shooting this regulator there are many possibilities as to what may be causing problems. Many
times, the regulator itself is not defective, but one or more of the accessories may be. Sometimes the process
may be causing difficulties.
The key to efficient trouble shooting is information and communication. The customer should try to be as precise
as possible in their explanation of the problem, as well as their understanding of the application and operating
conditions.
It is imperative the following information be provided by the customer:
Fluid (with fluid properties)
Range of flow rate
Range of inlet pressure
Range of outlet pressure
Range of fluid temperature
Range of ambient temperature
Pressure readings should be taken at every location that pressure plays a role - i.e., regulator inlet (as close as
possible to inlet port), regulator outlet (as close as possible to outlet port), etc.
Below are some of the more common complaints along with possible causes and remedies.
Possible Causes Remedies
A. Sticking of internal parts A. Remove internals, clean, and if necessary, replace.
B. Oversized regulator B. Check actual flow conditions; resize regulator for minimum
and maximum flow; if necessary, replace with smaller
regulator.
1. Erratic regulation, instability or hunting.
Possible Causes Remedies
A. Supply pressure is down (confiirm
on pressure gauge).
A. Increase supply pressure
B. Undersized regulator. B. Check actual flow conditions; resize regulator for minimum
and maximum flow; if necessary, replace with larger regulator.
Possible Causes Remedies
A. Differential pressure across dia-
phragm may have exceeded limits.
(See Table 1 in Tech Bulletin).
A. Be aware of limits as well as where the various pressures are
acting. Install pressure safety equipment as necessary.
Pressure limit for outlet is lower than the limit of the inlet.
3. Diaphragm continually breaks.
2. Downstream pressure will not reach desired setting.

IOM-CA1/SA1
8
Possible Causes Remedies
A. Body bolts not torqued properly. A1. Torque to proper value (see Section VII, F.13).
A2. Failed C-ring seal. Replace seal.
B. Pressures at diaphragm may be too
high for regulator design.
B. Consult factory.
Possible Causes Remedies
A. Contamination (debris) in regulator. A1. Remove internals, clean and if necessary, replace sealing
seating elements. *
A2. Install UHP filter at inlet.
B. Oversized regulator; plug operates
directly next to seat.
B. Check actual flow conditions; resize regulator for minimum and
maximum flow; if necessary, replace with smaller regulator.
* Excess seat leakage may be diagnosed when a failure of the dynamic side seal has occurred. Inspect both
potential internal leak paths.
C. Failure due to wear. C1. Replace seat.
C2. Replace all internal trim due wear.
D. Improper installation. D1. Failure to "coin" CTFE or VTFE seat; disassemble and "coin".
D2. Improper re-assembly. Disassemble and re-assemble per
instructions within IOM.
4. Leakage at diaphragm flange.
5. Leakage across seat.

IOM-CA1/SA1 9
SECTION IX
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–
IX. ORDERING INFORMATION
NEW REPLACEMENT UNIT VS PARTS "KIT" FOR FIELD RE
To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on
the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"),
a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code
typical format as follows: (last digit is alpha character that reflects revision level for the product).
PARTS "KIT" for FIELD REPAIR:
Contact your local Cashco, Inc., Sales Represen-
tative with the Serial Number and Product code.
Identify the parts and the quantity required to repair
the unit from the "BOM" sheet that was provided
when unit was originally shipped.
NOTE: Those part numbers that have a quantity indicated
under "Spare Parts" in column "A” reflect minimum
parts required for inspection and rebuild, - "Soft
Goods Kit". Those in column “B” include minimum
trim replacement parts needed plus those "Soft
Goods" parts from column "A".
If the "BOM" is not available, refer to the cross-
sectional drawings included in this manual for part
identification and selection.
A Local Sales Representative will provide quotation
for appropriate Kit Number, Price and Availability.
CAUTION
Do not attempt to alter the original construction
of any unit without assistance and approval from
the factory. All purposed changes will require a
new name plate with appropriate ratings and new
product code to accommodate the recommended
part(s) changes.
NOTE: In addition to ordering repair parts, it is recommended that a special double-posted spanner wrench
fitting be ordered for use in the maintenance of the ITA.
Double-Posted Spanner Wrench Fitting
Body Size Part Number
All A96-75-9-P0459-00
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to
modify or improve the designs or specifications of such product at any time without notice.
Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Cashco, Inc. product remains solely with the purchaser.

IOM-CA1/SA1
10
Figure 3:
Model CA1/SA1
Item No. Description
1 Adjusting Screw
2 Adjusting Screw Lock Nut
3 Closing Cap
4 Spring Chamber
5 Spring Follower
6 Range Spring
7 Nut Seal
8 Upper Diaphragm Plate
9
*Diaphragm
10 Closing Cap Seal
11 Flange Bolt Nuts
12 Flange Bolt
13
‡Piston-Guide Bearing
14 Thrust Washers
15
*Cage O-ring Seal
16 Shim
17 Cage Washer
18 Cage Cap Screw
19 Cage
20 Valve Plug
21
*Seat Ring
22 Return Spring
23 Body
27 *Dynamic Side Seal
27.1
*Cap Seal
27.2
*O-ring Energizer
27.3
*U-Cup Seal w/ Metal Energizer
28 * Diaphragm Seal
*Recommended Repair Parts
‡It is recommended that a special double-posted spanner
wrench fitting be ordered for use in the maintenance
of the ITA. To order, see NOTE in Section IX, Parts
Ordering Information.
Item No. Description
Opt-1 - Closing Cap

IOM-CA1/SA1 11
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.

IOM-CA1/SA1
12
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. CA1/SA1-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]
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.