cashco P7 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-P7
03/16
SECTION I
I. DESCRIPTION AND SCOPE
The Model P7 is a 1/2" (DN15) or 3/4" (DN20) pressure reducing regulator used to control downstream (outlet or P2 )
pressure. The unit is suitable for gaseous or liquid services. Refer to Technical Bulletin P7-TB for design conditions
and selection recommendations.
SECTION II
II. INSTALLATION
MODEL P7
PISTON SENSING SINGLE STAGE
PRESSURE REDUCING REGULATOR
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 outlet pressure gauge should be located ap-
proximately ten pipe diameters downstream, and
within sight.
5. All installations should include a downstream relief
device if the inlet pressure could exceed the pres-
sure 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 in-
stalling the regulator. Strainers are recommended.
7. In placing thread sealant on pipe ends prior to en-
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.
gagement, 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 inlet stamp on the main regulator body (1).
9. For best performance, install in well drained hori-
zontal pipe.
10. Regulator may be rotated around the pipe axis 360°.
Recommended position is with spring loaded knob
(38) or loading dome (2) or ratio loading upper case
(44) in vertical upwards position.
11. Regulators are not to be buried underground.
12. For insulated piping systems, recommendation is
to not insulate regulator.
Model P7
ISO Registered Company
Recommended Piping Schematic
For Pressure Reducing Stations

IOM-P72
SECTION IV
IV. STARTUP
SECTION V
V. SHUTDOWN
SECTION III
III. PRINCIPLE OF OPERATION
1. Movement occurs as pressure variations regis-
ter on the piston (5). The registering pressure
is the outlet, P2, or downstream pressure. The
range spring (28) or loading pressure (for dome
loaded or ratio loaded designs) opposes piston
(5) movement. As outlet pressure drops, the
range spring (28) or loading pressure pushes the
piston (5) down, opening the port; as outlet pres-
sure increases, the piston (5) pushes up and the
port opening closes.
2. A complete piston (5) failure will cause the regula-
tor to fail open.
For Spring Loaded Design the maximum outlet
pressure is indicated on the body as the upper range
spring pressure level, and is the recommended “upper
operative limit” for the sensing piston (see Section IV.
Startup, Step 7).
For Dome & Ratio Loaded Design the max outlet
pressure is 1500 psig (103.4 barg).
Max loading pressure for Ratio Loaded Design is 105
psig (7.2 barg).
DO NOT HYDROSTATIC TEST THROUGH AN
INSTALLED UNIT; ISOLATE FROM TEST.
CAUTION
1. 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.
2. Relax range spring (28) by turning the knob (38)
counter clockwise (CCW) until rotation comes to
a complete stop; or remove the loading pressure
for dome loaded or ratio loaded designs.
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.
4. Crack open the outlet (downstream) block valve.
5. Slowly open the inlet (upstream) block valve ob-
serving the outlet (downstream) pressure gauge.
Determine if the regulator is flowing. If not, slowly
rotate the regulator knob (38) clockwise (CW) or
increase the loading pressure until flow begins.
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 block valve and go to Step 2, then return
to Step 4.
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, reset the regulator set point by turn-
ing the knob (38) (CW) to increase outlet pressure
or (CCW) to reduce outlet pressure. Adjust the
loading pressure for dome or ratio loaded designs.
10. Reduce system flow to a minimum level and ob-
serve 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 (28) by
greater than 10%; i.e. 2-100 psig (.14-6.9 Barg)
range spring (28).
Do not walk away and leave a bypassed
regulator unattended.
CAUTION
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.
2. If the regulator and system are to both be shut
down, slowly close the inlet (upstream) block
valve. Close the outlet (downstream) valve only
if regulator removal is required.

IOM-P7 3
SECTION VI
VI. MAINTENANCE
To prevent damage to body, use soft jaws when
placing body in a vise. Position so that vise closes
over the flats on lower end of body.
5
SPRING UNDER COMPRESSION. Prior to removing
spring chamber, relieve range spring compression
by turning the knob counter clockwise (CCW) until
rotation comes to a complete stop. For DOME or
RATIO Loaded, remove all loading pressure. Failure
to do so may result in flying parts that could cause
personal injury.
WARNING
CAUTION
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, cleaning and disposal of
nonreusable parts, i.e. gaskets, etc.
3. Apply a thin coat of Christo Lube to all o-rings.
4. Refer to Figure 1, Figure 2 or Figure 3 for per-
tinent design.
B. Poppet Seat & Piston Replacement - Spring
Loaded Vented Design:
1. Securely install the body (1) in a vise with the
spring knob (38) directed upwards.
2. Relax range spring (28) by turning the knob (38)
counter clockwise (CCW) until rotation comes
to a complete stop. NOTE: It is not necessary
to remove the knob (38) before removing the
spring chamber(2)-(upper assembly) from the
body (1). Remove upper assembly by turning
spring chamber (2) (CCW). Lift upper assembly
off of range spring (28).
3. Remove spring (28), pin (40) and spring follower
(26).
4. Grab vent cap (25) by flats and pull up to remove
piston (5) and sleeve (3) from body (1). Remove
and replace o-ring (4).
5. With thumb, press down on top of vent cap (25)
to separate piston (5) from sleeve (3). Remove
and replace o-ring (6).
6. Secure piston (5) in a vise using the flats on
the sides of piston. Remove vent cap (25) by
turning (CCW).
7. Use a pair of needle nose pliers to grasp top of
poppet (23). Pull upwards to remove poppet,
poppet seat (24) and poppet spring (22).
8. Reinstall poppet spring (22) and poppet (23) in
piston (5). Slide new poppet seat / disc (24)
over poppet. Install vent cap (25) on piston (5),
use (CW) rotation to tighten metal to metal.
9. Insert smallest o.d. of piston (5) into largest i.d.
of sleeve (3). Press tightly together for metal
to metal contact. Press this assembly into body
(1); vent cap (25) oriented upwards.
10. Place spring follower (26) with smallest o.d.
next to piston. Install spring (28).
11. Place upper spring chamber assembly on body
(1). Turn spring chamber (2) (CW) to secure
tight to body. Remove knob cover (39).
12. Rotate vent screw (36) CCW to remove screw
and spring (35). Record number of revolutions
for removal of screw. _________
13. Lower pin (40) through top / center of adjusting
screw (34), pin should rest on top of poppet (23).
NOTE: insert a small diameter tool through
center of adjusting screw and carefully press
downward on pin (40) to confirm recoil of the
poppet spring (22).
14. Install spring (35) and vent screw (36) - recalling
the number of revolutions counted for removal
from above. Reinstall knob cover.
C. Piston Replacement - Spring Loaded
Non-Vented Design:
1. Instructions are similar to Vented with excep-
tion: Assembly does not include pin (40), per
B. 3, the poppet, (23) and poppet spring (22).
per B.7 & B.8. The poppet seat (24) is replaced
by a solid disc.
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.

IOM-P74
6. Insert smallest o.d. of piston (5) into largest i.d.
of sleeve (3). Press tightly together for metal
to metal contact. Press this assembly into body
(1).
7. To re-attach body assembly to upper & lower
case assembly, position body (1) on bonnet (2)
and rotate body (CW) to secure tight metal to
metal seal. NOTE: Align post (42) with recess
in piston (5).
F. Trim Inspection & Replacement: (All designs)
1. Remove pin (10) and baffle plate assembly (7)
(8)(9). NOTE: spring pin (9) is pressed into
baffle plate (7) flush to top surface. Pitot (8) is
threaded tight into bottom side of baffle plate
(7).
2. With body securely clamped in vise remove
seat (11) turning (CCW). Remove and replace
o-ring (27). At re-assembly, tighten seat (11)
metal to metal into body (1).
3. Remove body from vise and rotate end to end
180 degrees to reclamp body in vise with body
cap (16) upwards.
4. Turn body cap (CCW) to remove and replace
o-ring (17). At re-assembly tighten body cap
(16) metal to metal to body (1).
5. With a pick type tool, locate leading edge of
spiral retaining ring (21) in the body cap (16)
and lift upwards slightly. Grab the elevated
end with needle-nose pliers and rotate (CCW)
to remove. At re-assembly replace with new
retaining ring (21).
6. Remove retainer (20). Remove and replace
o-ring (19) and backup ring (18).
7. Grasp end of plug (12) and pull upwards to
remove. Slide return spring (15) off of plug
(12).
8. Secure plug (12) in a vise with vent screw (14)
directed upwards. Turn vent screw (CCW) to
remove and replace seat disc ((13). NOTE:
chamfer on seat disc (13) faces away from the
plug. At re-assembly tighten vented screw (14)
into plug per following torque values:
For Cv Size Torque to in/oz.
0.8 65
2.0 96
D. Piston Replacement - Dome Loaded Design:
1. Securely install the body (1) in a vise with the
loading dome (2) directed upwards.
2. Remove dome (2) by grasping the flats and
turning (CCW).
3. Grab piston (5), lift up to remove piston & sleeve
(3) from body (1). Remove and replace o-rings
(4 & 41).
4. With thumb, press down on top of piston (5) to
separate piston from sleeve (3). Remove and
replace o-ring (6).
5. Insert smallest o.d. of piston (5) into largest i.d.
of sleeve (3). Press tightly together for metal to
metal contact. Press this assembly into body.
6. Place dome (2) on body- turning (CW) to secure
body (1) and dome (2) firmly together.
7. Refer to Section IV for start up.
E. Piston Replacement - Ratio Loaded Design:
1. Securely install the upper & lower case assem-
bly (43) (44) in a vise with the body(1) directed
upwards.
2. Remove body (1) from upper & lower case as-
sembly (43)(44) and bonnet (2) by grasping the
flats on the body (1) and turning CCW. NOTE:
It is not necessary to dis-assemble upper &
lower case assembly. Do not remove post (42)
from upper & lower case assembly to maintain
alignment of post (42) with pressure plate (46).
3. Rotate body assembly end to end 180 degrees
and securely install in a vise with piston (5)
upwards.
4. Grab piston (5), lift up to remove piston & sleeve
(3) from body (1). Remove and replace o-ring
(4).
5. With thumb, press down on top of piston (5) to
separate piston from sleeve (3). Remove and
replace o-ring (6).
5
For DOME or RATIO Loaded remove all loading
pressure. Failure to do so may result in flying parts
that could cause personal injury.
WARNING

IOM-P7 5
9. Clean body (1) and all reusable parts according
to owner's procedures. NOTE: On regulators
originally supplied as “oxygen clean”, Option-M,
maintenance must include a level of cleanliness
equal to Cashco's cleaning standard #S-1134.
Contact factory for details.
10. Inspect and replace any necessary parts.
NOTE: Use only parts manufactured and sup-
plied by Cashco, Inc. for these products.
11. Insert plug (12) and spring (15) into body (1).
12. Place backup ring (18) into body cap (16), fol-
lowed by o-ring (19) and guide bushing (20) - flat
side up.
13. Insert spiral retaining ring (21) into groove be-
hind guide busing (20) to lock parts in place.
14. Thread body cap (16) into the body (1) metal
to metal, compressing o-ring (17) into chamfer
of body.
15. Remove body from vise and rotate end to end
180 degrees to reclamp body in vise with body
cap (16) downwards.
16. Thread seat (11) with o-ring (27) (CW) into body
(1) tighten metal to metal.
17. Position baffle plate assembly (7) pin side down
into body (1); align spring pin (9) in proper hole
in body so pitot (8) is visible in center of outlet
threaded connection.
18. Install pin (10) through center of baffle plate (7).
19. Refer to Section VI to re-assemble piston and
top works to a specific design.
G. Diaphragm Replacement - Ratio Loaded Design:
1. Securely install the body (1) in a vise with
upper & lower case assembly (43) (44)
directed upwards.
2. Remove all bolts (48) and nuts (49) from
upper & lower case assembly.
3. Remove upper case (44).
4. Remove & replace diaphragm (45).
NOTE: Ensure that pressure plate (46) is
aligned correctly on post (42),
5. Align bolt holes in upper case (44) with
holes in diaphragm (45) & lower case (43).
Insert bolts (48) through holes and thread nuts
(49) on bolts. Torque bolting and nuts to 35 ft.
lbs.
SECTION VIII
VIII. TROUBLE SHOOTING GUIDE
1. Erratic operation; chattering.
Possible Causes Remedies
A. Oversized regulator; inadequate rangeability. A1. Check actual flow conditions, re-size regulator for minimum and maximum flow.
A2. Increase flow rate.
A3. Decrease regulator pressure drop; decrease inlet pressure by placing a throttling orifice in
inlet piping union.
A5. Before replacing regulator, contact factory.
B. Worn poppet; inadequate guiding. Vented Design B. Replace trim (possible body replacement).
C. Weakened/broken poppet spring. Vented Design C. Replace poppet spring. Determine if corrosion is causing the failure.
SECTION VII
VII. CALIBRATION OF POPPET VENT - SPRING LOADED MODEL
Refer to Section IV - Startup - to establish system regulating pressure and flow conditions. Pop knob cover off of the
knob (38). Rotate vent adjustment screw (36) CW, until a hissing sound is heard - then stop. Then slowly turn the vent
adjustment screw CCW until the hissing sound stops. From this point, rotate the vent adjustment screw CCW one more
revolution and stop. The vent relieving function of this model is calibrated.

IOM-P76
4. Excessive pressure downstream.
Possible Causes Remedies
A. Regulator not closing tightly. A. 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 trim.
B. Downstream block.. B. Check system; isolate (block) flow at regulator inlet - not outlet. Relocate regulator if
necessary.
C. No pressure relief protection. C. Install safety relief valve, or rupture disc.
D. Restricted piston movement. D. Ensure no moisture in spring chamber at temperatures below freeze point.
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 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 quota-
tion for appropriate Kit Number.
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.
3. Sluggish operation.
Possible Causes Remedies
A. Fluid too viscous. A. Heat fluid. Contact factory.
2. Regulator can not pass sufficient flow.
Possible Causes Remedies
A. Regulator undersized. A1. Confirm by opening bypass valve together with regulator.
A2. Check actual flow conditions, re-size regulator; if regulator has inadequate capacity,
replace with larger unit.
B. Too much droop. B1. Review droop expected.
B2. Contact factory.

IOM-P7 7
Repair Parts
Item No. Description Kit B
1 Body
2 Spring Chamber
3 Sleeve
4 O-Ring........................................++
5 Piston
6 O-Ring........................................++
7 Baffle Plate
8 Pitot
9 Spring Pin
10 Body Pin
11 Seat Orifice................................++
12 Plug............................................++
13 Valve Seat Disc..........................++
14 Vent Screw(Valve Seat).............++
15 Return Spring
16 Body Cap
17 O-Ring........................................++
18 Backup Ring...............................++
19 O-ring..........................................++
20 Retainer
21 Spiral Retaining Ring...................++
Repair Parts
Item No. Description Kit B
22 Vent Poppet Spring
23 Vent Poppet
24 Seat............................................++
25 Vent Cap
26 Spring Follower
27 O-ring..........................................++
28 Range Spring
29 Spring Button
30 Set Screw (Spring Button)
31 Thrust Washer
32 Thrust Bearing
33 Thrust Washer
34 Adjusting Screw
35 Adjusting Screw Spring
36 Vent Adjustment Screw
37 Retaining Ring (Snap Ring)
38 Knob
39 Knob Cover
40 Pin
50 Nut
FIGURE 1
SPRING LOADED

IOM-P78
Repair Parts
Item No. Description Kit B
1 Body
2 Dome
3 Sleeve
4 O-Ring........................................++
5 Piston
6 O-Ring........................................++
7 Baffle Plate
8 Pitot
9 Spring Pin
10 Body Pin
11 Seat Orifice..................................++
12 Plug..............................................++
13 Valve Seat Disc............................++
14 Vent Screw...................................++
15 Return Spring
16 Body Cap
17 O-Ring.........................................++
18 Backup Ring................................++
19 O-Ring.........................................++
20 Retainer
21 Spirial Retaining Ring..................++
27 O-Ring.........................................++
41 O-Ring.........................................++
FIGURE 2
DOME LOADED
Repair Parts
Item No. Description Kit B
42 Post
43 Lower Case
44 Upper Case
45 Diaphragm..................................++
46 Diaphragm Pressure Plate
47 Cap Screw
48 Cap Screws
49 Nut
FIGURE 3
RATIO LOADED

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. P7-IOM
Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]
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.
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]