cashco PGR-2 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-PGR-2
10-22
I. DESCRIPTION AND SCOPE
Model PGR-2 is a pressure reducing regulator used to control downstream (outlet or P2) pressure. Sizes are
3/8" (DN10), 1/2" (DN15), 3/4" (DN20), 1". This model is applied primarily in gaseous service.
MODEL PGR-2
PRESSURE LOADED
PRESSURE REDUCING REGULATOR
II. REFERENCES
Refer to Technical Bulletin PGR-2-TB for technical
specifications for this regulator.
ABBREVIATIONS
CW – Clockwise
CCW – Counter Clockwise
ITA – Inner Trim Assembly
III. INSTALLATION
SECTION III
SECTION II
SECTION I
1. Regulator may be rotated around pipe axis 360
degrees. For ease of maintenance, the recom-
mended position is with the cover dome (2)
upwards.
2. Provide space below, above, and around regula-
tor for removal of parts during maintenance.
3. Install block valves and pressure gauges to pro-
vide means for adjustment, operation, bypass,
or removal of the regulator. A pipeline strainer
is recommended before inlet to remove typical
pipeline debris from entering valve and damaging
internal “soft goods”, primarily the dynamic seal.
4. The PGR-2 is designed to regulate pressure
via external sensing. Use 3/8" or 1/2" (DN10 or
DN15) outer diameter tubing to connect the sens-
ing port on the pilot to the piping down stream of
the main regulator. If PGR-2 is constructed with
self contained feature - tubing and connection in
downstream piping is not required.
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.
Model PGR-2
ISO Registered Company

IOM-PGR-2
2
1. When a loading pressure – PLoad – is applied to
the top side of a diaphragm, the outlet controlled
pressure – P2– will balance at approximately
.90 – .98 of the loading pressure - PL.
2. Movement occurs as pressure variations register
on the diaphragm. The registering pressure is the
outlet, P2, or downstream pressure. The loading
pressure fluid opposes diaphragm movement.
As outlet pressure drops, the loading pressure
pushes the diaphragm down, opening the port; as
outlet pressure increases, the diaphragm pushes
up and the port opening closes.
3. A diaphragm failure will tend to cause the regulator
to fall below setpoint. A loss of loading pressure
while inlet pressure is imposed will cause the
regulator to fail close.
V. STARTUP
1 Start with the block valves closed.
2. Rotate the adjusting screw (30.17) on the pilot
valve CCW so that main regulator is trying to be
controlled at 0 psig pressure. DO NOT rotate
the adjusting screw on the stabilizer, stabilizer
was preset and calibrated at the factory. NOTE:
If an adjustment to the stabilizer is necessary,
it is recommended that a gauge be installed in
optional port downstream of stabilizer. Once flow
is established, if an adjustment is needed, the
stabilizer should be set at 8 to 10 PSI above the
set point attempting to be controlled.
3. DO NOT rotate knob on metering valve, it was
preset at the factory at 2 to 3 full revolutions from
closed position. DO NOT close metering valve.
4. 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.
5. Crack open the outlet (downstream) block valve
to approximately 10% full open.
6. Slowly open the inlet (upstream) block valve to
about 25% open. Rotate the adjusting screw
SECTION V
CAUTION
DO NOT HYDROSTATIC TEST THROUGH AN INSTALLED
UNIT; ISOLATE REGULATOR FROM TEST. The "OUTLET
RATING" as printed 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.
CAUTION
Do not walk away and leave a bypassed regulator
unattended!
(30.17) on the pilot valve CW to increase setpoint
pressure upwards until the main valve is flowing.
Observe the outlet pressure gauge to ensure not
over pressurizing.
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 pres-
sure, close the inlet block valve and go to Step 2.
Close bypass valve approximately 25%, repeat
procedure.
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
rotating the adjusting screw (30.17) on the pilot
valve CW to change the setpoint to the desired
outlet pressure level. If downstream pressure is
unstable, rotate knob on metering valve in quarter
turn increments CW or CCW to combat instabil-
ity. NOTE: 1/4 turn increments are used due to
sensitivity, in some cases the changes to the P2
are significant. DO NOT rotate knob more than
6 full revolutions from closed position. Metering
valve is preset at factory 2 to 3 full revolutions from
closed position. DO NOT close metering valve.
11. Reduce system flow to a minimum level and
observe pressure set point. Outlet pressure will
rise from the set point of Step. The maximum rise
in outlet pressure on decreasing flow should not
exceed the 10%. If it does, consult factory.
SECTION IV
IV. PRINCIPLE OF OPERATION

IOM-PGR-2 3
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 any trapped upstream and downstream
pressure and loading pressure from PGR-2.
5. The regulator may now be removed from the
pipeline or disassembled for inspection and pre-
ventative maintenance while in-line.
VII. MAINTENANCE
SECTION VII
A. General:
1. The main regulator body may be serviced
without removing the regulator from pipeline.
The regulator is designed with quick-change
trim to simplify maintenance.
2. Record the name plate information to req-
uisition repair parts for the regulator. This
information should include: size, Serial
Number, and Product Code.
3. Refer to Section IX for recommended repair
parts. Only use original equipment parts
supplied by Cashco for rebuilding or repair-
ing regulators.
4. Owner should refer to owner's procedures
for removal, handling, cleaning and disposal
of nonreusable parts, i.e. gaskets, etc.
NOTE: On regulators originally supplied as
“special clean” – Opt-56, maintenance must
include a level of cleanliness equal to Cashco
cleaning standard #S-1542.
B. Main Valve Disassembly:
1. Securely install the body (1) in a vise with the
loading chamber (33) directed upwards.
2. Draw or embed a match mark between body
casting (1) and loading chamber (33) along
flanged area.
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.
SECTION VI
3. Remove all diaphragm nuts (9) and bolts (8).
4. Remove loading chamber (33), pressure plate
(3) and diaphragm(s) (12). NOTE: Refer to the
quantity of diaphragms (12) incorporated per
the bill of materials listing. Depending on outlet
pressure level, multiple metal diaphragms may
be “stacked”.
5. Remove pusher plate (11) and inspect for a
fit which limits its travel to a vertical direction.
Wear will show as excessive wobble in pusher
plate (11). If apparent, recommend trim
removal and inspection; go to Sub-Section C
following. Reinstall pusher plate (11).
6. Inspect pressure plate (3) to ensure no
deformation due to over-pressurization. If
deformed, replace.
7. Clean body (1) and diaphragm flange. NOTE:
On regulators originally supplied as “oxygen
clean”, Option 55, maintenance must include
a level of cleanliness equal to Cashco cleaning
standard #S-1134.
8. Position diaphragm(s) (12) into place. Visually
center pressure plate (3) onto diaphragm(s)
(12).
9. Aligning the matchmarks, place loading
chamber (33) over the above stacked parts.
Install all bolts (8) and nuts (9) by hand
tightening. Mechanically tighten bolting (8 & 9)
in a cross pattern that allows loading chamber
(33) to be pulled down evenly. Apply 16-20
Ft-Lbs torque to finish tightening bolts.
NOTE: Never replace bolting (8 & 9) with just any
bolting if lost. Bolt heads and nuts are marked
with specification identification markings. Use only
proper grades as replacements.
10. Spray liquid leak detector around bolting (8
& 9) and body (1) and loading chamber (33)
flanges and test for leakage. Ensure that an

IOM-PGR-2
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15. Spray liquid leak detector around body cap (5)
and body (1) for test for leakage. Test pressure
should be a minimum of 100 psig (6.9 Barg) at
the inlet. Outlet should be tested to upper value
of range spring (14) with a 100 psig (6.9 Barg)
minimum.
NOTE: When piston (15) assemblies are
used with comp seats, Cashco, Inc. does not
recommend attempting to remove the comp
seat. If composition seat is damaged, replace
entire piston assembly.
G. Pilot Valve Disassembly:
outlet pressure is maintained during this leak
test of at least mid-range spring level; i.e. 10-40
psig (.69 - 2.8 Barg) range spring, 25 psig (1.7
Barg) test pressure minimum.
C. Trim Replacement:
1. Install body (1) in a vise with the body cap (5)
on top and the body (1) flange downwards.
2. Loosen and remove body cap (5).
3. Remove piston spring (17), piston (15), and
cylinder (16). Do not remove pusher plate (11).
Inspect parts for excessive wear, especially
at seat surfaces. Replace if worn, nicked or
depressed.
4. Remove the cylinder gasket (18) and clean
contacting surface of body (1).
5. Clean flat mating surfaces of body (1) to body
cap (5) shoulder.
6. Clean debris from within body (1) cavity. Clean
parts to be reused.
NOTE: On regulators originally supplied as
“oxygen clean”, Option 55, maintenance must
include a level of cleanliness equal to Cashco
cleaning standard #S-1134.
7. Reinstall a new cylinder gasket (18). Press
firmly and evenly into place using the cylinder
(16). Do not use a “homemade” cylinder gasket.
Pipe sealant may be lightly coated to cylinder
gasket (18) surfaces prior to installation, except
when utilized as Item 6 above.
9. Reinstall the cylinder (16) concentrically within
the body cap (5) opening.
10. Slide the piston (15) slowly into place, assuring
that the piston (15) post slides into the female
groove of the pusher plate (11).
12. Place piston spring (17)
into piston (15) cavity.
13. Use pipe thread sealant applied to the body
cap (5) threads. Thread body cap (5) into body
(1). Impact until body cap (5) is metal to metal
against body (1) at the body cap (5) shoulder.
14. Bench test unit for suitable operation. NOTE:
Regulators are not tight shutoff devices. Even if
pressure builds up beyond set point, a regulator
may or may not develop bubble tight shutoff. In
general, tighter shutoff can be expected with
composition seat.
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.
1. Shut down system in accordance Section VI.
2. Disconnect the external sensing line, from
the pilot valve sensing port.
3. Loosen all fittings and remove tubing that con-
nect the inlet filter to the stabilizer, the cover
dome to the metering valve and the outlet of
the metering valve to the outlet of the body.
4. Loosen and remove the two nuts (24) that
secure the mounting bracket (3) and pilot to
the cover dome (2).
5. Remove pilot assembly from main valve.
6. Place the pilot valve body (30.1) in a vise with
the spring chamber (30.2) upwards.
7. Loosen adjusting screw nut (30.18) one revo-
lution CCW. Relax range spring (30.4) forces
by rotating adjusting screw (30.17) CCW until
removed from spring chamber (30.2).
8. Loosen the diaphragm flange bolts (30.19)
and nuts (30.21) uniformly and remove bolt-
ing.
9. Place match marks on body (30.1) spring
chamber (30.2) flanges. Remove spring
chamber.
10. Remove spring button (30.5), range spring
(30.4) and pressure plate (30.6).
11. Remove diaphragm (30.13).Examine dia-

IOM-PGR-2 5
phragm to determine whether failed; determine
if operating conditions are exceeding pressure,
pressure drop or temperature limits. If just
replacing the diaphragm, proceed to Step H.9
and skip the following instructions.
12. Grasp pusher post (30.12) and lift up to remove.
Place socket wrench over retainer (30.10) and
rotate CCW to remove from body.
13. Remove seal gasket (30.15), piston seal
(30.14) and a second seal gasket (30.15) from
bore inside the body.
14. To remove the stem (30.8), remove the body
from the vise and slowly turn upside down.
Stem will slide out of the body, Do Not let the
stem fall and hit the floor.
15. Place body (30.1) in a vise with the body cap
(30.3) upwards. Rotate cap bolts (30.20) CCW
to remove bracket and body cap. Remove
cap seal (30.16).
16. Remove return spring (30.11), ball holder
(30.9), and ball (30.22).
17. Place socket wrench over seat (30.7) and
rotate CCW to remove from body.
18. Remove body (30.1) from vise. Clean all
reusable metal parts according to owner's
procedures
H. Pilot Valve Reassembly:
1. Place body (30.1) in a vise flange face down.
2. Apply "Gasoila" or equivalent, thread sealant
to the threads of the seat (30.7). Engage the
seat threads into the body and apply 20 - 25
ft-lbs. torque. Place the ball (30.22), ball holder
(30.9) and return spring (30.11) onto seat.
3. Place the o-ring (30.16) into the groove in
the body cap (30.3) and place onto the body.
Position the bracket on the body cap and re-
install cap bolts (30.20). Make sure the return
spring (30.11) fits inside the bore of the body
cap. Tighten nuts evenly in a star crossing
pattern. Apply 15 - 18 ft-lbs. torque to tighten
the cap bolts.
4. Remove body from the vise. Reinstall body
again in vise with the bolt flange facing up.
5. Insert the stem (30.8) into the center hole of
the body and the seat (30.7), square end first.
6. Place one seal gasket (30.15), one piston seal
(30.14) and one seal gasket (30.15) into the
center bore on top of the stem (30.8). See
Detail "A". Ensure to align the seal and gas-
kets so they are centered inside the threaded
bore hole.
7. Engage the retainer (30.10) threads into the
center bore hole to hold the piston seal and
gaskets in place and apply 75 in-lbs. torque.
to tighten.
8. Insert pusher post (30.12) into retainer (30.10).
9. Place diaphragm (30.13) on bolt flange, cen-
tered between bolt holes. Center the pressure
plate (30.6) on top of the diaphragm.
10. Place range spring (30.4) in center of the
pressure plate (30.6) cup. Apply Mobile XHP
222 grease or equivalent into recessed area
of the spring button (30.5) and place on top of
the range spring. (Also lubricate the threads
of the adjusting screw lightly).
11. Engage threads of the adjusting screw (30.17)
into the spring chamber (30.2) three or four
revolutions and place the spring chamber over
the spring button and spring.
12. Align the match marks on the body and spring
chamber flanges. NOTE: Vent hole in the
spring chamber should be directly above the
sense port in the body.
13. Place flange bolts through holes in spring
chamber and body and engage nuts (30.21).
Tighten nuts evenly in a star crossing pattern.
Apply 15 - 18 ft-lbs. torque to finish tightening.
Secure the name plate (30.23) under one of
the flange bolts (30.19) above the "inlet" of
the pilot.
14. Rotate adjusting screw (30.17) CW into the
spring chamber (30.2) to where the nut (30.18)
comes in contact with the top of the spring
chamber. Pilot valve set pressure should
approach the set point prior to removal from
the piping installation. Retighten nut (30.18).
I. Mounting Pilot Valve to Main Valve:
1. Place the bolt holes for the mounting bracket
over the two longer bolts (23) installed through-
out the top of the cover dome (2). Engage
the final two nuts (24) and secure tight.

IOM-PGR-2
6
2, Re-install tubing and fittings that previously
connected the inlet filter to the stabilizer, the
cover dome to the metering valve and the
outlet of the metering valve to the outlet of
the body.
3. Re-connect the external sensing line to the
pilot valve sensing port.
for removal, handling, cleaning and disposal
of nonreusable parts, i.e. gaskets, etc.
3. Loosen fitting and remove tubing that con-
nect the inlet filter to the stabilizer, Remove
stabilizer from fittings that run between the
stabilizer and the pilot.
4. Secure stabilizer body (60.1) in a vise with
the spring chamber (60.2) oriented upwards
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.
J. Changing the filter element:
1. See Section IV.
WARNING
SPRING UNDER COMPRESSION. Prior to removing the
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
To prevent damage to body, use soft jaws when securing
the body in a vise. Position so that vise closes over the
inlet and the outlet connections.
DIAPHRAGM REPLACEMENT -
Inlet Filter
ELEMENT
(INSIDE)
BODY
COVER
2. Unscrew the filter cover from the body.
Remove old element and replace with new
element.
3. Screw cover on filter body and secure tight.
K. Disassembly of the Stabilizer:
1. Maintenance procedures hereinafter are
based upon removal of the stabilizer from
the pilot. Shut down system in accordance
Section VI.
2. Owner should refer to owner's procedures
1. Loosen adjusting screw nut (60.11) one
revolution CCW. Relax range spring (60.15)
forces by rotating adjusting screw (60.8)
CCW until removed from spring chamber
(60.2).
2. Loosen spring chamber (60.2) by placing
wrench on “flats” and rotating CCW making
sure not to use the flat where the vent hole
is located.
3. Remove spring chamber (60.2), spring
(60.15) and spring button (60.5).
4. Remove the diaphragm subassembly con-
sisting of the pressure plate nut (60.10),
lock washer (60.9), pressure plate (60.3),
diaphragm (60.12), pusher plate seal (60.13)
and pusher plate (60.4).
5. Loosen pusher plate nut (60.10) and separate
all parts (60.3, 60.4, 60.9, 60.12 & 60.13) of
the diaphragm subassembly.
6. Inspect pressure plate (60.3) to ensure no
deformation due to over-pressurization. If
deformed, replace.
7. Clean all reusable metal parts according to
owner's procedures.

IOM-PGR-2 7
8. Reassemble diaphragm subassembly by
placing pusher plate seal (60.13) over
threaded post of pusher plate (60.4), placing
diaphragm (60.12) and pressure plate (60.3)
over the threaded post. Assure the pressure
plate (60.3) is placed with curved outer rim
down next to the diaphragm (60.12) surface.
Place a thread sealant compound on the
threads of the pusher plate post (60.4). Apply
15 in-lbs torque to tighten the nut (60.10).
9. Place spring (60.15) over the pusher plate
nut (60.10) of the diaphragm subassembly.
10. Place multipurpose, high temperature grease
into depression of spring button (60.5) where
adjusting screw (60.8) makes contact.
Set spring button (60.5) onto range spring
(60.15); ensure spring button is laying flat on
top of spring.
11. Rotate the spring chamber (60.2) CW by hand
into the threaded portion of the body (60.1)
ensuring not to cross thread. Continue rotat-
ing CW until firmly seated against the upper
diaphragm. Tighten to 30-35 ft-lbs (41-47
N-m) torque value.
12. Reinstall adjusting screw (60.8) with nut
(60.11) into the spring chamber (60.2).
13. Pressurize with air and spray liquid leak de-
tector to test around body and spring chamber
for leakage. Ensure that an outlet pressure
is maintained during this leak test of at least
mid-range spring level; i.e. 20-80 psig (1.4-
5.5 Barg) range spring, 50 psig (3.4 Barg) test
pressure minimum.
TRIM REPLACEMENT -
1. Secure stabilizer body (60.1) in a vise with the
body cap (60.6) oriented up and the spring
chamber (60.2) downwards.
NOTE: Piston (60.14) assembly is a com-
position seat, Cashco, Inc. does not recom-
mend attempting to remove the composi-
tion seat. If composition seat is damaged,
replace entire piston assembly.
4. Clean flat mating surfaces of body (60.1) to
body cap (60.6) shoulder. Be careful not to
scratch either surface.
5. Clean debris from within the body (60.1) cav-
ity. Parts to be reused should be cleaned
according to owner's procedures.
6. Slide the post end of the piston (60.14),
slowly into the body cavity.
7. Place piston spring (60.7) over spring hub of
the piston (60.14).
8. Apply pipe thread sealant to the body cap
(60.6) threads. Thread body cap into body.
When body cap is fully down against body
at the body cap shoulder, impact the body
cap into the body tight. NOTE: When unit is
put into service and pressurized, these two
parts seal metal-to-metal with no gasket.
9. Bench test unit for suitable operation.
NOTE: Regulators are not tight shutoff de-
vices. Even if pressure builds up beyond set
point, a regulator may or may not develop
bubble tight shutoff. In general, tighter shut-
off can be expected with composition seat.
10. Pressurize with air and spray liquid leak
detector to test around body cap (60.6)
and body (60.1) for leakage. Test pressure
should be a minimum of 100 psig (6.9 Barg)
at the inlet.
11. Remove body from vise, rotate down side up
and secure body in vise with body cap down.
12. Reassemble diaphragm subassembly by
placing pusher plate seal (60.13) over
threaded post of pusher plate (60.4), plac-
ing diaphragm (60.12) and pressure plate
(60.3) over the threaded post. Assure the
pressure plate (60.3) is placed with curved
outer rim down next to the diaphragm (60.12)
surface. Place a thread sealant compound
on the threads of pusher plate post (60.4).
Apply 15 in-lbs. torque to tighten the nut.
13. Place spring (60.15) over the pusher plate
nut (60.10) of the diaphragm subassembly.
14. Place multipurpose, high temperature
grease into depression of spring button
(60.5) where adjusting screw (60.8) makes
CAUTION
To prevent damage to the body, use soft jaws when
securing body in a vise. Position body so that vise closes
over the inlet and the outlet connections.
2. Loosen and remove body cap.
3. Remove piston spring (60.17), and piston
(60.14). Note that the seat and piston guide
are integral parts of the body (60.1) casting.
Inspect integral seat and guide for excessive
wear, especially at seat surfaces. Replace if
worn, nicked or depressed. If integral seat is
nicked, use seat lapping compound to remove.

IOM-PGR-2
8
contact. (Also lubricate the threads of the
adjusting screw lightly).
15. Set spring button (60.5) onto range spring
(60.15); ensure spring button is laying flat on
top of spring.
16. Rotate the spring chamber (60.2) CW by hand
into the threaded portion of the body (60.1)
ensuring not to cross thread. Continue rotat-
ing CW until firmly seated against the upper
diaphragm. Tighten to 30-35 ft-lbs (41-47
N-m) torque value.
17. Rotate adjusting screw (60.8) CW into the
spring chamber (60.2) to where the nut
(60.11) comes in contact with the top of the
spring chamber. Stabilizer set pressure
should approach the set point prior to removal
from the piping installation. Retighten nut
(60.11).
18. Pressurize with air and spray liquid leak de-
tector to test around body and spring chamber
for leakage. Ensure that an outlet pressure
is maintained during this leak test of at least
mid-range spring level; i.e. 20-80 psig (1.4-
5.5 Barg) range spring, 50 psig (3.4 Barg) test
pressure minimum.
CALIBRATION -
If adjustments are necessary proceed with
the following steps:
1. Install a gauge in optional port downstream
of stabilizer.
2. Establish flow as close to normal operating
conditions as possible.
3. Set stabilizer 8 to 10 PSI above set point
(determined at time of order placement).
4. Adjust pilot to obtain desired P2.
5. If downstream pressure is unstable, adjust
by rotating metering valve in 1/4 turn incre-
ments. NOTE: It is important that 1/4 turn
increments are used due to sensitivity.
The P2changes can be significant in some
cases.
6. Verify that external sensing is tubed to
tap closest to where control of pressure is
desired.

IOM-PGR-2 9
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 regu-
lator 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:
• Type of Service (with fluid properties) • Range of outlet pressure
• Range of flow rate • Range of temperature
• Range of inlet pressure • Range of ambient temperature
Pressure readings should be taken at every location where 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.
Following are some of the more common complaints along with possible causes and remedies.
1. Erratic regulation, instability or hunting.
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 maxi-
mum flow; if necessary, replace with smaller regulator.
C. Metering Valve may not be adjusted correctly.
C. Rotate knob on metering valve in 1/4 turn increments to be more or
less sensitive to changes in P2 pressure. DO NOT fully close the
metering valve.
2. Downstream pressure will not reach desired setting.
Possible Causes Remedies
A. Supply pressure is down (confirm on pressure
gauge.)
A. Increase supply pressure.
B. Undersized regulator. B. Check actual flow conditions; resize regulator for minimum and maxi-
mum flow; if necessary, replace with larger regulator.
C. Pressure loading system pressure restricted. C1. Clean filter.
C2. Clean pilot valve.
D. Faulty loading pressure control device. D. Replace/repair loading pressure control device.
3. Diaphragm continually breaks.
Possible Causes Remedies
A. Stem seals (13) which protect fluorocarbon
elastomer in diaphragm assembly may have
deteriorated.
A. Replace with new stem seals (13).
B. Diaphragm nut (11) may not be torqued to
correct value.
B. Confirm torque value in accordance with Section VII, F-13.
4. Diaphragm continually breaks (all regulators).
Possible Causes Remedies
A. Differential pressure across diaphragm may
have exceeded limits.
A1. Be aware of limits as well as where the various pressures are acting.
Install pressure safety equipment as necessary.

IOM-PGR-2
10
5. Leakage at diaphragm flange.
Possible Causes Remedies
A. Body bolts not torqued properly. A. Torque to proper value (see Section VII, B-9).
B. Pressures at diaphragm may be too high. B. Consult factory.
6. Leakage across seat.
Possible Causes Remedies
A. Contamination (debris) in regulator. A. Remove internals, clean, and if necessary, replace sealing and
seating elements.
B. Oversized regulator; valve plug operates
directly next to seat.
B. Check actual flow conditions; resize regulator for minimum and maxi-
mum flow; if necessary, replace with smaller regulator.
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 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.

IOM-PGR-2 11
Assembled View
The PGR-2 is designed for external sensing. Use 3/8" or 1/2"
(DN10 or DN15) outer diameter tubing to connect the pilot sensing
port to a location in the piping down stream of the main regulator.
If PGR-2 is constructed with self contained feature - tubing and
connection in downstream piping is not required.
PILOT STABILIZER

IOM-PGR-2
12
Item No. Description
1 Body
3 Pressure Plate
5 Body Cap
8 Cap Screw (Flange Bolting)
9 Nut (Hex) (Flange Bolting)
11 Pusher Plate *
12 Diaphragm *
15 Piston *
16 Cylinder *
17 Piston Spring *
18 Cylinder Gasket *
33 Loading Chamber
* Recommended Spare Parts
Main Body Assembly

IOM-PGR-2 13
Item No. Description
30.1 Body
30.2 Spring Chamber
30.3 Body Cap
30.4 Range Spring
30.5 Spring Button
30.6 Pressure Plate
30.7 Seat
30.8 Stem
30.9 Ball Holder
30.10 Retainer
30.11 Return Spring
30.12 Pusher Post
Item No. Description
30.13 Diaphragm *
30.14 Piston Seal *
30.15 Seal Gasket *
30.16 Seal (Body Cap) *
30.17 Adjusting Screw
30.18 Jam Nut
30.19 Flange Bolts
30.20 Body Cap Bolts
30.21 Flange Nuts
30.22 Ball *
53 Name Plate (Not Shown)
55 Filter
57 Metering Valve
* Recommended Spare Parts
Pilot Assembly
Vent to Atmosphere
Sense Port
Pilot Inlet
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be con-
strued as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify
or improve the designs or specifications of such product at any time without notice.
Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Cashco, Inc. product remains solely with the purchaser.
30.20

Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax [phone]
www.cashco.com
email: [email protected]
Printed in USA IOM-PGR-2
Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]
Item No. Description
60.1 Body
60.2 Spring Chamber
60.3 Pressure Plate
60.4 Pusher Plate
60.5 Spring Button
60.6 Body Cap
60.7 Piston Spring
60.8 Adjusting Screw
60.9 Lock Washer
60.10 Nut (Pressure Plate)
60.11 Nut
60.12 Diaphragm *
60.13 O-ring *
60.14 Piston *
60.15 Range Spring
* Recommended Spare Parts
Inlet Outlet
Vent
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]

IOM-PGR-2 15
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-PGR-2
16
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.