cashco POSR-1 Instruction manual

MODEL POSR-1
PILOT OPERATED PRESSURE REDUCING REGULATOR
SECTION I
I. DESCRIPTION AND SCOPE
The POSR-1 is a pilot operated pressure reducing regulator used to control downstream (P2) pressure. The
POSR-1-20 is a pressure loaded (no pilot) option. Sizes are 1/2", 3/4" and 1" (DN15, 20 and 25). The unit is suitable
for steam service only. Refer to Technical Bulletin POSR-1-TB for design conditions and selection recommendations.
NOT RECOMMENDED FOR DEAD END SERVICE!
SECTION II
II. INSTALLATION
A. General:
IOM-POSR-1
02-16
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)
B. Piping the Valve:
1. An inlet block valve should always be installed.
2. If service application is continuous such that
shut down is not readily accomplished, it is
recommended that an inlet block valve, outlet
block valve, and a manual bypass valve be
installed.
3. Pipe unions are recommended for NPT
screwed installations to allow removal from
piping.
4. An outlet pressure gauge should be located
approximatelytenpipediametersdownstream,
and within sight.
FIGURE 1
Recommended Piping Schematic for POSR-1
FIGURE 2
Recommended Piping Schematic for POSR-1-20
WARNING
Do not dead end (no flow demand) downstream of POSR-1
if P1- Inlet Pressure is greater than maximum allowable
outlet design pressure.
Max. Allowable
Spring Range Outlet Pressure
5-15 psig (0.34-1.03 Barg) 100 psig (6.9 Barg)
10-40 psig (0.69-2.8 Barg) 200 psig (13.8 Barg)
30-80 psig (2.1-5.5 Barg) 200 psig (13.8 Barg)
70-150 psig (4.8-10.3 Barg) 200 psig (13.8 Barg)
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.
PI
SRV
Pilot
Valve
Main
Valve
TR
HP Cond. MP/LP Cond.
TR
PI
SRV
Airset or
Manual Loader
Air
Supply
TR
TR
HP Cond. MP/LP Cond.
Main
Valve
ISO Registered Company

IOM-POSR-12
to a point downstream at gauge location; use
1/4" OD metal tubing for distances 4 ft (1.2 m)
or less, and 3/8" OD metal tubing (requires
1/4" x 3/8" tubing adapter) for distances
greater than 4 ft. (1.2 m). The sensing line
should always be sloped downward so that
condensation will drain away from the pilot.
If regulator pipe line is expanding to a larger
pipe line, always connect sensing line to the
larger pipe line. NOTE: The POSR-1-20 does
not require a sensing line.
10. For best performance Cashco recommends
installing regulator in a well drained horizontal
pipe, properly trapped.
11. Recommended installation is with pilot valve
spring chamber vertical upwards. Orient such
that the spring chamber vent hole does not
collect rainwater or debris.
12. Regulators are not to be buried underground.
13. Forinsulatedpipingsystems,recommendation
is to not insulate regulator.
This increases the loading pressure on
the main valve’s plug and opens valve.
Partially closing the pilot valve’s plug will
reduce its flow to less than the amount
bleeding downstream, and allows the loading
pressure on the main valve’s diaphragm to
decay, allowing partial closing of the main
valve’s plug. This continues until steady-state
is developed.
4. The pilot valve’s diaphragm(s) senses the
downstream (P2) pressure and compares the
force generated to the force developed by the
pilot’s range spring.
5. If, during operation, the downstream (P2)
pressure falls below the pilot valve’s setpoint,
the main valve’s diaphragm senses the
reduced pressure on its underside and instantly
moves down, increasing the flow through the
main valve. At the same time, the pilot valve
5. All installations should include a downstream
relief device if the inlet pressure could exceed
the pressure rating of any downstream
equipment or the maximum allowable outlet
pressure rating of the unit.
6. Clean the piping of all foreign material including
chips, welding scale, oil, grease and dirt
before installing the regulator. Strainers are
recommended.
III. PRINCIPLE OF OPERATION
A. General:
1. The POSR-1 pilot obtains its operating
medium from the main valve body inlet.
Downstream pressure (P2) registers on the
underside of the main valve’s diaphragm and
the pilot valve’s diaphragm(s).
2. The loading pressure on the top side of the
main valve’s diaphragm is an intermediate
pressure higher than the downstream (P2)
pressure by the sum of the pressures required
to overcome the main valve’s plug unbalance
force and the piston spring’s force.
3. The pilot has a bleed orifice that continuously
bleedspart of the loading medium downstream.
In operation, the pilot valve’s plug can flow
more medium than is bleeding downstream.
SECTION III
CAUTION
For welded installations, all internal trim parts, seals and
diaphragm(s) must be removed from regulator body prior
to welding into pipeline. The heat of fusion welding will
damage non-metallic parts if not removed. NOTE: This
does not apply to units equipped with extended pipe
nipples.
CAUTION
DO NOT HYDROSTATIC TEST THROUGH AN INSTALLED
UNIT, INCLUDING PILOT; ISOLATE BOTH PILOT AND MAIN
VALVE FROM TEST. The upper range spring pressure
level listed on the nameplate is the recommended “upper
operative limit” for the sensing diaphragm(s) in the pilot.
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.
7. In placing thread sealant on pipe ends prior to
engagement, assure that excess material is
removed and not allowed to enter the regulator
upon start-up.
8. Flow Direction. Install so the flow direction
matches the arrow cast on the body.
9. The POSR-1 comes factory piped between the
pilot supply and pilot loading. Install an external
sensing line from the 1/4" NPT connection
opposite the factory piped pilot loading port

IOM-POSR-1 3
6. Slowly open the inlet (upstream) block valve
observing the outlet (downstream) pressure
gauge. Determine if the regulator is flowing.
If not, slightly close bypass valve, and then
slowly rotate the pilot valve adjusting screw
clockwise (CW) (viewed from above) until flow
begins.
For POSR-1-20 increase loading pressure
until flow begins.
the loading pressure to decay through the
bleed orifice. The reduced loading pressure
on the upper side of the diaphragm closes
the main valve’s plug enough to restore the
downstream (P2) pressure to the setpoint.
7. Pressure setpoint is adjusted by changing
the compression of the pilot’s range spring by
turning the adjusting screw either clockwise
(CW) or counter-clockwise (CCW). Turning the
adjusting screw clockwise (CW) will increase
the downstream (P2) pressure. Turning the
adjusting screw counter-clockwise (CCW) will
decrease the downstream (P2) pressure.
SECTION IV
IV. START-UP
A. General
1. Start with the block valves closed.
2. Ensure that the needle valve(s) on the sensing
line is opened and downstream (P2) pressure
is indicating on pressure gauge.
3. Relax the pilot valve range spring by turning
the adjusting screw counter clockwise (CCW)
(viewed from above) a minimum of three
(3) full revolutions. This reduces the outlet
(downstream) pressure setpoint.
For POSR-1-20 use manual loading valve to
set minimum loading pressure.
senses the reduced pressure and the pilot
valve’s plug increases its opening, elevating
the loading pressure on the upper side of the
main valve’s diaphragm. The combined actions
increaseflowenoughtorestorethedownstream
(P2) pressure to the setpoint.
6. If the downstream (P2) pressure rises above the
setpoint, the force developed by the increased
pressure on the underside of the diaphragm
instantly moves it upward and partially closes
the main valve’s plug. Simultaneously, the
pilot valve’s plug partially closes and allows
Outlet Pressure - P2
psig (Barg)
Loading Pressure - P3, psig (Barg)
@ P1Minimum @ P1Maximum
5 (0.34) 15 (1.03) 25 (1.7)
50 (3.45) 60 (4.1) 70 (4.8)
100 (6.90) 110 (7.6) 120 (8.3)
130 (8.97) 145 (10.0) 150 (10.3)
135 (9.31) 150 (10.3) – ( – )
4. Slowly open the bypass valve to preheat the
system piping and to allow slow expansion
of the piping. Assure proper steam trap
operation. Closely monitor outlet (downstream)
pressure via gauge to assure 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. Slowly open the outlet (downstream) block
valve until fully open. Slightly close the bypass
valve at same time.
CAUTION
Do not walk away and leave a bypassed regulator
unattended when on manual bypass!
7. Continue to alternate slowly closing the
bypass valve and then slowly opening the inlet
(upstream) block valve, especially when the
downstream piping system isn’t pressurized.
If the outlet (downstream) pressure exceeds
the desired pressure, close the bypass valve
until fully closed. If outlet pressure still remains
above desired level, rotate pilot’s adjusting
screw CCW (viewed from above) in 1/2
revolution increments until outlet pressure
reaches desired level. If outlet pressure is
below desired level, rotate pilot’s adjusting
screw CW (viewed from above) until desired
level is reached.
For POSR-1-20 adjust manual loading valve to
either increase or decrease loading pressure
until desired set point is reached. Do not
exceed limits.
CAUTION
Do not exceed Maximum Loading Pressure limits for P2
set point.

IOM-POSR-14
VI. MAINTENANCE
SECTION V
8. When flow is established steady enough that
the inlet (upstream) block valve is fully open,
begin to slowly close the bypass valve and
continue until fully closed.
9. Develop system flow to a level near its expected
normal rate, and reset the regulator setpoint
by turning the pilot valve adjusting screw
V. SHUTDOWN
A. General
1. On systems with a bypass valve, and where
system pressure is to be maintained as the
POSR-1 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. Close the needle valve on the
pilot valve’s sensing line.
2. If the regulator and system are to both be
shutdown, slowly close the inlet (upstream)
block valve. Close the outlet (downstream)
valve only if regulator removal is required.
Close the needle valve on the pilot valve’s
sensing line.
For POSR-1-20 close manual loading valve
and relieve loading pressure.
4. All indicated item numbers that are with
respect to the Pilot Valve will be in parenthesis
and underscored, i.e. (14), (PV). All item
numbers that are with respect to the Main
Valve will NOT be underscored, i.e. (1), (MV).
5. Refer to Figures 3 and 4 for item number
callouts.
6. Most pilot-operated valve operation problems
center around the pilot valve (PV). Cashco
always recommends full maintenance on any
POSR-1 pilot valve (PV) once a POSR-1 is
removed from the pipeline.
B. Separation:
1. Observe position of pilot valve (PV) with
respect to main valve (MV) before
disassembling.
2. Place main valve body (1) into a vise, oriented
to allow rotation of pilot valve (PV) together
with interconnecting pipe nipple (19).
3. Remove loading tubing (21) at both end fittings
(20) by rotating nut CCW (viewed from tube-
end).
CW (viewed from above) to increase outlet
pressure, or CCW to reduce outlet pressure.
10. Reduce system flow to a minimum level and
observe setpoint. Outlet pressure will rise from
the setpoint of Step 9. There should be no
more than a 10% variation in outlet pressure
over the maximum to minimum flow range.
SECTION Vl
CAUTION
Do not walk away and leave a bypassed regulator
unattended when on manual bypass!
CAUTION
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.
A. General:
1. Maintenance procedures hereinafterare 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. Cashco
recommends not reusing any gaskets, but
replacing with only new and factory supplied
gaskets.
3. This regulator is supplied from the factory
using a gasket sealing aid, Federal Process
Company, PLS 2, or equal. Such compatible
sealing aids may be utilized by the Owner, if
desired.

IOM-POSR-1 5
4. Place pipe wrench on interconnecting pipe
nipple (19) and rotate CCW (viewed from pilot
valve (PV) end) to removal. Remove main
valve (MV) from vise and set aside.
5. Place pilot valve body (1) in vise. Remove pipe
nipple (19) by rotating CCW (viewed from end
of nipple) by pipe wrench.
6. Inspect the inside of the inter-connecting pipe
nipple (19) for corrosion, scaling, debris, or
filming. Problems here will be an indication
of improper condensate corrosion control
which can affect the overall operation of the
POSR-1. Install an upstream strainer if scale
or debris appears at this point.
7. Remove pilot valve (PV) from vise and set
aside.
NOTE: Pilot valves (PV) supplied with a 5–15
psig (0.34–1.03 Barg) range spring (15) have
only one diaphragm (12) supplied; all other
spring ranges use two diaphragms (12).
7. Using a putty knife or similar tool, remove
diaphragm(s) (12) and diaphragm gasket
(13). Inspect diaphragm(s) (12) for cracks
or deformation. Radial creases and cracks
indicateoverpressure.Crackscircumferentially
indicate high cycles, and may be due to normal
cycling, or pulsing or chattering if premature.
Discard both diaphragm(s) (12) and gasket
(13).
8. Using a 7/8" deep well socket, remove bellows
(11) by rotating CCW (viewed from above).
Count and record the number of revolutions
required to remove the bellows (11) in the box
below:
Number of revolutions required to remove
bellows (11):________________.
Inspect the bellows (11) for a crack or joint
failure where leakage is occurring. Replace
bellows (11) if leaking.
9. Remove protruding stem extension (10).
10. Using a flat, sharp-edged tool, clean body (1)
flange where diaphragm gasket (13) seals.
11. Using a wire gauge tool, clean the 0.068"
(1.73 mm) diameter bleed orifice located in
the body cavity (smaller of two holes) of any
film or other buildup material that might be
restricting flow.
NOTE: Any significant blockage of the
bleed orifice will downgrade a POSR-1's
performance. If a buildup is forming, attempt to
determine the cause and remove the source.
12. Remove body (1) from vise and reorient with
body cap (9) on top; resecure body (1) in vise.
13. Remove body cap (9) by rotating CCW (viewed
from above) with hex-end wrench. Hammer-
rapping the wrench may be necessary, as the
body cap (9) has a metal-to-metal shoulder
joint with the body (1). NOTE: Plug (4.2) and
plug spring (7) may come out with body cap
(9) removal.
14. Remove plug spring (7) and plug (4.2) from
body (1) recess.
WARNING
SPRING UNDER COMPRESSION. Prior to removing body
flange bolts, relieve spring compression by backing out
the adjusting screw. Failure to do so may result in flying
parts that could cause personal injury.
C. Pilot Valve (PV):
1. Securely install the pilot valve body (1) in a vise
with the spring chamber (2) directed upwards.
2. Loosen locknut (20) by rotating CCW (viewed
from above) ONLY two revolutions. Relax
range spring (15) by turning adjusting screw
(19) CCW (viewed from above) until removed
from spring chamber (2). Set adjusting screw
(19) with locknut (20) aside.
3. Draw or embed a match mark between body
casting (1) and spring chamber casting (2)
along flanged area.
4. Remove all diaphragm flange nuts (18) and
bolts (17).
5. Remove spring chamber (2) by lifting upwards.
Remove range spring (15) and spring button
(16).
6. Remove pressure plate(14). Inspect to ensure
that the pressure plate (14) has not been
deformed by overpressure by placing a
thin, straight bar or ruler across the side that
touches the diaphragm (12). If the pressure
plate (14) does not touch the bar at its center
(i.e. a depression in center), the pressure plate
(14) is deformed and must be replaced.

IOM-POSR-16
15. Using needle nose pliers, carefully remove
the screen (6) from the body (1) recess.
16. Inspect body cap (9), screen (6), plug spring (7),
and plug (4.2) for buildup or filming. If parts are
“sticking” together, then improper condensate
corrosion treatment is likely. If scale or other
debris is present, then an upstream strainer
is recommended.
17. Using a 5/8" deepwell socket, rotate valve seat
(4.1) CCW (viewed from above) to removal.
18. Remove seat gasket (8) using a tool with a
bent sharp end. Discard the seat gasket (8).
19. Using a sharp edged tool, clean all gasket
surfaces, and metal-to-metal contact surfaces
of body (1), valve seat (4.1) and body cap (9).
20. Lap plug (4.2) with valve seat (4.1) using
a suitable lapping compound. Do for new
replacement plug (4.2) and seat (4.1) also.
21. Solvent clean all loose internal parts of pilot
valve (PV). Inspect the valve seat (4.1) and
plug (4.2) for wear. Replace the valve seat
(4.1) and plug (4.2) together, even if only one
piece shows significant wear. Solvent clean
body (1).
22. Place body (1) into vise with body cap (9)
opening upwards.
23. Place seat gasket (8) into recess.
24. Put thread lubricant onto valve seat (4.1), and
rotate valve seat (4.1) into threaded recess by
rotating CW (viewed from above) until seat
(4.1) shoulders against body (1).
25. NOTE: Replace screen (6) only if necessary.
Using a 3/4" (19 mm) round bar, form and
interlock the flat screen (6) similar to the
removed screen (6) being replaced. Slide
formed screen (6) off of bar. Insert the screen
into the body recess and over the hex points
of the valve seat (4.1). Ensure concentricity
of positioned screen (6).
26. Place plug spring (7) into recess of plug (4.2),
and position plug’s (4.2) stem-end through the
valve seat (4.1).
27. Place thread lubricant on threads of body cap
(9). Capture protruding plug (4.2) end and plug
spring (7) with body cap (9) recess. Rotate
body cap (9) CW (viewed from above) until
shouldering on body (1). Hammer rap wrench
handle to ensure tightness.
28. Remove body (1) from vise and reposition with
diaphragm flange oriented on top.
29. Place thread sealant/lubricant onto threads
of bellows (11). Insert flat-end of stem
extension (10) into the center of the bellows
(11); chamfered end of stem extension (10)
should be protruding bellows (11). Invert
bellows (11) with stem extension (10) into
body (1) recess. Allow stem extension (10) to
“fall” into threaded opening for bellows (11).
Align threaded portion of bellows (11); rotate
CW (viewed from above) the same number
of engaged revolutions recorded in article 8.
previous, this sub-section.
30. Place diaphragm gasket (13) onto body’s (1)
flange aligning cutouts of gasket (13) with bolt
hole openings.
31. Place diaphragm(s) (12) onto body (1)
positioned concentrically. NOTE: Reassemble
pilot valve (PV) ONLY with the number of
diaphragms (12) disassembled with; the 5–15
psig (0.34–1.03 Barg) spring range uses only
one diaphragm (12).
32. Concentrically position pressure plate (14)
onto diaphragm(s) (12).
33. Set range spring (15) over hub of pressure
plate (14).
34. Place multi-purpose, high temperature grease
into recess of spring button (16) where
adjusting screw (19) bears. Place spring button
(16) over top-end of range spring (15) with
greased recess on top side.
35. Clean threads of diaphragm bolting (17) (18).
Place thread lubricant on bolts (17). Engage
two sets of bolting (17) (18) for ease in rotation;
disengage.
36. Placethetwo bolts (17) of above, approximately
180° across through body (1) diaphragm
flange from underneath side. Hold bolts (17)
with fingers of one hand to keep from falling
downwards.
37. Set spring chamber (2) down over the two
protruding bolts (17), aligning the matchmarks
of article 3. previous, this sub-section.
38. Place the two nuts (18) onto bolts (17) of
above, and finger-tighten.
39. Place remaining bolts (17) through spring
chamber (2) bolt hole openings. Engage all

IOM-POSR-1 7
nuts (18) onto bolts (17) along underneath
side of body (1) flange and finger-tighten.
40. Remove the two upside-down bolts (17) and
nuts (18) and rotate to position of other bolts
(17). Place nameplate tag (21) over one of
the bolts (17) before replacing into bolt hole.
Finger-tighten nuts (18).
41. Observe through opening in top of spring
chamber (2) to ensure the concentricity of the
recess in the spring button (16) with the top
opening. It may be necessary to use an awl
or similar tool to realign the spring button (16)
as much as possible. The spring chamber (2)
is not tightened down, and may be temporarily
“shifted” to help ensure alignment for the
adjusting screw (19) engagement.
42. Place lubricant onto the upper exposed
threads of the spring chamber’s (2) adjusting
screw (19) opening. Place lubricant onto
the adjusting screw (19) lower-end threads.
Engage adjusting screw (19) back into spring
chamber (2) by rotating CW (viewed from
above). Engage only until resistance is made
with the range spring (15) via the spring button
(16).
43. Realign the spring chamber (2) flange with the
body (1) flange, and wrench-tighten bolting
(17, 18) in an alternating, crossing pattern.
Final tightening should be done with a torque
wrench to 15 ft.-lbs. (20 N-M).
D. Main Valve (MV):
1. Securely install the body (1) in a vise with the
loading chamber (2) directed upwards.
2. Draw or embed a match mark between body
(1) casting and spring chamber (2) casting
along flanged area.
3. Remove all cap screws (14) and nuts (15).
4. Remove loading chamber (2), diaphragms
(12), diaphragm gaskets (13) and pusher
plate (11). Clean body (1) and diaphragm (12)
flange surface.
5. Rotate cap screws (10) CCW to remove, lift
shield plate (9) out of body (1) cavity.
6. Remove body (1) from vise, rotate body (1)
with body cap (4) directed upwards and re-
secure body (1) in vise.
7. Loosen and remove body cap (4) using a hex
head wrench with a lever length of at least 15"
inches. The wrench should be rapped with a
hammer to loosen.
8. Remove piston spring (6), piston (3.2) and
cylinder (3.1). Inspect parts for excessive
wear, especially at seat surfaces. Replace if
worn.
9. Remove the cylinder gasket (8) and clean
contacting surface in body (1).
10. Clean flat mating surfaces of body (1) to body
cap (4) shoulder.
11. Clean debris from within body (1) cavity and
all parts to be reused.
12. Reinstall a new cylinder gasket (8). Use
the cylinder (3.1) to firmly and evenly press
the gasket (8) into place. Gasket surfaces
maybe lightly coated with pipe sealant prior
to installation.
13. Ensure cylinder (3.1) is concentrical within the
body (1) opening. Slide the piston (3.2) into
the cylinder (3.1).
14. Place piston spring (6) into piston cavity.
15. Apply pipe thread sealant to body cap (4)
threads and screw into body (1). When body
cap (4) shoulder is resting fully down against
body (1), use a wrench with 15" lever handle
and a hammer to impact the body cap (4) tight
WARNING
Never replace bolting (17, 18) with just any bolting if
lost. Bolt heads and nuts are marked with specification
identification markings. Use only proper grades as
replacements.
44. Continue CW rotation (viewed from above) of
adjusting screw (19) until locknut (20) touches
spring chamber (2). Back adjusting screw (19)
out by rotating CCW (viewed from above) two
revolutions. This position will approximate the
pressure setpoint prior to disassembly if the
locknut (20) is only loosened two revolutions as
directed in article 2. previous, this sub-section.
45. Pressure leak test pilot valve (PV) assembly
when rejoined with the main valve (MV)
assembly including interconnecting nipple
(19), tubing (21), and tubing fittings (20).

IOM-POSR-18
into the body (1). NOTE: Metal to metal seal
between body cap (4) and body (1).
16. Remove body (1) from vise, rotate body (1)
with body cap (4) directed downwards and
resecure body (1) in vise.
17. Reposition shield plate (9) in body (1).
Align hole for cap screw (10) with threaded
hole in body cavity. Insert and tighten cap
screw (10).
18. Reinstall the pusher plate (11). Ensure piston
(3.2) post slides into the hole of the pusher
plate (11).
19. Place new diaphragm gasket (13), two
diaphragms (12) and last diaphragm gasket
(13) in that order on body (1) flange. Visually
align these parts on body (1) diaphragm flange.
20. Place loading chamber (2) over the above
stacked parts. Install all cap screws (14) and
nuts (15) and hand tighten. Mechanically
tighten bolting (14 & 15) in a cross pattern
that allows loading chamber (2) to be pulled
down evenly. Recommended torques 15 to
20 ft/lbs.
NOTE: Never replace bolting (14 & 15) with
just any bolting if lost. Bolt heads and nuts
are marked with specification identification
markings. Use only proper grades as
replacements.
E. Reconnecting Pilot Valve (PV) to Main
Valve (MN)
1. Place main valve body (1) into vise, oriented
to allow rotation of pilot valve (PV) together
with interconnecting pipe nipple (19).
2. Place thread sealant on both threaded ends
of interconnecting pipe nipple (19).
3. Insert nipple (19) in main valve body (1). Hand
tighten. Rotate CW (viewed from nipple open
end) to tighten.
4. Rotate pilot valve (PV) CW (viewed from above
pilot valve) into open end of interconnecting
pipe nipple (19). Using a pipe wrench, tighten
the pilot valve (PV) to the main valve (MV) by
turning the pilot valve (PV) until tight and in
proper orientation with respect to each other.
5. Reinstall interconnecting tubing (21) between
main valve (MV) loading chamber (2) and pilot
valve (PV) body (1).
6. Leak test the combined unit per Section VII.
VII. LEAK TESTING
A. General:
1. A POSR-1 is a metal-to-metal seated design
with standard hardened trim in main valve
(MV) and pilot valve (PV).
2. The pilot valve (PV) can be seat leakage tested
without extensive setup.
3. There are two design pressures for a
POSR-1; one for the higher inlet pressure zone,
and another for the lower outlet pressure zone.
Recommended Test Pressures –
Inlet: 100 psig (7.0 Barg).
Outlet: 15 psig (1.03 Barg) for Pilot with
5–15 psig (0.34–1.03 Barg) spring
range.
40 psig (2.7 Barg) for Pilots with
15–150 psig (1.03–10.3 Barg) spring
ranges.
B. Seat Leakage – Pilot Valve (PV):
1. Disconnect tubing (21) that connects the pilot
valve (PV) body (1) to the main valve (MV)
loading chamber (2).
2. Disconnect pipe nipple (19) from main valve
(MV) body (1) and pilot valve (PV) body (1).
3. Remove tube fitting (20) from pilot valve (PV)
body (1) by rotating CCW (viewed from fitting
end).
4. Place temporary pipe plug into 1/4" – NPT
connection (PInt) after removal of fitting (20).
5. Install a hose fitting into the 1/2" FNPT port of
pilot valve (PV) body (1). Connect a length of
rubber hose to fitting. Place the open end of the
hose at the bottom of a jar with approximately
1/8" (3 mm) of water depth at about the same
elevation of the pilot valve PV).
SECTION VII

IOM-POSR-1 9
5. Close needle valve at outlet connection of main
valve (MV). Crack open the needle valve at
the pilot valve (PV) outlet.
6. Rotate adjusting screw (19) of pilot valve (PV)
CW (viewed from above adjusting screw) until
a point of high resistance occurs; this should
correspond to the diaphragm (12) pushing
against the body's (1) down travel stops.
Record the number of revolutions the adjusting
screw was rotated in the box below:
No. of revolutions the adjusting screw
was rotated ______________.
7. Slowly pressurize the inlet of the main valve
(MV) and pilot valve (PV) to 100 psig (6.9
Barg).
NOTE: If the pilot valve (PV) has any other
range spring (15) above 5–15 psig (.34–1.03
Barg), the test pressure can be raised to 200
psig (13.8 Barg).
8. Using a solution of leak detection fluid and
water, apply a liberal amount of the solution
to cover each external joint, including the
threaded fittings (20), tubing (21) and the
interconnecting pipe nipple (19) threaded
connections. Wait a minimum of five minutes to
allow sufficient time for a leak to form bubbles.
Repeat this procedure with a second five
minute wait.
9. Identify and mark any observed leakage.
Disassemble down to the point of leakage
and determine the cause of the leak. Repair
and reassemble per instructions in Section
VI. Retest per Section VII.
10. Shut off pressure to inlet connection of
main valve (MV) and remove all leak testing
equipment. Reset the adjusting screw (19)
back to its normal setpoint by rotating the
screw (19) CCW (viewed from above) the
same number of revolutions recorded in Article
6. previous, this sub-section.
6. Relax the range spring (15) by rotating the
adjusting screw (19) CCW (viewed from above
adjusting screw until fully loose. Keep track
of the number of revolutions in the box below:
No. of Revolutions adjusting screw rotated:
__________________.
7. Connect temporary air supply with in-line
adjustable airset regulator to P2outlet of pilot.
Slowly pressurize the pilot valve (PV) while
observing the jar with water. Bring pressure
to 50 psig (3.4 Barg). Wait a minimum of five
minutes. Observe for leakage of bubbles in the
water jar. If the number of bubbles is greater
than one (1) per minute, the leakage is at the
point where trim replacement is recommended.
(Recommend pressure integrity test per Sub-
Section D. herein.)
8. Remove leak test apparatus. Reinstall brass
fittings (20) using suitable thread sealant.
Reinstall all tubing (21).
C. Seat Leakage – Main Valve (MV):
Seat leakage rate for main valve cylinder
(3.1) and piston (3.2) should be equivalent
to ANSI/FCI 70-2, Class IV (approaches
0.1% of rated valve capacity).
D. Pressure Integrity Leak Test:
1. Test pilot valve (PV) and main valve (MV)
assembled together with all interconnecting
pipe (19), tubing (21) and fittings (20).
2. Insert tapped pipe plugs with hose fittings to
both inlet and outlet body (1) connections.
3. Install temporary hoses with tight shutoff
instrument needle valves at outlet connection
of main valve (MV) and of the pilot valve (PV).
4. Connect temporary air supply with in-line
adjustable airset regulator to inlet connection
of main valve (MV).
VIII.TROUBLE SHOOTING GUIDE
SECTION VIII
Possible Causes Remedies
A. Wet steam or condensate at the inlet. A. Install a steam trap on the inlet side of the regulator.
B. Clogged pilot valve screen. B. Clean or replace. Blowdown inlet drip leg. Install upstream strainer, if
severe.
C. Regulator oversized for flow conditions. C. Install correct size.
D. Insufficiently sloped line. D. Move tap from top of pipe to side; or, increase sensing tube to 3/8" OD.
1. Erratic or Noisy Operation.

IOM-POSR-110
2. Regulator won't maintain downstream set pressure.
Possible Causes Remedies
A. Valve undersized. A. Resize based on actual service conditions.
B. Incorrect range spring. B. Replace range spring. Replace range spring.
C. Failed bellows. C. Replace bellows assembly.
D. Pressure drop less than required 15 psid (1 Bard). D. Contact your Cashco Representative.
E. Insufficiently sloped line. E. Move tap from top of pipe to side; or, increase sensing tube to 3/8"
OD.
3. Leakage through the pilot spring chamber vent hole.
Possible Causes Remedies
A. Defective diaphragm. A. Replace diaphragm.
4. Excessive pressure downstream.
Possible Causes Remedies
A. Main valve or pilot plug not closing. A. Inspect the seating of the main valve and then the pilot plug seating.
Clean or replace. Check seat gaskets; replace.
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.
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-POSR-1 11
FIGURE 3
MV – MAIN VALVE
POSR-1 & POSR-1-20
ITEM NO. DESCRIPTION
1 Body
2 Loading Chamber
3 Cylinder/Piston Subassembly
3.1 Cylinder
3.2 Piston
4 Body Cap
6 Spring
8 Cylinder Gasket
9 Shield
10 Socket Head Cap Screw
11 Pusher Plate
12 Diaphragm
ITEM NO. DESCRIPTION
13 Diaphragm Gasket
14 Cap Screw
15 Nut
16 Nameplate
17 Drive Screw
23 Pipe Plug
Not Shown on Drawing
19 Pipe Nipple
20 Tube Fitting
21 Tubing

ITEM NO. DESCRIPTION
1 Body
2 Spring Chamber
4 Plug & Seat Assembly
4.1 Valve Seat
4.2 Valve Plug
6 Screen
7 Spring
8 Valve Seat Gasket
9 Body Cap
10 Stem
ITEM NO. DESCRIPTION
11 Bellows Subassembly
12 Diaphragm
13 Diaphragm Gasket
14 Pressure Plate
15 Range Spring
16 Spring Button
17 Cap Screw
18 Hex. Nut
19 Adjusting Screw
20 Adjusting Screw Lock Nut
21 Nameplate
25 Bleed Orifice
ITEMS NOT SHOWN
22 Handwheel
23 Locking Lever
24 Spring Pin
FIGURE 4
PV – PILOT VALVE
PInt P2
Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [email protected]
Printed in U.S.A. IOM-POSR-1
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]