cashco P4 Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-P4
01-17
SECTION I
I. DESCRIPTION AND SCOPE
The Model P4 is a high flow single stage pressure reducing regulator used to control downstream (outlet or P2 )
pressure. Sizes are 3/8" and 1/2" (DN10 and DN15) FNPT or 1/2" (DN15) with Tri-Clamp connections. The unit is
suitable for gaseous service. Refer to Technical Bulletin P4-TB for design conditions and selection recommendations.
SECTION II
II. INSTALLATION
MODEL P4
BALANCED 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 re-
lief device if the inlet pressure could exceed the
pressure 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
installing the regulator. Strainers are recom-
mended.
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.
7. In placing thread sealant on pipe ends prior to
engagement, ensure that excess material is
removed and not allowed to enter the regulator
upon startup.
8. Flow Direction: Install so the flow direction match-
es the inlet stamp on the main regulator body (1).
9. For best performance, install in well drained hori-
zontal pipe.
10. Basic Regulator - (Refer to Figure 2): Regula-
tor may be rotated around the pipe axis 360°.
Recommended position is with knob (4) vertical
upwards.
11. Regulators are not to be buried underground.
12. For insulated piping systems, recommendation is
to not insulate regulator.
Recommended Piping Schematic
For Pressure Reducing Station
P1
Outlet
@P2
SRV
Supply
@P1
Bypass
Model P4
Reducing
Regulator
Blowdown-Drain Blowdown-Drain
ISO Registered Company

IOM-P4
2
SECTION IV
IV. STARTUP
SECTION V
V. SHUTDOWN
1. Movement occurs as pressure variations register
on the diaphragm (7.1). The registering pressure
is the outlet, P2, or downstream pressure. The
range spring (15) opposes diaphragm move-
ment. As outlet pressure drops, the range spring
pushes the diaphragm down, opening the port; as
outlet pressure increases, the diaphragm pushes
up and the port opening closes.
2. A complete diaphragm failure will cause the
regulator to fail open.
The maximum outlet pressure is stamped on the body
as the upper range spring pressure level, and is the
recommended “upper operative limit” for the sensing
diaphragm (see Section IV. Startup, Step 7). Higher
pressures could damage the diaphragm. (Field
hydrostatic tests frequently destroy diaphragms. 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 the range spring (15) by turning knob (4)
counter clockwise (CCW) until rotation comes to
a complete stop.
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 knob (4) clockwise (CW) 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, and reset the regulator set point by
turning knob (4) CW to increase outlet pressure,
or CCW to reduce outlet pressure.
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 by greater
than 10%. Example with 2-100 psig (.14-6.9 Barg)
range spring at low flow the outlet pressure should
not exceed 110 psig (7.6 Barg), if it does, consult
factory).
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.
SECTION III
III. PRINCIPLE OF OPERATION
Do not walk away and leave a bypassed
regulator unattended.
CAUTION

IOM-P4 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 knob CCW until rotation
comes to a complete stop. 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. Refer to Figure 2 for basic regulator and Fig-
ure 1 for the diaphragm subassembly.
B. Diaphragm Replacement:
1. Securely install the body (1) in a vise with
knob (4) directed upwards.
2. Relax range spring (15) by turning knob (4)
CCW until rotation comes to a complete stop.
NOTE: It is not necessary to remove the knob
before removing the spring chamber (6) from
the body (1).
3. Remove spring chamber (6) by grasping the
flats and turning CCW. Upon removal, the
range spring (15), range spring clip (16), and
spring button (5) should remain inside the
spring chamber subassembly.
4. Remove diaphragm subassembly (7) consist-
ing of the actuator nut (7.3), diaphragm (7.1),
actuator post (7.2), actuator gasket (7.4),
actuator o-ring (7.5). Remove diaphragm
gasket (10).
5. Remove actuator nut (7.3) and separate all
parts of the diaphragm subassembly (7).
6. Clean body (1) diaphragm flange surface
and all reusable parts according to owner's
procedures. Do not scratch diaphragm
gasket seating surface. NOTE: On regu-
lators originally supplied as “oxygen clean”,
Option-M, maintenance must include a level
of cleanliness equal to Cashco's cleaning
standard #S-1134. On regulators originally
supplied for Sanitary Service, maintenance
must include a level of cleanliness equal to
Cashco cleaning standard #S-1576. Contact
factory for details.
7. Inspect and replace any necessary parts.
NOTE: Use only parts manufactured and
supplied by Cashco, Inc. for these products.
See Section VIII.
8. Reassemble diaphragm subassembly (7) by
placing the actuator gasket (7.4), diaphragm
(7.1), and actuator o-ring (7.5) over the
threads of the actuator post (7.2). Place a
thread sealant compound on the threads of
the actuator post (7.2) prior to installing the
actuator nut (7.3). Install actuator nut (7.3)
and tighten to the following torque value: 15
Ft-lbs (20 Nm).
9. Place the diaphragm gasket (10) onto the
body (1) diaphragm flange. Place diaphragm
subassembly (7) on top of the gasket (10).
10. Lubricate the threads of the body (1) with
a lightweight grease that is compatible with
service use. Rotate the spring chamber (6)
CW by hand onto the threaded portion of
the body (1) until firmly seated against the
diaphragm gasket (10). Tighten to the follow-
ing torque value: 65–70 Ft lbs (88–95 Nm).
11. Pressurize with air and spray liquid leak de-
tector around body (1) and spring chamber
(6) to test for leakage. Ensure that an outlet
pres
sure is maintained during this leak test
Figure 1: Diaphragm Subassembly
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-P4
4
of at least mid-range spring level; i.e. 2-100
psig (.14-6.9 Barg) range spring, 51 psig
(3.5 Barg) test pressure minimum.
C. Trim Replacement:
1. Remove spring chamber (6) and diaphragm
subassembly (7) per Section VI, Steps B.1.–
B.4.
2. Remove seat retainer (13) by turning CCW.
3. Remove poppet (8) and poppet spring (9).
4. Remove o-ring (11) and back-up ring (17).
5. Clean debris from within the body (1) cav-
ity. Clean all parts to be reused according
to owner's procedures. NOTE: On regula-
tors originally supplied as “oxygen clean”,
Option-M, maintenance must include a level
of cleanliness equal to Cashco's cleaning
standard #S-1134. On regulators originally
supplied for Sanitary Service, maintenance
must include a level of cleanliness equal to
Cashco cleaning standard #S-1576. Contact
factory for details.
6. Inspect all parts for damage and replace if
necessary. NOTE: Use only parts manufac-
tured and supplied by Cashco, Inc. for these
products. See Section VIII.
7. Place poppet spring (9) into body (1) cavity.
8. Place new o-ring (11) and back-up ring (17)
onto poppet (8).
9. Place poppet (8) inside the poppet spring (9).
The angled seating surface of the poppet
must face up toward the seat (12).
10. Install new seat retainer (13) with seat (12)
into body (1) cavity with the seat facing down-
ward toward the angled seating surface of
the poppet (8). Tighten seat retainer to the
following torque value: 12 – 15 Ft-lbs (16 – 20
Nm).
11. Reinstall diaphragm subassembly and spring
chamber subassembly per Section VI, Steps
B.9. – B.10.
12. 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.
13. Pressurize with air and spray liquid leak de-
tector around body (1) and spring chamber
(6) to test for leakage. Ensure that an outlet
pressure is maintained during this leak test
of at least mid-range spring level; i.e. 2-100
psig (.14-6.9 Barg) range spring, 51 psig
(3.5 Barg) test pressure minimum.

IOM-P4 5
SECTION VII
VII. 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.
A4. Install next step higher range spring.
A5. Before replacing regulator, contact factory.
B. Worn poppet; inadequate guiding. B. Replace trim ( possible body replacement).
C. Weakened/broken poppet spring. C. Replace poppet spring. Determine if corrosion is causing the
failure.
2. Regulator can't 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. Incorrect range spring (adjusting aluminum knob CW does not
raise pressure to proper level).
B. Replace range spring with proper higher range.
C. Too much droop. C1. Review droop expected.
C2. Contact factory.
3. Sluggish operation.
Possible Causes Remedies
A. Fluid too viscous. A. Heat fluid. Contact factory.
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 diaphragm movement. D. Ensure no moisture in spring chamber at temperatures below
freeze point.

IOM-P4
6
SECTION VIII
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–
VIII. 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-P4 7
Figure 2:
Repair Parts
Item No. Description Kit B
1 Body
2 Adjusting Screw
3 Knob Nut
4 Knob
5 Spring Button
6 Spring Chamber
7 Diaphragm Subassembly
7.1 Diaphragm -----------------------‡‡
7.2 Actuator Post
7.3 Actuator Nut
7.4 Actuator Gasket -----------------‡‡
7.5 Actuator O-ring ------------------‡‡
8 Poppet --------------------------------- ‡‡
9 Poppet Spring ----------------------- ‡‡
10 Diaphragm Gasket ----------------- ‡‡
11 O-ring ----------------------------------‡‡
12 Seat ------------------------------------ ‡‡
13 Seat Retainer ------------------------ ‡‡
15 Range Spring
16 Spring Clip
17 Back-up Ring-------------------------‡‡
21 Inline Filter---------------------------- ‡‡
39 Snap in cover
‡‡ Recommended Spare Part

IOM-P4
8
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-P4 9
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. P4-IOM
Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]
Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]
indicating the gauge is compliant with the ATEX Directive (See items 26, 27, and 28 in Appendix A). Until compliance
is determined, regulators should not be ordered with pressure gauges for use in potentially explosive environments.
3. Tied diaphragm regulators with outlet ranges greater than 100 psig should be preset to minimize the risk that improper
operation might lead to an outboard leak and a potentially explosive atmosphere (See item 6 in Table 1).
4. Regulators must be ordered with the non-relieving option (instead of the self-relieving option) if the process gas they are
to be used with is hazardous (flammable, toxic, etc.). The self-relieving option vents process gas through the regulator
cap directly into the atmosphere while the non-relieving option does not. Using regulator with the self- relieving option
in a flammable gas system could create an explosive atmosphere in the vicinity of the regulator.
5. Regulators with customer supplied parts are to be assumed to not have been evaluated with regard to ATEX and thus
are not to be used in a potentially explosive environment unless a documented evaluation for the specific customer
supplied parts in question has been made. Refer to Table 1 for all models and options that have been evaluated.
Product Usage
A summary of ATEX related usage issues that were found in the assessment are listed below.
1. Pressure regulators and control valves must be grounded (earthed) to prevent static charge build-up due to the flowing
media. The regulator can be grounded through any mounting holes on the body with metal to metal contact or the
system piping can be grounded and electrical continuity verified through the body metal seal connections. Grounding
of the regulator should follow the same requirements for the piping system. Also see item 30 in Table 1.
2. The system designer and users must take precautions to prevent rapid system pressurization which may raise surface
temperatures of system components and tubing due to adiabatic compression of the system gas.
3. Heating systems installed by the user could possibly increase the surface temperature and must be evaluated by the
user for compliance with the ATEX Directive. User installation of heating systems applied to the regulator body or
system piping that affects the surface temperature of the pressure regulator is outside the scope of this declaration and
is the responsibility of the user.
4. The Joule-Thomson effect may cause process gases to rise in temperature as they expand going through a regulator.
This could raise the external surface temperature of the regulator body and downstream piping creating a potential
source of ignition. Whether the Joule-Thomson effect leads to heating or cooling of the process gas depends on
the process gas and the inlet and outlet pressures. The system designer is responsible for determining whether the
process gas temperature may rise under any operating conditions. If a process gas temperature rise is possible under
operating conditions, then the system designer must investigate whether the regulator body and downstream piping
may increase in temperature enough to create a potential source of ignition.
The process gas expansion is typically modeled as a constant enthalpy throttling process for determining the temperature change.
A Mollier diagram (Pressure – Enthalpy diagram with constant temperature, density, & entropy contours) or a Temperature –
Entropy diagram with constant enthalpy lines, for the process gas, can be used to determine the temperature change. Helium
and hydrogen are two gases that typically increase in temperature when expanding across a regulator. Other gases may
increase in temperature at sufficiently high pressures.
Product Declaration
If the above issues are addressed by selecting options that do not have potential sources of ignition, avoiding options that
have not been assessed, and by taking the proper usage issue precautions, then Cashco regulators can be considered to be a
mechanical device that does not have its own source of ignition and thus falls outside the scope of the ATEX directive.