Instruction Manual

ManualsBrandsCashco ManualsSensorsPOSR-1

MODEL POSR-1

PILOT OPERATED PRESSURE RE DUC ING REGULATOR

SECTION I

I. DESCRIPTION AND SCOPE

The POSR-1 is a pilot operated pressure reducing reg u la tor used to control downstream (P

) 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

12-13

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

B. Piping the Valve:

1. An inlet block valve should always be in-

stalled.

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 in stal la tions to allow removal from

piping.

4. An outlet pressure gauge should be lo cat ed ap-

prox i mate ly ten pipe diameters down stream,

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 ﬂ ow demand) downstream of POSR-1

if P

- Inlet Pressure is greater than max i mum allowable

outlet design pressure.

Max. Allowable

Spring Range Out let 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 pro tec tion is recom-

mended to pro tect the reg u la tor from overpressure and

all down stream equip ment from damage in the event of

regulator failure.

SRV

Pilot

Valve

Main

Valve

HP Cond.

MP/LP Cond.

SRV

Airset or

Manual Loader

Air

Supply

HP Cond.

MP/LP Cond.

Main

Valve

Summary of content (12 pages)

PAGE 1
IOM-POSR-1 INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) 12-13 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.
PAGE 2
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 reguire a sensing line. 5.
PAGE 3
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. 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 increase flow enough to restore the downstream (P2) pressure to the setpoint. 7.
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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. (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. 9.
PAGE 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. 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). 5. Place pilot valve body (1) in vise. Remove pipe nipple (19) by rotating CCW (viewed from end of nipple) by pipe wrench. 7.
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14. Remove plug spring (7) and plug (4.2) from body (1) recess. 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.
PAGE 7
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 nuts (18) onto bolts (17) along underneath side of body (1) flange and finger-tighten. sembly including interconnecting nipple (19), tubing (21), and tubing fittings (20). D. Main Valve (MV): 1. Securely install the body (1) in a vise with the loading chamber (2) directed upwards. 40.
PAGE 8
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 into the body (1). NOTE: Metal to metal seal between body cap (4) and body (1). NOTE: Never replace bolting (14 & 15) with just any bolting if lost. Bolt heads and nuts are marked with specification indentification markings. Use only proper grades as replacemants. 16.
PAGE 9
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 P2 outlet 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.
PAGE 10
2. Regulator won't maintain downstream set pressure. Possible Causes A. B. C. D. E. Remedies Valve undersized. Incorrect range spring. Failed bellows. Pressure drop less than required 15 psid (1 Bard). Insufficiently sloped line. A. B. C. D. E. Resize based on actual service conditions. Replace range spring.Replace range spring. Replace bellows assembly. Contact your Cashco Representative. Move tap from top of pipe to side; or, increase sensing tube to 3/8" OD. 3.
PAGE 11
FIGURE 3 MV – MAIN VALVE POSR-1 & POSR-1-20 ITEM NO. 1 2 3 3.1 3.2 4 6 8 9 10 11 12 IOM-POSR-1 DESCRIPTION Body Loading Chamber Cylinder/Piston Subassembly Cylinder Piston Body Cap Spring Cylinder Gasket Shield Socket Head Cap Screw Pusher Plate Diaphragm ITEM NO.
PAGE 12
PInt P2 FIGURE 4 PV – PILOT VALVE ITEM NO. 1 2 4 4.1 4.2 6 7 8 9 10 DESCRIPTION Body Spring Chamber Plug & Seat Assembly Valve Seat Valve Plug Screen Spring Valve Seat Gasket Body Cap Stem ITEM NO. 11 12 13 14 15 16 17 18 19 20 21 25 22 23 24 Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: sales@cashco.com Printed in U.S.A. IOM-POSR-1 Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No.