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INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

IOM-CA4/SA4

11-13

I. DESCRIPTION AND SCOPE

Models CA4/SA4 are pressure reducing regulators used to control downstream (outlet or P2) pressure. Sizes are

3/4" (DN20), 1" (DN25), 1-1/2" (DN40), and 2" (DN50). With proper trim uti li za tion, the unit is suitable for liquid or

gaseous service. (NOTE: This product was formerly identiﬁ ed as a Model C4 or S4; a Model CA4/SA4 and C4/S4

are one and the same product.)

MODEL CA4/SA4

CA4 and SA4 - ULTRA HIGH PURITY, PRESSURE LOADED

PRESSURE REDUCING REGULATORS

SECTION I

II. REFERENCES

Refer to Technical Bulletin CA4/SA4-TB for tech ni-

cal speciﬁ cations of a Model CA4/SA4 reg u la tor.

ABBREVIATIONS

CCW – Counter Clockwise

CW – Clockwise

ITA – Inner Trim Assembly

SECTION III

SECTION II

III. INSTALLATION

1. Install per direction of ﬂ ow arrow indicated on

body, or "IN" and "OUT" markings.

2. Regulator may be rotated around pipe axis 360

degrees. For ease of maintenance, the rec om-

mend ed orientation is with the loading chamber

(4) upwards.

3. Provide space below, above, and around reg u la tor

for removal of parts during maintenance.

4. Install block valves and pressure gauges to pro-

vide means for adjustment, operation, bypass, or

removal of the regulator. A UHP ﬁ lter is rec om-

mend ed before inlet to remove typical pipe line

debris from entering valve and damaging internal

“soft goods”, primarily the dynamic seal and valve

seat.

CAUTION

Installation of adequate overpressure pro tec tion

is recommended to pro tect the reg u la tor and all

downstream equip ment from dam age in the event

of reg u la tor failure.

CAUTION

DO NOT HYDROSTATIC TEST THROUGH AN

IN STALLED UNIT; ISOLATE REGULATOR FROM

TEST. The "Outlet" rating as printed on the

nameplate is the rec om mend ed “upper op er at-

ing limit” for the sens ing di a phragm. Higher

pres sures could cause internal dam age. In ad-

di tion, note on the nameplate that the Inlet and

Outlet pres sure and temperature ratings are at

different levels.

Recommended Piping Schematic

for Pressure Reducing Station

Summary of content (12 pages)

PAGE 1
INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-CA4/SA4 11-13 MODEL CA4/SA4 CA4 and SA4 - ULTRA HIGH PURITY, PRESSURE LOADED PRESSURE REDUCING REGULATORS SECTION I I. DESCRIPTION AND SCOPE Models CA4/SA4 are pressure reducing regulators used to control downstream (outlet or P2) pressure. Sizes are 3/4" (DN20), 1" (DN25), 1-1/2" (DN40), and 2" (DN50). With proper trim utilization, the unit is suitable for liquid or gaseous service.
PAGE 2
SECTION IV IV. PRINCIPLE OF OPERATION 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. (NOTE: Fluctuations in P1 – Inlet Pressure will cause a deviation in P2 – Outlet Pressure due to inverse sympathetic ratio effect.) See Section VIII. 2. Movement occurs as pressure variations register on the diaphragm. The registering pressure is the outlet, P2, or downstream pressure.
PAGE 3
. Shutoff the outlet block valve. 4. Relieve the trapped upstream and downstream pressure and loading pressure. 5. The regulator may now be disassembled for inspection and preventative maintenance while in-line. SECTION VII VII. MAINTENANCE A. General: 13 19 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. 27.3 3. Refer to Section IX for recommended spare parts.
PAGE 4
in single revolution increments. The regulator contains a lower return spring (22); the ITA should rise as the cage cap screws (18) are backed out evenly. A downward holding force should be applied to the top of the piston-guide bearing (13) to prevent the ITA from popping up as the last threads of the cage cap screws (18) are disengaged. Remove washers (17). 6. Remove the ITA by pulling up on the pistonguide bearing (13). Set ITA aside. 7. Remove the lower return spring (22) from within the body (23). 8.
PAGE 5
E. Reassembly of the ITA: 1. Installation of dynamic side seal (27) (See Figure 1): a. Type CP: 1. Stretch o-ring energizer/seal (27.2) over lower circumference of pistonguide bearing (13), taking care not to “cut” o-ring energizer/seal (27.2). Using thumbs, work the o-ring energizer/ seal into the groove of the piston-guide bearing. NOTE: Use NO lubricants! 2. Position cap seal (27.1) ring with rectangular cross-section at end of piston-guide bearing (13). Stretch cap seal (27.
PAGE 6
5. Units with CTFE or VTFE seat ring (21): Due to the relative "hardness" of the CTFE and VTFE material, to obtain the best possible shutoff it is necessary to generate a "coined" seating chamfer. 6. To coin the seat ring: a. Close-off the outlet connection. b. The level of seat leakage can be quantified at the internal sensing passage. c. Pressurize the regulator's inlet with 50–100 psig (3.5–6.9 Barg) of UHP grade GN2. d.
PAGE 7
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 regulator 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.
PAGE 8
4. Leakage at diaphragm flange. Possible Causes 5. Remedies A. Body bolts not torqued properly. A1. Torque to proper value (see Section VII, F.13). A2. Failed C-ring seal. Replace seal. B. Pressures at diaphragm may be too high for regulator design. B. Consult factory. Leakage across seat. Possible Causes Remedies A. Contamination (debris) in regulator. A1. Remove internals, clean and if necessary, replace sealing seating elements. * A2. Install UHP filter at inlet. B.
PAGE 9
SECTION IX IX. ORDERING INFORMATION NEW REPLACEMENT UNIT VS PARTS "KIT" FOR FIELD RE 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).
PAGE 10
NOTES 10 IOM-CA4/SA4
PAGE 11
NOTES IOM-CA4/SA4 11
PAGE 12
Figure 3: Model CA4/SA4 Item No. 4 9 * 11 12 13 ‡ 15 * 16 17 18 19 20 21 * 22 Description Loading Chamber Diaphragm Flange Bolt Nuts Flange Bolt Piston-Guide Bearing Cage O-ring Seal Shim Cage Washer Cage Cap Screw Cage Valve Plug Seat Ring Return Spring 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. CA4/SA4-IOM Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 4243135 Fax. No.