Cashco POSR-1 - Manual (Page 5)

IOM-POSR-1 5
4. Place pipe wrench on interconnecting pipe
nipple (19) and rotate CCW (viewed from pi-
lot 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
fi lming. Prob lems here will be an in di ca tion
of improper condensate cor ro sion control
which can affect the overall operation of the
POSR-1. Install an upstream strainer if scale
or debris ap pears at this point.
7. Remove pilot valve (PV) from vise and set
aside.
C. Pilot Valve (PV):
NOTE: Pilot valves (PV) supplied with a 5–15
psig (0.34–1.03 Barg) range spring (15) have
only one di a phragm (12) sup plied; all other
spring ranges use two diaphragms (12).
7. Using a putty knife or similar tool, remove
diaphragm(s) (12) and di a phragm gasket
(13). In spect diaphragm(s) (12) for cracks or
de for ma tion. Radial creases and cracks in di-
cate over pres sure. Cracks circumferentially
in di cate high cycles, and may be due to nor mal
cy cling, or pulsing or chattering if pre ma ture.
Discard both diaphragm(s) (12) and gas ket
(13).
8. Using a 7/8" deep well socket, remove bel lows
(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 fl at, sharp-edged tool, clean body (1)
fl ange where diaphragm gasket (13) seals.
11. Using a wire gauge tool, clean the 0.068"
(1.73 mm) diameter bleed orifi ce located in
the body cavity (smaller of two holes) of any
fi lm or other buildup material that might be
restricting fl ow.
NOTE: Any signifi cant blockage of the bleed
orifi ce will downgrade a POSR-1's per for-
mance. If a buildup is form ing, attempt to de-
termine 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.
WARNING
SPRING UNDER COMPRESSION. Pri or to re mov ing body
fl ange bolts, relieve spring com pres sion by back ing out
the adjusting screw. Failure to do so may result in fl ying
parts that could cause personal injury.
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 ad just ing screw
(19) with locknut (20) aside.
3. Draw or embed a match mark between body
casting (1) and spring chamber casting (2)
along fl anged area.
4. Remove all diaphragm fl ange nuts (18) and
bolts (17).
5. Remove spring chamber (2) by lifting up wards.
Re move range spring (15) and spring button
(16).
6. Remove pressure plate(14). In spect to en sure
that the pressure plate (14) has not been
deformed by over pres sure by placing a
thin, straight bar or ruler across the side that
touch es the diaphragm (12). If the pressure
plate (14) does not touch the bar at its center
(i.e. a depression in center), the pres sure plate
(14) is deformed and must be replaced.