Cashco POSR-1 - Manual (Page 8)

IOM-POSR-1 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).
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 di a-
phragms (12) and last diaphragm gasket (13)
in that order on body (1) fl ange. Visually align
these parts on body (1) diaphragm fl ange.
20. Place loading chamber (2) over the above
stacked parts. Install all cap screws (14) and
nuts (15) and hand tighten. Mechanically
tight en 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 specifi cation indentifi cation
mark ings. Use only proper grades as replace-
mants.
E. Reconnecting Pilot Valve (PV) to Main
Valve (MN)
1. Place main valve body (1) into vise, ori ent ed
to allow rotation of pilot valve (PV) together
with in ter con nect ing pipe nipple (19).
2. Place thread sealant on both threaded ends
of in ter con nect ing 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 in ter con-
nect ing 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) be tween
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 de sign
with standard hardened trim in main valve
(MV) and pilot valve (PV).
2. The pilot valve (PV) can be seat leakage test ed
without extensive set up.
3. There are two design pressures for a
POSR-1; one for the higher inlet pressure
zone, and another for the lower outlet pres-
sure 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 fi tting (20) from pilot valve (PV)
body (1) by rotating CCW (viewed from fi tting
end).
4. Place temporary pipe plug into 1/4" – NPT
connection (P
Int
) after removal of fi tting (20).
5. Install a hose fi tting into the 1/2" FNPT port of
pilot valve (PV) body (1). Connect a length of
rubber hose to fi tting. Place the open end of the
hose at the bottom of a jar with ap prox i mate ly
1/8" (3 mm) of water depth at about the same
el e va tion of the pilot valve PV).
SECTION VII