120906_manual Minerva.indd
Contents
1. TAINH 1 1 ADVIS LSA HONVTVd NOLSId VAYANIN 1 TIVOS 2 2 C N NOISIAGY 1 0 N 610 0 610 6 tc 1 06N NIAHO 20 21152 CC 1 AANIV LAA 4110 Te 1 06N NIAHO6 O 10 06 1 55 ON 2110 6 1 ONISMOH VITO 96 1 dVO LVds dH 1710 1 LVJS dH 0710 96 1 06N ONIA O FTO 60 0 6 1 dV a TALS CYTO OM 1d 8010 60 0 N 706 10 706 6 CG 6010 0 N NIATO 606 T0 06 1 THAIMS LdOd 6610 61 1 OZN 610 10 610 6 81 1 1 3 9610 Al 5 5 10 Lad THAIMS LETO ST OZN ONIA O 10 1 NOLSId 9510 Al 1 HMO 5 cO LETO 1 NIJdS 4610 1 ddNNIHL HHHSVM 10 1610 OL 1 06N ONIA O OTO 0 6 1 NIVN veld 8 1 510 1 dVO LSNA 8110 9 1 06N 20 1102 g 1 AJALA 5110 1 HO 5510 5 1 HMOA 154 0056 4400 5 5 JONY HMOA TITO I ALO NOILdIJOSdO ON WALI ON LSTI LYVd GCHONWIVEG NOLSId SOL SV 3 1 SERVICE TOOL LIST2. 4 2 DISASSEMBLY OF THE SOPRASsub FIRST STAGE FOR OVERHAUL To view all of the parts used in the SOPRASsub first stage look at the inside front cover of this manual The bracketed numbers in the text refer to the corresponding circled item numbers on the exploded view drawing 4 2 1 Use the 6 and 8 adjustable wrenches to loosen the hose nut from the PORT of 1st stage Remove the hose assembly from the second stage Inspect the hose assembly for any cuts or cracks especially on the hose at the metal ferrules Blow the interior bores of the hoses Replace the hose assembly if any cuts or cracks are found Remove and discard the O rings from each end of the hose Clean rinse and blow dry the interior bores of the hoses Replace the hoses if necessary Note Hose Protectors are easier to slide back from the 1st stage end of the hose if they are twisted and pulled when the hose is still installed in the 1st stage If a hose protector is particularly difficult to pull back try removing the hose and soaking the hose protector end in hot water to soften it up Temporarily reinstall the hose and try pulling and twisting the hose protector again 4 2 2 Put the body into the fixture block or clamp carefully in a soft jawed bench vise Remove the yoke knob assembly 1 from the yoke 2 Use 1 HEX SOCKET to loosen and remove the yoke retainer 3 the dust cap 6 and saddle 7 Note If the regulator has a DIN wheel use
3. Put the swivel washer on the place of the cap 17 and insert the swivel retainer 15 into the cap 17 and then screw to the LP swivel with the cap assembly Tighten the swivel retainer 15 with a 5 16 HEX BIT SOCKET follow the Torque Specifications 4 4 4 Carefully guide the large end of the Piston into the Cap until it bottoms Use a gentle rocking motion if necessary to move the Piston into the Cap but do not cock it at too severe an angle since this may cause the Piston to gouge the sealing surface of the Cap 4 4 5 Support the Body 8 so that the Cap threaded end is facing up Use the same number of Shims 12 10 that were installed in the Spring Cavity when you took the Minerva serial apart there was one shim it goes on the Body side of the SPRING 11 If there were two Shims install one at each end of the SPRING Install the SPRING 11 on top of the Shim 4 4 6 Lubricate the threads on the Cap 17 with grease Put the Cap with its Piston 13 installed over the Spring and Shim sitting in the cavity of the body and screw them together as far as you can by hand Use the install tool can be put the piston into the body more easily 4 4 7 STAINLESS HANDLE BAR screw in hp port Put the body into the fixture block or on the table Use PIN SPANNER to snug the Cap 17 onto the body with 120 140 in Ibs 13 56 15 82 of torque see the photo INSTALL TOOL 4 4 8 Put the style cap 24
4. into the body 8 Install the pre lubricated see 4 4 1 O rings 33 onto the style cap and o ring 25 onto the body Screw the seat cap assembly to the body Tighten the hp seat cap 27 witha 1 4 HEX BIT SOCKET follow the Torque Specifications 4 4 9 Install the yoke retainer 3 into the yoke 2 Install the saddle 7 onto the yoke 4 4 10 Install the new inlet filter 4 and filter O ring 5 into the yoke retainer 3 4 4 11 Hand tighten the yoke yoke retainer into the body Note If the regulator has a DIN connection Install the new filter 4 and filter O ring 5 into the DIN housing 28 Hand tighten the DIN housing 28 into the body 4 4 12 Place the body carefully into a fixture so that the yoke retainer or DIN housing is facing up 4 4 13 Tighten the yoke retainer 3 or the DIN housing 28 with a 1 HEX SOCKET or 13 16 HEX DEEP SOCKET Tighten yoke retainer to 23 25 31 19 33 90 Tighten din housing to 16 18 ft lb 21 70 24 41 4 4 14 Install the new O rings 30 32 into Din retainer 31 4 4 15 Install the DIN wheel 29 into din housing 21 and hand tighten the din retainer 31 into the din housing 4 4 16 Tighten the din retainer with 1 4 HEX BIT SOCKET EE din retainer 31 to 120 130 In Ib 13 56 14 69 4 4 17 ao Install new O rings 20 22 from the kit onto port plugs 21 23 and install the port plugs into the appr
5. FIXTURE HOLDLE AND FIXTURE BLOCK O RING TOOL SET 4MM HEX BIT SOCKET 1 4 HEX BIT SOCKET 1 HEX DEEP SOCKET INSTALL TOOL 13 16 HEX DEEP SOCKET STAINLESS HANDLE BAR TORSION BAR YOKE RETAINER WRENCH SOPRA 4 0 SERVICE PROCEDURES FOR THE SOPRASsub Minerva SERIAL 4 0 1 Before you begin disassembly of the regulator test the first and second stages for output pressures and leakage Pre testing in this way will help the technician to pinpoint any specific problems requiring repair 4 0 2 The work area must be clean and well lighted with clean compressed air available to blow sand and dirt from parts 4 1 TOOLS AND PARTS LIST REQUIRED FOR SOPRASsub SERVICING Fixture block supply from SOPRASsub OR Soft jawed bench vise bench vise with rubber plastic aluminum or plastic jaw inserts PIN SPANNER AND HOLD SOCKET FOR END CAP 17 1 HEX SOCKET FOR YOKE RETAINER 3 4MM HEX BIT SOCKET FOR PORT PLUG 21 23 1 70MM DRILL BIT FOR HP SEAT 26 13 16 HEX DEEP SOCKET FOR DIN HOUSING 28 1 4 HEX BIT SOCKET FOR DIN RETAINER 31 SEAT CAP SCREW 27 5 16 HEX BIT SOCKET FOR SWIVEL RETAINER 15 5 25N M 3 8 TORQUE WRENCH ADJUSTABLE 19 110N M 3 8 TORQUE WRENCH ADJUSTABLE STAINLESS HANDLE BAR Ist STAGE ANNUAL SERVICE KIT CLEAN SHOP RAGS LTI Christo Lube MCG 1299 Dow Corning 111 Silicone Grease Intermediate Pressure Testing Gauge
6. a 1 70MM DRILL BIT Place one end of the drill bit on a flat hard surface Lower the large end of the seat cap over the drill bit until the flat end of the drill bit rests against the back side of the Seat Push the seat cap firmly down straight on the drill bit until the seat is pushed out of the seat cap Discard the old Seat 4 2 7 STAINLESS HANDLE BAR screw in LP port swivel Use a 5 16 HEX BIT SOCKET to remove the swivel retainer 15 and swivel washer 16 Remove and discard the o ring 18 from the cap 17 4 3 Cleaning and Inspection of the 151 Stage 4 3 1 Clean all metal parts of the first stage in an ultrasonic cleaner or cleaning solution See Section 5 3 for recommendations on cleaning solutions Remove the O rings before cleaning any metal parts since the soft O ring material will absorb cleaning energy from the ultrasonic cleaner reducing its effectiveness If major visible corrosion or deposits exist on parts use a bristle brush wooden or plastic stick to rub the deposits off Allowing acidic cleaning solutions to do all of the work if deposits are severe will result in damage to internal chrome plating which will make parts even more susceptible to future corrosion 4 3 2 Remove the regulator parts from the cleaning solution Rinse with clean fresh water then blow internal passageways dry with clean dry compressed air 4 3 3 Inspect all O ring grooves for scratches or wear If the regulator was leaking
7. 15 MINERVA SERVICE MANUAL of If 4 lt SOPRAS www soprassub com 2 0 SPECIFICATIONS SOPRASsub Minerva AIR FLOW 33 cu ft 935 liters min 1 atmosphere INHALATION RESISTANCE 0 9 2 0 2 3 5 08 cm w c 1 atmosphere EXHALATION RESISTANCE 0 6 1 52 cm w c max 1 atm RECOMMENDED LUBRICANT LTI Christo Lube MCG 111 A SOPRASsub FIRST STAGE REGULATOR TYPE siii balanced Piston Regulator swivel WE YOKE 0 88 DIN 0 70 KG INTERSTAGE PRESSURE 135 145 psi 9 4 10 bar 3000 psi inlet 207 bar LOW PRESSURE PORTS 5 3 8 4 UNF HIGH PRESSURE PORTS 2 7 16 20 UNF MATERIALS Body CDA 360 Brass O rings Buna N Seat TEFLON 2 1 Torque Specifications Description 120 140 in Ibs 13 56 15 82 16 18 ftlb 21 70 24 41 can PORT PLUGS 21 23 35 40 In Ibs 3 96 4 52 0 Hose inlet end Hose outlet end 3 0 SERVICE KIT LIST Minerva FIRST STAGE SERVICE KIT PART NO DESCRIPTION 0113 FILTER 3 904 01 HP SEAT qVNgTH g650 dTVOS SHLON 44S 1 dO T 1 4 5 601 5 d Ada ON ONIMVAC NO 1215 NOLSId VAHHNIA 111111
8. a 1 4 HEX BIT SOCKET to remove the DIN retainer 31 and DIN wheel 29 use a 13 16 HEX DEEP SOCKET to remove the Din housing 28 4 2 3 Remove the inlet filter 4 the filter O ring 5 and Din retainer o ring 30 if the regulator is DIN equipped Discard all o ring 4 2 4 Use a 4MM HEX BIT SOCKET to remove all port plugs 21 23 from the body Discard the port plug O rings 20 22 4 2 5 STAINLESS HANDLE BAR screw in hp port Put the body into the fixture block or on the table Use the PIN SPANNER to remove the Cap 17 from the Body 8 Remove any Spacer s 10 12 the Spring 11 and the Piston 13 from the Cap Remove and discard the O rings 14 from the piston Remove and discard the O rings 9 from the body Whenever possible try to remove the O rings by pinching them with the fingers and rolling them out of the groove A WARNING If a sharp pick is used to remove the O rings it should be made from soft brass not steel ANY scratches left in the groove when removing O rings will cause leaks bubbling out of the Cap ambient pressure ports and the piston will have to be replaced to stop these leaks 4 2 6 Put the body into the fixture block again with the hp seat cap 27 facing up Use a 1 4 HEX BIT SOCKET to remove the seat cap 27 Remove the o ring 25 from the body 8 Remove the o ring 33 and style cap 24 Remove the Seat 26 from the seat cap 27 by pushing it out with
9. air because of scratches or wear replace the parts If some corrosion deposits persist carefully wipe them away with a plastic scrubbing cloth or plastic or wooden dowel Blow any resulting dust out of the regulator parts 4 3 4 Closely examine the sealing cones orifices in the piston 13 where the Seat 26 of the Piston seal 4 4 PRELIMINARY ASSEMBLY OF THE FIRST STAGE 4 4 1 To determine the identity of each O ring in the Service Kit remove them from the bag and use the O ring Identification Chart on the front page of this manual each O ring over its corresponding picture on the page and read the description Before installing new O rings into the regulator lightly lubricate the O rings with LTI Christo Lube MCG 129 for enriched air regulators or Dow Corning 111 silicone grease The most effective way to lubricate the kit O rings is to put them in a small plastic bag with a pea sized amount of grease Rub the O rings and grease together in the bag until all the O rings are coated evenly Try not to wipe the lubrication off the O rings when assembling them onto other parts 7 a 4 4 2 Place the hp Seat 26 clean flat surface and press the seat 27 stem straight over the seat until the new seat is installed into the end of the Piston 4 4 3 Install the pre lubricated see 4 4 1 O rings 14 onto the piston O ring 9 onto the body 8 and o ring 18 onto the cap 17
10. opriate ports Use the 4MM HEX BIT SOCKET to tighten port plugs to 35 40 In Ibs 3 96 4 52 UM 4 4 18 Install the dust cap 6 and yoke knob 1 onto the yoke 4 5 SET UP AND TESTING THE FIRST STAGE Note The Minerva serial regulator has a BALANCE piston 1st stage For safety test the first stage regulator with at least one second stage installed The demand valve on the second stage acts as a relief valve in case of a malfunction 4 5 1 Install an intermediate pressure test gauge into one of the low pressure ports of the first stage and a functional 2nd stage into another low pressure port Plug any remaining open outlet ports with suitable port plugs Attach the regulator to a tank valve giving a source pressure of between 2700 and 3000 psig 186 210 Bar NOTE The following test determines the regulator s lock up pressure the pressure put out by the first stage during a no flow condition 4 5 2 Turn the air tank ON by SLOWLY while listening for any unusual air leaks If are heard turn the air off immediately and determine the source of the leak If no leaks are found watch the intermediate pressure gauge reading rise as you continue turning the air on slowly It should stop before 150 psi 10 2 bar 4 5 3 If the pressure gauge continues to rise above 150 psi 10 2 bar turn the air supply off immediately and inspect the regulator to determine the cause 4 5 4 Depress the 2nd stage p
11. rop When the purge cover is released the pressure should return immediately to the proper lock up pressure and stay there 4 5 7 Let the regulator sit with the tank valve turned on for several minutes The intermediate pressure reading may rise about 3 psi in the first three seconds after lock up but after that it should not rise more than another 4 psi 3 bar in five minutes If it rises more than 4 psi refer to the Trouble shooting Section 5 1 of this manual Note Never set the output pressure of the first stage above 150 psig 10 2 bar 50 HELPFUL HINTS 5 1 TROUBLESHOOTING POSSIBLE CAUSE RECOMMENDED ACTION Inlet filter clogged Replace the filter Air supply to 1st stage Verify the supply air pressure Make insufficient sure the customer had the air valve turned all the way on during the dive 1st improperly adjusted Refer to sections 4 5 of this manual A CREEPING INTERMEDIATE PRESSURE stage seat 26 PISTON 13 Seat 26 has not taken Let the Regulator sit with the pressure on shape of PISTON yet for a few minutes and measure pressure again B HIGH FREQUENCY HUMMING OR BUZZING DURING INHALATION POSSIBLE CAUSE RECOMMENDED ACTION Harmonic resonance between the Remove the main spring 11 flip it springs and other 1st stage over and re install components Replace spring or other components until resonance stops
12. urge cover fully then release it several times to clear particles from the regulator and to work the internal parts into place To prevent uncontrolled free flows after pushing the purge cover keep the deflator knob on the second stage in the negative position 4 5 5 The pressure range for Minerva serial Regulators at 3000 psi inlet pressure is 130 150 psi 9 10 2 bar Add Shims in either side of the spring to raise the intermediate pressure Remove Shims to lower the pressure The pressure increase per shim is not linear due to the rate of the spring so no specific increase per spring can be given Generally only add a shim if the intermediate pressure when the cylinder pressure is 3000 psi is below the 130 145 9 10 2 bar range Adding just one shim under these conditions will not push the intermediate pressure above the maximum 150 pressure Do not aim for a specific pressure within the range just add or remove shims to get the pressure within the range The optimal intermediate pressure for Minerva serial regulators is 140 psi 10 bar but any setting between 130 and 150 psi 9 10 2bar at 3000 psi 207 bar inlet pressure will provide good stable performance 4 5 6 After reaching the proper pressure setting push the purge cover on the second stage again several times and watch how the intermediate pressure reading responds When the purge cover on the second stage is depressed the intermediate pressure reading will d
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