XSTREAM SERVICE MANUAL
Contents
1. 565 4001 dasp 2001 xx 3M 9287 JM 9 S N 9 Sf W9 9 S 9 87 uonenpjo sap 66 1GGT daap scoop 11 SERVICE MANUAL XSTREAM Customer 1st stage G 5 8 Xstream DEEP90 4751 BK 1st stage G 5 8 Xstream DURATION90 5 2 001 85 1st stage G 5 8 Xstream DURATION9O 4751 GN 1 st stage G 5 8 Xstream DIVE90 DEEP9O 5 2 1 st stage Xstream DURATION9O EN 144 3 4752 VPVI NA OGUOREANO uleeJ sg N SSST x 06uomneinp 565 2813 06 Alp 06d p 79 2 PFL Ng 06UoneJnd 4 weasx o u 6 ureensy 8 99 IPSUM NO 9 S las F x 0892 yoelq 8 99 8 9 7 b 06uoneund yyqaq Buu O SS c8Z c 06 AIq 06d q B5uu o 2812 sod 8 E4NN MaJospullg 6197 06uoneund voya Duu O 6S 816c 06 AIq 06d q Duu o 8163 9L Z 4NN Me4ospuijg 0892 malos 1nueunsn pv 30 86 y9e q mesos JUSLUISN PV ME 8627 sod uieeJjsy OLXE N JeA09 MeJos DLUOJUO BE1S 1S ueeJsy 4102 2927 yoelq apes s uieeJsy Mg 9 p ueeJD ueeJsy ebeis Jeuueg N5 0 Gr yorjq ueesy e6eis yg 0 Sr wco rr uealsx oD01s Buiusnq uld g9Sr AP uoneunq i ME me am LI 06 Alp 06d p HA 0LSF 06 AIq 06d q Hi H2 49 1 Na 06uoneind eDejs was uuoO 2 06uone n2. p2 gt 7 5 bar 109psi Lower test pressure p3 p3 20 bar 290psi Stabilized outlet pressure p4 op1 Stabilzed oulet pressure after flow Q1 ceases often referred to as Interstage pressure or Intermediate pressure Figure is taken at p1 Unaqjustable 8bar lt p4 p1 lt 11bar 116psi lt p4 p1 lt 160psi Adjustable 8 4bar lt p40p1 lt 8 6bar 122psi lt p40p1 lt 125psi Stabilized outlet pressure p4 p3 Stabilzed oulet pressure after flow Q1 ceases often referred to as Interstage pressure or Intermediate pressure Figure is taken at p3 Unaqjustable 8bar lt p4 p1 lt 11bar 116psi lt p4 p1 lt 160psi Adjustable 8 4bar lt p40p1 lt 8 6bar 122psi lt p4 p1 lt 125psi Outlet pressure p5 Highest or lowest value of the outlet pressure see figure during a test where the inlet pressure varies from p1 to p3 for a flow equal to the standard discharge Q1 p5 is taken at 20 50 bar 290 725 psi p5 gt 7 5 bar Irregularity coefficient balance i The coefficient i is defined by i P4 p1 p4 p3 i 1 1 bar 16psi Coefficient of pressure increase upon closure R The coefficient R is defined by R p4 p2 R max 1 bar max 15psi Standard discharge 01 Corresponds approximately to a very light breath from the second stage Q1 2 L min 0 07 ft min Leakage Leakages above 12ml h is regarded as a leak Judgement shall be made after 1 minute of settl
3. ro remove o rings ONLY use o ring remover tool 2297 Make sure not to damage o ring and sealing surfaces Xstream first stage Step Parts Tools Instructions Replace Picture All first stages 2680 Blindscrew UNF 7 16 1 or 2 pcs 2679 Blindscrew UNF 3 8 2 3 or 5 pcs 1246 Allen key 5 mm i n u rr i 4568 Screw M3x10 Xstream 3 pcs 4767 BK Cover Xstream first stage black 4767 CE Cover Xstream first stage chrome 4766 Press spring 1 stage Xstream Step Parts Tools Instructions Replace Picture 4565 Pressure plate 1 stage Xstream 4570 BK Barrier 1 stage Xstream black 4570 WE Barrier 1 stage Xstream white 4570 GN Barrier 1 stage Xstream green a l A d 1 d 1 F a m b _ a a y A m iz A _ gt 1 x a r a m i ho M i F Am Thy l mAr y wes ui poz 1 iz Pm F 1 P F 14 1 E 3 I 1 i F 1 m des i 4 i a A r gt el d i pr y 5 a Wm A i ULA F em z v 1 R 2 a a pere F fy a z 1 a el 7 ET 1 Eu i 1 f F de a j 3 P si dl 1 k i i r a i A 2 l 4 P ir ry i a bf E j k a if y r V J i _ 7 f a 1 P a a R y du F em a hae e a 4 R i a 7 i y Ui po
4. 0 4824 Servicekit Xstream Duration90 1 st stage ncluded 758 de 552 de 563 de 782 55 918 59 557 59 de 423 de 007 59 de o o O o 4828 Servicekit Xstream Duration90 EN 144 3 1 st stage ncluded OC OJO o 758 552 DC DC 782 55 D 918 59 D 557 59 pe 423 DC 807 59 DC INISN I O 4825 Servicekit Xstream 2nd stage ncluded DC Rubber plate 145 DG 233 55 DC 856 59 DC 876 55 DC 896 55 oc NIN N 09 JO NIN Xstream Upgrade Kit 4826 Xstream upgrade kit for models below s n 310001 Included 423 dE 563 Pin bushing 1st stage Xstream Valve seat holder Xstream______________ tpc Lower pin guide Xstream________________ ltpc Upper pin guide Xstream_______________ tpc Stainl washer 1 stage Xstream______________ lt pc Sola aa Ja a IS Ia Co 10 EN oy l Servicing a Xstream 90 model leaves you 1 pcs washer 4581 4767 KIT Xstream adjustment kit for Xstream 1st stages with no adjustmentscrew Included 4767 CE Xstream 1st stage cover 4798 CH Adiustment screvv 4766 Adiustment spring 4761 Fits all Xstream 1st stages rd qiy 1 EN E NUAL XSTREAM FN SE Z EF YF mal 1 Y 1 away 15 Wai Xstream EN 144 3 upgrade kits 4880 GN Xstream Duration EN 144 3 kit Included 4851 GN Xstream Duration90 EN 14 3 kit Included 4878
5. 3 screws Used to untighten and tighten the connection stem on Xstream first stages 4594 Handle UNF 3 8 Used to hold straight Xstream models vvhen untightening and tightening the connection stem Used to unscrevv and screw Jetstream second stage cover 4 screvvs 2895 Screvv driver Pozi 1 2112 Assembly tool Used to mount together the metal cover and the metal housing and at the same time mount the locking ring on all Cyklon second stages 2299 Drift for LP valve Used to hold together the LP valve and the spring in the Cyklon second stage when mounting the locking ring To be placed on a table and with the 2299 drift inserted Gives you a greater force when holding together the Cyklon LP valve 3138 Holder for drift 2299 1304 Avvl Used vvhen removing locking rings 8510 Allen key 1 27 mm Used to adiust the cracking pressure on Triton second stages 8510 Allen key 1 27 mm qu 3758 Assembly fixture Used when inserting o rings into Triton second stage svvivel 3761 Allen key 4 mm 2215 Allen key 6 mm Screw driver 3 5 5 5 short 8 5 mm d J ens 2894 Test fixture for LP valve SIT tam 4593 Allen YNYD 2 5 m a teen trata ara 2714 Allen 3 mm Screw driver Pozi 1 2299 Drift for LP valve 4 1 3138 Holder for 2299 1304 Aw 3758 mi fixt Customer 3761 Dismounting tool Triton 4461 Drift 4463 Torque vvrench head To be used vvhen tight
6. the use of oxygen is essential for the human metabolism In addition oxygen concentration levels greater than in air can improve safety especially but not only by lowering the risk for DCS and Nitrogen narcosis Therefore Poseidon has taken every precaution using state of the art technology expertise industrial standards and knowledge to lower the risk as far as possible Both Xstream Deco and Xstream Duration are engineered for oxygen use assembled and cleaned in a clean room environment made up by materials chosen to expose lowest possible risk x failure effect product and are tested and approved for oxygen use It is strictly prohibited to use the Poseidon Xstream Deco Duration with oxygen ref definitions without being fully trained and certified in the use of oxygen by a recognised training agency Failure to have such training and certification could lead to death or serious personal injury It is likewise absolutely essential that the end user strictly follows the mandatory guidelines given in the users manual for the Xstream models Regular maintenance servicing and cleaning is a prerequisite for keeping the risk as low as possible Servicing and cleaning must be carried out by an authorised oxygen service dealer Poseidon has developed and verified a servicing and cleaning method which guarantee acceptable levels of contaminations Poseidon can not be held responsible for the effects of other un verified cleaning a
7. Connection stem Xstream Duration90 EN 144 3 4807 59 O ring EN 144 3 4876 GN Wheel Xstream Duration EN 144 3 4552 Cup type filter long Xstream 90 2918 59 4880 WE Xstream Deco EN 144 3 kit Included 4807 59 AL XSTREAM 6 Service The parts that needs to be replaced during a service are described in the Spare parts amp Servicekits section of this handbook Make sure that you have servicekits for the corresponding model and that you have all special tools required available The tools required are described in the Tools section of this hand book A For instructions on how to service the regulator follow the instruction below until you reach the GO TO FINAL INSPECTION text at the end of the instruction The instructions in this handbook must be followed in detail step by step Negligence can cause serious injury or even death A service includes the following 5 steps Complete disassembly of the first stage and second Inspection of disassembled parts Cleaning prior to assembly Assembly Final inspection and adjustment please refer to section 7 of this handbook 84 A Al bo not disassemble the regulator in the clean room environment All parts shall be taken to the clean room environment after inspection and after the pre cleaning process if such is needed Othervvise you risk to contaminate the clean room environment New parts should be stored in it s original packing until it is time for assembiy
8. always a possibility that the customer has altered the colors himself why it is important always to check the permanently marked article number as part of the identification of the product The pictures below show where to find the article and serial number 4790 BK 002 10 Xstream Deep Xstream Deep 4 1 4791 BK 001 47 Xstream Deep90 Xstream Deep90 5 2 4790 GN 002 13 4882 GN I 4791 GN 001 87 4881 GN 4792 YW Xstream Dive Octopus CE 0120 Meets or exceeds requirements in EU Directive 89 686 EEC Personal Protective Equipment Manufacturing assessment carried out by notified body SGS Yarsley ID no 0120 4790 BKModel identification E g 200001 Serial number 7 digit 1st digit denotes year of manufacture WP 300bar Working pressure 300 bar Oxygen Approved for use with 99 95 oxygen Nitrox 50 Approved for use with maximum 50 oxygen Service hamdbook gt This servicing handbook is available for download at the Extranet at http www poseidon se Make sure you have the latest issue before undertaking any servicing The handbook is available in English only Further assistance can be reached between 8 00 am to 4 30 pm GMT 1 at Poseidon Diving Systems Ph 46 0 31 7342900 ask for technical assistance Fax 46 0 31 7342901 e mail info poseidon se 1 Remove old part Destroy and give back to customer Replace vvith nevv part Visually inspect l Poseidon grease 1 article n
9. e 4 A E 2 5 x m f a f ES a ru 4538 BK 4538 VVE 4538 GN 4538 YVV 4538 GY Tools Instructions Servo valve Xstream Firm by hand Checkvalve Diaphragm silicone Diaphragm cover Cover Xstream 2nd stage Deep Cover Xstream 2nd stage Deco Cover Xstream 2nd stage Duration Cover Xstream 2nd stage Octopus Cover Xstream 2nd stage Dive Install valve tube Mouthpiece AIR 60 TO FINAL INSPECTION ONLY IF REPLACED Replace ru y W F 3 x k x x lt y lll il 1 F lt y A 3 FAN 4 1 fos m 1 4 _ a 1 j a 2 w 4 P F J s L w 1 i j 1 Li Qe 1 i 5 i 2 1 F he 1 7 a il 1 r k F 1 J j FF k P 1 y j 7 f im rz E 4 he l hy fa P i 1 4 R ML r FN i i i i r Al I I i 1 1 I 4 Y Fn myn he A a i a m w yh Y s LA L i L i m E 1 i 1 Y 1 j ar T 1 1 4 7 4 1 b i 1 1 i m 7 a 1 4 4 Y 1 i i L L i 1 4 gt s L Z 1 x si i L i a 1 i 1 2 1 h 4 Y h i hny a i a 1 1 L 4 1 L WI i 1 i i Yy AN y ri AA L m o T 7 Final inspection final i i Pr
10. once a year either by a service technician or by a from Poseidon appointed auditor The checklist in Appendix D should be used to make sure that all criterias are fulfilled For detailed instructions on hovv to perform and audit please refer to Appendix D Preparat ons and Pre clean ng 1 These preparations and the pre cleaning shall NOT be conducted in the clean room since it may then contaminate the clean room 2 If any part is visibly contaminated it shall be pre cleaned including the parts listed below which shall not be ultra sonic cleaned 3 Only undertake the pre cleaning if you are sure you can move on to the cleaning stage immediately after If the parts dry between the two stages of operation undesirable deposits can be left on part surfaces XSTREAM 6 SERVICE 4 Bag the parts below in a plastic bag for later assembly These parts shall not be ultra sonic cleaned 5 Use IPA and a toothbrush to agitate away all visible contaminants Rinse part s in municipal running water until all visible soil particulate and cleaning agent is removed When using IPA make sure you have sufficient ventilation Please refer to the safety instructions of the IPA 6 Use air of any quality to blow dry THE PROCESS BELOW SHOULD BE PERFORMED OUTSIDE THE CLEANROOM AREA Cleaning Wash your hands before this cleaning process Always ensure the UltraSonic cleaner is absolutely clean inside Fill the UlraSonic cleaner with Poseidon FineC
11. requirement for cleanliness this manual takes precedence Some methods equipment and detergents which are not mentioned in this manual can have a harmful or unknown effect on materials such as e g ozone cleaning systems strong acids etc and shall therefore be discarded The other standard procedures that can be used given the limitations above are EAN and Oxygen Servicing Procedures Fourth Edition ANDI IANTD Gas Blender amp Service Technician Program First Edition August 1999 MIL STD 1330D SH of the 20 September 1996 A The safety of your customer and yourself depends on you carefully and strictly following these instructions Negligence in any step can cause serious injury or even death A You must be certified by Poseidon as oxygen technician to undertake this procedure A Keep hands and tools clean and free from grease except for what is required and stated in this manual A Use protective clothing to prevent dust fingerprints hair and particles to contaminate A Use only dedicated and cleaned tools A Ensure your oxygen handling is in conjunction with national laws A Ensure no foreign contaminants such as e g liquids grease particulate dust and mist can enter into the cleanroom area The cleanroom area and work environment requirements The cleanroom area and vvork environment should be setup according to minimum demands listed in Appendix D A cleanroom area and work environment audit should be performed
12. ring 2nd stage Xstream EPDM 2297 O ring remover 2876 55 O ring 2nd stage Xstream EPDM 2297 O ring remover Vavle housing nut Xstream 3605 Combination tool 1 1 3606 Combination tool 2 L F F La a Rubber plate 2297 O ring remover 1233 55 O ring 2nd stage Xstream EPDM 2297 O ring remover 2297 O ring remover Valve insert 3606 Combination tool 2 2856 59 O ring Xstream 2nd st viton 2297 O ring remover Step Parts Valve insert Checkvalve Valve tube Xstream Servo valve Xstream Housing 1 stage 90 Xstream Housing 1 stage Xstream Roll diaphragm 1 stage Xstream Blindscrew UNF7 16 Blindscrew UNF3 8 Inspect 1 Ensure no circular cuts on bladder surface 2 Check O ring sealing surface 1 Check for damages on check valve edge 1 Check O ring sealing surfaces 1 Make sure not bent 1 Check sealing surfaces 1 Check sealing surfaces 1 Check for wear and tear 1 Check O ring sealing surfaces Picture XSTREAM Step Parts Inspect Picture Conn stem 1 stage Xstream 1 Check O ring sealing surfaces Conn stem 1 stage Xstream EN 144 3 Deco EN 144 3 Duration EN 144 3 Conn stem 1 stage 90 Xstream 1 Check O ring sealing surfaces Conn stem 1 stage Xstream EN 144 3 Duration90 EN 144 3 6 SERVICE ERI MANUAL XSTREAM Gleaning 60 U Xstream Deep Dive Cleaning A Make absolutel
13. 0bar Purge Check IP go to 9 if OK Close right valve N 3 al Purge Adjust IP 1 2 turn 1 5 bar Open right valve 8 Check IP loop to 4 9 Close right valve 10 Purge 11 Open left valve 20 bar 12 Check IP 13 Close left valve 14 Purge A 1 A o NJ 1 Open either left or right valve whichever gave the lowest IP 2 Check cracking pressure 3 Adjust cracking pressure 4 Close valve 5 Purge 36 SERVICE MANUAL XSTREAM 7 FINAL INSPECTION D 1 Hold the mouthpiece part of the cracking pressure gauge tight to the outlet of the 2 4 stage 2 Take a few rather slow and long inhalations from the mouthpiece part and simultaneously check the pressure gauge needle t shall during inhalation reach a maximum of 28 40 mm w c and at the end of the inhalation decrease again If the reading is too high unscrew the stopscrew as shown in the illustration below right Screw the valve tube away from the diaphragm as shown in illustration to the right If the reading is too low screw the valve tube towards the diaphragm Once the reading is correct tighten the stopscrew and then doublecheck the reading 3 Alternatively immerse the 2 stage as shown in the illustration A sizzling sound from the servo valve opening shall occur within the two markings TIP Some divers like the setting extremely light and some prefer a higher cra
14. A k j j a La F ta ir P x 3 a i a e A n al R T h h 3 a h h i J i i b a r P d y X a bu r r P i y gt gt gt o a nn r r hu a i k r m 7 nts i a r r r Li 4 f 4 8507 Oxygen grease 2 Deep Dive 3605 Combination tool 1 PN y i LL grease Deco Duration 6507 Oxygen grease 2 Deep Dive PN y grease Deco Duration PN R 6507 Oxygen grease 2 Deep Dive PN y 8516 Regulator grease Step Parts 2876 55 2876 55 1896 55 1896 55 2875 Vavle housing nut Xstream O ring 2nd stage Xstream EPDM O ring 2nd stage Xstream EPDM O ring 2nd stage Xstream EPDM O ring 2nd stage Xstream EPDM Valve tube Xstream Rubber plate Stop screvv Tools Instructions 3606 Combination tool 2 K Deco Duration 8507 Oxygen grease 2 El nU E 1 hl Deep Dive 8516 Regulator grease Deco Duration 6507 Oxygen grease 2 Deep Dive 8516 Regulator grease 2297 O ring remover va v VXxXOXoX X 2706 Allen key 1 5 mm Replace ru y y um um ds y es F Rz a r En A j j F my F 3 j 1 i si 4 iL i i L f y s i F 1 1 J F F P P P i P F j
15. Conn stem 1 stage Xstream 4871 Conn stem 1 stage Xstream EN 144 m Hindis UNE IE 3 Duration EN 144 3 Deco EN 144 3 st 4591 17mm borgas wrench bad NTI Torque wrench eet ised 774 3772 3118 Fal mr k A l ie ETT kaskas psl indebi koii T men an AS ETI Targus reach H im UI EE nn iam dim Use handle to hold first stage Torque setting 30 Nm Refer to section 9 for other units 1007 59 O ring viton Deco Duration 4807 59 O ring viton EN 144 3 Deco EN 144 3 Duration EN 144 3 1007 O ring Deep Dive ru R PN R All first stages 4555 Spring for ball Xstream 4556 Ball 1 stage Xstream 4760 Valve seat holder Xstream 4758 Zytel valve seat Xstream 4761 Valve seat spring Xstream Pin guide assembly Deco Duration 8515 Oxygen grease 1 j ar ij r i ki fi I gf nf i n TH l TH l E FU j ym i 6 1 Nm Refer to section 9 for other units Step Parts Pin guide assembly 4564 Roll diaphragm 1 stage Xstream 4570 BK Barrier 1 stage Xstream black 4570 WE Barrier 1 stage Xstream white 4570 GN Barrier 1 stage Xstream green 4565 Pressure plate 1 stage Xstream 4766 Adj spring 1 stage Xstream 4567 BK Cover Xstream first stage black 4567 CE Cover Xstream first stage chrome 4568 Screw cover M3x10 Xstream 3 pcs 4568 Screw cover M3x10 Xstream 3 pcs Tools Instructions Deep Dive 8507 Oxygen grease 2 I hi Hd HS
16. N 144 3 4778 Conn stem 1 stage 90 Xstream 4878 Conn stem 1 stage EN 144 3 Duration90 EN 144 3 Tools Instructions 2297 O ring remover 4591 17mm borga wrench bad TTI Torque wrench get inci YET 3772 3118 JOTA Om wad io oo 17 masm l iss k si ETI Tages wrwaci H Mm o 4554 Handie UNE ME j n PU DE il mwn mg dl mn 2297 O ring remover TTI Torque wrench get inci YET 3772 3119 S ama sa ls as ETI Tages reach H Mm iH Bi Mi rm imi ddl mn Replace Picture Step Parts 4576 BK Line protector Xstream black 4576 GN Line protector Xstream green 2918 O ring Deep90 Dive90 2918 59 O ring Viton Duration90 2297 O ring remover 4576 BK Wheel G5 8 Xstream black 4576 GN Wheel G5 8 Xstream green 4876 GN Wheel Xstream Duration EN 144 3 green 4552 Cup type filter long Xstream 90 All first stages 4556 Ball 1 stage Xstream 4555 Spring for ball Xstream 4559 Actuating pin Xstream Replace Picture Replace Picture Lower pin guide Xstream 3606 Combination tool 2 h 13 14 15 16 17 m ye end wrench 6 13 14 15 16 a LES 5 IP Pin bushing 1 stage Xstream Avo not pull out nor replace the Pin bushing while servicing Dive or Deep models This should only be done Screw in M3 screw 4568 in the pin while servicing Deco and Duration bushing and pull out models 2297 O r
17. RIAL NUMBER INTERSTAGE PRESSURE 8 6 bar q SURFACE STATIC CONDITIONS OF TEST ROOM TEMPERATURE 22 0 C WATER TEMPERATURE 20 3 C EXHALE TEMPERATURE 21 4 C HP SUPPLY PRESSURE 50 bar g TIDAL VOLUME 2 50 litre BREATH RATE 25 29 bpm VENTILATION RATE 63 2 lpm RESULTS INHALE PRESSURE 6 66 mbar LIMIT 25 mbar INHALE POS PRESSURE 2 36 mbar LIMIT 5 mbar EXHALE PRESSURE 15 90 mbar LIMIT 25 mbar EXT NORK OF BREATHING 1 19 J 1 LIMIT 3 0 Joules litre INHALE WORK 0 14 4 1 POS INHALE WORK 0 01 J l LIMIT 0 3 Joules litre EXHALE WORK 1 04 1 1 PRESSURE VOLUME DIAGRAM AT DEPTH OF 51 2 msw 168 fev TN 7 0707 A Dt eee om EXHALE 5 a een ee mo eels 15 Focal rg Ry N vi litre Z RAS A INHRLE bar on IP U 2 IP HAN 12 5 Bar g 4 ymn A ET IP MIN 18 7 Bar g REMARKS RDTF 9506 40 SERVICE MANUAL XSTREAM 10 OXYGEN STATEMENT 10 0xygen statement The Poseidon Xstream Deco Duration and Duration90 are all approved for use with gaseous oxygen up to 99 95 purity at maximum 300 bar supply pressure and a maximum gas temperature of 60 C Using gaseous mixtures containing oxygen at high pressure always presents a certain level of risk for equipment failure due to combustion Greater concentration oxygen greater pressure greater temperature respectively represents factors that contributes to increase the mentioned risk In diving operations
18. XSTREAM SERVICE MANUAL b A Ss RA Se oe Fd a TRA a A 4 x 1 SS gt N E gt h A b _ Y A w t Az de eU he _ Bw LO s a 4 _ lt el wi x we gt w i S vs J d gt y N Ro HD es 6 3 m 4 y Ys Table of contents 1 Safety regulations 272444444 148242X2X 4Nh 2 Improvements 4 Product upgrades 0 xv A inf l X U le Ki 5 H mmendation 3 Determination of required service 6 4 Tools and tool order form 7 r rt rvice kit 1 Xstream nd st 2 7 Final inspection 35 Setting final i i 35 Method for regulators cleaned for oxygen use gt f A Method all other r lator 9 Technical data 38 Torque table s sx xX3 sus 848 Productdata 0v0 S 8 4 4 khk 8 Conversion tables 39 Work of breathing CD Breathing curve DF Performan 4 10 Oxygen statement 41 11 Trouble shootin 42 12 t 4 APPENDIX A 44 FAS 555 d8 88 82828 77X 44 APPENDIXB SS Fundamental is hensi 15 Th ncept 4 APPENDIX C 46 Nomenclature regulator performance oo st stage regulator performance FG APPENDIXD GF leanroom an n cleaning requirement 41 1 SAFETY REGULATIONS SERVICE MANUAL XSTREAM 1 Safety regulations Ame instructions in this handbook must be followed in detail step by step Negligence can cause serious injury o
19. ality shall be conducted at least annually by an independent laboratory for the gas used to dry cleaned parts MH lt is strongly recommended to use filtered air for the purpose of drying and regulator testing wa 6 Disposal NN Disposal of water shall be in accordance with local state or federal regulations T Documentation The Poseidon Oxygen Service Center must have documented maintenance procedures routines covering 7 1 2 Tool cleaning APPENDDUD SERV XSTREAM APPENDIX E 0 ice authorisat Xstream and Oxygen Service Technician To become an authorised Xstream and Oxygen Service Technician you must attend an approved Poseidon Xstream and Oxygen handling service course The service course should strictly follow this service manual The only ones approved to hold such a course are Poseidon or Poseidon distributors After completed course a diploma will be issued as a proof of authorisation Xstream and Oxygen Service Center To become an authorised Xstream and Oxygen Service Center you must have access to a cleanroom environment and all the special tools mentioned in this servicemanual Service should only be performed by an approved Xstream and Oxygen Service Technician Once the conditions are fulfilled an approved Poseidon Xstream and Oxygen center sticker should be placed clearly visible on for example the shopdoor Service should always be done in line with the rule
20. cking pressure Ask your customer Technically Xstream can be adjusted from 0 mm w c to gt 100 mm w c The risk for a free flow increases with decreasing cracking pressure Below 25 mm w c in a certain attitude exhalation diaphragm the shallowest and inhalation diaphragm the deepest the regulator inhalation valve will stay permanently open bubbleing Above 40 mm w c the breath doesn t feel good 37 XSTREAM 9 Technical data Part subject to torque wrench Newton Meter Inch Pounds Foot Pounds Kilogram Meter use Inch lbs Ft lbs Kg Nm m Blind screws 53 9 4 4 0 7 0 6 0 1 First stage connection stem 20 2 177 18 17 2 2 0 2 to body Centre piece TET Valve house nut Servo valve Hose to 2nd stage General Maximum Operational depth Certified to 200 m 656 ft Typical Work of Breathing 50m on air 1 5 J l see diagrams below 62 5 l min Typical Work of breathing 200m on 1 7 J see diagrams below Trimix 62 5 l min Approved gas Air Air Trimix Air EAN 50 Air Oxygen Maximum working pressure 300 bar 4351 psi Gold water performance Exceeding EN 250 requirements for cold water use Approvals Type Approved acc to EU Directive Personal Protective Equipment 89 686 EEC Applicable Performance Standards EN 738 1 clause 6 6 6 6 2 NORSOK U 101 clause 5 2 5 5 5 9 EN 250 2000 Cleaned to hydrocarbon levels lt 50mg m2 8 particle level X 0 ring materials Lubricant
21. d distilled and filtrated water and rinse for another 5 minutes Ensure all cavities are carefully rinsed It is the internal rinsing which is the most important Dry the parts by using a cleaned blowgun and clean air and blow dry each part carefully Verification White light All parts shall be observed for the absence of contaminations under strong white light and for the accumulations of lint fibres This method will detect particulate matter in excess of 50 microns and other contaminations in relatively large amounts The part being examined must be recleaned if any contamination is detected using this method You shall have access to and use if found necessary a magnifying glass or a microscope with at least x10 magnification Ultraviolet light Black light Examine all parts in darkness using an ultraviolet light of between 3200 to 3800 Angstrom wavelength If a bluish white fluorescent blotch smear smudge or film is present the pert must be recleaned Ultraviolet light inspection will help to verify that cleaned surfaces are free from any hydrocarbon fluorescence If parts cannot be used immediately for assembly pack in clean plastic bags to avoid parts from being recontaminated 6 SERVICE SERVICE MANUAL XSTREAM A Lubricants shall be used sparingly Excessive quantities of lubricant can trap particulate and other contaminants developing apotential fire hazard A Parts marked with the O symbol are parts tha
22. d therefore the risk of a fire is present ranging from extremely lovv risk to extremely high risk The ignitability of the fuel the concentration of oxygen and the number of ignition sources and their likelihood to occur determines the level Of risk exposed Everything can combust in an oxygen rich atmosphere i e all materials can be regarded as fuels Polymers and organic materials are oftenly more easily ignitable than metals why they shall be avoided as far as possible in a regulator intended for oxygen rich mixtures in order to lower the risk for combustion Gaseous oxygen is a strong oxidiser The higher concentration the higher temperature and the higher pressure the greater its oxidising properties What you as a regulator service technician can do to reduce the risk is to remove the ignition sources Particulate Auto ignition Electrical sparks Adiabatic Compression Heat Frictional heat Resonance heat Ideally if you could remove them all there would be no risk for combustion Particulate material can ignite in at least two ways A small particulate travelling at high speed in a geseous stream can when it hits a surface create either a spark or transfer enough energy to trigger the absorbing materials auto ignition temperature Or second since a cluster of particulate material exhibits a large surface area it can pick up e g resonance heat more effectivcely and thereby reach its own A T Particulates must th
23. e IP increases beyond max limit Damaged HP seat and or o ring Service The 2 stage is hard to adjust to a Servo valve If the servo valve is bent to an Replace servo valve correct cracking pressure angle its rotation upon the setting procedure will alter the setting and be self readjusting when used thereafter Sieze of gas Valve insert 3440 and 1 stage If the valve insert 3440 has been Service amp replacement of 3440 leakage suppressed to excessive pressure for a longer period of time it can be damaged Reason being 1 stage failure 42 SERVICE MANUAL XSTREAM 12 Updates Version Date Updated by Comments 2003 03 20 Poseidon First issue Changes in section 5 Item numbers 2003 05 07 Poseidon 2004 09 24 Poseidon EN 144 3 2005 02 11 Poseidon Change in stage 26 of Service level B regarding the Pin bushing 2007 03 05 Poseidon Updated with new 15t stage article numbers Changes in service levels 7 DO BA a o XSIREAM APPENDIX A FAQ T s gt What shall be used viton or nitrile In short viton is less likely to ignite but if it does the fumes are extremely toxic Nitrile is more likely to ignite and releases more heat energy than viton but the fumes are less toxic Nitrile has normally better mechanical properties i e it is a better and more reliable seal Therefore the risk for and the consequences of either a failure because of ignition or a los
24. ed by 4777 Lower pin guide The part has been changed to withstand a greater torque 4562 replaced by 4762 Upper centre piece The part has been changed to correspond to the change of 4577 4581 Washer The part has been changed to ease assembly through a more precise fit 4423 O ring 4563 Pin bushing 1 stage Xstream Information about Xstream Upgrade kit 4826 4760 Seat holder and 4581 Washer are not critical parts to replace however old seat holders will not fit new seats and is therefore included in the Update kit Xstream at a special price 4777 Lower pin guide and 4762 Upper centre piece should be replaced and is therefore included in the kit at no cost Information about Xstream 1st stage covers During 2006 we began manufacturing Xstream DEEP DEEP90 DURATION DURATION90 and DECO 1st stages with chrome colored 1st stage covers with an adjustment screw Starting january 2007 all Xstream 1st stages regardless of model version will have a chrome colored 1st stage cover with an adjustment screw Information about Xstream Upgrade to cover with adjustment screw Any Xstream 1st stages that don t have a cover with an adjustment screw should be upgraded with a cover that has an adjustment screw This upgrade is not mandatory but recommended The upgrade is made using the Xstream Adjustable kit 4767 KIT that contains the following parts 1 x 4767 CE Xstream cover 1 x 4798 CH Adjustment screw 1 x 4766 Adjust
25. eeJsy oDe03s was uuoo ues lsx oDe01s uio js uuoo UOHA 1 uonein g 09ed uo i 641 deed Buu o uonudusos qi 99 28 2 812 sod Z 8 E4NN 6192 69 816 816 9 L Z4NN 0896 DLUOUUYO malos jueuisn py JO 96ZF yoelq maos jueunsn pV 8 86 sod OLXEIN 49AO MAINS 899h peys S ueensy 4 AOD 30 9 yop q oDe1s 1s ueeusy 4 AOD 9 U99J6 LULDJISX 5 Jalueg NO 0ZSF SIUM UWUEea11sx ebe s IM 04Sp yoe q uealisx obeys Joiueg Md O Sb 9927 9997 v95y 6SSV 091 ecyy e95y LLLV L9 y 0927 89 7 69 997 1997 999 9 24 Duuds GSGr 7 xx SHUM ureesy e9UM 9 87 wueal sx 9 87 uSaJb 9 8 99 eeUM NO 9 5p LULSNSX 8 99 9 yoejg uieeJjsy 8 99 9 LULSUISX oDepjs 4 USEA JUILIS L8Sy LULOUJSX 191114 d4 dn 2291 87 LZSV 69 2087T 69 001 1001 VVI NA 0090 UlE9J SX JM p88V xx VYFNd N TSST x 6c ze z daap 28 2 LGF PLP 9957 022p JM 0 St M 0 St d p g 0 6t 8 86 1 o gt apjuonednp 69 8167 daap 8162 8 2 9 g9c uopeinp daap xx x 65 087
26. ening MPV valves on tanks To be used vvith a torque vvrench Articles of consumption q Description a Used when dismounting Triton LP valve iz i y Used as a guide when installing locking pins on MPV valves I 8515 Oxygen grease 81 8507 Oxygen grease 2 8516 Regulator grease 3139 Oil silicone 20 g 4837 Lint free latex gloves 4838 Hair net 8515 Oxygen grease 1 Only approved oxygen grease vvhen lubricating oxygen critical parts on the high pressure side Approved for 300 bar 609C 8507 Oxygen grease 2 Used when lubricating oxygen critical parts on the low pressure side Approved for 110 bar 60 C Used for lubrication of air version regulators Used for lubrication of air version regulators 6 02 uo3ll s 110 GELE SERVICE MANUAL XSTREAM Customer o Spare parts amp service kits Second stage Xstream Deep 4670 BK Second stage Xstream Duration Second stage Xstream Deco Second stage Xstream Dive 4670 GN 4670 WE 4670 GY Second stage Xstream Octopus 4670 YW WE Was x WB Css MM 7 BE s ss s WE Wdda weajsx oDejs pu uu o eqn SALA 043 uieeJsy 86035 pug Duu o ueasx nu Buisnou e JeA Wdda ueesy oDejs pu uu o uesul eAJeA BUISNOU A EA dT UOJA 18 pug uee sy Buu O 9De1s pug uieoJjsy Jano sndoj90 ebe1s pug ueeJsy Jan
27. erefore be removed effectively All materials have a threshold temperature upon reached the material will start to burn automatically the Auto Ignition Temperature AIT The AIT depends on oxygen concentration such as at a higher concentration the lower threshold Hydrocarbons oil fingerprints grease have a very low AIT and are almost certain to combust in an oxygen rich environment at high pressures Combustion if it occurs can be anything from unnoticeable to catastrophic A low mass of e g some Nylon like plastic materials will only produce fumes containing carbon dioxid and water Other plastics e g viton will produce hydroflouric acids which even in extremely low concentrations can kill a diver if inhaled Viton has a significantly higher A T than Nylons why it is far less likely to burn if compared in exactly the same situation But the effects if it happens in a regulator is far worse Different materials when burning releases different amounts of energy Hydrocarbons have a high heat of combustion The produced heat can in turn act as an ignition source for less ignitable materials producing what s referred to as a kindling chain reaction Thereby the presence of materials with low AIT and high HC can ignite the nextcoming part downstream which in turn possibly can ignite etc There are no level of percentage of oxygen which can be guaranteed as safe There are only factors which increases or decreases the risk for combustio
28. esidue spilled chemicals and any foreign material which develop in the area shall be cleaned immediately At least monthly the clean room shall be completely cleaned It is recommended to keep cleanroom temperature close to standard room temperature and humidity less than 50 Since all tools will be kept free from grease the risk of them rusting increases the higher the humidity It is recommended to see to that the work area maintain a slight positive pressure so that the air flow will always be outward from the clean area The following activities are absolutely prohibited inside the cleanroom area e Smoking e Eating e The use of car heaters 2 Personnel clothing requirements rS The special clothing as described below must not be worn or taken outside the cleanroom y Jy Ml Lint free gloves shall be worn Regard everything you touch as contaminated unless you are sure it is clean This means you shall replace our gloves if they have been in contact vvith something you can suspect being contaminated Fe lin the clean room a hair net and a coverall laboratory coat shall be worn 77 yN These requirements apply to anyone being in the cleanroom including visitors and observers 3 Tools and eguipment reguirements The cleaning procedure as described for the regulator also applies to all tools and eguipment used un AE All tools and equipment used must be cleaned and kept clean t must be ensured that tools and equipmen
29. i j L i ia a z Fa n H Milo S r 4 TF j 21 WU d l TER uu 4 al k k L L k 2 a l 4 si il k e k k Wasa q i i D 2 kl i nn r L a ur j lt W W Tr 1 W u i Er y E w W w i 1 i KW L Va 7 L 4 L i i a ha k ha r f 4564 Roll diaphragm 1 stage Xstream Only use fingers Tools may puncture the diaphragm Pin guide assembly 3606 Combination tool 2 m 4761 Valve seat spring Xstream 4760 Valve seat holder Xstream 4758 Zytel valve seat Xstream 2297 O ring remover 4760 Valve seat holder Xstream 4758 Zytel valve seat Xstream 4760 Valve seat holder Xstream 4758 Zytel valve seat Xstream 1246 Allen key 5 mm Only for Xstream bottom mounted first stages Step Parts 1007 O ring Deep 1007 59 O ring viton Deco Duration 4807 59 O ring viton EN 144 3 Deco EN 144 3 Duration EN 144 3 Conn stem 1 stage Xstream Conn stem 1 stage Xstream EN 144 3 Deco EN 144 3 Duration EN 144 3 4576 BK Wheel G5 8 Xstream black 4576 WE Wheel G5 8 Xstream white 4576 GN Wheel G5 8 Xstream green 4876 GN Wheel Xstream Duration EN 144 3 green 4876 WE Wheel Xstream Deco EN 144 3 white Cup type filter Xstream 4591 Stainl washer 1 stage Xstream Only for Xstream 90 first stages 1007 O ring Deep90 Dive90 1007 59 O ring viton Duration90 4807 59 O ring viton EN 144 3 Duration90 E
30. ili FE Lu l i g 6 1 Nm Refer to section 9 for other units You should see the marking This side up on the barrier 4593 Allen key 2 5 mm 6 1 Nm Refer to section 8 for other units Deep Dive 8516 Regulator grease b l ELE 4593 Allen key 2 5 mm 6 1 Nm Refer to section 9 for other units Replace Tools Instructions Replace Picture 2680 Blindscrevv UNF 7 16 1 or 2 pcs 2679 Blindscrevv UNF 3 8 2 3 or 5 pcs 1246 Allen key 5 mm j FT im 7 _ XSTREAM A Parts marked with the O symbol are parts that must be replace at every service New parts should be stored in it s original packing until it is time for assembly Xstream second stage Step Parts 2856 59 2856 59 1233 55 1233 55 O ring Xstream 2nd st viton O ring Xstream 2nd st viton Valve insert O ring 2nd stage Xstream EPDM O ring 2nd stage Xstream EPDM Tools Instructions 3606 Combination tool 2 tool 2 EE fe gt 3606 Combination tool 2 tool 2 q Replace Picture Deco Duration 3605 Combination fool 1 PN y x E 2 ur z a Ciesa ES F x Um ME ri mi y n i R e ru I j a i Pi ig gt l a l p ib 5n 1 b hn a 4 4 i k May 4 i b E lt il i il i j j j R pr r Y Y E f La F k H R i
31. ing remover O ring Deep Dive O ring viton Deco Duration 2297 O ring remover Zytel valve seat Xstream On blindscrew UNF 3 8 2782 O ring Deep 2 or 3 pcs Dive 5 pcs 2782 55 O ring EPDM Deco 2 or 3 pcs Duration 2 or 3 pcs 2297 O ring remover On blindscrew UNF 7 16 2918 O ring Deep 1 pcs Dive 2 pcs 2918 59 O ring Viton Deco Duration 1 pcs 4798 Adjusting screw 1246 Allen key 5mm 19 Xstream second stage A remove o rings ONLY use o ring remover tool 2297 Make sure not to damage o ring surfaces Do not disassemble the exhalation check valve since this is not included in the servicing kit and can be hard to put back if taken out Step Parts Tools Replace Picture Mouthpiece AIR 4462 Pliers For cutting strap Screw driver 3 5 5 5 short 8 5 mm 4538 BK Cover Xstream 2nd stage Deep 4538 WE Cover Xstream 2nd stage Deco 4538 GN Cover Xstream 2nd stage Duration 4538 YW Cover Xstream 2nd stage Octopus Twist off 4538 GY Cover Xstream 2nd stage Dive Diaphragm cover Screw driver 3 5 5 5 short 8 5 mm Snap connection Diaphragm silicone Checkvalve Do not removel Unless damaged Servo valve Xstream Stop screvv 2706 Allen key 1 5 mm et ko 7 x A p 3 A Y q 4 A 7 k a 1 1 1 MP 2 4 4 2 N Ll 4 2 1 i 5 f ra i Y fr Replace Picture Valve tube Xstream 1896 55 O
32. ing time where after a p4 increase greater than 0 01 bar min is regarded a leakage This magnitude of leakage corresponds to an IP increase of 10 bars in 16 hours in a standard Xstream regulator w 70cm hose 27 5 APPENDIX D Check list 1 Gleanroom work environment requirements UR Bi The work area must be dedicated only for oxygen servicing Ideally a separate room or at least a space clearly marked out as an oxygen clean area e g by floor marking signs and or screens Ceiling walls and floor shall be non contaminant producing and be easily cleaned If the location is not sufficient in this respect sheets of polyethylene plastic can be taped to fully surround the work area iW AI The work area must be free from airborne dust and droplets It shall never be close to areas where machining takes place compressors are Or other activities which can produce a mist containing hydrocarbons or other flammable or particulate contaminants RN The work bench shall be sufficient in size as to enable a good organization of equipment tools and the regulator parts A clean polyethylene plastic sheet shall be used to protect the work bench It is recommended to have a roll of plastic sheet at one end of the work bench Used sheets shall be disposed if there are any signs of contamination LE B items incompatible with oxygen such as e g hydrocarbon oil and grease must not be stored or ever used in the area 1 Oil grease r
33. is used for Whenever you need to order a special Poseidon tool it is a good idea to copy this page and use it as an order form Fill in the number of tools required and fax it to the Poseidon distributor in the country where you are situated Don t forget to write the name of your shop in the head of this page Description EEEE O O o Jo Jo Jo lo 2297 O ring remover Used to remove o rings O Customer Open end wrench 6 13 23 mm Various open end wrenches in millimeters are essential or assembly and dissassembly of various things 4462 Pliers A specially made pair of pliers to be used when pulling out locRing pins from MPV valves and cutting the mouthpiece strap 3460 Regulator test Used to check or finally adjust the regulator 4830 Ultra Sonic Cleaner Used to clean all regulators Mandatory for Xstream Deco and Duration 3773 Torque wrench set Used to set the torque on various parts of the regulator 1246 Allen key 5 mm Used to unscrew blindplugs and to adjust IP on Xstream 1246 Allen key 5 mm 2705 Allen key 1 5 mm Used to untighten and tighten the locking screw on Jetstream and Xstream valve tube and G stopscrevvs on most first stages 2150 Plastic band pliers Used to tighten the plastic band around the mouthpiece so that the mouthpiece doesn t turn around M4 3605 Combination tool 1 Used to to screvv and unscrevv various parts on the first stage and second stages m 7 3606 Co
34. lean Ultra and water in the ratio 1 5 Let the UltraSonic cleaner reach its working temperature 60 70 C Place all parts in the basket The parts shall be placed so that no air is trapped inside Turn the part a few times under the solution until no bubbles are coming from it Ultra Sonic cleaning agitates away contaminants why it is important to finally place the part so that contaminants can drop out freely i e open holes pointing down as shown in the figure Ensure parts are not contacting each other since that may reduce the cleaning effectiveness 6 Immerse and ultra sonic clean the parts for 20 25 minutes 3440 rolling diaphragm and the servovalve shall only be cleaned for 10 minutes 8 Bring all parts needed to assemble the complete regulator to the clean room Keep the bagged 2 4 stage parts and the service kit parts in their bags until immediately before assembly PEA a THE PROCESS BELOW SHOULD BE PERFORMED INSIDE THE CLEANROOM AREA Rinsing and drying in the cleanroom From this stage and through the assembly stages cleanroom clothing including gloves shall be used Pick up each part from the basket and rinse carefully under running water at least 30 seconds per part or Rinse in two stages keeping the parts in the basket Immerse the basket with the parts in another container of at least 3 litres of clean water and agitate for at least 5 minutes Then replace the rinsing water with new clean water ideally deionise
35. mbination tool 2 Used to to screw and unscrew various parts on the first stage and second stages 3774 Bit holder for yoke Used to hold the short bit 2883 when dissassembling and assembling the yoke connection on regulators with fixed yoke 2883 Bit 6 mm L 30 mm Used when dissassembling and assembling regulators with fixed yoke Not for G5 8 connections 3397 10 Fixture for first stages Used to hold the first stage during dissassembly or assembly 3876 Tool kit for first stage Used to mount all inner details on first stages of type 3720 3790 and 3880 Customer Description 3761 Allen key 4mm Used to unscrevv and screvv safety valve on first stages type 3720 and 3790 2275 Allen key 6mm Used to untighten the connection stem on all first stages and to adjust P on first stages 2893 Screvv driver 3 5 mm 3372 Screw driver 5 5 mm short 2885 Screvv driver 8 5 mm 2705 Adjusting tool Used for various things Old Jetstream second stage covers adiusting Cyklon valve tube tank valves etc Used to adjust the cracking pressure on Jetstream and Xstream 2894 Test fixture for LP valve Used to test the leaktightness in vvater on Jetstream and Xstream servo valve 4592 Oxygen cleaned G5 8 wheel 4593 Allen key 2 5 mm 4591 17 mm torque wrench Used as an oxygen clean interface between regulator and testbox while checking and setting Used to unscrew and screw the first stage spring cover on Xstream
36. ment spring 1 x 4761 Seat spring All these parts must be replaced when upgrading the 1st stage Recommendations For regulators with serial numbers less than 310001 we recommend to offer the customer to replace the old type valve housing nut to the improved version with article number 4547 This will significantly reduce the inhalation effort However if the customer choses to keep his old valve housing nut it is perfectly safe to do so EN 144 3 Xstream Deco Xstream Duration and Xstream Duration90 are available also in EN 144 3 configurations i e regulators which comply with the new EN 144 3 standard See page 3 for correct article numbers Older Xstream models can be upgraded to comply with the same standard using an EN 144 3 upgrade kit See Spare Parts lists on page 13 for details 3 Determination of required service IMPORTANT To be covered by the Poseidon Lifetime Warranty program all Xstream regulators must be serviced at least once every 24 months The serviced regulator must also be registered on the Poseidon Extranet www poseidon se It is always acceptable to do a service or cleaning upon customers request 4 Tools and tool order form To service Poseidon regulators there is a number of tools required Some of the tools are special tools for Xstream and Poseidon and some other tools are standard tools available in most hardware stores Below you will find a list of all tools needed with a description of what it
37. n The O concept Poseidon has introduced the O concept which stands for oxygen engineered oxygen compatible oxygen clean and oxygen approved 04 In short oxygen engineered is taking every step to lower both the risk for combustion and the possible effect of combustion The design must reduce the number of ignition sources allow effective maintenance and cleaning materials must be selected as to break kindling chain reactions constructed to minimise effects of compression shocks etc Os Oxygen compatible is selecting materials which have the best combination of AIT HC Ol and the severity of a possible failure for its function in the sytem O3 Oxygen clean means that either a component or a complete system is cleaned from especially hydrocarbons and particulate to a level which gives an acceptible risk for ignition Oxygen approved means the product has passed tests conducted by independent organisations according to international standards APPENDIX XSTREAM APPENDIX G Nomenclature regulator performance 1 stage regulator performance The nomenclature to describe the regulator is as far as possible in accordance vvith EN ISO 2503 1998 Rated maximum inlet pressure p1 Rated maximum inlet pressure for which the pressure regulator is designed p1 300 bar 4351psi Rated maximum outlet pressure p2 Rated maximum downstream pressure for the standards discharge specified Q1 Figure taken at p1
38. n to 270 bar at 100 C Can put a Jetstream 2 stage on an Xstream 1 stage Yes Can I put a Cyklon 5000 2 stage on an Xstream 1 stage This combination is not CE approved The Cyklon 5000 2 stage require an IP at 11 5 bar which can only be set with a Xstream 1 stage that has an adjustment screw What is the expected service life of the servo valve If handled in accordance with the instructions given in the users manual it is not something that should be expected to need any replacement The most common problem is ingress of water due to immersion of an unpressurised regulator In such case salt crystals can form inside the servo valve and create a minor leakage Why do Poseidon refer to NORSOK U 101 TBD NORSOK U 101 is a Norwegian off shore standard for testing diving eguipment s performance down to 400m 1312 ft depth Its reguirements put greater demands on breathing resistance than EN 250 does Why isn t Xstream marked EN 250 EN 250 requires a limitation in use to maximum 50m depth Xstream is tested and fulfil all requirements of the EN 250 except for it is not limited to 50m but to 200m depth XSTREAM APPENDIX B APPENDIX B Fundamental hensi For a fire to occur three elements must be present A fuel an oxidiser and an ignition source f any of these three is non present combustion cannot take place All regulators being used vvith a gas containing any percentage oxygen exhibits all these elements an
39. nd servicing methods Failure to adhere to these mandatory requirements transfers the responsibility to the owner SERVICE MANUAL XSTREAM 11 Trouble shooting Effect Examine Reason Action Over pressure valve is opening s it only when hose is pulled If yes it is its normal function None Is it spontaneously opening If yes it may be a 1st stage error Service amp replacement of 3440 Immersed in water small bubbles are Check the cracking pressure see If the cracking pessure is too low the Adjust the cracking pressure coming from the mouthpiece section 5 1 valve is sligtly opened Does it stop after the regulator is If yes the valve was probably Instruct owner always to rinse the rinsed jammed with salt crystals regulator after every dive using fresh water The bubbles remain The servo valve is severly jammed by Service amp Instruct owner always to salt crystals rinse the regulator after every dive using fresh water The regulator free flows breaking the Check the cracking pressure see If the cracking pessure is too low it Adjust the cracking pressure surface section 5 1 increases the risk for free flow If the regulator hits the surface at a Instruct owner to either immerse certain attitude it can start a free flow slowly keep regulator in your mouth or hold your hand over the free mouthpice while entering the water Outward leakages at extremely cold Incorrect or damaged o rings conditions Th
40. o uoneund 96235 pug uieeJsy 19409 ooed 5e s pug uieeJjsy deed o6e1s pug uieeJsy 191409 euooijis uu65eijudeiq Ssst Jano9 ulBpludeiq 9 Sp uonuduss q SySy YEST AN 1911 9 82 1812 LVSV Orre 1886 GYLL 69 9986 89 69 LESY 68Sr M N Pe 0390 A9 8E6P MA SESP JM 8EGF N9 9 cr desp yg 9 6 AN ct Q 10 SERVICE MANUAL XSTREAM Customer DOLLOIT x m O 00 N lt r 002 09 1st stage G 5 8 Xstream DEEP 4 1 1st stage G 5 8 Xstream DEEP 002 12 1st stage G 5 8 Xstream DURATION 4 1 002 15 1st stage G 5 8 Xstream DECO 4 1 1st stage G 5 8 Xstream DURATION 1st stage G 5 8 Xstream DECO z Q o co N st LU O 00 N lt r 1st stage Xstream DURATION EN 144 3 1st stage Xstream DECO EN 144 3 Z st 00 co Lu st 00 co uoneinq o5S q Nada 41 Bun O uoneunq oo q uo i Buu O AIq d q Bun O uesnsx pegs Duuds 1sn pv ueansx pegs ajejd ainssaid uealsx 5 ubelydelp Oy uealsx uid Dunenioy ueansx epinb uid Jaddp uesnsx pegs Bulysnq uld uealsx epinb uid 18mo 7 Buds 1895 SALA UUE SX 1895 1898 SAMBA 1 Z uoneunq oo q uo i 641 doed Buu o uealsx ebe s eg ueansx oDe1s GUISNOH ul
41. o 8515 62 Poseidon grease 2 article no 8507 R Poseidon grease R article no 8516 Warning Negligence can cause serious injury or even death Improvements 777 Poseidon has made several improvements all introduced 2003 starting with serial number 310001 Also a 6 th member of the Xstream family is introduced the Xstream Dive Correspondingly article numbers have been changed to reflect these improved models Article numbers with the two first digits being 45 has been changed to 47 VVherever any text throughout this document refers to article numbers starting vvith 47 it also applies to the corresponding part product having an article number starting with 45 i e Item number 4790 BK is the new version of old Xstream 4590 BK Starting in 2006 all Xstream 1st stages are equipped vvith an adiustment screvv cover Older versions vvith no adiustment screvvs should be upgraded Product upgrades Regulators with serial numbers less than 310001 are subject to a mandatory update programme To obtain updated replacement parts order the kit 4826 and submit to Poseidon the serial number of the regulator by sending an email to service poseidon se vvith the serialnumber and date of service clearly marked Regulators fulfilling this criteria shall have the follovving parts replaced on its first service 4560 replaced by 4760 Seat holder Seats on regulators numbered after 310001 are different and will not fit older seat holders 4577 replac
42. operty st stage Setting SI units Setting common units Setting US units PI P2 P3 800 1100 kPa unadjustable 8bar 11bar unadjustable 116 160 psi unadjustable 840 860 kPa adjustable 8 4bar 8 6bar adiustable 122 125 psi adiustable 5750 kPa 5109 psi 110 kPa 1 1 bar 16 psi max 100 kPa 0 12 m h 0 07 ft min Internal leaktighiness 12 ml h Corresponds to a pressure climb of 0 01 bar min for a regulator with a 70 cm hose Property 2nd stage Setting S units Setting common units Setting US units CP cracking pressure 274 Pa to 392 Pa 28 to 40 mm w c 1 1 to 1 6 inch of water Method for regulators cleaned for oxygen use A uniess you do have access to an oxygen cleaned test station you must ensure you do not re contamine the regulator when doing the final adjustment and setting Re contamination can be caused by e g contaminated test gas contaminated gauge fittings contaminated regulator connection contaminated test station pipings etc 1 4 El LE 1 Slowly open cylinder valve 2 Check IP 3 Close valve 4 Purge o Adjust IP 1 2 turn 1 5 bar 6 Open valve 7 Check IP loop to 3 8 Close valve 9 Purge 1 Open valve 2 Check cracking pressure 3 Adjust cracking pressure 4 Close valve 5 Purge 35 MA Il Method for all other regulators 1 Open left valve 20 bar 2 Close left valve 20 bar 3 Purge Open right valve HP 200 30
43. p 06d p 1M8 86 F 06 8Be1s uiejs uuoo N b L 7b1 NI 06uoneund uoy 5uu O i 39 2924 06uone nq uoa Buu Q 06uopeunp g6doep gI 9 y 06 Aiq 06d q Buu o 4883 GN u01 d11950 NO 928p 06uoneinp 66 8167 06uopeinp N9 5 9f 06 Alp 06d 06 Alp 06d p 815 069Alp 06d p H9 9 SF 65 087 64 2004 069Alp 06d p 200 o6uopeunp 6 6 9 19 92 06uoneinp 06d p p 66 6 4 p SST 12 Customer 4821 Servicekit Xstream Deep 1 st stage Included 4822 Servicekit Xstream Deep90 Dive90 1 st stage Included Note A N o O 4 o 758 572 782 918 557 423 007 C C o C C C 758 552 782 918 nin 557 O ring Deep Dive 423 O ring Deep Dive Servicing a Deep90 leaves you 2 2782 and 1 2918 OC DC OC Oc OC 4823 Servicekit Xstream Duration Deco 1 st stage Included Oc OJO o io 758 572 DC 563 DC 782 55 D 918 59 557 59 DC 423 BE 007 59 DC 4821 Servicekit Xstream Duration EN 144 3 Deco EN 144 3 1 st stage Included 758 572 563 782 55 918 59 557 59 de 423 de 807 59 de OC DC Oc o o N O
44. r even death Special warnings are marked with this symbol A A xstream Deco and Xstream Duration are used by the customer with gasses with elevated oxygen content This requires special procedures while servicing to clean the regulator and to keep it clean Negligance to follow the instructions given in this manual introduces a risk for the customer of having a fire which in turn can cause serious injury or even death Servicing the above mentioned regulators shall always be conducted in a clean environment using clean tools as described in section 6 and in Appendix B ro enhance safety during servicing the regulators Xstream Deco and Xstream Duration shall be tested using clean air according to specification in 8 There is no need to test regulators in the servicing environment using gasses with gt 21 oxygen A Servicing must only be carried out by persons who have been trained and certified by Poseidon Servicing Xstream Deco and Xstream Duration requires an additional certification as POSEIDON OXYGEN TECHNICIAN Al oni POSEIDON original parts may be used for servicing Where stated POSEIDON original tools must be used SERVICE MANUAL XSTREAM 6 XX 2 INTRODUCTION 2 Introduction Marinas _ C C 8680202 T This manual contains servicing and repair instructions and product information for the Poseidon Xstream regulator series The different Xstream regulator models are most clearly identifed by their color There is
45. ration90 EN144 3 2918 59 O ring Viton Duration90 Duration 8515 Oxygen grease 1 b 2918 O ring Deep90 Dive90 Deep Dive 6507 Oxygen grease 2 PN R Parts Tools Instructions Replace Picture 4576 BK Line protector Xstream black 4576 GN Line protector Xstream green 4771 Conn stem 1 stage 90 Xstream 4878 Conn stem 1 stage Xstream EN 144 3 II yy Taqa wch wot incl X TILA ge E Duration90 EN 144 3 o ea h TTE Egan qud usan H Badan idi Haz VU ms aram E m ni ir a yel dn agi di nn Ensure line protector is correctly positioned vvith one slot facing to the bottom of the housing Torque setting 30 Nm Refer to section 9 for other units 1007 59 O ring viton Duration90 4807 59 O ring viton EN 144 3 Duration90 EN 144 3 o 1007 O ring viton Deep Dive y e Go to step 21 Xstream bottom mounted first stage 4581 Stainl vvasher 1 stage Xstream Cup type filter Xstream Deco Duration 8515 Oxygen grease 1 y y 4572 Cup type filter Xstream Deep Dive 8507 Oxygen grease 2 HE i l iD il ji il ii il 4576 BK Wheel G5 8 Xstream black 4576 WE Wheel G5 8 Xstream white 4576 GN Wheel G5 8 Xstream green 4876 GN Wheel Xstream green Duration EN144 3 4876 WE Wheel Xstream white Deco EN 144 3 Step Parts Tools Instructions Replace Picture 4571
46. ream hade 2 IP and 1HP 3 IP 1HP ports The specified ports for the different models are available from 2005 www onlineconversion com Known Unknown Multiply by x 9 TECHNICAL DATA SERVICE MANUAL XSTREAN Performance 60000 Work of breathing The diagram to the right show a calculated graph for Work of Breathing in Joules litre at Q 62 5 litres min The equation behind it is extracted from hundreds of tests from which coefficients for gas dependency average flow dependency and depth dependency is calculated Typical Work of Breathing at Depth 15 U Ai Inhalerexnale O inhale WoD Exhale Limi EN 250 Limit Norsok 101 lis maximum inaccuracy is within 10 Work of Breathing The equation assumes the most dense gas possible to safely breath is used i e a maximum tolerable pO pN at any depth Adding more Helium will lower the figures It is important to understand that this equation does not apply to any other m a m e w m m m m m Depth meters regulator since the coefficients and characteristics are strongly dependent on the regulator construction Breathing curve The diagram below shows a breathing DEMAND REGULATOR PERFORMANCE ANSTI POSEIDON curve for Xstream iai HN CERTIFICATE REFERENCE 0304 5 2384 DATE 02 04 2003 TIME 14 47 10 EQUIPMENT REGULATOR TYPE xstream deep 90 SE
47. s Poseidon 1 BAM appr 270 bar 100 C Poseidon 2 BAM appr 140 bar O 100 C Poseidon R silicone oil Colour Deco EN 144 3 Octopus 2 stage Flow Rat Inner Volume dead space Weight Technique Safety valve opening pressure 18 1 bar 261 14 psi Swivelling Materia Venturi assist Inhalation control me Dismountable w o tools Anatomic Mouthpiece XSTREAM st stage Flowrate l min gt 4000 I min gt 141 scfm Nominal inter stage pressure 8 5 bar 123 psi Weight with 70cm hose Deep 920 g Duration EN 144 3 Deco EN 144 3 Dive 1100 g Deep 90 Dur 90 EN 144 3 Anti Freeze protection Technique Vaive technique Seat material Test pressure Ports 5 IP UNF 3 8 2 HP UNF 7 16 Deep 4 IP UNF 3 8 Duration EN 144 3 1 HP UNF 7 16 Deco EN 144 3 Deep 90 5 IP UNF 3 8 Dur 90 EN 144 3 1 2 HP UNF 7 16 Connection Dive DIN 477 G5 8 Yoke adapter available Deep DIN 477 G5 8 Yoke adapter available Duration DIN 477 G5 8 EN 144 3 uporadeable Duration EN 144 3 EN 144 3 M26x2 Deco DIN 477 G5 8 EN 144 3 upgradeable Deco EN 144 3 EN 144 3 M26x2 Material Brass plastics stainless steel Hose Standard lengths hose 0 7 m 2 3 ft 0 9 m 3 ft 1 6 m 5 2 ft 2 15 m 7 ft Burst pressure Pll strength Material Safely inspection holes Wear protecting crimps Oxygen cleaned Available x Some of the older models of the bottom side mounted Xst
48. s and guidelines of this servicemanual Issue 2 2 Copyright O Poseidon Diving Systems AB 2005 All rights reserved No parts of this book may be reproduced in any form whatsoever without written permission of the publisher Service manual Xstream item Z 10069 XM
49. s of seal determines whether viton or nitrile shall be used What about the 40 rule In the past some claimed that using gasses containing les than 40 oxygen did not require any special procedures such as e g oxygen cleaning Since it is only a matter of what level of risk that can be accepted and Poseidon s standpoint is to lower the risk as far as possible for our customers safety Upstream valve and sieze of gas The servo valve of the Xstream and Jetstream is an upstream opening valve Because of its small size an extremely small force is required to crack it open and thereby allow the main valve to open Even if there is a first stage failure increasing the Interstage pressure the Interstage pressure will never be greater than twice the originally set IP because of the OPV In this situation the cracking pressure will be doubled but still very small why the regulator will work normally Unadjustable will it keep its setting Spontaneous alteration of setting is most commonly due to fatigue of springs Significant fatigue only occur if the spring is stressed beyond its plastic deformation threshold A correctly chosen spring will therefore not fatigue and keep its setting Can I use Ghristo Lube instead As per 31 1 2003 Christo Lube 111 is approved for use with 10096 oxygen to 110 bar at 60 C which is less than the maximum working pressure of Xstream Deco and can therefore not be used Poseidon 1 Grease is approved for10096 oxyge
50. t from this area is not shared with other servicing locations Tools used to disassemble the regulator must be regarded as contaminated and cannot be used for assembly unless they have been cleaned after the disassembly stage We therefore recommend having two sets of the required tools one of which is alvvays kept clean Tools have to be re cleaned every month or after 10 serviced regulators whichever comes first N An ultra sonic cleaner Poseidon XXXX shall be used In addition to the instructions for use and maintenance in the users manual the bath shall be cleaned with IPA and a lint free mop or lint free paper on a regular basis or when contamination can be suspected This is to ensure that a possible trace of an oil film on the inside of the bath is removed The solution in the ultrasonic bath shall be replaced after a maximum 30 times of use b earlier if signs of contamination is present c at least every fourth vveek 4 Rinsing water requirements 0K Water quality must be in level with or better than Chloride ion ppm Conductivity u cm Resistivity cm3 O Visual clarit No turbidity oil or sediment WIN A chemical analysis of the water quality shall be conducted at least annually by an independent laboratory an 0 Gas requirements Gas used for blow guns and for regulator testing must fulfill the following requirements o level of Solid particles 296 microns IN A gas analysis of the gas qu
51. t must be replaced at every service New parts should be stored in it s original packing until it is time for assembly Xstream first stage Step Parts Tools Instructions Replace Picture All first stages 4758 Zytel valve seat Xstream 4557 59 O ring viton Deco Duration Deco Duration ase 1 O ring Deep Dive Use bushing 4563 to install o ring Pin bushing 1 stage Xstream Make sure fully to the bottom Lower pin guide Xstream 3606 Combination tool 2 Oy Step Parts Tools Instructions Replace Picture 4759 Actuating pin Xstream 8507 Oxygen grease 2 if il if 5 b i T ii E l 4 Lubricate pin at top section only Leaving lovver end dry VVipe off excessive grease under the hat 4798 Adjusting screw On blindscrevv UNF 3 8 2782 55 O ring EPDM Deco 2 or 3 pcs Duration 2 or 3 pcs On blindscrew UNE 7 16 Deco Duration 2918 59 O ring Viton Deco Duration 1 pcs ase 1 b a y On blindscrew UNF 3 8 2782 O ring Deep 2 or 3 pcs Dive 5 pcs On blindscrew UNF 7 16 2918 O ring Deep 1 pcs Dive 2 pcs ru y 3 r ty o 1 aa Q y F ds nt J P gt 2 Xstream 90 first stage 4552 Cup type filter long Xstream 90 PN y ru y 4576 BK Wheel G5 8 Xstream black 4576 GN Wheel G5 8 Xstream green 4876 GN Wheel Xstream green Du
52. y sure Hydrochloric acid is NOT poured into the ultra sonic cleaner It would then destroy the ultra sonic cleaner and the parts attempted to be cleaned If corrosion or salt deposits occurs on metallic parts immerse part in concentrated Hempocid or 15 Hydrochloric acid for about 10 minutes Then rinse them thoroughly in fresh water and blovv them dry with air The synthetic parts must not be treated vvith solvents and must only be cleaned vvith fresh vvater Hempocid Acid Liquid detergent containing phosphoric acid 5 10 and bactericide for disinfectant cleaning Xstream Deco Duration Cleaning for Oxygen Use The process of cleaning for oxygen use and the information given herein shall be strictly adhered to Only then can Poseidon guarantee the regulator vvill be cleaned to a cleanliness level vvhich is acceptable for its intended use This process has been verified to produce hydrocarbon residual levels less than 50mg m2 and a particulate level less than Cleaning Test Level 100 ASTM G 93 Spec As an alternative oxygen servicing procedures can be carried out in accordance with other herein listed organizations standard procedures and requirements However the use of cleaning agents the order of the operating sequences and the time to treat parts during ultra sonic cleaning as specified in this manual must be adhered to Wherever there is a conflict between the procedures and set of requirements unless the other procedure represents a greater
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