POSEIDON Xstream Series Service Manual
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POSEIDON Xstream Series Service Manual

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XSTREAM
SERVICE MANUAL V2.9

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  • Page 1 XSTREAM SERVICE MANUAL V2.9...

  • Page 2: Table Of Contents

    SERviCE maNual - xSTREam 1. CONTENTS Table of contents 1. Safety regulations 2. Introduction Markings Service handbook Symbols used throughout the handbook Improvements Product upgrades Information about Xstream Upgrade kit 4826 Information about Xstream 1st stage covers. Information about Xstream Upgrade to cover with adjustment screw. Recommendations EN 144-3 Article number on o-rings...

  • Page 3: Safety Regulations

    If the Nitrox Ready status is to be maintained after servicing, only service kit marked with EAN40 and oxygen compatible lubricant may be used. 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”...

  • Page 4: Introduction

    2. Introduction Markings 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 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.

  • Page 5: Service Handbook

    Approved for use with EAN40 max Service handbook This servicing handbook is available for download at the Poseidon Extranet at http://extranet.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: Phone: +46 (0)31 7342900 ask for “technical assistance”...

  • Page 6: 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. com with the serialnumber and date of service clearly marked.

  • Page 7: Determination Of Required Service

    • All 1st stage components made out of metal are washed in an ultra sonic cleaner, using the Poseidon Fine clean Ultra liquid, for a time period of 10 - 15 minutes. •...
  • Page 8 4. Tools To service Poseidon regulators there is a number of tools required. Some of the tools are special tools for Xstream and Poseidon and some 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 is used for.
  • Page 9 4538-WE Cover Xstream 2nd stage (Deco) 4538-GN Cover Xstream 2nd stage (Duration) 4538-YW Cover Xstream 2nd stage (Octopus) 4538-GY Cover Xstream 2nd stage (Dive) 4539 Sticker Poseidon Xstream 4531 Checkvalve 4537-BK Housing 0011-278 O-ring Xstream 2nd st., viton 0010-025 O-ring...
  • Page 10 Item # Description 0012-028 O-ring (Deep) 0011-037 O-ring, viton (Deco/Duration) 4807-59 O-ring, viton (*/**) 4571 Conn. stem 1.stage Xstream 4871 Conn. stem 1.stage Xstream (*/**) 4572 Cup type filter Xstream 4581 Stainl. washer 1.stage Xstream 4576-BK Wheel G5/8” Xstream, black 4576-WE Wheel G5/8”...
  • Page 11 Item # Description 0013-032 O-ring (Deep 90/Dive 90/ Deep 90 EAN40) 0011-037 O-ring, viton (Duration90) 0011-335 O-ring. viton (Duration90 EN 144-3) 4778 Conn. stem 1.stage 90 Xstream 4878 Conn. stem 1.stage Duration90 EN 144-3 4552 Cup type filter long Xstream 90 0012-132 O-ring (Deep90/Dive90) 0011-277...
  • Page 12 SERviCE maNual - xSTREam 5. SPaRE PaRTS & SERviCE KiTS First stage 90 EAN40 0110-000 1st stage G 5/8” Xstream Deep90* *With serial number 1500001 or higher. Item # Description 0000-139 - Housing Xstream 90 4555 - Ball seat spring 0000-149 - Ruby ball 0013-349 - O-ring 4758 - Ball seat 4760 - Seat holder...
  • Page 13 SERviCE maNual - xSTREam 5. SPaRE PaRTS & SERviCE KiTS First stage Black 0110-010 1st stage 1st Stage Xstream Black G5/8”* Item # Description 0002-100 - Housing Xstream 90 4555 - Ball seat spring 0000-149 - Ruby ball 0013-349 - O-ring 4758 - Ball seat 4760 - Seat holder 4764 - Seat spring 0005-077 - Actuating pin...

  • Page 14: Spare Parts & Service Kits

    SERviCE maNual - xSTREam 5. SPaRE PaRTS & SERviCE KiTS Servicekits 4821 Servicekit Xstream Deep 1:st stage Included: 4758 Zytel valve seat Xstream 1 pc 4572 Cup type filter Xstream 1 pc 0010-353 (2782) O-ring (Deep/Dive) 3 pcs 0010-354 (2918) O-ring (Deep/Dive) 2 pcs 0015-059 (4557)

  • Page 15: Servicekits

    SERviCE maNual - xSTREam 5. SPaRE PaRTS & SERviCE KiTS Upgrade kits Xstream Upgrade Kit 4826 Xstream upgrade kit for models below s/n 310001 Included: 4760 Valve seat holder Xstream 1 pc 4777 Lower pin guide Xstream 1 pc 4762 Upper pin guide Xstream 1 pc 4581 Stainl.

  • Page 16: O-Ring Conversion Table

    SERviCE maNual - xSTREam 5. SPaRE PaRTS & SERviCE KiTS O-ring conversion table Old article number New article number Note 1007 0012-028 1007 59 0011-037 1145 0010-025 1145 55 0013-018 1156 0010-009 1156 59 0011-006 1164 0010-347 1233 0012-007 1233 55 0013-009 1365 0010-177...

  • Page 17: Service

    6. SERviCE SERviCE maNual - xSTREam 6. Service The parts that needs to be replaced during a service are described in the Spare parts & 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.
  • Page 18 6. SERviCE SERviCE maNual - 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 4564 Roll. diaphragm 1.stage Xstream Only use fingers. Tools may puncture the diaphragm Pin guide assembly 4764 Valve seat spring Xstream...
  • Page 19 6. SERviCE SERviCE maNual - xSTREam Only for Xstream bottom mounted first stages Step Parts Tools/Instructions Replace Picture 0012-028 O-ring (Deep) 0011-037 O-ring, viton (Deco/Duration) 0003-214 O-ring, viton EN 144-3 (Deco EN 144- 3/Duration EN 144-3) 4571 Conn. stem 1.stage Xstream 4576-BK Wheel G5/8”...
  • Page 20 6. SERviCE SERviCE maNual - xSTREam 4576-BK Line protector Xstream, black 4576-GN Line protector Xstream, green 0013-165 O-ring (Deep90 EAN40) 0012-132 O-ring (Deep90/Dive90) 0011-277 O-ring Viton (Duration90/Oxygen) 4576-BK Wheel G5/8” Xstream, black 4576-GN Wheel G5/8” Xstream, green 0000-151 Wheel Xstream Duration M26, green 0000-150 Wheel Xstream Deco M26, white 4552 Cup type filter long Xstream 90 Over pressure valve (only 1st stages with a built in OP...
  • Page 21 6. SERviCE SERviCE maNual - xSTREam 4559 Actuating pin, Xstream 4777 Lower pin guide Xstream 6 mm 4563 Pin bushing 1.stage Xstream Do 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 bushing while servicing Deco, Oxygen and and pull out.

  • Page 22: Xstream Second Stage

    6. SERviCE SERviCE maNual - xSTREam 0000-141 Adjusting screw Chrome Xstream second stage To 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.
  • Page 23 6. SERviCE SERviCE maNual - xSTREam Step Parts Tools Replace Picture 2875 Stop screw 4534 Valve tube Xstream 0013-001 O-ring 2nd stage Xstream, EPDM 0013-365 O-ring 2nd stage Xstream, EPDM 4547 Vavle housing nut, Xstream 2787 Rubber plate 0013-009 O-ring 2nd stage Xstream, EPDM 0010-025 O-ring 3440...

  • Page 24: Inspections

    6. SERviCE SERviCE maNual - xSTREam 0011-278 O-ring Xstream 2nd st., viton Inspections Step Parts Inspect Picture 3440 Valve insert 1. Ensure no circular cuts on bladder surface. 2. Check O-ring sealing surface 4531 Checkvalve 1. Check for damages on check valve edge 4534 Valve tube Xstream 1.

  • Page 25: Cleaning

    6. SERviCE SERviCE maNual - xSTREam Step Parts Inspect Picture 2680 Blindscrew UNF7/16 1. Check O-ring sealing surfaces 2679 Blindscrew UNF3/8, 4571 Conn. stem 1.stage Xstream 1. Check O-ring sealing surfaces 4871 Conn. stem 1.stage Xstream EN 144- 3 (Deco EN 144-3/Duration EN 144-3) 4778 Conn.

  • Page 26: Xstream Deco/Duration Cleaning For Oxygen Use

    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 will be cleaned to a cleanliness level which 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.)

  • Page 27: Cleaning

    Wash your hands before this cleaning process. Always ensure the UltraSonic cleaner is absolutely clean inside Fill the UlraSonic cleaner with Poseidon FineClean 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.
  • Page 28 6. SERviCE SERviCE maNual - xSTREam Deco/Duration/Oxygen/ 0016-036 O-ring, viton (Deco/Duration) 0013-394 O-ring (Deep EAN40) Deep EAN40 0015-059 O-ring (Deep/Dive) Deep/Dive 0015-012 O-ring 0013-392 O-ring (Deep EAN 40) Use bushing 4563 to install o-ring 4763 Pin bushing 1.stage Xstream Make sure fully to the bottom 4777 Lower pin guide Xstream 3 +/- 1 Nm...
  • Page 29 6. SERviCE SERviCE maNual - xSTREam On blindscrew UNF 3/8” 0010-353 O-ring Deep 2 or 3 pcs, Dive 5 pcs On blindscrew UNF 7/16” Deep/Dive 0012-132 O-ring Deep 1 pcs, Dive 2 pcs 4552 Cup type filter long Xstream 90 4576-BK Wheel G5/8”...
  • Page 30 6. SERviCE SERviCE maNual - xSTREam 0012-028 O-ring viton (Deep/Dive) Deep/Dive 180 degree model 4581 Stainl. washer 1.stage Xstream 4572 Cup type filter Xstream 4572 Cup type filter Xstream 4576-BK Wheel G5/8” Xstream, black 4576-WE Wheel G5/8” Xstream, white 4576-GN Wheel G5/8”...
  • Page 31 6. SERviCE SERviCE maNual - xSTREam 4555 Spring for ball Xstream Wider end facing upwards, towards the ball. 4556 Ball 1.stage Xstream 4760 Valve seat holder Xstream 4758 Zytel valve seat Xstream 4761 Valve seat spring Xstream Deco/Duration/Oxygen/ Pin guide assembly Deep EAN40 3 +/- 1 Nm Refer to section 9 for other units.
  • Page 32 6. SERviCE SERviCE maNual - xSTREam 4570-BK Barrier 1.stage Xstream black 4570-WE Barrier 1.stage Xstream white 4570-GN Barrier 1.stage Xstream green You should see the marking ”This side up” on the barrier. 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 Deco/Duration/Oxygen/...

  • Page 33: Xstream Second Stage

    6. SERviCE SERviCE maNual - xSTREam Xstream second stage Step Parts Tools/Instructions Replace Picture Deco/Duration/Deep EAN40 0011-278 O-ring Xstream 2nd st., viton Deep/Dive 0011-278 O-ring Xstream 2nd st., viton 3440 Valve insert 0010-025 O-ring Deco/Duration/Deep EAN40 0010-025 O-ring Deep/Dive 0013-009 O-ring 2nd stage Xstream, EPDM Deco/Duration/Deep EAN40 0013-009...
  • Page 34 6. SERviCE SERviCE maNual - xSTREam Step Parts Tools/Instructions Replace Picture 4547 Vavle housing nut, Xstream 3 +/- 1 Nm 0013-365 O-ring 2nd stage Xstream, EPDM Deco/Duration/Deep EAN40 0013-365 O-ring 2nd stage Xstream, EPDM Deep/Dive 0013-001 O-ring 2nd stage Xstream, EPDM Deco/Duration/Deep EAN40 0013-001 O-ring 2nd stage Xstream, EPDM...
  • Page 35 6. SERviCE SERviCE maNual - xSTREam Step Parts Tools/Instructions Replace Picture 4545 Servo-valve Xstream Firm by hand 4531 Exhalation diaphragm ONlY IF REPlACED 4533 Diaphragm silicone 4536 Diaphragm cover 4538-BK Cover Xstream 2nd stage (Deep) 4538-WE Cover Xstream 2nd stage (Deco) 4538-GN Cover Xstream 2nd stage (Duration) 4538-YW...

  • Page 36: Final Inspection

    7. FiNal iNSPECTiON SERviCE maNual - xSTREam 7. Final inspection Setting, final inspection Property 1st stage Setting SI units Setting common units Setting US units 30 MPa 300 bar 4351 psi >750 kPa > 7.5 bar >109 psi 2 MPa 20 bar 290 psi P4@p1,...

  • Page 37: Method For All Other Regulators

    7. FiNal iNSPECTiON SERviCE maNual - xSTREam Method for all other regulators SYSTEM CHECk: 1) Open left valve 20 bar 2) Close left valve 20 bar 3) Purge FIRST STAGE SETTING: 1) Open right valve HP (200-300bar) 2) Purge 3) Check IP (go to 9 if OK) 4) Close right valve 5) Purge 6) Adjust IP (1/2 turn = 1.5 bar)
  • Page 38 7. FiNal iNSPECTiON SERviCE maNual - xSTREam ADjUST THE 2 STAGE TO 28-40 MM.W.C. Hold the mouthpiece-part of the cracking pressure gauge tight to the outlet of the 2 stage Take a few rather slow and long inhalations from the m o u t h p i e c e part and simultaneously check the pressure gauge needle. It shall during inhalation reach a maximum of 28-40 mm.w.c, and at the end of the inhalation decrease again.

  • Page 39: Technical Data

    Deco/Oxygen O-ring materials Dive Nitrile, EPDM,Viton Deep Nitrile, EPDM,Viton Duration/Oxygen/EN 144-3 Viton, EPDM, Nitrile Deco/EN 144-3 Viton, EPDM, Nitrile Lubricants Poseidon 1; BAM appr. 270 bar @ 100°C Poseidon 2; BAM appr. 140 bar @ 100°C Poseidon R; silicone oil. Colour Dive Grey Deep Black Duration/EN 144-3 Green Deco/Oxygen White Octopus Yellow Warranty 24 months (if serviced)

  • Page 40: Conversion Tables

    SERviCE maNual - xSTREam 8. TECHNiCal DaTa 1st stage Flowrate (l/min) >4000 l/min (>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 Built in T.D.A Technique...

  • Page 41: Performance

    SERviCE maNual - xSTREam 8. TECHNiCal DaTa Performance 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 average behind it, is extracted from hundreds of tests, from which coefficients for gas dependency, average flow dependency, and depth dependency is calculated.

  • Page 42: Oxygen Statement

    9. OxYGEN STaTEmENT 9. Oxygen statement The Poseidon Xstream Deco, Duration, Duration90 and Oxygen 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.

  • Page 43: Updates

    SERviCE maNual - xSTREam 10. uPDaTES 10. Updates Version Date Updated by Comments 2003-03-20 Poseidon First issue 2003-05-07 Poseidon Changes in section 5. Item numbers. 2004-09-24 Poseidon EN 144-3 2005-02-11 Poseidon Change in stage 26 of Service level B regarding the Pin bushing...

  • Page 44: Appendix Afaq(T)'S

    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, Xstream Deep 90 regulators and 1st stages with serial number 1500001 and higher are delivered ”Nitrox Ready”...

  • Page 45: Fundamental Oxygen Risks Comprehension

    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 combustion. The O 4 concept Poseidon has introduced the O concept, which stands for oxygen engineered, oxygen compatible, oxygen clean, and oxygen approved.

  • Page 46: Nomenclature Regulator Performance

    SERviCE maNual - xSTREam aPPENDix C APPENDIX C Nomenclature regulator performance stage regulator performance The nomenclature to describe the regulator is as far as possible in accordance with EN ISO 2503:1998. Rated maximum inlet pressure, p1 Rated maximum inlet pressure for which the pressure regulator is designed •...

  • Page 47: Cleanroom And Oxygen Cleaning Requirement

    Tools have to be re-cleaned every month or after 10 serviced regulators, whichever comes first. 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.
  • Page 48 Issue 2.9 Copyright © Poseidon Diving Systems AB 2005 - 2013 All rights reserved. No parts of this book may be reproduced in any form whatsoever without written permission of the publisher. Service manual Xstream.

This manual is also suitable for:

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