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Tusa PLATINA R-100 Technical Manual

Balanced piston first stage regulator
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R-100
BALANCED PISTON FIRST STAGE REGULATOR
R-100 FIRST STAGE
TECHNICAL MANUAL
1
Revised v1.0-2000

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Summary of Contents for Tusa PLATINA R-100

  • Page 1 R-100 BALANCED PISTON FIRST STAGE REGULATOR R-100 FIRST STAGE TECHNICAL MANUAL Revised v1.0-2000...

  • Page 2: Table Of Contents

    R-100 BALANCED PISTON FIRST STAGE REGULATOR INDEX SECTION PAGE NO. GENERAL INFORMATION Important Information Lubricants and Sealants Tools Required DESCRIPTION AN OPERATION Terminology & Description of Operation Balanced Piston First Stage GENERAL (USER) RECOMMENDED MAINTENANCE General Care Guidelines Determining Service Intervals & Cycle life Determining Service Application Exposure of Equipment User Maintenance...

  • Page 3: General Information

    This manual is designed for use by authorised service technicians who have completed a training course in TUSA Regulator repair. This manual is intended for use only in connection with the TUSA Regulator Repair course as prescribed by Tabata Co., Ltd and is not meant for general distribution. Accordingly, Tabata Co., Ltd makes no representations or warranties or any kind concerning the...

  • Page 4: Tools Required

    TOOLS REQUIRED The following tools are recommended for servicing the R-100 regulators. Some tools listed are available from local sources. Special tools can be purchased upon request from the TUSA Technical Service Department using the indicated catalogue number. ITEM CATALOGUE NO.

  • Page 5: Description An Operation

    R-100 BALANCED PISTON FIRST STAGE REGULATOR DESCRIPTION AND OPERATION SECTION II TERMINOLOGY AND DESCRIPTION OF OPERATION The following discussion will introduce the proper terminology to be used through the manual. To help establish efficient communications when reporting problems to the factory or discussions with the customer we recommend that you utilize these terms.
  • Page 6 R-100 BALANCED PISTON FIRST STAGE REGULATOR DESCRIPTION AND OPERATION The piston will remain in the CLOSED position until the intermediate pressure in the LP hose is lowered by the actuation of the demand lever in the second stage regulator during inhalation. This lowering reduces the pneumatic force acting against the front of the HP piston head which permits the combined force of the HP spring and the ambient water pressure to move the HP piston to the OPEN position allowing high pressure air to flow into the swivel chamber again.

  • Page 7: General (User) Recommended Maintenance

    SECTION III GENERAL CARE GUIDELINES Tusa recommends to all Authorised Dealers that they take individual time with each customer to explain and demonstrate the following simple steps for care and maintenance of the regulator. This will help to ensure the following goals: Personalised contact with the customer insuring satisfaction.

  • Page 8: Determining Service Intervals & Cycle Life

    If you suspect your regulator has been exposed to excessive heat, please have it examined by your authorised TUSA service centre. DO NOT leave the regulator pressurized or attached to a SCUBA cylinder for an extended period of time when not in use.

  • Page 9: Determining Service Application

    R-100 BALANCED PISTON FIRST STAGE REGULATOR GENERAL (USER) RECOMMENDED MAINTENANCE DETERMINING SERVICE APPLICATION As you can see it is important to determine your customers dive habits to determine the best possible recommendation for service. Other factors to consider include the exposure of the equipment, extent of user maintenance, experience and application from the user and future planned use of the equipment.

  • Page 10: Inspection Techniques And Troubleshooting

    Section 5.1. SEALING SURFACES All metal parts use in TUSA regulators are made of either a corrosion resistant stainless steel or chrome plated brass. Handle all metal components with care to avoid scratches, dings or dents. Some components such as the first stage piston in the R-100 have a very smooth and polished surface on the stem.

  • Page 11: (C) Hoses & Rubber Components

    HOSES AND RUBBER COMPONENTS The examination, care and handling of all rubber components are well documented through out the TUSA Dealer Service Manual. Look for deterioration and cracking of rubber components resulting from age, misuse, or exposure to caustic cleaning compounds. Contact your factory representative should you have further questions.

  • Page 12: Troubleshooting

    R-100 BALANCED PISTON FIRST STAGE REGULATOR INSPECTION TECHNIQUES AND TROUBLESHOOTING TROUBLESHOOTING R-100 BALANCED PISTON FIRST STAGE SYMPTON POSSIBLE CAUSES RECOMMENDATIONS LOW FLOW OR HIGH INHALATION EFFORTS 1 Cylinder valve not open or clogged 1 Open valve completely or overhaul needed 2 Sintered filter (5) clogged 2 Replace sintered filter 3 HP spring (18) coil weak or fatigued...

  • Page 13: Disassembly/Assembly

    Warranty scheme annual service, please return these parts to your TUSA factory distributor along with a copy of the service report. Remember to record your findings as you proceed to allow both a complete record of the overhaul and future reference for servicing.
  • Page 14 R-100 BALANCED PISTON FIRST STAGE REGULATOR DISASSEMBLY / ASSEMBLY Prepare to remove the End-cap (22) by inserting one LP tightening bar into one of LP port in the end cap and one HP tightening bar into one of the HP ports in the body (13) Refer to Figure.
  • Page 15 R-100 BALANCED PISTON FIRST STAGE REGULATOR DISASSEMBLY / ASSEMBLY Remove any spring isolators (17) FIG. 5-f (using a pneumatic air gun) from the base of the piston head and inspect this area for signs of corrosion See Figure. 5-f. Also inspect the piston stem for unusual scratches, dings, dents or wear along its sealing surface.
  • Page 16 R-100 BALANCED PISTON FIRST STAGE REGULATOR DISASSEMBLY / ASSEMBLY Removal the piston stem o-ring (12) FIG. 5-i located within the internal o-ring groove of the main body (13), but must be attempted using only the proper tools and patience. View the main body through the piston entrance to locate the internal o-ring groove.
  • Page 17 R-100 BALANCED PISTON FIRST STAGE REGULATOR DISASSEMBLY / ASSEMBLY NOTE Use care and caution to avoid damage to the surface of the body (13). DO NOT over- tighten the vise onto the soft brass of the first stage. To remove the conical filter (5), first remove the filter retainer assembly with 3/8”...

  • Page 18: General Cleaning Methods

    Science has led to the use of engineered plastic polymers and thermoplastic resin alloys replacing traditional metal components. All metal parts used in TUSA regulators are made of either a corrosion resistant stainless steel or chrome plated brass. Handle all metal components with care to avoid scratches, dings or dents.

  • Page 19: Repair & Replacement Schedule

    The following repair and replacement schedule is recommended for the R-100 Balanced Piston First Stage. Tusa recommends full replacement of all soft seals (o-rings & seats) according to service use and cycle life of the regulator as discussed in Section 3.0.

  • Page 20: Assembly

    R-100 BALANCED PISTON FIRST STAGE REGULATOR DISASSEMBLY / ASSEMBLY ASSEMBLY R-100 BALANCED PISTON FIRST STAGE NOTE Prior to assembly, ensure that all parts have been inspected (both new and those that are being reused) and are of top quality. Ensure that all o-rings are clean, supple and lubricated as described in Section 5.1.
  • Page 21 (13) and against the second spring isolator. Refer to Figure 5-p Then place a genuine TUSA R100 piston bullet through the piston, from the orifice end. The bullet should be exposed out the end of the piston.
  • Page 22 R-100 BALANCED PISTON FIRST STAGE REGULATOR DISASSEMBLY / ASSEMBLY NOTE If tuning is required after assembly of the R-100 regulator it is recommended not to use Loctite until the intermediate pressure has been adjusted. Holding the body with your hand FIG.
  • Page 23 Immediately hand tighten. Using a slotted flat bar tool or a TUSA special wrench tool as shown in Figure 5-v, FIG. 5-w begin a firm, steady, clockwise force tightening the yoke retainer nut.

  • Page 24: Tuning And Adjustment

    R-100 BALANCED PISTON FIRST STAGE REGULATOR TUNING AND ADJUSTMENT SECTION VI R-100 BALANCED PISTON FIRST STAGE TUNING Refer all item numbers (99) to the schematics view for this regulator found after Section Prior to tuning the balanced piston first stage regulator, ensure that all cleaning, assembly and disassembly procedures have been followed closely.
  • Page 25 Replace spring isolators as required to adjust the intermediate pressure. Apply a light film of lubricant (see section 1.1) to both sides of the spring. Before installing the HP spring. Install a genuine Tusa piston FIG. 6-a installation bullet into the HP piston stem.

  • Page 26: Torque Specifications For R-100

    135 to 145 psi. Refer to Figure 6-b. This concludes the tuning & adjustment of the TUSA PLATINA R-100 Balanced Piston First Stage. Please refer to the Section 4.2 for troubleshooting. TORQUE SPECIFICATIONS FOR R-...

  • Page 27: Special Applications Guidance

    R-100 BALANCED PISTON FIRST STAGE REGULATOR SPECIAL APPLICATIONS GUIDANCE SECTION VII PERFORMANCE SPECIFICATIONS The performance specifications for the R-100 balanced piston first stage regulator is listed as follows and is subjected to change without notice: Weight: First stage with out hose 1.35 lb.

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