Kirby Morgan Air Control System 5 Operations and Maintenance Manual KMDSI Part #100-075 Patented, Patents Pending, Foreign Patents Apply

Kirby Morgan Air Control System 5 Operations and Maintenance Manual KMDSI Part #100-075 Patented, patents pending, foreign patents apply

MO BY RGA IR N K

D . IV c E In SYSTEMS, ™

Kirby Morgan Dive Systems, Inc. 1430 Jason Way Santa Maria, CA 93455, USA Telephone (805) 928-7772, FAX (805) 928-0342 E-Mail: [email protected], Web Site: www.KirbyMorgan.com

NOTE: This manual is the most current for the Kirby Morgan Air Control System 5. It is page dated September 2012. Future changes will be shown on page III and the changed pages will carry the date of change. Previous manuals may not reflect these updates.

B WARNING Diving with compressed breathing gas is a hazardous activity. Even if you do everything right there is always the danger that you may be killed or injured. No piece of diving equipment can prevent the possibility that you may be killed or injured any time you enter the water.

Kirby Morgan, SuperLite, BandMask, Band Mask, KMB, KMB-Band Mask, DSI, Diving Systems International, EXO, REX, Su- perFlow and DECA are all registered trademarks of Kirby Morgan Dive Systems, Inc. Use of these terms to describe products that are not manufactured by KMDSI is illegal.

The two dimensional images (such as photographs and illustrations) of our products are © copyrighted and trademarks of Kirby Morgan Dive Systems, Inc. The three dimensional forms of our products are trademark, trade design and trade dress protected.

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. This manual is made available for the express use of the owner of this Kirby Morgan product. No part of this manual may be reproduced, stored in any retrieval system, or transmitted, or used in any form or by any means, whether graphic, electronic, mechanical, photocopy, or otherwise by technology known or unknown, without the prior written permission of Kirby Morgan Dive Systems, Inc.

Document Number 120912001 Kirby Morgan Air Control System 5

Warranty Information

Kirby Morgan Dive Systems, Inc. warrants every new mask, helmet, or KMAC Air Control System to be free from defects in workmanship for a period of three hundred sixty five (365) days from date of purchase. This warranty covers all metal, fiberglass, and plastic parts. This warranty does NOT cover rubber parts, communications components, or head cushions. In addition, due to the electro- lytic nature of underwater cutting and welding, chrome plating cannot be warranted when the diver engages in these activities.

Should any part become defective, contact the nearest authorized KMDSI dealer. If there is no dealer in your area, contact KMDSI directly at (805) 928-7772. You must have a return authoriza- tion from KMDSI prior to the return of any item, Upon approval from KMDSI, return the defective part, freight prepaid, to the KMDSI plant. The part will be repaired or replaced at no charge as deemed necessary by KMDSI. This warranty becomes null and void if: 1) The product is not registered with KMDSI within ten (10) days of purchase. 2) The product has not been properly serviced and/or maintained according to the appropriate KMDSI manual. In addition, the user is responsible to ensure that all product updates as recommended by KMDSI have been performed. 3) Unauthorized modifications have been made to the product. 4) The product has been abused or subjected to conditions which are unusual or exceed the product’s intended service.

NOTE: Be sure to complete the enclosed warranty card and return it to KMDSI immediately. No warranty claims will be honored without a satisfactorily completed warranty card on file at KMDSI.

It is the responsibility of the owner of this product to register their ownership with Kirby Morgan Dive Systems, Inc., by sending the warranty card provided. This card is to establish registration for any necessary warranty work and provides a means of communication that allows KMDSI to contact the user regarding this product. The user must notify KMDSI of any change of address by the user or sale of the product.

All changes or revisions to this manual must be recorded in this document to ensure that the manual is up to date. Quantities marked in parenthesis.

Change Number Date Description of Change 1 06/11/2009 Updated table of contents layout. 2 02/17/2010 Corrected the PSI to BAR conversion in the Table of Equivalents 3 08/26/2010 Changed 5.3 Exploded Views & Parts Lists P/N 405-039 to 415-030 and description updates. 4 06/13/2012 Updated copyright format

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 III Kirby Morgan Air Control System 5 B WARNING Diving with compressed breathing gas is a hazardous activity. Even if you do everything right there is always the potential for serious injury or death. No one piece of diving equipment can prevent the possibility that you may be injured or killed any time you enter the water. The information in this manual is intended for users of KMACS and persons that maintain or service KMACS.

Warranty Information �� II Record Of Changes �� III Definition of Signal Words Used in this Manual �� VI Chapter 1.0 General Information �� 1 1.1 Definitions �� 1 1.2 Design Purpose �� 2 1.3 Specifications �� 3 1.4 General Description �� 3 1.4.1 Breathing Air Subsystem �� 3 1.4.2 Principle Operating Features �� 3 Chapter 2.0 Operating Instructions �� 9 2.1 Unpacking The KMACS 5 �� 9 2.2 First Use Of The KMACS 5 �� 9 2.3 Connecting The Air Supply �� 9 2.4 Connecting Diver’s Hoses To The KMACS 5 ��10 2.5 Pre-Dive Check �� 11 2.5.1 Testing L.P. Supply �� 11 2.5.2 Testing Communications �� 11 2.5.3 Testing The Pneumo ��12 2.6 Preparing The Diver ��13 2.7 The Dive Supervisor And The KMACS 5 Operator ��13 2.8 Descent ��13 2.9 Diver At Depth ��14 2.10 Changing Out High Pressure Cylinders ��14 2.11 Procedures During The Diver’s Ascent ��15 2.12 Decompression ��15 2.13 Completion Of Diving Operations ��15 Chapter 3.0 KMACS 5 Maintenance ��17 3.1 Recommended Maintenance Of The KMACS 5 ��17 3.2 Replacing The Battery ��17 Chapter 4.0 Troubleshooting the KMACS 5 System ��19 4.1 General ��19 4.2 No Communications ��19 4.3 No Pneumo Reading ��19 4.4 No Air To Diver ��20 Chapter 5.0 Appendix ��21 5.1 Emergency Procedures ��21 5.2 Communications Wiring Schematics ��22 5.3 Exploded Views & Parts Lists ��22 Table of Equivalents ��25 Appendix 1 Umbilical Supply Pressure Requirements & Tables ��26 High Pressure Bank Supply ��26 Low Pressure Compressor Supply ��26

For your protection, pay particular attention to items identified by signal words in this manual. These terms are identified as, CAUTION, WARNING and DANGER. It is especially important for you to read and understand these sections. B DANGER This word indicates an imminently hazardous situation, which if not avoided, could result in death or serious injury.

B WARNING This word indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

B CAUTION This word indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTICE This word is used to address practices not related to personal injury.

If English is not your native language and you have any difficulty understanding the language of any warnings as they appear in the manual, please have them translated. B WARNING Este é um aviso importante. Queira mandá-lo traduzir.

B WARNING Este es un aviso importante. Sirvase mandario traducir.

B WARNING Quest è un avviso importante. Tradurlo.

B WARNING Ceci est important. Veuillez traduire.

B WARNING Diese Mitteilung ist wichtig. Bitte übersetzen lassen.

If you have any questions concerning this manual or the operation of your KMACS 5, contact KMDSI (805) 928-7772 or by Email at [email protected] or Dive Lab Inc. (850) 235-2715 or at [email protected]

IMPORTANT: A word about this manual. We have tried to make this manual as comprehensive and factual as possible. We reserve the right, however, to make changes at any time, without notice, in prices, colors, materials, equipment, specifications, models and availability. Since some information may have been updated since the time of printing, please contact your local KMDSI dealer if you have any questions. Periodically KMDSI Operations and Maintenance Manuals are reviewed. Any updates/changes will be posted on the KMDSI website and may be downloaded for insertion/correction.

VI © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 Kirby Morgan Air Control System 5 Important Safety Information: This Kirby Morgan Air Control System 5 is intended for use by trained divers who have successfully completed a recognized training course in surface supplied diving

B WARNING Follow all the instructions in this manual carefully and heed all safety precautions. Im- proper use of this diving equipment could result in serious injury or death.

B WARNING Kirby Morgan Dive Systems, Inc. (KMDSI) warns all divers who use Kirby Morgan diving equipment to be sure to use only KMDSI original parts from a KMDSI authorized dealer. Although other parts, O-rings and fittings may appear to fit your Kirby Morgan equipment, they may not be manufactured to the same standards maintained by KMDSI. The use of any parts other than KMDSI original parts may lead to equipment failure and accidents.

B WARNING Diving in waters that are chemically, biologically, or radiologically contaminated is extremely hazardous. Although Kirby Morgan surface supplied diving systems may be adapted for use in some contaminated environments, special training, equipment, and procedures are necessary. Do not dive in a contaminated environment unless you have been thoroughly trained and equipped for this type of diving.

Read this manual before using or maintaining the KMACS 5, even if you have experience with other surface supplied diving systems. If you have purchased the KMACS 5 new from a dealer, be sure to send in the warranty registration card so we may keep you informed of any safety notices that affect this product. If you resell or loan this equipment to another diver, be sure this manual accompanies the equipment and that the person reads and understands the manual. In addition to the manual a log book should be used to log all repairs, maintenance and use.

B WARNING This KMACS 5 was completely checked and should be ready to dive as it was shipped from the factory. However, it is always the diver’s responsibility to check all the components of the KMACS 5 prior to diving.

B WARNING Diving is a life threatening occupation. Even if you do everything right you can still be killed or injured. None of the Kirby Morgan equipment can prevent accidents, injuries or death due to improper training, poor-health, improper supervision, improper job requirements, improper maintenance or acts of God.

This manual is supplied to the original purchaser of this equipment. If you have any questions about the use of the equipment or you need another copy of this manual, contact KMDSI or your nearest KMDSI dealer. It may also be downloaded free from the KMDSI website at www.KirbyMorgan.com.

If you have any questions regarding the use, maintenance, or operation of this equipment, contact KMDSI at (805) 928- 7772, fax: (805) 928-0342, or e-mail: [email protected].

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 VII Kirby Morgan Air Control System 5 B WARNING Never use the equipment without first completing all pre-dive maintenance and set up procedures. Failure to complete all pre-dive checks could result in equipment failure due to problems with the incorrect set-up of the equipment. This could lead to serious personal injury or death.

B WARNING Always read the Material Safety Data Sheet (MSDS) for any chemical - adhesive, cleaning agent, or lubricant - used on your KMACS 5. Some of these chemicals may cause serious bodily injury or death if used improperly or without the proper personal protective equipment.

Whenever KMDSI equipment is used in European Countries, which have adopted the CE certification programs, it must only be used with CE. certified components. Diving operations should only be conducted within the limits of the operational specifications, and in accordance with the rules and regulations established by the governing authority in the specific country or geographical location where the diving operations are being conducted. If you have any questions concerning this manual or the operation of your equipment, contact KMDSI (805) 928-7772 or at [email protected] or Dive Lab Inc. (850) 235-2715 or at [email protected]

B WARNING Some of the procedures shown in this manual are for illustration purposes only. When using chemicals or materials that require the use of hand or eye protection, always wear the appropriate personnel protective equipment. Failure to use personnel protective gear may result in serious personal injury.

If you have any questions regarding the use, maintenance, or operation of this equipment, contact KMDSI at (805) 928- 7772, fax: (805) 928-0342, or e-mail: [email protected].

Components requiring lubrication, should only be lubricated with oxygen compatible lubricants such as Christo Lube®, Flourolube®, or Krytox®. Lubricants must be used sparingly and should not be mixed with other lubricants.

B WARNING Kirby Morgan “High Pressure Components” (greater than 250 p.s.i.g., 17.24 bar) must not be used with pure oxygen, Nitrox, or any breathing gas mixtures with oxygen content greater than 23% by volume. Using oxygen mixtures in excess of 23% by volume may lead to a fire or explosion, which could result in serious injury or death.

B WARNING The KMACS-5 has not been designed or cleaned for oxygen or enriched oxygen use. The KMACS-5 is intended for air use only. Use of oxygen or enriched oxygen may lead to a fire or explosion, which could result in serious injury or death.

Kirby Morgan Air Control System 5 without communications.

Kirby Morgan Air Control System 5 with communications.

Kirby Morgan Air Control System 5 STOP! BEFORE GOING FURTHER- This manual will refer to location numbers in specific drawings, or in the exploded view, which is in the back of this manual. These numbers are called “location” numbers. They are used to find the referred to parts in the drawings in this manual only. They are not the part number. Next to the exploded drawing is a list of the “location” numbers that match the Kirby Morgan part numbers along with the name of the part. Always check the part number when ordering to make sure it is correct. When ordering, always specify the model number and serial number as well. Chapter 1.0 General Information

1.1 Definitions High Pressure (H.P.) Hose: A flexible hose designed The following terms may be unfamiliar to the reader. to carry a working pressure of gas (or air) of more They are defined as they relate to this manual and than 300 pounds (20.7 bars) per square inch. The diving. All parts locations are referenced by LETTER rated working pressure is usually indicated on the in the diagram on page 6. hose and must not be exceeded. The working pressure of the high pressure system on the KMACS 5 is 3500 KMACS 5—Kirby Morgan Air Control System psi (240 bars) 5: The Trademark name of the device this manual describes. The KMACS 5 contains all of the Whip: A hose complete with fittings at each end for components necessary to properly control and use in hooking up two pieces of deck equipment for monitor surface supplied air dives. Included in gas (or air) flow. For instance, the hoses and fittings the KMACS 5 is a two-way voice communicator used to connect the KMACS 5 to the high pressure for talking between the KMACS 5 operator and tanks are called “high pressure whips.” the diver(s), or diver-to-diver. The communicator operates in both the two wire and four wire mode. H.P.—High pressure: Usually any pressure over 300 psi. (20.7 bars). Scuba: Self Contained Underwater Breathing Apparatus. L.P.—Low pressure: Usually any pressure under 300 psi. (20.7 bars). SSAir Diving—Surface Supplied Air Diving: Diving operation where the diver is supplied Pneumofathometer: (pronounced “new-mo- breathing air by way of a hose which is part of the fathometer”) This device measures the diver’s depth. diver’s umbilical from the surface. Usually the source A small hose which is part of the diver’s umbilical of the breathing air is a compressor, but compressed runs from the KMACS 5 to the diver. The hose is air tanks on the surface can also be used. open at the diver’s end and attaches with a fitting to a gauge at the KMACS 5. The gauge is calibrated in feet and meters of sea water. A valve is installed on Diver’s Umbilical: Several components run together the upstream side of the gauge so the operator can from the KMACS 5 to the diver. These components use a small amount of breathing air to purge the water are joined together, usually by tape, forming the from the hose. When the hose has been purged of umbilical. The most common components used in the water and the valve is closed the excess air bubbles diver’s umbilical are: (A) a hose through which the out of the end of the hose at the diver's end. The air breathing air flows to the diver; (B) a multiconductor left in the hose will be at the pressure of the water wire for communications transmission; (C) another column and will show the exact depth of the diver (smaller) hose which is used to show the diver’s depth on the diver's pneumo gauge. on the pneumofathometer (see pneumofathometer, this section); (4) a strong line used as a strength Pneumo: Short for pneumofathometer. Used such member to prevent strain on the other components of as “pneumo-gauge,” “pneumo-valve”, “pneumo- the umbilical.In addition to shorter spaced taping, the hose”, to describe the parts that make up the umbilical should be taped every 10 feet with colored pneumofathometer subsystem. tape to indicate the length of the hose. © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 1 Kirby Morgan Air Control System 5 1.2 Design Purpose Dressed-in: A commercial diver’s suit was originally called a “dress.” Although the name changed to The Kirby Morgan Dive Control System 5 (KMACS “suit” the term “dressed-in” has remained to describe 5) is designed to provide a central control center putting the suit on. A diver who is “dressed-in” has for the operator/dive supervisor during a surface- a suit on. The term is also used to describe a diver supplied air dive. Provisions for the control of the who, in addition to his suit, has more, or all of his/ breathing air supply, diver depth monitoring, and her equipment on. voice communications are all located on a simple panel. The KMACS 5 is a full service control system Bailout Bottle: This is the emergency tank of for all Surface Supplied Air diving operations. breathing gas. “Bailout” which is the familiar term for parachuting from an airplane, also applies to the The KMACS 5 is fitted with shut off valves on the shallow water diver who ditches part of his diving diver’s air supply. The shut off valves are designed gear and swims to the surface. The “bailout” bottle to allow air to be shut off on either or both of the term came from this use. diver’s umbilicals. When the handles of the valves are vertical the valves are open and air is flowing to The bailout bottle is an independent air source the divers. When the valve handles are horizontal the connected directly to the diver’s mask or helmet via valves are shut and the air to the divers umbilicals a first stage scuba regulator and hose. The first stage is off. regulator must be equipped with an overpressure relief valve (Part #200-017). The overpressure By having total control located at one panel, the relief valve will vent pressure in the event of a first KMACS 5 operator can rapidly respond to the stage leak and prevent the low pressure hose from diver’s needs without leaving the control station. In rupturing, causing a complete loss of the diver’s a standard commercial Surface Supplied Air (SSAir) bailout supply. diving operation the KMACS 5 provides a backup air supply system which the operator can activate The bailout bottle is worn on the diver’s back, in the event of the main air supply failure (such as mounted to a harness. The diver’s umbilical should compressor malfunction). This can be accomplished be attached to this harness to prevent a direct pull on without leaving the control panel, which allows the the diver’s mask or helmet. operator to inform the diver and continuously monitor The size/volume of the bailout bottle should be umbilical supply pressure and depth at the same time. determined by the diver’s depth, or the distance required for a direct ascent to the surface. For deeper The compact size of the KMACS 5 usually makes it dives, or penetration dives inside wrecks or pipelines, possible to locate it at the water entry site, allowing a larger capacity bailout bottle should be used. the operator to tend the diver’s umbilical while maintaining control of the KMACS 5. The volume must be determined by the hazards of the dive, but should always allow at least 10 minutes In addition to its compact size, the ability of the breathing supply. KMACS 5 to use high pressure air allows SSAir diving from small boats or remote locations where transportation and setup of a compressor would be impractical. Two or more standard scuba bottles can be used as the breathing air supply.

For example, when commercial divers are working on an offshore rig, a common SSAir diving job is the inspection and cleaning of a propeller on a crew boat. This job can be performed easily and simply with the KMACS 5, a couple of scuba bottles, a full face mask or helmet, and an umbilical. Transportation to the job site is simple and a large surface support vessel is not needed. At the dive site, full communications, backup breathing supply, pressure readouts, and depth monitoring are provided by the KMACS 5. Figure 1 Divers with all of the gear they need to dive.

2 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 Kirby Morgan Air Control System 5 This is one of many situations where the KMACS 5 can be used to provide the safe and efficient operation Umbilical Pressure Range: 115-225 pounds per of SSAir diving. square inch. (8-15.5 bars) Regulator Output: 40 SCFM at 2500 psi (172 bars) 1.3 Specifications supply pressure with 150 psi (10.3 bars) delivery pressure. Use: For SSAir diving only. Enriched air (Nitrox) or pure oxygen MUST NOT be used. Compressed Relief Valve: Set at 300 psi (20.7 bars). air from high pressure tanks (scuba or other types of compressed air tanks), or from a compressor should Pneumofathometer Range: 0-250 FSW (feet of sea be the only supply to the KMACS 5 water) (0-76 meters). B Communicator: 4 wire system. Can also be used in WARNING 2 wire mode. Pure oxygen is a potential fire hazard, its use can lead to explosion of the KMACS Battery Type: Rechargeable, 12 volt system. 5. Pure oxygen also presents a physi- ological hazard to the diver. Battery Performance: 20 hours of continuous use between charges in 4 wire mode. Outer Dimensions: Length = 21 inches Charger: Will accept external 12 volt source. Width = 18 inches Height= 11 ½ inches Communicator Power Output: 20 watts. Weight: 54 pounds. (24.5 kilos) Communicator Frequency Response: 600 to 12,000 HZ. Shipping Weight: 60 pounds. (27 kilos) Direct Recording Capability: Yes. B CAUTION Decompression and other human limits 1.4 General Description must be observed. Decompression diving should not be conducted with the The KMACS 5 components are housed in a durable KMACS 5 unless a properly equipped polyethylene case. However, caution should be used recompression chamber facility with in transporting the KMACS 5. Rough handling will oxygen is immediately available at the rarely cause damage to the case, but it is possible dive site. In-water decompression is not to damage the calibrated pneumo gauges and/or recommended. the electronic components. The KMACS 5 should be treated as you would any expensive life support Recommended Maximum Dive Support Depth: 130 equipment. fsw (feet of sea water) (40 meters). 1.4.1 Breathing Air Subsystem High Pressure Supply Pressure Recommended Maximum: The diver’s breathing air subsystem starts with the 3500 psi. (240 bars) using the DIN fitting supply tank yokes (T) and connects to the diver’s 3000 psi (200 bars) using the yoke supply manifold. The high pressure hoses with the yokes are stored for transit by connecting them to the NOTICE posts on the panel inside the lid of the KMACS 5. The knurled knobs on the yokes should be tightened Although the high pressure gauges on until just snug. Excessive force should not be applied. the KMACS 5 are rated to 5000 psi (345 bars), this is a safety precaution only. 1.4.2 Principle Operating Features The regulator on the KMACS 5 is not designed to operate at pressures greater than 3500 psi (240 bars). 3. Dive Control Panel (A) The panel is the main frame to which the functional Low Pressure Supply Pressure Maximum: 250 components are mounted. In addition, the component pounds per square inch. (15.5 bars) © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 3 Kirby Morgan Air Control System 5 names and some instructions are on the panel. The must be turned all the way “UP” until it stops for the blue and orange lines (L, R) on the panel represent the BLUE supply. This places the selector valve handle flow paths of supply air from the two high pressure in line with the flow path indicating the “BLUE” air hoses/yokes (T). supply (R). The ORANGE supply is off when the Selector Handle is in the up position. 4. Red Diver Depth Gauge (C) (Pneumofathometer) After flowing through the Selector Valve the BLUE air supply enters the Breathing Air Supply Regulator This gauge indicates the “red” diver depth. The red (I) which reduces the high pressure breathing air to an diver pneumo valve knob (D), is turned to supply a adjustable range between 115-225 pounds per square small volume of air to the small pneumo hose that inch (psi) (8-15.5 bars). The BLUE air supply then is part of the diver’s umbilical. The gauge reads the goes to both diver’s umbilicals through the fittings pressure of the air in the pneumo hose. This pressure, on the manifold (E). measured in feet (or meters) of sea water, equals the water pressure at the diver’s depth. Red diver pneumo B CAUTION hose is attached to the red side fitting (F) When using H.P. air, the selector handle 5. Umbilical Pressure Gauge (B) must be turned up until it stops for BLUE supply or down until it stops for This gauge (B) is connected to the low pressure air Orange supply. Never allow the selector supply system that supplies both umbilical fittings. handle to stay in the marked “H.P. OFF It indicates the breathing air pressure that is in both ZONE”. Both high pressure air supplies are off in the yellow striped H.P. OFF the “red” and “white” diver umbilicals. When the air ZONE”. supply is from high pressure tanks (such as scuba tanks) the umbilical hose pressure can be varied by turning the regulator adjustment knob (I) 8. Orange Air Supply Flow Indicator Lines (L) 6. White Diver Depth Gauge (Q) The “ORANGE” air supply flow indicator line (Pneumofathometer) indicates the flow path of breathing air from entry This gauge indicates the “white” diver depth. The into the KMACS 5 to exit to the diver’s umbilical(s) white diver pneumo valve knob (P), is turned to at the fittings on the manifold (E). The second high supply a small volume of air to the small pneumo- pressure whip is color coded ORANGE. hose that is part of the diver’s umbilical. The gauge reads the pressure of the air in the pneumo-hose. Starting from the high pressure air tank, the ORANGE This pressure, measured in feet (or meters) of sea air supply flows through the whip into the KMACS water, equals the water pressure at the diver’s depth. 5. Following the ORANGE flow indicator line (L) it White diver pneumo hose is attached to the white shows the flow to the ORANGE Breathing Air Supply side fitting (F). Pressure Gauge (M), then to the Breathing Air Supply Selector Valve which is controlled by the Breathing 7. Blue Air Supply Flow Indicator Line (R) Air Selector Valve Handle (J). The Selector Handle must be all the way “DOWN” until it stops for the The “BLUE” air supply flow indicator line (R) ORANGE supply. The BLUE supply is off when the indicates the flow path of breathing air from entry Selector Handle is in the down position. into the KMACS 5 to exit to the diver’s umbilical(s) at the fittings on the manifold (E). There are two After flowing through the Selector Valve the high pressure whips which are color coded BLUE ORANGE air supply enters the Breathing Air and ORANGE. Supply Regulator (I) which reduces the high pressure breathing air to an adjustable range between l15-225 Starting from the high pressure air tank, the BLUE psi (8-15.5 bars). Then the ORANGE air supply goes air supply flows through the whip into the KMACS 5. to both diver’s umbilicals through the fittings on the Following the BLUE flow indicator line (R) it shows manifold (E). the flow to the BLUE Breathing Air Supply Pressure Gauge (N), then to the Breathing Air Supply Selector The air supply to both divers can be controlled by Valve which is controlled by the Breathing Air shut-off valves located on the manifold (H). When Selector Valve Handle (J). The Selector Handle (J)

4 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 Kirby Morgan Air Control System 5 the valve handle is up (vertical) the valve is open. When the valve handle is down (horizontal) the valve 11. Orange Breathing Air Supply Pressure is closed. Gauge (M)

9. Low Pressure Inlet Fitting (O) The Orange supply pressure gauge (M) indicates the pressure remaining in the “ORANGE” high The low pressure inlet fitting is positioned between pressure tank. (NOTE: If two divers are supplied by the connections for the two H.P. supply hoses. It the KMACS 5, both divers will be breathing from is marked by the arrow containing the words “L.P. the same selected high pressure supply). Supply”. Low pressure supply breathing air, usually from a compressor (with volume tank) is supplied Blue Air Supply through a whip (low pressure hose and fittings) that Flow Path Indicator Line attaches here. When the low pressure supply is the only air source, the supply pressure will be indicated on the umbilical pressure gauge (B). In the low pressure supply mode, the selector/valve handle will he positioned in the H.P. OFF ZONE.

10. Blue Breathing Air Supply Pressure Gauge (N)

The Blue supply pressure gauge (N) indicates the pressure remaining in the “BLUE” high pressure tank. (NOTE: If two divers are supplied by the Orange Air Supply Whip KMACS 5 both divers will be breathing from the Orange Air Supply same selected high pressure supply). Flow Path Indicator Line

Figure 2 Air flow paths from the H.P. cylinders.

A Dive Control panel F B Umbilical Pressure U G C E Red Diver Depth Gauge V D Pneumo Vaalve Handle, Red T E Divers Umbilical Breathing Hose W Attachment Fittings S F Pneumofathometer Hose Attachment Fittings G Pneumo Blocks (2) G H

R R H Shut-off Valves (2) IA RN FO LI CA RA R BA I Regulator Adjustment Knob S ANTA B A Q J Breathing Air Supply Selector Valve Handle P K Case L Orange Air Supply Flow Line M Orange Breathing Air Supply Gauge O

T P E D R E IV D

E E T H I

N R W

AIR CONTROL SYSTEM-5 U

Blue Breathing Air Supply Gauge S

S E R P L.P. SUPPLY L R L ICA I A UMB I N

O R F I L H.P. SUPPLY C A A AR B BAR T A O Low Pressure Inlet Fitting A SAN

H.P. SUPPLY

E N

F F

. .P H

H P T P Pneumo Valve Handle, White E D E R 250 PSI MAX AS VE 17.2 BARS MAX E DI R D C RE N Q B I White Diver Depth Gauge E S E A D E C R R Blue Air Supply Flow Line C N S Communicator D M L T Yokes w/DIN Fittings for H.P. Cylinder Attachment E U K Access door for storage compartment. F J V O-Ring Seal G H I W Communicator Panel

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 5 Kirby Morgan Air Control System 5 15. Regulator Adjustment Knob For 12. Yokes For High Pressure Cylinder Umbilical Pressure (I) Attachment (T) The regulator Adjustment Knob (I) allows the The yoke fittings (T) provided have standard U.S. operator to adjust the umbilical pressure within a scuba cylinder attachments as well as Din Fittings. range of 115 psi to 250 psi (8-17 bars). Incoming Each yoke has a bleeder valve to vent the remainder high pressure air from the ‘ORANGE” or “BLUE” of the pressure in the whip when changing out scuba supply is reduced by the internal regulator. The bottles. The yokes attach to posts mounted on the Adjustment Knob controls the regulator. Turning the panel in the lid of the KMACS 5 for storage and Knob clockwise decreases the umbilical pressure; transport. counterclockwise increases it.

13. Case (K) 16. Outlet Manifold Including Diver’s Umbilical Fittings (G) The Dive Control panel assembly (A) is attached to the bottom half of the case (K). The top half The “WHITE DIVER” and “RED DIVER” air of the case contains the communicator panel with supply umbilicals are connected to the KMACS 5 the yoke blocks and the communicator if there are at the manifold (E). The standard fittings coming communications. If there are no communications out of the KMACS 5 are male #6 JIC (3/8", 37°) there are only the yoke blocks. ( see picture in front flared fittings—other fittings for other umbilicals of manual). The top is not designed to be removed. may also be used. The diver’s air supply hoses must have matching female fittings. Shut-off valves are 14. Breathing Air Supply Selector Valve positioned between the manifold and the diver's air Handle (J) fittings. The air is on when the valve handle is vertical and is off when the valve handle is horizontal. This handle (J) controls the two position Breathing Air Supply Selector Valve and allows uninterruptedFigure 3 The “WHITE DIVER” and “RED DIVER” diving operations while full air supply tanks replace pneumofathometer hoses are also connected to the expended tanks. The selector valve controls ONLY KMACS 5 at the manifold (F). The fittings coming the high pressure air supply. It is NOT possible to out of the KMACS 5 are male #4 JIC ( ¼", 37°) flared shut off any low pressure supply connected to the fittings. The diver’s pneumofathometer hoses must low pressure inlet fitting (O), at the KMACS 5 itself. have matching female #4 JIC (¼", 37°) flared fittings with swivel nuts—other fittings may also be used. When changing out the H.P. air supply cylinders, always observe the diver’s umbilical pressure gauge 17. Pneumo Valve Knob, White Diver (P) (B) for any sudden fall in pressure. Should this occur, it indicates that the cylinder in use has mistakenly The Pneumo Valve Knob, White Diver turns on and been turned off. If so, immediately turn the cylinder off the air supply to the “WHITE” pneumofathometer back on and move the selector valve handle to select system. the full cylinder and change out bottles. 18. Pneumo Valve Knob, Red Diver (D) Due to the construction of the selector valve, it is not possible for gas to back-flow from one cylinder The Pneumo Valve Knob, Red Diver turns on and to the other. off the air supply to the “RED” pneumofathometer system. B CAUTION 19. O-Ring Seal (V) When using H.P. air, the selector handle must be turned up until it stops for The O-ring seal helps keep dust and moisture out of BLUE supply or down until it stops the KMACS 5 when the case is closed. The O-ring for ORANGE supply. Never allow the selector handle to stay in the marked seal is not pressure proof, however, and the KMACS “H.P. OFF ZONE”. Both high pressure 5 case will flood if the box is submerged. air supplies are off in the yellow striped H.P. OFF ZONE”.

The diver’s electronic communicator (S) is attached to the communicator panel. The battery for the communicator is located behind this panel.

21. Communicator (S) The KMACS 5 communicator is a standard open circuit/round robin diver’s communicator, which functions like a telephone. It can also be used as a 2 wire, “push-to-talk” system. It is connected to the diver’s umbilicals by “banana plug” fittings on the communicator. The communicator is mounted on the communicator panel. You should read and understand the accompanying radio operations manual supplied with the unit before using the unit. Improper use or connections could damage the radio.

B CAUTION Never connect the charger during a dive or when anyone is in contact with connected equipment. Although electrical shock danger is remote, connection of the recharging cord should only be done when the KMACS 5 is not in use.

Kirby Morgan Air Control System 5

Chapter 2.0 Operating Instructions

2.1 Unpacking The KMACS 5 2.2 First Use Of The KMACS 5

When you first receive your KMACS 5, carefully Place the Dive Control System on a firm surface. unpack it and examine it for any damage that may The KMDSI logo should be right side up. Release have occurred during shipment. Be sure to complete the latches and lift up the lid to expose the panels. the enclosed warranty card and return it to KMDSI immediately. No warranty claims will be honored When using the KMACS 5 aboard a vessel subject to without a satisfactorily completed warranty card on waves or swell be sure to tie the KMACS 5 securely file at KMDSI. in position so that it doesn’t fall. Thread a piece of line through the handles and fasten the ends to fittings Visually check the KMACS 5 to ensure that it has on the boat. Tie back the lid of the KMACS 5 as well not been damaged in transport. to prevent damage or injury.

Figure 5 Connecting a scuba air supply to the KMACS 5.

2.3 Connecting The Air Supply

Loosen the knurled knobs which connect the yokes Figure 4 Note the line which passes through the handle to their storage posts in the KMACS 5 and remove of the KMACS 5 and is secured to the rail to prevent the the yokes (T) from the blocks. Attach each yoke KMACS 5 from moving about.

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 9 Kirby Morgan Air Control System 5 to a high pressure cylinder as you would connect source should be used as the primary air supply and a scuba regulator to a tank. The knobs on the yoke scuba cylinders should be used as a backup, or reserve should be screwed down finger tight. Do not apply air source. excessive force to the knobs; air pressure from the tanks will create a good seal. Be sure the bleed valve Prior to connecting the low pressure hose to the on each yoke is in the closed position. Do not turn KMACS 5, the deck whip should be flushed with air the cylinders on at this time. to make sure no foreign matter is in the hose. Connect the deck whip to the low pressure compressor and while firmly holding the end of the hose start the compressor and flow air through the deck whip for at least one minute. Attach the low pressure hose to the low pressure inlet fitting (O) and screw the fitting down finger tight. While using one wrench to hold the low pressure inlet fitting tighten the hose fitting with a second wrench. Do not use excessive force as this will only damage the fitting and cause it to leak.

2.4 Connecting Diver’s Hoses To The KMACS 5

Each diver’s umbilical should be color coded with plastic tape to identify each individual hose. This action will not only serve to make it easier to connect the hoses, but will also serve to differentiate between hoses for purposes of inspection or repair.

A standby diver should always be equipped and ready to go to the diver’s aid whenever a surface supplied diver is working in the water. Generally, it is not necessary for more than one diver to be in the water at a given time when using surface supplied gear. However, a standby diver is considered essential for Figure 6 Always use the right size wrench to connect the hoses to the KMACS 5. safe, surface supplied operations. The standby diver can be either a scuba diver or another hose supplied Check the function of the selector handle to ensure diver since the KMACS 5 provides enough air for correct operation. two hose supplied divers. In contaminated water diving operations, however, both divers must be equally equipped with a vulcanized rubber dry suit, B CAUTION dry gloves, and Kirby Morgan dive helmet equipped with either a double exhaust system or the new Quad Low pressure compressors used for ™ breathing air should be specifically de- Valve exhaust system. signed for diving. Paint compressors or similar equipment are unacceptable for B WARNING diving applications. Contaminated water diving operations B are very hazardous. They should not be DANGER attempted without specialized training, If a low pressure compressor is used, procedures, and equipment. the intake must be at a sufficient distance from and upwind of the exhaust. Remove the protective caps from the outlets of the If exhaust gas is sucked into the intake, manifold (E, F) on the console. Connect the diver’s the diver will suffer from carbon monox- umbilical hose fittings (air supply hose and pneumo) ide poisoning. This can be fatal. to the KMACS 5. Remove the end caps from the hoses themselves and while firmly holding the end In normal use, a low pressure compressor or air of the hose, blow out the lines before connecting the

10 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 Kirby Morgan Air Control System 5 hoses to the mask or helmet, (refer to the manual Umbilical Supply Pressure Requirements & Tables" for the mask or helmet for the proper connection on page 26 for approximate pressure settings. procedures for your life support equipment). This action will prevent any foreign matter from entering 2.5.1 Testing L.P. Supply the helmet or mask breathing system. Once the hose With the air on at the bottles and the communications is blown out, immediately connect the fitting on the switched on, check the regulator function. The diver hose to the fitting on the mask or helmet. should insert his face in the mask/helmet and take several breaths to test the demand regulator. Connect the communications portion of the diver’s umbilical to the communications fittings on the To test the low pressure supply, place the selector communicator and to the mask or helmet. Be valve handle (J) in the “H.P. OFF” zone and the sure the proper connection is made with the right console will be running off the low pressure supply communications line for each diver. The wires in only. Observe the umbilical pressure gauge (B). As the diver’s umbilical should be marked so it is easy the compressor cycles, the gauge will rise and fall as to identify which plug connects to the earphone the compressor’s volume tank fills and empties. The terminals and which plug connects to the microphone maximum pressure for the L.P. inlet should be 225 terminals. psi. Again, check the mask/helmet function which will also confirm the low pressure supply routing. 2.5 Pre-Dive Check

Prior to EVERY dive, the following should be 2.5.2 Testing Communications checked: Test the communications between the diver and the KMACS 5. With the communicator (S) switched With the free flow and demand regulator on the mask/ on, turn the speaker switch to “on” and adjust the helmet(s) shut off, turn on the air supply at each of volume to a comfortable level for both the diver and the air cylinders. During operation with scuba bottles the KMACS 5 operator. In the 2 wire mode and the as the main supply, the selector valve handle must 4 wire mode without headset and boom microphone, be FULLY up or FULLY down. Fully up turns the the communicator functions similarly to a citizens “BLUE” supply on and the “ORANGE” supply off. band radio; i.e., the KMACS 5 operator must depress Fully down turns the “ORANGE” supply on and the the push to talk switch to speak to the diver. In “BLUE” supply off. the 4 wire mode, with headset and boom mic, the communicator functions like a telephone conference Note the air pressure in each cylinder by reading the call; i.e., everyone on the line can hear and speak to gauges (M,N). The low pressure supply should be everyone else. In either mode, for the diver to talk switched “OFF” at the source at this time. A check top side, it is only necessary for him to speak into the valve in the low pressure system prevents back flow oral/nasal microphone in his mask or helmet. If two to the compressor. divers will be working together using 2 wire mode, test the cross-talk functions at this time as well. Both cylinders should be full prior to diving. Load the regulator on the KMACS 5 using the regulator adjust- To extend the life of the battery, it is recommended ment knob (I). Observe the umbilical hose pressure that the communications be used in the 4 wire mode. (B) which should be set at 150 psi (10.3 bars) over Operation as a 2 wire system uses relays inside the top side pressure, or 165 psi (11.5 bars) The regula- unit which will cause a higher battery drain. tor used in the KMACS 5 is a non-venting regulator. If the regulator has been left set at a higher pressure B setting than is presently desired, the operator must CAUTION turn the regulator adjustment knob (H) clockwise In the 2 wire mode, when the push-to- and vent air from the system by bleeding either the talk switch is depressed, the KMACS 5 pneumo system or diver’s breathing apparatus. operator should keep all of his communications short (10-15 seconds) at any one time. This allows the diver to call As the diver descends, the KMACS 5 operator should for assistance if necessary. increase the regulator setting so that the umbilical pressure is always 150 psi (10.3 bars) over the pressure Plug the earphone connectors on the diver’s umbilical at the diver’s depth. Consult the table in "Appendix 1 into the earphone jacks on the communicator. Plug

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 11 Kirby Morgan Air Control System 5 the microphone connectors on the umbilical into the on an umbilical connector plug and touch the other microphone jacks on the communicator. This will probe from the meter to the wires (or connector) create a 4 wire system/round robin system. Test the at the opposite end of the diver’s umbilical. Upon system and adjust all volume controls. locating the other end of the same wire, the meter should indicate zero resistance, i.e., there is a complete, uninterrupted circuit. If touching none of the wires at the other end of the umbilical produces a zero reading and all readings are infinity (∼), this indicates a complete break in the wire. If the reading is somewhere between zero and infinity, and changes as the umbilical is moved, this indicates a partial break, and communications will be intermittent. In either case, a waterproof splice must be made in the wire.

2.5.3 Testing The Pneumo The pneumo supply may be tested in either the high pressure supply mode or the low pressure supply mode. To test the pneumo, select either mode and Figure 7 Preliminary testing of the umbilical with a volt- pinch the open end (diver’s end) of the red diver ohm meter to check for continuity. pneumo hose. With the hose crimped tightly shut, slowly open the red pneumo valve (D) momentarily, Unplug the earphone connectors on the diver’s ¼ turn, and observe the needle’s response on the red umbilical from the communicator and reinstall diver depth gauge (C). them in the connectors attached to the plugs for the microphone. This will change the communicator to a 2 wire system. Test this system and adjust volumes. NOTICE Do not “peg” the needle on the pneu- If there are no communications, recheck all of mofathometer with a maximum reading. the connections to ensure they are tight at each A test of pressure equal to 50 feet (15 junction. If the KMACS 5 has been operating in meters) on the gauge is satisfactory to a coastal environment, look for corrosion on the ensure correct operation. top side connectors which may interfere with the communications. If corrosion is evident, disassemble Close the valve after observing correct operation the connectors, clean, and retest. If corrosion is heavy, and release the end of the pneumo hose. The gauge replace the top side connectors. needle should return to zero. Repeat this procedure for the white diver. Substitute other masks or umbilicals to test for failures in the microphones or umbilical. Substitute one piece of new gear at a time to track the fault down. If the fault is in the mask or helmet, replace the earphones or microphones as needed. If the fault is in the umbilical, disconnect the umbilical and carefully inspect its length for damage. Look for obvious nicks or cuts. If there is physical damage to the outside of the communications wire there probably is a break on the inside, too. Test the continuity of the wire end-to end with a volt-ohmmeter. Uncoil the umbilical and lay it out flat with the two ends close to each other. Set the volt-ohmmeter to resistance (ohms) and hold one probe to one prong

With the hose attached to the harness, tuck the pneumo hose under the harness at the diver’s chest. This serves two purposes: 1) it provides instant access in the event the pneumo is to be used as an alternative air supply; 2) gas absorption and elimination of nitrogen is considered to occur at the diver’s chest level.

When diving under a potential decompression situation, a depth gauge or dive computer should be worn by the diver as a backup system. If decompression is anticipated there must be enough air on hand for the diver to complete the dive and the decompression obligation.

2.7 The Dive Supervisor And The KMACS 5 Operator

During the diving operation, one person should always be in charge to avoid confusion. Generally, this should be the most senior diver, by virtue of his diving experience.

The dive supervisor may not always be the KMACS 5 operator. The dive supervisor may want or need the freedom to direct the entire operation including the tenders and other personnel. As such, he is Figure 8 Carefully test the pneumo prior to every dive. responsible for making decisions regarding diving conditions and safety. However, the KMACS 5 2.6 Preparing The Diver operator must always be an experienced diver who understands the diver’s needs and has the diver’s best The diver should be dressed in with the appropriate interests always in mind. exposure suit for the local water temperature. The diver should be equipped with a harness to provide B WARNING an attachment point for his umbilical. By attaching the umbilical to the harness, the possibility of a direct The KMACS 5 operator must not leave pull on the diver’s helmet or mask will be eliminated. the dive control system unattended while the diver is in the water. The A bailout bottle should be mounted on the diver’s KMACS 5 operator is directly responsi- harness. Always dive with a bailout bottle, no matter ble for the diver’s safety and well being. how shallow the dive. The danger of entanglement is always present and a bailout bottle will give the The diver must follow the KMACS 5 operator’s diver that few extra minutes to free himself in the directions in regards to depth and time. The diver event he becomes hung up on fishing line, wire, or can NOT run the dive from the bottom. Thus, when other submerged objects. the dive supervisor himself is required to dive he should relinquish control to the next most senior diver The bailout regulator should be equipped with a quick remaining top side. disconnect whip to make it easier to dress the diver in and out. In addition, the bailout regulator should also 2.8 Descent be equipped with an over pressure relief valve (Part #200-017). This will permit the regulator to bleed off Upon entering the water, the diver should immediately and not rupture the low pressure hose connecting it recheck communications with top side and ensure that to the diver’s bailout or emergency valve, should the his mask or helmet is working correctly. When he/she first stage develop a leak. is ready to descend he should notify the KMACS 5

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 13 Kirby Morgan Air Control System 5 operator that he is, “Leaving the surface.” To operate the pneumo, turn the knob for the appropriate diver, counter clockwise, until the Both the diver and tender should communicate in a indicator needle on the depth gauge starts moving. normal tone of voice. It should not be necessary for When the depth gauge for the individual diver either person to shout to be heard. Although the quality indicates a depth that is known to be deeper than of the communications will usually be excellent, not all the diver, the knob is turned clockwise until it is off. divers speak clearly. The KMACS 5 operator should The indicator needle on the depth gauge will move listen carefully at all times to what the diver is saying. shallower as the air bubbles leave the open end of the pneumo hose at the diver. When the needle stops, Once the diver has entered the water, monitor his that is the diver’s actual depth. descent rate using the pneumo valve (D,P) and gauge (C,Q). The diver’s descent rate should not exceed 75 The diver should practice using the pneumo as an feet (23 meters) per minute. alternative air source under controlled conditions in shallow water. The pneumo hose should be bubbling when it is inserted in the diver’s mask, otherwise the diver will receive a blast of water when the pneumo is first turned on.

2.9 Diver At Depth Once the diver reaches the bottom, or his maximum planned depth, the diver should inform the KMACS 5 operator that he is, “On the bottom.” At this time, the KMACS 5 operator should ensure that he gets an accurate depth reading. The KMACS 5 operator should inform the diver that he is “Taking a pneumo...”, when he opens the pneumo purge valve. The diver should observe the end of the pneumo hose and immediately inform top side that, “He has bubbles...”. Once the diver has a flow of bubbles at the end of the hose, the pneumo valve (D,P) should be closed immediately. Should the diver move deeper at any time during his dive he must inform the KMACS 5 operator and another pneumo should be taken for a new maximum depth reading. If the KMACS 5 operator knows that the diver is moving over an uneven bottom he should periodically take additional pneumo readings to ensure that the diver has not accidentally gone deeper and neglected to notify top side. Keep in mind, Figure 9 KMACS 5 operator taking a reading with the however, that every pneumo reading does use some pneumo knob. The knob should be turned very slowly. air. If high pressure air is the air source and the dive is deep, or the diver is working hard, pneumo readings As the diver descends the KMACS 5 operator should be taken as sparingly as possible. should monitor the air supply pressure and insure the proper pressure for depth. If using the KMACS 2.10 Changing Out High Pressure 5 HP supply system the operator should slowly increase the supply pressure as the diver descend Cylinders and slowly decrease the pressure as the diver The KMACS 5 operator should continuously monitor ascends the KMACS 5 operator should try to the diver’s air supply at the two high pressure gauges keep the supply pressure within the minimum and (M,N) when diving with high pressure air as the maximum parameters in accordance with "Appendix 1 primary supply. When the initial supply source Umbilical Supply Pressure Requirements & Tables" pressure drops to between 300 and 500 psi (20.7 and on page 26 34.5 bars), depending upon depth, the diver should

14 © ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 Kirby Morgan Air Control System 5 be switched over to the second air source using the the diver should assume a relaxed and comfortable selector valve handle (J). While the diver is breathing position in the water. A weighted line or some other off the secondary source a fresh cylinder should be apparatus should be provided to the diver to assist put on line immediately. him in maintaining a proper depth. Decompression in mid-water, without a line or other method of To change out high pressure cylinders, first close fixing the diver’s depth, is NOT acceptable as it the cylinder valve on the tank which is low. Once is impossible to maintain an exact depth without the valve is closed, open the bleeder valve on the something to hang onto. yoke (T) and allow the pressure to bleed from the line. The high pressure whips are color coded to help An accurate pneumo should be taken at the diver’s the KMACS 5 operator to ensure he is selecting the decompression stop. There should be no unnecessary correct one. Always observe the umbilical pressure slack in the diver’s hose, i.e., no part of the umbilical gauge (B) carefully during this procedure. If the should be lower than the diver, as this will give a false KMACS 5 operator is not careful he may accidentally reading (deeper) of the diver’s depth. Make sure the turn off the high pressure cylinder supplying the end of the pneumo hose is held at the diver’s chest diver’s breathing air. If the umbilical pressure gauge with the open end pointing down. (B) needle starts to “fall”, turn the cylinder back on immediately and double check to ensure the correct 2.13 Completion Of Diving cylinder is being changed. Operations

When the high pressure whip is empty, unscrew the Immediately following the completion of diving knurled knob on the yoke (T) and attach the yoke to operations the dive station should be disassembled a fresh cylinder. Tighten the yoke knob finger tight, and the KMACS 5 protected from the weather. close the bleeder valve, and slowly open the cylinder tank valve. Read the new pressure on the appropriate Both high pressure and low pressure air supplies gauge (M,N). should be turned off at their source. Bleed the air from the diver’s umbilical(s) by opening the free flow 2.11 Procedures During The Diver’s valve(s) on the diver’s mask/helmet(s). Disconnect the Ascent mask/helmet(s) from the umbilical and the umbilical from the KMACS 5. Unplug the communications At the end of the dive, the diver should prepare connectors and turn off the communicator (S). Plug to leave bottom upon orders from the KMACS 5 both ends of the hose and cap the outlet manifold (E, operator. The KMACS 5 operator must carefully F) nipples on the KMACS 5 to prevent foreign matter note the diver’s depth and time on the dive log. The from entering either. KMACS 5 operator is responsible for monitoring the diver’s ascent rate which should not exceed 60 feet (18 meters) per minute, or slower if a dive computer is being used to monitor decompression/no decompression status. The diver should not leave the bottom until he is instructed to do so by the KMACS 5 operator. At the start of the diver’s ascent he should inform top side that he is, “Leaving the bottom.” The KMACS 5 operator should carefully note the time in the dive log. The KMACS 5 operator must monitor the diver’s rate of ascent carefully, observing his watch and the pneumo gauge (C,Q) . There is no need to pneumo the diver as he ascends because the air in the pneumo hose will automatically expand and vent the hose as the diver approaches the surface. Figure 10 All of the outlet fittings on the KMACS 5 must be capped prior to storage. 2.12 Decompression Open the bleed valves on the HP yokes (T) to allow If the diver has decompression stop(s) required as any remaining air to vent and replace the yokes on a result of his dive, slow the diver’s ascent as he their storage posts. Disconnect the low pressure air approaches his first stop. Upon reaching his first stop, source if used and cap the low pressure inlet (F)

If the KMACS 5 has been used on the ocean the panels should be wiped down with a clean rag dampened with fresh water. The O-ring seal (V) on the case may be periodically treated with Armor-All or other rubber protection.

Place the KMACS 5 in a dry area and recharge the communications.

Refill any high pressure cylinders (scuba) used during diving operations and store them in a secure location.

Chapter 3.0 KMACS 5 Maintenance

3.1 Recommended Maintenance Of Approximately every six months, the high pressure The KMACS 5 hoses should be treated with Armor-AIl or similar The KMACS 5 requires very little user maintenance. protection. With proper care, the KMACS 5 should last for years and give excellent service. Once a year, the KMACS 5 should be returned to On a daily basis, the KMACS 5 operator should your authorized dealer, or KMDSI , to service the inspect the high pressure whips attached to the yokes regulator, selector valve, and calibrate the diver’s (T) for signs of wear. depth gauges. This is especially important if the unit is used for deep, decompression, or repetitive dives. After each use the case, interior panels and high pressure hoses should be wiped down with a rag 3.2 Replacing The Battery which has a small amount of Armor-All. Never spray cleaners directly on the KMACS 5. The battery used with the KMACS 5 communicator is very reliable and will offer many years of service. However, storing the KMACS 5 with the battery drained can cause the battery to fail. The battery should be completely charged before storage. Gel cell batteries have an excellent shelf life if properly charged prior to storage.

To replace the battery, remove the screws which hold the communicator panel (W) into the top of the KMACS 5 box. Do not remove the screws which secure the communicator to the larger panel. Tilt the panel out but do not remove it from the lid. The battery is held in place by brackets and “Velcro” strips on the back of the large panel. Reach behind the panel and support the battery. Lift the panel and battery out as a unit.

Replace the old battery with a new unit. Position the new battery on the back of the large panel using the “Velcro” strips to hold it in place. Connect the leads back to the battery and push the communicator panel (V) back into its normal position. Install the screws which hold the large panel in place and tighten them in a staggered pattern.

Figure 11 After each use the case, interior panels and high pressure hoses should be wiped down with a rag which has a small amount of Armor-All. Never spray cleaners directly on the KMACS 5.

Kirby Morgan Air Control System 5 Chapter 4.0 Troubleshooting the KMACS 5 System

4.1 General

The KMACS 5 is an extremely simple system which should not malfunction if the instructions in this manual are followed. Most problems encountered in using the system can be easily remedied. The following information covers the common operating difficulties.

4.2 No Communications Symptoms Probable Cause(s) Remedy 1) No sound at either KMACS 5 a) Communication power not on. Activate switch and adjust or diver’s mask. volume.

b) Communications incorrectly Switch terminal wires. hooked up.

c) Communications not hooked up Plug into terminals. 2) Battery indicator does not Battery low or dead. Charge or replace battery, or respond. bypass battery with external power 3) Communications weak or a) Terminals covered with Clean Terminals with wire brush broken up. corrosion. to bright shiny metal.

b) Loose or nearly broken wires Trim back wires to full thickness 4) Communications will not work Headset not working Replace headset. with headset but works otherwise. Short in internal wiring. Return to factory for repair 5) Communications interrupted Break in diver’s communication Splice wire if damage is minor. when umbilical is moved. wire. Replace wire if damage is major. 6) Communications interrupted Break in splice at waterproof Replace splice or connector. when waterproof connector is connector or failure of connector. moved. Test with VOM. 7) Satisfactory communications a) One wire in cable is broken Stack connectors in microphone through one earphone or terminals. Communications works microphone only (4 wire mode). in two wire mode.

b) Microphone/earphones dead. Replace microphone/earphones. 8) No sound at either KMACS 5 Communicator not functional. Return to factory for repair after or mask. verifying no cure by following above procedures.

4.3 No Pneumo Reading Symptoms Probable Cause(s) Remedy 1) No air to diver’s end of a) Pnuemo hose not connected Attach fittings to KMACS 5 pneumo b) Pneumo plugged Flush hose with air to clear 2) Gauge reads sustained pressure Pneumo crimped or plugged. Check entire length of hose. at surface. Relieve any restrictions.

Symptoms Probable Cause(s) Remedy 3) Hose will not hold pressure and Pneumo fitting cracked or loose. Check fittings at console with gauge needle will not rise. soap and water solution. If fittings bubble, either tighten or replace as necessary. 4) Needle will not respond a) Hole in pneumo hose. Check hose; replace or splice as properly to flow. necessary.

b) Gauge mechanism damaged. Replace or repair gauge. Return to factory. 5) Air can be heard escaping into KMACS 5 internal plumbing may Return to factory for service. console interior. be cracked or broken.

4.4 No Air To Diver Symptoms Probable Cause(s) Remedy 1) No hose pressure in diver’s a) primary air source not Connect proper hose to console. umbilical connected. Open valve at low pressure b) Valve closed at low pressure compressor. source Move selector valve handle in c) Selector valve in “H.P. OFF” line with flow from either high zone. pressure source.

2) No gauge reading on high a) Valve closed at high pressure Open valve at high pressure pressure gauge. source source.

b) No Air Install full supply 3) Low hose pressure in diver’s a) Regulator not properly loaded. Rotate adjustment wheel in umbilical. appropriate direction.

b) Low H.P. supply Switch over to full tank 4) Air can be heard escaping from Fitting loose on diver’s hose, or Tighten fittings until snug. Do not hose. fittings damaged. over tighten. Replace fittings if damaged. 5) Umbilical registers pressure a) Mask improperly serviced. Clean and adjust mask. at console gauge, but no flow at mask. b) Blockage in supply hose Clear blockage from hose 6) Air can be heard escaping into Leakage in KMACS 5 plumbing. Return KMACS 5 to factory for console interior. service. 7) Umbilical hose pressure and Diver’s Umbilical cut or severed. Replace diver’s hose. supply pressure drops rapidly. 8) With high pressure air on and Regulator malfunction. Return KMACS 5 to factory for regulator loaded, no umbilical service pressure.

5.1 Emergency Procedures

The following are general recommended emergency procedures. However, it is up to the individual diver and dive supervisor to make judgements under specific conditions on how to best cope with particular situations.

Action Problem Diver Topside (Tender) 1) Loss of communications Revert to line pull sig- Revert to line pull signals and have diver abort nals and abort the dive the dive. Diver KMACS 5 Operator 2) Loss of primary air supply Shifts to EGS and noti- Shifts to KMACS 5 HP supply and regulator (LP compressor in use) fies topsides on EGS system and notifies diver to secure EGS at side Diver checks to insure block and test breathing on surface supply, abort the umbilical is clear dive. and stands by to abort when instructed. KMACS 5 Operator 3) Loss of primary air supply Notifies diver to shift to EGS, (HP in use) check umbilical clear, and standby to leave the bottom Diver KMACS 5 Operator Supervisor 4) Diver’s umbilical severed. Shift to EGS, check Secure air to the sev- Deploys standby diver umbilical clear then ered umbilical. Insure with tag line to assist surface slowly if standby divers supply in recovering and sur- ascent line is available is not compromised. facing the diver with otherwise standby to the severed umbilical. surface with assistance of the standby diver. 5) Pneumo will not operate. a) Dive hose should be marked with colored tape every 10 feet. Take depth readings from this. (will only be approximate)

b) Diver’s personal depth gauge can provide back up.

© ⅯⅯⅩⅡ Kirby Morgan Dive Systems, Inc. All rights reserved. Document #120912001 21 Kirby Morgan Air Control System 5 5.2 Communications Wiring Schematics If your KMACS has communications, refer to the radio manual, P/N 100-400 Two-Diver Air Intercom user guide. 5.3 Exploded Views & Parts Lists The following parts are not shown on the blow apart drawing and are listed for reference only.

Location Part # Description Qty Not Shown 420-100 Case, KMACS 5 1 Not Shown 415-030 Battery Charger Assembly 1

* The following parts in the interior plumbing require the use of Conical Seals, # 455-135. The conical seals are provided with the items listed below.

Location Part # Description 28 405-105 High Pressure Inlet Tube (blue) 31 405-105 High Pressure Inlet Tube (orange) 39 405-106 High Pressure Regulator Inlet Tube

KMACS 5 Operator:

Dive Location:

Weather Conditions:

Purpose of Dive:

Low Pressure Air Source Pressure:

High Pressure Air Source Pressure:

Cylinder # Start finish 1 ______2 ______3 ______4 ______5 ______6 ______

Dive Times: Diver Left Surface: ______

Diver Reached Bottom: ______

Diver Left Bottom: ______Maximum Depth:

Diver Reached Surface:______Total Bottom Time:

Repetitive Group: ______Decompression Required?: Y N

Decompression Schedule:______

Diver’s Signature______KMACS 5 Operator ______

Kirby Morgan Air Control System 5 Table of Equivalents

To Convert Into To Multiply By Into Convert Divide By To convert units appearing in Column 1 Atmospheres Feet of Water 33.9 (left column) into equivalent values in Atmospheres Inches of Mercury (Hg) 29.92 Column 2 (center column), multiply by Atmospheres PSI (LBS per Sq. Inch 14.7 factor in Column 3. Example: To convert BTU Foot Pounds 778.3 7 gallons into cubic inches, multiply BTU per hour Watts 0.2931 BTU per minute HorsePower 0.02356 7 × 231 = 1617. To convert units appear- Celsius (Centigrade) Fahrenheit oC x 1.8 + 32 ing in Column 2 (center) into equivalent Centimeters Inches 0.3937 values of units in Column 1 (left), divide Cubic Centimeters Gallons (U.S. Liquid) 0.0002642 by factor in Column 3. Example: To Cubic Centimeters Liters 0.0001 convert 25 horsepower into BTU per Cubic Feet Cubic Inches 1728 minute, divide 25 by 0.02356 = 1061 Cubic Feet Gallons (U.S. Liquid) 7.48052 Cubic Inches Cubic Feet 0.0005787 Cubic Inches Gallons (U.S. Liquid) 0.004329 Days Seconds 86.400 Degrees (Angle) Radians 0.01745 PSI BARS K/Pa Feet Meters 0.3048 Feet Miles 0.0001894 1 0.06895 6.895 Feet of Water Atmospheres 0.0295 15 1.03425 103.425 Feet of Water Inches of Mercury (Hg) 0.8826 Feet of Water PSI (Lbs per Sq. Inch) 0.4335 50 3.4475 344.75 Feet per Minute Miles per Hour 0.01136 100 6.895 689.5 Feet per Second Miles per Hour 0.6818 300 20.685 2068.5 Foot-Pounds BTU 0.001286 Foot-Pounds per Minute Horsepower 0.0000303 500 34.475 3447.5 Foot-Pounds per Second Horsepower 0.001818 1000 68.95 6895.0 Gallons (U.S. Liquid) Cubic Feet 0.1337 Gallons (U.S. Liquid) Cubic Inches 231 2000 137.9 1379.0 Gallons of Water Pounds of Water 8.3453 3000 206.85 20685.0 Horsepower BTU per Minute 42.44 Horsepower Foot-Pound per Minute 33,000 4500 310.275 31027.5 Horsepower Foot Pounds per Second 550 5000 344.75 34475.0 Horsepower Watts 745.7 Hours Days 0.04167 Hours Weeks 0.005952 Inches Centimeters 2.54 Inches of Mercury (Hg) Atmospheres 0.03342 Inches of Mercury (Hg) Feet of Water 1.133 Inches of Mercury (Hg) PSI (Lbs. per Sq. Inch) 0.4912 Inches of Water PSI (Lbs. per Sq. Inch) 0.03613 Liters Cubic Centimeters 1000 Liters Gallons (U.S. Liquid) 0.2642 Micron Inches 0.00004 Miles (Statute) Feet 5280 Miles per hour (MPH) Feet per Minute 88 Miles per hour Feet per Second 1.467 Ounces (Weight) Pounds 0.0625 Ounces (Liquid) Cubic Inches 1.805 Pints (Liquid) Quarts (Liquid) 0.5 Pounds Grains 7000 Pounds Grams 453.59 Pounds Ounces 16 PSI (Pounds per Sq. Inch) Atmospheres 0.06804 PSI (Pounds per Sq. Inch) Feet of Water 2.307 PSI (Pounds per Sq. Inch) Inches of Mercury (Hg) 2.036 Quarts Gallons 0.25 Square Feet Square Inches 144 Temperature (oF - 32) Temperature (oC) 0.5555 Tons (U.S.) Pounds 2000 Watts Horsepower 0.001341

In order to maximize the performance capabilities of the KMACS-5 and DCS-2 air control consoles, users should use the air supply information listed below. When using LP compressors, the user must know the what the compressor is capable of delivering to the divers at depth.

High Pressure Bank Supply

KMACS-5 Recommended Umbilical Supply Pressure (Surface Gage Reading) When Using The HP Regulator Supply System

Umbilical Supply Pressure Umbilical Supply Pressure Depth in P.S.I.G. in BAR Minimum Maximum Minimum Maximum FSW MSW P.S.I.G. P.S.I.G. Bar Bar 0-60 0-18 120 160 8.3 11 61-100 19-30 160 200 11 13.8 101-132 31-40 200 250 13.8 17.2

The HP supply table reflects the pressures required to supply two divers at depth working at a respiratory work rate of 62.5 liters per minute or less when being supplied by HP banks at a minimum HP pressure of 500 psig

Low Pressure Compressor Supply

Minimum Pressure (Surface Gage Reading) and volume at depth for two divers based on a maximum respiratory work rate of work rate of 50 RMV. Using 3/8" I.D. umbilical up to 300 feet (91meters) in length.

Minimum Pressure Depth Volume At Depth (Surface Gage Reading) Minimum Pres- Minimum Pressure Minimum CFM Minimum FSW MSW sure BAR At Depth LPM at Depth P.S.I.G. 0-60 0-18 120 160 12 338 61-100 19-30 160 200 17 483 101-132 31-40 200 250 21 600

The Low Pressure supply table reflects the minimum surface supply pressure and volume to enable two divers to work at a maximum respiratory work rate of 50 RMV. Based on a minimum HP supply pressure of 500 PSIG using 3/8" I.D. umbilical up to 300 feet (91meters) in length.