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Orca Spirit LTE - KISS Rebreather

1. TOO LOW IS BETTER AS IT IS QUICKER TO ADD OXYGEN TO THE LOOP THEN TO FLUSH IT To adjust the flow rate disconnect the oxygen delivery line where it attaches to the stainless steel elbow on the side of the scrubber head Attach a 0 1 litre per minute flow meter Dwyer VFB 60 SSV or equivalent to this line Disconnect the manual add valve supply line where it attaches to the add valve filter and connect a 0 300 psi gauge between these fittings Remove the clamp ring from the oxy gen regulator A and lift the black plastic plug B out of the regulator cap Connect the regulator to an oxy gen cylinder which has at least 800 psi remaining Slowly oxygen remember open the oxygen valve Note the gauge pressure and flow meter reading The relationship between the pressure setting and the 02 flow rate should match the table on the following page For those of you using the Miflex hoses The following photos show how the flow system can be checked and which parts you need All parts can be purchased through one of your local fittings suppliers This is just one method that can be used First remove the Miflex hose from the filter and attach an IP gauge Determine where the IP is set before you make any changes After you record that information reattach the hose Then remove the miflex hose which is attached to the plug side of the valve Attach your flow meter and short LP hose see above photo As per the inst
2. For the GEM Sidekick CCR only Ensure the student is comfortable rigging and securing the GS CCR diluent cylinder amp oxygen cylinder Ensure the student knows how to rig the GS CCR for best work of breathing Ensure the student understands the risk of high work of breathing and how to resolve it Buoyancy and trim control During the dive at depth During the dive at safety stop Minimum loop volume BOV familiarity GS CCR student will bail out to second stage as this unit does not have a BOV OC to CC CC to OC Take rebreather mouthpiece out of mouth in OC mode only and then return to BOV clearing it of water before switching to CC mode Bailout cylinder Bailout cylinder familiarity drills Bailout completely to 2nd stage attached to bailout cylinder PPO2 monitoring and control Raise PPO2 to desired level Drop PPO2 to desired level Start PPO2 level PPO2 monitoring every minute PPO2 not to exceed a working limit of 1 3 Manual Add Valve MAV check Static at constant depth monitor change in PO2 over a few minutes Diluent flushes Using ADV Using BOV GS CCR divers use 2nd stage Gas Shutdown Drills Carry out oxygen sensor verification at depth Carry out a linearity check of sensors at approximately 15 feet 5m on pure 02 Open circuit bailout including at least 2 OC ascents from approximately 60 feet 18m Demonstrate appropriate response to the following below Each dive should have a minimum of 2
3. The tools required to disassemble the valve are a wrench or Allen key small snap ring pliers and a jewellers screwdriv er First insert the snap ring pliers into the snap ring on the button end of the valve and remove ARAN H M e a e Ze DS wn EI od alt De Remove the nut with either the wrench or Alan key depending on which nut you have pull out the spring The spool and orifice are all that is left inside the valve To remove the spool and orifice push in the button using a jewellers screwdriver This will force the spool and orifice out the other end When you have the spool removed cut the old O rings away with a sharp knife and replace them with new V75 008 O rings which have been lubricated with an oxygen compatible lubricant such as Christolube Do not scratch the O ring grooves The orifice does not need to be removed unless it is damaged or plugged The parts in the valve are A snap ring B nut C spring D spool amp orifice E valve body 38 MSL 72 161 Jetsam Orca Spirit manual R 3 WARNING When reassembling the valve ensure that you do not over tighten the nut Re member when screwing any metal screws into plastic use only two fingers on the wrench If you over tighten the nut it will strip the threads and the valve will leak When attaching the valve to the filter and the hoses it is very important that you use a second wrench to hold the nut
4. 43 MSL 72 161 Jetsam Orca Spirit manual R 3 Once the valve is open you will see a small white button sitting on top of the spring Carefully remove the button and set it aside remember which way it came out Remove the spring and stretch it out a slight amount and then replace it Re insert the button replace the top of the valve and tighten As you are tightening push in on the valve as you turn it This will aid in turning the valve past the tab If required use the dental pick to lift the tab slightly When you pass the tab you will feel it click Tighten all the way and ensure that the valve is working properly by pushing down on the top Look inside the valve You should see the spring compressed with the white button sitting evenly Then unscrew the valve ensure that it stops turning when it reaches the tab Your valve is now ready to be replaced on your diving system 4 ADV problem If your counterlung volume is correct and the exhaust valve is in good working order and you still have a leaking exhaust with the feeling of too much gas in the loop you could have a problem with your ADV add ing too much gas into the system If this is happening you will also notice that your PPO2 is reading lower than usu al and that your buoyancy is off This could be caused by a stretched damaged or torn ADV diaphragm or a prob lem with the other components of the ADV Inspect the diaphragm for damage or fault To determine if this is the probl
5. KISS CCR Minimum Training Standards GENERAL REQUIREMENTS Diver must be at least 18 years old Academic portion minimum of 8 hours Equipment overview and maintenance minimum of 2 hours Minimum of 1 hour in Confined Water Minimum of 7 hours and 6 dives in Open Water Minimum of 2 dives deeper than 15m 50 feet Minimum of 1 dive deeper then 25m 90 feet Minimum course duration 5 full days Student to Instructor ratio for academic portion unlimited as long as practical Student to Instructor ratio for confined water 4 students per active instructor Student to instructor ratio for open water 4 students per active instructor This ratio should be reduced as required if the situation and or environmental conditions call for it It is recommended that the student finish the training course within 6 weeks of the starting date It is recommended that the student have access to or purchase a unit within 3 months of completing the training program Bailout cylinder must be carried on all dives Safety stops must be conducted on all dives minimum of 3 minutes at 6m 20 feet Depth limit not to exceed the diver s current certification level or the limit imposed by the training agencies course outline Students must write a written exam and achieve a passing grade of 80 or higher Only approved training agencies may teach a KISS rebreather course For GEM Sidekick CCR only Student must have some level of technical diver training At a min
6. 3 further than necessary to stop airflow will result in LEVER 9 slack and excessive spring load tension impairing proper performance CAUTION To avoid cutting the POPPET SEAT 10 with the knife edge of the ORIFICE 11 depress the PURGE BUTTON 31 while turning the ORIFICE 11 in or out d Hold the Second Stage with the mouthpiece 27 facing directly down and gently shake it up and down listening carefully for any rattle that may be present indicating lever 9 slack If slack is indicated the second stage must be disassembled and corrected 5 Purge the Regulator of all air to remove the In Line adjustment tool and connect the LP hose directly onto the coupling 2 using an 11 16 open end wrench Tighten to a torque of 35 to 40 in lbs 4 4 5 N m 6 Pressurize the Regulator again with a pure air source of 3 000 PSI 206 BAR Inhale lightly through the mouthpiece 27 Air should flow easily and smoothly without any hesitation or lag NOTE If hesitation or lag is detected refer to the Troubleshooting Section to determine possible cause and treatment 7 Clean and disinfect the mouthpiece 27 in warm soapy water before returning the BOV equipment to the customer BOV DIAGRAM AP TORQUETO 35 40 in lbs i e seo nossa Cs fen CC SOS 4 25684 POPPET CHAMBER right handverson 8 a esso sat e e asse EC A SSS a ec fon ferme SCS a a svi7__ poppetwasnen SS Co e fse ha EEN o
7. Rough spool 16 operation dirty or damaged mating surfaces clean lubricate replace O rings 18 29 housing 1 or spool 16 Water spool 16 1 mouthpiece 27 or Ty Strap 1 replace Ty Strap 9 and or 28 damaged loose or missing mouthpiece 27 2 bad O rings 18 24 25 29 2 replace O rings 18 24 25 3 Leak in Breathing Loop 29 3 see the Breathing Hoses and Counterlungs chapter BOV MODES The BOV has two modes that are alternated by moving the lever 34 Fig 1 OC OC Open Circuit Position used for bail out off of the rebreather o CC Closed Circuit Position BOV SPOOL DISASSEMBLY Figure NOTE O rings must be changed any time they show signs of decay or damage 1 Using an 11 16 open end wrench remove the LP hose end from the coupling 2 on the BOV Fig 2 NOTE To avoid internal corrosion and damage NEVER submerge the BOV assembly in liquid with the LP Hose removed from the COUPLING 2 Figure 2 2 Slide the silicone hose clamp covers off of the Oetiker clamps 3 Using Oetiker style pliers remove the Oetiker clamps that retain the BOV hose adapters into the inhalation and exhalation breathing hoses Fig 3 4 Unscrew the breathing hose nuts and remove the BOV breathing hoses and adapters 5 Pinch the hose adapter O rings to remove as shown Fig 4 Inspect the O rings and seating surfaces for deterioration and damage If found discard 6 Peel back the exhalat
8. WARNING Diver s choosing to purchase the unit without the display system s wired to the sensor head must ensure that they have the display port s wired properly by a qualified 26 MSL 72 161 Jetsam Orca Spirit manual R 3 facility prior to diving Also KISS Rebreather LLC strongly recommends that both display ports are wired with displays for redundancy Those that choose to dive the KISS OS with only one display system should limit their diving to recreational no stop diving WARNING THERE ARE VARIOUS DISPLAY SYSTEMS AVAILABLE FOR THE KISS REBREATHERS THEY INCLUDE BUT ARE NOT LIMITED TO THE KISS REBREATHER DISPLAY SHEARWATER COMPUTERS AND SHEARWATER HUD As with all electronics these components must be treated with care and respect This includes taking care to not drop bang or roughly handle them Also do not leave these components in a hot envi ronment such as a car or direct sunlight The heat amp or sun can and will damage any electronic components WARNING Do not mix sensor brands in your rebreather There are various sensor brands available for purchase If you mix brand A with brand B they will not work properly As the response times are different for each brand most electronics will not calibrate properly If they do calibrate they may not work correctly while diving as the different response times could cause an error reading The KISS displays and the Shearwater products all use the KISS Rebreath
9. diver emergencies that the diver must react to Hyperoxia Hypoxia amp Hypercapnia Diluent gas loss Oxygen gas loss Sensor s failure Dive computer failure PPO2 display failure Water in loop SCR mode Post dive cleaning of unit and briefing 59 MSL 72 161 Jetsam Orca Spirit manual R 3 Warranty The KISS Rebreather LLC Rebreather s boosters displays and mouthpieces are warranted for the period of 1 year All warranty and service work should be returned to our warehouse e The warranty applies to the original owner only e Mistreatment or neglect of the products will void the warranty e Parts not covered by the warranty are batteries and sensors e Circuit boards and meters sold separately without the case are not covered under the warranty e Warranty cards shipped with rebreather s boosters displays and mouthpieces must be completed and returned to KISS for the warranty to be valid e Completed liability waivers must be on file for the rebreather warranty to be valid e Modifications to the KISS rebreather will void the warranty Only approved modifications are allowed e Weare unable to determine if the parts are covered by the warranty until they have been inspected PROCEDURES FOR WARRANTY amp SERVICE WORK Prior to shipping please contact Mike Mizel at kissrebreather yahoo com to inform him of the shipment You will need to print out the warranty service form fill it in and ship it with your item This
10. e KISS HW PPO2 display and cable All hardwired no Fischer s e Secondary display options may include PPO2 display computer or HUD Not included e Display system and cable See above for options e Mouthpiece BOV LP regulator hose 2 quick connect hose stubs and 2 hose clamps e Stainless steel ballast rings for the loop hoses Our rings are 13 Ib each for a total of 1 04 Ib s when using our recommended 8 rings e Oxygen first stage and OPV e Sensors e Swivel elbows HP LP e Spare parts such as O ring kits See the back of the manual for a list of recommended spare parts e Diluent bailout regulator set e Diluent bailout cylinder eo Pressure gauges 7 MSL 72 161 Jetsam Orca Spirit manual R 3 KISS Orca Spirit BASIC Rebreather Kit INFORMATION amp INSTRUCTIONS FOR KEY UPGRADE COMPONENTS As rebreather s are becoming more and more main stream in the dive industry we are seeing many new dealers and divers interested in our products One of the popular requests that we get is can buy a KISS rebreather without the mouthpiece Another one is can buy a KISS rebreather without the first stage Well the answer is YES Based on customer comments and requests we have setup the KISS OS pricing structure so that dealers and divers may personalize their units The KISS OS BASIC is a bare bones system Dealers and divers can now add on the KISS compo nents they wish to buy and supply the balance of the kit themselv
11. would strongly sug gest that you have a new diaphragm on hand Insert the screws through the ADV cover until one or two threads are showing and then push the diaphragm through the screws Carefully place the assembly against the scrubber head and hold it firmly in place with one hand while turning the screws with the other If while placing the assembly against the head the diaphragm shifts start again It must be aligned properly Turn each screw only a half turn or so before alternating to another screw Watch carefully and stop turning as soon as the bottom of the screw touches the plastic cover There will be no gap between the underside of the screw and the cover but the screws will not have started getting more difficult to turn yet Look at the diaphragm and ensure that it looks proper It should not be twisted Turn the screws another 1 to 2 mm Then turn them another 1 mm Remem ber not to over tighten the screws If the screws are over tightened the diaphragm will leak If you are having a prob lem in this area do a positive pressure test and then back the screws off slightly until the leak stops The adjustment will be very slight We have tested this method both with and without lubricant on the diaphragm holes We have found that it is better to NOT use lubricant in this area as it can make it more difficult If you are using a new diaphragm ensure that when you attach the plastic button and screw to it that you do not over t
12. DIVE AND AFTER REASSEMBLY WITH THE MOUTHPIECE IN YOUR MOUTH THE GAS FLOW IS FROM LEFT TO RIGHT SUCK IN AND THE LEFT SIDE VALVE OPENS AND EXHALE AND THE RIGHT SIDE VALVE OPENS DO NOT POSITION THE MUSHROOM VALVES IN ANY OTHER DIRECTION 47 MSL 72 161 Jetsam Orca Spirit manual R 3 MOUTHPIECE REASSEMBLY Dive Rite or Apeks Second Stage e Inspect the mushroom valve carriers and the mushroom valves for damage Ensure that they are clean washed and disinfected and remove any debris IF THE MUSHROOM VALVES ARE DISTORTED OR DAMAGED THEY MUST BE REPLACED When attaching or removing the mushroom valves BE CAREFUL PULL ON THE STEM GENTLY amp ONLY HOLD THE STEM WHEN REMOVING THE VALVE e Ensure that the mushroom valve carrier O rings are clean free of debris and in good condition Lubricate the O rings and insert them onto the carriers These O rings need only LIGHT lubrication e Clean disinfect and inspect the mouthpiece body Hold the body with the rubber mouth bite towards you and the port for the 2nd stage regulator facing down Position the right side mushroom valve carrier with the valve facing out This is the exhale side and you will notice that this valve does not have a stem showing Position the left side mushroom valve carrier with the valve on the inside of the carrier You will notice that the left side valve has the stem facing out Ensure that the O rings do not extrude out of their grooves when you push them into place
13. Fischer cable which we hardwire into our sensor head is compatible with both our KISS FC PPO2 display and the Shearwater computer s This means that diver s who choose the KISS FC PPO2 display to start off with may easily upgrade to a Shearwater computer at a later date Our option s are e KISS HW PPO2 display the display is hardwired to the display cable the sensor head There are no Fischer con nectors in this system e KISS FC PPO2 display the display is connected to the cable via a Fischer connector The other end of the cable is hardwired to the sensor head e Shearwater computer there are two models available The computer will connect to the unit via a Fischer cable that is hardwired to the sensor head The Fischer connector is between the cable end and the computer e Shearwater HW HUD the HUD is hardwired to the sensor head There are no Fischer connectors in this system e Shearwater FC HUD the sensor head must be ordered with a Fischer connector secured to it The HUD is then attached to this connector using the mating Fischer plug which is on the HUD cable Utilizing the above option s the KISS OS may be customized for each diver The KISS OS has two display ports ma chined into the sensor head Option s that diver s may choose include the following e Nodisplay s No Fischer display cable s e Fischer display cables hardwired into both ports e KISS HW PPO2 display in both ports no Fischer connector al
14. If the cylinder is included in meas uring the depth then the depth is 6 inches 15 25 cm Those that wish to know the packing depth add 3 to 4 inches 7 6 to 10 16 cm for the wing and harness PLEASE SEE OUR PARTS LIST ON THE NEXT PAGE FOR A FULL LIST OF WHAT IS INCLUDED AND WHAT IS NOT It is a mechanical rebreather which adds O2 continuously by a feed orifice and manually as needed Compatible with Trimix Scrubber holds 6 2 lb 2 8 kg of Sofnolime 408 grade absorbent different brands may have different weights The cylinder is 14cuft and holds 3000 PSI of pressure The KISS Orca Spirit is a closed circuit rebreather designed for recreational and technical sport diving to the depth of 300 feet 91 meters Proper training outside the basic KISS rebreather course is required for any deep or technical diving For some types of diving extra gear must be carried or alternate gear configurations will be required Ensure you have the proper train ing gases and gear to conduct your planned dive 6 MSL 72 161 Jetsam Orca Spirit manual R 3 Parts List 1 KISS Orca Spirit BASIC includes 1 stainless steel stand which includes 3 Fastex clamps 2 wing attachment bolts 2 Fender washers with nuts manifold with adjustment set screw 1 off board accessory whip rebreather side 1 ADV LP hose with elbow 1 wing inflation LP hose 1 cylinder side off board accessory for the diluent cylinder 1 gas addition scrubber head which includes 1 scrubbe
15. an edit pressing MENU increments the current display SELECT button Right o In the menu system the select button saves the current value or executes the command e Out of the menu system the select button brings up information displays BOTH BUTTONS e When the computer is off pressing MENU and SELECT at the same time will turn the computer on Calibrate Start by following the procedures on the calibration page These instructions must be followed in order to ensure the unit is properly flushed with oxygen This is an important step which is required to ensure the calibration will be accu rate Once the unit is properly flushed with oxygen push the left MENU button unit you see Calibrate on the computer Push the right SELECT button and the confirmation message will display On the top line the millivolt reading will show Good sensors should be in the range of 35 60 mV at sea level in 100 oxygen The valid millivolt range for calibration is 30 70 mV This scales with percentage of oxygen and barometric pressure Pressing the MENU button will prevent the calibration Pressing the SELECT button will cali brate the sensor displays The displays should now all read 98 If any display shows FAIL the calibration has failed because the mV reading is out of range The system defaults to a calibration gas of 98 oxygen This is to compensate for the difficulty in completely filling the loop with 100 oxygen and also to allow for w
16. be too tight so as to restrict breathing Diver s may require the smaller lung set of 2 amp 4 liter due to the size of the lungs wrapping around the divers torso A very small person may not be able to properly fasten the 4 amp 4 liter lungs This is why they would use a 2 amp 4 liter config uration If the 4 amp 4 counterlung set can be properly secured to the diver and the lung volume is not to small then this is what we recommend WARNING IT IS IMPORTANT THAT THE LUNGS ARE PROPERLY SECURED TO THE CROSS BAR amp THEN PROPERLY THREADED THROUGH THE WING THEY MUST ALSO BE PROPERLY SECURED USING THE CLIP AT THE DIVERS WAIST IF THE LUNGS ARE NOT SECURED THEY WILL FLOAT UP AND BREATHING WILL BE DIFFICULT ENSURE THAT THE LUNGS ARE PUSHED ON STRAIGHT AND THAT THE RINGS ARE NOT OVER TIGHTENED AS THEY WILL SPLIT Crossbar e The cross bar may be installed either before the cylinder is secured or after Note that it is easier to install the crossbar AFTER the cylinder is secured as it will give you a reference point and aid in the installation e Inspect the crossbar to ensure that it is not damaged Also ensure that it is clean and ready to install on the unit There is a double O ring seal where the bar secures to the bottom of the canister 1 First wipe and clean the sealing area on the bottom of the scrubber canisters Then lubricant the sealing area well 2 Next wipe and clean the O ring areas on the crossbar Then lubricate
17. e ses see E at a fass Iewen Il ie Pue nous OOOO Cs o s Juge oO a o _ exnaustcover OOOO DIA CAL PIN DESCRIPTION NOTES e a aro ong em o ie ss one 2 b Tam orine _________ 21 b em DIAPHRAGM SS e ases VALVEHOLDER EXHALATION a c 25389 VALVEHOLDER INHALATION gt gt 24 b am orine 25 b arse EE 226 a 7765 MUSHROOMVAVE OWY 2 27 b oe MOUTHPIECE Li 28 a Lamm T STRAP 2 a jose jorne O 29 e eme _ coveRRING Jooo ar b e PURGECOVER Jo ooo 32 e em nenne oO 33 e om SCREW LEVER J o ooo 3 oe LEVER 2 POSTION s b Jam one
18. form can be obtained from the KISS website at www kissrebreathers com Your product should be returned to us with the following items e A copy of your original purchase receipt e The warranty service form Carefully box up the items being returned KISS Rebreathers LLC is not responsible for any damage incurred during shipping Ensure that the items are properly padded and shipped in a strong box and also that it is well sealed Don t forget to insert the above mentioned paperwork Please write in large clear letters WARRANTY RETURN MADE IN USA on the outside of the parcel and on any paperwork This is important as otherwise USA Customs will charge us a brokerage fee and duties which we pass on to you The parcel may be shipped via the post office or a courier All shipments must be prepaid and insured Any fees that KISS Rebreather LLC incurs must be paid for by the shipper This includes duties and brokerage fees for the item re entering the USA Note that if you ship via a courier such as UPS or Federal Express there will be a brokerage fee even if there are no duties While there may be no charges for the warranty work this brokerage fee must be paid for by the shipper 60 MSL 72 161 Jetsam Orca Spirit manual R 3 KISS ORCA SPIRIT RECOMMENDED PARTS amp O RING LIST We recommend that divers have a spare parts kit for their KISS OS O RINGS are available in the following packages 1 full kit which includes all O rings re
19. holding it up to the light and gently pulling the rubber will help HAVING SAID THAT THE DIAPHRAGM IS EASY TO CHECK IT IS ALSO WORTH NOTING THAT IF YOU ARE NOT HAVING A PROBLEM WITH THE DIAPHRAGM ASSEMBLY DO NOT DISSEMBLE IT WITH PROPER USE THE DIAPHRAGM WILL LAST FOR YEARS IF NOT DISTURBED NOTE A damaged ADV assembly will either deliver too much diluent gas or none at all NOTE It is important that the proper installation procedures are followed for the ADV as sembly and diaphragm the directions are on the following page The exhaust valve is a key component of the KISS diving system care should be taken that it is not damaged and properly maintained ADV IS DIFFICULT TO TRIGGER The position of the diver will effect the ADV If the diver is horizontal or face down the ADV will trigger easily If the diver is vertical then it will be a bit harder A well fitting harness is important this will greatly reduce the difficulties of being vertical in the water Also rolling to your right side while horizontal will assist in triggering the ADV If preferred diluent can be added via the mouthpiece Turn the knob about a 1 4 inch and diluent gas should flow into the loop Depending on where your IP is set and which second stage you are using you may need to lightly hit the purge button Lastly check the IP on the diluent first stage Ensure that it is in the correct range Remember the ADV is not meant to be easy to trigger l
20. hose MS Figure 36 TUNING THE SECOND STAGE 1 Prior to tuning the second stage check the following items a The demand diaphragm 21 purge cover 31 and cover ring 30 should be properly installed into the housing 1 with the Front cover ring 30 tightened until secure b Connect an In Line Adjustment Tool between the low pressure hose and coupling 2 C The mouthpiece 27 should be cleaned and disinfected with warm soapy water NOTE While pressurized the slotted blade of the In Line Tool will be held away from the ORIFICE 3 and will therefore need to be pushed inward and held while turning the ORIFICE 3 in either direction Locate the slotted head of the ORIFICE 3 by touch before attempting any adjustment Clockwise turns of the In Line Adjustment Tool turns the orifice 3 in toward the seat 5 increasing the opening effort Counterclockwise turns of the In Line Adjustment Tool turns the orifice 3 out away from the seat 5 reducing the opening effort 2 Pressurize the regulator with a pure air source of 3 000 PSI 206 BAR and listen to determine that a slight air flow is initially present 3 Use the In Line tool to turn the orifice 3 clockwise with very small fractions of a turn just until airflow is no longer present and pause to listen carefully for airflow or leakage after each adjustment Adjust the orifice 3 as required to achieve the desired opening effort NOTE Turning the ORIFICE
21. is leak ing diluent gas into the loop 2 Twisted counterlung s If the counterlung s are twisted or bunched up they will not be able to expand properly and breathing will be restricted 3 Counterlung s not pulled through wing harness properly If the counterlung s are not properly routed it is likely that they could be restricted in some manner This will cause the breathing to be restricted 4 Waist strap is too tight If the waist strap is cinched down to far it will restrict the lungs from properly inflating Loosen the adjustment strap on the lung s and they will properly inflate 45 MSL 72 161 Jetsam Orca Spirit manual R 3 MOUTHPIECE DISASSEMBLY Dive Rite or Apeks Second Stage The KISS bailout mouthpiece can go from closed circuit mode to open circuit with a turn of the switch It provides divers with an alternate method of adding diluent gas or even an al ternate diluent depending on the connection and if the off board accessory is being used It offers an easy way to purge the rebreather for verifying the sensor readings If the need for a sanity breath or emergency bailout arises this mouth piece will provide the diver with a fast simple way of getting a breath The mouthpiece is in closed circuit mode when the bar on the switch is horizontal First the hose attachments should be re moved Do this by removing the circ clips then pull the hose attachments away from the body Next the switch
22. it is cleaned after every dive It is important that it is kept clean and the knob should always turn smoothly Keeping your BOV clean is important as grit inside the moving parts can score the plastic Your local KISS dealer can assist you with servicing the BOV if you prefer not to do it Care should be taken to ensure that it is in good working order and not damaged Also be aware that if you wash your BOV with a powerful hose the valve disks may be blown off After cleaning be certain to inspect your gear and follow all the pre dive check s 63 MSL 72 161 Jetsam Orca Spirit manual R 3 IF THE MUSHROOM VALVES ARE DISTORTED OR DAMAGED THEY MUST BE REPLACED When attaching or removing the mushroom valves BE CAREFUL When attaching or removing the NEW valves PULL ON THE STEM GENTLY amp ON LY HOLD THE STEM WHEN REMOVING THE VALVE DO NOT CARRY THE VALVE OR VALVE CARRIER BY THE STEM Wing Harness amp Lung Positioning The OS LTE package includes a wing and harness system It is important that the KISS LTE wing and harness system is used with this unit as lung placement is critical When securing the wing harness system to the rebreather first place the wing so that the bolt holes are over the holes on the plate Then place the harness on top of the wing securing with the bolts Once secured pull the counterlung s through the slots on the wing and ensure that they sit on the inside of the harness shoulder strap Ensure t
23. next to the valve body in place Do not allow this nut to spin as it will over tighten and strip the plastic This will cause the valve to leak The valve body is not a substitute for a wrench Older KISS units were shipped with the Swagelok SS Teflon hoses New units are shipped with the Miflex hoses When attaching the manual add valve to these hoses remember that the inlet port is the one nearest the add button The hose which is attached to the oxygen first stage is attached to the inlet port NOTE The oxygen delivery system attaches to the rebreather via the elbow on the side of the scrubber head Please note that the male end of the elbow which screws into the head is NPT or pipe thread This is a tapered thread NOT a straight thread If you screw a fitting with a straight thread such as a swivel elbow into this port it will damage the rebreather head If this happens it is NOT repairable NOTE The Miflex hoses are tested and rated for oxygen use As they have standard regu lator hose fittings they can be replaced with other rubber LP hoses If you do so please en sure that the hoses you use are rated for oxygen use Also all low pressure hoses on the KISS should be inspected periodically to ensure that they are not damaged and in good working order This includes the oxygen hoses diluent hose BOV 2nd stage regulator hose ADV hose The KISS rebreather s are mechanically controlled The oxygen manual add valve houses a orifi
24. s must be certain that the cylinder they choose has the proper amount of gas for diluent wing amp drysuit inflation 19 MSL 72 161 Jetsam Orca Spirit manual R 3 and also for bailout Those doing any sort of technical and or decompression diving must carry a larger cylinder s and ensure that it is appropriate for the dive that they are planning The KISS OS BASIC includes one full set of the off board accessory This accessory is used to plumb the diluent bailout gas into the rebreather via the manifold The kit includes the rebreather side whip and the diluent cylinder side whip The off board accessory rebreather side includes 1 30 inch LP hose 1 check valve with quick disconnect male The off board accessory cylinder side includes 1 6 inch LP hose 1 quick disconnect female The cylinder side whip should be secured to the diver s first stage on the diluent bailout cylinder Those divers that wish to carry more then one diluent bailout cylinder may purchase a second cylinder side whip This would allow both diluent cylinder s to be open throughout the dive When the diver swaps the main off board whip from the first cylinder to the second the check valve will prevent any water from entering the system 20 MSL 72 161 Jetsam Orca Spirit manual R 3 21 MSL 72 161 Jetsam Orca Spirit manual R 3 Filling the Scrubber Canister The KISS OS has a bi axial scrubber design which is resistant to channelling It has
25. should be as evenly matched to your own lungs as possible If you find that when doing this test you can get more than one full breath into the loop before it is full then cinch down the straps Never use counter lung s where the volume is smaller than your own Very small people may require a 2 amp 4 liter to ensure proper place ment while most people will use 4 amp 4 liter lungs Those with very large lung volumes may require 4 amp 6 liter lungs In matching your tidal volume to the counterlung volume you will find that your buoyancy in shallow water can be ex ceptional Only KISS divers can hold their position in water that is only 3 to 4 feet deep If you are finding buoyancy difficult in water this shallow this is due to either being new on the rebreather or the counterlung s are too large While doing this test at the surface remember that underwater your required volume won t change If you find that your surface test went well but it feels like the lungs are too small underwater you probably have too much gas in the loop To correct this exhale some of the gas out of your nose Or you failed ensure that the lungs weren t twisted when threaded through the wing then this will cause either a decrease in lung volume amp or will increase the work of breathing See the work of breathing pages for more information NOTE The closer you can match the counterlung volume with your own the better your buoyancy will be Diving the KISS OS wi
26. style of ADV Bubbling Apeks Exhaust Valve If your counterlung volume is correct and the exhaust valve is in good working order and you still have a leaking ex haust with the feeling of too much gas in the loop you could have a problem with your ADV adding too much gas into the system If this is happening you will also notice that your PPO2 is reading lower than usual and that your buoyancy is off This could be caused by a stretched damaged or torn ADV diaphragm a ADV valve stem which is damaged and also if the seating area of the ADV valve stem has debris in it Inspect the diaphragm and valve stem for damage or fault When reinserting the ADV valve stem clean the underside of the valve s head and apply a small amount of lubricant to it This will keep it in good condition and help it to seal Also thoroughly clean the seating area NOTE ensure that the seating area of the valve stem is clean and debris free If there is the slightest amount of dirt in this area the valve stem will leak To determine if this is the problem shut off the diluent gas First you will notice your PPO2 stabilize and stop dropping Also the lungs will stop filling up all the way and the exhaust valve should stop purging 65 MSL 72 161 Jetsam Orca Spirit manual R 3 The diaphragm is simple to check Open the cover and pull the assembly out It should be fairly flat and not damaged You may need to look quite closely for small tears or holes Sometimes
27. the Fastex clamp to secure the canister in this position it will be properly positioned after the crossbar is secured NOTE The two Indexing marks should face each other This will ensure that the towers on the scrubber head are properly situated for loop hose placement NOTE The right side Gas Addition Head is the Exhale side the left side Sensor Head is the Inhale side e Slide the Sensor head amp canister through the left Fastex clamp this will be on the divers left side when wearing the unit This is the inhale side Note where the Indexing Mark is located Turn the canister until this mark is lined up facing the other canister Again place the canister higher then where you feel it should sit it will be properly placed once the cross bar is in place Tighten the Fastex clamp to secure the canister in this position Ensure that the exhaust valve is tightened all the way Counterlung s e Inspect the counterlung s Most divers very few will use a different size will be using a 4 amp 4 liter counterlung En sure that they have been properly cleaned and are ready to use l 2 NOTE FOR EASE OF ATTACHMENT A VERY SMALL AMOUNT OF LUBRICANT CAN BE APPLIED TO THE INSIDE OF THE COUNTERLUNG OPENING While you have inspected the crossbar in the above procedure you should inspect the O rings areas again prior to installation of the lungs Apply lubricant to the O First wipe and clean the sealing area on the inside
28. the lever 34 in place and start the lever screw 33 by hand clockwise Then continue tightening the lever screw 33 with a 5 32 L shaped Allen key Fig 13 DO NOT over tighten Figure 13 NOTE Be careful not to damage the sealing surface of the INNER SPOOL 16 and BOV HOUSING 1 NOTE If replacing the MUSHROOM VALVES 26 ensure not to place damaging stress on the VALVE HOLDERS 22 23 6 If removed replace the mushroom valves 26 by gently pulling the retainer stem through the valve holders 22 23 while twisting until the retaining flange is completely inside the valve holders 22 23 and properly seated Fig 14 DANGER DO NOT put lubricant on the MUSHROOM VALVES 26 Figure 14 7 Lightly lubricate and refit the valve holder O rings 24 25 Then press the valve holders 22 23 back into place Fig 15 Be careful not to pinch the O rings 24 25 8 Lightly lubricate and install the hose adapter O rings onto the hose adapters Figure 15 9 Slide the hose nuts and silicone sleeves over the ends of the breathing hoses Then install the BOV hose adapters onto the breathing hose ends Fig 16 Figure 16 10 Using Oetiker style pliers reattach the Oetiker clamps Fig 17 Figure 7 11 Slide the silicone hose clamp covers back into place Fig 18 Figure 18 12 Secure the mouthpiece 27 onto the BOV housing 1 with a new ty strap 28 positioning the locking tab of the
29. will need to be removed Remove the screw which holds the switch in place pull the switch off Then unscrew the attachment plate and pull the inner barrel out Alternatively you may leave the switch secured to the inner body and simply unscrew the attachment plate and remove the en tire assembly Finally the mushroom valve carriers can be removed From the inside of the body using either a blunt instrument or vour finger carefully push on the EDGE of the valve carrier not the valve DO NOT PUSH ON THE CENTER AS IT WILL DAMAGE THE CARRIER IF THE MUSHROOM VALVES ARE DISTORTED OR DAMAGED THEY MUST BE REPLACED When attaching or removing the mushroom valves BE CARE FUL PULL ON THE STEM GENTLY amp ONLY HOLD THE STEM WHEN REMOV ING THE VALVE THESE VALVES ARE EXPENSIVE TAKE CARE TO NOT DAMAGE THEM 46 MSL 72 161 Jetsam Orca Spirit manual R 3 MOUTHPIECE PARTS LIST Dive Rite or Apeks Second Stage Body Inner barrel Switch Switch screw Front cover Hose attachments 2 Plastic circ clips 2 Mushroom valve carrier 2 Mushroom valves 2 o Da PRI O rings Mushroom valve carrier 1 per side Inner barrel side port 2 per barrel Inner barrel end 2 per barrel Hose end 2 per side UNLESS OTHERWISE SPECIFIED O RINGS SHOULD ONLY BE LIGHTLY GREASED INSPECT ALL O RINGS FOR CRACKS AND OTHER DAMAGE REGULARLY DISINFECT ALL BREATHING LOOP PARTS REGULARLY MUSHROOM VALVES SHOULD BE TESTED PRIOR TO EVERY
30. you may secure a loop of bungee to your shoulder straps and slide the loop hose through this when securing to your tow ers The bungee loop will assist in holding the loop hoses in place As the BOV has an excellent work of breathing it also has a large air space which makes the mouthpiece more buoyant then other models NOTE For the mouthpiece to be comfortable the above instructions must be followed If you feel the mouthpiece either pulling up or down while diving adjust it by holding onto the mouthpiece and gently turning the hose by holding the end with your other hand DETERMINING THE CORRECT COUNTERLUNG SIZE To determine if the counterlung s are a suitable size you must first put the unit on and secure the lungs The amount of gas that the lungs hold can be adjusted by simply tightening or loosening the lung waist strap If when doing the test below the lungs are too small loosen the strap and try again If they are too large then you can tighten down the strap to adjust First put the mouthpiece into your mouth open the loop and inhale the gas into your lungs and then out of your nose until the loop is completely empty When the loop is empty close the BOV without allowing any air to enter Then take a large breath as much as you can hold put the BOV into your mouth open the loop and exhale all your air com pletely into the loop and then close the BOV 16 MSL 72 161 Jetsam Orca Spirit manual R 3 Ideally the lung size
31. you are required to change one of the LP hoses the scrubber canister s will need to be removed from the unit so that the area is accessible In order to make it easier to work with these hoses a set screw has been placed which locks the manifold in place You can see the set screw on the front of the plate when the wing harness is removed See photo Simply loosen the set screw slightly and the manifold can be moved Be certain to slide the manifold back to its original position and to tighten properly when finished The LP hoses secured to the manifold are as follows e Bottom This is the Off Board Accessory which is connected to the side mounted diluent bailout cylinder This LP hose is 30 inch e Top of manifold back right ADV 9 inch e Top of manifold back left Wing inflation 30 inch e Top of manifold front centre BOV 32 inch included when BOV is ordered from KISS Canisters e Atthis point your scrubber canisters are full with the heads secured see the scrubber filling section for filling amp head placement instructions 12 MSL 72 161 Jetsam Orca Spirit manual R 3 Slide the Gas Addition head amp canister through the right Fastex clamp this will be on the divers right side when wearing the unit This is the Exhale side Note where the Indexing Mark is located Turn the can ister until this mark is lined up facing the other canister Place canister a few inches higher than where it will likely sit Tighten
32. 1 loose or missing 1 Replace with new 2 Replace with new 3 Replace with new 4 Tighten until secure 5 Replace with new 6 Tighten or install SECOND STAGE DISASSEMBLY NOTE Be sure to check and record the intermediate pressure prior to disassembling the Explorer BOV Review the Troubleshooting section to better understand which internal parts may need replacing and to better advise the customer of the service required de Snip the plastic ty strap 21 that holds the mouthpiece 27 and remove the mouthpiece 27 Inspect the condition of the mouthpiece 27 to ensure that it is supple and free of any tears or corrosion Discard if found 2 Remove the LP hose from the Second Stage using an 11 16 open end wrench while holding the Hex portion of the coupling 2 secure with a 3 4 open end wrench CAUTION Ensure the Regulator is free of sand when removing the COVER RING 30 Figure 21 Y EXPLORE 3 Turning counterclockwise remove the cover ring 30 Fig 21 Then lift the purge cover 31 and inner ring 32 to expose the diaphragm 21 d Grasp the diaphragm 21 by the raised edges of the center and gently lift it out with a slight upward twist to remove Fig 22 Inspect the diaphragm 21 to ensure it is supple and free of any tears corrosion or other distortion Discard if found Figure 22 di Depress the lever 9 While holding it down remove the coupling 2 in a counterclockw
33. 2 independent canisters that can each be removed replaced and filled independently of the other this makes for quick and easy filling It also makes for easier storage of canisters due to the size and weight Spare canisters may also be purchased for those who wish to have spares This is a similar design to an earlier KISS rebreather but this is a much better and more efficient design Tests have shown that the area of the scrubber canister that does the most work is the scrubber face As the KISS OS has dual canisters this means that this area is doubled which makes this system very efficient The KISS OS scrubber canisters hold a total of 5 3 pounds of absorbent We use Sodasorb HP from diverssupplyinc net Please see the Scrubber Duration page for more information on duration testing and recommended dive times So dasorb HP is the brand of adsorbent that we used for testing and it is what we recommend The procedure to fill the scrubber canisters is as follows e Remove the ADV LP hose which is secured to the gas addition scrubber Head This will allow the gas addition scrubber head to be removed from the canister e On each canister loosen the threaded ring which secures the head s to the canister s e Loosen the Fastex clamp s which secure the canister s to the rebreather pull the canister s off the head s and set aside if the crossbar is still attached remove it e lf there is absorbent in the canister s dispose of it pr
34. 3 Working quickly so the hose remains soft push the hose stub onto the loop hose Push it on as far as it will go but leave a few millimeters of space so it doesn t touch the side of the stub and restrict the movement of the ring 4 Secure the hose stub using a hose clamp ensure that the hose clamp is properly tightened 5 Ensure that the O ring area on the hose stubs are clean and then apply lubricant 6 Push the hose stub onto the tower BOV lining up the lip on the tower BOV with the space on the hose stub 7 Turn the ring to secure 8 Inspect the area to ensure that all the O rings are properly seated and not pinched 9 To remove the hose stub push in on the stub and then turn the ring This is a similar method to opening and closing a child proof medicine bottle 18 MSL 72 161 Jetsam Orca Spirit manual R 3 SERVICE THE O RINGS ON THE HOSE STUBS AND THE CORRESPONDING SURFACES ON THE BOV ADAPTERS AND HOSE ATTACHMENTS SHOULD BE LUBRICATED ON A REGULAR BASIS PRIOR TO DIVING ENSURE THAT HOSES HAVE BEEN PROPERLY ATTACHED TO THE TOWERS AND TO THE BOV FAILURE TO DO SO COULD CAUSE INJURY OR DEATH Manual Add Valve MAV The MAV is the component that will add oxygen to your unit continuously and will also allow you to push a button to add gas as required Further on in this manual you will find a MAV trouble shooting amp service section For the purpose of gear assembly the valve is ready to go Once the unit is assembl
35. MSL 72 161 Jetsam Orca Spirit manual R 3 READ THE MANUAL IN ORDER TO FULLY UNDERSTAND YOUR NEW REBREATHER THE COM PONENTS HOW THEY WORK HOW TO HANDLE AND TREAT THEM YOU MUST READ THE MANUAL IN FULL FOR YOUR REBREATHER ORCA SPIRIT OWNERS SHOULD READ THE OS MANUAL SPORT KISS OWNERS SHOULD READ THE SPORT KISS MANUAL CLASSIC KISS OWN ERS SHOULD READ THE CLASSIC KISS MANUAL EXPLORER OWNERS SHOULD READ BOTH THE EXPLORER AND CLASSIC MANUALS CLASSIC OWNERS WHO HAVE UPGRADED TO SOME OF THE EXPLORER COMPO NENTS SHOULD READ BOTH THE CLASSIC AND EXPLORER MANUALS THIS SHOULD BE DONE PRIOR TO DIVING OR SERVICING THIS UNIT SPECIAL ATTENTION SHOULD BE PAID TO ALL NOTES amp OR WARNINGS THEY MUST BE READ AND UNDERSTOOD FAILURE TO DO SO MAY CAUSE SERIOUS INJURY OR DEATH YOU MUST BE A LEGAL ADULT IN THE AREA IN WHICH YOU LIVE IN ORDER TO PURCHASE AND DIVE A KISS REBREATHER As with all scuba diving equipment your KISS rebreather components should be serviced annually by a trained technician For those diving frequently servicing may be required more often ALL INFORMATION IN THIS MANUAL IS SUBJECT TO CHANGE Please visit our website www kissrebreathers com for updated manuals 2 MSL 72 161 Jetsam Orca Spirit manual R 3 THIS IS NOT A JOKE THIS DEVICE IS CAPABLE OF KILLING YOU WITHOUT WARNING Every time you use this rebreather you risk serious bodily injury or death These risks include but are
36. N FIRST STAGE OPV S MUST BE SECURED TO THE OXYGEN FIRST STAGE FAILURE TO DO ANY OF THESE MAY CAUSE INJURY OR DEATH 10 MSL 72 161 Jetsam Orca Spirit manual R 3 Unpacking amp Disassembly Congratulations You have just received your KISS Orca Spirit the first thing to do is en sure that all the parts you ordered are included in the box As you know the KISS OS can be shipped either as the BASIC unit or with various components added Please see the previous parts page for a list of what is included with the BASIC kit and what the optional extras are Go through the box and ensure that everything that you ordered has arrived Small items can be lost in bubble wrap so ensure that you look carefully in the packing ma terial also The OS ships with all the O rings installed and the unit is assembled The following instruc tions are for disassembling the OS e Remove the back cover Remove the wing harness from the front of the unit by loos ening the fitting s and setting them aside The counterlung s will slide through the slots and stay attached to the unit e You will see that the Sensor Head is secured to the Scrubber Canister using a threaded ring Loosen the Sensor Head by turning the ring left Once the ring has been disen gaged pull the head up to free it from the scrubber canister The ring will spin freely once clear of the threads e On the Gas Addition Head you will see that there is a LP hose attached to an
37. P hose inlet and suck gently into the mouthpiece Problems e Mushroom valve on the right could leak Remove the carrier and inspect it again e 2nd stage port leak Remove the inner barrel and inspect replace the 2 side port O rings e Front switch plate leak Remove the inner barrel and inspect replace the 2 barrel end O rings Other leaks Cover both the inhale and exhale sides of the mouthpiece as well as the LP hose inlet to the 2nd stage while gently blowing into the mouthpiece Also do this test while gently sucking from the mouthpiece These tests will determine if the rubber mouthpiece has a leak or if the 2nd stage regulator a fault The 2nd stage adapter O ring could also be causing a leak CLEAN AND INSPECT THE MOUTHPIECE AND SECOND STAGE AS REQUIRED SERVICING OF THE SECOND STAGE SHOULD BE DONE BY A QUALIFIED SERVICE TECH 49 MSL 72 161 Jetsam Orca Spirit manual R 3 Mouthpiece Servicing amp Troubleshooting Warning Your KISS mouthpiece or BOV including the 2nd stage is a key component of the KISS diving system and should be serviced yearly or more often if required When to service depends on how often you dive the environment you dive in and also how well it is cleaned after every dive It is important that it is kept clean and the knob should always turn smoothly Keeping your BOV clean is important as grit inside the moving parts can score the plastic Your local KISS dealer can assist you with servicing the BOV if
38. Push the carriers all the way in until you feel them push against the body These mushroom valves have a higher cost then those for the older KISS mouthpiece be gentle with them e Clean disinfect and inspect the inner barrel and the inner barrel O rings for damage There are 2 side port O rings and 2 end O rings Lubricate these O rings place them in their grooves and then apply a touch more lubricant If upon testing small leaks are apparent applying silicone grease to the inner barrel O rings could solve this problem Apply lubricant only to the O ring areas clean off the excess from the surrounding areas Lubricant on the non O ring areas of the inner barrel will make it difficult to turn the switch e To make the inner barrel easier to insert the switch can be pushed onto the barrel stub Insert the barrel twisting it slightly to ensure the port side O rings do not move out of their grooves Push and turn the barrel so it moves properly into position Watch the O rings while you do this to ensure that they stay in position e Replace the front cover ensuring that it is securely attached but not over tightened If it is over tightened it will be difficult to remove e Replace the switch Once the switch is attached rotate it from open to closed circuit mode and back several times to ensure correct action of the O rings Do this while looking into the second stage port to ensure that the O rings stay in their grooves e Clean insp
39. UST ALWAYS BE TIGHT AND TURNED ALL THE WAY IN ALSO THE DIVER SHOULD BE AWARE THAT IN A HEAD DOWN POSITION THE ADV MAY TRIGGER MORE RAPIDLY CAUSING A RAPID ADDITION OF GAS THIS WILL CAUSE BUOYANCY ISSUES WHICH MAY CAUSE THE DIVER TO HAVE AN UN CONTROLLED ASCENT WHICH MAY LEAD TO INJURY OR DEATH Anytime the ADV triggers you need to check your PPO2 you have either descended and compressed the gas in the loop or you have consumed enough oxygen to reduce the PPO2 significantly This may also have caused you to lose buoyancy and descend The position of the diver will effect the ADV If the diver is horizontal or face down the ADV will trigger easily If the diver is vertical then it is more difficult to trigger A well fitting harness is important this will greatly reduce the diffi culties of being vertical in the water 17 MSL 72 161 Jetsam Orca Spirit manual R 3 Diluent can also be added to the breathing loop via the mouthpiece Simply go to open circuit mode take a breath and then open the loop again and exhale the gas into the breathing loop Another way to add gas to the loop via the mouthpiece is to close the loop only a 1 4 inch for a second You may need to lightly push the purge button on the front of the 2nd stage A small amount of gas will blow directly into the breath ing loop Quick Disconnects The KISS OS is shipped with a quick connect system for the loop hoses You will see that the towers on the scrubber head
40. a few minutes for the oxygen percentage to drop The KISS rebreather should be flushed with oxygen prior to every dive to ensure that the displays are reading correctly and re calibrated every time the absorbent is changed 30 MSL 72 161 Jetsam Orca Spirit manual R 3 KISS PPO2 DISPLAY The KISS PPO2 display uses wet contacts to activate They are also used by the diver to calibrate and to move through the display To use these contacts the diver s fingers must be wet There are 3 wet contacts Left L Centre C and Right R e To activate the display push LC together e To start calibration push LC together and hold for 10 seconds You now need to choose your calibration gas We recommend using 98 To choose your calibration gas percentage o To increase the percentage push CR o To decrease the percentage push LC o To exit and to set calibration gas push LCR for 3 seconds e Atthis point the display will cycle through the millivolts for each sensor e Toexitthe millivolt reading and to save the calibration results push LC for 3 seconds You are now calibrated and ready to dive e If you wish to exit the millivolt readying and DO NOT wish to save the calibration results push CR for 3 seconds Once calibrated if the diver pushes CR for 10 seconds it will go to surface display for 10 minutes and then go to a 30 second countdown and finally to sleep The battery used in the KISS PPO2 display is a Saft LS14500 It has a lif
41. and have the correct lung size It should be noted that if the lungs on the unit are full and you then open the mouthpiece and start breathing while on the surface you will find that the air is difficult to exhaust through the exhaust valve If this happens it will feel like you can t properly inhale or exhale fully This generally happens after a diver does his pre dive testing and pre breathe and the unit s lungs are inflated To solve this problem simply exhale gas out of the loop through your nose Under water the exhaust valve will dump the gas for you 3 Stretch the valve s spring f the valve is clean and it was tightened all the way you may need to stretch the valve spring To do this turn the valve counter clockwise as far as it will go Do not force it When you can not turn it anymore stop There is a tab which must be lifted in order to allow the valve to be opened It is the small tab on the side of the valve Very carefully lift the tab with a dental pick and then carefully continue to turn the valve counter clock wise The tab will only need to be lifted while you turn the valve past it Then it can be released and you can continue to open the valve This is easiest to do if the bottom of the valve is pushed into the side of your knee Then as you lift the tab push on the top of the valve while continuing to turn it counter clock wise Be very careful to not break the tab If you do the entire valve is garbage
42. are not damaged I have done a negative pressure test on the fully assembled KISS rebreather and it maintains full vacuum pressure I have done a positive pressure test on the fully assembled KISS rebreather and it maintains full pressure have ensured that the counterlung s are properly positioned and not twisted or restricted in any way I have turned my displays on lve connected my diluent bailout cylinder to my rebreather have verified that the cylinder is full It has PSI BAR in it I ve checked the pressure gauge for any sign of leakage of diluent in the system I ve ensured that the ADV and the bailout regulator are working correctly The diluent gas am using is appropriate for the dive that am planning l ve opened the oxygen valve and checked that the cylinder is full It has PSI BAR in it I ve ensured that the manual add valve is working by pushing the button and watching the displays while breathing on the unit Also I ve ensured that the constant flow is working by listening for the flow l ve calibrated the sensors in oxygen have verified the sensor readings in air l ve ensured that the size of my bail out gas cylinder is adequate for the dive that am planning that it is full and that the regulator is working correctly have also ensured that my wing and drysuit inflation are working correctly I have pre breathed my KISS rebreather for at least 5 minutes before entering the water I will d
43. asher 8 lever 9 spacer 10 and lock nut 11 Discard the lock nut 11 and poppet washer 8 l 10 Examine the lever 9 and compare it with a new one to ensure that it is not bent or distorted in any way Discard if distortion is found 11 Examine the spring 7 with a magnifier and compare it with a new one to ensure correct tension and length Discard if found to be weakened or corroded Figure 27 12 Remove the seat 5 from the poppet 6 with the use of a dental probe and discard Fig 27 DO NOT attempt to reuse it 13 Examine the internal threads of the poppet chamber 4 to ensure they are clean gt and in good condition Refer to the Cleaning Section of the General Procedures Doc No 12 4025 for instructions regarding the cleaning of these threads 14 Turn the housing 1 face down Turning counter clockwise remove the exhaust cover screws 15 with a 3 32 Allen key Fig 28 Then lift the exhaust cover 14 from the housing 1 Figure 28 15 Inspect the overall condition of the housing 1 and the exhaust cover 14 to ensure they are free of any stress cracks distortions an are in good condition Ensure that all threading on the housing 1 is in good condition Discard either if any distortion or damage is found 16 Using a soft probe inspect the condition of the exhaust valve 13 to ensure that it is supple and free of any tears or corrosion and that it seals completely around the seat
44. at this plate can sit due to other components on the inside of this head See the top photo with the red arrow as an ex ample The top outer curve of the sensor holder should be oriented towards the tower opening Ensure that the wires are not pinched or stressed while you are doing this e Replace the bronze nut ensuring it is properly secured but not over tightened e Inspect the 4 press fit springs located on the edges of the underside of the head Ensure that they are all properly in place Should you need to insert the springs push them all the way in and turn counter clockwise e Using a clean cloth wipe any debris from the O ring area on the underside of the head Ensure this area is clean and ready for lubricant e Turn the head over and inspect the exhaust valve It should be in good working order and tightened all the way e Follow the instructions in the scrubber filling section and ensure that the top and inside edge of the canister is clean and properly lubricated This area should be lubricated very well e The O rings on the underside of the head should also be very well lubricated e Place the head on the canister pushing and rocking gently until the head is in place Inspect to ensure you do not see a pinched O ring then position the head so that the indexing mark is facing the other canister secure the threaded ring WARNING It is important that the display cables are properly wired Failure to do so may cause
45. ater vapour If you are using a calibration kit with no water vapour and 100 02 you can set the calibration gas to 100 It can also be set to other values if pure oxygen is not available The calibration takes into account the altitude at which the computer was turned on For exam ple if the altitude was 885 mBar or 87 ATA then with a 98 calibration gas the sensors would calibrate to 85 The Calibrate menu item will not display during a dive 33 MSL 72 161 Jetsam Orca Spirit manual R 3 Calibration Problems Here are some examples of common calibration problems In this display one sensor is flashing This shows that the sensor is voted out If it comes back within range it will be voted back in stop flashing and return to green A failed sensor is a different situation In this case the sensor failed calibration Changing the sensor won t make it register again Once a sensor has failed calibration the only way to bring it back is to successfully calibrate If the computer were to display a value with a new sensor it would be a meaningless value without calibration This display indicates a faulty sensor It is not within the normal range for a sensor in oxygen Most sensors are designed to output 10 mV 3 mV in air If the output is linear then that translates to a range of 30 to 70 as valid mV readings in 98 oxygen The computer will refuse to calibrate outside that range Three sensors all showing FAIL is usua
46. ave analysed it and have confirmed what percentage of 02 Helium Nitrogen it contains I am diving with mix in my third bailout cylinder have analysed it and have confirmed what percentage of 02 Helium Nitrogen it contains If I am using more cylinders I will also write down the mixture and ensure that I have analysed them and have confirmed what percentage of 02 Helium Nitrogen they contain ____ My absorbent has been used for hours which means that have hours left on it _____ My dive computer is in perfect working order ___ The battery voltage on my computer is _____ My buddy and have practiced bailout procedures and understand what to do in an emergency ____ My surface interval before this dive is ____ My CNS before this dive is l am using Ib kg of weight 53 MSL 72 161 Jetsam Orca Spirit manual R 3 This pre dive check should be done after your unit has been assembled your scrubber canister filled lungs attached all fittings hoses checked amp secure etc It should be done prior to entering the water INITIALS y have ensured that the Valve Disks mushroom valves on the Valve Plates are flat and smooth have done a BOV positive and negative diaphragm test to ensure that they are sealing properly have also ensured that they have been installed correctly and the gas flow is going in the correct direction left to right I have done a breathing hose positive and negative pressure test to ensure that my loop hoses
47. ce which allows oxygen to flow into the loop at all times In the event that more oxygen is required the button on this valve will need to be pushed The difference between diving a KISS rebreather manually and other rebreather s is that the constant flow of oxygen keeps our divers from getting too busy underwater Diving other rebreather s manually means that the only way oxygen gets into the loop is by pushing the button What does this mean to the diver It means that when you get to your maximum depth you will adjust your PPO2 and then unless you are working hard or going up and down in the water column you will only be pushing the button every 10 to 20 minutes This depends also on where the constant flow has been set If you find yourself pushing the button all the time then you need to increase the flow If you find that your oxygen is creeping up during normal diving activi ties then you will want to decrease the flow 39 MSL 72 161 Jetsam Orca Spirit manual R 3 Adjusting the 02 Flow Rate The oxygen injection rate can be adjusted to suit each individual diver The required flow rate depends on the physical size of the diver and the degree of exertion used during the dive If the flow rate is too high the PP02 will climb to dan gerous levels and the breathing loop will have to be purged to reduce the oxygen partial pressure to a safe level If the flow rate is set too low oxygen will have to be manually added more often during the dive
48. ding for all KISS OS BASIC rebreather pur chasers 8 MSL 72 161 Jetsam Orca Spirit manual R 3 BOV BAILOUT VALVE The BOV or rebreather mouthpiece is a key component on the KISS OS diving system Should divers choose to source their own BOV it is extremely important that they choose a product from a reputable company and that it comes fitted with a bailout 2nd stage regulator The integrated 2nd stage regulator is a key safety component for the diver Should the dealer or diver choose not to use a bailout type rebreather mouthpiece the warranty on that diving system will be revoked We can t stress enough the importance of this feature Required Parts The KISS OS BASIC will ship with the loop hoses as well as the parts to attach these hoses to the scrubber head s The customer will need to purchase a BOV amp parts with which to secure the mouthpiece to these hoses It is important that when choosing a method to secure the loop hoses to the BOV that the BOV can be removed easily This is important as the BOV mushroom valves valve disks must be inspected prior to every dive LOOP HOSE BALLAST RINGS The ballast rings may seem like an insignificant part of the rebreather but in reality they are an important part of the diving system Having either too much or too little weight on the loop hoses will cause much discomfort and stress to divers When the ballast is supplied by KISS Rebreathers 8 rings 4 per side are used The tota
49. don t hear this sound you have a leak Or if the whoosh isn t as strong as it usually is you have a leak After diving the unit for a while you will learn what sound to expect when releasing the pressure When you hear that sound you will feel confi dent that you did a good test If you have any uncertain feeling then you may have a small leak WARNING It is important to not leave the vacuum in the loop for more than a few mo ments as this will cause damage to the diaphragm If this happens the ADV will not work properly It will either stop working altogether or will continuously feed the diver diluent It will certainly allow water to leak into the ADV NOTE When doing your test it is VERY important to not suck so hard that you are damag ing the diaphragms When you do the negative test suck until you get a good seal and then immediately close off the BOV if you suck so hard that you feel the pressure building in the back of your throat neck area your ears pop or you feel your face turning red for ex ertion this is way too hard There is no need for this and it will damage the valves and dia phragms Suck just until you feel that pressure then close the valve Our BOV has a larger bore and has an excellent work of breathing In order to get that good work of breathing the valves are more flexible This means that with this we need to en sure that we have good testing habits Those divers who learned the testing procedur
50. e moved up and down the hoses underwater for proper placement mE With the loop hoses properly adjusted with no twists and the ballast properly placed the BOV will be weightless underwater The ballast rings should be placed fairly close to the mouthpiece Attach the mouthpiece to the hoses and then lift it so that it is level with the top of the unit Look at the loop hoses they should have a gentle curve If they are twisted adjust them by turning the end of the hose by the mouthpiece These steps are important If this isn t done then the mouthpiece will be uncomfortable The ballast rings will need to be adjusted again once in the water Positioning will be different for every diver While in the pool your instructor will demonstrate neutral mouthpiece buoyancy Ideally the mouthpiece will float neutrally in front of the divers face if the rings are placed properly and the loop hoses are not twisted If when doing this skill the mouthpiece is not floating in the desired area ensure that your hoses are not twisted and adjust your ballast rings To adjust the hoses underwater simply hold the mouthpiece with one hand and gently turn the hose with the other Again once the rings are properly placed they do not need adjusting again These steps are important If this isn t done then the mouthpiece will be uncomfortable If you feel that the mouthpiece is excessively buoyant even with properly placed ballast weight on the loop hoses
51. e object Select wisely to prevent accidentally cutting the POPPET SEAT 5 5 Place the poppet washer 8 over the threads of the poppet 6 and onto its shaft Place the spacer 10 onto the poppet 6 Thread the lock nut 11 clock wise onto the poppet 6 threads with your fingertips 6 Place the forks of the lever 9 over the poppet 6 shaft between the poppet washer 8 and spacer 10 Relax the poppet 6 and watch to ensure that the lever 9 is held in place 7 Hold the poppet 6 stationary with a flat blade jewelers screwdriver Then using a I 1 4 open end wrench tighten the lock nut 11 until 3 Threads are showing beyond the outer surface of the lock nut 11 Fig 32 Remove the tools and depress the lever 9 repeatedly to ensure smooth movement Figure 32 NOTE Using a screwdriver that is wider than the slotted end of the POPPET 6 will damage the LOCK NUT 11 8 Slide the poppet chamber 4 into the housing 1 as shown Fig 33 EXPLO ES Figure 33 9 Lubricate and install the coupling O ring 19 onto the coupling 2 Install the coupling 2 into the inlet tube of the housing 1 with the smaller opening facing in Turn clockwise using a 3 4 open end wrench to a torque of 35 to 40 in lbs 4 4 5 N m Fig 34 Figure 34 10 Lubricate and install the orifice O ring 17 onto the orifice 3 Lubricate the threads of the orifice 3 with a very light film of lubricant and insert
52. e of 8 years or 2500 hours of time The KISS PPO2 display has a battery warning WARNING The KISS PPO2 display is a key component on the OS diving system Care should be taken that it is properly maintained and not damaged in any way Diver s should ensure that they understand how the display works prior to diving Failure to do this may cause injury or death 31 MSL 72 161 Jetsam Orca Spirit manual R 3 CARE FOR YOUR FISCHER CONNECTOR AND THE CABLES Having Fischer connectors on a rebreather display system is a convenience that many divers enjoy While a lot of maintenance is not required some care is important in order to ensure that they operate properly The Fischer connector port is watertight and any water that gets in to the port cannot harm your head computer or HUD However should sea water get inside the port or the ends of your linking cable flush them with fresh water as soon as possible afterwards then leave them to dry completely BEFORE refitting the cap Regular maintenance should include 1 Inspectthe connectors and look for any signs of corrosion parts will start to turn green 2 If you see green corrosion rinse the connectors briefly with white vinegar and use a fine toothbrush to remove the build up Rinse well and let dry completely before refitting the protective caps 3 Keep the inner O ring lubricated by either applying a SMALL amount of grease on the metal end of the cable end that slides into the compute
53. e top ring has a seal inserted into it use your fingers to push it out and remove it Lubricate the O ring with oxygen compatible grease and ensure it is secured to the delrin plug 9 MSL 72 161 Jetsam Orca Spirit manual R 3 e Push the delrin plug firmly into position e Secure the top ring to the first stage body While turning the top ring in you will need to push the centre of the delrin plug to hold it firmly in position If you don t do this the delrin plug will want to push up and out making it difficult to secure the ring e Ensure that the ring is properly secured Once the delrin plug has been installed an OPV will need to be inserted into one of the low pressure ports The OPV is an important part of the first stage regulator and divers should not dive the KISS OS without one present It is important that both the delrin plug and the OPV be properly installed on the oxygen first stage If the delrin plug is not installed the oxygen delivery system on the OS KISS will not work properly Approved first stage regulator s e Dive Rite RG1208 ICE with environmental kit e Apeks DS4 with environmental kit WARNING IT IS VERY IMPORTANT THAT THESE INSTRUCTIONS ARE CAREFULLY FOLLOWED THE PROPER BOV MUST BE SELECTED FROM A REPUTABLE COMPA NY WHICH HAS AN INTEGRATED 2ND STAGE FOR BAIL OUT AS WELL THE AP PROPRIATE AMOUNT OF BALLAST FOR THE LOOP HOSES MUST BE SECURED THE DELRIN PLUG MUST BE PROPERLY INSERTED INTO THE OXYGE
54. ect and re fit the 4 hose attachment O rings there are 2 per side e Clean disinfect and inspect the 2 hose attachments and secure them to the mouthpiece using the 2 plastic U clips To attach push the hose attachments all the way against the body and then push the clip into the slots The hose attachments have a tight fit When pushing them into position be certain that the O rings are not dislodged from their grooves Applying a touch of lubricant to the inside sealing area of the hose attachment may help in pushing it into position NOTE when attaching and removing the mouthpiece from the loop hoses the quick disconnects should be used Do not use the hose attachments and plastic clips for this Clean disinfect and inspect the rubber mouth bite Attach it to the body using a zip tie and remove the sharp edges 48 MSL 72 161 Jetsam Orca Spirit manual R 3 MOUTHPIECE TEST In closed circuit mode cover the right exhale side and the LP hose inlet and blow gently into the mouthpiece The mushroom valve should seal and no gas should exit out of the second stage port or the front switch plate Problems e Mushroom valve on the left could leak Remove the carrier and inspect it again e 2nd stage port leak Remove the inner barrel and inspect replace the 2 side port O rings e Front switch plate leak Remove the inner barrel and inspect replace the 2 barrel end O rings In closed circuit mode cover the left inhale side and the L
55. ed and the wing harness system in place bring the MAV over the right shoulder of the harness and thread it through the D ring Alternatively you may use a small bungee loop which is tied to the D ring and slide the MAV through that Securing the MAV in this manner will keep the valve in the proper posi tion allowing the diver to find it easily An alternated method of placing your MAV is to have it come around the right side of your waist and then secure the MAV to a ring on your waist strap using bungee anda clip The diver must be certain that the MAV is properly secured and is easily accessible during any part of the dive This method is for those who do not wish the hoses to come over the shoulder For those that wish to run the MAV around the waist simply swap the position of the 2 oxygen hoses To do this first remove the shortest LP hose from the MAV and filter Leave the filter secured to the MAV It is very important that one wrench is placed on the nut closest to the plastic housing to hold it in place it must not move Then put another wrench on the end of the LP hose you wish to remove Turn this wrench while holding the first wrench secure The nut vou are holding secure must not spin If it does the threads on the plastic housing will be stripped Once this is done the short hose will still be secured to the scrubber head but the MAV will no longer be attached to it Remove this LP hose from the head Remove the longer LP hose from
56. elbow secured to the Automatic Diluent Valve ADV Loosen amp remove the elbow from the ADV and then loosen the ring from the Scrubber Canister and pull the head up to remove it e Inside the Scrubber canister you will see the securing screens Pull them out and lay them aside e Loosen amp remove the first stage regulator from the cylinder if ordered e Loosen the Fastex clamp which is securing the cylinder and remove the cylinder e You will see that 2 black circ clips are secured to the cross bar and attached to each other by a length of twine Pull the circ clips out of their slots and set aside e The crossbar can now be pulled free from the bottom of the scrubber canister While holding the canister firmly pull the bar straight down e The counterlung s are secured to the crossbar Turn the CL rings to loosen the lungs and pull them off the bar Set aside e Lay the OS down scrubber side up Loosen the Fastex clamps securing the canisters and remove them e The BOV will be packaged separately if ordered along with the loop hoses e The display will be packaged separately if ordered however if the cable is ordered it will be secured to the scrubber head The unit is now disassembled Further sections of this manual will discuss assembly scrubber packing sensor installa tion amp displays and trouble shooting 1 MSL 72 161 Jetsam Orca Spirit manual R 3 Assembly This section will discuss the full assembly o
57. em shut off the diluent gas First you will notice your PPO2 stabilize and stop dropping Also the lungs will stop filling up all the way and the exhaust valve should stop purging The diaphragm is simple to check Open the cover and pull the assembly out It should be fairly flat and not damaged You may need to look quite closely for small tears or holes Sometimes holding it up to the light and gently pulling the rubber will help 5 Check the IP on the diluent first stage It should be between 8 117 6 psi and 10 bar 147 psi 6 First stage needs to be serviced If the first stage is not functioning properly it could have a leak which could cause excess diluent gas to flow into the rebreather s loop NOTE A damaged ADV assembly will either deliver too much diluent gas or none at all NOTE It is important that the proper installation procedures are followed for the ADV as sembly and diaphragm Only those with proper training should service this regulator Those with no experience should take it to their local KISS dealer or send it to KISS head office for servicing The exhaust valve is a key component of the KISS diving system care should be taken that it is not damaged and properly maintained ADV IS DIFFICULT TO TRIGGER The position of the diver will effect the ADV If the diver is horizontal or face down the ADV will trigger easily If the diver is vertical then it will be a bit harder A well fitting harness is importa
58. er sensor K 22D The KISS OS BASIC does not include the sensors Many of our dealers stock the KISS K 22D sensor and are available directly from them Should you wish to order them with your unit please let us know your wish to add this product Prior to installing them it is best to open the bags and let them sit for at least 24 hours prior to calibration as they need to go through a wake up period Ideally open the bags about a week prior to use if possible New sensors will read low when first installed and will creep up slightly over the course of a week or so After that they seem to be stable for months on end Don t waste time calibrating the sensors if they are reading within a 1 2 percent These sensors should last for at least 1 to 1 1 2 years if they are not damaged or abused Oxygen sensors work on the same basis as a battery The more that they are used the more often they will need to be replaced An easy way to remember your sensors anniversary date is to write the date on the bag when you open it and keep the bag in safe place Also use a Sharpie black marker to write the date on the top lip of the sensor The K 22D sen sors are safe to dive if the millivolt reading is between 9 and 13 AND they can be calibrated in both air and oxygen Both the KISS display and the Shearwater computers will read the millivolts of the sensors or a volt meter can be pur chased at your local hardware or electronics store FWARNING It is
59. es This means that dealers can now personalize the units for their customers and provide their own first stages LP amp HP hose s amp BOV s rebreather mouthpiece Should dealers and divers wish to purchase some of the components from us they can pick and choose what they would like See the KISS OS price sheets for a complete list NOTE The upgrade prices are prices that are discounted from the regular parts pricing This pricing is only valid at the time the rebreather is ordered and must be included on the original invoice for the rebreather NOTE The Dealer s KISS instructor must be authorized to assemble the KISS OS BASIC kit If the shop has a KISS Instructor on staff the Sales Agent may authorize this instructor If the shop does not have a KISS instructor on staff then the shop must have a KISS Rebreather Instructor who is au thorized to assemble the KISS OS BASIC kit or Sales Agent on retainer in order to properly assemble the unit before use REQUIRED READING WARNING It is extremely important that dealers and divers who opt to purchase a KISS OS BASIC rebreather kit understand the importance of the various components that they must add on to their system in order to make it complete Failure to do so may cause injury or death The sections covered in the following two pages are for the BOV rebreather mouthpiece the loop hose ballast rings and the oxygen first stage regulator These pages are required rea
60. es years ago have to understand that the equipment has now changed and that our habits must also change Also ensure that the area where the Mushroom valve seal s is clean build up in this area will cause the diaphragm to leak To do the positive test tighten the exhaust valve by turning it fully clockwise Put the BOV into your mouth turn the knob and exhale into the loop until you hear the exhaust valve release and then quickly close the BOV without letting any air escape the loop The counterlung s should be expanded to their maximum size Listen carefully for any air leaks and ensure that the counterlung s remain firm for several minutes The oxygen tank valve and mouthpiece should be closed during these tests After the test is complete and you open the BOV again you will hear the sound of the pressure being released This is important 24 MSL 72 161 Jetsam Orca Spirit manual R 3 MSL 72 161 Jetsam Orca Spirit manual R 3 25 Sensor Installation the Sensor Head amp Display Options The KISS OS is a diving system where the display s may be customized to suit each individual diver The KISS OS can be configured with a KISS PPO2 display either hardwired completely or with a Fischer connector between the wrist display and cable This may be combined with one of the Shearwater computers or a Shearwater HUD Alternatively diver s may choose to use either 2 KISS PPO2 display s or 2 Shearwater Computer e whatever suits them The
61. extremely important that the sensors millivolt readings are in the correct range and that they can be calibrated in both oxygen and air If even just one of these 3 items doesn t comply DO NOT DIVE Failure to ensure that the sensors are working properly can result in serious injury or death WARNING On the following pages are the calibration instructions for the displays sys tems It is essential that the calibration procedures are followed properly Failure to do so can cause injury or death 27 MSL 72 161 Jetsam Orca Spirit manual R 3 e To install the sensor s first remove the Sensor Scrubber head from the canister e Secured to the threaded rod you will see a bronze nut remove it and set it aside e The carrier plate is now loose remove it from the head e Remove the O ring from the threaded end of each sensor it is not required and will give the sen sors better placement inside the head Thread the K 22D sensors on to the carrier plate Secure all 3 sensors e Thread the carrier plate with the sensor s attached onto the threaded rod with the connection ends facing the inside of the scrubber head Push the white molex plugs onto the sensor s Push firmly to ensure that they are properly attached Do not stress the wires while you are doing this e Gently push the plate and sensors into position The plate will rest on the ledge just on the in side edge of the housing You will see that there is only one position th
62. f your KISS OS It assumes your scrubber canister has been filled and is ready to dive The next section will discuss scrubber packing O Ring Installation As mentioned earlier in the manual all the O rings for the KISS OS have been installed As each section is discussed O ring placement will be mentioned when required At the back of this manual you will find a recommended spare parts sheet There you will find a list of the O ring names and what kit configurations are available As with any piece of scuba diving equipment the various components and O rings should be checked annually and serviced as required For those doing extensive diving the various components and O rings should be checked more frequently Servicing of your KISS OS can be done by you your dealer or the parts can be returned to us NOTE ALL O RINGS SHOULD BE LIGHTLY LUBRICATED DO NOT USE EXCESS AMOUNTS OF LUBRICANT THE O RINGS SHOULD ONLY BE SLIGHTLY SHINY Inspect With the unit stripped first inspect all LP hoses fittings the manifold and components attached to the frame of the unit Ensure that they are in proper working order that the LP hoses are not dam aged all connections are tight threaded rods are straight and clean and nothing is damaged Manifold You will see the manifold located in between the 2 scrubber canister s on the back of the unit During assembly the manifold and LP hoses need only to be inspected prior to diving If
63. hat the lungs are not restricted or entangled in any way WARNING IT IS IMPORTANT THAT THE LUNGS ARE PROPERLY SECURED TO THE CROSS BAR amp THEN PROPERLY THREADED THROUGH THE WING THEY MUST ALSO BE PROPERLY SECURED USING THE CLIP AT THE DIVERS WAIST IF THE LUNGS ARE NOT SECURED THEY WILL FLOAT UP AND BREATHING WILL BE DIF FICULT ENSURE THAT THE LUNGS ARE PUSHED ON STRAIGHT AND THAT THE RINGS ARE NOT OVER TIGHTENED AS THEY WILL SPLIT NN _ ER 64 MSL 72 161 Jetsam Orca Spirit manual R 3 Automatic Diluent Valve ADV The ADV on the OS LTE diving system works in the same manner as that on the standard Orca Spirit However the ac tual component is different The ADV on the Orca Spirit is a Mikron second stage while the ADV on the OS LTE is the original KISS version The KISS ADV system is comprised of the ADV diaphragm and ADV valve stem This is a popular system as it has few parts which decreases the possibility of failure The ADV will add diluent gas to your breathing loop after the loop volume has been reduced by either descending or breathing down the volume of oxygen The diver will get the feeling that there is no more air in the loop to breath All the diver needs to do is suck hard to trigger the ADV and it will feed him more gas This is similar to the action of a second stage regulator The ADV has been setup tight enough that it doesn t add diluent without the diver being aware But it add
64. he rubber to check for damage Check your rubber mouth bit for damage and for a proper fit onto the mouthpiece They generally come in a variety of attachment sizes Ensure that the one you choose fits properly There are some specialized rubber mouth bits which while a pleasure to dive just do not fit properly on our mouthpiece Seacure is one of them and after time it will always leak Also check for a tear underneath the zip tie which holds the rubber mouth bit in place Damage here will also cause water to leak into the system Many cases of water into the loop come from torn or damaged rubber mouth pieces Loose lips IT SHOULD BE NOTED THAT A LEAK ON THE MOUTHPIECE INCLUDING THE RUBBER MOUTH BIT WILL NOT BE DETECTED ON THE POSITIVE AND NEGATIVE TESTS THIS IS WHY IT IS VERY IMPORTANT TO KEEP YOUR MOUTHPIECE PROPERLY SERVICED AND CLEANED ALSO ALWAYS CARRY A SPARE RUBBER MOUTH BITE MOST MOUTHPIECE LEAKS ARE FROM THIS 51 MSL 72 161 Jetsam Orca Spirit manual R 3 Pre dive Checklist s This pre dive checklist is a combination of the KISS checklist and what some of the A N D I instructors are using The instructors and divers who use this checklist have reported that their skill level on the rebreather increased quicker and that they understood their units better which made them more organized and safe divers I have edited the check list to make it work for a KISS diver to use for every dive The first part of our new check li
65. ighten this assembly Again this is a case where over tightening can cause a leak On the other hand if the button as sembly is loose air can leak through this area NOTE Severely over tightening the ADV diaphragm screws can damage the threads on the KISS head 67 MSL 72 161 Jetsam Orca Spirit manual R 3 KISS Rebreather LLC www kissrebreathers com info kissrebreathers com 68 MSL 72 161 Jetsam Orca Spirit manual R 3 HOLLIS BOV Bail Out Valve SPECIFICATIONS Torques Inlet Coupling 35 to 40 in lbs 4 4 5 N m LP Hose 35 to 40 in lbs 4 4 5 N m Intermediate Supply Pressure Preferred 138 psi 9 5 bar Acceptable 137 to 139 psi 9 4 9 6 bar Opening Effort IP 138 psi 9 5 bar Recommended Setup Range Octopus 1 5 to 2 2 inches of Water TOOLS REQUIRED Standard Tools Inch Pounds Torque Wrench 1 4 Open End Wrench 3 4 Open End Wrench 11 16 Open End Wrench 1 8 Allen Key 3 32 Allen Key Flat Blade narrow Jeweler s Screwdriver Cotton Swab Q Tip Specialty Tools Tribolube 71 Christo Lube MCG 111 Intermediate Pressure Gauge O ring Tool Kit In line Adjustment Tool BOV SPOOL TROUBLESHOOTING Failed mushroom valve checks obstructed or damaged mush clean replace mushroom valves room valves 26 valve holders 26 valve holders 22 23 and 22 23 or O rings 24 O rings 24 25 25 Leaking gas out of Breathing Loop worn O rings 18 24 25 29 replace O rings 18 24 25 29
66. illed and that the gas has been analyzed and confirmed to be oxygen Diver s should always ana lyze their own gas so they are certain they know what they are diving e The cylinder placement area is at the bottom of the stainless steel stand It is designed to work with E a SS Fastex clamp The Fastex clamp is similar to a hose clamp but is much easier to use The size of y d the clamp is pre set at the warehouse To open and close the clamp simply use the lever If for any reason you need to adjust the size of the clamp use either a nut driver or screw driver to make the adjustment see photo 1 Slide the filled cylinder into the Fastex clamp at the bottom of the unit with the cylinder valve facing the right 2 Turn the cylinder so that the valve opening is facing the divers back This ensures that the first stage will sit properly and the hoses are correctly aligned 3 Secure the first stage to the cylinder 4 Open cylinder and double check the pressure on the pressure gauge Close cylinder 5 Double check that the scrubber canister s and cross bar are properly positioned and ad just as necessary Also double check that the counterlung s are still properly situated and not bunched up or twisted in anyway Double check that the ADV LP hose has been secured to the gas addition head Wing Harness e The final step is to secure the wing amp harness system Due to the design of the KISS OS Rib Wrap counterlu
67. imum Advanced Nitrox or Recreational Trimix or equivalent Students must be able to rig a side mount rebreather as well as 2 cylinders GEM SIDEKICK CCR CROSS OVER INFORMATION FOR KISS CERTIFIED DIVERS A diver who is certified on a KISS CCR Classic Sport Orca Spirit is still required to do a GEM Sidekick CCR cross over This includes Minimum of 200 minutes of in water time Minimum of 60 minutes of confined water training included in 200 minutes Overview of the KISS GS CCR operating system CCR CROSS OVER INFORMATION A diver who is certified by a KISS approved training agency on an approved closed circuit rebreather must meet all of the KISS train ing standards The exception is as follows Minimum of 60 minutes confined water training Minimum of 180 minutes of open water training conducted over 3 open water dives SCR CROSS OVER INFORMATION A diver who is certified by a KISS approved training agency on an approved semi closed circuit rebreather must meet all of the KISS training standards For an SCR diver to qualify for this cross over they must have at least 20 SCR dives with one dive in the previ ous 3 month period This standard includes the KISS GEM and KISS GEM Sidekick SCR The exception is as follows Minimum of 60 minutes confined water training Minimum of 360 minutes of open water training conducted over 6 open water dives EQUIPMENT REQUIRED KISS Classic Classic Explorer Sport Orca Spirit GS CCR unmodified a
68. ing surface of the housing 1 NOTE If the EXHAUST VALVE 13 is in good condition it is not necessary to remove it The HOUSING 1 may be cleaned with it attached 17 If the exhaust valve 13 requires replacement it may be removed by grasping it at the flange and pulling it straight out snipping the retainer stem if necessary Discard NOTE If replacing the EXHAUST VALVE 13 ensure not to place damaging stress on the HOUSING 1 Very little pressure is enough to crack one of the ribs in the EXHAUST VALVE 13 support 18 lt is not necessary to remove the housing plug 12 unless installing a right hand A poppet chamber 4 To remove the housing plug 12 release the locking tabs and press Figure 29 the housing plug 12 out of the housing 1 Fig 29 WARNING To change the hose outlet side it is necessary to change the POPPET CHAMBER 4 with a right hand version The two parts are not interchangeable Mounting one of the POPPET CHAMBER 4 on the wrong side would cause performance issues SECOND STAGE REASSEMBLY NOTE Prior to Reassembly it is necessary to inspect all parts both new and those that are being reused Check to ensure that O rings are clean and supple and that every part and component has been thoroughly cleaned and dried WARNING Use only genuine Hollis parts subassemblies and components whenever assembling Hollis products DO NOT attempt to substitute another manufacturer s part for a Hol
69. ion mushroom valve 6 gently hold it open Then using the rubberized end of a pencil wooden dowel or other blunt instrument insert the tool through the exhalation valve holder 22 and gently push out the inhalation valve holder 23 assembly Fig 5 Figure 5 NOTE DO NOT push on the center of the INHALATION VALVE HOLDER 23 ONLY push on the outer edge Li Turn the BOV over and press out the exhalation valve holder 22 in the same fashion as in step 6 8 Remove the valve holder O rings 24 25 and clean the O ring 24 25 grooves Fig 6 Inspect the O rings 24 25 for damage If found discard Figure 6 9 The mushroom valves 26 may be removed by grasping them at the flange and pulling them straight out snipping the retainer stem if necessary Fig 7 Discard 10 Examine the valve holders 22 23 for cracks and other damage discard if found Otherwise wash sanitize and remove any debris from the valve holders 22 23 LI Snip the plastic ty strap 28 that holds the mouth piece 27 and remove the Figure 7 mouthpiece 27 Inspect the condition of the mouthpiece 27 to ensure that it is supple and free of any tears or corrosion Discard if found d 12 Using a 1 8 L shaped Allen key remove the lever screw 33 lever 34 and O ring 35 by turning counterclockwise Fig 8 Inspect the O ring 35 for any signs of decay Discard if found p A NOTE Be ca
70. irit Specific Scrubber head s Canister s Lung attachment and placement GEM Sidekick CCR Specific Scrubber head canister lung attachment MATCH OXYGEN FLOW RATE TO DIVER S METABOLIC RATE Diver must understand how the Manual Add Valve constant flow works This includes how to determine if the diver s oxygen flow must be adjusted and also how to either lower or raise the constant flow of oxygen AUTOMATIC DILUENT VALVE Diver must understand how the Automatic Diluent Valve ADV works Divers should understand how diluent gas is added on descent automatically and how the diver may add gas manually 58 MSL 72 161 Jetsam Orca Spirit manual R 3 ASSEMBLY Diver must use the KISS manuals and checklist to assemble their unit and carry out assembly checks CORRECT SCRUBBER PACKING PROCEDURES LOOP VOLUME Diver must know how to determine the correct counterlung sizes required and know how to attain minimum loop volume ASSEMBLY amp PRE DIVE CHECKLISTS UNIT OPERATION The diver must demonstrate proficiency with the following skills Pre Dive planning amp checks before every dive proper assembly of unit prior to dive Analyze all gas s prior to dive oxygen diluent bailout cylinder Calibration and verification of Oxygen sensors Calibrate in O2 and verify with air Pre breathing for 5 minutes before every dive Bubble checks at the start of every dive Proper control of secondary equipment amp or dive computers used
71. ise direction using a 3 4 open end wrench Fig 23 Remove the coupling O ring 19 from the coupling 2 and inspect for any signs of decay Discard if found 1 ke 23 iil All 6 Using a narrow slotted blade screwdriver remove the orifice 3 by turning it counter clockwise inside the coupling 2 Figure 23 When it has disengaged completely from the threads press it out with the use of a cotton swab Use caution to avoid nicking or scratching the delicate knife edge of the orifice 3 as this is done Remove and discard the orifice O ring 17 Inspect the orifice 3 carefully with the use of a magnifier to ensure that it is perfectly free of any scoring or nicks If found discard and DO NOT attempt to reuse it FXPLO ER S While tilting lift the poppet chamber 4 and poppet 6 assembly out of the BOV housing 1 Fig 25 P 8 Place the poppet chamber 4 and poppet 6 assembly open end down on the workbench Using a narrow flat blade jeweler s screw driver hold the poppet 6 secure At the same time remove the lock nut 11 with a 1 4 open end or box wrench in a counter clockwise direction Fig 26 Figure 26 NOTE There will be a sudden ejection as the poppet 6 disengages from the LOCK NUT 11 Ensure the open end of POPPET CHAMBER 4 and POPPET 6 assembly is facing down against a padded section workbench This will prevent damage or loss of parts 9 Remove the poppet 6 spring 7 poppet w
72. it fully assembled exhaust valve closed Then put the BOV into your mouth turn the knob and inhale the gas from the loop into your lungs and exhale it out of your nose until it is impossible to inhale any further When the loop is empty there should be no leakage into the rebreather and you shouldn t feel any extra gas sneaking into your mouth If you don t feel any extra gas close the loop while inhaling The breathing hoses should be tighter as there is 23 MSL 72 161 Jetsam Orca Spirit manual R 3 a vacuum in the loop This will cause the BOV to sit higher than usual and the ridges on the hoses to be close together If you watch the hoses while you are drawing the gas out of the loop you will see how they constrict Also look at the counterlung s They should be completely flat Once you close the mouthpiece watch the hoses and lungs closely Don t look away You need to notice if anything changes such as a slight droop in the hoses and or the mouthpiece dropping or the lungs shift slightly showing that gas might be going back into them Leave the loop closed for a few moments 60 seconds is adequate to see if the vacuum holds and then open the loop to let air back in Longer is not necessary and will damage the diaphragm The next most important part of doing your negative test watching the lungs and hoses is the first is when you release the pressure and open the mouthpiece You should hear a whoosh as pressure is released If you
73. l hardwired e Fischer display cable hardwired into main port only e KISS HW PPO2 display in main port only no Fischer connector cable is hardwired e Fischer display cable hardwired into main port and Shearwater HUD hardwired into secondary port e KISS HW PPO2 display hardwired into main port and Shearwater HUD hardwired into secondary port e Fischer display cable hardwired into main port and Fischer plug hardwired into secondary port for use with Fischer HUD or dual ended Fischer cable e KISS HW PPO2 display hardwired into main port and Fischer plug hardwired into secondary port for use with Fisch er HUD or a dual ended Fischer cable KISS Rebreather LLC recommends that all divers recreational or technical dive with 2 fully independent displays As you can see above there are options for no display and also for keeping the secondary port empty We have offered these options so that our customers may have the head wired by another source and utilize a display system that we don t sell Those that choose to dive the KISS OS with only 1 display must limit their diving to recreational no stop diving as the bailout procedure for a failure is to end the dive and ascend We strongly recommend that those doing technical diving have both display ports wired with displays for redundancy Should a customer choose to have their sensor head wired by another source they must choose a facility that is quali fied to do this type of work
74. l weight of our ballast rings are 1 04lb or 13lb each This is important information as other SS rings on the market while looking very similar are ac tually a lighter weight If you choose to use these rings ensure that you know what the total weight will be and that you purchase enough of them There are also other ballast systems on the market Again be certain that you know what the total weight of those systems will be Good features to watch for in a ballast system is the ability to move the weight up or down the hoses while underwa ter This is why SS rings work so well they are easily moved during the dive It is important to be able to move them during the dive as this is the only time the diver will truly know if the weight is properly positioned Moving the rings up or down slightly can make a difference in the comfort of the diver OXYGEN FIRST STAGE REGULATOR The oxygen first stage regulator is located on the bottom of the rebreather and is secured to the on board cylinder Dealers and divers that choose to use their own first stages must choose a first stage from the approved list below Prior to final assembly of the rebreather the oxygen first stage must be modified The top ring of the first stage must be removed the environmental plug and seal removed and the KISS delrin plug with O ring inserted To do this Loosen the top ring of the first stage Tip the first stage over and the environmental plug will fall out Th
75. larms For example a fire bell is a bad alarm It is bad because the absence of a ringing bell doesn t mean there is no fire It just means the alarm isn t ringing The fire bell may not be ringing because the battery is dead the smoke detector isn t in the right place the installer screwed up the installation there is a foreign object stuck in the ringer etc It doesn t mean that everything is ok A good alarm is one where there is an obvious difference between the lack of function and the lack of an alarm A solid green light doesn t do that The second point to consider is there are integrated HUD s and redundant HUD s Integrated HUD s can notify you for features such as deco ceilings and distance from set point But they can t do that and be redundant also If you wish to have redundancy then the HUD needs to be calibrated separately and it can t display deco information unless it has a separate decompression computer with ts own set of tissues gases etc built into it The third point to consider is that there are HUD s that just display the set point or PPO2 of the gas in the rebreather This version is very useful for scootering low visibility filming and manually maintaining set point 35 MSL 72 161 Jetsam Orca Spirit manual R 3 With the Shearwater HUD we tried to find the best of all worlds It displays the PPO2 only which makes it a redundant PPO2 meter Since it uses three LED s simultaneously it can display them
76. lis part regardless of any similarity in shape size or appearance Doing so may render the product unsafe and could result in serious injury or death of the user 1 If removed replace the exhaust valve 13 by gently pulling the retainer stem through the housing 1 until the retaining flange is completely inside the housing 1 and properly seated Fig 30 Figure 30 2 Replace the exhaust cover 14 onto the exhaust portion of the housing 1 by pressing it in place with the tabs and screw holes aligned Then using a 3 32 Allen key e tighten the screws 15 clockwise until tight Fig 31 DO NOT over tighten e W i m H la NM La F IL al di Figure 31 3 Replace the poppet seat 5 into the poppet 6 with the side that is perfectly smooth facing out Ensure that it is completely seated flush with the inner rim of the poppet 6 DO NOT use adhesive d Apply a light film of lubricant to each end of the spring 7 and place it into the poppet chamber 4 Next fit the poppet 6 into poppet chamber 4 Turn the parts over onto a clean drive deep wall socket with the same diameter as the poppet 6 Then compress the spring 7 until the threaded portion of the shaft is completely visible Hold it in this position NOTE It is ideal to match the socket size so the socket walls match the metal rim of the POPPET without contacting the POPPET SEAT 5 It is possible to use another clean smooth surfac
77. lly caused by an accidental calibration in air or a calibra tion with the cable unplugged Plugging the cable back in won t change anything Failed cali brations can only be fixed by successful calibrations 34 MSL 72 161 Jetsam Orca Spirit manual R 3 SHEARWATER HUD SHEARWATER WARNING Never risk your life on only one source of information Use a second computer or tables If you choose to make riskier dives obtain the proper training and work up to them slowly to gain experience This system will fail It is not whether it will fail but when it will fail Do not depend on it Always have a plan on how to handle failures Automatic systems are no substitute for knowledge and training No technology will keep you alive Knowledge skill and practiced procedures are your best defense Except for not doing the dive of course SHEARWATER PRODUCT CONFIGURATION Shearwater Research Inc designs and builds both computers and HUD s Heads Up Display for rebreather diving These systems may be fitted to your KISS OS by hardwiring a cable into the scrubber head For further information on the Shearwater computers please contact your local Shearwater dealer INTRODUCTION TO THE SHEARWATER HUD In order to explain the logic behind the design of the Shearwater HUD we have included their introduction in this write up The logic of the Shearwater HUD is as follows The first point to consider is there are bad alarms and good a
78. lout cylinder first second stage e PPO2 display and or computer e Pressure gauges e 3 K 22D sensors 62 MSL 72 161 Jetsam Orca Spirit manual R 3 KISS OS LTE INFORMATION amp INSTRUCTIONS ABS PLATE STAND The Orca Spirit LTE has a light weight yet durable attachment plate and stand which is made from an ABS material It takes the place of the stainless steel stand on the original unit As the Orca Spirit LTE is not designed to use a cover any size cylinder may be used with this stand Heavier and larger cylinder such as aluminum 20 cuft or stainless steel 27 cuft cylinders are appropriate should the diver wish to have a larger supply of oxygen The photo to the right shows the correct lung positioning Webbing Cylinder Straps The Orca Spirit LTE ships with webbing cam straps for securing the canister s and cylinder The advantage of these straps is that they fold down flat when not in use This is ideal for travel HOLLIS BOV The OS LTE includes the new HOLLIS BOV This BOV is highly regarded for it s small size incredible light weight and ease of breathing When using this BOV on the OS LTE no ballast rings are required on the loop hoses Warning Your KISS mouthpiece or BOV including the 2nd stage is a key com ponent of the KISS diving system and should be serviced yearly or more often if required When to service depends on how often you dive the environment you dive in and also how well
79. maintenance testing and opera tion of the rebreather before diving this equipment The rebreather can malfunction while diving even when properly assembled and having passed all pre dive tests Only carrying adequate bailout gas and having the training and skills necessary to utilize the bailout sys tem can reduce but never eliminate the risk of equipment failure 3 MSL 72 161 Jetsam Orca Spirit manual R 3 4 MSL 72 161 Jetsam Orca Spirit manual R 3 TABLE OF CONTENTS Specifications Parts List KISS OS BASIC Information amp Instructions Unpacking amp Disassembly Assembly Manifold Canister s Counterlung s Crossbar Cylinder Wing harness Loop hose ballast amp BOV orientation Counterlung sizing Automatic diluent valve ADV Quick Disconnects MAV placement Diluent cylinder and the off board gas accessory whip Filling the Scrubber amp duration Positive Negative Testing Sensor Installation the sensor head and display options Sensor Information Calibration KISS PPO2 display Care for Fischer Connectors amp Cables Shearwater computers Shearwater HUD Manual Add Valve Metering Orifice Adjusting the Oxygen Flow Rate Manual Add Valve Trouble Shooting Exhaust Valve ADV Work of Breathing Mouthpiece Dive Rite amp Apeks 2nd stage Disassembly Mouthpiece parts list Dive Rite amp Apeks 2nd stage Mouthpiece Dive Rite amp Apeks 2nd stage Reassembly Mouthpiece Testing Mouthpiece Servicing a
80. mp Troubleshooting Pre dive Checklist s Training amp Basic Skills KISS Minimum Training Standards Warranty Recommended parts and amp O ring kits OS LTE addendum HOLLIS Mouthpiece Manual Photo s by Jim Abernethy and Doug Ebersole Page 6 Page page 8 Page 11 Page 12 Page 12 Page 12 Page 13 Page 14 Page 15 Page 15 Page 16 Page 16 Page 17 Page 18 Page 19 Page 19 Page 22 Page 23 Page 26 Page 29 Page 30 Page 31 Page 32 Page 33 Page 35 Page 38 Page 40 Page 42 Page 43 Page 46 Page 47 Page 48 Page 49 Page 50 Page 52 Page 56 Page 57 Page 60 Page 61 Page 62 Page 69 MSL 72 161 Jetsam Orca Spirit manual R 3 SPECIFICATIONS KISS ORCA SPIRIT Weight of the unit completely assembled with wing amp harness and full scrubber canister s is 42 Ib 19 g The travel weight no absorbent deduct 5 3 pounds 2 4 g is about 37lb 16 7g The weight of the unit without the cylinder and no absorbent is 28lb 12 7g This would be the weight of the system for flying without the cylinder The height of the unit ready to dive is 23 inches 58 4cm If the crossbar was removed for travel then the height measures 20inches 50 8cm The widest part of the unit is the cylinder which is 13 4 inches 34 cm The width of the unit with the cylinder removed is 10 inches 25 4 cm This is the width of the top plate which is the widest point The depth of the unit with the scrubber canisters secured to the frame is 5 5 inches 14 cm
81. nd in good working condition Or if the diving system was shipped in the Basic configuration then the add ons must meet the acknowledged standards for this system Depth gauge amp bottom timer or dive computer 57 MSL 72 161 Jetsam Orca Spirit manual R 3 Mask fins weight line cutter or knife Wetnotes or slate and pencil Exposure suit suitable for the required dive Oxygen analyzer or access to one Bailout cylinder and regulator set appropriate for the planned dive Off board diluent bailout cylinder with regulator set appropriate for the planned dive Orca Spirit GS CCR Off board oxygen cylinder and first stage appropriate for the planned dive GS CCR Training material as outlined by approved training agencies EQUIPMENT FAMILIARITY UNDERSTAND LAYOUT AND DESIGN OF THE KISS REBREATHER ASSEMBLY DISASSEMBLY The following objectives need to be done by the diver Fully disassemble and reassemble each of all the following components with reference to the KISS user s manual for their particular unit paying attention to o ring location and condition Oxygen Sensors Sensor Housing PPO2 display system Classic Classic Explorer Specific Scrubber canister base o rings x 2 Head canister o rings x 2 Head Exhaust tube o ring inside head x 1 Counterlung attachment o rings x 4 Quick Disconnect Hose Stubs 8 in total Sport Kiss Specific Inhale Pod Change sensors check o rings Exhale Pod Check o Ring Orca Sp
82. ng s we highly recommend the use of the KISS OS wing amp harness system It is im portant that the wrapped counterlung s are correctly positioned and not constricted in any way l First note where the 2 threaded rods are located on the front of the stand You will see that there are several holes in which the rod may be secured If this is the first time you are diving the KISS OS you may need to secure the wing amp harness and then try the rig on to determine if the unit needs to be moved up or down Ideally the top of the unit should be just at or above your shoulders 2 If you need to move the threaded rod this must be done prior to assembling the unit as both the canisters and cylinder must be removed to do this You loosen the rod by using an Allen key accessed on the scrub ber side of the unit Place the rod s where you wish them to be and then tighten securely 3 Slide the wing amp harness over the threaded rod pulling the counterlung s and the off board gas accessory whip through the slots and ensuring they are properly situated You will see that the wing can be slid up or down place it where it suits you and then place a fender washer over the rod and finally secure with the nut Tighten securely Note those that are using a soft back plate will need to secure the stabilizing plate on top of the harness It is required to make the harness fit firmly to the rebreather 4 Once the wing amp harness have been attached ensure
83. not limited to hypoxia hyperoxia hypercapnia exposure to caustic chemicals hypothermia decompression sickness DCS embolism and drowning Participation in rebreather diving can result in serious injury or death to you the diver The warning on the KISS Orca Spirit rebreather is not a joke Before beginning your dive you must consider the risks involved The KISS OS consists of many parts All of these com ponents will eventually fail Careful maintenance assembly and testing will not prevent this from happening At best it will delay the failure The KISS OS is not automatic in any way It requires constant monitoring a complete awareness of the potential problems likely to be encountered and full knowledge of how to deal with whatever problems may occur If you do not have adequate training equipment physical conditioning and a proper mind set do not get in the water The diver YOU has the final responsibility for his or her own safety and actions while using this rebreather All components of the KISS OS must be in good working order and be properly assembled and tested to reduce the risk of failure Regardless of the training and experience of the diver and the reliability of the rebreather the risk of serious injury and or death can never be reduced to zero This manual is not a complete text on the maintenance and operation of the KISS OS The diver must complete a proper training course covering the
84. nt this will greatly reduce the difficulties of being vertical in the water Also rolling to your right side while horizontal will assist in triggering the ADV If preferred diluent can be added via the mouthpiece Turn the knob about a 1 4 inch and diluent gas should flow into the loop Depending on where your IP is set and which second stage you are using you may need to lightly hit the purge button Lastly check the IP on the diluent first stage Ensure that it is in the correct range Remember the ADV is not meant to be easy to trigger lt was designed this way so that the diver would know when they were triggering it If it was too easy then diluent gas could be fed into the breathing loop without the diver being aware of what was happening 44 MSL 72 161 Jetsam Orca Spirit manual R 3 WORK OF BREATHING There are several things that can cause a high work of breathing 1 Too much gas in the loop This can happen if the loop has gas in it the mouthpiece is closed and then the diver puts the mouthpiece in his mouth and blows more gas into the loop The exhaust valve will probably not release any gas if the diver is on the surface It will feel like you can not get a full breath and the breathing will be difficult Dump part of the loop exhale out of your nose If this is the cause you will notice the difference immediately Also if this happens it won t be possible to trigger the ADV This can also happen if the ADV is faulty and it
85. o notice a problem 42 MSL 72 161 Jetsam Orca Spirit manual R 3 Exhaust Valve ADV amp Work of Breathing In this section you will find information about the exhaust valve ADV and work of breathing We have helpful hints and trouble shooting The Apeks exhaust valve and the ADV work in harmony If you are having difficulties with either one it makes sense to check both BUBBLING APEKS EXHAUST VALVE There are several things that can cause this problem Over the next few pages 6 situations are listed and described 1 Theexhaust valve is not tightened down all the way or there is debris in the valve To tighten the valve simply turn the dial clockwise To remove debris open the valve all the way and rinse well If you need to take the valve apart see the instructions below NOTE Please take care to not have any loose absorbent sit on the top canister cover If this happens and you go upside down the absorbent granules will likely find their way in side your Apeks exhaust valve which will cause a leak 2 Counterlung s are cinched down to tight or are the wrong size too small The loop volume is at its maximum so the counterlung s are completely full As oxygen or diluent is added the exhaust valve will purge This could hap pen if the counterlung volume is too small for the diver The counterlung volume should be as close to your own lung volume as possible but never any smaller Ensure that you have the lungs properly adjusted
86. of the lung Then apply a very light amount of lubricant to this area Next wipe and clean the counterlung attachment which is secured to the crossbar ring s While applying the lubricant double check that the O rings are not damaged or indented If you feel an indent or other damage while applying the lubricant change the O ring for a new one Push the counterlung onto the counterlung attachment you will need to push firmly As you push the lung in place you will feel a circular flange which is at the perimeter of the lung opening Push firmly on this flange Itis important that they are pushed all the way on and are straight When this is done correctly the retaining ring will eas ily engage the threads on the lung Ensure that the lung s are facing the correct direc tion visualize the bar attached to the unit the lungs should wrap towards the out side front of the unit The attachment ring s should spin freely to secure the lung s in place When the ring s are secure there should be an 1 8 inch gap in between the ring and face of the counterlung and the gap should be evenly spaced For those divers using 2 amp 4 liter counterlung s the larger lung should be on the right side and the smaller lung on the left side Do not apply excess force when tightening the ring It is not required and the ring will break Using a tool to tighten this ring usually results in damage or breakage to the ring Place the crossbar amp counte
87. on with purchasing a unit KISS courses are set up through a number of training agencies Links to their websites are available on the KISS website atwww kissrebreathers com The instructor you choose must be a KISS certified and insured instructor that works with one of these agencies During your KISS rebreather training you will be required to learn and do various skills These are skills that all rebreath er divers need to know How these skills are performed is dependent on the particular rebreather that you are diving Therefore even if a diver has already trained on a closed circuit rebreather the diver will still need to learn KISS spe cific skills It is very important that during your course these skills are learned and mastered And after training re viewed on a regular basis It is important that all the skills covered in your training course are learned and mastered Under no circumstances should anyone dive a KISS rebreather until they have completed an approved training course Some of these skills are listed below Please note that this is only a partial list of the required skills HYPOXIA Low PPO2 HYPEROXIA High PPO2 OC BAILOUT Required when the loop is flooded or there is a display or CO2 problem DILUENT FLUSH Required when the diver needs to verify that the displays are reading correctly or to bring the PPO2 to a safe level HYPERCAPNIA High CO2 e DILUENT LOSS 56 MSL 72 161 Jetsam Orca Spirit manual R 3
88. operly DIVER SHOULD BE CHECKING THEIR PPO2 DISPLAYS EVERY MINUTE KNOW YOUR PPO2 AT ALL TIMES OR YOU WILL DIE Manual Add Valve Troubleshooting If the flow rate is lower than it should be in relation to the pressure one of the following things has happened e The filter has become clogged and should be replaced e The orifice has become partially plugged and must be replaced DO NOT TRY TO CORRECT A LOW FLOW RATE BY INCREASING THE REGULATOR PRESSURE If the flow rate is higher than it should be in relation to the pressure one of the following things has happened e The orifice has become loose where it screws onto the valve e The valve O ring is worn or damaged e The spring is broken or weakened and is not holding the valve closed The oxygen first stage will have a plastic plug installed to prevent the pressure from increasing with depth and increas ing the oxygen flow rate If the pressure is inconsistent the high pressure seat or diaphragm may be damaged The reg ulator should be serviced regularly and maintained in an oxygen clean condition WARNING It is very important that this valve is in good working order with proper flow rates and good O rings Ensure that you rinse your gear after diving in salt water and if you flood your rebreather and you think water has gotten into the valve service it If you pay attention to how often you usually add oxygen to your rebreather during a typical dive it will be easier for you t
89. operly and follow the cleaning instructions in this manual to prepare for filling e Atthe bottom of each scrubber head there is a double O ring seal Inspect the area and wipe away any debris Use a clean towel for this It is recommended that the O rings be left in place and not removed each time for inspection Constantly removing and replacing the radial O ring s may cause a leak if they are not seated properly It is best to carefully wipe this area clean e Inorder to prevent spillage or confusion it is recommended that one canister is filled at a time and then secured to one of the scrubber heads e Fill the first canister half way and then tap the side with a screwdriver handle or something simi lar This is required to settle the absorbent properly e Next add more absorbent using the bottom thread on the top of the canister as a fill line e Press the top screen into place and while pushing down on the screen with steady pres sure tap the side of the canister again to settle the absorbent using a screw driver han dle or similar It is best to tap a couple of times while pressing spin the canister slightly and repeat Turning the canister slowly while tapping ensures that the top screen is properly placed and flat and also ensures the absorbent is properly settled The screen needs to be lined up with the bottom thread on the top of the canister e Note that the tapping does not need to be hard e Once the canister i
90. ot allow the condensation to evaporate If the KISS OS has moisture in the head from diving or from being in a humid environ ment and it is then sealed up tight the wires from the end of the display will start to cor rode If this happens whatever display or computer you are using will not work proper ly It is extremely important that the head is allowed to dry out if the unit is to be sealed up This means that after a dive trip don t just drop the unit on your work bench and walk away from it At the very least drop the canister s off and let the head s dry This will help keep your wires in good working order Sea water on the sensors will probably cause them to fail As your sensors start to age you will notice that they are harder to calibrate slower to react and will drift more after calibration Electrolyte which is a gel like substance is inside the sensors If you notice this substance leaking out of the sensors do not touch it as it is caustic Do not dive with a leaking sensor The readings will be high 29 MSL 72 161 Jetsam Orca Spirit manual R 3 Calibration The following procedures are for preparing the KISS OS for calibration The steps outlined here must be done first in order for the calibration to be accurate The displays should be calibrated with oxygen The procedure for this is as follows 1 Ensure that the diluent and oxygen cylinder valves are closed If the diluent cylinder is not at
91. ouble check that my oxygen and diluent cylinders are open that my displays are on and my computer is properly programmed before enter the water Once in the water will do a bubble check with my buddy to double check that there are no leaks in my system The diluent tank is NOT an adequate gas supply for emergency situations 54 MSL 72 161 Jetsam Orca Spirit manual R 3 POST DIVE CHECK LIST OS DISASSEMBLY After diving the KISS OS your diving system will need to be disassembled and cleaned Follow the disassembly proce dures at the front of the manual follow with the cleaning instructions below e Rinse the rebreather wing amp harness fully with fresh water Be certain to rinse the first stages valves and any reg ulators very well e The loop components should be rinsed and sanitized after diving In order to disinfect the components a product such as Virkon must be used Virkon is a product that comes in powder form which must be mixed with water Follow the package directions for use e After sanitizing rinse all components in fresh water Set out to dry Counterlung s can easily be dried by turning them partially inside out Once your components are dry the unit may be stored for future use 55 MSL 72 161 Jetsam Orca Spirit manual R 3 TRAINING amp BASIC SKILLS As with most rebreather s training is a requirement for purchasing a KISS rebreather Training can be done prior to purchasing a unit or in conjuncti
92. oxygen try increasing the setting by 0 05 LPM The PP02 should slowly rise when you are hanging motionless in the water but you should have to add 02 at regular intervals during the dive when maintaining a constant depth The metering orifice flow rate will decrease as the depth ambient pressure increases The amount it decreases depends on the upstream pressure regulator pressure setting versus the downstream pressure depth This is not a fault it is physics 41 MSL 72 161 Jetsam Orca Spirit manual R 3 WARNING The oxygen injector is a convenience It is not a controller in any way The only device regu lating the oxygen partial pressure is your brain The automatic oxygen add does not reduce the need to monitor the three partial pressure displays It only reduces the number of times you have to press the oxygen add button The displays should be checked constantly during the dive The oxygen regulator can fail and stop delivering 02 or it can fail and increase the flow drastically The orifice can become plugged and stop delivering oxygen The add valve O rings can fail and increase the amount of 02 being added to the breathing loop Any of these things can kill you but any of these problems can be overcome if you are aware of the conditions in the breathing loop The manual oxygen addition valve is a key component of the KISS diving system care should be taken to ensure that it is not damaged serviced as required and is functioning pr
93. quickly A typical 1 3 takes about 2 seconds to read After a few dives many divers have said that they do not need to consciously read the displays they look at the display and their brain recognizes the number of flashes When there is a problem with a sensor it is noticeable immediately as one of the LCD s flashes different from the oth ers As the diver knows what to expect when something different happens it really jumps out at them The Shearwater HUD does not display continuously there is usually 5 seconds between the displays Also as the PPO2 gets farther from 1 0 the light DENSITY gets higher If you are more than 0 50 away from 1 00 the power is turned up to the high intensity LED s so they get brighter At 0 20 you have three very bright red LED s flashing just about contin uously in the corner of your eye OPERATION The HUD has a single button on the box which is used for powering on off and calibration Power On Off One push of the HUD button will turn the HUD on while one subsequent push will turn the HUD off Calibration The Shearwater HUD calibrates only to oxygen 0 98 to be exact This allows for imperfect oxygen flushes and water vapour To calibrate push the HUD button three times within 1 second This may take a little practice but it is intended to prevent accidental calibrations Once you successfully do the calibration sequence all three lights will come on bright red for 5 seconds If thi
94. quired for the KISS OS 1 BOV kit 1 MAV kit 1 Cross bar kit Any individual size excluding the 2 canister O rings and the BOV O rings 6 pieces Any individual size canister O rings and BOV O rings 3 pieces Recommended spare parts 1 full O ring set 1 set Molex plug and contacts 10 gold pins and 3 white plugs 1 Mushroom Valve 1 set wing attachment screws 1 set BOV circ clips 2 These can be used for the BOV or the crossbar Other spare parts good to have but not as important 1 BOV hose attachment 1 Scrubber head tower 1 Loop hose 1 Counterlung 61 MSL 72 161 Jetsam Orca Spirit manual R 3 Orca Spirit LTE Addendum The KISS OS LTE is the newest diving system from KISS Rebreather LLC The LTE while very similar to the standard OS does have some unique characteristics The KISS OS LTE Addendum will outline the differences between the LTE and standard OS The Orca Spirit LTE package includes most of the component s required to dive this system The low price includes e the ABSstand plate e gas addition scrubber head e sensor scrubber head e 2 scrubber canisters with protective black coating e crossbar and counterlung s e oxygen manual addition valve e HOLLIS bailout mouthpiece e 1 full off board gas accessory for adding the diluent gas e Wing e harness with crotch strap e oxygen first stage with delrin plug e 2 17 inch loop hoses Not included with this kit e Oxygen cylinder e Diluent bai
95. r 9 slack 3 Lever 9 bent 4 Orifice 3 incorrectly adjust ed 5 Insufficient intermediate 1 Lever 9 slack present 1 Lever 9 slack present 2 Lever 9 bent 3 Orifice 3 incorrectly adjust ed 1 Adjust orifice 3 and lock nut 11 to arrive at correct spring load tension and lever 9 height Refer to Tuning section 2 Refer to First Stage Trouble shooting chart 3 Replace with new 4 Replace with new 5 Replace with new 6 Replace with new and re adjust Refer to Tuning sec tion 7 Replace Poppet washer 8 spacer 10 and lock nut 11 with new 8 Replace with new 9 Turn in clockwise to adjust Refer to Tuning 1 Replace with new and re adjust Refer to Tuning sec tion 2 Tighten to correct spring load and lever 9 height Refer to Tuning section 3 Replace with new 4 Adjust to correct contact Refer to Tuning section 5 Refer to First Stage Trouble shooting chart 1 Tighten lock nut 11 onto POPPET 9 Shaft Refer to 1 Tighten lock nut 11 onto poppet 6 shaft Refer to Tuning section 2 Replace with new 3 Adjust orifice 3 to cor rect contact Refer to Tun Water entering Second Stage 1 Tearin mouthpiece 27 2 Exhaust valve 13 distorted or damaged 3 Diaphragm 21 distorted or damaged 4 Cover ring 30 not tight on housing 1 5 Cracked or damaged hous ing 1 6 Mouthpiece ty strap 2
96. r Fischer connector to lubricate the inner O ring of the bulkhead connector Filling the connector with food grade mineral oil once a year will also work This will serve to improve the seal and make the connection more reliable If you have a sensor which is reading erratically this could be a solution 4 Ifyou use the mineral oil drain any excess prior to replacing the caps 5 Use the protective caps The caps will help keep your connectors clean keep the lubricant in and any debris and water out Remember the cleanliness of the contacts is essential to the integrity of the link Following these simple steps will en sure that your system works properly Look after your cable and connectors and they will look after you Also be certain that you are using the correct Fischer cable for the computer that you are diving There are some that are not compatible with all computers 32 MSL 72 161 Jetsam Orca Spirit manual R 3 Shearwater Computers Some of the basic Shearwater information is included here This information has been obtained from the Shearwater manual Please note that this information is subject to change for full and current information on the Shearwater computers diver s should download the most current manual from the Shearwater website Buttons MENU button Left e From the default display pressing MENU brings up the menu Once in the menu system MENU moves to the next menu item e If the current function is
97. r head elbow 1 automatic diluent valve ADV 1 hose attachment quick connect tower 1 indexing mark 1 threaded ring 4 springs 1 sensor scrubber head which includes 1 port for the main display 1 port for a secondary display 1 hose attachment quick connect tower 1 indexing mark 1 threaded ring 4 springs 1 sensor attachment plate 1 bronze nut 1 exhaust valve 3 display wire sets with molex pins and plug 2 scrubber canisters which include for each canister Base with attached screen top screen 1 crossbar which includes 1 set 2 black circ clips 2 counterlung attachments 2 counterlung rings 1 Manual Add Valve MAV set which includes 1 MAV amp filter 2 oxygen rated LP hoses 1 KISS OS cylinder and valve 1 KISS OS cover options available are the skeleton SS frame black ABS or the 1 2 size industrial cover SS 1 Wing amp harness system 4 amp 4 liter counterlung s with strap system in place 1 delrin plug for the oxygen first stage 2 quick connect hose stubs with 2 hose clamps to secure loop hoses to towers 2 17 inch loop hoses 22 inch are also available upon request 1 warranty card 1 CD with manual DISPLAY OPTIONS e No display no display cable no Fischer cable e Fischer cable only This is hardwired to the Sensor head e Fischer cable and KISS PPO2 display Cable is hardwired to the scrubber head and display is fitted to cable via a Fischer con nector e Fischer cable and Shearwater computer
98. reful not to damage the sealing surface of the inner METAL SPOOL 16 and BOV HOUSING 1 Figure 8 13 Using your thumbs gently press the spool 16 out of the BOV housing 16 Fig 9 Figure 9 14 Remove the four O rings 18 24 25 29 from the grooves of the spool 16 Discard the schedule A O rings 18 29 Inspect the other O rings 24 25 for any signs of decay Discard if found 15 Inspect the spool 16 O rings 18 24 25 29 channels the lever O ring 35 mounting face and inside the BOV housing 1 for damage nicks gouges etc that would prevent the O rings 18 24 25 29 35 from sealing properly If damage is found the damaged part must be replaced BOV SPOOL REASSEMBLY Li Lubricate the O ring channels for the 3 spool O rings 18 in the metal spool 16 H ZER Fig 10 Then install the four O rings 18 24 25 29 NOTE Using a syringe simplifies this task and reduces waste Lubricating the 3 spool O ring grooves directly also improves SPOOL 16 rotational movement Figure 10 2 Lightly lubricate the internal walls of the BOV housing 1 3 Being careful not to pinch any O rings press the spool 16 into the BOV housing 1 Fig 11 NOTE Ensure that the holes for the installation of the LEVER Figure II 34 are aligned when installing the SPOOL 16 4 Holding the lever screw 33 in one hand place the O ring 35 in the groove as shown Fig 12 Figure 12 5 Hold
99. ring then secure using clamp e Repeat the procedure with the other canister Duration Cold water 7 C 45 F 2 hours Warm water 24 C 75 F 3 5 hours WARNING Divers have been known to travel great distances with their rebreather s assembled and the scrubber canister s packed A word of warning the great the distance traveled the more likely the absorbent can settle with the large and small granules separating This could cause channeling which in turn could cause a problem with Car bon dioxide which could cause serious injury or death How to avoid this Travel shorter distances only Also it is far less likely to happen if you travel with the rebreather in a vertical position rather then having it lay flat as laying it flat will increase the chances of the absorbent settling If the rebreather must be laid flat then remove the canis ter s from the unit and keep them vertical After the car or boat ride or both visually check the canister s The Or ca Spirit canisters are clear and you are easily able to visually inspect them prior to a dive If you see large granules and air spaces at the top and smaller granules and dust at the bottom then you know this has happened If you see this prior to diving you must pour out the absorbent and repack the canister s When arriving at your dive destina tion either by car or by boat it is very important that diver s pre breathe their units for at least 5 minutes This is not to warm
100. rlung assembly on the back of the unit where it will sit and feed the counter lung s through the slots on the wing assembly At this point the crossbar is not yet secured to the unit you are only positioning it and ensuring the counterlung s are properly placed and positioned Following this procedure will ensure that no fabric is caught when securing the lungs to the crossbar This could happen if the crossbar was first secured to the canister s and then the lungs attached 13 MSL 72 161 Jetsam Orca Spirit manual R 3 NOTE KISS OS divers who are familiar with the KISS Classic diving system should be aware that the counterlung sizes used on the Classic will not be the same as on the OS D Divers that used a 2 amp 4 liter set on the Classic will use a 4 amp 4 liter set on the OS o Most divers that used 2 amp 2 liter on the Classic will use a 4 amp 4 liter set with a small minority requiring 2 amp 4 liter set on the OS o Most divers that used a 4 amp 4 liter set on the Classic will likely still be able to use a 4 amp 4 liter set however those who have an exceptionally large lung volume may need a 4 amp 6 liter set on the OS Divers need to understand that the rib wrap lung system on the OS is different from back or shoulder mounted lunge on other units Diver s are easily able to personalize the size of their 4 amp 4 Itr lungs simply by loosening or tightening the strap system and should be prepared to make adjustments They should never
101. roperly packed if you forgot to change the absorbent or if the canister is completely empty Also if your mouthpiece valve disks mushroom valves are in place and working properly While some of these things may sound silly very experienced divers have jumped into the water with either no absorbent or with completely used up absor bent The pre breath is a minimum of 5 minutes as this much time is required for our bodies to tell us that something is wrong The bottom line is that this 5 minute pre breath confirms your system check has been done and that all is working DIVERS SHOULD FOLLOW THE PRE DIVE CHECKLISTS BEFORE EVERY DIVE AND KEEP A COPY OF THE CHECKLIST WITH THE KISS REBREATHER AT ALL TIMES 52 MSL 72 161 Jetsam Orca Spirit manual R 3 Predive Checklist NAME DATE DIVE LOCATION PLANNED DEPTH PLANNED SET POINT TODAY S DIVE NUMBER INITIALS y I have checked my diluent bailout system and it is in perfect working order ____ My bailout system is appropriate for the dive depth am planning of feet meter ____ My sensors are months old ____ The millivolt readings on mysensorsis j ____My PPO2 display uses batteries and they have hours left on them ____ have analysed my 02 cylinder and it has 02 ___lam diving with diluent in my main diluent bailout cylinder have analysed it and have confirmed what percentage of 02 Helium Nitrogen it contains I am diving with mix in my secondary bailout cylinder h
102. ructions on the next page adjust your flow Once you have adjusted the flow you can remove the flow meter and hose and reattach the IP gauge This will allow you to verify your flow reading with the IP of the first stage using the chart on the next page r NOTE IT IS VERY IMPORTANT THAT TWO WRENCH S ARE USED WHEN REMOVING HOSES OR FITTINGS FROM THE MANUAL ADD VALVE ONE MUST BE USED TO ENSURE THAT THE FITTING ON THE VALVE DOES NOT SPIN SEE THE PHOTOS AT THE TOP OF THE PREVIOUS PAGE WHICH SHOW HOW TO DO THIS PROPERLY 40 MSL 72 161 Jetsam Orca Spirit manual R 3 0 0035 orifice Note that some of these pressure settings are beyond the recommended adjustment range of the regulator and may result in erratic performance Use at your own risk These figures are typical but not absolute due to slight variations in the accuracy of the gauge and the tolerance of the metering orifice If your flow rates are more than 15 different than these see the troubleshooting guide to determine the problem To change the pressure use a 6mm hex key to turn the regulator adjustor under the black plastic plug Clockwise in creases the pressure counter clockwise reduces the pressure Turn the wrench slowly and do not insert it too far into the regulator or it will hit the diaphragm and cause the pressure to surge So where should the flow rate be set 0 75 LPM is a good starting point If you find you have to constantly add
103. s doesn t happen then you didn t do the calibration command successfully try again DISPLAY DESCRIPTIONS pere After calibration each of the sensors should be flashing one orange That means the PPO2 is between 0 95 and 1 05 Remember the actual value it uses for calibration is 0 98 If a sensor fails calibration it will flash one red and one green It can be useful to look at the millivolts on your alternate display to see why a sen sor didn t calibrate In these two example pictures sensor one has failed and is alternating between red and green GENERAL FLASH PATTERN The number of green flashes is the number of tenths above 1 0 Therefore 3 green flashes is 1 3 PPO2 The number of red flashes is the number of tenths below 1 0 Therefore 2 red is 0 8 PPO2 Example 0 80 is RR RR RR 0 20 is RRRRRRRR__RRRRRRRR _ RRRRRRRR__ 1 3 is GGG GGG GGG You will notice from the above example s that the farther away from 1 0 the shorter the interval between flash sets 36 MSL 72 161 Jetsam Orca Spirit manual R 3 BATTERY WARNING When you turn the HUD on if it flashes orange for 30 seconds this indicates a low battery The battery is contained in the box with the processor To change the battery you will need to remove the top cover Replace the battery with a 3 6 volt Lithium Saft 14500 Ensure when replacing the cover that the O rings are properly secured cleaned and lubricated lt would be beneficial to carry a spare bat
104. s enough gas so that a reasonable descent rate can be maintained Anytime the ADV triggers you need to check your PPO2 you have either descended and compressed the gas in the loop or you have consumed enough oxygen to reduce the PPO2 significantly This may also have caused you to lose buoyancy and descend The position of the diver will effect the ADV If the diver is horizontal or face down the ADV will trigger easily If the diver is vertical then it is more difficult to trigger A well fitting harness is important this will greatly reduce the diffi culties of being vertical in the water Also rolling to your right side while horizontal will assist in triggering the ADV Diluent can also be added to the breathing loop via the mouthpiece Simply go to open circuit mode take a breath and then open the loop again and exhale the gas into the breathing loop Another way to add gas to the loop via the mouthpiece is to close the loop only a 1 4 inch for a second You may need to lightly push the purge button on the front of the 2nd stage A small amount of gas will blow directly into the breath ing loop In the Exhaust Valve ADV Work of Breathing section of this manual you will see information on the ADV Some of this information is relevant to both styles of ADV while other information is specific to the component For ease we have repeated the ADV section of Bubbling Apeks Exhaust Valve here along with other relevant information to this
105. s filled the screen in place and properly positioned take a clean cloth and wipe off the scrubber dust from the top and inside edge of the canister Ensure this area is clean it is your sealing surface e Apply lubricant to the inside edge and top edge of the canister You should lube these area s very well e Double check that the O ring areas on the scrubber head are still clean wipe if required and then apply lubricant to them These area s should also be lubricated very well e While holding the canister firmly gently push and rock the scrubber head into place This should keep the radial O ring from becoming dislodged If you push the canister on crooked this O ring may pop out of position This is most likely to happen when the O ring is first installed Once the canister has been in place for several hours or a few dives it is unlikely that this O ring will easily be dislodged If this O ring does get pinched you may need to change it as the indentation could cause a leak Inspect the area to ensure that the O ring has not been pinched 22 MSL 72 161 Jetsam Orca Spirit manual R 3 e Tighten the ring to secure the head to the canister The action of the ring turning will tighten the head to the canis ter and pull it down into place e Slide the canister through the proper Fastex clamp and position it so that the Indexing Mark is facing the opposite canister This ensures that all hoses will be properly oriented Tighten the threaded
106. s have a lip in which the quick disconnect hose stubs are secured The unit is shipped standard with 2 hose stubs which will be fitted to your loop hoses with hose ni clamps prior to shipping If you choose to order your unit with the BOV then 4 hose stubs will be included with your kit These extra 2 hose stubs hose clamps are for se curing the loop hoses to the BOV which also uses our quick disconnect system If you choose to source your own BOV then you will need to also source an attachment method for that BOV NOTE THE TOWERS ARE THREADED INTO THE SCRUBBER HEADS AND SEAL WITH AN O RING WHILE THE TOWERS ARE DESIGNED TO BE DIFFICULT TO TURN IT IS STILL IM PORTANT THAT THEY ARE NOT ACCIDENTLY UNSCREWED WHILE REMOVING OR INSTALLING THE BREATHING HOSE A LOOSE TOWER WILL LEAK CHECK THE TOWERS PRIOR TO DIV ING TO ENSURE THEY ARE TIGHT The procedure to install the hoses stubs to the loop hoses are as follows l First soak the ends of the loop hoses in hot tap water for several minutes This will soften the rubber on the hoses making it easier to install the hose stubs Some dives may find that they need to soak the hose ends in water that has been boiled This will certainly make it easier 2 Shake the water from the hose and then apply silicone grease to the inside of the loop hose It is best to use a thicker lubricant for this rather then a thin oxygen type lubricant Apply lubricant to the outside of the hose stub
107. serious injury or death Also It is important that the sensors are properly installed If the sensor O ring is left on or they are not turned all the way into the head response times may be delayed Ensure that the O rings are in good condition that the area is clean and the components are not damaged Lastly if the wires are pinched under the plate the scrubber head will not be water tight Water damage in this area will ruin the sensors and or the electronics If the wires do get pinched inspect them for damage 28 MSL 72 161 Jetsam Orca Spirit manual R 3 SENSORS When you open up your new K 22D sensors they will have a millivolt reading between 9 and 13 millivolts As long as they are in that range they are safe to use WARNING You also need to ensure that they can be calibrated in Oxygen and that they read correctly in air This is very important Even if a sensor is reading in the proper range as it ages you may no longer be able to calibrate it properly IF THIS HAPPENS THE SENSOR MUST BE DISCARDED FAILURE TO USE A PROPER SEN In diving applications the sensor will last 1 to 1 5 years depending on how often you dive and how they are stored Sensors should be allowed to dry out after your day of diving especially if you are diving in a humid environment This means that you need to leave the loop hoses or scrubber canister off overnight to allow air to circulate through the scrubber head Leaving the unit sealed up will n
108. st are items that must be addressed and or confirmed prior to suiting up for the dive Those that are using this tool usu ally keep several blank copies in a small binder with their dive gear The second part of the check list are items that are usually checked shortly before a dive This list can also be printed out but other options are to copy it onto a dive slate or wet notes in a permanent ink marker A point worth noting is that all pilots have a check list which they go through every time they fly Diving a rebreather should be no different While rebreather diving doesn t necessarily take more preparation or clean up time than open circuit diving there are very specific things that need to be checked and confirmed prior to getting into the water Using this check list will only add a few seconds more time to your preparation but could make all the difference in having a pleasurable time in the underwater environment It certainly assists in creating competent happy divers One part of the 2nd check sheet is worth discussion That is the 5 minute pre breath that is required prior to diving Note that this pre breath is NOT to warm up the scrubber It is to determine if the scrubber and the rebreather are working properly lt gives you a chance to monitor your display system to ensure that it is working And most im portantly to determine how you feel during and after the pre breath It will help you determine if your scrubber has been p
109. t was designed this way so that the diver would know when they were triggering it If it was too easy then diluent gas could be fed into the breathing loop without the diver being aware of what was happening 66 MSL 72 161 Jetsam Orca Spirit manual R 3 SEE BELOW FOR INSTRUCTIONS ON REINSTALLING THE ADV DIAPHRAGM Note that proper assembly procedures must be followed Prior to removing the ADV diaphragm it would be good to have a spare diaphragm handy as reinstalling an old diaphragm can be tricky if it is stretched NOTE A damaged ADV diaphragm assembly amp or valve stem will either deliver too much diluent gas or none at all NOTE It is important that the proper installation procedures are followed or the diaphragm will leak It is also important that proper testing procedures are followed so that the diaphragm is not stretched out Installing the ADV diaphragm When you are ready to attach either the original diaphragm or a new one first inspect it If you are reinstalling the original one this is very important If the diaphragm has stretch marks by the screw holes it would be best to use a new one instead A diaphragm in this condition is very difficult to reinstall The stretch marks are a result of doing long negative tests on the unit Remember a negative test should only be about 1 minute long Please see testing section for the proper testing instructions Again if you are planning on opening up the diaphragm area
110. tached to the off board accessory whip then be certain that the sealing cap is attached to the whip 2 Drawallofthe gas out of the loop Do this by putting the BOV into your mouth open the loop inhale the gas into your lungs and then exhale it out of your nose When the loop is flat close the BOV switch without allowing any gas to leak back into the loop Note it is important that you do not exhale any gas back into the loop while doing this 3 With the loop closed open the oxygen tank and press the manual add valve button adding oxygen into the loop until the exhaust valve burps the exhaust valve should be fully closed 4 Repeatsteps 2 amp 3 until the loop has been completely flushed with oxygen This usually takes 3 to 4 flushes 5 Oncetheloophas been completely flushed close the oxygen cylinder and open and close the mouthpiece quickly to bring the gas in the loop to ambient pressure With the loop closed calibrate to 1 00 Note once the above procedures have been completed the calibration procedures for the display that is being used must be followed The readings should be verified with air To verify with air first ensure that both tank valves are turned off Then re move the loop hose which is attached to the exhaust side of the mouthpiece Put the mouthpiece into your mouth open the loop and breathe This will draw fresh air through the loop and eliminate the pure oxygen which you flushed the loop with It will take
111. tery in your spares kit as they aren t available in some remote areas This should not be a cause for concern as the battery should last many months even years REBREATHER ATTACHMENT The box should be attached to the loop hose behind the divers head Use the enclosed Velcro for this In this location it will not be in the way and it is also possible to reach the button Attach the HUD tie to either side of the BOV It is handy to attach it to the left side so that dumping the right loop hose after a dive isn t effected Wrap the cable for the HUD around the loop hose and then snap on to the attachment The HUD attachment consists of 2 pieces one part attaches to the BOV with the tie and the other the HUD snaps into The two parts are joined by mag nets These are extremely strong magnets Slide magnets apart and back together only 37 MSL 72 161 Jetsam Orca Spirit manual R 3 Manual Add Valve Metering Orifice The manual add valve is for adding oxygen to the loop The O rings should be changed annually or if the flow rate changes more the orifice All components in the add valve must be clean oil free with the O rings lightly lubricate frequently The inlet of the valve is protected by a 15 micron filter This filter will NOT stop seawater from contami nating the orifice All components in the add valve must be clean oil free with the O rings lightly lubricated with oxy gen compatible grease
112. th counterlung with the straps FULLY open will re sult in greater buoyancy changes This can cause the user to lose control of their buoyancy which can lead to injury or death AUTOMATIC DILUENT VALVE ADV The ADV is located on the top of the gas addition scrubber head The ADV will add diluent gas to your breathing loop after the loop volume has been reduced by either descending or breathing down the volume of oxygen The diver will get the feeling that there is no more air in the loop to breath All the diver needs to do is suck hard to trigger the ADV and it will feed him more gas This is how a second stage regulator works The ADV has been setup tight enough that it doesn t add diluent without the diver being aware But it adds enough gas so that a reasonable descent rate can be maintained As you can see there is an adjustment knob on the ADV reg ulator It is very important that this knob is always tight and turned all the way in The ADV on the KISS OS has been designed to be easier to activate then past ADV designs As such diver s must be aware of body position at all times and understand that a head down position will cause the ADV to activate more rapidly then usual If the diver is in this position then he must be prepared to vent the loop and change to a horizontal position This will aid in preventing a buoyancy issue which is may cause an unwanted ascent WARNING THE ADJUSTMENT KNOB ON THE ADV REGULATOR M
113. that the lungs are flat and smooth where they slide through the slot Also ensure that they are not tangled in the harness See photo 5 Ensure that the threaded rod is not damaged in anyway If it is the wing and harness may not be secure causing a failure Be certain to inspect these parts prior to diving and replace as required WARNING IT IS IMPORTANT THAT ALL KISS OS O RINGS ARE IN GOOD CONDITION THAT THE COMPONENTS DISCUSSED PRIOR AND AFTER THIS WARNING ARE NOT DAMAGED AND THAT THE SEALING AREAS ARE CLEAN IF THEY AREN T THE O RINGS MAY LEAK CAUSING THE REBREATHER TO FLOOD THIS MAY LEAD TO SERIOUS INJURY OR DEATH 15 MSL 72 161 Jetsam Orca Spirit manual R 3 Loop Hose Ballast amp Mouthpiece Placement While the purchase of the loop hose ballast system is optional when purchasing your rebreather they are required to dive the KISS OS They are available for purchase from KISS The KISS system uses 8 SS rings 4 per loop hose Our rings are 13 Ibs each which makes a total weight of 1 04 Ibs If you choose to source your ballast rings from another company be certain that you know the weight of their rings They are not all the same and many rings from other companies can be up to 50 less in weight which would require you to purchase a many more then if using the KISS ballast If you have purchased your ballast rings from KISS they will be installed on your hoses prior to dell A gt shipping The type that we use can b
114. the MAV following the above instructions Then remove it from the first stage Swap the position of the LP hoses the longer one should now be secured to the scrubber head turn the elbow so it is facing down and the shorter LP hose should be secured to the first stage The shorter LP hose from the first stage should now be attached to the filter on the MAV Be certain to secure it to this port as it is important that the incoming gas is filtered The Longer LP hose from the scrubber head should now be attached to the other port on the MAV no filter port Follow the same instructions as above to properly tighten the hoses A wrench must be placed on the nut closest to the plastic housing to hold it secure while you tighten the hose fitting Please see the MAV trouble shooting and service section for photos and more instructions If in doubt please call KISS for advice Diluent Cylinder and the Off Board Gas Accessory The diluent cylinder on the KISS OS is side mounted and doubles as the diver s bailout gas In this configuration the diluent cylinder is referred to as off board diluent gas as the cylinder is not secured to the main rebreather The ad vantages of this are that diver s may customize the system to suit their diving needs It also keeps the main rebreather small light flexible and easy to travel with KISS recommends that a minimum of 40 cuft should be used as the diluent bailout cylinder when diving recreationally Diver
115. the O rings well While applying the lubricant double check that the O rings are not damaged or indented If you feel an indent or other dam age while applying the lubricant change the O ring for a new one 3 Insert the cross bar into the bottom of the scrubber canister s The proper technique is to push up on the crossbar pushing it into the bottom of the canisters and while doing this insert the circ clips 4 Ifyou secured the cylinder first then it is easier to attach the cross bar The procedure for this is that after you insert the crossbar into the bottom of the canister s you may push down on the canister s which will cause the crossbar to push against the cylinder enabling you to easily insert the circ clips To do this en sure that the Fastex clamps are loose i E E 5 Once the crossbar has been secured to the canister s and the lungs are sitting cor rectly the canisters may moved to their final position Loosen the Fastex clamp s TH if they are not already and position the canister s properly If the cylinder is not already in place you may wish to wait It will be much easier to properly place the assembly Re attach the ADV LP hose to the gas addition head This may be finger tight or may be lightly secured with a wrench 14 MSL 72 161 Jetsam Orca Spirit manual R 3 Cylinder e This step outlines how to secure the oxygen cylinder to the unit Prior to this the diver should ensure that the cyl inder has been f
116. the orifice 3 into the coupling 2 with the Knife Edge of the orifice 3 facing in CAUTION Be careful to protect the delicate knife edge of the ORIFICE 3 as this is done 11 Using a narrow shafted slotted blade screwdriver gently turn the orifice 3 clockwise into the coupling 2 until the knife edge is barely contacting the poppet seat 5 DO NOT continue to turn the orifice 3 any further beyond this point which will cause the lever 9 to drop Doing so will also damage the poppet seat 5 requiring its replacement NOTE For best sensitivity of touch during step 11 place your finger gently on the LOCK NUT 11 while slowly turning the ORIFICE 3 As soon as contact is made you will feel the LOCK NUT 11 begin to turn Hold the screwdriver by the shaft rather than by the handle 12 Place the diaphragm 21 inside the housing 1 with the raised Center facing up and ensure that it seats flush into the groove of the housing 1 Fig 35 Set the inner ring 32 in place over the diaphragm 21 Ensure that it sits flush 13 Place the purge cover 31 into the cover ring 30 Then install the purge cover 31 and cover ring 30 in a clockwise direction into the housing 1 Ensure that the cover ring 30 is correctly seated on the threads Hand tighten until secure Fig 36 14 Secure the mouthpiece 27 onto the housing 1 with a new ty strap 28 positioning the locking tab of the ty strap 28 towards the LP
117. ty strap 28 towards the breathing hose 13 Using an 11 16 open end wrench tighten the LP hose end to the coupling 2 clockwise onto the BOV housing 1 Fig 19 14 Screw the hose nuts clockwise onto the BOV Figure 19 15 Install the HUD bracket and HUD to the exhalation hose nut Attach an O ring to the underside of the HUD bracket to secure it NOTE To avoid damage slide the HUD bracket over the hose nut from the side WARNING Check for leaks and proper operation before use of the BOV DANGERS Ensure the mushroom valves are installed correctly with gas flow from diver s left inhalation side to diver s right exhalation side as shown by the arrow Fig 20 Figure 20 SECOND STAGE TROUBLESHOOTING Free flow or leakage present Excessive inhalation resistance Rattle heard inside Second Stage Little or no air flow when Purge Button is depressed 1 Excessive lever 9 height 2 Excessive intermediate pressure from first stage 3 Lever 9 bent 4 Damaged or worn poppet seat 5 5 Damaged orifice 3 6 Lock nut 11 over tightened onto shaft of poppet 6 7 Poppet washer 8 bent or distorted 8 Poppet spring 7 weak ened worn or incorrect part 9 Orifice 3 incorrectly adjust ed 1 Lock nut 11 over tightened onto poppet 6 shaft causing excessive spring 7 tension 2 Lock nut 11 insuffi ciently tightened onto pop pet 6 Shaft causing leve
118. up the absorbent but rather to ensure that everything is working as it should Remember this can happen on any rebreather With the KISS Orca Spirit you have the advantage of being able to visually inspect the canister s as they are clear NOTE The scrubber assembly gas addition head amp the sensor head are key parts of the rebreather and care should be taken to ensure that they are not damaged and are working properly WARNING IF CANISTER O RING IS PINCHED AND THERE IS A LEAK YOU WILL HAVE A SERI OUS FLOOD THIS COULD CAUSE SERIOUS INJURY OR DEATH POSITIVE NEGATIVE TESTING Once the KISS OS has been completely assembled you are ready to do the positive and negative pressure tests While these tests will give you the best indication of any leaks in the system it is still a good idea to do a quick bubble check when you enter the water That s where buddies come in handy WARNING IT IS VERY IMPORTANT THAT THE POSITIVE NEGATIVE PRESSURE TESTS ARE COMPLETED AND THAT THEY ARE DONE PROPERLY ANY LEAKS THAT ARE PRESENT ARE MOST LIKELY TO BE CAUGHT WHILE DOING THESE TESTS WHEN DOING YOUR TESTS YOU SHOULD BE VERY CERTAIN THAT THEY PASS IF YOU HAVE ANY DOUBT AND ARE UNSURE THAT THE TEST PASSED YOU PROBABLY HAVE A SMALL LEAK FIND IT THE KISS UNITS HOLD VERY GOOD POSITIVE AND NEGATIVE TESTS To do the negative test first ensure the plug is secured to the male end of the off board accessory All gases should be off the un
119. ustment check to see if your second stage is still bubbling and adjust as necessary Once the bubbling has stopped and the flow has been adjusted to your liking you can dive the unit with the adjustment knob on the left turned all the way in This will also limit the chances of the regulator free flowing When you want to breath on the 2nd stage you will just need to dial it out to where you find it comfortable If after all that you still have a bubbling 2nd second stage the problem could be with the seat inhale diaphragm exhale diaphragm or it could be debris Your local dive shop should be able to service the 2nd stage for you NOTE When doing your negative pressure test it is possible to damage the exhaust dia phragm in the second stage If your inhalation is extremely hard for an extended period of time this can happen Also on the new BOV the 2nd stage exhaust diaphragm can be dis torted if the negative is too hard causing the test to fail 50 MSL 72 161 Jetsam Orca Spirit manual R 3 WATER INTRUSION First determine if the water is sea water from diving or fresh water if you are not fresh water diving this could be condensation If it is sea water service your BOV and ensure that the O rings are all in good shape Also clean and lubricate at this time Inspect the inhalation and exhalation diaphragms on the second stage Look for any tears or punctures You may need to hold these parts up to the light and gently pull on t
120. you prefer not to do it Care should be taken to ensure that it is in good working order and not damaged Also be aware that if you wash your BOV with a powerful hose the valve disks may be blown off After cleaning be certain to inspect your gear and follow all the pre dive check s IF THE MUSHROOM VALVES ARE DISTORTED OR DAMAGED THEY MUST BE REPLACED When attaching or removing the mushroom valves BE CAREFUL When attaching or removing the NEW valves PULL ON THE STEM GENTLY amp ON LY HOLD THE STEM WHEN REMOVING THE VALVE DO NOT CARRY THE VALVE OR VALVE CARRIER BY THE STEM TROUBLESHOOTING BUBBLING SECOND STAGE First determine if the diluent first stage IP is creeping If it is you will probably have to replace the HP seat in the first stage Once you know that your first stage is in good working order check to see where the IP is set Ideally it should be around 8 to 10 bar with 10 bar 147 psi being the maximum Once the IP has been set you will want to ensure that the 2nd stage is adjusted properly Turn the adjustment knob on the second stage so that it is in the middle position If there is an adjustment knob Remove the LP hose opposite of the knob The adjustment screw is on the inside on the 2nd stage where you removed the LP hose Use a screw driver to adjust the flow Your adjustments should be minimal only a millimeter or so at a time Most 2nd stages are very sensitive and require a light touch After each adj

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