Kirby Air Conditioner 5 User's Manual
Contents
1. it is only necessary for him to speak into the oral nasal mi crophone in his mask or helmet If two divers will be working together test the cross talk functions at this time as well To extend the life of the battery it is recommended that the communications be used in the 4 wire mode Operation as a 2 wire system uses relays inside the unit which will cause a higher battery drain CAUTION In the 2 wire mode when the push to talk switch is depressed the KMACS 5 operator should keep all of his communications short 10 15 seconds at any one time This allows the diver to call for assistance if necessary Plug the earphone connectors on the diver s umbili cal into the earphone jacks on the communicator Plug the microphone connectors on the umbilical into the microphone jacks on the communicator This will create a 4 wire system round robin system Test the system and adjust all volume controls a a Te S Was M l E N AAN SCH Fig 8 Preliminary testing of the umbilical with a volt ohm meter to check for continuity 2003 KMDSI Document 041112001 KMACS 5 MANUAL Unplug the earphone connectors on the diver s um bilical from the communicator and reinstall them in the connectors attached to the plugs for the micro phone This will change the communicator to a 2 wire system Test this system and adjust volumes If there are no communications recheck all of the connections to ensure they are t2. orange 40 405 106 S S Tube Assembly H P 20 2003 KMDSI Document 041112001 KMACS 5 EXPLODED VIEWS amp PARTS LISTS Communications Panel Part 530 017 415 105 530 035 430 075 410 003 Description Screw Communicator Screw Washer Gasket Foam Part 415 056 430 060 455 065 510 491 455 317 KMACS 5 MANUAL Description Battery Gel Cell 12V Retainer Ring Filter O Ring Yoke Din Assembly 18 21 445 105 450 106 420 125 420 120 445 115 COND PWN ra Panel Auxiliary Yoke Retainer Arrow Orange Arrow Blue Door Storage Compartment 410 006 410 007 455 054 405 175 405 176 Hose Protector Orange Hose Protector Blue Hose H P Supply Hose Yoke Assem Blue 18 23 Hose Yoke Assem Orange 18 23 420 160 330 405 530 070 420 105 410 145 415 110 Slide Latch Lock washer Screw Box Plastic Grommet Cable Batter 2003 KMDSI Document 041112001 455 135 Conical Seal 400 046 KMACS 5 with Communicator 400 045 KMACS 5 No Communicator Bracket for no comm version not shown 440 004 Mount Bracket 530 078 Screw 530 540 Washer 21 KMACS 5 MANUAL pued ute 001 Srr yoyorlg FND 0Z0 Srr qunoy PUI dH ION 061 SSt WN CSI SoP ISLAM SII Oc r wey dT dea 00 SSr ToYyseM YET OSL ToyseM 9 I Ocr MOA UT d T III S r MOQIA U
3. KMACS 5 MANUAL Section 3 0 KMACS 5 Maintenance 3 1 RECOMMENDED MAINTENANCE OF THE KMACS 5 The KMACS 5 requires very little user maintenance With proper care the KMACS 5 should last for years and give excellent service On a daily basis the KMACS 5 operator should in spect the high pressure whips attached to the yokes S for signs of wear After each use the case interior panels and high pressure hoses should be wiped down with a rag which has a small amount of Armor All Never spray cleaners directly on the KMACS 5 Fig 12 After each use the case interior panels and high pressure hoses should be wiped down with a rag which has a small amount of Armor All Never spray cleaners directly on the KMACS 5 16 Approximately every six months the high pressure hoses should be treated with Armor AIl or similar protection Once a year the KMACS 5 should be returned to your authorized dealer or KMDSI to service the regulator selector valve and calibrate the diver s depth gauges This is especially important if the unit is used for deep decompression or repetitive dives 3 2 REPLACING THE BATTERY The battery used with the KMACS 5 communicator is very reliable and will offer many years of service However storing the KMACS 5 with the battery drained can cause the battery to fail The battery should be completely charged before storage Gel cell batteries have an excellent shelf life if properly charged prior to
4. Water a allons of Water i Horsepower pU par Minute 33 000 Horsepower Foot Pounds per Second oe 7 Horsepower Watts ie Horsepower Days eee aoe Weeks 54 ours 2 Inches eeneg 0 03342 Inches of Mercury Hg Feet of Water 1 133 Inches of Mercury Hg PSI Lbs per Sq Inch Ge Inches of Mercury Hg PSI Lbs per Sq Inch 1000 Inches of Water Cubic Centimeters 0 2642 Tuer Gallons U S Liquid Liters Inches 0 00004 Micron Feet 5280 Miles Statute Feet per Minute e 67 Miles per hour MPH Feet per Second i Miles per hour Pounds 0 0625 Ounces Weight Cubic Inches 1 805 Ounces Liquid Quarts Liquid 0 5 Pints Liquid Grains 7000 Pounds Grams _ Pounds Ounces oe Pounds Atmospheres PSI Pounds per Sq Inch Feet of Water 2 307 PSI Pounds per Sq Inch Hg 2 036 PSI Pounds per Sq Inch Gallons 0 25 Quarts Square Inches Cer 55 Square Feet Temperature C EI Temperature F 32 Pounds 2000 Tons U S Horsepower 0 001341 Watts 25
5. be heard escaping from hose Fitting loose on diver s hose or fittings damaged Tighten fittings until snug Do not over tighten Replace fittings if damaged 5 Umbilical registers pressure at console gauge but no flow at mask Mask improperly serviced Clean and adjust mask 18 2003 KMDSI Document 041112001 Symptoms 6 Air can be heard escaping into console interior Probable Cause Leakage in DCS plumbing KMACS 5 MANUAL Remedy Return KMACS 5 to factory for service 7 Umbilical hose pressure and supply pressure drops rapidly Diver s Umbilical cut or severed Replace diver s hose 8 With high pressure air on and regulator loaded no umbilical pressure Regulator malfunction 5 0 APPENDIX 5 1 EMERGENCY PROCEDURES Return DCS 2A to factory for service The following are general recommended emergency procedures However it is up to the individual diver and dive supervisor to make judgements under specific conditions on how to best cope with particular situations Problem Action 1 Loss of communications a Abort dive if operations are not absolutly necessary b Use line pull signals as per this appendix section 2 Loss of primary air supply Switch to emergency backup system and abort dive 3 Diver s umbilical severed a Diver switches to bailout bottle and aborts dive b Standby diver ente
6. of the KMACS 5 usually makes it possible to locate it at the water entry site allow ing the operator to tend the diver s umbilical while maintaining control of the KMACS 5 In addition to its compact size the ability of the KMACS 5 to use high pressure air allows SSAir diving from small boats or remote locations where transportation and setup of a compressor would be impractical Two or more standard scuba bottles can be used as the breathing air supply For example when commercial divers are working on an offshore rig a common SSAir diving job is the inspection and cleaning of a propeller on a crew boat This job can be performed easily and simply with the KMACS 5 a couple of scuba bottles a full face mask or helmet and an umbilical Transporta 2003 KMDSI Document 041112001 tion to the job site is simple and a large surface support vessel is not needed At the dive site full communications backup breathing supply pressure readouts and depth monitoring are provided by the KMACS 5 This is one of many situations where the KMACS 5 can be used to provide the safe and efficient opera tion of SSAir diving 1 3 SPECIFICATIONS Use For SSAir diving only Pure oxygen MUST NOT be used Compressed air from high pressure tanks scuba or other types of compressed air tanks or from a compressor should be the only supply to the KMACS 5 CAUTION Pure oxygen is a potential fire hazard its use can lead to explosion of
7. ownoug UEN oqny A QUIOSSY JOImInZa MOQTA IPWN TH Assy oqny SS JOSE AJLA 10 99T9S dH PIL unt AMN eas eruo MOQTA IPWN Opasems A quiassy Aoq asney gH qL FWO dH NL PUI Ajddng 21 QAL do yoursg ALW sury O dn yoeg 0 0 0IF 3 eee ee asney oun ud NYM NL Apog meng om V W oum uq WYM QNL PMO N uondiaseg Hed 4 wo opu la IIL UNY ALN asney eoriquiy qn Aoq ewy Aea ownd IIL 19908 LAN H I addin LAN HI Aea Ouln uq OO Ia 3IL UNY ALW SLIB IUMUIH ULZION AQALY uo JSISUI SABAIS soseds Supo UJM Tests AG p 94 JJo SIYULIIEM AUB PIOA Jpm suonnyysqns Aue AyeuonIppy Ayes mod ozip edoofl Arem pue juswdmbo 3 10ddns O INOA GERT REN PALA ARAMA Ta IY UJIA 9J 9J r IILA Su pd S 191njJIVINULUL 19Y 0 JOaSn JY L supd Ju ur op d r gurSrio ueo Aqary ATuo sr ONINAVM NOLLOAVO sury O TI0 01IS mews dep sury O t 0 0Sr Surq O I0 O1S was usid LE0 OSh 5 Surq O OTO O1S sury O dn yoeg 00 01IF AOE s pnlouD S g8 0 0Sr Surq O OTO OTS D ownd poy QNL PPMO G2 D AVO AG 7 j JUNON 10MIN ISUSPAA DA N ul NI osney oum uq poy 2001 SA ga Wik i 1ojo uuoo QNL SENS E an j 3oolg Poet e gt E S Surq O Snd dT E Te Jojo uuoO QNL WS TE IIL UNY ALW IddIN LAN 91 Mogi JOSUdg 1o je n3 q NL mog y IPWN JUIWISUBIIY SUIQUIN IOL19 UT TT ARA YOU TT ioljo uuoo u
8. representations and undertakings between KMDSI its dealers and the buyer relating to the Products This warranty allocates the risks of product failure between KMDSI and the buyer which allocation is recognized by both parties and is reflected in the price of the goods The buyer acknowledges that it has read this agreement understands it and is bound by its terms Table of Contents Section Title 1 0 General Information 1 1 Definitions 1 2 Design Purpose 13 Specifications 1 4 General Description 1 4 1 1 4 2 e e oN ON CA A UU NY ra O O e E E Q H Breathing Air Sub System Principle Operating Features Dive Control Panel Red Diver Depth Gauge Umbilical Pressure Gauge White Diver Depth Gauge Blue Air Supply Flow Indicator Line Orange Air Supply Flow Indicator Line Low Pressure Inlet Fitting Blue Breathing Air Supply Gauge Orange Breathing Air Supply Gauge High Pressure Cylinder Yokes Bottom of Case Air Supply Selector Valve Handle Regulator Adjustment Knob Outlet Manifold Pneumo Valve Handle White Diver Pneumo Valve Handle Red Diver O Ring Seal Communicator Panel 19 Communicator 2 0 Operating Instructions 2 1 Unpacking the KMACS 5 22 First Use of KMACS 5 Page AQ ND QD Ch Ch A Ch Uu ni KR Q WN ro oo NN AY oo Section Title 23 Connecting the Air Supply 24 Connecting Divers Ho
9. storage To replace the battery remove the screws which hold the communicator panel V into the top of the KMACS 5 box Do not remove the screws which secure the communicator to the larger panel Tilt the panel out but do not remove it from the lid The battery is held in place by brackets and Velcro strips on the back of the large panel Reach behind the panel and support the battery Lift the panel and battery out as a unit Replace the old battery with a new unit Position the new battery on the back of the large panel using the Velcro strips to hold it in place Connect the leads back to the battery and push the communica tor panel V back into its normal position Install the screws which hold the large panel in place and tighten them in a staggered pattern 2003 KMDSI Document 041112001 Section 4 0 KMACS 5 MANUAL Trouble Shooting the KMACS 5 System 4 1 GENERAL The KMACS 5 is an extremely simple system which should not malfunction if the instructions in this manual are followed Most problems encountered in using the system can be easily remedied The following informa tion covers the common operating difficulties 4 2 NO COMMUNICATIONS Symptoms Probable Cause s Remedy 1 No sound at either KMACS 5 or diver s mask a Communication power not on b Communications incorrectly hooked up c Communications not hooked up Activate switch and adjust volume Switch terminal w
10. suit was origi nally called a dress Although the name changed KMACS 5 MANUAL to suit the term dressed in has remained to describe putting the suit on A diver who is dressed in has a suit on The term is also used to describe a diver who in addition to his suit has more or all of his her equipment on Bailout Bottle This is the emergency tank of breathing gas Bailout which is the familiar term for parachuting from an airplane also applies to the shallow water diver who ditches part of his diving gear and swims to the surface The bailout bottle term came from this use The bailout bottle is an independent air source con nected directly to the diver s mask or helmet via a first stage scuba regulator and hose The first stage regulator must be equipped with an overpressure relief valve Part 200 015 The overpressure relief valve will vent pressure in the event of a first stage leak and prevent the low pressure hose from rupturing causing a complete loss of the diver s bailout supply The bailout bottle is worn on the diver s back mounted to a harness The diver s umbilical should be attached to this harness to prevent a direct pull on the diver s mask or helmet The size volume of the bailout bottle should be determined by the diver s depth or the distance required for a direct ascent to the surface For deeper dives or penetration dives inside wrecks or pipelines a lar
11. the KMACS 5 Pure oxygen also presents a physiological hazard to the diver Outer Dimensions Length 21 inches Width 10 1 2 inches Height 17 1 2 inches Weight 54 pounds 24 5 kilos Shipping Weight 60 pounds 27 kilos Recommended Maximum Dive Support Depth 130 fsw feet of sea water 40 meters CAUTION Decompression and other human limits must be observed Decompression diving should not be conducted with the KMACS 5 unless a properly equipped recompression chamber facility with oxygen is immediately available at the dive site In water decompression is not recommended High Pressure Supply Pressure Maximum 4500 pounds per square inch 300 bars Low Pressure Supply Pressure Maximum 225 pounds per square inch 15 5 bars 2003 KMDSI Document 041112001 KMACS 5 MANUAL CAUTION Although the high pressure gauges on the KMACS 5 are rated to 5000 psi 345 bars this is a safety precaution only The regulator on the KMACS 5 is not designed to operate at pressures greater than 4500 psi 300 bars Umbilical Pressure Range 115 225 pounds per square inch 8 15 5 bars Regulator Output 40 SCFM at 2500 psi 172 bars supply pressure with 150 psi 10 3 bars delivery pressure Relief Valve Set at 300 psi 20 7 bars Pneumofathometer Range 0 250 FSW feet of sea water 0 76 meters Communicator 4 wire system Can also be used in 2 wire mode Battery Type Rechargeable 12 volt
12. will usually be excellent not all divers speak clearly The KMACS 5 operator should listen carefully at all times to what the diver is saying Once the diver has entered the water monitor his descent rate using the pneumo valve D O and gauge C P The diver s descent rate should not exceed 75 feet 23 meters per minute As the diver descends the KMACS 5 operator should adjust the regulator H on the KMACS 5 to provide 150 psi 10 3 bars over the pressure at the diver s depth at all times This provides the best breathing performance from the diver s demand regulator 2003 KMDSI Document 041112001 KMACS 5 MANUAL Fig 10 KMACS 5 operator taking a reading with the pneumo knob The knob should be turned very slowly It is essential that the KMACS 5 operator keep pace with the diver s descent and not lag behind in his depth monitoring If this occurs it is possible for the diver to exceed his maximum planned depth without the KMACS 5 operator being aware this has occurred To operate the pneumo turn the knob for the ap propriate diver counter clockwise until the indica tor needle on the depth gauge starts moving When the depth gauge for the individual diver indicates a depth that is known to be deeper than the diver the knob is turned clockwise until it is off The indicator needle on the depth gauge will move shallower as the air bubbles leave the open end of the pneumo hose at the diver When the need
13. 5 operator At the start of the diver s ascent he should 2003 KMDSI Document 041112001 inform top side that he is Leaving the bottom The KMACS 5 operator should carefully note the time in the dive log The KMACS 5 operator must monitor the diver s rate of ascent carefully observing his watch and the pneumo gauge C P There is no need to pneumo the diver as he ascends because the air in the pneumo hose will automatically expand and vent the hose as the diver approaches the surface 2 12 DECOMPRESSION If the diver has decompression stop s required as a result of his dive slow the diver s ascent as he ap proaches his first stop Upon reaching his first stop the diver should assume a relaxed and comfortable position in the water A weighted line or some other apparatus should be provided to the diver to assist him in maintaining a proper depth Decompression in mid water without a line or other method of fixing the diver s depth is NOT acceptable as it is impos sible to maintain an exact depth without something to hang onto An accurate pneumo should be taken at the diver s decompression stop There should be no unnecessary slack in the diver s hose i e no part of the umbili cal should be lower than the diver as this will give a false reading deeper of the diver s depth Make sure the end of the pneumo hose is held at the diver s chest with the open end pointing down Fig 11 All of the ou
14. 5 bars 14 5 barsi 12 1 bars 50 6 bars 15 5 bars 13 1 bars 60 7 bars 15 5 bars 14 1 bars 2 5 1 TESTING L P SUPPLY With the air on at the bottles and the communications switched on check the regulator function The diver should insert his face in the mask helmet and take several breaths to test the demand regulator To test the low pressure supply place the selector valve handle I in the H P OFF zone and the console will be running off the low pressure supply only Observe the umbilical pressure gauge B As the compressor cycles the gauge will rise and fall as the compressor s volume tank fills and empties The maximum pressure for the L P inlet should be 225 psi Again check the mask helmet function which will also confirm the low pressure supply routing 2003 KMDSI Document 041112001 2 5 2 TESTING COMMUNICATIONS Test the communications between the diver and the KMACS 5 With the communicator R switched on turn the speaker switch to on and adjust the volume to a comfortable level for both the diver and the KMACS 5 operator In the 2 wire mode the communicator functions similarly to a citizens band radio i e the KMACS 5 operator must de press the push to talk switch to speak to the diver In the 4 wire mode the communicator functions like a telephone conference call i e everyone on the line can hear and speak to everyone else In either mode for the diver to talk top side
15. ANY IMPLIED WARRANTIES FOR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE PRODUCT COVERED BY THIS WARRANTY IS MARKETED AND SOLD BY KMDSI SOLELY FOR COMMERCIAL OR INDUSTRIAL USE AND IS NOT A CONSUMER PRODUCT INTENDED FOR PERSONAL FAMILY OR HOUSEHOLD USE In purchasing any Product subject to this warranty the buyer agrees that its sole and exclusive remedy and KMDSI s entire obligation in contract tort or otherwise under this contract will be repair or replacement at KMDSI s option of the Product or any parts which KMDSI determines during the applicable warranty period are defective in workmanship or material covered by this warranty All exchanged parts are the property of KMDSI The buyer s exclusive remedy and the KMDSI s entire liability in contract tort or otherwise is the payment by KMDSI of the buyer s actual damages up to but not to exceed the amount paid by the buyer for the Product In no event shall KMDSI be liable to the buyer for indirect special incidental or consequential damages including but not limited to damages for lost profits lost sales loss of business opportunity or for injury to persons or property arising out of the use of the Products Any claim or action for breach of warranty must be commenced within one year following delivery of the Product to the buyer Buyer acknowledges that this warranty is the sole and exclusive warranty of the Product and that it supersedes any and all oral or written
16. E air supply flow indicator line Q indi cates the flow path of breathing air from entry into the KMACS 5 to exit to the diver s umbilical s at the fittings on the manifold G There are two high pressure whips which are color coded BLUE and ORANGE Starting from the high pressure air tank the BLUE air supply flows through the whip into the KMACS 5 Following the BLUE flow indicator line Q it shows the flow to the BLUE Breathing Air Supply Pressure Gauge M then to the Breathing Air Supply Selec tor Valve which is controlled by the Breathing Air Selector Valve Handle 1 The Selector Handle I must be turned all the way UP until it stops for the BLUE supply This places the selector valve handle in line with the flow path indicating the BLUE air supply Q The ORANGE supply is off when the Selector Handle is in the up position CAUTION When using H P air the selector handle must be turned up until it stops for BLUE supply or down until it stops for Orange supply Never allow the selector handle to stay in the marked H P OFF ZONE Both high pressure air supplies are off in the yellow striped H P OFF ZONE After flowing through the Selector Valve the BLUE air supply enters the Breathing Air Supply Regulator H which reduces the high pressure breathing air to an adjustable range between 115 225 pounds per square inch psi 8 15 5 bars The BLUE air sup ply then goes to both diver s umbilic
17. I AH S8I SSr VH Sw CCl Ory TOYSeM SOC OEL SUIMBIP SuIquIN d 1011901 WOI LC A A QuIassY IAPA 10 99 9S OrFI SSp lpueH 4o1 599 9S MIDS PS OrI 0 F IPueH 4o 99 9S STT OTH yu unsn pv J1ole nS q WAS 0ZI 0Sr Junoy JOJL NSoy ISUSPAA 9ZI 0c r 1ole n8 2 MN INON STI OSY MOINS IS OII Oc F juousn py 10m3 y qouy OLT OSr qA SET OCr SUILMPIP SUIQUINI 1013AU WOJ 981 A A quiassy AeA oum udq S0 SSP TOYsSeM OCT OLP T PIOH 9SOH I T 0rF d 1 9neD gett MYM Snep ownsug I 0 0rF poy asney ownoug 010 0rr MIOS OLO OES JOAOD SMWO Orl OTr sury O P10 01S APPA JO MYS VA OIISH IPH APA ZIZ 0rF dos pueH OIZ Orr ToyseMm FCIOCE lt 6 AQ 19S PLH 1939o6S Trio PPNO Ier dey o00 SSr MOA SS tr SSr asuey APA SpI SSY Apog AA SI SSr oum uq dep 00 S r Aoq d SS TEO SSY yoorg oum uq prI 0St MIOS 0 0c ToyseM GO M S III OcF wx sasney pue Suiquniq zapen FE L O8F ZENS SIG fra Voran TOYSeM FCI p 9Jumn ojA Putu q mag TIOE uondinos q AUS 4 NS 2001 KMDSI Document 010925001 22 KMACS 5 MANUAL MOQ A JOSu S Ioe Nsay 9T7O SST JopulfAD Joyensay LcCT0er ynuyso7T Uo AN ZZO OEF I89S pray IZI OIF Surq O 6II OIF Dan uolsid Z 0 0Sr suuds o00 S r s dep Surq O 0 0Sr a312 Bury dn yoeg g00 0Ir AT OARA YOOYD 7 1 Surq O S900 01S l ATLA PPA Ajddng
18. Kirby Morgan Air Control System 5 Operations and Maintenance Manual Part 100 075 SOs MS a SYSTE ANTA BARBARA CA KMDSI 1430 Jason Way Santa Maria California United States of America Postal Code 93455 Telephone 805 928 7772 Fax 805 928 0342 Kirby Morgan Air Control System 5 KMACS 5 Dive Control System 2A DCS 2A DCS 3 and DCS 1 are trademarks of KMDSI Use of these terms to describe products that are not manufactured by KMDSI is not permitted Manual prepared by Marine Marketing and Consulting amp KMDSI 2003 KMDSI Document 041112001 This page not used Definitions of Signal Words Used in this Manual DANGER This word indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING This word indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION This word indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Warranty Information KMDS I warrants every new mask helmet SCUBA regulator or air control system K MACS each a Product to be free from defects in workmanship for a period of ninety 90 days from the date of purchase from a KMDSI authorized dealer This warranty covers all metal fiberglass and plastic parts but does NOT cover rubber parts communications componen
19. L Blue Air Supply Flow Path Indicator Line Orange Air Supply Flow Path Indicator Line Fig 3 Air flow paths from the H P cylinders 8 BLUE BREATHING AIR SUPPLY PRESSURE GAUGE M The Blue pressure gauge M indicates the pres sure remaining in the BLUE high pressure tank NOTE If two divers are supplied by the KMACS 5 both divers will be breathing from the same selected high pressure supply 9 ORANGE BREATHING AIR SUPPLY PRESSURE GAUGE L The Orange pressure gauge L indicates the pres sure remaining in the ORANGE high pressure tank NOTE If two divers are supplied by the KMACS 5 both divers will be breathing from the same selected high pressure supply 10 YOKES FOR HIGH PRESSURE CYLINDER ATTACHMENT S The yoke fittings S provided have standard U S scuba cylinder attachments as well as Din Fittings Each yoke has a bleeder valve to vent the remain der of the pressure in the whip when changing out scuba bottles The yokes attach to posts mounted on the panel in the lid of the KMACS 5 for storage and transport 11 CASE J The Dive Control panel A is attached to the bottom 6 Blue Air Supply Whip om Orange Air Supply Whip half of the case J The top half of the case contains the communicator panel with the yoke blocks and the communicator if there are communications If there are no communications there are only the yoke blocks see picture in front of manual The top i
20. MACS 5 case will flood if the box is submerged 18 COMMUNICATOR PANEL V The diver s electronic communicator R is attached to the communicator panel The battery for the com municator is located behind this panel 19 COMMUNICATOR R The MK3 KMDSI communicator is a standard open circuit round robin diver s communicator which functions like a telephone It can also be used as a 2 wire push to talk system It is connected to the diver s umbilicals by banana plug fittings on the communicator The communicator is mounted on the communicator panel You should read and understand the accompanying radio operations manual supplied with the unit before using the unit Improper use or connections could damage the radio CAUTION Never connect the charger during a dive or when anyone is in contact with connected equipment Although electrical shock danger is remote connection of the recharging cord should only be done when the KMACS 5 is not in use KMACS 5 MANUAL Section 2 0 OPERATING INSTRUCTIONS 2 1 UNPACKING THE KMACS 5 When you first receive your KMACS 5 carefully unpack it and examine it for any damage that may have occurred during shipment Be sure to complete the enclosed warranty card and return it to KMDSI immediately No warranty claims will be honored without a satisfactorily completed warranty card on file at KMDSI Visually check the KMACS 5 to ensure that it has not been damaged in tr
21. als through the fittings on the manifold G 2003 KMDSI Document 041112001 6 ORANGE AIR SUPPLY FLOW INDICATOR LINES The ORANGE air supply flow indicator line indicates the flow path of breathing air from entry into the KMACS 5 to exit to the diver s umbilical s at the fittings on the manifold G The second high pressure whip is color coded ORANGE Starting from the high pressure air tank the OR ANGE air supply flows through the whip into the KMACS 5 Following the ORANGE flow indica tor line K it shows the flow to the ORANGE Breathing Air Supply Pressure Gauge L then to the Breathing Air Supply Selector Valve which is controlled by the Breathing Air Selector Valve Handle H The Selector Handle must be all the way DOWN until it stops for the ORANGE supply The BLUE supply is off when the Selector Handle is in the down position KMACS 5 MANUAL After flowing through the Selector Valve the OR ANGE air supply enters the Breathing Air Supply Regulator H which reduces the high pressure breathing air to an adjustable range between 115 225 psi 8 15 5 bars Then the ORANGE air supply goes to both diver s umbilicals through the fittings on the manifold G 7 LOW PRESSURE INLET FITTING N The low pressure inlet fitting is positioned between the connections for the two H P supply hoses It is marked by the arrow containing the words L P Supply Low pressure supply breathing air usually f
22. ansport Fig 5 Note the line which passes through the handle of the KMACS 5 and is secured to the rail to prevent the KMACS 5 from moving about 8 2 2 FIRST USE OF THE KMACS 5 Place the Dive Control System on a firm surface The KMDSI logo should be right side up Release the latches and lift up the lid to expose the panels When using the KMACS 5 aboard a vessel subject to waves or swell be sure to tie the KMACS 5 securely in position so that it doesn t fall Thread a piece of line through the handles and fasten the ends to fit tings on the boat Tie back the lid of the KMACS 5 as well to prevent damage or injury 2 3 CONNECTING THE AIR SUPPLY Loosen the knurled knobs which connect the yokes to their storage posts in the KMACS 5 and remove the yokes S from the blocks Attach each yoke to a high pressure cylinder as you would connect a scuba regulator to a tank The knobs on the yoke should be screwed down finger tight Do not apply Fig 6 Connecting a scuba air supply to the KMACS 5 2003 KMDSI Document 041112001 excessive force to the knobs air pressure from the tanks will create a good seal Be sure the bleed valve on each yoke is in the closed position Do not turn the cylinders on at this time ven d OECREaS 115 PSI WN D BARS Min Ze 4 Fig 7 Always use the right size wrench to connect the hoses to the KMACS 5 Check the function of the selector handle to ensure correct operation If a
23. e break in the wire If the reading is some where between zero and infinity and changes as the umbilical is moved this indicates a partial break and communications will be intermittent In either case a waterproof splice must be made in the wire 11 KMACS 5 MANUAL 2 5 3 TESTING THE PNEUMO The pneumo supply may be tested in either the high pressure supply mode or the low pressure supply mode To test the pneumo select either mode and pinch the open end diver s end of the red diver pneumo hose With the hose crimped tightly shut slowly open the red pneumo valve D momentarily 1 4 turn and observe the needle s response on the red diver depth gauge C CAUTION Do not peg the needle on the pneumofathometer with a maximum reading A test of pressure equal to 50 feet 15 meters on the gauge is satisfactory to ensure correct operation Close the valve after observing correct operation and release the end of the pneumo hose The gauge needle should return to zero Repeat the above pro cedure for the white diver 12 2 6 PREPARING THE DIVER The diver should be dressed in with the appropriate exposure suit for the local water temperature The diver should be equipped with a harness to provide an attachment point for his umbilical By attach ing the umbilical to the harness the possibility of a direct pull on the diver s helmet or mask will be eliminated A bailout bottle should be mounted on the diver
24. e is usually indicated on the hose and must not be exceeded The working pressure of the high pressure hose on the KMACS 5 is 5000 psi 345 bars Whip A hose complete with fittings at each end for use in hooking up two pieces of deck equipment for gas or air flow For instances the hoses and fittings used to connect the KMACS 5 to the high pressure tanks are called high pressure whips H P High pressure Usually any pressure over 300 psi 20 7 bars L P Low pressure Usually any pressure under 300 psi 20 7 bars Pneumofathometer pronounced new mo fath ometer This device measures the diver s depth A small hose which is part of the diver s umbilical runs from the KMACS 5 to the diver The hose is open at the diver s end and attaches with a fitting to a gauge at the KMACS 5 The gauge is calibrated in feet and meters of sea water A valve is attached between the hose and the gauge so the operator can use a small amount of breathing air to purge water from the small hose When the valve is shut off excess air bubbles out of the hose at the diver s end and the air left in the hose will be at a pressure equal to the pressure of the water column This is the exact depth of the diver Pneumo Short for pneumofathometer Used such as pneumo gauge pneumo valve pneumo hose to describe the parts that make up the pneu mofathometer subsystem Dressed in A commercial diver s
25. e pneumo purge valve The diver should observe the end of the pneumo hose and immediately inform top side that He has bubbles Once the diver has a flow of bubbles at the end of the hose the pneumo valve D O should be closed immediately Should the diver move deeper at any time during his dive he must inform the KMACS 5 operator and another pneumo should be taken for a new maximum depth reading If the KMACS 5 operator knows that the diver is moving over an uneven bot tom he should periodically take additional pneumo readings to ensure that the diver has not accidentally gone deeper and neglected to notify top side Keep in mind however that every pneumo reading does use some air If high pressure air is the air source and the dive is deep or the diver is working hard pneumo readings should be taken as sparingly as possible 14 2 10 CHANGING OUT HIGH PRESSURE CYLINDERS The KMACS 5 operator should continuously moni tor the diver s air supply at the two high pressure gauges L M when diving with high pressure air as the primary supply When the initial supply source pressure drops to between 300 and 500 psi 20 7 and 34 5 bars depending upon depth the diver should be switched over to the second air source using the selector valve handle I While the diver is breathing off the secondary source a fresh cylinder should be put on line immediately To change out high pressure cylinders first close the cylinder va
26. er into equivalent values of units in Column 1 left divide by factor in Column 3 Example To convert 25 horsepower into Btu per minute divide 25 by 0 02356 1061 0 06895 1 03425 3 4475 6 895 20 685 34 475 68 95 137 9 206 85 10 275 44 75 2003 KMDSI Document 041112001 6 895 103 425 344 75 689 5 2068 5 3447 5 6895 0 1379 0 20685 0 31027 5 34475 0 KMACS 5 MANUAL Table of Equivalents TO CONVERT INTO MULTIPLY BY INTO TO CONVERT DIVIDE BY Feet of Water SC 2 Atmospheres Inches of Mercury Hg 1 47 Atmospheres PSI LBS per Sq Inch ae Atmospheres Foot Pounds H Gen BTU We 0 02356 BTU per hour HorsePower S BTU per minute Fahrenheit Cx 1 8 32 Celsius Centigrade Inches 0 3937 Centimeters Gallons U S Liquid 0 0002642 Cubic Centimeters Liters 0 0001 Cubic Centimeters Cubic Inches a Cubic Fest Gallons U S Liquid Cubic Feet Cubic Feet 0 0005787 Cabic Teles Gallons U S Liquid Gg Cubic Inches Seconds x Se Days Radians Degrees Angle Meters 0 3048 ie E Feet of Wat 0 8826 Ce or Waler Inches of Mercury Hg 0 4335 Feet of Water PSI Lbs per Sq Inch SE Feet of Water Miles per Hour o 6818 Feet per Minute Miles per Hour I Feet per Second BTU 0 001286 Foot Pounds Horsepower 0 0000303 Foot Pounds per Minute Horsepower 0 001818 Foot Pounds per Second Cubic Feet 0 1337 Gallons U S Liquid Cubic Inches 231 GE GE Liquid Pounds of
27. ger capacity bailout bottle should be used Fig 1 Divers with all of the gear they need to dive 1 2 DESIGN PURPOSE The Kirby Morgan Dive Control System 5 KMACS 5 is designed to provide a central control center for the operator dive supervisor during a surface supplied air dive Provisions for the control of the breathing air supply diver depth monitoring and voice communications are all located on a simple panel The KMACS 5 is a full service control system for all Surface Supplied Air diving operations The KMACS 5 is fitted with shut off valves on the diver s air supply The shut off valves are designed to allow air to be shut off on either or both of the diver s umbilicals When the handles of the valves are vertical the valves are open and air is flowing to the divers When the valve handles are horizontal the valves are shut and the air to the divers umbilicals is off By having total control located at one panel the KMACS 5 operator can rapidly respond to the diver s needs without leaving the control station In a standard commercial SSAir diving operation the KMACS 5 provides a backup air supply system which the operator can activate in the event of the main air supply failure such as compressor malfunc tion This can be accomplished without leaving the control panel which allows the operator to inform the diver and continuously monitor umbilical supply pressure and depth at the same time The compact size
28. he most senior diver by virtue of his diving experience 2003 KMDSI Document 041112001 The dive supervisor may not always be the KMACS 5 operator The dive supervisor may want or need the freedom to direct the entire operation includ ing the tenders and other personnel As such he is responsible for making decisions regarding diving conditions and safety However the KMACS 5 operator must always be an experienced diver who understands the diver s needs and has the diver s best interests always in mind CAUTION The KMACS 5 operator must not leave the dive control system unattended while the diver is in the water The KMACS 5 operator is directly responsible for the diver s safety and well being The diver must follow the KMACS 5 operator s directions in regards to depth and time The diver can NOT run the dive from the bottom Thus when the dive supervisor himself is required to dive he should relinquish control to the next most senior diver remaining top side 2 8 DESCENT Upon entering the water the diver should imme diately recheck communications with top side and ensure that his mask or helmet is working correctly When he she is ready to descend he should notify the KMACS 5 operator that he is Leaving the surface Both the diver and tender should communicate in a normal tone of voice It should not be necessary for either person to shout to be heard Although the qual ity of the communications
29. helmet refer to the manual for the mask or helmet for the proper connection procedures for your life support equipment This action will prevent any foreign matter from entering the helmet or mask breathing system Once the hose is blown out immediately connect the fitting on the hose to the fitting on the mask or helmet Connect the communications portion of the diver s umbilical to the communications fittings on the communicator and to the mask or helmet Be sure the proper connection is made with the right com munications line for each diver The wires in the diver s umbilical should be marked so it is easy to identify which plug connects to the earphone ter minals and which plug connects to the microphone terminals 2 5 PRE DIVE CHECK Prior to EVERY dive the following should be checked With the free flow and demand regulator on the mask helmet s shut off turn on the air supply at each of the air cylinders During operation with scuba bottles as the main supply the selector valve handle must be FULLY up or FULLY down Fully up turns the BLUE supply on and the ORANGE supply off Fully down turns the ORANGE sup ply on and the BLUE supply off Note the air pressure in each cylinder by reading the gauges L M The low pressure supply should be switched OFF at the source at this time A check valve in the low pressure system prevents back flow to the compressor Both cylinders should be f
30. ight at each junction If the KMACS 5 has been operating in a coastal en vironment look for corrosion on the top side connec tors which may interfere with the communications If corrosion is evident disassemble the connectors clean and retest If corrosion is heavy replace the top side connectors Substitute other masks or umbilicals to test for failures in the microphones or umbilical Substitute one piece of new gear at a time to track the fault down If the fault is in the mask or helmet replace the earphones or microphones as needed If the fault is in the umbilical disconnect the umbili cal and carefully inspect its length for damage Look for obvious nicks or cuts If there is physical damage to the outside of the communications wire there probably is a break on the inside too Test the continuity of the wire end to end with a volt ohmmeter Uncoil the umbilical and lay it out flat with the two ends close to each other Set the volt ohmmeter to resistance ohms and hold one probe to one prong on an umbilical connector plug and touch the other probe from the meter to the wires or connector at the opposite end of the diver s umbilical Upon locat ing the other end of the same wire the meter should indicate zero resistance i e there is a complete uninterrupted circuit If touching none of the wires at the other end of the umbilical produces a zero reading and all readings are infinity this indicates a complet
31. ires Plug into terminals 2 Battery indicator does not re spond Battery low or dead Charge or replace battery or bypass battery with external power 3 Communications weak or broken up Terminals covered with corro sion Clean Terminals with wire brush to bright shiny metal 4 Communications will not work with headset but works otherwise Headset not working Short in internal wiring Replace headset Return to factory for repair 5 Communications interrupted when umbilical is moved Break in diver s communication wire Splice wire if damage is minor Re place wire if damage is major 6 Communications interrupted when waterproof connector is moved Break in splice at waterproof connector or failure of connector Test with VOM Replace splice or connector 7 Satisfactory communications through one earphone or micro phone only 4 wire mode a One wire in cable is broken b Microphone earphones dead Stack connectors in microphone terminals Communications works in two wire mode Replace microphone earphones 8 No sound at either KMACS 5 or mask 2003 KMDSI Document 041112001 Communicator not functional Return to factory for repair after verifying no cure by following above procedures 17 KMACS 5 MANUAL 4 3 NO PNEUMO READING Symptoms Probable Cause Remedy 1 No air to diver s end of pneumo P
32. le stops that is the diver s actual depth Most umbilicals are made up with the diver end of the pneumo hose having about two feet 6 meters of loose hose The diver can use this hose as an air supply for inflating lift bags or for taking an exact 13 KMACS 5 MANUAL reading of the bottom depth In an emergency the pneumo air can be used as a breathing air supply for a diver The diver tells the KMACS 5 operator to Turn on the pneumo air then inserts the hose into the mask or helmet When using the pneumo in this mode the air pressure should be regulated by the KMACS 5 operator to be slightly greater than the diver s depth For example if the diver is at 100 feet 30 meters the pneumo should be opened until the gauge reads a depth of 110 feet 33 meters so that a positive pressure exists The diver should practice using the pneumo as an alternative air source under controlled conditions in shallow water The pneumo hose should be bubbling when it is inserted in the diver s mask otherwise the diver will receive a blast of water when the pneumo is first turned on 2 9 DIVER AT DEPTH Once the diver reaches the bottom or his maxi mum planned depth the diver should inform the KMACS 5 operator that he is On the bottom At this time the KMACS 5 operator should ensure that he gets an accurate depth reading The KMACS 5 operator should inform the diver that he is Taking a pneumo when he opens th
33. lve on the tank which is low Once the valve is closed open the bleeder valve on the yoke S and allow the pressure to bleed from the line The high pressure whips are color coded to help the KMACS 5 operator to ensure he is selecting the correct one Always observe the umbilical pressure gauge B carefully during this procedure If the KMACS 5 operator is not careful he may acciden tally turn off the high pressure cylinder supplying the diver s breathing air If the umbilical pressure gauge B needle starts to fall turn the cylinder back on immediately and double check to ensure the correct cylinder is being changed When the high pressure whip is empty unscrew the knurled knob on the yoke S and attach the yoke to a fresh cylinder Tighten the yoke knob finger tight close the bleeder valve and slowly open the cylinder tank valve Read the new pressure on the appropriate gauge L M 2 11 PROCEDURES DURING THE DIVER S ASCENT At the end of the dive the diver should prepare to leave bottom upon orders from the KMACS 5 operator The KMACS 5 operator must carefully note the diver s depth and time on the dive log The KMACS 5 operator is responsible for monitoring the diver s ascent rate which should not exceed 60 feet 18 meters per minute or slower if a dive computer is being used to monitor decompression no decom pression status The diver should not leave the bot tom until he is instructed to do so by the KMACS
34. nent names and some instructions are on the panel The blue and orange lines K Q on the panel represent the flow paths of supply air from the two high pressure hoses yokes S 2 RED DIVER DEPTH GAUGE C PNEUMOFATHOMETER This gauge indicates the red diver depth The red diver pneumo valve knob D is turned to supply a small volume of air to the small pneumo hose that is part of the diver s umbilical The gauge reads the pressure of the air in the pneumo hose This pressure measured in feet or meters of sea water equals the water pressure at the diver s depth 3 UMBILICAL PRESSURE GAUGE B This gauge B is connected to the low pressure air supply system that supplies both umbilical fittings It indicates the breathing air pressure that is in both the red and white diver umbilicals When the air supply is from high pressure tanks such as scuba tanks the umbilical hose pressure can be varied by turning the regulator adjustment knob H 4 WHITE DIVER DEPTH GAUGE P PNEUMOFATHOMETER This gauge indicates the white diver depth The white diver pneumo valve knob O is turned to supply a small volume of air to the small pneumo hose that is part of the diver s umbilical The gauge reads the pressure of the air in the pneumo hose This pressure measured in feet or meters of sea water equals the water pressure at the diver s depth 5 BLUE AIR SUPPLY FLOW INDICATOR LINE The BLU
35. nuemo hose not connected Attach fittings to KMACS 5 2 Gauge reads sustained pressure at surface Pneumo crimped or plugged Check entire length of hose Relieve any restrictions 3 Hose will not hold pressure and gauge needle will not rise Pneumo fitting cracked or loose Check fittings at console with soap and water solution If fittings bubble either tighten or replace as necessary 4 Needle will not respond properly to flow a Hole in pneumo hose b Gauge mechanism damaged Check hose replace or splice as necessary Replace or repair gauge Return to factory 5 Air can be heard escaping into console interior KMACS 5 internal plumbing may be cracked or broken Return to factory for service 4 4 NO AIR TO DIVER Symptoms Probable Cause Remedy 1 No hose pressure in diver s umbilical a primary air source not con nected b Valve closed at low pressure source c Selector valve in H P OFF zone Connect proper hose to console Open valve at low pressure com pressor Move selector valve handle in line with flow from either high pressure source 2 No gauge reading on high pressure gauge Valve closed at high pressure source Open valve at high pressure source 3 Low hose pressure in diver s umbilical Regulator not properly loaded Rotate adjustment wheel in ap propriate direction 4 Air can
36. ondr 5s Gq OcI SSr Litt SvI SOr OcI SOV LOI SSt 90I SOV 0cI 0cr Dk 96I SSP SEL SSY PAK SOE SSP POI SOV SOI SOr OII SOF LIT SSY SOI SOr cOI SOv I91 SOV Ov0 SSV O8I SSV LOI SOv 0r0 SSr IK ak ecI SSV TSO SSP 0F0 SSr 0O8 I S r 09 S0F 9c1 0cr 0OSI SOF 6rI SSP CrI OST elO O1S T90 0SE 6tI SSr O8 I S r CTI SSV OcI SSV SSI SOV KIK 6r0 SST vCO SSV Wed Cl cO THOT oCh O Cl eo st oO oO oO cry ery cry cry cry st st st st T c nN N Ka N N WM vi NN Co Oh Eco Cl o zt vo ei Cl Cl Cl CH CH Vi Oo eN CO Cl CO st Cl cn st i OD Gi 2001 KMDSI Inc All Rights Reserved Docu 000525002 010627001 KMACS 5 MANUAL KMACS 5 DIVE LOG Diver Date KMACS 5 Operator Dive Location Weather Conditions Purpose of Dive Low Pressure Air Source Pressure High Pressure Air Source Pressure Finish Dive Times Diver Left Surface Diver Reached Bottom _ Diver Left Bottom Maximum Depth Diver Reached Surface Total Bottom Time Repetitive Group Decompression Required 24 2003 KMDSI Document 041112001 To convert units appearing in Column 1 left column into equivalent values in Column 2 center column multiply by factor in Column 3 Ex ample To convert 7 gallons into cubic inches multiply 7 x 231 1617 To convert units appearing in Column 2 cent
37. r talking between the KMACS 5 operator and the diver s or diver to diver The communicator operates in both the two wire and four wire mode The KMACS 5 will supply plenty of air for two surface supplied divers Scuba Self contained underwater breathing appa ratus SS Air Diving Surface Supplied Air Diving Diving operation where the diver is supplied breathing air by way of a hose which is part of the diver s umbilical from the surface Usually the source of the breathing air is a compressor but compressed air tanks on the surface can also be used Diver s Umbilical Several components run together from the KMACS 5 Dive Control System 2A to the diver These components are joined together usually by tape forming the umbilical The most common components used in the diver s umbilical are A a hose through which the breathing air flows to the diver B a multiconductor wire for communications transmission C another smaller hose which is used to show the diver s depth on the pneumofathometer see below 4 a strong line used as a strength mem ber to prevent strain on the other components of the umbilical The umbilical should be taped every 10 feet with colored tape to indicate the length of the hose 2003 KMDSI Document 041112001 High Pressure H P Hose A flexible hose de signed to carry a working pressure of gas or air of more than 300 pounds 20 7 bars per square inch The rated working pressur
38. rom a compressor with volume tank is supplied through a whip low pressure hose and fittings that attaches here When the low pressure supply is the only air source the supply pressure will be indicated on the umbilical pressure gauge B In the low pres sure supply mode the selector valve handle will he positioned in the H P OFF ZONE CAUTION When using H P air the selector handle must be turned up until it stops for BLUE supply or down until it stops for ORANGE supply Never allow the selector handle to stay in the marked H P OFF ZONE Both high pressure air supplies are off in the yellow striped H P OFF ZONE Dive Control panel Umbilical Pressure Red Diver Depth Gauge Pneumo Valve Handle Red Divers Umbilical Breathing Hose Attachment Fittings Pneumofathometer Hose Attachment Fittings Outlet Manifold Regulator Adjustment Knob Breathing Air Supply Selector Valve Handle Case Orange Air Supply Flow Line Orange Breathing Air Supply Gauge Blue Breathing Air Supply Gauge Low Pressure Inlet Fitting Pneumo Valve Handle White White Diver Depth Gauge Blue Air Supply Flow Line Communicator Yokes w DIN Fittings for H P Cylinder Attachment G Access door for storage compartment O Ring Seal Communicator Panel A B C D E F G H I J K L M N o P Q R S T U v 2003 KMDSI Document 041112001 KMACS 5 MANUA
39. rs water and supplies first diver with air from pneumo 4 Pneumo will not operate a Dive hose should be marked with colored tape every 10 feet Take depth readings from this will only be approximate b Diver s personal depth gauge can provide back up 5 2 DIVER LINE PULL SIGNALS of Pulls From Tender to Diver From Diver to Tender Are you all right T am all right or 1 When diver is descending one T am on the bottom pull means Stop Going down Lower me down or 2 During ascent this means Give me slack 2003 KMDSI Document 041112001 You have come up too far go back down until we stop you 19 KMACS 5 MANUAL From Diver to Tender of Pulls From Tender to Diver 3 Stand by to come up Take up my slack 4 Come up Haul me up 5 3 COMMUNICATIONS WIRING SCHEMATICS If your KMACS has communications refer to the radio manual 5 4 EXPLODED VIEWS amp PARTS LISTS The following parts are not shown on the blow apart drawing and are listed reference only Location Part Description Qty Not Shown 420 100 Case KMACS 5 1 Not Shown 405 039 Battery Charger Assembly l The following parts in the interior plumbing require the use of Conical Seals 455 135 the conical seals are provided with the items listed below Location Part Description 29 405 105 Inlet Tube H P blue 31 405 105 Inlet Tube H P
40. s Incoming high pressure air from the ORANGE or BLUE supply is reduced by the internal regulator The Adjustment Knob controls the regulator Turning the Knob clockwise decreases the umbilical pressure counterclockwise increases it 14 OUTLET MANIFOLD INCLUDING DIVER S UMBILICAL FITTINGS G The WHITE DIVER and RED DIVER air supply hoses are connected to the KMACS 5 at the manifold G The fittings coming out of the KMACS 5 are male 6 JIC 3 8 37 flared fittings The diver s air supply hoses must have matching female 6 JIC flared fittings with swivel nuts The WHITE DIVER and RED DIVER pneumo fathometer hoses are also connected to the KMACS 5 at the manifold G The fittings coming out of the KMACS 5 are male 4 JIC 1 4 37 flared fittings The diver s pneumofathometer hoses must have matching female 4 JIC 1 4 37 flared fit tings with swivel nuts 15 PNEUMO VALVE KNOB WHITE DIVER O The Pneumo Valve Knob White Diver turns on and off the air supply to the WHITE pneumofathometer system 16 PNEUMO VALVE KNOB RED DIVER D The Pneumo Valve Knob Red Diver turns on and off the air supply to the RED pneumofathometer system 2003 KMDSI Document 041112001 KMACS 5 MANUAL 17 O RING SEAL U The O ring seal helps keep dust and moisture out of the KMACS 5 when the case is closed The O ring seal is not pressure proof however and the K
41. s harness Always dive with a bailout bottle no matter how shallow the dive The danger of entanglement is always present and a bailout bottle will give the diver that few extra minutes to free himself in the event he becomes hung up on fishing line wire or other submerged objects The bailout regulator should be equipped with a quick disconnect whip to make it easier to dress the diver in and out In addition the bailout regulator should also be equipped with an over pressure relief valve Part 200 015 This will permit the regulator to bleed off and not rupture the low pressure hose connecting it to the diver s bailout or emergency valve should the first stage develop a leak With the hose attached to the harness tuck the pneumo hose under the harness at the diver s chest This serves two purposes 1 it provides instant access in the event the pneumo is to be used as an alternative air supply 2 gas absorption and elimina tion of nitrogen is considered to occur at the diver s chest level When diving under a potential decompression situa tion a depth gauge or dive computer should be worn by the diver as a backup system If decompression is anticipated there must be enough air on hand for the diver to complete the dive and the decompres sion obligation 2 7 THE DIVE SUPERVISOR AND THE KMACS 5 OPERATOR During the diving operation one person should always be in charge to avoid confusion Generally this should be t
42. s not designed to be removed 12 BREATHING AIR SUPPLY SELECTOR VALVE HANDLE D This handle D controls the two position Breathing Air Supply Selector Valve and allows uninterrupted diving operations while full air supply tanks replace expended tanks The selector valve controls ONLY the high pressure air supply It is NOT possible to shut off any low pressure supply connected to the low pressure inlet fitting N at the KMACS 5 itself CAUTION When using H P air the selector handle must be turned up until it stops for BLUE supply or down until it stops for ORANGE supply Never allow the selector handle to stay in the marked H P OFF ZONE Both high pressure air supplies are off in the yellow striped H P OFF ZONE When changing out the H P air supply cylinders always observe the diver s umbilical pressure gauge B for any sudden fall in pressure Should this occur it indicates that the cylinder in use has mistakenly been turned off If so immediately turn the cylinder back on and move the selector valve handle to select the full cylinder and change out bottles Due to the construction of the selector valve it is impossible for gas to back flow from one cylinder to the other 2003 KMDSI Document 041112001 13 REGULATOR ADJUSTMENT KNOB FOR UMBILICAL PRESSURE H The regulator Adjustment Knob H allows the operator to adjust the umbilical pressure within a range of 115 psi to 225 psi 8 15 5 bar
43. ses 2 5 Pre Dive Checklist 2 5 1 Testing the L P Supply 2 5 2 Testing Communications 2 5 3 Testing the Pneumo 2 6 Preparing the Diver 27 Dive Supervisor and KMACS Operator 2 8 Descent 29 Diver at Depth 2 10 Changing out High Pressure Cylinders 2 11 Procedures During the Diver s Ascent 2 12 Decompression 2 13 Completion of Diving Operations 3 0 Maintenance 3 1 Recommended Maintenance 3 2 Replacing the Battery 4 0 Troubleshooting 17 41 General 42 No Communications 43 No Pneumo Reading 4 4 No Air to the Diver 5 0 Appendix 5 1 Emergency Procedures 5 2 Diver Line Pull Signals 5 3 Communications Wiring Schematics 54 Exploded Views amp Parts Listz 5 5 Dive Log Master Sheet Page 10 10 11 12 12 12 13 14 14 14 15 15 16 16 16 17 17 18 18 19 19 19 20 20 24 Kirby Morgan Air Control System 5 with no communications Kirby Morgan Air Control System 5 with communications KMACS 5 MANUAL Section 1 0 GENERAL INFORMATION 1 1 DEFINITIONS The following terms may be unfamiliar to the reader They are defined as they relate to this manual and diving All parts locations are referenced by LETTER on the diagram Figure 5 Page 8 KMACS 5 Kirby Morgan Air Control System 5 The Trademark name of the device this manual describes The KMACS 5 contains all of the components necessary to properly control and monitor surface supplied air dives Included in the KMACS 5 is atwo way voice communicator fo
44. system Battery Performance 20 hours of continuous use between charges in 4 wire mode Charger Will accept external 12 volt source Communicator Power Output 8 watts Communicator Frequency Response 600 to 12 000 HZ Remote Operation Capability Yes with optional unit Direct Recording Capability Yes 1 4 GENERAL DESCRIPTION Only equipment certified and tested according to EN 250 E DIN 58 642 may be used with the KMACS 5 when conducting diving operations in European EC compliant countries The KMACS 5 components are housed in a durable polyethylene case However caution should be used in transporting the KMACS 5 Rough handling will rarely cause damage to the case but it is possible to damage the calibrated pneumo gauges and or KMACS 5 MANUAL the electronic components The KMACS 5 should be treated as you would any expensive life support equipment 1 4 1 BREATHING AIR SUBSYSTEM The diver s breathing air subsystem starts with the supply tank yokes K and connects to the diver s supply manifold The high pressure hoses with the yokes are stored for transit by connecting them to the posts on the panel inside the lid of the KMACS 5 The knurled knobs on the yokes should be tight ened until just snug Excessive force should not be applied 1 4 2 PRINCIPLE OPERATING FEATURES l DIVE CONTROL PANEL A The panel is the main frame to which the functional components are mounted In addition the compo
45. th plastic tape to identify each individual hose This action will not only serve to make it easier to connect the hoses but will also serve to differentiate between hoses for purposes of inspection or repair A standby diver should always be equipped and ready to go to the diver s aid whenever a surface supplied diver is working in the water Generally it is not necessary for more than one diver to be in the water at a given time when using surface sup plied gear However a standby diver is considered essential for safe surface supplied operations The standby diver can be either a scuba diver or another hose supplied diver since the KMACS 5 provides enough air for two hose supplied divers In contami nated water diving operations however both divers must be equally equipped with a vulcanized rubber dry suit dry gloves and Kirby Morgan dive helmet equipped with either a double exhaust system or the new TriValve exhaust system CAUTION Contaminated water diving operations are very hazardous They should not be attempted without specialized training procedures and equipment Remove the protective caps from the outlets of the manifold G on the console Connect the diver s umbilical hose fittings air supply hose and pneumo to the KMACS 5 Remove the end caps from the hoses themselves and while firmly holding the end of the hose blow out the lines before connecting the 9 KMACS 5 MANUAL hoses to the mask or
46. tlet fittings on the KMACS 5 must be capped prior to storage 2003 KMDSI Document 041112001 KMACS 5 MANUAL 2 13 COMPLETION OF DIVING OPERATIONS Immediately following the completion of diving operations the dive station should be disassembled and the KMACS 5 protected from the weather Both high pressure and low pressure air supplies should be turned off at their source Bleed the air from the diver s umbilical s by opening the free flow valve s on the diver s mask helmet s Disconnect the mask helmet s from the umbilical and the umbilical from the KMACS 5 Unplug the communications connectors and turn off the com municator R Plug both ends of the hose and cap the outlet manifold G nipples on the KMACS 5 to prevent foreign matter from entering either Open the bleed valves on the HP yokes S to allow any remaining air to vent and replace the yokes on their storage posts Disconnect the low pressure air source if used and cap the low pressure inlet N to prevent foreign substances from entering the KMACS 5 If the KMACS 5 has been used on the ocean the panels should be wiped down with a clean rag dampened with fresh water The O ring seal U on the case may be periodically treated with Armor All or other rubber protection Place the KMACS 5 in a dry area and recharge the communications Refill any high pressure cylinders scuba used during diving operations and store them in a secure location 15
47. ts or head cushions Any defect of the product in workmanship or material covered by this warranty discovered within ninety 90 days from the date of purchase must be promptly communicated in writing to the nearest authorized KMDSI dealer or if no such dealer in the buyer s country contact KMDSI directly at 805 928 7772 No Product returns will be accepted by KMDSI without a returned merchandise authorization RMA number from KMDSI Upon receipt of the RMA from KMDSI the buyer should return the defective Product or part freight prepaid to an authorized KMDSI dealer or the KMDSI plant as directed by the RMA KMDSI will repair or replace the Product at no charge within a reasonable time as it deems necessary This warranty is null and void if 1 The Product is not registered with KMDSI within ten 10 days of purchase or 2 The Product has not been properly serviced and or maintained according to KMDSI factory recommended procedures described in the manual or Product updates have not been performed as recommended by KMDSI or 3 Unauthorized attachments or modifications have been made to the Product or 4 The Product has been used for purposes other than those for which it was designed or otherwise has been abused misused or subjected to unusual conditions or the Productis intended service has been exceeded EXCEPT AS SPECIFICALLY PROVIDED HEREIN THERE ARE NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO
48. ull prior to diving Load the regulator on the KMACS 5 using the regulator adjustment knob H Observe the umbilical hose pressure B which should be set at 150 psi 10 3 bars over top side pressure or 165 psi 11 5 bars The regulator used in the KMACS 5 is a non vent ing regulator If the regulator has been left set at a higher pressure setting than is presently desired the operator must turn the regulator adjustment knob H clockwise and vent air from the system by bleeding either the pneumo system or diver s breathing apparatus As the diver descends the KMACS 5 operator should increase the regulator setting so that the 10 umbilical pressure is always 150 psi 10 3 bars over the pressure at the diver s depth Consult the table below for approximate pressure settings TABLE 1 Suggested Regulator settings for the KMACS 5 Depth fsw Pressure Optimal Minimum 0 14 7 psia 150 psig 150 psig 33 29 4psia 165 psig 150 psig 66 44 1 psia 180 psig 150 psig 99 58 8 psia 195 psig 160 psig 132 73 5 psia 210 psig 175 psig 165 88 2 psia 225 psig 190 psig 198 102 9 psia 225 psig 205 psig TABLE 1 Metric Suggested Regulator settings for the KMACS 5 Depth Meters Pressure Optimal Minimum 0 1 bar 10 3 bars 10 3 bars 10 2 bars 11 4 bars 10 3 bars 20 3 bars 12 4 bars 10 3 bars 30 4 bars 13 4 bars 11 0 bars 40
49. vailable a low pressure compressor should be used as the primary air supply and scuba cylinders should be used as a backup or reserve air source CAUTION Low pressure compressors used for breathing air should be specifically designed for diving Paint compressors or similar equipment are unacceptable for diving applications Contact KMDSI for a list of equipment manufacturers who supply compressors with breathing quality air DANGER If a low pressure compressor is used the intake must be at a sufficient distance from and upwind of the exhaust If exhaust gas is sucked into the intake the diver will suffer from carbon monoxide poisoning This can be fatal 2003 KMDSI Document 041112001 KMACS 5 MANUAL Prior to connecting the low pressure hose to the KMACS 5 the deck whip should be flushed with air to make sure no foreign matter is in the hose Con nect the deck whip to the low pressure compressor and while firmly holding the end of the hose start the compressor and flow air through the deck whip for at least one minute Attach the low pressure hose to the low pressure inlet fitting N and screw the fitting down finger tight While using one wrench to hold the low pressure inlet fitting tighten the hose fitting with a second wrench Do not use excessive force as this will only damage the fitting and cause it to leak 2 4 CONNECTING DIVER S HOSES TO THE KMACS 5 Each diver s umbilical should be color coded wi
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