Dive Rite O2ptima eCCR User Manual
USER MANUAL
USER MANUAL
USER MANUALUSER MANUAL
March 2018 – Rev A
www.diverite.com
This is the user manual for the Dive Rite O2ptima eCCR rebreather.
This user manual is proprietary and copyright Lamartek, Inc. 2018. It may not be reproduced, changed,
or distributed without authorization from Lamartek, Inc.
All information contained in this manual has been carefully reviewed and is believed to be accurate,
however it is subject to change. Rebreather technology is constantly and rapidly evolving. Please check
www.diverite.com to ensure that you have the latest version of this manual.
Companies and/or product names cited in the manual are trademarks belonging to their respective
companies.
The O2ptima is manufactured in the USA by:
Lamartek, inc. dba Dive Rite
175 NW Washington Street
Lake City, FL, 32055 USA
Phone (386) 752-1087
www.diverite.com
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General Safety Statements and Warnings
DO NOT use the O2ptima without successfully completing an O2ptima
specific training program.
DO NOT use the O2ptima without reading and understanding this manual
in its entirety.
Reading this user manual DOES NOT replace unit specific training. This
manual does not provide directions for diving with closed circuit rebreather
equipment. This manual is only intended to be a guide for the proper
maintenance, setup, operation, and basic service of the O2ptima
rebreather.
As with any piece of equipment, this rebreather will eventually fail. Even
careful maintenance, assembly, and testing will not prevent this from
happening. It is possible that any part of this unit may fail at any time.
Because of this, it is essential that a separate, independent bailout system
be taken by the diver on every dive. The bailout system must be configured
to allow safe termination of the dive and return to the surface in the event
of a malfunction at any point during the dive.
All components of the rebreather must be in good working order and be
carefully maintained, assembled, and tested to reduce the risk of failure.
Participation in rebreather diving can result in serious injury or death.
These risks can be reduced, but never eliminated.
Knowledge and training are the best tools for avoiding accidents.
Rebreather diving is a physically as well as mentally demanding activity.
If you do not have adequate training, equipment, physical conditioning, and
proper mind-set, do not get in the water.
As the diver, YOU have the final responsibility for your own actions and
safety while using this rebreather.
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Table of Contents
General Safety Statements and Warnings .................................................................................................. 3
Introduction .................................................................................................................................................. 7
Design Philosophy ........................................................................................................................................ 7
System Overview .......................................................................................................................................... 8
The Breathing Loop ...................................................................................................................................... 9
Component Features & Functions ............................................................................................................. 10
Counter Lungs ................................................................................................................................ 10
Breathing Hoses & Fittings ............................................................................................................. 10
Divesoft BOV + ADV + MAVs .......................................................................................................... 10
Overpressure/Dump Valve ............................................................................................................ 11
Scrubber Canister ........................................................................................................................... 12
Scrubber End Cap & Water Trap .................................................................................................... 12
Electronics Head ............................................................................................................................ 12
Oxygen Sensors .............................................................................................................................. 13
Controller ....................................................................................................................................... 14
Electronics/Battery Canisters......................................................................................................... 14
HUD ................................................................................................................................................ 15
Regulators, Hoses, & Gauges ......................................................................................................... 15
Cylinders & Valves .......................................................................................................................... 16
Stand .............................................................................................................................................. 16
Cover .............................................................................................................................................. 17
Harness .......................................................................................................................................... 17
Air Cell ............................................................................................................................................ 17
Micropore ExtendAir Cartridge Overview ................................................................................................. 19
Assembling the O2ptima ............................................................................................................................ 21
Importance of Checklists................................................................................................................ 21
Gas Analyzation .............................................................................................................................. 21
Installing the Cylinders and Regulators ......................................................................................... 21
How to Install a Micropore ExtendAir Cartridge ............................................................................ 22
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How to Pack the Scrubber ............................................................................................................. 23
Installing the Scrubber Assembly ................................................................................................... 26
Installing the Electronics Head ....................................................................................................... 27
Installing the Scrubber End Cap & Water Trap .............................................................................. 28
Mounting the Electronics/Battery Canisters ................................................................................. 30
Installing the Air Cell & Harness ..................................................................................................... 31
Installing the Cover ........................................................................................................................ 33
Installing the Loop Hoses ............................................................................................................... 33
Basic Operation & Use ............................................................................................................................... 35
Harness Adjustment ....................................................................................................................... 35
Adding Trim Weights ..................................................................................................................... 35
Oxygen Sensor Calibration ............................................................................................................. 35
BOV Operation ............................................................................................................................... 36
Breathing on the Loop ................................................................................................................... 37
Electronic vs Manual Operation .................................................................................................... 37
Diluent Injection............................................................................................................................. 38
Servicing, Maintenance, & Cleaning .......................................................................................................... 38
Post Dive Procedures & Cleaning ................................................................................................... 38
Oxygen Sensor Care ....................................................................................................................... 39
Oxygen Sensor Replacement ......................................................................................................... 41
Battery Replacement ..................................................................................................................... 43
Battery Recommendations ............................................................................................................ 44
Storage ........................................................................................................................................... 44
Annual Service ............................................................................................................................... 45
Recommended Care Products ....................................................................................................... 45
Technical Specifications ............................................................................................................................. 45
Revisions & Changes in Documentation .................................................................................................... 46
Appendix I: Checklists ............................................................................................................................... 47
Assembly Guide Checklist .............................................................................................................. 48
Survival Checklist ........................................................................................................................... 49
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Pre-flight Checklist ......................................................................................................................... 49
Post Dive Checklist ......................................................................................................................... 50
Appendix II: Galvanic Oxygen Sensors Applied to Closed Circuit Rebreathers
by Analytical Industries, Inc. .............................................................................................................. 51
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Introduction
Congratulations on your purchase of the O2ptima rebreather! First produced in late 2005, the O2ptima
has been a leader in the rebreather market for over a decade. During that time it has been used for
cutting edge exploration and world class expeditions all over the planet. Dive Rite has made a strong
commitment to ensuring that it is one of the most reliable, capable, and high performing rebreathers on
the market. The O2ptima design continues to evolve as refinements are made and new technology
becomes available. We are certain that this unit will provide you with many unforgettable hours
exploring your underwater world.
Design Philosophy
The design parameters for the O2ptima were simple:
Keep the breathing loop as short as possible
Use proven, state of the art electronics
Be fully compatible with the Micropore ExtendAir cartridge
Maintain a rugged and durable package in the smallest profile possible
These parameters were originally chosen in order to produce a rebreather ideally suited to underwater
cave exploration. The unique challenges of the cave environment demanded a unit that was as safe and
reliable as possible while maintaining a minimal profile. The end result was a rebreather that is not only
highly suitable for cave diving, but also any other type of technical diving where a direct ascent to the
surface is not always possible.
By utilizing a horizontally mounted scrubber canister behind the divers head, the breathing loop was
kept as short as possible. This helps to create the lowest possible work of breathing and allows the use
of smaller diameter loop hoses. This in turn increases comfort and reduces diver fatigue. Mounting the
scrubber canister at the highest point of the loop has the additional advantage of reducing the likelihood
of water entering the scrubber. This, combined with the use of the Micropore ExtendAir cartridge,
greatly reduces the possibility of a “caustic cocktail.”
The O2ptima now utilizes Shearwater electronics for their proven and unparalleled reliability and
functionality.
At Dive Rite, we understand that one size does not fit all, so in addition to the standard O2ptima
features there are a number of options to ensure a proper fit for any diver and mission. Contact Dive
Rite or visit www.diverite.com for more details.
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System Overview
The O2ptima is an electronically controlled, constant PPO2, fully closed circuit rebreather (eCCR). It has
built-in decompression calculation and mixed gas capabilities. The following features come standard on
the unit:
Back mounted counterlungs with 6.5 Liter loop volume
Redundant Shearwater DiveCAN electronics including heads-up display (HUD) and Petrel 2
controller
Dual use scrubber canister design that can be used with Micropore ExtendAir cartridges or
packed with loose CO2 absorbent
Divesoft BOV + ADV + MAVs standard (all-in-one Bail Out Valve with Automatic Diluent Valve
and Manual Add Valves for O2 and diluent) DSV optional
Dual water traps
Regulators and hoses
(4) AI R22 Oxygen Sensors
CCR XT air cell utilizing abrasion resistant SuperFabric
Kydex cover for abrasion protection
Stainless Steel and StarBoard frame and stand
AL 20 oxygen and diluent cylinders with valves
Dive Rite TransPac Harness (Transplate harness optional)
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The Breathing Loop
The O2ptima incorporates a back mounted, dual counterlung design. The breathing loop consists of the
BOV or DSV, breathing hoses and hose fittings, inhalation and exhalation counterlungs, scrubber
canister, canister end cap, and electronics head. Gas flows in a clockwise direction—from the left
shoulder—to the diver—to the right shoulder.
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Component Features and Functions
Counterlungs
The O2ptima uses two detachable back mounted
counterlungs. The counterlung position keeps
them as close to the diver’s lung centroid as
possible providing excellent breathing
characteristics in a variety of diver positions. They
are adjustable for optimal positioning and easily
unzip from the center panel to remove for cleaning
and inspection.
The counterlungs consist of an abrasion resistant
outer bag and a removable welded polyurethane
inner bladder. The bladder is accessible through a
zipper on the side of each counterlung.
The back side of the counterlungs attach directly to the scrubber canister. The breathing loop hoses
attach to the front of the counterlungs using threaded connections.
The exhalation counterlung has an overpressure/dump valve located at the bottom of the lung. An
internal water trap is located in the bottom of the exhalation counterlung to make de-watering the loop
easy.
Breathing Hoses & Fittings
The hose diameter and lengths have been specifically chosen to
provide the best balance of comfort and low work of breathing. The
hose lengths are some of the shortest in the industry due to the
location of the behind-the-head scrubber canister. This not only keeps
the work of breathing low, but also reduces drag and uncomfortable
vibrations occasionally encountered with excessive hose lengths when
scootering or swimming against strong flow.
The hoses have threaded fittings attached to the counterlung ends.
Each fitting utilizes a double O-ring seal to help ensure loop integrity. The hoses are 15 inches in length
standard. Other sizes are available for improved fit on smaller divers.
Divesoft BOV + ADV + MAVs
The Divesoft BOV (Bail Out Valve) comes standard on the O2ptima.
(The Dive Rite DSV is optional.) The BOV features an integrated ADV
(Automatic Diluent Valve) and manual oxygen and diluent addition
valves.
The BOV and ADV functions are controlled by the knob on the front
of the BOV. With the knob turned horizontally, the BOV is in closedcircuit mode and you are breathing “on the loop”. Bailing out is
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accomplished by turning the knob 90 degrees so that is vertical. This closes the loop and activates opencircuit mode using the integrated 2nd stage. The BOV is plumbed to the onboard diluent tank. Because of
the small size of the tank, the BOV does not eliminate the need for a separate, independent bailout
system.
The integrated ADV can be activated or deactivated by pressing the button on the knob and rotating the
knob 180 degrees. The ADV only functions in closed circuit mode and does not affect open circuit
operation, i.e. when the knob is vertical the open circuit function is the same even if it is turned 180
degrees.
The ADV uses a built in demand valve that is activated by negative loop pressure against a diaphragm in
the same manner as a standard second stage regulator. The ADV design feeds diluent gas directly to the
BOV. This provides a fast, hands-free method of receiving a known breathable gas as well as supplying
additional gas to increase loop volume.
The BOV should be turned to open circuit mode (vertically) when on the surface or during a bailout
procedure to prevent water from entering the loop.
The integrated Manual Addition Valves (MAVs) are located on the front of the BOV. The green button on
the right side of the diver’s mouth is the oxygen addition button, and the black button on the diver’s left
is the diluent addition button. Low pressure supply hoses are attached to the threaded fittings located
next to each button.
Manual diluent addition is injected just upstream of the BOV to provide an immediate known breathable
gas mix. Manual oxygen addition is injected downstream of the BOV so that it must travel through the
loop before being inhaled. This prevents oxygen spikes to the diver and ensures that the gas mixture is
homogenous before traveling over the oxygen sensors and being inhaled.
The BOV uses a snap ring system to attach the hose fittings to the BOV body. To remove the fittings for
cleaning or inspection of the mushroom valves, simply remove the wire snap ring from its locking groove
and gently pull the fitting away from the body. Pull straight out and avoid twisting the fittings.
If the BOV is unused for a period of time, the knob may become difficult to turn. This is normal and is
due to the lubricant taking a set. Turning the knob back and forth several times before the dive will
redistribute the lubricant and ensure that the knob is smooth and easy to turn.
Overpressure/Dump Valve
The O2ptima uses a special loop overpressure valve (OPV) located on
the front side of the exhalation (right) counterlung. A specific spring is
used to optimize the cracking pressure for rebreather counterlung use.
Do not replace with a standard drysuit exhaust valve as they can have a
much higher cracking pressure which can lead to lung overexpansion
injuries.
This valve will normally be operated in the open position (turned fully counter-clockwise). Divers with a
large tidal volume may find that they need to close the OPV slightly in order to maintain proper loop
volume. The valve can also be manually opened by pressing on the valve. The valve is screwed into a
welded flange on the counterlung inner bladder.
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During an ascent, the gas in the loop will expand, increasing buoyancy and slightly increasing the
breathing effort. Even though the maximum volume in the O2ptima’s breathing loop is relatively small,
it is important to set the OPV properly so that buoyancy shifts will be kept to a minimum without any
diver action.
Scrubber Canister
The scrubber canister contains the scrubbing media that removes CO2 from
the breathing loop. The O2ptima uses an axial style scrubber canister and can
be used with either Micropore ExtendAir cartridges or loose packable CO2
absorbent.
Assembly is slightly different depending on which scrubber media is used. The
wave spring and top plate with screen are not used when using an Extendair
cartridge. The finger nut is reversible. It is used in one direction when packing
loose CO2 absorbent and is flipped over when using Extendair cartridges. See
the How to Pack the Scrubber section for more information on properly
seting up the scrubber canister.
Scrubber End Cap & Water Trap
The scrubber end cap contains a snap-in water trap in the shape of a
cone. This shape prevents excess water from entering the scrubber
canister regardless of the diver’s position in the water.
The shape of the cone also assists in mixing the exhaled gas with
added oxygen into a homogenous blend. The result is even gas flow
through the scrubber canister and accurate readings by the oxygen
sensors.
The end cap has an O-ring and a flat seal that seals against the scrubber canister and an additional Oring that seals the water trap. These O-rings and seal require cleaning and maintenance and should be
replaced on an annual schedule at a minimum.
The end cap attaches to the scrubber body by aligning the marks on the cap and body, pressing the cap
into place, and the turning the cap clockwise until the mark is aligned with the “locked” position
marking.
Electronics Head
The electronics head contains the solenoid, oxygen sensors (4),
sensor disk, sensor wiring harness, and oxygen injection premix
tube. These components are responsible for analyzing the oxygen
content of the breathing gas and injecting oxygen as needed.
The controller (Shearwater DiveCan system) interprets the
readings from the oxygen sensors and makes decisions on when to
add oxygen via the solenoid.
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The injected oxygen travels through the premix tube to the exhalation side of the scrubber canister
where it is blended with the loop gas before going through the scrubber material. This reduces O2
“spikes” by ensuring that the gas mixture is homogenous before passing over the oxygen sensors.
Oxygen Sensors
The O2ptima uses four oxygen sensors. These sensors are threaded into
the sensor disk mounted inside the electronics head. Dive Rite uses
Analytical Industries, Inc. type R22D sensors.
Oxygen sensors have a finite life. They are a consumable item and must be
replaced at regular intervals. They are typically replaced during the annual
service, but may need to be replaced prior to this.
The sensor labeling includes a “Sell by” date of 4 months after
manufacture and a “Do not use after” date of 16 months after
manufacture. Sensors must not be used after this date even if they appear
to still be functioning correctly.
Four sensors are used to provide redundancy and the ability to cross check their values against each
other to determine if a sensor is not reading correctly. Sensors 1 and 2 are shared between the
controller and the HUD. Sensor 3C is only connected to the controller, and sensor 3H is only connected
to the HUD. By comparing sensor readings between the HUD and the controller it is easy to determine if
a sensor is not reading correctly.
If sensor values 1, 2, and 3C do not agree, the controller automatically uses a voting logic to make an
educated guess of which sensor is not reading correctly. Having an independent “4th sensor” display on
the HUD allows the diver to independently verify the controller’s voting logic.
Beginning in Q1 of 2018 Dive Rite will begin shipping all new rebreather units with digital O2 cells. These
new sensors from Analytical Industries operate as traditional analog sensors but provide several benefits
including:
Automatic warning for use of sensors past expiry date
Advanced notification for sensor ordering/replacement
Monitors for early sensor failure by recording and observing calibration results
All Dive Rite rebreathers produced after September 2017 are compatible with the new digital sensors.
For more information on oxygen sensors, see the Oxygen Sensor Care section and also Appendix II:
Galvanic Oxygen Sensors Applied to Closed Circuit Rebreathers by Analytical Industries, Inc.
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Controller
Dive Rite has chosen to use Shearwater electronics to control
and monitor the O2ptima. The controller is a DiveCAN Petrel 2
handset. The controller allows diver control of the PPO2
setpoint and PPO2 monitoring of oxygen sensors 1, 2, and 3C.
It also functions as a full featured dive computer displaying
depth, dive time, decompression information, and other
important dive information.
It is recommended to use a second standalone dive computer
with decompression information as a backup in addition to the
controller.
For detailed information on the DiveCAN Petrel controller, please see the Shearwater Petrel DiveCAN
Rebreather Controller Model Operations Manual.
Electronics/Battery Canisters
There are two external electronics & battery canisters on the O2ptima.
They are mounted behind the air cell in elastic sleeves on each side of
the tanks.
The canister on the (diver’s) left side of the unit contains the SOLO
(SOLenoid and Oxygen) electronics board and battery. The battery is a
standard 9 volt battery that powers the SOLO board as well as the
oxygen solenoid. The Petrel 2 controller handset has its own internal
battery and does not rely on the 9 volt.
The canister on the (diver’s) right side of the unit contains the OBOE
(Oxygen BOard Electronics) board and battery. The OBOE board
controls the HUD. The battery is a standard AA type. This battery only
powers the OBOE board and HUD.
By locating the batteries in these external compartments, they are completely isolated from the head
and the breathing loop. This is important because as batteries age or are damaged they can release toxic
chemicals. Obviously this is not something you want to have in your breathing gas.
The batteries are accessed via a threaded cap on the end of each canister. The caps are double O-ring
sealed to ensure water integrity. These O-rings must be inspected and maintained when the canisters
are opened to reduce the chance of flooding. See the Battery Replacement section for additional
information.
The electronics canisters connect to the controller and HUD using wet pluggable, waterproof
connectors. Regular lubrication of the inside of these connectors with a light coating of silicone grease
such as Molykote 111 will increase their usable life.
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HUD
The O2ptima includes a Shearwater HUD (Heads-Up
Display). The HUD displays the PPO2 readings of oxygen
sensors 1, 2, and 3H. These values are displayed using
three columns of LEDs. Each column represents a different
sensor. The colored LEDs flash using a modified Smither’s
code to convey the PPO2 values. A “color blind” mode is
also available. The HUD can be setup for right or left eye operation. The HUD can be turned on manually
by pressing the button on the end of the housing. There are also wet contacts which automatically turn
the unit on in case it was not turned on prior to the dive.
Your life depends on always knowing the PPO2 in the breathing loop while diving a rebreather. Do not
make assumptions about how the HUD displays PPO2 values. Previous versions of the HUD used
different blink patterns. Refer to the latest Shearwater HUD User Manual for a detailed description of
the HUD blink pattern and operation.
The Shearwater NERD (Near Eye Remote Display) is also available as an option.
(https://www.shearwater.com/products/nerd/) The NERD replaces the standard HUD providing a
numerical readout of the 3 sensor PPO2 values and also serving as a backup computer with fully
redundant decompression and dive information.
Regulators, Hoses, & Gauges
Dive Rite first stages with DIN connectors are used for both
diluent and oxygen supply. First stage intermediate pressure
(IP) is set to 85 psi for the oxygen regulator and 140 psi for
the diluent regulator. The oxygen regulator IP must be set no
higher than 85psi due to the maximum rated pressure of the
solenoid.
Each regulator is connected to a manifold which supplies gas
to the rest of the rebreather. Over-pressurization valves
(OPVs) are installed in the manifolds for safety. Because there are no second stages installed there is no
way for excess pressure to be released. The over-pressurization valve must be in place in the event of a
first stage high pressure seat failure to prevent high pressure gas from reaching all of the downstream
components.
An OPV that is releasing pressure indicates a malfunction and the dive should be terminated
immediately. The OPV should be inspected for bubbling during the S-drill at the beginning of the dive.
The first stages need to be serviced annually by an Authorized Dive Rite service center or directly by Dive
Rite. Call Dive Rite directly (1-800-495-1046) or email support@diverite.com to schedule service.
Braided nylon Airflex LP hoses are used for gas supply throughout the O2ptima. Green hoses designate
oxygen, and black hoses designate diluent. Airflex hoses are flexible, yet tough. The hose lengths are
optimized for streamlined routing.
High quality brass and glass SPGs are included to monitor oxygen and diluent tank pressures. BAR
gauges are used to help simplify gas consumption calculations.
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Cylinders & Valves
The O2ptima is supplied with two aluminum 20 cf (3L) cylinders—
one for oxygen and one for diluent. Left and Right hand valves are
included. One of the valve handwheels is green to designate oxygen
use.
The cylinders are held in place with cam straps and Velcro straps. No
additional cylinder mounting hardware is necessary.
The AL20 cylinders are a good compromise between weight and gas
volume. They are an excellent choice for general rebreather diving.
Other recommended cylinders that will work well with the O2ptima
are:
Aluminum 13 cf (2L)
Steel AA LP13 cf (2L)
Steel AA LP15 cf (2L)
Steel AA LP27 cf (4L)
Steel AA HP32 cf (4L)
Divers should select cylinders based on their dive duration, travel logistics, and buoyancy characteristics.
Stand
The O2ptima uses a hybrid stand consisting of a light weight, laser cut
stainless steel backplate attached to a machined StarBoard plastic
brace and foot.
The backplate is contoured to sit close to your back like a set of
doubles. Slots in the plate accommodate cam straps to attach the
cylinders.
StarBoard is a high impact, marine grade polymer. It is very durable
and will flex under a load without breaking. StarBoard also has
excellent buoyancy characteristics. It is very close to neutrally buoyant
in fresh water. The foot is very boat friendly and has integrated
mounting rails for accessories. Hand cut-outs on the bottom of the
foot make it easy to carry and maneuver the unit on land.
The scrubber canister mounts to the top of the backplate using a special rubberized cam strap to grip
the canister and prevent shifting. A StarBoard brace underneath the canister provides additional
stability.
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Cover
A Kydex cover protects the back of the unit from hazardous overhead
environments. It provides hard shell protection for the scrubber
canister, hoses, and cylinders. It also keeps the hoses and cords
tucked in, reducing drag and potential snag points.
The cover attaches with six plastic buckles—two on the top and two
on each side.
Slots at the top and sides of the cover are ideal for adding pockets to
hold additional ballast weight, if necessary.
Holes on the sides of the cover allow optional mounting of Dive Rite’s
QRM receivers for quick and secure attachment of accessories such as
a battery canister or small drysuit inflation bottle.
Custom covers are also available. Contact Dive Rite directly for more
information.
Harness
The O2ptima comes standard with either a TransPac XT or TransPlate XT
harness, but can be used with any standard technical style backplate
with 11 inch bolt-hole centers.
Modeled after a mountaineer’s backpack style harness, the TransPac
incorporates a soft backplate and wrap around hip pads and waist belt
to evenly distribute weight across the hips and back. Ergonomic
shoulder pads and contoured lumbar support pad provide additional
comfort. Shoulder, hip, and crotch strap D-rings provide multiple
locations for attaching accessories. Quick release buckles on the chest
strap and at the bottoms of the shoulder straps make harness removal
fast and easy. TransPacs are available in a full range of sizes and are
easily adjustable to all body types.
The TransPlate harness is a hybrid design for divers who prefer a
traditional metal backplate but want the support of a backpack style harness for better weight
distribution. When used with a 6 pound steel backplate, divers can minimize or remove additional
ballast weight.
Air Cell
The custom designed CCR XT wing comes standard on all O2ptimas. Providing 40 lbs of lift, the CCR XT
wing was designed specifically for use with the O2ptima.
A 360 degree flow-through design allows gas to flow freely as the diver moves in the water. The wide
center section puts the lift to the outside edges of the unit and prevents raising it off the center of the
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