PP-OM-794 Rev1
OM338
OPERATING AND MAINTENANCE
MANUAL
for the
TWO DIVER, SURFACE CONTROL,
HP/LP AIR IN TRANSIT CASE,
HINGED LID
(Part No: PP033AA)
(Intentionally Blank)
OM338 i
PP-OM-794 Rev1 Approval Sheet
APPROVAL SHEET
DIVEX
MANUAL NUMBER: OM338
ADVITIUM NUMBER: PP-OM-794
DOCUMENT TITLE: Two Diver, Surface Control, HP/LP Air in Transit Case, Hinged Lid
REV DATE BY CHECK APP COMMENTS
0 11 October 2006 Christine Bain Original Issue
1 28 August 2012 Debbie Allan Simon Bryce Mark Stevens ECN:15335
2
3
4
5
6
7
ORIGINAL ISSUE DATE: 11 October 2006
ORIGINAL DOCUMENT BY: Christine Bain
CHECKED BY:
APPROVED BY:
ii OM338
Approval Sheet PP-OM-794 Rev1
(Intentionally Blank)
OM338 iii
PP-OM-794 Rev1 Table of Contents
CHAPTER 1 - SAFETY NOTICE .................................................................................................... 1
CHAPTER 2 - TECHNICAL SPECIFICATION ...............................................................................3
CHAPTER 3 - GENERAL DESCRIPTION .....................................................................................5
CHAPTER 4 - INSTALLATION ......................................................................................................7
CHAPTER 5 - PRE-DIVE CHECK .................................................................................................. 9
CHAPTER 6 - OPERATION .........................................................................................................11
CHAPTER 7 - PNEUMO OPERATION ........................................................................................ 13
CHAPTER 8 - CYLINDER CHANGE OVER ................................................................................15
CHAPTER 9 - AUXILIARY LOW PRESSURE INLET .................................................................17
CHAPTER 10 - LOW H.P. WARNING .........................................................................................19
CHAPTER 11 - MAINTENANCE .................................................................................................. 21
CHAPTER 12 - MAINTENANCE SCHEDULE - 6 MONTHLY ..................................................... 23
CHAPTER 13 - APPENDICES .....................................................................................................25
TABLE OF CONTENTS
iv OM338
Table of Contents PP-OM-794 Rev1
(Intentionally Blank)
OM338 1
PP-OM-794 Rev1 Chapter 1
CHAPTER 1 SAFETY NOTICE
1.1 This unit must only be operated by suitably qualified personnel.
1.2 Read the instructions thoroughly before operating this equipment.
1.3 Only genuine manufacturer's spare parts may be used and the substitution of parts
from other manufacturers will invalidate the warranty and may cause damage to the
equipment. When ordering spare parts, please quote the serial number of the
assembly and the part numbers required.
1.4 This panel has been designed to supply air to breathing apparatus, for diving, and
the manufacturers will not be responsible for its use for any other purpose.
1.5 The user must make him/herself familiar with and observe national legal
requirements concerning the safe use and maintenance of the equipment. The
manufacturers ensure that the equipment complies with such regulations on
delivery but it remains the responsibility of the user to comply with the legal
requirements in use.
1.6 It is the responsibility of the user to establish the flow and pressure of air required for
the breathing apparatus to be employed and to ensure that the supply is adequate
for the use envisaged. This responsibility includes the provision of an adequate
reserve air supply.
CAUTION
COMPRESSED AIR IS POTENTIALLY DANGEROUS THIS EQUIPMENT
MUST BE USED CORRECTLY MISUSE COULD CAUSE SERIOUS
INJURY.
2 OM338
Chapter 1 PP-OM-794 Rev1
(Intentionally Blank)
OM338 3
PP-OM-794 Rev1 Chapter 2
CHAPTER 2 TECHNICAL SPECIFICATION
Inlet Pressure L.P. 15 BAR maximum (220 psi)
H.P. 350 BAR maximum (5075 psi)
Hose Connections LP inlet 3/8" BSP male
HP inlet 1/4" BSP male
Diver supply 3/8" BSP male
Pneumo 1/4" BSP male
Overall External Dimensions Length 730mm (29”)
Width 610 mm (24”)
Height 380 mm (16”)
Weight approximately 40 kg (88lbs)
Pipework H.P. 8mm x 1mm stainless steel
L.P. 10mm x 1mm stainless steel
4 OM338
Chapter 2 PP-OM-794 Rev1
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OM338 5
PP-OM-794 Rev1 Chapter 3
CHAPTER 3 GENERAL DESCRIPTION
3.1 The DIVEX two-diver, Surface Control, H.P./L.P. air panel will supply low pressure
breathing air to two divers working simultaneously, to a depth of 60 metres in fresh
or salt water.
3.2 The panel contains four completely separate high pressure lines, two for each diver.
Non-return valves ensure that the air to one diver cannot be diverted to the other. As
a back-up, one L.P. inlet line is fitted, which can supply either diver with air.
3.3 Each diver's depth can be monitored using the pneumo gauges which measure the
hydrostatic pressure in an open ended hose from the panel to each diver.
3.4 The controls are packaged within a strong plastic transit case.
6 OM338
Chapter 3 PP-OM-794 Rev1
(Intentionally Blank)
OM338 7
PP-OM-794 Rev1 Chapter 4
CHAPTER 4 INSTALLATION
(Refer to Drawing PP33110S1
Using a high pressure air supply.
4.1 Ensure all on/off valves are in the OFF position.
4.2 Ensure the H.P. / L.P. regulator controls are turned fully anti-clockwise.
4.3 Connect the H.P. hose assembly to the high pressure air cylinders, ensuring that the
cylinder valves remain in the OFF position.
4.4 Connect the diver's air line from the umbilical to the diver’s L.P. outlet on the panel.
4.5 Connect the diver's Pneumo hose from the umbilical to the panel pneumo connection.
4.6 Connect the diver's end of the umbilical to the appropriate breathing apparatus.
8 OM338
Chapter 4 PP-OM-794 Rev1
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OM338 9
PP-OM-794 Rev1 Chapter 5
CHAPTER 5 PRE-DIVE CHECK
5.1 With all lines connected and the diver dressed in all his equipment but holding the
face/mask helmet, turn on the H.P. cylinder.
5.2 Turn on the H.P. inlet valve slowly (3).
5.3 Read the H.P. inlet pressure (4). Ensure that there is adequate cylinder pressure.
5.4 Use the H.P./ L.P. regulator (1) to set the correct L.P. pressure for the diver's breathing apparatus.
5.5 Slowly open the 1/4 turn diver supply outlet valve (2).
5.6 Confirm with the diver that an adequate air supply is being received at the mask/helmet.
10 OM338
Chapter 5 PP-OM-794 Rev1
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OM338 11
PP-OM-794 Rev1 Chapter 6
CHAPTER 6 OPERATION
6.1 The panel works automatically but the operator should continuously monitor the
H.P. / L.P. air supply and the L.P. supply to the diver (s).
6.2 When the diver is descending and ascending, the control panel operator may have
to adjust the H.P. / L.P. regulator (1) depending on the mask/helmet configuration.
6.3 Under conditions of very low ambient temperature or when using inadequately
filtered "wet" air, icing could occur within the H.P./L.P. regulator. This could be
indicated by fluctuating or falling low pressure as shown on the LP gauge (5). If any
signs of icing are noticed diving should be terminated immediately.
12 OM338
Chapter 6 PP-OM-794 Rev1
(Intentionally Blank)
OM338 13
PP-OM-794 Rev1 Chapter 7
CHAPTER 7 PNEUMO OPERATION
7.1 The divers’ depths can be read from the pneumo gauges (13).
7.2 Turn on the pneumo valve (6) to supply air to the pneumo hose in the umbilical and
allow the air to flow for enough time to ensure it is bubbling out of the open, diver
end.
7.3 When the air has bubbled out of the hose end, close off the supply valve (6) and
read the hydrostatic pressure (shown as diver depth) on the pneumo gauge (13).
7.4 The depth must be checked periodically using the above method, particularly if the
diver is changing depth whilst working. When his work is completed and the diver is
returning to the surface, the gauge will automatically read his decreasing depth
without the operator supplying more air to the pneumo hose.
14 OM338
Chapter 7 PP-OM-794 Rev1
(Intentionally Blank)
OM338 15
PP-OM-794 Rev1 Chapter 8
CHAPTER 8 CYLINDER CHANGE OVER
8.1 Slowly turn on the reserve air supply via the H.P. inlet valve (7). Confirm there is an
increase in pressure on the H.P. gauge (4).
8.2 Turn off the original air supply at the H.P. inlet valve (3).
8.3 Purge the H.P. hose to the cylinder to be removed. Disconnect the cylinder and
replace it with a charged H.P. air cylinder.
8.4 Slowly turn on the new air cylinder.
NOTE
Items 3 and 7 are identical and serve the same purpose. They are separately
identified here only to illustrate the cylinder changing procedure.
16 OM338
Chapter 8 PP-OM-794 Rev1
(Intentionally Blank)
OM338 17
PP-OM-794 Rev1 Chapter 9
CHAPTER 9 AUXILIARY LOW PRESSURE INLET
9.1 The panel has the facility for an auxiliary low pressure inlet. This low pressure air
supply must not exceed 15 Bar. To use, connect the supply hose to the L.P. inlet and
direct the supply to the appropriate diver using one of the red-handled auxiliary
valves (8).
NOTE
It is not advisable to use the L.P. supply for both divers at once as the deeper
diver could experience a shortage of gas.
18 OM338
Chapter 9 PP-OM-794 Rev1
(Intentionally Blank)
OM338 19
PP-OM-794 Rev1 Chapter 10
CHAPTER 10 LOW H.P. WARNING
10.1 The system comprises a battery pack (9), pressure switch, warning On/Off switch
(10), red warning LED (11) and a high frequency buzzer (12). During normal
operation, the On/Off switch (10) must be in the on position. The pressure switch is
set to operate when the H.P. supply pressure falls below 50 Bar. When this occurs,
the pressure switch illuminates the warning LED (11) and the buzzer (12) sounds
continuously. The panel operator will establish which H.P. supply is low by finding
the illuminated LED (11). The buzzer (12) may then be cancelled by switching the
warning switch (10) Off while supply cylinders are changed over. It is important that
the warning switch (10) is returned to the on position after completion of the cylinder
change.
20 OM338
Chapter 10 PP-OM-794 Rev1
(Intentionally Blank)
OM338 21
PP-OM-794 Rev1 Chapter 11
CHAPTER 11 MAINTENANCE
11.1 Very little maintenance is required and with the exception of the H.P. inlet valves (3
& 7) all components are factory assembled with no user serviceable parts.
11.2 Periodically inspect the panel for damage or signs of wear.
11.3 Check for air leaks by listening or by pressurising the panel, closing the valves and
observing any pressure drop on the gauges. If a leak is suspected, remove the
panel from its case and test for the leak with a liquid soap and water solution.
Tighten any pipe connections only with the panel de-pressurised.
11.4 General Instructions for the Removal of any Component
Depressurise the system. Remove panel from case. Undo nut unions and remove
the relevant piping. Remove the component. Repair or replace component. Remake
all threaded joints using Locite 542 Hydraulic Seal or equivalent. Ensure that all
mating surfaces and olives are clean. Do not over tighten the nut unions. Test for
leaks. Return panel to case.
11.5 H.P. Panel Valve. Refer to drawing U1011.
These can be serviced in situ. Remove rubber handle by releasing the retaining nut.
Unscrew the spindle nut and retract the spindle complete. Remove and inspect the
valve seat. If it is undamaged, refit, If damaged, renew. Clean all items with a high
quality industrial wiper. Re-assemble the valve, fitting a new Teflon spindle seal, O
Ring and Copper Washer. Lubricate with light a smear of Molybdenum-Disulphide
grease or any acceptable breathing air quality grease (e.g. Vaseline).
H.P. valve recommended spares (Service kit DD051201)
11.6 H.P. Non-Return Valve. Refer to drawing PP33004S1.
Test the HP non-return valves by pressurising the panel then disconnecting one H.P.
hose at a time and opening the corresponding valve checking for air loss from the
inlet connection. If there is any air escaping, the faulty non-return valve should be
replaced.
11.7 H.P. Regulator
Servicing must be carried out by an approved engineer, trained by the manufacturer
in the correct maintenance of the regulator (4). If no local approved engineer is
available, the units must be returned to DIVEX for service.
The only permissible routine service is to clean the filter, located between the regulator and the H.P. inlet.
22 OM338
Chapter 11 PP-OM-794 Rev1
Remove the panel from the case. Locate and remove the filter. Unscrew the end
pieces and remove the filter element. Clean and replace all items in reverse order.
Ensure spill valve exhaust port is kept open.
11.8 Gauges
These should be inspected on a regular basis to check for fluid loss. Also ensure
that the pointer returns to zero when the pressure is released. The gauges should
be calibrated in accordance with national regulations.
Damaged gauges should be replaced.
CAUTION
When replacing any components ensure that the previously noted
procedures regarding cleanliness, sealants and re-assembly of nut unions
are adhered to.
OM338 23
PP-OM-794 Rev1 Chapter 12
CHAPTER 12 MAINTENANCE SCHEDULE - 6 MONTHLY
12.1 Inspect lid and outer casing for damage. Check hinges and catches for correct
operation.
12.2 Remove H.P. Panel Valve. Disassemble as described in Section 11.5 Inspect. Wipe
clean with a high quality industrial wiper, lubricate with approved grease and reassemble.
12.3 Check for free movement of 90° Diver Outlet Valves, Pneumo Valves and L.P.
Isolator Valve. Section 11 for replacement.
12.4 Test H.P. Regulator by pressurising the system until the safety relief valve "blows" at
300 PSI. When reducing pressure (turning valve anti-clockwise) listen for the
release of air through the Spill Valve.
12.5 Inspect all gauges for leakage of fluid and check that the needle returns to zero
when the system is depressurized.
12.6 Pressurise complete system and listen for leaks.
24 OM338
Chapter 12 PP-OM-794 Rev1
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OM338 25
PP-OM-794 Rev1 Chapter 13
CHAPTER 13 APPENDICES
Drawing: PP33004S1 Fit-Out Schematic
PP33110S1 Diver Air Panel Assembly
U1011 H.P. Control Valve spare parts
26 OM338
Chapter 13 PP-OM-794 Rev1
(Intentionally Blank)
58
58
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48
38475
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19 19
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18
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38 5 1119 19
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5534
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38475
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28 35
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OR
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3131
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OR
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2020
TITLE
DIMENSIONAL TOLERANCES
MACHINING FABRICATION
NOTES
MATERIAL
DRAWING No.
PART No. PRODUCT / PROJECT No.
FINISH
REV
SHT OFSCALESIZE
DIVEX OWNS THE COPYRIGHT OF THIS DOCUMENT AND ANY DESIGN RIGHT HEREIN. IT IS SUPPLIED IN CONFIDENCE AND MUST NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT I S SUPPLIED AND MUST NOT BE REPRODUCED WITHOUT PERMISSION IN WRITING FROM THE OWNERS.
ALL DIMENSIONS SHOWN ARE IN MM (UOS)
ALL DIMENSIONS BEFORE PLATING (UOS)
REMOVE ALL SHARP EDGES AND BURRS
THIRD ANGLE
PROJECTION
PP
FIT-OUT SCHEMATIC,
SURFACE CONTROL PANEL
N/A
PP33004S1
A1 NTS 1 1
R04
DIVEX LIMITED
ENTERPRISE DRIVE
WESTHILL
ABERDEEN
AB32 6TQ
UNITED KINGDOM
REFER TO PARTS LIST
N/A
REV
DO NOT SCALE DRAWING
R01
ECN No BY DATE
DESCRIPTION
R00
AUTH. BY
ISSUED FOR MANUFACTURE - - -
R02
R03
R04
R05
R06
REFER TO ECN GR 11/10/06 RTW
RE-POSITION RELIEF VALVES GR 20/11/06 RTW
UPDATED TO SHOW L.P.
SUPPLY PRESSURE GAUGE
GR 09/04/09 RTW
BOM UPDATED JJM 13/09/11 MS
8865
6750
9342
14288
4
DENOTES CHANGES MADE AT THIS REVISION
4
4
ITEM PART No. DESCRIPTION QTY.
1 GP341HC GAUGE, DEP TH, 6" DIA, PB, 230FT/70M, 0.25% ACC 2
2 DD320003 GAUGE,63MM,CLAMP FIX,400B/6000PSI 1/4"BSP BK ENTRY 2
3 DD320007 GAUGE, 6 3MM, C LAMP, 25BA R/370P SI, BACK E NTRY 3
4 RP308 REG,3/8"NPT ,350BAR,2 OFF 1/4"NPT GA,0-30BAR OUT 2
5 PP032901 ADAPTOR, BUL KHEAD , 1 /4" N PT(M) X 1/4" NPT (F) 6
6 PP032902 ADAPTO R, BUL KHEAD , 10L TUBE X 3/8" NP T(F) 3
7 FP339 NUT, 10 L TUBE, S316 3
8 FP340 FERRULE, 10 L TUBE, S316 3
9 DD310312 VALVE, NEE DLE( N), P/M, 1/4" NP TF, BR ASS, WP 2 07BAR 2
10 VB214 VALVE,BALL, 3/8" BSP FEMALE, LG HANDLE, PAN EL MNT 2
11 DD360135 VALVE, RISING STEM, 1/4"NP TF, SOFT SEAT, WP 350BAR 4
12 VR208 VALVE,RELIEF, ATM DIST, 20.0 BAR, 1/4" N PT 2
13 FP202 TEE, F EMALE PI PE, 1/ 4" FN PT, BRAS S, WP2 20BAR 2
14 DD310384/1 TUBE, 10MM X 1. 0 W.T. ST.STEEL , /1M, SS 316 AS R EQ
15 DD310389/1 TUBE ,8MM X 1. 0 W .T. ST. STEEL, / 1M, SS 31 6 AS R EQ
16 DD400914 TEE , E QUAL, 10L 2
17 F28865 FILTE R, IN LINE, 1/4"FN PT, SS, WP 344BAR, N O ELEMEN T 2
18 DD310319 VALVE, CHECK/NON-R ETURN, 1/4" NPTF, SS, WP 413BAR 4
19 DD401087 ELBOW, STUD, 8S X 1/4" NPT M 12
20 DD401128 SEAL,BONDED, 1/4" BSP ST. STEEL, SELF CEN TRING 2
21 DD401073 EBLOW. STUD, 10L X 3/8" BSPT M 7
22 DD401075 ELBOW, STUD, 6L X 1/4" NPT M 8
23 PP032905 CROSS, 3 X 3/8" BSPT MALE, 1 X 1/8" NPT FEMALE 1
24 FJ203 CONNECTOR, MALE, 4-JIC X 1/4MNP T, BRASS, W P227BAR 2
25 DD400220 COUPLING, STRAIGHT, 6S 2
26 DD400820 COUPLING, GAUGE, 1/4" BSP X 6S STANDPIPE 2
27 FJ303 CONNECTOR, MALE, 6-JIC X 3/8"MNPT, BRASS, WP227BAR 3
28 FP397 NIPPLE, RED, HEX, 3/8"MNPT-1/4"MNPT, SS, WP 500BAR 2
29 DD360328-1 SWITC H,P RESSUR E, L P.OI L PR ESS. C/W DI N C AP 2
30 DD400680 CROSS, EQUAL, 8S 2
31 DD310323/1 TUBE , 6MM X 1.0 W. T., ST. STEEL 316, / 1M AS REQ
32 DD400801 COUPLING, GAUGE, 1/4" BSP X 6L 3
33 DD400157 TE E, SWIV EL RUN, 6L 2
34 DD400293 STUD, 10L X 3/8 " BSP T M 4
35 DD400573 STUD, 8S X 1/4" NPT M 2
36 DD400681 STAND PIP E, 1 0L X 6L 2
37 FP215 ELBOW, FEMALE-FEMALE, 1/4" NPT, BRASS 2
38 FJ299 FTG,CONNECTOR,MALE, 4JIC-1/4"MNPT, C /W N&F, S316 4
39 DD310312-PN NUT,PANEL MOUNTING 2
40 FE034 FILTER, ELEMENT, 40-55 MICRON, SS 2
41 FP290 PLUG, HEX HEAD, 1/4"MNPT, SS, WP551BAR 6
42 DD400795 WASHER, 1/4" BSPP GAUGE SEAL, MAV STYLE, STEEL 5
43 DD400518 STUD, 6L X 1/ 4" NPT M 2
44 DD400148 STUD , STAN DPI PE, 8S X 1/4" BSP M 2
45 DD401029 ELBOW, STUD, 10L X 3/8" N PT M 2
46 DD310393 VALVE, NON-RETURN, BRASS, 3/8 BSP(F), 25 BAR MWP 3
47 FN1 02 LOCKNUT, M20 X 1.5, 5MM THICK, S316 9
48 FW130 WASHER, FORM A, M20 9
49 DD400149 TEE, SWIVEL RUN, 10L 2
50 DD403011 ADAPTOR, BRASS,1 /4"BSPP M CON ED X 1/4"N PTM HE X NI PPLE 2
51 DD403015 ADAPTOR, BRASS, 3/8" BSP M X 3/8 " NP T M 3
52 DD405005 ADAPTOR, 1/4"NP T(M) X 1/4"BSP (M),600 0 PSI MAX 4
53 DD401080 ELBOW, STUD, 6S X 1/4" NPT M 2
54 FP342 TEE, FORGED BODY, 3/8 " BSPT FEMALE 2
55 FP325 FTG,NIPP LE, HEX, BRASS, 3/8 " BSPT M 2
56 FP344 BUSH , RE DUCIN G, 3 /8" B SPT(M) X 1/4" NPT(F) 2
57 DD401076 ELBOW, STUD, 6L X 1/8" NPT M 1
58 VB314 VALVE, BALL, 3/8"BSP FEMALE, RED HANDLE, PANEL MNT 2
4
4
4
4
4
4
10 12 1147
3
1
6
8
2
13
5
9
1
1
1
1
DENOTES CHANGE MADE AT THIS REVISION
PROJECTION
A2
SIZE
1:2
SCALE
11
OF
SHT
R01
REV
PANELS
21/07/2008
GR
FINISH
PRODUCT / PROJECT No.
PP033AA
PART No.
DRAWING No.
MATERIAL
NOTES
THIRD ANGLE
±0.5°
±3.0
±1.5
±0.5
ANGULAR TOLERANCE
SIZE >500
SIZE >100 <500
SIZE >0 <100
±0.5°
±0.05
±0.2
±1.0
ANGULAR TOLERANCE
TWO DECIMAL PLACE
ONE DECIMAL PLACE
FABRICATION
MACHINING
NO DECIMAL PLACES
DIMENSIONAL TOLERANCES
DO NOT SCALE DRAWING
REMOVE ALL SHARP EDGES AND BURRS
ALL DIMENSIONS BEFORE PLATING (UOS)
ALL DIMENSIONS SHOWN ARE IN MM (UOS)
N/A
N/A
DIVEX OWNS THE COPYRIGHT OF THIS DOCUMENT AND ANY DESIGN RIGHT HEREIN. IT IS SUPPLIED IN CONFIDENCE AND MUST NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS SUPPLIED AND MUST NOT BE REPRODUCED WITHOUT PERMISSION IN WRITING FROM THE OWNERS.
PP33110S1
DIVER AIR SUPPLY,
AA VARIANT,
GENERAL ASSEMBLY
TITLE
DIVEX LIMITED
ENTERPRISE DRIVE
WESTHILL
ABERDEEN
AB32 6TQ
UNITED KINGDOM
Tel : +44(0)1224 740145
Fax : +44(0)1224 740172
email : info@divexglobal.com
www.divexglobal.com
A B
DC
1
2
4
3
2
1
4
3
D
A B
C
DATE
R00
R01
R02
R03
R04
R05
REV
BY
ECN No
DESCRIPTION
AUTH.BY
R06
SW
ISSUED FOR MANUFACTURE
UPDATED BALLOONS
SB
29/10/2012
MS
15335
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