Kirby Air Control System User Manual

Kirby Morgan Air Control System 5

Operations and Maintenance Manual

Part # 100-075

KMDSI

United States of America

Telephone (805) 928-7772

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 & KMDSI .

1430 Jason Way

Santa Maria, California

Postal Code 93455

Fax (805) 928-0342

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

KMDSI warrants every new mask, helmet, SCUBA regulator or air control system (KMACS) (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 components, 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 Productís intended service has been exceeded.

EXCEPT AS SPECIFICALLY PROVIDED HEREIN, THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, 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 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 Page #

1.0 General Information 1

1.1 Deﬁnitions 1

1.2 Design Purpose 2

1.3 Speciﬁcations 3

1.4 General Description 3

1.4.1 Breathing Air Sub System 4

1.4.2 Principle Operating Features 4

1. Dive Control Panel 4

2. Red Diver Depth Gauge 4

3. Umbilical Pressure Gauge 4

4. White Diver Depth Gauge 4

5. Blue Air Supply Flow Indicator Line 4

6. Orange Air Supply Flow Indicator Line 5

7. Low Pressure Inlet Fitting 5

8. Blue Breathing Air Supply Gauge 6

9. Orange Breathing Air Supply Gauge 6

Section Title Page #

2.3 Connecting the Air Supply 8

2.4 Connecting Diver’s Hoses 9

2.5 Pre-Dive Checklist 10

2.5.1 Testing the L.P. Supply 10

2.5.2 Testing Communications 11

2.5.3 Testing the Pneumo 12

2.6 Preparing the Diver 12

2.7 Dive Supervisor and KMACS Operator 12

2.8 Descent 13

2.9 Diver at Depth 14

2.10 Changing out High Pressure Cylinders 14

2.11 Procedures During the Diver’s Ascent 14

2.12 Decompression 15

2.13 Completion of Diving Operations 15

3.0 Maintenance 16

3.1 Recommended Maintenance 16

10. High Pressure Cylinder Yokes 6

11. Bottom of Case 6

12. Air Supply Selector Valve Handle 6

13. Regulator Adjustment Knob 6

14. Outlet Manifold 7

15. Pneumo Valve Handle, White Diver 7

16. Pneumo Valve Handle, Red Diver 7

17. O-Ring Seal 7

18. Communicator Panel 7

19. Communicator 7

2.0 Operating Instructions 8

2.1 Unpacking the KMACS 5 8

2.2 First Use of KMACS 5 8

3.2 Replacing the Battery 16

4.0 Troubleshooting

4.1 General 17

4.2 No Communications 17

4.3 No Pneumo Reading 18

4.4 No Air to the Diver 18

5.0 Appendix 19

5.1 Emergency Procedures 19

5.2 Diver Line Pull Signals 19

5.3 Communications Wiring Schematics 20

5.4 Exploded Views & Parts Listz 20

5.5 Dive Log Master Sheet 24

Kirby Morgan Air Control System 5 with no communications.

Kirby Morgan Air Control System 5 with communications.

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 a two-way voice communicator for talking between the KMACS 5 operator and the diver(s), or diver-todiver. 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.

KMACS 5 MANUAL

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 pressure 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).

Scuba: Self contained underwater breathing apparatus.

SSAir 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 member 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.

L.P.: Low pressure. Usually any pressure under 300 psi. (20.7 bars).

Pneumofathometer: (pronounced “new-mo-fathometer”) 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”, “pneumohose”, to describe the parts that make up the pneumofathometer subsystem.

Dressed-in: A commercial diver’s suit was originally 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 “dressedin” 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 connected 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 larger capacity bailout bottle should be used.

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 surfacesupplied 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 malfunction). 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 of the KMACS 5 usually makes it possible to locate it at the water entry site, allowing the operator to tend the diver’s umbilical while maintaining control of the KMACS 5.

Fig. 1 Divers with all of the gear they need to dive.

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-

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 operation of SSAir diving.

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)

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 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)

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 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.

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 recompressi on chamber facilit y 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)

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 tightened 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 component 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)

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 pneumohose 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 “BLUE” air supply ﬂow indicator line (Q) 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). 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 Selector Valve which is controlled by the Breathing Air Selector Valve Handle (I). 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.

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)

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 supply then goes to both diver’s umbilicals through the ﬁttings on the manifold (G).

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Kirby Air Control System User Manual

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Frequently Asked Questions

User Manual