Kirby Morgan Air Control System 5 Operations and Maintenance Manual Part # 100-075 D IV c n . K Y MORGA B N IR I ES , YSTEMS 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 .
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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.
Table of Contents Section Title Page # Section Title Page # 1.0 General Information 1 2.3 Connecting the Air Supply 8 1.1 Definitions 1 2.4 Connecting Diver’s Hoses 9 1.2 Design Purpose 2 2.5 Pre-Dive Checklist 10 1.3 Specifications 3 2.5.1 Testing the L.P. Supply 10 1.4 General Description 3 2.5.2 Testing Communications 11 1.4.1 Breathing Air Sub System 4 2.5.3 Testing the Pneumo 12 1.4.
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.
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.
KMACS 5 MANUAL 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. 1.3 SPECIFICATIONS Use: For SSAir diving only. Pure oxygen MUST NOT be used.
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.
KMACS 5 MANUAL 6. ORANGE AIR SUPPLY FLOW INDICATOR LINES After flowing through the Selector Valve the ORANGE air supply enters the Breathing Air Supply Regulator (H) which reduces the high pressure breathing air to an adjustable range between l15-225 psi (8-15.5 bars). Then the ORANGE air supply goes to both diver’s umbilicals through the fittings on the manifold (G).
KMACS 5 MANUAL Blue Air Supply Flow Path Indicator Line Blue 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 is not designed to be removed. 12. BREATHING AIR SUPPLY SELECTOR VALVE HANDLE (I) Orange Air Supply Whip Orange Air Supply Flow Path Indicator Line Fig.
KMACS 5 MANUAL 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 bars). 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.
KMACS 5 MANUAL Section 2.0 OPERATING INSTRUCTIONS 2.1 UNPACKING THE KMACS 5 2.2 FIRST USE OF 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. Place the Dive Control System on a firm surface. The KMDSI logo should be right side up.
KMACS 5 MANUAL 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. 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.
KMACS 5 MANUAL hoses to the mask or 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.
KMACS 5 MANUAL 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 depress the push to talk switch to speak to the diver.
KMACS 5 MANUAL 2.5.3 TESTING THE PNEUMO 2.6 PREPARING THE DIVER 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).
KMACS 5 MANUAL 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 including 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.
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.
KMACS 5 MANUAL 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.
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 inspect 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.
Section 4.0 Trouble Shooting the KMACS 5 System KMACS 5 MANUAL 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 information covers the common operating difficulties. 4.2 NO COMMUNICATIONS Symptoms Probable Cause(s) Remedy a)Communication power not on. Activate switch and adjust volume. b) Communications incorrectly hooked up.
KMACS 5 MANUAL 4.3 NO PNEUMO READING Symptoms Probable Cause Remedy 1) No air to diver’s end of pneumo Pnuemo 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.
KMACS 5 MANUAL Symptoms Probable Cause Remedy 6) Air can be heard escaping into console interior. Leakage in DCS plumbing. 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. Regulator malfunction. Return DCS- 2A to factory for service 8) With high pressure air on and regulator loaded, no umbilical pressure. 5.0 APPENDIX 5.
KMACS 5 MANUAL From Tender to Diver From Diver to Tender 3 “Stand by to come up” “Take up my slack” 4 “Come up” “Haul me up # of Pulls 5.3 COMMUNICATIONS WIRING SCHEMATICS If your KMACS has communications, refer to the radio manual 5.4 EXPLODED VIEWS & PARTS LISTS The following parts are not shown on the blow apart drawing and are listed reference only.
KMACS 5 MANUAL KMACS 5 EXPLODED VIEWS & PARTS LISTS Communications Panel Key# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part # 530-017 415-105 530-035 430-075 410-003 445-105 450-106 420-125 420-120 445-115 420-160 330-405 530-070 420-105 410-145 415-110 Description Screw Communicator Screw Washer Gasket, Foam Panel, Auxiliary Yoke Retainer Arrow, Orange Arrow, Blue Door, Storage Compartment Slide Latch Lock washer Screw Box, Plastic Grommet Cable, Battery © 2003 KMDSI Document # 041112001 Key# 17 18 19
22 36 27 28 29 30 31 32 33 34 35 18 19 20 21 22 23 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Key# Description 430-111 Screw 430-134 Washer 430-134 Washer 430-111 Screw 430-075 Washer 530-035 Screw 450-144 Pneumo Block 455-032 SS Elbow 455-007 Cap, Pneumo 455-157 Valve Body 455-145 Valve flange 455-143 SS Elbow 455-006 Cap, Umbilical Outlet 430-141 Socket Head Screw 430-134 Washer 440-210 Handle Stop 440-212 Valve Handle 425-110 Kit, Shut Off Valve 510-014 O-Ring 420-140 Gauge Cover 530-070 S
Part # 455-024 455-049 455-026 405-155 455-120 455-122 455-180 455-149 350-062 510-013 450-142 455-149 405-150 430-126 405-160 455-180 455-040 455-051 455-123 455-121 455-051 455-040 405-107 455-180 455-040 405-161 405-102 405-105 455-117 405-110 405-105 405-104 455-305 455-032 455-135 455-196 455-140 430-120 405-106 455-197 405-120 405-145 455-047 455-130 Key# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Description Connecto
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: Cylinder # Start Finish 1 _______________________________ 2 _______________________________ 3 _______________________________ 4 _______________________________ 5 _______________________________ 6 _________________________________ Dive Times: Diver Left Surface: ________________ Dive
KMACS 5 MANUAL Table of Equivalents To convert units appearing in Column 1 (left column) into equivalent values in Column 2 (center column), multiply by factor in Column 3. Example: To convert 7 gallons into cubic inches, multiply 7 x 231 = 1617. To convert units appearing in Column 2 (center) 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.
