Aqua Lung SEA-4500 User manual

Survival Egress Air
(SEA-4500)
User's Manual
Rev 09/14

2SEA-4500 User's Manual
COPYRIGHT NOTICE
This user's manual is copyrighted, all rights reserved. It may not, in whole or
in part, be copied, photocopied, reproduced, translated, or reduced to any
electronic medium or machine readable form with out prior consent in writing
from Aqua Lung America, Inc.
©2014 Aqua Lung International
SEA-4500 User’s Manual PN 103641
You can contact a Technical Advisor via e-mail at:
[email protected]
[email protected]
[email protected]
TRADEMARK NOTICE
Aqua Lung®is a registered trademark of
Aqua Lung America, Inc.
Warnings, Cautions and Notes:
Pay special attention to information provided in Warnings, Cautions
and Notes that are accompanied by one of these symbols:
A NOTE is used to emphasize important points, tips and reminders.
A WARNING indicates a procedure or situation that, if not avoided,
could result in serious injury or death to the user.
A CAUTION indicates any situation or technique that could
cause damage to the product and could subsequently result in
injury to the user.

3
General Precautions and Warnings ............................................................ 4
Product Description...................................................................................... 6
Preparation and Setup.................................................................................. 7
General Filling Procedures...................................................................... 7
Filling Methods for SEA-4500 ................................................................. 9
Filling SEA-4500 with a HP Fill Adapter ................................................. 9
Adjusting Mouthpiece Position .............................................................. 12
Changing the SEA-4500 Mouthpiece ................................................... 13
Pre-Issue Checklist..................................................................................... 14
Pre-Flight Inspection .................................................................................. 16
Post-Flight Inspection ................................................................................ 16
Care and Maintenance................................................................................ 17
Inspection and Service............................................................................... 19
Warranty Information ................................................................................. 19
Technical Specications ............................................................................ 20
SEA-4500 Parts ........................................................................................... 21
Notes ............................................................................................................ 22
TABLE OF CONTENTS

4SEA-4500 User's Manual
The SEA-4500 is intended for use only as an emergency device
to assist a crew member or passenger in making an emergency
egress from a submerged aircraft. Due to its limited air volume, it
is not intended for use while scuba diving or egressing from depths
greater than 45 ft/ 13.5 m.
Before using the SEA-4500, it is important to receive in-water
survival training which simulates an emergency egress situation.
You must also learn basic principles and techniques for breathing
compressed air underwater. Use of the SEA-4500 without proper
training is dangerous and can result in serious injury or death.
Visual inspection and factory prescribed service for the SEA-4500
must be performed at least once every two years by a factory trained
and qualied service technician. Repair, service and visual inspection
must not be attempted by untrained or unqualied personnel.
DO NOT attempt to overll the SEA-4500 beyond 4500 PSI / 310
BAR at 70ºF/ 21ºC. Doing so may seriously weaken the cylinder
and cause it to rupture, resulting in serious injury or death.
The SEA-4500 is designated compatible for use only with normal,
atmospheric, compressed air (21% oxygen and 79% nitrogen by
volume). DO NOT attempt to ll with other gases, including pure
oxygen or air which has been enriched with oxygen exceeding
21% in content. Failure to observe this warning may result in
serious injury or death due to re and explosion or the serious
deterioration and failure of the equipment.
DO NOT ll or use the SEA- 4500 if it has been exposed to extreme
heat exceeding 250º F / 121º C or open ame. Instead, discharge
the cylinder completely and return it to a qualied technician for
inspection and possible hydrostatic testing.
GENERAL PRECAUTIONS AND WARNINGS

5
DO NOT apply any type of petroleum-based lubricant, such
as household oil or motor oil to any part of the SEA-4500.
The SEA-4500 does not require any lubrication under normal
circumstances, except that which is performed during annual
inspection and service by a factory trained service technician.
DO NOT apply any type of aerosol spray to the SEA-4500. Doing
so may cause permanent damage to certain plastic components,
including the second stage housing.
During training exercises, it is important to ensure that the SEA-4500
is always pressurized whenever it is submerged in order to prevent
the entrance of water into the system. Whenever the system has been
completely emptied of air underwater, it is important to return the
SEA-4500 as soon as possible to a qualied technician for visual
inspection and any necessary service before attempting to rell it.
It is important to ll the SEA-4500 only with dry, ltered air with
a water vapor content that does not exceed -65°F / -53ºC dew
point. Excess water vapor in the air can cause ice to form inside
the SEA-4500 and interfere with the operation of the system at
colder temperatures.

6SEA-4500 User's Manual
PRODUCT DESCRIPTION
• SEA-4500 balanced diaphragm rst stage with integral ll port, dial pressure
gauge, safety plug assembly, 360 degree swivel and On / Off knob. Black
aluminum components are utilized on rst stage for a low reective signature.
• 20 in (50.8 cm) or 27 in (68.6 cm) braided medium pressure (MP) hose with tool
free swivel allows for quick and easy exchange of the second stage when needed.
• Ergonomic low volume balanced second stage with indexable mouthpiece
allows for variable regulator orientation.
• Light weight composite / carbon ber cylinder 13 cu. in. or 17.5 cu. in. ,
4500 PSI / 310 BAR.
SEA-4500 Components (Fig. 1)
Figure 1
Fill Port
First Stage
360º Swivel
Braided
Hose Composite / Carbon Fiber
Cylinder
Mouthpiece
Cover
Indexable
Mouthpiece
Safety Plug Assy
Dial Pressure
Gauge
Second
Stage
On / Off
Knob
Component Identication

7
The purpose of this manual is to familiarize you with the correct setup, lling,
inspection and maintenance of the SEA-4500.
The SEA-4500 is packaged fully assembled and ready to use after it has been
lled with air. Before using it, however, it is very important to carefully read
and understand the procedures outlined in this manual for lling the unit and
performing a preight inspection.
PREPARATION AND SETUP
General Filling Procedures
NOTE: The average duration of air supply listed in the Technical
Specications section of this manual is based on a completely
full SEA-4500 composite / carbon ber cylinder, lled to 4500 PSI /
310 BAR with a volume of 13 cu. in. or 17.5 cu. in. of air. It is strongly
recommended that the SEA-4500 be lled to 4500 PSI / 310 BAR
(cold ll), in order to provide maximum breath volume.
1. Before attempting to ll the SEA-4500, ensure that the ll adapter and rst
stage are completely dry – especially in the area surrounding the ll port.
2. The SEA-4500 is congured with a 4500 PSI/ 310 BAR composite / carbon
ber cylinder. Examine the cylinder markings to verify it is rated for a ll pressure of
4500 PSI/ 310 BAR, has a current visual inspection and hydrostatic test date (Fig. 2).
Figure 2
Maximum Fill
Pressure
Month & Year of Manufacture (Hydro Date)
NOTE: The SEA-4500 1 3 cu. in. or 17.5 cu. in. composite / carbon
ber cylinders require hydrostatic testing every 5 years. (Fig. 2).

8SEA-4500 User's Manual
WARNING: DO NOT attempt to ll the SEA-4500 if the cylinder
markings indicate that it is assembled with a non standard cylinder
rated for a different ll pressure than 4500 PSI / 310 BAR. Doing so
may result in rupture or explosion in the event of re or overlling.
Instead, immediately return the unit to a qualied technician and
do not use under any circumstances.
Figure 3
Figure 4
3. Turn the valve handwheel clockwise
until it is completely closed. To ensure
the valve is closed, check to see if the
red indicator ring is visible in the
handwheel (Fig. 3).
4. Depress the second stage purge
button to ensure that the system is
completely depressurized.
5. Unscrew the ll port cap from the
ll port (Fig. 4).
6. Closely inspect the ll port opening
to ensure that no debris, residue or
moisture is present.
CAUTION: If moisture is found to be present inside the ll port opening,
this indicates that water may have entered the SEA-4500 rst stage
and cylinder. DO NOT ll or attempt to use the SEA-4500 until it
has received complete inspection and any required service by a
qualied technician.
"OFF"
POSITION
Red indicator
ring visible

9
WARNING: DO NOT attempt to loosen or remove the rst stage hose
tting or safety plug assembly under any circumstances. Doing so
could result in a dangerous malfunction of the SEA-4500 which
could result in serious injury or death.
Filling SEA-4500 with a HP Fill Adapter
NOTE: The SEA-4500 system does not include a HP ll adapter. This
adapter (PN 102865) may be purchased separately (Fig. 5).
O-Ring
NOTE: The HP ll adapter (PN 102865) may be used to ll cylinders
up to a pressure rating of 4500 PSI / 310 BAR. (Fig. 5).
CAUTION: Do not attempt to ll the SEA-4500 directly from a compressed
air lling station unless you have received the necessary training and
authorization to do so. If done incorrectly, this procedure poses certain
hazards which may cause severe injury or death.
CAUTION: The SEA-4500 dial pressure gauge is for reference only.
Use the ll system gauge to indicate accurate cylinder pressure.
Figure 5

10 SEA-4500 User's Manual
1. Remove the protector cap from the threaded male tting on the ll adapter.
Inspect the ll adapter to ensure that the o-ring is present and seated evenly
at the base of the threads. Check the threads of the male tting, making sure
they are clean and not damaged.
Figure 6
2. Fit the threaded male tting of the ll
adapter into the ll port of the rst stage
and turn the adapter nut clockwise
by hand until snug. DO NOT apply a
wrench or otherwise overtighten the
ll adapter (Fig. 6).
3. Close the bleed valve screw on the
ll adapter by turning it clockwise until
nger tight.
WARNING: DO NOT attempt to ll the SEA-4500 from a compressor
or air supply where the regulated pressure exceeds 4500 PSI / 310
BAR. Doing so may weaken and damage the safety plug assembly
and cylinder.
NOTE: The SEA-4500 will ll with the valve handwheel in the completely
closed position (red indicator ring visible). In this position the pressure
gauge will not register psi. This is not recommended.
Figure 7
4. While holding the rst stage and ll
adapter secure, turn the SEA-4500
valve handwheel counter-clockwise
until it is completely open. When the
handwheel is in the open position, the
red indicator ring is not visible (Fig. 7).
Bleed Valve
Screw
Adapter
Nut
"ON"
POSITION
Red indicator
ring not visible