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

11
5. Ensure that the SEA-4500 is supported and turn the compressor valve very slowly
counter-clockwise until it is slightly open to ll the cylinder with approximately 500 PSI /
34.5 BAR. Turn the compressor valve shut and wait 45-60 seconds before proceeding
to ll the cylinder any further. Repeat this procedure to ll the cylinder very slowly
in small increments of 500 PSI / 34.5 BAR or less, until it is lled to 4500 PSI / 310
BAR. Make sure the dial pressure gauge shows that the cylinder is lling properly.
NOTE: Always ll the cylinder as slowly as possible by turning the
handwheel of the supply valve slowly to control the rate of ll. Rapid
lling will generate heat and will result in an incomplete ll after the
cylinder cools. If the cylinder is warm to the touch afterward, the ll
rate was too rapid.
6. To conserve the limited air supply of the SEA-4500, it is strongly recommended
that you perform the following pre-issue inspection of the second stage purge
while the SEA-4500 is pressurized and connected to the ll adapter:
a. Briey depress the purge button to ensure that sufcient airow is provided
to clear the second stage of water.
b. Immediately after releasing the purge button, listen closely to ensure
that the second stage does not continue to ow any air.
7. While holding the rst stage and ll adapter secure, turn the SEA-4500 valve
handwheel clockwise until it stops and the red indicator ring is visible. Turn
the compressor valve completely closed.
8. Hold the second stage purge button depressed until air ow can no longer
be heard from the second stage and the MP hose is depressurized.
9. Open the bleed valve screw on the ll adapter to relieve the line pressure.
10. While holding the SEA-4500 cylinder, turn the adapter nut counter-clockwise
to loosen and remove from the rst stage. Replace protector cap on the threaded
male tting of the ll adapter. Return the ll adapter to its storage location.
11. Thread the ll port cap back into the ll port until nger tight.

12 SEA-4500 User's Manual
Adjusting Mouthpiece Position
The second stage incorporates a position keying feature that enables the user
to adjust orientation of the second stage body in relation to the mouthpiece. This
unique feature keeps the hose closer to the body and allows for more exibility
in various cylinder-mounting congurations.
Figure 8
The mouthpiece-to-body default
position is horizontal which allows
the hose to route either to the right
or left of the regulator second stage.
The mouthpiece boss on the body is
hexagonally shaped, which allows the
mouthpiece to rotate to six different
positions (Fig. 8).
Hexagonal Mouthpiece Boss
Hexagonal Mouthpiece
WARNING: The mouthpiece clamp must always be installed
before returning regulator to service. Failure to install the clamp
will result in mouthpiece separating from regulator body during
deployment of regulator.

13
Changing the SEA-4500 Mouthpiece
Figure 9
1. Mount SEA-4500 cylinder in user
preferred position.
2. Remove the black clamp with side
cutters and discard (Fig. 9).
3. Rotate the mouthpiece to preferred
position (Fig. 10).
4. Install a new black clamp with the
clamp tab positioned in-line with the
center of the right bite-tab on the
mouthpiece. Since the mouthpiece is
of a lower prole design than standard
SCUBA-style mouthpieces the clamp
tab should be orientated in this manner
so that the clamp tab does not interfere
with the users lips (Fig. 11).
Figure 10
Figure 11

14 SEA-4500 User's Manual
PRE-ISSUE CHECKLIST
Before each use, the unit must be given a thorough visual inspection and
functional test by a qualied technician. NEVER use a SEA-4500 which shows
signs of damage, leakage or substandard performance until it has received
inspection and service from a qualied technician.
1. Carefully inspect the medium pressure hose to ensure it is securely connected
into its respective port on the rst stage and onto the second stage. Inspect the
length of the hose to ensure that it is not blistered, cut or otherwise damaged.
Inspect the hose ttings for any signs of corrosion.
2. Visually inspect the entire system for any external damage, such as dents,
gouges, cracks or severe external corrosion.
3. While the SEA-4500 valve is
completely shut and the system is
depressurized, inspect the pressure
gauge to ensure that it is securely
fastened to the first stage. Closely
examine the pressure gauge to
ensure that it reads zero (Fig. 12).
Figure 12
CAUTION: If the pressure gauge does not read zero when the
valve is shut and the system is depressurized, DO NOT attempt
to use the system until it has received inspection and service
from a qualied technician.
CAUTION: DO NOT attempt to open the SEA-4500 valve without
rst checking to ensure that the MP hose and pressure gauge
are securely fastened to the rst stage.
4. Turn the SEA-4500 valve handwheel counter-clockwise until it is completely
open. In the open position, the red indicator ring is not visible in the handwheel.
“0 PSI”

15
5. Closely examine the pressure
gauge to determine whether the
needle is within the “GREEN ZONE”,
indicating that the SEA-4500 cylinder
is full (Fig. 13).
Figure 13
6. Immerse the SEA-4500 in water to check for any signs of free ow from the
second stage, leakage from the hose, pressure gauge, safety plug assembly, rst
stage or cylinder neck. If leakage is found, do not attempt to use the SEA-4500
until it has received service from a qualied technician. When complete, remove
the water from the SEA-4500 1st & 2nd stages and reinstall the mouthpiece cover.
NOTE: If the second stage purge was checked during the lling procedure,
it is not necessary to repeat steps 7 & 8.
7. Briey depress the purge button to ensure that sufcient airow is provided
to clear the second stage of water.
8. Immediately after releasing the purge button, listen closely to ensure that the
second stage does not continue to allow any air ow.
9. Turn the valve handwheel clockwise until it is completely closed. In the closed
position, the red indicator ring is visible in the handwheel.
Provided that these pre-issue inspection requirements have all been met,
the SEA-4500 is now ready for use.
GREEN
ZONE
NOTE: The operational range for composite / carbon ber cylinder
units is 3000 - 4500 PSI (206 - 310 BAR). A 13 cubic inch (63.4 L)
composite / carbon ber cylinder is equivalent to a 1.5 cubic foot (42.5
L) aluminum cylinder when both are lled to 3000 PSI (206 BAR).
A 17.5 cubic inch (85.5 L) is equivalent to a 2.0 cubic foot (56.6 L)
aluminum cylinder when both are lled to 3000 PSI (206 BAR). Aqua
Lung classies composite / carbon ber cylinders by oodable volume
(cubic inch) and aluminum cylinders by expanded volume (cubic feet).
Values in liters are metric expanded capacity.

16 SEA-4500 User's Manual
PRE-FLIGHT INSPECTION
The pre-ight inspection shall be performed on the SEA-4500 prior to each ight
by the air crew member to whom the unit is assigned. Pre-ight procedures are
as follows:
WARNING: Strict compliance with pre-flight and post-flight
inspections shall be adhered to by all air crew members
utilizing the SEA-4500. Any signs of discrepancies shall be
reported immediately to maintenance personnel.
1. With the system off, visually inspect the SEA-4500 for signs of damage.
Inspect front cover, exhaust cover and ttings for tightness. Inspect for tamper
dot (if command uses tamper dot) on front cover. Inspect hose for cuts and
blistering. Inspect for contamination, dirt and signs of corrosion.
CAUTION: Do not press the purge button when the SEA-4500 is on.
Purging of the SEA-4500 will deplete the pressure below the “GREEN
ZONE” and it will have to be topped off by maintenance personnel.
2. Turn the SEA-4500 “ON” by rotating the ON/OFF knob to the left
(counter-clockwise), the red indicator ring should not be visible through
the elongated holes on the knob. Ensure that the gauge reads in the
“GREEN ZONE”. If the gauge does not read in the “GREEN ZONE” report
discrepancy to maintenance personnel.
POST-FLIGHT INSPECTION
1. Upon completion of ight, turn handwheel “OFF” (clockwise), so that red indicator
ring is visible through the elongated holes on the handwheel. Depress the purge
button to relieve pressure in hose and second stage. Check SEA-4500 for signs
of damage and contamination. Report discrepancies to maintenance personnel.

17
CARE AND MAINTENANCE
It is important to provide the proper preventative maintenance in order to
ensure the best possible performance and reliability of the SEA-4500. The
following maintenance procedures should be performed routinely after each
use of the equipment.
1. After each in-water training session, the SEA-4500 must be cleaned, inspected
and prepared for the next use or storage.
2. As soon as possible after training, the SEA-4500 should be soaked thoroughly
for at least one hour in warm (not over 120ºF / 49ºC) tap water to loosen and
dissolve salt (if used in salt water) and mineral deposits. Before soaking, turn
the valve to the “ON” position to pressurize the system. This will best prevent
the entrance of moisture into the system through the second stage.
CAUTION: If the SEA-4500 cylinder does not contain air, it is important
to ensure that the valve is completely turned to the “OFF” position
and the second stage purge button is not depressed while the system
is submerged or wet. Moisture may otherwise be allowed to enter the
valves and the cylinder, which will require that the system be returned
to a qualied technician for inspection and service.
3. After the system has been properly soaked, it is important to rinse the rst
stage, the second stage mouthpiece and the openings in the second stage front
cover with a pressurized stream of water. This will remove the salt and mineral
deposits that were loosened during soaking.
4. When it has been properly soaked and rinsed, wipe the system as dry as
possible with a clean towel and gently shake the rst and second stage to
dislodge any water inside them.
5. Check to ensure that the SEA-4500 valve is turned to the “OFF” position
and depress the purge button of the second stage to ensure that the system is
completely depressurized before storing or transporting.
NOTE: Due to the light weight aluminum rst stage, the SEA-4500
is not recommended for continuous use in salt water. The aluminum
rst stage is susceptible to galvanic corrosion and needs to be rinsed
thoroughly after use in salt water.

18 SEA-4500 User's Manual
6. Due to the possibility of re and exposure to extreme heat, the SEA-4500
must be stored either completely full or completely empty. If the system is
exposed to re while partially lled, the cylinder wall may rupture before the
internal pressure becomes great enough to burst the safety plug assembly. For
this reason, Aqua Lung recommends that the cylinder be completely emptied
and the valves kept shut to prevent the entrance of moisture before storing the
system for an indenite period.
WARNING: DO NOT store the SEA-4500 partially lled. Doing so
may prevent the safety plug assembly from functioning properly
in the event of re or exposure to extreme heat. This may cause
the cylinder to rupture or explode, possibly resulting in severe
injury or death.
7. Store the SEA-4500 completely dry, in a clean equipment box or sealed inside
a plastic bag. When possible, avoid storing it where it may be exposed to extreme
heat or an electric motor, which produces ozone. Prolonged exposure to extreme
heat, ozone, chlorine and ultraviolet rays can cause premature degradation of
rubber parts and components and must be prevented.
8. When transporting the SEA-4500, take the necessary precautions to ensure
that it is surrounded by a protective cushion to prevent undue shock or impact.
9. Do not use any type of solvent or petroleum based substances to clean or
lubricate any part of the regulator. Do not expose the regulator to aerosol spray,
as some aerosol propellants attack or degrade rubber and plastic.

19
INSPECTION AND SERVICE
1. It cannot be assumed that the SEA-4500 is in good working order on the basis
that it has received little use since it was last serviced. Remember that prolonged
or improper storage can still result in internal corrosion and/or deterioration of
o-ring seals and valve springs.
2. It is imperative that you obtain factory prescribed service for your SEA-4500 at
least once every two years from a qualied technician, including a visual inspection
of the cylinder and complete overhaul of the rst and second stage regulators. Your
SEA-4500 may require this service more frequently, depending on the amount
of use it receives and the environmental conditions it is used in.
3. If the SEA-4500 is used for training purposes in salt water, chlorinated or silted
fresh water, it will require complete overhaul and factory prescribed service every
three to six months or whenever it is suspected that moisture has entered the
system. Use in chlorinated swimming pool water will accelerate the deterioration
of most rubber components and require more frequent service than in other
typical conditions.
4. DO NOT attempt to perform any disassembly or service of your SEA-4500.
Doing so may cause the system to dangerously malfunction. All service must
be performed by a qualied technician.
WARNING: Do not attempt to loosen or remove the rst stage hose
tting, gauge 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.
OBTAIN FACTORY PRESCRIBED SERVICE FOR YOUR SEA-4500 AT
LEAST ONCE EVERY TWO YEARS. YOUR PERSONAL SAFETY AND THE
MECHANICAL INTEGRITY OF YOUR SEA-4500 DEPEND ON IT.
WARRANTY INFORMATION
For detailed information on product warranties, please refer to the Terms and
Conditions Section of the Aqua Lung Military and Professional Buyers Guide.
The buyers guide can be viewed or downloaded from the Aqua Lung Military
and Professional website at www.aqualung.com/militaryandprofessional

20 SEA-4500 User's Manual
TECHNICAL SPECIFICATIONS
Cylinder Volume
13 cu. in. (oodable volume)
2.24 cu. ft./ 63.4 L (expanded volume)
17.5 cu. in. (oodable volume)
3.02 cu. ft./ 85.5 L (expanded volume)
Cylinder Material Composite / Carbon Fiber
Cylinder Length with Regulator
13 cu. in. - 11.0 in / 28 cm
17.5 cu. in. - 12.75 in / 32.4 cm
Rated Cylinder Pressure 4500 PSI / 310 BAR
Medium Pressure Hose Length
20 in / 50.8 cm
or
27 in / 68.6 cm
First stage Hose Connection 360 degree swivel
Regulator First Stage Balanced Diaphragm
Regulator Second Stage Balanced Second Stage
Pressure Indicator Gauge 0-5000 PSI / 0-345 BAR
Over Pressure Relief Safety Plug Assembly
HP Module Mounted, 7250 PSI / 500 BAR
System Weight
SEA-4500 w/ 13 cu. in. Composite / Carbon
Fiber Cylinder Empty 1.57 lb. / 0.71 kg
SEA-4500 w/ 17.5 cu. in. Composite / Carbon
Fiber Cylinder Empty 1.69 lb. / 0.77 kg
Duration of Air Supply
**Approximate breaths at 20 FSW:
13 cu. in. Cylinder - 23 Breaths
17.5 cu. in. Cylinder - 31 Breaths
**Based on an average breath volume of 1.5 liters at a breathing rate of
10.5 bpm, with a starting supply pressure of 4500 PSI / 310 BAR.