Hollis Explorer User manual

NO LIMIT
user Manual
REV.2

DANGERS, WARNINGS, CAUTIONS, AND NOTES
Pay attention to the following symbols when they appear throughout this docu-
ment. They denote important information and tips.
This is the operations manual for the
HOLLIS EXPLORER
This manual, specifications and features of the Explorer are proprietary and
copyright Hollis Inc., 2012.
This document cannot be copied or distributed without the prior agreement and
authorization from Hollis Inc.
All information contained is subject to change. Contact the manufacturer for the
latest information. www.hollisgear.com
The EXPLORER is manufactured in the USA by Hollis Inc.,
2002 Davis Street, San Leandro, CA 94577. USA
Ph [phone]
EC Type approved by SGS UK Ltd. Weston-super-Mare. BS22 6WA. Notified
Body No. 0120.
Testing conducted by ANSTI Test Systems. Hants.
To ensure your user information is up to date. Please check
www.hollisgear.com/support.asp for updates to this manual.
For warranty information see www.hollisgear.com/support_warranty.asp
DANGERS: are indicators of important information that if ignored would lead
to severe injury or death.
WARNINGS: are indicators of important information that if ignored could lead
to severe injury or death.
CAUTIONS: are indicators of information that if ignored may lead to minor to
moderate injury.
NOTES: indicate tips and advice that can inform of features, aid assembly, or
prevent damage to the product.
!
CAUTION
!

WARNING:
USE OF THE EXPLORER MANUAL
This user manual does not, nor is it intended to
contain any information needed to safely dive with
any type of SCUBA apparatus. It is designed as a
guide for the proper setup, operation, maintenance,
and field service of the Hollis Explorer only. It does
NOT take the place of a recognized training agency
instructor-led diver-training course or its associated
training manual(s) and materials. This user manual
is intended to be used only as a type specific ad-
dition to such training and materials, and as a user
reference. This manual cannot be used as a sub-
stitute guide for any other type of Self Contained
Underwater Breathing Apparatus (SCUBA).
EXPLORER DESIGN TEAM
Bob Hollis
Kevin Gurr
HollisExplorer
User Manual
Document Control Number: 12-4102
Rev. 2
Publish Date: 7/26/2013
!
Photo by:
www.HINDL.com

iv |
GENERAL SAFETY
STATEMENTS + WARNINGS
WARNING:
GENERAL SAFETY
No person should breathe from, or attempt to operate in any way, a Hollis Explorer rebreather, or any
component part thereof, without first completing an appropriate Hollis Certified user-training course.
Further, no Explorer diver should use a Hollis Explorer without direct Hollis instructor supervision until
they have mastered the proper set-up and operation of the Hollis Explorer rebreather. This includes
new Explorer divers as well as Explorer certified divers who have been away from diving for an extend-
ed period of time and would benefit from an instructor-led refresher course to regain skills and mastery
of the Hollis Explorer. Failure to do so can lead to serious injury or death.
WARNING:
NITROX STATEMENT
The EXPLORER equipment is classified as being suitable for use with nitrogen-oxygen (Nitrox) breath-
ing gas mixtures containing up to 40% oxygen by volume without the need for special preparation,
cleaning , or component parts.
If Explorer equipment is subsequently used with equipment, or connected to an air supply system, that
is not rated for Oxygen Service, it can subsequently be used with Nitrox (up to 40% O2) as long as the
equipment is maintained in accordance with the procedures and parts specified in the Hollis EXPLOR-
ER Product Service Guide.
The EXPLORER was designed for use with Nitrox (up to 40% O2). DO NOT use gas mixtures with a
higher fraction of oxygen greater than 40% with your EXPLORER.
WARNING:
CAUSTIC MATERIAL
The CO2absorbent used in the scrubber is caustic alkaline material. Take steps to protect yourself from
direct lung and skin contact. Furthermore, poor management of the breathing loop could lead to water
contact with the CO2absorbent, causing a “caustic cocktail” (very caustic liquid). This could lead to se-
vere chemical burns and if inhaled - possible drowning. Proper handling procedures, pre-dive checks,
dive techniques, and maintenance mitigates this risk.
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| v
WARNING:
DESIGN AND TESTING
The Hollis Explorer has been designed and tested, both in materials and function to operate safely
and consistently under a wide range of diving environments. You must not alter, add, remove, or re-
shape any functional item of the Hollis Explorer. Additionally, NEVER substitute any part of the Hollis
Explorer with third-party items which have not been tested and approved by Hollis for use with the
Explorer.
This includes, but is not limited to, hoses, breathing assemblies, electronics, breathing gas delivery
assemblies and their constituent parts, sealing rings, valves and their constituent parts and sealing
surfaces, latches, buoyancy devices, inflation and deflation mechanisms and on-board alternate
breathing devices.
Altering, adding, removing, re-shaping or substituting any part of the Hollis Explorer with non-ap-
proved parts can adversely alter the breathing, gas delivery or CO2absorption characteristics of the
Hollis Explorer and may create a very unpredictable and dangerous breathing device, possibly lead-
ing to serious injury or death.
Non-approved alterations to functional parts of the Explorer will automatically void all factory war-
ranties, and no repairs or service work will be performed by any Hollis service professional until the
altered Explorer unit is brought back into factory specifications by a Hollis service professional at the
owner’s expense.
WARNING:
COMPUTER / CONTROLLER-SPECIFIC WARNINGS
This computer is capable of calculating deco stop requirements. These calculations are predictions of
physiological decompression requirements. Calculations are for contingency use only. The Explorer
in this “sport” configuration is not intended for decompression use.
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!

vi |
TABLE OF CONTENTS
General Safety Statements & Warnings
PART 1
YOUR NEW EXPLORER
SECTION 1
REBREATHER LIFE SUPPORT SYSTEM
RULES
SECTION 2
BATTERIES
SECTION 3
UNIT LAYOUT
SECTION 4
COVER REMOVED
SECTION 5
GAS FLOW
SECTION 6
MECHANICAL FEATURES
PART 2
OUT OF THE BOX
SECTION 1
INITIAL ASSEMBLY
PART 3
LIFE SUPPORT SYSTEM
(COMPUTER)
SECTION 1
GENERAL OPS
SECTION 2
AUTOMATIC TURN ON
SECTION 3
DISPLAY SYMBOLS
SECTION 4
SCREEN ICONS
SECTION 5
DIVE SCREENS
SECTION 6
STATUS SCREENS
SECTION 7
MAIN MENU
SECTION 8
SETUP MENU
iii-v SECTION 9
BAILOUT & GAS CONFIGURATION
SECTION 10
DCP (DIVE CONTROL PARAMETER)
SECTION 11
RMS(RESOURCES MANAGEMENT SYSTEM)
SECTION 12
O2SENSOR CALIBRATION
SECTION 13
O2SENSOR VOTING
SECTION 14
CDM (CANISTER DURATION METER)
SECTION 15
DISPLAY & ALARM SYSTEMS
SECTION 16
ALARM FLOW DIAGRAMS
SECTION 17
GAS RESERVES
SECTION 18
MOD (MAXIMUM OPERATING DEPTH)
SECTION 19
DECO CONTINGENCY
SECTION 20
INTERNET REPROGRAMMING
PART 4
GETTING READY TO DIVE
SECTION 1
GEAR PREP
SECTION 2
PRE-DIVE SETUP
SECTION 3
COMPLETING PRE-DIVE CHECKS
SECTION 4
USER FAULT FINDING & TESTING
PART 5
MANDATORY DIVING SKILLS
SECTION 1
EXPLORER BASICS
SECTION 2
IN-WATER SKILLS CHART

SECTION 3
EXPLORER SKILLS COMPLETED
PART 6
COMPLETE DISASSEMBLY &
REASSEMBLY
SECTION 1
THE FULL DEAL
PART 7
USER MAINTENANCE & AB-
SORBENT STORAGE
SECTION 1
O2 SENSORS
SECTION 2
SANITIZING
SECTION 3
CO2ABSORBENT
SECTION 4
SERVICE
SECTION 5
MAINTENANCE SCHEDULE
PART 8
APPROVED PRODUCTS &
GLOSSARY
SECTION 1
APPROVED PRODUCTS
SECTION 2
GLOSSARY
| vii

2 |
Your New Explorer
Rebreather LifE Support
System Rules
Rules for EXPLORER Diving
1. Always complete all pre-dive checks. Pay special attention to BOV
mushroom valve tests.
2. Always pre-breathe the Explorer Sport Rebreather until the system
passes its’ tests.
3. Do not modify the EXPLORER without the manufacturer’s written con-
sent.
4. Do not use a full-face mask, Unless approved by Hollis for use with the
EXPLORER
5. Always analyse your gas.
6. Never dive a unit you suspect is leaking and has not passed all the pre-
dive tests.
7. Never leave your BOV open on the surface
8. Ensure your BC is inflated at the surface.
9. Take time to adjust your weight correctly, do not dive over-weighted.
10. Always dive with buoyancy control and buoyancy inflation.
11. Practice a skill on every dive.
12. Avoid unnecessary mask clearing.
13. Regularly sanatize the unit.
14. Never exceed the CO2alarms.
15. Never hold your breath
16. Never start a dive with a low battery alarm.
17. Always carry bailout gases of sufficient volume for the planned dive as
per your training agency recommendations.
DANGER: Read and understand this list prior to using this unit.
If you do not understand any or all of this section please con-
tact your training agency or Hollis.
IF IN DOUBT BAIL OUT!
!
1.1

1.2
BATTERIES
The EXPLORER uses Lithium Polymer batteries. These rechargeable bat-
teries are very efficient and provide many years of reliable operation.
Rechargeable Lithium batteries can be recharged at any time and do not
have a significant memory affect, which would otherwise cause unreliable
battery operation. The batteries are UL listed (flight safe) and are double
sealed to reduce the chance of leakage to a minimum.
As extra confidence, the LSS Module battery pack includes 3 separate
batteries to ensure operation even under multiple battery failure scenarios.
During diving the battery reserve alarm will indicate when there is still suf-
ficient battery to allow a return to the surface with a small reserve. The unit
MUST then be charged prior to diving again.
The handset has its own battery that is charged from the EXPLORER Mod-
ule automatically.
The user should keep the batteries recharged and topped up to ensure
there is always maximum capacity for any dive.
A fully charged battery pack will display 1000 minutes of battery life.
DANGER: The battery estimate is based on current tempera-
ture, light usage on the handset, DCP setting and other vari-
ables. Changes in conditions (i.e. cold water) may shorten burn
times. Plan dives accordingly, and always monitor the HUD and
Wrist Displays for system operation status.
NOTE: The EXPLORER must be fully charged before its rst
use. Always dry the Optocon charge connector before attach-
ing the charging connector. Damage may result if this is not
done.
Check that all parts of the charger are kept dry and only used indoors.
Battery level alarms will activate when the batteries get low. When Battery
level alarms will activate when the batteries get low. When a battery low
alarm is activated this will be displayed on the Status screen.
WARNING: DO NOT dive a battery level, which is less than
twice your expected dive time for the next dive.
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4 |
ASSEMBLED UNIT
1.3

Cover Removed
| 5
1.4

6 |
GAS FLOW
As the diver exhales gas flows through the hose (blue arrow) and over the
right shoulder. It then enters the absorbent filter and flows across the Ox-
ygen and CO2sensors in the Sensor Module and through the inhale hose
(red arrow) and back to the mouthpiece.
Gas also naturally flows in and out of the exhale and inhale counterlungs.
BOV
(Bailout Valve)
Filter
“In - Out”
Indicator
Exhale
Counterlung
Inhale
Counterlung
Electronics
O2&CO2
Sensors
Absorbent
Filter
1.5

Mechanical Features
The EXPLORER is an electro-mechanical rebreather. Over time certain soft-
ware and hardware optional extras and/or software upgrades will become
available. Please check www.HollisGear.com for details.
HARNESS/BCD
EXPLORER uses a custom bolt fitting, backplate, Solo webbing harness,
and Hollis C45LX Wing. There is an optional EXPLORER BCD available.
COUNTERLUNG
The EXPLORER comes complete with dual back-mounted counterlungs
(BCL). These are attached to the canister by a screw threaded O-ring
fitting.
CYLINDER
EXPLORER uses a 5L/40cuft cylinder with an inline valve. Dives over 18
m/60 ft requires that an additional bailout cylinder of a minimum capacity
of 3 L/20 cuft be used in conjunction with the 5L/40 cu ft cylinder.
USA Only Cylinder Options Chart
Capacity Working pressure
Manufacturer WC (L) WC (CU/FT) BAR PSI
Beever (Eurocylinders) 5 41 232 3410
Luxfer (US) 4.9 40 204 3000
Catalina 4.3 35.26 204 3000
Faber 5 41 232 3410
Faber 6 49 232 3410
NOTE: The Explorer can accomadate a maximum 5.5 in/14 cm
diameter tank.
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1.6

8 |
CC
OC
Fig. 1.1
EU Only Cylinder Chart
Capacity Working pressure
Manufacturer WC (L) WC (CU/FT) BAR PSI
Faber 5 41 232 3410
Beever (Eurocylinders) 5 41 232 3410
OUTER CASE
The outer case is made from high impact plastic.
OVER-PRESSURE VALVES
EXPLORER uses a combined water release and balanced Loop Control
Valve (LCV). The balanced valve ensures that, the underwater release
pressure is near-constant in any orientation. When the unit vents it also
removes any water from the exhale counterlung. This is best conducted in
a heads up position.
In addition there is a master (high flow) over pressure release valve that is
set to 40mb to help control ascents.
BOV (BAILOUT VALVE)
EXPLORER comes with a BOV. The BOV attaches to the on-board nitrox
circuit. The BOV is designed as the primary bail out (providing a sufficient/
planned volume is carried).
The BOV has two modes (Fig. 1.1):
• OC (Open Circuit Position)
• CC (Closed Circuit Position)
When the mouthpiece is open, the BOV is in the closed circuit position and
when the mouthpiece is closed it is open circuit position.
INTELLIGENT HUD (HEADS UP DISPLAY) & BUD (BUDDY UNIVERSAL
DISPLAY)
The Intelligent HUD (Heads Up Display) is attached to the BOV in the div-
ers line of sight. There is also a BUD (Buddy Universal Display) display in

the EXPLORER Module for Dive Buddy/Instructor use.
These displays give full alarm status at all times using a visual and a tactile
alarm system.
SENSORS
The EXPLORER uses 3 oxygen sensors and one gaseous CO2sensor. It
also uses a wireless HP sensor.
All sensors are automatically calibrated by the electronic control system.
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1.6

10 |
out of the box
initial assembly
The parts to assemble your EXPLORER include:
1. The Front Case
2. The Back Case
3. The Canister (pre-assembled in the Case Front)
4. The Sensor Module (Pre-assembled into the Canister)
5. The Life Support System (LSS) Module (Pre-assembled into the Canis
ter) secured in the system case
6. The Right Hand End Cap (Pre-assembled into the Canister)
7. The Regulator First Stage (Pre-assembled in the Case Front)
8. The Buoyancy Control Device (BCD)
9. The 5L/40cuft SCUBA cylinder and valve
10. Two Breathing Hoses
11. The combined Dive-Surface Valve (DSV) and Bail-out Valve (BOV)
12. The Absorbent Filter (pre-assembled into the Canister – User Pack
version only)
13. One Exhale counterlung
14. One Inhale counterlung
15. One Loop Control Valve (LCV) counterlung port/tube
16. Three Oxygen Sensors
17. One CO2Sensor - Optional
18. One power charger
ASSEMBLY
Step 1.
Remove all parts from the split top box.
Step 2.
Undo the rubber latches at the base of the Case Front/Back assembly and
lift up the Case Back until the hinge at the top is free (Fig. 2.1). Place to
one side.
Fig. 2.1

Step 3.
Open the box with the Oxygen and CO2sensors in it. Remove the sensors
from the box and open up the airtight bags.
DANGER: All sensors must be allowed to sit in an AIR atmo-
sphere for at least twelve hours prior to use in the EXPLORER.
The Sensors can be immediately assembled into the Sensor
Module but this module should not be fully installed for at least
12 hours after unsealing the sensors packages.
WARNING: After an initial calibration and dive the sensors
should be calibrated again after 24 hours.
Step 4.
Remove the LSS Module by turning the lock ring ½ turn counterclockwise.
Note the orientation in the Canister.
Visually*inspect the large sealing O-rings for damage (Fig. 2.2).
Pull the Sensor Module out from the Canister.
Remove the yellow and black CO2sensor filter cap as shown below (Fig.
2.3). This is a simple O-ring push fit and is retained in place once the Sen-
sor Module is assembled into the Canister, as are all the oxygen sensors.
Push the three oxygen sensors and one CO2sensor onto their respective
connection points as shown in the picture below.
NOTE: Ensure the oxygen sensors are installed with the white
membrane facing up, as shown.
Inspect the the yellow membrane in the CO2 sensor cap to ensure it's flat in
the holder. Then replace the Sensor Module, and refit the cap (Fig. 2.4).
Fig. 2.2
Fig. 2.3
Fig. 2.4
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* The O-ring pick is used in the photo for illustration purposes. It is not
necessary to remove the O-ring before every dive.
2.1
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12 |
Fig. 2.5
Fig. 2.6
Fig. 2.7
Fig. 2.8
Step 5.
Move the LSS module to one side and peel the Optocon charging/
download connector protection cap off as shown (Fig. 2.5).
Plug in the power charger. You will need to rotate the cable end
connector until the key way aligns. Then push it in and tighten up the
black lock ring. The lock ring will spin freely once the connector is ful-
ly assembled. Once connected and power is applied then a red light
will appear on the Electronic Head.
To remove unscrew the ring (which will rotate freely until pulled back
to start the thread) and pull out the connector.
When charging, a Red light appears on the LSS Module. It turns
Green when the LSS Module if fully charged. A full charge takes ap-
proximately 10 hours.
EXPLORER has 3 battery status displays with the charger connected:
1. Battery Charging (Empty) (Fig. 2.6)
2. Battery Charging (Fig. 2.7)
3. Battery Charged (Fig. 2.8)
Once fully charged the LSS Module can be refitted to the Canister.

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To view the charge status of your EXPLORER, do the following:
1. Remove the charger (if attached).
2. Do a long hold of any button on the handset and the Hollis splash
screen (Fig. 2.9) will display. This screen will timeout after 3 seconds
and the "Do Predive" screen (Fig. 2.10) will display.
3. Continue to do a short push of the either button until you see the
central window change to battery status (Fig. 2.11).
WARNING: DO NOT start a dive with a battery minutes display
of less than twice the dive time you intend to do. The Pre-dive
sequence will fail if the battery minutes are too low.
Step 6.
If required attach the BCD to the Case Front using the screws supplied.
Connect the LP inflator hose.
Step 7.
Inspect the mushroom valves in the BOV and make sure they are in place.
Put the BOV into the CC (Closed Circuit) position (Fig. 2.12). Look into one
side of the BOV at the mushroom valve. If you can see daylight through the
other side of the BOV then the valve is not seated correctly.
With the BOV lever in the Closed Circuit position, breathe off the BOV and
ensure the mushroom valves function correctly as per the instructions in
the ‘BOV Assembly’ subsection in the "Complete Disassembly & Reassem-
bly" Part of this manual.
Attach the regulator LP hose to the BOV and gently tighten the nut
to the hose inlet (Fig. 2.13, item C). After inspecting the hose end
O-rings, attach the breathing hoses to the BOV. Ensure the white hose
end goes to the inhale side (Fig. 2.13, item B) of the BOV.
Fig. 2.9

Fig. 2.10
Fig. 2.11
CC
OC
Fig. 2.12
Fig. 2.13
A B
C
2.1
!

14 |
Fig. 2.14
Fig. 2.15
Fig. 2.16
Fig. 2.17
Fit the breathing hose alternate ends to the Canister. Ensure the white
hose end goes to the white coded Canister port.
Confirm the ADV LP feed hose is fitted correctly and tightened to a
torque of 50-60 in-lbs/5.6-6.7 N-m (Fig. 2.14).
Step 8.
Remove the Counterlungs from the packaging. Visually inspect them
for damage.
The Exhale counterlung (Fig. 2.15) is the one with the mushroom valve
in the base (this valve is seated in the LCV port).
The LCV port cap is removed by a ¼ turn counterclockwise. This gives
access to the mushroom valve. Inspect the mushroom valve and LCV
port O-ring and the Canister port O-rings for damage (Fig. 2.16).
Attach the LCV port cap to the counterlung. Twist the cap until it clicks
shut.
If not already installed, attach the LCV tube open end to the LCV on the
Canister, using the clip provided (Fig. 2.17).