Kirby morgan 100-075 User manual

Kirby Morgan Air Control System 5

Operations and Maintenance Manual

KMDSI Part #100-075

Patented, patents pending, foreign patents apply

Kirby Morgan Dive Systems, Inc.

1430 Jason Way

Santa Maria, CA 93455, USA

Telephone (805) 928-7772, FAX (805) 928-0342

E-Mail: [email protected], Web Site: www.KirbyMorgan.com

NOTE: This manual is the most current for the Kirby Morgan Air Control System 5. It is page dated August 2013.

Future changes will be shown on page III and the changed pages will carry the date of change. Previous manuals

may not reect these updates.

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Document Number 130805001

Kirby Morgan, SuperLite, BandMask, Band Mask, KMB, KMB-Band Mask, DSI, Diving Systems International, EXO, REX, Su-

perFlow and DECA are all registered trademarks of Kirby Morgan Dive Systems, Inc. Use of these terms to describe products

that are not manufactured by KMDSI is illegal.

The two dimensional images (such as photographs and illustrations) of our products are © copyrighted and trademarks of Kirby

Morgan Dive Systems, Inc. The three dimensional forms of our products are trademark, trade design and trade dress protected.

this Kirby Morgan product. No part of this manual may be reproduced, stored in any retrieval system, or transmitted, or used in any

form or by any means, whether graphic, electronic, mechanical, photocopy, or otherwise by technology known or unknown, without

the prior written permission of Kirby Morgan Dive Systems, Inc.

BWARNING

Diving with compressed breathing gas is a hazardous activity. Even if you do everything

correctly there is always the danger that you may be injured or killed. No piece of div-

ing equipment can prevent the possibility that you may be injured or killed any time you

enter the water.

Kirby Morgan Air Control System 5

Warranty Information

NOTE: Be sure to complete the enclosed warranty card and return it immediately, or you may register your

purchase online at www.kirbymorgan.com—go to Support.

KMDSI warrants every new Mask, Helmet, Scuba Regulator, Manifold Block or Kirby Morgan Air Control

System 5 (KMACS 5) (each, a Product) to be free from defects in workmanship for a period of three hun-

dred sixty ve (365) days from the date of purchase from a KMDSI authorized dealer. This warranty covers

all metal and plastic parts, but does NOT cover rubber parts, communications components, or head and chin

cushions. In addition, due to the electrolytic nature of underwater cutting and welding, chrome plating can-

not be warranted when the diver engages in these activities.

Any defect of the product in workmanship or material covered by this warranty discovered within three

hundred sixty ve (365) 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 recommend-

ed procedures described in the manual or Product updates have not been performed as recommended by

KMDSI, or

3) Unauthorized attachments or modications 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 Product’s 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 COM-

MERCIAL 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 pe-

riod 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 (in-

Kirby Morgan Air Control System 5

cluding, but not limited to, damages for lost prots, lost sales, loss of business opportunity, or for injury to

persons or property arising out of the use of the Product). 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 super-

sedes 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 reected in the price of the goods. The buyer

acknowledges that it has read this agreement, understands it, and is bound by its terms.

Record Of Changes

It is the responsibility of the owner of this product to register their ownership with Kirby Morgan Dive Systems,

Inc., by sending the warranty card provided. This card is to establish registration for any necessary warranty

work and provides a means of communication that allows KMDSI to contact the user regarding this product.

THE USER MUST NOTIFY KMDSI OF ANY CHANGE OF ADDRESS BY THE USER OR SALE OF

THE PRODUCT.

All changes or revisions to this manual must be recorded in this document to ensure that the manual is up to

date. Quantities marked in parenthesis.

Change Number Date Description of Change

106/11/2009 Updated table of contents layout.

2 02/17/2010 Corrected the PSI to BAR conversion in the Table of Equivalents

308/26/2010 Changed 5.3 Exploded Views & Parts Lists P/N 405-039 to 415-030 and

description updates.

406/13/2012 Updated copyright format

5 08/01/2013 Updated verbiage, images and layout throughout the manual.

Kirby Morgan Air Control System 5

BWARNING

Diving with compressed breathing gas is a hazardous activity. Even if you do everything

correctly there is always the potential for serious injury or death. No one piece of diving

equipment can prevent the possibility that you may be injured or killed any time you enter

the water. The information in this manual is intended for users of KMACS and persons

that maintain or service KMACS.

Table Of Contents

Warranty Information �� II

Record Of Changes �� III

Denition of Signal Words Used in this Manual �� VI

Chapter 1 General Information�� 1

1.1 Denitions �� 1

1.2 Design Purpose and General Description �� 2

1.3 Specications�� 2

1.4 General Description�� 3

1.5 Principle Operating Features �� 3

Chapter 2 Operating Instructions�� 7

2.1 Unpacking The KMACS-5 �� 7

2.2 First Use Of The KMACS-5�� 7

2.3 Connecting The Air Supply �� 7

2.4 Connecting Divers’ Hoses To The KMACS-5 �� 8

2.5 Pre-Dive Check �� 8

2.5.1 Testing L.P. Supply�� 9

2.5.2 Testing Communications �� 9

2.5.3 Testing The Pneumo �� 10

2.6 Descent �� 10

2.7 Diver At Depth �� 11

2.8 Changing Out High Pressure Cylinders�� 11

2.9 Procedures During The Diver’s Ascent �� 11

2.10 Completion Of Diving Operations�� 11

Chapter 3 KMACS-5 Maintenance �� 13

3.1 Recommended Maintenance Of The KMACS-5 �� 13

3.2 Replacing The Battery �� 13

Kirby Morgan Air Control System 5

Chapter 4 Troubleshooting the KMACS-5 System �� 15

4.1 General �� 15

4.2 No Communications �� 15

4.3 No Pneumo Reading�� 15

4.4 No Air To Diver �� 16

Chapter 5 Appendix �� 17

5.1 Communications Wiring Schematics�� 17

5.2 Exploded Views & Parts Lists �� 17

Table of Equivalents�� 19

Appendix 1 Umbilical Supply Pressure Requirements & Tables�� 20

High Pressure Bank Supply �� 20

Low Pressure Compressor Supply �� 20

Kirby Morgan Air Control System 5

Denition of Signal Words Used in this Manual

For your protection, pay particular attention to items identied by signal words in this manual. These terms are

identied as, CAUTION, WARNING and DANGER. It is especially important for you to read and understand

these sections.

BDANGER

This word indicates an imminently hazardous situation, which if not avoided, could result This word indicates an imminently hazardous situation, which if not avoided, could result

in death or serious injury.in death or serious injury.

BWARNING

This word indicates a potentially hazardous situation, which, if not avoided, could result

in death or serious injury.

BCAUTION

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.

NOTICE

This word is used to address practices not related to personal injury.

If English is not your native language and you have any difculty understanding the language of any warnings as they

appear in the manual, please have them translated.

BWARNING

Este é um aviso importante. Queira mandá-lo traduzir.

BWARNING

Este es un aviso importante. Sirvase mandario traducir.

BWARNING

Quest è un avviso importante. Tradurlo.

BWARNING

Ceci est important. Veuillez traduire.

BWARNING

Diese Mitteilung ist wichtig. Bitte übersetzen lassen.

IMPORTANT: A word about this manual. We have tried to make this manual as comprehensive and factual as possible.

We reserve the right, however, to make changes at any time, without notice, in prices, colors, materials, equipment,

specications, models and availability. Since some information may have been updated since the time of printing, please

contact your local KMDSI dealer if you have any questions. Periodically KMDSI Operations and Maintenance Manuals

are reviewed. Any updates/changes will be posted on the KMDSI website and may be downloaded for insertion/correction.

IMPORTANT SAFETY INFORMATION: This Kirby Morgan Air Control System 5 is intended for use by trained

divers who have successfully completed a recognized training course in surface supplied diving

Kirby Morgan Air Control System 5

BWARNING

Follow all the instructions in this manual carefully and heed all safety precautions. Im-

proper use of this equipment could result in serious injury or death.

BWARNING

Kirby Morgan Dive Systems, Inc. (KMDSI) warns all divers who use Kirby Morgan diving

equipment to be sure to use only KMDSI original parts from a KMDSI authorized dealer.

Although other parts, O-rings and ttings may appear to t your Kirby Morgan equipment,

they may not be manufactured to the same standards maintained by KMDSI. The use of

any parts other than KMDSI original parts may lead to equipment failure and accidents.

BWARNING

Diving in waters that are chemically, biologically, or radioactively contaminated is ex-

tremely hazardous. Although Kirby Morgan surface supplied diving systems may be

adapted for use in some contaminated environments, special training, equipment, and

procedures are necessary. Do not dive in a contaminated environment unless you have

been thoroughly trained and equipped for this type of diving.

Read this manual before using or maintaining the KMACS-5, even if you have experience with other surface

supplied diving systems. If you have purchased the KMACS-5 new from a dealer, be sure to send in the

warranty registration card so we may keep you informed of any safety notices that affect this product.

If you resell or loan this equipment to another diver, be sure this manual accompanies the equipment and that

the person reads and understands the manual. In addition to the manual, a log book should be used to log all

repairs, maintenance and use.

BWARNING

This KMACS-5 was completely checked and should be ready to dive as it was shipped

from the factory. However, it is always the diver’s responsibility to check all the compo-

nents of the KMACS-5 prior to diving.

BWARNING

Diving is a life threatening occupation. Even if you do everything correctly you can still

be injured or killed. None of the Kirby Morgan equipment can prevent accidents, inju-

ries or death due to improper training, poor-health, improper supervision, improper job

requirements, improper maintenance or acts of God.

Kirby Morgan Air Control System 5

BWARNING

Never use the equipment without rst completing all pre-dive maintenance and set up

procedures. Failure to complete all pre-dive checks could result in equipment failure

due to problems with the incorrect set-up of the equipment. This could lead to serious

personal injury or death.

BWARNING

Always read the Material Safety Data Sheet (MSDS) for any chemical - adhesive, cleaning

agent, or lubricant - used on your KMACS-5. Some of these chemicals may cause seri-

ous bodily injury or death if used improperly or without the proper personal protective

equipment.

Whenever KMDSI equipment is used in European Countries, which have adopted the CE certication programs,

it must only be used with CE. certied components. Diving operations should only be conducted within the limits

of the operational specications, and in accordance with the rules and regulations established by the governing

authority in the specic country or geographical location where the diving operations are being conducted.

If you have any questions concerning this manual or the operation of your equipment, contact KMDSI (805)

928-7772 or at [email protected] or Dive Lab Inc. (850) 235-2715 or at [email protected]

BWARNING

Some of the procedures shown in this manual are for illustration purposes only. When

using chemicals or materials that require the use of hand or eye protection, always wear

the appropriate personal protective equipment. Failure to use personal protective gear

may result in serious personal injury.

This manual is supplied to the original purchaser of this equipment. If you have any questions about the use

of the equipment or you need another copy of this manual, contact KMDSI or your nearest KMDSI dealer. It

may also be downloaded free from the KMDSI website at www.KirbyMorgan.com.

If you have any questions regarding the use, maintenance, or operation of this equipment, contact KMDSI at (805) 928-

7772, fax: (805) 928-0342, or e-mail: [email protected].

Components requiring lubrication, should only be lubricated with oxygen compatible lubricants such as Christo

Lube®, Flourolube®, or Krytox®. Lubricants must be used sparingly and should not be mixed with other lubricants.

BWARNING

Kirby Morgan “High Pressure Components” (greater than 250 p.s.i.g.,

17.24 bar) must not be used with pure oxygen, Nitrox, or any breathing gas

mixtures with oxygen content greater than 23% by volume. Using oxygen

enriched mixtures in excess of 23% oxygen by volume may lead to a re

or explosion, which could result in serious injury or death.

BWARNING

The KMACS-5 has not been designed or cleaned for oxygen or enriched

oxygen use. The KMACS-5 is intended for air use only. Use of oxygen or

oxygen enriched breathing gas may lead to a re or explosion, which could

result in serious injury or death.

Kirby Morgan Air Control System 5

Kirby Morgan Air Control System 5 with communicator.

Kirby Morgan Air Control System 5 without communicator.

Kirby Morgan Air Control System 5

STOP!

BEFORE GOING FURTHER-

This manual contains an exploded view drawing of the KMACS-5 in the back. Next to the

exploded drawing is a list of the “location” numbers along with the Kirby Morgan part num-

bers. Always use the part number (not the location number) when ordering. It will also help

to specify the model number and serial number as well.

Chapter 1

General Information

1.1 Denitions

The following terms may be unfamiliar to the reader.

They are dened as they relate to this manual and

diving. All parts locations are referenced by LETTER

in the diagram on page 5.

KMACS-5—Kirby Morgan Air Control System

5: The Trademark name of the device this manual

describes. The KMACS-5 contains the features

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-

to-diver. The communicator operates in both the two

wire and four wire mode.

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 from the surface, which

is part of the divers’ umbilical. Usually the source of

the breathing air is a compressor, but compressed air

tanks on the surface can also be used.

Divers’ Umbilical: Several components run

together from the KMACS-5 to the diver. These

components are joined together, usually by tape or

twisting, forming the umbilical. The most common

components used in the divers’ umbilical are: (1) a

hose through which the breathing air ows to the

diver; (2) a multiconductor wire for communications

transmission; (3) another (smaller) hose which is used

to show the divers’ depth on the pneumofathometer

(see pneumofathometer, this section); (4) a strong

line used as a strength member to prevent strain on

the other components of the umbilical.

H.P.—High pressure: Usually any pressure over

300 psi. (20.7 bars).

L.P.—Low pressure: Usually any pressure under

300 psi. (20.7 bars).

High Pressure (H.P.) Hose: A exible hose designed

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 system on the KMACS-5 is 3500

psi (240 bars)

Whip: A hose complete with ttings at each end for

use in hooking up two pieces of deck equipment for

gas (or air) ow. For instance, the hoses and ttings

used to connect the KMACS-5 to the high pressure

tanks are called “high pressure whips.”

Pneumofathometer: (pronounced “new-mo-

fathometer”) This device measures the divers’ depth.

A small hose which is part of the divers’ umbilical

runs from the KMACS-5 to the diver. The hose is

open at the divers’ end and attaches with a tting to

a gauge at the KMACS-5. The gauge is calibrated in

feet and meters of sea water. A valve is installed on

the upstream side of the gauge so the operator can

use a small amount of breathing air to purge the water

from the hose. When the hose has been purged of

water and the valve is closed the excess air bubbles

out of the end of the hose at the diver's end. The air

left in the hose will be at the pressure of the water

column and will show the exact depth of the diver

on the diver's pneumo gauge.

Pneumo: Short for pneumofathometer. Used such

as “pneumo-gauge,” “pneumo-valve”, “pneumo-

hose”, to describe the parts that make up the

pneumofathometer subsystem.

Dressed-in: A commercial divers’ suit was originally

called a “dress.” Although the name changed to

“suit” the term “dressed-in” has remained to describe

putting the suit on. A diver who is “dressed-in” has

a suit on. The term is also used to describe a diver

Kirby Morgan Air Control System 5

who, in addition to his suit, has more, or all of his/

her equipment on.

Bailout Bottle: This is the diver's emergency tank

of breathing gas.

The bailout bottle is an independent air source

connected directly to the divers’ mask or helmet via

a rst stage scuba regulator and hose. The rst stage

regulator must be equipped with an overpressure

relief valve (Part #200-017). The overpressure

relief valve will vent pressure in the event of a rst

stage leak and prevent the low pressure hose from

rupturing, causing a complete loss of the divers’

bailout supply. The bailout bottle is worn on the

divers’ back, mounted to a harness.

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

1.2 Design Purpose and General

Description

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

the electronic components. The KMACS-5 should

be treated as you would any expensive life support

equipment.

The Kirby Morgan Dive Control System 5

(KMACS-5) is designed to provide a central control

center for the operator/dive supervisor during a

surface-supplied 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 tted with shut off valves on the

divers’ air supply. The shut off valves are designed

to allow air to be shut off on either or both of the

divers’ umbilicals. When the handles of the valves

are vertical the valves are open and air is owing 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

divers’ needs without leaving the control station. In

a standard commercial surface supplied air (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 divers’ umbilical while

maintaining control of the KMACS-5.

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. Transportation 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 efcient operation

of SSAir diving.

1.3 Specications

Use: For SSAir diving only. Enriched air (Nitrox)

or 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

Kirby Morgan Air Control System 5

BWARNING

Pure oxygen is a potential re hazard,

its use can lead to explosion of the

KMACS-5. Pure oxygen also presents a

physiological hazard to the diver.

1.4 General Description

Outer Dimensions: Length = 21 inches

Width = 18 inches

Height= 11 ½ inches

Weight: 54 pounds. (24.5 kilos)

Shipping Weight: 60 pounds. (27 kilos)

BCAUTION

Decompression and other human limits

must be observed. Decompression div-

ing should not be conducted with the

KMACS-5 unless a properly equipped

recompression chamber facility with

oxygen is immediately available at the

dive site. In-water decompression is not

recommended.

Recommended Maximum Dive Support Depth: 130

fsw (feet of sea water) (40 meters).

High Pressure Supply Pressure Recommended

Maximum:

3500 psi. (240 bars) using the DIN tting

3000 psi (200 bars) using the yoke

NOTICE

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 de-

signed to operate at pressures greater

than 3500 psi (240 bars).

Low Pressure Supply Pressure Maximum: 250

pounds per square inch. (15.5 bars)

Umbilical Pressure Range: 115-225 pounds per

square inch. (8-15.5 bars)

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: 20 watts.

Communicator Frequency Response: 600 to 12,000

HZ.

Direct Recording Capability: Yes.

1.5 Principle Operating Features

1. Main Control Panel (A)

The main panel is the 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 (L, R) on the panel represent the

ow paths of supply air from the two high pressure

hoses/yokes (T).

2. Red Diver Depth Gauge (C)

(Pneumofathometer)

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 divers’ 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 divers’ depth. The divers’

pneumo hoses are attached to the matching color side

ttings (F). Red diver to red pneumo tting.

3. Umbilical Pressure Gauge (B)

This gauge (B) is connected to the low pressure air

supply system that supplies both umbilical ttings.

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 (I)

4. White Diver Depth Gauge (Q)

(Pneumofathometer)

This gauge indicates the “white” diver depth. The

white diver pneumo valve knob (P), is turned to

supply a small volume of air to the small pneumo-

Kirby Morgan Air Control System 5

hose that is part of the divers’ 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 divers’ depth. The

divers’ pneumo hoses are attached to the matching

side ttings (F). White diver to white pneumo tting.

5. Breathing Air Subsystem (T)

The divers’ breathing air subsystem starts with the

supply tank yokes (T) and connects to the divers’

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.

6. Blue Air Supply Flow Indicator Line (R)

The “BLUE” air supply flow indicator line (R)

indicates the ow path of breathing air from entry

into the KMACS-5 to exit to the divers’ umbilicals

at the ttings on the manifold (E). There are two

high pressure whips which are color coded BLUE

and ORANGE.

Starting from the high pressure air tank, the BLUE air

supply ows through the whip into the KMACS-5.

Following the BLUE ow indicator line (R) it shows

the ow to the BLUE Breathing Air Supply Pressure

Gauge (N), then to the Breathing Air Supply Selector

Valve which is controlled by the Breathing Air

Selector Valve Handle (J). The Selector Handle (J)

must be turned all the way “UP” until it stops for the

BLUE supply. This places the selector valve handle

in line with the ow path indicating the “BLUE” air

supply (R). The ORANGE supply is off when the

Selector Handle is in the up position.

After owing through the Selector Valve the BLUE

air supply enters the Breathing Air Supply Regulator

(I) 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 divers’ umbilicals through the ttings

on the manifold (E).

BCAUTION

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”.

7. Orange Air Supply Flow Indicator Lines

(L)

The “ORANGE” air supply flow indicator line

indicates the ow path of breathing air from entry

into the KMACS-5 to exit to the divers’ umbilicals

at the ttings on the manifold (E). The second high

pressure whip is color coded ORANGE.

Starting from the high pressure air tank, the ORANGE

air supply ows through the whip into the KMACS-5.

Following the ORANGE ow indicator line (L) it

shows the ow to the ORANGE Air Supply Pressure

Gauge (M), then to the Air Supply Selector Valve

which is controlled by the Breathing Air Selector

Valve Handle (J). The Selector Handle must be all

the way “DOWN” until it stops for the ORANGE

supply. The BLUE supply is off when the Selector

Handle is in the down position.

After flowing through the Selector Valve the

ORANGE air supply enters the Breathing Air

Supply Regulator (I) 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 divers’ umbilicals through the ttings on the

manifold (E).

The air supply to both divers can be controlled by

shut-off valves located on the manifold (H). When the

valve handles are up (vertical), the valves are open.

When the valve handles are down (horizontal), the

valves are closed.

8. Low Pressure Inlet Fitting (O)

The low pressure inlet tting is positioned between

the connections for the two H.P. supply hoses. It

is marked by the arrow containing the words “L.P.

Supply”. Low pressure supply breathing air, usually

from a compressor (with volume tank) is supplied

through a whip (low pressure hose and ttings) that

attaches here. When the low pressure supply is the

only air source, the supply pressure will be indicated

on the umbilical pressure gauge (B). In the low

pressure supply mode, the selector/valve handle will

be positioned in the H.P. OFF ZONE.

9. Blue Breathing Air Supply Pressure

Gauge (N)

The Blue H.P. supply pressure gauge (N) indicates

the pressure remaining in the “BLUE” high pressure

tank. (NOTE: If two divers are supplied by the

KMACS-5 both divers will be breathing from the

same selected high pressure supply).

Kirby Morgan Air Control System 5

AMain Control Panel

B Umbilical Pressure Gauge

C Red Diver Depth (Pneumo) Gauge

D Pneumo Valve Handle, Red

E Divers Umbilical Hose Attachment Fittings

(#6 JIC Male)

F Pneumo Hose Attachment Fittings

(#4 JIC Male)

G Pneumo Blocks (2)

H Shut-off Valves (2)

I Regulator Adjustment Knob

J Air Supply Selector Valve Handle

K Case

L Orange Air Supply Flow Line

M Orange H.P. Air Supply Gauge

N Blue H.P. Air Supply Gauge

O Low Pressure Inlet Fitting (#8 JIC Male)

P Pneumo Valve Handle, White

Q White Diver Depth Pneumo Gauge

R Blue Air Supply Flow Line

S Communicator

T Yokes w/DIN Fittings for H.P. Cylinder

Attachment

U Access door for storage compartment.

V O-ring Seal

W Communicator Panel

S

A

N

T

A

B

A

R

B

A

R

A

C

A

L

I

F

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R

N

I

A

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A

B

A

R

B

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H.P.SUPPLY

L.P. SUPPLY

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.

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250PSI MAX

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D

AIR CONTROL SYSTEM-5

I

U

M

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Figure 2

10. Orange Breathing Air Supply Pressure

Gauge (M)

The H.P. Orange supply pressure gauge (M) indicates

the pressure remaining in the “ORANGE” high

pressure tank. (NOTE: If two divers are supplied by

the KMACS-5, both divers will be breathing from

the same selected high pressure supply).

Blue Air Supply

Flow Path Indicator Line

Orange Air Supply

Flow Path Indicator Line

Orange Air Supply Whip

Figure 3 Air ow paths from the H.P. cylinders.

11. Yokes For High Pressure Cylinder

Attachment (T)

The yoke ttings (T) provided have standard U.S.

scuba cylinder attachments as well as Din Fittings.

Each yoke has a bleeder valve to vent the remainder

of the pressure in the whip when changing out scuba

bottles. The yokes attach to posts mounted on the

panel in the lid of the KMACS-5 for storage and

transport.

12. Case (K)

The Dive Control panel assembly is attached to the

bottom half of the case (K). 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.

13. Breathing Air Supply Selector Valve

Handle (J)

This handle (J) controls the two position Air Supply

Selector Valve and allows uninterrupted diving

operations while full air supply tanks replace

expended tanks. The selector valve controls ONLY

Kirby Morgan Air Control System 5

the high pressure air supply. It is NOT possible to

shut off any low pressure supply connected to the

low pressure inlet tting (O), at the KMACS-5 itself.

When changing out the H.P. air supply cylinders,

always observe the divers umbilical pressure gauge

(B) for any sudden fall in pressure. Should this occur,

it may indicate that the cylinder in use has mistakenly

been turned off or breathed dry. If so, immediately

turn the cylinder back on and move the selector valve

handle to select the full cylinder and change out the

expended cylinder.

Due to the construction of the selector valve, it is

not possible for gas to back-ow from one cylinder

to the other.

BCAUTION

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”.

14. Regulator Adjustment Knob For

Umbilical Pressure (I)

The regulator Adjustment Knob (I) allows the

operator to adjust the umbilical pressure within a

range of 115 psi to 250 psi (8-17 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.

15. Outlet Manifold Including Divers’

Umbilical Fittings (G)

The “WHITE DIVER” and “RED DIVER” air

supply umbilicals are connected to the KMACS-5

at the manifold (E). The standard ttings coming

out of the KMACS-5 are male #6 JIC (⅜", 37°)

ared ttings—other ttings for other umbilicals

may also be used. The divers’ air supply hoses must

have matching female ttings. Shut-off valves are

positioned between the manifold and the divers’ air

ttings. The air is on when the valve handle is vertical

and is off when the valve handle is horizontal.

The “WHITE DIVER” and “RED DIVER” pneumo

hoses are also connected to the KMACS-5 at

the manifold (F). The ttings coming out of the

KMACS-5 are male #4 JIC ( ¼", 37°) ared ttings.

The divers’ pneumofathometer hoses must have

matching female #4 JIC (¼", 37°) ared ttings with

swivel nuts—other fittings may also be used.

16. Pneumo Valve Knob, White Diver (P)

The Pneumo Valve Knob, White Diver turns on and

off the air supply to the “WHITE” pneumofathometer

system.

17. Pneumo Valve Knob, Red Diver (D)

The Pneumo Valve Knob, Red Diver turns on and

off the air supply to the “RED” pneumofathometer

system.

18. O-ring Seal (V)

The O-ring seal helps keep dust and moisture out

of the KMACS-5 when the case is closed. The

O-ring seal is not pressure proof; however, and the

KMACS-5 case will ood if the box is submerged.

19. Communicator Panel (W)

The divers’ electronic communicator (S) is attached

to the communicator panel. The battery for the

communicator is located behind this panel.

20. Communicator (S)

The KMACS-5 communicator is a standard open

circuit/round robin divers’ communicator, which

functions like a telephone. It can also be used as a

2 wire, “push-to-talk” system. It is connected to the

divers’ umbilicals by “banana plug” ttings on the

communicator. The communicator is mounted on the

communicator panel. You should read and understand

the accompanying radio operations manual supplied

with the unit before using the unit. Improper use or

connections could damage the radio.

BCAUTION

Never connect the charger during a dive

or when anyone is in contact with con-

nected equipment. Although electrical

shock danger is remote, connection

of the recharging cord should only be

done when the KMACS-5 is not in use.

Kirby Morgan Air Control System 5

Chapter 2

Operating Instructions

2.1 Unpacking The KMACS-5

When you rst 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

le at KMDSI. You may also register your purchase

for warranty online at www.kmdsi.com. Under

“Support” see Product Registration Form.

Visually check the KMACS-5 to ensure that it has

not been damaged in transport.

Figure 4 Note the line which passes through the handle

of the KMACS-5 and is secured to the rail to prevent the

KMACS-5 from moving about.

2.2 First Use Of The KMACS-5

Place the Air Control System on a rm surface. The

KMDSI logo should be right side up. Release the

latches and lift up the lid to expose the panels.

When using the KMACS-5 aboard a vessel subject

to waves or swell, be sure the KMACS-5 is secured.

Tie back the lid of the KMACS-5 as well to prevent

damage or injury.

Figure 5 Connecting a scuba air supply to the KMACS-5.

2.3 Connecting The Air Supply

Loosen the knurled knobs which connect the yokes

to their storage posts in the KMACS-5 and remove

the yokes (T) from the blocks. Attach each yoke

to a high pressure cylinder as you would connect

a scuba regulator to a tank. The knobs on the yoke

should be screwed down nger tight. Do not apply

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.

Kirby Morgan Air Control System 5

Figure 6 Always use the right size wrench to connect the

hoses to the KMACS-5.

Check the function of the selector handle to ensure

correct operation.

BCAUTION

Low pressure compressors used for

breathing air should be specically de-

signed for diving. Paint compressors or

similar equipment are unacceptable for

diving applications.

BDANGER

If a low pressure compressor is used,

the intake must be at a sufcient dis-

tance from and upwind of the exhaust.

If exhaust gas is sucked into the intake,

the diver will suffer from carbon monox-

ide poisoning. This can be fatal.

In normal use, a low pressure compressor or air

source should be used as the primary air supply and

scuba cylinders should be used as a backup, or reserve

air source.

Prior to connecting the low pressure hose to the

KMACS-5, the deck whip should be ushed with air

to make sure no foreign matter is in the hose. Connect

the deck whip to the low pressure compressor and

while rmly holding the end of the hose start the

compressor and ow air through the deck whip for

at least one minute. Attach the low pressure hose to

the low pressure inlet tting (O) and screw the tting

down nger tight. While using one wrench to hold

the low pressure inlet tting tighten the hose tting

with a second wrench. Do not use excessive force as

this will only damage the tting and cause it to leak.

2.4 Connecting Divers’ Hoses To The

KMACS-5

Each divers’ umbilical should be color coded with

plastic tape to identify each individual hose. This

action will not only serve to make it easier to connect

the hoses, but will also serve to differentiate between

hoses for purposes of inspection or repair.

BWARNING

Contaminated water diving operations

are very hazardous. They should not be

attempted without specialized training,

procedures, and equipment.

Remove the protective caps from the outlets of the

manifold (E, F) on the console. Connect the divers’

umbilical hose ttings (air supply hose and pneumo)

to the KMACS-5. Remove the end caps from the

hoses themselves and while rmly holding the end

of the hose, blow out the lines before connecting the

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 tting on the

hose to the tting on the mask or helmet.

Connect the communications portion of the divers’

umbilical to the communications fittings on the

communicator and to the mask or helmet. Be sure

the proper connection is made with the correct

communications line for each diver. The wires in the

umbilicals should be marked so it is easy to identify

which plug connects to the earphone terminals and

which plug connects to the microphone terminals.

2.5 Pre-Dive Check

Prior to EVERY dive, the following should be

checked:

With the free ow and demand regulator on the mask/

helmet(s) shut off, turn on the air supply at each of

the air cylinders. During operation with scuba bottles

Kirby Morgan Air Control System 5

as the main supply, the selector valve handle must

be FULLY up or FULLY down. Fully up turns the

“BLUE” supply on and the “ORANGE” supply off.

Fully down turns the “ORANGE” supply on and the

“BLUE” supply off.

Note the air pressure in each cylinder by reading the

gauges (M,N). The low pressure supply should be

switched “OFF” at the source at this time. A check

valve in the low pressure system prevents back ow

to the compressor.

Both cylinders should be full prior to diving. Load

the regulator on the KMACS-5 using the regulator

adjustment knob (I). Observe the umbilical hose

pressure (B) which should be set at 150 psi (10.3

bars) over top side pressure, or 165 psi (11.5 bars)

The regulator used in the KMACS-5 is a non-venting

regulator. If the regulator has been left set at a higher

pressure setting than is presently desired, the operator

must turn the regulator adjustment knob (I) clockwise

and vent air from the system by bleeding either the

pneumo system or divers’ breathing apparatus.

As the diver descends, the KMACS-5 operator should

increase the regulator setting so that the umbilical

pressure is always 150 psi (10.3 bars) over the pressure

at the divers’ depth. Consult the table in “Appendix 1

Umbilical Supply Pressure Requirements & Tables”

on page 20 for approximate pressure settings.

2.5.1 Testing L.P. Supply

With the air on at the bottles and the communications

switched on, check the regulator function. The diver

should insert his face into the mask/helmet and take

several breaths to test the demand regulator.

To test the low pressure supply, place the selector

valve handle (J) in the “H.P. OFF” zone and the

console will be running off the low pressure supply

only. Observe the umbilical pressure gauge (B). As

the compressor cycles, the gauge will rise and fall as

the compressor’s volume tank lls and empties. The

maximum pressure for the L.P. inlet should be 225

psi. Again, check the mask/helmet function which

will also conrm the low pressure supply routing.

2.5.2 Testing Communications

Test the communications between the diver and the

KMACS-5. With the communicator (S) 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 and the

4 wire mode without headset and boom microphone,

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. In

the 4 wire mode, with headset and boom mic, the

communicator functions like a telephone conference

call; i.e., everyone on the line can hear and speak to

everyone else. In either mode, for the diver to talk

top side, it is only necessary for him to speak into the

oral/nasal microphone in his mask or helmet. If two

divers will be working together using 2 wire mode,

test the cross-talk functions at this time as well.

To extend the life of the battery, it is recommended

that the communications be used in the 4 wire mode.

Operation as a 2 wire system uses relays inside the

unit which will cause a higher battery drain.

BCAUTION

In the 2 wire mode, when the push-to-

talk switch is depressed, the KMACS-5

operator should keep all of his commu-

nications short (10-15 seconds) at any

one time. This allows the diver to call

for assistance if necessary.

Plug the earphone connectors on the divers’ umbilical

into the earphone jacks on the communicator. Plug

the microphone connectors on the umbilical into the

microphone jacks on the communicator. This will

create a 4 wire system/round robin system. Test the

system and adjust all volume controls.

Figure 7 Preliminary testing of the umbilical with a volt-

ohm meter to check for continuity.

Unplug the earphone connectors on the divers’

umbilical from the communicator and reinstall

them in the connectors attached to the plugs for the

microphone. This will change the communicator to a

2 wire system. Test this system and adjust volumes.

Kirby Morgan Air Control System 5

If there are no communications, recheck all of the

connections to ensure they are tight at each junction.

Look for corrosion on the top side connectors which

may interfere with communications. If corrosion is

evident, disassemble the connectors, clean, and retest.

If corrosion is heavy, replace the top side connectors.

If a failure is detected, you may substitute other

masks/helmets or umbilicals to track the fault down.

Substitute one piece of new gear at a time. If the fault

is in the mask or helmet, replace the earphones or

microphones as needed.

If the fault is in the umbilical, disconnect the

umbilical and carefully inspect its length for damage.

Look for obvious nicks or cuts.

If there is physical damage to the outside of the

communications wire, there probably is a break on

the inside too. Test the continuity of the wire end-to

end with a volt-ohmmeter.

Uncoil the umbilical and lay it out at with the two

ends close to each other. Set the volt-ohmmeter

to resistance (ohms) and hold one probe to one

prong on the umbilical connector plug and touch

the other probe from the meter to each of the wires

(or connector) at the opposite end of the divers’

umbilical. Upon contact with the other end of the

same wire, the meter should indicate zero resistance,

i.e., there is a complete, uninterrupted circuit. If

none of the wires at the other end of the umbilical

produces a zero reading, and instead all readings are

innity (∼), this indicates a complete break in the

wire. If the reading is somewhere between zero and

innity, and changes as the umbilical is moved, this

indicates a partial break, and communications will be

intermittent. In either case, a waterproof splice must

be made in the wire.

Repeat the check procedures described above for

each prong on the umbilical plug.

2.5.3 Testing The Pneumo

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 (divers’ end) of the red diver

pneumo hose. With the hose crimped tightly shut,

slowly open the red pneumo valve (D) momentarily,

¼ turn, and observe the needle’s response on the red

diver depth pneumo gauge (C).

NOTICE

Do not “peg” the needle on the depth/

pneumo gauge with a maximum read-

ing. A test of pressure equal to 50 feet

(15 meters) on the gauge is satisfactory

to ensure correct operation.

Close the valve after observing correct operation

and release the end of the pneumo hose. The gauge

needle should return to zero. Repeat this procedure

for the white diver.

Figure 8 Carefully test the pneumo prior to every dive.

BWARNING

The KMACS-5 operator must not leave

the dive control system unattended

while the diver is in the water. The

KMACS-5 operator is directly responsi-

ble for the divers’ safety and well being.

2.6 Descent

Upon entering the water, the diver should immediately

recheck communications with top side and ensure that

the mask or helmet is working correctly. When ready

to descend, the diver noties the KMACS-5 operator

by saying, “Leaving the surface.”

Once the diver has entered the water, monitor his

descent rate using the pneumo valve (D,P) and gauge

(C,Q). The divers’ descent rate should not exceed 75

feet (23 meters) per minute.

Kirby Morgan 100-075 User manual

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