O.M.G. CASTORO C96 PRO User manual

ITALY
Redatto: Dario Chericoni - UTE
Approvato: Dario Chericoni - DIR
Revisione: 00
Edizione: 16 Aprile 2002
TECHNICAL
MANUAL
MT A026
OFFICINE
MECCANICHE
GENERALI
OPERATIONS AND MAINTENANCE MANUAL
FULLY CLOSED CIRCUIT OXYGEN REBREATHER CYCLIC TYPE

Warranty Information
O.M.G. snc warrants every rebreather Castoro C96PRO to bee free from defects
in workmanship for a period of one (1) year from date of purchase. This warranty
don't cover rubber parts.
Should any part become defective, contact your nearest authorized O.M.G.
dealer. If there is no dealer in your area contacts O.M.G. directly at +039
187632128 or FAX [phone]. You must have a return authorization from
O.M.G. . Upon approval from O.M.G., return the defective part, freight prepaid to
O.M.G. plant. The part will be repaired or replaced at no charge as deemed
necessary by O.M.G.
This warranty becomes null and void if:
- The product has not been properly serviced and maintaned according to the
appropriate O.M.G. Manual
- Unauthorized modifications have be made to the product
- The product has been abused or subjected to conditions which are unusual or
exceed the product's intended sevice.

TABLE OF CONTENTS
WARRANTY INFORMATION 1
TABLE OF CONTENTS 2
SIGNAL WORDS 3
1.INTRODUCTION 4
2.TECHNICAL DATA 5
3.DESCRIPTION 6
4.FUNCTIONAL DESCRIPTION 8
5.PRE-DIVE PREPARATION 10
6.DIVE 13
7.MAINTENANCE 14

Definitions of Signal Word
Used in this Manual
Danger:
Warning:
Caution:
.
This words indicates an imminently hazardous situation, which if not
avoided, will result in death or serious injury
This words indicates a potentially hazardous situation, which if not avoided,
could result in death or serious injury.
This words 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 pratices.
Due to the constant improvements of it's product, O.M.G. snc reserves the right to modify them, saving the essential
characteristics here to described and illustrated.

1. INTRODUCTION
Castoro C96PRO is a new fully closed circuit oxygen rebreather designed by O.M.G. firm in La
Spezia, Italy, for recreational and technical use.
Castoro C96PRO is one of the most compact and lightest weight fully closed circuit oxygen
rebreather on the market.
CASTORO C96CPRO has an innovative soft shield composed of keviar-cordura wich keeps and
protects the polyurethane rubber breathing bag from possible cutting and abrasion under special
operating conditions.
An optional jacket, w/out buoyancy compensator, allows to wear the C96 PRO, fast and
comfortably. Moreover, the jacket is equipped of several fast-releasing weight pockets, both on
the back and sides, so as to correctly balance the diver.
Figure 1- Fully Closed Circuit Oxygen Rebreather CASTORO C96PRO

2. TECHNICAL DATA
Manufacturer: O.M.G. snc, Via Vincinella Loc. Ponzano S. Stefano
Magra, La Spezia
Order No 402-001.00
Working Principle: cyclic
Breathing Gas: pure oxygen
Cylinder (two type available):
volume 1,5 litres 2 litres
pressure: 200 bar200 bar
material: aluminium alloy steel
Breathing Bag Volume: 9,5 litres
Carbon Dioxide Scrubber : soda lime, abt 2 kg
Duration: according to the activity up to 3 hours
Maximum Depth: 6 metres, (ppO 1,6 ATA)
Weight: 6 kg, ashore
Dimensions: L 400 mm x W 400 mm x H 110 mm
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CASTORO c96
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3. DESCRIPTION
Castoro C96PRO consists of the following main components (see figure 2):
Breathing bag. Made with poliurethane rubber sheets high frequency electronically
welded. The breathing bag has been placed in manner to give a small hydrostatic
pressure difference as possible, i.e. low inhalation and exhalation resistance.
Cylinder. Two cylinder type are available on request:
1,5 litres/200 bar realized in aluminium alloy for decrease the magnetic level
2 litres/200 bar realized in steel alloy
Shut-off valve assy. Open or close the gas flow from the cylinder, includes the manual
actuating type bypass, the pressure reducer and the safety valve
Pressure gauge. Test the internal cylinder pressure.
Canister. Contains the soda lime wich absorbs the carbon dioxide due to respiration
acts. The canister is made in such way that it becomes completely surrounded by a
gas flow wich prevents the soda lime from beeing cooled down by surrounding water.
Hose connector. Carries the inhalation and exhalation hose gases in proper manner to
and from soda lime canister .
Inhalation and exhalation hose. Both hoses are provided with non return valves wich
control in proper manner the flow direction.
Mouthpiece. The mouthpiece contains a rotary valve wich isolates the circuit from the
atmosphere when it is in closed position. In the open position, the rotary valve supplies
the oxygen to the diver.
Mouthpiece retainer Help to retain the mouthpiece in the diver's mouth
Harness The harness (neck strap and waist strap) are easy to adjust to desidered lenghts.
Soft shield made with high resistance kevlar cordura. Contains the breathing bag
equipped with the hose connector and hoses, protecting the breathing bag against
tearing and abrasions.
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CASTORO C96PRO - Figure 2, Main Components

4. FUNCTIONAL DESCRIPTION
Rebreather is a simply device that capture and recirculate the exhaled breath, scrub out the
carbon dioxide produced by the respiratory functions and add oxygen to replenish what
comsumed.
Castoro C96PRO is a cyclic type fully closed circuit oxygen rebreather.
Instead of a one-way gas circulation, to and from breathing bag as pendular type, the gas
circulates in two separate directions.
During the respiratory cycle the gas circuit is as in figure 4.
High pressure gas (see figure 5) passes from the oxygen cylinder through the bypass valve into the
breathing bag, expanding same and assuming the environmental pressure.
The diver inhales the oxygen from the breathing bag through the inhalation hose and
mouthpiece and exhales the respiration gases through the exalation hose into soda lime canister
(the non-return valve contained in each hose, controls in proper manner the flow direction).
The soda lime absorbs and fixes the carbon dioxide contained in the respiration gases and
purifies fully the non metabolized oxygen.
Therefore the oxygen passes in the breathing bag and the cycle starts again.
CASTORO C96PRO - Figure 4, Breathing Loop
BREATHING BAG
OXYGEN CYLINDER
INHALATION
HOSE
EXALATION
HOSE MOUTHPIECE
SODA LIME
CANISTER

Actuating the by-pass lever is possible to restore the oxygen metabolized or to inflate quickly the
breathing bag.
An high pressure gauge screwed on valve assy shows the pressure rate of the cylinder.
CASTORO C96PRO - Figure 5, Functional Diagram

5. PRE-DIVE PREPARATION
Checks and Refills Oxygen Cylinder.
Warning:
Warning
Checks and Fill Soda Lime Canister
Warning:
Before every dive with the rebreather it is necessary to check the following
Open the shut-off valve and verify the pressure value on the gauge; If the pressure value is less
than 190 bar refill the cylinder with pure oxygen as follows:
open slowly the shut-off valve; the high pressure oxygen flow may
burn or explode
close the shut-off valve
push down the bypass button to assure wich the pressure discharge (make sure that high
pressure gauge indicates zero).
unscrew the gauge hose nut with the spanner wrench size no 28, PN 400-900, and remove
the gauge complete fom the rebreather
connect the high pressure refilling hose to refilling connection
open the shut-off valve
follows the relevant instructions to refilling the cylinder.
verify the cylinder test date; discarge and replace if necessary
unscrew the lock screw of the hose connector
remove the hoses connector complete with corrugated hoses and mouthpiece from the
breathing bag.
remove the soda lime canister from the breather bag (to remove canister, take it firmly with
the filler plug in vertical position and rotating slowly the canister draw it.
make sure don't damage the breathing bag torus gasket
CASTORO C96PRO
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points:
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unscrew the canister plug and fill, using a funnel, with the appropriate soda lime (fill the
canister a bit at a time and tap the sides of the canister to ensure that it is packed with no
gaps).
soda lime dust is caustic and can cause chemical burns
if the soda lime isn't packed tightly in the canister this can lead to “channelling”, where
the exaust gas passes through the scrubber without coming into full contact with the carbon
dioxide absorbent.
screw the plug, verify the canister O ring (discharge and replace if necessary) and put
the canister into the rebreathing bag.
verify the seating of canister, put down with care the canister and insert the torus gasket
in the seating
install the hoses connector complete and turning gently the same assuring that the
gasket goes into filter seating.
lock with the screw
Caution:
Warning:
Figure 6 a, Refilling Soda Lime Figure 6 b, Tapping the Sides of Canister

Final Check
Once you have completely assembled the rebreather, test it to ensure there are no leaks
make sure that the four way valve is turned in closed position (lever down ward)
slowly open the shut-off valve
push down the bypass button and inflate moderately the breating bag
submerge the rebreather in a tub of water and looking for leaks
if a leak is detected, it is necessary locate and repair it before the dive
Leaks can occur any number of places; check the breathing bag and hoses for punctures; check
all the fitting and hoses connector to make sure they are properly closed.
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6. DIVE
Donning the Rebreather
On Surface
Dive with Rebreather
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insert the neck strap on the neck
insert the waist strap
adjust and put the breathing bag at the same height of diver's counterlungs
open shut-off valve
put the four way valve lever in up ward
inflate a little bit the breathing bag actuating the bypass button
put mouthpiece and rotate the four way lever in down ward
inhale with mouth and exhale with nose within the breathing bag is empty
rotate the four way valve lever in up ward and leave mouthpiece.
This operation clean the bag from the other gases inside
: It’s very important to make properly this operation to make sure wich no nitrogen gas is
Still in the breathing bag..
put mouthpiece with the four way valve lever in up ward
exhale all the air from the counterlungs through the four way valve
rotate the four way valve lever in down ward
inflate a little bit the breathing bag actuating the bypass button
start the dive and during the first breath exhale from nose (in this manner the nitrogen gas into
the counterlungs is completely blow away)
inflate when necessary, to compensate the oxygen usage, actuating the bypass button
DANGER
: It’s very important to make properly this operation to make sure wich no nitrogen gas is
Still in the breathing bag..
DANGER

7. MAINTENANCE
Post Dive
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rinse with fresh water the rebreather with the four way valve lever in up ward
draw out the canister fom the breathing bag
empty the canister from soda lime
rinse the canister with fresh water and blow out residual soda lime granules from canister
rinse with fresh water hoses connector complete of hoses and four way valve
disinfect this assy with a bactericide solution and rinse again
rinse into the breathing bag, disinfect with a bactericide solution and rinse again
allow to dry all the components at a shady place before assembly
lubricate with YNX grease, PN 300- 500, as illustrated in figure 7.ONLY
CASTORO C96PRO - Figure 7, Lubrication Chart
CASTORO c96
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FOMBLIN YNX
FOMBLIN YNX
FOMBLIN YNX
FOMBLIN YNX
FOMBLIN YNX
FOMBLIN YNX

CAUTION
Biennial Maintenance
Overhaul
Breathingh Bag Repair
CAUTION:
:all the components must be grease only with YNX grease, PN 300-500. Any other kind
of oils and greases may burn or explode in contact with a pure oxygen flow.
Test the cylinder
Overhaul the shut-off valve (manufacturer workshop)
Major overhaul of complete rebreather (manufacturer workshop)
Material and tools required:
emery cloth grain size 100*
Aquasure adhesive*
brush*
cleaning gasoline
poliurethane rubber patch*
punches and scissor
inflate the rebreathing bag, localize and mark the damaged area
roughen with emery cloth
clean with gasoline and let dry up for about fifteen minutes
roughen and clean the patch
coat with Aquasure adhesive the surfaces of patch and breathing bag
Aquasure adhesive contains toluene. Use only in well airy area. Avoid prolonged
breathing of vapors do not use closed to heat or flames. Do not ingest. If swallowed do not
induce vomiting. Seek medical aid immediately. Avoid contact with skin or eyes. Keep out of
reach of children.
place patch in position and press on it firmly
complete hardening takes place after one day.
(Every Four Years)
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*material contained in maintenace and repair kit, PN 401-015

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test repair before using
Material and tools required:
Aquasure adhesive*
emery cloth grain size 100*
brush*
cleaning gasoline
localize the puncture on the damaged hose
roughen with emery cloth
clean with gasoline and let dry up for about fifteen minutes
coat with Aquasure adhesive the surface roughened with a thickness of about 1,5 mm
complete hardening takes place after one day.
test repair before using
Aquasure adhesive contains toluene. Use only in well airy area. Avoid prolonged
breathing of vapors do not use closed to heat or flames. Do not ingest. If swallowed do not
induce vomiting. Seek medical aid immediately. Avoid contact with skin or eyes. Keep out of
reach of children.
Hoses Repair
CAUTION:
*material contained in maintenace and repair kit, PN 401-015