Ocean Technology Systems MK-7 BUDDY-LINE User manual

Two-Diver Intercom
“Technology in Depth”
User Guide
MK-7 BUDDY-LINE®

- Notice -
This manual and the information contained herein are provided for use as a
maintenance and operation guide. No license or rights to manufacture, pro-
duce, and/or sell either the manual or articles described herein are given.
Undersea Systems International, Inc., dba Ocean Technology Systems, re-
serves the right to change specifications without notice. It is recommended
that all users read and fully understand this manual before using the MK-7
BUDDY-LINE®.
All statements, technical information, and recommendations herein are
based on tests we believe to be reliable, but the accuracy or completeness
thereof is not guaranteed; and the following is made in lieu of all warran-
ties, expressed or implied, including the implied warranties of merchant-
ability and fitness for purpose: Seller’s and Manufacturer’s only obligation
shall be to replace such quantity of the product proved to be defective.
Before using, the user shall determine the suitability of the product for
intended use, and the user assumes all risk and liability whatsoever in con-
nection therewith. Neither Seller nor Manufacturer shall be liable either in
tort or in contract for any loss or damage—direct, incidental, or conse-
quential—arising from the use of or the inability to use the product. No
statement or recommendation not contained herein shall have any force or
effect unless it is in an agreement signed by officers of the Seller and Manu-
facturer.
- IMPORTANT SAFETY NOTICE -
(Please read before using product.)
IT IS ABSOLUTELY ESSENTIAL THAT ALL DIVERS ARE PROPERLY
TRAINEDANDEQUIPPEDANDFULLYUNDERSTANDTHEOWNER’S
MANUAL BEFORE ATTEMPTING TO USE THE AQUACOM®MK-7
BUDDY-LINE®.
WHILE THE AQUACOM®MK-7 BUDDY-LINE®PROVIDES DIVERS
WITH GOOD UNDERWATER COMMUNICATIONS, IT DOES NOT
CHANGE OR ELIMINATE THE POTENTIAL HAZARDS OF DIVING!
Ocean Technology Systems - 3133 W. Harvard St., Santa Ana, CA 92704, USA
Telephone [phone] - Toll-free [phone] - Fax [phone]
©Copyright2003OceanTechnology Systems
P/N 506018-000 REV B
i

Table of Contents
Section 1, Introduction ...........................................................1
Section 2, MK-7 BUDDY-LINE®Specifications: .................2
Section 3, Functions & Features.............................................3
3.1 Functions .........................................................................3
3.2 Features............................................................................5
Table 3.1 (Recommended Line-Pull Signals).........................5
Figure 3.1 (MK-7 Exploded view) .........................................7
Figure 3.2 (Com-Rope®& EMA-2 assemblies) .....................7
Section 4, Operation ...............................................................8
4.1 Setup for the Tender ........................................................8
4.2 Setup for the Diver(s) ......................................................8
Figure 4.1 (Com-Rope®setup)................................................9
Section 5, Batteries............................................................... 12
Section 6, Troubleshooting.................................................. 13
Section 7, Maintenance ........................................................15
Section 8, Helpful Hints ...................................................... 16
Important Safety Notes......................................... i,4,11,15,16
Warranty Information ........................................................... 17
ii

SECTION 1
INTRODUCTION:
Congratulations! You have just purchased the finest, state-of-the-art hard-
wire intercom in the world. Your new MK-7 BUDDY-LINE®two-diver air
intercom represents state-of-the-art technology and innovation—the choice
of discriminating divers throughout the world. Please take the time to read
this User Guide. With proper care and use, your Ocean Technology Sys-
tems product will provide you with the ultimate in high-quality communi-
cations and reliability.
The MK-7 BUDDY-LINE®is a compact, self-contained two-diver air in-
tercom providing clear communications between the operator and diver(s).
The MK-7 BUDDY-LINE®offers four-wire (round-robin or open-micro-
phone) type communications.
This manual will cover Specifications, Operating Instructions, Four-Wire
Communications, Batteries, Helpful Hints, and Warranty Information.
These guidelines and illustrations are presented to assist you. If you need
additional information, do not hesitate to confer with your local Ocean
Technology Systems (OTS) Dealer or Representative. If you require ser-
vice, contact Ocean Technology Systems, 3133 W. Harvard Street, Santa
Ana, California, 92704, USA - Telephone [phone], Fax (714) 966-
1639, www.oceantechnologysystems.com.
1

SECTION 2
2.1 MK-7 BUDDY-LINE®SPECIFICATIONS:
Input Voltage: 12 VDC.
Input Current: 600 mA peak.
Idle Current: 30 mA.
Frequency Response: 600 Hz to 10 kHz.
Microphone Type: Dynamic
Power Output: 2 watts RMS.
Battery Type: Eight AA Alkaline batteries (Alkaline only).
Battery Life: 12 hours using eight AA Alkaline batteries.
Battery Options: RB-11 NiMH rechargeable battery pack. RC-16
battery charger (charging time: 14 hours).
Housing: Injection-molded, high-impact plastic.
Size: Height: 6.750” from bottom to top of connector
Width: 4.250” from latch to latch
Depth: 2.750” from front knob to rear buckle
Weight: 1.0 pounds, without batteries.
ComRope Length: Up to 1200 feet.
ComRope: Nylon, static Kernmantle rope specially de-
signed with two 18 awg and two 24 awg wires
manufactured in the center. Breaking point ap-
proximately 5800 lbs. for the rope and 500 lbs.
for the communication wires.
2

SECTION 3
FUNCTIONS & FEATURES:
3.1 Functions:
The MK-7 BUDDY-LINE®hard-wire system utilizes the “four wire” ap-
proach. It is a closed loop comparable to a telephone system. A typical
hard-wire system consists of a surface intercom, a headset with a boom
microphone, a Com-Rope®(set up for four wires, shielded or true spiral
four),a diver microphone/earphone assembly, a maskmicrophone, and some
sort of diving mask with accommodations for a microphone. The MKII-G
AGA full-face mask is what most professionals prefer, according to our
statistics. A hard-wire system requires a physical connection (i.e., umbili-
cal/Com-Rope®) between the listener and talker. The signal travels over the
communication Com-Rope®.
Most hard-wire intercoms can be configured for either two- or four-wire
operations. Four-wire communications is defined as a duplex communica-
tion route. Two wires provide the uplink signal path, and two additional
wires provide the downlink path. This allows everyone to be online simul-
taneously (similar to a telephone conference call). Since you never cut off
the diver while talking, as is the case with a two-wire system, the four-wire
system provides the safer approach of the two configurations. Due to the
increased efficiency achieved with a four-wire system (duplex) and its sim-
plicity of use, the MK-7 is designed for four-wire operation only.
The standard MK-7 configuration functions as follows: After the system is
powered up and all connections are properly made, the tender’s speech is
picked up by the boom microphone located on the headset. The voice is
amplified by the upper electronic module and routed through the Com-
Rope®. Connected to the Com-Rope®at the diver’s end is the earphone/
microphone assembly (typically an EMA-2). The tender’s speech is repro-
duced by the earphone part of the EM cable. When the diver speaks, his
voice is picked up by the mask microphone located inside the mask being
used. The voice is routed through the Com-Rope®, received by the upper
electronic module, amplified, and then routed to the tender’s headset. If a
second diver is on-line he will hear and talk as well in the same manner.
The volume of the tender and diver(s) is controlled by separate volume
controls on the outside of the upper electronic module.
3

- IMPORTANT SAFETY NOTE -
IT IS EXTREMELY IMPORTANT THAT THE DIVERS ARE
DRESSED OUT IN A MANNER THAT WILL STRAIN-RE-
LIEVETHE COM-ROPE®. COMMERCIAL DIVESCHOOLS
TYPICALLY INSTRUCT TO HAVE THE COM-ROPE®
TETHERED TO THE DIVER’S HARNESS OR BUOYANCY
COMPENSATOR WITH A QUICK RELEASE. IF SOMEONE
PULLS ON THE COM-ROPE®AND THE DIVER LOSES
CONTROL OF THE COM-ROPE®, THE PULL IS ON THE
HARNESS, NOT ON THE FULL-FACE OR DIVE MASK.
THISWILLELIMINATEACCIDENTAL REMOVALOF THE
DIVER’S MASK.
ADDITIONALLY, THEDIVERS SHOULD BE DRESSED OUT
TO ALLOW A QUICK DISCONNECT FROM THE COM-
ROPE®IF THE OCCASION ARISES WHERE A DIVER
MUST FREE HIMSELF FROM THE COM-ROPE®.
IN THE EVENT DIVERS AND THE SURFACE TENDER
LOSE VOICE COMMUNICATIONS, BOTH SHOULD HAVE
IN PLACE A BACK-UP ROPE-PULL SYSTEM FOR COM-
MUNICATION. SEE TABLE 3.1 FOR THE LINE-PULL SYS-
TEM RECOMMENDED BY OCEAN TECHNOLOGY SYS-
TEMS.
4

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Table 3.1: Recommended Line-Pull Signals1
1Source: U.S. Navy Diving Manual
5

3.2 Features:
Note: See Figures 3.1 & 3.2.
ITEM DESCRIPTION
1. Headset with boom microphone
2. Noise-canceling boom microphone
3. Female Amp connector on the headset side
4. Record out plug (male mini—line level)
5. Small o-ring
6. Male Amp connector on upper electronic module
7. Gripper ring
8. Female Amp connector (for Com-Rope®)
9. Upper electronic module
10. Tender volume control
11. Diver 1 and Diver 2 volume controls
12. Housing large o-ring
13. Battery snap
14. Eight-cell battery holder (SP-8)
15. Stainless steel latch
16. Lower housing (battery compartment)
17. Male Com-Rope®Amp connector
18. Com-Rope®
19. Hi-Use®connector (goes to Com-Rope®)
20. Hi-Use®connector (goes to diving mask)
21. EMA-2 ear/mic. assembly for AGA
See Figure 4.1, Page 8
22. Dual earphones of EMA-2
23. Hot Mic®microphone element
24. Hi-Use®connector (connects to EMA-2)
NOTE: THECOM-ROPE®CANBE SETUPFORMANYTYPES
OF DIVING MASKS AND/OR EARPHONE/MICROPHONE
ASSEMBLIES. IF YOU ARE NOT SURE ABOUT WHAT TO
ORDER, CONSULT AN OTS DEALER OR OTS DIRECT FOR
THE CONFIGURATION YOU REQUIRE.
6

EXPLODED VIEW OF MK-7 BUDDY-LINE®SYSTEM
Figure 3.2, Com-Rope®& EMA-2 assemblies
Figure 3.1, MK-7 Buddy-Line®
7

SECTION 4
OPERATION:
Before operating the MK-7, make certain the batteries are fresh or
fully charged (see battery section). Ensure that all o-rings are in
place and free of debris or foreign matter. Verify that all connec-
tions are securely fastened. Ensure the divers are dressed in such a
manner that the umbilical/Com-Rope®will not snag. These proce-
dures should be performed before each dive.
After you have completed the above steps, proceed as follows:
4.1 SETUP FOR THE TENDER
4.1.1 Place the headset with boom microphone on your head so the two
earphones are comfortably over your ears and the boom micro-
phone is within 1/4” of your lips.
4.1.2 Connect the Amp connector located on the headset to the upper
electronic module’s Amp connector (see Figure 1, # 3 & 6).
4.1.3 Locate the Amp connector on the Com-Rope®and mate it to the
Amp connector located on the top of the electronic module (see
Figure 1, #8 and Figure 2, #17).
4.1.4 Secure the MK-7 to your belt (or wherever is most comfortable)
by using the belt holder located on the back of the upper module.
NOTE:IT ISRECOMMENDED THATTHE MK-7 MAIN MODULE
HAVESOME SORTOFSTRAIN RELIEFATTHE TENDER’SEND
TO KEEP THE DIVER AND/OR COM-ROPE®FROM PUTTING
EXCESS STRAIN ON THE CONNECTORS. EXCESS STRAIN ON
THECONNECTORSWILLCAUSEDAMAGE TO THEMK-7AND/
OR LOSS OF COMMUNICATIONS.
4.2 SETUP FOR THE DIVER(S)
8
4.2.1 Although the MK-7 Buddy-Line®can be used with various full-
face or mouth masks, the most common full-face mask chosen is

4.2.2. The MKII-G AGA full-face mask should already have the EMA-2
earphone/microphone assembly installed. If not, install it per the
EMA-2 instruction manual.
4.2.3. Locate the Hi-Use®connector on the Com-Rope®and connect it to
the Hi-Use®connector on the EMA-2. Ensure the Hi-Use®con-
nectors are free of debris and lightly lubricated with a good-grade
silicone.
4.2.4 Strain-relieve the Com-Rope®in two places on the diver’s end.
The first point should have some sort of “D-ring” heavily taped or
tied about 4 feet from the Hi-Use®connector. This “D-ring” will
be clipped onto the diver’s harness or buoyancy compensator via a
carabiner or some good quality, quick disconnector. This connec-
tion will help prevent the Com-Rope®from pulling on the diver’s
full-face mask (see Figure 4.1).
9
Figure 4.1
the AGA full-face mask. The following are the set up procedures,
if you have an AGA full-face mask. You should have already con-
nectedthe headset and Com-Ropes®ifyouarefollowingthis manual
(see 4.1, Setup for the Tender). We are also assuming you ordered
and have the Com-Rope®set up for four-wire communications with
a male Amp on one end and a Hi-Use®connector on the other end.

4.2.5 The diver should tie the Com-Rope®, making a hand loop about 6
inches in diameter about 10 feet from the Hi-Use®connector (Fig-
ure 4.1). The diver will now be secured to his harness or buoyancy
compensator and have a hand-hold he should hold during the dive.
The diver should have control of the Com-Rope®throughout the
dive. He should feel what is going on, giving topside directions
when slack needs to be taken up or when more rope needs to be
paid out. If the diver lets go of the hand-hold, the carabiner–D-ring
combination will absorb the tension. In the event the diver must
break lose of the Com-Rope®totally (i.e., in an emergency), the
diver should let go of the Com-Rope®hand-hold and unsnap the
device holding the D-ring. The diver then should let topside know
what is going on before he detaches the Hi-Use®connectors. The
diver then should proceed directly to the surface and reestablish
communications (see notes on page 10).
4.2.6. The tender should ensure the Com-Rope®on his end is also strain-
relieved in some manner. This will prevent the diver or topside
tenderfrompulling on theconnectionsmade on the MK-7BUDDY-
LINE®electronic module.
4.2.7 After all connections are made, you can test the system. Have the
diver(s) don the full-face mask. The tender will don the headset
with boom microphone. The boom microphone should be posi-
tioned 1/4” from the tender’s lips (keep the microphone as dry as
possible).
The MK-7 BUDDY-LINE®will power up the moment the headset
and boom microphoneare connected. There is not an On/Offswitch.
As long as the headset is plugged in, the MK-7 will be On and
drawing power.
The tender controls all volumes. The volume control labeled “Ten-
der” controls the volume of the tender’s voice to both divers. The
individual volume controls labeled “Divers” controls what the ten-
der will hear from each diver. The tender should adjust all vol-
umes a little at a time until everyone can hear well. Rotating any
control clockwise brings the volume up. Counterclockwise brings
the volume down.
10

NOTE
IF THE DIVER IS SET UP PROPERLY, THE TENDER’S PULL-
ING ON THE COM-ROPE SHOULD PULL ON THE DIVER’S
HAND LOOP FIRST. IF THE DIVER IS NOT HOLDING THE
HAND LOOP, THE STRAIN SHOULD GO TO THE BELT “D-
RING,”NOTTHEDIVER’SFULL-FACEMASKORDIVER’SEAR-
PHONE/MICROPHONE ASSEMBLY.
ENSURE THE DIVER IS DRESSED OUT SO THAT NO UNNECES-
SARY LOOPS THAT CAN ENTANGLE HIM ARE PRESENT.
NOTE
EXCESSIVEVOLUMEWILL CAUSE DISTORTIONANDHINDER
COMMUNICATIONS. ADJUST ALL VOLUMES SLOWLY UNTIL
EVERYONE HEARS CLEARLY. A GOOD RULE TO FOLLOW IS,
“LESS VOLUME IS BETTER THAN TOO MUCH NOISE.”
- IMPORTANT SAFETY NOTE -
THE DIVER SHOULD BE DRESSED IN SUCH A MANNER THAT
HE CAN DISCONNECT FROM THE COM-ROPE®AND DISCON-
NECTFROMTHEEARPHONE/MICROPHONEASSEMBLY.IFIT
BECOMES NECESSARY TO MAKE AN EMERGENCY ASCENT
AND THE DIVER HAS TO BREAK VOICE COMMUNICATIONS
AND LINE PULLS CANNOT BE ESTABLISHED, THE DIVER
SHOULD SURFACE AND ESTABLISH COMMUNICATIONS AS
SOON AS POSSIBLE.
- SAFETY NOTE -
ITISNOTRECOMMENDED TORELY SOLELY ON MK-7BUDDY-
LINE®VOICE COMMUNICATIONS. A BACK UP SAFEGUARD,
SUCH AS LINE PULLS, SHOULD BE ESTABLISHED AND PRAC-
TICED.
NO POWER!
IF YOU CONNECT THE HEADSET WITH BOOM MICROPHONE
AND THE MK-7 DOES NOT POWER UP, VERIFY THE BATTER-
IES ARE FRESH (NEW) AND THE BATTERY SNAP IS CON-
NECTED. IF USING RECHARGEABLE BATTERIES, VERIFY
THEY HAVE BEEN FULLY CHARGED.
11

SECTION 5
BATTERIES:
The MK-7 BUDDY-LINE®is provided with an SP-8 eight-cell AA battery
holder located in the lower housing (Figure 1, #14). It is recommended to
use Alkaline batteries only. To install the batteries, follow these steps:
1. Locate the latches on the sides of the lower housing (Figure 1,
#15). Pull up on the latches simultaneously.
2. Separate the upper and lower modules while being careful not to
damage the battery snaps, wires, or o-ring (Figure 1, #12 & 13).
3. Remove the eight-cell battery holder (Figure 1, #14) and install
eight fresh, 1.5 volt Alkaline AA batteries per the diagram on the
SP-8.
4. Carefully connect the wire harness connector (Figure 1, #13) to
the SP-8 battery holder. Verify that both spring-type connectors
mate firmly and that you have not accidently bent the connectors.
5. Verify that the o-ring (Figure 1, #12) is in place, lightly lubricated
with a good-grade silicone grease, and that is it free of debris.
6. Insert the SP-8 battery holder into the lower housing. Carefully
mate the upper and lower housings together. Ensure that you do
not pinch any wires and that nothing is on the o-ring or mating
surface.
7. Connect the latches from the lower housing to the upper strikes.
Pull down the latches simultaneously until fully down. This will
spring-load the upper and lower assemblies.
8. Look all around the MK-7 to verify the upper and lower assem-
blies appear evenly attached with no high spots.
12

SECTION 6
TROUBLESHOOTING:
Problem: Corrosion buildup on the connectors.
Possible Cause and Remedy
PC Failure to wash and lubricate connectors after use in salt water.
RRemove salt water residue or corrosion from the unit by wiping
with a cloth saturated in warm, fresh water (detergent if neces-
sary). Periodically check the connectors to ensure they are clean
and lightly lubricated with a high-grade silicone grease.
Problem: Poor or no communications.
Possible Cause and Remedy
PC Batteries are bad or dead.
R. Replace AA batteries with fresh ones. Charge the battery pack if it
is a rechargeable pack.
PC Connectors are not properly connected or are damaged.
RClean and check all connectors. Replace damaged ones.
PC Headset with boom microphone is not plugged in.
RConnect headset; unit should power up.
PC Diver(s) cannot hear topside, but topside can hear divers.
RCheck topside microphone and make sure the tender volume is
turned on and the microphone is about 1/4” from the tender’s lips.
PC Diver(s) can hear topside, but topside cannot hear the divers.
RCheck all connections. Check the diver’s microphone. Verify the
diver’s volume controls are turned up.
PC Tender and divers hear light music over the intercom.
RThis happens if you are using an unshielded umbilical and are close
to a transmitting station. The only way to solve this problem is to
change to a shielded Com-Rope®.
13

Problem: A strong but distorted signal is received.
Possible Cause and Remedy
PC You are speaking too loudly into the microphone.
RSpeak with more moderate volume, slowly and distinctly.
PC Your volume controls are set at too high a level.
RSlowly adjust your volumes as to not overdrive the system.
14

15
SECTION 7
MAINTENANCE:
The MK-7 BUDDY-LINE®is virtually maintenance-free and should give
yougreat service during the life of theunit. The following are recommended
service tasks:
1) Try to keep the headset with boom microphone as dry as possible.
2) Do not store the Com-Rope®in a sealed container without drying
it first. It will mold if not dry.
3) If the Com-Rope®is used in salt water, soak it in freshwater for
about five minutes before drying.
4) If salt water gets onto the headset and/or MK-7, wipe it with a
clean cloth and freshwater. Warm water and a mild soap solution
can be used. Wipe it off with freshwater before drying.
5) Disconnect all connectors when storing.
6) Lightly lubricate the Hi-Use®connector with a good-grade sili-
cone grease.
7) If the MK-7 is not going to be used for a long period of time, the
batteries should be removed.
- PLEASE NOTE -
ALTHOUGHTHE MK-7BUDDY-LINE®ISARUGGEDLY
CONSTRUCTED PIECE OF YOUR DIVING GEAR, IT
SHOULD BE TREATED LIKE AN ELECTRONIC PIECE
OF EQUIPMENT!
! ! ! CAUTION ! ! !
USEANY STANDARDSAFE ENTRY INTOTHEWATER,
BUT BE AWARE OF THE ADDITIONAL EQUIPMENT
YOUAREWEARING.BECAUSE THECOM-ROPE®CAN
SNAGON THINGS,BE AWAREOF OBSTACLES INTHE
AREA AND AVOID THEM. MAKE SURE THERE IS
NOTHINGIN THEWATERTHE DIVERMAY HITUPON
ENTRY.

SECTION 8
HELPFUL HINTS:
A. All training should be conducted in a controlled environment such
as a swimming pool.
B. All personnel who intend to use this system should read and fully
understand this manual and equipment before they use it.
C. Divers should be dressed in such a manner that they can discon-
nect quickly from the Com-Rope®and/or earphone/mic. assembly.
D. The Com-Rope®should be strain-relieved at both the diver’s and
tender’s end. It is extremely important the divers have the Com-
Rope®strain-relieved to their harness or buoyancy compensator
and not to the full-face mask.
E. The topside tender is in control of the rope topside, ensuring that it
is not getting tangled and that it is not a safety hazard for those
walking about.
F. The divers should be aware of their surroundings, making sure
they do not become entangled.
G. When a diver must enter the water by jumping into the water, the
following is the recommended procedure: The diver should step
up to the end of the pier or edge from which he is about to jump.
The Com-Rope®will be connected to the diver, and the diver will
be holding onto the hand loop he has made on the Com-Rope®.
The tender should lower enough slack so as to just touch the water.
The diver looking out toward the horizon will start his giant step.
As the diver steps off, he turns to face the tender holding on to the
Com-Rope®. When he enters the water, he should be looking at
the tender.
16
- SAFETY NOTE -
IF THE DIVER PLANS TO MAKE A JUMP, IT IS EXTREMELY
IMPORTANT THETENDERDOES NOTFORGETTOPUTSLACK
IN THE COM-ROPE®. THE COM-ROPE®SHOULD JUST TOUCH
THEWATER WHILESTILL BEING ATTACHED TOTHE DIVER.
THIS GIVES THE DIVER THE AMOUNT OF ROPE NECESSARY
TO HIT THE WATER WITH SOME SLACK. IF THERE IS NO
SLACK IN THE ROPE, THE DIVER COULD BE SERIOUSLY
HURT BY BEING HUNG OR JARRED.

Undersea Systems International
dba
Ocean Technology Systems
LIMITED WARRANTY
The MK7 BUDDY-LINE®is fully warrantied against defects in
materials and workmanship for a period of one year from the
time of purchase. Our obligation under this warranty is limited
to the replacement of any part or parts that prove to our satis-
faction to have been defective and that have not been misused or
carelessly handled. Labor is warrantied for one year from time
of purchase. The complete unit and/or part must be returned to
our factory, transportation charges prepaid.
We reserve the right to decline responsibility where repairs have
beenmadeor attempted by otherthananOcean Technology Sys-
tems factory-trained service center or properly trained person-
nel. In no event shall Ocean Technology Systems be liable for
consequential damages.
Ocean Technology Systems
3133 W. Harvard St., Santa Ana, CA 92704, USA
Telephone [phone] - Toll-free [phone] - Fax [phone]
www. oceantechnologysystems.com, [email protected]
© Copyright 2003 Ocean Technology Systems
17