rEvo Rebreathers rEvo III micro FT User manual

Manual rEvo III
1
MANUFACTURER’S MANUAL
FOR ASSEMBLY, USE AND MAINTENANCE
rEvo III mCCR
(rEvo III standard, mini, micro FT
(*optional rEvo III hCCR, rMS
CE version
Version 0.4.en Paul Raymaekers
changes in italic

Manual rEvo III
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Warning!
Diving without training is both dangerous and life threatening!
Diving a rebreather without training by a recognised agency is not only
stupid but equates to suicide!
A rebreather is a machine and machines break!
Don’t ask yourself W ET ER a problem will occur as it is inevitable, ask
yourself W EN it will occur!
Be alert to signs of subtle changes in your rebreather as they are often a
sign of pending problems!
When a problem arises: correct and regulary maintained skills plus their
appropriate application will make the difference between life and death!
This individual manual does not replace in any way training and does not
equip you in any way for rebreather diving !
If you don’t understand this warning or you think it is not necessary to take
training, then do NOT dive a rebreather, and especially not a rEvo!
The manufacturer and recognised training agencies do not want to be part of
stupid behaviour that can kill!
Do not change anything on your unit, as this will void the CE type approval
and can turn your unit into a unsafe and dangerous rebreather!
You have been warned!

Manual rEvo III
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left: rEvo III standard right: rEvo III mini
rEvo III micro FT rEvo III mini rEvo III standard

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Chapter 1:
Technical Specifications . 5
Overvie of the rEvo III . 6
Chapter 2: rEvo components
2.1 The breathing hoses. 8
2.2 Counterlungs. 9
2.3 ADV. 9
2.4 Orifice. 9
2.5 The scrubbers. 10
2.6 Backplate, Wing & Harness. 10
2.7 Manual addition of oxygen and diluent. 11
2.8 Cylinders ith quick release. 12
2.9 Stainless steel carrying handle / (soft) eight fixation. 13
2.10 Upright position. 13
2.11 OPV. 14
2.12 Measuring PPO2 ith the rEvodream and the HUDs. 14
2.13 Moisture absorber 15
2.14 Set-point controller (optional) 15
Chapter 3: Using the rEvo for the first time!
3.1 Mounting the harness and ing. 16
3.2 Fitting the O2 cells. 16
3.3 Assembly and greasing of the O-rings. 18
3.4 Filling the scrubbers. 18
3.5 Calibration of the oxygen cells. 19
3.6 The orifice. 20
Chapter 4: Diving with the rEvo.
4.1 Considerations prior to each dive. 21
4.2 Pre-dive checks. 21
4.3 Immediate pre-dive: earing the rebreather,
immediately before entering the ater. 22
4.4 Entering the ater, bubble-check, during diving,
exiting the ater. 22
4.5 Maintenance bet een several dives on the same day. 24
4.6 Maintenance at the end of the day. 24
4.7 General maintenance 25
Chapter 5 general maintenance
Appendix A: Drills. 27
Appendix B: Al ays – Never. 28
Addendum 1 : Top Marker 32
Addendum 2: Check list 33

Manual rEvo III
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Chapter 1: Technical Specifications
1.1 Limitations of use:
→This unit is intended to be used by trained people only.
→The use of the unit is only allo ed hen an independent alternative gas
source is carried at all time by the diver, that can be used at any time during
the dive, and that has enough capacity to safely end the dive in case of
malfunctioning of the unit.
→Only oxygen compatible grease like Tribolube 71 should be used any here
in the unit.
→Max certification depth: 40m ith diluent air.
→Max certification depth ith trimix or heliox, and PPN2 <= 4.0 bars: 80m
(mCCR) / 100m (hCCR)
→Temperature conditions during use: ater temperature minimum 4° Celsius,
maximum 34° Celsius.
→Scrubber endurance: at 40m depth, 4° Celsius, CO2 production of 1.6l/min
STPD, 40 RMV (2liter tidal volume), using 2.7kg Sofnolime 797: time until
the PPCO2 of the inhaled gas reaches 5mbar: >160 minutes. Time until
the PPCO2 of the inhaled gas reaches 10mbar: >170 minutes.
→Scrubber endurance: at constant depth of 100m, 4° Celsius, CO2
production of 1.6l/min STPD, 40 RMV (2liter tidal volume), using 2.7kg
Sofnolime 797, using any trimix or heliox (PPN2 <= 4.0 bars): time until the
PPCO2 of the inhaled gas reaches 5mbar: >75 minutes. Time until the
PPCO2 of the inhaled gas reaches 10mbar: >85 minutes.
→Max ork rate conditions: 75 RMV at 40m depth, CO2 production of 3l/min
during 5 minutes.
→PPO2 limits during correct use: minimum 0.5 bar, max 1.55 bar.
→Work of breathing: at 40m depth, 4° Celsius, 75 RMV (3liter tidal volume),
using 2.7kg Sofnolime 797: <2.05 J/liter in horizontal position and <2.20 in
vertical position.
→Work of breathing: at 100m depth, 4° Celsius, 75 RMV (3liter tidal volume),
using 2.7kg Sofnolime 797, using any trimix or heliox (PPN2 <= 4.0 bars)
<2.45 J/liter in horizontal position and <2.75 in vertical position.
→Scrubber content: 2 canisters each containing 1.35kg Sofnolime 797.
→Approved scrubber material: Sofnolime 797.
→Tank content: oxygen and diluent tank: 2 or 3 litre .
1.2 Dimensions and features:
→ Weight of the rEvo ready to dive (full 3 litre steel cylinders, packed canister,
stainless steel housing, BCD, backplate = 31 kg (including 2.7 kg
absorbent). (micro FT ith 2l cylinders: 24 kg)
→ Empty eight ( ithout absorbent and cylinders) = 17.5kg.
→ Size: ith steel 3-litre cylinders: 64 x 40 x 18 (cm).
→ Constant oxygen flo by means of an orifice, manual oxygen and diluent
addition, automatic diluent valve.
→ T o completely independent programmable PPO2 monitors ith LED- indication
on t o HUDs (rEvodream).
→ Securely attached mouthpiece.
→ Ergonomically integrated backplate to create a minimal static WOB ( ork of
breathing).

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Overvie of the rEvo III.
1. Inflator connection.
2. Manual diluent addition valve.
3. Manual oxygen addition valve.
4. Absolute pressure oxygen regulator (APR).
5. Auto diluent valve (ADV).
6. Orifice + one- ay valve.
7. Oxygen cells.
8. Inhale lung.
9. Exhale lung.
10. Exhale scrubber (upper canister).
11. Inhale scrubber (lo er canister).
12. Mouthpiece.
13. HUD's (LED-indication on mouthpiece).
14. Diluent cylinder.
15. rEvodreams (PPO2 displays).
16. Oxygen cylinder.

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The rEvo III mCCR is a manually operated closed circuit rebreather based on the CMF
principle: (constant mass flo ). During diving a constant flo of oxygen bleeds into
the breathing loop of the rebreather. The flo rate is high enough to provide a diver in
rest ith a life sustaining breathable oxygen flo . The flo rate can be adjusted to the
individual metabolic rate of the diver. But it is kept lo enough to be safe. During the
dive the diver controls and monitors their PPO2 ith the help of the LED-indication of
the HUD and their handsets: hen needed they can manually add oxygen through the
oxygen addition valve to maintain the desired PPO2.
It must be clear that the standard rEvo III mCCR is not an electronically controlled
rebreather: there is no computer hich decides hen oxygen has to be added: that is
the role of the diver. If they do not monitor and adjust the PPO2 regularly, this ill
lead to hypoxia, unconsciousness and ultimately, death. (* ith the optional hCCR
electronics, the rEvo becomes a fully electronically controlled rebreather)
Easy to setup, easy to transport, easy to dive and easy to maintain:
The rEvo III mCCR has been designed ith one clear purpose in mind: simplicity in
setup, simplicity in use and simplicity in maintenance. The user has access to all
rebreather parts. Oxygen cells, ADV, orifice, scrubber-canisters, moisture pads can be
reached by demounting the main cover, removing one scre .
This unique design means that the rebreather has only 4 connections ith O-rings
used by the diver: 2 for the breathing hoses and 2 for the main cover: the scrubber
lid (each ith a double o-ring). The risk of leaking, rong connections, rong
assembly and forgotten o-rings has thus been reduced to a minimum!

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Chapter 2: the rEvo component parts: general description
2.1 The breathing hoses:
The breathing hose assembly has
been made in such a ay that the
mouthpiece can be opened and
closed in all conditions (very cold
and very arm ater). A safety
attachment strap, a ‘gag’, has
been added to the mouthpiece.
When correctly adjusted and for
example in the case of
unconsciousness, the mouthpiece
remains in the mouth of the diver.
Adjustable hose- eights are added to assure a
comfortable in- ater position of the hoses and
mouthpiece. The HUDs are designed to be
attached to the mouthpiece. An extra cover goes
over the rubber hoses to prevent external
damage. (picture: cover protection only mounted
on the right hose)
The connections of the breathing hose are cleary marked, so that inhale and exhale
side can not be s itched: all connectors on the exhale side are marked ith a groove
(no groove on the inhale side), plus the diameters of the connections are different, to
avoid any faulty connection.

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2.2 Counterlungs:
The rEvo counterlungs are made of food-compatible PU, sealed ith high frequency
elding technology and are permanently elastic. Both counter lungs (inhale and
exhale) are backmounted. Both lungs are protected by a liner and are fitted in a
stainless steel case. This case is produced in such a ay it perfectly fits the back of
the diver.
The placement of the counter lungs provide the diver a clear chest-area. The lungs do
not limit the movement or the vision of the diver. That ay it is easy to ork ith
stages. The case provides excellent lung-protection in hazardous environments like
recks or caves.
The hoses for manual addition of oxygen and diluent are fed into the exhale lung. The
ADV and orifice are also situated in the exhale lung.
The exhale and inhale lung are connected by t o serially placed scrubber canisters.
Both canisters are thermally isolated by an additional air chamber. The oxygen cells
are located beneath the canister in the inhale lung. The flo of the arm gasses in
the breathing loop, coming from the second canister, keep the cells dry. An anti-
collapse hose is mounted in the inhale lung.
An “over pressure valve (OPV)” is mounted on top of the unit, on the exhale side. The
cable entry port is mounted on the inhale lung side.
2.3 ADV:
The “auto-diluent-valve (ADV)” is activated by the pressure created hen the exhale
lung ‘bottoms out’ (for example during descent). Diluent is injected into the exhale
lung. Access to the ADV is possible for breathing resistance adjustment ( hen
necessary). See photograph below(2 4 orifice)
2.4 Orifice:
To guarantee a constant oxygen flo , an orifice is used. This orifice (a small opening
situated in the oxygen hose allo ing oxygen flo ing through) gives, at a fixed inlet
pressure, a constant oxygen inflo , independent of the outlet pressure. (Within the
manufacturer’s limits of use of the rEvo).
The result is a constant flo even hen the depth increases. To keep the inlet
pressure fixed, a special first stage regulator is used.

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The output pressure of the regulator is depth
independent (“Absolute Pressure Regulator”
(APR)).
The orifice is situated in the exhale lung and
is easily accessible for maintenance. On the
outside of the orifice a non-return-valve
(one- ay-valve) is mounted to avoid dirt,
moisture or dust, coming from the exhale
lung, and hich could possibly enter the
orifice.
!!!!!!!!!!!!!!!!!!!!!!!!!!! picture rMS tray
2.5 The scrubbers:
The scrubbers take care of the “removal” of CO2 from the exhaled gases.
The rEvo has a unique dual scrubber-system consisting of t o serially mounted
scrubbers. During diving, gas flo s from the upper scrubber to the lo er scrubber.
This configuration has some important advantages: it allo s a compact rebreather
design, lo ork of breathing resistance and a higher safety level.
•Compact design: using t o scrubbers ith a large diameter and lo height,
results in a limited total thickness of the rebreather (maximum 180 mm at the
point here the rebreather is in contact ith the back of the diver). This design
ensures a perfect streamlining of the diver during diving.
•Lo internal breathing resistance: mounting the scrubbers directly on the lungs
in the body of the rEvo, results in reducing restrictions in gas flo to a
minimum. Most non rEvo-rebreathers have their lungs and canisters connected
by tubes or hoses of 30 mm or even less. The rEvo scrubbers are connected to
the lungs through an opening of 154 mm diameter, resulting in an extremely
lo WOB ( ork of breathing) in a normal diving position.
•Increased safety hile using the rebreather: during diving, condensation is kept
in the lungs ithout affecting the scrubber, both in horizontal and vertical
position. The risk of channelling is reduced significantly hen using t o
canisters compared to a normal single radial or axial canister.
2.6 Backplate, Wing & Harness:
The rEvo uses an ergonomic split back-plate, a harness and a ing BCD.

Manual rEvo III
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The harness, ith rotation fittings, is mounted on the split backplate. The shoulder
piece is rounded on top of the rebreather, follo ing the curve of the shoulders. The
straps of the harness are attached to this shoulder piece.
The lo er back piece can be adjusted in height by the user, in order to customize the
backplate to the diver’s length. The shoulder straps of the harness are threaded
through the lo er part of the backplate, here they can be connected around the
diver’s aist. A rubber protection plate is
mounted over the backplates , held in
place by the straps.
The construction of the split backplate, the
rounded upper section combined ith the
thin stainless steel case and the built-in
ing, afford a perfect fit of the rebreather
to the diver’s back creating very lo drag
and optimal streamlining.
Hydrostatic pressure differences are kept
to a minimum due to the counterlungs
position close to the diver’s back.
2.7 Manual addition of oxygen and diluent:

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The buttons for manual addition of diluent and oxygen are situated at the bottom of
the stainless steel case allo ing them to be found very easily (they cannot be moved,
because they are not attached to a separate hose). This concept prevents extra hoses
running over the chest and shoulders of the diver. The buttons also have an extra
strong spring to avoid a 'stuck-open' situation after pushing the valve.
Oxygen addition during diving only needs to be done in short bursts, hile the diver
continues breathing on the loop. In this ay peaks of PPO2 are avoided.
!!!! picture + text: alternative / extra front mounted injection + offboard gas
connection
2.8 Cylinders ith quick release:

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The cylinders are attached to the stainless steel housing by means of a “quick release”
system. This offers a very quick and easy mounting and demounting of the cylinders.
This method allo the valves to be immediately and correctly positioned to ards the
first stages.
On both sides of the stainless steel housing, slits are provided here 'quick release'
clamps can be locked-in to attach small devices such as light canisters. A short and a
long clamp are supplied ith each rEvo.
2.9 Stainless steel carrying handle / (soft) eight fixation
On top of the rebreather a stainless steel carrying handle is situated hich covers the
complete idth of the rebreather.If necessary t o people can simultaneously lift the
rebreather. Also, the handle orks to protect the hose connectors, the inlet ports and
the breathing hose. The
handle can easily be
removed for travelling.
On top of the rebreather,
bet een the cylinders, a
grid is mounted here
soft eights can be
attached (max. 3 kgs).
In remote locations,
here no soft eights are
available, it is possible to
fix normal eights.

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2.10 Upright position:
The rEvo has been designed in such a ay that it can
easily stand upright in a detached position, even ithout
cylinders.
Rubber ‘feet’ are mounted to avoid possible damage to
the case.
2.11 OPV:
The ‘Over-Pressure Valve’ is mounted on the
exhale lung, at the top of the rebreather. This
valve ensures venting of the rebreather in
case of overpressure, for example hen an
ascent ith a closed mouthpiece occurs (in
case of open circuit bail-out). The relief
pressure is factory set and should not be
adjusted.
2.12 Measuring PPO2 ith the rEvodream and the HUDs:
In order to be able to monitor
the PPO2 constantly, each rEvo
is equipped ith t o
rEvodreams. Each rEvodream
has an LCD display, moun-ted
on the pressure gauge and a
HUD. The HUD has three LEDs
(orange, green & red) to
indicate the PPO2 value. The
LCD display is normally used to
check and compare the values
indicated by the HUD and to
calibrate the unit.
The basic philosophy of the
rEvodream is that hen
everything is OK and optimal (correct PPO2), there is a constant permanent light
signal (a continuous green in the middle on the HUD: green means: OK, safe). Small
deviations over or under the optimal PPO2 ill sho a short pulse of orange (under,

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belo the green LED) or red (over, above the green LED), together ith the constant
green LED. This is a small deviation of the optimal zone, but still safe (green is ON!).
When the deviation increases, more orange or red pulses ill appear. But as long as
the green LED is permanently on, it is still safe to breathe the gas. The increased
frequency of the orange and red pulses ill attract the attention of the diver. As soon
as the PPO2 comes out of the safe zone, the green light disappears and only the
orange or red LED is flashing: this means DANGER!!!
During normal use the diver ill press the O2 manual addition valve hen the orange
LED flashes shortly, to get back in the 'green-only' zone (by raising the PPO2 slightly).
The rEvodream (on, off, calibration, change settings) can completely be operated by
gently knocking on the bottom or side of the housing: there are no external s itches
or connections hatsoever. This designs guarantees a longer life for the unit and
avoids the risk of flooding.
To operate the rEvodream: see separate rEvodream manual
2.13 Moisture absorber
At the bottom of the inhale lung, a moister absorber is installed: this prevents
condensation ater flo ing into the counterlung or getting into the breathing hose.
This moisture absorber is rolled into a small tube, and mounted at the bottom of the
inhale lung under the non-collaps tube. That ay the absorber isb blocked and can not
move around in the counterlung.
Photos: how to roll moisture absorber and mount it in the counterlung

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New pictures with new sensor tray
2.14 Set-point controller (optional)
Set-point controller (optional) (type:
shear ater pursuit set-point controller)
The rEvo can be supplied ith set-point
controller that automatically maintains a
pre-defined PPO2. In this case an
automatic valve is mounted in parallel
in the orifice on the oxygen pressure
line, hich is piloted by the rist-
mounted controller.
When equipped ith this option, the
diver does not longer has to manually
maintain himself the preferred set-point
anymore; he must ho ever verify all the
times the partial pressure of the oxygen of the gas he is breathing in, is in the correct
range! The full user manual and orking explanation can be found in the separate
manual.
Xxxxxxxxxxxxxxxx ne picture predator controller

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Chapter 3: Using the rEvo the first time!
3.1 Mounting the harness and ing:
When shipped the rEvo is completely assembled. The unit (harness and backplate)
needs to be adjusted to the body of the diver. When adjusting the harness the dive
suit has to be taken into account. The best position of the unit is hen the rEvo is
fixed on the diver’s back as high as possible: the harness should be fixed closely to
the diver’s back, so that the curve of the backplate follo s the fysical forms of the of
the back of the diver as much as possible.
Wrong Correct
A minimal WOB can only be guaranteed hen fixing the rEvo in a correct ay. The
harness has to be slightly re-adjusted after the first dive in confined aters.
3.2 Fitting the O2 cells:
Minimum 3 oxygen cells should be used during diving: 2 cells mounted on the first
rEvodream, 1 cell mounted on the second rEvodream.
To have an easy access to the cells one can remove the carrying frame from its
protective hood.

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!!!! ne pictures !!!!!!!!!!!!!!!!!!!!!!!!!!!
Secure the cell ith the black holding scre and connect the right Molex connector to
the cell. Be sure that the connector is fitted in the right position (see picture). Do not
use force as this may damage the pins on the cell.
Make it a habit to position the cells in the same place and order: position one and t o
for the first rEvodream and position number three for the second rEvodream ( hich is
using only one cell). The first rEvodream should be the one on the right oxygen SPG
and right HUD. The second rEvodream should be fitted on the left side (and left
diluent SPG) and the left HUD. By keeping a fixed position for each cell it ill be easier
to decide hich cell to replace. Note do n the date hen each specific cell is installed:
rite the date on the cell itself to kno its exact age.
ow to use and when to replace oxygen cells:
Minimum 3 oxygen sensors must be used during diving: this is the ay to start up
ith a ne unit. The date of installation is marked on each cell.
After 6 months a 4
th
cell is added, so both rEvodreams ill from that moment display
2 sensors. Follo ing process applies unless a sensor has failed before its 6 months of
use: the oldest cell that is still in the unit, is replaced ith a ne cell, unless a cell
clearly reacts slo er then the other cells. In that case the slo er cell is replaced of
course.
If you have to choose bet een more than one cell to be replaced, change the cell that
reacts slo er on a sudden increase in PPO2.
As explained further do n, at least once every eek of diving, cells must be checked
for current-limiting at the start of a dive.
Adding a ne sensor every 6 months reduces the possibility of losing more than one
cell during diving (the sensors in the unit, coming from different production batches,
ill all have a different diving history after being in use for a hile)

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The recommended oxygen sensors are R22D-rEvo.

Manual rEvo III
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3.3 Assembly and greasing of the O-rings:
If the O-rings of the cover have not been greased yet, or hen the grease is
contaminated or the rings are damaged and need to be replaced: remove the four O-
rings from their seats, clean them ith a lint-free cloth, or use a neutral soap.
Take a small amount of oxygen compatible grease and spread the grease onto the
ring by pulling the ring bet een thumb and forefinger. Be sure that the grease is
spread equally over the ring. Be careful not to use too much grease as the excess ill
be pushed a ay hen replacing the cover onto the canister.
A small amount of grease can also be put onto the inside of the cover after cleaning it
first.
Warning: use only oxygen compatible grease for all O-rings on the rEvo!
The O-rings of the breathing hose connectors can also slightly be greased ithout
removing them ( hen they are not contaminated: check for sand or dirt traces first, if
contaminated remove and clean as above).
3.4 Packing the scrubbers:
Unscre the handle of the scrubber, take out the spring, remove the grid and the
mesh (be sure not to lose any parts). Thro a ay the used scrubber material and
remove the remaining dust by slightly tapping on the canister..
Be sure to take into account local environmental regulations regarding toxic
waste!
Make sure the filter stays inside the canister.
Packing the canisters is done best in the open air to avoid scrubber dust. If there is
ind be sure to be up ind so that the ind blo s any dust a ay. Position the canister
on a horizontal surface: pour the absorbent from a height of approximately 20-30 cm
into the cassette. Let the ind carry a ay the absorbent dust. Keep filling until a
small pyramid of absorbent is formed in the canister (keep 1 cm free from the top of
the canister).