JFD Divex SLS Mk IV Operation And Maintenance Manual
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JFD Divex SLS Mk IV Operation And Maintenance Manual

Secondary life support system backpack
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Operation and Maintenance Manual
for the
Secondary Life Support (SLS Mk IV)
System Backpack
Part Number: B44771
Document Number: P1939-OM-131
Revision: 11

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  • Page 1 Operation and Maintenance Manual for the Secondary Life Support (SLS Mk IV) System Backpack Part Number: B44771 Document Number: P1939-OM-131 Revision: 11...
  • Page 2 (Intentionally Blank)
  • Page 3 © 2015 JFD Copyright of this document is the property of JFD and it may not be copied, used or otherwise disclosed in whole or in part except with prior written permission from JFD or, if this document has been furnished under a contract with another party, as expressly authorised under that contract.
  • Page 4 (Intentionally Blank) OM131 Approval Sheet P1939-OM-131 R11...
  • Page 5 REFACE The Secondary Life Support (SLS) System is an emergency breathing apparatus intended for use by professional saturation divers, operating from a diving bell. The system is intended for use in the event of a fundamental failure of a diver’s primary life support system (e.g. loss of primary breathing gas, loss of hot water, etc).
  • Page 6 (Intentionally Blank) OM131 Preface P1939-OM-131 R11...
  • Page 7 IST OF BBREVIATIONS Abbreviation Definition Centimetre Carbon Dioxide Foot or feet Water Inch Joule Kilogram Pound (weight) Left Hand Litres per minute Litre Metre mbar Millibar Millimetre Metres seawater Mark Newton Norwegian Petroleum Directorate NUTEC Norwegian Underwater Technology Centre Oxygen Pounds per square inch Right Hand Respiratory Minute Volume...
  • Page 8 (Intentionally Blank) OM131 List of Abbreviations P1939-OM-131 R11...
  • Page 9 ARNINGS Failure to maintain the SLS System Mk IV Backpack in accordance with this Manual (using original SLS System spare parts) or use by a person or persons unfamiliar with its operation, could result in a serious hazard or fatal injury to personnel. This SLS System Mk IV Backpack contains a high-pressure helium / oxygen mixture for breathing purposes.
  • Page 10 (Intentionally Blank) viii OM131 Warnings P1939-OM-131 R11...
  • Page 11 ABLE OF ONTENTS Page Chapter 1 - Introduction ........................... 1 Chapter 2 - Technical Description ........................13 Chapter 3 - Operating Information ......................... 31 Chapter 4 - Maintenance Instruction ......................53 Chapter 5 - Parts Catalogue .......................... 91 OM131 P1939-OM-131 R11 Table of Contents...
  • Page 12 (Intentionally Blank) OM131 Table of Contents P1939-OM-131 R11...

  • Page 13: Table Of Contents

    1 - I HAPTER NTRODUCTION ONTENTS Page Purpose of equipment ........................2 General description ......................... 2 Performance and Limitations ......................5 1.3.1 Work of breathing ........................... 5 1.3.2 Oxygen partial pressure / endurance ....................5 1.3.3 Carbon dioxide scrubbing / thermal performance ................. 11 OM131 P1939-OM-131 R11 Chapter 1...

  • Page 14: Purpose Of Equipment

    URPOSE OF EQUIPMENT The Secondary Life Support (SLS) System is an emergency breathing apparatus designed for use by professional saturation divers, operating from a diving bell. It is intended for use in the event of a fundamental failure of a diver’s primary life support system (e.g. loss of primary breathing gas, loss of hot water, etc).
  • Page 15 Fig 1.1 SLS System Mk IV OM131 P1939-OM-131 R11 Chapter 1...
  • Page 16 Fig 1.2 SLS system layout OM131 Chapter 1 P1939-OM-131 R11...

  • Page 17: Performance And Limitations

    ERFORMANCE AND IMITATIONS The SLS System has been proven in extensive unmanned and manned testing. A selection of unmanned test data is presented below. 1.3.1 Work of breathing Fig 1.3 shows the work of breathing in Joules per Litre as a function of breathing rate in lpm RMV at a depth of 400 msw using heliox gas.
  • Page 18 Fig 1.4 Partial pressure of oxygen at 50 msw Fig 1.5 Partial pressure of oxygen at 100 msw OM131 Chapter 1 P1939-OM-131 R11...
  • Page 19 Fig 1.6 Partial pressure of oxygen at 150 msw Fig 1.7 Partial pressure of oxygen at 200 msw OM131 P1939-OM-131 R11 Chapter 1...
  • Page 20 Fig 1.8 Partial pressure of oxygen 250 msw Fig 1.9 Partial pressure of oxygen at 300 msw OM131 Chapter 1 P1939-OM-131 R11...
  • Page 21 Fig 1.10 Partial pressure of oxygen at 350 msw Fig 1.11 Partial pressure of oxygen at 400 msw OM131 P1939-OM-131 R11 Chapter 1...
  • Page 22 Fig 1.12 Partial pressure of oxygen at 450 msw Fig 1.13 Partial pressure of oxygen at 500 msw OM131 Chapter 1 P1939-OM-131 R11...

  • Page 23: Carbon Dioxide Scrubbing / Thermal Performance

    1.3.3 Carbon dioxide scrubbing / thermal performance The thermal protection in the SLS System is provided by a combination of passive means and recovery of the heat generated by the exothermic absorption of CO in sodalime. Thermal protection consists of: Stored heat from hot-water system.
  • Page 24 Depth Charging Pressure Duration 50 msw 300 bar (max) 30 mins* 50 msw 175 bar 30 mins 50 msw 100 bar (min) 17 mins 100 msw 300 bar (max) 30 mins* 100 msw 250 bar 30 mins 100 msw 100 bar (min) 12 mins 150 msw 300 bar (max)
  • Page 25 2 - T HAPTER ECHNICAL ESCRIPTION ONTENTS Page System Description ........................14 Backpack Housing Assembly ....................... 16 2.2.1 Main backpack housing ........................ 17 2.2.2 Scrubber door assembly ....................... 17 2.2.3 CO2 scrubber canister ........................17 2.2.4 CO2 scrubber canister lift mechanism ..................17 2.2.5 Thermal regenerator ........................

  • Page 26: System Description

    YSTEM ESCRIPTION A schematic diagram of the SLS System is shown in Fig 2.1. As the diver exhales, gas passes via the diver's mouthpiece through the Helmet Interface Assembly and is directed by the check valves through an insulated hose to the Backpack. It then passes through the CO scrubber canister and up through the thermal regenerator into the counterlungs.
  • Page 27 Because the counterlungs are tightly packed, there is very little gas available for the diver to inhale after activation, hence a demand valve situated on top of the SLS System Backpack supplies the gas for his first breath. Then, as the diver exhales, the counterlungs are filled and from then on the SLS System functions in its semi-closed circuit mode.

  • Page 28: Backpack Housing Assembly

    ACKPACK OUSING SSEMBLY The major components of the backpack housing assembly are shown in Fig 2.2. Item Description Item Description Backpack Housing Moulding Gas Cylinder Manifold Relief Valve Canister Lift Mechanism Lid Screw Assembly Penetrators Two Stage Regulator Thermal Regenerator Assembly Protection Cap Housing Side Door Single Stage Regulator...

  • Page 29: Main Backpack Housing

    2.2.1 Main backpack housing The main Backpack (Fig 2.2, Item 1) contains the gas cylinders and manifold (Fig 2.2, Item 9), the charging point and the associated regulators (Fig 2.2, Items 4 & 6) in its lower part. The upper part of the Backpack contains the CO scrubber housing (Fig 2.2, Item 8) the canister lift mechanism (Fig 2.2, Item 10), the thermal regenerator (Fig 2.2, Item 12) and the penetrators (Fig 2.2, Item 11).

  • Page 30: Gas Injection System

    NJECTION YSTEM Item Description Gas Cylinders and Manifold Bottle Bracket Assembly Two Stage Regulator Single Stage Regulator Demand Regulator c/w Protection Cap Charging Point / Check Valve Overpressure Indicator Fig 2.3 Gas injection system OM131 Chapter 2 P1939-OM-131 R11...

  • Page 31: Gas Cylinders And Manifold

    Fig 2.3 shows the principle components of the gas injection system. In operational mode, gas flows from the cylinders (Fig 2.3, Item 1) to the two stage regulator (Fig 2.3, Item 3). The first stage of this regulator reduces stored gas pressure to an interstage pressure of around 15 barg (217 psig). The second stage reduces the pressure further to precisely 1 barg (14.5 psig).
  • Page 32 Fig 2.4 Two-stage regulator Fig 2.5 Spool valve OM131 Chapter 2 P1939-OM-131 R11...

  • Page 33: Injection Orifice

    Fig 2.5 shows the spool valve in another cross-section through the two-stage regulator. This illustrates the position of the pull ring (Fig 2.5, Item 17) on the spool (Fig 2.5, Item 14). The spool valve is moved from the closed to the open position by pulling the actuation cable. A bullet on the end of the cable contacts the two ball bearings (Fig 2.5, Item 36) in the centre of the spool, drawing the valve to the open position.

  • Page 34: Demand Regulator

    Fig 2.7 Single stage regulator The function of the single stage regulator is to maintain a positive pressure inside the SLS System while it is in its stand-by mode. Gas is supplied to the regulator from a connection on the Helmet side-block.
  • Page 35 Fig 2.8 Demand regulator The purpose of the demand regulator is to supply cylinder gas to the SLS System when inhaling from deflated counterlungs and to compensate in gas volume during any descent whilst the SLS System is activated. Normally, this regulator will function only during the first inhalation when using the SLS System. To prevent it from passing gas when not required, it is biased such that it will flow gas only when subjected to a negative pressure of 26 to 27 cm WG.

  • Page 36: Overpressure Indicator

    The internal pressure within the SLS System will vary between the single stage regulator set pressure of 138 mbar (2 psi) and the overpressure valve set pressure of 172 mbar (2.5 psi) as the diver’s ambient pressure changes during upward or downward excursions. 2.3.8 Overpressure indicator The overpressure indicator provides a visual indication that positive pressure is maintained in the...

  • Page 37: Counterlungs And Enclosures

    Item Description Part No. Harness C35650 Counterlung Enclosure Divers Right DM46630B Counterlung Enclosure Divers Left DM36010B Actuation Sleeve Assembly C45540B Actuation Cable Assembly C2937 Counterlung Assembly CA2607 Weight Pocket D308 Handle Retaining Band D302 Rescue Lifting Point Cable Wiper Sleeve D328 Bush D322...
  • Page 38 These are an important feature and are fitted to protect the cables and sleeves from damage or grit ingress, as this could compromise the actuation of the SLS System. Fig 2.10 Actuation cable assembly (Part No: C2937) Item Description Part No Counterlung Cable Assy, Short DM3572 Regulator Actuation Cable Assy...

  • Page 39: Hose Connections And Interfaces

    ONNECTIONS AND NTERFACES The SLS System Backpack hose connections to the Helmet are shown in Fig 2.11. Fig 2.11 Hose Connections and Interfaces Item Description Part No Single Stage Regulator Hose D2751 Inhale / Exhale Hoses C28700 Counterlung Hose (each) C3253A Hot Water Shroud Hose Kit CB156...

  • Page 40: Inhale / Exhale Hoses

    2.5.1 Inhale / exhale hoses The outer hose ducts on top of the SLS System Backpack are connected to the Helmet by two large bore, fabric reinforced hoses (Fig 2.11, Item 2). These are fitted with threaded (O-ring type) connectors at each end. A second pair of shorter hoses (Fig 2.11, Item 3) connect the inner hose ducts to the counterlungs, mounted one on each of the diver’s shoulders.
  • Page 41 The two hot water systems utilised for diver heating are as follows: Primary Gas Heating (Ultrajewel 601) The diver’s primary gas heating system utilises the DSI Heating Shroud Kit. This flows hot water over the Helmet side-block assembly, the bent tube assembly and the Ultraflow 601 regulator body. The supply of hot water is taken via a splitter block and requires a flow of 2 to 6 lpm of hot water (taken from the suit supply of 10 to 30 lpm).
  • Page 42 (Intentionally Blank) OM131 Chapter 2 P1939-OM-131 R11...
  • Page 43 3 - O HAPTER PERATING NFORMATION ONTENTS Page Preparation for use ........................32 3.1.1 Gas bottle charging ........................32 3.1.2 scrubber canister replacement ..................... 37 3.1.3 scrubber canister filling ......................39 Pre-dive procedures (Bell checks) ....................40 Operational procedures ........................ 44 3.3.1 Actuation ............................

  • Page 44: Preparation For Use

    REPARATION FOR USE 3.1.1 Gas bottle charging It is essential that the gas cylinders be completely empty before filling and that the correct gas mix is used for the diving depth. Failure to do this could result in an extreme hazard to the diver. The following table provides the limits of the gas mixtures, which should be used within the cylinders of the SLS System at various diving depths.
  • Page 45 Diver Minimum Maximum Diver Minimum Maximum Excursion Heliox % O Heliox % O Excursion Heliox % O Heliox % O Depth (MSW) Depth (MSW) 6.65 28.5 8.15 23.5 17.8 35.5 15.7 14.4 13.4 5.75 12.4 21.9 11.6 5.55 11.0 18.4 10.5 17.0 10.2...
  • Page 46 Example Use of the Table 3.1: SLS System gas mixtures versus diving depth. A saturation dive is to be conducted at a working depth from 195 to 205 msw. The divers will be living in Saturation at a depth of 190 msw. The bell will normally be launched to a depth of around 190 msw.
  • Page 47 Fig 3.1 Gas bottle charging The SLS System cylinders should not be charged whilst they are inside a dive system. Remove the SLS System backpack cover (Fig 3.1, Item 1). Ensure that the spool valve (Fig 3.1, Item 2) is set in the stand-by position and the actuation cable bullet is visible (if the actuation cable is installed).
  • Page 48 Charge the SLS System to the required charging pressure (see Table 3.2 for details). Slowly pressurise the gas cylinders. Ensure, using torch, that an excessive temperature rise does not occur within the cylinders during this operation. If the cylinders become too warm to touch, stop charging and leave the cylinders to cool before continuing.

  • Page 49: Co 2 Scrubber Canister Replacement

    Depth Charging Pressure Duration 50 msw 300 bar (max) 30 mins* 50 msw 175 bar 30 mins 50 msw 100 bar (min) 17 mins 100 msw 300 bar (max) 30 mins* 100 msw 250 bar 30 mins 100 msw 100 bar (min) 12 mins 150 msw 300 bar (max)
  • Page 50 The scrubber canister should be replaced using the following procedure: Fig 3.2 Scrubber Canister Replacement Remove the outer door (Fig 3.2, Item 1) by unscrewing its knurled knob. Remove the scrubber door (Fig 3.2, Item 2) by unscrewing its knurled knob and rotating the tommy bar to the position indicated on the door.

  • Page 51: Co 2 Scrubber Canister Filling

    OTES (1) Always ensure the CO scrubber canister is correctly installed prior to diving. (2) Ensure that the scrubber door is not over-tightened (see section 4.5.1, page 78). (3) Do not pressurise or de-pressurise the scrubber canister too rapidly during transfer in and out of the equipment lock or medi-lock, otherwise damage may occur.

  • Page 52: Pre-Dive Procedures (Bell Checks)

    DIVE PROCEDURES ELL CHECKS With personnel in the bell, ensure that the actuation cable is in place, the counterlungs are properly packed and that the spoon valve is in the stand-by position with the cable bullet visible. Ensure that the gas cylinders are charged with the correct gas mix for the dive depth (see section 3.1.1 for details).
  • Page 53 Fig 3.3 Hose Lanyards OM131 P1939-OM-131 R11 Chapter 3...
  • Page 54 Fig 3.4 SLS System Mk IV - Rear View OM131 Chapter 3 P1939-OM-131 R11...
  • Page 55 Fig 3.5 SLS System Mk IV - Front View OM131 P1939-OM-131 R11 Chapter 3...

  • Page 56: Operational Procedures

    Fig 3.6 SLS System Mk IV - Side View PERATIONAL PROCEDURES 3.3.1 Actuation The SLS System Mk IV is shown in Fig 3.4, Fig 3.5 and Fig 3.6. It is shown ‘as rigged’ for operational use, and may be actuated in the event of: Loss of primary gas supply.

  • Page 57: Equipment Lock Transfer Procedures

    The SLS System is actuated by the following actions: Rotate the interface handle on the helmet and grasp the mouthpiece in the mouth. Pull the actuation handle on the backpack harness. If the actuation handle is not pulled the diver will run out of breathing gas as the system has now become open circuit.

  • Page 58: Post-Dive Procedures

    DIVE PROCEDURES 3.4.1 Post-dive check list (Normal operations) Check the SLS System contents gauge. Recharge the cylinders if any loss of gas is indicated. Check also against Table 1.1, page 12 or Table 3.2 or SLS System duration at working depths to ascertain if charging is required.
  • Page 59 Replace the counterlungs and their hoses. Re-install the sponge pad (Fig 3.7, Item 5) and scrubber lift mechanism. Reload the actuation cable assembly (section 3.4.4). Recharge the cylinders with the appropriate heliox gas mix for the diving depth (section 3.1.1). Install a refilled scrubber canister and check the door seal (section 3.1.2 and section 3.1.3).

  • Page 60: Discharging The Gas Cylinders

    Item Description Part No Thermal Regenerator D2498C Gasket D2477C RH Regenerator Housing D2474E LH Regenerator Housing D2473D Absorbent Sponge Pad D300 Fig 3.7 Thermal Regenerator Removal 3.4.3 Discharging the gas cylinders Prior to filling the gas cylinders with a new mix or performing regulator or bottle maintenance, discharge the gas cylinders as follows: Actuate the SLS System by pulling the rip cord to discharge the gas cylinders.

  • Page 61: Reloading The Actuation Cable Assembly

    The gas mix within the cylinders is not breathable at atmospheric pressure therefore venting must be carried out in a well-ventilated area to avoid hazards. Leave the SLS System for at least 5 minutes until the last of the gas is vented. Check that the contents gauge reads ‘zero’...

  • Page 62: Reloading The Spool Valve

    Fig 3.8 Lacing procedure of Counterlungs 3.4.5 Reloading the spool valve To reload the spool valve, proceed as follows: Actuate spool valve by pushing on the pull ring (Fig 3.9, stages 1 and 2). Re-thread the actuation cable into the armoured sheathing (Fig 3.9, stage 2). OM131 Chapter 3 P1939-OM-131 R11...
  • Page 63 Fig 3.9 Reloading the Spool Valve A second bullet located further along the cable limits the travel and prevents the cable from projecting beyond the spool valve. Ensure end of the bullet on the cable can be seen through the hole in the end of the spool (Fig 3.9, stage 3).
  • Page 64 (Intentionally Blank) OM131 Chapter 3 P1939-OM-131 R11...
  • Page 65 4 - M HAPTER AINTENANCE NSTRUCTION ONTENTS Page Storage ............................54 Maintenance schedules ........................ 54 4.2.1 Weekly maintenance schedule ..................... 54 4.2.2 Monthly maintenance schedule ....................54 4.2.3 Six monthly maintenance schedule ....................54 4.2.4 Annual maintenance schedule ...................... 55 Preventative maintenance procedures ..................

  • Page 66: Storage

    TORAGE Do not store under positive pressure, leave inner side door lightly closed. Always manually check activation after storage and before issuing for diving. AINTENANCE SCHEDULES 4.2.1 Weekly maintenance schedule Clean (See Section 4.3.1.1 for details). Visual Inspection (See Section 4.3.1.2 for details). Check spool valve actuation (See Section 4.3.1.3 for details).

  • Page 67: Annual Maintenance Schedule

    4.2.4 Annual maintenance schedule Visual inspection and testing of gas cylinders and HP pipework (See Section 4.3.4.1 for details). Strip down and service of two stage regulator (See Section 4.3.4.2 for details). Strip down and service of single stage regulator (See Section 4.3.4.3 for details). Strip down and service of demand regulator (See Section 4.3.4.4 for details).
  • Page 68 Fig 4.1 Weekly Maintenance - Main Housing Item Description Part No Backpack Housing Moulding D294 Relief Valve VR300 Lid Screw Assembly C2606D Two Stage Regulator CA2602 Demand Regulator (inc. Protective Cover D313) CA2604 Single Stage Regulator CA2603 Gas Cylinder Retainer J2489B Refillable Sodalime Canister C32540...
  • Page 69 Item Description Part No Thermal Regenerator Assembly D2498C Housing Side Door D281 Sealing Washer DM217 Locknut D275 O-Ring RN031-7 Duct D2480 Duct Insert D276 Retaining Nut D2939A Penetrator Body D277 Fig 4.2 Weekly Maintenance - Harness and Counterlungs (Part No. CA2604) Item Description Part No...

  • Page 70: Check Actuation Of Sls System Backpack

    Item Description Part No Counterlung Assembly CA2607 Weight Pocket D308 Handle Retaining Band D302 Rescue Lifting Point Cable Wiper Sleeve D328 Bush D322 4.3.1.3 Check actuation of SLS system backpack Remove the outer door, scrubber door and CO scrubber canister. Actuate the SLS System by pulling the actuation handle.

  • Page 71: Monthly Maintenance Procedures

    As this regulator is non-venting the internal pressure should be released before adjustment and be allowed to build up again after adjustment. Check the flow through the regulator using the test flowmeter with the test connector plug inserted in the injection orifice penetrator. With the supply set at 10 to 15 bar, the flowmeter ball should lie between 1.0 and 2.0 lpm on the scale.

  • Page 72: Check Scrubber Canister Seal

    4.3.2.3 Check scrubber canister seal Check the condition of the scrubber canister sealing gasket (Fig 3.7, Item 2, page 48) inside the scrubber housing. Replace it if damage is observed. See Section 4.5.2.2, notes 8. to 13. 4.3.2.4 Check operation of two stage regulator Ensure that the gas cylinders are empty by activating the SLS System and pressing down on the demand valve diaphragm with the demand valve activating tool (Divex Part No M2922) from the Tool and Test Kit.

  • Page 73: Check Operation Of Demand Regulator

    Insert the flowmeter connector (Divex Part No. DM32580) from the Tool and Test Kit into the main supply penetrator. Connect a breathing quality AIR supply to the SLS System Helmet and set a supply pressure equal to the expected helmet supply pressure from the tables in chapter 3 of the SLS Helmet Manual OM112.

  • Page 74: Replace Actuation Cable Wiper Sleeves

    4.3.2.7 Replace actuation cable wiper sleeves Replace the wiper sleeves (Divex Part No. D328) on the counterlung end of the actuation cable sleeves. Actuate the SLS System Backpack by pulling its actuation handle. Remove the old wiper sleeves from the counterlungs. These are located at the ends of the actuation cable sleeves where the counterlung actuation cable enters the sleeve.
  • Page 75 Fig 4.3 Monthly Maintenance Over Pressure Indicator Type 1 Item Description Part No Overpressure Indicator Main Body D263 Overpressure Indicator Top Cap D264 Overpressure Indicator Bottom Cap D265 Overpressure Indicator Lens D266 O-ring RN016-7 O-ring RN020-7 Flat Bottom Grubscrew, 6 UNF x 1/8” FB079 Rotowink DM263...
  • Page 76 Fig 4.4 Monthly Maintenance Over Pressure Indicator Type 2 (Part No: DM262) Item Description Part No Overpressure Indicator Main Body D263 Overpressure Indicator Top Cap D264 Mesh Retaining Sleeve D321 Overpressure Indicator Lens D266 O-ring E14629 O-ring E14738 O-ring E14783 Rotowink DM263 Mesh...

  • Page 77: Perform Leak Test

    4.3.2.9 Perform Leak Test Perform a leak check on the SLS System Backpack as follows: Connect a single hose between the inhale and exhale hose spigots. Ensure that the scrubber door is in place and closed tight. Connect a 10 bar supply to the single stage regulator hose. Ensure that the gas cylinders are charged to a minimum pressure of 20 bar.
  • Page 78 Fig 4.5 Six Monthly Maintenance - Gas Cylinders (Part No: C2626) Item Description Part No Bracket J2489B Bolt (long) FB075 Securing Stud D305 Jubilee Clip FC047 Pipework Bracket MC406 Pipework Clip MC407 Screw FB248 FN001 Heatshrink (Black) EM190 Andoe Kit DM2945 Ensure that the gas cylinders are empty by activating the SLS System and pressing down on the demand valve diaphragm with the demand valve activating tool (Divex Part No.

  • Page 79: Annual Maintenance Procedures

    Remove the gas cylinders for inspection by a competent person, as follows: Remove the single stage regulator and two stage regulator from the SLS System Backpack (section 4.3.4.2 and section 4.3.4.3). Remove the banjo bolt from the demand regulator supply manifold. Unscrew the four retaining bolts (Fig 4.5, Items 2 and 3).
  • Page 80 The screws securing the mounting plate (Fig 4.7, Item 37) to the regulator body (Fig 4.7, Item 1) should not be removed as they are secured in place using Studlock (Loctite 601). Remove the banjo bolt (Fig 4.7, Item 5) on the two stage regulator and release the regulator completely.
  • Page 81 Remove the pull ring (Fig 4.7, Item 17). Withdraw the spool (Fig 4.7, Item 14) from the circlip end. Inspect all components for damage or wear and replace as necessary. Replace all O-rings. Lightly lubricate O-rings before re-assembly using an oxygen compatible lubricant (e.g.
  • Page 82 Fig 4.7 Annual Maintenance - Two Stage Regulator OM131 Chapter 4 P1939-OM-131 R11...
  • Page 83 Item Description Part No Body Sub Assembly D2792 End Cap (2nd Stage) D2285 End Cap (1st Stage) D2691F Piston D2203E Banjo Bolt D2640 Spring Support Plate D2281 Spring Adjustment Plate D2212B Banjo Fitting 1st Stage Banjo D4541A Slip Ring D2282 Diaphragm Support Plate D22070 Valve Seat Retainer...

  • Page 84: Strip Down And Service Of Single Stage Regulator

    Item Description Part No Grub Screw FB079 Gasket VM052 Relief Valve PO20640 Ball Bearing RK231 Mounting Plate D29010 Spring RK223 Spring RK235 Mesh D32870 4.3.4.3 Strip down and service of single stage regulator Ensure that the gas cylinders are empty by activating the SLS System and pressing down on the demand valve diaphragm with the demand valve activating tool (Divex Part No.
  • Page 85 Replace all O-rings. Lightly lubricate O-rings before re-assembly using an oxygen compatible lubricant (e.g. Christo-lube fluorinated grease - Divex Part No SM034). Lightly lubricate the diaphragm support plate faces which contact the diaphragm, with christo-lube. The edge of the diaphragm must remain dry. Re-assembly is the reverse of the above.
  • Page 86 Fig 4.8 Annual Maintenance - Single Stage Regulator OM131 Chapter 4 P1939-OM-131 R11...

  • Page 87: Strip Down And Service Of Demand Regulator

    Item Descriptions Part Nos Single Stage Regulator Body D2284 Regulator End Cap D2285 Diaphragm Support Plate D22070 Spring Support Plate D2281 Spring Adjustment Plate D2212B Valve Seat Retainer D2286 Valve Seat RK221 Valve Pin D22020 Banjo Fitting Ref only Banjo Mounting Bolt D26940 Slip Ring D2282...

  • Page 88: Perform Six Monthly Maintenance

    Check the valve seat (Fig 5.12, Item 3) for wear and replace as necessary. If the valve seat or valve stem (Fig 5.12, Item 4) has been replaced then the roller fork (Fig 5.12, Item 12,) may require adjustment, as follows: With the regulator mechanism assembled check the play on the roller fork (Fig 5.12, Item 12).

  • Page 89: Fault Diagnosis

    AULT DIAGNOSIS A schedule of possible faults and remedies for various conditions of reduced performance of the Backpack is shown in Table 4.1 to aid fault diagnosis. Fault Probable Cause Solution External gas leak from Main O-ring cut or torn. Replace main O-ring seal on scrubber door.

  • Page 90: Corrective Maintenance

    ORRECTIVE MAINTENANCE 4.5.1 Scrubber door replacement and torque setting Fig 4.9 Corrective Maintenance - Scrubber Door Assembly (Part No: C2606) Item Description Part No Strong Back D2621 Screw D2485 Door D2605H Handwheel D2483F Guard D2884A Spacer D2283A O-ring RN1245-7 O-ring RN611-7 Screw FB068...

  • Page 91: Upper Penetrator Replacement

    To replace the scrubber door and set the torque, proceed as follows: Remove the old scrubber door from the Backpack. Lightly lubricate the main O-ring (Fig 4.9, Item 7) on the new scrubber door using an oxygen compatible lubricant (e.g. Christo-lube fluorinated grease - Divex Part No SM034). Install the new scrubber door into the Backpack and tighten it lightly to just 'finger tight' only.
  • Page 92 Clean off the old silicone and wipe the contact areas with silicone primer (Divex Part No. SM021). Fit a new O-ring (Fig 4.11, Item 3) to the upper penetrator (Fig 4.11, Item 1) and apply a bead of silicone sealant (Divex Part No. SM006) around the sealing face of the penetrator. Re-install the penetrator into the scrubber housing and refit the locknut (Fig 4.11, Item 2) using the tools described in Step 2 above, and with a moistened finger carefully wipe the excess silicone sealant smooth before it sets.

  • Page 93: Inhale / Exhale Hose Penetrators

    4.5.2.2 Inhale / exhale hose penetrators Release the wing nut and remove the thermal regenerator (Fig 3.7, Item 1, page 48). Peel off the scrubber canister gasket (Fig 3.7, Item 2) and carefully remove the RH / LH regenerator housing (Fig 3.7, Item 3 / 4) as required. Using the duct spanner (Divex Part No.

  • Page 94: Lower Penetrator Replacement

    4.5.3 Lower penetrator replacement OTES (1) Both lower penetrators can be easily removed from the SLS System for replacement or cleaning. (2) Removal of the internal components on the main supply penetrator is not recommended. Fig 4.12 Corrective Maintenance - Lower Penetrator Item Description Part No...

  • Page 95: Charging Point Check Valve Seat Replacement

    The SLS System should not be dived for a period of twenty four (24) hours after the silicone sealant has been applied to allow it to fully cure. 4.5.4 Charging point check valve seat replacement Ensure that the gas cylinders are empty by activating the SLS System and pressing down on the demand valve diaphragm with the demand valve activating tool (Divex Part No.

  • Page 96: Burst Disc Replacement

    Unscrew the first gas bottle from its manifold (the charging point cannot be turned until the bottle is removed). Unscrew the check valve. Unscrew the spring retainer (Fig 4.13, Item 2) and withdraw. Take out the spring (Fig 4.13, Item 7) and valve pin (Fig 4.13, Item 4). Remove the valve seat (Fig 4.13, Item 5) using a small stud extractor.

  • Page 97: Demand Regulator Body Replacement

    Ensure that the gas cylinders are empty by activating the SLS System and pressing down on the demand valve diaphragm with the demand valve activating tool (Divex Part No. M2922) from the Tool and Test Kit. Remove the plug (Fig 4.14, Item 1) taking care to avoid damaging the face of the plug contacting the burst disc (Fig 4.14, Item 2).
  • Page 98 Remove the actuation sleeve, which is shown in Fig 4.15, as follows: Remove the two screws (Fig 4.15, Item 4) that secure the actuation sleeve to the harness waistband, and pull the actuation sleeve from the harness via the webbing duct on the left hand side of the harness waistband, ensuring that it does not snag inside the double thickness harness backplate.

  • Page 99: Fitting Of Sls Harness Assembly

    Item Description Part No Screw, C’sk Slotted, 1/4” UNC x 1/2” Long FB132 Reaction Bracket, Divers Right D323 Reaction Bracket, Divers Left D325 Hose Barb D324 Wiper Sleeve* D328 Cable Tie* DST034 *Reference only. Not included in C45540B 4.5.7.1 Fitting of SLS harness assembly The correct procedure for fitting the SLS MkIV Harness Assembly (order code C35650) is detailed below the following captions: Pass the webbing strap under the backpack lower support pin and through the reinforced...
  • Page 100 Fig 4.17 Take the webbing strap and pass it under the support pin at the top of the backpack, and then through the second half of the reinforced loop at the top of the harness as per Fig 4.18. Fig 4.18 Pass the webbing through top buckle as per Fig 4.19.
  • Page 101 Fig 4.19 Take the remaining portion of webbing and loop it back through the top buckle to prevent slippage and tidy the loose end. Fig 4.20 Incorrect fitting of the harness will lead to excessive movement of the backpack potentially causing discomfort to the diver as well as premature wear and failure of the webbing straps.

  • Page 102: Counterlung And Enclosure Replacement (Part No: Ca2607)

    4.5.8 Counterlung and enclosure replacement (Part no: CA2607) Fig 4.21 Corrective Maintenance - Counterlung Item Description Part No Outer Washer D279 Retaining Nut D2488A Counterlung bag and internal components are only available as part of assembly CA2607. Disconnect the counterlung hoses. Remove the counterlung and enclosure assembly from the harness.
  • Page 103 5 - P HAPTER ARTS ATALOGUE ONTENTS Page Backpack housing assembly drawings and parts lists ..............92 Tool and test kit ..........................93 5.2.1 Divex SLS system backpack torque setting .................. 96 OM131 P1939-OM-131 R11 Chapter 5...
  • Page 104 ACKPACK HOUSING ASSEMBLY DRAWINGS AND PARTS LISTS Following are the detailed assembly drawings and their associated parts lists. Together these provide details of all parts used within the SLS System Backpack. All parts can be obtained from Divex Ltd. Drawing No. MTO Number Description P1939229S1 (Fig 5.2)
  • Page 105 OOL AND TEST KIT The Tool and Test Kit for the SLS System Mk IV contains specialised tools required to supplement the standard tools of the Maintainer, and is shown in Fig 5.24. The contents of the Tool and Test Kit are listed below. Fig 5.1 Tool and Test Kit - SLS System Mk IV (Part No: C10203) Item...
  • Page 106 The contents of the Spares Kit C10202 for the SLS System Mk IV is listed below. Part No Description C28500 Helmet Hose Assy, SLS C28700 Hose Assy, In/Exhale, SLS MKIV C2937 SLS, Actuation Handle/Cable Assembly DM29300 Kit, SLS Demand Regulator Spares (Comprises:) DM222 Diaphragm, Demand FB032...
  • Page 107 Part No Description DM29350 Flap Valve Spares Kit (Comprises:) DM2494A Mushroom Flap Valve, 3MM Hole DE109 Mushroom Flap Valve, C/W Tail RN026-7 O-ring RN028-7 O-ring RN030-7 O-ring DM29360 Kit, SLS Main Regulator Spares (Comprises:) D2206F DVR EQP, SLS V/V Pin 2nd Stage D22830 Diaphragm, 2nd Stage Regulator, SLS E13991...
  • Page 108 Part No Description MC111 Circlip, External, 9MM RN1245-7 O-ring RN611-7 O-ring Other useful part numbers include: Part No Description CA2607 Counterlung C45800 Counterlung Hose Assembly C32540 Refillable Sodalime Canister D328 Cable Wiper Sleeve D322 Counterlung Enclosure Bush D267 Valve Seat These parts are not included in the spares kits.
  • Page 109 Fig 5.2 Backpack Assembly (Drawing P1939229S1) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 110 ITEM NO. PART NO. DESCRIPTION QTY. MANUFACTURER/SUPPLIER D294 HOUSING P1939-DG-182 D280 HOUSING LID P1939-DG-082 D281 HOUSING SIDE DOOR P1939-DG-088 D283 SERIAL NUMBER PLATE P1939-DG-130 D2486 RETAINING NUT 82486 D32960 HOT WATER HOSE SURROUND 83296 D33070 WASHER 83307 FW007 Ø1/2" PLAIN WASHER MC111 EXTERNAL CIRCLIP D1500/0090...
  • Page 111 Fig 5.4 Scrubber Housing Assembly (Drawing P1939131S1) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 112 Fig 5.5 Lid Screw Assembly (Drawing P193982606S1) OM131 Chapter 5 P1939-OM-131 R11...
  • Page 113 Fig 5.6 SLS System (Mk IV) Inhale/Exhale Duct Assembly (Drawing P1939-DG-142) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 114 SLS System (Mk IV) Inhale/Exhale Duct Assembly- Spares List: Item Description Part No Duct D2437 Locknut D270 O-ring RN031-7 OM131 Chapter 5 P1939-OM-131 R11...
  • Page 115 Fig 5.7 SLS System (Mk IV) Counterlung Duct Assembly (Drawing P1939-DG-159) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 116 SLS System (Mk IV) Counterlung Duct Assembly- Spares List: Item Description Part No Duct D2487 Locknut D275 O-ring RN031-7 OM131 Chapter 5 P1939-OM-131 R11...
  • Page 117 ITEM NO. PART NUMBER DESCRIPTION QTY. D277 Body, Penetrator, SLS RN010-7 O-Ring RN018-7 O-Ring Nut, Hex, Special, 7mm Thick, 9/16" x FN016 18UNF, 316SS MC109 Lee Jet, 800H NOTES : MATERIAL: DIVEX LIMITED TEL : +44 (0)1224 740145 DIVEX OWNS THE COPYRIGHT OF THIS DOCUMENT AND ANY DESIGN RIGHT ENTERPRISE DRIVE FAX : +44 (0)1224 740172 EMBODIED HEREIN.
  • Page 118 Fig 5.9 SLS System (Mk IV) Gas Schematic (Drawing P193940S1) OM131 Chapter 5 P1939-OM-131 R11...
  • Page 119 ITEM PART No. DESCRIPTION QTY. D2792 Two Stage Regulator Body D2203E Piston D2691F End Cap D4541A Inlet Banjo Fitting RN806-7 O-Ring RK225 Compression Spring RN020-7 O-Ring RN010-7 O-Ring MC121 8mm Circlip, External D2794E Valve, Shuttle VM052 Gasket, Relief Valve DM399 Valve, Safety Relief RK231 Ball Bearing, 5/32"...
  • Page 120 ,7(0 3$57 1R '(6&5,37,21 47< ' %RG\ 6LQJOH 6WDJH 5HJXODWRU '0 (OERZ 6ZLYHO 0& 6HDOLQJ :DVKHU 13 3OXJ  %63 +. &RPSUHVVLRQ 6SULQJ ' 9DOYH 3LQ 5. 9DOYH 6HDW ' 5HWDLQHU 9DOYH 6HDW ' 3ODWH 'LDJKUDJP 6XSSRUW ' 'LDSKUDJP ' (QG &DS '% $GMXVWPHQW 3ODWH 6SULQJ...
  • Page 121 ,7(0 3$57 1R '(6&5,37,21 47< ' %RG\ 'HPDQG 5HJXODWRU '0 /LG 6XE$VVHPEO\ 5. 9DOYH 6HDW 5. 9DOYH 3LQ 5. &RPSUHVVLRQ 6SULQJ '( 6HDW 5HWDLQHU 51 2ULQJ '% 6SULQJ 3DG 5. &RPSUHVVLRQ 6SULQJ ' 9DOYH $GMXVWPHQW 6FUHZ '% &DS '0 5ROOHU /HYHU 51 25LQJ 51...
  • Page 122 ITEM PART No. DESCRIPTION Qty. D304 SPIGOT FE013 FILTER ELEMENT D2219 RING, RETAINING DE924 COVER SET, EARPHONE DST034 CABLE TIE BLACK DD330303 WHIPPING TWINE,GREEN BRAID 400mm DIVEX OWNS THE COPYRIGHT OF THIS DOCUMENT AND ANY DESIGN RIGHT HEREIN. IT IS SUPPLIED IN CONFIDENCE AND MUST NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS SUPPLIED AND MUST NOT BE REPRODUCED WITHOUT PERMISSION IN WRITING FROM THE OWNERS. NOTES MATERIAL TITLE...
  • Page 123 Fig 5.14 SLS System (Mk IV) Bottle Assembly OM131 P1939-OM-131 R11 Chapter 5...
  • Page 124 (Drawing P1939-DG-82626) SLS System (Mk IV) Bottle Retainer Assembly- Spares List: Item Description Part No Bottle Retainer J2489B Bolt, Panhead FB075 Securing Stud D305 Jubilee Clip FC047 Bracket, Pipework Support MC406 Pipework Securing Clip MC407 Screw, Self Tapping FB248 1/4”-20 UNC Hex Nut FN001 Heatshrink (Black) EM190...
  • Page 125 Fig 5.15 SLS System Rotowink General Assembly (Drawing P1939-DG-59) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 126 SLS System (Mk IV) Bottle Retainer Assembly- Spares List: Item Description Part No Main Body D263 Top Cap D264 Mesh Retaining Sleeve D321 Lens D266 O-ring E14629 O-ring E14738 O-ring E14783 Rotowink DM263 Mesh D319 OM131 Chapter 5 P1939-OM-131 R11...
  • Page 127 Fig 5.16 SLS System (Mk IV) Hot Water System (Drawing P1939156S1) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 128 Fig 5.17 SLS System Set Hot Water Hose Assembly (Drawing P193983281S1) OM131 Chapter 5 P1939-OM-131 R11...
  • Page 129 Fig 5.18 Shroud Hot Water Hose Assembly (Drawing P1939-DG-83282) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 130 Fig 5.19 SLS System Hot Water Shroud Assembly (Drawing B82840) OM131 Chapter 5 P1939-OM-131 R11...
  • Page 131 SLS System (Mk IV) Bottle Retainer Assembly- Spares List: Item Description Part No Modifications to Shroud D2838 Support Collar D2839 Cable Tie FC029 Tube, Corrugated DE115 Shroud, Regulator DE116 Flange DE117 OM131 P1939-OM-131 R11 Chapter 5...
  • Page 132 Fig 5.20 Refillable Canister Assembly (Drawing P1939-DG-035) OM131 Chapter 5 P1939-OM-131 R11...
  • Page 133 Fig 5.21 SLS System (Mk IV) Harness Assembly (Drawing P1939137S1) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 134 Fig 5.22 SLS System (Mk IV) Actuation Cable Assembly (Drawing P1939-DG-115) OM131 Chapter 5 P1939-OM-131 R11...
  • Page 135 Fig 5.23 SLS System (Mk IV) Counterlung Assembly (Drawing P1939-DG-56) OM131 P1939-OM-131 R11 Chapter 5...
  • Page 136 PART No. Qty. ITEM DESCRIPTION DM3254 REGULATOR PRESSURE TEST KIT DM32580 FLOWMETER ASSEMBLY MANOMETER ASSEMBLY DM32570 SM034 CHRISTO-LUBE GREASE LOCKNUT SPANNER M2920 M2921B DUCT SPANNER M2922 DEMAND VALVE ACTUATING TOOL TOOL, SPANNER, COMBINATION, 5/16" AF TA097 MC328 STORAGE CASE D311 IN/EXHALE DUCT PROTECTION COVER ASSEMBLY TA024 ALLEN KEY (3/32")

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