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1. 11341 USER MAINTENANCE ABSORBENT amp SERVICE OXYGEN SENSORS APPROVED OXYGEN SENSORS The EXPLORER is only approved to use Hollis EXPLORER Oxygen Sen sors Hollis EXPLORER Oxygen Sensors have temperature ranges as detailed below Operating temperature range 0 40 C Storage temperature 20 to 50 C Recommended storage temperature 5 to 15 C OXYGEN SENSOR CARE O WARNING For the sensor life prediction alarms to operate correctly the oxygen sensors if removed MUST be replaced in the same position O WARNING In the event of a faulty sensor all three sensors should be replaced together as it cannot be guaranteed that the scenario that made the first sensor fail has not affected all the sensors O WARNING Number each individual sensor before removal so they can be replaced in the same position Basic care includes e NEVER store sensors in any gas other than air e NEVER subject sensors to high temperatures i e Car trunks e NEVER freeze sensors left in cars overnight e NEVER subject sensors to physical shocks e NEVER subject sensors to vacuum e NEVER submerge sensors in liquids e Never attempt to open a sensor housing e Sensors deteriorate very slowly and near the end of their useful life may show a reading drift soon after calibration e always change all 3 sensors together and after a maximum of 12 months from first usage e Water and corrosion on the sensor jack plug may give false
2. EAC LOSss USER MANUAL EXPLORER ORT REBREATHER Ug a g lt This is the operations manual for the HOLLIS EXPLORER This manual specifications and features of the Explorer are proprietary and copyright Hollis Inc 2012 This document cannot be copied or distributed without the prior agreement and authorization from Hollis Inc All information contained is subject to change Contact the manufacturer for the latest information www hollisgear com The EXPLORER is manufactured in the USA by Hollis Inc 2002 Davis Street San Leandro CA 94577 USA Ph 510 729 5100 EC Type approved by SGS UK Ltd Weston super Mare BS22 6WA Notified Body No 0120 Testing conducted by ANSTI Test Systems Hants To ensure your user information is up to date Please check www hollisgear com support asp for updates to this manual For warranty information see www hollisgear com Ssupport_warranty asp DANGERS WARNINGS CAUTIONS AND NOTES Pay attention to the following symbols when they appear throughout this docu ment They denote important information and tips A DANGERS are indicators of important information that if ignored would lead to severe injury or death WARNINGS are indicators of important information that if ignored could lead to severe injury or death a CAUTIONS are indicators of information that if ignored may lead to minor to moderate injury NOTES indicate tips and advice that c
3. IME Thu Oct 25 15 37 23 2012 IX 36 mite 1P USE 600psi Fig 3 10 ABOUT This screen shows information about the software installed in the EXPLOR ER the serial number of each connected element and information that may be required by your service center Software updates for the EXPLOR ER are available from http hollis com support asp Please check regu larly for updates Once a new update has been installed this screen will report the new version of software installed Fig 3 17 TURN OFF This selection shuts down the Explorer electronics 4andset Ver 4 0C SIN 01234567894BCDEF0O122 sensor Module Fig 3 11 29 SETUP MENU MAIN MENU SCREEN FIG 3 72 The EXPLORER has a simple menu system which is available while at the surface To access the Main Menu short press any button MENU NAVIGATION Action Button Press To Make A Change Short push both buttons enter the modification screen Exit The Menu Long push both buttons Scroll Down Short push right button Scroll Up short push left button SETUP MENU OPTIONS UNITS This option allows for the switching between metric and empirial unit modes LOGGING INTERVAL This option allows for the selection of how frequently the computer takes a snapshot of dive data stored for later download Using a shorter interval results in more data points per dive and fewer stored dives for download data respectively Longer data intervals result
4. It is assumed that CO levels in the region of 15 20mB are potentially very dangerous and potentially fatal and the user could easily lose conscious ness with little or no warning and as such it is potentially extremely danger ous to work at any CO level above the 10mb range MAIN FEATURES The CO sensor consists of a proprietary combination of filters and sensors that together provide a robust CO monitoring system for breathing loops in rebreathers The CO sensor is able to compensate for pressure and humidity environments as normally achieved in a diving rebreather system The EXPLORER version is powered from the LSS Module rechargeable battery The CO sensor requires occasional calibration EXPLORER has a sophis ticated logging system that minimizes the number of calibrations It also removes the need to use CO calibration gasses WHAT SHOULD EXPECT TO SEE ON THE CO SENSOR READINGS As a unique CO sensor in an active breathing loop some user education is required to understand the benefits features and limitations of the de vice From this standpoint it is worth the user taking a short time to under stand more of how CO is dealt with in the breathing loop CO filter endurance is reduced by increased depth low water temperature and high work rate CO generation variables As the user pushes the CO absorbent filter towards or past the end of its CE tested limits the levels of CO in the loop may be surpri
5. The EXPLORER can be fully activated in three separate ways 1 By button push 2 By breathing breath detection as a low PPO of 0 17 is reached 3 At depth gt 1 15 bar absolute pressure or about 5 ft 1 5 m DANGER The batteries must be charged for the automatic sys tems to work If the batteries are not charged the unit will not MENU turn on and not support life To turn on EXPLORER simply press both buttons on the handset and hold for 3 seconds After which the Hollis solash screen and then the training acknowledgement screen Fig 4 2 will appear A DANGER It important that you have read this manual and are properly trained in order to complete the Pre dive sequence and dive EXPLORER safely If you have not undertaken these steps yet do not proceed any farther By selecting CONFIRM the Pre dive sequence starts and you will be prompted through the sequence At the end of a successful Pre dive sequence you will see the check resources screen Fig 4 3 At this point you should cycle through the screens by pressing the left or right button to check that all resourcesare adequate to com plete the dive After a few seconds the display will time out to the Dive 7 screen Fig 4 4 MENU DCP STAT Fig 4 4 81 EMERGENCY START UP SYSTEM ESS 00 52 58 Should you have no option other than to enter the water immediately EXPLORER will activate the display and show all pertinent alarms in the STATUS screen
6. The EXPLORER uses advanced empirical techniques to ensure the accura cy of the ambient air calibration WARNING When refitting an oxygen sensor or after calibration of the sensors a full Pre Dive sequence MUST be completed The user can cause the largest error in oxygen sensor calibration If the calibration is not done in ambient air the sensors will not give the correct readings after calibration Therefore do not execute a manual calibration without ensuring the sensors are exposed to air at ambient pressure The units testing for good and bad oxygen sensor calibration is deter mined from the sensor mV level detected during calibration At 1O00mBar atmospheric pressure the range the unit can calibrate for is approximately 5mV to 15mV However if a sensor that would normally show 7 5mV in air has an enriched gas applied to it of 40 Oxygen during calibration then the sensor will give 14 28mV and the calibration will pass but the sensor will be reading only about half of the actual ambient Oxygen 36 Recommendations e Never store sensors for long periods of time before use they have expiration dates e Never subject sensors to high temperatures i e inside cars garages etc e Never freeze sensors left in cars overnight e Never subject sensors to physical shocks e Never subject sensors to vacuum e Never submerge sensors in liquids e Never attempt to open a sensor They contain a caustic chemical e Sensors
7. CO ABSORBENT STORAGE A DANGER Once a CO filter has been packed it should remain so Do not attempt to remove absorbent from a part used filter and dry it refurbish or re pack the absorbent in any way After a dive and providing the absorbent filter remains in a sealed state i e within a closed EXPLORER loop it may be used again until the limit of the absorbent timer is reached Storage for more than 24 hours is not recom mended and a used absorbent filter removed from the canister should be discarded HANDLING ABSORBENT Q WARNING CO absorbent may cause burns to eyes and skin First aid treatment is as follows e Inhalation Remove from exposure Seek medical attention e Skin Contact Drench with clean water and seek medical attention if skin becomes inflamed e Eyes Irrigate thoroughly with clean water Seek medical attention e Ingestion Wash out mouth thoroughly with clean water Seek medical attention Safety data on absorbent products can be found at http www molecular products co uk For User packed filters always fill filters in a well ventilated environment Avoid contact with eyes and skin 113 SERVICE Your instructor will educate you on what you the end user can service yourself For all other service needs your Hollis Explorer Technician has been trained in the proper skills to service your your Hollis equipment Always follow the Maintenance Schedule at the end of this chapter to keep your EXP
8. 2319psi Any decompression information NOTE The Status screen disappears after 5 seconds of inac tivity if no alarms or 30 seconds if an alarm is present Alter natively a long press of both buttons will Hide the screen 27 7 28 MAIN MENU MAIN MENU SCREEN FIG 3 7 The EXPLORER has a simple menu system which is available while at the surface To access the Main Menu short press any button MENU NAVIGATION Action Button Press Enter Highlighted Short push both buttons Menu Item Long push both buttons Scroll Down Short push right button Scroll Up short push left button MAIN MENU OPTIONS SETUP setup is a basic settings menu See the following Setup Menu section for further details NDL PLAN It is a dive planner based on current tissue state surface interval and a DCP setting for the next dive Fig 3 8 PC LINK This screen is a gateway to updating the internal software and download ing the log information to a PC Fig 3 9 Further details can be found in the Internet Reprogramming section of this manual LOGBOOK The Log Book screen is where you access recorded information on previ ously completed dives Fig 3 10 MENU SETUP NDL PLAN PC LINK LOGBOOK ABOLIT Fig 3 7 NDL PLANNER O390Ft 100Ft 110ft SI 00 hours 29min 23min O1 min DCP 50 l gt Fig 3 8 PC LINK MODE Fig 3 9 LOG BOOK AX DEPTH 120ft SURATION 30min
9. 34 Auto DCP Mode Example shallow dive using 40 Nitrox Auto DCP mode a begins at 10m depth DCP set to 95 wu ydeq 12m NDL too high gt 60 DCP will remain at 10 NDL 167mins NDL 89mins DCP 50 DCP 10 NDL control using DCP begins at 10mins NDL 46mins fu 5mins 18m DCP 95 DCP 95 10mins 52mins NDL 130mins DCP 95 Dive Time minutes NDL 60mins DCP 50 60mins NDL too high gt 60 DCP will setto 10 to save gas 68niins RMS RESOURCES MANAGEMENT The control of PPO is the prime function for EXPLORER in addition it monitors a range of dive resources The unit is able to make advanced decisions based on available resources in order to modify the PPO and provide for a better dive outcome The unit constantly monitors all resources such as available gas filter duration etc and keeps the dive within parameters that allows for a safe bailout ascent The unit uses a forward looking algorithm to determine the best PPO at any given time to avoid or reduce decompression allow for a safe open circuit ascent and stay within safe battery and filter dura tions Resources monitored include e Depth e NDL e PPO e PCO e Battery e HP gas e CNS Oxygen toxicity e Filter CO filter Resources are generally expressed in minutes and are noted in the cen ter of the dive screen Fig 3 20 The controlling most critical resource is shown This can change through
10. Electronics operation SMB deployment 100 User demonstrates comfort remov ing and replacing equipment User demonstrates competency and understanding of the use of the elec tronics User demonstrates deployment of an SMB followed by a safe ascent stopping at 6 m 20 ft while using the EXPLORER no stop times and endurance To ensure a diver is comfortable in the equipment can remove it in an emergency and im prove abillity to dive equipment from a small vessel To ensure the diver understands all functions with a fo cus on the STATUS system To ensure the diver can maintain buoy ancy and monitor displays while tasked with SMB deployment This skill is to be completed at the surface with weights removed and BCD inflated On the surface the diver should be able to demon strate navigation of the STATUS screens and an abillity to describe each screens meaning In the water the diver should be able to comfortably inter pret all displayed information This skill teaches students the rela tionship between PO changes due to ascent and buoy ancy changes Remove water from the breathing loop with the LCV HUD BUD use STATUS monitoring Gas share witha buddy User demonstrates how to clear water from the breathing loop Understand Hand set computer operation STATUS monitoring Menu System amp HUD BUD User demonstrates gas sharing
11. It is vital that you correct anything in error immediately before continuing to dive If you enter the water without completing the relevant Pre dive checks MENU and ESS mode is activated you will be given an O C bailout alarm red HUD warning you to return to the surface immediately to complete the Pre dive checks After 1 minute underwater if nothing else is alarming the bailout alarm will stop A DANGER The ESS should never be used as a routine diving start up system A full Pre dive check MUST always be con ducted to ensure safe operation The ESS is designed ONLY as a safe guard If you have not completed pre dive checks abort the dive and perform a proper pre dive on the surface Fig 4 6 LESS THAN 2 HOUR PRE DIVE SEQUENCE j If you have completed a Pre dive Sequence within the last 2 hours then upon reactivating the unit assuming there is nothing wrong with the sys tem it will display the Hollis splash screen followed by two screens Fig 4 5 4 6 It will then allow you to dive immediately TURNING OFF The EXPLORER cannot inadvertently turn off while submerged Although Fig 4 7 while at the surface if no button pushes are detected within 15 minutes it will automatically turn off to save power Fig 4 7 MENU SETUP To manually turn off EXPLORER then select the Menu option and do a MDL PLAN long press of the left button OFF Fig 4 8 PC LINK LOGBOOK ABOLIT Fig 4 8 82 FILLING THE GAS SU
12. New dives must not be performed on the filter once CO levels in the 5 10 mB region have occurred regardless of how short a duration Some rebreather fatalities are possibly due to users pushing the CO filter with strenuous activity near the end of the filter life Increased depth or reductions in temperature when the CO filter is near the end of its life are also not advised as the filter is less able to cope with high CO levels So increased depth coupled with muscular activity and cold are a very bad combination when near the end of filter life where CO levels are already raised NOTE Conversely reducing your depth and work rate and returning to warmer water are all good ways to manage CO levels until you can return to the surface and change the filter In any event if a CO alarm is seen the EXPLORER will force an immediate action to return you to the surface 53 54 GASEOUS CO SENSOR SYSTEM CONSTRUCTION The CO sensor system comprises of a Sensor and a removable change able filter The basic principle of the system is to use Infra Red technology to detect carbon dioxide CO in the retreaters breathing loop However certain contaminants and in particular moisture will affect the sensors abili ty to read accurately To help with this issue the assembly comes complete with a user changeable filter system that can be simply disconnected from the Sensor Module and serviced by the diver Fig 3 22 A DA
13. Sensors Breathing CO Removal HP Gas HP Gas Loop Ae Content Analysis S 25 26 DIVE SCREENS Sereen Description Q Q Dive Time Q MENU DCP STAT Qs AUTO DCP fh Arr N MODE O On MANUAL DCP 3 7 fi fi i i O E MODE y Dive Screen when ascent rate bar is 1 2 full then rate is 30 ft min 10 m min Dive Screen with menu bar accessed by a single push of any button Status Screen accessed by a short double push of the right button DCP Auto Mode short push of both buttons to change modes DCP Manual Mode short push both buttons to change modes 1 increment change by short push of either button 10 increment change by long push of either button STATUS SCREENS The Status STAT screens show all key resources in a simple format The screen is accessed from the main screen by a short double push of the right button and then a short push of either the left or the right button moves around the screen The Status screen also incorporates a color coded Action Panel to give instructions The items that can be displayed are Screen Description _ RATTERY Battery time in minutes CNS oxygen toxicity time in min utes PPCO Partial pressure of carbon dioxide in millibars mbar Carbon dioxide absorbent filter estimated remaining time High pressure nitrox gas supply remaining in minutes at current depth and workload min
14. amp COLOR SCREENS The EXPLORER can be routinely dived by using the HUD Heads Up Display as the main underwater human interface This frees up the diver to concentrate on the dive at hand The HUD is in the divers vision and attached to the BOV It utilizes color LED s and a vibration feature to get your attention when necessary Additionally the EXPLORER has a BUD Buddy Universal Display on the side of the LSS Module for the Buddy Instructor to see your status at a glance Both the HUD and BUD indicate the same color codes lf the HUD BUD system changes from Green for go mode to a flashing green blue then the diver can refer to the main wrist display and investigate the additional information on the STATUS display The wrist display utilizes color as an alert for general status changes and couples this alert with unprecedented clarity of information that can be reviewed in further detail The HUD BUD color screens on the wrist display and uncluttered screen layouts are key to providing the diver and dive team with essential information in high stress scenarios 60 DEFINITIONS Alarm state These are mostly alarm ing conditions but not always They could represent a state of the system that is displayed in some way other than via the HUD or STATUS screens Alarm Display The method by which an alarm state is passed to the user On the LSS module the HUD BUD and tactile alarm are used On the handset this is
15. high concentrations of chlo rine ammonia gasoline Benzene or any petrochemical based solvent Basically any product with the suffix ene in it Polishes wax automotive cleaning products Glues binding agents plastic fillers other than those spe cifically listed in the maintenance and troubleshooting or approved products sections of the manual A DANGER Never attempt to clean your rebreather or any part of your rebreather in a dishwasher or any other type of ma chine that employs high pressure jets of cold warm or scald ing hot water 118g GLOSSARY Absorbent chemical media used to remove CO from exhaled gas Absorbent Filter Mechanical assembly where the CO absorbent is housed ADV automatic diluent valve a valve that automatically adds fresh gas supply to the counter lungs as it collapses from increased pressure of depth or if it is needed after venting too much gas as in a mask clearing exercise Bailout redundant gas supply system Balance Tube The tube between the exhale counterlung and the LCV This tube removes water from the counterlung and controls breathing loop pressure with the LCV BUD Buddy Universal Display Universal display on side of LSS module codes identical to HUD BCD Buoyancy Control Device the harness buoyancy compensator assembly BOV bail out valve Breakthrough where absorbent scrubber fails no longer removing CO at an adequate rate Breathing Hos
16. is based on the calibrated value from all cells in alarm state OK 66 SURFACE HUD BUD ALARMS Red Do Not Dive Alarms Dive Hours Remaining 0 Depth Senso No Commsor Stal No Commsor Stal Ascent Rate Commsor Stal me E ee Bee Very High gt 10mbar ay py PPCO No Comms Sensor Stale or Failure Failed Cal PPO Low Very High No Comms Stale High Span or Bad Cells i TRE a Fai ee Fail _ o Interface Mismatch or Missing LSS module LSS IIC Comms Cell 1 Bad or Cell 2 Bad or PPO Cell Cell 3 Bad one only vve No Comms or Stale Very High Not diving and CNS 2100 Loss of LSS module comms in the handse o pierre Battery No Comms or Stal Empty either LSS module or handset battery gt Charge lt 10 Charging and Empty either LSS module or handset battery Charge lt 10 No Comms or a Solonoid Valve Pressure Difference OK v PPO Bad Cell States e Cell input timed out e Cell input stale e Calibrated sensor input gt 3 00 bar e Calibrated sensor input lt 0 15 bar e Raw sensor input lt 7 mV e Cell input excluded having failed calibration e Calibrated cell input gt 0 2 bar from the other two cells only a single cell can be in this state PPO Do Not Dive alarm states are No Comms All PPO cell alarms are No Comms Stale Any PPO c
17. 70 bar V Low Control If 2 or 3 cells in state OK and predive complete and PPO lt 0 20 bar where PPO PPO setpoint i e the difference between the average PPO and the setpoint The average PPO is based on the calibrated value from all cells in alarm state OK 70 PRIMARY ELECTRONIC BAILOUT SCENARIO CHART None Bad sensor Bad sensor readings error greater than 0 5 PPO PPO ex ceeds safe limits or mul tiple sensor errors Wireless HP data loss Very High CO gt 10 mb System OK Usable Green Y loop Usable Blue Y Fail loop Green safe mode Usable Blue Y Fail loop Green safe mode Usable Y depen loop dant on DCP PO Usable Blue Y STATUS screen action loop Green panel will show AS CEND NOW HP panel will be in Magenta No Comms Usable Blue STATUS screen action loop Green panel will show AS Unus Y depen dant on DCP PO STATUS screen action panel will show AS CEND NOW STATUS screen action panel will show AS CEND NOW PO panel will be in Magenta No Comms BAILOUT CEND NOW able loop see Alarm Tables for lower priority alarms BAILOUT None Stay on EXPLORER Stay on EX PLORER and ascend Stay on EX PLORER and ascend Ascend on open circuit Stay on EX PLORER and ascend Stay on EX PLORER and ascend Ascend on open circuit On board 3 sensor driven On board 3 sensor driven P
18. AND OPEN MOUTHPIECE CONFIRM im S8 ENSURE MOUTHPIECE CLOSED OPEN HP CYLINDER VALVE CONFIRM cm 888 ox 40 EVACUATE LOOP TO TEST ADY m o M EE NEY CO FILTER FIT TED 104 66 Y ES Te MANUAL CO2 SENSOR OR O2 CELL CALIBRATION ne eia Hatra PHO Ss J mm 929 FILL LOOP THEN EVACUATE LOOP AND CLOSE MOUTHPIECE CHH CONFIRM ma SR j PLEASE WAIT 34s PRESSURISING OOP mm 8 EE ES BLOCK NOSE AND BREATHE MIE FOR 49 SECONDS fim 8 ox 36 CHECK BAILOUT AND BCD From the dive screen each resource must then be checked Fig 4 70 Once you have checked each resource the STATUS display will show SYSTEM OK DIVING WITHIN 2 HOURS OF A SUCCESSFUL PRE DIVE SEQUENCE If you start a dive within two hours of a successful Pre dive being conduct ed then EXPLORER will display the following Startup screen Fig 4 11 Now you can simply select DIVE or go through the Pre dive sequence again by selecting PREDIVE MENU Fig 4 10 PREDIVE Fig 4 11 91 g2 USER FAULT FINDING amp TESTING PRE DIVE PRIMARY ERROR MESSAGES amp THEIR MEANINGS Message Meaning The batteries in the EXPLORER must be charged prior to diving CO sensor is unable to calibrate and must be replaced or removed the 5 minute pre breather system will be activated O sensor s unable to calibrate or failed LSS Sensor Module Recharge unit and try again Retu
19. BOV then the valve is not seated correctly With the BOV lever in the Closed Circuit position breathe off the BOV and ensure the mushroom valves function correctly as per the instructions in the BOV Assembly subsection in the Complete Disassembly amp Reassem bly Part of this manual Attach the regulator LP hose to the BOV and gently tighten the nut to the hose inlet Fig 2 13 item C After inspecting the hose end O rings attach the breathing hoses to the BOV Ensure the white hose end goes to the inhale side Fig 2 13 item B of the BOV Fig 2 10 BATTERY min IIo Fig 2 11 Fig 2 12 Fig 2 13 13 Fit the breathing hose alternate ends to the Canister Ensure the white hose end goes to the white coded Canister port Confirm the ADV LP feed hose is fitted correctly and tightened to a torque of 50 60 in lbs 5 6 6 7 N m Fig 2 74 Step 8 Remove the Counterlungs from the packaging Visually inspect them for damage The Exhale counterlung Fig 2 15 is the one with the mushroom valve in the base this valve is seated in the LCV port The LCV port cap is removed by a turn counterclockwise This gives access to the mushroom valve Inspect the mushroom valve and LCV port O ring and the Canister port O rings for damage Fig 2 16 Attach the LCV port cap to the counterlung Twist the cap until it clicks shut If not already installed attach the LCV tube open end to th
20. BREATHING FEEL The breathing feel of EXPLORER is partially controlled by the LCV Having removed the case cover this can be seen underneath the Canister This is an adjustable valve over a small range Oriented as shown Moving the valve to the left vents more easily and to the right it vents at a slightly elevated pressure Fig 4 7 The LCV is a hydrostatically balanced valve this means that in any swim position it releases gas from counterlungs at approximately the same pres sure and rate In addition it is a water drain device and it is connected to the exhale counterlung via a water drain tube such that as water enters the counterlung condensed exhaled breath then it moves through the tube and out of the LCV regularly throughout the dive THE AUTOMATIC DILUENT VALVE The EXPLORER also has an automatic diluent addition valve ADV which compensates for loss of gas volume To activate the ADV either descend or exhale through your nose and breathe in The ADV is designed to help maintain a breathable lung volume in conjunction with the LCV The ADV on the Explorer is a simple tilt lever system that in the relaxed position no gas applied will remain open It seals when gas is applied If moisture is present in the system and extreme freezing temperatures are experienced that are able to form ice within the rebreather this valve could freeze in the open position Freezing of ADV s is a common failure mode in most reb
21. Oxygen readings Seawater may dry leaving a deposit on the jack connectors and the sensor membrane Always leave the sensor jack locking ring finger tight on the sensor socket If you Suspect corrosion remove the sensor from the sensor module and clean the jack plug with a cloth and contact cleaner 44 e Check the sensor membrane A certain amount of moisture will always appear on and around the sensors If you suspect excessive water has made contact with the sensor faces Remove excess water carefully with a paper tissue and leave to dry in a warm area If the jack socket on the sensor is wet the sensor may be damaged as the electronics inside the sensor will also be wet Q WARNING Flooded sensors must be replaced 11353 SANITIZING The recommended sanitizing product for the EXPLORER is Steramine This sanitizer is available through your Hollis dealer Please see www Steramine com for Safety Handling Instructions Basic sanitizing can be conducted by making up a solution in the correct quantities and soaking or wiping the part with the solution WARNING The use of any other sanitizing may damage the component parts of the rebreather in particular the mushroom valves Items to be sanitized are e The mouthpiece and hoses e The counterlungs e The canister tube and all its internal components WARNING You MUST make sure you read the Material Safety Data information before using 414 CO ABSORBENT
22. done via the GUI Graphical User Interface displays and the STATUS screen which also has an ACTION Panel reflecting the HUD and a message containing a single user action Some alarm displays vary depending on other system states such as other alarms or the dive status e g diving not diving ALARM CODES With the EXPLORER a key task has been to process the fault levels and error conditions to indicate the status of the rebreather Further the LED states are configured for color blind as well as highly stressed divers The position of the LED s coupled with the flashing or solid states provide conditions that cannot be confused with one another During stressful dive scenarios the position and status is quickly understood to speed up the desired response correction by the diver The status sceens on the wrist display add one more level of security by adding extra information on an alarm states WARNING This information is in English and all users should be adequately trained in interpreting this information appropri ately 61 62 There are 3 main warning levels associated with the HUD BUD and on screen displays Solid Green This code means there are no detected prob lems Flashing Green amp Blue Warning It is activat HUD BUD ed when a manage able error situation is amp l in place Yellow wrist display Magenta wrist display Loss of communica only tion between sensors or modules
23. feet in Honduras and Bonaire filming shipwrecks and deep reefs In 1990 Bob amp Oceanic developed the Phibian rebreather which at the time was the only commercially available unit HOLLIS REBREATHER DEALER SUPPORT COMMITMENT As a consumer you will receive a greater level of support from a Hollis Rebreather Dealer Not because a non Rebreather dealer doesn t care about support Instead the Hollis Rebreather Dealer has a greater level of commitment to the complete product line A Hollis Rebreather Dealer has perfected their diving skills and is at their peak of instruction They will provide access to rebreather training service consumables upgrades and travel The view from a Hollis rebreather into the underwater realm is like a view from no other place on earth Hollis Gear promises to deliver an experience like no other In 2000 Hollis parent company American Underwater Products under two separate contracts with the United States Naval surface Warfare Command developed and delivered a unit called the ATUBA Advanced Tactical Underwater Breathing Apparatus That led to the develooment and success of the Prism 2 eCCR technical rebreather All of that experience has been leveraged to bring you something new the Hollis Explorer eSCR the world s first electronically controlled semi closed rebreather for recreational divers AMERICAN UNDERWATER PRODUCTS ENVIRONMENTAL QUALITY POLICY American Unde
24. in fewer data points less detail but the space to store more dives TIME DATE This is the clock and calendar setting Fig 3 13 Q NOTE When the EXPLORER is first powered up from a flat battery you will be asked to update the date and time 30 SETUP UNITS Imperial FtipsifdegF LOGGING INTERVAL 10s TIME DATE DEFAULT GAS HP PAIRING SERVICE MODE Off t CHANGE L Fig 3 12 23 17 59 i k E i F T f Fig 3 13 DEFAULT GAS FIG 3 74 DEFAULT GAS Set this to your normal dive gas During the Pre dive if EXPLORER ana 40 EAN lyzes a different gas it will alarm and ask you to recheck the analysis For See further detail on proper use of this function see the following section Bail YOL 40 CUF I out and Gas Configuration HP PAIRING 4 Fig 3 14 To pair the HP transmitter first press SEARCH any transmitters in range will be displayed Then press PAIR The word PAIRED will appear once the HP PAIRING transmitter is recognised Fig 3 75 The transmitter ID is written on the transmitter attached to the first stage in your EXPLORER Fig 3 16 Please confirm this is the correct transmitter NOTE The HP transmitter MUST have pressure applied to it to activate and be seen by the system If the regulator is not pressurized the the transmitter will be off and not sending a signal Fig 3 15 SERIAL NUMBER BM XXXXKXKX KARX SERIAL NUMBER Fig 3 16 SE
25. or Unpaired Resource Low estimated time remaining o prevent reaching the 30bar reserve gas pressur once on the surface expired High or V High Contro Initial Diving After No Resource Checks on RR Resource Low estimated time remaining to prevent a Very High state once on the surface expired Resource Low estimated time remaining to prevent an Empty state once on the surface expired Resource Low estimated time remaining to prevent an Empty state once on the surface expired OK Too Shallow 65 PPO Bad Cell States Are As Follows e Cell input timed out e Cell input stale e Calibrated sensor input gt 3 00 bar e Calibrated sensor input lt 0 15 bar e Raw sensor input lt 7 mV e Cell input excluded having failed calibration e Calibrated cell input gt 0 2 bar from the other two cells only a single cell can be in this state PPO Ascend Alarm States Are High Span PPO cell span gt 0 5 bar if 2 or 3 cells in state OK Bad Cells 1 cell in state OK or no cells in state OK but with different high low alarm states or the same alarm states and no O C bailout case V Low Control If 2 or 3 cells in state OK and PPO lt 0 20 bar V High Control If 2 or 3 cells in state OK and PPO 0 70bar where PPO PPO setpoint i e the difference between the average PPO2 and the setpoint The average PPO
26. picture above sur rounded by a spring DANGER If you do not insert an absorbent filter the device seals off the breathing loop to prevent you from taking a CC breath You must not dive without a CO filter fitted CANISTER DISASSEMBLY ASSEMBLY e Remove the counterlungs and hoses by unscrewing the hose lock rings Clean and inspect the sealing face for each end cap seal and the hose ends counterlung ports e Then unscrew the LP feed to the ADV Fig 6 6 e Disconnect the LCV balance cap and tube from the exhale counterlung to the Canister at the counterlung This is a 1 2 turn counterclockwise unlock e Inspect the LCV counterlung mushroom valve and cap sealing ring for damage Replace re grease as required e The Canister can be removed for washing service if needed by unscrew ing the 4 Canister securing screws from the case e In normal diving operations the canister should be flushed with fresh water and rinsed with sanitizing liquid and wiped clean without removing it from the case PROFESSIONALLY PACKED ABSORBENT FILTER DISASSEMBLY ASSEMBLY e Disassemble and Discard the absorbent material as per local regula tions Wash the Absorbent Filter in warm soapy water to remove absorbent 108 debris Disinfect as required e Inspect the Filter for damage especially around the Quad ring sealing face e Inspect and replace the quad ring seal as recommended in the mainte nance chart e Inspect the upper and lo
27. required additional gas supplies for diving in mixed teams open circuit closed cir cuit Please check with your agency for details DANGER It is vital that a breathable open circuit bailout is car ried at all times for all depths of the dive of sufficient volume to allow for a safe ascent to the surface at a stressed breathing rate DANGER For deep long duration dives the on board gas sup ply should only be treated as a short term gas supply used for a limited period until the off board bailout gas can be accessed WARNING In depths shallower than 18 m 60 ft you must be able to provide gas to another diver buddy This will require the use of an additional second stage octo attached to your EX PLORER first stage if you are not carrying an external bailout cylinder NOTE The BOV is connected to the on board gas supply Dives shallower than 18 m 60 ft dives can be conducted using only this available gas as a bailout providing that the gas en durance alarms are not exceeded on the unit NOTE Certain training agencies may required additional gas supplies for diving in mixed teams open circuit closed cir cuit Please check with your agency for details L Z 78 The following is offered as a guide when configuring the EXPLORER for a range of diving conditions This must be used in conjunction with the recommendations from your Hollis approved training agency Depth On board Gas Off board Gas Less th
28. selecting STAT from the pop up menu using a short push of the right button It can also be accessed in service mode by selecting STAT a short push of both buttons from the Startup screen Note that in both cas es the STAT button indication is colored blue as are all button indicators modified by service mode Once in the STATUS screen a short press of the left or right button scrolls MENU round the information options These are a a PPO average of the 3 sensors b CO sensor c HP gas d Battery life e No Decompression Limit NDL f Decompression Information g Filter CO filter h CNS i A general Warnings Window the ACTION Panel detailing any alarm in progress This mostly displays SYSTEM OK or DO PREDIVE as in the D above example unless there is another fault to report SERVICE MODE Service mode is accessed in the Setup Menu With this mode set each pre dive screen shows additional text information relevant to the test being performed METRICS Also it enables an extra blue STAT button on the Startup screen Fig Fig 3 4 3 2 which if selected with a long push of both buttons not indicated will allow access to detailed service sub screens Your Hollis dealer will use information on these screens to assist with any servicing required A short push of STAT will just display the STATUS screen and relevant resources as during a dive To enable fault diagnosis put the EXPLORER i
29. some oth er problem is likely to be the cause These include e Oxygen sensors have become wet e Current gas exposed to the Oxygen sensors is not what you think it is e The min jack connection is corroded Check the readings on the STATUS screen average or Service Mode STATUS Screen all 3 sensors If a sensor is reading incorrectly first remove it and clean the mini jack connector This can be done with Hollis approved elec trical contact cleaner or simply by wiping the connector with a lint free cloth DO NOT scratch the connector with a metal instrument Then look for droplets of moisture on the sensor membrane Use a rolled tissue to gently wick any moisture drop lets from the sensor WITHOUT making contact with the sensor membrane itself Pushing on the sensor membrane face can destroy the sensor If neither of these corrects the reading then the sensor should be replaced The Oxygen sensors vary only slightly over time Temperature atmospheric pressure and moisture have far greater short term effects on the readings Calibrations carried out once a week should be more than sufficient unless the EXPLORER has been transported to different climates or significantly different ambi ent conditions 39 40 So calibration checks not actual calibrations should be car ried out regularly to ensure the oxygen PPO sensing system is performing correctly Calibrations should be done more sparingly as it takes time to e
30. to 1 Check that all functions of the EXPLORER have a high likelihood of oper ating correctly 2 Detect assembly errors 3 Detect breathing loop errors 4 Advise the user of system measurements that are outside correct operating parameters including a High Pressure readings too low b High Pressure readings dropping too quickly possible leaks c Battery Levels d PPO partial pressure of oxygen in the breathing loop e Calibration of PPO CO sensors performed correctly f Ensure the CO absorbent is functioning correctly and the filter is inserted correctly and is sealed THE COMPLETE PASS MODE PRE DIVE SEQUENCE The complete sequence is detailed on the following page This sequence assumes all tests pass OK and no Pre dive has been conducted within one hour The full screen chart is available on the CD enclosed with the prod uct An APP for any Android device is available at http hollis com support asp and on the enclosed CD with your EXPLORER 859 1m 00 52 58 I HAVE READ AND UNDERSTOOD THE MANUAL I HAVE COMPLETED 4 RECOGNISED TRAINING COURSE I KNOW HOW TO OPERATE l THIS EQUIPMENT i MENU CONFIRM mm 3 CHECK RUBBER MOUTHPIECE AND MUSHROOM VALVES mm 99 PLEASE WAIT 255 NEGATIVE TESTING LOOP r TT EE OPEN MOUTHPIECE CONFIRM e xcs CE CHECKED OK CONFIRM 90 PLEA SE Wy H pan I TT SERFORMING SYSTEM CHECKS TT ia CONNECT HOSES CLOSE HP CYLINDER VALVE
31. very high workload in 4 C 39 2 F it should read 5 mb The CO sensor will benefit from calibration at the start of a dive sequence and if the sequence is longer than 1 week at the start of each new dive week When having not been used for over a month or if you suspect a bad reading see additional notes on filter care a calibration must be done prior to diving It is good practice for the user to check the approximate validity of the CO readings regularly ideally prior to any dive Simple testing by breathing directly onto the sensor should see the reading rise within approximately 1 minute Also exposure to clean fresh outside air should give a reading in the order of 0 4 mB The unit will respond faster with the filter removed So the user must familiarize themselves with the operation and assembly of the system to be confident the device is work ing correctly Consult your Hollis dealer if in doubt Q WARNING If you wish to calibrate the unit you must ensure you are in fresh ventilated outside air DO NOT calibrate in a closed room The calibration method is discussed above and is detailed step by step in the pre dive sequence ELECTRICAL CONNECTION The connector for the CO sensor is imbedded into the Sensor Module next to the 3 x O sensors It is vital this connection is kept clean hollis approved contact cleaner or NOTE If moisture is present when this connection is mated then contact corrosion may occur
32. white ID O rings to the left hand side in hale side of the mouthpiece 105 e Repeat for the right hand side black hose MOUTHPIECE HOSE ASSEMBLY TESTING In open circuit mode immerse the mouthpiece Block the exhale hose end green and blow into the inhale hose end red Faults e If bubbles come out of the mouthpiece there may be a leak in the barrel activation handle seals Return to your Hollis dealer for repair EXPLORER LSS MODULE DISASSEMBLY ASSEMBLY e Remove the LSS Module by twisting the lock ring anti clock wise 1 2 turn e Inspect amp clean O ring and sealing surfaces re grease and refit the LSS Module sealing O rings e Refit the head by lining up the solenoid post pushing it into the Canis ter and turning the lock ring clockwise by 180 degrees to 3 O clock Fig 6 7 NOTE Ensure the lock ring is in the 9 O clock position for the O rings to engage then twist it by 180 degrees to 3 Fig 6 1 O clock to lock The Case Back Cover will not fit correctly if the lock ring is in the wrong position 106 SENSOR MODULE DISASSEMBLY ASSEMBLY OXYGEN SENSOR MAINTENANCE TESTING e Remove the Sensor Module Fig 6 2 from the Canister e Remove all 3 oxygen sensors Fig 6 3 e Inspect the Thermal Profile Monitor TPM body and O ring for damage and clean the TPM with warm soapy water NEVER expose the sensors to water e Clean the sensor jack connectors with a soft cloth look fo
33. 4 is greater than 1 6bar when diving then an ASCEND NOW alarm 41 42 will be displayed Diver Action Ascend on the rebreather 7 lf the average of all sensors is less than 0 17 or greater than 2 0 when diving then a BAILOUT alarm will display NOTE This alarm will supersede those in rules 1 2 3 4 5 and 6 Diver Action Open circuit Bailout to surface 8 If two or more sensors are removed from the averaging because of rules 1 2 3 or 4 then the system will inject gas for 1 second out of every 3 as a fail safe This will cause an ASCEND NOW alarm Diver Action Ascend on the rebreather Rebreather switches to Fail safe mode EXAMPLES 1 Sensor 1 0 65bar sensor 2 0 60bar sensor 3 0 70bar All sensors used 2 Sensor 1 0 3bar sensor 2 0 60bar sensor 3 0 70bar Sensors 2 and 3 still used 3 Sensor 1 O 3bar sensor 2 0 60bar sensor 3 0 9bar Failsafe inject for 1 second out of every 3 Sensors are greater than 0 5 apart across all 3 sensors 0 3 to 0 9 CDM CANISTER DURATION METER The EXPLORER Canister Duration Meter CDM is comprised of three main parts 1 A patented absorbent temperature profile duration meter 2 An Oxygen Injection Meter based on CE tested durations 3 A gaseous CO sensor The readings from all of these devices together can be used to report a high confidence status regarding the state of the Absorbent Filter Howev er user experienc
34. Although the displayed minutes are at CE CO generation standards the minutes will tick down more slowly if the diver is breathing at a reduced rate This will be the most common scenario However in the unusual condition of CO generation at an elevated rate compared to 1 6ltr min then the minutes will tick off more quickly If the diver knows a particu larly strenuous dive is ahead they should allow extra conservatism in the minutes remaining counter for that dive The Oxygen Injection Meter should be used in conjunction with the Tem perature profiler and the Gaseous CO sensor to determine the appropriate state of the filter The remaining Oxygen injection meter percent is dis played on the STATUS screen as a Filter minutes The Oxygen Injection Meter minutes are reset when the absorbent is replaced and confirmed in the Pre Dive Sequence WARNING The CO Absorbent Filter Alarm will activate when there is sufficient duration to allow an ascent to the surface with an additional approximate 10 minutes reserve remaining At such time the diver should ascend to the surface on closed circuit DANGER If in doubt of the condition of the CO filter replace the absorbent and perform full pre dive checks Filter time re maining must exceed the planned dive time OPERATION AND INTERACTION OF TEMPERATURE PROFILER AND OXYGEN INJECTION METER The thermistor bar chart of the temperature profile through the filter is shown to give t
35. E CHECKS SECTION 4 USER FAULT FINDING amp TESTING PART 5 MANDATORY DIVING SKILLS SECTION 1 EXPLORER BASICS SECTION 2 IN WATER SKILLS CHART SECTION 3 EXPLORER SKILLS COMPLETED PART 6 COMPLETE DISASSEMBLY amp REASSEMBLY SECTION 1 THE FULL DEAL PART 7 USER MAINTENANCE amp AB SORBENT STORAGE SECTION 1 O SENSORS SECTION 2 SANITIZING SECTION 3 CO ABSORBENT SECTION 4 SERVICE SECTION 5 MAINTENANCE SCHEDULE PART 8 APPROVED PRODUCTS amp GLOSSARY SECTION 1 APPROVED PRODUCTS SECTION 2 GLOSSARY Vil YOUR NEW EXPLORER REBREATHER LIFE SUPPORT SYSTEM RULES A DANGER Read and understand this list prior to using this unit If you do not understand any or all of this section please con tact your training agency or Hollis Rules for EXPLORER Divin 1 Always complete all pre dive checks Pay special attention to BOV mushroom valve tests 2 Always pre breathe the Explorer Sport Rebreather until the system passes its tests 3 Do not modify the EXPLORER without the manufacturer s written con sent 4 Do not use a full face mask Unless approved by Hollis for use with the EXPLORER 5 Always analyse your gas 6 Never dive a unit you suspect is leaking and has not passed all the pre dive tests 7 Never leave your BOV open on the surface 8 Ensure your BC is inflated at the surface 9 Take time to adjust your weight correctly do not dive over weighted 10 Always dive
36. Filter Filter i In Out Indicator Electronics Inhale Exhale Counterlung Counterlung MECHANICAL FEATURES The EXPLORER is an electro mechanical rebreather Over time certain soft ware and hardware optional extras and or software upgrades will become available Please check www HollisGear com for details HARNESS BCD EXPLORER uses a custom bolt fitting backplate Solo webbing harness and Hollis C45LX Wing There is an optional EXPLORER BCD available COUNTERLUNG The EXPLORER comes complete with dual back mounted counterlungs BCL These are attached to the canister by a screw threaded O ring fitting CYLINDER EXPLORER uses a 5L 40cuft cylinder with an inline valve Dives over 18 m 60 ft requires that an additional bailout cylinder of a minimum capacity of 3 L 20 cuft be used in conjunction with the 5L 40 cu ft cylinder USA Only Cylinder Options Chart Beever Eurocylinders 3410 Faber 6 a 22 o NOTE The Explorer can accomadate a maximum 5 5 in 14 cm diameter tank EU Only Cylinder Chart 3410 Beever Eurocylinders 3410 OUTER CASE The outer case is made from high impact plastic OVER PRESSURE VALVES EXPLORER uses a combined water release and balanced Loop Control Valve LCV The balanced valve ensures that the underwater release pressure is near constant in any orientation When the unit vents it also removes any water from the exhale counterlung This i
37. ICS The primary diving skills required to use the EXPLORER will be covered in your chosen agency s training program and will not be reviewed here However there are certain unit specific skills which must be covered during your training course These are detailed below LEAK TESTING See PART 4 Section 4 CALIBRATION See PART 3 Section 12 HARNESS ADJUSTMENT See PART 4 Section 1 BUOYANCY CONTROL AND TRIM Initially in shallow confined water you will be required to maintain a hov ering simulated decompression stop You will then practice short ascents descents initially Ascents will be made from progressively deeper depths and will involve the use of a Surface Marker Buoy OPEN CIRCUIT BAILOUT On every dive you will practice switching to the BOV and or bailout stage bottle On some dives you may be required to conduct additional bailouts possibly back to the surface as defined by your instructor Preparing the unit for diving and maintenance cleaning You will be shown how to assemble the unit and complete the pre dive check sequence In addition you will be shown how to care for your unit post dive FLOOD RECOVERY Condensate will naturally collect in the exhale hose on the diver s right This will be accompanied by a gurgling noise Water is allowed to then move into the top of the exhale counterlung This 95 is acceptable for the following reasons 1 Water entering the counterlung is forced out again by th
38. It is usually associated with DO NOT dive or OC bailout but could just be a warning Flashing Red It is activated when amp Vibrating there is an urgent issue alarms blue green state of the HUD or if the source of the alarm changes OK Procede with dive as planned The correct response will be displayed on the STATUS screen and will often tell the diver to ascend slowly on closed circuit monitoring the wrist display Check the status and for any message on the wrist display an react accordingly DO NOT start the dive If already diving the diver should switch to the bailout gas and ascend NOTE Red alarms take priority in the HUD over Green Blue NOTE Yellow on the display is equivalent to the alternating NOTE The HUD vibration alarm will vibrate every second for 5 seconds then repeat the 5 second alarm every 30 seconds ALARM FLOW DIAGRAMS The following sections contain flow diagrams to indicate which actions HUD indication will be used separated into diving and surface cases The following flow charts should be used in sequence where an OK from the red HUD cases leads to blue green HUD cases Note the following decompression tissue model O C Bail Out alarm states used in the dia gram No Comms Pressure Sensor alarm is No Comms Stale Pressure Sensor alarm is Stale Missed Stop Deco Ceiling violated for more than 1min This alarm state latches f
39. LORER in peak condition The EXPLORER also keeps a log of usage hours and it will display a service reminder when it is close to the service interval Fig 7 1 Fig 7 1 116 MAINTENANCE SCHEDULE KEY E before every dive A annually C at canister change 30 every 30 hours of diving 100 annually or if damaged prior damaged prior Quad Seal U CO sensor filter sponge U E swap 10 hours or if dam Change the sponge aged for a dry one every dive Replace after 10 hours 200 annually or if damaged prior If pre dive failed 200 annually or if leaks damaged prior Hose end O rings U Mouthpiece barrel O rings End cap O rings U Adv diaphragm Oxygen CO sensor connections 200 annually or if damaged prior 200 annually or if damaged prior Clean at annual Inspect for damage service Clean with contact cleaner Deoxit Gold GN5 Whichever comes Inspect for damage first 12 months or the DO NO USE AFTER DATE If damaged User pack version only 200 annually or if Water flush every damaged prior 2 days Disinfect counterlungs at ie O Oxygen sensors Absorbent Filter mesh Counterlungs and LCV port mushroom valve O ring GO O end of each trip or sooner if required Steramine 447 Hoses mouth piece assembly LCV assembly Regulator first stage Regulator second stage BOV mn Pe 118 See separate items Fresh water flush o
40. NGER It is vital that to maintain accurate CO readings the performance of the filtration system is maintained and a dry piece of absorbing material fitted before every dive Calibration of the sensor must be confirmed periodically by exposing it to air CO readings in air should be 0 4 0 1 mb If in doubt then recalibrate the sensor NOTE Readings in air should be between 0 4 0 1mb CO FILTER CARE A DANGER For accurate CO readings a clean and dry piece of absorbent material must be fitted prior to every dive Different environments will produce different amounts of moisture and hence the filter change out routine may vary Absorbing Material Membrane Filter Body Filter Cap Fig 3 22 The filter cap attaches to the filter body and is a push fit The basic con struction of the filter starts with a specialist filter membrane in the cap the yellow material backed up by a water absorbing material the central sponge like material in the picture NOTE The filter cap retains the membrane yellow materi al that must NEVER be removed The Sensor itself is not a user serviceable part and damage may result if it is tampered with If the filter cap membrane becomes damaged it must be replaced The yellow water absorbing material center of picture is removable The EXPLORER is supplied with spare absorbing material Simply remove one and refit a new one Fig 3 23 The absorbing material will become
41. O On board 3 sensor driven PO 71 72 GAS RESERVES DYNAMIC RESERVE The EXPLORER monitors the high pressure HP contents of the on board gas supplies The EXPLORER includes two warning system for the HP contents 1 Pressure below reserve level 2 Rate of use of gas is too high or too low indicating either a leak or that the HP cylinder valve is turned off and gas injection is being unsuccessfully attempted The gas supply reserve level is dynamically adjusted based on depth because ascent times vary with depth and assumes a stressed breathing rate of 20 l min on open circuit bailout using the on board cylinder If the system sees this reserve limit approaching it will warn the diver to ascend BAILOUT TO OPEN CIRCUIT Should the operation of the EXPLORER generate an emergency alarm red HUD LED and vibrating HUD then the diver must bailout to open circuit on either the in board supply above 18 m 60 ft or the off board supply below 18 m 60 ft Q NOTE Decompression calculations for the ascent profile will assume air as a breathing gas to provide additional safety during a bailout ascent MOD MAXIMUM OPERATING DEPTH The EXPLORER will warn on the main display if the maximum operating depth of the unit is exceeded This MOD is based on three things 1 Amaximum depth of 40 m 130 ft 2 Amaximum depth such that the gas attached to the unit as measured cannot result in a PPO exceeding 1 6bar 3 W
42. PPLY CYLINDERS The nitrox cylinder has a maximum fill pressure This is stamped on the cylinder and must be checked before filling Refer to regional limitations for maximum fill pressures Install the nitrox cylinder into the case and tighten the cam band Now install the regulator DIN connection A DANGER Although the EXPLORER will analyze its own gas supply it is still important that you always analyze your gas prior to use C1 WARNING If you suspect that the cylinders have become con taminated with salt water or other contaminants then you must get the cylinder inspected and cleaned as appropriate GAS ENDURANCE Gas endurance is defined by the Dive Control Parameter DCP setting With the cylinder pressurized to 200 bar 2940psi and assuming a usable gas pressure of the working pressure minus the regulator interstate pres sure of 11 bar 161psi this equates to 189 bar 2779psi available Assuming a DCP setting of 50 and a worst case FO of 32 The EX PLORER gas supply will last a maximum of 189 minutes based on normal swimming work rates The EXPLORER will continuously update gas minutes remaining through out the dive for any DCP setting and work rate DANGER High pressure gas cylinders especially nitrox cylin ders must have their cylinder valves opened slowly to avoid risk of injury This duration is also dependent on how much loop venting mask clearing BCD drysuit inflation occurs NOTE Cylinder valves fo
43. RNINGS This computer is capable of calculating deco stop requirements These calculations are predictions of physiological decompression requirements Calculations are for contingency use only The Explorer in this sport configuration is not intended for decompression use V vi TABLE OF CONTENTS General Safety Statements amp Warnings iii v PART 1 YOUR NEW EXPLORER SECTION 1 REBREATHER LIFE SUPPORT SYSTEM RULES SECTION 2 BATTERIES SECTION 3 UNIT LAYOUT SECTION 4 COVER REMOVED SECTION 5 GAS FLOW SECTION 6 MECHANICAL FEATURES PART 2 OUT OF THE BOX SECTION 1 INITIAL ASSEMBLY PART 3 LIFE SUPPORT SYSTEM COMPUTER SECTION 1 GENERAL OPS SECTION 2 AUTOMATIC TURN ON SECTION 3 DISPLAY SYMBOLS SECTION 4 SCREEN ICONS SECTION 5 DIVE SCREENS SECTION 6 STATUS SCREENS SECTION 7 MAIN MENU SECTION 8 SETUP MENU SECTION 9 BAILOUT amp GAS CONFIGURATION SECTION 10 DCP DIVE CONTROL PARAMETER SECTION 11 RMS RESOURCES MANAGEMENT SYSTEM SECTION 12 O SENSOR CALIBRATION SECTION 13 O SENSOR VOTING SECTION 14 CDM CANISTER DURATION METER SECTION 15 DISPLAY amp ALARM SYSTEMS SECTION 16 ALARM FLOW DIAGRAMS SECTION 17 GAS RESERVES SECTION 18 MOD MAXIMUM OPERATING DEPTH SECTION 19 DECO CONTINGENCY SECTION 20 INTERNET REPROGRAMMING PART 4 GETTING READY TO DIVE SECTION 1 GEAR PREP SECTION 2 PRE DIVE SETUP SECTION 3 COMPLETING PRE DIV
44. RVICE MODE Service Mode allows access to more detailed information about the EXPLORER It can be accessed by your Dealer A separate Service Manual is available through www HollisGear com 31 BAILOUT AND GAS CONEFIGURATION DEFAULT GAS SETTING The EXPLORER has the capability to analyze the dive gas attached to the system If this gas differs significantly from what the EXPLORER expects the programmed Default Gas then a warning will be given during the pre dive sequence This is to help protect against absent or faulty gas analysis by the gas supplier and user DEFAULT GAS To change the Default Gas when the unit turns on go to the SETUP menu 409 EAN screen and highlight Default Gas by repeated short presses then a short pes a push of both left and right buttons to select Fig 3 17 The gas can now be set VOL 40 CUFT The Default Gas information is used to drive bailout gas calculation using t cylinder size and hence gas time remaining and when the unit performs Fig 3 17 its gas analysis checks if the gas analyzed is not the default gas then a warning will display to prompt you to re analyze the gas or calibrate the oxygen sensors If the analyzed gas is not what you expected the Default gas but is still usable you can simply start the dive without having to change the Default gas but you must change the cylinder size if it is incorrect If the analyzed gas is lower than expected within 5 then it will r
45. Screen s Action Panel and the HUD will flash red and a vibrating alarm will sound in the mouthpiece From the Main Dive Screen a double press of the right button will bring up the STATUS screen Fig 3 6 so that the user can determine at a glance the status of the system while doing a check This can be useful to deter mine why a check is not working correctly 24 AUTOMATIC TURN ON FAILSAFE FEATURE Normal practice and training is for the user to turn the EXPLORER on by hand and go through the pre dive checks The following failsafe additions are to reduce diver error where the EXPLORER is turned off prior to breath ing on the unit The basis for the auto breathe software is to reduce the chance of accidental injury or death by breathing on an EXPLORER that is in off sleeping state EXPLORER uses detection of a diver breathing the unit to automatically turn the unit on BREATHING DETECTION TURN ON RULES The EXPLORER will turn on if PPO drops to 0 17bar Therefore even with the unit incorrectly assembled gas not turned on the system will detect the fall in PPO and will activate It will then alarm and force the user to properly complete the pre dive sequence Once turned on the unit will attempt to maintain a breathable PPO based on the DCP Dive Control Parameter setting and the supply gas expected If sensors are removed or read 0 00 then the unit will only turn on with depth or by the user pressing a switch This fe
46. This may give false read ings on the CO sensor 57 58 white vinegar and a soft brush can be used to achieve this Inspect this connection regularly MECHANICAL FITTING The sensor should be fitted into the EXPLORER Sensor Module Check the O rings around the filter carrier are not damaged Ensure the O rings are lightly greased Ensure the absorbing material is clean dry and not damaged The filter assembly should be periodically checked for water or mechanical dam aged It is advised to keep spare replacement filters The filter is the main protection for the sensor from the breathing loops general environment lf damage occurs to the filter or it becomes exhausted then damage will result to the CO sensor itself So always keep in it good condition NOTE After a days diving you can remove the Sensor Mod ule from the rebreather and keep the Sensor Module and the sensors in a dry environment air conditioning if possible until the next dive Removing the CO filter assembly to venti late the CO sensor is also advised CALIBRATION SCREEN To access the CO feature for calibration go to the CO option in the Pre dive screens WARNING The CO sensor MUST always be calibrated in fresh clean air outside preferably at sea level Select the CO option Fig 3 25 and EXPLORER will prompt you through the setup procedure and calibration will occur automatically Always check that the sensor reading after cal
47. aced NOTE Post dive if you want to do another calibration you must remove the filter cap to calibrate The same system should be used to just check the calibration There is no need to constantly calibrate but it is good practice to check the calibration at the start of a dive sequence using the above method Once it is calibrated to confirm the operation gently breathe across the sensor face until the reading changes Now re install the filter prior to div Ing After calibration and with the sensor inserted into the loop if a full pre breathe with fresh absorbent is undertaken the CO reading should fall to Omb This is normal Post dive and with no gas flow breathing you may see a small rise in CO levels due to gas density and pocketing After a pre breathe this should stabilize Blowing into the sensor face may also create the same affect until it is used again normally in the breathing loop WARNING If at anytime you see a reading that is abnormal you should check the calibration Abnormal readings could include 1 A reading fixed at zero or any other number when you are breathing directly onto the sensor face with the rebreather disassembled 2 An abnormally high reading during a dive 3 Readings that change up and down not in one direction This could be a faulty sensor or a faulty connection into the Sensor Module NOTE Under CE conditions after approximately 50 minutes at 40 m at 1 6 I of CO
48. an 18m 60ft 5 200 bar 2940 psi Not required 1000 1 40 cuft Nitrox 32 to 40 gt 19m 63ft to 5 200 bar 2940 psi Air to 40 nitrox of 40m 130ft 1000 1 40 cuft Nitrox sufficient volume for an 32 to 40 ascent from depth with a 150 5 3 cuft reserve at the surface after an open circuit ascent Bailout gas volumes should be calculated based on the depth of the dive and the ascent gas requirements Cylinders can be positioned on D ring attachment points on the harness or optional EXPLORER BCD Your Instructor and Training Agency will detail how to calculate for suffi cient bailout gas volumes COUNTERLUNG VOLUME The volume of gas in the counterlungs will affect the breathing feel of the unit Too little gas will make inhaling difficult and too much will make exhaling difficult All retreaters have optimal positions in the water where they have a better or worse breathing feel due the hydrostatic effects of the counterlung position and the breathable volume within the counter lungs It is important to balance the volume in the breathing loop so that exces sive inhale or exhale pressure is not experienced Under certain situations the EXPLORER will vent during the exhaled breath This will result in a drop in oxygen levels and more gas addition by the system It is possible to balance the loop to an extent by venting a small amount through your nose particularly on ascents if the need arises ADJUSTING THE
49. an inform of features aid assembly or prevent damage to the product EXPLORER DESIGN TEAM Bob Hollis Kevin Gurr HollisExplorer User Manual Document Control Number 12 4102 Rev 2 Publish Date 7 26 2013 Kel REBREATHER This user manual does not nor is it intended to contain any information needed to safely dive with any type of SCUBA apparatus It is designed as a guide for the proper setup operation maintenance and field service of the Hollis Explorer only It does NOT take the place of a recognized training agency instructor led diver training course or its associated training manual s and materials This user manual is intended to be used only as a type specific ad dition to such training and materials and as a user reference This manual cannot be used as a sub stitute guide for any other type of Self Contained Underwater Breathing Apparatus SCUBA Photo by AAA m UB eee a a iV GENERAL SAFETY STATEMENTS WARNINGS WARNING GENERAL SAFETY No person should breathe from or attempt to operate in any way a Hollis Explorer rebreather or any component part thereof without first completing an appropriate Hollis Certified user training course Further no Explorer diver should use a Hollis Explorer without direct Hollis instructor supervision until they have mastered the proper set up and operation of the Hollis Explorer rebreather This includes new Explorer divers as well as Explorer certified div
50. as test sequence if the first stage transmitter battery is low a warning will appear Fig 6 7 or if low at the start or end of a yellow warning Fig 6 8 will appear A DANGER If you are in doubt as to the HP readings on EXPLOR ER you must check it by attaching a normal gauge and hose to the HP post PUTTING ASSEMBLIES TOGETHER POKO e Ensure the Canister is in place and secured with it s 4 screws e Fit the Sensor Module EXPLORER Module and Right Hand end cap along with a new Absorbent Filter e Fit the LP hose to the ADV e Fit the counterlungs and the LCV port cap to the exhale counterlung e Fit the LP hose to the BOV e Fit the hoses to the BOV e Fit the cylinder and the DIN wheel e Connect the LP hose to the BCD inflator Fig 6 8 440 COMPLETE EXPLORER TEST Follow the on screen pre dive sequence If the unit fails the negative or HP leak test and the fault is not easily recog nizable Follow these steps e Remove the LCV hose from the Canister or restrict the hose to stop the counterlung venting through the LCV e Turn on the gas e Put the BOV into closed circuit mode e Inflate the counterlungs by blowing into the loop until it is full then put the BOV in open circuit mode e Fully submerge the unit and look for leaks NOTE The OPV situated under the Canister will vent some bubbles THIS IS NORMAL Look for other leaks Finally complete all on screen pre dive checks before diving
51. ata available there is no practical system to achieve this The duration of the absorbent changes with CO generation temperature depth and re 49 breather design People have achieved over 8 hours duration with relatively small absorbent loads but this has been in warm water with low breathing rates and shallow depths It is currently not known what the effects are when an absorbent filter working at a CO level of say 2mBar that has been used in a shallow scenario is taken deeper and the work rate is increased We know that the CO would increase but do not know how fast In field tests we have seen the CO jump quickly from 3mBar to 6mBar just by the diver going deeper near the end of absorbent duration This same rise will not occur if the filter is at the start of its life Forecasting potential duration with the CO sensor will be possible in the future after more development but this is not currently the main function of the CO sensor Its current functionality is as an active warning device for CO absorbent system issues It can detect for bad absorbent no absorbent high work rates and general CO seal issues 1 WARNING Currently the CO sensor reading should not be used as a duration meter for the rebreather It is vital that it is used to report and alarm for a high CO reading that could occur with a faulty seal or exhausted absorbent Our bodies produce the same CO quantities independently of depth So just stay
52. ature is included to conserve battery power when the user takes out PPO sensors for storage or during transport Other current rebreather designs and CE approvals require a reduced safety margin than achieved even with this power save scenario In other words the chance of the user taking out the sensors and acciden tally not turning the unit on before breathing falls into user set up error that should not routinely occur due to training and a good pre dive check re gime Other errors such as failing to turn on cylinders etc are much more likely and should be reduced by proper training and the intelligent alarm systems as in the EXPLORER If the diver does not have HP gas turned on alarms on the HUD forwards and rear facing HUD and Primary display will occur as soon as auto turn on occurs Hence this method provides increased warnings whenever loop PPO is breathed when the unit is off po Breathing the loop in all circumstances where the unit is breathable and PPO sensors operative will cause a safe turn on A DANGER The additional safety features described in this section should NEVER be used as routine The user should ALWAYS turn on the unit and pre dive checks carried out as required in training and the operations manual 23 DISPLAY SYMBOLS Most screen commands soft buttons are actually the written word in English but movement commands are expressed using icons Moves the cursor to the next field to the righ
53. ay normally cause PPO alarms to be triggered are inhibited if they are of the correct characteristic expected during a descent or setpoint change e There is a significant amount of mechanical design required to achieve a moisture tolerant breathing loop that reduces distortion of the readings from the PPO CO sensors to a minimum The reliability of the PPO readings is further improved by employing a voting algorithm for the PPO sensors that can ignore data from rogue sensors The EXPLORER design is simple to use but this simplicity does not mean that the system is simple in terms of data processing or control analysis The EXPLORER includes many levels of warning and system analysis simplified through experience and intelligence to provide a straightforward human interface that does not routinely overload or annoy with status or 17 18 false warnings It takes considerable system intelligence and design experience to ensure the warnings do not overload or falsely advise the user of problems If falsely warned too many times then there is a reduced likelihood of the diver responding correctly to a truly dangerous and potentially life threat ening situation Mechanically it is vital that simple mechanical tasks required to set up the EXPLORER are not ambiguous and prone to user error THE HEADS UP DISPLAY The Heads Up Display HUD is an ergonomic addition for the diver as it gives a simplified and quick to follow view of th
54. bent life This is currently a work in progress CO CARBON DIOXIDE SENSOR FOR EXPLORER This section describes the operation of the CO sensor as fitted to the EXPLORER rebreather The EXPLORER CO sensor is the world s first commercially available car bon dioxide sensor proofed and designed by VR Technology for operation in a high humidity high oxygen rebreather breathing loops The CO sensor actively measures carbon dioxide while the user is breath ing on the loop It can thus warn of high CO levels before unconscious ness or other symptoms occur in time for the user to perform remedial tasks such as finishing a dive reducing activity or even bailing out to other gas sources BACKGROUND It should be noted that this is the first use of a CO sensor in an active user breathing loop As such new data on CO levels will be obtained that will identify areas of adjustment of common practice and improved use of the CO readings as time goes on Much of the research in CO poisoning has been conducted with military levels of exertion and requirements From this research the 5 to 10 mBar limits for CO were formalized as the upper working range for CO by a diver undergoing considerable exertion Thus the alarm levels within the EXPLORER have been initially set as 5mB and 10mB As the user moves into the 5 mB range although no symptoms may occur it is highly advis able that the dive be terminated as soon as possible 51
55. correctly Critical components and potential failures are e The filter seal around the Absorbent filter e A poorly packed user pack only filter e Used or out of date absorbent material Below is a graph of the data log from a chamber breathing system test dive 1 6litres of CO are being fed into the system every minute The external water temperature is approximately 4 degrees Celsius It shows the thermistor readings on an arbitrary scale canister remaining percent prediction and depth in meters The endpoint of the graph is when the CO levels reach 5 mBar break through 8 Thermistors The thermistor curves at the beginning of the dive as the canister heats up have a different shape to the middle to latter part of the dive It is not sufficient to simply look for the position of the hottest part of the canister This will give poor predictions of canister duration The algo rithm first normalizes temperature difference data Then uses a tech nique to determine which part of the curve the system is on begin ning middle or end It then correlates a look up of the measured data into the suitable reference data to determine the canister duration The filter should always be kept sealed until required for use Once installed the filter should be changed within 24 hours even if it has not been fully used through breathing When installed and being unused the EXPLORER should have its breathing loop closed so that external air d
56. deteriorate very slowly and near the end of their useful life may show a drift soon after calibration e The oxygen sensors are not covered by the warranty they must be replaced every 12months or at their do not use after date or sooner depending on the pp02 they are stored in and the hours of use e Oxygen sensor usage temperatures are Operating temperature range 0 40 C 32 104 F Storage temperature 20 to 50 C 4 122 F Recommended storage temperature 5 to 15 C 41 C to 59 C A DANGER Always be careful when doing manual calibrations AIR must be exposed to the sensors and NO OTHER GAS Calibrations should be conducted routinely However prior to starting a dive sequence it is advisable to check the oxygen and CO sensor calibration by opening the EXPLORER Module and removing it and the Sensor Module place them together Fig x x and turn the unit on Then go to the STATUS screen and view the PPO and CO If the PO is not 0 21 and the CO is not 0 3 0 4mb for the CO then a calibration must be performed 37 In general Oxygen and CO sensors do not drift excessively Constant cal bration every dive is not required Periodically check sensors and keep them dry between dives if possible and especially during storage WARNING Use calibration sparingly not as a routine task that may mask other potential problems CONDUCTING AN O SENSOR CALIBRATION During the Pre dive sequence yo
57. e The large hoses that connect the Canister assembly to the BOV Breathing Loop parts of the rebreather that breathing gas circulates within Canister Mechanical assembly where the Absorbent Filter is housed Caustic Cocktail very alkaline liquid water mixed with CO absorbent material CCR CC closed circuit rebreather CO carbon dioxide Diluent a gas used for breathing volume and to reduce the fraction of oxygen in the Breathing Loop Dive Control Parameter DCP The control to define how high the oxygen level is set for the dive profile Exhale Counterlung The counterlung positioned behind the diver s right shoulder FO fraction of oxygen Graphical User Interface GUI The display system for communicating information to the diver Heads Up Display HUD the LED display positioned in front of the mask HP high pressure Inhale counterlung the counterlung positioned behind the diver s left shoulder IP intermediate pressure 120 LCV Port the port on the exhale counterlung that houses the exhale counterlung mushroom valve This port links to the LCV via a balance tube Life Support System LSS Module the diver s left hand electro mechanical assembly Loop Control Valve LCV the valve in the canister that controls the amount of exhaust gas exiting the rebreather and controls the breathing loop pressure LP low pressure Maximum operating depth MOD the maximum depth a given gas can be used safely Mushroo
58. e LCV on the Canister using the clip provided Fig 2 17 Fig 2 16 Fig 2 17 14 Inspect the Canister port O rings on the Inhale counterlung and attach the counterlung to the Canister The assembled orientation of the Counter lungs and the LCV tube should be as shown Fig 2 18 The LCV tube is on the underside of the counter lung in the figure and is not visible Step 9 Remove the Right hand End Cap by twisting the lock ring 1 2 turn counter clockwise and visually inspect the sealing O ring Fig 2 19 EXPLORER can be used with two types of absorbent filter e Professionally pre packed e Single use Pre packed The Professionally pre packed version can be filled with granular absor bent by a qualified dive professional See you Instructor or Hollis dealer for more information The Single Use pre packed version comes in a sealed bag and the filter CANNOT be taken apart or refilled NOTE If the unit is supplied with a Professionally pre packed absorbent Filter then this will be assembled inside the Canis ter Reach into the Canister and pull out the Filter by grasping the central yellow pull tab Inspect the Filter quad ring for damage Clean the ring groove and the ring and lightly grease the ring before refitting Fig 2 20 WARNING This Quad Ring should be replaced every 30 hours of dive time or annually whichever comes sooner NOTE The Single Use Pre packed Absorbent Filter comes suppli
59. e LCV system 2 A small amount of water will not affect the CO absorbent performance Moving water into the water removal system allows you to purge the water through the LCV To move water into the LCV system Close the mouthpiece put the hos es above your head and shake the hose squeezing the exhale hose like squeezing an accordion will move water down the hose quickly Now return to the loop and keep breathing normally If water continues to enter the loop attempt to locate the leak and fix it A common leak point might be a mouthpiece that is not fully open or closed or a rubber mouthpiece which has not been properly secured to the BOV lf water is in the inhale hose again close the mouthpiece and move the water across to the exhale hose and evacuate as above BAILOUT AND ASCENTS Open circuit bailouts become necessary if a loop is unbreathable high CO or low high PO or flooded In the unbreathable scenario the loop will need to vent during the ascent This is done automatically by the OPV and the LCV combined 1 WARNING Ascents must be practiced on the training course while on open circuit and with a loop full of gas Venting will occur naturally if the diver is weighted correctly With a flooded loop the diver must carry sufficient additional buoyancy to overcome approximately 5 kg 42 Newtons 11 Ibs of buoyancy loss IN WATER SKILLS In water skills are a vital element of dive training It is important espec
60. e and refit the O rings e Refit the mushroom valves to the carriers A DANGER DO NOT put grease on the mushroom valve e Having cleaned and disinfected the BOV outer hold the BOV in your hand with the mouthpiece towards you and the second stage port facing forwards Position the right hand side mushroom valve carrier with the valve facing out and the left hand side valve carrier with the valve facing in into the mouthpiece Install the valve carrier assembly in by pressing on the edges of the carrier do not press on the center of the mushroom valve Ensure the O rings around the mushroom valve carriers have not extruded out of their grooves A DANGER Check the flow in the BOVis from diver s left to diver right with the mouthpiece in the diver s mouth e Inspect and clean the rubber mouthpiece Refit with a tight cable tie Remove sharp edges from the cable tie BOV PRIMARY TEST In closed circuit mode block the right hand exhale side and blow do not apply excessive force into the mouthpiece The inhale diver s left side mushroom valve should seal and no gas should exit out of the second stage exhaust port or the front diaphragm plate Faults e Mushroom valve inhale side leak Remove the carrier and inspect again e BOV barrel O ring or activation handle O ring leak Replace O ring In closed circuit mode block the inhale diver s left side and suck into the mouthpiece iDa Faults e Mushroom valve right ha
61. e and training should also be used to determine the va lidity of the readings given Absorbent Filters are a key item in the rebreath er and prone to miss use Great care should be taken when determining if a dive can be safely performed with the filter in its current state Flooding long time between uses improper assembly improper packing can all contribute to the canister duration meter reporting false readings Use great care in assembling the device and in completing pre breathe checks on the Absorbent Filter and breathing loop The CDM is a useful feature as an aid to predicting absorbent duration Q WARNING NEVER dive a partially used Absorbent Filter after 24 hours beyond its initial packing or opening irrespective of the CDM meter reading This includes partially used filters that have been stored in a sealed loop or container TPM TEMPERATURE PROFILE MONITOR This meter relies upon the heat producing reaction of the CO absorbent Temperature sensors are used to determine the status of the CO absor bent has been performed in laboratory conditions for many years The system detects a complex reaction heat wave front through the absorbent as it is being used The duration of the Absorbent Filter depends mainly on the amount of CO being produced by the diver and the depth of the dive A DANGER The TPM will not detect breakthrough conditions of a poorly packed Absorbent Filter or failing seal Therefore Pre breathe checks mu
62. e noted With the Explorer s back mounted counterlungs it is important that the Explorer is as close to the diver s back as possible Your instructor will teach you how to weight yourself correctly Q WARNING Over weighting is dangerous With an empty BCD no additional bailout cylinder and 50 bar 735 PSI in the main cylinder you should be able to begin slowly to submerge in a controlled fashion by exhaling slightly too much and the ADV will add gas O WARNING It is important to perform weight checks in confined shallow water with at least 50 bar 735 psi bailout gas prior to any open water diving HARNESS BCD POSITIONING When adjusting the harness try and imagine that the center of the count er lungs should be within 100 mm 4 inches of the tip of your sternum to give an optimum breathing performance While the BCD harness must be comfortable it should not be loose The harness will sit differently on land compared to when you are in the water 76 OCTOPUS BAILOUT amp CYLINDER CONFIGURATIONS While the exact gas requirements for any type of diving are a matter of per sonal choice and predicted by specific level of EXPLORER certification and training agency it is vital that a breathable open circuit bailout is carried at all times for all depths of the dive of sufficient volume to allow a safe ascent to the surface with a stressed breathing rate e gt gt Q o 9 NOTE Certain training agencies may
63. e orientation in the Canister Visually inspect the large sealing O rings for damage Fig 2 2 Pull the Sensor Module out from the Canister Remove the yellow and black CO sensor filter cap as shown below Fig 2 3 This is a simple O ring push fit and is retained in place once the Sen sor Module is assembled into the Canister as are all the oxygen sensors Push the three oxygen sensors and one CO sensor onto their respective 2 connection points as shown in the picture below NOTE Ensure the oxygen sensors are installed with the white membrane facing up as shown Inspect the the yellow membrane in the CO sensor cap to ensure it s flat in the holder Then replace the Sensor Module and refit the cap Fig 2 4 Fig 2 4 The O ring pick is used in the photo for illustration purposes It is not necessary to remove the O ring before every dive 12 Step 5 Move the LSS module to one side and peel the Optocon charging download connector protection cap off as shown Fig 2 5 Plug in the power charger You will need to rotate the cable end connector until the key way aligns Then push it in and tighten up the black lock ring The lock ring will spin freely once the connector is ful ly assembled Once connected and power is applied then a red light will appear on the Electronic Head To remove unscrew the ring which will rotate freely until pulled back to start the thread and pull out the conn
64. e status of the EXPLORER The HUD as 3 main warning levels e Flashing Red plus vibration alarm warning is activated when a dive should be aborted on open circuit or not started e If diving the diver should switch to the bailout gas e The HUD vibration alarm will vibrate every 1 4 second for 10 seconds and then repeat the 10 second alarm every minute e Flashing Green and Blue Leeds warning is activated when a manage able error situation is in place The correct response is to ascend slowly on closed circuit monitoring the Primary display e Solid Green means there are no detected problems C1 WARNING If any other light sequence or a no light scenario is experienced then the diver should refer to the wrist display for information C1 WARNING If no wrist display is seen the diver MUST switch to open circuit and ascend The LED states are configured for color blind as well as highly stressed div ers The positions of the LED s the flashing or solid state provide condi tions that cannot be confused with one another Also during stressful dive scenarios the position and status is quick to comprehend and therefore intuitively the desired response is performed PRE DIVE CHECKS With current technology not all aspects of the safety and working nature of the EXPLORER system can be performed or determined automatically Therefore when turning on the EXPLORER there are a series of pre dive checks that must be pe
65. e tested or approved These are available from your Hollis Dealer A DANGER ONLY the Hollis CO sensor must be used with this unit No other sensors are tested or approved WARNING All non user servicing must be performed by an approved Hollis service facility Explorer service technician BOV DISASSEMBLY There are very few parts that should be removed by the customer within the BOV assembly since many parts especially the second stage compo nents require additional set up by a trained Explorer technician e Unscrew the breathing hose ends e Remove and inspect the hose ends O rings for damage e Using the rubberized end of a pencil or other blunt soft instrument insert the pencil through one of the mushroom valve carriers moving the mush room valve aside first and gently push out the opposite carrier assembly e Remove the mushroom valve carrier O rings e Gently pull out the mushroom valve e Remove the mouthpiece cable tie and the rubber bite mouthpiece NOTE DO NOT push on the center of the carrier ONLY push on the outer edge 408 BOV REASSEMBLY e Clean the mushroom valve carrier O ring and the groove around the mushroom valve carriers Lightly grease and refit new O rings e Inspect the mushroom valve and mushroom valve carrier for damage Wash disinfect and remove any debris from the carrier e Clean the mushroom valve carrier O ring and the groove around the mushroom valve carriers Lightly greas
66. easily read their dis plays Divers should carry a minimum 3 liter of bailout gas for dives deeper than 18 m 60 ft Safety decompression stops should be conducted on all dives 27 98 Pre dive checks Calibration of Explorer In water leak buoyancy and trim checks IN WATER SKILLS CHART Accurately complete all checks without bypassing any items Complete calibra tion of O amp CO sensors Diver checks them selves and buddy for leaks Diver maintains buoyancy and trim checks To confirm the EX PLORER has been prepared correctly the function of the absorbent and the monitoring system function To confirm calibra tion of all sensors on primary elec tronics with air CAL sequence To ensure no LP HP or breathing loop leaks are present that either were missed by Pre dive checks or occurred after checks Make buoyancy and trim adjustments Follow on screen sequence using the primary display Explain sensor calibration rules in manual impor tance of sensor po sition date stamp logging system O sensor voting logic system and CO filter replacement Check LP HP and breathing loop fittings hoses while submerged be tween the surface and 6 m 20 ft Look for incorect ly configured or stowed equipment Ensure proper weighting should be neutral with full counterlungs Emphasis should be placed on good trim Carry and use of additional bailout ga
67. ector When charging a Red light appears on the LSS Module It turns Green when the LSS Module if fully charged A full charge takes ap proximately 10 hours EXPLORER has 3 battery status displays with the charger connected 1 Battery Charging Empty Fig 2 6 2 Battery Charging Fig 2 7 3 Battery Charged Fig 2 8 Once fully charged the LSS Module can be refitted to the Canister Fig 2 5 DAT TERY Fig 2 6 BATTERY Fig 2 7 DAT TERY Fig 2 8 To view the charge status of your EXPLORER do the following 1 Remove the charger if attached 2 Do along hold of any button on the handset and the Hollis splash screen Fig 2 9 will display This screen will timeout after 3 seconds and the Do Predive screen Fig 2 70 will display 3 Continue to do a short push of the either button until you see the central window change to battery status Fig 2 17 Q WARNING DO NOT start a dive with a battery minutes display of less than twice the dive time you intend to do The Pre dive sequence will fail if the battery minutes are too low Step 6 If required attach the BCD to the Case Front using the screws supplied Connect the LP inflator hose Step 7 Inspect the mushroom valves in the BOV and make sure they are in place Put the BOV into the CC Closed Circuit position Fig 2 12 Look into one side of the BOV at the mushroom valve If you can see daylight through the other side of the
68. ed in a sealed bag and is available from your Hollis deal er This also has a quad ring fitted which must be inspected prior to use For Professionally pre packed systems pack the Absorbent Filter as per instructions Insert the scrubber into the canister and seat it by pressing it into position Then refit the end cap by aligning the tab on the end cap and pressing in The O ring pick is used in the photo for illustration purposes It is not necessary to remove the O ring before every dive Fig 2 18 Fig 2 20 15 16 on the clear center While pressing firmly twist the lock ring to 3 O clock with your fingers until fully closed as shown Fig 2 27 NOTE The Case Back will not fit and lock properly if the end cap lock rings are not in the correct orientation Step 10 Fit the SCUBA cylinder Ensure the HP hose fits into the slots in the case under the cylinder Tighten the cam strap Inspect the HP DIN wheel O ring for damage and attach the DIN wheel Step 11 Attach the HUD to the HUD bracket and fit the hose wraps as shown Fig 2 22 Fit the LP hose wraps as shown Fig 2 23 Step 12 Refit the Case Back and secure the two clips at its base Fig 2 24 WARNING Ensure that the counterlungs are not pinched during installation of the Case Back Pinching counterlungs could puncture or cut the counterlungs leading to flooding and risk of drowning Step 13 Turn on the wrist displa
69. ell alarm is Stale High Span PPO cell span gt 0 5 bar if 0 2 or 3 cells in state OK Bad Cells None or 1 cell in state OK Very High If O 2 or 3 cells in state OK and average PPO 2 0 bar Low If O 2 or 3 cells in state OK and average PPO lt 0 17 bar where PPO PPO setpoint i e the difference between the average PPO and the setpoint The average PPO is based on the calibrated value from all cells in alarm state OK Zero cells OK with the same high low alarm state in which case all three are used in the average 6s Blue Green Alarms High Smbar lt s CQ2 lt co mse High or V High Control if the predive Sequence is complete Es V Low Control if the predive sequence is complete Low AP lt 50bar No Comms or Stale No Comms or Stal Usage High 10barimin 2 HP Usage gt 2bar min or Usage V High gt 10bar min Surface No Resource Checks Predive Low 10 lt Filter lt 50 Low either LSS module or handset battery 10 lt Charge lt 30 Charging and Low either Loo LSS module or handset battery lt 100 Fail or Solonoid Valve Loss of LSS module comm in the handset 69 PPO Blue Green Do Not Dive alarm states are High If 2 or 3 cells in state OK and average PPO 1 6 bar V High Control If 2 or 3 cells in state OK and provide complete and PPO 0
70. en MISSED STOP USE TABLES Too Shallow Deco Ceiling violated Blue Green DECO for lt 1 min DESCEND NOW At Stop Within 1 m 3 3 ft below Blue Green AT STOP the next stop WAIT x MINS Near Stop Within 3 m 10 ft Blue Green NEAR STOP of the next stop ASCEND TO x M FT Too Deep gt 3 m 10 ft below ceiling Blue Green DECO ASCEND TO x M FT NOTE When you have decompression stops to complete or if any alarm is showing the STATUS display will remain on and not automatically time out 74 INTERNET REPROGRAMMING The EXPLORER can be automatically reprogrammed and upgraded with new software downloads from the Internet The PC Link option enables use of this feature Contact the manufacturer web site or your dealer for more information Some updates will be available for a fee Other updates will be free To check if you re EXPLORER has any available updates and to obtain the reprogramming software then please go to http hollis com support asp A DANGER After new software is installed you MUST recalibrate the oxygen and CO sensors rae GETTING READY TO DIVE GEAR PREP WEIGHTING As the counterlungs inflate the diver may experience movement in the EXPLORER This is minimized by tightening the harness or adding trim weights to the pocket available on the top of the case A weight of up to 2 3 kg 4 4 6 6lbs can be used If the EXPLORER is allowed to move on the divers back a change in breathing resistance may b
71. eplace the gas used else the default gas will be used On this screen you can also input the cylinder size A DANGER It is important that the correct cylinder size is en tered for EXPLORER to correctly calculate the remaining resource times BAILOUT GAS It is not necessary to set a bailout gas Whether the bailout is under taken on the onboard attached gas or on an external gas supply the EXPLORER assumes 21 oxygen and 79 nitrogen as the bailout gas This is to ensure as safe an ascent as possible in an emergency All bailout decompression calculations are based on 21 oxygen and 79 nitrogen 32 DCP DIVE CONTROL PARAMETER DYNAMIC PO The EXPLORER is a dynamic PO controller This means it can vary the PO that it maintains based on the value of certain resources A higher DCP Dive Control Parameter value means less decompression higher PO but more gas usage and a lower PO is the opposite For a set DCP the actual PO will vary throughout the dive profile The DCP can be set to AUTO or MANUAL mode O Q MANUAL DCP MANUAL MODE In manual mode the diver can set the DCP using the screen shown Fig s Q 3 16 A long hold of either the or button will jump the DCP value by 10 m OD E AUTO MODE er O 0 i d amp rt g AUTO mode automatically adjusts the DCP throughout the dive to give the best compromise between maximum NDL and minimum gas usage Fig 3 19 While s
72. ers who have been away from diving for an extend ed period of time and would benefit from an instructor led refresher course to regain skills and mastery of the Hollis Explorer Failure to do so can lead to serious injury or death WARNING NITROX STATEMENT The EXPLORER equipment is classified as being suitable for use with nitrogen oxygen Nitrox breath ing gas mixtures containing up to 40 oxygen by volume without the need for special preparation cleaning or component parts If Explorer equipment is subsequently used with equipment or connected to an air supply system that is not rated for Oxygen Service it can subsequently be used with Nitrox up to 40 O2 as long as the equipment is maintained in accordance with the procedures and parts specified in the Hollis EXPLOR ER Product Service Guide The EXPLORER was designed for use with Nitrox up to 40 O2 DO NOT use gas mixtures with a higher fraction of oxygen greater than 40 with your EXPLORER WARNING CAUSTIC MATERIAL The CO absorbent used in the scrubber is caustic alkaline material Take steps to protect yourself from direct lung and skin contact Furthermore poor management of the breathing loop could lead to water contact with the CO absorbent causing a caustic cocktail very caustic liquid This could lead to se vere chemical burns and if inhaled possible drowning Proper handling procedures pre dive checks dive techniques and maintenance mitigates this r
73. fall into the water or injure him or herself The actual minutes remaining number displayed to the diver comes from the Oxygen Injection Monitor This gives a consistent and reliable reading of current absorbent duration based on Oxygen injection Always remember to reset the absorbent duration when a new filter is fitted You will be prompted to do this during the Pre dive sequence Fig 3 21 DANGER DO NOT reset the absorbent duration unless a new filter with fresh absorbent has been fitted Fig 3 21 Always change the absorbent when the low filter alarm appears or before if you suspect the absorbent is not operating correctly or close to the end of its life be conservative be safe A DANGER If an absorbent filter is not fitted the green central indicator will not be visible on the Right Hand End Cap and it will not be possible to breathe off of the loop No matter how many safety monitoring systems are in place use your own common sense and discipline to ensure you do not push the life support systems beyond their designed limitations It is your life being supported respect the equipment and its limitations 48 CARBON DIOXIDE SENSING MODULE Premise The EXPLORER comes with an option to fit a CO sensor The user can elect to buy this from new or upgrade to the sensor later The CO sensor gives many advantages as detailed below EXPLORERS not fitted with CO sensors or that have had their CO sensor te
74. hallow less than 10 m the DCP will remain at its current val ue This defaults to 50 each time the unit is switched on The first time the dive exceeds 10 m depth the DCP will automatically be set high to reduce the NDL but then as the diver ascends and the NDL naturally increases then the DCP will start to automatically reduce to save gas while maintain MODE ing a long NDL gt 1 hr At the start of the dive the DCP will automatically 7 set high to reduce the NDL but then as the diver ascends and the NDL naturally increases then the DCP will start to automatically reduce to save gas while maintaining a long NDL gt 1 hr Fig 3 19 NOTE Auto Mode is the default If on a dive where Manual Mode has been selected and you then surface and complete the dive Auto Mode will be the default at the start of the next dive HOW AUTO MODE WORKS By setting Auto DCP prior to diving the following events occur 1 The DCP will automatically be set to 95 for the first 10 minutes of the dive but only after the diver exceeds 10 m of depth 33 2 If the NDL is then less than 60 minutes the DCP will stay set to 95 to maximize the NDL 3 If at any point on the ascent the NDL is in excess of 60 minutes then the DCP will reduce to save gas and maintain the NDL at 60 minutes 4 The minimum DCP will only go to 105 so if a dive profile means that even with 10 the NDL is greater than 60 minutes then the DCP will stay at 10
75. he diver information on the activity of absorbent inside the filter This should have a peak when the filter is being breathed on From cold it will take about 5 minutes for the CO reaction to cause a visible peak This peak should then continue and grow higher The tem perature bars fill from the left to the right as the filter is being used This screen is in the Pre dive sequence If there is no peak then there is a problem with the filter This could be caused by 1 Flooded filter 2 Filter not fitted 3 Filter empty all used up 47 During pre breathe the unit needs to be breathed on to see a change in the thermal profile This does not guarantee correct operation but has a high likelihood of correct operation Any sense of dizziness nausea or oth er CO symptoms should also be used to alert the diver that the filter is not operating correctly A small bypass due to a badly fitted filter or CO seals could give this scenario of a good peak but an amount of CO could still bypass the filter If this occurs stop breathing on the EXPLORER This will be indicated and alarmed for by the Gaseous CO sensor Replace the absorbent and or check filter packing and seating a CAUTION Pre breathing any rebreather should be done in a safe seated position where the diver can monitor displays and any potential symptoms of CO poisoning Pre breathing should never be conducted while walking or standing in a place where the diver could
76. hen a maximum PPO of 1 6 bar is reached The EXPLORER will not freeze the user out of operation if these depths are exceeded However the system and diver are operating beyond the normal recommended conditions and therefore these limits should never be routinely exceeded Q WARNING Exceeding these limits is not condoned by the man ufacturer and is not a safe diving practice and must be avoided If an MOD alarm is seen then you should ascend immediately to a depth where the alarm is not displayed This depth reduction should be at least 6 m 20 ft but could be more if the MOD has been exceeded by a large amount SS DECOMPRESSION CONTINGENCY The EXPLORER is designed for recreational diving without decompression All dives however require safety decompression stops to be conducted consult your training agency for information If you accidentally stray into decompression the system will generate a green blue HUD alarm the decompression stop and stop time will be displayed on the STATUS screen This feature is designed for contingency purposes only A DANGER The EXPLORER is not designed for use with gases other than Nitrox WARNING Decompression diving significantly increases the risk of decompression illness Various alarms will be generated if elements of decompression are vio lated Please see the Deco States Table below and the EXPLORER flow charts for further detail DECO STATES Missed Stop Missed deco stop Blue Gre
77. ially when teaching complex skills or equipment that training is progressive Non progressive training only serves to scare and confuse students and 96 at best reduce the learning experience to a series of hoops that should be jumped through This is not the goal at all the desire to learn should be nurtured by making the experience as informative fun and as exciting as possible Only then will the subject matter and key survival skills be remembered As in all training while certain skills must be mastered first before the student can progress safely to the next level there are always issues that affect the training sequence These can include 1 Environment 2 Support logistics 3 The students ability to learn Your instructor will sequence skills according to standards of the agency you will be certified through Though all agencies will complete the same list found in the In Water Skills Chart section of this chapter additional skills may vary by agency DIVING SAFETY GUIDELINES After ALL drills involving a cylinder or valve isolation the instructor should confirm the valves are again open before completing the dive All divers must enter the water with enough gas in their BC to allow the diver to safely float on the surface The Pre Dive sequence must not be done sitting on the edge of a boat or pontoon It MUST be done when prompted with the nose blocked seated in a safe location and in a way they can
78. ibration reads approximately 0 4 0 1 mBar DIVE SCREENS In the Main Dive screen Fig 3 26 the CO reading is found by access ing the STATUS screen by a double press of the right button Then scroll Fig 3 26 through the screens to see CO Scrolling through the screens to the CO display will now display the CO reading in Millibars in the central window Fig 3 27 CE TESTING OF CO SENSOR Gaseous CO sensor module m F ar Tests conducted at ANSTI test systems As can be seen from the graph below the CO sensor readings keep in close correlation with the ANSTI Teledyne Lab CO analyzer The Blue trace is the ANSTI detector The CO sensor is represented in pink The quick occasional changes to the Blue ANSTI trace are calibration tests to ensure accuracy of the measured readings Fig 3 27 104 KEY 6 BLUE ANSTI PINK CO2 sensor 4 inside breathing loop Y scale CO2 mbar 4 0 It can be seen from the graph that after 60 minutes there is less correlation between the in loop and ANSTI readings This is due to the rapid ascent rate pressure change causing a temporary temperature drop The CO sensor will quickly recover from the temperature drop To a lesser extent there is also the reverse condition at the beginning of the dive where the chamber is being pressurized and the temperature is rising Within a few minutes the readings are correlated 59 DISPLAY amp ALARM SYSTEMS HUD BUD
79. ife A DANGER The battery estimate is based on current tempera ture light usage on the handset DCP setting and other vari ables Changes in conditions i e cold water may shorten burn times Plan dives accordingly and always monitor the HUD and Wrist Displays for system operation status NOTE The EXPLORER must be fully charged before its first use Always dry the Optocon charge connector before attach ing the charging connector Damage may result if this is not done Check that all parts of the charger are kept dry and only used indoors Battery level alarms will activate when the batteries get low When Battery level alarms will activate when the batteries get low When a battery low alarm is activated this will be displayed on the Status screen WARNING DO NOT dive a battery level which is less than twice your expected dive time for the next dive ASSEMBLED UNIT VNN NY 4 Freer Arr aaa pansy EXC LOSER COVER REMOVED GAS FLOW As the diver exhales gas flows through the hose blue arrow and over the right shoulder It then enters the absorbent filter and flows across the Ox ygen and CO sensors in the Sensor Module and through the inhale hose red arrow and back to the mouthpiece Gas also naturally flows in and out of the exhale and inhale counterlungs A i ees x mi api Wy a BOV Bailout Valve N O amp CO Sensors Absorbent
80. ing shallow does not reduce CO It can however help the CO absorbent perform more efficiently Therefore a low CO reading on a filter that has been used in shallow water for some time may rapidly increase if towards the end of its life it is taken deeper or the work rate increases Be aware that the CO reading can rise dramatically for higher work rates and deeper depths especially when an absorbent has been used for over 50 of its recommended duration Therefore in order of priority the EXPLORER is fitted with a gaseous CO sensor a metabolism click counter providing an estimate of oxygen con sumed hence CO generated and a TPM giving an indication of thermal activity within the filter These three features give a more accurate indica tion of absorbent life remaining The use of the CO readings is four fold 1 To ensure active absorbent has been fitted 2 To ensure the absorbent sealing systems are operative 3 To warn of reducing absorbent efficiency in order to give the diver time to respond by reducing depth temperature or work rate to avoid an inci dent occurring 4 To warn of rare situations when excessively high CO levels may require immediate bailout to safe open circuit gas A DANGER The CO sensor should NOT be used to determine absorbent duration NOTE As more actual dive data becomes available it may be possible to model the CO curves and generate some level of prediction of remaining absor
81. isk WARNING DESIGN AND TESTING The Hollis Explorer has been designed and tested both in materials and function to operate safely and consistently under a wide range of diving environments You must not alter add remove or re shape any functional item of the Hollis Explorer Additionally NEVER substitute any part of the Hollis Explorer with third party items which have not been tested and approved by Hollis for use with the Explorer This includes but is not limited to hoses breathing assemblies electronics breathing gas delivery assemblies and their constituent parts sealing rings valves and their constituent parts and sealing surfaces latches buoyancy devices inflation and deflation mechanisms and on board alternate breathing devices Altering adding removing re shaping or substituting any part of the Hollis Explorer with non ap proved parts can adversely alter the breathing gas delivery or CO absorption characteristics of the Hollis Explorer and may create a very unpredictable and dangerous breathing device possibly lead ing to serious injury or death Non approved alterations to functional parts of the Explorer will automatically void all factory war ranties and no repairs or service work will be performed by any Hollis service professional until the altered Explorer unit is brought back into factory specifications by a Hollis service professional at the owner s expense WARNING COMPUTER CONTROLLER SPECIFIC WA
82. m valve a flexible one way flapper valve that permits the gas to flow in a circular path through a rebreather Negative Pressure Check a test placing the Breathing Loop under a vacuum condition to check for leaks O oxygen OC open circuit Optocon The wireless transmission system used in Explorer to send data between the Oxygen Sensor Galvanic oxygen sensors LSS and Sensor Module OPV over pressure valve PCO Partial pressure of carbon dioxide PO Partial pressure of oxygen Positive Pressure Check a test that looks for leaks in the Breathing Loop when pressurized PPO PO partial pressure of oxygen QD quick disconnect Quad Ring a specially designed sealing ring that creates a positive seal on the CO canister It is replaced every 30 hours of use Sensor Module Electro mechanical assembly where the oxygen sensors CO sensor and Thermal Profile Monitor are housed Setpoint The PO that Explorer supplies based on the DCP setting TPM Thermal profile Monitor The device that monitors the usage of the CO absor bent The Right Hand End Cap End cap that when removed gives access to the CO filter WOB work of breathing 4241 OUR HISTORY Bob Hollis had his first rebreather experiences in the mid 60 s He used Draeger units to allow him to get close to sea Otters and other marine life in Monterey Bay In 1970 Hollis made some of the first dives on the Electrolung rebreather using Heliox down to 300
83. mporarily removed by the user can still be dived but with no CO sensor fitted a 5 minute pretreated of the absorbent filter will be forced in stead of the normal 1 minute A DANGER With no CO sensor fitted careful monitoring of filter duration is vital There is little confirmed data on actual absorbent durations typical for sport diving rebreather use Sports divers often push the absorbent duration be yond the published CE durations because they assume that they will not be creating as much CO as the CE trials or operate at the same tempera ture or depths The problem can arise that if a diver has gone deep and works hard per haps to rescue another diver when the absorbent duration is near its limit the extra depth and work rate push the CO to dangerously high levels very quickly The CO sensor will help by giving feedback in this scenario and advise the diver of the high CO levels The diver should then reduce their work rate and reduce their depth and finish the dive as safely as possible or bail out to open circuit as indicated The relatively fast rise in CO readings is also an indication that the absorbent cannot be pushed any harder without causing even higher CO levels A question asked already by many divers who have seen the system in operation is Can the CO reading be used to determine the duration remaining in the filter The answer in principle is yes However with the current knowledge and d
84. n the system case 6 The Right Hand End Cap Pre assembled into the Canister 7 The Regulator First Stage Pre assembled in the Case Front 8 The Buoyancy Control Device BCD 9 The 5L 40cuft SCUBA cylinder and valve 10 Two Breathing Hoses 11 The combined Dive Surface Valve DSV and Bail out Valve BOV 12 The Absorbent Filter pre assembled into the Canister User Pack version only 13 One Exhale counterlung 14 One Inhale counterlung 15 One Loop Control Valve LCV counterlung port tube 16 Three Oxygen Sensors 17 One CO Sensor Optional 18 One power charger ASSEMBLY Step 1 Remove all parts from the split top box Step 2 Undo the rubber latches at the base of the Case Front Back assembly and lift up the Case Back until the hinge at the top is free Fig 2 1 Place to one side Fig 2 1 Step 3 Open the box with the Oxygen and CO sensors in it Remove the sensors from the box and open up the airtight bags A DANGER All sensors must be allowed to sit in an AIR atmo sphere for at least twelve hours prior to use in the EXPLORER The Sensors can be immediately assembled into the Sensor Module but this module should not be fully installed for at least 12 hours after unsealing the sensors packages Q WARNING After an initial calibration and dive the sensors should be calibrated again after 24 hours Step 4 Remove the LSS Module by turning the lock ring 1 2 turn counterclockwise Note th
85. n this list daily Disinfect end of each trip or soon er if required Wash at end of dive 200 annual or if Fresh water flush tri damaged prior after dive trip Wash at end of dive 200 annual or if Flush with fresh damaged prior water Replace if not holding a negative Wash at end of dive 200 annual or if Flush with fresh needs adjustment water prior Wash at end of trip Aor if damaged Flush with fresh prior water and disinfect as required APPROVED PRODUCTS AND GLOSSARY APPROVED PRODUCTS CO SCRUBBER MATERIAL Intersorb 812 8 12 mesh or Sofnolime 8 12 mesh OXYGEN SENSORS Hollis EXPLORER Sensors CLEANING PRODUCTS Steramine 1 G Tablet White Vinegar Crystal Simple Green or Dawn or similar mild dish detergent MAINTENANCE PRODUCTS Dow Corning 7 Silicone non O clean parts only CRISTO LUBE MCG 111 Tribolube 71 DeoxIT Gold GN5 Electrical Contact Cleaner Other products not listed may be appropriate for use with the Explorer If there is a particular product which you wish to use please call the factory to make sure the product does not contain chemical components which may be harmful to components within the rebreather or the diver oe CAUTIONS Consult manufacturer Material Safety Data Sheets for further safety recommendations for these materials Never use the following products or families of products on ANY part or surface of the Explorer rebreather Products which contain alcohol
86. ncy and trim checks Student__ Instructor 4 Carry and use of additional bailout gas Student Instructor 5 Dive Control Parameter Adjustment Student__ Instructor 6 Remove and replace unit on surface Student Instructor 7 Electronics operation Student Instructor 8 SMB deployment Student Instructor 9 Remove water from the breathing loop with the LCV Student____ Instructor 10 HUD use STATUS monitoring Student Instructor 11 Gas share with a buddy Student___ Instructor IN WATER SKILLS 12 Equalizing ears Student Instructor 13 Mask clearing skills Student___ Instructor 14 Drysuit use where applicable Student__ Instructor 15 Reducing compliant lung volume Student___ Instructor 16 Follow dive plan not exceeding depth or dive time Student_____ Instructor 17 Maintain depth while making Safety Stop Student Instructor 18 Omitted decompression procedures Student___ Instructor IDa COMPLETE DISASSEMBLY amp REASSEMBLY OF COMPONENTS THE FULL DEAL INTRODUCTION The information below will enable complete disassembly cleaning rebuild ing and testing of the EXPLORER Rebreather Further disassembly must be performed by a qualified Hollis EXPLORER Technician GENERAL NOTES ON ASSEMBLY 1 All O rings should be lightly lubricated 2 Inspect all O rings for cracks and other damage during each assembly 3 Sanitize all breathing loop parts DANGER Only Hollis Explorer Oxygen sensors must be used with this unit No other sensors ar
87. nd side leak Remove the carrier and inspect again e BOV barrel O ring or activation handle O ring leak Refer to a Hollis ser vice center e Remove both hoses from the Canister leave connected at the BOV DSV Put the BOV DSV in open circuit mode Block the exhale hose end and blow into the inhale hose end Submerge the BOV and look for leaks from the mouthpiece or hose ends hoses e If bubbles are seen from the mouthpiece outlet then the barrel O rings need replacing Refer to your Hollis dealer e If bubbles are seen at the hose ends then replace the hose end O rings e If bubbles are seen along the hoses then refer to your Hollis dealer BOV SECONDARY TEST In open circuit mode with the second stage BOV HP gas turned OFF Remove the breathing hoses Block both inhale exhale and mouthpiece ports and the LP inlet to the second stage Then suck from the mouth piece Faults e If a leak is heard the Exhaust valve or the diaphragm may need replac ing If a fault is found Refer to a Hollis service center BREATHING HOSE ASSEMBLY Clean inspect the hose end O rings and assemble BREATHING HOSE ASSEMBLY TESTING Block one end of the hose and blow into the other Look for leaks along the hose while submerging it Repeat for the other hose MOUTHPIECE HOSE ASSEMBLY e Connect the LP feed which should be over the diver s right shoulder to the BOV Replace the LP hose end O ring if required e Fit the breathing hose with the
88. nsure the correct conditions are exposed to the sensors Often a bad calibration causes more confusing problems than small errors due to temperature change User error caused by failure to use the appropriate ambient gas air is a big source of sensor errors 1 Don t over calibrate 2 If something seems wrong check everything Do not just execute a calibration to fix the reading You could be making matters worse 3 Keep sensors dry 4 When doing a calibration do ensure the sensors are ex posed to air force air over the sensors do not just assume they must be exposed to air by now 5 Just removing hoses is not enough to get air to the sen sors Either the breathing routine described in the Pre Dive sequence must be used or the Sensor Module should be re moved from the EXPLORER and sensors allowed to stabilize in ambient air 6 If the EXPLORER has had a change in climate or significant ambient conditions these are good reasons to check calibra tion 7 The readings from the oxygen sensors change with tempera ture If you are diving in warmer or colder water than normal PPO readings will vary Ensure calibrations take place at a temperature as close to diving conditions as possible OXYGEN SENSOR VOTING VOTING METHOD The EXPLORER has a method of automatically removing Oxygen sensor sensors from the PPO averaging and entering a fail safe mode when it is not possible to resolve an accurate PPO reading Rule
89. nto Service Mode Having se lected STAT with a long hold of both buttons from the Startup screen you will access two extra screens Fig 3 3 3 4 plus alarm and metric screens not shown a During Pre dive additional information will be displayed on each Pre dive screen such as the PO and internal loop pressure Fig 3 5 Your Hollis dealer may need access to this information to help with any issues Please see the separate EXPLORER Service Manual for details STATUS SCREEN COLORS There are four color states of the STATUS screen Each color provides Fig 3 5 additional information The four color states are Green No problem with the information Yellow The system is informing you of a low level alarm such as low HP gas supply The STATUS Screen s Action Panel will give information regarding the warning or action to be taken and in the case of the low HP gas example the value in the HP window will also be in yellow This will result in a flashing Green Blue HUD Fig 3 6 Magenta indicates unreliable data on the reading being taken This could be caused by a failed sensor Such as a low wireless HP battery This will be coupled with an action to be taken displayed on the STATUS Screen s Action Panel This will result in a flashing green blue or red Red A major alarm Indicating that information resource has now become critical forcing an open circuit bailout OC Bailout will be displayed on the STATUS
90. oes not accelerate the degradation of the filter However once open and used even if only a little the filter will continue to degrade and 46 change its characteristics post dive Therefore as previously stated the filter should always be changed within 24 hours of opening and or use Partially used filters should be stored in the EXPLORER with a closed breathing loop Although the algorithm that analyzes the thermistor curve is adequately accurate during diving if the filter is not being breathed on the thermistors curve will be abnormal It also takes time for the absorbent to rise to nor mal operating temperatures Therefore for routine use the addition of the Oxygen injection meter described in the next section is used to report the filter percentage remaining to the user OXYGEN INJECTION METER The CO created by the diver is in direct proportion to the oxygen breathed The oxygen metabolized by the body is replaced by the in jection of oxygen into the breathing loop By knowing the volume of gas injected the amount of metabolized oxygen and therefore the amount of CO created can be estimated From tests the duration of the filter types has been determined and the corresponding volume of CO ab sorbed before the absorbent begins to reduce its effectiveness Using these principles the system measures the amount of gas injected by the solenoid valve and converts it to a percentage of minutes remaining at CE CO rates
91. op cleaning 3 Recharging 4 Cylinder filling 5 Absorbent changing 6 BCD CARE OF OXYGEN AND CO SENSORS The Sensor Module SM is easily removed from the unit by removing the Life Support System Module LSS and pulling the SM out The SM carries the three oxygen sensors and the CO sensor Post dive the CO filter yellow cap sponge should be replaced as de tailed At the end of a days diving the complete SM should be removed and the LSS cap refitted and kept in a dry low humidity and ambient tempera ture environment The CO filter cap should be removed for the non diving period LOOP CLEANING After a dive the hoses should be removed and fresh water should be flushed through the complete assembly and be allowed to drain out To remove excess water push the hose corrugations together like using a concertina to squeeze the water out Disinfect the unit as per the Explorer Rebreather Maintenance Chart PART 7 Section 4 RECHARGING Please see Batteries PART 1 section 2 B7 CYLINDER FILLING All dives must start with a full cylinder All gas must be analyzed prior to use ABSORBENT CHANGING Absorbent must be changed in accordance with the section in the manual titled The Absorbent Filter BCD Drain any water from the BCD Re inflate and the operate dump valves and the inflator to confirm everything is OK ss COMPLETING PRE DIVE CHECKS PURPOSE These tests are designed
92. or 24 hours Too Shallow Deco Ceiling violated for lt 1min At Stop Within 0 1 bar deep of the next stop Near Stop Within 0 3 bar deep of the next stop Too Deep Greater than 0 3 bar deep of the next stop 63 IN WATER HUD BUD ALARMS Red OC Bailout Alarms Decompression U D O No VR IC Comms LSS IIC Comms ensor Boar Comms Predive U a a 2 Battery Pressure Difference OK v 64 Near Stop or Too Deep Missed Stop No Comms or Stal At Stop Too Shallow Sensor Failure Failed Ca No Comms or Stale _ ee Low lt 0 17bar Fait Fail nterface Mismatch or Missing LSS module Fait Initial Diving After No Prediv No Comms or Stale Loss of LSS module comms in the handse No Comms or Stale No Comms or Stale Very High gt 10mbaz Blue Green Alarms MOD Exceeded depth gt 40m or too deep for the d Nit MEAS EG LUO hi Commsor Stale Depth Sensor No Commsor Stale Fast 20m min lt Depth Rate lt 10m mir or Very Fast Depth Rate lt 20n min Ascent Rate No Commsor Stale At Stop Gaua V Low Control No Comms Stale m High Span or o ka Se Cell1 Bad or Cell 2 Bad or Cell3 Bad one only No Comms Stale
93. out the dive and another resource may take its place Alarms will be activated when resources reach certain levels as defined in the Alarm Tables In addition should a resource alarm be triggered for any reason occur the STATUS screen will appear This will not only note the resource level but can also tell the user the direct action required i e ASCEND NOW SYSTEM 61 CNS min Fig 3 20 35 OXYGEN SENSOR CALIBRATION The EXPLORER is able to perform accurate calibration of the Partial Pres sure Oxygen PPO sensors in ambient air This has particular importance on the ease and accuracy of achieving calibrated sensors The EXPLORER is able to measure atmospheric pressure during calibra tion and make the appropriate calibration adjustments for the sensors even at altitude When performing sensor calibrations it is important that the calibration gas and ambient pressure are known By using ambient air as the calibration gas this is known accurately Calibration Errors When Oxygen sensors are new or completely dry anda calibration is undertaken a small difference will be not ed when another calibration is done after a dive This is because the humidity inside a unit post dive affects the sensor membranes permeability to a small safe degree In general it is good practice to calibrate a unit in an as dived state i e with humidity in the loop This is per formed naturally during the Pre Dive Check sequence
94. r damage and corrosion A DANGER After sensor replacement you must ensure the unit is calibrated by completing a full pre dive sequence A DANGER It is important that oxygen sensors are maintained and cared for Avoid excessive moisture Some moisture will always form during a dive but if the rebreather has been flood ed the sensors MUST be replaced CO SENSOR TESTING DISASSEMBLY ASSEMBLY Having removed the Sensor Module carefully remove the CO sensor protection cap and the CO sensor Fig 6 4 Handle the CO sensor with care e Inspect the mini jack connector and carefully wipe clean with a soft cloth e Remove the yellow sponge inside the cap and allow it to dry A DANGER A dry sponge must be fitted prior to every dive to ensure accurate CO readings e Replace the sponge every 10 dives e Refit the Sensor Module into the Canister A DANGER After replacement you must ensure the unit is cali brated by completing a full pre dive sequence Fig 6 4 107 CANISTER END CAP DISASSEMBLY ASSEMBLY e Remove the Right Hand end cap by twisting the lock ring counter clock wise turn e Inspect clean O ring and sealing surfaces re grease and refit the end cap sealing O rings Fig 6 5 e Refit the head by pushing it into the canister and turning the lock ring clockwise by 180 degrees to 3 O clock Fig 6 5 NOTE The Diver s Right Side End Cap contains the Go No Go Device This is the green piece in the
95. r use with the EXPLORER must be certified in accordance with EN12021 for use in Europe 83 84 THE ABSORBENT FILTER The unit has been tested under CE requirements for CO absorbent filter duration The weight of absorbent in the filter is approximately 1 5kg 3 3lbs Tests were conducted with Molecular Products 797 Grade CO Absorbent WARNING Using any other absorbent will change and possibly reduce the Canister duration and could lead to injury or even death CANISTER DURATION At 40m 130ft of depth with Nitrox 32 as a diluent at 4 C 39 F water tem perature with a CO injection rate of 1 6 I min and a ventilation breathing rate of 40 l min and a 1 5 kg 3 3 lbs absorbent load of a Hollis Approved absorbent See Unit Specification the unit will last 40 minutes at 40 m 130 ft as an extreme test Ref EN14143 2003 This duration changes significantly with higher temperatures and low er work rates continued Below is a table of endurance versus depth and changing workloads with temperature MINUTES TO 5MB CO REFERENCE 40 m 130 ft 40 l min 4 C 39 F ming 40 m 130 ft 120 minutes 22 5 l min Normal 15 C 59 F reserve swimming capacity 40 m 130 ft 40 l min 15 C 59 F ming A DANGER Ventilation rates up to 40 l min are referenced as Normal swimming and rates of 40 I min and above are refer enced as Hard swimming Under strenuous conditions howev er consumption rates may be significantl
96. reathers The EXPLORER design assumes this and provides an additional link to the Pre dive alarm sequence to warn of such a failure If the valve is frozen open then gas will freely flow into the circuit This will give a HIGH HP usage alarm and the unit will fail its Pre dive sequence This is the correct failure mode for this device If the system had been pressurized and then it froze and hence the valve failed closed again pre dive will fail momentarily until counterlung collapse removes the icing as the lever activates then pre dive will pass unless there is a leak due to icing then the pre dive will again fail high gas flow alarm Fig 4 1 i 79 80 This system was developed because in use no units are completely free from moisture and ADV free flows due to icing regularly occur though there has not been an alarm for it PRE DIVE SETUP Having assembled and tested the unit upon receipt it is still critical that all pre dive tests are conducted prior to diving The EXPLORER is equipped with a set of pre dive checks that are built into the electronics prompting the diver to test certain aspects of the unit prior to diving Additionally there are several manual tasks that should be com pleted prior to this final system check These checks automatically start once you turn the unit on A complete flow chart of all the screen layouts can be found on the enclosed CD and in the rear of this manual TURN ON SYSTEMS
97. rformed The EXPLORER also gives guidance in performing these checks These checks are displayed in sequence on the EXPLORER wrist display unit Some of these checks rely completely on the diver to perform them correctly i e Close open mouthpiece Other tests can be positively checked for by the electronics control system and the user needs to confirm that these are OK to dive with i e that the high pressure cylinder is adequately filled Information regarding the current status of EXPLORER and all available resources can be reviewed prior to conducting Pre Dive Checks using the STATUS screen DATA LOGGING EXPLORER has a sophisticated data logging system that not only records all the units sensors depth time PO etc but also records any alarms and error messages such as missed Pre dive checks This information can be retrieved through the data download software and is available in detailed form to Hollis Service Technicians Users can obtain dive download software from http hollis com support asp STATUS SCREEN The EXPLORER has two levels of detailed information available to the diver The primary method is via the STATUS screen There is an additional set of STATUS screens in service mode described in the section 6 of this chap ter The STATUS screen shows as soon as the EXPLORER is turned on Fig 3 1 Fig 3 1 In addition it can be viewed at any point on the dive by pressing any 13 00 13 button and
98. rn to dealer if problem persists Negative test failed Ensure Cyl inder is attached Ensure Mouth piece is fully in OC mode Fill loop until vent valves exhausts then attempt negative test again O sensor s unable to calibrate and must be replaced and or their connectors cleaned Message Meaning ES Da CALIBRATE Low HP gas in dive cylinder If HP reduces by gt 50bar 735 psi or does not reduce by at least 5bar 73 5 psi Make sure cylinder valve is fully open Check cylinder size is correct in DEFAULT GAS Menu Do not use unlisted cylinders Submerge unit and look for LP HP leaks BC infla tor failures etc Wireless HP sender battery is low Analyzed gas is not what is expected by the DEFAULT GAS setting Analyze gas and check setting 93 94 Message Meaning CONFIRM The LCV and OPV are not vent ing at the correct pressure Flush valves with fresh water and repeat test If the problem persists return the unit to your dealer You have stopped breathing while conducting a pre breathe se quence Repeat the test If the error per sists return the unit to your dealer lf the Predive sequence is com pleted the STATUS window is active and you see the above alarm then HP usage is greater than 1bar min 14 7 psi min This could indicate a leak in the HP or LP circuit internal pipe work BC or BOV Submerge to locate the leak MANDATORY DIVING SKILLS EXPLORER BAS
99. rwater Products is committed to the preservation of our oceans and supports outreach and awareness programs that develop an understanding of the oceans importance to life on earth the fragility of marine ecosystems the damage done by pollution and the threat of overfishing We produce innovative products of the highest quality manufactured in an environmentally sustainable manner that meets or exceeds our customer s expectations and regulatory requirements JOLLIS HOLLISGEAR COM
100. s 1 If a single sensor is below 0 15 bar or above 3 00bar then it will be removed from the averaging a BAD CELL DO NOT DIVE alarm will be displayed if not diving or ASCEND BAD CELL if diving Diver Action Ascend on the rebreather 2 If a sensor is less than 7mv then it will be removed from the averaging a BAD CELL DO NOT DIVE alarm will be displayed if not diving or ASCEND BAD CELL if diving Diver Action Ascend on the rebreather 3 If one sensor is 0 2 bar away from the two remaining sensors then it will be removed from the averaging a BAD CELL DO NOT DIVE alarm will be displayed if not diving or ASCEND BAD CELL if diving Diver Action Ascend on the rebreather 4 If all three cells are removed from the averaging for the same reason i e all low or all high then all cells will be used in the averaging Super seding rules 1 2 and 3 a BAD CELLS DO NOT DIVE alarm will be displayed if not diving or ASCEND BAD CELLS if diving Diver Action Ascend on the rebreather unless superseded by rule 7 5 If the difference between the highest sensor and the lowest is greater than 0 5bar then the system will inject gas for 1 second out of every 3 as a fail safe This will cause an ASCEND NOW alarm Diver Action Ascend on the rebreather Rebreather switches to Fail safe mode 6 If the average of all sensors not removed from the averaging by rules 1 2 3 or
101. s Carry external bailout gas cylinder on dives deeper than 18 m 60 ft Practice use of the BOV and external bailout Perform static and dynamic open circuit bailout drill Include at least 2 OC ascents from bottom the bottom to approximately 6 m 20 ft To verify bailout systems function To ensure the diver is correctly weighted to maintain depth control under all urgent emergen cy conditions To reinforce how to deal with a hyper Capnia situation and reinforce involved muscle memory The unit should be weighted to offset the buoyant volume of the EXPLORE Additional weight is needed to com pensate for their exposure suits and additional bailout cylinder Switch to off board open circuit via the BOV Ascend slowly The biggest buoyancy change is in the last 10 m 33 ft and ideally the student should remain horizontal within this depth range Weighting should be such that automatic venting should control the ascent This skill should be conducted twice 1st along a contoured bottom or shot line the 2nd time with an SMB 99 Using the primary display adjust the DCP with both the manual and auto matic settings Use the Manual and Auto DCP settings on the primary con troller To fully under stand the function adjustment of the DCP and how dif ferent settings effect Dive Control Parameter Adjustment Remove and replace unit on surface
102. s best conducted in a heads up position In addition there is a master high flow over pressure release valve that is set to 40mb to help control ascents BOV BAILOUT VALVE EXPLORER comes with a BOV The BOV attaches to the on board nitrox circuit The BOV is designed as the primary bail out providing a sufficient planned volume is carried The BOV has two modes Fig 1 1 e OC Open Circuit Position e CC Closed Circuit Position When the mouthpiece is open the BOV is in the closed circuit position and when the mouthpiece is closed it is open circuit position INTELLIGENT HUD HEADS UP DISPLAY amp BUD BUDDY UNIVERSAL DISPLAY The Intelligent HUD Heads Up Display is attached to the BOV in the div ers line of sight There is also a BUD Buddy Universal Display display in the EXPLORER Module for Dive Buddy Instructor use These displays give full alarm status at all times using a visual and a tactile alarm system SENSORS The EXPLORER uses 3 oxygen sensors and one gaseous CO sensor It also uses a wireless HP sensor All sensors are automatically calibrated by the electronic control system 10 OUT OF THE BOX INITIAL ASSEMBLY The parts to assemble your EXPLORER include 1 The Front Case 2 The Back Case 3 The Canister pre assembled in the Case Front 4 The Sensor Module Pre assembled into the Canister 5 The Life Support System LSS Module Pre assembled into the Canis ter secured i
103. singly high or could be low if the variables are less extreme but could accelerate rapidly dependant on the rebreather design Some divers feel they are getting more duration because they are not producing as much CO as that used in CE trials or that other variables are less extreme within their diving environment Information from field use with the CO sensor indicates the filter dura tions are actually quite close to the CE durations and the 5 mB CO point However 5 mBar of CO is not fundamentally damaging Metabolism and 52 respiration can occur to some degree even up to 20mB CO However the amount of exertion and other pressure related effects mean that this is un advisable and CO poisoning and death may occur at levels in the 10 20 mB range in some cases So some of the extended durations currently ex perienced are due to the user taking the CO level into the 5 10 mB range without any obvious symptoms of CO poisoning The user must be aware that strenuous exertion when CO is at these elevated levels can quickly cause the CO levels to rise rapidly As the symptoms of CO poisoning are almost impossible for the user to recog nize they will just pass out and may drown However the readings from the CO sensor showing that CO levels are rising while still not exhibiting symptoms should be used as much as anything to limit the strenuous activity and further use of the filter after the dive has finished A DANGER
104. st always be carried out to ensure CO is being absorbed correctly by the filter 43 44 The TPM contains 5 Thermostats arranged longitudinally through the canister absorption path The readings from these 5 thermistors are logged and analyzed by the system In this manual it is not appropriate to explain this data analysis in detail However it is appropriate to describe some of the limitations of the device The CO absorbent produces heat when CO is absorbed However there is also a temperature rise even when incomplete absorption of the CO in the breathing gas is achieved This is a potentially dangerous situation as the system appears to be working correctly as there is still a measurable temperature rise and wavefront in the system The human body is tolerant to only approximately 5 to 10mBar of CO ref CE standards for a life sup port system A well packed fresh Absorbent Filter absorbs all the exhaled CO for a period of time until an amount of CO starts to creep through When this level reaches 5mb it is assumed there is no life left in the filter However even at 5mb there is still considerable thermal activity within the filter A DANGER So be aware that a well packed and well maintained Absorbent Filter is key in achieving a life support system The CDM is not a substitute for good system maintenance and Pre Dive checks Always use your training and discipline to ensure the sub systems in the EXPLORER are operating
105. t to edit or moves the STATUS display one window to the right Moves the cursor to the next field to the left to edit or moves the STATUS display one window to the left i A single bracket indicates a short push of the button to perform the action in this case move left A double bracket indicates a short push of both buttons to perform the action in this case move to left Moves the cursor up to the next option as in a menu list In this case a short push of the left button A down arrow moves the cursor down f A short push increments the information by 1 digit A long push increments the information in multiples A minus sign decrements the digit EXITS to the previous page and SAVES the information ENTERS the selected item page A double bracket around a function indicates a long push j of both buttons In this case to exit the page oA SCREEN ICONS During the Pre dive tests icons appear across the top of the screen starting on the left As each level of Pre dive is completed successfully a green icon appears indicating the test has passed successfully Note that all icon colors as with any numerical displays match the alarm severity yellow indicates a blue green HUD state In addition a grey icon indicates a test not yet performed WARNING A red icon means a failure of the test alarm which if ignored would make EXPLORER unsafe to dive The icons are Battery amp Computer O
106. u have the option to calibrate the oxygen and CO sensors from the Calibration screen Fig x x Selecting O will display another series of screens that will guide you through the calibra tion Please see descriptions later in the manual for calibrating the CO sensor SUMMARY OF DO S AND DON TS OF OXYGEN SENSOR CALIBRATION When calibrating sensors there are two factors that the EX PLORER takes into account 1 Ambient pressure 2 Ambient AIR oxygen content These two factors multiply to determine the partial pressure of the oxygen exposed to the Oxygen sensor Example 20 9 oxygen at 1000mBar 0 209mBar partial pressure of oxygen 20 9 oxygen at 750mBar 15 675 mbar partial pressure of oxygen The EXPLORER uses ambient air as the calibrating gas because its composition is accurately known This is in contrast to say a cylinder of compressed oxygen that can vary from supplier to supplier as well as around the world from at least 94 to 100 38 To achieve a good calibration some basic rules must be ob served 1 The Oxygen sensors must be exposed to the pure calibrating gas So for an air calibration the sensors must be flushed with air Just taking the hoses off is NOT sufficient as pockets of gas can be enveloping the sensors 2 DO NOT routinely execute calibrations to remedy a rebreath er that seems to be showing the wrong PPO If the rebreather had previously been accurately displaying PPO then
107. wer steel mesh for damage Your Hollis dealer can replace damaged meshes e Fill with CO absorbent as per the manual and label and refit the top nut and spring ABSORBENT FILTER QUAD RING DANGER This is the most important seal in the system and should be regularly cleaned and inspected It is vital in prevent ing CO bypass e If you are using the single use CO filter then each filter comes with a new quad ring seal DANGER This is not a normal O ring and must not be replaced with anything else e If you are using the ProPack Filter then this seal MUST BE REPLACED EVERY 30 HOURS OF USE DANGER The ProPack CO filter Quad ring seal must be re placed every 30 hours of use COUNTERLUNG DISASSEMBLY ASSEMBLY e Remove the counterlungs by unscrewing the connectors e Remove the exhale counterlung LCV mushroom valve cap 1 2 turn lock e Sanitize and inspect the counterlungs COUNTERLUNG TESTING e Attach the BOV exhale side right of the mouthpiece to the exhale counterlung canister port e Unclip the exhale counterlung LCV port cap from it s hose and block the 10S end of the exit tube e With the BOV in CC mode Fully inflate the counterlung Immerse and look for leaks e Repeat for inhale counterlung there is no LCV cap to cap off REGULATOR WIRELESS HP TRANSMITTER TESTING e Connect a diving cylinder e Turn on the wrist display and complete the pre dive sequence e During the Pre dive HP g
108. wet during a dive The used absorbing material can be dried out preferably in an air conditioned environment as it will become moist during a dive Fig 3 23 WARNING Each absorbing material piece should only be used for a maximum of 10 dive hours or if damage is noted replaced immediately or sooner if the readings from the CO sensor are not within the expected range i e almost Omb at the end of the Pre dive sequence with a new filter fitted A DANGER Failure to replace the absorbing material may result in faulty CO readings If debris is noted on the front face of the membrane yellow material or if it is Suspected that contamination is restricting the flow through the mem brane it should be replaced 55 56 CALIBRATION During the Pre dive sequence you are prompted if you want to calibrate the CO sensor Fig 3 24 The ONLY source of calibration gas is fresh air With the filter removed and the sensor in fresh air the CO reading should read 0 4mb 0 1mb Leave the sensor exposed for at least 5 minutes The on screen prompts will guide you through the calibration This involves removing the exhale hose from the mouthpiece and breathing the unit for one minute to circulate fresh air into the system Fig 3 24 1 WARNING At the end of a Pre dive sequence with a new filter fitted the CO readings should be almost Omb If this is not the case then the sensor must be recalibrated as above or re pl
109. with buoyancy control and buoyancy inflation 11 Practice a skill on every dive 12 Avoid unnecessary mask clearing 13 Regularly sanatize the unit 14 Never exceed the CO alarms 15 Never hold your breath 16 Never start a dive with a low battery alarm 17 Always carry bailout gases of sufficient volume for the planned dive as per your training agency recommendations IF INDOUBT BAIL OUT BATTERIES The EXPLORER uses Lithium Polymer batteries These rechargeable bat teries are very efficient and provide many years of reliable operation Rechargeable Lithium batteries can be recharged at any time and do not have a significant memory affect which would otherwise cause unreliable battery operation The batteries are UL listed flight safe and are double sealed to reduce the chance of leakage to a minimum As extra confidence the LSS Module battery pack includes 3 separate batteries to ensure operation even under multiple battery failure scenarios During diving the battery reserve alarm will indicate when there is still suf ficient battery to allow a return to the surface with a small reserve The unit MUST then be charged prior to diving again The handset has its own battery that is charged from the EXPLORER Mod ule automatically The user should keep the batteries recharged and topped up to ensure there is always maximum capacity for any dive A fully charged battery pack will display 1000 minutes of battery l
110. witha buddy To learn how to sur vive a partial flood due to mouthpiece loss etc To understand the STATUSdisplay and the HUD light and vibration motor alarms To understand the set up menus of EXPLORER To practice deploy ing and receiving a second stage bailout Towards the end of a dive move to an upright position switch to open cir cuit and shake loop above head to any drain water from mouthpiece and hose then return to CCR Continue breathing as nor mal and the LCV system will vent wa ter from the loop If on an ascent simply continue ascending until the counter lung over pressurizes Water will drain through the LCV Using the Simulator APP and during dives review the STATUS informa tion Using the Simu lator APP and the display understand the surface menu s Stay on the EX PLORER Allow a Buddy to use the Buddy regulator Initially conduct in a horizontal swim then during an as cent to 6m 20ft 101 EXPLORER SKILLS COMPLETED DRY SKILLS 1 Management of O rings Student Instructor 2 Assemble the unit Student __ Instructor 3 Proper dive planning Student__ Instructor 4 Post dive care Student ___ Instructor 5 Complete Explorer Exam Student Instructor with a minimum score of 80 missed questions reviewed with instructor IN WATER SKILLS 1 Pre dive checks Student Instructor 2 Callibration of EXPLORER Student ___ Instructor 3 In water leak buoya
111. y by doing a long hold of either buttons Complete the pre dive sequence as instructed Fig 2 22 Fig 2 23 Fig 2 24 LIFE SUPPORT SYSTEM COMPUTER GENERAL OPERATION The EXPLORER Life Support System LSS is designed around a breathing loop high pressure gas sources and electronics control system all highly integrated to give an intelligent but simple display of status to the diver while providing life support This gives the user a simple Check and Dive functionality that makes the EXPLORER the easiest Rebreather to prepare for diving while ensuring system integrity and improving safety It uses intelligent monitoring and design experience to determine the appropriate tests and checks that the diver needs to perform to get the EXPLORER ready for use Any problems are described clearly on the STATUS screen with the re quired action The integrated system design means that failures or problems with any part of the system are communicated to the diver either in pre dive checks and procedures or as data values graphics or instructions There is sig nificant background analysis that produces a warning system sensitive to changes in expected levels but intelligent enough to not confuse and over load the diver with information and situations that may be routine during a dive These electronic alarms combined with varying levels of mechanical user controls ensure the LLS is maintained Examples e PPO changes that m
112. y higher Regardless of conditions or readings on the computer the scrubber should NEVER be used for more than 2 hours C1 WARNING These tests were conducted using Hollis approved absorbent grade and durations can only be duplicated using this grade DO NOT use any other type of absorbent with the EXPLORER Safety data on absorbent products can be found at http Awww molecularproducts co uk Tests conclude that depth gas density temperature and CO generation all massively affect absorbent duration The EXPLORER employs a highly efficient axial canister design which not only offers greatly extended dura tions when compared to other designs employing a similar absorbent load but it is less affected by the commonly experienced high loss of efficiency associated with increased depth 85 86 FILLING STEPS PROPACK VERSION ONLY A DANGER DO NOT perform this action unless you are certified to do so 1 Remove the Filter from the Canister Inspect the quad ring for cleanli ness damage and clean replace with a small amount of grease Fig 4 9 2 Unscrew the yellow top nut and canister lid and inspect the meshes for damage 3 Remove any excess absorbent stains from the canister components with warm soapy water and then rinse in fresh water Then allow it to dry 4 Fill the canister in a well ventilated environment Raise the absorbent barrel at least 200mm 8 inches above the canister to allow dust to blow away as
113. you fill Fill to the top of the canister making sure absorbent is at an even depth across the canister 5 Pack the absorbent by tapping the sides for at least 1 minute 6 Fill to the top again 7 Pack the absorbent by tapping the sides for at least 1 minute 8 Refill with Absorbent to the top Tap down as required until you can fit the lid Refit the lid and the spring under the yellow nut 9 Screw down the top nut 10 Wipe any dust from inside the canister 11 Look into the Canister head and run your finger around the sealing face for the quad ring removing any debris 12 Insert the filled Filter into the Canister 13 Refit the Right Hand end cap 14 Dispose of old absorbent as normal household waste Do not leave it lying around for animals to ingest Filling instructions are also found on the side of the canister tube FILLING STEPS PRE PACKED VERSION ONLY 1 Remove the Filter from it sealed packaging 2 Inspect the quad ring for cleanliness damage 3 Apply a small amount of grease to the quad ring 4 Wipe any dust from inside the canister 5 Install the filter 6 Refit the Right Hand end cap 7 Dispose of old absorbent filter as normal household waste Do not leave it lying around for animals to ingest Fig 4 9 POST DIVE During a diving sequence it is important that a small amount of daily main tenance is undertaken These fall into 5 categories 1 Care of oxygen and CO sensors 2 Lo

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