User Guide For

MK3-KMDSI Communicator
Two-Diver Air Intercom
(Communicator P/N 415-107)

Document #160502001
Document P/N 100-401

SuperMask, Kirby Morgan, DSI, Diving Systems International, EXO, SuperFlow

and DECA are all registered trademarks of Kirby Morgan Dive Systems, Inc.
Use of these terms to describe products that are not manufactured by KMDSI
is not permitted.

The two dimensional images (such as photographs and illustrations) of our prod-
ucts are © copyrighted and trademarks of Kirby Morgan Dive Systems, Inc. The
three dimensional forms of our products are trademark/trade dress protected.

© Copyright MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. This
user guide is made available for the express use of owner of this Kirby Morgan
product. No part of this user guide may be reproduced, stored in any retrieval
system, or transmitted, or used in any form or by any means, whether graphic,
electronic, mechanical, photocopy, or otherwise by technology known or un-
known, without the prior written permission of Kirby Morgan Dive Systems, Inc.


WARRANTY
LIMITED WARRANTY
The MK3-KMDSI is fully warranted against defects in materials and workmanship for a period of one (1) year from
the time of purchase. Our obligation under this warranty is limited to the replacing of any part or parts which prove to
our satisfaction to have been defective, and which have not been misused or carelessly handled. Labor is warranted
for one (1) year from time of purchase. The complete unit and/or part must be returned to our factory, transportation
charges prepaid. We reserve the right to decline responsibility where repairs have been made or attempted by other
than an Ocean Technology Systems factory-trained service center or properly trained personnel. In no event shall
Ocean Technology Systems be liable for consequential damages.

2950 Airway Avenue (D-3), Costa Mesa, CA 92626 USA

Telephone (714) 754-7848, Fax (714) 966-1639

Kirby Morgan® thanks you for your purchase.

II © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001
 

Table Of Contents

II Warranty

1 Definitions of Signal Words and Terms Used in this

Guide

3 Important Information—Please Read!

3 Introduction

3 Equipment Specifications

4 Panel Functions

6 2-Wire Mode

7 4-Wire Mode

8 Charging the Batteries

8 Power Indicators

10 Replacing the Battery

11 Removing/Replacing the Communicator

11 Removing
12 Replacing

12 Helpful Hints

14 Records

14 Notes

© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 III
This page intentionally left blank
 Definitions of Signal Words and Terms Used in this Guide

Definitions of Signal Words and

Terms Used in this Guide
The original language of the Kirby Morgan Manuals is English. Trans-
lation into other languages will be provided upon request. KMDSI may
charge a fee for these services.

Throughout this user guide we will use certain words to call your at-
tention to conditions, practices or techniques that may directly affect
your safety. Pay particular attention to information introduced by the
following signal words:

B DANGER
This word indicates an imminently hazardous situation, which
if not avoided, could result in death or serious injury.

B WARNING
This word indicates a potentially hazardous situation, which, if
not avoided, could result in death or serious injury.

B CAUTION
This word indicates a potentially hazardous situation, which if
not avoided, may result in minor or moderate injury. It may also
be used to alert against unsafe practices.

NOTICE
This word is used to address practices not related to personal
injury.

This operation user guide contains important safety information and

should always be available to those personnel operating this equipment.
Read, understand, and retain all instructions before operating this
equipment to prevent injury or equipment damage.

If you sell or loan this equipment to another person, be sure that this
user guide accompanies the gear when you transfer possession to them.

© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 1
This page intentionally left blank
 Important Information—Please Read!

Important Information—Please Read!

Your new MK3-KMDSI Two-Diver Air Intercom represents state-of-
the-art technology and innovation—the choice of discriminating divers
throughout the world. Please take the time to read this owner’s manual.
With proper care and use, your MK3-KMDSI will provide you with the
ultimate in high-quality communications.

The following guidelines and illustrations are presented to assist you.

If you still need additional information, do not hesitate to confer with
your local KMDSI (Kirby Morgan Dive Systems, Inc.) dealer or rep-
resentative. If you are not able to adequately obtain service, contact
KMDSI, or Ocean Technology Systems, 3133 West Harvard Street,
Santa Ana, CA 92704 , Telephone (714) 754-7848, Fax (714) 966-1639,
Email: [email protected] www.oceantechnologysystems.com

Introduction
The MK3-KMDSI is a compact, self-contained, Two-Diver Air Intercom
providing 2- or 4-wire communications between the operator and one
or two divers. Please note that standard 4-wire cable is necessary when
using this product in the 4-wire mode.

This manual covers Specifications, Operating Instructions, 2-Wire or

4-Wire Communications, Batteries, Helpful Hints, and Warranty In-
formation.

Equipment Specifications
Battery Life: 12 hours nominal (depending on the num-
ber of divers and/or volume levels)
Battery Type: KMDSI supplied Gel-cel (contact KMDSI
for further information)
Power Output: 20 Watts into 4 ohms
Frequency Response: 600 to 12,000 Hz
Front Panel: 1/8" aluminum, chemically-treated and
coated with a tough, durable, urethane fin-
ish to withstand the marine environment
Size: Width: 11 3/4"
Height: 6 1/8"
Thickness: 1/8" aluminum 6061-T6

© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 3
Panel Functions

Panel Functions

10

8
11

7
12
13

6
14
15

5
4
16

17

3
2
1

4 © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001
 Panel Functions

1. External Battery/ Allows tender to use a 12-volt

Charger 12 Volt alternate source, or charge the
rechargeable battery from the
front panel.
2. Panel Speaker Heavy-duty panel speaker pro-
vides maximum audio power for
overriding surrounding noise.
3. Recorder/Out Permits tender to record diving
operations. Female RCA/phono
connector.
4. Headset Allows the use of a headset.
5. REM/GND Remote push-to-talk receptacle
(used with headset w/ptt).
6. Mic Used with hand-held microphone
or headset w/mic).
7. Microphone Banana-style connectors. Permits
hook-up for either 2-wire or 4-wire
communications (see Fig 2 & 3).
8. Earphone Allows tender to set intercom up
for 4-wire (round-robin) mode (see
Fig 3).
9. Diver to Tender Volume 1 Controls volume of diver #2 to
tender.
10. Diver to Tender Volume 2 Controls volume of diver #1 to
tender.
11. Cross Talk Used in 2-wire mode to cross-talk
divers.
12. Diver Select Allows tender to control commu-
nications to either diver #1, diver
#2, or both divers.
13. Low Battery Low battery indicator.
14. Push-to-Talk (PTT) Switch used in 2-wire mode by
tender to talk to divers.
15. Green LED Indicates power ON.
16. Tender to Diver Volume Turns unit ON and controls ten-
der volume down to both divers.
17. Speaker On/Off Allows tender to turn front panel
speaker ON or OFF.

© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 5
2-Wire Mode

2-Wire Mode
In normal 2-wire operations, the two wires within the diver communica-
tion cable is connected to the corresponding binding post (divers #1 and
#2) on the surface unit. This allows the tender to talk to either diver
individually, or both divers simultaneously. The divers may also com-
municate with each other when the tender engages the cross-talk switch.
The surface unit speaker functions as speaker and microphone. When
the system is used where conditions are noisy, the tender can switch off
the speaker and use a headset and boom microphone; however, when
using a headset with boom mic, the tender must still use the push-to-
talk (PTT). The divers’ communication is the primary signal. When the
tender uses the PTT control, his signal becomes the primary signal.

If a speaker is located in a diving bell or recompression chamber, the

MK3-KMDSI can be used as the communications link between the div-
ers and the outside.

DIVER 1 DIVER 2

EARPHONE EARPHONE

MICROPHONE MICROPHONE

6 © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001
 4-Wire Mode

4-Wire Mode
The 4-wire mode provides continuous open-line communications between
the tender and divers. In this mode (black), everyone hears each other
simultaneously. Therefore, the earphones, speakers and microphones
must be isolated to prevent feedback. All earphones are connected in
parallel—four wires are required to connect all stations: two for the mi-
crophones, and two for the headset and earphones. The diver earphones
should be connected to the earphones’ mode (black) binding post and
microphones to the mic (red) binding posts on the surface unit. The
phone plug on the tenders’ headset should be connected to the headset
phone jack. The red plug (tender’s microphone) should be connected to
the microphone jack. The diver’s microphone can also be connected to
either diver #1 and diver #2 jacks. When set in the 4-wire mode, every-
one is online together, similar to a telephone conference call, as long as
the tender is using a headset mic combo. If this combo is not used, the
tender will be required to use the Push To Talk button to communicate.
NOTE: The DIVER SELECT switch must be in the “BOTH” position!

DIVER 2
DIVER 1

EARPHONE EARPHONE

MICROPHONE MICROPHONE

NOTE:
In the four wire mode, the headset is
mandatory, for open line communications. Not using a head-
set will require the tender to use the Push To Talk button.
© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 7
Charging the Batteries

Charging the Batteries

The operating time for a fully charged battery is approximately 12
hours. The exact operating time depends on the age of the battery and
the ambient temperature. Charging should be done with the unit turned
off. Typical charge time from a low battery warning when using the pro-
vided OTS charger connected to a secure AC power supply is three to four
hours. If connected to another source like a vehicle that has its engine
running and the vehicle battery voltage is between 13.8 and 14.7 volts,
it’s about an 8 hour charge depending on the condition of the battery.

When charging the batteries the GREEN LED power light will turn on
and remain on for the entire time the unit is plugged in. The charger is
designed to remain plugged into the supplied power and connected to
the battery for extended time without damaging the battery. It is recom-
mended that charging time not exceed 12 hours. The batteries do not
have memory and can be placed on charge at any time. The charger for
the MK3-KMDSI is Kirby Morgan P/N 415-150. It is recommended to
connect the two leads from the battery charger into the communicator
first, and then followed by plugging the power cord from the charger
into the supplied power second.

Match the Red and Black probes to

the Red and Black receiving holes
on the lower left panel of the com-
municator to connect the charge to
the MK3-KMDSI communicator.

Power Indicators
There are two LED lights on each side of the Tender to Diver Volume
control knob. The LED on the left is the power on indicator and will emit
a strong green color when turned on and when charging or operating
from an external power supply. The green LED will remain green until
the battery drops below 8 volts. The LED on the right side of the control
knob is RED in color and is the low battery warning light. When the
battery level drops to 8 volts, the red light will turn on (solid). There is
also a tone every 30 seconds that will be heard. When the battery level
drops below 7 volts, the red light will begin to blink. The tone will also
continue to be heard every 30 seconds.

8 © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001
 Power Indicators

Testing Communications Test the communications between the diver

and the KMACS 5. With the communicator (S) switched on, turn the
speaker switch to “on” and adjust the volume to a comfortable level for
both the diver and the KMACS 5 operator.

In the 2 wire mode and the 4 wire mode without headset and boom
microphone, the communicator functions similarly to a citizens band
radio; i.e., the KMACS 5 operator must depress the push to talk switch
to speak to the diver. In the 4 wire mode, with headset and boom mi-
crophone, the communicator functions like a telephone conference call;
i.e., everyone on the line can hear and speak to everyone else. In either
mode, for the diver to talk top side, it is only necessary for him to speak
into the oral/nasal microphone in his mask or helmet. If two divers will
be working together using 2 wire mode, test the cross-talk functions at
this time as well. To extend the life of the battery, it is recommended
that the communications be used in the 4 wire mode. Operation as a 2
wire system uses relays inside the unit which will cause a higher bat-
tery drain.

B CAUTION
In the 2 wire mode, when the push-to-talk switch is depressed,
the KMACS 5 operator should keep all of their communications
short (10–15 seconds) at any one time. This allows the diver to
call for assistance if necessary.

Plug the earphone connectors on the diver’s umbilical into the earphone
jacks (Black) on the communicator. Plug the microphone connectors on
the diver’s umbilical into the microphone jacks (Red) on the communica-
tor. This will create a 4 wire system/round robin system. Test the system
and adjust all volume controls.

Unplug the earphone connectors on the diver’s umbilical from the com-
municator and reinstall them in the connectors attached to the plugs
for the microphone(stack the jacks). This will change the communicator
to a 2 wire system. Test this system and adjust volumes. If there are
no communications, recheck all of the connections to ensure they are
tight at each junction. If the KMACS 5 has been operating in a coastal
environment, look for corrosion on the top side connectors which may
interfere with the communications. If corrosion is evident, disassemble
the connectors, clean, and retest. If corrosion is heavy, replace the top
side connectors on the umbilical. Substitute other masks or umbilicals
to test for failures in the microphones or umbilical. Substitute one piece
of new gear at a time to track the fault down. If the fault is in the mask

© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 9
Replacing the Battery 
or helmet, replace the earphones or microphones as needed. If the fault
is in the umbilical, disconnect the umbilical and carefully inspect its
length for damage. Look for obvious nicks or cuts. If there is physical
damage to the outside of the communications wire there probably is a
break on the inside, too. Test the continuity of the wire end-to end with
a volt-ohmmeter. Uncoil the umbilical and lay it out flat with the two
ends close to each other. Set the volt-ohmmeter to resistance (ohms) and
hold one probe to one prong on an umbilical connector plug and touch
the other probe from the meter to the wires (or connector) at the opposite
end of the diver’s umbilical. Upon locating the other end of the same
wire, the meter should indicate zero resistance, i.e., there is a complete,
uninterrupted circuit. If touching none of the wires at the other end of
the umbilical produces a zero reading, this indicates a complete break
in the wire. If the reading is not a steady zero and the reading changes
as the umbilical is moved, this indicates a partial break, and commu-
nications will be intermittent. In either case, a waterproof splice must
be made in the wire.

Replacing the Battery

The battery used with the KMACS 5 communicator is very reliable and
will offer many years of service. However, storing the KMACS 5 with
the battery drained can cause the battery to fail. The battery should
be completely charged before storage. Gel cell batteries can have an
excellent shelf life if properly charged prior to storage. However, it is
imperative that they be charged after six to nine months of storage.

To replace the battery, remove

the screws which hold the com-
municator panel into the top of
the KMACS 5 box. Do not remove
the screws which secure the com-
municator to the larger panel.

10 © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001
 Removing/Replacing the Communicator

Tilt the panel out but do not re-

move it from the lid.

The battery is held in place by

brackets and Velcro ® strips on
the back of the large panel. Reach
behind the panel and support the
battery. Lift the panel and battery
out as a unit.

Replace the old battery with a new unit. Position the new battery on
the back of the large panel using the “Velcro” strips to hold it in place.
Connect the leads back to the battery and push the communicator panel
back into its normal position. Install the screws which hold the large
panel in place and tighten them in a staggered pattern.

Removing/Replacing the Communicator

Removing
Verify that the communicator is turned off and all connections from the
umbilical and headset are removed. There are six screws that secure
the MK3 communicator in place.

Remove the six screws using a #2

Phillips screwdriver and set aside
in a safe place where they will not
be lost.

© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 11
Helpful Hints

Carefully pull the communica-

tor slightly away from KMACS
5 top panel. The communicator
is connected to the battery with
a three pin connector and cannot
be removed completely without
disconnecting the connector.

Disconnect the battery connectors by simply pulling them apart and

complete separation is possible.

Replacing
When replacing a communicator verify the unit is in the off position
Bring the communicator close the KMACS 5 top panel and either lay it
down close to the panel or have someone hold the communicator while
connecting the male and female together. Once the battery connection
is made, fit the communicator into the appropriate slot ensuring that
the battery cable is free from pinching. Using a #2 Phillips screwdriver,
tighten screws in a staggered star pattern until all screws are secure.

Helpful Hints
1. Before diving operations, check to be sure microphone, earphones
and wire connections are functioning properly. Ninety percent (90%)
of all problems in communications turn out to be a problem with
one of the above.

2. When in 4-wire mode, you must use headset with boom microphone
and the DIVER SELECTOR switch must be in the “BOTH” posi-
tion, to have open communications between divers and the divers
to topside. If feedback is present, switch the front panel SPEAKER
to “OFF” (see Panel Functions 17 on page 5).

3. Avoid excessive tender-to-diver volume. Most of the time, when

there is too much volume, the diver will hear distortion and ask for
more volume.

4. Before diving operations always check the battery, a solid green LED
light should be on, indicating a charged battery. The red colored LOW
BATTERY LED indicator light (see Panel Functions 13 on page 5)
indicates the battery needs to be charged or replaced. The charger
for the MK3-KMDSI communicator is Kirby Morgan P/N 415-150.

12 © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001
 Helpful Hints

5. Make certain all umbilical communication wires are secured into

topside banana connectors. Verify that topside connectors are se-
curely inserted into topside jacks and in the proper place.

© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 13
Records

Records
MK3-KMDSI Serial Number:

Date of Purchase:

KMDSI Dealer:

Dealer Phone Number:

Dealer Email or Website:

Notes


14 © MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001
 Records

Notes



© MMXVI Kirby Morgan Dive Systems, Inc. All rights reserved. Document #160502001 15
 1430 Jason Way, Santa Maria, CA 93455
Phone: 805/928-7772 Fax: 805/928-0342
www.kirbymorgan.com E-mail: [email protected]