The Extreme Lightweight Diving System (XLDS) is a combination of assemblies and components designed and engineered as a complete surface supplied diving system allowing for rapid set-up and deployment. The System was designed and engineered by Dive Lab, Inc., primarily for Military and Paramilitary use, and is intended to meet specific performance goals and engineering requirements. The XLDS is available in two models, the XLDS-RDC-2 (two (2) diver) and XLDS-RDC-3 (three (3) diver). Both the two and three diver Systems consist of four major sub assemblies that work as a complete breathing air supply System primarily designed for use with Kirby Morgan Helmets and Full Face Masks, but will also work with other demand mode equipment as outlined in the User Guide.


  • Lightweight and Portable
  • Rapid Set-up and Deployment
  • Ease of Operation
  • HP and LP cross connect capabilities for added redundancy and safety
  • Low Maintenance
  • Durable / Reliable
  • Certified Performance Capabilities
  • Modular System, allows the use of various high-pressure supply sources
  • Performance based on a minimum HP supply pressure of 400 PSIG

XLDS Specifications

Box Weight: 87 pounds
Outer Dimensions:
Length: 28 inches
Width: 27 inches
Height: 15 inches
Number Diver Circuits: 3 (Red, Green, & White)
Max Depth: Using 1/4 I.D. Umbilical one
continuous length up to 330 long, 165 fsw

Maximum High Pressure Supply: 3000-5000 PSIG
Minimum Console Supply Pressure: 375 PSIG
Maximum Low Pressure Outlet Pressure: 375-400 PSIG
Low Pressure Relief Setting: 400-420 PSIG
High Pressure Gauges: 3, 0-5000 PSIG
Low Pressure Gauges: 3, 0-600 PSIG
Pneumofathometer Gauges: 3, 0-250 FSW
Surface Supply Console Flow Capability
Maximum Flow: with 400 PSIG HP supply and
Reducer set static to 350 PSIG, 800 slpm (28 scfm)

Maximum Flow: with 700 PSIG HP supply, reducer
Set static to 350 psig, 1475 slpm (52 scfm)

Maximum Flow: with 700 psig HP supply, reducer
Set static to 225 psig, 1190 slpm (42 scfm)

Maximum Flow: with 400 PSIG HP supply, reducer
Set to 225 psig, 790 slpm (27.9 scfm)

Work of Breathing Performance

Work of breathing performance data is based on one diver breathing from a HP supply of 400 PSIG with the SCC regulator set static at 350 PSIG. The I.P. of the ICS set between 150-160 PSIG. Umbilical length, 330.

100 FSW 62.5 RMV 75 RMV
MK-21 1.41 J/L 1.99 J/L
KM-37 1.43 J/L 1.44 J/L
M-48 SF 2nd 1.21 J/L 1.46 J/L
MK-20 1.10 J/L 1.40 J/L
EXO-26BR 1.00 J/L 1.16 J/L
132 FSW 62.5 RMV 75 RMV
MK-21 1.66 J/L 1.90 J/L
KM-37 1.48 J/L 1.61 J/L
M-48 SF 2nd 1.54 J/L 1.93 J/L
MK-20 1.25 J/L 1.57 J/L
EXO-26 BR .92 J/L 1.28 J/L
165 FSW 62.5 RMV 75 RMV
MK-21 1.90 J/L 2.50 J/L
KM-37 1.70 J/L *
M-48 SF 2nd 1.81 J/L *
MK-20 1.61 J/L *
EXO-26BR .82 J/L 1.62 J/L
*Could not perform at this work rate.

XLDS Performance

Rapid Deployment Air Control Console

The Breathing Gas Control Console regulates and controls the divers breathing air supplies and Pneumofathometer air for depth sensing. Both the Two Diver (XLDS-RDC-2) and Three Diver Console (XLDS-RDC-3) have one complete circuit for each diver laid out in a simple fashion and the components used in each Console are the same. Supply to each Divers circuit starts with a VCO O-ring fitting or # 437 JIC fitting attached to a stainless steel Street T connected to each divers Pressure Regulator. The Regulator is rated for a maximum inlet supply pressure of 5000 PSIG and a maximum outlet pressure of 400 PSIG. Reduced air pressure passes through a one-way valve allowing air to only travel into the Manifold. Each Manifold Assembly contains a 0-600 PSIG reduced Pressure Gauge, Pneumofathometer Supply Valve, Relief Valve (set to relieve between 390-420 PSIG), and Diver Supply Valve. Each Manifold also has a NPT auxiliary supply port, as well as a and 3/8 straight thread gauge calibration port, and a main supply cross connect which allows intermediate air from either circuit to be lined up to the other divers reduced pressure circuit(s). Each diver low-pressure supply valves (500 PSIG) are quick acting quarter turn valves. The Manifold is the foundation that holds all gas train components and secures to a 1/2 thick nylon foundation plate through bolted to the Console Box making the piping system secure. The Pneumofathometer Gauges on the 2 Diver Console are mounted in the Console Lid along with or without an installed diver intercom (Optional). On the 3 Diver Console, the three Pneumofathometer Gauges are mounted on the left side of the Console above the high pressure reducing regulators. The 3 Diver Console can be equipped with several different diver intercom units (optional) but does not have a diver intercom integrated into box. Both 2 and 3RDC’s are normally equipped with index locking quick connect fittings for attaching the Pneumofathometer and breathing air supply Umbilicals.

XLDS System Restrictions

The XLDS with Umbilicals and Diver Worn Manifold Compensating System, Umbilical length is restricted to a maximum length of 330 (100meters).

When RDC-2 or 3 is used as a Standard Control Console with 3/8 Umbilicals, Umbilical length should be restricted to 600 (200 meters) or less and a maximum diving depth of 220 fsw. The system must only be operated and used within the guidelines of this User Guide and the operation specifications described in this Guide.

Ultra Light Umbilicals

The XLDS Umbilicals have been specially designed for use with the Manifold Compensating System and RDC-2 or RDC-3 and are not intended to be used for conventional surface supplied diving. The Umbilical Assembly is comprised of four major components that are twisted together to form the complete Umbilical Assembly, Breathing Gas Hose, Communications /Strength Member, Penumofathometer Hose, and 20 Grab Line. The divers end has a D Ring with Snap Shackle that is attached to the Communication/Strength and Grab Line for securing to the Diver Worn Harness.

The I.D. Gas Supply Umbilical has a design pressure of 1500 PSIG and is rated for a normal maximum system working pressure of 400 PSIG. Both ends have SS swaged MPT fittings. The topside end is equipped with a male Hansen series 3000 quick connect coupling that mates to the RDC via a female non-valved socket. At the divers end is a valved Hansen series 3000 female QD socket that mates to the non-valved male plug attached to the Intermediate Compensating System (ICS) interface whip.

Communication Strength Member

The Communication/Strength Member contains four (4) wires for communications and a polyester strength member. The assembly is encased in a polyurethane jacket. The strength member has a safe lifting capacity of 300 LBS and a minimum breaking strain of 1200 LBS.

Pneumofathometer Hose

The Pneumofathometer Hose is made from black nylon plastic, 3/16 I. D. rated for a maximum internal pressure of 250 PSIG.

Grab Line

The Grab Line is twisted into with the first 20 feet of Umbilical at the divers end to allow for easier handling by the tenders and to aid in lifting if necessary. The Line is standard 3/8 or braided nylon.

Diver Worn Harness and Manifold Compensating System

The diver worn Intermediate Compensating System (ICS) was designed to allow I.D. air supply Umbilicals to be used with standard demand mode Helmets and Masks. The System allows divers the ability to dive to depths previously only attainable when using heavy 3/8 Umbilicals and large support systems. The ICS System with accumulator attaches to the right side of the modified Miller Bell Harness, and fits securely behind the right arm in a specially fitted holster. The Umbilical attaches to the ICS which reduces the normal Umbilical supply of 350 PSIG to between 145-165 PSIG over ambient pressure to the demand mode Helmet or Mask being used. Because the Manifold Volume Tank receives medium pressure high velocity air from the Umbilical, the system is capable of providing the necessary peak flows required to attain respiratory work rates (RMV), as high as 75 RMV, with specified Helmets and Masks to depths of 140-165 FSW.

High Pressure Air System

The standard high-pressure air attachment to SCUBA Cylinders are SCUBA A Yokes, rated for a maximum supply pressure of 3500 PSIG. All standard RDC-2 and RDC-3Whips are rated for a maximum working pressure of 5000 PSIG or as marked on the Whip. Other Whips up to 25 feet in length can be used, providing they have a minimumI.D. of .112.
Proper rated DIN fittings as well as CGA fittings can be used to their appropriate working pressure up to the systems maximum supply pressure of 5000 PSIG. Each divers circuit comes standard with two Cylinder attachment Whips and Yokes that attach to a Routing Block and Shut-off Valves. Each supply system allows attachment to two single SCUBA Cylinders, or two sets of twin SCUBA Cylinders, if twin Cylinders are being used. Each divers circuit should always be set-up with each Yoke attached to a fully charged Cylinder, and only one Cylinder supply should be on line at a time so that when the gas supply reaches 400 PSIG it can be secured and the other supply opened. By keeping the System set-up in this manner, the depleted Cylinder(s) can then be changed out, and a full Cylinder placed in the ready without interruption of breathing air. Prior to attaching the Cylinders, each HP circuit should be inspected for signs of damage.

Diver Intermediate Compensating Manifold Gas Flow

The divers Umbilical Snap Shackle attaches to D ring on the left side of the Harness. The Umbilical female QD connects to a male QD plug that is attached to a short (10 ) interface Whip that is threaded into the Compensating Manifold One Way Valve. The One Way Valve allows the umbilical gas to supply the Manifold Regulator and Accumulator. The Manifold Regulator reduces the Umbilical supply to a normal supply pressure between 150-165 PSIG over ambient. Air then travels up a 5/16 intermediate Whip to the Helmet or Mask being used. The Manifold is also equipped with a multi-turnEGS Valve for interface with the emergency air system.

Emergency Gas System

The Emergency Gas System is attached to the modified Miller Bell Harness. The Emergency Gas System is made up of a good quality first stage SCUBA Regulator and high-pressure Cylinder. Cylinder capacity must be selected based on the depth and potential hazards that may be encountered. It is strongly recommended that the cylinder capacity be sufficient to allow a normal ascent to the surface or to a place of safety where breathing gas can be restored. The Regulator used with the Cylinder should be equipped with a KMDSI Relief/Bleed Valve. The Bleed Valve allows excess pressure to vent from the EGS supply Whip in the event the first stage develops a minor leak. Without the Bleed Valve a minor first stage leak could cause the pressure within the EGS to rise above the maximum safe working pressure (250 PSIG) causing the Whip to rupture resulting in loss of the EGS system.