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Ros SEASTAR Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL
Remote Ocean Systems claims proprietary rights to the information disclosed herein. This
document is furnished in confidence on the express understanding that neither it nor any
reproduction thereof will be disclosed to others or used for the purpose of manufacture
or procurement. Approved for internal release only. Distribution is limited.
© 2021 Remote Ocean System
10-01313 REV D

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  • Page 1 OPERATION AND MAINTENANCE MANUAL Remote Ocean Systems claims proprietary rights to the information disclosed herein. This document is furnished in confidence on the express understanding that neither it nor any reproduction thereof will be disclosed to others or used for the purpose of manufacture or procurement.

  • Page 2: Table Of Contents

    5. Maintenance ............................19 5.1. Scheduled Maintenance ..........................19 5.2. Unscheduled Maintenance .......................... 19 5.2.1. Open the Seastar ........................... 19 5.2.2. Close the Seastar ........................... 20 5.2.3. Remove the Reflector and LED Array ....................21 5.2.4. Replace the Window, Reflector and LED Array ..................22 5.2.5.
  • Page 3 Figure 10. DC Inrush Current ........................... 17 Figure 11. Driver Circuit Card Connections ......................20 Figure 12. Closing the Seastar ..........................21 Figure 13. Window, Reflector and LED Array Replacement ..................22 Figure 14. Top Layer 120VAC Driver Board ......................24 Figure 15.

  • Page 4: Warranty

    The laws of the State of California shall govern this warranty. In the event the defect is determined to be within the terms of this warranty then ROS agrees to repair and/or replace (at ROS' discretion) the product or defective portion at no charge to the Purchaser. This warranty does not apply to expendable items or to normal wear-and-tear, and is conditional upon performance of normal preventative maintenance procedures.

  • Page 5: Customer Assistance

    SEASTAR OPERATION AND MAINTENANCE MANUAL Customer Assistance ROS, Inc. uses a worldwide network of stocking distributors and representatives who are familiar with our products and are able to provide assistance during installation and/or operation of these products. If you have any questions or problems with this product that are not covered by this manual or instruction, please contact our agent in your area, or contact us directly by phone or FAX or e-mail.

  • Page 6: Change Record

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Change Record DESCRIPTION DATE SEE EC-03199 08JUN20 SEE EC-03210 18JUN20 SEE EC-03228 20AUG20 SEE EC-03358 03MAY21 10-01313 REV D...

  • Page 7: Introduction

    SEASTAR OPERATION AND MAINTENANCE MANUAL 1. Introduction The Seastar (Figure 1) is a high-powered, light-weight, compact light for deep-ocean use. Options include flood or spot reflectors, and 120 VAC or 24 VDC power. AC powered lights provide full-range, flicker-free phase cut dimming.

  • Page 8: Product Specifications

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL 2. Product Specifications Table 1 shows the mechanical specifications for the Seastar. Table 2 shows the electrical specifications. Figure 2 shows the spot and flood beam patterns. Table 1. Mechanical Specifications Spot...

  • Page 9: Figure 2. Beam Patterns

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Figure 2. Beam Patterns 10-01313 REV D...

  • Page 10: Installation

    3.1. Mounting Figure 3 shows the outline of the Seastar. If an ROS provided mounting kit is not used, the Seastar may be mounted by clamping the body of the light or using the three, 10-32 holes in the end bell. It is not recommended ROTECTION ABOVE 4 0 °C...

  • Page 11: Operation

    0VDC. To change the light output intensity adjust the voltage supply between between 0-10VDC, with 10VDC setting the light output to 100% intensity. 4.3.1. AC Triac Dimming Figure 5 shows the Seastar light output when used with a triac dimmer. The test was performed using a Lutron DVCL-153P-WH dimmer. 10-01313 REV D...

  • Page 12: Ac Crydom Dimming

    Figure 5. AC Lux Output with Triac Dimming 4.3.2. AC Crydom Dimming Figure 6 shows the Seastar light output when used with a Crydom dimmer. The test was performed using a 10PCV2415 Crydom dimmer. Figure 6. AC Lux Output with Crydom Dimming...

  • Page 13: Ac Inrush Current

    This version is a 24VDC standard power light controlled by 0-10VDC voltage supply, with max power of 130W. 4.4.1. 24VDC With Analog Dimming Figure 8 shows the Seastar dimming properties when used with a 0-5V or 0-10V analog dimmer. 10-01313 REV D...

  • Page 14: Serial Dimming Operation

    ROS Eos GUI, or by sending serial commands from a customer device or software. Table 3 lists ROS VISCA serial parameters. Table 4 lists commands and inquiries that may be sent to the Seastar, along with their expected responses. Table 5 lists standard response messages.

  • Page 15: Figure 9. Lux Output Vs Serial Dimming Percent

    = address 1 - 7 Returns 88 30 0y y = x + 1 When setting the address of an ROS VISCA device, any connected devices will respond, causing collisions. Consequently, only one device can be connected to a bus when setting the address.
  • Page 16 REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Table 4. Serial Commands and Inquiries Command Packet Note Set Intensity 8x 01 10 01 yy ff x = address yy = Intensity (0x00 – 0x64 hex, 0 - 100 decimal) Returns Command Completed if successful...

  • Page 17: Dc Inrush Current

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Table 5. Serial Response Messages Response Packet Note Command Completed z0 5y ff z = address + 8 y = socket (default 1) Returned when the command has been executed Syntax Error...

  • Page 18: Temperature Protection

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL 4.5. Temperature Protection 4.5.1. 120VAC The AC light will reduce the current output of the driver up to half the total value if an overheating condition is detected by the driver. The light will have to be power cycled to return to normal operation.

  • Page 19: Maintenance

    Pre- and post-operation checks are listed in Section 4. No other scheduled maintenance is recommended. 5.2. Unscheduled Maintenance 5.2.1. Open the Seastar Opening the Seastar entails removing the end bell, bezel, and window. In order to open the Seastar, e.g., to troubleshoot or inspect internal components, proceed as follows. Refer to Figure 11. WARNING Disconnect the Seastar from power prior to servicing or troubleshooting internal components.

  • Page 20: Close The Seastar

    SEASTAR OPERATION AND MAINTENANCE MANUAL Figure 11. Driver Circuit Card Connections 5.2.2. Close the Seastar In order to close the Seastar after it has been opened, proceed as follows. CAUTION The acrylic window and o-rings should not normally be reused once the Seastar has been disassembled as this may lead to leaks in service.

  • Page 21: Remove The Reflector And Led Array

    5.2.3. Remove the Reflector and LED Array In order to remove the reflector and gain access to the LED array, proceed as follows. Refer to Figure 13. WARNING Disconnect the Seastar from power prior to servicing or troubleshooting internal components. 1. Open the Seastar (5.2.1).

  • Page 22: Replace The Window, Reflector And Led Array

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL 2. Remove and discard the window. 3. Remove and discard the window o-ring. 4. Remove and save the reflector screws. 5. Remove and save the reflector. 6. Remove and save the thick yellow plastic cushion and the thin, translucent plastic insulator.

  • Page 23: Replace The Connector

    5. Place the thin, translucent insulator over the cushion and align the holes. NOTE If the reflector is severely misaligned to the LEDs, Seastar light output may be reduced as much as 10%. 6. Place the reflector over the insulator. Align the cutouts to the LEDS, and install the two reflector screws.

  • Page 24: Remove And Replace The Driver Circuit Card

    5.2.6. Remove and Replace the Driver Circuit Card To replace the driver circuit card, proceed as follows. Refer to Figure 17. WARNING Disconnect the Seastar from power prior to servicing or troubleshooting internal components. 1. Remove the end bell and disconnect the wiring (5.2.1).

  • Page 25: Figure 15. U4 On Top Layer 24Vdc Driver Board

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Figure 15. U4 on Top Layer 24VDC Driver Board Figure 16. Q1 on Bottom Layer 24VDC Driver Board 5. Insert and tighten the two mounting screws shown in Figure 17. 6. Close the Seastar (5.2.2).

  • Page 26: Figure 17. Ac Driver Circuit Card Replacement

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Figure 17. AC Driver Circuit Card Replacement 10-01313 REV D...

  • Page 27: Troubleshooting

    6.1. Leaking The Seastar has three seals, one under the window, one at the end bell, and one under the connector. These seals are unlikely to leak when assembled correctly, and are not sensitive to minor assembly deviations. If a leak is discovered during the warranty period, contact Remote Ocean Systems for warranty support.

  • Page 28: Light Output Suddenly Stopped

    Replacing a shorted component may not address the root cause of failure, leading rapidly to a second failure. If the root cause of a short cannot be confidently identified and resolved, contact ROS support prior to replacing any components or rebuilding the light.
  • Page 29 Disconnect the Seastar from power prior to servicing or troubleshooting internal components. Seastar contains high voltages and currents, and should be serviced only by trained technicians. 9. If the problem has not been identified and resolved, open the light (5.2.1).

  • Page 30: Serial Light Does Not Respond To Commands

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Figure 19. Driver Input and Output Power Pins 6.5. Serial Light Does Not Respond to Commands If the light does not respond to serial commands, consider the following guidance. 1. If the light does not operate or draw current, consider the guidance in Section 6.4.

  • Page 31: Parts List

    7. Parts List Table 7 lists the parts in the Seastar. Figure 20 shows the front explode view. Figure 21 shows the back explode view. The main connector assembly is not listed, since it depends on the specific customer configuration.

  • Page 32: Figure 20. Front Explode View

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Figure 20. Front Explode View Figure 21. Back Explode View 10-01313 REV D...

  • Page 33: Table 8. Rebuild Kits

    REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL Table 8. Rebuild Kits PART_ID DESCRIPTION 10-01276-01 PAD THERMAL SEASTAR 60-20037-4 O-RING 2-037 70 SHORE BUNA N 60-20148-4 O-RING 2-148 70 SHORE BUNA N 62-20320-4 TERMINAL RING 22-18AWG #4 INSULATED 62-20156-4 SCREW SHHX 4-40X0.25 IN 316SS 62-00077-4 SCREW FHHX 4-40X0.375 IN 316SS...

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