DeepSea Power & Light SeaArc 2 400w HMI User manual

SeaArc®2 400w HMI
Operation Manual
Rev. 01/15/2010
DEEPSEA POWER & LIGHT
4033 Ruffin Rd., San Diego, CA 92123-
PHONE: [phone] FAX: [phone]
WEB: www.deepsea.com

Table of Contents
Limited Warranty 3
Specifications
Ballasts 4
Lighthead 5
Installation and Operation 6
Lamp replacement 7
General Information 7
Lamp life and indications for replacement 7
Relamping procedure 8
Opening the lighthead 8
Closing the lighthead 11
Dome, Cowl and Reflector removal and installation 14
Ballast Drawings
Single/Dual Ballast Outline 17
Twin Ballast Outline 18
Twin Ballast Assembly 19
Assembly Endcap 21
Lighthead Outline 22
Final Assembly Lighthead 23
Igniter Assembly 24
Appendix
Ballast Dimmer/Enable Option 25

3
Limited Warranty:
DeepSea Power & Light warrants that the goods (except internal electronic components) sold
under this contract will be free from defect in material and workmanship for a period of one year
from the date of shipment from the factory, if they have been properly used. Internal electronic
components are warranted for 90 days from the date of shipment from the factory, if they have
been properly used.
This warranty will be limited to the repair or replacement of parts and the necessary labor and
services required to repair the goods. IT IS EXPRESSLY AGREED THAT THIS WARRANTY
WILL BE IN LIEU OF ALL WARRANTIES OF FITNESS AND IN LIEU OF THE
WARRANTY OF MERCHANTABILITY. This warranty is the exclusive and only warranty to
pass with the goods under this contract. No agent, employee, or representative of the Seller has
any authority to bind Seller to any information, representation, or warranty concerning the goods
sold under this contract, and unless an affirmation, representation, or warranty made by an agent,
employee, or representative is specifically included within this contract, it will not be
enforceable by Buyer.
If notice of defect is given to DeepSea Power & Light, Inc. within such 90 day or one year
warranty period, the sole obligation of DeepSea Power & Light, Inc. shall be to furnish new or
repaired parts free of charge in exchange for parts which have been proved defective and does
not include any other costs such as the cost of removal of the defective part, installation, labor, or
consequential damages of any kind, the exclusive remedy being to require DeepSea Power &
Light, Inc. to furnish such new parts. Under no circumstances shall the Buyer be entitled to
recover any incidental damages as that term is defined in Commercial Code §2715
This Warranty does not apply to the MSR400HR lamp - On average these lamps will
function properly for 650 hours but may not and as actual hours of operation are
impossible to verify our policy is that we will not replace lamps under warranty.

4
Specifications:
Ballasts:
MECHANICAL: See drawings on pages 17 and 18
Single ballast Dual ballast
Case material Titanium 6AL-4V Titanium 6AL-4V
Length 12.7 in (32.3 cm) 21.8 in (55.4 cm)
Diameter 5.8 in (14.7 cm) 5.8 in (14.7 cm)
Air weight 21.06 lb (9.56 Kg) 34.25 lb (15.54 kg)
Water weight 11.76 lb (5.34 Kg) 20.45 lb (9.28 kg)
ENVIRONMENTAL:
Depth rating: 19,680 ft (6000 m)
Design safety factor: 1.5 X depth rating
Temperature: -5 to +40 deg C
ELECTRICAL:
Connector:
Ballast input, Ballast input, Ballast output
no dimmer with dimmer
LPBH2MP LPBH5MP LPBH3FS
Pin 1: Power Pin 1: Power Socket 1: Power
Pin 2: Power Return Pin 2: Power Return Socket 2: Power Return
Pin 3: Ground to Shell Socket 3: Ground to Shell
Pin 4: Dimmer (+)
Pin 5: Dimmer (-)
Input voltage: 105v to 265v AC or DC
Input current/steady state current: 5 amps max at 105v DC
6 amps max at 120v AC
Inrush current: 30 amps DC, 35 amps AC
Output power: 400 watts
Output wave shape: Square Wave
Output frequency: 300 HZ +\- 10%

5
Lighthead:
MECHANICAL: See drawing on page 22
Lighthead body: Titanium 6AL-4V
Dome retaining cowl: Delrin
Dome: Borosilicate glass
Length: 10.8 in (31.5 cm)
Diameter: 5.3 in (16.5 cm)
Air weight: 8.5 lb (3.86 kg)
Water weight: 3.15 lb (1.43 kg)
ENVIRONMENTAL:
Depth rating: 19,680 ft (6000 m)
Design safety factor: 1.5 X depth rating
Temperature: -5 to +40 deg C
ELECTRICAL:
Connector:
LPBH3MP
Pin 1: Power
Pin 2: Power Return
Pin 3: Ground to Shell
Input voltage: From Ballast (400 W, 300 Hz Sq.Wave)
Input power: 400 watts
Average lamp life: 650 Hours
Recommend lamp replacement interval: 650 Hours
Note: Average lamp life is related to a burning cycle of 3.5 hours on and 0.5 hours off duty
cycle. Because the risk of arc tube rupture increases as the lamps age, it is advised not to use the
lamp longer than the recommended replacement time. Lamps tend to exhibit difficulty during hot
re-strike as they approach the end of their service life.

6
Installation and Operation
Assembly:
1. Remove the protective connector cover on the ballast end-cap.
2. Plug the lighthead to ballast interconnect cable into the lighthead.
3. Plug the other end of the interconnect cable into the ballast output connector.
4. Plug the ballast power cable into the ballast input connector.
5. Reinstall the protective connector cover on the ballast end-cap.
6. Connect the ballast power cable to the power source through a proper on/off switch and
circuit protector (fuse/circuit breaker).
7. The light is now ready to test.
NOTE - DC INPUT: The input is not polarity sensitive (either pin can be plus and the other
minus). The input is less than 5 amps when running but the surge current at turn on can be as
high as 30 amps.
NOTE - AC INPUT: The input is less than 6 amps when running but the surge current at turn on
can be as high as 35 amps.
Warning: Whenever AC power is used in the vicinity of water, we strongly recommend that a
Ground Fault Interrupt (GFI) or other protective device is utilized to minimize the chance of
electric shock due to a short circuit.
Operation:
Apply power to the ballast to turn on the light. At turn on there is a delay of approximately 3
seconds before the lamp will strike. After the lamp strikes it goes through a warm up stage that
takes 60 to 90 seconds to complete.
Warning: The lighthead must be submerged in water when running or it will overheat and
cause damage to the seals and dome. The ballast can be run dry (in air) for up to 15 minutes
without causing damage.
Warning: HMI lights emit a significant amount of UV radiation that can cause sunburn and
damage to the eyes. The borosilicate glass dome filters out some of the harmful UV when the
lamp is installed in the lighthead. Do not run the lamp with the dome removed.
To turn off the light, remove power to the ballast.
To restart the light wait 10 seconds and then re-apply power to the ballast. There will be a delay
of approximately 3-5 seconds before the lamp will restrike. The lamp does not require the full
warm up cycle as it is still warm but it could be as much as 30 seconds until the lamp is at full
color temperature and light output.
HMI lamps start best when cold. If a lamp fails to restrike, allow several minutes for the lamp to
cool and then attempt to strike the lamp again. Though immediate restriking of the lamp is
supported, the recommended practice is to allow at least two minutes between restrikes and
longer periods when possible.

7
Lamp Replacement
General Information
It is important when opening the lighthead for servicing to take all reasonable steps to ensure that
the work is carried out in a clean dry stable environment. It is useful to have a selection of clean
plastic bags readily at hand for storage of parts.
Tools required to service the lighthead:
3/16" spanner wrench Latex gloves
1/4" spanner wrench Eye protection
3/8" spanner wrench Reagent grade alcohol
1/4" Medium slotted screw driver Paper towels
Lamp Life and Indications for Replacement
The manufacturer's rated lamp life is 650 hours. This is based on manufacturer tests using a work
cycle of 3.5 hours on and 0.5 hours off. The manufacturer also states that replacement is
recommended after 650 hours due to an increased risk of the bulb shattering.
As the HMI lamp ages, starting will become more difficult and "dropping out" may occur. Lamp
"drop out" is when the lamp only gets part way through its warm up cycle and unexpectedly goes
out. Light output will slowly decrease over the lamps lifetime and a shift in color temperature
may occur. Older lamps will also become more difficult to restrike.
NOTE: It is normal for the inside of the arc tube (the smaller inner glass bulb) to appear
stained. Different lamps may appear quite different in color and degree of staining.
The lamp should be replaced if:
1. Physical damage is apparent such as:
Cracking, blistering or whitening of the outer bulb.
Cracks in the inner bulb.
Damage to the lamp base pins.
Damage to the ceramic compound at the lamp's base.
2. Air has leaked into the outer quartz envelope. This will cause a yellow film on the inside
of the outer envelop, a result of oxidation of Molybdenum at high temperature in the
presence of oxygen.
3. The lamp fails to ignite and the ballast is known to function properly. Test the ballast
with another lighthead to verify that the ballast is working. Replace the lamp and test the
lighthead with the ballast. If the lamp ignites properly then lamp was bad. If lamp does
not ignite contact DeepSea for instructions.
4. The lamp ignites but drops out before achieving full output.
5. The lamp is difficult to ignite or restrike.

8
RELAMPING PROCEDURE
Opening the Lighthead
1. Disconnect the ballast power and ballast to lighthead interconnect cables.
2. Remove the lighthead from the vehicle and take to a clean, dry work area.
3. Place a protective dummy plug on the connector.
4. Using a 1/4" pin diameter spanner wrench, place the spanner pin in one of the 1/4" holes
in the lighthead body (where the lighthead head and lighthead body join). Place a 3/16"
pin diameter spanner wrench in one of the 3/16" holes in the lighthead head. See figure 1.
Figure 1
5. Leveraging the spanner handles, unscrew, counter clockwise, the lighthead head from the
body. The threads are standard right-hand threads. DO NOT DISTURB THE DOME
RETAINING COWL. Take care to ensue that the spanner wenches are well seated in
their respective holes. Wrench slippage will result in damage to the Tiodized finish. If
necessary, use a soft mallet to tap the spanner wrenches in order to free the parts.
6. After loosening the lighthead body and head, the pieces may be easily unscrewed by
hand. It takes approximately 3 1/2 rotations to fully separate the pieces.
7. Carefully remove the lighthead body and attached lamp from the lighthead head. The
lamp fits very close to the reflector and care must be taken to not damage the lamp or
reflector during disassembly. We recommend that the lighthead head be placed dome
down on the work table and that the lighthead body be pulled straight up from the head.
See figure 2.

9
Figure 2
8. Place the lighthead head in a clean zip lock bag and set aside.
Remove the lamp
Warning: When handling the HMI lamp, wrap the lamp in several layers of clean dry paper
towel to protect against injury in the event that the lamp shatters or breaks.
The lamp fits tightly in the socket and there is some risk of breakage during removal. The lamp
is a bi-pin type base and does NOT unscrew or rotate, it pulls straight out from the socket. Wrap
the lamp in a clean, dry paper towel and then grasp the lamp as close to the base as possible.
Gently pull straight up from the socket. See figure 3. If necessary, use a very slight side to side
rocking motion to facilitate removal. The rocking motion should be in the plane of the base.
The base pins, lamp pinch and arc tube pinch seal will lie in this same plane. Dispose of the
lamp properly. The lamp contains a small amount of mercury and Krypton-85.
Figure 3

10
Lamp handling Notes
HMI lamps must be absolutely clean prior to use. Fingerprints or other contaminants on the
quartz envelop will damage the lamp when it becomes hot. Substances such as sodium and
potassium diffuse into the hot quartz and cause divitrification of the glass. In turn, the glass may
become opaque and brittle and may blister or crack.
Hydrocarbon contaminants will leave black carbon deposits causing a hot spot resulting in loss
of light output and overheating. Once the lamp is operated with contaminants on the glass, the
lamp is permanently damaged. DO NOT touch the lamp envelope during handling. Prior to use,
thoroughly clean the glass envelope with reagent grade alcohol, another high purity organic
solvent, or the cleaning device supplied with the replacement lamp. See figure 4.
Figure 4
Installing the lamp
1. Install new O-rings before installing the new lamp, this reduces the likelihood of
contaminating the lamp's outer glass envelope (bulb) with O-ring grease.
2. Remove the lamp from its box. See figure 5.
Figure 5

11
3. Visually inspect the lamp inside the sealed plastic bag before opening. Do not break the
seal on the plastic bag if the lamp is broken or damaged.
4. Wrap the bulb with a clean, dry paper towel. Holding the lamp by the paper towel
carefully seat the lamp so that it bottoms out in the socket. See figure 6.
Figure 6
5. Clean the lamp with the special towel provided by the lamp manufacturer inside the
lamp box or with a clean paper towel well moistened with reagent grade alcohol.
Closing the Lighthead
1. Verify that the O-rings have been installed. See figure 7.
Figure 7
2. Place the head assembly, dome side down, on the work surface, this orientation helps
prevent the 2-039 O-ring from falling out of its groove during reassembly and reduces the
risk of lamp breakage. See figure 8.

12
Figure 8
2. Carefully align the lighthead body such that the lamp passes cleanly through the
hole in the parabolic reflector in the head assembly. See figure 9.
Figure 9
4. If possible, dry nitrogen purge the inside of the lighthead for one minute before engaging
the threads of the two assemblies. Ensure that the nitrogen nozzle does not introduce any
contamination onto the O-rings and sealing surfaces or cause the 2-039 face seal O-ring
to pop out of its groove in the head section. A low nozzle pressure is recommended. See
figure 10.

13
Figure 10
5. Screw the pieces together. Verify that the bore seal Teflon back up ring is on the low
pressure side (towards threads) of the 2-142 O-ring and that it stays in its groove and does
not catch as it enters the bore during assembly.
6. Ensure that the 2-039 O-ring is in place and does not get pinched as the head section
bottoms against the body section.
7. It is VERY important that the body and head sections bottom metal-to-metal against
each other. The rotation of one part against the other will end abruptly when these parts
meet. Torque to approximately 20 ft lbs. If the body and head sections are not fully
seated, the threads may jam at high pressure resulting in damage to the lighthead.
Lightheads damaged in this way may become difficult or impossible to open.
8. Reinstall lighthead on vehicle.
9. Reconnect ballast power and interconnect cables.

14
Dome, Cowl and Reflector removal and installation:
1. Remove cowl from lighthead body.
2. Remove snap ring from cowl.
3. Remove Monel mesh from around reflector.

15
4. Remove old reflector then install new reflector.
5. Ensure everything is absolutely clean and dry inside the cowl, dome and reflector. Reagent
grade alcohol may be use for cleaning. Any residue left inside the lighthead will result in
smoke which will coat the internal components and cause the lighthead to overheat.
6. Insert Monel Mesh around reflector -- make sure reflector sits evenly in dome.
7. Install snap ring.

16
8. Tighten cowl onto lighthead body.

17
Ballast Drawings:
Please Note: These drawings are for standard products and connectors.

18

19
DUAL BALLAST ASSEMBLY
PLEASE NOTE:
THESE DRAWINGS ARE FOR STANDARD CONNECTORS AND PINOUTS

20
DUAL BALLAST ASSEMBLY
PLEASE NOTE:
THESE DRAWINGS ARE FOR STANDARD CONNECTORS AND PINOUTS