Master-Lee HELIOS-75K User manual

Master-Lee Engineered Products, Inc.
5631 Route 981 Latrobe, PA 15650 Phone: [phone] Fax: [phone]
www.MasterLee.com
MASTER-LEE ENGINEERED
PRODUCTS,INC.
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HE
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-7 75 5K K
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Document Number: EDS-18-110
Revision: 3
Issued On: 11/23/2021

Master-Lee Engineered Products, Inc.
5631 Route 981 Latrobe, PA 15650 Phone: [phone] Fax: [phone]
www.MasterLee.com
MASTER-LEE ENGINEERED PRODUCTS,INC.
HELIOS 75K FLOODLIGHT SYSTEM
U
US
SE ER R M
MA
AN NU UA AL L
Document Number: EDS-18-110
Part Number: D3183
Revision: 3
Issued On: 11/23/2021

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Helios-75K Floodlight System – User Manual
Table of Contents
1. Safety.............................................................................. 2
2. Electrical Requirements.................................................. 4
3. Inspection ....................................................................... 4
4. Operation Instructions .................................................... 5
5. Lens & O-Ring Replacement.......................................... 6
6. Parts List......................................................................... 7
7. Technical Specifications................................................. 8

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Helios 75K Floodlight System – User Manual
1. SAFETY
”READ AND
UNDERSTAND
ALL
INSTRUCTIONS” – Failure to follow the
SAFETY RULES listed below and other
safety precautions, may result in serious
personal injury.
Work Area Safety
•Do not operate light in explosive
atmospheres, such as in the
presence of flammable liquids,
gases or dust. Excessive heat from
electrical sources may ignite dust or
fumes.
•Do not store or operate around
rotating/moving equipment. The
electrical cord may become
entangled in rotating equipment or
severed by moving parts which may
cause electrical shock to nearby
personnel.
•Do not handle the light while it’s
operating in open-air. Excessive
heat generated in open-air operation
may put personnel at risk of burns if
handled.
Electrical Safety
•Before plugging in the light, be
certain the outlet voltage supplied
is compatible with the voltage
identified on the name plate.
Incompatible outlet voltage may
result in serious hazards and/or
damage to the equipment.
•Do not expose the Power Console
to wet environments. Water
entering the Power Console will
increase the risk of electric shock.
•Never use the cord of the Power
Console to carry or support the
light. Keep cord away from heat,
oil, sharp edges or moving parts.
Damaged cords increase the risk of
electric shock.
Personal Safety
•Do not look directly at the source
of light while it is energized.
Temporary or permanent vision
impairment may occur as a result.
•Be sure the dimmer knob is turned
to the full “CCW” position before
plugging into an electrical outlet or
connecting the light cord. Personal
injury, such as vision impairment,
may occur if the light is energized in
full power in proximity to personnel.
•Check that all cord connections
are tight and secure. Loose or
partial electrical connections may
increase the risk of electric shock
and/or damage to the components.
•Do not store anything on top of the
Power Console or light panel.
Placing items on top of the Power
Console or light panel obstructs the
view of warning and operating
information and may cause damage
to the component.
SAVE THESE INSTRUCTIONS!

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Helios 75K Floodlight System – User Manual
”READ ALL INSTRUCTIONS” – Failure to follow the SAFETY
RULES listed below and other safety precautions, may result in
serious personal injury.
Operation and Care
•Ensure the cover of the light panel
is tightly fastened.If loose, water
may enter the enclosure and cause
damage to the lighting components.
These are factory torqued to 60 in-
lb.
•Ensure all cord connectors are free
of moisture and are clean before
making connections. Dirt or
moisture may cause the light to
malfunction and/or may decrease the
life expectancy of the components.
•Handle, package, and use all
components with care. The lens of
the light panel is made of an impact-
resistant plastic but can fracture if
struck with excessive force causing a
hazard and/or Foreign Material risk.
•Do not position the light panel in
close proximity to moving,
mechanical equipment.Temporary
and/or permanent damage to the
components may occur if struck,
reducing performance of the light or
rendering it inoperable.
Service
Disconnect plug
from Power
Console before
performing any assembly, adjustment or
repair to avoid possible injury.
•Service and/or repair must be
performed only by Master-Lee
personnel with the exception of
lens replacement. Service or
maintenance performed by
unqualified personnel may result in
incorrect reassembly which could
cause serious hazard.
•Do not remove the cover of the
Power Console. Removal of the
cover increases the risk of damage to
internal components and electrical
shock to personnel.
•Lens and O-Ring shall be replaced
with the manufacturer specified
parts as outlined in this document.
Failure to use the specified parts may
lead to product failure.
•Decontamination or cleaning of the
lighting assembly shall be
performed with care. Hand-
washing with wet rags or a mild
cleaning solution may be performed
on the lighting assembly and cord.
Use of pressure applied water may
damage the components.
SAVE THESE INSTRUCTIONS!

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Helios 75K Floodlight System – User Manual
2. ELECTRICAL REQUIREMENTS
•Connect the Power Console plug (included) to a 120-Volt branch circuit with a minimum
breaker rating of 15-Amps.
•The Helios-75K is provided with a cord having a 3-prong, grounded plug, w/ locking
system. Only plug the cord into outlets also having a 3-prong outlet of the same size.
•Replace damaged cords immediately. Use of damaged cords can shock, burn or
electrocute.
•If an extension cord is necessary, a cord with adequate size conductors should be used to
prevent excessive voltage drop, loss of power or overheating. The table below shows the
correct size to use depending on cord length.
Recommended Size of Extension Cord
Cord
Length
(ft)
Cord Size in A.W.G
25
18
50
16
100
12
3. INSPECTION
•Inspect light panel and lens for water infiltration and/or damage. Failure to replace
the lens, if visibly damaged or discolored, may result in breakage, poor performance, or
water leaks. The lens should be completely transparent. Discoloration of the lens may
indicate embrittlement due to excessive radiation exposure.
•Inspect all bracket and lens cover fasteners for signs of degradation, damage, or
wear. Failure to replace damaged fasteners may result in electrical and/or mechanical
failure.
•IF used in the reactor core or within close proximity of irradiated fuel assemblies,
THEN perform a visual inspection after approximately 7-10 days of exposure to the
radiation. Failure to inspect and replace the lens, as necessary, may increase the risk of
breakage and reduce the emission of light.
•Inspect cable strain relief and carabiners for signs of degradation, damage, or wear.
Failure to replace damaged support components may result in damage or personnel
injury.
•Inspect electrical cables for cuts, wear, fretting, kinks, or any visible signs of
degradation. Use of damaged electrical cables may increase the risk of electrical shock.
•Inspect electrical fittings for wear, damaged threads, or bent pins. Use of damaged
electrical fittings may increase the risk of electrical shock.
•Inspect components for cleanliness. Dirt, oil, or chemicals may impair performance
and longevity of the components.

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Helios 75K Floodlight System – User Manual
4. OPERATION INSTRUCTIONS
Injury to personnel may occur from looking directly at the energized
light source or from physically touching the light body, which may be
hot.
4.1. Instructions for connecting the Light Panel Cable
4.1.1. Verify cleanliness of the connectors.
4.1.2. Connect the Light Panel Cable to the Power Console, ensuring the keyways are
aligned correctly.
4.1.3. Lightly hand-tighten the connector.
4.1.4. For downward lighting, connect the Carabiners to
the clips on the Light Panel nearest to the cable
connector, when installed.
4.1.5. For horizontal lighting, remove the two (2) 5/16”
bolts, Nordlock washers, and clips and reinstall in
the two holes nearest to the outer diameter of the
light panel and connect the Carabiners.
4.1.6. Ensure slack exists in the cable when the Light
Panel is free-hanging, as shown. This is done by
sliding the cable strain relief upwards or
downwards on the cable.
Injury to personnel may occur IF the energized panel is touched while
operating. Allow a minimum of 15 minutes for the light panel to cool
down prior to handling.
4.2. Instructions for turning ON the light panel
4.2.1. Verify the Dimmer Control knob is fully turned to the “CCW” position.
4.2.2. Verify the light panel is properly and safely positioned (i.e. away from personnel,
combustible materials, etc.) and installed on the Guide Stud Mount.
4.2.3. Plug the power cord into a properly rated electrical outlet.
4.2.4. Depress the Power “I/O” rocker switch to turn on the light.
4.2.5. Slowly turn the Dimmer Control knob “CW” to the desired light level.
IMPORTANT INFORMATION:
The Helios-75K light panel is equipped with an automatic thermal regulation control
circuit which protects the components from overheating and damage. Water is the ideal
coolant to permit the light panel to operate continuously at 100% power. When
operated in open air, the Helios-75K will slowly reduce output power to maintain safe
operating temperatures. After extended use in open-air the output level will be at
approximately 35% power.

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Helios 75K Floodlight System – User Manual
4.3. Instructions for installing/removing the Light Panel into/from the reactor vessel
4.3.1. Ensure all electrical connections are tight, the
Carabiners are securely attached, slack exists
in the cable between the Light Panel and strain
relief, and the light functions normally.
4.3.2. Perform a final visual FME inspection of all
components entering the water.
4.3.3. Slowly lower the Light Panel into the water
using the Light Panel Cable.
4.3.4. Position the Light Panel near the inside
diameter of the reactor vessel and continue
lowering to the desired level. Master-Lee
recommends a distance of 2-10’ below the flange for optimal lighting
coverage.
4.3.5. IF the Light Panel interferes with movement of fuel assemblies, THEN carefully
reposition the Light Panel until the fuel assemblies have been moved.
4.3.6. When activities are completed, slowly raise the Light Panel from the reactor vessel
using the Light Panel Cable.
4.4. Instructions for turning OFF the light panel
4.4.1. Depress the Power “I/O” rocker switch to turn off the light.
4.4.2. Verify the panel is not emitting light.
4.4.3. Unplug the power cord from the electrical outlet.
4.4.4. Allow a minimum of 15 minutes for the light panel to cool down prior to handling.
5. LENS &O-RING REPLACEMENT
Power cord must be disconnected from an electrical source prior to
performing service. Failure to remove electrical potential to the light
panel will increase the risk of electric shock.
5.1. Remove the twelve (12) ¼”-20 socket head cap screws and Nordlock washers from the
light panel cover.
5.2. Remove the stainless steel light panel cover.
5.3. Remove the lens and dispose.
5.4. Remove the O-ring and dispose.
5.5. Clean and inspect the O-ring groove for signs of degradation, debris, damage, etc.
5.6. Lightly apply Molykote 111 to the new O-ring.
5.7. Install the new O-ring into the groove ensuring it does not twist or kink.
5.8. Clean and inspect the new lens (verify free of cracks, scratches, discoloration, etc.).
5.9. Install the lens and stainless steel light panel cover, aligning with the mount holes.
5.10.Install the twelve (12) ¼”-20 socket head cap screws and Nordlock washers and torque
to 40 in-lb.

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Helios 75K Floodlight System – User Manual
6. PARTS LIST
Failure to use replacement parts as identified herein or as
recommended by the manufacturer may result in reduced performance
and/or the potential risk of hazard or injury to personnel.
Part No. Description Provided w/ System Quantity
D3183
Helios 75K Drop Floodlight System, includes
the following items:
n/a 1
D3184
Helios-75K Light Panel w/ 100’ cable
Yes
1
D3189
Power Console with:
-Detachable and locking 6’ power cord Yes 1
C3206
Helios-75K Lens Replacement Kit, includes:
-(1) Lens
-(1) O-Ring
-(1) Molykote 111 (pack)
Yes 1

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Helios 75K Floodlight System – User Manual
7. TECHNICAL SPECIFICATIONS
Physical –Panel Light
Part Number
D3183
Length
12 in
Height
12 in
Width
3 in
Weight
13 lb
Cable
100’ Length; Rubber jacket
Material
MIL-A-8625-Type III, Hard coat anodized
aluminum; Stainless steel protective lens cover
Lens Material
Polycarbonate
Lighting/Electrical
Operating Voltage
90~305 VAC, 50~60Hz
Current @ 100% Power
Up to 5.0 Amps AC
Size/Weight (Power Console)
13” x 11” x 3”; 12 lbs.
Light Output
Up to 78,000 Lumens
Light Color Temperature
5000K (white light)
LED Life
50,000 hours (>70% lumen output)
Radiation tolerance
Approved for extended use in Reactor Core & near fuel assemblies
Waterproof depth rating
100-ft
Dimming
100-10% manual; 100-30% auto (temperature based)
Light Panel positions
Vertical hanging (custom brackets available)
Operating temperature (8F)
165 (max. in-air); ~135 (in water)
Power Factor %
98
LED Efficacy (@ 85C)
152 lumens/watt
LED Flux (@85C)
70,900 lumens
FME Equipped
Yes
Protection
Thermal Overload; Short Circuit; Over Voltage; Fuse
Warranty
2-Year; Limited; Parts replacement