Ros HPS-1000/Q Operating instructions

ROS
HPS-1000/Q
DROPLIGHT SYSTEM
OPERATING AND MAINTENANCE MANUAL
SERIAL NUMBER: __________
SALES ORDER: __________
5618 Copley Drive
San Diego, CA 92111-7902
TEL: [phone]
FAX: [phone]
www.rosys.com
80-06003B 05APR04

TABLE OF CONTENTS
WARRANTY ..................................................................................................................III
CUSTOMER SERVICE..................................................................................................IV
GENERAL DESCRIPTION.............................................................................................1
DESIGN FEATURES......................................................................................................2
SPECIFICATIONS..........................................................................................................3
HPS-1000/Q DROPLIGHT .......................................................................................................3
HPS-1000 IN-AIR BALLAST POWER SUPPLY......................................................................3
CABLE MANAGEMENT SYSTEM...........................................................................................3
INSTALLATION AND OPERATION...............................................................................4
OPERATIONAL CHECK..........................................................................................................4
INSTALLATION........................................................................................................................4
MAINTENANCE..............................................................................................................5
CAUTION........................................................................................................................6
APPENDIX......................................................................................................................7
80-06003B 05APR04II

WARRANTY
Remote Ocean Systems, Inc. (hereinafter called “ROS”) warrants its products as stated below
subject to the conditions specified.
ROS warrants its products, when operated under normal conditions, to be free from defects in
material or workmanship for a period of one year from the date of purchase provided that
inspection by ROS discloses that such defects developed under normal and proper use. ROS
products repaired or replaced pursuant to this warranty shall be warranted for the unexpired
portion of the warranty applying to the original product. The liability of ROS under this warranty
shall exist subject to the following conditions:
(a) ROS is properly notified of such defects by Purchaser, and the defective product
is returned to ROS, transportation charges paid by Purchaser.
(b) ROS shall be released from all obligations under its warranty in the event repairs
or modifications are made by persons not authorized by ROS.
(c) Representative and warranties made by any person, including distributors and
representatives of ROS, which are inconsistent or in conflict with the terms of this
warranty, shall not be binding upon ROS unless reduced to writing and approved
by an officer of ROS. ROS shall in no event be liable for other direct, special,
incidental, consequential, indirect or penal charges.
(d) This warranty shall be governed by the laws of the State of California.
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’s 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.
Our commitment to quality and customer service directs us to constantly strive to improve our
products. The materials and specifications presented in our manuals and data sheets are
correct and accurate to the best of our knowledge, and are presented in good faith. However,
the information is not guaranteed and is subject to change without notice.
LIMITATION OF REMEDIES
Purchaser assumes all risk and liability for results obtained in any installation, operation, or use
of the product. Purchaser’s sole remedy for any breach of warranty by vendor shall be limited to
the “express remedies” set forth above. Otherwise, in no event shall vendor, its agents, or
employees be liable to the original purchaser or any third party for any consequential or
incidental damages or expenses of any nature arising directly out of or in connection with the
use of vendor products. Even if vendor has been advised of the possibility of such damages or
expenses. In any event, unless otherwise contrary to state law, vendor liability under this limited
warranty shall not exceed the purchase price of the product.
80-06003B 05APR04III

CUSTOMER SERVICE
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, fax, or e-mail.
TEL: [phone]
FAX: [phone]
E-mail: [email protected]
80-06003B 05APR04IV

GENERAL DESCRIPTION
The HPS-1000 Droplight System was designed specifically for use in nuclear reactor
vessels and spent fuel storage pools. The light head uses a high-pressure sodium
discharge light. Because of the very high efficiency, the 1000-watt HPS lamp produces
the equivalent light of seven 1000-watt incandescent lights and will last ten times as
long as an incandescent light used under the same conditions.
In addition to the high efficiency and long lifetime, the construction of the HPS bulb is
extremely rugged with no filaments to break, the actual service lifetime under adverse
handling conditions will far exceed that of standard incandescent droplights.
The HPS-1000 Droplight System includes the droplight, with detachable power cable,
and a regulating ballast power supply. The 1000-watt HPS bulb in the droplight is
permanently bonded to an electropolished stainless steel base. A flexible insulating
compound provides shock mounting, and eliminates the need for bulb sockets, o-rings,
gaskets, or lip seals which could leak and cause premature failure. An outer quartz
envelope surrounds the sodium arc tube. For added protection, an electropolished
stainless steel screen completely encloses the bulb.
The configuration of the droplight allows it to be easily lowered through small openings
(light diameter is 3.5 inches), and recovered without snagging problems. The
detachable power cable is constructed of flexible IEEE-383 rated polyurethane, which
contains no halogens and is easy to wipe down to minimize contamination. The HPS
1000 Droplight is also available with two different reflectors. The standard reflector
directs the light downward. The optional side looking reflector directs the light to the
side and has a weighted base to stand self supported in the flow holes of the lower core
support plate. Either reflector can be quickly and easily installed or removed for use in
confined areas.
The in-air ballast power supply for the droplight is contained in a lightweight aluminum
air-cooled housing, and includes an on-off power switch and a cooling fan. The input
power cord has a smooth IEEE-383 polyurethane jacket for easy decontamination and
long life. The power supply is 12 x 12 x 6 inches and weight is 36 pounds.
In the standard configuration, a handle is supplied for ease of transport. In an optional
configuration, the ballast power supply is mounted on high-density polyethylene along
with a cable management system. In the cable management system, power is passed
through slip rings in the system reel and the droplight cable is wound onto the reel. The
HPS-1000 Droplight can then be connected to the cable connector and lowered without
tangles. In both configurations the HPS-1000 Droplight System is coupled to the light
head by a Kellums grip attached to the cable for secure deployment and retrieval and
also provides strain from the connector interface.
80-06003B 05APR041

DESIGN FEATURES
The primary design features of the HPS-1000 Droplight System are as follows:
1. Exceptionally long life (10 times longer than an incandescent bulb).
2. Very high efficiency (140,000 lumens for 1000 watt light).
3. Direct plug in replacement of existing fixtures.
4. Secure lamp retention with mating cable protecting connector interface.
5. Smooth electropolished stainless steel finish for minimum corrosion, maximum
service life, and easy decontamination.
6. Ballasts designed for maximum life.
7. Stainless steel screen protects HPS bulb and retains fragments if bulb is
accidentally broken.
8. Stainless steel light base permanently bonded to bulb and connector. No
gaskets, lip seals, or sockets to fail.
9. Wet Mateable lamp and ballast connectors.
10.Quick and easy bulb and module replacements.
11.Smooth, rugged radiation tolerant polyurethane cable for easy decontamination
and long life. Easy replacement if damaged.
12.Optional cable management system allows easy handling and operation from low
dose area.
80-06003B 05APR042

SPECIFICATIONS
HPS-1000/Q DROPLIGHT
POWER: 1000 Watts
OPERATION DEPTH: 100 Feet
LAMP TYPE: High Pressure Sodium Discharge
LAMP OUTPUT: 140,000 Lumens (Initial Output)
LAMP LIFETIME: 10 time longer than an incandescent bulb
DIAMETER: 3.5 Inches
LENGTH: 17 Inches including connector
WEIGHT IN AIR: 5.25 Pounds
WEIGHT IN WATER: 0.25 Pounds
HOUSING MATERIAL: Electropolished 304 stainless steel
PROTECTIVE COVER: Electropolished stainless steel screen
CONNECTOR: Underwater mateable BH3MP
REFLECTORS (OPTIONAL) Standard or lower core plate flow hole side looking
HPS-1000 IN-AIR BALLAST POWER SUPPLY
POWER RATING: 1000 Watts
VOLTAGE INPUT: 120 VAC, 60 Hz
OVERALL SIZE: 12 x 12 x 6 inches
WEIGHT: 36 Pounds
ENCLOSURE: Brushed Aluminum
POWER SWITCH: Power Switch Push button (Lighted)
CABLE GLANDS: Weather proof nylon 66
POWER CORD: IEEE-383 rated polyurethane jacketed
LIGHT CABLE: IEEE-383 rated polyurethane jacketed
LAMP CONNECTOR: IL3FS
POWER CONNECTOR: Nylon 66 120VAC straight plug
MOUNTING:
Option #1 High-density polyurethane platform
(When used with cable management system)
CABLE MANAGEMENT SYSTEM
REEL SIZE: 14 x 18 x 20 Inches
PLATFORM SIZE: 36 x 20 x 1 Inches
SLIP RINGS: 3 Conductor
PLATFORM MATERIAL: High density polyurethane
80-06003B 05APR043

INSTALLATION AND OPERATION
The HPS 1000 Droplight System is a sturdy assembly designed to withstand the harsh
demands of underwater operation. However, a few precautions are recommended in
order to prevent damage and assure trouble-free operation during the life of the
equipment.
NOTE: All ROS, Inc. products are thoroughly tested and inspected prior to
shipment. However, damage may occur during transit. After unpacking the
equipment, carefully inspect it for any sign of damage. If damage is detected a
claim should be submitted to the freight carrier, with a copy to ROS, Inc.
After the initial inspection, connect and operate the equipment as instructed in the
following section. If the equipment fails to operate, please contact the Customer
Service Manager at ROS, Inc.
OPERATIONAL CHECK
After unpacking, an operational check should be made prior to use of the HPS-1000.
Plug in 120 VAC power for a brief period of time (less than one minute) to verify the light
will operate.
CAUTION
THE LAMP IS DESIGNED FOR IN WATER USE ONLY. DO NOT BURN IN AIR FOR
MORE THAN 5 MINUTES.
INSTALLATION
The HPS-1000 Droplight can be mounted and operated in any position underwater. For
most fuel pool and reactor vessel applications, it is simply lowered by the
interconnecting cable to the desired position.
In the optional cable management system the ballast power supply and cable reel are
mounted to a high-density polyethylene platform. The HPS-1000 Droplight is simply
reeled in or out to the desired location.
Either configuration allows for use of the standard reflector or lower core plate flow hole
side looking reflector.
80-06003B 05APR044

MAINTENANCE
The HPS-1000 Droplight system was designed to provide a long lifetime of service with
very little maintenance. Maintenance is generally limited to cleaning and replacement of
bulb assemblies.
Ballasts are generally good for 5-7 years. After this period, the capacitor may change
value due to heat and age or the striker may give out. If the striker gives out, the lamp
will not strike. If the capacitor changes value, the ballast will deliver improper power
that will cause the lamp to run hot or run cold. The result is a considerable reduction in
lamp life. Ballasts older than 7 years old should be replaced or rebuilt to ensure
optimum performance.
The design of the bulb assembly compliments this long lifetime. The bulb is potted into
a stainless base with a flexible insulating compound. This eliminates all o-rings, which
could leak, or bulb sockets which could corrode and fail. When the bulb requires
replacement, the entire bulb and stainless steel base are replaced as a unit. The
protective stainless steel screen can be re-used on the replacement lamp assembly.
To replace the lamp assembly:
1. Turn off the HPS-1000 Droplight Ballast and unplug the power cord from the source.
2. Retrieve the HPS-1000 Droplight assembly.
3. Unlock Kellums grip from the lamp assembly.
4. Unscrew the connector locking sleeve and unplug the connector.
5. Unscrew the protective stainless steel screen and remove.
6. Screw new lamp into screen.
7. Plug in the connector and screw on locking sleeve.
8. Hook Kellums grip onto lamp base.
80-06003B 05APR045

CAUTION
LAMP AND STAINLESS STEEL SCREEN MAY BE VERY HOT AFTER
PROLONGED OPERATION. EITHER WAIT FOR SCREEN AND BULB TO COOL OR
USE PROTECTIVE GLOVES TO CHANGE LAMP ASSEMBLY.
USE OF AN INCORRECT POWER SOURCE MAY CAUSE PERMANENT DAMAGE
TO THE BALLAST POWER SUPPLY.
DO NOT PLUG OR UNPLUG INTERCONNECT CABLES WITH THE POWER ON.
THIS CAN SEVERELY DAMAGE THE INTERCONNECT CABLES.
WARNING
DO NOT CONNECT A MULTIMETER TO THE OUTPUT OF THE LAMP
CONNECTOR. THE VOLTAGE IS VERY HIGH (5000-7500 VOLTS) AND WILL
DESTROY ANY VOM. ONLY TRAINED PERSONEL WITH THE CORRECT
EQUIPMENT SHOULD ATTEMPT OUTPUT MEASUREMENTS.
80-06003B 05APR046

80-06003B 05APR047
APPENDIX
Droplight HPS-1000 Drawings
80-02100 HPS-1000/Q Droplight Assembly
80-50114 Cable Management System, DLBA-1000
80-02109 Ballast Assy, In-Air Ballast, 115VAC, 60Hz, HPS-1000
80-02007 Wiring Diagram, In-Air Ballast, 115VAC, 60Hz, HPS-1000