Ros SEASTAR User manual

10-01313 REV D
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

REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL
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Contents
WARRANTY ...................................................................................................................................................4
Customer Assistance......................................................................................................................................5
Change Record...............................................................................................................................................6
1. Introduction...............................................................................................................................................7
2. Product Specifications................................................................................................................................8
3. Installation...............................................................................................................................................10
3.1. Mounting...................................................................................................................................................... 10
3.2. Electrical....................................................................................................................................................... 10
4. Operation ................................................................................................................................................11
4.1. Pre-Operation............................................................................................................................................... 11
4.2. Post Operation ............................................................................................................................................. 11
4.3. AC Operation................................................................................................................................................ 11
4.3.1. AC Triac Dimming .................................................................................................................................. 11
4.3.2. AC Crydom Dimming ............................................................................................................................. 12
4.3.3. AC Inrush Current.................................................................................................................................. 13
4.4. DC Operation................................................................................................................................................ 13
4.4.1. Analog Dimming .................................................................................................................................... 13
4.4.2. Serial Dimming Operation ..................................................................................................................... 14
4.4.3. DC Inrush Current.................................................................................................................................. 17
4.5. Temperature Protection .............................................................................................................................. 18
4.5.1. 120VAC .................................................................................................................................................. 18
4.5.2. 24VDC .................................................................................................................................................... 18
4.6. Electrical Protection..................................................................................................................................... 18
4.6.1. 24VDC .................................................................................................................................................... 18
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. Replace the Connector .......................................................................................................................... 23
5.2.6. Remove and Replace the Driver Circuit Card ........................................................................................ 24
6. Troubleshooting.......................................................................................................................................27
6.1. Leaking ......................................................................................................................................................... 27
6.2. Light Output Gradually Decreased............................................................................................................... 27
6.3. Light Flickers or Intermittently Stops........................................................................................................... 27
6.4. Light Output Suddenly Stopped................................................................................................................... 28
6.5. Serial Light Does Not Respond to Commands.............................................................................................. 30
7. Parts List..................................................................................................................................................31

REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL
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Figures
Figure 1. Seastar.........................................................................................................................................................7
Figure 2. Beam Patterns .............................................................................................................................................9
Figure 3. Installation Outline................................................................................................................................... 10
Figure 4. Sample Wiring .......................................................................................................................................... 10
Figure 5. AC Lux Output with Triac Dimming .......................................................................................................... 12
Figure 6. AC Lux Output with Crydom Dimming...................................................................................................... 12
Figure 7. AC Inrush Current ..................................................................................................................................... 13
Figure 8. Lux Output vs Analog Dimming Percent................................................................................................... 14
Figure 9. Lux Output vs Serial Dimming Percent..................................................................................................... 15
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. U4 on Top Layer 24VDC Driver Board .................................................................................................... 25
Figure 16. Q1 on Bottom Layer 24VDC Driver Board .............................................................................................. 25
Figure 17. AC Driver Circuit Card Replacement....................................................................................................... 26
Figure 18. Connections............................................................................................................................................ 28
Figure 19. Driver Input and Output Power Pins ...................................................................................................... 30
Figure 20. Front Explode View................................................................................................................................. 32
Figure 21. Back Explode View.................................................................................................................................. 32
Tables
Table 1. Mechanical Specifications.............................................................................................................................8
Table 2. Electrical Specifications ................................................................................................................................8
Table 3. Serial Parameters....................................................................................................................................... 15
Table 4. Serial Commands and Inquiries ................................................................................................................. 15
Table 5. Serial Response Messages ......................................................................................................................... 17
Table 6. Threads Size vs. Recommended Torque.................................................................................................... 24
Table 7. Bill of Materials.......................................................................................................................................... 31
Table 8. Rebuild Kits ................................................................................................................................................ 33

REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL
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WARRANTY
ROS, 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) Purchaser properly notifies ROS of such defects 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) Representations and warranties made by any person, including distributors and representatives
of ROS, which are inconsistent or 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 damages.
(d) 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.
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.
LIMITATIONS 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 projects, 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.

REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL
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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.
TEL: [phone]
FAX: [phone]
Sales: [email protected]m
Web Site: www.rosys.com
Technical Support: [e-mail]

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

REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL
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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. DC lights provide dimming via 0 –10 V analog, 0 –5 V analog, or RS48 serial commands. Custom input
connectors and pinouts may be specified. The light may be installed at any angle.
Figure 1. Seastar

REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL
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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
Wide
Weight in air
1.9 lb (.86 kg)
1.8 lb (.81 kg)
Weight in water
1.0 lb (.41 kg)
.91 lb (.45 kg)
Depth rating
20,000 ft (6 km)
Operating temp
-10 to 40°C
Storage temp
-25 to 100°C
Light output
9,000 lux
10,000 lm
Beam angle (50%)
50°
105°
Table 2. Electrical Specifications
AC
DC
Voltage
110 –130 VAC
20 –26 VDC
Current
1.3 A
6.0 A
Inrush current
2.5 A, 10 ms
27 A, 1 ms
Color temperature
6300 K
Color rendering index
65

REMOTE OCEAN SYSTEMS SEASTAR OPERATION AND MAINTENANCE MANUAL
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Figure 2. Beam Patterns

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3. Installation
WARNING
The Seastar is an industrial product designed for use in rugged underwater
environments. The Seastar installation and power system should be designed by
a qualified engineer and installed by qualified technicians.
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
to clamp to the bezel of the light.
3.2. Electrical
The Seastar pinout will depend on customer selections; Figure 4 shows the default wiring. The ground pin should
be wired to earth ground.
WARNING
The Seastar should be operated only through a circuit with ground fault
interrupt protection.
REM OTE OCEAN SYSTEM S CLAI M SPROPRI ETARY RI GHTS TO THE
I NFORM ATI ON DI SCLOSED HEREI N. THI S DOCUM ENT I S FURNI SHED I N
CONFI DENCE ON THE EXPRESS UNDERSTANDI NG THAT NEI THER I T NOR
ANY REPRODUCTI ON THEREOF W I LL BE DI SCLOSED TO OTHERS OR
USED FOR THE PURPOSE OF M ANUFACTURE OR PROCUREM ENT.
APPROVED FOR I NTERNAL RELEASEONLY. DI STRI BUTI ON I S LI M I TED.
NOTES: UNLESS OTHERW ISE SPECIFIED
1. M ATERIAL:
HOUSING:ALUM INUM 6061-T6
ENDBELL:ALUM INUM7075-T6
BEZEL:ALUM INUM 6061-T6
WINDOW: PLEXIGLAS G
2. FINISH: HARD ANODIZE, BL ACK
3. DEPTHRATING:20,000 ft(6 km )SEAWATER
4. WEIGHT AIR / W ATER:
SPOT:1.9 /1.0 lb (.86 / .45 kg)
FLOOD:1.8 /.91 lb(.81 /.41 kg)
5. M INIM UM LIGHT OUTPUT:
SPOT:9,000 lx
FLOOD:3,600 lx,10,000 lm
6. BEAM ANGLE AT50% INTENSITY
SPOT:38°
FLOOD:110°
7. OPERATIONALTEM P: 40 °C.SELF-DIM M INGTHERM AL PROTECTIONABOVE 40 °C
8. POWER:
120 VAC,1.0 A
24 VDC,4.6 A
9. DIM M INGOPTIONS:
AC:PHASE CUT DIM M ING
DC:RS485,0 -5 V,0 -10 V
10. DEPENDINGON CUSTOM ER SELECTABLE CONNECTOR.
C
B
AA
B
123
45
6
7
8
8765 4 3 2 1
C
D
SHEET 1 O F 2SCALE: NO NE
REVDWG . NO .
D
SI ZE
TI TLE:
1+
CAG E
10-01314
NEXT ASSY USED O N
2T637
D
APPRO VALS
APPLI CATI O N
APPRO VED
M . POGUE
APPRO VED
CHECKED
DRAW N
DATEUNLESS O THERWI SE SPECI FI ED
DI M ENSI O NI NG AND TO LERANCING I AW ASM E Y14. 5 2009
•DI M ENSI O NS ARE I N I NCHES•TO LERANCES: ANG LES±1°• .XXX±. 005
. XX±.01
.X±.03
REM O VE BURRS AND BREAK SHARPEDG ES .015 M AX•UNSPECI FI ED RADI I . 015 M AX
•M ACHINE TO O L M ISM ATCH.003 M AX•
SURFACE TEXTURE: 63
•
SEASTAR - INSTAL LATION AND
OUTL INE
17OCT19
PROTOTYPE
REVISIONS
REV DESCRIPTION
EC NO.
DATE APPROVED
Ø3.31
3.31 FLOOD
3.55 SPOT 1.375
Ø3.05
1.66
2.00
Ø3X10-32 UNF -2B .25 DEEP
DEPENDINGON
CONNECTOR
Figure 3. Installation Outline
1 EARTH GROUND
2 120 VAC, 1P, 1.5 A SUPPLY
3 120VAC RETURN / NEUTRAL
AC WIRING
1 EARTH GROUND
2 24VDC,5A SUPPLY
3 24VDC RETURN
DC SERIAL
4 RS485 +
5 RS485 -
1 EARTH GROUND
2 24VDC,4A SUPPLY
3 24VDC RETURN
0 - 10 (0 - 5) V DIMMING
4 0-10 (0-5) V+
5 0-10 (0-5) V -
Figure 4. Sample Wiring