complete housing

Review of the Salvo 35W Video Lighting System

by Liz Hanks

Boring Background (Skip)

I ventured into underwater videography about a year ago after doing underwater photography for 15 years. I decided to start off with a Sony HC3 in a Seatool housing, and use my existing modeling light (the 20W halogen Fisheye FIX Light) as a temporary video light. The combination made for a very lightweight and compact setup, ideal for travel. Most of my diving is done in the Monterey California area though, with only a single far away tropical dive per year, so I soon started looking into more powerful lighting solutions. I was surprised at how difficult it was to find a system that met my requirements:
After all, cheap and low weight/low volume weren't on the list...

While I was deep into investigative mode, my dive buddy gave me a 10W HID UK Light Cannon for Christmas. I quickly bought a second one, and with his help, mounted them both with a pair of Loc-Line arms to my housing. I decided this was a good stop-gap measure while I found an ideal high-powered solution. With the highest potency rechargeable C cell batteries available, I got 4.5 hours of burn time, which meant no recharging necessary during my typical 4-5 dive weekends in the cold Monterey waters.  The new lights made my housing very top heavy under certain shooting conditions though, and had a pronounced hot spot, so the search continued.

I discovered that one of the local dive shops carried the Green Force lights and were quite happy with their customer's feedback. I had already decided that a pair of Green Force HID 100 Impact with an  110 degree flood lens and a pair of Flexi III canisters would do nicely. They were advertised as 30W HIDs, the burn time as 3 hours, and a nice wide beam. I spent the next few months trying to verify that the HID 100 Impact were in fact 30W HIDs (since there is apparently no such bulb or ballast). After numerous phone calls, e-mails, and web searches, the answer finally came from a French underwater video forum.  One of the divers had bought a HID 100 Impact, unscrewed the lid, and discovered a 21W HID bulb inside. At around the same time, I heard that the beam angles on some of the Green Force lights were also overstated (110 degrees was really something like 80).  Also at around the same time, my videographer dive buddy reminded me to take a look at the Salvo lights.

I think I had originally dismissed Salvo because I couldn't find out information on things like beam angles on their site and their setup seemed more geared for cave divers than videographers. I looked again, made a list of questions, called the guys up, and placed an order within a day. 
I settled on a pair of  35W HID light heads, each with its own 15.6 amp Li-Ion battery and canister (note that the pictures on their site all show two light heads sharing a single canister but alternatives are available).

The Lights

The standard configuration for the Salvo 35W HID light heads and the 15.6 amp Li-Ion battery and canister includes two light heads, a single canister, and a wet Y connector joining the three pieces. This is set up so that a single large canister can be mounted on your tank or BC and disconnected from your housing and lights when jumping in the water or getting back onto the boat. It's just as easy to order separate light head/canister pairs, along with fixed (or wet) connectors of any length.



light head and canister The picture to the left shows a pair joined by a 3ft fixed cord.

Each light head is 8" (20.3cm) long and provides 3000 Lumens at 6000 degrees Kelvin (compared to 450 Lumens for a UK Light Cannon 10W HID). It includes a Lumedyne reflector which produces produces a fairly even 80 degree beam angle.  

The battery provides the 35W HID light with 4 hours of burn time and comes with a 90-240V charger. The canister is 10.75" (27.2cm) long and 2 lbs (1.1 kg) negative underwater.

The canisters are manufactured from a solid rod of Delrin so there are no extra seams that could leak. The latches have a lock that prevents them from opening accidentally underwater.

The canister lid has a unique design that prevents leaks in cases of switch and cord damage.
The on/off switch is protected by a silicone membrane and is easy to operate underwater with thick gloves.  

Charging a  battery is quite simple:  You flip open the two latches that hold the back on, disconnect the battery from the back of the canister and connect it to the charger.


tapped holes The light heads come standard with three tapped 1/4"-20 holes for mounting video arms. I also ordered a universal adapter to mount the lights onto my existing UltraLight arms.


housing and light head
The light heads are quite large, especially in comparison to the tiny Seatool HC3 housing, but their output justifies the size.

The bulb in the light head is sealed behind a thick test tube that slides over a pair of O-rings.

For light output comparison purposes, Salvo has published a  chart along with a picture showing the intensities of various focusable lights.


The Arms

I already owned parts for two separate arm systems (Loc-Line/Flex arms and Ultralight) and needed to chose between them for the initial setup with the Salvo lights. The Salvo light heads are pretty heavy but would still have worked pretty well with the thicker gauge Loc-Lines. Connectors are always a problem with the flexible arm systems though, and I wanted to see how I liked the combination of Ultralight ( ULCS) arms and video lights, so I went with those.

The ULCS arm systems also have the advantage of adding positive buoyancy to the overall system, something my new setup desperately needed. I found out that in spite of the ULCS web site not being up-to-date, there were some new extra thick buoyancy arms out there. The manufacturer codes are of the form "ULCS DB-BLxx", compared to the older "ULCS DB-Bxx", which are thinner and less buoyant.  I ordered 4 of the DB-BL12's as well as 4  ULCS BA-AQN base adapters (2 for the housing and 2 for future use with the light heads, if necessary).


two types of arms
The thickness of the DB-BL12 buoyancy arms made it difficult to pair them together and collapse them into a fairly tight bundle for transportation. I opted instead for a shorter standard arm coupled with a longer buoyancy arm.

The Custom Bracket

In order to secure the large battery canisters to the bottom of the housing, a custom bracket had to be built.  Most housings don't lend themselves to easily adding unexpected appendages to their bottoms. Luckily, I have a very generous and smart dive buddy with the willingness, skill set, and tools to build such an animal. Unluckily, said dive buddy had to move recently to the East coast. Power Points with design drawings, pictures with annotated measurements, and PDFs with housing scans flew back and forth as e-mail attachments until a concrete plan had been finalized.

housing measurements
The Seatool HC3 housing comes standard with a single handle. A second optional handle screws into two 1/4"-20 holes in the bottom. This extra handle is used as a second, stabilizing grip, as a place to stick your wide angle wet lens when shooting macro, and as an anchor for one of the light heads.

The bracket design had to make room for this extra handle and secure itself somehow to the bottom of the housing.

The design made use of the two extra handle holes, as well as two of the five smaller holes that already have screws in them securing an existing plate to the bottom of the housing.


Since the extra handle and its screws would be in the way of the battery canisters, the bracket was designed to have two levels:  a top level with a main plate that secures onto the bottom of the housing, and a bottom level with one piece for each canister to screw into. The two levels were separated by spacers to give the extra handle a place to slide into. Double-sided tape was added to the bottom of the housing to secure the main plate further and take a bit of pressure off the screws.
bracket collage


The remaining work consisted of attaching the battery canisters to the very bottom of the bracket system.  


canister orig config
The canisters come standard with a nylon loop secured with two metal rings that aid in attaching the canister to a BC, a wing, etc. None of these pieces are particularly useful in attaching the canisters to the bracket.


The key piece that did the trick was a plastic "lyre" which can clamp nicely on to a canister and has a hole at its base for a screw. These parts don't seem to be available in the U.S., so my trusty dive buddy brought some back with him on his last trip to France. The metal rings that came with the canisters were kept to add some extra security as they prevent the canister from sliding back and forth.
canister collage

An alternative to the plastic lyre parts would be stainless steel clamping/conduit hangers (shown on the McMaster-Carr site in this sketch; under part #3006T95).  These would work fine with Salvo's hard plastic canisters but would be less useful for securing aluminum canisters (like Green Force's), due to the electrolytic reaction that would occur with the sea water.

Results

With all the pieces put together, the 3 lb. camcorder and housing was transformed into a 20 lb. light-wielding cornea-nuking beast.
final collage

Underwater, the result was impressive. The lighting was subtle at a distance of about 6 ft., and grew stronger as I approached the reef. Large portions of the reef were illuminated and gone were the two discrete ugly blobs of light that I saw with the UK Light Cannons. The diffusion made for subtle transitions where the light fell off.  For close-up shots, I angled the lights outward so as to not overpower the subject.
dangling starfish wolf eel
anem closeup liz and lights

Overall, the setup is still quite negatively buoyant. The canisters themselves are 4 lbs. negative and the two buoyancy arms only compensate for about a third of that. Everything else in the setup is also negative (the regular  arms, the clamps, the bracket, the light heads, and the housing with the wide angle lens).  I expect to make further adjustments to help neutralize the buoyancy.

I had two problems on my first weekend of diving with the new lights.  Both were minor and predictable.

light head adapter with two screws
The universal adapter I ordered with the light heads had a single screw. After a few dives, one of the light heads started freely rotating since the adapter came lose. A quick tightening before the next dive didn't last long.

I've since replaced the universal adapters on each light head with the same parts I'm using on the housing handles (the
ULCS BA-AQN base adapters, seen in the picture on the left). I expect this to solve the rotation problem since these adapters have two screws.
bent handle
The weakest link in the whole system was the poorly supported base of the extra housing handle. The weight of the light heads coupled with a particularly bumpy trip back from Big Sur to Monterey caused a severe bend in the metal base.

Luckily the base unscrews easily from the vertical grip, so I've ordered a bar of Delrin as a replacement. It will be larger in all dimensions than the original base, and will fill the gap between the two bracket plates, reducing the pressure on the screws that secure the handle to the housing.

One other minor issue I had was dealing with the cords.  They're fairly stiff, which means they'll last longer than flimsy cords, but the combination of their stiffness and the length I chose makes it difficult to get them out of the way of operating the controls and adjusting the lights.  I think this will be at least partially solved by moving the cords in front of the arms before clamping them to the light heads, but it still won't be as easy to deal with as the flexible sync cords I'm used to dealing with in underwater photography.

I've only taken the unit down for one weekend of diving so far.  More results and frame grabs will follow later.  So far though, I'm quite impressed with the quality of the light construction and with the response time from Salvo for orders and questions.

Price

The pair of lights each with a battery, canister, and charger was US$3300 from Salvo. The ULCS arms and clamps can be bought for around $200-$300 from Reef Photo & Video. The parts for the bracket ran between $100 and $200 and were bought at McMaster-Carr and at various hardware stores.

Summary Statistics

The following table summarizes the characteristics of a single light head and battery.

Light type 35W HID
Light output 3000 Lumens
Light temperature 6000 Kelvin
Beam angle 80 degrees
Battery type 15.6 Amp Li-Ion
Burn time 4 hours
Charge time 10 hours (from complete discharge)
Ballast size 8" (20.3cm) long, including reflector
Canister size Length: 10.75" (27.2cm);  Diameter: 2.75" (7cm)
Canister dry weight 5.8 lbs (2.6 kg)
Canister buoyancy 2 lbs (1.1 kg) negative underwater




Last modified on 27-September-2007

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