User Instruction & Installation Manual FX380 Manual Control 2Kw
Contents
1. 3 i i I d q li 2 O CA N H TERN CO N 3 o A d ED a E o Y Ti bio s IE ep je a e gt dU Y sa 890103 daddy gab ASU SIHOVI 866092 ra 3 1IVI30 HLIM Ad zum LHonowa 694 GIS vze003 x sal Hornso os 3sn Ex V imi o aswors30 33 Z 29 Y o SEG Navya sui sv L SLINI NO dasn di eat mum a TEUER RUN PEN ENT 8 NOLLO3POMd TONY GHIHL SNIMVMO JIVIS LON OG IS IA LL al 6 8 L 3 S ta L LI Ol 6 8 9 g g e L LI SCLCN susod sj sanuao siet uon uy S3HL3ATTIIN NI SNOISN3MIO TIY VO MYC dOOBEXJ glo 2908 OSI oL bunsDo alg Ke E ENER a393H0 LHS ON 990 0N Leva NOLLAIN9S3Q HSINI VISALYA OLLA Z908 OSI ol buten puns S35NVN3T0L 66 9 ava SU Nuvu 133HS NO LNOO ZY 6661 PHZ 18 NOLIOS AVOY NOINA CAL INK SLHSITHOSV3S SIONV 34 Eee AGI YO MAC dOOBEX4 90ZZV SPIE r0vz vo MIZ AJOBEX4 GZIZY S ON XeW sz OH sieuo2 ag sapa peuipou jno2. WS HJLV dH IGtEecgl LNO Ovc d YOLINSI T HJNHOJSNVHL VSP 1H NI ASL HINOLSNO AA q3llddns SNIV ddNVd lOSLINOO s sq gt 2 A SE NM 19M SY L gt S LINI ON m NO q3sn A SIVI30 NOLVOLICON O Tiene Pol ur amer POYd 319NV QGMIH 11V9S LON OQ 15313 En St FL L zt m ol 6 a Fa E S z L Loic V9 xz Gosex4 mE ME oe bicis tel LHS ON aen Lave NOLAIIIS AI HSINH ELERI OLO Z908 OSI eL S39NV83TOL ELAS CEE 133HS NO 1N09 LY spe THe 218 NOLTOS OO NOINN GALINO SLHOMHOYVAS SIONY4 arva Sa mwan SIWSITESWVES SPULE a GLEN SET MOVE WO MAC GOBEXA S V S ON XpN GZ 08 SUN eg estra posto p anal 1 i FILIVYd OYYONYIS e o O 511130 ONIXIL 3554 tr a PA O D a Ge 3 H gil p Co Ni al a o gt ET t Fa oo ne a D u A Ms eos o o H 9 a e ea 890193 1300 Y Lj SCv SIL 7 SSHOLYT 96
3. E er S Sa A WS ei aj e sa 890103 a3aav 3 IJ S0 F ASIL S3HO1V jJ 866093 em Y LW TIVLJG HLIM zo 3NM NI LHANOCYMI e M S sal ou sen di 2191 a Vlioi d3N9IS30 39 z e 28 pag Wang eu SY L 9JOLI 5 SLINI a mo NO dasn sa SH NOLYOBICON re uugs op of oz du Er E NOLLO3POYd 319NV HIHI SNIMVSHGO JIVIS LON OQ ISU LL OL 6 8 L 9 S e 4 L LL oL 6 8 L 9 S v e k susod ap sequeo ou uonbuy SFBLINMIW NI SNOISN3WIG TY L ECLON VO D089X4 pr on ew 819 2908 OSI o buten alg Fe Sil qvos 2935 1HS ON SYA ON Lavd NOIL didasag HSINIJ Ion OLLO 2908 OS OL Bunen pups S3oNvHil0l 66 9 avaj GO NMYaQ 133HS NO 1NO9 ZW 666 PHe 18 NOLIO8 dvOsS NOIN GSLIAT SIH9 IH9 1V3S SIONVHJ 9 ISU AGLI WD MHZ O08 X4 9OZZV s gi MOPZ WD MAZ DOBEXA LTLZV s on Con sz ou sieuios yoesg sebpa peulyooui jno jip wngag Td OFLL V NO NAOHS SV JOLOVHd DYVANVIS LI JO Li CIIVASTINDI D Lg S310H ES i J O Or 310H SIIV130 ONIXI4 3Sv8
4. Much future grief can be avoided by having a competent electrical contractor install and connect this unit Caution We make suggestions in this manual as to minimum wire sizes to be used Refer to and conform to the codes applicable in your area Caution Observe polarity of the conductors which carry the D C output of the power supply to the lamphouse Reversed polarity will immediately destroy the xenon bulb upon application of power Warning When the electrical installation is complete there are two sources of primary power within the unit Turn off all power when adjusting or servicing the power supply Warning This unit can run warm to very hot Allow at least 15 minutes after turning off the power for the unit and its components to cool down before attempting any service procedures Holes are provided in the end section of the power supply case for conduit entries Install conduit in a manner which allows some movement for service if required Refer to drawings for connection information Model8502 Primary line 240v 10 gauge minimum 110v 8 gauge minimum 30 ampere breaker or fuse 240v 40 ampere breaker or fuse 110v D C output 4 gauge minimum Warning The power supplies have two sources of power Disconnect turn off primary power before making adjustments or service procedures Output power adjustment Warning The power supply stores energy after primary power is switched off Wait a minimum of tw
5. amp J Tighten the knurled screw G on the rear lampholder assembly to hold the lamp in position Fasten the front lampholder mounting block back in position it will be necessary to pull the front socket against its spring to fit over the lamp When in place tighten the front knurled screw F Fasten the front and rear lampholder leads as wiring diagram ensuring the connections are secure The front bezel and rear bezel can now be replaced Removal is the reverse of the above 6 Operating Instructions This equipment is designed for use out of doors in free air Never place anything on or cover the searchlight when in use as this may present a hazard The PSU should be housed below deck in doors Never leave the PSU exposed to weather conditions The searchlight can be positioned using the elevation and baseplate lockwheels When in the desired position the lockwheels must be securely fastened to prevent damage The beam of the searchlight can be adjusted to give a variety of beam types By turning the focus lockwheel positioned on the Rear bezel assembly clockwise anti clockwise the lamp holder mechanism moves through spot to flood positions When the desired beam is achieved simply release the lockwheel Please note that itis advisable to leave the heater permanently on in order to remove condensation from the searchlight head The heater specified on this equipment is self regulating and will shut off when it re
6. jo ungaq JOLIvYd GYVONYIS y y gt I D o me a D d 0 0 Z V NO NMOHS SY sl AaJDYaS INDI Syl SITOH 3 sen vci 162 ER E Da pose a j an MI 1 EW E 0758 310H a d Se S 5 S7130 9NIXIJ 3SVA 3 2 We ETS NS Emm M M E D D o e D 3 of d o Ze O W oo Rr k Tal d 8 O n sa 890193 qaqay NA 90v AGLI SIHOLVI Leg 866093 LW 1130 DU LS L 20 3NM NI 1H9noug i gt x x y OL Q3N0l530 33 Z 904 L 28 EG Wa Ja SV ta SAN NO d3sn awa OA si wwas de de d d E 7 NOlLO3POSd JIONV QOMIHL SNIMVAD 31795 LON OG isald LL OL 6 8 L 9 E z l 10 Spare Parts List The following spare parts can be ordered directly from the manufacturer Part Number Description C15392 00 Power Supply unit 240v C23860 00 Step Up Transformer C12081 00 Ignitor 240V C12080 00 Ignitor 115v C20224 00 Fan 240V C21573 00 Fan 115v D20195 Lamp C08919 00 Front glass C08920 00 Front glass gasket C23277 01 Heater amp Fuse Assembly C13737 00 Reflector C21502 01 Base lockwheel assembly C21503 01 S ide lockwheel assembly C11148 00 O ring seal Deck amp Cabin C10170 00 O ring seal Deck Ped Cabin Ped C20281 00 Bellows C22072 00 Seal In order to prolong the life and per
7. to adopt please contact your distributor agent or the manufacturer who will be able to advise the best course of action for your product 9 Wiring Diagram amp General Assembly Drawings Drawing Number C23114 Description 240v Xenon Wiring Diagram C24495 A2781 A2724 A2723 A2725 115v Xenon Wiring Diagram FX380 Deck General Assembly FX380 Deck Pedestal General Assembly FX380 Cabin General Assembly FX380 Cabin Pedestal General Assembly S3HI3NITIN NI SNOISNANIO TV MESES NYYOVIO ONIBIM NON3X Tivos TETE THS ON OUG ON LYYd NOLL dl49s3g HSINI4 Vla FO 9 17 avo Sa Ma 133HS NO 1NOO C V rooz PAC 18 NOLIOS OVO NOINA QO3LImdd SId911d98V SIONV SJ SLADITHIUVAS TUE TT SONILLJS 1NIALSAPQV O INdINO LAdLNO JO 810 Z908 OSI o1 6unsog ag ug 3409 m OLLO 2908 OSI o1 bunsoo pups m TU 3 susod x seajue2 ajon 3 up nbuy m 3 pJouo5 HG 4409 2S S O 0 SISNVATIOL g S ON xDN SZ OY sieuioo YDag e 0 sabps poulyonuu jno ip tinged JdOLOvad CYVONVIS 431 V3H a SS E 031114 di YAWOLSNI AG G3Naans 5 WG 34309 HOLIMS YILVIKH IGVEZI YOLINII dd L NY4 Nya OrLVvVX 335 6 vX 335 dv l LELYX 335 UI AS og LHOMHOYVIS gt sa p
8. 0 5 cm Height 15 38 cm Length 19 48 25 cm Weight 145 lbs 65 9 Kg Cooling Convection Warning When this appears in this text itindicates a hazard to personnel Caution When this appears in this text it indicates a procedure which can result in equipment damage if not properly accomplished Receiving the Power supply The units are shipped with the power supply bolted to a shipping skid and enclosed in a heavy cardboard cover held in place by banding Physical damage to the container or its contents should be reported to the carrier immediately Unpacking Cut the banding strips and lift the cardboard cover off of the unit Remove the four bolts holding the power supply to the skid Place the unit in the location selected for installation Locating the power supply The power supply is convection cooled and the location selected should provide a minimum of 6 clearance around the case The area should have free movement of air to dissipate the heat generated by operation of the power supply Provide a space large enough to allow service of the unit if required Caution Do notallow anything to be placed upon the power supply case the perforated top is for ventilation and must not be obstructed Try to select a location as close to the lamphouse as practical Many users install the power supply adjacent to the searchlight where space is available and local codes permit Electrical installation and connection Caution
9. 0 minutes for cooling down after turning the searchlight off m Never place anything on or cover the searchlight when in use m Ensure the lamp has cooled sufficiently before removal m Hundue force appears necessary to remove the lamp the equipment should be inspected by a competent person or contact the manufacturer m When disposing of lamps there are several options available m Return the lamp via the supplier to the lamp manufacturer in its complete packaging m Because ofthe cold internal pressure of the lamp is approximately 8 bar the lamp must first be depressurized before disposal Place the lamp in its protective jacket in a plastic bag and drop from a height of 1 to 2 metres onto a hard surface m XBO lamps do not contain materials which are harmful to the environment and thus are not subject to special waste disposal regulations m Due to the vast range of lamps available it may appear possible that more powerful lamps can be used in the equipment than for which it was designed Even when the unit will physically accept a higher wattage lamp this substitution is not recommended and is dangerous This action will also void any warranties on the equipment m Always refer to the lamp manufacturers technical data when dealing with lamps 3 Technical Information This product has been designed to operate in accordance with the product specification The FX380 2000 watt searchlight has the following features All marine grad
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11. Electrical Engineer Please referto the following table for the trouble shooting of Xenon lamps m Wrong Polarity m Lamp incorrectly fitted m Anode large electrode m Faulty wiring must always be on top in vertical burning position m Check polarity transpose connections if necessary Cap overheated Faulty contacts m Checkterminals tighten or Cap temperature above Cooling equipment renew 230 C defective m Check cooling equipment and replace if necessary Arc unsteady Lamp operated outside m Correct current setting current control range m Check magnetic Magnetic stabilisation for stabilisation horizontal operation defective Bulb draws in air Crack in graded seal m Check terminals tighten caused by overheated cap or renew Maximum cap temperature 230 C Glass erosion on fused Lamp operated outside m Correct current setting quartz bulb current control range m Check meter Lamp service life exceeded m Electrodes damaged m Current ripple too high m Have power supply W Premature blackening m Auxiliary mirror incorrectly inspected adjusted m Adjust auxiliary mirror m Asymmetrical blackening m Lamp operated too long in m Turn lamp through 180 of lamp in horizontal same position after half service life burning position Failure of Lamp to Ignite In the event of the xenon lamp failing to light the following steps should be taken 1 Check that the mains supply is connected to the input of the PSU On operating the switch if the l
12. Francis EE HI User Instruction amp Installation Manual FX380 Manual Control 2Kw Xenon Searchlight Product Reference Number A2197 115v Deck A2781 240v Deck A2207 115v Deck Pedestal A2724 240v Deck Pedestal A2206 115v Cabin A2723 240v Cabin A2208 115v Cabin PedestalA2725 240v Cabin Pedestal Manufacturers details Distributor details Francis Searchlights Ltd Union Road Bolton Lancashire BL2 2HJ UK Tel 44 0 1204 558960 Fax 44 0 1204 558979 http www francis co uk E mail sales francis co uk Manual Part Number C23115 Issue 5 CONTENTS 1 Introduction 2 Safety Precautions 3 Technical Information 4 Unpacking and Installation Instructions 5 Electrical Installation 6 Operating Instructions 7 Fault Finding 8 Maintenance and Servicing 9 Wiring Diagram 8 General Assembly Drawings 10 Spare Parts List 1 Introduction It is imperative that this manual is read carefully and understood before installing your equipment For your future reference please keep this manual in a safe place Thank you for specifying a product from the Francis Searchlights range All Francis products are designed to give complete customer satisfaction and are manufactured to the highest engineering standards in order to ensure optimum performance and service life The Francis Xenon range combine features proven over many years service in the most hazardous conditions in both ma
13. R SUPPLY an VOLTAGE NJA YON x 3n ubisap Aq A1ni duis MATH NI S31VIDOSSV d Qoo gt T gt f e y Ki d 2 kit D FE IS vac NEU Le SYSTEM RATING CHART FOR 6OHz DOMESTIC SYSTEM COMPOSITION 30 POWER SUPPLY 502 POWER SUPPLY 516 POWER SUPPLY i Lig 2 5108 LAMPHOUSE Lamp LAMPHOUSE 85108 LAMPHOUSE era Lum tilo vos NS unos Oe To compu sema Loca coni CWAKS POWER input gt ES f e IN ABSENCE OF ANY GOVERNING CODE LSE As a I MANS PONER INPU u 25 0 28240 25 SIZES RECOMMENDED IN CHART OR LARGER t c gt 2 LONTRIL POWER INPUT as s 6 ju 3 a e d 1 L P ASSOCIATES INC N POWER WIRING 1 s 30 35 4DC 22 30 30 8540 magro 40 70ADC rc acia pine stante Be Ee a r pe PM cere 6 15 83 CCC bi T PIETILALONTRO WIRING E s 6 us 3 o gt i CONTROL WIRING INTERCONNECTION DIAGRAM E ym gt S8 LU CODE WENT mses ILLUMINATION SYSTEMS AS series 4 Unpacking and Installation Instructions The following instructions should be read and fully understood prior to installing the equipment to ensure that the correct procedures are followed and all safety precautions are observed Note If the equipment has been in storage for a considerable amount of time it is advisable to conduct a routine ma
14. TTED Do not twist or bend the fused quartz bulb when fitting the lamp as mechanical stresses MUST be avoided Ensure that the spring contacts firmly surround the pins on the cap of the lamp Do not apply unnecessary force when tightening the screws After inserting the lamp ensure that there is sufficient axial play in the lampholder The lamp must be capable of unimpeded expansion when it warms up to operating temperature Mechanical forces must not be applied to the fused quartz bulb Electrical leads must be arranged in such a way that there is a sufficient air gap approximately 40mm between them and the lamphouse in order to prevent flashovers from the ignition voltage All flexible leads must have strain relieving clamps Before putting the lamp into service for the first time check the polarity of the electrical connections INCORRECT POLARITY WILL CAUSE IMMEDIATE DESTRUCTION OF THE LAMP Before the protective jacket is removed suitable protection must be worn i e face mask and gloves with wrist protection Never touch the quartz bulb with bare hands as fingerprints will make the glass cloudy and cause a severe loss of light This may also cause recrystallisation and thus weaken the bulb material Should the bulb be inadvertently touched remove fingerprints with methylated spirit and a clean soft paper towel The bulb should then be wiped with distilled water NOTE ALWAYS WEAR MASK AND GLOVES DURING CLEANING All packaging and
15. aches the dew point temperature This product should not be used for any purpose other than for which it was designed Any modifications to the product should not be undertaken without consulting the manufacturer Setting to Work Safe service in use necessitates the strict observance of the following precautions Any article fabricated from quartz or glass is inherently fragile and care should therefore be taken at all times when handling lamps Eye protection must be worn when handling lamps that have been removed from their packaging materials The protective jacket should not be removed from the lamp for safety reasons as there is a remote possibility of the lamp shattering violently especially if it is subjected to mechanical shock or vibration Ensure that the power rating of the Xenon lamp to be fitted is suitable for the lamphouse and power supply equipment rectifier Always isolate the equipment from the supply before inserting a lamp Before inserting the lamp ensure that all contacts are clean Contacts must be renewed at the slightest sign of corrosion Sanding or filing down corroded areas is not recommended as this will only make the conducting surface between the pin and lampholder smaller thus causing the lamp to overheat The inert gas Xenon used in XBO lamps are under a pressure of several bar even when the bulb is cold FOR SAFETY REASONS THE LAMP MAY ONLY BE INSERTED INTO THE LAMPHOUSE WITH THE PROTECTIVE JACKET FI
16. amp does not light switch off mains supply and check all fuses 2 On pressing remote starting switch the lamp still does not ignite check the searchlight head On your command get an operator to activate the starting switch for approximately 10 seconds During this time listen for any noise cracking or hissing coming from within the barrel If this arcing is heard switch off the supply atthe mains Remove the rear bezel to expose the two supply leads to the xenon lamp Using a dry cloth wipe these leads to remove any dust moisture or condensation that may have formed around the inside of the barrel Replace the rear bezel ensuring the latches are located and perform the check again listening for the cracking If the lamp still fails to ignite switch off atthe mains and replace the xenon lamp in accordance with the safety procedures within this manual and the manufacturers information Any further tests to be carried out with regards to lamp failure must be conducted by a competent electrical engineer and should not be carried out in an explosive atmosphere 3 Before a xenon lamp will ignite the electrically insulated gas between the electrodes must be ionised This is done by the ignitor which produces a high frequency voltage up to 30 000 volts or higher The ignitor is activated by switching the lamp on and a crackling or hissing noise should be heard The ignitor is housed within the rear of the searchlight barrel This is a totally enca
17. e S L into the PSU 3 core 1 5mm cable to the Heater in the Searchlight customer may need to provide a suitable junction box to extend these three cables 3 metres supplied amp the mains cable to the PSU to be supplied by the customer The searchlight head is pre wired When the light is in operation the output from the PSU should be approximately 24v dc at 80amps Basic Operation When the searchlight is switched on a 240v or 115v supply is fed to the PSU and linked to the ignitor Also from the PSU a dc output is fed to the lamp The ignitor ionises the gas within the lamp and this strikes the light Fitting instructions for the 2Kw xenon lamp Referring to the diagram overleaf 1 2 3 4 5 6 7 8 9 10 11 Unfasten the eight Latches A on the front and rear of the searchlight Remove the front bezel B and rear bezel C assemblies Unscrew the two M6 hexagon screws D from the front lampholder mounting block E and remove the front lampholder assembly from the mounting bracket Loosen the knurled screw on the front F and rear G lampholder assembles From the rear unscrew the P T F E bush H and remove the countersunk screw J Now you can remove the rear lampholder socket K and fix the negative end ofthe lamp using the M8 x 10 grubscrew L The lamp can now be inserted make sure thatthe negative cathode end ofthe lamp is towards the rear of the searchlight re fit item H
18. e materials and fixings Electronic power supply unit Parabolic aluminium reflector electro formed nickel rhodium plated Stove enamel painted Full 360 horizontal rotation Vertical movement 45 to 25 Internal self regulating heater The searchlight also performs to the following optical data Xenon light source Lamp Wattage 2000 Watts Supply voltage 220 240V or 110 115V Peak Beam Candlepower 56 031 160 lux Range 7 485 metres Divergence 1 5 Temperature range 50 C In order that the searchlight operates correctly it is imperative that competent personnel are responsible for the installation operation and servicing of this equipment Failure to adhere to this advice may cause premature failure or incorrect operation of the searchlight which may damage the equipment or cause personal injury Technical information on the Xelamp Power Supply Unit and Ignitor are included overleaf For more detailed information please contact the manufacturer PSU ref Model 8502 Xelamp Ignitor ref AS 16040A Irem Power Supply fixings centres 440 x 152 using M8 screws Power Supply Details Model 8502 General Description Output Power 1400 2200 watts Voltage 22 30 volts D C Current 50 85 amperes D C Ripple 5 peak to peak Input Current 25 22 amperes maximum 40 amperes maximum Voltage 208 237 VAC 110 120 VAC Phase S ingle Frequency 60 Hz 50Hz available Output Adjustments 9 steps Size Width 12 3
19. formance of your product we recommend that you only specify Francis Searchlights spare parts This will ensure that any warranties on your equipment will not be invalidated When ordering spare parts please contact the Sales Department at Francis Searchlights Limited Please quote searchlight model and serial number at all times This will enable a fast response to your spares requirements
20. ight Disable the lamphouse ignitor by removing primary power to the ignitor Connect your VOM to the power supply D C output Observe polarity Turn on the power supply If you read 110 VDC or more the boost circuit is operating If the D C voltage is low on the order of 50 volts it is likely that diodes 5 and or 6 have failed Current limiting resistor R1 may be open C Main power supply Power supply bank D1 D4 A shorted diode will cause the primary current to go high and will trip the circuit breaker in the sub panel An open diode will cause the projected picture to have a pronounced flicker and may result in somewhat lower operating current Capacitors C1 C2 C3 A shorted capacitor or capacitors will raise the primary current and trip the circuit breaker in the sub panel C1 C2 C3 If these are open or have lost capacity ability to store energy they will cause either a noticeable flicker in the projected picture or ignition problems or both If in doubt disconnect the capacitors one at a time After disconnecting a capacitor if no change in ignition or flicker is observed then the capacitor is having no effect Replace it Low capacity or an open capacitor affect ignition because there is insufficient surge current to reliably light the bulb If disconnecting a capacitor does change either flicker or ignition then the capacitor is functioning Reconnect it High ripple current caused by a diode failure will result in overheat
21. ing of R 3 You may use a clamp on A C ammeter on the common D C line to the capacitor bank as an indirect method of checking ripple The 8502 capacitor bank will have a nominal 25 ampere AC current flow Higher current indicates a high ripple condition Lower currents may indicate open or deteriorated capacitors Current into the capacitor bank varies with adjustment of the power output As the output power is decreased current flow of the capacitor bank will decrease Diode testing and replacement To testa diode it must be disconnected from the circuit in which it is used In many failure modes the diode failure can be tentatively identified by discoloration of the bright surface because of excessive heat You will still have to disconnect the diode and make further checks to verify failure After disconnecting the diode sue your VOM on the R x 1 scale With the meter leads connected in one direction the reading should be zero or close to it reversing the meter leads the indication should be a very high resistance If the diodes does not exhibit these characteristics replace it If you have removed a diode from its heatsink or you are installing a new diode observe the following instructions Clean the area of the heaksink in which the diode is to be installed Warning You must use heatsink compound It is caustic in nature Do not use for fingers keep it away from your eyes and do not ingest Follow instructions on the container in
22. intenance check on all parts before installation Safety Precautions This equipment should not be connected to an electrical supply before being installed Installation procedures should be adhered to in order to ensure a safe working environment and reduce the risk of damage or personal injury Preparing the Mounting Position Mark out and drill the fixing holes through the deck Fit the O ring in position and bolt the searchlight base securely On an uneven surface it is necessary to use a suitable sealant such as silicone in order to ensure a weatherproofed joint If anti vibration mounts are to be fitted the fixing holes for the mounts should also be marked out and drilled Prior to manoeuvring the searchlight into its fixing position the AV mounts should be fitted to the base When in the desired position bolt the searchlight firmly down 5 Electrical Installation For safety purposes only competent personnel should perform the electrical installation All equipment should be installed to current Electrical Regulations and Standards In order to obtain the maximum light output from the searchlight it is essential that the full operating voltage of the lamp fitted be applied to the lampholder contacts Method of Electrical Connection 1 Disconnectthe supply before working on the electrical system 2 The searchlightmustbe connected to a fused electrical supply using suitably sized cable 3 Ifthe searchlight is loca
23. o minutes for the capacitor charge to bleed off Taps are provided on TB1 to alter the output of the power supply Small current changes may be made by moving the tap from H to M to L Highest current is on H the lowest is on L Larger current changes may be made by moving the tap from 4 to 5 to 6 Highest current is on 4 the lowest is on 6 One input line must be on H M or L The second line must be on 4 5 or 6 When the primary line is high 120 240 VAC tap 5 or 6 should be used For 110 208 VAC use any tap 4 5 or 6 When changing taps do not insert wire into the connector so far as to clamp on the insulation rather than the bare wire Be sure to tighten the connector screws Routine maintenance Warning The power supply has two sources of power Turn off power before servicing the unit Warning This unit can run warm to very hot Allow at least 15 minutes after turning off the power for the unit and its components to cool down before attempting any service procedures At 6 month intervals clean dust out of the unit Inspect all electrical connections Look for discoloration due to overheating Be sure all components are clean and tight Troubleshooting Much data can be obtained from the volt ammeter built into the lamphouse control panel In addition the following instruments will be needed to perform all trouble shooting operations that can be done in the field Portable volt Ohm ammeter VOM must be capable of supplying cur
24. ool MIMMO 1833 SY L SINI k NO 0351 di ZUNG e ame du de d rar A DEES Odd HIONV HIH OINIMVAG FTIVIS LON OQ 1S8 W s SIYLIWNMIN NI SNOISNANIO TIY LISGTTZO WYYOYIG ONIYIM NONSX ASILI INJ EE LAS ON D80 0N LHvd NOILdl42S3d HSINIJ 607 KAS Sq NMVag 133HS NO LNOO 8007 PAZ 19 NOLIOg VOY NOINA OJLINET SLHOTIHOSVJ3S SIONV M3 L A I q R 9 Y 4 s S IL 2 ug 3409 nSd O i p SONILLIS LN3ALSOPOV 3 GZ 3809 819 7908 OSI OL bunspo alg A 0119 Z908 OSI OL Bunsog pubs N e 3 susod S94 U99 ajoH 3 uninbuy SISISIS 3 jgpjeues5 Ia 3 S ON SIONVATIOL G E r S S Li SO XDW GZ ON sisujioo 0214 AAA a s p p uluopuu ln3 p nde JOLLOvYd GYVGNVLS 31 V3H a c o ES a 49 4 Q3LLIH 41 HINOISNO AB CINddns GL 3409
25. psulated unit and repair is not advised If found to be faulty a new ignitor must be fitted 8 Maintenance and Servicing In order to prolong the service life and performance of your searchlight the following maintenance guidelines are recommended m Maintenance checks should be conducted before every voyage or at least every three months m Before checking disconnect the equipment from the supply m Visually inspect the condition of the equipment m Any major or minor structural damage should be rectified immediately in order to reduce sympathetic wear m After inspection it may be necessary to clean the inside of the searchlight The following procedure should be adhered to Remove the front bezel Clean the front glass inside and out using a proprietary glass cleaner or metal polish Clean the reflector if required Check the reflector mounting gaskets If signs of corrosion or damage are evident replace as necessary Ensure that the lampholder is free from corrosion or other damage Check earthing point for conductivity m itis advisable to check all seals and gaskets for signs of degradation Renew if necessary m Upon completing all maintenance requirements the searchlight should be tested for full working order approximately 20 minutes WI Every six months the external movement mechanisms i e lockwheels elevation and pan mechanisms should be lightly lubricated If in any doubt as to the correct servicing procedures
26. rent to forward bias a silicon diode on R X 1 range Some digital instruments cannot consult operator s manual for instrument concerned Clamp on A C ammeter capable of Y ampere or better resolution Xenon lamp power supplies have two stages of operation 1 Before igniting the bulb At this time the voltage at the power supply output terminals reaches open circuit value 110 VDC or greater 2 After igniting the bulb At this time the voltage at the power supply output is determined by the load placed on the power supply by the xenon lamp 18 30 VDC Power supply difficulties can be separated into one of three areas for purposes of diagnosis and repair A Power line problems B Boost circuit Open circuit voltage problems C Main power supply problems A Primary power problems Power to the power supply is supplied from the sub panel The PSU power contactor K1 will operate when the lamphouse is switched on in the absence of primary power to K1 If there is D C voltage out of the power supply as indicted on the lamphouse voltmeter you have primary power H there is no lamphouse voltmeter use your VOM If there is no DC output voltage and K1 operates check the primary line with a VOM to locate the point of failure B Boost circuit problems open circuit voltage Loss of the open circuit voltage due to boost circuit problems will result in the following Ignitor will not fire in the AUTO mode Bulb will not l
27. rine and land installations In order to prolong the life and performance of your product we recommend that you only specify Francis Searchlights spare parts This will also ensure that any warranties on your equipment will not be invalidated Information on spares ordering and parts is provided in this manual Should you ever need to contact Francis Searchlights Ltd regarding your equipment please quote the Product Serial Number at all times 2 Safety Precautions The following instructions must be adhered to in order to ensure a safe working environment and the safety of the user Note When unpacking or manoeuvring the searchlight into its fixing position the lifting handles must be used in order to prevent damage to the equipment or personal injury m Because of the high internal pressure within the lamp there is a risk of explosion in either a hot or cold state m During operation this lamp emits intense UV radiation which is harmful to the eyes and skin Suitable protection should be worn m The high luminance of the arc can cause severe damage to the eye if viewed directly ALWAYS wear suitable protective goggles when viewing the lamp m Always use protective jackets supplied with the lamp m Should it be necessary to examine the lamp with the front bezel removed always use a protective shield and wear goggles to ensure a safe working environment m Searchlights get hot Never touch the unit when lit and always allow 15 to 2
28. ted a considerable distance from the supply provision must be made in the cable size in order to overcome the voltage drop The following table should be used for indication purposes only The PSU should NOT be positioned no more then 5 meters away from the searchlight The following table below indicates the maximum length of cable to be used for the AC supply cable from the control panel to the searchlight Searchlight 115v 2Kw 240v 2Kw Cable Size mm BMTRS 37 MTAS 6 34MTRS 150MTRS 4 Whenever possible cable terminations should be made below deck and with approved terminal devices 5 Ifa spare auxiliary fuse or circuit breaker is not available one of the correct type and rating should be fitted and connected to a positive supply It is advisable to locate a bus bar or main connection and avoid any direct connection to the supply 6 For110 220v AC products the following colour coding system should be used for the customer supply cable Brown Live Blue Negative Green Yellow Earth m Note This equipment must be earthed Installation Guidelines A typical installation and connection routine for the searchlights is as follows Referring to wiring diagram C 23114 a supply is fed to the PSU which then provides a common feed to all other functions and equipment Cables required to be connected by the customer 4 core 6mm cable from the S L into the PSU doubling up the pairs 3 core 1 5mm cable from th
29. the protective jacket must be retained for re use Whenever removing a lamp the protective jacket must always be used for safety reasons Notes 1 XBO lamps are designed for dc operation only The dc current may only be varied within the limits of the current control range An XBO lamp operates best at rated current over the life of the lamp the current may be increased to its maximum value to compensate for loss of light The output of the lamp can be reduced by operating the lamp at minimum current but this does not prolong the life of the lamp For safety reasons XBO lamps should be replaced once they reach the end of their average lamp life and not later than 1 25 times they re average lamp life After this time there is an increased risk of the lamp exploding The anode positive cap marked must be on top when the lamp is inserted in the vertical position If the anode is incorrectly inserted the arc will be unstable the bulb will blacken more quickly and the lamp will prematurely fail 4 The HT lead from the high voltage terminal of the ignitor must be connected to the cathode negative cap marked If the lamp is connected with the wrong polarity it will be irreparably damaged after a very short time 5 In all circumstance the lamp manufacturers data should be referred to when dealing with lamps N LA 7 Fault Finding All fault finding must be conducted by a competent person or qualified
30. which the compound is packaged You may obtain heatsink compound at your local electronics dealer Apply the compound with a wood or plastic spatula a popsicle stick will work well A thin layer of compound is adequate Use internal star washers as opposed to split washers When tightening the diodes in the model 8502 power supply the torque should be 90 in lbs 125 in lbs In replacing diodes observe polarity Model 8502 diodes 1 3 are 1N3291R types diodes 2 4 are 1N 32915 types DC OUTPUT 22 30 VOLTS 50 85 vos 00 2200 WATTS SEE DEN 550235 TCR INTERCONNECT AND RATING INFORMATION POWER INPUT 19 208 240 VAC amp OwR LI O SIE DEN 30235 Fot Te econ Mi RECT AND laTINAS AfORMANOU 2 x CONTROL INPUT f n f va 60 wt lt s z L amp 110251 Sit INTER CON WEIT AND RATINGS INFORMATION A Ki eL po ACE INSZGIE DOC AMP ee DODE INAS IO AMP 400V 91 1 CONTACTOR 2 POLE CHOKE r man TOU TERMINAL sue CURTIS 4 6 INPUT DOUTPUT CUEREMT 15 ADJUSTED BY CHANGING POSITION OF WEES reZ TERMINAL BLOCK OUTPUT z is OM TB LETTERS H L FOR SMALL INCREMENTS He HIGHEST LeLOWE ST I NUMBERS 4 6 FOR LARGE INCREMENTS 4 WGHEST 6 LOWEST FOR 240 VAC INPUT USE ONLY 6 DS FOR ZOR VAC INPUT USE any NOEMALLN 4 OS a S8 8 91S8 Z0S8 L0S8 LP A MODEL 8501 SEE DEN 5OVIF OR MODEL 502 SEE Dwa SO2OIE Ot LP A MODEL 8508 LAMPHOUSE MODEL 8516 SEE PAG 451601A SEE DWG 851065 POWE
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