ACR Electronics RCL-600 SEARCHLIGHT User manual

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TROUBLE SHOOTING AND PARTS REPLACEMENT MANUAL
FOR THE REMOTE CONTROLLED, XENON SEARCH LIGHT, RCL-600

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PLEASE BE VERY CAREFULL DURING THE TESTING
AND TROUBLE SHOOTING OF THIS LIGHT. THERE ARE
HIGH VOLTAGES ON SOME OF THE CIRCUITS.
Table of Contents
RCL-600
●Lamp does not turn on ……………..……………………………………………..Page 3
●Elevation faulty……………………. ………………………………………… ……Page 4
●Rotation faulty……………………….…………………………………………..….Page 5
●No Focus control…………………….………………………………..……………Page 6
HOW…
1. to remove the Power head………………………………………………………Page 7
2. to check the Ballast……………………………………………………..............Page 8
3. to check the output (Lamp) of PCB PP-207A..……………………….............Page 10
4. to replace the Ballast…………………………………………………………….Page 11
5. to replace the Starter……………………………………………………………..Page 14
6. to replace the Brush holder……………………………………..………………Page 16
7. to check the output (Elevation) of PCB PP-207A..…………………………….Page 19
8. to check the output (Rotation) of PCB PP-207A..…………………................Page 20
9. to replace the PCB (PP-207A)……………………..…….……………………...Page 21
10. to replace the Elevation motor………………………………………...............Page 23
11. to replace the PCB (PP-208A)……………………………………….………….Page 25
12. to check the Rotation gear………………………………………………………Page 27
13. to replace the Rotation motor…………………………………………………..Page 30
14. to repair continuous Rotating light………………......................…………….Page 33
15. to check the Focus motor……………………………………………………….Page 36
16. to change the Focus motor……………………………………………………..Page 38

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RCL-600 TROUBLE SHOOTING
①If 24V DC is measured:
②No 24V DC output?
RCL-600 TROUBLE SHOOTING
Lamp does not turn on
Replace the lamp according to the instructions
Remove the power head according to the directions on page 7. Turn on the
power by pushing the power button on the remote control panel. Check on
the 1st and 2nd contacts from the left side of PCB receptacle (see picture 3,
page 8) whether 24V DC is present.
Does not turn on?
onononon the lamp
Check the Ballast, which is built into the power head, according
to directions on pages 8and 9. “How to check the ballast”.
The Starter is faulty.
Replace the starter according to
directions on pages 14 and 15.
The Ballast is faulty.
Replace the ballast according to
directions on pages 11, 12 and 13.
There is a possibility of a problem inside the driver PCB.
Replace the printed circuit board PP-207A according to directions on page 10.
“How to check the print circuit board PP-207A”.
There is a possibility that the brush holder faulty.
Replace the brush holder according to directions on pages
16, 17 and 18.
The printed circuit board PP-207A is faulty.
Replace the printed circuit board PP-207Aaccording to directions on page 21 and 22.
Normal
Abnormal
Normal
Abnormal

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Elevation control faulty
Y= Yes (Normal)
N= No (Abnormal)
Remove the power head according to the instructions on page 7. Turn on the power
by pushing the „power on‟button on the remote control panel. Move the joy stick
to initiate elevation action while measuring on the 3rd and 4th contacts, from the left side
of the card receptacle, whether 9V DC is present (see picture 3, page 8).
YES NO
The Elevation motor is faulty.
Replace the elevation motor according to the directions on pages 24 and 25.
Check the print circuit board PP-207A according to the directions on page 20.
YES NO
Replace the brush holder according Replace the printed circuit board PP-207A
to the directions on pages 17, 18 according to the directions on pages 22
and 19. and 23.
NO
Replace the printed circuit board PP-208A according to the directions on pages 26 and 27.
RCL-600 TROUBLE SHOOTING

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Searchlight does not rotate.
No (Abnormal)
Manually turn the search light slowly through 360 degrees. (Either right or left)
Very hard to turn? Easy to turn (free) Turn, but with resistance
There is a possibility of problems with the rotation
motor or the rotation gear. Check the rotation action
according to the directions on page 28, 29 and 30.
Check for corrosion in the bearings or mechanical obstruction.
Check and repair.
Check the printed circuit board PP-207A according to the directions on pages 22 and
23.
NO
There is a possibility that the rotation motor or remote control panel is out of order.
Replace the rotation motor according to the instruction on pages 31, 32 and 33.
If there is no improvement, replace the printed circuit board PP-208A of the remote
control panel according to the instruction on pages 26 and 27.
RCL-600 TROUBLE SHOOTING

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Focus not functioning
Yes (Normal)
No (Abnormal)
Check the focus motor according to the instruction on pages 37, 38.
YES
There is a possibility of corrosion in the lamp holder and focus NO
driving rack and this will prevent smooth functioning.
Repair the relevant part or send the unit in toACR for repair.
The focus motor is faulty.
Replace the focus motor according to the instruction on pages 39 and 40.

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1. Method to remove the complete power head
1-1 Use the following tools
・Phillips screw driver
・6 mm Hexagonal wrench
1-2 Working procedures
1) Loosen 4 screws as marked in picture 1and carefully remove the front frame assembly.
Picture 1
2) Loosen and remove 2 screws as indicated in picture 2.
Power head
Picture 2
3) Carefully pull out the complete power head.

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2. Method to check the ballast
2-1 Use the following tools
・Philips screw driver
・6mm Hexagonal wrench
・DC Multimeter
2-2 Procedures to check
1) Remove the power head according to the instruction on page 7“How to remove the power head”.
2) Loosen and remove 2 screws as indicated in picture 3and remove the card edge receptacle from
inside the search light. (See picture 3)
Picture 3
3) Remove 2 cable plugs on the ballast, as indicated in picture 4.
4) Take the card edge receptacle and plug into the Ballast P.C.B. assembly (Refer picture 4)
Picture 4
Plug-in P.C.B.
24V
9V

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5) Turn on the power source by pushing the power button on the remote control panel. Measure on
the terminals (indicated in picture 5) whether 170+ DCV are available.
Picture 5
－Terminal
＋Terminal

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3. Method to check PCB PP-207A (Lamp does not turn on)
3-1 Use the following tools
・Hexagonal wrench of 4mm
・DC Multimeter.
3-2 Procedure
1) Remove the search light and place upside down.
2) Loosen and remove 8 screws as indicated in picture 6. Carefully lift the bottom cover off the base.
Picture 6
3) Remove 2 cable connectors (P and N) as indicated inside circle in picture 7.
Picture 7
4) Turn on the power source by pushing the power button on remote control panel. Measure on
terminals P (+) and N (-)with the DC Multimeter for 24V output. (Refer to picture 7)

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4. Method to replace the ballast
4-1 Use the following tools
・Phillips screw driver
・Pliers
・7mm flat spanner
・6mm Hexagonal wrench
・Silicon compound
・Ballast (PXE-150-DC24)
4-2 Procedure for exchanging the PCBs
1) Remove the power head according to the instruction on page 7.
2) Remove the spring with pliers as indicated by the arrow in picture 8.
Picture 8
3) Remove cables connected to the starter. See picture 9.
Note: Remove cables after marking them in order to replace them in their proper order.
Picture 9

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4) Remove the 4 cables as indicated in picture 10 and 11.
Picture 10
Picture 11
5) Loosen and remove all screws (6) as indicated in picture 12.
Remove the complete ballast assembly with fitting plate
Picture 12

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6) Loosen and remove the 4 screws as indicated in picture 13.
Remove the ballast PCB from fitting plate by sliding it sideways to break the silicon
heating compound seal. Install the new PCB.
Note: Install the ballast after applying a suitable amount of silicon heating
compound between the ballast and fitting plate.
Note
Picture 13

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5. Method to replace the starter
5-1 Use the following tools
・Phillips screw driver
・Flat head screw driver
・Pliers
・6 mm flat spanner
・New Starter unit (STX-10)
5-2 Replacement procedure
1) Remove the power head according to the instruction of page 7.
2) Remove the spring by pliers where is the arrow mark on picture 14.
Picture 14
3) Remove cables connected to the starter as shown in picture 15.
Note: Remove cables after marking them in order to replace them in their proper order.
Picture 15

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4) Loosen and remove all the screws (6) as marked in picture 16.
Remove the fitting plate complete with Ballast assembly.
Picture 16
5) Loosen and remove 4 screws as indicated in picture 17, remove and replace the
starter.
Picture 17
Fitting plate

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6. Method to replace the brush holder
6-1 Use the following tools
・Phillips head screw driver
・4 mm Hexagonal wrench
・8mm Box wrench, Spanner or Wrench
・Brush holder assembly (B3A00140)
6-2 Procedures for change
1) Remove the search light and place upside down on a suitable surface.
2) Loosen and remove 8 screws as shown in picture 18. Carefully lift the bottom cover off the base.
Picture 18
3) Remove all the cables connected to the PCB in order to place the bottom cover to
one side. (See picture 19)
Picture 19

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4) Loosen and remove 4 screws as indicated in picture 20.
Carefully remove the printed circuit board PP207
Picture 20
5) Loosen and remove 3 screws as indicated in picture 21.
Carefully pull out the brush holder complete with mounting plate.
Picture 21

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6) Loosen and remove 4 screws as indicated in picture 22.
Replace the complete brush holder assembly.
Picture 22
Carefully reverse the process to re assemble the light.

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7. Method to check the printed circuit board PP-207A (Elevation)
7-1 Use the following tools
・Phillips head screw driver
・4mm Hexagonal wrench
・8 mm Box wrench
・DC Multimeter
7-2 Procedure
1) Remove the search light and place upside down on a suitable surface.
2) Loosen and remove 8 screws as indicated in picture 23. Carefully lift the bottom cover off the base.
Picture 23
3) Turn on the power source on the remote control panel and move the joy stick in elevation.
Measure +-8V between terminals 3 and 4 of CN2, as indicated in picture 24.
Picture 24

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8. Method to check the print circuit board PP-207A (Rotation)
8-1 Use the following tools
・Phillips head screw driver
・4mm Hexagonal wrench
・8 mm Box wrench
・DC Multimeter
8-2 Procedure
1) Remove the search light and place upside down on a suitable surface.
2) Loosen and remove 8 screws as indicated in picture 25. Carefully lift the bottom cover off the base.
Picture 25
8-3 Turn on the power source on remote control panel and move the joy stick to the right or left.
Measure approx. 8V between terminals 1and 2of CN3 where is the arrow mark on picture 26.
Picture 26