Francis Searchlights A2963 User manual

User Instruction & Installation Manual
FX560
2 Kilowatt Xenon Searchlight
Product Reference Number:
A2963 –FX560D 2Kw 240v A2256 –FX560D 2Kw 115v
A2964 –FX560DP 2Kw 240v A2258 –FX560DP 2Kw 115v
A2965 –FX560C 2Kw 240v A2257 –FX560C 2Kw 115v
A2966 –FX560CP 2Kw 240v A2259 –FX560CP 2Kw 115v
Manufacturer’s details: Distributor details:
Manual Part Number: C23160
Issue: 7 19.3.13
Francis Searchlights Ltd
Union Road, Bolton
Lancashire, BL2 2HJ, UK
Tel: [phone]
Fax: [phone]
http://www.francis.co.uk
E-mail: [e-mail]

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 - General Assembly & Wiring Diagrams
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 marine 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.
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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, suitable
lifting points must be used in order to prevent damage to the equipment or personal
injury.
Because of the high internal pressure within the lamp, there is a risk of explosion in either a
hot or cold state;
During operation this lamp emits intense UV radiation which is harmful to the eyes and
skin. Suitable protection should be worn;
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;
Always use protective jackets supplied with the lamp;
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;
Searchlights get hot. Never touch the unit when lit and always allow 15 to 20 minutes for
cooling down after turning the searchlight off;
Never place anything on or cover the searchlight when in use;
Ensure the lamp has cooled sufficiently before removal;
If undue force appears necessary to remove the lamp, the equipment should be inspected
by a competent person or contact the manufacturer;
When disposing of lamps there are several options available:
Return the lamp, via the supplier, to the lamp manufacturer in its complete
packaging
Because of the 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;
XBO lamps do not contain materials which are harmful to the environment and thus are not
subject to special waste disposal regulations;
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.
Always refer to the lamp manufacturer’s technical data when dealing with lamps.
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3 - Technical Information
This product has been designed to operate in accordance with the product specification. The
FX560 2000 watt searchlight has the following features:
All marine grade materials and fixings;
Electronic power supply unit;
Parabolic glass reflector;
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 –110/120v or 220/240V;
Peak Beam Candlepower –108,084,800 lux;
Range –10,396 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 Irem Ignitor are included overleaf.
For more detailed information please contact the manufacturer.
PSU ref: Model 8502 (Xelamp)
Ignitor ref: AS16040A (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 Single
Frequency 60 Hz (50Hz available)
Output Adjustments 9 steps
Size Width 12” (30.5 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, it indicates 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 not allow 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
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.
Model 8502 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
two 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 current 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 ¼ 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. If 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 light.
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 overheating of R3. 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 test a 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 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 1N3291S types.

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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 maintenance 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.
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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) Disconnect the supply before working on the electrical system;
2) The searchlight must be connected to a fused electrical supply, using suitably sized cable;
3) If the searchlight is located 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 (mm²)
Distance Max
Distance Max
1.5
8 MTRS
37 MTRS
2.5
14 MTRS
60 MTRS
4
22 MTRS
96 MTRS
6
34 MTRS
150 MTRS
10
57 MTRS
250 MTRS
4) Whenever possible cable terminations should be made below deck and with approved
terminal devices;
5) If a 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) For 110/220v AC products, the following colour coding system should be used for the
customer supply cable:
Brown - Live
Blue - Negative
Green/Yellow - Earth
Note: This equipment must be earthed.
7) For ease of use, a single pole switch, of the appropriate rating should be fitted in a
convenient location. All cable lengths should be kept to a minimum.

Installation Guidelines
A typical installation and connection routine for the searchlight is as follows:
Referring to wiring diagram C23114, 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 cores 6mm cable from the Searchlight to the PSU, doubling up the pairs,
3 cores 2.5mm cable from the Searchlight to the PSU.
3 cores 1.5mm cable from the Searchlight to the Heater switch. (Customer may need to provide
a suitable junction box to extend these three cables –3 metres supplied).
The searchlight head is pre-wired along with the connecting cable to the motor gearbox.
Basic Operation
When the searchlight is switched on a 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) Unfasten the ten latches (A) on the front and rear of the searchlight;
2) Remove the front bezel (B) and rear bezel (C) assemblies;
3) Unscrew the two M6 hexagon screws (D) from the front lampholder mounting block (E)
and remove the front lampholder assembly from the mounting bracket;
4) Loosen the knurled screw on the front (F)and rear (G) lampholder assembles;
5) The lamp can now be inserted, make sure that the negative (cathode) end of the lamp
is towards the rear of the searchlight;
6) Tighten the knurled screw (G) on the rear lampholder assembly to hold the lamp in
position;
7) 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);
8) Fasten the front and rear lampholder leads as wiring diagram, ensuring the
connections are secure;
9) The front bezel and rear bezel can now be replaced.
10) Removal is the reverse of the above.

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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 base 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 dome clockwise/anti-clockwise the lampholder
mechanism moves through spot to flood positions. When in the desired beam is achieved
simply release the lockwheel.
The heaters specified on this equipment are self-regulating and will shut off when they reach
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 is 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 FITTED;
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 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;
2) 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 their average lamp life. After this time there
is an increased risk of the lamp exploding;
3) 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 circumstances the lamp manufacturer’s data should be referred to when dealing with
lamps.
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7- Fault Finding
All fault finding must be conducted by a competent person or qualified Electrical Engineer.
Please refer to the following table for the trouble-shooting of Xenon lamps.
Fault
Cause
Remedy
Wrong Polarity
Lamp incorrectly fitted
Faulty wiring
Anode (large electrode)
must always be on top in
vertical burning position
Check polarity, transpose
connections if necessary
Cap overheated
Cap temperature above
230°C
Faulty contacts
Cooling equipment
defective
Check terminals, tighten or
renew
Check cooling equipment
and replace if necessary
Arc unsteady
Lamp operated outside
current control range
Magnetic stabilisation for
horizontal operation
defective
Correct current setting
Check magnetic
stabilisation
Bulb draws in air
Crack in graded seal
caused by overheated cap
Maximum cap temperature
230°C
Check terminals - tighten
or renew
Glass erosion on fused
quartz bulb
Lamp operated outside
current control range
Lamp service life
exceeded
Correct current setting
Check meter
Electrodes damaged
Premature blackening
Current ripple too high
Auxiliary mirror incorrectly
adjusted
Have power supply
inspected
Adjust auxiliary mirror
Asymmetrical blackening
of lamp (in horizontal
burning position)
Lamp operated too long in
same position
Turn lamp through 180°
after half service life