Francis Searchlights A7164 User manual

User Instruction & Installation Manual
FX380 Remote Control
2 Kilowatt Xenon Searchlight
Product Reference Number:
A7164 –Variable Speed Motor Unit 240v
A7163 –Variable Speed Motor Unit 115v
Manufacturer’s details: Distributor details:
Manual Part Number: C27403
2.11.17 Issue: 2
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 - Wiring Diagram & General Assembly
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 depressurised 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
FX380RC 2000 watt searchlight has the following features:
All marine grade materials and fixings;
Electronic power supply unit;
Parabolic aluminium reflector, electro-formed nickel rhodium plated;
Powder coated & Stove enamel paint finish;
385° horizontal rotation;
Vertical movement +30˚ to -35˚;
Variable speed 1-23˚/sec (Pan), 1-8˚/sec (Tilt);
RS485 connectivity & auto home positioning;
Remote focus facility;
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 –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. AS16040A (Irem)
Power Supply fixing 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 lamp house 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 lamp house. 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 lamp house 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 lamp house 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 lamp house voltmeter you have primary
power. If there is no lamp house 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 lamp house 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 (refer to drawing C21501). 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. On an uneven surface
it may be necessary to use a suitable sealant such as silicone, in order to ensure a
weatherproofed joint.
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5 - Electrical Installation
Note: ~
When the main power is first applied to the searchlight, the searchlight will carry out a
self-test, it will Pan to the left limit and Tilt down to the limit, once this is complete, the
searchlight will then move to the centre and horizontal, during this please do not try and
operate the searchlight while this test is being carried out. Once the searchlight is back
at centre the searchlight can then be operated normally, by pressing the Panel button on
the control panel.
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 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 junction box 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.

Installation Guidelines
A typical installation and connection routine for the FX380RC searchlight is as follows:
Referring to wiring diagram C27401 a supply is fed to the junction box, which then provides a
common feed to the motor gearbox, searchlight, power supply unit and joystick panel.
The searchlight has been pre-wired with 3 meters of cable from the motor gearbox to junction
box provided. The searchlight head is pre-wired along with the connecting cable to the motor
gearbox.
Cables required to be connected by the customer: -
2 pair twisted 0.22mm 100 ohm screened cable from the joystick panel to the junction box.
3 cores 2.5mm cable from the PSU to the junction box.
4 cores 6mm cable from the PSU to the junction box.
Supply cable to the junction box.
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.
All other facilities are fed via the control panels and motor gearbox.
When the light is in operation, the output from the PSU should be approximately 24v dc at
80amps.

Fitting instructions for the 2Kw xenon lamp
Referring to the diagram overleaf:
1) Unfasten eight 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) Attach the NEGATIVE (cathode) end of the lamp to the lamp holder socket (H) which
is supplied separately, using the M8 x 10 grub screw (J).
6) The lamp can now be inserted with the lamp holder socket into the lamp holder rear (I),
the negative (cathode) end of the lamp is towards the rear of the searchlight.
7) On the rear lamp holder, tighten the knurled screw (G) onto the lamp holder socket (H)
to hold the lamp in position.
8) 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).
9) Fasten the front and rear lampholder leads as wiring diagram, ensuring the
connections are secure.
10) The front bezel and rear bezel can now be replaced.
11) 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 searchlight can be remotely positioned via the joystick control panel, with the facility for
movement up, down, left and right. (See Fig 1 below for aid to instructions)
To operate the panel, press panel button (1), the button will light up & the joystick (4) is now
operational. To switch the lamp on or off press the lamp button (2)
The speed of movement depends on the more pressure applied to the joystick (4) the faster the
searchlight moves. When in the desired position the joystick should be released so that it
returns to dead centre.
On remote focus models the beam of the searchlight can be adjusted to give a variety of beam
types. Using the focus button (3) on the joystick panel, the desired beam can be achieved for
any particular application. The beam will move continuously through ‘spot’ to ‘flood’. In order to
fix the beam type, simply release the focus button at the desired position.
To return the searchlight to Factory set auto home position (forward and horizontal) simply
switch off the joystick panel using the panel button (1) and then press the lamp button (2), the
searchlight will then move to the pre-programed home position.
To set a new Home position, move the searchlight to the desired home position, switch off the
panel (1), move the joystick to the downward position ↓ and simultaneously press the Lamp
button (2).
There is the option for added slave panels, the slave panel has all the features of the main
control panel i.e. joystick, focus and on/off.
When the lamp is switched on, this will illuminate the Lamp button (1) on both the Main & Slave
Control panel, also when the Focus button (3) is pressed, both Focus buttons will be
illuminated.
The brightness of the panel can be increased or decreased by holding the panel switch (1)
down and moving the joystick left and right, left to decrease right to increase.
Fig 1

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 lamp
house 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 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 lamp house, 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 re-crystallisation 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;