Francis Searchlights FR 230 Operation manual

FR 230 Searchlight
User Information

FR 230 Searchlight i
Contents
Page
USER INFORMATION FOR FR 230 SEARCHLIGHT
INTRODUCTION.......................................................................................1
SAFETY PRECAUTIONS ...........................................................................1
TECHNICAL DATA ...................................................................................2
UNPACKING INSTRUCTIONS.....................................................................2
INSTALLATION INSTRUCTIONS..................................................................3
Safety Precautions...........................................................................3
Preparing the Mounting Position......................................................3
Mounting the Searchlight .................................................................3
Power Supply Requirements............................................................3
OPERATING INSTRUCTIONS.....................................................................4
Setting to Work ................................................................................4
Testing.............................................................................................5
FAULT FINDING ......................................................................................6
Fault.................................................................................................6
Remedy ...........................................................................................6
MAINTENANCE AND SERVICING REQUIREMENTS .......................................7
SPARE PARTS LISTS
BARREL ASSEMBLY ................................................................................8
LAMPHOLDER.........................................................................................9
DECK MOUNT ......................................................................................10
DECK PEDESTAL MOUNT ......................................................................11
CABIN TRAINER MOUNT........................................................................12
CABIN PEDESTAL TRAINER MOUNT........................................................13
SEAL KITS ...........................................................................................14
SPARE PARTS ORDERING .....................................................................15
PARTS DISPOSAL.................................................................................15
SALES AND SERVICE ............................................................................15
GUARANTEE ........................................................................................15

FR 230 Searchlight 1
User Information for FR 230 Searchlight
It is imperative that this manual is
read carefully before installing or
using your equipment. For your
future reference this manual
should be kept in a safe place.
Introduction
Thank you for specifying a product
from the Francis Searchlights Ltd
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 FR Series Searchlights
combine design features proven over
many years of 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.
Please complete the following boxes
for your future reference purposes.
Product
Number Serial Number
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 manoeuvring the
searchlight into its fixing
position, suitable lifting
points must be chosen in
order to prevent damage
to the equipment or
personal injury.
Prevent rain, snow, condensation
and water droplets from contacting
the lamp as this may cause bulb
failure, and possible shattering;
Quartz halogen lamps run with a
high internal pressure in excess of
atmospheric. Whilst the
construction is inherently strong,
there is a slight risk of the lamp
shattering;
Never look directly into an
illuminated searchlight as this may
cause severe damage to eyesight.
If it is necessary to inspect a lamp
whilst in operation, always wear
suitable protective goggles;

FR 230 Searchlight 2
Should it be necessary to examine
the lamp with the front bezel
removed, always use a protective
shield to ensure a safe working
environment;
Never attempt to clean the lamp
when in use;
Searchlights get hot. Never touch
the unit when lit and always allow
at least ten minutes for cooling
down after turning off;
Ensure the lamp has cooled
sufficiently before removal. During
the cooling down period avoid
mechanical or thermal shock to
the lamp as this may cause
shattering;
If undue force appears necessary
to remove the lamp, the
equipment should be inspected by
a competent person, or contact
the manufacturer;
When breaking a lamp for
disposal, care must be taken to
ensure that the fragments are
safely contained. Precautions
must be taken against flying glass
and other fragments. This
operation should be performed
outdoors or in a well ventilated
area. In ALL cases reference
should be made to the lamp
manufacturers instructions packed
with the lamp;
Due to the vast range of lamps
available, it may appear possible
that more powerful lamps can be
used in the equipment for which it
was designed. Even when the unit
will physically accept a higher
wattage lamp, this substitution is
not recommended as it could be
dangerous.
Technical Data
Voltage
(V) Range (M) PBCP (x1000) Divergence
(°) Watts
(W) Lamp Cap
12 643 414 2 100 GX6.35
24 784 614 2 150 GX6.35
120 912 832 4.9 300 GX6.35
240 888 790 4.9 300 GX6.35
Unpacking Instructions
Care should be taken when
unpacking the searchlight, so as not
to cause damage to the equipment or
cause personal injury. A visual
inspection of the equipment should be
conducted to check for damage
during transit or damaged lamps.
Enclosed in the packing is the flange
sealing gasket. This should be
retained for installation purposes.

FR 230 Searchlight 3
Installation Instructions
The following instructions should be
read and fully understood prior to
installing the equipment to ensure
correct procedures are followed and
all safety precautions are observed.
Note: If the equipment has
been in storage for a
considerable 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 injury.
Preparing the Mounting
Position
Using the template provided mark out
and drill the fixing holes through the
deck or cabin roof. In the case of
cabin control models, a centre hole is
also required to allow the mechanism
to pass through.
Mounting the Searchlight
Fit the ‘O’ ring in position and bolt the
searchlight base securely down. On
an uneven surface it is necessary to
use a suitable sealant, such as
silicone, in order to ensure a weather
proofed joint.
For cabin control models it is
necessary to remove the underdeck
control assembly prior to installation.
Using the allen key provided, the five
grubscrews on the underdeck
mechanism should be loosened to
allow the underdeck control assembly
to be removed. The outer tube can
then be positioned through the centre
hole. The searchlight base can then
be securely fixed as stated above.
Upon installation, re-assemble the
underdeck control mechanism,
ensuring that the grubscrews are
secure and the mechanism operates
correctly.
Power Supply Requirements
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 maximum light
output from the searchlight, it is
essential that the full operating
voltage of the lamp fitted is applied to
the lampholder contacts.
Method of Electrical Connection
Disconnect the supply before working
on the electrical system.
The searchlight must be connected to
a fused electrical supply, using
suitably sized cable.
If the searchlight is positioned 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 only.
12v 100w
Cable Size Max
1.5mm22 M
2.5mm2 3 M
4mm2
5 M
6mm2
7 M
10mm2
12 M

FR 230 Searchlight 4
24v 150w 250w
Cable Size Max Max
1.5mm25 M 3 M
2.5mm2 8 M 5 M
4mm2
13 M 8 M
6mm2
20 M 12 M
10mm2
34 M 20 M
120v 300w
Cable Size Max
1.5mm213 M
2.5mm2 21 M
4mm2
32 M
6mm2
50 M
10mm2
84 M
230v 300w
Cable Size Max
1.5mm224 M
2.5mm2 39 M
4mm2
62 M
6mm2
96 M
10mm2
161 M
Whenever possible cable terminations
should be made below deck and with
approved terminal devices.
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.
When wiring the negative supply, the
direct connection to a battery or
supply, or metal hull/object, should be
avoided. It is advisable to use a
suitable commoning block or
connection.
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.
Operating Instructions
This equipment is designed for use
out of doors, in free air.
Never place anything on, or cover, the
searchlight when in operation as this
may present a hazard.
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 ‘spreads’.
Using the focus knob underneath the
searchlight barrel the beam can be
moved from ‘spot’ to ‘flood’ positions.
The searchlight is fitted with an IP66
Drainage Plug to allow efficient water
draining should any ingress occur.
The Breather Unit at the rear of the
searchlight ensures a steady airflow
to prevent any vacuum forming within
the barrel.
After use, the searchlight should be
returned to the horizontal position in
order that a level plane is provided to
allow for any water drainage.
Note: 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 before
consulting the
manufacturer or agent.

FR 230 Searchlight 5
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 sleeve
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
submitted to mechanical shock or
vibration.
Quartz lamps should not become
contaminated with oils, grease or
come into contact with skin.
When fitting the lamp:
Always isolate the equipment from
the supply before inserting a lamp;
Ensure the circuit is suitably
fused;
Ensure that the lamp is of the
recommended type and rating;
Check the lampholder is in good
condition. If the contacts show any
sign of corrosion the lampholder
should be replaced;
Check that the lampholder is in a
good dry condition. Never allow
water to collect in the lamp fitting
or come into contact with the
lamp.
To fit the lamp:
Loosen all the thumbscrews on
the front of the searchlight,
allowing the bezel and glass to
hang clear on the captive bolt;
For easier access the light shield
may be removed by firstly undoing
the centre screw;
Cut open one end of the protective
sleeve surrounding the lamp;
Using the sleeve to prevent the
fingers coming into contact with
the lamp, position the two lamp
pins above the holes in the
lampholder;
Gently push the lamp into the
lampholder and discard the
protective sleeve;
Replace the light shield, fixing the
centre screw in position;
Position the front bezel onto the
searchlight and tighten the
thumbscrews until hand tight.
Testing
Upon correct installation and
connection to an electrical supply, the
equipment can be tested in order to
ensure it's correct performance. This
work must be carried out by a
competent person with some
knowledge of electrical equipment.
Equipment required:
Multi-meter with leads;
Ammeter.
Using the equation P=VI the
approximate power output of the
equipment can be calculated in the
following way:

FR 230 Searchlight 6
Using the multi-meter take a
voltage reading;
Using the Ammeter, take an amps
reading from the live cable to the
lamp;
Multiply these values together to
give an approximate wattage.
For Example:
Using a 240v 1000w Tungsten
Halogen lamp,
Voltage reading : 240v
Amps reading: 4 amps
Therefore:
Wattage = 240 x4 = 960 watts.
Fault Finding
If a fault occurs the following
procedures should be adopted. Any
work to be carried out should be
conducted by a competent person. A
multimeter should be used for fault
finding purposes.
Fault
Lamp Fails to light
Causes
1) Power not supplied
2) Fuse blown
3) Failed lamp
Remedy
1) Check voltage at supply/battery. If
necessary recharge battery. If
supply is not present fault is at
customer supply. If power is
present, see remedy 2.
2) Check fuse for visual failure. If
none noticeable check fuse for
continuity. If fuse found to be
faulty, replace with new part. If
found to be working correctly see
remedy 3.
3) Firstly, check supply at lampholder
connecting block (within
searchlight barrel). If supply
present, disconnect unit from
power supply before removing
lamp. If noticeable damage to
filament is present, the lamp will
have failed. The lamp can also be
checked using a multimeter for
continuity of the filament. Replace
new lamp following all precautions
mentioned previously and lamp
manufacturers instructions.

FR 230 Searchlight 7
Maintenance and
Servicing Requirements
In order to prolong the service life and
performance of your searchlight, the
following maintenance guidelines are
recommended:
Maintenance checks should be
conducted before every voyage or
every three months;
Before checking, disconnect the
equipment from the supply;
Visually check the condition of the
equipment;
Any major or minor structural
damage or defect should be
rectified immediately;
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 rubber reflector
mounting pads. If signs of
corrosion or damage are
evident, replace as necessary;
Ensure the lampholder is free
from corrosion or damage;
Check the earthing point for
conductivity;
Check lampholder assembly
for signs of damage or wear. If
required apply a little grease to
the focus assembly;Upon
completion of these checks,
the searchlight should be
tested for full working order
(approximately 15 minutes);
Every six months the external
movement mechanisms, i.e.
lockwheels, elevation and pan
mechanisms, may be lightly
lubricated.
Note: It is advisable to check
all seals and gaskets for
degradation. If
replacement is necessary
the kit numbers are
quoted in the back of the
spares lists.

FR 230 Searchlight 8
Spare Parts Lists
Barrel Assembly
Item No. Description Part No. No. Off
1 Front Bezel Assembly C14327-01 1
2 Front Bezel C10597-38 1
3 Front Glass C08865-00 1
4 Front Glass Gasket C08835-00 1
5 Reflector C06675-00 1
6 Screw M5 x 8 Pan Hd. C10140-00 3
7 Washer M5 S/C Spring C09231-00 3
8 Barrel Sub-assembly C16886-01 1
9 Fluted Nut C08812-22 3
10 Mirror Clip Sub Assembly C10055-01 3
11 Screw M5 x 6 Pan Hd. C15258-00 3
12 Drainage Plug C20070-00 1
13 Breather Unit Assembly C22268-01 1

FR 230 Searchlight 9
Lampholder
Item No. Description Part No. No. Off
1 FR230 L.V L/H Conversion Kit C13033-01
1 FR230 H.V L/H Conversion Kit C16888-01
2 Lampholder Assembly ( FR 230 L.V.) C16982-01 1
2 Lampholder Assembly ( FR 230 H.V.) C16891-01 1
3 Focus Wheel Assembly C09888-01 1
4 Spring C08827-00 1
5 Screw M4 x 30 Hex. Hd. C16764-00 4
6 A.V. Washer C16763-55 4
7 A.V Mount C16761-00 4
8 A.V. Bush C16762-01 4
9 Washer M4 Nylon C15272-00 4
10 Washer M4 Plain C04376-00 4
11 M4 S/C Washer C08793-00 4
12 Domenut M4 C11183-00 4
13 L.V. & H.V. GX6.35 Lampholder C16878-00 1

FR 230 Searchlight 10
Deck Mount - C15070-01
Item No. Description Part No. No. Off
1 Elevation Lockwheel Assembly C15395-01 1
2 Lockwheel Assembly C11025-01 1
3 'O' Ring Seal C10168-00 1
4 Screw M10 x 20 Hex. Hd. C08094-00 1
5 Washer M10 Plain C08091-00 1
6 Trunnion Spacer C10254-01 1
7 Cable Gland C10158-00 1
8 Floating Stop C08929-22 1

FR 230 Searchlight 11
Deck Pedestal Mount - C15154-01
Item No. Description Part No. No. Off
1 Elevation Lockwheel Assembly C15395-01 1
2 Lockwheel Assembly C11025-01 1
3 Pedestal Assembly C10073-38 1
4 'O' Ring Seal C10170-00 1
5 Screw M10 x 20 Hex. Hd. C08094-00 1
6 Washer M10 Plain C08091-00 1
7 Trunnion Spacer C10254-01 1
8 Floating Stop C08929-22 1

FR 230 Searchlight 12
Cabin Trainer Mount - C15164-01
Item No. Description Part No. No. Off
1 Base 'O' Ring Seal C10168-00 1
2 Lockwheel Assembly C11026-01 2
3 Bellows Bottom Bush C20269-01 1
4 Bellows C20281-00 1
5 Bellows Top Bush C20270-01 1
6 Spigot 'O' Ring Seal C10169-00 1
7 Washer M10 Plain C08091-00 2
8 Screw M10 x 20 Hex Hd. C08094-00 2
9 Trunnion Spacer C10254-01 2
10 U-Piece Bush C08932-01 2
11 Screw M6 x 20 Pan Hd. C10174-00 2
12 U-Piece Assembly C10086-38 1
13 M8 x 35 Hex Screw C08796-00 1
14 M8 Plain Washer C06999-00 1
15 Cable Gland C10158-00 1
16 Floating Stop C08929-22 1
17 Washer M12 Plain C08370-00 1
18 ‘O’ Ring C21967-00 1

FR 230 Searchlight 13
Cabin Pedestal Trainer Mount - C15165-01
Item No. Description Part No. No. Off
1 Base 'O' Ring Seal C10170-00 1
2 Lockwheel Assembly C11026-01 2
3 Bellows Bottom Bush C20269-01 1
4 Bellows C20281-00 1
5 Bellows Top Bush C20270-01 1
6 Spigot 'O' Ring Seal C10169-00 1
7 Washer M10 Plain C08091-00 2
8 Screw M10 x 20 Hex Hd. C08094-00 2
9 Trunnion Spacer C10254-01 2
10 U-Piece Bush C08932-01 2
11 Screw M6 x 20 Pan Hd. C10174-00 2
12 U-Piece Assembly C10086-38 1
13 M8 x 35 Hex Screw C08796-00 1
14 M8 Washer C06999-00 1
15 Floating Stop C08929-22 1
16 Washer M12 Plain C08370-00 1
17 ‘O’ Ring C21967-00 1

FR 230 Searchlight 14
Seal Kits
Description Part No.
Deck Gasket Seal Kit C17110-01
Cabin Gasket Seal Kit C17089-01
Deck Pedestal Gasket Seal Kit C17111-01
Cabin Pedestal Gasket Seal Kit C17112-01

FR 230 Searchlight 15
Spare Parts Ordering
In order to prolong the life and
performance of your searchlight it is
recommended that only Francis
Searchlights Ltd. spare parts are
specified. Reference should be
made to the relevant spares section
in this manual. The part number
should be quoted at all times so that
a price and delivery time can be
supplied.
Spare parts or accessories can be
obtained from your distributor/agent
or directly from the manufacturer.
Parts Disposal
It is essential that all parts are
disposed of correctly and safely to
ensure no risk to other personnel.
When disposing of lamps the
procedures outlined in this manual
and the lamp manufacturers leaflet
must be adhered to.
The reworking or modification of
parts should not be undertaken
before consulting the manufacturer
or agent.
Sales and Service
For sales and service please
contact your agent/distributor or
contact the manufacturer direct at:
Francis Searchlights Limited
Union Road
Bolton
BL2 2HJ
England
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
http://www.francis.co.uk
Guarantee
This product is covered with a 12
month warranty. Any claim whilst
under warranty should be
addressed to the Quality Manager
at Francis Searchlights Ltd.

FR 230 Searchlight 16

FR 230 Searchlight 17
FR 230 Booklet Part Number C17128-00
Issue 10 February 2012
Agent/Distributor Stamp
The manufacturer reserves the right to change the information contained within
this booklet without prior notice
FRANCIS SEARCHLIGHTS LTD Cert No. 2094
UNION ROAD,BOLTON, BL2 2HJ, ENGLAND BS5750 Part 1
Tel [phone] Fax: [phone] (ISO 9001)
http://www.francis.co.uk