Francis Searchlights FR480 User manual

User Instruction & Installation Manual
FR480 Remote Control 1 & 2 Kilowatt
Tungsten Halogen Searchlight
Product Reference Number:
A7130 –FR480RC 1Kw 115/240v
A7131 –FR480RC 2Kw 115/240v
Manufacturer’s details: Distributor details:
Manual Part Number: C27548
2.11.17 Issue: 3
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 Diagram
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 FR range combines 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.
Prevent rain, snow, condensation and water droplets from contacting the lamp as this may
cause bulb failure and possible shattering;
Quartz halogen bulbs run with a high internal pressure in excess of atmospheric. Whilst the
construction is inherently strong, there is a slight risk of the bulb 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;
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;
Never attempt to clean a lamp whilst in use;
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 breaking a lamp for disposal, care must be taken to ensure the glass fragments are
safely contained. This operation must be performed out of doors in free air. In all
circumstances refer 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 than for which it was designed. Even when the unit will
physically accept a higher wattage or voltage 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
FR480RC searchlight has the following features:
All marine grade materials and fixings;
Parabolic glass reflector;
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. (Optional);
Toughened front glass;
The FR480RC 1Kw searchlight also performs to the following optical data:
1000 Watt T/H 1000 Watt T/H
Supply voltage 110/115v 220/240v
Peak Beam Candlepower 2,073,000 Lux 2,078,000 Lux
Range 1440 metres 1441 metres
Divergence 4.5° 4.5
Operational temperature with heater -50°C (-20without) -50°C (-20without)
The FR480RC 2Kw searchlight also performs to the following optical data:
2000 Watt T/H 2000 Watt T/H
Supply voltage 110/115v 220/240v
Peak Beam Candlepower 2,351,000 Lux 2,701,000 Lux
Range 1533 metres 1643 metres
Divergence 6.5° 6.5
Operational temperature with heater -50°C (-20without) -50°C (-20without)
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.
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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 and bolt the searchlight firmly down. On and 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 following table below indicates the maximum length of cable to be used for the AC
supply cable:
Searchlight
120v 1Kw
120v 2Kw
230v 1Kw
230v 2Kw
Cable Size (mm²)
Distance Max
Distance Max
Distance Max
Distance Max
1.5
18 MTRS
9 MTRS
68 MTRS
34 MTRS
2.5
30 MTRS
15 MTRS
111 MTRS
55 MTRS
4
48 MTRS
24 MTRS
176 MTRS
88 MTRS
6
74 MTRS
37 MTRS
275 MTRS
137 MTRS
10
125 MTRS
62 MTRS
460 MTRS
230 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 FR480RC searchlight is as follows:
Referring to wiring diagram C27426, a supply is fed to the junction box, which then provides a
common feed to the motor gearbox, searchlight 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.
Supply cable to the junction box.
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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

When fitting the lamp:
-Always isolate the equipment from the supply when inserting a lamp;
-Ensure the circuit is suitably fused;
-Ensure the lamp is of the correct power rating and type;
-Check lampholder is in good condition. If the contacts show any sign of corrosion, replace
the lampholder;
-Check 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 fluted nuts on the front of the searchlight, remove the bezel and glass and
store in a safe place;
-For easier access the light shield/spill ring may be removed by undoing the fasteners;
-Position the two pins above the holes in the lampholder;
-Gently push the lamp into the lampholder;
-Replace the light shield/spill ring and front bezel assembly, ensuring the fluted nuts are
securely fastened.
Testing
Upon correct installation and connection to an electrical supply, the equipment can be tested in
order to ensure its’ correct performance. A competent person with some knowledge of electrical
equipment must carry out this work.
Equipment required: Multimeter with leads
Ammeter
Using the equation P=VI, the approximate power output of the equipment can be calculated in
the following way:
-Using the multi-meter, take a voltage reading across terminals 3 & 7 in the searchlight;
-Using the ammeter, take an amp reading from the live cable to the lamp;
-Multiply these figures together to give an approximate wattage (Power output).
For example:
Using a 240v 1000w Tungsten halogen lamp:
Voltage reading = 240v; Amps reading = 4 amps
Therefore, Wattage = 240 x 4 = 960 watts
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