Francis Searchlights FX380D User manual

User Instruction & Installation Manual
FX380 Manual Control
1Kw Xenon Searchlight
Product Reference Number:
A2771 –FX380D 1Kw 240v A2770 –FX380D 1Kw 115v
A2773 –FX380DP 1Kw 240v A2772 –FX380DP 1Kw 115v
A2775 –FX380C 1Kw 240v A2774 –FX380C 1Kw 115v
A2777 –FX380CP 1Kw 240v A2776 –FX380CP 1Kw 115v
Manufacturer’s details: Distributor details:
Manual Part Number: C20332
29.4.15 Issue: 12
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 Drawings
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 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, the lifting
handles 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
FX380 1000 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 Deck & Deck Pedestal 40, Cabin & Cabin Pedestal +40-20;
Internal self-regulating heater.
The searchlight also performs to the following optical data:
Xenon light source;
Lamp Wattage - 1000 Watts;
Supply voltage - 220/240V or 110v/115v;
Peak Beam Candlepower - 45,000,000 Lux;
Range - 6,700 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 Power Supply Unit and Ignitor are included overleaf. For more
detailed information please contact the manufacturer.
PSU ref.: ECG 1000 XE
Ignitor ref. ZG 60 XE

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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 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 1Kw
240v 1Kw
Cable Size (mm²)
Distance Max
Distance Max
1.5
17 MTRS
75 MTRS
2.5
28 MTRS
123 MTRS
4
44 MTRS
195 MTRS
6
68 MTRS
304 MTRS
10
115 MTRS
509 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;

Installation Guidelines
A typical installation and connection routine for the searchlights is as follows:
Referring to wiring diagram X4737, a 240v or 115v AC supply should be connected to the
Power Supply Unit as shown, which then provides a common feed to all other functions and
equipment.
Cables required to be connected by the customer: -
4 cores 4mm cable from the Searchlight into the PSU, doubling up the pairs.
4 cores 1.5mm cable from the Searchlight to the PSU.
Mains supply cable.
(Customer may need to provide a suitable junction box to extend these cables –3 metres
supplied). The searchlight head is pre-wired.
When the light is in operation the output from the PSU should be approximately 19v dc at
54amps.

Upon striking, the running wattage of the lamp can be calculated by using the equation:
P = VI
Where P= Power (watts)
V= Voltage (V)
I = Current (Amps)
Instruments required: D.C. Ammeter & Multi meter
Procedure
1) With the multi meter, test the DC voltage in the searchlight head. This should be
approximately 19 volts.
2) With the D.C ammeter, test the current of the red DC cable at front of searchlight. It should
read approximately 54 amps.
3) Multiply these readings together, as shown above, to obtain the desired wattage required,
usually about 1026watts.

Fitting instructions for the 1Kw 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) The lamp can now be inserted, make sure that the negative (cathode) end of the lamp
is towards the rear of the searchlight & the cathode (-ve) adaptor is securely fastened
to end of lamp;
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. When replacing the lamp retain cathode (-ve)
adaptor C13544-37 for re-use. (See instruction 5 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.
The searchlight can be positioned using the elevation and base lock wheels. 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 lamp holder
mechanism moves through spot to flood positions. When 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 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 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;