Francis Searchlights FX560D User manual

User Instruction & Installation Manual
FX560
3 Kilowatt Xenon Searchlight
Product Reference Number:
A7079 –FX560D 3Kw 240v 1 Phase 50/60Hz
A7081 –FX560DP 3Kw 240v 1 Phase 50/60Hz
A7080 –FX560C 3Kw 240v 1 Phase 50/60Hz
A7082 –FX560CP 3Kw 240v 1 Phase 50/60Hz
Manufacturer’s details: Distributor details:
Manual Part Number: C27528
Issue: 1 1.4.17
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 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.
◼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 3000 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 - 3000 Watts;
◼Supply voltage –220/240V;
◼Peak Beam Candlepower –175 Million lux;
◼Range –13,251 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 Irem Power Supply Unit and Ignitor are included overleaf. For
more detailed information please contact the manufacturer.
PSU ref: Model EX-100D/1
Ignitor ref: AS16040A

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 mains supply, provision must
be made in the cable size in order to overcome the voltage drop.
The PSU should NOT be positioned any more than 5 meters away from the
Searchlight with the standard 4 cores 16mm cable supplied, if this distance needs to
be extended a larger cross-sectional cable will need to be fitted.
The following table below indicates the maximum length of cable to be used for the AC
supply cable.
Searchlight
1 phase 230v
Cable Size (mm²)
Distance Max
3 cores 2.5mm
27 MTRS
3 cores 4mm
43 MTRS
3 cores 6mm
65 MTRS
3 cores 10mm
114 MTRS
3 cores 16mm
174 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 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 searchlight is as follows:
Referring to wiring diagram C27527, 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 16mm cable from the Searchlight to the PSU
3 cores 2.5mm cable from the Searchlight to the PSU
(Customer may need to provide a suitable junction box to extend these cables –3 metres
supplied).
The Mains cable to the PSU to be supplied by the customer
The searchlight head is pre-wired
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 3Kw 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) 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 (I)
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 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

Failure of Lamp to Ignite
In the event of the xenon lamp failing to light the following steps should be taken:
1) Check that the mains supply is connected to the input of the PSU. On operating the switch,
if the lamp does not light, switch off mains supply and check all fuses;
2) On pressing remote starting switch the lamp still does not ignite, check the searchlight
head. On your command get an operator to activate the starting switch for approximately
10 seconds. During this time listen for any noise (cracking or hissing) coming from within
the barrel. If this arcing is heard switch off the supply at the mains. Remove the rear bezel
to expose the two supply leads to the xenon lamp. Using a dry cloth wipe these leads to
remove any dust, moisture or condensation that may have formed around the inside of the
barrel. Replace the rear bezel, ensuring the latches are securely fastened, and perform the
check again, listening for the cracking. If the lamp still fails to ignite, switch off at the mains
and replace the xenon lamp in accordance with the safety procedures within this manual
and the manufacturer’s information.
Any further tests to be carried out with regards to lamp failure must be conducted by a
competent electrical engineer and should not be carried out in an explosive atmosphere.
3) Before a xenon lamp will ignite, the electrically insulated gas between the electrodes must
be ionised. This is done by the ignitor which produces a high frequency voltage (up to
30,000 volts or higher). The ignitor is activated by switching the lamp on and a crackling or
hissing noise should be heard. The ignitor is housed within the rear of the searchlight
barrel. This is a totally encapsulated unit and repair is not advised. If found to be faulty a
new ignitor must be fitted.
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8 - Maintenance and Servicing
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 at least every three
months;
◼Before checking, disconnect the equipment from the supply;
◼Visually inspect the condition of the equipment;
◼Any major or minor structural damage should be rectified immediately in order to reduce
sympathetic wear;
◼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;
◼Clean the reflector if required;
◼Check the reflector mounting gaskets. If signs of corrosion or damage are
evident, replace as necessary;
◼Ensure that the lampholder is free from corrosion or other damage;
◼Check earth point for conductivity;
◼It is advisable to check all seals and gaskets for signs of degradation. Renew if necessary;
◼Upon completing all maintenance requirements, the searchlight should be tested for full
working order (approximately 20 minutes).
◼Every six months the external movement mechanism i.e. lockwheels, elevation & pan
mechanism should be lightly lubricated.
If in any doubt as to the correct servicing procedures to adopt please contact your
distributor/agent or the manufacturer who will be able to advise the best course of
action for your product.
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9 –General Assembly & Wiring Diagrams
Drawing Number Description
A7079 FX560D 3Kw G.A.
A7081 FX560DP 3Kw G.A.
A7080 FX560C 3Kw G.A.
A7082 FX560CP 3Kw G.A.
C27527 240v 3Kw 1 Phase Xenon Wiring Diagram