Francis Searchlights LX480 User manual

User Instruction & Installation Manual
LX480 Remote Control
2 Kilowatt Xenon Searchlight
Product Reference Number:
A7154 –Variable Speed Motor Unit 240v
Manufacturer’s details: Distributor details:
Manual Part Number: C28039
17.1.19 Issue: 1
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 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 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
LX480RC 2000 watt searchlight has the following features:
◼All marine grade materials and fixings;
◼Electronic power supply unit;
◼Parabolic glass reflector;
◼Instant lamp re-strike. No cooling down time required;
◼Economical 2400 hour lamp life;
◼Powder coated & Stove enamel painted;
◼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.
◼Toughened front glass;
◼Sealing to IP56;
The searchlight also performs to the following optical data:
◼Xenon light source;
◼Lamp Wattage - 2000 Watts;
◼Supply voltage –220v-240v;
◼Peak Beam Candlepower –90,364,036 lux;
◼Range –9,506 metres;
◼Divergence - 1.5° spot to 10˚ flood;
◼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.: 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 do 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 heatsink 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 mains 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:
Searchlight
240v 2Kw
Cable Size (mm²)
Distance Max
1.5
37 MTRS
2.5
60 MTRS
4
96 MTRS
6
150 MTRS
10
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/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 LX480RC 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 100ohm 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 joystick panel and motor gearbox.
When the light is in operation, the output from the PSU should be approximately 24v dc at
83amps.
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 24 volts.
2) With the D.C ammeter, test the current of the red DC cable at front of searchlight. It should
read approximately 83 amps.
3) Multiply these readings together, as shown above, to obtain the desired wattage required,
usually about 1992watts.

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.
Switch On
The panel is activated using the PANEL button. This will illuminate brightly when the panel is
active. Alternate operations of the PANEL button will switch the panel on and off.
Lamp Control
When the panel is active pressing the LAMP, button will switch the lamp on or off.
If the control panel is switched off with the PANEL button the lamp will switch off.
Focus Control
The lamp focus can be adjusted using the FOCUS button. Lamp focus will adjust continuously
whilst FOCUS is pressed.
Beam Direction
The beam direction can be adjusted using the joystick when the panel is active. Moving the
joystick left or right will pan the beam clockwise or anticlockwise.
Moving the joystick up or down will move the beam up or down. The speed of movement is
proportional to the movement of the joystick. It is possible to move the beam in both directions
at once by moving the joystick diagonally.
Home
The lamp can be returned to a pre-set home position. By default, this is dead ahead with the
beam level although different positions can be programmed as described below.
To send the lamp to the home position switch the panel off then press the LAMP button.
Set New Home Position
To set a new home position move the lamp to the new desired home position. Switch the panel
off then press the joystick down to its limit and press the lamp button. The current position will
now be the new home position.
Set Motion Limit (only available when Remote Focus is fitted)
The lamp travel can be limited in either axis and either direction. To set a new limit, switch the
panel on and move the lamp to the desired limit position. Switch the panel off then press and
hold the focus button whilst moving the joystick full travel in the direction of the desired limit.
Hold in this position for 4 seconds. For example, to set a limit to the tilt up motion; -
1. Switch panel on and drive lamp to desired tilt up limit position.
2. Switch panel off.

3. Press and hold the FOCUS button and hold joystick in the full up position for 4
seconds.
4. Tilt up motion will now be inhibited above the current position.
Clear Motion Limits
Motion limits as set above can be cleared by switching the panel off then pressing and holding
the focus button and lamp buttons together for 10 seconds.
Adjusting Panel Illumination
The panel illumination and indicators intensity can be adjusted to suit ambient light levels. To
adjust the intensity, switch the panel on then switch it off with the PANEL button and keep the
PANEL button pressed. To increase intensity, move the joystick to the right. To decrease move
to the left. Note that the panel button must be kept depressed whilst the joystick is moved. All
indicators will illuminate whilst adjustments are performed. Adjustment is complete when the
panel button is released.
Obtaining Fault Status
Fault codes can be accessed by switching the control panel on with the PANEL button and
keeping the PANEL button pressed for 10 seconds. Fault codes are indicated by the PANEL
button flashing a number of times related to the fault. Fault codes are detailed below. If more
than one fault is present the PANEL button will indicate them in sequence.
1. Pan Limit. –Either of the pan limit switches operated. Note that this
may not actually be a fault. The LED will flash when a limit switch is
operated under normal circumstances i.e. the lamp is at the limit of
travel. This will also indicate when a variable limit is reached.
2. Tilt Limit. –Either of the tilt limit switches operated. Note that this may
not actually be a fault. The LED will flash when a limit switch is
operated under normal circumstances i.e. the lamp is at the limit of
travel. This will also indicate when a variable limit is reached.
3. Pan motor over current. –The pan motor is taking excessive current.
The motor will be disabled for a period when this occurs. Fault
indication will remain until power is removed or the fault is corrected.
4. Tilt motor over current. –The tilt motor is taking excessive current. The
motor will be disabled for a period when this occurs. Fault indication
will remain until power is removed or the fault is corrected.
5. Focus motor over current. –The focus motor is taking excessive
current. The motor will be disabled for a period when this occurs. Fault
indication will remain until power is removed or the fault is corrected.
6. FBUS interface over current. –The speed control card supplies 24VDC
to the remote-control panels. This fault indicates the 24VDC output is
taking excessive current. The FBUS supply output will switch off. To