Francis Searchlights LX480RC Guide
CONTENTS
1. Introduction
2. Safety Precautions
3. Technical Information
4. Unpacking and Installation Instructions
5. Electrical Installation
6. Start-up and Operating
6.1. FBUS Data & Panel Addresses
7. Fault Finding
7.1. Problems After Installation
7.2. Obtaining Fault Status
8. Maintenance and Servicing
9. Wiring Diagram & General Assembly
10. Spare Parts List
General Information:
Francis Searchlights Ltd
Union Road, Bolton, BL2 2HJ
United Kingdom
T: 00 44 (0)1204 558 960
W: www.francis.co.uk
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 to ensure optimum performance and service life.
The Francis Xenon range combines features proven over many years in the most hazardous
conditions in both marine and land installations.
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
always quote the Product Number and Serial Number of the product you have, this is located on
the name plate, inside the front of the barrel to the right.
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.
2 –Safety Precautions
The following instructions must be adhered to, 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 to prevent damage to the equipment or personal injury.
•Only suitably qualified personnel may install the products.
•Prevent rain, snow, condensation, and water droplets from contacting the lamp as this may
cause bulb failure and possible shattering.
•Xenon bulbs run with a high internal pressure more than 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.
•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 manufacturer’s 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.
3 –Technical Information
Electrical
Input voltage:
240 VAC.
Input current:
8.5 Amp Max
PSU output voltage:
28v DC
PSU current:
70 Amps
Wattage:
2Kw
Dimensions
Height:
1245mm
Width:
691mm
Depth:
692mm
Weight: Searchlight –PSU Box
68Kgs –22Kgs
Searchlight Performance
Lamp power:
2000w
Range @ 1 Lux:
9506m
Lamp life (approx.)
3000h
Divergence:
1.5 - 10°
PBCP (Peak Beam Candle Power):
90,000,000 cd
Colour temperature:
6000K
Luminous flux:
75,000 lumens
Searchlight movement
Pan rotation:
385°
Tilt elevation:
Up 30° & Down 35°
Pan speed:
Variable Speed 1 to 23°/sec
Tilt Speed:
Variable Speed 1 to 8°/sec
Material, colour, IP rating
Searchlight barrel head:
Stainless Steel BS1449 304S31
Gearbox housing:
Stainless Steel BS1449 304S31
Crutch:
Aluminium BS1474 6082 T6
Paint finish powder coated & stove enamel paint:
Ash Grey BS4800 00A01, Steel Blue RAL 5011
IP rating:
IP66 Gearbox –IP56 Searchlight & PSU Box
Operating temperature:
-50°C to +50°C
Certification approval:
Lloyds TA:
IEC 60945: 2002
Russian Maritime Register of Shipping:
Parts XI & XVII, Part IV
ISO9001 2015:
Quality Management System
4 –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, 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. 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, to ensure a weatherproofed joint.
Please refer to the drawing C27312-01 for the Joystick Panel cut out size, which you can find at
the back of this manual.
Rear of Searchlight Base Fixings, 4 Holes Ø12.5
Equally Spaced on a Ø350.00
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.
Referring to wiring diagram C28413 (at the back of the manual), a supply is fed to the junction box,
which then provides a common feed to the motor gearbox, searchlight, PSU, 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 with the PSU mounted within 7m of the junction
box, if the PSU cannot be installed within 7m of the junction box, then the correct cable should be
fitted to compensate for the voltage drop. (See DC table on next page).
•2 pair twisted 0.22mm 100ohm screened cable from the joystick panel to the junction box.
•5 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.
3m of cable supplied
by Francis.
4 core 6mm
5 core 2.5mm
2 pair twisted screened
main supply
cable supplied
by customer
2 pair twisted
screened cable,
supplied by
customer
cables supplied by
customer
4 core 6mm
5 core 2.5mm
Searchlight
Junction
Box
Joystick Panel
PSU
Enclosure
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 lamp holder 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 located a considerable distance from the supply, provision must be
made in the cable size to overcome the voltage drop.
The following table below indicates the maximum length of cable to be used for the supply cable,
from the mains supply to the junction box.
Searchlight
240v
2Kw
Cable Size
(mm²)
Distance
Max
1.5
41m
2.5
70m
4
112m
6
168m
10
297m
The following table below indicates the maximum length of cable to be used for DC cable, from the
PSU to the junction box.
Searchlight
2Kw
Cable Size
(mm²)
Distance
Max
4 core 6mm
10M
4 core 10mm
17M
4 core 16mm
25M
4 core 25mm
40M
4 core 35mm
51M
•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/ratings
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.
•For 240v 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.
6 –Start-up and Operating
When fitting the lamp
•Always isolate the equipment from the supply when inserting a lamp.
•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 the circuit is suitably fused.
•Ensure the lamp is of the correct power rating and type.
•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 lamp holder smaller, thus
causing the lamp to overheat.
•The inert gas used in Xenon 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.
•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 lamp holder. 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 lamp house, 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.
Notes:
•Xenon lamps are designed for dc operation only. The dc current may only be varied within
the limits of the current control range. Xenon lamps operate 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.
•For safety reasons, 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.
•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.
•The HT lead from the high voltage terminal of the Ignitor, must be connected to the cathode
(negative cap marked ‘- ‘). If the lamp is fitted with the wrong polarity, it will be irreparably
damaged after a very short time.
•In all circumstances the lamp manufacturer’s data should be referred to when dealing with
lamps.
To fit the Xenon lamp
Always isolate the equipment from the supply when fitting a 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 lamp holder mounting block (E)
and remove the front lamp holder assembly from the mounting bracket.
4) Loosen the knurled screw on the front (F) and rear (G) lamp holder 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 lamp holder 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 lamp holder 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.
Testing
Upon correct installation and connection to an electrical supply, the equipment can be tested to
ensure its’ correct performance. A competent person with some knowledge of electrical equipment
must carry out this work.
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:
•Using the multi-meter, take a voltage reading.
•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:
•With the multi meter, test the DC voltage in the searchlight head. This should be
approximately 28 volts.
•With the DC ammeter, test the current of the red DC cable at front of searchlight. It should
read approximately 70 amps.
•Multiply these readings together, as shown above, to obtain the desired wattage required,
usually about 1960watts.
Voltage reading = 28v; Amps reading = 70 amps.
Therefore, Wattage = 28 x 70 = 1960 watts
Start-Up
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.
Operating
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 joystick 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 searchlight 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 searchlight 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 searchlight 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 searchlight travel can be limited in either axis or either direction. To set a new limit switch the
panel on and move the searchlight 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 searchlight 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.
6.1 - FBUS Data & Panel Addresses
The Francis bus (FBUS) is a custom communication protocol based on RS485 two wire bi-
directional communication hardware. The system provides a simple bi-directional link between
searchlights and control panels. The system allows given panels to communicate with different
searchlights and allows several panels to communicate with the same searchlight.
FBUS Address Switches
Setting Searchlight Address Value
The searchlight address is set using the Dip switches on the Speed Controller PCB located inside
the Gearbox Assembly (see drawing C29537-01). With the address switches using simple binary
input.
Each switch has a binary value as details below; -
Dip Switch
Searchlight
10
1
9
2
8
4
7
8
6
16
If only 1 Searchlight is used, then all switches will be set to off.
The address value is the sum of the numbers above which are active when the switch is on.
For example, if switches 8 and 10 are on, and all others are off, the address value would be 5.
Note that switches 1-3 are not used for address selection and should be switched off.
Standard Control Panel –Searchlight (Lamp) Address
Dip
Switch
Searchlight
1
16
2
8
3
4
4
2
5
1
Standard Control Panel –Control Panel Address
Dip
Switch
Control
Panel
1
8
2
4
3
2
4
1
EXAMPLES
Standard control panel –panel address set to 5
Switch 1 = Off
Switch 2 = On (Value 4 added to address)
Switch 3 = Off
Switch 4 = On (Value 1 added to address)
4 + 1 = 5
Speed control card - lamp address set to 11
Switch 6 = Off
Switch 7 = On (Value 8 added to address)
Switch 8 = Off
Switch 9 = On (Value 2 added to address)
Switch 10 = On (Value 1 added to address)
8 + 2 + 1 = 11
ADDRESSING SYSTEM
Every searchlight must have a unique address. The addresses should be sequential and should
start from zero. If there were three searchlights in a system the addresses should be set to 0, 1
and 2.
Control panel –panel addresses use the same system being sequential and start from zero.
It is essential that all panels have a unique address with no duplication however note that
searchlights and panels can be the same address. For example, on a system with two panels and
two searchlights, the panel addresses will be 0 and 1 and the lamps addresses will be 0 and 1.
Control panel lamp addresses are defined by the system configuration. If two panels are used to
control the same searchlight, they must still have individual panel addresses, but the lamp
addresses can be set to the same address value as the searchlight which is to be controlled. Any
number of panels can control the same lamp.
Multiple Searchlights, Control Panels and Master Control Panel
7 –Fault Finding
7.1 Problems at Installation
•If the searchlight completes the Self-Test, e.g., Pan left, Tilts down then returns to centre
and the LEDs on the joystick panel are not illuminate, then please check the 4 data cables
connections on the FBUS connector located on the back of the control panel assembly, as
these data cables could be swapped around, you can check the voltages on the 4
connections, you should get as shown below.
o24 & + = 18-24v DC
o24 & - = 18-24v DC
o0 & + = 2.2v DC
o0 & - = 2.2v DC
o24 & 0 = 18-24v DC
•If the searchlight completes the Self-Test, e.g., Pan left, Tilts down then returns to centre
and the LEDs on the joystick panel are illuminated, but you are unable to control the
searchlight via the control panel, then please check the data + & - connections on the FBUS
connector located on the back of the control panel assembly, as these data cables could be
swapped around.
•If you have more than 1 searchlight in the installation and 2 or more searchlights are
moving at the same time in the same direction, then please check the dip switch settings on
the speed controller PCB, see Setting Searchlight Address Value.
Failure of Lamp to light
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 lamp
switch, if the lamp does not light, switch off mains supply and check all fuses.
2. On pressing the lamp switch and the lamp still does not ignite, check the searchlight head.
On your command get an operator to activate the 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 located, 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
32,000 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.
Failure of Remote Focus Facility
The remote focus mechanism is controlled by a small electric motor situated at the rear of the
searchlight barrel. If the focus of the light fails, the following procedure should be adopted:
1. Remove the rear bezel from searchlight barrel and examine focus mechanism. If parts have
become loose, tighten fasteners. The mechanism operates on a lever action, and this
should be checked for correct positioning.
2. If the mechanism is okay, check the supply to the motor. This can be done by simply
placing a multi-meter across the motor terminals.
3. If supply is present, this indicates that the motor has failed. Replace the focus motor
ensuring that the assembly is correct.
7.2 - Problems After Installation
Please note, if the searchlight does not complete the self-test, you will not be able to operate the
searchlight in any direction or switch the lamp on. Please refer to section 7.3 Obtaining Fault
Status below, to confirm the fault.
Once you have confirmed the fault via the control panel, please contact Francis Searchlights for
If the control panel is not communicating with the searchlight and none of the LED’s on the control
panel are lighting up, then you will need to access the speed controller PCB inside the gearbox
(see drawing C29537-01), to access the speed controller PCB you will need to remove the 8 off
M8 screws that hold the motor top to the gearbox housing and then lift the searchlight up out of the
gearbox housing, taking care not to damage the assembly, the Status LED located near the top of
the card (labelled “STATUS”) on the speed controller PCB, shown below.
During faults normal status LED operation is overridden. The status LED will flash red several
times with the number of flashes corresponding to the specific fault. If there are multiple faults the
LED will flash accordingly with a gap between each fault flash sequence. Fault details are
provided on the next page, with the number of flashes indicated on the left.
The Status LED has several functions as detailed below.
Software Version
When power is applied to the speed control card the status LED will flash green. The number of
flashes corresponds to the software version.
FBUS Normal operation
When the system is operating from FBUS the status LED will illuminate static green. When a valid
FBUS data signal is received the LED will switch off momentarily to indicate data reception. If data
is continuous the LED will flash green slowly.
If the Status LED does not light up, then please check the 24v DC supply from the PSU within the
gearbox, as shown on drawing C29537-01 Item 5, if there is no output from the PSU then this will
need to be replaced.
This manual suits for next models
1
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