Francis Searchlights VX500RC Guide

VX500RC 150W 24V Xenon
Remote Control Searchlight
User / Installation Manual
Product Part Number:
A7185 –VX500RC 24V 150w Xenon Variable Speed Remote Control Searchlight
PLEASE NOTE!
Please read this manual before installation.www.francis.co.uk
C27397 Issue 12 14.3.23 EC1935

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
E: [email protected]
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 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 junction box name plate.
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:
24VDC
Input current:
6.5A Max
PSU output voltage:
17v DC Max
PSU current:
8.8A Max
Wattage:
150w
Dimensions
Searchlight Height:
340mm
Width:
500mm
Depth:
533mm
Weight:
17Kgs
PSU Height:
430mm
Width:
278mm
Depth:
130mm
Weight:
5Kgs
Searchlight Performance
Lamp power:
150w
Range @ 1 Lux:
2760m
Lamp life (approx.)
1200h
Divergence:
1.5° - 10°
PBCP (Peak Beam Candle Power):
7,600,000 cd
Colour temperature:
6000 K
Luminous flux:
3,200 lumens
Searchlight movement
Pan rotation:
350°
Tilt elevation:
Up 23° & Down 23°
Pan speed:
Variable Speed 1 to 36°/sec
Tilt Speed:
Variable Speed 1 to 3.5°/sec
Material, colour, IP rating
Searchlight barrel head:
Aluminium LM6 Die Casting
Paint finish powder coated & stove enamel paint:
Signal White to RAL 9003
IP rating, Searchlight, PSU:
IP66 Searchlight –IP54 PSU
Operating temperature:
-20°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.
Rear of Searchlight Base Fixings, 4 Holes Ø8.2
Equally Spaced on a Ø220.00

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 C27391 (at the back of the manual), a supply is fed to the junction box,
which then provides a common feed to the searchlight and joystick control panel.
The searchlight has been pre-wired with 3 meters of cable from the Searchlight to junction box
provided and the Xenon Lamp is already fitted in the searchlight.
If the installation requires the junction box to be mounted more than 3m away from the searchlight,
then we would recommend additional junction box is installed to connect the additional cable. The
correct cable should be fitted to compensate for the voltage drop over the distance between both
junction boxes.
Cables to be supplied by the customer:
•2 pair twisted 0.22mm 100ohm screened cable from the joystick panel to the junction box.
•Mains supply cable to the junction box.
Searchlight Joystick Panel
2 Pair twisted screened cable supplied by customer
Junction Box
2 Pair twisted screened cable 3 metres
supplied by Francis
mains supply cable
Supplied by customer
7 core 1.5mm 3 metres supplied by Francis 150w.

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
24v
150w
Cable Size
(mm²)
Distance
Max
1.5
5M
2.5
9M
4
14M
6
22M
10
38M
The following table below indicates the maximum length of cable to be used for the DC cable, from
the searchlight to the junction box.
Searchlight
150w
Cable Size
(mm²)
Distance
Max
7 cores 1.5
9M
12 cores 1.5
21M
•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.
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.
•Do not apply unnecessary force when tightening the screws.
•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.
Always isolate the equipment from the supply when fitting a lamp

Before fitting the lamp:
•Loosen and remove five M8 socket bolts with the sealing washers on the underneath of the
searchlight, then remove the upper hood off the searchlight & store along with the bolts and
washers in a safe area.
To fit the Xenon lamp
•Fit the lamp holder lead over the thread of the negative end of the lamp and then
screw into the rear lamp holder (DO NOT OVER TIGHEN)
•Connect the front lead to the positive end of the lamp and secure in place with the
knurled nut.
After fitting the lamp
•Replace the upper hood, ensuring the groove aligns correctly with the glass gasket re-place
the bolts and washers and make sure they are securely fastened.

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.
•Multiply these figures together to give an approximate wattage (Power output).
For example:
•With the multi meter, test the DC voltage in the junction box across terminals 5 & 6. This
should be approximately 17 volts.
•With the DC ammeter, test the current of the wire/wires in terminal 6 in the junction box. It
should read approximately 8.8 amps.
•Multiply these readings together, as shown above, to obtain the desired wattage required,
usually about 150 watts.
e.g.
Voltage reading = 17v; Amps reading = 8.8 amps
Therefore, Wattage = 17 x 8.8 = 150 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 the reflector will Tilt down to the limit, once this is complete, the
searchlight will then move to the centre position, 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 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 all directions. 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.

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 joystick 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 Searchlight (see drawing A7185). 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 dip 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 Joystick Panel –Searchlight (Lamp) Address
Dip
Switch
Searchlight
1
16
2
8
3
4
4
2
5
1

Standard Joystick Panel –Control (Panel) Address
Dip
Switch
Control
Panel
1
8
2
4
3
2
4
1
EXAMPLES
Standard joystick 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 lamp must have a unique address. The addresses should be sequential and should start
from zero. If there were three lamps 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 lamps
and panels can be the same address. For example, on a system with two panels and two lamps,
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 lamp, they must still have individual panel addresses, but the lamp addresses
can be set to the same address value as the lamp which is to be controlled. Any number of panels
can control the same lamp.

Multiple Searchlights, Joystick Panels and Master Joystick 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 joystick panel, then please check the data + & - connections on the
FBUS connector located on the back of the joystick 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 Emarc Lamp to light
Please refer to the following table for the troubleshooting of Xenon lamps.
Fault
Cause
Remedy
Wrong Polarity
Lamp incorrectly fitted
Anode (large electrode) must
always be on top in vertical
burning position
Faulty wiring
Check polarity, transpose
connections if necessary
Cap overheated
Cap temperature above
230°C
Faulty contacts
Check terminals, tighten or
renew
Cooling equipment
defective
Check cooling equipment
and replace if necessary
Arc unsteady
Lamp operated outside
current control range.
Correct current setting
Magnetic stabilisation
for horizontal operation
defective
Check magnetic stabilisation
Bulb draws in air
Crack in graded seal
caused by overheated
cap
Check terminals - tighten or
renew.
Maximum cap
temperature 230°C
Glass erosion on fused
quartz bulb.
Lamp operated outside
current control range.
Correct current setting
Lamp service life
exceeded.
Check meter
Electrodes damaged
Premature blackening
Current ripple too high
Have power supply inspected
Auxiliary mirror
incorrectly adjusted
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 lamp
switch, if the lamp does not light, switch off mains supply and check all fuses.
2. On pressing the lamp switch the lamp still does not ignite, check the searchlight. 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 searchlight. If this
arcing is heard switch off the supply at the mains. Remove the searchlight top to expose the
two supply leads to the lamp. Using a dry cloth wipe these leads to remove any dust,
moisture or condensation that may have formed around the inside of the searchlight.
Replace the searchlight top, ensuring the gaskets 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 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
14,000 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. This
is a totally encapsulated unit and repair is not advised. If found to be faulty a new ignitor
must be fitted.

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 joystick panel, please contact Francis Searchlights for
ordering the required parts, [email protected]
If the joystick panel is not communicating with the searchlight and none of the LED’s on the
joystick panel are lighting up, then you will need to access the speed controller PCB inside the
searchlight (see drawing A7185), to access the speed controller PCB, you will need to remove the
5 off M8 bolts & washers, that are located beneath the searchlight head, then you can access the
speed controller PCB, the Status LED located near the top of the card (labelled “STATUS”) on the
speed controller PCB, as 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.