Francis FX560RC User manual
User Instruction & Installation Manual
FX560 Remote Control
5-Kilowatt Xenon Searchlight
Product Reference Number:
A7290 –FX560RC 5Kw 440v 3 phase 50/60Hz
Manufacturer’s details: Distributor details:
Manual Part Number: C29238
Issue: 1 3.8.21
Francis Searchlights Ltd
Union Road, Bolton
Lancashire, BL2 2HJ, UK
Tel: +44 (0) 1204 558960
Fax: +44 (0) 1204 558979
http://www.francis.co.uk
E-mail: sales@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 service 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 Serial Number.
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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.
◼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.
◼Xenon 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
FX560RC 5Kw searchlight has the following features:
◼All marine grade materials and fixings.
◼Electronic power supply unit.
◼Instant re-strike no cooling down time.
◼Parabolic Glass reflector.
◼Powder coated & Stove enamel paint finish.
◼385° horizontal rotation.
◼Vertical movement ±30˚.
◼Variable speed 1-23°/sec (Pan), 1-8°/sec (Tilt).
◼Variable Speed LED joystick (Dimmable).
◼RS485 connectivity & auto home positioning.
◼Toughened super clear Opti white front glass.
◼Remote focus facility.
◼Sealing IP66 Gearbox, IP56 Searchlight
◼IP20 Power Supply with IP65 Cover.
◼Internal self-regulating heater (Gear Box & Barrel).
◼Weight Searchlight 88Kgs & PSU Assembly 61Kgs.
The searchlight also performs to the following optical data:
◼Xenon light source.
◼Lamp Wattage - 5000 Watts.
◼Supply voltage –440V three phase 50/60Hz.
◼Peak Beam Candlepower –417,000,000 lux.
◼Range –20,420 metres @ 1 lux.
◼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 Irem Power Supply Unit and Irem Ignitor are included overleaf.
For more detailed information please refer to Irem operating manual supplied.
PSU ref: Model EX-170GM3E 00831731 (Irem)
Ignitor ref: AS16040A (Irem)
(INPUT) 4 CORE 2.5mm TE2 50mm WELDING CABLE S50
2 CORE 1.5mm (D1)
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, 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, 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.
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 to overcome the voltage drop.
The following table below indicates the maximum length of cable to be used for the 3
phase 440v AC supply cable to the PSU:
Searchlight
440v 5Kw
Cable Size (mm²)
Distance Max
1.5
71 MTRS
2.5
120 MTRS
4
192 MTRS
6
286 MTRS
10
505 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/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:
6) For 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 FX560RC searchlight is as follows:
Referring to wiring diagram C29237, a supply is fed to the power supply unit, which then
provides a common feed to the motor gearbox, searchlight, and joystick panel.
The searchlight has been pre-wired with 1 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.
14 metres of 35mm DC welding cable from the Interface Output Enclosure to the Power Supply
Unit is supplied.
14 metres of 5 core 1.5mm cable from the Interface Output Enclosure to the Power Supply Unit
is supplied.
3 metres of 3 core 1.5mm cable 230v supply to the Interface Input Enclosure is supplied.
2 pair twisted 0.22mm 100ohm screened cable from the Interface Input Enclosure to the
Joystick Control Panel is supplied.
Cables required to be connected by the customer: -
Ethernet cable from the Interface Output Enclosure to the Data Switch.
Fibre Optic cable from the Data Switch to the network.
Ethernet cable from the Interface Input Enclosure to the network.
Ethernet cable from the network to the computer.
3 cores 1.5mm 230v Supply to the Interface Output Enclosure
2 pair twisted 0.22mm 100ohm screened cable from the Interface Output Enclosure to the
Junction Box.
5 cores 2.5mm cable from the Interface Output Enclosure to the Junction Box.
185mm Welding Cables from the Interface Output Enclosure to the Junction Box.
Supply cable to the Power Supply Unit.
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 control panels and motor gearbox.
When the light is in operation, the output from the PSU should be approximately 34.5v dc at
145amps.
Fitting instructions for the 5Kw xenon lamp
Referring to the diagram overleaf:
1) Unfasten 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 M5 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
restore this output, remove the supply from the speed control card for a
period.
7. Anti-condensation heater output over current. –The 24VDC anti
condensation heater output is taking excessive current. The heater
output will switch off. To restore this output, remove the supply from the
speed control card for a period.
8. Limit Switch Error. Some lamp types do not use all or some limit
switches. If an invalid limit switch input is detected it is probable the
speed control card is set to the wrong product or there is a wiring error.
9. Datum Error. The start-up datum system has not completed correctly.
10.Product type not set or corrupt. The product type has not been set, has
been set incorrectly or is corrupt.
11.Supply voltage out of tolerance. The 24V supply is outside the range
18-30V.
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, always, 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 lamp
house 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 Xenon 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, 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) Xenon lamps are designed for dc operation only. The dc current may only be varied within
the limits of the current control range. Xenon 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, Xenon 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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