Francis FX230 User manual

User Instruction & Installation Manual
FX230 Deck & Cabin 150 Watt
Xenon Searchlight
Product Reference Number:
A2432 – FX230 Deck
A2433 – FX230 Cabin
Manufacturers details: Distributor details:
Manual Part Number: C15817
Issue : 7
Francis Searchlights Ltd
Union Road, Bolton
Lancashire, BL2 2HJ, UK
Tel: [phone]
Fax: [phone]
http://www.francis.co.uk
E-mail: [e-mail]

CONTENTS
1 - Introduction
2 - Safety Precautions
3 - Technical Information
4 - Unpacking and Installation Instructions
5 - Electrical Installation
6 - Operating Instructions
7 - Fault Finding
8 - Maintenance and Servicing
9 - General Assembly and Wiring Diagrams
10 - Spare Parts List

1 - Introduction
It is imperative that this manual is read carefully and understood before
installing your equipment. For your future reference please keep this manual in
a safe place.
Thank you for specifying a product from the Francis Searchlights range. All Francis products are
designed to give complete customer satisfaction and are manufactured to the highest engineering
standards in order to ensure optimum performance and service life.
The Francis Xenon range combines features proven over many years service in the most
hazardous conditions in both marine and land installations.
In order to prolong the life and performance of your product, we recommend that you only specify
Francis Searchlights spare parts. This will also ensure that any warranties on your equipment will
not be invalidated. Information on spares ordering and parts is provided in this manual.
Should you ever need to contact Francis Searchlights Ltd. regarding your equipment, please quote
the Product Serial Number at all times.
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2 - Safety Precautions
The following instructions must be adhered to, in order to ensure a safe working environment and
the safety of the user.
Note: When unpacking or manoeuvring the searchlight into its fixing position, suitable
lifting points must be used in order to prevent damage to the equipment or personal injury.
Because of the high internal pressure within the lamp, there is a risk of explosion in either a hot
or cold state;
During operation this lamp emits intense UV radiation which is harmful to the eyes and skin.
Suitable protection should be worn;
The high luminance of the arc can cause severe damage to the eye if viewed directly.
ALWAYS wear suitable protective goggles when viewing the lamp;
Always use protective sleeves 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, return the lamp, via the supplier, to the lamp manufacturer in its
complete packaging;
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 manufacturers 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
FX230 150watt searchlight has the following features:
All marine grade materials and fixings;
Parabolic electro-formed nickel, bright rhodium coated reflector;
Stove enamel painted;
Full 360° horizontal rotation;
Vertical movement ±45° (Deck); -20°to 40° (Cabin);
Remote focus facility;
Internal self-regulating heater;
Instant lamp re-strike. No cooling down time required;
Economical 1200 hour lamp life;
Toughened front glass;
Supplied with control panel incorporating focus control and on/off switch;
Luminous flux 2900;
Colour temperature 6000K;
Sealing to IP56.
The searchlight also performs to the following optical data:
Xenon light source
Lamp Wattage - 150 Watts;
Supply voltage – 10.8v to 30v DC;
Peak Beam Candlepower – 5,479,861 lux;
Range – 2,341 metres;
Adjustable lamp focus, 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.
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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, using the template provided. 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.
In the case of cabin control models, a centre hole is also required to allow the mechanism to pass
through.
Fit the ‘O’ ring in position and bolt the searchlight down securely. On an uneven surface it is
necessary to use a suitable sealant, such as silicone, to ensure a weatherproofed joint.
For cabin control models it is necessary to remove the underdeck control assembly prior to
installation.
Using the Allen key provided, the five grubscrews on the underdeck mechanism should be
loosened to allow the underdeck control assembly to be removed. The outer tube can now be
positioned through the centre hole. The searchlight base can now be securely fixed as stated
above.
Upon installation, re-assemble the underdeck control mechanism ensuring the grubscrews are
secure and the mechanism operates correctly.
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5 - Electrical Installation
For safety purposes, only competent personnel should perform the electrical installation. All
equipment should be installed to current Electrical Regulations and Standards.
In order to obtain the maximum light output from the searchlight, it is essential that the full
operating voltage of the lamp fitted be applied to the lampholder contacts.
Method of Electrical Connection
1) Disconnect the supply before working on the electrical system;
2) The searchlight must be connected to a fused electrical supply, using suitably sized cable;
3) If the searchlight is located a considerable distance from the supply, provision must be made in
the cable size in order to overcome the voltage drop. The following table should be used for
indication purposes only:
Searchlight 12v 150w 24v 150w
Cable Size (mm²) Distance Max Distance Max
6.0 5 MTRS 20 MTRS
10.0 8 MTRS 34 MTRS
4) Whenever possible cable terminations should be made below deck and with approved terminal
devices;
5) If a spare auxiliary fuse or circuit breaker is not available, one of the correct type and rating
should be fitted and connected to a positive supply. It is advisable to locate a bus bar or main
connection and avoid any direct connection to the supply:
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6 - Operating Instructions
This equipment is designed for use out of doors, in free air. Never place anything on, or cover, the
searchlight when in use as this may present a hazard.
The searchlight can be positioned using the elevation and baseplate lockwheels. When in the
desired position the lockwheels should be securely fastened to prevent damage.
The beam of the searchlight can be adjusted to give a variety of beam types. Using the remote
focus switch on the control panel, the desired beam can be achieved for any particular application.
The beam will move continuously through ‘spot’ to ‘flood’. In order to fix the beam type; simply
release the switch at the desired position.
Please note that a heater is fitted in the searchlight and is hardwired so that it is permanently on.
The heater specified on this equipment is self-regulating and will shut off when the dew point
temperature is reached. It should be noted that the power to the searchlight must be left on to allow
the heating element to function correctly.
The searchlight is also fitted with an IP66 drainage plug to allow for efficient water drainage should
any ingress occur. The breather at the rear of the searchlight ensures a steady airflow to prevent
any vacuum forming within the barrel.
After use the searchlight should be returned to the horizontal position in order that a level plane is
provided to allow for any water drainage.
This product should not be used for any purpose other than for which it was designed. Any
modifications to the product should not be undertaken without consulting the manufacturer.

Setting to Work
Safe service in use necessitates the strict observance of the following precautions.
Any article fabricated from quartz or glass is inherently fragile and care should
therefore be taken, at all times, when handling lamps;
Eye protection must be worn when handling lamps that have been removed from their
packaging materials. The protective sleeve 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 lamp to be fitted is suitable for the lamphouse and
power supply equipment;
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;
Do not twist or bend the fused quartz bulb when fitting the lamp as mechanical
stresses MUST be avoided;
When inserting or removing a lamp, always hold it securely by its’ base in order to
prevent breakage between base and bulb;
The lampholder must not exercise mechanical tensions on the lamp, neither during
insertion or operation. Contacts must not discolour during use;
For safety reasons, the lamp should be replaced once it has reached its’ average life,
and not later than 1.25 times the stated life. With continuing use the risk of the lamp
exploding increases due to alterations within the quartz;
Before the protective sleeve 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 sleeve must be retained for re-use. Whenever
removing a lamp, the protective sleeve must always be used for safety reasons;
In all circumstances the lamp manufacturers data should be referred to when dealing with
lamps.
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7- Fault Finding
All fault finding must be conducted by a competent person or qualified Electrical Engineer.
Please refer to the following table for the trouble-shooting of Xenon lamps.
Fault Cause Remedy
Wrong Polarity Lamp incorrectly fitted
Faulty wiring Anode (large electrode) must always be on top in
vertical burning position
Check polarity, transpose
connections if necessary
Cap overheated
Cap temperature above
230°C
Faulty contacts
Cooling equipment
defective
Check terminals, tighten or
renew
Check cooling equipment
and replace if necessary
Arc unsteady Lamp operated outside
current control range
Magnetic stabilisation for
horizontal operation
defective
Correct current setting
Check magnetic
stabilisation
Bulb draws in air Crack in graded seal
caused by overheated cap
Maximum cap temperature
230°C
Check terminals - tighten
or renew
Glass erosion on fused
quartz bulb Lamp operated outside current control range
Lamp service life
exceeded
Correct current setting
Check meter
Electrodes damaged
Premature blackening Current ripple too high Auxiliary mirror incorrectly
adjusted
Have power supply
inspected
Adjust auxiliary mirror
Asymmetrical blackening
of lamp (in horizontal
burning position)
Lamp operated too long in
same position Turn lamp through 180° after half service life

Failure of Lamp to ignite
In the event of the lamp failing to light the following steps should be taken:
1) Check that the supply is connected to the input of the PSU and check all connections as per
the wiring diagram. On operation if the lamp does not light, switch off supply and check all
fuses;
2) Check the searchlight head. On your command get an operator to switch on the light for
approximately 2 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. Remove the front and rear
bezels to expose the two supply leads from the ignitor 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 barrel. Replace the front and rear bezels, ensuring the swing bolts are securely
fastened, and perform the check again, listening for the cracking. If the lamp still fails to ignite,
switch off at the supply and replace the lamp in accordance with the safety procedures within
the manual and the manufacturers 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 25,000 volts
or higher). Switching the lamp on activates the ignitor. A cracking or hissing noise should be
heard. The ignitor is housed within the rear of the searchlight barrel. 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 on the rear bulkhead
assembly within the searchlight barrel. If the focus of the light fails the following procedure should
be adopted:
1) Remove the rear bezel from the searchlight barrel and examine focus mechanism. If parts
have become loose, tighten fasteners. The mechanism operates on a cam 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
multimeter 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;
4) If no supply is present there is a fault on the control panel (check all terminations are secure)
or with the supply. This should be examined and rectified accordingly.
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8 - Maintenance and Servicing
In order to prolong the service life and performance of your searchlight, the following maintenance
guidelines are recommended:
Maintenance checks should be conducted before every voyage or at least every three months;
Before checking, disconnect the equipment from the supply;
Visually inspect the condition of the equipment;
Any major or minor structural damage should be rectified immediately in order to reduce
sympathetic wear;
After inspection it may be necessary to clean the inside of the searchlight. The following
procedure should be adhered to:
Remove the front bezel;
Clean the front glass inside and out using a proprietary glass cleaner or metal
polish;
Clean the reflector if required;
Ensure that the lampholder is free from corrosion or other damage;
It is advisable to check all seals and gaskets for signs of degradation. Renew if necessary;
Upon completing all maintenance requirements the searchlight should be tested for full working
order (approximately 20 minutes).
If in any doubt as to the correct servicing procedures to adopt please contact your
distributor/agent or the manufacturer who will be able to advise the best course of action for
your product.
Notes for Lamp Fitting/Removal for FX230 150w Xenon
To fit lamp:
Remove lamp from packaging, ensuring protective jacket is still in place;
Remove front and rear bezels from searchlight by unfastening the swing bolts. Care should be
taken when removing the rear bezel assembly so that no damage to the PSU is incurred;
Now remove the spill rings from the front of the searchlight by removing the clips;
Place the lamp extender onto the negative (-) end of the lamp, place the lamp through the
lampholder HT/reflector boss and secure with T-bar at rear;
Place the HT lead (red) over the front of the lamp (positive) and secure in position using the
lamp heatsink;
Now screw the Tufnol insulator into the lamp heatsink and ensure that the HT lead is tightly
secured to prevent any arcing;
Place the PTFE bush over the insulator and fix mechanism in position by pushing the retaining
clip through the insulator;
Replace the spill rings in front of barrel and fix in position with clips;
Replace front and rear bezel assemblies and fasten down swing bolts securely, ensuring
bezels are central to barrel and a good seal is achieved;
Reverse this procedure for lamp removal.
Note: The protective lamp jacket must be removed prior to lamp strike. Retain jacket for future use.
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9 – General Assembly and Wiring Diagrams
Drawing Number Description
X4182 FX230 Deck General Assembly
X4152 FX230 Cabin General Assembly
X4200 Wiring Diagram
X4194 Cabin Control Panel Cut-out
X4193 Control Panel Wiring
Control Panel
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10 – Spare Parts List
The following spare parts can be ordered directly from the manufacturer:
Part Number Description
D8151 150w Xenon Lamp
C15885-01 Control Panel Assy
C08865-00 Front glass
C08835-00 Front glass gasket
C16410-00 Motor - Remote Focus
C16592-00 Ignitor
C16596-00 150w Xenon PSU
C22268-01 Breather Assy
C15929-00 Reflector
F4906 Quick Release Filter unit
C15903-01 Junction Box Assy
C15866-01 Lampholder H.T.
C15299-18 Lamp Connector
C14230-00 Retaining Pin
In order to prolong the life and performance of your product, we recommend that you only specify
Francis Searchlights spare parts. This will ensure that any warranties on your equipment will not be
invalidated.
When ordering spare parts please contact the Sales Department at Francis Searchlights Limited.
Please quote searchlight model and serial number at all times. This will enable a fast response to
your spares’ requirements.