Perko 9304 User manual

XR Series
500 WATT MARINE SEARCHLIGHT
Model 9304
Operator’s/Maintenance Manual
(Covers Standard 110 VAC and
Optional 220 VAC Power Supplies)
Manufactured By
We Make it Right, Right Here!!
Miami, FL
9/08
9304-PTD-51F

OPERATOR’S MANUAL
WITH
MAINTENANCE SUPPLEMENT
FOR
MODEL 9304
XR Series 500 WATT MARINE SEARCHLIGHT
(Covers Standard 110 VAC and
Optional 220 VAC Power Supplies)
© COPYRIGHT 1999-2008
BY PERKO, INC.
ALL RIGHTS RESERVED. THIS BOOK OR PARTS THEREOF, MAY NOT BE
REPRODUCED IN ANY FORM WITHOUT PERMISSION OF PERKO, INC.
3

TABLE OF CONTENTS
CHAPTER I INTRODUCTION PAGE
1-1 General 6
1-2 Description 6
CHAPTER II- INSTALLATION
2-1 General 10
2-2 Unpacking 10
2-3 Installation 10
2-4 Post Installation and Checkout 13
CHAPTER III INSTALLATION AND OPERATIONAL CHECKOUT
3-1 Preoperational Checks 15
3-2 Lamp Ignition 15
3-3 Manual-Beam Focus Adjustment 15
CHAPTER IV OPERATING PROCEDURES
4-1 General 17
4-2 Lamp Ignition 17
4-3 Main Operation 17
4-4 Turn-Off 17
CHAPTER V OPERATOR MAINTENANCE
5-1 General 18
5-2 Inspection 18
5-3 Cleaning 18
5-4 Lubrication 18
5-5 Testing 18
5-6 Xenon Lamp Removal 19
5-7 Xenon Lamp Installation 19
CHAPTER VI MAINTENANCE
6-1 General 21
6-2 Detailed Functional Description (110 VAC) 21
6-3 Detailed Functional Description (220 VAC) 22
CHAPTER VII WARRANTY & REGISTRATION
7-1 Warranty Policy 27
7-2 Instructions for Installing Xenon Lamps 28
7-3 18 Month Limited Warranty 31
7-4 Lamp Failure Report 32
7-5 Warranty Registration 33
7-6 Purchase Notification 34
4

APPENDIX A
7-1 Optional Heater Package Installation Guide 35
LIST OF ILLUSTRATIONS
2-1 500 Watt Marine Searchlight 14
Interconnect Diagram
9304-1-A 500 Watt Marine Searchlight
Outline Drawing Foldout
9304-2-B 500 Watt Marine Searchlight Foldout
Power Supply Exploded View
9304-3-A 500 Watt Marine Searchlight Foldout
Power Supply Outline Drawing
9304-4-A 500 Watt Marine Searchlight Foldout
Yoke & Base Drawing
9304-5-B 500 Watt Marine Searchlight with 110 VAC Power Supply Foldout
Schematic Drawing
9304-6-B 500 Watt Marine Searchlight with 220 VAC Power Supply Foldout
Schematic Drawing
9304-7-B 500 Watt Marine Searchlight with 220 VAC Power Supply Foldout
Schematic Drawing
LIST OF TABLES
6-1 500 Watt Marine Searchlight Parts List 25
5

500 WATT MARINE SEARCHLIGHT
CHAPTER I
1-1 GENERAL. This manual contains descriptive theory, installation procedures and maintenance
instructions for the XR Series 500 Watt Marine Searchlight, Model 9304, which will hereinafter be referred
to as the 500 Watt Searchlight (figure 1-1).
NOTE
All service and/or installation work on Xenon Searchlights
should be preformed by a Qualified Marine Electrician!!
1-2 DESCRIPTION.The 500 Watt searchlight is comprised of a head assembly, a yoke and base
assembly, a Power Supply unit, a remote control panel, a remote ammeter, and either manual or electric
directional controls.
The head assembly housing, the yoke arms and the base are made of aluminum. All components of the
searchlight which are exposed to the weather are painted with epoxy paint. White is the standard color.
The head assembly is supported at its approximate center of gravity by two stainless steel shoulder bolts
extending through holes with bushings in the yoke arms. These bolts engage threaded holes in bosses on
each side of the housing.
The yoke arms are attached to the yoke support plate. The yoke support plate rotates around the spindle
of the base plate on two tapered bearings. A sliding stop plate, located around the base of the rotating
cover allows approximately 380 degrees of azimuth rotation of the searchlight (approximately 190 degrees
either side of dead ahead). The stop is necessary to prevent the electrical cable in the bottom of the head
assembly housing from being severely stressed by wrapping around the yoke. The yoke support plate is
retained on the base by a nut at the top of the spindle. A rubber boot is provided around the base of the
yoke support plate for weather protection. The base is fastened to the ship’s structure with four bolts
through four holes provided in the base plate.
The major components of the 500 Watt Searchlight are described
individually as follows:
6
Yoke & Base
Searchlight Head
Optical Assembly
Power Supply
Remote Ammeter
Control Panel

a. Head Assembly. The head assembly is comprised of the head, to which is fastened the front window
assembly, rear cover and the rack assembly.
The front window assembly contains a tempered clear glass sealed into a machined aluminum frame with
a rubber gasket. The window assembly is joined to the housing with a floating hinge along the lower edge
of the housing. When closed, the window assembly and a gasket is held tight against the front flange face
of the housing by three over-center clamps. A moisture proof and air tight seal is effected by the clamps.
The rear cover is attached to the housing in the same manner as the front window assembly. A gasket
seal also is provided in the rear cover.
The electrical cable passes through a water tight feed-thru in the searchlight housing wall.
The gasket in the front window assembly and the rear cover, together with the watertight feed-thru for the
electrical cable, provide an effective moisture proof, air tight seal so that the entire housing, when closed,
is protected against the intrusion of water and air.
The support assembly is fastened to the housing with four radial bolts extending inward through the hous-
ing wall and engaging threaded holes in the mounting plate. The support assembly contains the reflector,
blower motor, the lamp and the necessary high voltage electrical components to initiate lamp ignition.
The gear rack assembly attaches to two angle brackets which in turn are fastened to two mounting boss-
es attached to the bottom of the searchlight housing. This mounting arrangement provides for sufficient
positive adjustment of the gear rack so that it can be properly aligned and meshed with the mounting spur
gear which gives the head vertical movement.
b. Yoke and Base Assembly.The yoke and base assembly is comprised of two yoke arms bolted to a
yoke support plate and a base plate having a central spindle. The yoke support plate rotates on two
tapered roller bearings mounted on the base plate spindle. These bearings require lubrication. A different
bearing housing
is centrally positioned on top of the rotating cover and fastened by two machine bolts. The mechanical
directional controls fit into this housing such that the outer tube (azimuth directional control) is clamped to
this housing by a special clamp.
The inner rod (elevation directional control) extends through this housing such that the end of the rod
extends approximately one inch above the center of the gear rack on the bottom of the searchlight hous-
ing. An oil seal located in the bearing housing surrounds the inner rod as it passes through the bearing
housing to prevent water from leaking into the pilot house. A pinion gear fastened to the end of the inner
rod meshes with the gear rack to provide vertical motion of the searchlight head (See Mechanical
Directional Controls).
c. Power Supply.
WARNING
The following equipment contains voltages and current which are hazardous to
human life. Extreme caution must be exercised when performing tests required while power is on.
The XR Series Power Supply, PERKO # 9511-000-110 operates on 120 VAC, 60 Hz. (Standard)
The XR Series Power Supply, PERKO # 9511-000-220 operates on 220VAC, Single Phase 60 Hz.
(Optional)
The Power Supply will accommodate input voltage variations from approximately 115 to 130 VAC or 215
to 250 VAC respectively from the ship’s power generators.
7

CAUTION
XR Series power supplies are factory wired for a specific input voltage. Do not connect the ship’s power
to the Power Supply until a qualified technician determines that the ship’s voltage to
be connected to the Power Supply is the same as that for which the Power Supply can
accommodate. It may be necessary to reposition transformer jumpers at the time of
installation to match the Power Supply with the ship’s voltage.
The function of the Power Supply is to convert the ship’s alternating current to direct current required by
the xenon lamp for proper operation. The lamp requires approximately 20 volts at approximately 20 to 25
amperes DC. The Power Supply also provides power to the high voltage and boost circuits necessary to
ignite the xenon lamp and to sustain its operation.
The Power Supply is a 20 VDC, 25 amp Power Supply operated on appropriate ship’s power. The Power
Supply is mounted in a cabinet suitable for bulkhead mounting and with ample access space for cable
connections. The standard (110 VAC) and optional (220 VAC) power supplies cannot be field adjusted to
subsitute for each other and must be operated at their intended ship’s supply voltage.
d. Controls. There are two control systems which perform different functions. The electrical control sys-
tem controls the power to the searchlight while the mechanical directional control system controls the
azimuth (horizontal) and elevation (vertical) movement of the searchlight head. These systems are
described as follows:
(1) Electrical Controls. Remote Control Panel STANDBY/ON/IGNITE Switch (Figure 2-1) - the
“STANDBY” position removes power from the lamp circuit. This is essentially an “OFF” position. The “ON”
position energizes the ignition circuit and automatically starts the lamp operation. In addition, the “ON”
position maintains power to the lamp so that operation is sustained. If this position fails to start the lamp,
position the switch to the “IGNITE” position until the lamp is observed to be operating and then release
pressure on the spring-loaded switch. The remote ammeter will also indicate the lamp is operating by
showing 20 - 25 amperes of current flow. To turn the lamp “OFF”, position switch into the “STANDBY”
position.
NOTE
Should the lamp fail to ignite in the “ON” (or “IGNITE” positions after approximately ten seconds)
or
should it fail to sustain operation after initial ignition, the lamp may be faulty.
Beam Focus Switch - This switch applies power to an electric motor which drives the focus mechanism.
Holding the BEAM switch engaged continuously will cycle the focus mechanism continuously from the
compact mode to the spread mode. The BEAM switch should be held in position until the desired beam
pattern is obtained. Small adjustments may be obtained by momentarily engaging the beam focus switch.
NOTE
The beam pattern size may be changed (within limits) independent of the focus mechanism
by making an adjustment within the searchlight head. This adjustment should be made
ONLY by qualified and trained service personnel. Refer to paragraph 3-3.
A green power indicator light is provided on the control panel to indicate that power is applied to the elec-
trical system.
8

A remote ammeter is provided with the Power Supply. This instrument should be located in the pilot house
at a convenient location so that the pilot on watch can monitor the current being supplied to the lamp. A
current indication which falls within the 20 to 25 ampere range is satisfactory. Should the current indication
fall outside this range.
(2) Mechanical Controls. The mechanical controls provide the azimuth (horizontal) and elevation
(vertical) movement to the searchlight head. These controls are comprised of a handle assembly located
in the pilot house, a hollow tube and solid shaft, both of which extend from the handle assembly upward
through the pilot house ceiling to the base of the searchlight. The hollow tube is clamped to a bearing
housing fastened to the rotating yoke and base assembly. The lower end of this tube is clamped to the
handle assembly. Moving the handle in a horizontal plane moves the searchlight head horizontally. The
solid shaft is located inside the hollow tube. The lower end of this shaft is fastened to a miter gear such
that when the control handle is twisted, the solid shaft rotates within the tube. The upper end of the solid
shaft extends through the bearing housing previously mentioned and to a point approximately one inch
above the gear rack fastened to the bottom of the searchlight head housing. A fiber or nylon spur gear is
fastened to the upper end of the solid shaft, and this gear engages the gear rack. Twisting the control han-
dle provides rotary motion to the spur gear which causes the gear rack to move, thus imparting vertical
rotational movement to the searchlight head.
A ceiling mount is provided to cover the rough opening made in the ceiling to allow the shaft and tube to
pass through. This mount has a friction screw clamp to prevent the light from swinging freely in azimuth or
to lock it in a desired position.
This mechanical directional control assembly (known also optional as a lever gear control) is supported
from the rotating yoke and base assembly. Provision is made to allow additional support by the installation
of a solid rod and base plate extending from the bottom of the handle assembly to the pilot house control
console.
9

CHAPTER II
INSTALLATION
2-1 GENERAL. The following paragraphs contain instructions for unpacking, installing and perform-
ing post installation inspection and checkout of the 500 Watt Searchlight.
2-2 UNPACKING.The searchlight components are packaged according to best commercial practice.
Care should be exercised when unpacking to prevent damage to any of the searchlight components.
Packages should be examined prior to opening for evidence of possible damage in shipment. Any ship-
ping damage should be reported to the freight carrier or its representative. Immediately upon unpacking,
check the contents of the shipping containers against the packing list. Make sure components are not dis-
carded with the packing material. Report any shortages directly to PERKO, Inc.
WARNING
A spare xenon lamp may be shipped with a searchlight. It is not necessary to open this
lamp package. Xenon lamps contain xenon gas under pressure in a quartz tube and,
if mishandled, may explode.
WARNING
The searchlight head and the Power Supply should each be handled by two or more
persons because of the weight and/or bulk of these two components.
2-3 INSTALLATION.
a. Preliminary
Remove the Yoke and Base and Mechanical Control components from their shipping containers and
inspect for damage. If undamaged, place the Yoke and Base, Mechanical Control elevation rod, and
Mechanical Control azimuth tube near the customer-provided (1/2" X 21" dia.) support plate with mounting
studs. Place the remaining Mechanical Control components near the operator's station.
b. Mechanical Installation
WARNING
DO NOT FASTEN the Yoke and Base to the Support Plate until an adequate layer of
moisture sealant has been applied between the base plate and support plate.
(1). At the support plate (ON the Roof), place the Yoke and Base on the support plate, aligning the
four holes in the searchlight base with the studs in the mounting plate such that the Yoke rotates from for-
ward to aft in either port or starboard directions approximately 190 degrees. The rotational stop should be
felt with the Yoke pointed in the 190 degree aft position. Remove the Yoke and Base from the support
plate and apply an adequate layer of moisture sealant. Replace the Yoke and Base on the support plate
and fasten it using four customer-provided nuts with locking washers (or bolts).
(2). Remove the shaft housing from the Yoke and Base by removing the 5/16" mounting bolts.
(3). Align, insert and lower the azimuth tube through the 1.5" diameter hole taking care that it does
not fall through the ceiling above the operator's station.
(4). Support the azimuth tube to prevent it from falling, while placing the shaft housing over the end
of the azimuth tube, and fasten the housing to the tube using the shaft housing clamps provided (see
Detail, Drawing 9304-1).
10