WISKA SW450 User manual

Operating instructions
Searchlight
SW450/SW450A (2000W)

Date
Designation
Reason for change
05/2005
Operating Instructions
SW450 Edition 1
Adaptation circuit diagram
07/2023
Operating Instructions
SW450 Edition 2
Revision
List of abbreviations
DIN
Deutsches Institut für Normung (German Institute for standardization)
DIN EN ISO 12100
Safety of Machinery standard
EN
European Standard
FL
Remote steering
IP 23
Protection against penetration of foreign bodies > 12mm
Protection against light water spray
IP 56
Protection against dust deposits, protection against contact, protection
against dust deposits inside
Protection against strong jet water, protection against strong jet water
from any angle.
ISO
International Organization for Standardization
(International Organisation for Standardisation)
RCU
Remote Control Unit (Remote Control)
Pan (H)
Turn horizontal
Tilt (V)
Turn vertical
cd
Candela, unit of measurement for light intensity in one direction
Lumen
Unit of measurement of luminous intensity in all directions
Lux
Unit for the illuminance on a surface
Corridors and traffic routes: 100 lx, office: 500 lx, general workplace
precision mechanics or similar > 1,000 lx
Changes

About these operating instructions
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 2
Table of contents
1About these operating instructions...............................................................4
1.1 Structure and purpose of these operating instructions..............................4
1.2 Users and target groups .................................................................................4
1.3 Safety instructions ..........................................................................................4
1.3.1 Standard safety instructions ..............................................................................4
1.3.2 Structure of safety instructions ..........................................................................5
1.3.3 Embedded safety instructions ...........................................................................5
1.4 Label and symbols ..........................................................................................6
1.5 Personal protective equipment ......................................................................6
2For your safety.................................................................................................7
2.1 General safety instructions ............................................................................7
2.2 Specific safety instructions............................................................................8
2.3 Intended use.....................................................................................................9
2.4 Foreseeable misuse ........................................................................................9
2.5 Qualification of users/expertise .....................................................................9
2.6 Danger areas and danger points....................................................................9
3Technical description....................................................................................10
3.1 Function and design .....................................................................................10
3.2 Product overview...........................................................................................11
3.3 Mounting devices ..........................................................................................11
3.3.1 Deck mounting device (optional) .....................................................................11
3.3.2 Column mounting device (optional) .................................................................12
3.3.3 Electric pan/tilt unit FL52 (optional) .................................................................12
3.4 Power supply .................................................................................................13
3.4.1 Junction Box (optional) ....................................................................................13
3.5 Remote control/ operating device (optional) ..............................................13
4Transport, unpacking....................................................................................14
4.1 Transport/ Lift/ Move .....................................................................................14
4.2 Unpacking ......................................................................................................14
5Mounting.........................................................................................................15
5.1 Mounting.........................................................................................................15
5.1.1 Mounting the pan/ tilt unit ................................................................................15
5.1.2 Mounting the searchlight on a column or foot .................................................16
5.1.3 Mounting on a column or base with internal steering linkage .........................17
5.1.4 Mounting the RCU remote control unit ............................................................18
5.2 Electrical connections ..................................................................................19
5.2.1 Electrical connection values of the drive .........................................................19
5.2.2 Notes on mains connection .............................................................................19
5.2.3 Connecting.......................................................................................................20
6Commissioning..............................................................................................21
6.1 Before commissioning..................................................................................21
6.2 General commissioning................................................................................22

About these operating instructions
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 3
7Operation........................................................................................................23
7.1 Operating the searchlight (with FL52 pan/tilt unit) ....................................23
7.2 Manual operation ...........................................................................................24
7.3 Switching off the searchlight .......................................................................24
7.4 Use of RCU-E or RCU-E-F remote control unit (with remote focus) ........25
7.5 Remote focus (option) ..................................................................................25
8Troubleshooting ............................................................................................26
9Maintenance ...................................................................................................28
9.1 Maintenance ...................................................................................................28
9.2 Cleaning..........................................................................................................29
9.3 Repair..............................................................................................................29
9.3.1 Handling of halogens lamps. ...........................................................................30
9.3.2 Replace the halogen lamp...............................................................................31
9.3.3 Replace the primary reflector ..........................................................................32
10 Spare parts .....................................................................................................35
11.2 Decommissioning..........................................................................................36
11.3 Storage ...........................................................................................................36
12 Technical data................................................................................................37
12.1 Specifications ................................................................................................37
12.1.1 SW450 searchlight head .................................................................................37
12.1.2 Pan & tilt unit FL52 ..........................................................................................38
12.1.3 RCU remote control unit (optional) ..................................................................38
12.2 Protection class.............................................................................................39
12.3 Nameplate.......................................................................................................39
12.4 Dimensions ....................................................................................................39
12.5 Electrical connection diagram .....................................................................42
12.6 Service and maintenance plan .....................................................................43
13 Supplier documentation and certificates....................................................45
13.1 CE Declaration of Conformity ......................................................................45
13.2 UKCA Declaration of Conformity.................................................................46

About these operating instructions
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 4
1 About these operating instructions
1.1 Structure and purpose of these operating instructions
Operating instructions are important when assembling, maintaining and operating. These must
be observed to avoid hazards, reduce repair costs and downtime, and increase reliability and
lifespan.
Read the instructions thoroughly! WISKA Hoppmann GmbH is not responsible for damage or
malfunctions due to non-compliance with the operating instructions.
1.2 Users and target groups
These operating instructions apply to operators, technical personnel and operating personnel.
If a chapter is designed for a specific target group, it is mentioned in the introduction.
Every person who operates and maintains the product must have read and understood the
contents of these operating instructions and must follow all safety instructions and handling
instructions to handle the product safely. Provide appropriate product training and instructions
to each user.
You may not work on the product without these instructions.
1.3 Safety instructions
1.3.1 Standard safety instructions
WISKA safety instructions are based on the SAFE principle and derived from residual hazards
in the risk assessment:
•Keyword
The keyword reflects the gravity of the hazard (danger, warning, caution, note).
•Type and source of the hazard
The type and source of the hazard derive from the standard DIN EN ISO 12100.
•Consequences
Shows the possible consequences of non-compliance.
•Escaping from or avoiding the situation
That lists how to avoid or evade the hazard.
Keyword
Nature and source of the hazard
The consequences arising from this hazard
Escape and avoid the hazard.

About these operating instructions
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 5
1.3.2 Structure of safety instructions
The chapter describes the setup and use of the safety instructions. Before describing a
potentially dangerous situation, a warning indicates the situation to be avoided.
DANGER
Danger refers to a hazardous situation that can result in imminent death or severe injury
if not avoided.
WARNING
Warning refers to a hazardous situation that may result in death or severe injury if not
avoided.
CAUTION
Caution refers to a hazard with a low level of risk that, if not avoided, could result in
minor or reversible injury to persons.
ATTENTION
Caution indicates the possibility of material damage to the product and its function.
1.3.3 Embedded safety instructions
Additional embedded safety notes are used for procedural activities and avoid interrupting the
reading flow of descriptive activities to a higher degree. These look as follows:
1. ...take ...
2. ...remove...
Burns due to hot surfaces.
Searchlights in operation heat up and can cause burns.
Make sure that the searchlight has cooled down before starting work.
Wear appropriate personal protective equipment.
3. ...take out…
4. ...detach...
The assembly is ready for exchange.

About these operating instructions
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 6
1.4 Label and symbols
Symbol
Meaning
Usage
Hazard symbols
Warns of imminent danger.
Safety and warning notice
Hazard symbols
Warns of an electrical hazard.
Safety and warning notice
Hazard symbols
Warns of suspended loads when
working overhead.
Safety and warning notice
Commandment sign
Disconnect the system from the
power supply before working on
it.
Safety and warning notice
Commandment sign
Observe the operating
instructions.
Safety and warning notice
Commandment sign
Ground before work and use
Safety and warning notice
Information
Installation only by a qualified
electrician.
Safety and warning notice
1.5 Personal protective equipment
Symbol
Meaning
Safety helmet
Always wear it in the work areas with suspended loads.
Work clothes
Wear at all times to protect the body from external influences.
Safety gloves
Wear at all times to protect the hands from external influences.
Safety shoes
Always wear in the work area.

For your safety
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 7
2 For your safety
2.1 General safety instructions
Always follow these safety precautions:
Read these instructions for use fully before using, maintaining or repairing the product. Failure
to do so may place people and the product at risk.
Observe all safety instructions in the operating manual.
Observe national and local regulations when working on the product and installing it.
Only qualified electricians may perform service or repair work.
Before starting work, disconnect the electrical system from the power supply and secure it so
it will not turn on again.
Disconnect the system from the power supply when working with the pan and tilt device. Take
the remote control unit off as well.
The mounting position must always be secure and accessible.
Ensure the lights are handled and installed per their operating instructions.
Make sure that the lamp matches the searchlight.
Do not tamper with unauthorized products; the resulting hazards are not predictable.
Unauthorised modifications cancel the operating license and product warranty.
Always use genuine spare parts bought from WISKA.
The use of unapproved spare parts cancels the warranty.
Turn off the appliance if smoke, intense heating, or noises occur.
Never touch during thunderstorms.
If temperatures are low or icy, use gloves only.
The product may heat up while operating. Only touch the searchlight with proper personal
protective equipment.
Never look straight into the light source. You may have damage to your eyes.
Never direct a searchlight on an individual. It may be severely dazzled, and it can cause eye
injuries.
Make sure nobody is in the swivel and tilt area while the searchlight is controlled using the
optional remote control.

For your safety
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 8
2.2 Specific safety instructions
WARNING
Halogen lamps emit harmful UV rays into the eyes.
•Never look straight into a light source.
WARNING
Hazard of burns.
•Do not touch the searchlight while in operation. The housing can reach as high
as 150 °C.
•Always allow the searchlight to cool before servicing or repairs.
WARNING
Danger of glare
•Never look straight into the light source. This puts your eyes at risk.
•Switch off the device before any activity.
•For testing, point the searchlight towards the water or open terrain.
CAUTION
Crush hazard, break hazard.
Limbs may get caught between the searchlight and the base and cause serious injury.
•Ensure that there are no people in the immediate vicinity of the searchlight
before turning or rotating it.

For your safety
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 9
2.3 Intended use
The WISKA searchlights are designed to illuminate large and/or distant objects by hand or
automatically. The crew can detect obstacles or danger areas or look for objects or people
floating in the water. The searchlight supports mooring maneuvers and night navigation.
The searchlights are primarily designed for seagoing vessels and safety applications in coastal
areas.
The searchlight range (1 lux on target) depends on external factors. The field is between 710
and 1140 meters.
2.4 Foreseeable misuse
Use the searchlight only for the activities specified in the intended use. Any other activities are
not permitted.
It is prohibited to illuminate or dazzle persons with it. The brightness is so high that people may
get hurt. It is not permitted to dazzle vessel traffic or traffic in the vicinity of the shore or to give
false signals.
The searchlight is not suitable for illuminating rooms on a ship or in buildings.
2.5 Qualification of users/expertise
Knowledge of a qualified electrician is required to assemble, put into service and repair.
Technical personnel shall be trained to connect mechanical and electrical connections and test
the function securely. Ensure appropriate equipment for carrying and handling. Professional
knowledge as a specialist in waste management and personal protective equipment is needed
for dismantling and recycling.
2.6 Danger areas and danger points
Danger areas or danger points are, among others:
•The lamp may break or split unless properly replaced.
•Halogen light also gives off harmful UV rays to the eyes.
•Surface temperatures during and after use can be as high as 180°C.
•The swivel range of the pan/tilt device must be free of obstacles.
•When running by RCU, the swivel range is not visible.

Technical description
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 10
3 Technical description
3.1 Function and design
The searchlight is designed to light the shipping route manually or remotely. The SW450
provides a 2000W light source. A searchlight shall give as much light as possible on a long-
range target. The achievable distance depends on several external factors. The light is reflected
and must return to the viewer. The resulting interference effects, such as proximity lighting,
restrict the possible range. The range depends on the position of the lamp in relation to the
searchlight mirror and the lamp’s power. Focusing adjustment with a narrow light beam or via
the remote control with suitably selected lateral distance reduces the field of view interference.
A lack of contrast reduces the range additionally.
The luminous intensity l in Candela cd indicates the performance of a searchlight. Fog or
precipitation can reduce performance.
The searchlight housing is made of stainless steel in octagon form and provides the necessary
accessibility options. The tilt angle may reach +/-45° when mounted on one column and +/-30°
on the deck. A handle on the back of the searchlight serves for manual alignment.
The front frame is secured to the housing via quick-release fasteners. The integrated front
window includes an extra tempered safety glass. It guards the lamp.
The lamp mirror is either a silver-glass parabolic mirror (SW450) or an aluminum mirror
(SW450A). The lamp is a halogen lamp.
The mounting pedestal is available in various versions:
•Deck assembly,
•Column mounting,
•Deck mounting with with steering linkage inside operation,
•Column mounting with with steering linkage inside operation,
•Electric pan-tilt unit.
Mock
thrower
Housing

Technical description
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 11
3.2 Product overview
SW 450 on the pan-tilt unit Searchlight head (mounting device required)
Figure 1 Product overview
Pos.
Designation
Pos.
Designation
1
Searchlight housing
2
Front glass pane
3
Quick-release fasteners
4
FL52 pan/tilt unit (optional)
5
Mounting plate
or other mounting device
3.3 Mounting devices
3.3.1 Deck mounting device (optional)
The deck mounting device provides a fixed connection between the vessel and the searchlight.
It is mounted on a rotational mounting plate. The rotation and inclination are adjusted using a
manual lever.
Figure 2 Deck mounting device Figure 3 with steering linkage inside operation
2
3
1
4
5

Technical description
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 12
The basic design of the deck mounting device with its inside operation is like that of the regular
deck mounting device. Rotation and inclination are controlled from the cabin using a steering
linkage.
3.3.2 Column mounting device (optional)
The column mounting device is different from the regular deck mounting device only in height.
Rotation and inclination function the same way.
Figure 4 Column mounting device Figure 5 with steering linkage inside operation
The basic structure of the deck mounting device with internal operation is similar. Rotation and
inclination are controlled from the cabin using a steering linkage.
3.3.3 Electric pan/tilt unit FL52 (optional)
The electric pan/tilt unit is controlled remotely. Electrically controlled actuators ensure rotation
and tilt. Depending on the version, a preset or pan degree is selectable.
Figure 6 Electric pan/tilt unit FL52

Technical description
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 13
3.4 Power supply
3.4.1 Junction Box (optional)
The searchlight is usually equipped with a 3m cable. A junction box extends the possible
distance between the searchlight and the ballast.
The junction box is connected between the ballast and the searchlight.
[Front view] [Side view]
Figure 7 Junction Box
3.5 Remote control/ operating device (optional)
One of the preconditions for a remote-control operation is a searchlight mounted on an electric
pan/tilt unit. The RCU's installation site is usually located on the bridge to direct the searchlight
to the desired target as quickly as possible. A remote control with selector switch is optional for
controlling multiple searchlights.
Figure 8 RCU operation (the figure shows an example)
The standard RCUs are designed as follows:
•Power on/off switch for Pan/Tilt unit,
•Power on/off switch for the searchlight,
•Optional selector switch for controlling multiple searchlights,
•Joystick for control and alignment,
•Optional push-button for focusing unit.

Transport, unpacking
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 14
4 Transport, unpacking
WARNING
Risk of injury from suspended loads.
If the product or its parts detach, serious injuries are likely to occur.
Always wear your personal protective equipment.
Do not go into the swivel area or under the product.
Carefully secure the load before unpacking and assembly.
4.1 Transport/ Lift/ Move
The product comes on one or several palettes, depending on the composition. It is weather
resistant and stable packed.
Check the transport packaging for damage. In case of damage, contact our customer service.
If required, store it temporarily in the original packing material. The searchlight must not tip over.
Transport the product to the installation location by an appropriate means of transport suitable
for its weight.
4.2 Unpacking
1. Loosen lashing straps on the packaging and remove packaging materials.
2. Remove product and documents.
3. Dispose of packing materials.
The product is unpacked.

Mounting
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 15
5 Mounting
CAUTION
Danger caused by high product weight (up to 65 kg)
Another person is needed to mount the searchlight.
5.1 Mounting
NOTE
High weight
Before starting the installation, determine the appropriate torques for the stand.
The scope of delivery is dependent upon the selected options.
5.1.1 Mounting the pan/ tilt unit
If the searchlight has been ordered with the pan/tilt unit, it is delivered pre-assembled on the
FL52 drive.
Figure 9 Mounting holes FL52
Pan/Tilt Unit Setup:
1. If there are no fastening points: Mark a circle with a diameter of 330mm.
2. If there are no fastening points: Pre-drill four holes in the circle.
3. Move the pan/tilt-unit into the desired position.
Tipping hazard.
The searchlight head is not centered on the pan/tilt drive.
Never place at an angle.
4. Fasten the screws (M8/ M6).
The searchlight is mounted.

Mounting
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 16
5.1.2 Mounting the searchlight on a column or foot
Alternatively, the searchlight can be mounted on a column or foot.
Figure 10 Mounting holes column/foot
Mount searchlight
If there are no fastening points: Mark a circle with a diameter of 300 mm.
If there are no fastening points: Pre-drill four holes in the circle.
Place the foot/ column with its holes on the drilled holes.
Fasten the screws (M16).
If necessary, screw the searchlight head onto the base/column
The searchlight is mounted.

Mounting
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 17
5.1.3 Mounting on a column or base with internal steering linkage
The stand or column configuration is also available with internal mechanical actuation. The
mechanical steering link runs in an inner tube of the column and must therefore be installed
downwards. There must be sufficient space downwards to permit use.
Figure 11 Mounting holes foot/ column with steering linkage for interior operation
Mount searchlight
If there are no fastening points: Mark a circle with a diameter of 300mm.
If there are no fastening points: Pre-drill four holes in the circle.
If there is no hole: Drill a hole with a 50mm diameter in the center
Place the foot/column with the holes on the drilled holes.
Fasten the screws (M16).
If necessary, screw the searchlight head onto the base/column
The searchlight is mounted.

Mounting
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 18
5.1.4 Mounting the RCU remote control unit
A remote-control unit is necessary if the searchlight is equipped with a pan/ tilt unit.
The remote-control is available in the form of either a built-in RCU-E unit or a wall mount unit
RCU-A. Electrically and functionally, they are the same. The size varies with the range of
functions.
NOTE
Cable lengths, cable cross-sections
Ensure the wires are of sufficient size (cross-section) for the cable length. Minimal 8x1,5
mm² for a standard RCU-E or 9x1.5 mm² for an RCU-
E with focus.
Maximal 200 m between RCU-E and PSUX a 1,5 mm² wire cross-section.
When installing remote controls, all four holes must be drilled and, if necessary, installation
openings must be made. The size of the remote-control units varies with the searchlight’s
equipment. The dimensions of the holes are shown on the enclosed dimension sheet.
Figure 12 RCU-E (Standard) Figure 13 RCU-A (standard)
([Unit: mm] Dimensions are approximate)
Mounting
Mark and pre-drill four holes according to the dimensional sheet.
RCU-E only: Saw a cutout according to the dimensional sheet for recessing.
Position the remote control on the holes.
Fasten the screws (RCU-E: M5, RCU-KL: M3)
The remote-control unit is ready for wiring.

Mounting
Operating Instructions SW450/A-2000 Ver 2.0 -07 /2023 Article no: 30078456001 19
5.2 Electrical connections
DANGER
Danger to life from electricity.
Short circuits and body short circuits may occur when working on open circuits.
Work on electrical components only by a qualified electrician.
Make sure the equipment is disconnected from the electrical connection.
Secure the power supply against being switched on again.
Cover open parts of external installations.
If necessary, short-circuit the plant components.
Test whether the system is de-energized.
5.2.1 Electrical connection values of the drive
Supply voltage: 230 VAC, 50/60 Hz.
Device fuses: Check the specific unit's electrical diagram for values.
Two replacement fuses included.
If applicable: The connections between the remote-control unit and the pan and tilt unit are
shown in the enclosed wiring diagram or in chapter 12.5 Electrical connection diagram.
5.2.2 Notes on mains connection
Compliance with applicable national and international regulations is required.
The main switch and fuse must be disconnected while working.
The connection must be correct and unambiguous.
Proper zeroing/grounding must be verified (individual components must be connected to a
common grounding point).
NOTE
A switch is required between the ballast and the searchlight to operate manually. The
switch shall be placed close to the searchlight or ballast.
The switch can be up to 200 metres from the PSUX if a 1.5mm² wire section. The switch
is
connected to the PSUX terminal block (refer to chapter 12.5 Electrical connection
diagram).
Recommended switch characteristics:
1-pole, 250VA, 50W switching capacity, IP-rating according to the installation location.