WISKA SX 450 Series User manual

Instruction Manual
Searchlight
SX 450 Series/Remote Focus(optional)

Contents
1About this manual .......................................................................................2
1.1 Warning symbols and markings used in this manual ......................................2
1.2 Who should read these instructions ...............................................................2
2Safety ...........................................................................................................3
2.1 General information .......................................................................................3
2.2 Working with Xenon lamps ............................................................................3
2.3 Protective measures......................................................................................4
2.4 Operating requirements .................................................................................5
2.5 Maintenance / cleaning..................................................................................5
3Overview ......................................................................................................6
3.1 Assembly drawings........................................................................................6
3.2. Technical specifications.................................................................................7
3.3 Unit nameplates ............................................................................................9
3.4 Dimensions .................................................................................................10
4Installation ................................................................................................. 14
4.1 Unpacking the unit.......................................................................................14
4.2 Installation................................................................................................... 14
4.3 Electrical connections..................................................................................15
5Operation ................................................................................................... 16
5.1 Control unit RCU .........................................................................................16
5.2 Turning on the searchlight ...........................................................................16
5.3 Turning off the searchlight ...........................................................................17
5.4 Remote focus (option) .................................................................................17
6Maintenance............................................................................................... 18
6.1 Cleaning......................................................................................................18
7Replacing defective parts ......................................................................... 18
7.1 Before you begin .........................................................................................18
7.2 Construction overview .................................................................................19
7.3 Changing the lamp ...................................................................................... 20
7.4 Changing the primary reflector.....................................................................22
7.5 Changing the secondary reflector ................................................................23
7.6 Replacing the ignition unit............................................................................24
8Disposal .....................................................................................................25
9Spare parts ................................................................................................ 26
10 Annex.........................................................................................................28
10.1 Annex Data sheet SX450 remote focus (option)...........................................28
10.2 Electric Circuit Diagrams..............................................................................29

About this manual
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1 About this manual
1.1 Warning symbols and markings used in this manual
Danger! Failure to observe this warning poses the risk of personal injury or
death.
Danger of electrical shock! Failure to observe this warning poses the risk of
personal injury or death from electrocution.
Wear protective clothing!
-Safety goggles to protect eyes
-Face mask with throat protection
-Safety gloves with wrist protection.
Failure to observe this warning poses the risk of personal injury or death.
Attention! Failure to observe this precaution poses a risk of damage to the
environment and the product.
Operating instructions that are to be followed in a certain order are
numbered.
A bullet point sets off operating instructions consisting of only a single Step
or of Steps which can be carried out in any order.
An arrow precedes confirmation messages in response to completed
operation steps.
A dash precedes listing items.
1.2 Who should read these instructions
These operating instructions are intended for all personal assigned to install maintain and
operate the searchlight.
Danger of electrical shock! All electrical work related to installing and
repairing the searchlight should only be carried out by qualified electricians.
Wear protective clothing! Personnel assigned to maintain and care the
searchlight must wear protective clothing for all the work where it is
recommended further on in this manual. Personnel must also be trained on
how to use it.

Safety
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2 Safety
Be sure to observe the following safety instructions. Failure to do so will pose a danger to
yourself and others.
2.1 General information
Intended use
The searchlights the SX 450 Series are designed to shine a spotlight on distant objects. The
searchlights have a range between 6700 m and 9600 m, depending on the type of unit.
The searchlights are designed for use on ships, in particular for polar voyages through icy
waters.
Due to its high intensity, the searchlight is not to be used to illuminate persons near the
searchlight.
It is not designed for lighting rooms on the ship or in buildings.
Danger! The searchlight should not be altered or modified in any way due to
the danger this to persons and damage which may occur to the searchlight.
Failure to observe this will void the approval certificate.
Only original spare parts may be used.
The use of unauthorized spare parts will void any warranty.
Danger of burns! Never touch the searchlight during operation. The housing
may reach temperatures as high as 150 °C. Always allow the searchlight to
cool down before carrying out maintenance work or repairs. In case of burns,
immediately cool the burned area and get medical help.
Danger of blinding! Never look into the source of light during operation. This
poses a danger to your eyesight. Never point the searchlight at people.
Danger of crushing! Danger of cutting! Be sure that there are no persons
directly next to the searchlight before rotating or tilting the searchlight. Persons
standing near the searchlight may get limbs caught between the searchlight
and base, and serious injuries may result.
2.2 Working with Xenon lamps
Danger of explosion! Xenon lamps are under high pressure even if not in
use (20 bar). During operation, the pressure may rise to as much as 70 bar.
For this reason, the following safety precautions must be observed when
working with Xenon lamps:
Transport
•Always store and transport xenon lamps in their protective shroud.
•Keep the protective shroud in a safe place after installing the lamp.
•Place xenon lamps back in their protective shroud immediately after taking
them out of the searchlight.

Safety
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Required protective clothing
Never open the searchlight when not wearing appropriate protective clothing. Always wear
protective clothing while near to an uncovered xenon lamp or while moving a xenon lamp without
its protective shroud.
The required protective clothing consists of:
- Safety goggles to protect eyes
- Face mask with throat protection
- Safety gloves with wrist protection
Operating the lamp
•Never touch the bare lamp bulb with your bare hands. Before screwing
in the lamp, remove any fingerprint smudges using a non-abrasive, lint-
free cloth and alcohol solution.
•Check the lamp for any scratches, cracks, or other signs of damage. Do
not use damaged lamps.
•Be sure to observe the correct polarity. Installing the lamp with the wrong
polarity renders the lamp useless.
Service life
Xenon lamps have an average life of about 1,500 operating hours. Replace the lamps at the
latest when this level of service life has been reached.
Disposal
Xenon lamps must be fractured to depressurise them before
disposal.
Danger of explosion! Depressurise the lamp bulbs in a suitably safe place. Be sure
that there are no other people in the immediate vicinity.
Wear protective eyewear and clothing!
2.3 Protective measures
Temperature
- The installed xenon lamp becomes very hot during operation. A
thermostat controlled blower circulates air in the housing to reduce the
temperature by conducting heat to the outside.
- To avoid moisture accumulation and facilitate ignition, a minimum
temperature of 6 °C inside the lamp housing is required. To ensure that
the minimum temperature is maintained, the searchlight housing is
equipped with a thermostat- controlled heater. The heater also protects
the searchlight from freezing.
- The optional FL52 pan and tilt unit can additionally be equipped with an
optional thermostat-controlled heating unit (Option: ICE-version).
Attention! To ensure that the minimum temperature is maintained during cold
weather conditions:
•Keep the searchlight ready for operation by leaving the main switch S8
in ON condition. Turn on the searchlight only through the switch S1,

Safety
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which may be located on the control unit or may exist as a separate
switch.
•Do not turn on the searchlight immediately if power has been cut off for
a prolonged period of time while the temperatures were at 6 °C or less.
First, place the searchlight in standby mode by switch S8 and wait until
the minimal internal operating temperature has been reached inside the
housing.
Radiation/ Emission of dangerous particles
•Xenon lamps emit UV light, which is hazardous to your eyes. The special
design of the searchlight prevents direct eye contact with the arc
searchlight.
-If a Xenon lamp should explode during operation, the robust housing will
stay intact and prevent hot glass shards from being expelled.
2.4 Operating requirements
Protection Class
The searchlight, power supply unit and the optional drive unit have an IP 56 protection class
rating (dust-protected, heavy seas and powerful water jets). All electrical cables may only be
inserted through appropriate cable glands to maintain this protection class.
Requirement for placement
Where to install
- the searchlight: under normal operating conditions, the housing of the
searchlight will reach temperatures up to 150 °C. Mount the searchlight
only in an environment that can resist this heat. To rule out all potential
dangers: do not store any explosive or easily inflammable materials in
the immediate area of the searchlight. Such materials include gasoline,
paper and paint.
- The power supply unit PSUX: Install the PSUX at a cool place which is
not exposed to direct sunlight, vented hot air or other dissipated heat from
fuel tanks
Attention! The searchlight and power supply unit PSUX are operating under
high voltage. To prevent electromagnetic interference with the compass, make
sure an appropriate distance is maintained between the searchlight, the power
supply unit PSUX and the compass. Also, do not run cables in the direct
proximity of the compass.
2.5 Maintenance / cleaning
Before carrying out maintenance or cleaning work:
•Turn off the main switch.
•Make sure the entire electrical system is dead.
•Wait until the searchlight has cooled down.
•Wear protective clothing when opening the searchlight.

Overview
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3 Overview
3.1 Assembly drawings
Basic configuration
Configuration with drive unit FL52 and
control unit RCU
1 Searchlight SX 450
2 Power supply unit PSUX
3Drive unit FL52
4Control unit RCU for FL52
S1 ON/OFF switch for searchlight
S8 Main power switch
S2 ON/OFF switch for the drive unit
1
3

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Technical specifications
There are four types of SX450 Searchlights, which differ from each other,
basically by the performance of its Xenon lamp. The two types of lamps
are 1000 W and 2000 W. The following table will show the technical details
of each type in individual columns.
To differentiate between the four types, you may consult the nameplate of
your searchlight.
(for optional remote focus see data sheet Annex. 1.1)
Type SX450/xxx FL52 230 V 50/60 Hz
Manufacturer WISKA Hoppmann GmbH
Searchlight type
SX450/1000
SX450/20001
Lamp:
Type of lamp
Xenon arc lamp
Illumination
64 Mio. cd
92 Mio. cd
Range
8000 m
9600 m
Diffusion angle
1,8 ° I/10
2,7 ° I/10
Lamp power
1000 W
2000 W
Average service
life of lamp
1500 h
Glass parabolic
reflector
Ø450 mm
Secondary
reflector
Ø 100 mm
Focus
fixed focus
Housing:
Material
stainless steal 1.4301
Colour
Traffic white, RAL 9016
Diameter
522 mm
Depth
505 mm
Weight
30 kg
31 kg
Protection class
IP 56
Operating
temperature
-25°C .. +55°C
Power supply unit PSUX
Supply voltage
230 V 50/60 Hz
F1 fuse
60 A
F2 fuse
16 A
F3 fuse
6 A
Dimensions w/d/h
500x340x500 mm
Weight
60 kg
Protection class
IP 54
1With electronic power supply as per attached datasheet PSUX-E

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3.1.1.1.1.1.1.1.1 Lamp ignition sequence
1.
Standby booster voltage (PSUX)
Approx. 100V DC
2.
High frequency ignition voltage
(searchlight)
20 KV .. 50 KV
3.
Operating voltage
18…28 V DC
Drive unit FL52
Rotation and tilt drive unit made of salt water-resistant stainless steel
with grips for holding and operating the searchlight
Standby heater
Optional
Power cable
3 m
Power consumption
80 W (220 W*)
Horizontal rotation
185°; 2°/s
Vertical tilt
+30° to -30°; 1,2°/s
Height of drive unit without shaft
approx. 416 mm
Base plate diameter
368 mm
Weight
42,6 kg
Protection Class
IP 56
Colour
RAL 9016
*with optional standby heater
Control unit RCU-E
Remote control with ON/OFF switch for searchlight and drive unit,
position control switch (joystick) and indicator lamps for installation in
a control panel.
Front
120 x 200 mm
Height + Joystick
90 x 170 mm
Weight
2,1 kg
Protection class
IP 23
Control unit RCU-A
Remote control with ON/OFF switch for searchlight and drive unit,
position control switch (joystick) and indicator lamps for wall mount
installation.
Front
200 x 200 mm
Height + Joystick
80+ 85 mm
Weight
2,5 kg
Protection class
IP 23

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3.3 Unit nameplates
Nameplate
1 Product designation
2 Product specification
3 Product serial number
4 Manufacturer
1
2
3
4

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3.4 Dimensions
Searchlight with foot and on a
column

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Searchlight with foot and on a column with internal mechanical operation

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Searchlight with drive unit FL52 and Control unit RCU

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Power supply unit
PSUX-K
PSUX-E
PSUX-EO
500

Installation
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4 Installation
4.1 Unpacking the unit
Check that all parts have been included in the package. Do not operate the searchlight if there
has been damage during transportation or parts are missing. Please contact your WISKA agent
or our distribution partner in your country. You will find the address on the back of these
operating instructions or go to www.wiska.de.
Remember to protect the environment and recycle the packaging.
4.2 Installation
Installing the searchlight with FL52 drive unit
If your searchlight was ordered with its electromechanical drive unit the searchlight comes pre-
assembled on the FL52 drive unit.
At least two persons are required for installation due to the weight of the searchlight.
1. Pre-drill four holes along a ø 330 mm circle in diameter. For more
information see chapter 3.4 Dimensions.
2. Place the drive unit at desired location and tighten screws.
3. Connect earth cable.
Installing the searchlight on a rest or a column.
As an alternative, the searchlight can be mounted on a low base rest or a column.
At least two persons are required for installation due to the weight of the searchlight.
1. For mounting, four holes have to be drilled in a circle of ø 300 mm in
diameter, see chapter 3.4 Dimensions.
2. Place the drive unit at desired location and tighten screws.
3. Connect earth cable.
Installing on a rest or a column equipped with internal mechanical
operation
As an option, the configuration with rest or column can be equipped with an additional internal
mechanical operation. The mechanical linkage runs in an internal pipe of the rest of the
column.Consequently the pipe must be brought down. To do so, an additional hole of ø50 mm
has to be drilled in the middle of the ø300 mm circle.
See also chapter 3.4 Dimensions.
Installing the power supply unit PSUX
At least two persons are required for installation due to the weight of the PSUX.
Be sure to observe the instructions in chapter 2.4 Operating requirements on where to install
the power supply unit.
The Power supply unit comes with four brackets for wall mounting.
The searchlight and the drive unit come with a 3 m power cable. If the PSUX is installed farther
away from the searchlight, bear in mind that the supply voltage for the PSUX must be 230V.
Installing the remote control unit RCU
If the searchlight is equipped with an electromechanical drive unit, a control unit is also required.
The control unit is available as panel mount unit RCU-E and as wall mount unit RCU-A.
Electrically and functionally are both units identical.

Installation
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To install the units, drill the required holes and make openings if required, as shown in chapter
3.4 Dimensions.
Make sure to provide wires of sufficient size (cross-section) for the cable length.
4.3 Electrical connections
Danger of electrical shock! Electrical connections may only be completed
by qualified personal. Be sure the power cord is dead and nobody can
accidentally resume the power supply during installation!
The circuit diagram is enclosed separately, or you find it in chapter 3.5
Diagram.
Connected load values
Supply voltage: 230 VAC, 50/60 Hz.
Unit Fuses: 1 x 6 A,1 x 16 A, 1 x 60 A included,
for SX450/1600: 1 x 6 A,1 x 16 A, 1 x 100 A.
(Also 2 spare fuses 60A or 100A are shipped with the unit.)
Waterproof (IP56) installation of all cables
1. Unscrew the cover on the underside of the PSUX power supply unit and
remove it.
2. Drill holes matching the cable size and insert cable fittings into holes.
3. Feed the cable through the cable fittings and fasten firmly.
4. Be sure to use the appropriate wire size for current and distance!
Attention! To ensure IP56 protection class:
The unit sheathing must have a waterproof seal: pull the fittings firmly
into place so that the seals are wrapped tightly around the cable fitting!
4. Connect cables in accordance with the circuit diagram (see separate
circuit diagram or chapter 3.5 Circuit diagram).
Note: The cable from the searchlight and FL52 drive unit can be
connected directly to the power supply unit (PSUX) or via an optional
junction box.
Power supply
•Be sure to observe any applicable international or local country
regulations! Connect to the power supply while ensuring reverse polarity
protection!
Before first use:
•Check that installation has been carried out correctly. Reverse polarity
will destroy the Xenon lamp.
•Check to be sure that grounding and zero current works properly!
•Reinsert fuses.

Operation
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5 Operation
Further on, the operation will be described together with the electromechanical drive unit FL52
and its remote control unit RCU.
If your configuration is not equipped with such operating features, you should have special
attention to the following points:
- To direct the searchlight, only use the appropriate handles. Do
not touch the housing of the searchlight during operation -
Danger of burns!
- Ensure that at power-on and during operation, nobody is in
front of the searchlight - Danger of blinding!
- Switch S1 to turn on the searchlight, as described in chapter
5.2. It is a separate switch in your configuration and is not
located in the RCU. Because there is no electromechanical
drive unit, switch S2 and the joystick is not available.
- Continue reading with chapter 5.2 Turning on the searchlight.
5.1 Control unit RCU
1 Drive unit indicator lamp
S2 ON/OFF switch for the drive unit
2 Joystick for the drive unit
S1 On/off Switch for Searchlight
3 Searchlight indicator lamp
4 Push button for remote focus (option)
5.2 Turning on the searchlight
Danger of burns! Never touch the searchlight during operation. The housing
may reach temperatures as high as 150 °C. In case of burns, immediately cool
the burned area and get medical aid.
Danger of blinding! Never look into the light source during operation. This
poses a danger to your eyesight. Never point the searchlight at people. Before
you turn on the searchlight, make sure that nobody is in front of the
searchlight.
4 2

Operation
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1. Turn the main power switch S8 on the PSUX power supply unit to position
ON. This supplies power to the searchlight's internal heating system.
Attention! If ambient temperatures are below 6°C, wait until the housing
interior has been heated to at least 6 °C before igniting the arc.
Before you ignite the lamp, make sure that all work has been completed and
nobody is in front of the searchlight.
2. Turn on switch S1. This triggers the lamp.
3. In case you operate the searchlight using an electromechanical drive unit
FL52, you should turn it on also with switch S2, which is also located on the
RCU. The drive unit is now operational and can be controlled by means of the
joystick on the RCU.
→If the lamp does not initiate or if it flashes several times, either the ignition
voltage for the lamp is insufficient, or the lamp is defective.
See chapter 7.3 Changing the lamp for more information on replacing the
lamp.
5.3 Turning off the searchlight
Attention! To ensure operational readiness: only turn off the searchlight using
the S1 and, if you work with an RCU, with the S2 switch on the control unit.
Do not turn off the S8 switch on the power supply unit because the thermostat
controlled internal heater and blower should stay on all the time.
5.4 Remote focus (option)
As an option, the searchlight SX450 series can be equipped with a remote
focus device. The remote focus is an endless motor drive device, which will
focus and defocus the lamp against the mirror. A push-button on the remote
control unit RCU will start (press push button). Just stop pushing the button if
the request focus level (diameter of the light spot) is reached and the chosen
focus is set.

Maintenance
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6 Maintenance
6.1 Cleaning
Clean the front glass panel of the searchlight when required. When cleaning,
check if the fasteners are firmly in place and check for rusting/corrosion.
No cleaning of the searchlight interior is required. In the course of use, slight
discoloration of the reflector surface will occur. This has no adverse effect on
the unit and does not diminish the power of the lamp.
Danger of blinding! Make sure that nobody can turn on the searchlight while
cleaning.
7 Replacing defective parts
7.1 Before you begin
1. Turn the main switch S8 to OFF.
2. Make sure the entire electrical system is dead and it can not
be turned on accidentally.
3. Wait until the searchlight has cooled down.
4. Read chapter 2.2 Using Xenon lamps.
5. Wear protective clothing (safety goggles, face mask with throat
protection and safety gloves with wrist protection).
6. when opening the searchlight housing. Do not touch the lamp
with your bare hands.
7. Keep the xenon lamp in its protective shroud.

Replacing defective parts
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7.2 Construction overview
The following figure should help to understand the assembly of the searchlight
before you begin with replacement work.
To do the actual replacement work, follow the instructions on the following
pages!
All functional components are assembled on the inside chassis. The inside
chassis is mounted in the housing employing three screws 10 and two braces
7. The lamp carrier 5is fastened with screw 8to the inside chassis and carries
the lamp 9and the secondary reflector 4.
1
Construction
2
3
4
1 Rear panel with blower
2 Inside chassis
3 Housing
4 Front panel with quick-release clamps
Inside chassis
1 Primary reflector
2 Ignition unit
3 Bracket for ignition unit
4 Secondary reflector
5 Lamp carrier
6 Rubber buffer
7 Brace
8 Lamp (light source)
9 Fixure points for inside
chassis
10 Focus setting
1 2
5
6
3
7
9 8
4
9