WISKA SX450-2000+E User manual

OPERATING INSTRUCTIONS
SEARCHLIGHT
SX 450-2000+E

About these instructions SX450-2000+E Rev.21082012E
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SX450-2000+E Rev.21082012E About these instructions
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Contents 1.ABOUT THESE INSTRUCTIONS 4
1.1Symbols and guidance signs in these instructions..........................4
1.2Who are these instructions for?.......................................................4
2.SAFETY 5
2.1General information.........................................................................5
2.2Handling Xenon lamps ....................................................................5
2.3Safety devices.................................................................................6
2.4Operating conditions........................................................................7
2.5Maintenance / Cleaning...................................................................7
3.AN OVERVIEW OF THE UNIT 8
3.1Layout drawing................................................................................8
3.2Technical data.................................................................................9
3.4Dimensions....................................................................................10
3.5Circuit diagram............................................................................14
4.INSTALLATION 16
4.1Unpacking......................................................................................16
4.2Mounting........................................................................................16
4.3Electrical connections....................................................................17
5.OPERATION OF THE SEARCHLIGHT VIA RCU 18
5.2.1Remote control unit RCU (optional for RC (FL51)).......................18
5.2.2Switching unit RCU (optional for D/C/DP/CP)...............................18
5.3Switching on..................................................................................19
5.4Switching off..................................................................................19
6.MAINTENANCE 19
6.1Cleaning ........................................................................................19
7.REPLACEMENT OF DEFECTIVE PARTS 20
7.1Before starting work.......................................................................20
7.2Assembly overview........................................................................20
7.3Lamp replacement.........................................................................21
7.4 Replacing the fan...........................................................................23
7.5 Replacing the auxiliary mirror........................................................24
7.6 Replacing the igniter......................................................................24
8.DISPOSAL 25
9.SPARE PARTS 26
10.APPENDIX 27

About these instructions SX450-2000+E Rev.21082012E
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1. About these instructions
1.1 Symbols and guidance signs in these instructions
Danger! There is a risk to life and limb if the warning is not followed.
Risk of electric shock! There is a risk to life and limb from electricity if the
warning is not followed.
Wear protective clothing!
- Safety glasses to protect the eyes
- Face mask with neck protection
- Safety gloves with artery protection.
There is a risk to life and limb if the warning is not followed.
Use disposable gloves! Use disposable gloves for the following work to protect
the material and your health.
Attention! There is a risk to the environment and the device if the warning is not
followed.
Operating steps, that should take place in a certain order, are numbered
sequentially.
Operating steps, that only consist of one step or that don’t have to be followed in
a certain sequence, are marked with a point.
Feedback from executed actions begins with an arrow.
Enumerations begin with an enumeration line.
1.2 Who are these instructions for?
These instructions are intended for the personnel that are assigned with the assembly,
operation and maintenance of the searchlight.
Danger of electric shock and short circuit! All electrical installation and repair
work may only be carried out by a qualified electrician!
Wear protective clothing! Personnel charged with the maintenance and care of
the searchlight must be given suitable protective clothing for handling Xenon
lamps and must be instructed in their use.
1, 2, 3, …

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2. Safety
The following safety instructions have to be strictly followed! Otherwise you put yourself
and others in danger.
2.1 General information
Intended use
The SX 450/ 2000 searchlight is designed for lighting large and far away objects. The
range of the searchlight is up to 9,600 m.
Because of its intense light power the searchlight may not be used to illuminate persons in
the nearby surroundings.
It is not suitable for illuminating, spaces on the ship or in buildings.
Danger! Unauthorised conversions and changes to the searchlight are not
allowed, since this can endanger persons and may damage the unit.
Only original spare parts may be used. Disregard will result in the loss of the
warranty claim and the approval for the device.
Risk of getting burned! Never touch the searchlight during operation without
protection. The casing can reach 140°C. Always allow the searchlight to cool
down before maintenance and repair work. In case of burns cool the injured area
immediately and seek medical help.
Risk of glare! Never look into the light source during operation. This is dangerous
for the eyes. Never point the searchlight directly at anyone.
Risk of crushing! Risk of shearing! Before rotating or tilting the searchlight
using the optional remote control: Make sure that there is nobody right beside it. A
persons limbs can get trapped between the searchlight and the moving
mechanism and sustain serious injured.
2.2 Handling Xenon lamps
Strictly follow the safety instructions below when handling Xenon lamps:
Risk of explosion! Xenon lamps are under a high pressure, even when they are
cold (20 bar). This pressure increases to 70 bar during operation. Therefore,
strictly follow the safety instructions below when handling Xenon lamps:
Transport
Always store and transport Xenon lamps in their protective sleeve.
• Keep the protective sleeve in a safe place after installation of the lamp
• Always immediately replace used Xenon lamps in their protective sleeve after
dismantling!
• Never touch the lamp with your fingers.
Operation
• Never touch the naked lamp bulb with your bare hands. Remove fingerprints
on the lamp before installation with an alcohol solution and a soft lint-free
cloth.
• Check the lamp for scratches, cracks or other damage before installation.
Don’t continue using damaged lamps.
• Pay attention to correct polarity. Incorrect polarity will immediately destroy the
lamp.

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Lifetime
• The average lifetime of the Xenon lamp is 1500 hours, depending on the lamp
manufacturer and on the frequency and duration of switching on of the lamp.
Replace the lamp and the internal fan upon reaching the average service life of
the lamp at the latest.
Disposal
• Xenon lamps must be decompressed before disposing of the glass bulb
• Risk of explosion! Decompress the glass bulb in suitable surroundings. Make
sure that there are no other persons in the immediate vicinity.
• Wear protective clothing!
2.3 Safety devices
Temperature
• The installed Xenon lamp develops intensive heat during operation. To reduce
the heat, a thermostat-controlled fan generates a circulating air stream in the
casing, which dissipates the heat from the inside via the searchlight casing.
• To ensure that no condensate can form on the inside of the searchlight, it is
necessary for the ignition process to have a minimum temperature of 6 °C
inside the searchlight. To ensure this minimum temperature, a thermostatically
controlled heater is integrated in the casing. At the same time the heater
protects the searchlight against freezing.
• In order to protect the gear of the optional movement unit from freezing, a
thermostat-controlled heater is also integrated in the movement unit FL51.
Attention! Ensuring the minimum temperature at cold ambient temperatures:
• Keep the searchlight in standby mode (main switch on the PSUX-E ON). Only
switch it using the controller (RCU).
• Don’t switch on the lamp immediately, if the searchlight is de-energised at
temperatures around or below 6 °C for a longer period of time. Switch to
standby mode with the main switch on the PSUX-E, and wait until it has
reached the minimum required temperature inside.
Radiation/escape of dangerous particles
• Xenon lamps radiate UV light which is harmful to the eyes. The special
searchlight casing prevents you from looking directly into the arc.
• If the Xenon lamp explodes during operation, the casing remains intact and
contains any heated glass splinters.

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2.4 Operating conditions
Installation location of the searchlight
Under normal use conditions the casing surface temperatures can go up to 140 °C. Only
install the searchlight close to heat resistant material. To eliminate any dangers: Never
store any explosive or highly flammable materials right beside the searchlight. These
include petrol, paper and paint for example.
The installation location of the power supply unit Xenon PSUX-E
The power supply unit is intended for outdoor use (IP66; -25°C - +55°C). Mount it such
that good air circulation is ensured.
In addition there is the possibility of extending the temperature ranger up to -50°C by
means of additional heaters, with the same IP protection class 66, by replacing the cover.
If you wish to install these indoors, there is a possibility of equipping the PSUX-E with a
special cover containing additional fans (IP44). These provide improved air circulation of
the electronic components.
2.5 Maintenance / Cleaning
Before carrying out maintenance or cleaning work:
Set the main switch on the PSUX-E to OFF.
Make sure that the complete electrical system is de-energised.
Wait until the searchlight has cooled down.

An overview of the unit SX450-2000+E Rev.21082012E
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3. An overview of the unit
3.1 Layout drawing
Basic configuration searchlight head and power supply unit PSUX-E
1
3
2 4
5 6
1 Searchlight head SX 450-2000+E
2 Quick release clamp
3 Front glass
4 Handle
5 Power supply unit PSUX-E
6 Main switch (PSUX-E)
Cable (lamp operation)
5G10mm²
(
Ø 22mm/ len
g
th 3m
)
Cable (supply line)
5G1.5mm² (Ø 10.9mm/ length 3m)

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3.2 Technical data
Type: SX450-2000+E / SX450F-2000+E / SX450IC- 2000+ E /
SX450ICF-2000+E
Manufacturer: WISKA Hoppmann & Mulsow GmbH
Searchlight head
Type SX450-2000+E SX450F-2000+E SX 450IC-2000+E SX 450ICF-2000+E
Lamp Xenon 2000 W
Luminous intensity
[cd] in focus 92x10
6
Range [1lx/ ¼lx] 9600m/19180m
Lamp power 2000W
Average lamp
lifetime [h] 1500
Mirror type Silver-plated glass mirror
Colour Traffic white, RAL 9016
Dimensions 550x522
Weight
Protection rating IP 56
Special features Remote focus Suitable up to – 50°C Suitable up to -50°C
+ remote focus
Type: PSUX+E
Manufacturer: WISKA Hoppmann & Mulsow GmbH
Specification
Protection against external mechanical loads in
accordance with EN50102 IK08
Operating voltage 230V +/- 10%
Operating frequency 47-63Hz
Operating current 14A@180VAC 9A@265VAC
Switch-on current PSUX+E 15A max.
Power factor 0.98
THD <10%
Lamp power for XBO lamp 2000W
Output current 105A max.
Output voltage 20V-40V (DC)
Idle state booster voltage 200V max.
Switch-on current, lamp 105A max.
Ignition voltage (in the searchlight head) 35 kV max.
Short circuit protection Yes
Circuit monitoring Yes
Ignition fault protection Yes
Overheating protection Yes
Monitoring end of lamp service life Yes
Weight 28kg

An overview of the unit SX450-2000+E Rev.21082012E
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3.4 Dimensions
Searchlight head with foot D450 (A) Searchlight head on pedestal DP450 (B)

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Searchlight head with cabin control C450 (C) On pedestal with cabin control CP450 (D)

An overview of the unit SX450-2000+E Rev.21082012E
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Searchlight head with Searchlight head with
pan/tilt unit FL51 (E) pan/tilt unit FL51 (E)
Overhead mounting
Remote control RCU-E (F) and control switch RCU-E-CS (G)

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Power supply unit PSUX-E 2000W Basic (G)

An overview of the unit SX450-2000+E Rev.21082012E
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3.5 Circuit diagram
Block diagram

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Circuit diagram SX450/ 2000 +E
The circuit diagram is enclosed separately and/or is shown here as an example only (and may
deviate from that delivered!)

Installation SX450-2000+E Rev.21082012E
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4. Installation
4.1 Unpacking
Check the delivery!
Don’t start the unit if there is transport damage or missing parts!
Contact WISKA or our sales partner in your country.
The address can be found at the back of these instructions or on the internet under
www.wiska.de.
Think about the environment and send the packing for recycling!
4.2 Mounting
Mounting the searchlight with a foot or on a pedestal (A and B)
Alternatively, the searchlight can be mounted on a suitable foot (A) or on a pedestal (B).
Because of the weight of the searchlight, installation requires at least 2 persons.
1. Four holes have to be drilled here in a circle of 300 mm ø for installation: see chapter
3.4 Dimensions.
2. Fit the movement unit and bolt it on.
3. Connect the earth cable
Mounting the searchlight with cabin control or on a pedestal with cabin control (C
and D)
If equipped with a manual foot or pedestal (C or D) cabin control, the linkage must be fed
downwards. This requires a central hole in addition to the fixings. See chapter 3.4
Dimensions.
Mounting the searchlight with an FL51 (E) pan/tilt unit
If the searchlight was ordered with a movement unit, it is delivered pre-assembled on the
movement unit FL51.
Because of the weight of the searchlight, installation requires at least 2 persons.
1. Four holes have to be drilled on a circle of 330 mm ø for installation: see chapter 3.4
Dimensions.
2. Fit the movement unit and bolt it on.
3. Connect the earth cable
Mounting the power supply unit PSUX-E
Because of its weight, the PSUX-E requires installation with at least 2 persons.
Follow the details for the installation location in chapter 2.4 Operating conditions.
The PSUX-E power supply unit is fitted with 4 lugs for wall mounting.
Searchlight and movement unit are fitted with 3 m long connection cables.
If you wish to install the PSUX-E further away from the power supply grid, please observe
that the power supply voltage of the PSUX-E must be guaranteed within the range of 230
V +/- 10% when subjected to loads. The connection between the PSUX-E and the
searchlight should be as short as possible. It may be extended up to a maximum of 25m
with ship installation cable without the consent of the manufacturer; a three-core screened
cable with a minimum cross-section of 25mm² should be used.
Installation of the RCU controller
The searchlight always requires an RCU whether it is equipped with an electromechanical
movement unit FL51 or not. The control unit RCU is not only available as an attachment
device for

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wall mounting, but also as a built-in device for installation into a suitable control panel.
The units are electrically and functionally identical. Make the required holes and openings
for installation, see Dimensions in chapter 3.4
Dimensions . Be sure to choose the right
cable cross-section in relation to the cable length when making the connections.
4.3 Electrical connections
Danger of electric shock and short circuit! Electrical connections may only be carried
by a qualified electrician. Please ensure that the mains connection is off and that nobody
can accidentally energise the connections during installation! The circuit diagram is
enclosed separately or can be found in the Appendix, Chapter 10 Exemplary circuit
diagram (this may deviate from that delivered!)
Electrical connected loads for the searchlight system
Mains voltage: 230 ±10% V AC, 50/60Hz // (at least 2500VA / watts).
Device fuse: 1 x 6.3 A
(2 spare 6.3 A fuses are included with the PSUX-E)
Waterproof (IP56) installation of all connection lines
1. Loosen the locking screws of the PSUX-E on the underside (5xM25) and top side (1xM40)
and remove the cover.
2. Insert correctly sized (tailored to the cable diameter) waterproof cable glands into the
holes.
3. Feed the lines through the cable glands und fix them.
4. Make sure that an adequate cross-section is used for the amperage and cable length.
Attention! Cable lengths longer than 5 m between the PSUX-E and the searchlight head
should be discussed with WISKA!
Attention! To guarantee the IP56 protection class:
The device casing has to be waterproof: Tighten the cable glands firmly, such that the
seals close tightly round the cables!
5. Connect the cables in accordance with the circuit diagram (see separately enclosed circuit
diagram).
Note: The cable from the searchlight and the movement unit FL51 can either be
connected directly or via a junction box to the PSUX-E using ship wiring cable.
Mains connection
Please observe the valid national and international provisions and the regulations of the
individual classification societies!
Prior to commissioning:
Check for correct installation. Wrong connections can destroy the Xenon lamp or the
searchlight.
Attention! Incorrect polarity of the Xenon lamp leads to destruction of the Xenon lamp or
the searchlight! Xenon lamps are polarised DC lamps with a very high current. Such
current values demand that both cathode (minus) and anode (plus) are highly specialised
for their respective purposes: the cathode must supply a strong flow of electrons, which
the anode must collect. This clear dimensioning of the electrodes also means that
incorrect polarity has severe consequence: the lamp is destroyed within fractions of a
second, in particular the cathode.
Check for correct connection of the earth / ground!
Insert the fuse.

Operation of the searchlight via RCU SX450-2000+E Rev.21082012E
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5. Operation of the searchlight via RCU
Each SX searchlight system has an RCU, which can either consist of only a control switch
to switch on a searchlight, or into which other functions are also integrated, such as e.g.
the control of a gear (see item 5.2.1)
Attention!
• Only use the control knobs provided for setting up the searchlight. Never touch
the searchlight casing during operation since there is a risk of getting
burned!
• Make sure that nobody is in front of the searchlight when switching on or
during operation, - Risk of glare!
• The switch S1, for switching on a searchlight, which is described in section
5.2.1, is situated in your case not in the RCU, but is mounted separately. As no
electromechanical movement unit exists, switch S2 and the control lever are
absent.
• Now read on from item 5.3 Switching on.
5.2.1 Remote control unit RCU (optional for RC (FL51))
1 Drive indicator lamp
S2Drive on/off switch
2 Drive control lever
S1Searchlight on/off switch
3 Searchlight indicator lamp
5.2.2 Switching unit RCU (optional for D/C/DP/CP)

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5.3 Switching on
Risk of getting burned! Never touch the searchlight during operation without
protection. The casing can reach 140 °C. In case of burns cool the injured area
immediately and seek medical help.
Risk of glare! Never look into the light source during operation. This is dangerous
for the eyes. Never point the searchlight directly at anyone. Before switching on
make sure that nobody is near the searchlight.
1. The main switch on the power supply unit PSUX-E should always be ON, so that
the heater and the fan in the searchlight head are provided with current.
Attention! If the ambient temperature is below 6 °C and the PSUX-E is not
switched on, wait until the internal heater warms up the inside of the casing to at
least 6 °C before igniting the lamp.
2. Turn switch S1 on. The searchlight lamp should light up after a delay time of
approx. 5 seconds at the latest.
3. If the lamp does not ignite or only flashes a few times when switched on, either
the operating voltage is too low or the lamp is defective, see Chapter 7.3 Lamp
replacement and replace the lamp.
4. Before switching on the searchlight and the movement unit, if present, make sure
that all work on the searchlight has been completed.
5. If a pan/tilt unit is fitted, switch this on as well with switch S2 on the RCU
controller. The pan/tilt unit is now also ready for use and can be moved with the
control lever.
5.4 Switching off
1. Switch the searchlight off with the lamp switch. This is switch S1 on the RCU.
2. If you are using a pan/tilt unit, you can now also switch this off with switch S2 on
the RCU. This prevents control using the joystick.
Attention! To ensure standby mode: Only switch off the searchlight using switch
S1 and additionally switch S2 if you are using a movement unit.
The main switch on the PSUX-E always remains switched on, such that the heater
and the fan stay in operation. Unless the system is decommissioned for a longer
period of time. It can then be decommissioned via the main switch on the PSUX-
E.
6. Maintenance
6.1 Cleaning
Clean the front glass on the outside as needed. When doing so check the function of the
fixing clamps and inspect them for rust. Cleaning the inside of the searchlight is not
necessary. A thin, coloured film develops on the mirror surface and inner front glass in the
course of time. This is harmless and does not affect the light power.
Risk of glare! Ensure that the searchlight cannot be switched on during cleaning
work.

Replacement of defective parts SX450-2000+E Rev.21082012E
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7. Replacement of defective parts
7.1 Before starting work
1. Make sure that the complete electrical system is de-energised and that it cannot
be switched on again accidentally. For this, set the main switch on the PSUX-E to
OFF.
2. Make sure that the complete electrical system is de-energised and that it cannot
be switched on again accidentally.
3. Wait until the searchlight has cooled down.
4. Read chapter 2.2 How to handle Xenon lamps.
Wear protective clothing (safety glasses, face mask with neck protection and
safety gloves with artery protection), when opening the searchlight casing.
5. Do not touch the lamp with your bare hands und cover the Xenon lamp with its
protective sleeve
7.2 Assembly overview
The following illustrations should help you to better understand the design of the
searchlight, before starting with the replacement work. Follow the instructions on the
following pages for carrying out the replacement work!
1
4
2 5 7 6
3
Attention: The inner chassis is electrically polarised (minus pole), and has no
connection to ground/earth of the searchlight system. The two poles (+ & - ) are
electrically floating (potential) and have no electrical connection whatsoever to
ground/earth and to the outer casing wall.
1. Casing
2. Front glass
3. Quick release clamp
4. Inner chassis
5. Igniter
6. Rear wall
7. Fan