SS450 RX Xenon Searchlight ERCU 1000W

Version Disney Cruises

Center Searchlight
2145418

INSTALLATION AND MAINTENANCE MANUAL

1
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

EUROPEAN DIRECTIVE 89/336/EEC

ELECTROMAGNETIC INTERFERENCE

INSTALLATION GUIDELINES

This instruction is located in every product manual, a copy of which is supplied with every item.

- During the design and construction of this product we minimize electromagnetic interference.
This does not guarantee any system interference.

- Care must be taken to consider the effects of each unit on existing sensitive
equipment in the area.
The installation cabling between parts of the equipment can also negate the protection
measures taken within the equipment.

- This instruction does not override local electrical regulations but should be read in conjunction
with them.

EQUIPMENT SPECIFICATION SCHEDULE

Important: Enter the details of the searchlight equipment delivered to you in the areas below.
This will help in future with the identification of spare parts, fault diagnosis, equipment upgrades, etc.

Serial number: ______________________________

Product part number: ______________________________

Supplier (Agent/Distributor) ______________________________

Date supplied: ______________________________

Date fitted/ Commissioned: ______________ / _______________

Lamp fitted: Type: __________ Voltage: ________ Wattage _______

Supply Voltage; Volts: __________ Hz: _____

Service history: (Serviced / Repaired)

Date: ________ Description: _______________________ Parts fitted: ___________

Date: ________ Description: _______________________ Parts fitted: ___________
Date: ________ Description: _______________________ Parts fitted ___________
Date: ________ Description: _______________________ Parts fitted ___________

Remarks: _______________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

2
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

INDEX OF CONTENTS

POINT DESCRIPTION PAGE No.

JPEG Image of SS350/450X series searchlight 1

European Directive 89/336/EEC 2
1.0 Safety instructions 3
2.0 Location, installation, Cabin Version 4-5
3.0 Location, installation, ERCU Version 5-6
4.0 Location/fitting Version with pedestal 6
5.0 Searchlight Focus 7
9.0 Auxiliary panel 7
7.0 Fault finding/troubleshooting 8
8.0 Recommended spares 9
Addresses 10

Appendix 0 Certificate Searchlight GL

Appendix 1 Searchlight installation and fixing arrangements Version Xenon ERCU
Appendix 2 Wiring diagrams
Appendix 3 Standard arrangement main panel
Appendix 4 Standard arrangement auxiliary panel.

Notice: Ice Version means:

This searchlight is equipped with a twin heater in the searchlight and in the ERCU for defrosting and
recovering ice at low ambient temperatures. Please check them every month.

1.0 SAFETY INSTRUCTIONS

1.1. Searchlight equipment supplied with mains voltage can kill if wrongly or incorrectly
installed or used.
1.2. Check the condition of all the searchlight equipment received making sure that a product manual
is with it. Keep the product manual in a safe place.
1.3. Always ensure that competent and qualified electrical or engineering personnel carry out all
installations. Cabling runs must be free of any obstructions, in accordance to the wiring plan;
crimping, pinching or tight bending that might cause an electrical short or a failure in power
supply.
1.4. Never use the equipment or the spare parts for anything other than for the intended purpose.
1.5. Regularly maintained equipment will be less prone to premature failure in service than neglected
equipment. Follow the suggested service schedules, monitor lamp life carefully and change lamp
when approaching the stated life or when a noticeable deterioration in performance has been
observed.
1.6. Please pay attention, that the searchlight housing becomes very hot during operation, please
check before touching the housing.
1.7. Always use the company’s recommended spare parts. Failure to do so may invalidate the
company’s warranty.

3
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

2.0 LOCATION/FITTING – CABIN MOUNTED SEARCHLIGHT

(CABIN CONTROL)
2.1 Establish the location for the installation of the searchlight and control panel. Consider the
following points:
2.1.1 The centre line mounting height of the searchlight.
2.1.2 Access to the searchlight.
2.1.3 The method by which the searchlight will be operated.
2.1.4 Ensure there is sufficient operating and maintenance area provided in the vicinity
of the searchlight.
2.1.5 Avoid positioning the searchlight near any sensitive equipment.
2.1.6 Avoid positioning the searchlight where the light beam will be interrupted by
obstacles.

2.2 UNDERDECK CONTROL

2.2.1 The cabin control module is designed to suit Deck/ceiling gabs up to 250mm
Thickness. If the gab is wider, you have to modifying the length of the push rod.
2.2.2 On completion of the drilling of the centre hole, the stainless steel push rod
must be Positioned through the hole and the searchlight from below. Be careful
with the O-ring in the centre hole. Do not damage it.
2.2.3 The cabin control assembly must be fitted with the push rod inserted through the
centre hole. Make sure, that the assembly is axially aligned throughout.
2.2.4 The deck heard/ceiling must be supported internally to ensure the cabin control
mechanism can be used without distorting the deck heard/ceiling. An illustration
of a typical installation is shown in appendix.
2.2.5 The ceiling flansh must be secured to the cabin ceiling with 3 x studs or screws.
2.2.6 The 2 x retaining screws in the ceiling flange must be tightened onto the under
deck control tube following the final adjustment, for height an lever alignment
2.2.7 The cabin control handle must be locked into a horizontal position relative to the
ships deck.

2.3 “U” PIECE

2.3.1 The “U” piece assembly is factory fitted to searchlight barrel.

2.3.2 Fix the searchlight barrel into the straight ahead and horizontal position, making
sure it aligns with the cabin control lever.
2.3.3 Secure the push rod top to the transversely with the M10 studs and the self
securing nuts.
2.3.4 Any remaining push rod protruding below the control lever should be cut off
after drilling and fitting the transversely mounted secure ting bolt.

NOTE: Our standard cabin control searchlight is supplied with one push rod. On pedestal version
controlled searchlights, two push rods are supplied which are joined together with a jointing tube. Two push
rods are supplied to allow for ease of transport.

4
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

2.4 ELECTRICAL INSTALLATION

2.4.1 All conductors should be sized to limit voltage drops to a minimum and run
together in high amperage installations. This is particularly important on DC
installations.
2.4.2 All installations must be supplied through a suitable fuse. The fuse must switch
of both poles.
2.4.2.1 (NOT provided).
2.4.3 The searchlight has 3 pcs of 2.0 metres of marine grade cable fitted. This should
be terminated in a weatherproof junction box or plug (NOT supplied) Take care
not to interfere with the pan and tilt movement of the searchlight.
2.4.4 All xenon searchlights are supplied from the vessels AC 115V or 220Vsupply.
2.4.5 The company does not fit a lamp in the searchlight; lamps are supplied
separately. Before fitting the lamp ensure it conforms to usage in terms of
wattage, voltage, lamp cap pattern and manufacture.
2.4.6 Fitting lamp: DISCONNECT SUPPLY VOLTAGE BEFORE FITTING.

2.5 MOUNTING THE LAMP

2.5.1 Lock the searchlight in horizontal position.

2.5.2 Release the latches on the rear access cover and withdraw it to the limit of the
internal guide bars.
2.5.3 Remove the safety pins from the internal guide bars. Take out the complete
cover including all. Put it on the deck. Danger. Work very carefully.
2.5.4 IMPOTEND: Fore handling with the xenon lamp, wear hand gloves, helmet
and eye protection.
2.5.5 Remove lamp from the container and observe the manufacturers instructions. Do
not touch the glass enclosure with contaminants or by hand.
2.5.6 Remove the threaded transport rod from the front and rear lamp holder
connections.
2.5.7 Install the lamp with the –pole inside. Lock the lamp with the supplied wing nut
with the hand as tight as you can. Do not apply any strong pressure. Connect
the +pole wire on the top of the lamp. Tighten the boles with a key.
2.5.8 Refit the rear access cover and switch on the light. Secure the guide bars with the
delivered safety clamps.
2.5.9 Leave for 15 minutes in the power-on position to ensure there is no early lamp
failure. During this burn-in period some smoking may occur as paint gases burn
off. This is usually Minimal and will cease within the burn-in period.

2.6 XENON LAMP POWER SUPPLY UNIT- Sep up

WARNING: The rectifier power supply stores energy after the power is switch off. Wait a minimum of
30 minutes for the capacitors to discharge.
2.6.1 The power unit is fitted with output current adjustment. These take various forms
depending on lamp wattage.
2.6.2 Final adjustment of the DC lamp output current as recommended by the lamp
manufacturer can be set (See list below). Normal operation is:
Switch 1: position high, switch 2: position2. The power has to be around
50 A. If the Power is to low, because the DC cables are to long, you can put
the switch 2 higher.
2.6.3 Power supply set up details. Notice: to high power reduce the live of the
lamp.
500W - 28 Amps
1000W - 50 Amps
1600W - 65 Amps
2000W - 80 Amps

5
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

IMPORTANT NOTE: THE POWER SUPPLY IS NOT WATERPROOF AND BECOMES WORM:
INSTALL UNDER DECK IN WELL VENTILATED ROOMS OR SPACES.

3.0 LOCATION FITTING/ELECTRICIAL INSTALLATION OF ERCU

(REMOTE CONTROL)
Establish the location for the installation of the ERCU as shows in Point 2.1. Consider the following points:

3.0.1 The vertical and horizontal movement of the ERCU. The ERCU is pre-set to tilt
of 30° forward and 15° backward. Any change at the adjustment of limit switches Could
result in a motor damage.

3.1 FITTING AND ELECTRICIAL CONNECTION OF THE SEARCHLIGHT.

3.1.1 Secure the ERCU to the mounting position by using 3 x M10 studs or screws.
The maintenance cover has to be on the rear side.
3.1.2 Install the control panel on the bridge.
3.1.3 The length and the diameter of the cable run from the bridge control panel to the
Searchlight. See wiring diagram. Only use screened cables.
3.1.4 Mont the searchlight head on the ERCU. Connect the tilt rod with the rear
“U” Piece.
3.1.5 The factory mounted connecting 3 cables is roundly 1, 5 m long. 1 is the
Control cable a 2 are the DC cables for the xenon lamp. You have to connect it
into the connection box at the ERCU with cable glands. Tighten the cable glands
strongly.
NOTE: For installation. The connecting cable must be long enough to allow
pan function.
3.1.6 Cable the installation according to the wiring diagram.
3.1.7 All wires a connection must be sufficing dimensioned. The connectors have to
be strongly tightened.
3.1.8 All installations must be supplied through a suitable fuse. The fuse must switch
of both poles (NOT provided). If a space heater is attached a second fuse is
needed to supply the space heater separately.

3.2 SETTING TO WORK OF THE SEARCHLIGHT

3.2.1 Switch on the ship fuse for power supply. The searchlight is ready for work.
3.2.2 Press the main switch on the panel. The red lamp over the switch lights up. The
searchlight is on. See appendix main panel.
3.2.3 Press the ignition button for aprox. 3 sec. The xenon lamp lights up.
3.2.3.1 Note: If Between pressing the main switch and the ignition button is
more than 20 sec. a protector inside the ignitor switches
automatically of. Switch of the main switch and start again.
3.2.4 Test the function of the ERCU with the 8 position Joystick. See appendix main
panel.
3.2.5 Notice: The searchlight setting points of the pan function is reduced on 100°
to the port and 100° to the starboard side.
The settings points of the tilt function are 15° up and 35° down.

6
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

4.0 LOCATION AND FITTING VERSION WITH PEDESTAL

The standard length of a pedestal is 1m. The operation height is raised up by 1 m, when the module is used
between the deck and the searchlight. The fitting of a pedestal to a cabin control searchlight includes the
use of 2x 890mm posh rods. The installation of the pedestal between deck and remote control version is the
same procedure than only the searchlight on Deck. In this case, you have to use the delivered pedestal
fixing kid.

5.0 SEARCHLIGHT FOCUS

Following installation the searchlight beam should be checked for correct focus.

5.1 Moving the lamp towards the reflector will widen the beam.
5.2 Moving the lamp away from the reflector will narrow the beam.
5.3 To adjust the focus;
5.3.1 Switch on the light
5.3.2 Move the focus switch on the searchlight control panel to the spot position and
check The beam narrows down to a spot beam.
5.3.3 Move the focus switch to the flood position and check the beam expands.
5.3.4 The focus movement stops if the switch is in the centre position.
5.3.5 If the switch is left in either the spot or flood position the focus will continually
shift from spot to flood and back again.
5.3.6 It is a feature of all Xenon searchlights, that after a certain point the expanded
beam has a dark area in the centre that grows as the beam expands. This is
unavoidable.
5.3.7 Check the light beam against a target whilst moving the lamp until the optimum
setting is obtained.

6.0 AUXILARY PANEL (Optional)

6.1 The auxiliary panel can only run in dependence with the main panel. The auxiliary panel can
not replace the main panel.
6.2 For function the main switch on main panel have to be pressed, with the ignition button, the
lamp will be set in work (see 3.2.2). The searchlight can now be used from the main panel.
For using the auxiliary panel, you must press the button POWER OVERRIDE on the auxiliary
panel. If the red control lamp is on, the auxiliary panel if active. The pan/Tilt plus the focus
function can now be driven from here. On the main panel these functions are now inactive.
Other auxiliary panel are now blocked. If the functions shell be given back to the main panel,
you have to press the POWER OVERRIDE a second time, the control light switches of and
the auxiliary panel is now inactive. See appendix auxiliary panel.
6.3 The main switch on the main panel is active at any time. The searchlight can be switched of at
any time.

7
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

7.0 FAULT FINDING/TROUBLESHOOTING

7.1 Searchlight beam not out
7.1.1 Check the power is present at the control panel, searchlight and power supply.
105-120V or 215-245V
7.1.2 Check the isolator/fuse is switched on and the correct ignition sequence has been
followed, namely a. Power on, –max 20sec- b. Lamp ignition.
7.1.3 Check the lamp electrodes for damage, check the lamp holder of for corrosion.
7.1.4 Check voltage is present at the ignitor.
7.1.5 With the power ON but without lamp ignition activated. Check the no load
voltage across the +and - terminal on the power supply with a meter. This should
be approximately 110V minimum.
7.1.6 If the main voltage is lower than minimum, adjust the power supply to increase
settings.

7.2 Water in barrel

7.2.1 Check drain holes in the bottom of the barrel are clear. Some water due to
condensation is normal
7.2.2 Check the condition and fitting of the front and rear gaskets. Replace if
necessary
7.2.3 Check the operation and fit of rear latches and front glass retaining blocks.
7.2.4 Check cable glands and all screws and rivets are securely fitted with necessary
water seals.
7.3 Water on the bridge the push rods (cabin version).
7.3.1 Check the o-ring on the top of the push rods tube. Check the gaskets between
Searchlight, pedestal and deck. Change if damaged.
7.3.2 Check the push rod is correct mounted.

7.4 Smoke in barrel

7.4.1 When the light is first switched on some smoke is generated by the burning off
of paint inside the barrel. This is normal. It is advisable to run the light for 15
minutes or more and then open the rear access cover to release the smoke.

7.5 Searchlight does not move

7.5.1 PAN/TILT (Cabin version) Check the lock knob on the under deck control is
unlock.
7.5.2 PAN/TILT (Remote control). Check the pan and tilt motor have no failed. Check
the power supply at the control panel. Check the power on button and the
joystick are functional.

7.6 Oxidation
7.6.1 Searchlights are often installed close to funnels/stacks. Sulphur emissions from
funnels can mix with seawater or rain to form sulphuric acid. This can cause
some oxidation on the surface of stainless steel searchlight parts. This is only
superficial and will not progress beyond the surface. No damage will be caused
to the searchlight due to oxidation.

7.7 Morse signalling shutter does not move (Naval Version) (optional)
7.7.1 Check steel locking pin is fully removed.
7.7.2 Check return spring is still intact and has not failed.
7.7.3 Check none of the shutter vanes inside the light are damaged.
7.7.4 Check all the shutter moving parts and clean and grease where necessary. Use
very high temperature grease.

8
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
 SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

8.0 RECOMMENDED SPARES AND SERVICING PERIODS

8.1 RECOMMENDED SPARES

8.1.1 SPARE PARTS

ITEM PART
DESCRITION No.

Front Glass SS 350 2200820

Front Glass SS 450 2200676
Front and Rear gasket 350mm 2200805
Front and Rear gasket 450mm 2200679
Ignitor 230V 2200982
Focus Motor 230V 2200695
Parabolic Mirror 350mm 2201027
Parabolic Mirror 450mm 2201004
Heater 2200853

IMPORTANT:
When order spare parts, please note type and serial number of the searchlight.

8.2 SERVICING PERIODS

The company recommend that searchlights should be serviced at 3 MONTHLY intervals with a visual and
functional check before every voyage.

Typical checks and service actions:

- Clean lens glass inside and out

- Clean the reflector if needed using only a very clean soft cloth and soap
and water. Do not use any spirits, thinner, solvents or abrasives.
- Check the condition of front and rear barrel seals
- Check the condition of the lamp holder, if burned or oxidized, please change.
- Check and change the lamp if damaged or if approaching stated life.
- Check the condition of the supply cables and replace if damaged.
- Check and clear out the drain holes on the underside of the barrel.
These have small pins and washers fitted which must be left in
- Make sure the searchlight moves freely in the pan and tilt mode
- Check the movement of the Morse code signalling apparatus (navy version). Clean off
any dirt or sand on the shutter parts. Grease all moving parts with high temperature
grease if necessary.

9
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]
SS450 RX Xenon Searchlight ERCU 1000W
Version Disney Cruises
Center Searchlight
2145418

Do you need some spare parts, not

shown in this documentation, please
contact us.
Tel: 00 49 40 547322 0
Fax: 00 49 40 547322 99
And: [email protected]

Or for technical problems

Tel: 00 49 40 547322 21 or 27
And [email protected]

KARL DOSE GMBH

HAMBURG
13.04.2010
JENS SCHMELZER

Made in Germany

10
Karl Dose GmbH Försterweg 77 D-22525 Hamburg
Tel.: (+49) 40 54 73 22 0 Fax: (+49) 40 54 73 22 99
Internet: www.karl-dose.de
E-mail: [email protected]