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- Page 1 We Make it Right, Right Here!! XR Series 500 WATT MARINE SEARCHLIGHT Model 9304 Operator’s/Maintenance Manual (Covers Standard 110 VAC and Optional 220 VAC Power Supplies) Manufactured By Miami, FL 9304-PTD-51F 9/08...
- Page 3 XR Series 500 WATT MARINE SEARCHLIGHT Covers Standard 110 VAC and Optional 220 VAC Power Supplies) © COPYRIGHT 1999-2008 BY PERKO, INC. ALL RIGHTS RESERVED. THIS BOOK OR PARTS THEREOF, MAY NOT BE REPRODUCED IN ANY FORM WITHOUT PERMISSION OF PERKO, INC.
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Page 4: Table Of Contents
TABLE OF CONTENTS CHAPTER I INTRODUCTION PAGE General Description CHAPTER II- INSTALLATION General Unpacking Installation Post Installation and Checkout CHAPTER III INSTALLATION AND OPERATIONAL CHECKOUT Preoperational Checks Lamp Ignition Manual-Beam Focus Adjustment CHAPTER IV OPERATING PROCEDURES General Lamp Ignition Main Operation Turn-Off CHAPTER V OPERATOR MAINTENANCE General... - Page 5 APPENDIX A Optional Heater Package Installation Guide LIST OF ILLUSTRATIONS 500 Watt Marine Searchlight Interconnect Diagram 9304-1-A 500 Watt Marine Searchlight Outline Drawing Foldout 9304-2-B 500 Watt Marine Searchlight Foldout Power Supply Exploded View 9304-3-A 500 Watt Marine Searchlight Foldout...
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Page 6: General
CHAPTER I GENERAL. This manual contains descriptive theory, installation procedures and maintenance instructions for the XR Series 500 Watt Marine Searchlight, Model 9304, which will hereinafter be referred to as the 500 Watt Searchlight (figure 1-1). NOTE All service and/or installation work on Xenon Searchlights should be preformed by a Qualified Marine Electrician!! DESCRIPTION. - Page 7 Extreme caution must be exercised when performing tests required while power is on. The XR Series Power Supply, PERKO # 9511-000-110 operates on 120 VAC, 60 Hz. (Standard) The XR Series Power Supply, PERKO # 9511-000-220 operates on 220VAC, Single Phase 60 Hz.
- Page 8 CAUTION XR Series power supplies are factory wired for a specific input voltage. Do not connect the ship’s power to the Power Supply until a qualified technician determines that the ship’s voltage to be connected to the Power Supply is the same as that for which the Power Supply can accommodate.
- Page 9 A remote ammeter is provided with the Power Supply. This instrument should be located in the pilot house at a convenient location so that the pilot on watch can monitor the current being supplied to the lamp. A current indication which falls within the 20 to 25 ampere range is satisfactory. Should the current indication fall outside this range.
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Page 10: Chapter Ii- Installation
Immediately upon unpacking, check the contents of the shipping containers against the packing list. Make sure components are not dis- carded with the packing material. Report any shortages directly to PERKO, Inc. WARNING A spare xenon lamp may be shipped with a searchlight. - Page 11 (15). Tilt the Searchlight Head (window up) and install the rack support and rack assembly to the bot- tom of the Searchlight Head as shown in Drawing 9304-1. Tighten (finger-tight) rack mounting hardware to allow for final positioning when the rack engages the spur gear.
- Page 12 The Power Supply unit is heavy and should be handled and installed by two or more persons. (1) The Power Supply for the XR Series Model 9304 500 Watt xenon searchlight is supplied in a NEMA electrical enclosure measuring 20-1/4 inches high by 16-1/4 inches wide by 9-1/4 inches deep.
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Page 13: Post Installation And Checkout
(4) In the pilot house, determine the desired location for the remote ammeter and the electrical con- trol panel. (5) Cut a 2 inch by 3 inch opening in the pilot house console for the electrical remote control panel. A minimum of 3 inches clearance is needed behind the console opening. (6) Using the remote control panel face plate as a template, drill four mounting holes, one in each corner. -
Page 15: Chapter Iii Installation And Operational Checkout
CHAPTER III INSTALLATION AND OPERATIONAL CHECKOUT NOTE The following checkout procedures are to be performed by competent technicians. PRE-OPERATIONAL CHECKS. Prior to applying power to the searchlight, all cabling should be rechecked for proper connections. Ship’s power should be off. The Power Supply circuit breaker should be in the OFF position and the remote control panel STANDBY/ON/IGNITE switch A3S1 should be in the STANDBY position. - Page 16 (3) Ignite the searchlight and direct the beam toward a relatively flat, vertical surface approximate- ly 100 feet away. (4) Swing spherical link downward away from the motion transfer arm. Physically move the motion transfer arm to obtain the desired beam pattern. Adjust the position of the spherical link until the retaining screw passes through the link and into the motion transfer arm without changing the position of the motion transfer arm.
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Page 17: Chapter Iv Operating Procedures
CHAPTER IV OPERATING PROCEDURES GENERAL. The following procedures provide the necessary information for lamp ignition, opera- tion and turn-off of the 500 Watt Searchlight. LAMP IGNITION. Perform the following procedure in the sequence written: (1) Close the disconnect switch located near the ship’s Power Supply to apply power to the searchlight Power Supply. -
Page 18: Chapter V Operator Maintenance
CHAPTER V OPERATOR MAINTENANCE GENERAL. This chapter contains preventive maintenance instructions essential for maintaining the components of the searchlight. The instructions include inspection, cleaning and lubrication; opera- tional testing of controls and 500 Watt xenon lamp and removal/replacement. WARNING High voltages exist in the searchlight electronics. Allow searchlight to cool off 15 minutes before positioning Power Supply circuit breaker A1CB1 or ship’s power to OFF. -
Page 19: Xenon Lamp Removal
XENON LAMP REMOVAL. Perform the following steps in the following sequence: Position STANDBY/ON/IGNITE switch A3S1 to STANDBY. Allow searchlight to cool approximately 15 minutes until cooling fans stop running. Position searchlight Power Supply circuit breaker A1CB1 to OFF and disconnect ship’s power. - Page 20 (h) Remove the extractor. (i) Reinstall lamp plate. (j) Replace wire lead on anode end of lamp and tighten, again using two wrenches. (k) Close and clamp searchlight window. (l) Perform operational test on lamp. Refer to Paragraph 5-5 for test procedures.
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Page 21: Chapter Vi Maintenance
Power Supply assembly A1, searchlight head assembly A2, remote control panel A3, and remote current meter A4. Refer to Figure 9304 5-B for searchlight schematic diagram. The searchlight operates from a 115 VAC, 60 Hz power source which is applied through a 20 ampere cir- cuit breaker A1CB1 to transformer A1T1. -
Page 22: Detailed Functional Description (220 Vac)
Power Supply assembly A1, searchlight head assembly A2, remote control panel A3, and remote current meter A4. Refer to Figure 9304 7-B for searchlight schematic diagram. The searchlight operates from a 220 VAC, 60 Hz power source which is applied through a 15 ampere cir- cuit breaker A1CB1 to transformer A1T1. - Page 23 Transformer A1T1 provides 115 V to chopper assembly A1XA1 which is used to produce the 30 KV pulse ignite voltage for the xenon lamp A2DS1. When main contactor A1K1 is energized, approximately 80 VDC is applied between the anode and cathode of xenon lamp A2DS1.
- Page 24 which provides 24 VDC and ground return to focus motor A2A1. With +24 VDC and ground return, the focus motor moves the focusing mechanism attached to the xenon lamp in or out. Setting VARIABLE BEAM WIDTH switch A3S2 to the up position provides +24 VDC to terminal 3 and ground return to terminal 1 of DC focus motor A2A1 driving the focusing mechanism in one direction.
- Page 25 TABLE 6-1 PARTS LIST Description PERKO Part S&T Part Number Number SEARCHLIGHT HEAD 9504-000 ------------ Front Glass (Replacement) 9504-001 103D474P2 Gear Rack Assembly (Heated) 9574-000 ------------ Replacement Rack Heater Element 9571-003 111A810 Removable Optical Assembly 9524-000 ------------ Focus Motor 9521-088...
- Page 26 Description PERKO Part S&T Part Number Number MECHANICAL CONTROL 9530-000 103D552 Azimuth Tube 9530-002 9530-002 Ceiling Mount 9530-005 9530-005 Elevation Rod 9530-001 9530-001 Handle Assembly 9530-003 9530-003 Optional Support Base 9530-009 9530-009 Optional Support Rod 9530-012 9530-012 Roll Pin (1/8 X 5/8")
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Page 27: Warranty Policy
Avoid looking directly at an operating lamp. This may damage your eyes. There should be no direct exposure to the eyes or skin from an operating lamp. The Perko XR Series Xenon lamp warranty is void unless the lamp is operated according to the recommendations in this information package. -
Page 28: Instructions For Installing Xenon Lamps
This warranty is limited to the lamp only. Any further claim for indemnification is excluded. Perko will provide a lamp purchase credit for any xenon lamp which fails prema- turely due to any defect in material or workmanship provided that it has been operated on proper auxiliary equipment at no higher than the “Recommended... - Page 29 Insure proper current connections and polarity. Incorrect polarity will immediately dam- age the lamp. Remove the protective cover and tighten the lamp using a lamp extractor tool (Perko Figure # 9582 000). WARNING! Before taking the protective cover off the lamp, put on a protective mask, chest protector and leather gloves.
- Page 30 after the lamp has been shut off. Discolorations on the base shells indicate inadequate cool- ing. For safety reasons, XR Series Xenon Lamps should be replaced once they reach the end of their warranty life period and not later than 125% of this period. After this time there is increased risk of the lamp exploding.
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Page 31: Month Limited Warranty
A copy of the Warranty Registration Form is attached. 3. Lamp Failure Report - received by Perko, Inc within twenty (20) days of the date on which the lamp was removed from the searchlight. A copy of the Lamp Failure Report is attached. -
Page 32: Lamp Failure Report
This document, when properly completed by the first retail purchaser or his agent of the XR Series 500 watt Xenon lamp and returned to Perko, Inc., will satisfy the lamp failure report requirement in the limited eighteen (18) month warranty for XR Series 500 watt Xenon lamps for marine searchlights. -
Page 33: Warranty Registration
This form must be completed and returned by the person installing the lamp in a marine searchlight within ten (10) days from the date on which the lamp was first installed. Mail or fax to: PERKO, INC 16490 N. W. 13th Ave. Miami, FL 33169-5707... -
Page 34: Purchase Notification
Date Completed: ______________________ This form must be completed and returned by an authorized distributor for products manufac- tured by Perko within thirty (30) days of the first retail purchase. Mail or fax to: PERKO, INC 16490 N. W. 13th Ave. - Page 35 APPENDIX B Optional Heater Package 500 Watt XR Series Marine Searchlights Installation Guide...
- Page 36 Heater Connections All heater elements are designed to operate on 120 V.A.C. Switch and supply leads must be sized to accommodate a 10 amp load. As shown in the appropriate schematic in Figure 2, all heater elements are connected in parallel. When installing the interconnecting supply wiring to the trunnion bolts and the rack, be sure to allow enough slack for both azimuth and elevation movements of the searchlight head to its...
- Page 37 XR SERIES MARINE SEARCHLIGHTS Trunnion Bolt (x2) Rack (x1) Base (x1) See Note 1 D.E.C. Base (x3) Fig. 9304 (500W) Shown See Note 2 NOTES: 1. Base Heater is Only Supplied with Manual Control. 2. D.E.C. Heaters are Only Supplied with D.E.C. Base.
- Page 38 120W 432W 360W 120W TOTAL = 1032 W (8.6A) 2 CONDUCTOR 16AWG (CUSTOMER FURNISHED) NOTES: Attach PERKO Supplied caution plate prominently adjacent to switch. Determine supply wire gauge (AWG) based on load and length to watertight junction box. Figure 2:...