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ACR Electronics RCL-600 Trouble Shooting And Parts Replacement Manual

For the remote controlled, xenon search light
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TROUBLE SHOOTING AND PARTS REPLACEMENT MANUAL
FOR THE REMOTE CONTROLLED, XENON SEARCH LIGHT, RCL-600
1

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Summary of Contents for ACR Electronics RCL-600

  • Page 1 TROUBLE SHOOTING AND PARTS REPLACEMENT MANUAL FOR THE REMOTE CONTROLLED, XENON SEARCH LIGHT, RCL-600...

  • Page 2: Table Of Contents

    PLEASE BE VERY CAREFULL DURING THE TESTING AND TROUBLE SHOOTING OF THIS LIGHT. THERE ARE HIGH VOLTAGES ON SOME OF THE CIRCUITS. Table of Contents RCL-600 ● Lamp does not turn on ……………..……………………………………………..Page 3 ● Elevation faulty……………………. ………………………………………… ……Page 4 ● Rotation faulty……………………….…………………………………………..….Page 5 ●...

  • Page 3: Lamp Does Not Turn On

    There is a possibility that the brush holder faulty. Abnormal Replace the brush holder according to directions on pages 16, 17 and 18. The printed circuit board PP-207A is faulty. Replace the printed circuit board PP-207A according to directions on page 21 and 22. RCL-600 TROUBLE SHOOTING...

  • Page 4: Elevation Faulty

    Replace the printed circuit board PP-207A to the directions on pages 17, 18 according to the directions on pages 22 and 19. and 23. Replace the printed circuit board PP-208A according to the directions on pages 26 and 27. RCL-600 TROUBLE SHOOTING...

  • Page 5: Rotation Faulty

    Replace the rotation motor according to the instruction on pages 31, 32 and 33. If there is no improvement, replace the printed circuit board PP-208A of the remote control panel according to the instruction on pages 26 and 27. RCL-600 TROUBLE SHOOTING...

  • Page 6: No Focus Control

    There is a possibility of corrosion in the lamp holder and focus driving rack and this will prevent smooth functioning. Repair the relevant part or send the unit in to ACR for repair. The focus motor is faulty. Replace the focus motor according to the instruction on pages 39 and 40.

  • Page 7: To Remove The Power Head

    1. Method to remove the complete power head 1-1 Use the following tools ・ Phillips screw driver ・ 6 mm Hexagonal wrench 1-2 Working procedures 1) Loosen 4 screws as marked in picture 1 and carefully remove the front frame assembly. Picture 1 2) Loosen and remove 2 screws as indicated in picture 2.

  • Page 8: To Check The Ballast

    2. Method to check the ballast 2-1 Use the following tools ・Philips screw driver ・6mm Hexagonal wrench ・DC Multimeter 2-2 Procedures to check Remove the power head according to the instruction on page 7 “How to remove the power head”. Loosen and remove 2 screws as indicated in picture 3 and remove the card edge receptacle from inside the search light.
  • Page 9 Turn on the power source by pushing the power button on the remote control panel. Measure on the terminals (indicated in picture 5) whether 170+ DCV are available. －Terminal ＋Terminal Picture 5...

  • Page 10: To Check The Output (Lamp) Of Pcb Pp-207A

    3. Method to check PCB PP-207A (Lamp does not turn on) 3-1 Use the following tools ・Hexagonal wrench of 4mm ・DC Multimeter. 3-2 Procedure 1) Remove the search light and place upside down. Loosen and remove 8 screws as indicated in picture 6. Carefully lift the bottom cover off the base Picture 6 3) Remove 2 cable connectors (P and N) as indicated inside circle in picture 7.

  • Page 11: To Replace The Ballast

    4. Method to replace the ballast 4-1 Use the following tools ・Phillips screw driver ・Pliers ・7mm flat spanner ・6mm Hexagonal wrench ・Silicon compound ・Ballast (PXE-150-DC24) 4-2 Procedure for exchanging the PCBs 1) Remove the power head according to the instruction on page 7. 2) Remove the spring with pliers as indicated by the arrow in picture 8.
  • Page 12 4) Remove the 4 cables as indicated in picture 10 and 11. Picture 10 Picture 11 5) Loosen and remove all screws (6) as indicated in picture 12. Remove the complete ballast assembly with fitting plate Picture 12...
  • Page 13 6) Loosen and remove the 4 screws as indicated in picture 13. Remove the ballast PCB from fitting plate by sliding it sideways to break the silicon heating compound seal. Install the new PCB. Note: Install the ballast after applying a suitable amount of silicon heating compound between the ballast and fitting plate.

  • Page 14: To Replace The Starter

    5. Method to replace the starter 5-1 Use the following tools ・Phillips screw driver ・Flat head screw driver ・Pliers ・6 mm flat spanner ・New Starter unit (STX-10) 5-2 Replacement procedure 1) Remove the power head according to the instruction of page 7. 2) Remove the spring by pliers where is the arrow mark on picture 14.
  • Page 15 4) Loosen and remove all the screws (6) as marked in picture 16. Remove the fitting plate complete with Ballast assembly. Picture 16 5) Loosen and remove 4 screws as indicated in picture 17, remove and replace the starter. Fitting plate Picture 17...

  • Page 16: To Replace The Brush Holder

    6. Method to replace the brush holder 6-1 Use the following tools ・Phillips head screw driver ・4 mm Hexagonal wrench ・8mm Box wrench, Spanner or Wrench ・Brush holder assembly (B3A00140) 6-2 Procedures for change 1) Remove the search light and place upside down on a suitable surface. Loosen and remove 8 screws as shown in picture 18.
  • Page 17 4) Loosen and remove 4 screws as indicated in picture 20. Carefully remove the printed circuit board PP207 Picture 20 5) Loosen and remove 3 screws as indicated in picture 21. Carefully pull out the brush holder complete with mounting plate. Picture 21...
  • Page 18 6) Loosen and remove 4 screws as indicated in picture 22. Replace the complete brush holder assembly. Picture 22 Carefully reverse the process to re assemble the light.

  • Page 19: To Check The Output (Elevation) Of Pcb Pp-207A

    7. Method to check the printed circuit board PP-207A (Elevation) 7-1 Use the following tools ・Phillips head screw driver ・4mm Hexagonal wrench ・8 mm Box wrench ・DC Multimeter 7-2 Procedure 1) Remove the search light and place upside down on a suitable surface. Loosen and remove 8 screws as indicated in picture 23.

  • Page 20: To Check The Output (Rotation) Of Pcb Pp-207A

    8. Method to check the print circuit board PP-207A (Rotation) 8-1 Use the following tools ・Phillips head screw driver ・4mm Hexagonal wrench ・8 mm Box wrench ・DC Multimeter 8-2 Procedure 1) Remove the search light and place upside down on a suitable surface. Loosen and remove 8 screws as indicated in picture 25.

  • Page 21: To Replace The Pcb (Pp-207A)

    9. Method to change the PP-207A PCB. 9-1 Use the following tools ・Phillips head screw driver ・4mm Hexagonal wrench ・Printed circuit board (PP-207A) 9-2 Procedure 1) Remove the search light and place upside down on a suitable surface. Loosen and remove 8 screws as indicated in picture 27. Carefully lift the bottom cover off the base. Picture 27 3) Remove all the cables where connected to the print circuit board.
  • Page 22 1) Loosen and remove 4 screws as indicated in picture 29. Replace PCB. Picture 29...

  • Page 23: To Replace The Elevation Motor

    10. Method to replace the elevation motor 10-1 Use the following tools ・Phillips head screw driver ・6mm Hexagonal wrench ・Flat screw driver ・7mm Spanner ・Pliers ・Elevation motor (TE-24SM-12-256S) 10-2 Procedures to check motor. Remove the power head according to the instruction of page 7 “How to remove the power head”. Remove the spring with pliers where indicated in picture 30.
  • Page 24 4) Loosen and remove 3 screws as indicated in picture 32. Picture 32 Loosen and remove 2 screws as indicated in picture 33 and remove the elevation motor. Picture 33 Loosen and remove 4 screws as indicated in picture 34 and replace motor. Picture 34...

  • Page 25: To Replace The Pcb (Pp-208A)

    11. Method to replace the PP-208A PCB inside Joystick control. 11-1 Use the following tools ・Phillips head screw driver ・7mm Spanner ・Printed circuit board (PP-208A) 11-2 Replacement procedure Loosen and remove 4 screws as indicated in picture 35. Open the cover. Picture 35 (Remote control panel CPF99) 2) Remove all the connectors from the printed circuit board as indicated in picture 36.
  • Page 26 3) Loosen and remove 4 screws (4 places) as indicated in picture 37 and replace printed circuit board (PP-208A). Picture 37...

  • Page 27: To Check The Rotation Gear

    12. Procedure to check the rotation gear 12-1 Use the following tools ・Phillips head screw driver ・4mm Hexagonal wrench ・8mm Box wrench ・3mm Hexagonal wrench ・Tube of „Loctite‟ („Slip‟ prevention fluid) 12-2 Procedure 1) Remove the search light and place upside down on a suitable surface. Loosen and remove 8 screws as indicated in picture 38.
  • Page 28 4) Loosen and remove 4 screws (4 places) as indicated in picture 40. Remove the printed circuit board. Picture 40 5) Loosen and remove 3 screws as indicated in picture 41. Remove the turning motor with fitting plate complete. Picture 41...
  • Page 29 6) Check whether the 2 screws, as indicated in picture 42, came loose. Picture 42 12-3 If the screws are loose, remove both, apply Loctite fluid to both screws‟ tread and turn them in firmly.

  • Page 30: To Replace The Rotation Motor

    13. Procedure to replace the rotation motor 13-1 Use the following tools ・Phillips head screw driver ・4mm Hexagonal wrench ・8mm Box wrench ・5.5mm flat spanner ・Rotation motor (TE-400G-12-200SD) 13-2 Replacement procedure 1) Remove the search light and place upside down on a suitable surface. Loosen and remove 8 screws as indicated in picture 43.
  • Page 31 4) Loosen and remove 4 screws as indicated in picture 45. Remove the printed circuit board. Picture 45 5) Loosen and remove 3 screws as indicated in picture 46. Remove the turning motor with fitting plate complete. Picture 46...
  • Page 32 6) Loosen and remove 3 screws as indicated in picture 47. Remove and replace rotation motor. Picture 47 Note : When installing the new motor assembly, make sure that there is a small gap between the turning pinion and turning gear as indicated in picture 48. Picture 48...

  • Page 33: To Repair Continuous Rotating Light

    14. Procedure to correct continuous rotation of the light. 14-1 Use the following tools ・Phillips head screw driver ・4mm Hexagonal wrench 14-2 Procedure 1) Turn off the power source 2) Remove the search light and place upside down on a suitable surface. Loosen and remove 8 screws as indicated in picture 49.
  • Page 34 5) Loosen and remove 4 screws as indicated in picture 51. Remove the printed circuit board. Picture 51 Check whether the 2 screws, as indicated, in picture 52 came loose. Picture 52...
  • Page 35 7) If the screws are found to be loose, adjust the limit switch to the position indicated by the red arrow and fasten the 2 screws as indicated by the blue arrow. There must be a small margin of space as indicated by the green arrow. (Refer to picture 53) Picture 53...

  • Page 36: To Check The Focus Motor

    15. Procedure to check the focus motor 15-1Use the following tools ・Phillips head screw driver ・6mm Hexagonal wrench ・7mm flat spanner 15-2 Procedure Remove the power head according to the instruction on page 7 “How to remove the power head”. Loosen and remove 2 screws as indicated.
  • Page 37 4) Loosen and remove 2 screws as indicated in picture 56. Remove the focus motor. Picture 56 5) After removal of the focus motor, operate the joy stick on the remote control panel to the right or left and ascertain whether the focus motor is functioning.

  • Page 38: To Change The Focus Motor

    16. Replacement of the focus motor 16-1 Use the following tools ・Phillips head screw driver ・6mm Hexagonal wrench ・7mm flat spanner ・Focus motor (TE-20-69E-500S) 16-2 Replacement procedure Remove the power head according to the instruction of page 7 “How to remove the power head”. Remove the connector as indicated in picture 57 Picture 57 3) Loosen and remove 2 screws as indicated in picture 58.
  • Page 39 Note: Allow for a small gap between the motor pinion and focus driving rack as indicated in picture 59. Replace the focus motor and adjust the complete assembly to be as vertical as possible. If no margin for space is allowed, or the focus motor is installed diagonally, there is a possibility that the focus motor will not function smoothly during focus operation.

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