SEARCHLIGHT SYSTEM BY COLORLIGHT INSTALLATION MANUAL Revision nr: F1.
Safety reminder Remember to break all electrical power to system before starting any work in the electrical box or the searchlight unit. All information in this manual was correct at time of publication. However, as our engineers are always updating and improving our products, your system's software might provide a slightly different appearance or modified functionality than presented in this manual.
CONTENT 1. WARNINGS AND INFORMATION ..................................................................................... 5 2. WARRANTY CONDITIONS ................................................................................................ 8 3. MAINTENANCE AND SERVICE PLAN .............................................................................. 9 4. COLORLIGHT SEARCHLIGHT SYSTEM .........................................................................10 5. INSTALLATION....................
16.4 Category 3: Usage Stats ...........................................................................................39 16.4.1 16.4.2 16.4.3 16.4.4 16.5 Category 4: Settings .................................................................................................40 16.5.1 16.5.2 16.5.3 17. (3.1) Left Light ..................................................................................................................... 39 (3.2) Right Light ...............................................
1. WARNINGS AND INFORMATION High voltage! Before opening any part of the searchlight system, make sure all power is switched off! Bulbs HID (High-intensity discharge) bulbs operate at a high internal pressure and high temperature and should be handled with care. Never bump, drop, apply excessive stress, or scratch the bulb.
UV-light! (models -12, -21, -22) The UV-light used by ColorLight is chosen for most efficient result in marine applications. The wavelengths are below 400 nanometers, thus not visible for the human eye. An intensive radiation is generated from the high luminance of the arch inside the bulb and should not be glared into from close distance. Intentionally ColorLight is allowing a small leakage of white light making the beam vaguely detectable in fog.
Light beam heat damage and Ethernet communications guard OP WDT This searchlight is built for use on long distances and the high-intensity light from the searchlight can, if set at a narrow beam, cause severe damage to surfaces closer than 1 meter. To avoid that the searchlight is forgotten with the light on, always use the feature “off and park” when not using the searchlight.
2. WARRANTY CONDITIONS A correctly installed searchlight system from ColorLight requires no planned regular maintenance or service during the first 10 years in operation (except changing the bulbs after they are used up). The “Maintenance and Service plan” describes how to keep the product in good condition. The warranty is conditioned by below mentioned key points. Before powering up the unit, make sure that: Vibration dampers are mounted correctly according to user’s manual.
3. MAINTENANCE AND SERVICE PLAN Although the system does not require regular maintenance to function, we recommend, however, that this preventive maintenance plan is followed in order to keep the searchlight in good condition and in time detect if something is wrong and needs to be corrected. Recommended inspection on a weekly basis 1. Make visual inspection of the searchlight housing and cabling. Look for any potential mechanical damage caused by external force.
4. COLORLIGHT SEARCHLIGHT SYSTEM ColorLight has with its newly developed control system for searchlights opened for a flexible and future-proof system in which several searchlight assemblies (CL20, CL25 and CL35) and operator panels can be connected to a dedicated network and communicate via the Ethernet protocol. Control-computers and navigation equipment are other examples of devices that can be part of this network.
5. 5.1 INSTALLATION Physical handling of the searchlight Lift only the searchlight by the temporary lift loop on top of the center house. Lifting at the lamp houses may damage the construction. After safely fixed the searchlight, remove the lift loop.
6. CLI-30001, ANTI VIBRATION KIT Service instruction no: CLI-30001 Revision date: 2012-12-19 Applicable models: CL25-**, CL35-** Spareparts needed (refer to CL spareparts list) 1: CLS-25130 Anti vibration-kit × 1 (included in delivery) 2 Tools and supplies required: 1 17mm ratchet wrench × 1 2 17mm wrench × 1 3 4 Important information This instruction shows how to install the anti-vibration kit which consists of four dampers with integrated stainless steel tubes.
2. Push the dampers tube part thru the mounting holes in the foundation. 3. Mount the dampers rubber part from other side of the foundation. 4. Lower the searchlight on top of dampers and mount bolt washers and nuts as shown in figure 1.
5. The lock nut is tightened with two wrenches size 17mm, tighten nut firmly. The dampers rubber part will be compressed slightly, after assembly the searchlight will be rigidly secured but still resistant to vibrations.
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3. Remove the front glass; this is best done with a suction cup tool. 4. Remove the defective bulb from the socket. 5. Remove the old sealing. Make sure that the flange surface is clean.
6. Fit the new sealing against the flange. Make sure to place the sealing joint in line with the lower inner hole of the glass holder bracket. 7. Press the new sealing against the flange with your hands. 8. Open a package with a new bulb. Avoid touching the bulb glass with your fingers.
9. Wipe the bulb with a dry, lint-free cloth dipped in isopropyl (rubbing) alcohol. 10. Make sure the bulb is dry before installing it in the socket. 11. Put back the glass again.
12. Fit brackets again by loosely attaching all the screws a few turns. 13. Turn the brackets in the correct position. 14. Tighten all screws crosswise with ratchet wrench size 8mm.
15. Tighten all screws crosswise. 16. Done, turn on power and test the bulb, also remember to perform searchlight synchronization, please see: 11. Actions after installation or power failure.
8. ELECTRICAL SYSTEM IMPORTANT! The electric supply to the e-box must be disconnected before beginning any work inside the box; it’s not enough to turn off the internal main switch. 8.1 Electrical-box The e-box is designed to be as compact as possible but still allow service personnel to easily replace any broken component. The design consists of a sandwich construction where the upper section plate is the searchlight connection part and the bottom section plate is the electronic lamp driver part.
8.2 Cabinet card Color Lights control system is stable and future-proof, and the cabinet card is equipped with a number of inputs and outputs as to allow the communication with the searchlight but also communicate with computers, radio receivers, limit switches etc. (via optocoupler). On the output side, we have relay controlled alarm output (NO, NC) for external alarm handling and outputs for controlling relays (via optocoupler).
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8.4 Electrical box installation Tools and supplies required: 1 Screwdriver 0,6×3,5 mm 2 Adjustable wrench type Bacho 8071 3 Wrench 13 mm 4 Important information The complete system is undergoing final testing before delivery and therefore has the searchlight cables installed in box. 1. Ensure that the switch Q01in box is set to off. 2.
8.5 Operator panel connections The operator panel is designed to be immersed into the bridge panel, for dimensions, see drawing in section 17.2.1 Operator Panel. The following connections are available on the back of the panel: 1. Power supply 9-28 VDC via local power supply on the boat or 24VDC via terminals in the E-box. One of the benefits of supplying power to the panel from the box is that the panel will be de-energized together with the e-box via the main switch. 2.
8.6 Ethernet wiring ColorLight searchlight systems should be connected to their own dedicated network; they should never be connected into the vessels existing computer network. An Ethernet cable supplied by ColorLight complies with the standard TIA/EIA-568-B and is always tested together with the complete searchlight system to ensure full functionality.
9. OPERATOR PANEL, OVERVIEW 9 1 1 2 5 3 6 4 7 8 1. "Soft button": the function appears in the display window next to the button. 2. Left lamp on/off, standard for -12, -21 (optional for -11, -22 if “Single lamp mode” = On *1). 3. Left focus (same function as No.4 *2), (move left to spot *3). 4. Left focus (same function as No.3 *2), (move left to flood *3). 5. Right lamp on/off, standard for -12, -21 (optional for -11, -22 if “Single lamp mode” = On *1). 6. Right focus (same function as No.
10. DISPLAY SYMBOLS AND MESSAGES Symbol for switched off white light. Symbol for switched on white light. Error symbol for white light indicates a problem during switch on or if the bulb breaks down during operation. The operator has three switch-on attempts in a two minute interval without setting the sum alarm output. Symbol for switched off UV light (black light). Symbol for switched on UV light (black light).
This symbol indicates that the bulb has less than 200 hours left of expected lifetime. This warning can be chosen by the operator to be shown or not. please see User’s Manual, 11.8.4 Lamp life for more detailed instruction. Each bulb has its own symbol showing in the lower left or right corner of the display. This symbol indicates that the expected lifetime of the bulb now has expired.
11. ACTIONS AFTER INSTALLATION OR POWER FAILURE At system startup, the panels will start to scan the network to find connected electrical boxes, during this time, the panel software version will be displayed. If not the panel made contact by displaying home screen within 30 seconds, it may be due to the following: Electrical box is not turned on, applies only if the panel has a separate power supply. There are problems in the network cabling between the electrical box and the operator panel.
12. STARTING SYSTEM When the system is in sleep the buttons and symbols glows with orange light and the display is totally shut down to save power. Buttons and symbols are always active but dimmed to a lower intensity during sleep. Pressing any button on the operator panel will activate the system and the display will now show the position indicator* image or just the ColorLight logotype.
13. JOYSTICK FUNCTIONS The joystick (8) moves the searchlight horizontally and vertically. There are no limitations to the movement of the searchlight thanks to the slip ring technology developed by ColorLight. The more the joystick is moved to its end position the faster the searchlight rotates. Searchlight rotation speed can be set, please see User’s Manual, section 11.8.5 Maximum rotation speed. The vertical axis reaction according to the joysticks movement can be reversed if decided by operator.
14. SWITCH ON LIGHT The searchlight is equipped with two bulbs with either double white (CLXX-11) or double UV (CLXX-22) or a combination of white and UV light. As default the double white or double UV will be turned on by pressing button(2) or (5), both lights will then be lit with a slight delay in between, no matter which button is used. To turn off the light, press button (2) or (5) again.
15. FOCUS 15.1 Type 1, continuous focus (standard) Note: Button numbers below refers to OPERATOR PANEL, OVERVIEW. Spot Flood Pressing the focus buttons (3) or (4) changes the focus for the left lamp house and buttons (6) or (7) changes focus for the right lamp house. Release the button when the required focus is found. As long as a focus button is pressed the bulb moves in and out which changes the focus of the light between 4-20 degrees for model CL20, CL25 and 3-20 degrees for model CL35.
15.2 Type 2, absolute focus (optional for CL25) Note: Button numbers below refers to OPERATOR PANEL, OVERVIEW. Spot Flood This feature enables adjusting a defined beam width (focus) of the lamps by means of a step motor. Focusing from control panel is made in 20%-steps by pressing the focus button for spot or flood repeatedly, or, if the buttons is held longer than 0,6 second, the focus moves directly to desired end position.
16. CABINET CARD MENU SYSTEM This chapter describes the menu system of the ColorLight Cabinet Card displayed on the onboard LCD. Down OK Right 16.1 Menu navigation The user interacts with the menu system using the three buttons, the “Down” button, the “Right” button and the “OK” button. 16.1.1 Down Button The main function of the “Down” button is to shift between the menu categories. It also has two alternate generic functions. 1.
16.2 Category 1: About In this chapter all of Category 1 menu items will be explained. 16.2.1 (1.1) MAC Address Displays the MAC address of the Cabinet Card, according to the standard (IEEE 802) in six groups of two hexadecimal digits, separated by colons (‘:’), in transmission order, e.g. “01:23:45:67:89:ab”. One exception from the standard is made, the leftmost colon is missing, due to the 16 character limit of the LCD. 16.2.2 (1.
16.3 Category 2: Diagnostics (support tool) In this chapter all of Category 2 menu items will be explained. 16.3.1 (2.1) Start Press the OK button to run the on-board diagnostic test suite to sense the electrical and mechanical condition of the searchlight. (contact Colorlight for help with this feature). T1. Measurement of voltage and current when the searchlight is in “non operating mode” T2 (HCW). Measurement of current drawn by the horizontal motor; motor rotates clockwise for 30 seconds. T3 (HCCW).
16.4 Category 3: Usage Stats In this chapter all of Category 3 menu items will be explained. 16.4.1 (3.1) Left Light Displays the usage of the left light source in hours:minutes:seconds, e.g. “Left: 1:23:45”. 16.4.2 (3.2) Right Light Displays the usage of the right light source in hours:minutes:seconds, e.g. “Right: 1:23:45”. 16.4.3 (3.3) Reset Left Resets the usage counter of the left light source. A confirmation message, “If sure press OK”, is displayed upon entering the menu.
16.5 Category 4: Settings In this chapter all of Category 4 menu items will be explained. 16.5.1 (4.1) OP WDT Ethernet communications guard OP WDT (Operator Panel Watchdog Timer) This searchlight is built for use on long distances and the high-intensity light from the searchlight can, if set at a narrow beam, cause severe damage to surfaces closer than 1 meter. To avoid that the searchlight is forgotten with the light on, always use the feature “off and park” when not using the searchlight.
16.5.2 (4.2) OP WDT Stats Displays a counter that keeps track of the number of times the Ethernet communication has recovered from an OP WDT event. In case of suspected cable problems with connected operator panels, this counter can be helpful when troubleshooting. 16.5.3 (4.3) OP WDT Reset Resets the OP WDT counter. A confirmation message, “If sure press OK”, is displayed upon entering the menu. Press the “OK” button at this point to reset the counter and exit the menu.
17. TECHNICAL DATA CL25 17.
17.2 Mechanical drawings 17.2.
17.2.
17.2.3 Searchlight CL25 The searchlights cable glands are rated IP68 but for extra protection during heavy weather situations it’s still recommendable to install the searchlight so the cable exits are facing the stern. The longer part of the lamp house peak shall be set down. This extra long peak is to reduce disturbing reflections from the foredeck, if any.
18. TECHNICAL DATA CL35 18.
18.2 Mechanical drawings 18.2.
18.2.
18.2.3 Searchlight CL35 The searchlights cable glands are rated IP68 but for extra protection during heavy weather situations it’s still recommendable to install the searchlight so the cable exits are facing the stern. The longer part of the lamp house peak shall be set down. This extra long peak is to reduce disturbing reflections from the foredeck, if any.
19. SUPPORT If you have questions about the searchlight and its features, please contact ColorLight technical support worldwide, see www.colorlight.com for contact details. Or contact ColorLight head office: ColorLight AB Engineering-ColorLight cl@colorlight.com Phone: +46 353 8270 Fax: +46 35 38279 Need technical Support? Follow the link below and fill out the form, we will contact you shortly. http://www.colorlight.com/tech-support/service-request.
INSTALLATION MANUAL CL25, CL35 Page 51
VISIBILITY | VERSATILITY | VALUE We look forward to serve you with the Future Searchlight Solution - wherever you are ColorLight AB Kassakällor SE-313 95 Åled Sweden Phone: +46 35 38280 Fax: +46 35 38279 www.colorlight.com e-mail: info@colorlight.
