MANUAL NO. M10SL421-2 INSTRUCTION MANUAL INSTALLATION, OPERATION, & MAINTENANCE 10" SEARCHLIGHT, DEC 105 SERIES FIRST SERIAL NO. 63661 LAST SERIAL NO. LIST OF PAGES IN ORDER OF APPEARANCE: P42i- i P4211 thra6 DWG 7722 DWG 7754 PN 9862X PL 7693 DWG 7693 DWG WD6068 PN C8160 PN 8171X The Carlisle & Finch Co. 4562 W. Mitchell Avenue Cincinnati, OH 45232-1798 USA.TABLE OF CONTENTS 1, GENERAL PURPOSE . . 1.1 Purpose 1.2 Major Components . . . 1.3 Drum and Door Assembly 1.4 Base and Yoke Assembly 1.5 Optical System... . 1.6 Pilot House Controls . 2. INSTALLATION 2... Pe Thich 6 2.2 Unpacking and installing : : 3. OPERATION . . . 3.1 Lighting Searcniight 3.2 Directing Beam. . . 3.3 Focusing Beam . . . 4, MAINTENANCE. 2... 4.1 Relamping . 2... 412. Focus Adjustment . - 4.3 Replacing Reflector 4.4 Replacing Cover Glass 4.5 4.6 Cleaning Reflector and Cover Ordering Replacement Parts . 5. ILLUSTRATIONS AND PARTS LISTS Searchlight, Distant Electric Control Drum & Door Assembly Focus Assembly PL 7693 Drive Assembly DWG 7693 Drive Assembly WD -6068 Wiring Diagrams PN C8160 Controller Glas PN 8171X Enclosure & Bracket Assembly P4a2t Page Donn BREE wow Neosooe1. GENERAL DESCRIPTION 1.1 Purpose. This incandescent searchlight is used for navigational purposes to light up shore lines, buoys, obstructions, other vessels, etc., and for any other purpose where a projected beam of light is required. 1.2 Major Components. 1 Drum and Door Assembly 1 Base and Yoke Assembly 1 Optical System which includes: i Lamp 1 Reflector 1 Louvre Assembly 1 Lampholder 1 Focus Assembly 1 Pilot House Controls 1.3 Drum and Door Assembly. The drum is formed of heavy gauge brass and contains the optical system. The door, also brass, contains the cover glass and is fastened to the drum by means of clamps. The back dome is opened on some searchlights for relamping. 1.4 Base and Yoke Assembly. 1.4.1 The base is made of heavy gauge brass or aluminum as specified. The base contains the drive assembly and terminal block for making the electrical connections. A heater on the drive unit helps prevent condensation. The low wattage heater must be energized continuously to be effective. The heater is shown on the drive assembly drawing and the wiring diagram in this book. 1.4.2 The drive assembly, shown on @ drawing in this book contains two reversible 120 volt AC motors to drive the searchlight in azimuth and elevation. Both motors have self-contained brakes to prevent overtravel when position controller is released. The brakes are released automatically when the motors start. A sliding stop allows in excess of 360 degrees horizontal rotation but limits the travel to prevent accidental wind-up of the electrical cable between drum and ase. 1.4.3 Slip clutches in both vertical and horizontal drive trains Prevent demage to the gearing and also allow the drum to be moved manually to facilitate lamp changing and other maintenance functions. 1.4.4 The brass yoke is fastened to the horizontal drive train by two setscrews. The 12 and 15-inch searchlights have a Woodruff key in addition to the setscrews. The yoke is positioned on the drive shaft such that the stop position of the horizontal motion is just beyond dead astern (as indicated by the stuffing tube in the base) when approached from either direction. The stop prevents excessive wind-up of the electrical cable between drum and base. pa2t .1.5 Optical System. 1.5.1 Lamp. The searchlight can be furnished with a variety of lamps dépending upon what was specified on the original order or contract. 1.5.2 Reflector. The reflector is parabolic glass back silvered with a corrosion-resistant coating over the silver. The combination of a perfect parabolic reflector with a light source of zero dimen- sions (point source) at the focal point of the parabola would produce a perfectly round cylindrical beam of uniform intensity. Because it is impracticable to produce a perfect parabola and because the lamp filament is not a point source, the searchlight beam is a divergent projection of the lamp filament. 1.5.3 Louvre Assembly. These concentric rings in front of the lamp prevent the unretlected rays produced by the lamp from leaving the drum while permitting the essentially perallel reflected rays to pass through. The front "spill light" if not blocked by the louvres would otherwise light up the foreground and/or reflect back from haze, fog, rain, or snow making it difficult for the observer to see beyond. 1.5.4 Lampholder. The focus assembly drawing in this book shows the particular Tampholder supplied for the searchlight for which this book is intended. It is adjusted to accept the lamp specified with the searchlight. 1.5.5 Focus Assembly. The focus assembly consists of the lampholder, louvre “assembly, Dase and stand assembly, various fasteners, etc., and is shown on the focus assembly drawing in this book. 1.6 Pilot House Controls. 1.6.1 The searchlight manufacturer does not normally supply the off-on control which is usually furnished by the installing activity. It may be a manual switch rated to handle ‘the incandescent: iain: load or a pilot device to operate a magnetic contractor rated for the incandescent lamp load. 1.6.2 The up, down, right, and left motions of the searchlight are controlled by’ one or more 4-way lever controllers. The lever is spring-centered to the off position. The electrical circuit is such that no special interlocking is required for multiple station control. In the event of conflicting commands from two control stations, no motion occurs until one controller is released. No electrical damage results. The electric lever controller may be flush mounted in a control console if the electrical connections are protected. An optional enclosure and bracket assembly is furnished when specified to house the controller for surface mounting. 4212. INSTALLATION 21 Wiring. Refer to wiring diagram wD6068. 2.1.1 Install switch and fuses or circuit breaker (not supplied by The Carlisle & Finch Co.). Run 3-conductor electric cable (not supplied) from switch to searchlight location. The third conductor is for grounding. Run 2-conductor electric cable (not supplied) from power side of switch for connection to heater terminals. Heater is to prevent condensation in the searchlight base and is to be energized continuously, night « day, at dock or under way. It consumes approximately 18 watts. 2.1.2 Run G6-conductor electric cable from each remote controller to searchlight location. It may be more convenient to run 6-conductor cable between controllers. See wiring diagram DWG WD6068. This electric cable can be ordered from The Carlisle & Finch Co., complete with terminals, 10 feet long (part no. 81885), or 20 feet long (part no. 8188D), or bulk cable without terminals (part no. 8200), specify length. 2.2 Unpacking and Installing. 2.2.1 The searchlight is completely assembled and packed in one carton, Take care not to mar finish surfaces when removing it from the carton. 2.2.2 Carefully and gently lay searchlight over on its front surface so as to expose terminal block inside lower part of base assembly. Connect cable assembly ("GND, "1", & "2") to corresponding designations on terminal block. 2.2.3 Connect the six conductors of electric cable from the remote controller and the two conductors for heater circuits to the properly numbered terminals on terminal block in searchlight base. 2.2.4 After wiring is complete position searchlight in place so that stuffing tubes face towards the stern of the vessel. Fasten searchlight to deck making certain that the base gasket is in place and that there is a good watertight joint between base and deck. 4213. OPERATION 3,1 Lighting Searchlight. Turn the searchlight off and on by means of the seareniight switch (not normally” supplied by searchlight manufacturer) installed on the vessel for this purpose. The incandes- cent lamp lights almost instantaneously in a manner similar to an ordinary household lamp. Turn switch off when beam not required. The heater circuit (to prevent condensation) is to remain energized at all times. 3.2 Directing Beam. 3.2.1 Usually the searchlight is wired such that the electric lever controller is not energized until the beam is turned on. However it is possible to connect the searchlight system such that the position control can be turned on independently from the beam. In either case, the position control must be "on" for the searchlight to respond to the commands of the electric lever controller. 3.2.2 Move the lever in the direction desired to move the beam. 3.2.3 Vertical and horizontal motions are limited by stops. Release lever when motions reach ends of travel to prevent unnecessary wear. 3.2.4 Horizontal travel is limited by sliding stop in base. The normal position for end of travel is just beyond dead astern when approaching from either direction. If searchlight reaches end of its horizontal travel before beam is on desired target, move the lever to the opposite direction to swing beam around to other side. 3.3 Focusing Beam 3.3.1 Complete focus instructions are in the MAINTENANCE section of this book. However, it is sometimes desireable for the operator to change the beam from spot to semi-flood. This can be accomplished by means of the knurled focus knob located at the bottom of the drum. 3.3.2 Loosen focus knob by turning in direction to loosen a right hand threaded nut. 3.3.3 Change the beam shape by sliding the knob fore and aft to obtain the most useable beam. 3.3.4 Tighten the focus knob. 3.3.5 Refocus to a spot beam before securing the light after using with a spread beam. Make sure focus knob is tight. Pa2t4, MAINTENANCE 4.1 Relamping. WARNING: LOCK SEARCHLIGHT POWER SWITCH IN OFF POSITION BEFORE OPENING SEARCH- LIGHT TO GAIN ACCESS TO LAMP AND LANP- HOLDER. Follow instructions contained on drawing titled “FOCUS ASSEMBLY." 4.2 Focus Adjustment. Follow instructions contained on the drawing titles "FOCUS -ASSENBLY - 4.3 Replacing Reflector. 4.3.1 Remove the clamps that hold the reflector in place. 4.3.2 | Remove old primary reflector, If reflector pads (10 and 12-inch searchlights only) need replacing, scrape off old pads and replace with new ones. Fasten pads in place with shellac. 4.3.3 Replace clamps, screws, lockwashers, and nuts. 4.3.4 Snug up but do not tighten all screws. Slide each clamp towards reflector using finger pressure and tighten carefully. Excessive pressure will result in reflector breakage due to heat expansion. Proper clamp force is achieved when reflector can be rotated under clamps when grasped by hands on opposite edges while not being so loose as to shake. 4.4 Replacing Cover Glass. 4.4.1 Remove the frame and place it front side down on a flat surface. 4.4.2 Remove fasteners, clamps, and damaged glass. 4.4.3 Scrape old sealant from the metal surface. 4.4.4 Lay a continuous bead of new sealant on.the:.seating -fkarige :of the frame. 4.5.5 Place cover glass on the sealant and press down evenly and firmly so sealant flattens out to approximately 1/16 inch thick completely filling the space between glass and frame. 4.4.6 Replace clamps and fasteners. Tighten all screws evenly to distribute pressure equally at all points. 4.4.7 Scrape off excess sealant and clean both sides of cover glass. 4.4.8 Fasten frame and cover glass assembly to searchlight. Pa2t4.5 Cleaning Reflector and Cover Glass. Clean as frequently as required. Dirt seriously reduces the Iight output. Use a clean soft cloth and a good grade detergent on the primary reflector. Any commer- cial glass cleaner is satisfactory for the front glass. Never use scratchy material. 4.6 Ordering Replacement Parts. Identify parts from the assembly drawings and order by part number. Do not confuse part number with Piece number in parts list. Always give searchlight serial number when ordering parts. pa2tSe Sue Se SLO ote “She eaea XC986 g fe oan me SHOOEea WAGE “assv_snd03 "nul OIHO “ILYNNIONIO "09 HONIS @ J1SMYVO_SHL nececeeanern nee |§l ‘XTBNORS BONN SNDO4 NBLHOU-3 “C “OaNWv180 SI 3Z1S_WW38 O34IS30 TUNA YOLOTLGY NOU! 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NAIA, ASSY 34AN07 i HOLOTURY ABV lo/e [Si GN #1 S04 G300¥] NS 66/L | _“S3ONVHO_ON “NRVUORY] Vv ONL Ob aay [a NORE res no Gash SH42 1 64468 41 1 GND 40 2 10564 39 2 8178 38 37 36[ 1 |emx © 35 34 33 8 LPS4D04P8 32 2 4150 3 1 2509AB so} 4 | cras79-15 23] 4 | BocR6s2—10 28 27 26 2s] 1 | s1a7x 24 23 22 21} 2 | cRas79-15 20 2 6OCR632-6 JUMPER ELECTRIC LABEL "GND” CHANNEL CAPACITOR CAPACITOR MOTOR MSCR, 10-24 X 500, PAN HD PH, SELF LK IDENTIFICATION STRIP TERMINAL BLOCK LK WSHR, #6, EXT T MSCR, 6-32 X .625, PAN HD PH CLUTCH ASSY LK WSHR, #6, EXT T MSCR, 6-32 X .375, PAN HD PH 19 |AS REQ] 12652-1 SHIM’ — (,005_ BLUE) 13 18 [AS REQ| 12652-2@ | SHIM 0075. TRANSMATT) 13 17 [AS REQ| 12652-3 SHIM (020 YELLOW) 13 16} 1 | 80CR420-6 | SET SCR, .250-20 X .375, SOC HD (PART OF PC 25) 1s} + | 36778 BEARING, FLANGED 14| 4 | 8099 FLOATING STOP 10 13] 2 | 80CR420-6 | SET SCR, .250-20 x .375, SOC HD 12] 1 | 3677R BEARING, FLANGED 11} 1 | 9243x HEATER ASSY 10 9 | 4 | 60cR632-10 | MSCR, 6-32 X .625, PAN HD PH 8 | 4 | cr4s79-15 | LK WSHR, #6, EXT T 7 1 | 8733x CLUTCH ASSY 6 1 | 8634 MARKER STRIP 5 1 | 7291 PLATE, HORIZONTAL DRIVE 4 1 | 7280 PLATE, VERTICAL DRIVE 3] 1 EA LABELS "HI" & "H2" 2] 2 | 4574-8 FLAT WSHR, #6 4 << no] ory TOMER DESORPTION Nove ea] ORE THE CARLISLE & FINCH CO. RPA |2/10/95 a ET CINCINNATI, OHIO THLE USED pene ASSY FOR 10, 12, & 15 EC INC SRCHLT PARTS LIST FOR a DRAWING NO: a A PL7693 D (FILE NO: PL7693-1) ‘SCALE NONE [sHeer_ 1 oF 367 2 CR4579-15 LK WSHR, #6, EXT T 66 2 6OCR632-4 MSCR, 6-32 X .250, PAN HD PH 65 1 4336 THERMOSWITCH 64 | AS REQ | 9669 ‘SEALANT 4 63 2 4932X HEATER ASSY 3 620 1 4930 HOUSING 61B 1 7564 ‘SHAFT 68 1 4948 WIRE LEAD 67 2 CR4579-15, LK WSHR, #6, EXT T 66 2 6OCR632-4 MSCR, 6-32 X .250, PAN HD PH 65 1 4336 THERMOSWITCH 64 | AS REQ | 9669 ‘SEALANT 4 63 1 4932X HEATER ASSY 3 62¢ 1 4930 HOUSING BIA 1 7563 SHAFT See] i | Bee Shar PLICABLE TO 7292X—H ONLY 628 1 8087 HOUSING 61B 1 7564 SHAFT 60B 1 8104 ‘SHAFT PARTS APPLICABLE TO 7293x ONLY 624 1 8087 HOUSING 61A 1 7563 ‘SHAFT 60A 1 8105 ‘SHAFT PARTS APPLIC) TO _7292x ONLY 55 3 6375 CABLE TIE (TO TIE MOTOR & CAP LEADS) 54 4 63758 CABLE TIE, RELEASABLE 12 iy 4 10436X WIRE LEAD 51 2 9124 INSULATION 50 1 26608 KEY, .125 X .125 X .375 49 : CR4595-7 KEY, WOODRUFF, .125 X .500 48 3 23296 TERMINAL W 47 6 2329W, TERMINAL 6 46 2 (3782-2 STRAP 44 1 8205X MOTOR ASSY Ea} ee = = TITLE ‘DRAWING NUMBER | REV PARTS LIST PL7693|DNOTES: 1. LUBRICATE LOCATIONS MARKED © WITH MULTI-PURPOSE GREASE, VALVOLINE X-ALL OR EQUIVILENT AT ASSY. 2. INCANDESENT SEARCHLIGHTS ONLY. XENON DOES NOT USE THE TERMINALS. 3. SUPPLIED ONLY WHEN ANTI-ICING HEATER IS SPECIFIED. 4. ON OUTSIDE ONLY TO SECURE HEATER IN PLACE. 5. ADD "-H" TO CAT. NO. FOR OPTIONAL ANTI-ICING HEATER. 6. (2) ON TERM 2, (1) EACH ON 3,4,5,&6. 7. CLEARANCE .002/.004. 8 10. LOCATE UPPER TAB BETWEEN 2 SET SCREWS. 11. 1 EACH ON GND, 1, & 2. (FOR CABLE TO DRUM) 12. RELEASABLE FOR FIELD REPLACEMENT OF CAPACITOR. 13. USE EQUAL QTY SHIM(S) EACH OF 4 CORNERS FOR PROPER MESH OF BEVEL GEARS. DESIGNED FOR .020 THK. SHIM (#12652-3 YELLOW) AT EACH CORNER. ADD OR SUBTRACT EQUAL THICKNESSES EACH CORNER AS REQ. 14, SET THERMOSWITCH AT MINIMUM SETTING (C.C.W. 1 O'CLOCK) ON ASSEMBLY. 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