Colorlight CL25 Installation manual
SEARCHLIGHT SYSTEM
BY COLORLIGHT
INSTALLATION MANUAL
Revision nr: F1.6
Revision date: 2014-04
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.
If your system lacks any function presented in this manual, there is possibly a software update
available to resolve this, please contact ColorLight for more information.
COPYRIGHT COLORLIGHT © 2014. All rights reserved
Page 2 INSTALLATION MANUAL CL25, CL35
CONTENT
WARNINGS AND INFORMATION ..................................................................................... 5 1.
WARRANTY CONDITIONS ................................................................................................ 8 2.
MAINTENANCE AND SERVICE PLAN .............................................................................. 9 3.
COLORLIGHT SEARCHLIGHT SYSTEM .........................................................................10 4.
INSTALLATION .................................................................................................................11 5.
5.1 Physical handling of the searchlight .......................................................................11
CLI-30001, ANTI VIBRATION KIT.....................................................................................12
6.
CLI-30005, REPLACING THE BULB ................................................................................15 7.
ELECTRICAL SYSTEM .....................................................................................................21 8.
8.1 Electrical-box ............................................................................................................21
8.2 Cabinet card ..............................................................................................................22
8.3 Electrical-box overview ............................................................................................23
8.4 Electrical box installation .........................................................................................24
8.5 Operator panel connections.....................................................................................25
8.6 Ethernet wiring ................................ ................................................................ ..........26
OPERATOR PANEL, OVERVIEW.....................................................................................27 9.
DISPLAY SYMBOLS AND MESSAGES ........................................................................28 10.
10.1 Ebox alarm relay ................................................................................................ .......29
ACTIONS AFTER INSTALLATION OR POWER FAILURE ...........................................30 11.
STARTING SYSTEM .....................................................................................................31 12.
JOYSTICK FUNCTIONS ................................................................................................32 13.
SWITCH ON LIGHT .......................................................................................................33 14.
FOCUS...........................................................................................................................34 15.
15.1 Type 1, continuous focus (standard) .......................................................................34
15.2 Type 2, absolute focus (optional for CL25) .............................................................35
CABINET CARD MENU SYSTEM .................................................................................36 16.
16.1 Menu navigation........................................................................................................36
16.1.1 Down Button ........................................................................................................................ 36
16.1.2 Right Button ......................................................................................................................... 36
16.1.3 OK Button ............................................................................................................................ 36
16.2 Category 1: About .....................................................................................................37
16.2.1 (1.1) MAC Address .............................................................................................................. 37
16.2.2 (1.2) IP Address .................................................................................................................. 37
16.2.3 (1.3) Light Model ................................................................................................................. 37
16.2.4 (1.4) SW Version ................................................................................................................. 37
16.3 Category 2: Diagnostics (support tool) ...................................................................38
16.3.1 (2.1) Start ............................................................................................................................ 38
16.3.2 (2.2) View Results ............................................................................................................... 38
INSTALLATION MANUAL CL25, CL35 Page 3
Approvals
written by:
Anders Holst
reviewed by:
Jonas Boslander
approved by:
Mattias Svensson
16.4 Category 3: Usage Stats ...........................................................................................39
16.4.1 (3.1) Left Light ..................................................................................................................... 39
16.4.2 (3.2) Right Light ................................................................................................................... 39
16.4.3 (3.3) Reset Left .................................................................................................................... 39
16.4.4 (3.4) Reset Right ................................................................................................................. 39
16.5 Category 4: Settings .................................................................................................40
16.5.1 (4.1) OP WDT ...................................................................................................................... 40
16.5.2 (4.2) OP WDT Stats ............................................................................................................ 41
16.5.3 (4.3) OP WDT Reset ........................................................................................................... 41
TECHNICAL DATA CL25 ................................................................ ..............................42 17.
17.1 Specifications CL25 ..................................................................................................42
17.2 Mechanical drawings ................................................................................................43
17.2.1 Operator Panel .................................................................................................................... 43
17.2.2 Electrical box ....................................................................................................................... 44
17.2.3 Searchlight CL25 ................................................................................................................. 45
TECHNICAL DATA CL35 ................................................................ ..............................46 18.
18.1 Specifications CL35 ..................................................................................................46
18.2 Mechanical drawings ................................................................................................47
18.2.1 Operator Panel .................................................................................................................... 47
18.2.2 Electrical box ....................................................................................................................... 48
18.2.3 Searchlight CL35 ................................................................................................................. 49
SUPPORT ................................ ......................................................................................50 19.
Page 4 INSTALLATION MANUAL CL25, CL35
WARNINGS AND INFORMATION 1.
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. This could cause
the bulb to burst! Do not operate any bulbs with any traces of scratches, cracks, or
physical damage
Always transport the bulb in the provided protective case or cover until installation!
Save the protective case or cover and packaging materials (box) for bulbs that
have been used to their rated service life. Use the protective case when disposing
of the bulbs.
Always use safety glasses and body protection when installing or removing the
bulbs.
When changing bulbs be sure to not touch the surface of the bulbs with bare
fingers. If inadvertently touched with bare fingers it should be degreased
immediately with alcohol and a soft lint free cloth. Be sure to wipe dry the bulb
surface afterwards.
Never touch the bulb when it is on, or soon after it has been turned off, as it is hot
and will cause serious burns. Bulbs should be allowed to cool for a minimum of ten
(10) minutes after the light is turned off.
The light should never under any circumstances be turned on without frontglass.
INSTALLATION MANUAL CL25, CL35 Page 5
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. Avoid quick switch on and switch off as it may shorten
the lifetime of the bulb. Allow a couple of minutes cool down period, if possible.
UV-light overheat
CL20, CL25 and CL35 searchlights are designed and built primarily for the marine
environment.
UV light generates a lot of heat and we use ambient air as a coolant for our lamp
body. For uses other than marine this must be taken into account so that sufficient
cooling is available or to adapt the operating time to prevent overheating damage
such as cracked UV glass.
Eye safe exposure time for UV
CL25-12/21, CL35-12/21: Max 2 minutes at 1 m. Max 4 minutes at 2 m. Max 9
minutes at 4 m. Max 65 minutes at 9 m.
CL25-22, CL35-22: Max 1 minute at 1 m. Max 2 minutes at 2 m. Max 4 minutes
at 4 m.
Max 30 minutes at 9 m.
Welding eye glasses are recommended if you for some reasons have to expose
your eyes longer periods at those close distances.
We see no reason for such exposure even at service activities. Sunglasses are
also good protection.
Reflectors
The parabolic reflectors developed by ColorLight have an extremely smooth
surface to focus the light in wide or narrow beam. Bare fingers should never touch
the reflector surface. If inadvertently touched, the reflector surface should
immediately be degreased with alcohol and a soft lint free cloth.
Page 6 INSTALLATION MANUAL CL25, CL35
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.
If however a hardware failure occurs that breaks the Ethernet communication
between the box and operator panel, a safety function will step in and
automatically turn off the light within 3 seconds, the OP WDT will also interrupt an
ongoing sweep or surveillance activity.
OP WDT is disabled by default, to enable see 16.5.1 (4.1) OP WDT.
If protection hoods are used over searchlight body the system main power switch
in the electric box should be off; this is a precaution to reduce the risk of fire if the
hoods are not removed before turning the lights on.
Cleaning
Never wash the searchlight with water under high pressure because this can
penetrate through the seals and cause damage to mechanical and electrical
components.
Do not use strong solvents such as thinner or acetone to clean the searchlight
body or the operator panel.
Deicing
Removal of ice should be done with caution. Physical violence can damage the
front glass or the searchlight driving mechanics. Instead turn on the lights and let
the heat melt the ice.
Recycling and disposal
HMI bulbs used for model CL25 and CL35 contains mercury and must be recycled
or disposed according to applicable local and national regulations.
INSTALLATION MANUAL CL25, CL35 Page 7
WARRANTY CONDITIONS 2.
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.
The mechanical fundament where the searchlight is placed is robust.
Warranty seal on the service hatch is unbroken.
Outgoing cable radius from the searchlight is smooth and not stressed.
All cables used for the installations are as per ColorLight’s specifications or as per
separate made agreement.
Signal cables are not placed together with high power cables.
Electrical connections are made according to electrical scheme and wiring diagram.
Length of cables are not exceeding the recommended maximum lengths as stated
below:
Power cables between searchlight and E-box for 230 VAC-system: Max 30 meter
Power cables between searchlight and E-box for 24 VDC-system: Max 5 meter
Remote cable / Ethernet cable between E-box and remote control: Max 100 meter
(longer distance requires an amplifier or fibre optic version).
E-box (EB) is placed in an non-condense environment with a minimum temperature of
+5 C (indoor) if not customised for other installation.
The remote panel (OP) is bridge mounted in an IP54 environment. If placed outside it
must be under a protection hood when not in use.
Remote panel is screwed in bridge panel, properly grounded and correct installed.
After above checkpoints are verified the system should be started up as per User’s
Manual to verify the functionalities.
In case of any questions related to the warranty, please contact us at info@colorlight.com for
additional support.
Page 8 INSTALLATION MANUAL CL25, CL35
MAINTENANCE AND SERVICE PLAN 3.
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. A damage can lead to reduced or nonfunctionality.
2. Make a visual inspection of the searchlight glasses. Verify that they are without any
crack or broken in any way. A crack can lead to water penetration inside the housing
followed by potential electrical and mechanical problem.
3. Perform a function test. Start up the searchlight system, rotate the searchlight in
horizontal and vertical direction. Check the “lamp life” statistics in order to plan any
potential replacement of bulb. The system is programmed to give a warning when there
is less than 130h of lamp bulb lifetime remaining.
4. Clean the searchlight. Rinse with fresh water to wash away the salt deposits. If more
dirty, use a very soft sponge and soap that is not caustic, contains strong solvents such
as acetone or thinner base. The house can be both polished and waxed for a shiny and
durable surface, but the glass should under no circumstances be waxed. Under no
circumstances can the searchlights be washed with high pressure water as this can lead
to penetration inside the housing followed by potential electrical and mechanical
problem.
5. Deicing. Winter time the system should be deiced with caution. First turn the lights on to
let the heat melt the ice before operating the system horizontally and vertically.
INSTALLATION MANUAL CL25, CL35 Page 9
COLORLIGHT SEARCHLIGHT SYSTEM 4.
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.
For external communication between the electrical box and its various controllers we use the
TCP / IP protocol through the Ethernet infrastructure, but for internal communication between
the box and searchlight we have chosen to work with CAN bus technology.
CAN (Controller Area Network) is a network standard originally developed for the automotive
industry and with only two wires it’s possible to transmit a variety of control data and
information.
The searchlights drive motors (horizontal and vertical) are of the type brushless servo motors,
with excellent performance, long lifetime and high reliability.
The motor drivers are located inside the searchlight and are of an "intelligent" type, which
constantly analyzes the motor condition, and if problems arise, such as tripped over current
protection; this will be presented as an alarm in the operator panel.
Page 10 INSTALLATION MANUAL CL25, CL35
Lift here!
INSTALLATION 5.
Physical handling of the searchlight 5.1
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.
INSTALLATION MANUAL CL25, CL35 Page 11
1
2
1
17mm ratchet wrench × 1
2
17mm wrench × 1
3
4
CLI-30001, ANTI VIBRATION KIT 6.
Service instruction no: CLI-30001
Revision date: 2012-12-19
Applicable models: CL25-**, CL35-**
Spareparts needed (refer to CL spareparts list)
Tools and supplies required:
Important information
This instruction shows how to install the anti-vibration kit which consists of four dampers with
integrated stainless steel tubes.
The dampers main function is to absorb the harmful vibrations that can damage the mechanics
and shorten the life of the bulbs. Searchlight installations without dampers will
uncompromisingly, void the warranty.
Figure 1
1. Overview of the damper assembly and its parts.
Page 12 INSTALLATION MANUAL CL25, CL35
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.
INSTALLATION MANUAL CL25, CL35 Page 13
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.
Page 14 INSTALLATION MANUAL CL25, CL35
CL25-**
1
CLN0166 (HMI / UV bulb 400W) × 1
2
CLS-25330 Front glass sealing × 1
CL35-**
1
CLN0094 (HMI / UV bulb 575W) × 1
2
CLS-35318 Front glass sealing × 1
1
8mm Ratchet Wrench × 1
2
Suction cup tool × 1
3
Lint-free cloth
4
Isopropyl (rubbing) alcohol
CLI-30005, REPLACING THE BULB 7.
Service instruction no: CLI-30005
Revision date: 2013-09-09
Applicable models: CL25-**, CL35-**
Spareparts needed (refer to CL spareparts list)
Tools and supplies required:
Important information
This instruction shows how to replace the bulb and front glass sealing on the CL25 model
equipped with white or UV light but the procedure is the same for the CL35.
It’s recommended to replace the front glass sealing when replacing the bulb, reflector or front
glass to reduce the risk of water ingress between front glass and lamp housing.
Regarding safe handling of bulbs please read: Warnings and Information, page 5
1. Turn off system power before servicing.
2. Start by removing all the four glass holder brackets that keeps the glass in place. Use a
ratchet wrench size 8mm.
INSTALLATION MANUAL CL25, CL35 Page 15
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.
Page 16 INSTALLATION MANUAL CL25, CL35
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