PRODUCT SUPPORT MANUAL Y1-03-0158 Rev. D RCL-75 Product No. 1946 Remote Control Searchlight System ACR Electronics, Inc. 5757 Ravenswood Road Fort Lauderdale, Fl 33312 +1(954) 981-3333 · Fax +1 (954) 983-5087 www.acrelectronics.com Email: Info@acrelectronics.com A Chelton Group company TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 FORWARD .............................................................................................................1 SEARCHLIGHT......................................................................................................1 UNPACKING THE UNIT ......................................................................................2 WIRING ..................................................................................................................4 INSTALLATION ....................................................................................................4 OPERATION...........................................................................................................7 CARE AND MAINTENANCE...............................................................................8 BULB REPLACEMENT.........................................................................................8 SPECIFICATIONS and WARRANTY.................................................................12 ACCESSORIES.....................................................................................................13 TEMPLATES ........................................................................................................13 i Y1-03-0158 Rev. D 1.0 FORWARD Congratulations and thank you for purchasing the ACR RCL-75 Searchlight. The combination of computer aided design; high quality raw materials and quality-controlled manufacturing produce a superior product. The Test Facility at ACR can reproduce some of the harshest environmental conditions known to man. This assures that the products we produce can stand up to the tough marine environment. With proper care and maintenance, your searchlight will be in service for years to come. ACR is proud to be ISO 9001certified, the International Standard for Quality. Note. It is important to read this entire instruction manual carefully for proper installation and operation of this product. 2.0 SEARCHLIGHT The RCL-75 was specially designed for mariners who require a high intensity remote controlled searchlight that is compact, light weight and can stand up to the tough marine environment. The RCL-75 Searchlight System contains an intense light beam that produces 180,000 peak candlepower by combining two 55W halogen lamps with our unique optical quality, parabolic reflectors. All functions of the Searchlight can be electrically operated by remote control from the pilot area of the vessel using the remote control Point PadTM, and interconnecting cable supplied with the RCL-75. The sleek, robust design and modern construction materials of the searchlight body makes it attractive for recreational and commercial vessels. The searchlight is made of an UV resistant ASA plastic to resist yellowing, and is gasketed and finished to be resistant to the weather. The Searchlight Unit can be mounted where desired (see Figure 1 and Figure 2), using appropriate length 1/4" diameter, stainless steel fasteners. When mounting, be sure that the unit is able to rotate 361° without hitting any obstructions. Refer to Paragraph 4 for wiring details. Caution - DO NOT mount the searchlight upside down. 1 Y1-03-0158 Rev. D FIGURE 1 3.0 UNPACKING THE UNIT FIGURE 2 Every effort is made to assure that the RCL-75 has been delivered in good condition. It is important to make sure that all parts are present before you begin installation. (see Figure 3) The RCL-75 Searchlight contains the following: Light Assembly Deck Mount 17' wire harness Remote Control Point PadTM and extra cover for flush mounting 4 ea. S/S Allen Bolts 4 ea. S/S Nuts 4 ea. S/S Flat washers 4 ea. S/S Lock washers Special L wrench (Allen wrench and Phillips head screwdriver) 2 ea. U clamps for Remote Control Point PadTM flush mount Mounting Gasket Surface Mount Gasket Flush Mount Gasket Part Number A3-06-2177 A1-18-1724 9426 9428 A1-05-0734-1 A1-05-0736 A1-05-0741 A1-05-0737 T1-04-0047 A1-17-1366 A1-25-0132 A1-25-0135-1 A1-25-0135-2 Y1-03-0158-1 " " Light Base Mount Template* Remote Control Panel Template (Flush)* Remote Control Panel Template (Surface)* *Templates are on a separate sheet in this box. If by chance your kit is missing a part, please call our Toll free Customer Service Phone at (800) 432-0227. Please provide the Serial number of your unit and location of purchase. 2 Y1-03-0158 Rev. D FIGURE 3 3 Y1-03-0158 Rev. D 4.0 WIRING The RCL-75 has two wiring requirements: 1. Connect the remote control to the light 2. Connect the light to 12-volt power with 15 amp rated wiring. The light works best with 13.5 volts. Caution - The connectors on each side of the wire harness are different. Test fit connector to switch before running the harness to the light. A 17' wiring harness to connect the remote control to the light has been supplied for ease of installation. The wire should be run from the switch to the light. Do not run wire near sharp edges. When passing through bulkheads, use a cable outlet (available at marine hardware stores). After cable has been run, the remote control is ready to be connected. The light needs to be connected to a power source. It is recommended to use 14 Gauge AWG for this installation. Positive lead should be fused with a (15 Amp fuse). For wire runs over 16 feet, use 12 Gauge AWG. Precautions should be taken to make power connections as water tight as possible. 5.0 5.1 INSTALLATION Location Selection In order for the RCL-75 to achieve maximum performance, care and consideration should be given to the selection of a mounting location for the Searchlight and Remote Control Panel. Typical mount locations include, bow pulpit, fore deck, and cabin hardtop. See Figure 1 and 2. Caution: Do not mount the searchlight upside down. Mounting surface should be flat and parallel to the water's surface. Keep in mind that the further the light is from the pulpit, the greater the chance that light will reflect off the boat into the operator's vision. Before installing the light or remote control switch, find a suitable path for the wires to run. There are two sets of wires, a 17' wiring harness, which will connect the light and the remote control panel, and power leads which will connect the light to a power source. A path will be needed for both. Wire should be kept from contact of sharp edges, and tight radii. If wire needs to pass through a bulkhead, use a cable outlet (available at marine hardware stores). Wire should be supported where necessary by the use of cable straps. The location selected must be sufficiently rigid to support the weight of the total installation at the same time, considering surroundings hazards such as equipment movement, hatches being opened, accidental covering, personnel traffic, etc. 4 Y1-03-0158 Rev. D Depending on the location selected, your light will need 1/4" diameter stainless steel bolts, nuts, and washers. If mounting area is robust enough panhead lag screws may be used. If the surface area can be reached from the under side, through bolting with lock nuts and washers should be used. 5.2 Tools and fasteners needed for installation 4 ea. 1/4" dia. bolts 4 ea. Lock nuts 4 ea. Washers 4 ea. 1/4" dia. Lag screws 1 ea. 1 ea. 1 ea. 1 ea. 1 ea. and and or 1/4" Drill bit for bolt holes or 17/64" Drill bit for lag screws 15/16" Drill bit for cable clearance 13/64" Drill bit for remote switch mounting bolts Tube of silicone or bedding compound to close hole around cable. Option: 1"mounting riser shapeable for irregular surfaces. (P/N 9427 - Figure 4) Caution - Be careful when using electrical power tools around water. Electric shock could occur. 5.3 Mounting the Remote Control Point PadTM The Point PadTM should be located within reach of the helm station. Point PadTM has two mounting options. Flush mount and Surface mount.(see Figures 6 & 7) Both mounting options require access to the backside of the mounting location. (see Templates ­ Y1-03-0158-1) Make sure there are no obstructions behind the area where the switch is to be located. (i.e. bulkheads, wires, plumbing, hardware.) Check in advance to verify the wiring harness can be routed to this location. Use Templates for hole pattern. 5.3.1 Surface Preparation for Remote Control Point PadTM Make sure area is clean and dry. Mark hole locations for drilling. Verify that drill hole will not impact or harm other items (wires, plumbing, hardware bulkhead). 5.4 Mounting the Light Remove deck mounting plate from light base (4 Allen bolts). Save the bolts and washers. Locate the mounting plate on the spot that you want your light. Rotate the plate so that the arrows are pointing forward and the length of the arrow is aligned parallel to the keel. Mark the 4 mounting holes, starting with the one between the 2 arrows. Mounting holes are in 90° increments. (See template Y1-03-0158-1) 5 Y1-03-0158 Rev. D FIGURE 4 5.4.1 Surface Preparation for light Make sure surface is clean and dry. Verify that drill holes will not impact or harm other items (wires, plumbing, hardware or bulkheads). Decide on the use of screws or bolts. Can the backside of mounting surface be reached to install nuts and washers? Note: If the mounting surface is not flat, a special shapeable plate can be purchased, (P/N 9427), to adapt the light base to the surface. This plate can also be used to raise the light 1" if desired. (see Figure 4) Drill 4 mounting holes (1/4") and a centered cable clearance hole (3/4"). Put the mounting gasket on the deck mount (or shaped plate, if used). Use caulk or bedding compound to seal bolt and wire holes before deck mount is attached to deck. The plates are keyed to each other and to the light, be sure the arrows are pointing in the correct direction. (the light will rotate 180° either way from the arrows). Use marine grade 316 stainless steel bolts, nuts, and lock washers to fasten the plate(s) to the mounting surface. Install and connect the control cable and (+) Red and (-) Black power leads. Seal hole if desired. Leave at least 8" of wire coiled in the base of light to allow for servicing. (see Figure 5) Seat the light assembly on the deck mount. Make sure the key is mated and the gasket edge is not pinched. Reinstall the four (4 ) stainless steel Allen bolts with the flat washer next to the plastic and the lock washer under the bolt head. (Allen wrench for these bolts is furnished). Tighten securely. 6 Y1-03-0158 Rev. D FIGURE 5 6.0 OPERATION The remote control Point PadTM is simple to operate. A red LED tells you that power is available. A green LED lights when the light is in use. The ON/OFF button turns the dual beams ON and OFF. The control disk is pushed down in the direction you want to aim the light. Elevation and rotation can be operated at the same time and with the light in the ON or OFF mode. FIGURE 6 FIGURE 7 7 Y1-03-0158 Rev. D 7.0 CARE AND MAINTENANCE The RCL-75 is relatively maintenance free. Clean the exterior of the light with a mild detergent and water if desired. Rotate the light left, then right and up then down periodically to keep motors and turning surfaces clean and operational. Caution ­ DO NOT rotate light manually. This will strip the gear rack. 8.0 BULB REPLACEMENT The bulbs are rated at over 200 hours of operation. If one burns out, you can replace it with a prefocused, desiccated bulb assembly from ACR. (Product No. 9403) We recommend that you replace both bulbs at the same time. Note: One bulb will continue to run if one burns out, to give you 100,000 CD to get home with. To replace a bulb: 1) Do not rotate light head by hand. This will strip the gear rack. Do not remove the front bezel to replace the bulbs. Before replacing bulb, move lens via remote control to the farthest down position, then it is recommended to remove the light from its mounting location. Lamps should be changed while light is at a suitable work place. 2) Remove top cover, (4 top screws at sides of front, and 4 counter sunk phillips screws attaching top cover to lower case). Use L wrench furnished with light. (see Figure 8) 3) Carefully remove top cover by lifting straight up. (see Figure 9) 4) Observe shape and position of the bulb wire loop. (see Figure 10) 5) Disconnect bulb wires from terminal block and with small wire snips, remove the cable ties from bulb wires. (see Figure 11) 6) At the point where the grey bulb wire passes through the partition wall, remove the sealant with a razor, screwdriver or snips. Beneath the sealant is a wire sleeve. Hold this sleeve with needle nose pliers and push through the partition wall. (see Figure 12) 7) Gently remove the entire reflector assembly from the body ...