lumishore THX 803 Installation guide

EOS Thru-Hull Integrated System
BEFORE YOU START
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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
THX 803 & THX 1603 Thru-Hull Light
Lumishore EOS Full Colour Change light
Installation and Operating Guide
Congratulations! You have purchased a LUMISHORE advanced technology underwater light. Every care has been
taken to ensure your Thru-Hull light arrives in perfect condition, so please enjoy the ultimate experience in
underwater lighting.
LUMISHORE Thru-Hull high intensity lights are designed for those owners who prefer the integrity of a thru-hull
installation in a light that employs the most powerful, ecient and cost eective underwater LED lighting on
the market today. The LUMISHORE Thru-Hull is suitable for many sizes and types of watercraft, including Sports
Boats, Cruisers, Yachts and Super Yachts.
Please read the following pages before attempting installation to ensure complete understanding of
the LUMISHORE LED lights.
• High Intensity LED light – Do not stare into the LED module at close proximity.
• Always ensure that the vessel’s power source and battery are disconnected or isolated prior to installation
• A qualied professional should carry out both the electrical and mechanical installation. If in doubt please contact LUMISHORE
• Always use a suitable fuse or circuit breaker to protect the complete system. Each light to be individually fused.
• The Thru-Hull maybe installed into GRP (Glass Reinforced Plastic or Fibreglass) and wooden hulls.
• For metal hull or carbon bre installations an isolation kit will be required.
• The light should be installed 6” - 10” (150-250mm) below the minimum load waterline.
• For best results install the lights between 2.5ft (0.8m) and 6.5ft (2m) apart.
• Never try to install or remove light with the vessel in the water.
• Lights should not be exposed to any temperatures in excess of 150°F (65°C). For example, next to hot engine components or
where exhaust emissions could be expelled onto the light while underwater.
• Do not over tighten the retaining bolts. A force of 3Nm on each bolt should not be exceeded.
• All LUMISHORE products should have a bonding to the DC system via bonding strap for galvanic protection.
• Choose a location - The light must be installed onto a at (not curved) surface. Mount on transom or side hull only.
1
LED ARRAY SHOWN
FOR ILLUSTRATION
PURPOSES ONLY

Planning the Installation & Wiring Diagram
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Ensure correct electrical polarity. Incorrect installation will invalidate warranty!
All connections need to be made waterproof. Use
a suitable junction box or waterproof connectors.
Ensure DMX terminator is installed
Distribution Panel
Battery
Install DMX
terminator
PN: 24-0087
2 Core Power cable
keep as short as possible
If extended consult cable
gauge guide (Pages 3 & 4)
DMX Cable 1m length supplied. Extension
Cables available(see cable extension table on page 4)
DMX Cable 1m length supplied. Extension
Cables available(see cable extension table on page 4)
3m Light Cable (Do Not Cut)
Junction
Box
Junction
Box
Junction
Box
STV 2204-i
TO
OR
MFD
Lumi-Link
Command Center
Note: For detailed installation instructions please refer to the
installation manual that came with your controller / command center
DMX Cable 5m length supplied. Extension
Cables available(see cable extension table on page 4)

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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
Cable Gauge Tables
15 ft 10 ft 20 ft 25 ft 30 ft 40 ft 50 ft 60 ft 70 ft 80 ft 90 ft
100 ft 120 ft 130 ft 110 ft
0 to 6 ft
CURRENT F L O W IN AMP S
Critical
3%
VOLTAGE DROP
16
AWG
14
AWG
12
AWG
10
AWG
8
AWG
6
AWG
2
AWG
4
AWG
6
AWG
8
AWG
10
AWG
12
AWG
14
AWG
16
AWG
2
AWG
4
AWG
6
AWG
8
AWG
10
AWG
12
AWG
14
AWG
2
AWG
4
AWG
6
AWG
8
AWG
10
AWG
12
AWG
1
AWG
14
AWG
2
AWG
4
AWG
6
AWG
1
AWG
0
AWG
8
AWG
10
AWG
12
AWG
2|0
AWG
2
AWG
6
AWG
1
AWG
0
AWG
4
AWG
8
AWG
10
AWG
3|0
AWG
0
AWG
2|0
AWG
1
AWG
2
AWG
4
AWG
6
AWG
8
AWG
3|0
AWG
6
AWG
4|0
AWG
2|0
AWG
0
AWG
1
AWG
2
AWG
4
AWG
4|0
AWG
3|0
AWG
2|0
AWG
0
AWG
1
AWG
2
AWG
4
AWG
6
AWG
8
4|0
AWG
4
AWG
3|0
AWG
2|0
AWG
0
AWG
1
AWG
2
AWG
6
AWG 4
AWG
4|0
AWG
3|0
AWG
0
AWG
1
AWG
2
AWG
4|0
AWG
3|0
AWG
2|0
AWG
0
AWG
1
AWG
2
AWG
4
AWG
4|0
AWG
3|0
AWG
2|0
AWG
0
AWG
1
AWG
2
AWG
4
AWG 1
AWG
4|0
AWG
3|0
AWG
2|0
AWG
0
AWG
4|0
AWG
3|0
AWG
2|0
AWG
4|0
AWG
3|0
AWG
2|0
AWG
0
AWG
1 2
AWG AWG
It is important to use the correct cable gauge for the installation. This can be spilt into two sections; Power source to
Junction box and Junction box to each light.
First, calculate the cable gauge required from the power source to the junction box. The method for doing this is:
1. Calculate the TOTAL CURRENT IN AMPS of the circuit. i.e. (number of lights x max current) at chosen voltage.
2. Find circuit LENGTH IN FEET along the left side of the chart. Note that the total length of the circuit
is the ROUNDTRIP distance from power source (usually the battery) to the junction box and back.
3. Read o the cable gauge required for the TOTAL CURRENT for the circuit length.
3
Max Currents
Model Max Current (12V DC) Max Current (24V DC)
THX 803 8.8A
THX 1603 N/A
4.4A
6.5A

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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
Cable Gauge Tables - Continued
All of the DMX cables can be extended using Lumishore premolded extension cables. (DO NOT cut and splice cables)
Fuse Table
Model
THX803
THX1603
12V
15A
Fuse Rating
24V
7.5A
N/A 10A
Model
THX803
THX1603
14AWG
Gauge Max Length of Cable
12V
Do Not Extend
14AWG N/A
24V
32ft
30ft
AWG to Metric conversion table
AWG Size Cross sectional Area Cable diameter
10
8
6
4
18
16
14
12
2
5.2mm²
8.3mm²
13mm²
20mm²
1mm²
1.3mm²
2.0mm²
3.3mm²
33mm²
2.5mm
3.2mm
4.1mm
5.1mm
0.8mm
1.3mm
1.6mm
2.0mm
6.5mm
Note : The cable distance there and back has been taken into consideration in these calculations.
DMX Extension Part Number
60-0403
60-0404
1m
5m
15m 60-0405
DMX Connector Pinouts
Front View
Male
Data-
(White)
Data+
(Black)
GND
(Scrn)
Female
Data-
(White)
Data+
(Black)
GND
(Scrn)
Extending the Light Power Cable
The light power cable can be extended, however the correct cable gauge should be used. See the tables below.
The tables below give the minimum cable gauge required depending on the supply voltage, and distance from
the power Source to the lights. Please ensure that the correct cable gauge is used in the installation
4

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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
Planning the Mechanical Installation (THX803 & 1603)
Bonding Attention: Failure to bond the lights properly and maintain the appropriate protection will invalidate
the LUMISHORE warranty.
LUMISHORE lights should be connected to the vessel’s DC Bonding system to ensure protection from electrolytic /
galvanic corrosion. All bonding connections should be fully checked prior to returning the vessel to the water.
LUMISHORE lights have integrated circuitry to protect lights from external issues, but these are dependent upon
correct bonding.
Installation into a metal or carbon bre hull requires an isolation sleeve kit. In this case DO NOT Bond lights.
• Location - Positioning will be dependent on both external and internal obstacles; consideration should be given to
installation wiring and internal access within the vessel. Ideally the light modules should be installed 6” to 10”
(150-250mm) below the water line and spaced between 2.5ft to 6.5ft (0.8-2m) apart.
• Select a at surface, make sure that both the internal and external surfaces of the hull are even and parallel. It may
be necessary to sand or grind the surface.
• A hole will be drilled to allow the Thru-Hull light to be inserted. Care must be taken to ensure there is unrestricted
access inside the hull
• The light is temperature sensitive and must not be located close to the exhaust or other heat sources.
• If multiple lights are installed, each light should be evenly spaced to ensure the best water illumination. The number
of lights and the spacing on your vessel will depend on a few factors: vessel size, location of lights and water clarity.
Model
THX803
THX1603
Part Number
60-0208
60-0209
Installation Considerations
5
Isolation
Sleeve kit
Metal Hull - Isolation Sleeve
Bonding
connection
point

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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail] 5
www.Lumishore.com
Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
Light Installation
Tools Required
Drill/Driver
5mm Allen Wrench Marine Sealant
(Use only 3M 4200)
Rags for clean-up
1. Measure the position of the lights on a at part of the hull. Mark carefully, and double-check for internal obstacles.
2. Check the required hole size against the table below. Drill a perpendicular hole through the hull using an appropriate
cutter for the hull material.
3. The exposed inner hull surface must be properly sealed to prevent water intrusion into the hull before the Thru-Hull
is secured in place.
4. Before inserting the Thru-Hull light ensure that the hull surface is free from dirt and grease and remove any existing
anti-foul from the hull surface.
5. Using an approved adhesive (3M 4200 Marine (recommended) or similar), apply liberally a continuous bead of sealant
around the entire circumference of the sealant groove, on the base of the stem and on the shaft of the Thru-Hull.
6. Feed the connector and cable through the hole in the hull avoiding any strain on the cable. Gently insert the stem of
the Thru-Hull light assembly through the hole in the hull.
7. Apply even pressure with a slight circular motion until the Thru-Hull is ush with the hull surface.
8. From inside the vessel, feed the supplied washer down the shaft of the Thru-Hull tting. Screw the locking nut in place
and tighten the retaining bolts so that they are hand tight (less than 1Nm) - Do not tighten fully at this stage, excess
pressure will push all of the sealant out.
9. Remove excess sealant that is squeezed from behind the light with a rag.
10. Allow the sealant to cure according to the sealant manufacturer’s instructions. Once fully cured, using a 5mm Allen
wrench, re-tighten each retaining bolt (force less than 3Nm). Care should be taken not to exceed this force as damage
to the light module or hull of the vessel may occur.
11. Attach the vessel’s bonding protection to the bonding bolt on the locking ring.
Note: Do not use an alcohol-based solvent as this may have an adverse eect on the sealant
Hole-saw
Model
THX 803
THX 1603
Hole Size
27mm (1.0625”)
27mm (1.0625”)
Hole Size W/Delrin Sleeve
34mm (1” 11/32)
34mm (1” 11/32)
Rear Side Apply sealant
6

69
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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
The locking nut and retaining bolts should be inspected on a regular basis to ensure they are kept tight. LUMISHORE
recommends general inspection of the light module, driver and cable attachments every month.
LUMISHORE lights require simple cleaning. Lights should be checked often to ensure the light body and lens area
are free from sea growth. In the event that your light requires cleaning, we recommend the use of a soft cloth or
soft bristled brush. The glass should be kept clean with a plastic scraper or soft brush. Regular cleaning of the lens
will ensure that the light module delivers maximum optical output. DO NOT use an abrasive cloth or cleaning agent
as permanent damage to the lens may occur.
DO NOT use any abrasive cleaning materials as these may damage the body of the light.
DO NOT use any cleaning uids that contain solvents, acids or alkalis.
DO NOT clean using pressure washing or sandblasting equipment.
Slight discolouration of body may occur over life. This does not aect performance, and is not subject to warranty.
Due to nature and high build quality it may on rare occasions be possible to see small levels of condensation,
this is normal for high power LEDs and will disappear after cooling and does not harm operation in any way.
No chemicals, cleaners, chemical sprays or sandblasting should ever be applied / used on lights — this will
negate warranty
To prolong device lifetime and prevent marine growth build up, a good quality anti-fouling system must be used to
coat the external body of the device. This should be renewed regularly.
If lights are covered for any reason e.g. Maintenance or Painting. DO NOT switch the lights on until the covers are removed.
Maintenance and Cleaning
The underwater lighting system should always be tested before the boat goes back in the water. Check that each
light comes on, and all lights change in sequence as per the system operation section above. See the problem solving
guide for advice on resolving any issues.
Once the boat is back in the water, check for any water ingress on the installed lights. Any ingress should be dealt with
immediately. The lights should be checked several times over the rst 24-hours and periodically after that to ensure
installation is satisfactory.
Testing the Lights
If you have questions or comments, please e-mail [e-mail] or call USA [phone],
United Kingdom [phone], or France [phone].
Product Support
Maintenance & Product Support
7

7
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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
In the event of one or more of the lights not lighting up then check the LED status on the driver (at the back of the light).
The LED will either be continually ON (healthy), OFF (no power to driver) or ashing. Please refer to the table below for
what the number of ashes means and what action to take.
Thank you!
For purchasing LUMISHORE lights
In the event of an issue, record the serial number(s) of the light(s) and contact your local dealer.
Troubleshooting
LUMISHORE Ltd warrants the Thru-Hull lighting system to be free from defects in workmanship for a period of three
years, starting from the date of original purchase. Should your lighting system have a problem during this period,
please contact your dealer as soon as you become aware of the defect.
Misuse, abuse, improper installation, neglect, improper shipping, damage caused by disasters (e.g. re, ood and
lightning), installation by unqualied personnel, unauthorized repair or modication will void this warranty.
For the avoidance of confusion and doubt, non compliance with all installation, maintenance and operating
instructions in this document constitute non conformance with warranty terms.
Full warranty details are available at www.lumishore.com.
Warranty
Warranty & Troubleshooting
LED Status
No LED light on driver
Solid LED
Flashing 2 times
Flashing 3 times
Flashing 4 times
Flashing 7 times
Flashing 8 times
Continuous rapid ashing
Light temp too high
Driver temp too high
LED array voltage out of range
Light not detected
Driver program corrupt
Could happen when light is out of water or next
to exhaust
Driver is mounted too close to an engine or exhaust
Check the connections between light and driver
Check light in each colour to determine if all colours
are working
Light is not connected or cable is cut or pinched
Light has been connected incorrectly to the driver
Reset driver by switching o power for 1 minute, and
then switching on again
Contact LUMISHORE if problem persists
Meaning
No power to driver
Power On
Low input voltage to driver
Action to take / Things to check
Check fuse / breaker
Check connections
Check voltage at input to driver connections
Driver is receiving voltage and operating properly
Check the switch is operating correctly
Check power connections or battery voltage
If a light does not switch on, or function normally, it should be disconnected from the power source
8

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Lumishore UK Unit 2, Technium 1, Kings Road, Swansea, SA1 8PH, UK | [phone] | [e-mail]
Lumishore USA 7137 24TH Court East Sarasota, Florida 34243 |[phone] | [e-mail]
Overall Dimensions
9
On
O
THX803 Light Unit
LED ARRAY SHOWN
FOR ILLUSTRATION
PURPOSES ONLY
25mm
(0.98in)
110mm
(4.33in)
152mm
(5.98in)
12mm
(0.47in)
140mm
(5.51in)
180mm
(7.08in)
38mm
(1.49in)
Power
Fuse Holder
Light Input
DMX
Input
DMX
Output
170mm
(6.69in)
THX 1603 Light Unit
LED ARRAY SHOWN
FOR ILLUSTRATION
PURPOSES ONLY
25mm
(0.98in)
152mm
(5.98in)
130mm
(5.12in)
12mm
(0.47in)
230mm
(9.05in)
38mm
(1.49in)
Power
Light Input
Fuse Holder
DMX
Input
DMX
Output
221mm
(8.70in)