Oceanled EXPLORE Series User manual

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OceanLED MANUAL / EXPLORE SERIES/ E6 & E7 TH/ REVISION 1
INSTALLATION & OPERATION MANUAL
EXPLORE SERIES E6 & E7 TH

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
1
Preface
READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL
CAUTION
(Risk Group 2): Possibly hazardous optical radiation emitted from this product. Do not stare at the operating
lamp. Maybe harmful to the eye.
WARNINGS
Before installing your OceanLED Light, read and follow all warning notices and instructions which are
included. Failure to follow safety warnings and instructions can result in property damage, severe injury or
even death.
Before installing your OceanLED Light, check local laws for restrictions regarding the use of coloured lights
in your area.
Do not operate lights out of water for a period longer than 5 minutes followed by an OFF period of at least 1
hour. Exceeding this may cause damage to the light unit.
Ensure the bonding point of the light is fitted to the cathodic protection system on the vessel. Check
conductivity between earth bonding point and aluminium bronze front bezel. If mounting the light to metal,
carbon fibre or wooden hull, ensure that suitable measures have been put in place to account for the effects
of galvanic corrosion or wood deterioration, i.e., use of Delrin sleeve components (Isolation Kit).
Salt is an inherently corrosive material. Metal parts and certain natural and man-made surfaces are
particularly susceptible to corrosion and deterioration when used in and around saltwater. Some OceanLED
lights contain combinations of plastic and polymer products which are impervious to saltwater corrosion,
however, screws and fasteners used for the installation must be of a marine grade type stainless steel or
equivalent and monitored annually to ensure the lights remain in service for years to come.
Never connect/disconnect lights with power applied as irreversible damage may occur. Ensure polarity of
power connections is correct. Failure to do this may invalidate the warranty.
Explore E6 & E7 TH light is for mounting directly to a flat surface. Ensure front of lights are always fully
submerged and not fitted on planning / running surfaces that may impact on water since this may damage
the product. Also ensure the rear of the light is in a dry area and not subject to a wet environment. Failure to
do this may invalidate the warranty.
Do not submerse your cable ends in water; cable and connections exposed to underwater submersion will
not be covered by warranty.
Never Use Solvents! Cleaners, fuel, and other products that may contain strong solvents, such as acetone,
that attack many plastics greatly reducing their strength and irreversibly damaging the special lens coatings
and cable sheathings.
Never clean lights using a high-pressure jet wash –this will invalidate warranty. Please avoid coating the
front of the light/lens without consulting OceanLED. Failure to do so will invalidate your warranty.
DANGER
RISK OF ELECTRIC SHOCK OR ELECTROCUTION
This underwater light must be installed by a licensed or certified electrician in accordance with all applicable
local codes and ordinances. Improper installation will create an electrical hazard which could result in death
or serious injury to swimmers, installers, or others due to electrical shock, and may also cause damage to
property. Always disconnect the power to the light at the circuit breaker before servicing the light.

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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Contents
1 Installation Checklist.......................................................................................................................................................3
2 Overview.........................................................................................................................................................................4
3 Preparing The Hull .........................................................................................................................................................6
4 Installation.......................................................................................................................................................................7
4.1 Installing The Light Fixture......................................................................................................................................7
4.2 Installation Of The Driver With The AC Power Kit................................................................................................13
4.3 Installation Of The Driver With The DC Power Kit................................................................................................16
4.4 Control System Installation....................................................................................................................................19
4.5 Finalising The Installation......................................................................................................................................23
4.6 Test YourInstallation..............................................................................................................................................23
5 Operation / Maintenance..............................................................................................................................................24
5.1 Operation...............................................................................................................................................................24
5.2 Maintenance..........................................................................................................................................................24
5.3 Replacement Parts................................................................................................................................................25
6 Troubleshooting............................................................................................................................................................26
6.1 Troubleshooting Problems And Their Solutions ...................................................................................................26
7 Appendix.......................................................................................................................................................................30
7.1 Overall Dimensions ...............................................................................................................................................30
7.2 Essential Test........................................................................................................................................................31
7.3 Light Setup.............................................................................................................................................................32
7.4 Cable Gauge Chart 12V........................................................................................................................................34
7.5 Cable Gauge Chart 24V........................................................................................................................................35
7.6 Explore Th Angled Beam Details..........................................................................................................................36
7.7 Example Of The DC Installation Of Mixed XFM And TH E6 & E7 Lights.............................................................37
8 Warranty.......................................................................................................................................................................39
PRE-TEST
Always test the lights prior to installation. Failure to do this may result in additional installation time and could invalidate
the warranty.
IMPORTANT NOTICE
Attention Installer: This manual contains important information about the installation, operation and safe use of this
product. This information should be given to the owner and/ or operator of this equipment.
WARRANTY COVERAGE
Please refer to www.oceanled.com/warranty for full warranty statement.

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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1 Installation Checklist
1. Decide on light spacing –OceanLED recommendations available.
Rear of lights must never be exposed to wet environments inside the hull.
2. Decide on light angles (only applies for E7 installs)–OceanLED Personalised Service available on
request.
The Explore E6/E7 TH lights can also be mixed with the Explore E6/E7 XFM –Please refer to
Appendix Section 7.7 for the installation example.
3. Ensure the correct power kit is selected and installed (AC or DC power kit).
4. Ensure correct cable gauge is used (refer to relevant cable gauge chart).
5. Control system chosen (switch control, OceanLED DMX control kit, 3rd party DMX control)
Max 32 lights per DMX chain (as per recommended by the DMX standard).
6. Preparing the hull (Isolation kit required for conductive hull materials or wooden hulls).
7. Ensure the lights have been fitted in the correct orientation, and with the correct beam angle.
8. Find the appropriate dry location for the driver and AC power pack if used.
9. Correct marine sealant applied evenly around the bezel. Ensure fully watertight seal is created after
sealant cures.
10. Correct clamping of light fixture onto hull. Never leave vessel unchecked for a few days after install.
Always check routinely for a few days after installation to ensure the install is correct and fully
sealed.
11. Light(s) correctly bonded and vessel bonding system check carried out (refer to relevant schematic
and test procedures).
12. Test installation BEFORE entering water. Never connect/ disconnect lights whilst powered ON.
Never leave lights ON out of water for longer than 5 minutes followed by an off period of 1 hour.
13. Troubleshooting if required - most issues can be resolved by following the guidelines.

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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2 Overview
Kit Includes
Explore TH Light
(with 2m Connection Cable)
Clamping Kit
DC Driver
AC Power Pack
(110/220V AC to 24V DC)
Power Link Cable 1.5m
Power Cable 1.5m
Fuse
Identifying your model
Explore E6/E7 TH
Explore E6/E7 TH

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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Product Components Breakdown
Power Source
Most installations will utilize on-board 12/24V DC power supply from a marine battery in which case the Explore DC
Power Kit should be purchased. If AC power is being used on the vessel, an ExploreAC Power Kit must be purchased.
Please check the Explore E6/E7 TH Light Choice Diagram available in the Appendix (Section 7.3) to evaluate all the
options currently offered by OceanLED.
Use the chart below to determine the power supply requirements.
Power Consumption and Recommended Fuse Values
Model
Current @ 12V
DC
Current @ 24V
DC
Max Nominal
Power
consumption
Minimum PSU Power
(15% reserve)
Recommended
fuse
12V/24V DC
E6/E7 TH Dual
White/Blue
7.8 A
4.7 A
113W
130W
10 A
E6/E7 TH Colour
DMX
6.8 A
3.2 A
82W
94W
10 A
Locking Latches
Light Unit
Compression
Washer
2m Connection Cable
(hard wired to the light)
Bonding Kit
(Nut + Shakeproof Washer)
Bolts
Mounting Holes
Light Input
Power Input
12/24V DC
Explore TH DC Driver

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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3 Preparing the Hull
The Explore TH unit requires an additional 60mm / 2.36” free space from the rear of the light body to allow for
the cable clearance. (See overall dimensions in the Appendix).
OceanLED recommends using a qualified installer / technician when making modifications to your vessel.
Please also consult the manufacturer for more detail on modifications and installation.
If lights are to be fitted to a conductive or wooden hull, an Isolation Kit must be used. Contact OceanLED for
additional details.
DELRIN ISOLATION KIT
Isolation of the metal parts of the Explore TH Series Light from
conductive or wooden hulls to prevent galvanic corrosion issues.
The isolation kit is easily fitted to the rear of the light fixture using
a suitable adhesive.
PART NUMBER
019914 E-TH Delrin Isolation Sleeve Kit
For the correct orientation of the light, the logo should typically face upwards and parallel with the water line
(see Appendix Section 7.6).
Depth/Spacing
Ideally mount your lights at similar depth levels to ensurematching colour consistency through the water. Deeper lights
will look duller and possibly differ in colour compared to shallower mounted units.
Spacing / Install Depth
E6/E7 TH
Recommended Spacing
2.5-3m (8-10’)
Recommended Installation depth (From the light waterline)
300mm (12”)
Hull Thickness
Maximum hull thickness –80mm (3.15”)
Hole Cut Out
Hole Cut out size - 25mm (1”) / With Isolation Kit 32mm (1.25”)
Overall Dimensions
See overall dimension schematic –See Appendix (Section 7)

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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4 Installation
4.1 INSTALLING THE LIGHT FIXTURE
Additional items required not supplied by OceanLED:
•Marine sealant - 3M 4200 or equivalent
•Cable ties
•Waterproof Cable Connectors / Junction Box* (optional)
•Allen key (5mm)
•Thread lock - Loctite 243 or equivalent.
*Optional 4-Way Junction box available from OceanLED. Please contact OceanLED or your representative for further information.
OceanLED recommends dry fitting all products. Before applying sealant, please ensure the surface is clean
of any dust, dirt or grease. When installing, be sure that the light fits the area and secures to the hull using
the appropriate hardware before applying any sealant.
When applying sealant to the light fixture, use OceanLED packaging material such as the light cardboard box
when placing the light on the ground face down to prevent lens damage.
Never use power tools to secure your lights; hand tighten only.
Explore E6/E7 TH
Light Kit Includes
Explore E6/E7 TH Light
Locking Latch Kit

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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Installation Overview:
Exploded view of the assembly
Exploded view of the assembly with the Delrin Isolation Kit

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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Installation (Once hull preparation is complete)
1. Testlight(s) before fitting.
2. If using a Delrin Isolation Kit, fit the isolation kit tube inside the Isolation kit disc (chamfered sides together) and
apply marine sealant on the back of the disc to seal between the disc/tube and the hull. Insert the part into the
drilled hole in the hull. Press the disc into the hull to spread the sealant around to ensure good adhesion.
3. Apply sealant to the back perimeter of the light body and around flange to ensure a complete unbroken seal
around thelight.
Make sure sealant fills in the recess groove on the reverse of the light head.
4. To guarantee correct light orientation ensure the OceanLED logo on the reflector is in the correct orientation
before inserting it in the hull (typically the logo is located at the top). For Explore E7 TH angled fitment, ensure
the light angle is correct for the location before fitting the light. If available, follow the OceanLED Light
Placement Chart (LPC) where the required angle for each light position around the hull will be detailed.
For further details, see the diagram in the Appendix (Section 7.6).

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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5. Insert the light body into the hull, feeding the stem through first and seat into place. Press the light hard into
the hull and twist slightly to spread the sealant around behind the light to ensure good adhesion.
This process is made much easier if a second person is inside the hull to receive the light and install the
clamping equipment whilst supporting the light from the outside. Breakages due to lights falling out of the
hull are NOT covered under warranty and can cause serious bodily injury as can any falling object.
*Installation With Delrin Isolation Kit

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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6. If using aDelrin Isolation Kit,insert the isolationkit rear washer over the stem and locate it flush with the hull.
7. Insert the stainless-steel compression washer over the stem at the back.
The stainless-steel compression washer does not need to be flat to the hull, the washer can compensate a
slightly uneven surface.
8. Place the two locking latches together to form a circle, ensuring you pair 1 threaded and 1 non-threaded hole
together. Fix the latches together using one of the bolts provided so that the bolt slightly extends from the other
side of the latch. Pre-assemble the bonding attachment parts in the following order: M4 bolt, M4 nut, M4 shakeproof
washer,bondingeyelet.Positionthebondingeyelet,nutandshakeproofwasherclosetotheM4bolthead,whileallowing
the bonding eyelet to rotate on the bolt and fit the bolt assembly into the middle thread hole of the locking latch. Fit the
third bolt to the middle threaded hole of the second locking latch and fit the fourth bolt to the remaining hole but do not
joinwiththesecondlatchyet.
Bonding Eyelet
M4 Shakeproof Washer
M4 Nut
M4 Bolt
Locking Latches
*Installation With Delrin Isolation Kit

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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9. Locate the latches into the appropriate grooves(depending on hull thickness)on outside of the stem so that the
end of the bolt is close to the washer. Fix the two latches together and screwdown the joining bolt to the same
position as the others.
*Installation With Delrin Isolation Kit
10. Tighten the locking bolts using a 5mm Allen key, applying thread lock at point of thread contact with locking
latches. Torqueto 2Nm. DO NOTover-tighten locking bolts.
11. Lock the bonding wire eyelet in place with the nut and shakeproof washer. Tighten the locking nut using a
10mm spanner.
12. Once you are satisfied that the unit is fully tightened, you will notice that sealant has squeezed out from
around the perimeter of the light. Using a thinner or cleaner, apply to cloth and wipe off excess sealant to
leave a clean seal. AVOIDCONTACTWITH LENS. If youdo not see sealant squeeze out fromthe body,you
have not used enough sealant or tightened the unit enough to the hull. Carefully examine the installation to
make sure the sealant you have installed on the unit is fully watertight. If in doubt, remove light, re-apply
sealant and re-install.
13. Connect the light bonding wire to the vessel’s cathodic protection system.
BONDING: The light MUST be attached to the vessels bonding / cathodic protection system. Once fitted it is
mandatory to check that there is full continuity between the vessel’s cathodic protection system and the
aluminium bronze front bezel. Please see the bonding check schematic in the Appendix (Section 7.2).

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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4.2 INSTALLATION OF THE DRIVER WITH THE AC POWER KIT
Additional items required not supplied by OceanLED:
•Screws to secure the Explore AC PowerPack and DC Driver
•Waterproof connectors/ Junction Box
•Sufficient cable to connect the Explore ACPowerPack to power source.
•Suitable fuse /breaker(s)
Always consult a qualified electrician when connecting OceanLED light fixtures.
Never use power tools to secure the DC Driver or Explore AC Power Pack: hand tighten only.
When connecting light units, please note that all OceanLED lights will operate within a specific voltage range.
Please check the electrical information to ensure cable gauge, fuse and breakers size follow the
recommendations.
Always mount the Explore DC Driver and AC Power Pack in a dry location, it should not sit in standing water
at any time.
Connecting the DC Driver
1. Find the appropriate location for the driver bearing in mind that the distance from the light is predetermined by
the 1.8m long lightcable and cannot be extended. Ensurechosenlocationisnearenough to connect lightcable
without applying undue stress.
2. Fix Explore DC Driver into required position and secure with four screws.
3. Connect the plug from the light into the 10 pin port on the driver.
4. Repeat the process for the remaining drivers.
5. Connect the drivers in chain with the Control Link Cable (see the connection diagram on the next page).
6. Connect the Terminator in the last driver in chain.
DC Driver
(12-24V DC)
AC Power Pack
(Input: 100-240VAC, Output:
24VDC/ 6.3A, 150W, IP67 Rated)
Power Link Cable 1.5m

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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Explore DC Driver Connection Diagram Example with Switch Control (with the AC Power Kit)
Connecting AC Power Pack
The 3-core input is for power (Brown=Live; Blue=Neutral; Green/Yellow=Earth) and the two pin Deutsch
Connector is for the driver.
1. Depending on the model and number of lights installed, you will need to pull the correct sized power cable from
the AC Power (breaker/fuse panel) to the Explore AC Power Pack locations. Ensure the correct sized tinned
marine grade cable is used to avoidvoltage drop issues.
2. Fix Explore AC Power Pack into required position. The maximum distance between the AC Power Pack and the
DC Driver is predeterminedby thelength of the PowerLink Cable (1.5m). Ensure chosen Explore AC Power Pack
locationis nearenough to connect the Power Link Cable to the DC Driver cable without applying undue stress.
Never leave the bare cables unprotected. Take care to not leave the bare wire ends in bilge water before
making the waterproof connections. Water deposits in the connectors and cables will cause corrosion. Over
time water can also work its way into the unit along the inside of the cable due to capillary action causing the
light to fail. This will NOT be covered under warranty.
3. Connect the Deutsch connector from the AC Power Pack to the DC Driver using the Power Link Cable.
4. Connect the Explore AC Power Pack to the ACPower.Ensure the size fuse/breaker,cable and connector have
the correct specification and are watertight. Make sure any heatshrink used completely encapsulates the outer
wire sheath (the use of glue-lined heatshrink is highly recommended to ensure water tightness).
Corrosion of wire and/or water ingress into the light unit via cable is NOT covered under warranty.
5. Secure cables ensuring where the cable exits the light it is not under undue stress.
6. Install and connect the lighting control system, please see chapter 4.4 for the control system installation. Finish
and test the light units BEFORE the vessel goes into the water. Do not operate lights out of water for a
period longer than 5 minutes followed by an OFF period of at least 1 hour. Exceeding this may cause
damage to the light unit.
Driver 2
Driver 3
Control Link
Cable
Control Link
Cable
Momentary
Switch
Terminator
Light 1
Light 2
Light 3
Driver 1
Power In
12/24V DC
Control Out
Control In
Light Input
Control In
Control Out
Light Input
Light Input
Control Out
ControlIn
Power Link Cable
Power In
12/24V DC
Power In
12/24V DC
AC Power
Pack
Power Link Cable
AC Power
Pack
Power Link Cable
AC Power
Pack

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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Example of the AC Installation (i.e. with the AC Power Kit)

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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4.3 INSTALLATION OF THE DRIVER WITH THE DC POWER KIT
Additional items required not supplied by OceanLED:
•Screws to secure the DC Driver
•Waterproof connectors/ Junction Box* (optional)
•Sufficient cable to run connections to power source.
•Suitable fuse /breaker(s)
*Optional 4-Way Junction box available from OceanLED. Please contact OceanLED or your representative for further information.
Always consult a qualified electrician when connecting OceanLED light fixtures.
When connecting light units, please note that all OceanLED lights will operate within a specific voltage range.
Please check the electrical information to ensure cable gauge follow the recommendations.
Never leave the bare cables unprotected. Take care to not leave the bare wire ends in bilge water before
making the waterproof connections. Water deposits in the connectors and cables will cause corrosion. Over
time water can also work its way into the unit along the inside of the cable due to capillary action causing the
light to fail. This will NOT be covered under warranty.
Always mount the Explore DC Driver in a dry location, it should not sit in standing water at any time.
For complete instructions on DC connections, please refer to ABYC codes of practice and other applicable
codes and ordinates for DC connections.
Where multiple lights are fitted, and especially on 12V systems, it is advised to use a relay system to supply
the switched power to the lights, to reduce load on the switch and voltage drops caused by long cable runs
to the switch location.
Connecting the DC Driver
1. Find the appropriate location for the driver bearing in mind that the distance from the light is predetermined by
the 1.8m long light cable and cannotbeextended. Ensurechosenlocationis nearenoughtoconnectlightcable
without applying undue stress.
2. Fix ExploreDCDriver into requiredposition, using four mounting holes secure the driver with the four screws.
3. Connect the plug from the light into the 10 pin port on the driver.
4. Repeat the process for the remaining drivers.
5. Connect the drivers in chain with the Control Link Cable (see the connection diagram on the next page).
6. Connect the Terminator in the last driver in chain.
DC Driver
(12-24V DC)
DC Power Cable 1.5m
Fuse Kit

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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Explore DC Driver Connection Diagram with Switch Control (with the DC Power Kit)
Connecting the DC Power Kit
1. It is imperative that either the OceanLED supplied fuse is fitted to the power circuit of each light or a suitable
protection device is used to protect the cable/light unit. It is important to also ensure the polarity is correct.
Failure to do so will void the warranty of the unit. It is recommended to use our 4-way fused junction box. See
the table in Section 2 for power consumption and recommended fuse values.
2. Using waterproof butt splices or IP66 waterproof junction boxes, make the connections at either end of the
system to attach the lights to the DC system. (Red wire = +12/24V DC, Black wire = GND). Make sure any
heatshrink used completely encapsulates the outer wire sheath (the use of glue-lined heatshrink is highly
recommended to ensure water tightness).
Corrosion of wire and/or water ingress into the light unit via cable is NOT covered under warranty.
3. Secure cables ensuring where the cable exits the light it is not under undue stress.
4. Install and connect the lighting control system, please see chapter 4.4 for the control system installation.
5. Finish and test the light units BEFORE the vessel goes into the water.
Never install a new light fixture then leave the vessel in the water unchecked for several days.
Driver 2
Driver 3
Control Link
Cable
Control Link
Cable
Momentary
Switch
Terminator
Light 1
Light 2
Light 3
Driver 1
Power In
12/24V DC
Control Out
Control In
Light Input
Control In
Control Out
Light Input
Light Input
Control Out
ControlIn
Power Cable
Power In
12/24V DC
Power In
12/24V DC
12/24V DC
Power Source
Power Cable
Power Cable
12/24V DC
12/24V DC
10A Fuse
10A Fuse
10A Fuse

EXPLOREE6 & E7 TH.
INSTALL & OPERATION MANUAL
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Example of the DC Installation (i.e. with the DC Power Kit)
Use the tables in the
Appendix (Section 7.4 &
7.5) as a guide to the
required cable gauge.

EXPLORE E6 & E7 TH.
INSTALL & OPERATION MANUAL
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4.4 CONTROL SYSTEM INSTALLATION
Switch Control
Additional items required not supplied by OceanLED:
•Push switch (Normally open, momentary type).
To use Switch Control, the Explore Control Input Cable and Terminator Kit is required.
To connect the lights to enable control of all lights using a single switch, Explore Control Link Cables must
be used. The quantity of Control Link Cables required per installation is equal to the number of lights minus
1 (Example: If 10 lights are used, 9 control link cables are required). Please consult the Explore TH Light
Choice Diagram in the Appendix (Section 7.3) for details.
Ensure power is disconnected before attempting to connect or solder any wire.
1. Connect one contact of the switch to the red wire of the Explore Input Control Cable. Connect the black
(Ground), yellow (DMX +) and brown (DMX -) wires together and connect to the other contact of the switch:
2. Plug the Switch cable to the ‘Control In’Connector of the first driver.
3. Using the ControlLink Cable,connect the ‘ControlOut’of the firstdriver to‘ControlIn’ofthe next driver. Repeat
until all the drivers are connected. Check the diagram below for clarification.
4. Plug the Explore Terminator to the ‘Control Out’of the last driver.
5. Test the light units BEFORE the vessel goes into the water.
Control Switch Connection Diagram Example
Driver 2
Driver 3
Control Link
Cable
Control Link
Cable
Momentary
Switch
Terminator
Driver 1
Control Out
Control In
Control In
Control Out
Control Out
ControlIn
Momentary
Switch