Oceanled EXPLORE E2 User manual

LIGHT. YEARS AHEAD. WWW.OCEANLED.COM
OceanLED MANUAL / EXPLORE SERIES / E2 / REVISION 1
INSTALLATION & OPERATION MANUAL
EXPLORE E2

EXPLORE E2.
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 operating
lamp. May be 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,
wood, or carbon fibre hull, ensure that suitable measures have been put in place to account for the effects of
galvanic corrosion 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 salt water. 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 warranty.
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 warranty.
Never Use Solvents! Cleaners, fuel, and other products that may contain strong solvents, such as, but not
limited to, 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.
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.

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INSTALL & OPERATION MANUAL
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Contents
Preface ..............................................................................................................................................................................1
1 Installation Checklist.......................................................................................................................................................3
2 Overview.........................................................................................................................................................................4
3 Preparing the Hull...........................................................................................................................................................5
4 Installation.......................................................................................................................................................................6
4.1 INSTALLING THE LIGHT FIXTURE.......................................................................................................................6
4.2 ELECTRICAL INSTALLATION (12/24V DC)........................................................................................................10
4.3 FINALISING THE INSTALLATION.......................................................................................................................13
4.4 TEST YOUR INSTALLATION...............................................................................................................................13
5 Operation / Maintenance..............................................................................................................................................14
5.1 SINGLE COLOUR STROBE.................................................................................................................................14
5.2 MAINTENANCE....................................................................................................................................................14
5.3 LIGHT CARTRIDGEREMOVAL...........................................................................................................................14
5.4 LIGHT CARTRIDGE RE-INSTALLATION............................................................................................................15
6 Troubleshooting............................................................................................................................................................16
6.1 TROUBLESHOOTING PROBLEMS AND THEIR SOLUTIONS.........................................................................16
7 Appendix.......................................................................................................................................................................18
7.1 OVERALL DIMENSIONS......................................................................................................................................18
7.2 ESSENTIAL TEST ................................................................................................................................................19
7.3 CABLE GAUGE CHART 12V...............................................................................................................................20
7.4 CABLE GAUGE CHART 24V...............................................................................................................................21
8 Warranty.......................................................................................................................................................................22
PRETEST
Always test the lights prior to installation. Failure to do this may result in additional installation time and could invalidate
the warranty. Never leave lights ON out of water for longer than 5 minutes followed by an off period of 1 hour.
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/downloads for full warranty statement.

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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. Ensure correct cable gauge is used (refer to relevant cable gauge chart).
3. Preparing the hull (Isolation kit required for conductive hull materials or wooden hulls). Ensure hull
thickness is below the maximum 60mm (2.36”)
4. Make sure the lights have been fitted following the correct orientation.
5. Correct marine sealant applied evenly around bezel.
Ensure fully watertight seal is created after sealant cures.
6. 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.
7. Light(s) correctly bonded and vessel bonding system check carried out (refer to relevant schematic
and test procedures).
8. 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.
9. Troubleshooting if required - most issues can be resolved by following the guidelines.

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2 Overview
Product components breakdown
Power Source
Most installations will utilize on-board 12/24V DC power supply from a marine battery. However, if AC to DC power
supply is being used, please allow at least 15% reserve for voltage fluctuations due to variables beyond your control
such as ambient temperature and supply voltage fluctuations. This is to ensure your lights are always receiving the
proper voltage and to ensure the power supply is not “overloaded”, causing premature failure. Use chart below in
determining power supplies.
Identifying your model
Explore E2 Single Colour Narrow Beam
Explore E2 Single Colour Wide Beam
A- Light Unit
C- Compression
washer
D- Clamping
clips + bolts
E- Locking
ring

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Power Consumption and Recommended Fuse values
3 Preparing the Hull
When installing an Explore unit, please ensure there is enough space on the inside of the vessel to remove
the insert for maintenance/after sales services. The XFM unit requires an additional 120mm / 4.7” from the
rear of the mounting tube to allow the insert to be removed for maintenance. (See overall dimensions in the
Appendix).
Ensure that the part of the light inside the vessel has a diameter of 100mm/ 4” around it free from any
insulation material.
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 assembled in a conductive or wooden hull, an Isolation Kit must be used. Contact OceanLED for
additional details.
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
E2
Recommended Spacing
1-1.5m (3-5’)
Recommended Installation depth (From the light waterline)
100-200mm (4-8”)
Maximum Hull Thickness
Maximum hull thickness: 60mm (2.36”)
Hole Cut Out
Hole Cut out size - 62mm (2.44”) / With Isolation Kit 64mm (2.5”)
Overall Dimensions
See overall dimension schematic –in the Appendix, Chapter 7.
Model
Current @ 12V
DC
Current @ 24V
DC
Max Nominal
Power
consumption
15% reserve in
Watts
Recommended
fuse 12V/24V DC
E2 Ultra White
3.5A
1.5A
42W
50W
4A
E2 Midnight Blue
3.5A
1.5A
42W
50W
4A

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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.
DO NOT remove the light cartridge from the mounting tube during installation. The light cartridge MUST stay
fitted inside the mounting tube throughout the installation process to avoid the introduction of potential
contaminants that may damage the product and void warranty. The light cartridge can only be removed for
maintenance or after sales purposes and OceanLED must be contacted prior to any light cartridge being
removed from the mounting tube.
OceanLED recommends dry fitting all products. 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.
Explore E2
Kit Includes
Explore E2
Clamping Kit

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Installation (Once hull preparation is complete)
1. Testlight(s) before fitting into the hull.
2. If using a Delrin Isolation Kit, insert the Isolation Kit front washer into the drilled hole and apply marine sealant to
seal between the Front Washer and thehull. The Front Washer is identified by a raised edge and the Rear
Washer is flat.
3. Apply marine sealant to the rear of the mounting tube assembly’s bezel to ensure a complete unbroken seal
around thelight.
Make sure sealant fills in the recess groove on the reverse of the light bezel:
4. Ensure the light orientation is correct with the cable gland at the back positioned at the bottom (see image
below)perpendicular to thewaterline. If there is not enough space at the back of the light for the cable, the
light orientation can be changed to the cable gland positioned at the top, perpendicular to thewaterline.
Sealant
Cable gland pointing
downwards perpendicular
to waterline
Delrin Isolation Kit: Front Washer
Washer

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5. Insertthecompletelightunit(mountingtube assembly + lightcartridge) intothehull, pressing the light hard
into the hull and twist slightly to spread the sealant around behind the light to ensure goodadhesion.
This process is made much easier if a second person is inside the hull to receive the light and install the
locking 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.
6. If using a Delrin Isolation Kit, insert the Isolation Kit Rear washer over the mounting tube and locate it flush with
the hull. The Rear washer is identified as flat.
7. Insert the stainless-steel compression washer over the mountingtube.
The stainless-steel compression washer does not need to be flat to the hull, a slightly uneven surface can
be compensated by the washer.
Delrin Isolation Kit: Rear Washer

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8. Place the two clamping clips together to form a circle, ensuring you pair 1 threaded and 1 non-threaded
hole together. Fix the clips together using one of the longer screws provided so that the clips are located
approximately halfway down the length of the screw. Locate the clips into the appropriate grooves
(depending on hull thickness) on outside of the mounting tube so that the end of the screw is close to the
washer. Fit the second longer screw provided into the remaining holes, fixing the two clips together. Leave
the shorter screw out to connect the light to the vessel’s cathodic protection system.
9. Tighten the locking screws using a 5mm Allen key,applying thread lock at point of threadcontactwith locking
ring. DO NOT over-tighten locking screws, as you could damage the mounting tube, and this will not be
covered under warranty.
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 seal youhaveinstalled on the unit is fully watertight. If in doubt, remove light, re-apply sealant
and re-install.
10. Connect the bonding cable to the remaining screw and lock in place with shake-proof washer provided.
Tighten the locking screw using a 5mm Allen key, applying thread lock at point of thread contact with the
clamping clips.
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 vessels cathodic protection system and the outer
bezel of the mounting tube assembly (see bonding schematic –Appendix Chapter 7).

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4.2 ELECTRICAL INSTALLATION (12/24V DC)
Additional items required not supplied by OceanLED:
•Junction box* / waterproofconnectors
•Sufficient cable to connect to DC PowerPack
*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.
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.
1. Depending on the model and number of lights installed, you will need to pullthe correct sized power cable from
the DC power source (breaker/fuse panel) to the light locations to supply constant power to the light units. It is
imperative that the correct sized tinned marine grade cable is used to avoid voltage drop issues.
See Chapter 7: Appendix for recommended cable gauges.
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. Make sure any heatshrink used completely encapsulates the
outer wire sheath (the use of glue-lined heat shrink is highly recommended to ensure water tightness).
Never install a new light fixture then leave the vessel in the water unchecked for several days.
3. It is imperative that either the OceanLED supplied fuse on each power line to eachlight or a suitable protection
device is used to protect the cable/light unit. Failure to do so will void the warranty. See table in Chapter 2:
Power Consumption and Recommended Fuse values. Make sure any heatshrink used completely
encapsulates the outer wire sheath (the use of glue-lined heat shrink is highly recommended to ensure water
tightness).
4. Securecablesensuringwhere the cableexits the light it is not under undue stress.Finishand test the light units
BEFORE the vessel goes into the water. Never leave lights ON out of water for longer than 5 minutes followed
by an off period of 1 hour.
Explore E2
Kit Includes
Fuse Kit

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Fuse Kit Connection Overview:
12/24V DC Connection Diagram:
FUSE
OPTIONAL
PUSH TO BREAK
SWITCH
(NOT SUPPLIED)
FUSE
FUSE
POWER
SWITCH
(NOT SUPPLIED)
FUSE/BREAKER
(NOT SUPPLIED)
RED
BLACK
2M (79”) LIGHT CABLE
DC CABLE TO POWER SOURCE
(NOT SUPPLIED)
EXPLORE E2
LIGHTS

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WIRING SCHEMATIC WITH POWER JUNCTION BOX:
WIRING SCHEMATIC WITH 3RD PARTY JUNCTION BOX:

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4.3 FINALISING THE INSTALLATION
The Explore XFM mounting tube is constructed from corrosion resistant Aluminium Bronze and does not require further
protection. The glass is pre-coated with a specialized Tritonium® coating which helps to prevent marine growth from
adhering to the glass.
No paint or any type of anti-fouling agent should be applied to the glass and/or bezel, as damage may
occur to the light due to chemical incompatibility and will immediately void the warranty. However, if bottom painting of
the bezel is deemed essential, then an area of at least 5mm should be left uncoated around the glass lens:
The protective lens sticker should be removed once all work on the vessel is complete.
Please do not use any un-authorised cleaning products to remove excess paint or antifoul off the glass or
within 5mm of the glass. OceanLED recommends using Isopropyl Alcohol (IPA) only.
4.4 TEST YOUR INSTALLATION
Always test the lights BEFOREthe vessel goes back into the water. At this final stage make sure all of the system is
operational. If you have any issues, please contact your local OceanLED representative.
Never install a new light fixture then leave the vessel in the water unchecked for several days.
Never leave lights ON out of water for longer than 5 minutes followed by an off period of 1 hour.
When the vessel is placed in the water, immediately check for leaks. Note that very small leaks may not be
readily observed. It is best not to leave the vessel in the waterfor more than 3 hours before checking it again.
If there is a small leak, there may be considerable bilge water accumulation after 24 hours. If a leak is
observed, youmust TAKE ACTION IMMEDIATELYto prevent damage.
Coated area
Un-coated area

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5 Operation / Maintenance
5.1 SINGLE COLOUR STROBE
Toenter strobe mode, with the light on, toggle the power off then quickly back on. They should now strobe in a random
pattern. The lights can be reset from strobe mode by simply turning off, waiting 10 seconds, then turn on again.
5.2 MAINTENANCE
Marine growth can build up quickly on the light and can reduce the light’s performance injust a few weeks.
To help prevent this, all OceanLED lights have been coated with a specialized Tritonium® coating which helps to
prevent marine growth fromadhering to the glass. Lightsshouldbe cleaned with a boat brush or similarbi-weekly,or as
needed tokeep the lens of the lightclean.
Growth varies greatly around the world and maintenance is imperative to the proper operation and longevity of the
product. If heavy fouling occurs, growth can be removed from the lens using a plastic scraper and moderate pressure
underwater.If cleaning the lens while the boat is out of the water,wet the lens before scraping. Never scrape or try to
removebarnacles from a dry lens.
Never use high pressurejet wash to clean the lens / bezel as this will damage the seals and void the warranty
5.3 LIGHT CARTRIDGEREMOVAL
Before proceeding with this operation, you MUST seek permission from either the manufacturer or your
OceanLED representative or you will void the warranty.
DO NOT remove the light cartridge from the mounting tube during installation. The light cartridge MUST stay
fitted inside the mounting tube throughout the installation process to avoid the introduction of potential
contaminants that may damage the product and void the warranty.
Additional items required not supplied by OceanLED:
•M8 Bolt
•13mm Spanner (for the M8 bolt)
1. Ifthevessel is inwater checkthatthefrontglassis presentandintact.Neverremovea cartridge withthevessel
in water if damage to the glass lens is suspected.
2. Turn power off and disconnect the light cable connection from the electrical installation.
3. Remove the Locking Ring from the mountingtube.
4. To ease removal process; undo the cable gland nut to allow air to enter the unit and prevent a vacuum being
created when removing the light cartridge. Failure to do so could damage the light cartridge.
5. Fit the M8 bolt into M8 threaded hole on the rear of the light cartridge.
6. Remove the light cartridge from the mounting tube by pulling the M8 bolt.

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5.4 LIGHT CARTRIDGE RE-INSTALLATION
Additional items required not supplied by OceanLED:
•Isopropyl Alcohol (IPA)
Before installing the light cartridge, clean the inside of the mounting tube with Isopropyl Alcohol (IPA) cleaner
and let it dry. Failure to do this may introduce potential contaminants that may damage the product and void
your warranty.
Lubricant substances of any kind MUST NEVER be used to ease the insertion of the light cartridge into the
mountingtubeas this willdamage thelight and void the warranty. Should any helpto insertthe light cartridge
be needed, OceanLED recommend the use of a small quantity of Isopropyl Alcohol sprayed onto the O-Ring
on the back of the light cartridge.
1. Inspect the mounting tube and light cartridge to ensure no contaminant (grease, debris, dirt) and/or water are
present.
2. Undo the cable gland to actasa breather.Failure todosowill make the installationprocess significantly harder
and could damage the light and void the warranty.
3. Align the light cartridge with the mounting tube. Push the light cartridge in slowly until it bottoms out against the
front bezel. Please see Chapter 4 Installation.
4. Tighten the cable gland.
5. Fit the Locking Ring.
6. Connect the power cable and test the light. Re-check if the light is pointing the right wayup.

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6 Troubleshooting
6.1 TROUBLESHOOTING PROBLEMS AND THEIR SOLUTIONS
EXPLORE SERIES
PROBLEM
CHECK
CAUSE
FIX
Light does
not look
bright
Check that there is no marine
growth on the lens
Marine growth
Clean the lens as per
maintenance advice
Check voltage supply to the
light is between 11V and 32V
DC (The light will still work
between 9 and 11 volts however
at reduced brightness)
Voltage is either too
high or too low
Investigate reason for high or
low voltage and fix
Check voltage supply is stable
and does not fluctuate
Voltage is fluctuating
Investigate reason for voltage
fluctuation and fix
Check that the electrical
connections between the
light and the supply cable
have been made correctly and
recommended cable gauge has
been used
Poor electrical
connection
Remake connection and seal
joint correctly
Confirm all LEDs are illuminated
1 or more LEDs are not
working
Contact your dealer.
Check lights to see if water is
present inside the light
Water present
Contact your dealer.
Check cable connections for
corrosion
If corrosion is present
It is not advised to reuse the
cable if water is present inside.
Contact your dealer
for a replacement. This is NOT
covered by the warranty
Light has
water inside
Check integrity of lens
Light will require
replacing
This is not covered by the
warranty - Contact your dealer
for a replacement light. Only
use genuine OceanLED parts
Check connections to make sure
they are not submerged in water
Light will require
replacing
This is not covered by the
warranty
Check cable to make sure there
is no damage to the cable
Cable will require
replacing
This is not covered by the
warranty. Only use genuine
OceanLED parts
Checked all factors that are
above, and the light still does
not work
Light faulty
Contact your dealer for a
replacement light

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EXPLORE SERIES
PROBLEM
CHECK
CAUSE
FIX
Light does not
light up
Check that the electrical
connections between the light
and the supply cable have been
made correctly
Poor electrical
connection
Remake connection and seal
joint correctly
Check that the wiring polarity is
correct, red to positive and
black to negative
Polarity incorrect
Change the wiring polarity
and seal joint correctly
Check that there is power
supply to the light cable
connection
Poor electrical
connection
Trace the cables back,
checking at joints until break
has been located. Then rectify
the problem and seal joint
correctly
Check that the electrical
connections between the supply
cable and the light circuit
breaker or fuse have been
made correctly
Poor electrical
connection
Remake connection and seal
joint correctly
Check that the in-line fuse is
intact and not blown
Replace fuse
If fuse keeps blowing, then
there is a short circuit in the
light system that must be traced
and rectified. If no external short
can be located contact your
dealer
Check that the light supply
circuit breaker is closed, or the
fuse has not blown
Close circuit breaker /
replace fuse
If breaker / fuse keeps blowing,
then there is a short circuit in
the light system that must be
traced and rectified. If no
external short can be located
contact your dealer

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7 Appendix
7.1 OVERALL DIMENSIONS

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7.2 ESSENTIAL TEST
Perform this bonding check after installation of the light and before moving the vessel back into the water.
Refer to bonding information in the installation sections in this manual. If in doubt, please contact OceanLED.
1. Connect the light assembly to the cathodic protection system as explained in Chapter 4.
2. Measure the electrical continuity between the front bezel and the sacrificial anode. This test should give a
reading of up to 0.5Ω (Ohms). This procedure will guarantee electrical continuity between the front bezel,
the mounting tube and the sacrificial anode.
If you have any questions regarding the above, please contact OceanLED:
[phone] or [e-mail]
Aluminium Bronze
Front Bezel
Bonding Screw
Aluminium Bronze
Mounting Tube
Sacrificial Anode
YES!
NO!
The Resistance reading
between the bonding
screw and the sacrificial
anode will not prove any
continuity between the
light fixture and the
bonding system.
The Resistance reading
between the front bezel and
the sacrificial anode will show
whether the light fixture is
electrically connected to the
bonding system of the vessel.