Underwater Hull Light

Installation and Maintenance

Instructions Manual

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Installing Light Cartridge

•   Lube threads and O-Ring

•   Guide LED cartridge into housing cartridge of LED emitters

•   Hand tighten into bronze housing

•   Once the ring is free, carefully withdraw the lamp assembly from the housing.

•   NOTE: Ensure the area local to the light is relatively dry, thus ensuring bilge water can not enter the opened housing. Also ensure the withdrawn lamp assembly DOES NOT come in con­tact with water at any time. It MUST remain clean and dry at all times. Should the assembly come in contact with water, contact your nearest supplier for further advice. Do not re-assemble and re-energize.

•   Inspect the housing to ensure it is completely clean and dry. The lens may be cleaned if neces­sary using a soft cloth on the end of a wooden dowel or similar. Re inspect after cleaning to en­sure no cloth or other cleaning fibers remain inside the housing. NEVER spray lubricants, degreasing agents or other similar products into the housing! Carefully re-fit the lamp assembly into the housing ensuring the front end of the reflector case locates correctly into the front end of the lamp housing. This can be felt by moving the assembly around until it drops neatly into posi­tion with the rear end cap snug against the silicone seal.

•   Re-fit the outer lock ring.  Again it is recommended to apply a thin layer of Lanolin based grease to the thread and surface in contact with the end cap.

•   Tighten the locking ring by hand ensuring it is TIGHT.

•   NOTE: At no point is it necessary to loosen the cable gland nut, however it should be checked to ensure it is secure and snug around cable.  DO NOT pull excessively on the cable!

Other Maintenance

•   Check to ensure the underwater lens is clean and free of marine growth. It may be cleaned using a nylon brush or plastic scraper.

•   Replacement parts and accessories: A full range of Replacement parts and accessories are avail­able. Please contact your supplier for any requirements.

Should there be a malfunction for any reason, please consult your nearest agent or Aqua Lights directly. The housing should not be opened under any circumstances unless by a suitably qualified and authorized technician.

Safety and General Information

THE FOLLOWING INFORMATION IS IMPORTANT TO THE SAFE OPERATION OF THIS EQUIPMENT, ACCORDINGLY MUST BE OBSERVED AND ACTIONED AS NECESSARY.

•   This Light should only be installed by suitably trained trades persons experienced in the fitting of through hull equipment and marine Mains Voltage AC electrical systems.

•   It is important that the housing is electrically bonded to the vessels cathodic protection ground­ing system. Failure to solidly ground will result in corrosion, leading to serious damage or loss of vessel, property and life. Regular checks/testing must be carried out to ensure the metal housing is electrically bonded to the vessels cathodic protection grid.

•   If the housing shows signs of excessive corrosion (other than surface contamination) or physical damage, the vessel should be hauled so a complete assessment can be performed. Any signs of water ingress must be addressed immediately.

•   As this equipment operates on mains voltages, it is of the utmost importance that all equipment is maintained in first rate working order at all times. Regular inspections should be carried out to ensure all wiring is in good condition, clear of wet areas and not exposed to mechanical inter­ference.

•   Any suspect equipment must be repaired or replace.

•   The Lens and Bezel have been carefully designed with a smooth, flush surface to allow easy cleaning.

•   Never operate the vessel with the lamp housing end cap removed.

Limited Warranty

Aqua Lights warrants these fixtures to be free of defects in parts and workmanship for 3-year from the date of shipment. Bronze has lifetime warranty for barrel. This warranty does not apply to defects resulting from action of the user such as misuse, improper wiring, operation outside of specification, improper maintenance or repair or unauthorized modification. Bulbs are not covered under warranty as they are a purely consumable item that may be adversely affected by environmental factors beyond our control. Aqua Lights specifically disclaims any implied war­ranties or merchantability or fitness for a specific purpose and will not be liable for any direct, in­direct incidental or consequential damages. Aqua Lights’ total liability is limited to repair of the fixture at our facility in Alpharetta, Georgia, or replacement of the product outright.

Under no circumstances is Aqua Lights responsible for reimbursement of expenses related to ves­sel haul-outs, technician or yard personnel travel expenses, yacht storage, labor performed during removal and/or replacement of fixture, or expedited shipping costs for replacement parts. These are assumed liabilities of the customer and part of the terms of sale between Aqua Lights and its customer.

The warranty set forth above is inclusive and no other warranty, whether written or oral, is ex­pressed or implied. If it should become necessary to return a fixture for service during or beyond the warranty period, call our customer service desk at (770) 754-9967.

Installation Instructions

The following tools and supplies are required for a proper install: • Variable speed drill • Hole saw -  1.25-inch hole for the AL35 watt mini-light -  2.5-inch hole for our AL100 lower series and the Aqua Cam - 4.5 inch hole for AL175 and higher series.  • Tape measure • Pencil • Sand paper 180 grit • Phillips screw driver • Wrenches • 3M 5200 Marine adhesive white or black de pending on your hull color. • Optional two part epoxy for filling cored fiberglass ves­sels. • Optional stir stick for epoxy. • Optional utility knife for trimming back core material.
1.  Drill hole with hole saw: • The hole for the Aqua Light should be located a mini­mum of 6 inches below the water line for the AL75 and lower series, and 12 inches below the water line for the AL100 and higher series. • The Aqua Cam should be located as far below the water line as practical for the best viewing angle. • The best method is to locate your position on the hull, leaving room to service the light with adequate room for ventilation around the fixture as the housing will warm up after prolonged use. • Never use your lights when the housing is out of the water except when testing the light on initial install for less then 5 minutes. • When the location has been marked, find the same spot on the inside of the hull and check your clear­ances. Then drill the pilot hole from inside the vessel, as this will ensure the proper placement of the light fix­ture. • Finish drilling the final hole using the proper whole saw from the outside. Always being careful, the drill may come in contact with a screw or other hardware that might cause the drill to jump. • Inspect the hull for core material. If you have core ma­terial, this must be sealed to avoid the entry of water into the core. It will also enhance the strength of the edges of the glass material.
2.  Trim core to allow room: • Trim core to allow room for two-part epoxy or vessel manufacturer recommended material allow set.
3.  Apply epoxy to dry: • Clean core material, leaving no visi­ble core. • Fill it to an even level amount. • Sand clean and inspect for bubbles or pin holes.
4.  There is an O-ring supplied with the light to be used when installing on smooth level surfaces of fiberglass or metal. • If the surface is irregular, disregard the O-ring. • The surface should be clean of debris and moisture at this time, and you should use the 180-grit sand paper to rough the adhesion points. • Apply a generous amount of 3M 5200 Marine Adhesive Sealant. • A 1/2-inch bead completely around the flange and some on the shaft of the light will be sufficient. The adhesive should be ejected from around the bezel of the light. • If it is tightened this way you know you have a proper seal.
5.  Insert light with a twisting motion. • If installing the Aqua Cam, be sure to return to the top mark so that you will have a proper display on your TV monitor.
6.  Tighten the locking nut. • On some vessels, if the hull is thin like a solid glass boat or aluminum vessel, make a spacer out of teak, Delron, Starboard to fill the gap.
7.  Tighten the leveling bolts. • Tighten the leveling bolts so that the fixture is locked into position. Torque bolts to 30 ft lbs.
8.  Tighten SS locking bolts lock nuts.
9.  Attach light source to base.
10.  Insert light source, retaining spring into fixture.
11.  Add light source backing.
12.  Tighten water tight cable gland with 7/8" wrench hand tight.
13.  Run cabling to power source. • Run cabling to power source for halogen lights they will require seven amps for each light AL50 and AL75. • Then attach red wire to positive and black to negative.
AL9MC Customer Assembly Drawing
aqua lights 785 Branch Drive  Alpharetta, GA 30004  USA (866) 924-2782 • sales@aqualights.us