Ray-1a/2a General Operating Instructions

General Operating instructions

WARNING: The lamps get very HOT! A 20W Lamp unit soon reaches 100C if left running whilst stationary. KEEP AWAY FROM CHILDREN

It is always advisable to unplug lamps from the battery when in transit. This avoids lamps accidentally turning on and melting or setting fire to your luggage, garage, house, car, train etc. When stationary, always try and run a 20W Lamp on the dipped setting and ideally run for not more than 10 minutes on the main beam setting - when stationary. This will help to prolong the life of the internal components.


Fitting Lamp Unit to Helmet

Depending on the type of helmet air vent system, there are various options available to achieve the best fit for your helmet. The standard setup is using an appropriate length velcro strap, which is then passed through the carbon bracket slots, the helmet air vents and back through the buckle, as shown below.


If you have a helmet with a wide central air vent, the adapter plate (which is available from LiteOption), needs to be fitted. Firstly remove the foam on the bottom of the main bracket so the adapter plate can be fitted flush against it. Bolt the adapter plate in position with the 4mm bolt supplied with the grooves for the velcro strap to the sides. The bracket should now bridge the central vent. Choose an appropriate length velcro strap and fit as above.

NOTE: Ensure the light assembly is securely held in position with velcro strap i.e. foam pad under bracket is compressed by approx 50%. A loose light on a fast rocky downhill is not advisable…!!

Finally fit the adhesive velcro cable guide to the rear of the helmet and pass the cable through it.

Cable Routing

There are several ways that the cable assembly can be routed, depending on whether you use a Camelbak/hydration pack, bumbag or just a standard riding top with rear pockets. Although the battery and electronics are completely sealed and therefore waterproof,  we recommend the battery sits in the bottom of your Camelbak. The cable then passes out of the Camelbak with the drink-tube and over the right hand shoulder. The harness is then tied to either the drinks tube or rucsac strap with the supplied velcro strap. The small velcro strap is used as a cable tidy and can be slid down the two cables to a point where the cables part , to keep them out of the way of stray branches. The switch and cable clip can then be connected to the central chest strap or one of the rucsac straps – whichever you prefer.

Switch Operation

The Ray-1a uses a special locking switch that operates in a different way to most switches. DO NOT FORCE IT – READ THIS FIRST!!!

It has three positions: OFF/DIPPED(14W)/MAIN(20W). The OFF position is when the flat on the yellow knob is angled towards the switch. To select the DIPPED setting, LIFT the knob and move the switch to the central position. To select the MAIN beam setting, the knob can be flicked to the final position – without lifting.

With a little practice, switch operation becomes second nature whilst on the move i.e. flicking between the two light settings and the action of having to lift the knob to select off, means that there should not be any accidental switching off of the light.

Now connect the main harness to the battery, noting the keyway notches on each mating half of the weather proof connectors – it will only fit one way and may be stiff when new and try put the light.

Battery Life

In normal operation the light will probably be used with a combination of the two modes i.e. main beam for most off road cycling and dipped for easy fire trail or road cycling. In this way the battery life is maximised and car drivers don’t screech to a halt as you look up for the next bridleway sign!!

With a fully charged battery on main beam the light will last for just over two hours - on dipped for just over 3hrs. So when switching between the two modes expect around 2hrs. When the bulb dims switch it off as this will prolong battery life.


Nickel Metal Hydride Battery Care and Maintenance

Important:- Never allow battery to run flat. Turn off lamp immediately it starts to fade. The NiMh cells are not like Ni-Cad or SLA and will only dim in the last final minutes of the discharge curve. This means you get maximum run time from your battery. When we say 2hrs we mean it. Do not continue to use them when dim. Failure to do this can result in reduced battery life. Recharge as soon as possible. These are not Ni-Cad batteries so do not attempt to flatten before charging or leave in a discharged state.

FIRST CHARGE: Charge for 24 Hours before use with standard or fast charger to properly condition battery.

The battery includes a temperature trip, so if the pack feels hot and the red indicator on the charger doesn’t light up, it can take up to 20 minutes to reset after the battery is taken off charge. This situation could occur if the battery is still warm from being used or is on charge in a warm room.

General Care

Keep battery well charged. This includes regular charging over the Summer and storage periods exceeding 1 month. Doing this maintains all the cells at the same level and reduces the chance of cell imbalances in the pack, (if a weak cell is allowed to develop and the battery is then run low, the weaker cell can go into reverse causing problems and necessitating a repair). With the fast charger this can be achieved by leaving on trickle mode indefinitely.

Fast Two Stage Battery Charger

The charger is specifically designed for NiMh batteries - a Ni-Cad charger will not work for these cells. These cells require the correct charge termination mechanism or their performance drops rapidly. Also this charger is intelligent enough to handle the charging of a partially discharged battery. The two-stage charger, fast charges until 90-95% full then automatically switches to pulsed trickle charge - so no worries about overnight charging. Charge time approx. 3 hours for a fully discharged battery. A constant green light indicates main charge in progress, a flashing green light indicates main charge complete and trickle charge initiated and is ready for use. The battery can be expected to get warm during charging especially after a deep discharge. This may cause the thermal switch inside the battery to trip and cause an early termination of the charging process. To ensure battery is fully charged repeat the charging process two or three times before use. We recommend that when not in use the battery is left on the fast charger in trickle mode continuously, this will ensure the cells are kept well charged, balanced and maintained. Leave on trickle charge even over Summer or at least carry out an overnight charge/trickle charge once per month.

Storing over Summer

Charge battery fully before storing for any length of time exceeding 1 month. Store battery in a cool environment, 0-20C.

To revitalise battery after Summer: Charge fully. Use only approximately of battery. Fully recharge again. You are now ready to go.

Bulb Changing

1.    To remove:-

         Ensure lamp assembly is cool.

         With carbon housing unscrew 3mm allen screws and remove carbon shroud and bulb – with alloy housing unscrew bezel by hand to remove bulb.

         Remove bulb assembly and carefully hold the ceramic bulb holder and remove old bulb.

2.    To replace:-

         Hold bulb holder and gently push in new bulb so that pins are fully inserted in the ceramic holder.

          Avoid twisting lamp holder leads.

         On carbon housing replace carbon shroud with 3mm allen screws and on alloy housing screw bezel back in place until hand tight, taking care to ensure ‘o’-ring is seated correctly under lamp.