Ray-2b 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 Low pwr 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.

Light Operation

The Ray-2a uses a simple non-latching pushbutton switch to operate the light. The light has THREE power levels Hi/Med/Low and each setting includes a 10min warning to indicate battery life – after this period the light will turn OFF to prevent damage to the battery. To get the most run-time out of a battery, when the light first starts to flash, change down to a lower setting. This will reduce the current and increase the run-time. The electronics will also turn off if the bulb filament blows to save power.

Battery Life

During use, the microprocessor is constantly monitoring the battery and will give an approx 10minute warning of battery life left, on each of the power settings. This is indicated by a slow flicker of the light at 2 to 3sec intervals. At the end of this warning period, to prolong battery life, the light will turned OFF to prevent damage to the cells. Obviously the best thing to do when this 10 minute flicker period starts is to reduce to a lower power setting or the lowest setting for max run time. This will reduce the load on the battery and so stop the flickering. If the light is kept on at some point it will start to flicker again and if it's already on the lowest setting, then you have approx 10mins until the light finally goes out!!

Normal operation of the light will probably be used with a combination of the High and Medium settings i.e. High/Med setting for most off road cycling and the Low setting 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, run time is as follows:--


Nickel Metal Hydride Battery Care and Maintenance

Important:- The Ray-2a will NOT allow the battery to run flat, but will turn off at a pre programmed level to protect the battery. The turn off point is indicated by the light “flickering” in the last 10mins of the battery discharge. 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. Allow battery to cool and then recharge as soon as possible.

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/green 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 fully charging the battery approx once per month.

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.

         Unscrew bezel by hand.

         Remove bulb assembly and carefully hold the ceramic bulb holder to 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.

         Replace bezel and ‘o’-ring and tighten until hand tight, taking care to ensure ‘o’-ring is seated correctly under lamp.