Megaray MR175mk2 User manual

ULTRA HIGH INTENSITY SEARCHLIGHT
LIMITED
Somerset House I 11 York Street I Randburg I Johannesburg I 2194 I South Africa
All Corres ondence to: PO Box 78800 I Sandton I 2146 I South Africa
Tel: [phone] I Fax: [phone]
e-mail: [e-mail] I web: www.megaray.com
M
K2
OPERATOR AND
ORGANIZATIONAL
MAINTENANCE MANUAL

1
TABLE OF CONTENTS
P
AGE
Table of Contents 1
Safety Summary 2
CHAPTER 1
–
INTRODUCTION
1.1 Purpose and Scope 4
1.2 List of Abbreviations 4
1.3 Description of t e Equipment 4
1.4 Megaray Standard Kit 5
1.5 Megaray Portable Searc lig t System 6
1.6 Battery Vest 7
1.7 Battery C arger 9
1.8 Carry Strap 10
1.9 Picatinny Rail 11
CHAPTER 2
–
OPERATING INSTRUCTIONS
2.1 Preparing t e Unit for Operation 12
2.2 Connecting Unit to a Power Source 12
2.3 Switc ing t e Unit
“
ON
”
14
2.4 Lig t Mode Selection 15
2.5 Adjusting Beam Divergence 16
2.6 “Over Temperature” 17
2.7 Tripod Mounting 18
CHAPTER 3
–
OPTIONAL
ACCESSORIES
3.1 Optional Accessories 19
3.2 IR Filters 20
3.3 Hard Carry Case 21
CHAPTER 4
–
MAINTENANCE
4.1 Cleaning 22
4.2 C anging t e Lamp 22
APPENDIX
Appendix A Warranty Information 26
LIST OF FIGURES
Figure 1 List of Abbreviations 4
Figure 2 Megaray Standard Kit 5
Figure 3 Megaray Lig t Unit 6
Figure 4 Battery Side Panel 7
Figure 5 Battery Power Indicator LEDS 7
Figure 6 Battery Vest 8
Figure 7 Power Cable 8
Figure 8 Battery C arger 9
Figure 9 Attac ment for Carry Strap Hook 10
Figure 10 Picatinny Rail Used to Mount a Nig t Vision Device or Similar 11
Figure 11 Connecting t e Power Cable to t e Megaray from t e Battery Vest 12
Figure 12 External Power Cable Being Connected to Searc lig t 13
Figure 13 Megaray ON/OFF Switc 14
Figure 14 Megaray Lig t Unit Label 14
Figure 15 Lig t Mode Switc 15
Figure 16 Adjusting Beam Divergence 16
Figure 17
Beam Diameter at a Given Distance 17
Figure 18 T readed Hole in t e Heat Sink 18
Figure 19 Optional Accessories 19
Figure 20 IR Filters 20
Figure 21 C art of IR Filter Curves 20
Figure 22 Installing IR Filter or Clear Spreading Lens on Lens Housing 20
Figure 23 Hard Carry Case 21
Figure 24 Protective Cut-out Foam-liner inside Hard Carry Case 22
Figure 25 Troubles ooting Table 23
Figure 26 Specifications 25

2
SAFETY SUMMARY
WARNING CAUTION NOTE
Hig lig ts an essential operation or maintenance procedure, w ic , if not strictly observed,
could result in injury.
Hig lig ts an essential operation or maintenance procedure, w ic , if not strictly ad ered to, could result
in damage to, or destruction of, equipment or loss of mission effectiveness.
Hig lig ts an essential operation or maintenance procedure t at deserves additional emp asis, but is
not considered essential to t e protection of personnel or equipment.
Battery s ould be inspected for bulging prior to use. If t e battery s ows signs of bulging, do not use.
Battery contains lit ium t at could emit sulfur dioxide and may explode if andled improperly. DO NOT
carry battery loosely or in cases w ere t ey could s ort-circuit and cause damage or injury. Do not
replace battery in a potentially explosive atmosp ere. Sparking on connecting may occur w ile installing
or removing battery and cause an explosion. Serious injury to personnel may result from failure to
comply wit t is warning. Consult local Property Disposal Officer and DLSC Handbook 41601 for proper
battery disposal.
HOT SURFACES: During operation, t e bottom eat sink temperature could reac 158°F/70°C.
Prolonged contact can cause skin burns.
HIGH VOLTAGE: T ere are ig voltage levels present inside t e unit for up to t ree minutes after
switc ing off.

3
HIGH PRESSURE: T e xenon gas in t e lamp is under ig pressure. Repair and maintenance
tec nicians s ould always andle t e lamp very carefully. Protective and and face gear s ould always
be worn w en testing t e lamp w ile t e unit is open and t e lamp is exposed.
Personnel working in close proximity to an operating Megaray s ould avoid pointing t e beam onto
exposed skin.
Never point t e Megaray beam at anyone, or look into t e output lens of t e beam w et er in t e visible
mode or wit IR filters. Permanent eye damage and blindness could result.
Megaray must not be operated at angles greater t an 45° in an upward direction from t e orizontal.

4
CHAPTER 1
INTRODUCTION
1.1 PURPOSE AND SCOPE
T e purpose of t is manual is to provide descriptive information, operating instructions and
maintenance procedures for t e Megaray 175mk2 portable ultra ig intensity searc lig t
( ereafter referred to as Megaray). T e manual will cover t e Megaray, all ancillary equipment
associated wit t e standard kit and optional accessories t at may be used wit t e Megaray.
1.2 LIST OF ABBREVIATIONS
T e following list of abbreviations may be used in t is manual:
A
Amps
DC Direct Current
ft Feet
g Grams
hrs Hours
Hz Hertz
In Inc es
IR Infrared
kg Kilograms
LED Lig t Emitting Diode
Mts Meters
min Minutes
mm Millimeters
Yds Yards
nm Nanometers
oz Ounces
RA# Return Aut orization Number
V Volts
VAC Volts, Alternating Current
VDC Volts, Direct Current
Figure 1. List of Abbreviations
1.3 DESCRIPTION OF THE EQUIPMENT
T e standard Megaray is a compact, battery powered, ultra ig intensity searc lig t system
intended for general and specific illumination tasks. General illumination tasks include, but are
not limited to:
 General battlefield illumination
 Sniper suppression
 Obstacle illumination
 Crowd control
 Covert illumination for electro optical (EO) sensors
 Searc and rescue
 Improvised explosive device (IED) detection
 Traffic control

5
1.4 MEGARAY STANDARD KIT
T e Megaray system consists of t e following standard components (Figure 2)
Item Part Number
Picture Descri tion
1 MR - SS
S oulder strap
2 MR - 175SC
S ipping and storage soft case
3 MR – 175MK2
Megaray lig t unit
4 LB - 175
Lit ium polymer battery
5 MR - 175MAN
Operator and Organizational Maintenance Manual
6 MR - 3330
Battery vest including power cable
7 BC - 175
Battery c arger
8 MR – PIC1
Picatinny rail
Figure 2. Megaray Standard Kit

6
1.5 MEGARAY PORTABLE SEARCHLIGHT SYSTEM
1.5.1 Megaray Lig t Unit
1
Lens ousing
6
“
Battery Low
”
LED
2
Picatinny rail
7
“
Over - Temperature
”
LED
3
Air vents
8
“
Power On
”
LED
4
Power connection
9
Mode selector switc
5
Bottom eat sink
1
0
Main
“
ON/OFF
”
switc
Figure 3. Megaray Light Unit
1
2
3
4
5
6
7
8
9
10

7
1.6 BATTERY VEST
T e battery vest assembly is worn on t e torso of t e operator and contains pockets for
accessories.
1.6.1 Composition
T e battery vest consists of one 22.2V 16Amp- our lit ium polymer maintenance-free
rec argeable battery oused in t e battery vest. T e power cable connects to t e battery and to
t e Megaray or c arger (Figure 6).
1.6.2 Power Cable
T e power cable connects to t e battery vest on t e rig t and side of t e battery vest and is
secured to t e vest wit a velcro strap (Figure 6). T e battery remains in t e battery vest during
rec arging. T e same cable and connector used to connect t e Megaray lig t unit to t e battery
vest is used to connect to t e battery c arger (Figure 7).
1.6.3 Battery
T e battery c arge level can be c ecked on t e “C ange level indicator” by touc ing t e touc
pad indicator (see Figure 4). T e battery power indicator lig ts will be lit to s ow ow muc
battery power is left (see Figure 5).
Figure 4. Battery Side Panel
LED’s
Indicative lights
illumninated
Charge level
5 2 red, 1 yellow and 2 green 100% - fully c arged
4 2 red, 1 yellow and 1 green 80%
3 2 red, 1 yellow and 0 green 60%
2 2 red, 0 yellow and 0 green 40%
1 1 red, 0 yellow and 0 green 20% - empty, rec arge
Figure 5. Battery Power Indicator LEDS
Change level
Indicator - LED 1-5
Touch ad
indicator

8
1.6.4 Battery Vest
T e Lit ium polymer battery is oused in t e battery pouc on t e rear of t e battery vest. T e
battery remains in t e battery vest during rec arging. T e Power cable (Figure.7 ) connects t e
Battery vest to t e Megaray and t e Battery C arger.
Figure 6. Battery Vest
Figure.7 Power Cable
Battery
ouch in which
the Lithium olymer
battery is housed

9
1.7 BATTERY CHARGER
T e battery c arger is provided to rec arge t e Lit ium polymer battery in t e battery vest. T e
battery c arger operates on an input voltage range of 100 – 240VAC. It delivers an output current
of 4A (max), w ic allows for a maximum rec arge time of five (5) ours from w en t e battery
is completely disc arged.
1.7.1 Power Cable
T e power cable for connecting t e Megaray to t e battery vest is situated on t e rig t and side
(in t e carrying position) of t e battery vest, in front of t e battery pouc . W en t e battery vest
requires rec arging, t e same power cable is used to connect to t e Megaray battery c arger.
1.7.2 C arging t e Lit ium Polymer Battery
C arging t e Megaray Lit ium polymer battery using t e custom Megaray battery c arger is
quick and uncomplicated. On top of t e c arger t ere is a LED lig t, w ic indicates ow far t e
c arging process is:
 Red LED = C arging
 Yellow LED = Close to fully c arged
 Green LED = Fully c arged (or disconnected from battery)
T e c arger is equipped wit a standard Megaray military type connector for connecting to t e
Megaray power cable.
Use only t e Megaray c arger, as supplied wit t e Megaray, to c arge t e battery.
Figure 8. Battery Charger
LED light

10
1.8 CARRY STRAP
An adjustable s oulder carry strap attac es wit t e carry strap ooks on t e Megaray MR175
MK2, as illustrated below (Figure 9).
Figure 9. Attachment for Carry Stra Hook

11
1.9 PICATINNY RAIL
A picatinny universal 6 inc rail. T e Picatinny rail allows ot er equipment to be mounted to t e
Megaray (Figure. 10).
Figure 10. Picatinny Rail Used to Mount a Night Vision Device or Similar

12
CHAPTER 2
OPERATING INSTRUCTIONS
2.1 PREPARING THE UNIT FOR OPERATION
T e Megaray is ready for immediate use w en unpacked and requires no preparation or
assembly.
2.2 CONNECTING UNIT TO A POWER SOURCE
2.2.1 Battery Vest
T e Megaray system is equipped wit military connectors t at connect in only one way to ensure
proper contact and to prevent accidental reverse polarity connection. T e lig t unit is equipped
wit a male connector w ic connects to t e female connector of t e attac ment you are
connecting it to as demonstrated below (Figure 11) w ere t e battery vest connects to t e
Megaray™.
To connect:
a. Press t e connectors toget er firmly after insertion w ile turning cable connector.
b. Tig ten t e female connector until t e red band is not visible.
Figure 11. Connecting the Power Cable to the Megaray from the Battery Vest
T is met od requires a little practice, but once mastered, enables t e operator to connect t e
Megaray lig t unit power cable to its battery vest swiftly and wit out aving to look at t e
connectors. T is met od comes in andy w en Megaray needs to be connected in t e dark.
Fem
ale
connector of
cable
M
ale connector
on Megaray
Red band on Male
connector
Tighten
the female
connector until the
red band is not
visible

13
2.2.2 External Power Source
T e optional extension power cable is used to connect t e lig t to an external power source. T e
Megaray lig t unit is equipped wit an integral switc mode power supply enabling t e unit to
function on any DC voltage input between 12VDC and 30VDC. It automatically adjusts itself to
t e input voltage. Common external power sources are car, truck, boat or aircraft battery. T e
external power source s ould deliver at least 20A from a 12V power source, or 9A from a 24V
power source. Currents below t ese levels may not be sufficient to ignite t e Megaray’s s ort
arc xenon lamp.
2.2.2.1 External Power Cable
T e external power cable is equipped wit a female connector on t e one end (identical to t e
female connector on t e battery vest) and two eavy-duty alligator clips on t e ot er end.
Figure 12. External Power Cable being Connected to Searchlight
T e alligator clips are color coded to indicate polarity. Color coding is standard
red = positive (+) and black = negative (-).
2.2.2.2 Ensure Polarity
Alt oug t e Megaray is reverse polarity protected t e unit will not function if incorrectly
connected.
Fem
ale
connector
of external
power cable
M
ale connector
on Megaray

14
2.3 SWITCHING THE UNIT “ON”
T e Megaray is equipped wit an ON/OFF switc located on t e upper front part of t e pistol-
type andgrip (Figure 13). T e lig t comes on w en t e switc is pressed once and goes off
w en t e switc is pressed again. W en t e Megaray is switc ed on, t e red “Power ON” LED
(Figure 14) situated inside t e label area of t e lig t unit glows indicating t at t e power supply
module and electronic circuit are functioning correctly.
Figure 13. Megaray ON/OFF Switch
Figure 14. Megaray Light Unit Label
Power
“
ON
”
L D
Over Temperature L D
Battery
“
LOW
”
L D

15
2.4 LIGHT MODE SELECTION
T e Megaray as two different lig t modes, w ic are selected using t e mode selector switc .
T e mode selector switc is situated at t e bottom front of t e unit (Figure 15). T e following
modes are selectable:
a. Strobe: In t is mode t e lig t beam flas es at eig t cycles/second (8Hz) in ig
beam mode. Mode switc is in t e forward position.
b. Hig beam: In t is mode Megaray operates at continuous lig t output. Mode switc is
in t e backward position.
Figure 15. Light Mode Switch
Strobe
Continuous

16
2.5 ADJUSTING BEAM DIVERGENCE
Megaray’s beam divergence (angle) is adjusted by sliding t e lens ousing (Figure 16) forward
or backward.
2.5.1 Decreased Beam Divergence
As t e lens ousing moves forward (Figure 16 - A), t e beam divergence decreases to a
minimum of 2°. Maximum lig t intensity is obtained at t is angle.
2.5.2 Increased Beam Divergence
As t e lens ousing is moved backwards (Figure 16 - B), t e beam angle increases until t e
maximum beam of 6° is ac ieved.
Figure 16. Adjusting Beam Divergence
Lens housing in fully
extended osition results
in minimum beam
divergence (2°) with
maximum range and
beam intensity
Lens housing in fully
retracted osition results
in maximum beam
divergence (6°) with
reduced range and beam
intensity but increased
area illumination
B
A

17
MR 175
-
BEAM DIAMETER AT A
GIVEN
DISTANCE
Distance
50
100
200
500
800
1000
1500
2000
Mts
55
109
219
547
875
1094
1640
2187
Yds
Beam
Diameter
2°
1.75
3.50
7.00
17.5
28.00
35.00
52.37
70.00
Mts
1.91
3.82
7.65
19.14
30.62
38.28
57.27
76.55
Yds
6°
5.25
10.51
21.02
52.5
84.08
105.1
157.65
210.20
Mts
With
CSL 074
lens
5.74
11.49
22.99
57.42
91.95
114.94
172.48
229.88
Yds
74°
75.36
150.72
301.42
753.60
1205.70
1307.20
2260.60
3014.02
Mts
82.41
164.83
309.64
824.15
1318.57
1429.57
2472.22
3296.17
Yds
Figure 17. Beam Diameter at a Given Distance
2.6 “OVER TEMPERATURE”
T e Megaray’s lamp generates ig operational temperature levels as do a large number of ig
- power electronic components. W en t e unit is switc ed on t ere is a rapid build-up of eat. If
t is eat is not dissipated t e unit will automatically switc off until it cools off w ereupon t e
operation can t en be restarted.
2.6.1 Temperature Control
T e Megaray is equipped wit two eat sinks and an electric fan to maintain critical temperature
levels. T ere are also two eat sensors t at automatically switc t e unit off s ould t e
temperature rise above a predetermined level. T e sensors monitor t e temperatures of t e
xenon lamp and t e bottom eat sink.
Operating t e lig t from an external 12V source causes ig er temperature levels
t an at 24V (or ig er).
2.6.2 Over Temperature Trip
Alt oug t e lamp is forced air cooled by an electric fan assembly, ig ambient temperatures
may cause t e unit to trip w en using ig beam continuously. If t e unit switc es off because
of over eating it resets itself and is operable as soon as it as cooled down. W en t e unit trips
an LED on t e label marked “TEMP” situated alongside t e “POWER ON”, will illuminate and
t e lamp will switc off. Care must be taken not to obstruct air movement over air vents and eat
sinks.

18
2.7 TRIPOD MOUNTING
Megaray can be mounted on any standard p otograp ic Gorilla tripod (Figure 18).
Figure 18. Threaded Hole in the Heat Sink
Any standard ¼ inc tripod screw fits into t e t readed ole at t e bottom of t e Megaray. T e
ole is situated on t e bottom eat sink directly in front of t e cooling fins (Figure 18).

19
CHAPTER 3
OPTIONAL ACCESSORIES
3.1 OPTIONAL ACCESSORIES
T e Megaray system offers t e following optional accessories (Figure 19) to be used wit t e
Megaray standard kit (Figure 2).
Item Part Number
Picture Descri tion
1 MIR - 103 Covert IR filter
2 MIR - 102
Semi covert IR filter
3 CSL - 074 Clear spreading lens
4 EMC - 031
External power cable
5 MRT - B 0
Tripod wit ball ead
6 NVD - 804
Nig t Vision Device
7 HCC - 001
Hard carry case wit
custom insert (SVA60foam)
Figure 19. O tional Accessories