 We
like all kinds of flashlights, but we have some definite ideas about how
good ones should work:
 The
NewBeam's electronics maintain a constant current through the LEDs so
that the flashlight's brightness is steady even while the batteries' voltage
declines. Most other LED flashlights just let the brightness follow the
batteries' voltage down. That gives a nice bright light when the batteries
are fresh, but then a very long period of gradually diminishing light.
To use up all of the energy in the batteries, you spend a lot of time
with a dim light! We think that the light should be constant for as much
of the batteries' useful life as possible.
 Of
course, eventually the batteries will become too weak to maintain this
constant brightness. When this happens, you don't want to be left in the
dark. With weak batteries, the NewBeam will revert to a "reserve"
mode of operation. The brightness will gradually diminish, as the batteries
are allowed to supply whatever they can.
We
think that the red low battery indicator is one of the NewBeam's best
features. Our first prototypes didn't have it, and we soon noticed that
you can't tell when the batteries are going dead! The color of the LED
light doesn't change, and the gradual decline in brightness is difficult
to judge. Although the NewBeam will continue to give many hours of useful
light after the red indicator comes on, you will know that you have used
most of the energy in the batteries and that it is time to change them.
These installation instructions are also included with the product. Note:
installation of the NewBeam LED module will void the Mag Instrument warranty
on your Mini Maglite® flashlight. Please follow these instructions
carefully.
CHECK FOR COMPATIBILITY
The NewBeam LED module is intended for use only with current models of
Mag Instrument's Mini Maglite® 2-cell AA flashlight.
1. Unscrew flashlight head until it comes off. The bulb will be lit. Do
not remove batteries.
2. Remove the bulb by gently pulling it out with your fingers.
3. If the black plastic piece from which you removed the bulb has two
holes beside the holes where the bulb came out, you have an older flashlight.
To use the NewBeam LED module, you need to purchase a new Mini Maglite®
flashlight.
REPLACE
THE REFLECTOR AND LENS
4. At front of flashlight head, unscrew metal ring.
5. Remove shiny reflector and replace it with adapter sleeve from the
kit.
6. If lens is scratched, replace it with the new lens from the kit. The
o-ring should stay in front of the lens.
7. Screw metal ring back on.
INSTALL THE CONVERSION MODULE
Make sure the batteries are in the flashlight.
The batteries keep the switch from falling into the flashlight barrel.
8. In the flashlight barrel, remove and discard the plastic piece marked
"DO NOT REMOVE," using your fingernails or a knife to pry it
out.
9. Install the NewBeam LED module by inserting its two round pegs into
the holes where the pegs of the "DO NOT REMOVE" piece came out.
Be very careful to push the module straight into place; don't try to force
it at an angle.
10. If the module did not light, try again with the pegs in the opposite
holes. It will light when you get it right.
11. Screw flashlight head firmly back into place, so that the light goes
off.
12. To fully seat the NewBeam LED module, tap the front of the flashlight
against a firm surface.
FREQUENTLY ASKED QUESTIONS:
Q: What kind of LEDs are used in the NewBeam? What is the intensity
rating?
A: We use Nichia LEDs of the highest intensity category (“rank”)
available. Because of their production variation, Nichia cannot guarantee
availability of their highest rank LEDs, so neither can we, however to
date, all NewBeam modules sold have used Nichia’s rank “S”
LEDs, and we expect that this will continue to be true. The intensity
rating of these LEDs is 9,200 mcd typical (7,800 mcd minimum, 11,000 mcd
maximum), at an LED current of 20 mA. Since the NewBeam drives the LEDs
at 30 mA, the typical NewBeam intensity will be approximately 3 x 30/20
x 9,200 = 41,000 mcd = 41 cd.
Q: What is the
NewBeam LED current, and does it the overdrive the LEDs?
A: The NewBeam model presently available drives the LEDs at a constant
nominal current of 30 mA. This is Nichia's maximum rating for the LEDs,
so they are not being overdriven. Models with different LED current (brightness)
may be offered in the future.
Q: Can I use my
NewBeam converted flashlight with rechargeable batteries?
A: Certainly! Actually, the NewBeam works better with NiCd or NiMH batteries
than the stock flashlight because it will produce full brightness with
the lower voltage of these batteries while the incandescent bulb tends
to run a bit dim and yellow. Note that NiCd and NiMH batteries will self
discharge more quickly than alkaline batteries, so they are not a good
choice for flashlights which are used infrequently. Also, NiCd and NiMH
batteries tend to have a very steep end of discharge curve compared to
alkalines. That is, when they run out of energy, they do so very quickly.
So the remaining burn time after the NewBeam battery indicator comes on
will be less with NiCd and NiMH batteries. However, if you use the flashlight
a lot and go through a lot of batteries, the rechargeables will work well
for you.
Q: Can the NewBeam
be used with lithium batteries? Will that make it brighter?
A: The NewBeam can be used with 1.5 Volt lithium batteries (Energizer
91, etc) since these have the same voltage as regular alkalines. The long
storage life and high capacity of these makes them attractive for emergency
light use, caving, etc. The brightness will be the same as with alkaline
batteries. We do not recommend the use of higher voltage lithium batteries
(see NewBeam voltage range FAQ below).
Q: I want to use
the NewBeam with a higher voltage battery. What is the operating voltage
range of the NewBeam?
A: There are a few points to make on this:
*The NewBeam is designed and intended only for use in 2 AA Mini Maglite
flashlights with 1.5 Volt batteries. We realize that some people use the
NewBeam module in creative ways. Please realize that you are on your own
as Opalec does not offer warranty or application support for these uses.
*With higher battery
voltages, the red battery indicator LED (2.0 Volts), and reserve function
(1.8 Volts) will not be very useful.
*Higher voltage battery
strings can experience reversed cells, which may damage some batteries
and create leakage. This isn’t likely to happen with 2 x 1.5 Volt
cells, since the NewBeam will not discharge the batteries below 1.8 Volts,
but it is possible with more and/or higher voltage cells.
Q: At what voltage
does the NewBeam's red indicator LED come on?
A: The indicator comes on when the battery voltage drops below 2.0 Volts.
The brightness remains regulated down to 1.8 volts.
Q: Will putting
the batteries in backwards damage the NewBeam?
A: No, reverse polarity will not damage the NewBeam or discharge the batteries.
Q: Why won't the
NewBeam work in older Mini Maglite® flashlights?
A: Mag Instrument changed the plastic parts of the Mini Maglite® flashlight
switch a few years ago. The older design used curved plastic projections
to hold the front plastic part into the switch. Then they changed to a
design which uses two round plastic pegs. We had to choose one, and of
course we chose the new one. The NewBeam may function in older Mini Maglite®
flashlights, but it is not held in place well and is not recommended.
Q: Can I remove
the NewBeam and convert the Mini Maglite® flashlight back to the incandescent
lamp?
A: We don't think you'll want to, but yes, you can. You'll need to save
the plastic piece (marked "do not remove"), and the reflector,
which the installation instructions ask you to remove, so that you can
put them back in. Other than that, just follow the instructions in reverse.
Q: Is there anything
special about the replacement lens included with the NewBeam kit? Do I
need to use it?
A: The lens is of good quality, abrasion-resistant plastic similar to
that provided with a new Mini Maglite® flashlight. It is provided
so that if you are putting the NewBeam into a well-used flashlight with
a scratched-up lens, you can change it and have sparkling new optics.
There is no need to replace the lens unless the old one is scratched.
Save it for later.
Q: Why can't I
focus the Mini Maglite® flashlight with the NewBeam installed?
A: The stock Mini Maglite® flashlight uses a tiny point source bulb
and focuses by moving it up and down within a parabolic reflector. The
LEDs used in the NewBeam focus the light by the shape of their plastic
lenses. The beam pattern and focus of the light cannot easily be changed.
The reflector won't do it (and must be removed for the NewBeam to fit,
anyway).
Q: Will installing
the NewBeam void the warranty on my Mini Maglite® flashlight?
A: Yes. Mag Instrument discourages taking apart the switch of the flashlight
yourself. They state that this operation is best performed by their service
department, and they do not sell the switch as a service item. Part of
the switch is removed to install the NewBeam, and this constitutes an
"alteration," which voids the Mag Instrument warranty.
Q: Does Opalec
make the NewBeam in other colors?
A: Not yet, but we probably will. We have played with prototypes in several
other colors, including a blue version for theatrical stage use, and a
low intensity blue/green version for aviation vision use. Please email
us if you are interested in this.
Q: My NewBeam flickers
and the red LED comes on. I’ve tried new batteries and that doesn’t
help.
A: This is usually caused by a poor contact somewhere in the flashlight.
If you have another known good flashlight, you can check that the NewBeam
is okay by moving it to that one. Here are some flashlight troubleshooting
tips:
*Check that the batteries
slide freely inside the battery tube, and that the spring in the end cap
is strong enough to push them into good contact with the switch in the
front of the flashlight. Sometimes corrosion from a previous battery leak
will form a high spot of inside the battery tube - look for this, and
if present, correct it.
*Gently polish the
tip of the spring with a soft cloth.
*If the threads of
the battery end cap are dirty, clean them, and also the threads inside
the battery tube with an old toothbrush and Scotchbrite.
*Check that the battery
ends are clean or clean them with Scotchbrite.
*A frequent location
of poor contact is inside the lip at the top of the flashlight tube, where
the switch makes contact. You can check for this by removing the flashlight
head and rotating the NewBeam module a few turns. If this helps for awhile,
the problem is likely to be in the switch. Working on the switch is tricky,
but if you want to try, here is how. Remove the NewBeam module, remove
the battery end cap, and carefully slide the batteries out. The switch
will come out, too, a black cylindrical part with tiny metal contacts.
Be very careful not to lose or damage these contacts. With the switch
out, you can clean inside the lip – often just wiping with a Q tip
will do it, but sometimes a thick film of dirt and aluminum oxide builds
up, which must be removed. You can try some alcohol or if necessary escalate
to water and a mild abrasive cleanser on the Q tip or a small piece of
Scotchbite. Make sure that the inside of the tube is dry before you put
everything back together because moisture inside the flashlight will cause
the contact to degrade again. While you have the switch out, clean the
contacts, one at the front of the switch and one on the back. The front
one falls out, so be careful not to lose it! The contacts are plated,
so don’t be too vigorous with your cleaning, just polish them a bit
with a small piece of clean cloth. To reassemble, carefully slide the
switch back into the tube, check to make sure the tiny front contact is
still in place, then slide the batteries in and screw the end cap on.
Now you can replace the NewBeam module and screw the head back on the
flashlight.
The NewBeam LED module
is warranted to be free of defects in materials and workmanship for a
period of one year from date of purchase. Opalec will replace, free of
charge, any defective module under the terms of this warranty.
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