This is my Mag2D LuxIII nFlex mod with 8 brightness levels. Maximum brightness level reconfigured for 1000mA.
Pewter Mag2D, LuxIII TX1J emitter, blue glow ring, O-Sink, nFlex converter, UCL lens, smooth reflector, using 3xCR123 or 6AA NiMH batteries.
The bulb shaft has been cut 3mm above the base of the shaft. Then the switch was modded to a momentary pushbutton switch (off-on) and connected via the yellow wires to SWA and SWB of the nFlex. The little spring at the bottom of the switch (+ battery) was isolated from the original switch contacts and connected to the IN+ of the converter using the red wire. The black wire is going straight from the small metal strip that makes contact with the flashlight body (- battery) to the IN- of the converter. Finally two small slots were cut in the remaining part of the bulb shaft at the top of the switch. The converter board was placed upright in the slots and glued in place.
The nFlex converter is a high efficiency microcontroller based step down converter. A single momentary push button switch is used to turn the flashlight on/off and to select the brightness level. The nFlex is shipped configured for 350mA maximum drive level but can be reconfigured to 500mA, 700mA or 1000mA. There are 7 equally spaced brightness levels in addition to the nightlight level.
The nFlex is reverse polarity protected by a schottky diode in series with the IN+. Since I don't need polarity protection in this application I soldered a wire across the schottky diode to get some more time in regulation.
You can read more about the nFlex converter here and here .
To modify the switch to a momentary push button the switch was disassembled and the teeth at the outside of part A and B were removed. It has to be mentioned that in fact only the teeth of part B have to be removed to change the stock clicky in a momentary push button switch. After removing the teeth both parts were glued together.
This is my 6AA battery holder. It's based on the 6AA holder sold by Elektolumens.
Beamshots from nightlight level to maximum brightness. Distance from the flashlight to the wall was 2m.
Lux reading at 1m using a Meterman LM631 at different brightness levels (input voltage = 7.2V):
Smooth reflector (level 1-8): 500 Lux, 1.100 Lux, 2.180 Lux, 3.490 Lux, 4.920 Lux, 6.560 Lux, 8.500 Lux, 10.550 Lux.
OP reflector (level 1-8): 320 Lux, 710 Lux, 1.390 Lux, 2.230 Lux, 3.140 Lux, 4.190 Lux, 5.410 Lux, 6.700 Lux.
Brightness at level 8 started dropping when Vin < 6.2V.
Vin=6.0V =>10.500 Lux; 5.4V => 9.940 Lux; 4.8V => 9.670 Lux.
The nFlex shuts off at 3.6V
Thanks to George for this very nice converter!!! /ubbthreads/images/graemlins/thumbsup.gif
Thanks for looking.
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