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Contents
1. Turn ON Procedure Two terms that you need to understand When it comes to the power button you can either CLICK it or PRESS it The only difference cic PRESS between the two is the time that the button is held down lt 0 3 gt 0 3 sec sec The first thing that you ll notice is that if you simply connect power and click the button nothing will happen Don t worry This is because of the safety turn on feature called Superlock ship the lights with Superlock enabled but you can disable it as long as you re OK with the possibility of a single click turning the light on procedure available on web site The light can be turned on into 2 different modes STEADY mode and FLASH mode but take note that you must START with the LIGHT OFF to enter either of these modes There is no method for switching between STEADY mode and FLASH mode without first turning the light OFF So with Superlock enabled shipping default the two turn on possibilities are as follows lt 03 lt 03 lt 03 lt 03 lt 03 gt 03 gt sec 4 gt sec lt gt sec gt sec lt gt sec s lt sec gt OFF Click Click Click Steady Mode ON at Last OFF Click Click PRESS Flesh Mode ON at Used Power Level Last Used Selection lt 0 3 lt 0 3 lt 0 3 lt 0 3 sec sec gt sec gt sec In practice when performing the turn on into flash mode sequence it s best just to hold down the button on that last PR2. 1 min dace Flashing 1 pulse per sec Apie perset Flashing 1 pulse per sec 2 short OFF blips every 20 Same as above only with a double seconds until 1 minute warning pulse FF bli 2 Flashing double pulse per 3 short O b ips every 20 Sane as above on wiih a tiple pise sec until cutoff seconds until cutoff Main LED will pulse 10 times Main LED will pulse 10 times Main LED will pulse 10 times then shut then shut down then shut down down To gain a full understanding of the battery status reporting take a look at the battery discharge curve below This was taken with a DS 500 taillight running at steady L5 with a Magicshine MJ 6038 4400mAH battery The shape of this curve is typical for lithium ion with the steepest rolloff occurring at the full discharge levels Note that the Medium Low and Cut off threshold voltage levels are all adjustable as needed The values shown here are the default values loaded into the Build 4 and later firmware Although subtle there will always be some voltage loss in the cable between the battery and light Higher current and longer cables will increase this effect Practically this means that when running at much lower power levels with lower current the points on the horizontal time axis red dotted lines will move slightly to the right on a percentage basis With the headlight on L5 drawing more current they will move slightly to the left again on a percentage basis This plot is intended primarily
3. bike the proper orientation is for the ridges of the lens to run vertically Colored Filter Use and Lens Cover Removal The colored headlight filters were designed with daytime use in mind and can be installed simply by removing the center screw and adding the filter to the front face of the light Tighten to the same tightness as without the filter The lens cover should stay on and does not need to be removed when adding or removing the color filter If swapping or replacing LED lenses becomes necessary for any reason you should follow the general procedure outlined below to remove the lens cover This should only be done in a clean relatively dust free environment You want to avoid touching the domes of the LEDs as well as being careful not to get silicon grease on the lenses themselves 4 After the lens cover is off of the oring slowly lift it straight off green arrow being careful not to pull the lenses out with it There is silicon grease around the oring and bottom edge of the cover so be careful not to get it on the lenses 3 Pull top edge slightly in direction of black arrow while firmly holding the bottom in place with your thumb at the RED X In essence you re rotating the cover to pop it off the oring 1 First remove center screw 2 Grasp lens cover with thumb at bottom and fingers at top 5 Tore install make sure the lenses are properly seated in their alignment holes and set the cover straig
4. do not expose the battery to excessive heat All charging and storage environments should be near room temperature for best performance 8 DO take care not to drop the battery onto hard surfaces They contain an immense amount of energy in a very small package At any sign of trauma or damage to the battery you should immediately discontinue use dispose of safely and replace with a new pack Warranty These lights are tough really tough and should provide you with years of trouble free service due to the extreme level of over engineering If anything breaks in the first year just send it back for repair All you need to do is pay the postage to ship it to me Accidents do happen though so even if you do manage to damage the plastic bits or the power cable several years down the road can replace these things for you a minimal cost Just email me first at DesignShineLighting gqmail com All mail correspondence should go to 137 Holbrook Drive Huntsville AL 35806 Since I m only a pass through battery provider can only help with battery issues to the extent that they are covered by the Original supplier DS User s Manual Build 4 and Up
5. fine When you received your light you may have also received a spare wired power connector This is for your future use if you ever find that you need to adapt a generic battery to the proper power connector In most cases for stand alone taillight or single battery dual light use battery mounting will consist of stowing the battery in a saddle bag However in the for solo headlight use many batteries use a Velcro or otherwise strap system to secure the battery to the underside of the stem or a section of tubing as shown below When mounting the battery under the stem be sure to prevent any binding or rubbing of the battery on any portion of the non rotating steerer tube When using a strap its important to get as much cinching force on the battery as possible for a secure mount In general you will want to position the D ring of the strap on the TOP of the tube so that you can very tightly cinch the strap by pulling down before making the Velcro connection If your strap has a slight bit of stretch to it you should pull it tightly enough to begin to feel this slight stretch before you cinch it down AQ Ban E Typical Stand Alone Headlight Battery Mounting Locations Battery Charging and Maintenence Lithium ion battery charging and care are relatively simple and require that only a few good habits be established for maximum life regardless of the brand of the battery 1 Always charge the battery in a
6. here goes with the official disclaimers please do take the time to read them all or my wife is going to make me call a lawyer Most of these fall into the common sense category but had to state them See website for full disclaimer 1 Never under any circumstances look directly at the lights from close range while in your hand or point the lights directly at anyone s eyes at close range 2 Never shine the light directly on your skin from close range 1 8 inch or less It CAN burn you if you leave it there too long 3 Never use level 4 or 5 on the taillight at night and it is highly recommended that you run the taillight in steady mode at night or appropriate flash mode When using level 5 on the headlight at night please be comfortable enough with the operation of the light to be able to dim quickly to level 3 or lower for oncoming cars 4 Never turn the lights on and leave un attended If the heat sink fins were partially blocked overheating and damage is a possibility with long periods of operation with no airflow 5 Never turn the lights on and leave in contact with flammable materials 6 If at any time you find the light has become too hot to touch and or to press and hold the button to turn off simply disconnect the battery wire normally this should not happen 7 NEVER under any circumstance leave the battery pack in an un attended car that is going to be left in the sun for any length of time In other words
7. if the battery and light are running in sub freezing temps run times are going to be lower by some percentage margin Your mileage may vary on this one For the purposes of these run time calculations there is an assumption of room temperature Please note that these numbers represent good engineering estimates but there may be some need to tweak up or down depending on a particular battery pack and or the relative age of the pack The tables below combine empirical test data with the known electrical characteristics of the light to arrive at a best estimate for the run times at the various power levels and flash modes Flash mode 4 is a special condition for the taillight Although borderline acceptable for nighttime use the out the back battery indication system will momentarily set the light to steady level 5 for 3 seconds at 20 second intervals during the medium and low battery periods Since the out the back indication is enabled by default for the taillight this could result in an un intentional and dangerous blasting of level 5 at night Color Legend Good nightime use Power Level Lumens Daytime ONLY dangerous at night Steady Flashing Steady Flashing w 111 110 0 S 1400 A sg 179 228 prey 378 ttt o o da o 520 70 88 Forbatteries of different capacities 78 35 45 multiply run time values results at Flash mode 1 Level 5 on off 11 7 149 4400mAH by
8. to instruct you on the status indication system but it also illustrates the somewhat inexact science of determining run times It should also be noted that even after the light has shut off automatically you will normally be able to turn it on several more times for 1 minute intervals as a last ditch method for getting out of the woods until the battery itself hits its internal protection limit This option should NOT be used with any unprotected battery packs Magicshine MJ 6038 4400mAH Battery Voltage Voltage drop due to pack s internal resistance 50 to 20 zone Constant ON status LED 20 to 1 min warning 100 to 50 zone No Out the front back indication occurs once 1Hz status LED blink status LED illumination or every 20 seconds new for build 4 Build3 Continuous out the out the front back shown here and earlier would time out f front back indication indication after 5 cycles a every 20 seconds Medium warn threshold 7 1V Low warn threshold 6 7V Cut off threshold 6 2 Battery Voltage at Steady L5 Run Time Hours DS User s Manual Build 4 and Up Run Times Now that you ve seen some of the Logic behind the battery status indication system let s take a look at how to determine overall run times Run times are primarily dependent to two factors total power consumption and battery capacity Toa lesser degree run times can be dependent on temperature In general
9. understanding of the limits of operation try this experiment With the lights indoors and sitting on a hard surface or mounted on the bicycle turn the lightt on steady at level 5 high Watch and periodically feel the light until you see the light level automatically drop down to a lower level somewhere between 4 and 6 minutes later At this point carefully and momentarily touch the case of the light at various places It will be very hot in fact slightly painful if you were to hold it for an extended amount of time but not quite hot enough to burn you Make a mental note of how this feels This should be the hottest that the headlight ever gets and the temperature trip point has been chosen to provide the optimum usability level on the bike so that momentary stops on the bike do not have time to trip the thermal protection circuit In fact even a mild breeze will generally allow sustained Level 5 operation Colored Lenses The colored lens covers should be handled carefully and do avoid wiping it if dry to avoid scratching Unlike the clear lens cover which is made from high temperature polycarbonate the colored lenses are Acrylic and not as tolerant to high temperatures As such it is recommended that you only use the colored lenses in flashing modes and preferably only outdoors to avoid any excess heat damage to the clarity of the filter This is very unlikely but worth mentioning As you know these lights are EXTREMELY powerful so
10. view in bright sun This method will always be active Method number two is referred to as out the front back indication In this case the main LEDs will be used to tap out a simple message similar to Morse code from which you can determine the battery status Note that when either light is first turned on you should see a short flash of the on board LED to indicate the health of the controller By default the headlight comes with the out the front indication disabled and the taillight has the out the back indication enabled However just like with every other aspect of the controller these settings can be changed to suite your preference And speaking of making changes to the controller there are two good resources to help you get started with this First you should visit the DesignShine Forums site and read the 5i entry to the All things Batteries thread Here you will find a direct link to download the Reprogramming Instructions PDF file http www designshinelighting com showthread php 96 Secondly you can always find THIS manual and the full up user s manual for the controller board at https sites qgoogle com site designshinelighting user manuals DS User s Manual Build 4 and Up The following table is intended to show you the behavior of the lights battery status indication system for every possible combination of operation mode and approximate battery discharge level Although I ve programm
11. vision but not too intense when looked at directly Nice simple but bold pattern for nighttime taillight L1 L2 Toggle Evenly spaced 500ms duration toggling Use this if you find yourself running low on battery between level 1 and level 2 and you need to extend your run time or even better switch to L1 steady While in Flash Mode switching from one mode to the next is a cyclical operation simply we requiring a CLICK between modes see right You may notice about 1 second of delay when i yer 1 n switching between modes 3 and 4 where the light remains off This is completely normal You pa 7 Flash may also notice on occasion that the light will ignore your CLICK request to switch modes This 6 Clickto 3 is likely just a small timing issue and totally normal Note when you re in flash mode and press j wwitchto j and hold to turn the light off it will remember the particular mode number and come on in that aa i mode the next time you power up in flash mode 5 l node Determining Battery Status ao m a The head and taillights use the exact same battery monitoring circuitry and logic However there are multiple methods with which you can determine the approximate charge level of the battery The first method is with an LED mounted internally on the circuit board which will be visible through the small oval viewing window in the case lid immediately next to the power button you may need to shade slightly to
12. ESS until you see flashing begin Note also that with Superlock disabled you would simply remove the first 2 clicks from both sequences Turn OFF Procedure To turn off simply press and hold until the light turns off The behavior will be slightly different depending on which mode you were in steady or flashing If in steady mode the light cycles down to the lowest power level then you ll see a flash indicating that you ve reached L1 followed by a 2 second safety delay and power down If in flashing mode you just simply keep holding the button you may see some odd flashing until the light turns off This will take between 2 and 3 seconds Steady Mode Options Taillight Within steady mode for the taillight you have 5 discrete power level steps These may be referred to throughout the manual as Level 1 L1 Level 2 L2 etc To move UP by one power level you CLICK and to move down by one power level you PRESS Once you re at L1 a subsequent PRESS will cause the light to flash alerting you to the fact that you ve reached the lowest power level Similarly once at L5 a CLICK will cause the light to flash indicating you re already at L5 You may notice that the jump in the light level between L1 and L2 is fairly strong This is because L1 is designated as limp home mode drawing only a minimal amount of current for the longest possible run times L1 is also a very good option for nighttime taillight use Headlig ht TIP A
13. at were developed specifically for either the head or tail The first three in yellow should be reserved for daytime only where as the last three grey are generally appropriate for night DesignShine Build 4 and up Flash Patterns ate ase ae Best Application Lsonorr impe on off flash roughly 3 per second at Daytime ONLY either light Best for solo riding 1 lsoworr ON OFF i the highest power level Slightly longer run times than EMS mode Modeled after Emergency Medical Service When you need the highest level of recognition this L5 EMS lights High intensity rapid 11Hz 4 burst is it Absolutely daytime ONLY flash with 400ms delay between bursts EXTREMELY dangerous at night Simple on off flash roughly 3 per second at Daytime ONLY either light A little more polite L3 ON OFF NF i level 3 for group riding or for daytime battery conservation Designed for the headlight for nighttime Short L5 L3 L5 Solid level 3 operation with 40ms burst to urst givesa nice eye catching flash but not long Lightening level 5 You ll find yourself wondering was n0ugh to be blinding Very ridable at night since Strike that lightening it s not overly stroby NOT RECOMMEND FOR TAILLIGHT USE AT NIGHT Designed for the taillight for nightime The triple L1 L2 Triple Solid level 1 operation with 120ms Triple pulse is very effective from dusk to dark at catching Pulse pulse to level 3 attention in peripheral
14. ed the lights with reasonably good VOLTAGE detection levels for the 50 and 20 discharge levels there will be some variation perhaps significant from one battery manufacturer to the next and between fresh vs old batteries This is where the FLEX in the DSFlex controller can be very handy If you find after running your light through a few discharge cycles that you d like to have a little more or less warning time for either the 50 or 20 levels then the voltage thresholds can be easily be changed Note that even a change of 0 1V in the threshold levels can make a big difference in the warning times so recommend making no more than a 0 1V change at atime also recommend NOT changing the default cutoff threshold value Full instructions for how to adjust the warning times can be found again at http www designshinelighting com showthread php 96 Battery Internal Status LED Optional Out the Front Back Main LED Indication meve always active Tail enabled by default Head disabled One short status LED blip to indicate controller heath 100 to 50 No Status LED Illumination Normal Operation Normal Operation Flash rn n ntaril 1 short OFF blip with 20 es PARON SAS pe naea mome mary with steady burn at the current high seconds between blips This i 50 to 20 power level for 3 seconds with a single warning cycle will continue until pulse to the current low level after 1 5 discharge reaches 20 seconds l h l 20 t0
15. he ratio ESMEE Tae ss umera e 77 EAM Level 1 2 triple pulse 34 0 43 3 EIMA Level 1 2togge 266 338 NOTE Maximum headlight output will be limited to Level 4 in any EE during the LOW battery warning period DS User s Manual Build 4 and Up E d B2 S22 Mounting Options Mounting of the lights is very straight forward but it s important to always make sure that your mount is secure and that the attach point is strong enough to handle the repetitive shock loads due to the mounted weight of the light Each light with the extension bar weighs in at roughly 120 grams Specifications of the mounting hardware are shown below 6 32 5 64 Nylon headlight only Alternate mounting holes for offset options patch locking hold down screw Cateye H 27 spacer aka quick release 8 32 5 64 Set screw for locking position of light DS Extender Bar Mounting System From the diagram above you can see that there are two screws that are used to hold the light firmly to the extension bar Without exception when setting the angle of the light you should adhere to the following sequence 1 2 3 4 Check that the set screw is unscrewed slightly and NOT contacting the housing Using the provided 5 64 Allan wrench set the angle of the light and fully tighten the hold down screw if there is not already some friction Lock the angle by lightly tightening the set screw D
16. ht down over the lens and onto the oring Push straight down evenly at the black dotted arrows to fully seat then re install screw with adequate tightness Lens Cover Removal Process DS User s Manual Build 4 and Up E d 2 f The cover is able to be removed and re installed many times without the need for additional silicon grease But if it becomes obvious that a good seal is not being made between the lens cover and o ring the silicon grease can be obtained very inexpensively in the plumbing section of Home Depot or similar stores A small hobby paint brush would then be used to LIGHTLY brush a coat of grease around the sealing surface of the clear lens cover Although unlikely but if sealing ever becomes a problem for the small white o rings that seal against the lenses themselves then a VERY light film of this grease could also be used at that junction would recommend cutting off the head of Q tip and just using the edge of the paper stick with an extremely small amount of grease to perform this operation if ever necessary Battery Mounting All build 4 and up lights will be configured for 7 4V li ion pack use in order to take advantage of the many off the shelf options that are available for powering these lights When it comes time to replace the battery a good source compatible batteries is Action LED lights com In general any 7 4V battery with the Magicshine style 2 1mm power connector will work just
17. inal spacers along with the additional included thick spring rubber spacer The figures below also show the recommend orientation of the H32 clamp on the left seat stay Pay particular attention to the preferred orientation of the camlock handle In general after your first few rides with the light just double check to insure that your mounts are staying exactly where you set them and if not you may need to put another turn on the cam lock handle You MUST find the right combination of spacer material such that the camlock screw does not protrude too high into the light mounting area as illustrated below Left Camlock lever to the left is best Max Height OK 7 Te F TM Too high will damage spacer i oy For the headlight either the H32 or H31 may be used depending on the diameter of the bars at the mount point It s recommended to mount as close to the stem as possible In fact with the current design you may choose to use one of the offset mounting holes on the underside of the mount see previous page to move the light body closer to centerline of the stem Note that either light can be mounted to EITHER side of the extension bar as required by your particular application Simply 1 remove the hold down screw 2 remove and re install the set screw from the other side of the extender bar then 3 re attach the light to the opposite side of the bar This allows for even more flexibility in various mounting si
18. lthough the diagram shows the turn The steady mode operation for the headlight varies Process entering L2 it will actually turn slightly from the taillight and has been optimized for 0 the last used power level Click easy dimming for oncoming vehicles riders The i light has been configured to use power levels 2 3 lt lt See tum on gt gt 5 C_Click gt gt 3 15 and 5 in a low medium high arrangement The OFF low Szcz med high diagram to the right shows the complete sequence _ A of operating events for the headlight in steady mode In practice for nighttime use youll simply be clicking back and forth between L3 and L5 as necessary Lightening Flash mode 4 see next Press page is also a very good nighttime headlight option nee For general road use with traffic or anytime there are oncoming vehicles at night you should use L3 or lower as the primary headlight power level to avoid blinding oncoming drivers DS User s Manual Build 4 and Up Flash Mode Options Although the new version of the firmware for these lights will allow any of the 6 flash pattern placeholders to be completely customized refer to the most recent DSFlex Manual for details the factory default patterns have been customized for DesignShine and are shown below Flash modes operate identically between the headlight and taillight however there a couple of patterns th
19. ming angles The quick release also facilitates easy removal for commuters There are two basic clamps as shown to the right Both clamps incorporate several degrees of left right aiming capability Because the taillight will often be mounted on a vertically oriented tube you should in this case relieve the clamp of its free movement by rotating the clamp base into its most downward position before setting the angle of the light body In other words after you mount the light you should push down on the light body until the clamp movement stops Re adjust the angle of the light body with the set screw at this point if necessary in order to achieve the optimal aiming angle H31 oversize clamp 28 to 32 mm When aiming the lights lve found that straight back parallel to the ground is optimum for the taillight and the headlight should be angled down very slightly so that the front edge of the spot beam is around 15 16 feet in front of the wheel There is definitely an optimum aiming angle for the headlight which may take a bit of experimentation to find Thankfully once the angle of the camp is set properly it will never move accidentally during vibration H32 standard clamp 10mm up to 28mm In practice I ve found that the H32 works fine on 27 2mm seat posts by removing both of the thin spacer pieces For seat stay applications similar to below you may need to use some combination of the orig
20. o NOT over tighten Only a small amount of tightening is required When removing the screws just the opposite is required If you try to loosen the hold down screw before loosening the set screw you may find that it s almost impossible and you may damage the head of the screw The hold down screw has a nylon patch on the threads which makes it grab tightly by design If the screw is removed and re inserted multiple times the locking nylon function will eventually diminish This is OK In practice once the set screw is tightened the extension bar acts like a spring and puts binding forces on both screws to prevent any accidental loosening Although the H 27 spacer can be removed recommend leaving it on the extender bar If helmet mounting is desired without the extender bar a separate H 27 spacer should be obtained that can be mounted directly to the light body in place of the extender bar Note that the small Philips screw not shown on the opposite side of the bar acts as an anti rotation pin for the H 27 and is actually threaded into the aluminum bar This screw should never be over tightened in order to avoid stripping these threads DS User s Manual Build 4 and Up E d 2 A 3 AA LCE Pid A Satel The basic mounting philosophy for the lights is to permanently attach the appropriate clamp s to the bikes that will be using the lights This way you can easily swap the lights between bikes without having to reset the ai
21. room temperature environment Be especially cautious to NEVER charge the battery below freezing 2 Plug in the charger first green light will come on then plug in the battery If the battery is depleted low enough the light will turn red and stay red until charging is complete If the battery is nearly full then the light may remain green when the battery is plugged in 3 Remove the battery from the charger as soon as reasonably possible after the charge cycle is complete 4 If you plan to store the battery unused for more than a month it is recommended to first drain the battery to HALF CHARGE Storing a battery with a full charge will quickly diminish its capacity Li ion cells in general have a life span independent of the number of charge cycles So even if the pack is not used its life expectancy is still only 2 to 3 years which is typical for the li ion chemistry 5 Charging an empty 4400maH pack will take anywhere from 5 to 7 hours with a low cost automatic 1 amp charger More or less time will be required for higher or lower capacity packs respectively DS User s Manual Build 4 and Up Safety Precautions and Warranty Heating These lights have very robust heat management characteristics designed to prevent any damage to YOU or to the LEDs and electronics But still you should exercise extreme care when operating the light in a no air flow environment Definitely KEEP OUT OF REACH OF CHILDREN To increase your own
22. the ratio Flash mode 2 Level 5 EMS on off 10 9 13 9 desired pack capacity in maH 4400 Flash mode 3 Level 3 on off 37 3 475 Flash mode 4 Level 3 5 Lightening 10 9 139 AEAMULLERA Level 1 2 triple pulse 83 7 106 5 EAMA Level 1 2toggle 639 814 A similar headlight runtime analysis was performed and the results are shown below Take note of the recommended times of day for the given power levels and flash modes Ultimately you need to use good judgment when you set the light so that you re not at risk of blinding or dis orienting the drivers around you During dusk dawn and nighttime hours you should avoid levels 4 and 5 completely and in general in low light settings flash modes 4 through 6 are preferable since they all use a pulse ON technique to avoid the dis orienting effect of on off flashing at night The steady power cycle operation of the headlight page 1 is setup specifically to allow easy dimming for on coming traffic with a single click if you find that you prefer riding at night on level 5 Color Legend Good nightime use Power Level Lumens Daytime ONLY dangerous at night r 2 Flashina Steady Flashing 1 7 A z 92 a7 3 655 6z 79 908 40o 50 1402 20 25 For batteries of different capacities Flash mode 1 Level 5 on off 67 85 multiply run time values results at flash mode 2 Level EMS orot 62l 79 4400mMAH by t
23. tuations DS User s Manual Build 4 and Up E d B2 G22 Additional Instructions for H31 Mount Vibration Damping Due to a very subtle change in the mold between the H32 which is very solid and the H31 there is a small amount of undesirable vertical rocking movement possible with the headlight on the extension bar not an issue with taillight use If this becomes a problem while riding even with the H32 a small piece of rubber tubing standard vacuum line hose can be wedged into the hole of the H31 clamp to form a damper and effectively mitigate this issue Other similar materials could be used If you received an H31 clamp for use with a headlight a small rubber tube has already been put in place to illustrate how it should be used see below You want to push the rubber tube as far down on the threaded stud as possible and still have at least 1 2 sticking up H31 Mount with Optional Vibration Damping Tube Installed Horizontal vs Vertical Taillight Operation Although the light will ship setup for vertical operation the new removable lens cover will allow you to reorient the elliptical lens for optimum performance from either mounting orientation If you have a need for both orientations with the same light it is highly recommended that you pick the orientation that will be used MOST often rather than continually removing the lens cover and swapping lenses When viewing the elliptical lens from the rear of the
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