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Old 06-30-2013, 11:33 AM #1
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Question 1.5W Police Host Laser Repair

I bought one of the 1.5W Police Host lasers that BLord had up a while back. Sometime in December I was having some issues getting it to function properly (flickering, brownouts, etc), eventually when I tried to turn it on I got a puff of smoke...
At the time I set it aside, intending on asking someone here for advice, and promptly forgot about it

Well, I ran across it yesterday and decided to open it up and look through it. The first thing I found was that the wires connecting the driver and diode had twisted to the point of breakage (pretty certain that's my fault), but otherwise it looked fine at first. So I reconnected and shrink-wrapped the wires and lo and behold.... nothing.
Then I thought to open the switch/charger circuit sandwiched between the batteries and driver, and it was most definitely FRIED. The boards and connections were fine, but the wiring inside it was burnt through in three or four spots.
I plan on taking it over to a friends and soldering on some new wires today, but I thought I'd get some feedback first to make sure I don't fry something expensive.
On a related note, the surviving bits of wire inside were probably the smallest gauge I've lain eyes on.

tl;dr
Shiny laser make smoke signals, I find broken driver wires and well done circuit for side-clicky. I think can fix but want ask questions.

So far my thoughts are that:
(a). I twisted the driver leads to the point that they became exposed and shorted the circuit, resulting in the tiny wires in the switch overheating.
(b). The wires in the clicky circuit were too small to begin with and were slowly degrading the entire time until they shorted and went *poof*. The twisted wires could have happened when I was playing around trying to figure out wtf happened.
(c). I wasn't careful enough with the run time and the wires burnt out because they happened to be the weakest link and I should be grateful it wasn't something expensive.
or (d). Something is horribly wrong and when I put it back together it's going to make more interesting smells from shinier parts.

Any thoughts from the experts out there? Or just someone who sorta knows their stuff? I'm just trying to avoid burning it out again. Should I be fine with just adding some wire that's a bit thicker?

PS: Blord, if you read this, I LOVE this laser and I am in NO way complaining about your work.


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Old 06-30-2013, 12:54 PM #2
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Default Re: 1.5W Police Host Laser Repair

Firstly, some pics are always helpful.
Secondly, if you have the means, you could try directly driving the diode with a PSU to confirm it is still alive.
Many of these hosts force us to use twisted wires. It's unfortunate, but true. Heavier gauge wire is almost always a plus.
Based on your concise examination, it sounds to me like the switch is where your failure is. Praying to the diode gods is no more a waste than any other prayer...so, good luck.
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Old 06-30-2013, 02:09 PM #3
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Default Re: 1.5W Police Host Laser Repair

If you want repair I can fix it. It has been some time ago when I was working on these casing. Hopefully the details will come back to me when I have this laser in my hands again.

PM me if you want to repair by me. You pay only for the parts and shipping. Labor is free.
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Old 06-30-2013, 02:27 PM #4
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Default Re: 1.5W Police Host Laser Repair

Thanks for the advice SBA! Many prayers are being made
I'm pretty sure it's an easy fix, but my experience is somewhat minimal so I wanted to touch base with someone here.
I appreciate the offer Blord, if it gets too complicated I might have to take you up on that haha

Either way I'll update in a couple hours.
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Old 07-01-2013, 03:40 AM #5
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Default Re: 1.5W Police Host Laser Repair

GOT IT!!!!
I may have gone a bit overboard with the wire, I upgraded to 18 gauge haha, and there are a couple pieces that are slightly melted/burnt, BUT IT WORKS!
I didn't expect my first soldering project to go quite so well, or be that fun.
You guys have me hooked...
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Old 07-01-2013, 06:19 AM #6
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Default Re: 1.5W Police Host Laser Repair

glad it worked out for you
have fun and stay safe

Last edited by will manners; 07-01-2013 at 06:19 AM.
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Old 07-01-2013, 08:14 AM #7
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Default Re: 1.5W Police Host Laser Repair

I am glad it works out.

18AWG wires are too thick for the laser. Be careful next time when opening the laser you may torn the diode pins off.
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Old 07-01-2013, 05:11 PM #8
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Default Re: 1.5W Police Host Laser Repair

I only used 18AWG for the switch. I didn't even actually replace the broken wires between the driver and diode, just reconnected them and put heat-shrink on it. My soldering is still too indiscriminately melty
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