Help, my bluray dimming...

Alright, after double checking everything and loosing my nervers over this, I decided to make another 'help' thread,
This is what I've been waiting for weeks... A pen host, bluray, modules, drivers (thank you billg519!!) lithiums (thank you ReNNo!!) and i cannot believe I've failed somewhere...
The driver used is 1117, set to 100mA, also has 470ohm resistor across cap, to bleed it if I forget to discharge it.
Lithiums are 10440, Ultrafire, rated at 'unafamous' 600mAh, actuall 300mA.
Now, i had the 1117 PCB fitted inside aixiz module entirely, and another PCB with the switch and makeshift 'spring' contact to the batteries. That one is glued in place (twice, after i had to break a screwdriver to get it out.)

The problem is, that when i turn the laser on, (takes a few clicks WTH), it starts at great power, burns mathes like never before, and then it settles down to some low power, and after that, it turns into very faint light, you can see the yellow artifacts around the beam more clearly that the dot. And then it goes numb.
At first when i assembled it, it worked great and all, after one minute it started to dim. I thought WTF and got the remaining pair of lithiums inside. Again works great, however again... dimming after few seconds.
I charged both pairs of batteries. Again same thing
I thought, maybe it is overheating, since it has a lot of kick... I dissasembled everything, breaking the glue seal, putting termo paste (Spire Bluefrost) on the module, this time had truble setting up the switch so i prolonged the wire interconnecting PCB's, glued the swtich board in the host again, put module back in it's place. Got thermo paste all over my room btw.

Lighted up... dimmed. Switched the batteries. Dimmed. Lossed nerves again. Posted this.

Please someone tell me what the hell did I screw UP!:thinking:

Use dummy load to check current and voltage with this driver.
If everything is fine, then diode is dying...

I highly doubt the diode is dying. Hook a Volt meter up to the battery and constantly check the voltage level while the laser is on. I am willing to bet that your voltage will drop to abnormal levels (Less than 2.8Volts per battery) under a load. MY GUESS>>>>>BAD BATTERIES

DealExtreme / Ultrafire has been selling/producing a lot of bad 10440 batteries.

The only other thing to check is to see if your driver is overheating.

iskor12 said:

I highly doubt the diode is dying. Hook a Volt meter up to the battery and constantly check the voltage level while the laser is on. I am willing to bet that your voltage will drop to abnormal levels (Less than 2.8Volts per battery) under a load. MY GUESS>>>>>BAD BATTERIES

DealExtreme / Ultrafire has been selling/producing a lot of bad 10440 batteries.

The only other thing to check is to see if your driver is overheating.

Click to expand...

Well, after teasting load measurement, i saw that the current started to drop from 100 to 0 mA, linearly, and I'm waiting for a couple of batteries to be for one whole hour on a charger, then I'm going to test them.
Thanx

EDIT, no it is not overheating, everything remains dead cold.

OK this is the case
I've held a pair of batteries on charger for one hour or more, then a bluray laser gave good kick, burned up like 20 matches, 7 of them in a row. Module only started to feel warm.
But hell, after that, it again started dimming at next match.
It is 11:23 PM . I will be holding the batteries on charger whole night, tommorow i will let you know if it broughts me some good.

Looks like the batteries need a shock to get them on.
Otherwise...
Has anybody run PHR off 2x 10440, through 1117 driver?
If yes, expected lifetime of one charge of the batts?

I usually run off 3 x 10440. With two 10440, there is a max of 8.4V to start. The diode will require a forward voltage of around 5.5V This leaves only 2.9V of overhead for the regulator. The batteries will voltage sag, and there will not be enough voltage overhead for the regulator. Current will drop. 10440's are not protected, so it is possible to damage them by overdischarge or overcharge in a bad or faulty charger. Since your laser always comes to life again, the diode is probably OK. The batteries may not be in great shape and must be sagging quickly. Do you have a 9V wall adapter or similar power supply that you could test the laser with? I usually test off a bench supply and if all is good, then I try the batteries. My 10440's seem to need more than an hour in my charger ... I will admit to having one laser that uses PHR, 1117 driver, and 2 x 10440 because its in an old green pen host. It works well with good batteries, but they will sag and power soon goes down, though not bad like your batteries. This is why I build with 3 x 10440, CR2, or CR123.

Hmm yes, but it seems the longer the laser os off, the longer it will be at full power next time.
Regulator has 1.2 V drop, if i know correctly. Even if it has only 15 minutes run time, I don't care as long as it works as a fancy pen laser. However 1 minute...
Acctualy I do have one of those 'universal' adapters, that have 6 way switch for choosing voltages between 3 and 12 V, polarity switch, and 6 attachments most commonly used. However, when set to 9V, it gives 11.xx wothout load. I'm afraid I'm gonna damage something with it. Power most likely drops when has a load, but batteries of 8.4 on empty load also drop under load.
Not good.
Next build is probably going to be one of those PocketPal imitation flashlights, i have one of those lying around here. However, I'd prefer 2x 14500. I always like to keep power source practical.
My red lasers are run off 2x AA, standard, my green off 2x AAA's. My bluray is 2x 10440 for now. Keeping it simple to reload/recharge.

Well everything is fine for now with da batts.
Anyway, i think i promised some photos

Driver on the diode


Buidlind WIP




Now, dot shot with flash on


With flash off, longer exp


Beam:

The batteries in your photo are the exact same that I have. Perhaps they just needed a few cycles of useage to settle them down and get them fully charged. If you are going to make your own hosts in the future (you mentioned access to CNC), 3 x CR2 doesn't take up too much room, I have made several blurays this way. Congrats on your now working bluray pen build!!! Nice visible beam in the last photo, even with the lights on.

Eudaimonium said:

However, I'd prefer 2x 14500. I always like to keep power source practical.
My red lasers are run off 2x AA, standard, my green off 2x AAA's. My bluray is 2x 10440 for now. Keeping it simple to reload/recharge.

Click to expand...

I think the UltraFried batteries are dropping. Two quality #14500 batteries or one #18650 with a boost driver would give you plenty of run time.

LarryDFW

I am telling you that it is the batteries.....my guess still hasn't changed

Guys ok, it is now settled, i have changed the pairs of batteries used.
Guess that original pairs should not be interchanged. It is working very nicely now, burning matched faster than my red, burnes skin unfocused (5 mm dot). It is very good, no power drop noticed so far, working for maybe 15 minutes (added up total).
Now i only have to print out a warning sticker to cover ut the sctrached part near the module.

Thanks guys for all the help, this is the best build I've built so far
I'm seriously hoping to sell it here in Croatia for good price, so I can order more PHR's, and batteries.

iskor12 said:

I am telling you that it is the batteries.....my guess still hasn't changed

Click to expand...

listen to this man he's been here before... this has been discussed in detail before...these batteries will work for your application just remember
to totally charge them when you receive them.

After that always take them out when not using them and always charge them they are a bit of a nuisance

Haven't charged them dor 2 days, still raining coherent hell. Nice visible beam at night, too bad it goes blurry down the road
A'ight me bredda yo I think we settled this, seen?

:thinking::thinking: those translation engines are crap

jander6442 said:

:thinking::thinking: those translation engines are crap

Click to expand...

LOL never seen Little Jacob or Badman in GTA4?
Or at least heard Sean Paul?
You gotta love that jamaican patois language :crackup: