[quote author=ElektroFreak link=1228016015/0#8 date=1228031191]I think daguin's hit the nail on the head here. The problem was the bad connection to the diode. You had said that the diode came disconnected, which left it vulnerable to a lot of things. If it disconnected while powered up, that kills diodes instantly. You're best bet is to double- and triple-check your connections for strength and soundness. Make sure that nothing will exert too much strain on the connections during assembly. Your diode didn't blow for no reason, there was a clear reason..
EDIT: Also I think it should be stated that PHR diodes are NOT rated to run at the currents most people run them at. 60mW is their maximum rated output, anything above that and anything could happen..