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BB750 'Miracle' repair

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EvilLithiumMan

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Nov 20, 2003
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613
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Chula Vista, CA
BB750 \'Miracle\' repair

(So exactly who is the Patron Saint of Sandwich Repair?)

Shortly after Xmas I recieved a Badboy 750 board and a TX1K emitter. I had already built up a BB500/Q3 combo and felt I could tackle more. I carefully assembled my module. I double, triple and quadruple checked the connections. I then hooked up some test leads and connected it to two NiMH cells. The room came alive with photons. I was thrilled.

The only thing left to do was to pot the assembly and place it into the MiniMag. I decided to try the module in the MiniMag prior to potting; that shouldn't hurt anything, right? Well, I don't know what happened, but my module never came on. When I removed it from the flashlight, the odor told me something was horribly wrong - the 1N5817 schottky diode was blown - I could clearly see a crack in the SMT device.

I was really upset. What the Hell happened? I couldn't complain to Wayne - after all, the module worked fine outside of the light. I must have done something wrong; just don't know what. Threw the blown module into my scrap bin and cried my self to sleep. I knew there was no way that I could repair it.

[Scene switches to calendar on wall with the days falling away to denote passage of time]

Last night Wayne put up some BB750 S bin and MM+ T bin modules for sale. They didn't last long. And it must have lit a fire under my ***. I knew I had some 1N5817 diodes available. But I also knew my 20 year old Weller Solder Station and 'precision' tip were not the right tools. But I just had to make an attempt.

Here's what I had to start with:
Start.jpg

... And the end result:
Finish.jpg


I know it doesn't look too elegant, but damn if that puppy doesn't throw a boatload of photons. (Runs hot though. Really don't care to run it more than a couple of minutes without a cool down period).
 
Re: BB750 \'Miracle\' repair

That brought a smile to my face like few things have in recent memory! /ubbthreads/images/graemlins/smile.gif Thanks for sharing. I do crazy stuff like that all the time. You did a hell of a job with what you had, and that counts for a lot in my book!
 
Re: BB750 \'Miracle\' repair

Man, I've used lots of those axial 5817s. Didn't realize how big they are compared to the board.

Been staring under the microscope too much. /ubbthreads/images/graemlins/grin.gif

Thanks for sharing.

I enabled some of the diodes on the grey kit section if you haven't potted it and would like to put a replacement diode on the board.

The diodes will now be the more efficient CRS08 which has a lower Vf and makes the board a few % more efficient.

Wayne
 
Re: BB750 \'Miracle\' repair

EvilLithiumMan,

Very nice. That's the DIY way /ubbthreads/images/graemlins/thumbsup.gif

Wayne,

Sorry OT. It's good to hear you will use CRS08. When do you start using it? Are you also going to sell it in the grey kit section?
 
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Re: BB750 \'Miracle\' repair

The grey kit diode from now on will be the CRS08.

Wayne
 
Re: BB750 \'Miracle\' repair

Thanks. I assume you will eventually update the description. BTW, are you going to use CRS08 on your converter boards after the current stock runs out?
 
Re: BB750 \'Miracle\' repair

Collapse Proof Sandwich:
Burn-in1.jpg


All - Thank you for the kind words /ubbthreads/images/graemlins/smile.gif.

Wayne - I've always wondered what 'Grey Kit Parts' meant. Thanks for the heads-up on the CRS08 diode; I will probably pick up a couple of them, but doubt I will touch my repaired BB750 board. (Although I seldom choose to 'Stop while you're ahead', I'm going to make an exception here).

I've been doing a lot of comparing the BB750/TX1K with the MM+ Lux III S bin I bought in December. Using Powerx 2200mah NiMH cells in each, the BB750 started with 1.3A load on the cells and ended up at 2A at the cutoff voltage of 1.95V. The MM+ had a fairly consistant load of 930-960ma. I got 1 hour and 5 minutes of run time with the BB and 2 hours with the MM+ which cut off at 1.6V. Naturally the BB was the brighter of the two, but the MM+ was no slacker. I'm surprised how well the BB took the heat; I ran it for up to 20 minutes continuous during the tests. I can't imagine however, anyone getting a 5 watt Luxeon to run in a MiniMag. I think the Lux III is the practical limit.
 
Re: BB750 \'Miracle\' repair

... and all his stuff has that nice "Road Warrior" look to it /ubbthreads/images/graemlins/wink.gif

seriously, some ace cobbling there, Evil

heck, I wish I could solder teensy things with a chisel tip

hideo
 
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