Help needed! Emisar DS1 modded to green Osram NM1

Hey gang! Looking for advise on this one. This stuff is why I hate modding. I did a simple emitter swap on my DS1. Swapped in a green NM1 on 20mm mcpcb. Carefully soldered the original mcpcb and replaced with the Osram. Tested to make sure the retaining screws aren't shorting on the leads as they are very close. All good. Assembled it and it came on immediately. Switch still ramps up and down. Double-click jumps to highest setting. Problem is it won't turn off. Made a video demonstrating this hoping someone here might be able to direct me to a cause or solution.

Thanks in advance!

Hi JM, have not seen you around on BLF for a while.

I have nothing in the form of a solution, but the problem may be caused by the very low Vf of the NM1. Very low Vf emitters can do funny things with drivers, like in quad emitter lights with BLF-A6 drivers low Vf leds makes the light drop out of turbo the moment you enter it. For the BLF-A6 driver, DEL at the time figured a solution with an extra resistor uncoupling a capacitor or something like that (I’m not an electronics geek, but I used the trick and it worked). I do not know this driver so in this case I’m not sure if something similar is happening, or if a similar solution can be found. I hope someone on BLF can help you further.

Great to hear from you! What you say makes a lot of sense and you could be right. I can still turn it on and off via tail cap lockout and if that is the only problem I can live with it. Will see if anyone else has other ideas. I wish I knew how to open it but I have no clue how to pop the driver out of this thing to try the resistor thing.

This is not normal. When the light is off, no current should flow, independent of the forward voltage of the LED. This looks like a leaky 7135 or even the big FET. Or a short with high resistance somewhere else.

I agree with SammysHP. My first guess is a high resistance short between ground and LED negative. In my experience this can happen at the LED footprint. You can check this by desoldering the MCPCB from the light and just measuring the resistance between the LED negative and the copper MCPCB core.

I’m guessing you didn’t take any ESD precautions.