Strange, there is no edit button.
Anyway, here is an update.
To recap, my son's Archon (and my Savior) arrived a few days ago.
When I connected the charger to the charging port on the Savior, the charge indicator went from green to red, and charged the saber without issue.
When I connected the charger to the Archon's port, the charging indicator, continuously flashed red.
I tried both chargers, and both worked ok with the Savior but not the Archon.
I swapped the batteries between sabers, and the behavior was unchanged. All four batteries also charged via the stand-alone charger.
I replaced the batteries in the Archon and it stopped working.
I pulled the battery carrier again, inspected the wiring/electronics, and didn't see any issue.
I reinstalled the batteries, and received the "obsidian" declaration.
Upon pushing the carrier back into the hilt, I thought I saw a tiny spark jump from the carrier/electronics to the hilt.
I'm not 100% on this.
Again the saber was dead.
It seemed like reseating the batteries didn't reliably bring the saber to life, so I assumed the issue was intermittent due to a wire being moved.
I pulled the carrier again, reseated the batteries, moved things around a bit and got the obsidian declaration.
I pushed the carrier back into the hilt, and the saber ignited ok.
I pulled the emitter tube, slid the emitter/heat sink out, and discovered a white wire was severely pinched. I took a picture (I'll try to post it).
The insulation was intact on one side of the pinch, but the conductor was exposed on the other. Some of the conductor appeared to be severed.
I wrapped the pinched wire with silicone tape to prevent folding or shorting and put everything back together.
It seems to work fine now.
When connected to the charging port, the charge indicator is glowing steady red, which I assume means it is charging.
I will give it a little while to see what happens.
If all seems fine I plan to cut the wire and solder it back together.
For reference, I'm a former master mechanic, and have an electronics background, but I'm a bit out of practice regarding my soldering skills.
As long as I can pull enough of the wire harness out to allow room for the procedure, I should be fine.
I emailed Ultrasabers as well to alert them of the issue, in case my repair was incidental, and ineffective.
Bob
