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@Gordon
Hi - I haven't come across this before at all! So the Puck works when the battery is half inserted?
I think you'd have to try and have a look and see if you can spot anything - I guess it could be shorting out on the PCB somehow, or I guess the opposite could be happening - maybe when pushed in further the battery actually loses connection to the Puck? That might happen if the bottom of the battery used was actually a bit concave?