I've been having some odd connection problems with bluetooth as well. I 
have two IOIO boards and two dongles, so I have more things to try than 
you. :) I have seen situations on a number of occasions where things were 
working fine, and then the next day I can't connect. This is very bad, 
because in order to do development you need your phone USB connected to 
your computer so you can download and run/debug your software, and 
therefore you connect to the IOIO through bluetooth (which needs to be 
reliable). I've had problems with both dongles (two different brands). I've 
had to unpair/re-pair the dongles, turn off/on bluetooth on the phone, even 
reboot the phone.

One board is an IOIO Mint. Unbeknownst to me prior to purchasing it, the 
IOIO in the Mint is the old V1.0 model and it runs old firmware. The other 
board is a new IOIO OTG from Sparkfun. I made a power supply for it using a 
spare wall wart that delivers 2 amps at 12V. I am using a DC-DC converter 
<http://www.amazon.com/gp/product/B008BHAOQO/ref=oh_aui_detailpage_o03_s00?ie=UTF8&psc=1>to
 
step the voltage down to 9V and it appears to be working well, I am getting 
good 5V and 3.3V outputs from the IOIO.

Today I hooked my phone directly to the IOIO-OTG via USB and it would not 
connect (yes I had USB debugging disabled). The bluetooth dongles would 
work - sometimes. Like you I was using the Hardware Tester app to verify 
connection. Reading back through the postings I saw where it was remarked 
that the Hardware Tester is 'old' and not recommended, which is a shame.

I decided to go to the trouble of installing the latest firmware on the 
IOIO-OTG and made sure I had the corresponding most recent versions of the 
pre-packaged Hello IOIO and IOIO Simple App installed on my phone (I 
discarded the Hardware Tester). Immediately I was able to connect via the 
USB cable with both apps. I was also able to connect via bluetooth with 
both dongles. I don't know if this will be the case tomorrow. :) I did 
notice that the Simple App (installs as IOIO Sample App for some reason 
though that is not the package name) drives the I/O channel very hard, 
doing continuous analog pin readings inside the looper probably. This was 
causing bluetooth to disconnect and reconnect at times, though with the 
cable it was very steady.

The two different firmware versions on my boards appear to be a more 
serious issue than I expected. Apparently I can't write software that will 
run against both boards because the Android libraries are specific to the 
firmware version. 

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