Hi Carl
I would like to wait to see your images before I pass full judgement but what I will say is I have found the tuning of some of the chineese scanners out the box can be....lets say 'variable'. Particularly where the ilda tp is concerned, often it wont be displayed well at all and yes letters in particular can suffer. Unfortunately you cant expect much time spent tuning for the money they cost but the good news is that they can be made good. See attached image which is of the ilda tp displayed on a set of scanners the same as yours that I have tuned to 20k - it didnt take me hours and hours, maybe 30min or so and it looks pretty damn good - the bends you can see in for example in the right hand vertical line are due to the towel I was using as a 'projection screen' (you know how important it is to always know where your towel is...). As promised I will happily apply this tune to your scanners at the meet - in fact best will be if I show you what to do on the first set and you follow suit on the second set. And to answer your question I doubt there will be improvement if you go for differentail input - I reckon its scanner tune thats your issue.
I would agree with Frank, test the volts and preferably current draw at the point where power goes onto the driver board to see if its pulling too hard. Those power packs that come with CNI lasers are normally good for 4 amps and if that head is pulling near that I would say something is wrong. Even with the Tecs working hard I would only expect to see it blip to 3amps or so occasionally. The fans often change speed as the laser comes on but it should just be a subtle change of tone rather than a real drop in speed so I would monitor the 5V input - the heatsink fan on the CNI will be a 25mm 5V jobbie.
If operating the laser normally without blanking to the desk connected, ie just turned on in CW mode - what does the output do when you first turn it on? do you get the same dip in brightness?
Rob