⚠️ Before troubleshooting:
- Disconnect battery
- Disconnect power supply
- Allow components to cool
- Review Safety Guidelines
- Visual Inspection: Check for loose connections or damaged components
- Polarity Check: Verify all polarized components and connections
- Power Supply: Confirm correct voltage and current capability
- Module Configuration: Verify modules are correctly installed
- Multimeter Testing: Measure voltages at key test points
Symptoms: Circuit appears dead, no indication of power
Possible Causes:
- Reversed input power polarity
- Faulty power supply
- Blown protection fuse/component
- Short circuit
- TODO: Additional causes
Solutions:
- Verify input power supply voltage and polarity with multimeter
- Check for short circuits between power rails
- Test protection components
- TODO: Additional solutions
Safety Note: Never apply battery power until input power tests successfully.
Symptoms: Battery connected but charge current is zero or very low
Possible Causes:
- Battery already fully charged
- Battery protection circuit activated
- Incorrect charge current setting resistors
- Faulty charging IC
- Battery below minimum voltage (deep discharge)
- TODO: Additional causes
Solutions:
- Measure battery voltage (should be within TODO range)
- Verify charging IC enable pin state
- Check charge current sense resistor values
- Measure voltage at key IC pins per datasheet
- TODO: Additional solutions
Safety Note: If battery is swollen, damaged, or leaking, do not attempt to charge. Dispose of properly.
Symptoms: Charging current too high or too low
Possible Causes:
- Incorrect module configuration
- Loose connection
- Damaged component
- TODO: Additional causes
Solutions:
- Verify module configuration settings
- Recalculate expected charge current: TODO formula
- Check all connections are secure
- TODO: Additional solutions
Symptoms: Output voltage not within expected range
Possible Causes:
- Incorrect feedback resistor values
- Faulty boost IC
- Insufficient input voltage
- Inductor saturation (overcurrent)
- TODO: Additional causes
Solutions:
- Verify feedback resistor values
- Calculate expected output: TODO formula
- Check input voltage under load
- Measure inductor current
- TODO: Additional solutions
Symptoms: ICs, MOSFETs, or inductors become excessively hot
Possible Causes:
- Excessive current draw
- Insufficient PCB copper area
- Faulty switching components
- Short circuit
- Operating outside specifications
- TODO: Additional causes
Solutions:
- Immediately disconnect power
- Allow components to cool
- Measure output current
- Check for short circuits
- Verify component ratings
- Add heat sinking if necessary
- TODO: Additional solutions
Safety Note: Overheating lithium-ion batteries is extremely dangerous. If battery is hot, remove from charger immediately and monitor in safe location.
Symptoms: Device won't operate, battery voltage very low
Possible Causes:
- Battery discharged below protection threshold
- Protection circuit failure
- TODO: Additional causes
Solutions:
- Measure battery voltage
- TODO: Recovery procedures (if safe)
- TODO: Additional solutions
Warning: Attempting to charge an over-discharged Li-ion battery can be dangerous. Proceed only if battery is undamaged and within recoverable range.
TODO: Instructions for voltage/current measurements at test points
TODO: Instructions for checking switching waveforms (if applicable)
TODO: Refer to IC datasheets for diagnostic procedures
Stop immediately and seek expert help if:
- Battery is swollen, leaking, or damaged
- Components are smoking or have burned smell
- You detect any signs of fire or thermal runaway
- Battery temperature exceeds TODO °C
- You are unsure of the problem
If you've tried these troubleshooting steps and still need help:
- Review the Assembly Instructions for proper construction
- Check the Bill of Materials for correct component values
- Review Safety Guidelines
- Visit the Support section for additional help
⚠️ Important: When requesting support, provide photos of your assembly and multimeter readings.
Last Updated: TODO
Revision: See Revision Notes