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Battery Board Testing

Information about Healthy Batteries

Voltage Range Status
3 - 3.2V Danger Zone
3.2 - 3.4V Low
3.4 - 3.7V Normal
3.7 - 4V High
4 - 4.2V Danger Zone

The cells may end up in the danger zone for one of two reasons: - Undervoltage: Concern for the health of the battery but not a safety concern. - Overvoltage: Concern for the health of the battery and the safety of the people around the battery. Overcharging can cause the battery to explode.

CAUTION: Before proceeding with this test, ensure the batteries you utilize all have a voltage of 3.4V and above and are balanced (each cell within +- 0.05V from each other).

The main objectives in testing the battery board are to verify that the battery protection network and voltage regulation are functioning properly. Follow these steps:

  1. Insert Batteries into the Holders

    • Insert batteries into the battery holders on the bottom side of the board, starting on the right and moving towards the left. Follow the posted polarity on the board.

  2. Check Battery Connection

    • Flip the board over and observe the various test points.
    • Use a voltmeter to test the pack voltage. Place the positive probe into the PACK+ test point and the negative probe into the B- test point. The voltage should be greater than 6V.
    • If the pack voltage is below 6V, follow troubleshooting steps:
      • If voltage is below 6V but not 0V, recharge the cells.
      • If voltage is at 0V, check battery polarity and solder joint connections.
      • Test voltages across each cell; replace any cell sitting at 0V.

  3. Battery Protection Check

    • Test the pack voltage against ground. Place the positive probe into the PACK+ test point and the negative probe into the GND test point. The voltage should match the pack voltage.
    • If the voltage differs, check for overcharge or over discharge protections.

  4. Jump J18 for Power

    • Jump J18 on the top side of the board with a jumper to bypass the feet switches and RBF switch.

  5. Voltage Regulation Test

    • Test the 3.3V on the board. Place the positive probe into the 3.3V test point and the negative probe into the GND test point.
    • If 3.3V is not generated, troubleshoot by ensuring battery protection hasn't triggered and that the pack voltage is passing through.

  6. Functionality Test of Feet Switches and RBF Switch (Optional)

    • Remove J18 jumper and connect the switches.
    • Test all points against GND, then depress the RBF switch and retest.
    • Replace switches if they do not function properly.

  7. Final Steps

    • Remove the J18 Jumper (or switches if used) and remove the batteries, starting on the left and moving to the right.