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ADC for VBUS monitor saturates
ESP32-S2 ADC max voltage is ~2.5V.
Change voltage divider to allow for greater input range.
Light enters bootloader when first connected to power
When battery is first connected, or battery cuts off voltage to light, the light will boot into bootloader.
This issue occurs when:
- Battery is first connected to light (during assembly)
- Battery is drained below 3V and firmware does not detect (it looks for <3.3V) and shut down, the power to the light is cut off by battery
The cause is:
- ESP32 samples IO0 pin at boot up, if its low, it enters bootloader instead of the app
- There is a 10n cap added to IO0 pin for ESD protection (since this contact is exposed to the user)
- The IO pin has an internal pull-up in the ESP32- when the chip boots it pulls this up but it is too slow from the 10n, it is still low when sampled and enters bootloader
The fix is:
Add external 10k pull-up to IO0 pin, tested and this fixes the issue. It did increase sleep current from 29uA to 30uA, but this is a good trade off for fixing the boot issue.
SPI Flash too small
Change part to 32Mbit part, since 512k is not supported.
When battery is connected light needs power cycle to turn on
When battery is connected, sometimes the light will not turn on. A reset with the hard reset line or disconnecting and reconnecting the battery fixes it.
This will be an issue if the battery gets very low and has an under voltage cutoff. This would force the user to manually reset the light using the reset pads.
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