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Chinese HW-465abc 12V UPS Outputs 3.4V Unless Pressing Chip—Possible Causes and Fixes?

epolet 945 7
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  • Cold solder or package contact on XR2981 U4

    #1 21851697
    epolet
    Level 6  
    Posts: 12
    Rate: 1
    I have a small Chinese-made UPS.

    Green UPS module PCB with USB‑C port, “2R2” inductor, and IC labeled U4 in the center
    Dual 18650 battery holder with metal contacts and “BeilaMoo” marking.

    Currently, I am using the version with a 12 V output, but it is behaving oddly: it typically outputs only about 3.4 V. However, if I press on the chip XR2981 in the center of the board (labeled “U4” on the picture), it temporarily outputs the correct 12 V.
    I have already tried resoldering the contacts, but the issue persists.
    Interestingly, I own two identical UPS units, and both exhibit the same defect. They have never been used and have been stored in their packaging for about a year.
    Does anyone have an idea what might be causing this behavior, and how it could be resolved?

    AI: Could you provide the exact brand and model number of the UPS units?
    It is a no-name UPS. Just bought on AliExpress.
    AI: When testing, what are you using as the input power source and what (if anything) is connected to the UPS output? Also, have you checked the battery condition or voltage?
    Input was from a USB charger. The batteries' condition was good, but without them it exhibits the same behavior as described. It behaves the same with a small load and without any.
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  • #2 21851957
    D214d3k
    Level 39  
    Posts: 3837
    Help: 543
    Rate: 633
    Try adding lead tin and remove that grey tin. It looks overheated. Re-solder from scratch.
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  • Bad chip contact suspected from pressure-dependent fault

    #3 21852166
    epolet
    Level 6  
    Posts: 12
    Rate: 1
    I don't quite understand. Should I first add solder to the chip's pins and then remove it? There seems to be an acceptable amount of tin there now.
    Re-soldering the entire chip might be an option, but only as a last resort.

    The overheating suggestion doesn't seem to be realistic: mechanical action is what's important. Simply pressing with a finger to dissipate the heat doesn't help. You have to actually press. It looks like a bad contact on the board. But simply bending the board or pressing near the chip doesn't help either. You have to press specifically on the chip.
  • #4 21892288
    bennettlyle912
    Level 3  
    Posts: 3
    Both units have the exact same issue, it’s almost definitely a common design flaw with this board, not a random part failure. If I were you, I’d just reflow the whole chip with some flux and a hot air station.
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  • #5 21892438
    epolet
    Level 6  
    Posts: 12
    Rate: 1
    Thanks for the idea.
    But those two devices were bought together with the third one, which works fine already for a couple of years. While the mentioned two were lying in the box.
  • #6 21892484
    Wawrzyniec
    Level 38  
    Posts: 4006
    Help: 392
    Rate: 1075
    Remove the chip, clean the board underneath it, inspect it, fix the vias around the chip with wire, solder the chip in.
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  • #7 21906287
    jonas123
    Level 2  
    Posts: 3
    >>21851697 >>21851697 Is the issue resolved?
  • #8 21906747
    epolet
    Level 6  
    Posts: 12
    Rate: 1
    Still not resolved as of the not first priority issue.

Topic summary

LABEL_AI_GENERATED
A no-name Chinese 12 V UPS board from AliExpress intermittently outputs only about 3.4 V, but the voltage returns to 12 V when pressure is applied directly to the XR2981 chip (U4). Re-soldering the contacts did not fix the fault, and the same behavior occurs on two identical unused units stored for about a year, while a third unit from the same batch works normally. Suggested remedies include reflowing or re-soldering the IC with flux and hot air, replacing the grey/overheated solder, removing the chip to inspect and clean the PCB underneath, and repairing possible bad vias or board-level contact defects around the regulator IC.
AI summary based on the discussion. May contain errors.
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