eFuse V2.1 fix: datasheet-derived OVLO ladder + ILIM correction
Works the TPS25961 fix out from the datasheet rather than from memory, and re-solves it against resistors already on the BOM. OVLO: TI's 3-resistor ladder (eq 7/8) -> R46 620k->150k, R47 100k->10k, new R48 12k + R49 2.2k (=14.2k). UVLO 8.93 V typ, unchanged from today; OVLO 15.21 V typ, 15.81 V worst case. The OVLO ceiling is set by U3 (TPS562201, 4.5-17 V input), not by the eFuse -- that rules out a tempting 3-resistor solution tripping at 17.24 V. ILIM: R45 100k -> 33k. 0.516 A sat BELOW the board's own 621 mA inrush, so the part entered current limiting on every power-on (-> thermal shutdown -> retries -> latch-off). Inrush control comes from the fixed 5.17 V/ms slew rate, not ILIM, so raising ILIM costs no inrush protection; it is pure fault protection at ~27x the measured 56 mA load. Every value is already stocked and 620k loses its only user: one FEWER unique part, +2 placements. Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
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@@ -245,10 +245,25 @@ schematic changes.
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2026-09-16, FAB-BLOCKER for V2.1).** OVLO (pin 2) is tied to GND, which on
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the TPS25961 selects the internal *fixed* overvoltage cutoff ~5.98 V — so a
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12 V rail is permanently in overvoltage lockout and the eFuse passes
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nothing (bench-confirmed: 12V_EXI=0, GC_ON=0, W5100 unpowered). **Fix:**
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OVLO divider off 12V_RAW, R_top ≈ 1.1 M / R_bottom ≈ 100 k → trip ~15 V.
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See REVIEW.md eFuse entry. Bench workaround: feed 12 V onto 12V_EXI (C65+ /
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U3 VIN) to bypass it. This must be fixed before any V2.1 fab order.
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nothing (bench-confirmed: 12V_EXI=0, GC_ON=0, W5100 unpowered).
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**FIX WORKED OUT FROM THE DATASHEET 2026-10-02 — values final, needs
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schematic + PCB work.** TI 3-resistor ladder (§8.2.3.2), EN/UVLO tapped at
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R1–R2 and OVLO at R2–R3, plus an ILIM correction:
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R46 620 k -> **150 k** (C93947) R1, top: 12V_RAW -> EN/UVLO
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R47 100 k -> **10 k** (C25744) R2: EN/UVLO -> OVLO
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R48 NEW -> **12 k** (C25752) \ R3 = 14.2 k in series,
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R49 NEW -> **2.2 k** (C25879) / OVLO -> GND
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R45 100 k -> **33 k** (C25779) ILIM 0.52 A -> 1.52 A
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U13 pin 2 (OVLO): disconnect from GND, wire to the R47/R48 junction.
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Gives UVLO 8.93 V typ (unchanged from today) and OVLO 15.21 V typ,
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15.81 V worst case — under U3's 17 V input rating, which is what actually
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caps the OVLO target. ILIM must exceed the board's own 621 mA inrush;
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0.52 A did not, so the part current-limited on every power-on.
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**Every value is already on the BOM and 620 k loses its only user, so this
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is one FEWER unique part, +2 placements.** Full derivation, tolerance
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analysis and the rejected alternatives are in REVIEW.md §eFuse.
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Bench workaround meanwhile: feed 12 V onto 12V_EXI (C65+ / U3 VIN), or
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lift U13 pin 2 (done on the lab unit). Must be fixed before any V2.1 fab.
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- [x] **D9 "USB" LED dark — OPEN SOLDER JOINT on its anode pad — FIXED by
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reflow 2026-09-30. Assembly defect on this unit, NOT a design bug.**
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Symptom: D9 never lights, on USB-only or GC power. Measured 3V3 on the
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