Troubleshooting Emisar D4k with boost driver

I’m trying to determine the cause of an issue with my boost-driven D4K. I seem to have lost the full range of ramping. I can turn the light on and ramp to approximately 25% brightness (very rough estimate), then when I continue trying to ramp up it maintains the same brightness but begins to flicker. If I ramp back down past the threshold at which the issue begins to appear, the flicker stops and normal ramping resumes. Double clicking into turbo mode produces the same outcome - brightness limited to same threshold and LEDs flicker until I double-click out of turbo.

I have not changed the ceiling value on this light, but just to be safe I did a ‘factory reset’ (loosen tailcap, hold button, tighten tailcap, release button after flashing stops). The issue persists.

The light is a CuTi model, but I found no copper shavings inside the tube or touching the driver. It is less than 2 years old, but it’s taken a few knocks and drops.

I’m concerned the driver might be fried, but would like to make sure I’m not overlooking anything before I reach out to Hank. Thanks in advance for any ideas.

I’d say some component solder joint in the power path is damaged, like inductor perhaps.

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Sounds plausible. I’m looking at the driver now and there is actually a joint that looks potentially iffy. On the component labeled V2 one of the legs is missing a blob and possibly even a soldering pad? Or is it supposed to be like that?

Photo:

Can’t really see much about joint quality from the picture, U2 is the LDO providing 2.8V to the MCU, if there was a problem with it the driver wouldn’t turn on at all.

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You’re right, of course. Also it was very helpful to get your take on this, thank you.