While using a Pixhawk PX4 Pro, I encountered some issues due to an incorrect battery connection, which affected both the Pixhawk and the connected RFD900ux telemetry module. Below, I have detailed the problems and my observations. I would appreciate your support and suggestions for resolving these issues.
Problems Encountered:
RFD900ux Telemetry Module:
The port and cable of the RFD900ux module connected to the TELEM1 port were burned.
When connected to the Pixhawk, the module emits a faint red light at 3-4 second intervals, but no light is visible when connected to a computer.
Pixhawk TELEM1 Port:
There is slight discoloration on the TELEM1 port.
The port still supplies power, but telemetry communication with QGroundControl cannot be established.
Pixhawk General Condition:
The Pixhawk distributes power but experiences slight heating.
The receiver and remote control connect successfully, but the SD card is not recognized.
*I tried inserting the SD card into the computer and phone, but it didn’t work.
Previously functional telemetry modules no longer establish a connection with QGroundControl via the TELEM1 or TELEM2 ports.
Possible Scenarios:
Damage to the Pixhawk’s internal circuitry (particularly the power regulator or communication lines).
Partial or complete failure of the TELEM1 port.
Both TELEM1 and TELEM2 ports may be damaged.
Support Request:
Based on these symptoms, I would like to know if the Pixhawk is repairable.
Given that the RFD900ux module burned out while other Pixhawk functions remain operational, could the issue be limited to the telemetry ports?
What might be causing the SD card failure and slight overheating?
Do you recommend any hardware tests or software diagnostics?
If additional information or logs are needed, I can provide them. Thank you in advance for your assistance.
Do you mean a Holybro Pixhawk 4 or 6 or similar? Or a Cube?
PX4 Pro is that other firmware, not directly related to hardware.
I would say it was a significant over-voltage (or spikes) causing failure of the internal voltage switching and control circuitry, potentially taking out the RFD too.
The 5volt supply to accessories is current-limited under normal circumstances, so there’s no reasonable way for the RFD radio to draw too much current without causing the 5volts to accessories to cut out completely. Typically the RFD radios are also quite rugged and handle over-voltages and high temperatures.
Anything odd would also be logged in Power.Flags with the following values (they add up):
1 MAV_POWER_STATUS_BRICK_VALID // main brick power supply valid
2 MAV_POWER_STATUS_SERVO_VALID // main servo power supply valid for FMU
4 MAV_POWER_STATUS_USB_CONNECTED // USB power is connected
8 MAV_POWER_STATUS_PERIPH_OVERCURRENT // peripheral supply is in over-current state
16 MAV_POWER_STATUS_PERIPH_HIPOWER_OVERCURRENT // hi-power peripheral supply is in over-current state
32 MAV_POWER_STATUS_CHANGED // Power status has changed since boot
You will probably need to replace the flight controller and power brick at minimum.
Thank you for your response. To clarify,my flight controller is a Pixhawk Orange Cube.I observed smoke coming out of both ports of the cable when the RFD900ux was connected to TELEM1 I have a few follow-up questions regarding the damage caused by incorrect battery wiring:
Protection Mode in Pixhawk Orange Cube:
Does the Orange Cube have any built-in protection mechanisms (e.g., voltage spike/surge protection) that could have triggered a “safe mode” during incorrect power input? Or is such damage always fatal to the board?
Checking Power.Flags Without SD Card:
Since my SD card is no longer functional, how can I check the Power.Flags values you mentioned? Is there an alternative way to access this data (e.g., via USB or MAVLink telemetry)?
Assessing Pixhawk’s Usability:
How can I determine if my Orange Cube is completely dead or partially functional? Currently:
It powers on and distributes power (5V rail seems active).
The receiver and radio link work (manual control is possible).
Telemetry ports (TELEM1/TELEM2) fail to communicate with QGC.
SD card is undetected.
RFD900ux Paired Module Status:
The RFD900ux module connected to TELEM1 is damaged (burnt port/cable), but when powered by the Pixhawk, it emits a faint red LED every 3-4 seconds. Does this indicate:
The module is partially functional but corrupted?
The Pixhawk’s TELEM1 port is supplying unstable power?
Or is the RFD900ux entirely dead (and the LED is residual power)?
Tried a different telemetry radio on TELEM1/TELEM2: No communication with QGC.
You let the smoke out. There’s no putting it back. The likelihood of either smoked component working properly again is very low. Replace the components.
If you choose to use them in a partially functional state, the likelihood of further failure is high. And that will certainly cost you more time and money.
I’m trying to find a way to reuse my Pixhawk Cube Orange by loading firmware via SD card, as I can no longer connect to it via USB. The SD card I was using before is completely damaged and unreadable.
I want to confirm whether my Cube Orange is truly dead or if there’s still a chance to recover it. From a previous parameter file I saved from QGroundControl before the issue, I know the following:
Stack: PX4 Pro
Vehicle: Fixed Wing
Version: -1.-1.-1
Git Revision: (Not available)
Is there any known method to force a firmware flash using only an SD card, especially for a situation where USB is unresponsive? Any help or insight would be greatly appreciated. Thank you!
Let me know if you want to personalize it more or add any technical details!
Currently, no autopilot ships with a bootloader capable of flashing from the SD card. Updating the bootloader is required to support flashing from SD card. Note that updating the autopilot’s bootloader is an operation which can make your board non-operational, and difficult to recover. More-so with boards that do not expose a “boot0” pin, such as the CubeOrange.
So the short answer is no.
And the slightly longer answer is that this was never relevant to ArduPilot. User should be seeking answers in the CubePilot or PX4 user support site(s), though they will say the same thing. It’s smoked.
