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TP4056 CHRG LED stays on for hours — is the charge ever going to terminate?

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Original Question

Asked by stale_biscuit_03 ·

Built a small Li-ion charger using one of those cheap blue TP4056 modules from AliExpress. Battery is a single-cell 2000 mAh flat LiPo (nominal 3.7V) I salvaged from an old power bank. Wired VCC to 5V USB, BAT+ and BAT- to the battery terminals, didn't connect anything to OUT+ or OUT-.

The red CHRG LED came on straight away which I expected, but it's been on for something like six or seven hours now and the STDBY LED has never come on. Did the charge complete at some point and I missed it, or is something stuck?

I don't have a way to check the battery voltage right now (multimeter probe is missing). The module isn't getting hot. Is it normal for it to take this long, or do I have a wiring problem?

From the knowledge baseHow Do Lithium-Ion Batteries Charge?

3 Replies

charge_controller_charlie
Accepted Answer

Six or seven hours for a 2000 mAh cell isn't obviously wrong, but it depends heavily on what the PROG resistor on that module is set to.

The TP4056 charges in two phases — constant current (CC) until the battery reaches 4.2 V, then constant voltage (CV) at 4.2 V until the current naturally drops off as the cell fills. The CHRG LED stays on through both phases. It only goes out when the charging current falls below about 10% of the programmed charge rate. That CV tail takes time, especially at lower charge currents.

Finding your charge current

The PROG pin resistor sets the charge current. Most stock blue TP4056 modules ship with a 1.2 kΩ resistor, which gives roughly 1000 mA (1 C for your cell). At that rate, 2000 mAh should hit 4.2 V in around two hours, then spend another hour or so in CV taper. If you see a 2 kΩ or 3 kΩ resistor instead, the current is 600 mA or 400 mA respectively — the CC phase alone stretches to five hours or more.

Measure RPROG with a multimeter (it's the only resistor on the board, near the PROG pin) to confirm what you're actually charging at.

What to check if it's been six-plus hours and still charging

Find your multimeter probe. Once you have it:

  1. Measure the BAT pin voltage. If it's still below 4.1 V, the CC phase isn't finishing — either the charge current is too low for that cell, or there's high internal resistance in an old salvaged cell.
  2. If BAT is sitting at 4.2 V but the LED is still on, you're in the CV phase and the current hasn't dropped far enough for termination. This can happen with a degraded cell whose internal resistance is high enough that the termination current threshold never quite triggers.
  3. Check the TEMP/NTC pin. Some modules leave this floating, which is usually fine; others have a thermistor pad. If the TEMP pin voltage is outside the TP4056's acceptance window, charging suspends and can behave oddly.

The CC/CV charging process explains what the charger IC is actually doing in each phase if that helps fill in the picture.

One thing to note: salvaged cells from old power banks can have elevated internal resistance and may not accept a full charge normally. If the cell is a few years old and has been through a lot of cycles, that might be contributing.

thermal_runaway_tony

A couple of things worth flagging given the cell is a salvage unit.

The TP4056 itself terminates based on voltage and current, not cell state of health. If a degraded cell has an internal short or high self-discharge, the charger can keep supplying current indefinitely — the BAT pin might sit below 4.2 V forever while the cell dissipates the charge as heat. That's not a normal operating mode.

The cell protection circuit (the small IC + MOSFETs soldered to the cell's PCM board) is the last hardware line of defence against overcharge. Before you leave this running unattended, I'd make sure the cell's protection circuit is intact — if you salvaged a bare cell without the protection PCB, you're relying entirely on the TP4056 terminating correctly. The battery protection circuit article covers what that PCM board actually does.

If the module isn't getting warm and you're not seeing anything unusual, a salvaged cell taking a long time to charge is usually fine. Just worth being heads-up until you've confirmed the charge current and the BAT voltage with a meter.

beans4dinner

The one measurement that clears this up immediately is BAT pin voltage.

  • Below 4.1 V after 6 hours? Charge current is too low for that cell size. Find the PROG resistor and swap it for 1.2 kΩ if it isn't already.
  • At 4.2 V and still showing CHRG? You're in CV taper mode, it'll terminate eventually. Old cells with high internal resistance can drag this out.
  • Voltage bouncing or not moving at all? Protection circuit on the cell may be tripping on the charge current or there's a bad connection somewhere.

Go find that probe.

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