Start With These Basic Checks

• Make sure the iPod hold switch is not in the ON/locked position.
• Verify the orientation of the battery and power connector. The battery connector and the flex cable connecting the Boxy Pixel board to the iPod motherboard must both be installed in the correct orientation. Please review the installation instructions if you are unsure.
• Inspect the flex cables and connectors for visible damage, bent contacts, tears, or incomplete insertion.

Step 1: Test the Battery Directly on the iPod

Disconnect the Boxy Pixel daughterboard entirely and connect the battery directly to the original iPod motherboard.

If the iPod powers on with the battery connected directly to the original iPod motherboard, this confirms that the battery is good.

Step 2: Test the Boxy Pixel Daughterboard Outside the Housing

Perform these tests with the Boxy Pixel daughterboard outside of the iPod housing. This helps eliminate pressure, flex-cable strain, or contact with the housing as possible causes.

1. Disconnect the daughterboard from the iPod and disconnect all other unnecessary components.
2. Connect a known-good battery to the Boxy Pixel daughterboard.
3. Turn on the Bluetooth switch.
4. Look at the small blue colored Bluetooth board. A red LED should blink when Bluetooth is turned on. Depending on the board, another blue LED may also illuminate continuously.

If the Bluetooth LED activates, this indicates that battery power is reaching the daughterboard and Bluetooth module.

Step 3: Check USB-C Charging

1. Leave the known-good battery connected to the Boxy Pixel daughterboard.
2. Connect a known-good USB-C charging cable and power source.
3. A red/amber LED on the daughterboard should illuminate continuously to indicate charging.
4. Disconnect the battery while leaving USB-C power connected.
5. The charge-status LED should change to green. With no battery connected, the charging circuit interprets the battery as fully charged.

If these LEDs behave normally, the daughterboard's charging circuit is responding as expected and the Boxy Pixel daughter board is good.

Step 4: Verify Power Is Leaving the Boxy Pixel Board

If you have a digital multimeter, you can verify that voltage is reaching the power output flex cable.

1. Connect one end of the Boxy Pixel power flex cable to the daughterboard.
2. Do not connect the other end of the flex cable to the iPod yet.
3. Locate the two exposed copper test points on the underside of the power flex cable.
4. Set your multimeter to measure DC voltage.
5. Carefully measure the voltage across the two copper test points.

You should measure approximately 4 volts DC. A reading somewhat above or below 4 volts can be normal depending on battery charge level and operating conditions.

If you measure approximately 4 volts, power is successfully leaving the Boxy Pixel daughterboard through the power flex cable.

If you measure no voltage, first disconnect power and verify the orientation and seating of the power flex cable. Then repeat the test.

Temperature Warning

The daughterboard may feel slightly warm while charging. It should never become hot.

If the board becomes hot, disconnect the battery and USB-C power immediately and verify that the battery connector has not been inserted upside down or incorrectly.

If your iPod repeatedly displays "Very Low Battery", shows the Apple logo and restarts, or refuses to fully boot even though you are using a known-good battery, the problem may not actually be the battery.

We have found that some of these cases are caused by a marginal connection somewhere in the battery/power path. The original iPod connectors are now many years old, and small differences in connector wear, flex-cable thickness, seating, or contact pressure can affect the connection.

Step 1: Confirm the Battery Directly on the Original iPod Motherboard

Before troubleshooting the Boxy Pixel power path, connect your known-good battery directly to the original iPod motherboard, bypassing the Boxy Pixel daughterboard and power flex cable.

• Make sure the battery connector is installed in the correct orientation.
• Make sure the connector is fully inserted and properly locked.
• Attempt to boot the iPod.

If the iPod boots normally when the battery is connected directly to the motherboard: the battery is capable of powering the iPod. Continue with the steps below to troubleshoot the Boxy Pixel power path.

If the iPod still shows "Very Low Battery" when the battery is connected directly to the original motherboard: the Boxy Pixel daughterboard and its power flex cable are probably not the cause. Skip down to the "If the Problem Happens Even With the Battery Connected Directly" section below.

Step 2: Reseat the Boxy Pixel Power Flex Cable

Disconnect all power before removing or reinstalling flex cables.

1. Remove the power flex cable from both connectors.
2. Inspect both ends of the flex cable for damage, contamination, folded contacts, or unusual wear.
   
3. Reinsert the flex cable straight and evenly into each connector.
4. Make sure the cable is fully inserted before carefully closing the locking mechanism.
5. Test the iPod again before installing everything back into the housing.

A flex cable can appear to be installed correctly while still making marginal electrical contact, so reseating it is an important first step.

Step 3: Try the Black Boxy Pixel Power Flex Cable

Some Boxy Pixel shipments may include an additional black power flex cable that was with the housings (not with the electronics). The black version has slightly thicker ends than the standard white flex cable.

We introduced this alternate cable after finding that some older iPod connectors appear to make more reliable contact with a slightly thicker flex-cable end.

If your order includes both a white and black power flex cable and you experience a persistent "Very Low Battery" warning with the white cable, try the black cable before assuming the daughterboard is defective.  If not, you can see step below.

Step 4: Kapton Tape Method for a Loose or Worn Connector

Some customers have successfully corrected this problem by adding a very small amount of thickness to the end of the power flex cable using Kapton tape.

This may help when an older connector has slightly reduced contact pressure or when normal manufacturing tolerances result in a marginal connection.

1. Disconnect the battery and USB-C power.
2. Remove the power flex cable.
3. Place a small piece of Kapton tape on the non-contact side of the flex-cable end.
4. Do not cover the exposed electrical contacts.
5. Trim the tape so that nothing extends beyond the edges of the flex cable.
6. Carefully reinstall the flex cable.
7. Make sure the connector closes normally and does not require excessive force.
8. Test the iPod again.

One thin layer is usually all that should be attempted. If the connector becomes difficult to close, remove the tape rather than forcing the locking mechanism.

Step 5: Check the Output Voltage

If you have a digital multimeter, check the output of the Boxy Pixel daughterboard before connecting the power flex cable to the iPod.

1. Connect a known-good battery to the Boxy Pixel daughterboard.
2. Connect the power flex cable to the Boxy Pixel daughterboard.
3. Leave the iPod end of the power flex cable disconnected.
4. Locate the two exposed copper test points on the underside of the power flex cable.
5. Set the multimeter to DC voltage.
6. Measure the voltage across the two copper test points.

You should see approximately 4 volts DC. The exact voltage will vary with the battery's state of charge.

If you have approximately 4 volts at the end of the flex cable but the iPod still reports "Very Low Battery," pay particular attention to the connection between the flex cable and the original iPod motherboard.

If there is no voltage at the end of the flex cable, recheck the flex-cable orientation, seating, battery connection, and daughterboard before continuing.

Step 6: Test Everything Outside the Housing

Do not troubleshoot this problem with the iPod completely assembled.

Connect the motherboard, battery, Boxy Pixel daughterboard, power flex cable, and required components outside of the front and rear housings. Then test the iPod.

If the iPod works outside the housing but develops the "Very Low Battery" warning after assembly, something inside the housing may be placing pressure on a flex cable, connector, battery, storage adapter, or daughterboard.

Reassemble the unit in stages and test after each stage to identify when the problem begins.

If the Problem Happens Even With the Battery Connected Directly

If a known-good battery is connected directly to the original iPod motherboard and the iPod still displays "Very Low Battery" or repeatedly restarts, the problem is likely elsewhere in the original iPod.

Older iPods can display similar symptoms for several different reasons. Before replacing additional Boxy Pixel components, try the following:

• Leave the iPod connected to a known-good charger for several hours.
• Try another known-good charging cable and power source.
• Reset the iPod by holding Menu + Center/Select until the Apple logo appears.
• Inspect the original iPod battery connector for damage, looseness, or contamination.
  
• Check and reseat the storage ribbon cable and iFlash/HDD connection.
• If using an iFlash adapter, verify the SD card or cards and storage configuration.
• If the iPod can enter Disk Mode, use this to help determine whether the unit can remain powered and communicate with a computer.

A repeated Apple-logo / "Very Low Battery" cycle can sometimes be caused by an original iPod hardware, storage, or software problem rather than the battery itself.

If the iPod is recognized reliably by a computer but continues to have software-related boot problems, a reset or restore may be appropriate. Restoring an iPod erases its contents, so do not use a restore as the first troubleshooting step.

What the Results Tell You

• Battery works directly on the iPod, but not through the Boxy Pixel power path: concentrate on the power flex cable, connector seating, connector condition, and daughterboard output.
• White cable gives "Very Low Battery," but the black cable works: continue using the black cable. Carefully avoid excessive force when inserting or locking it.
• Kapton tape fixes the problem: this strongly suggests that the connection at one of the flex-cable connectors was marginal.
• Approximately 4 volts is present at the power flex output but the problem continues: inspect and troubleshoot the connection at the original iPod motherboard.
• The same problem occurs with the battery connected directly to the original iPod motherboard: troubleshoot the original iPod, battery connector, storage system, and charging system rather than the Boxy Pixel daughterboard.