I should have mentioned before that usually if the battery is the problem ya don’t get any light at all from the PnC kit, so I’d rule it out from the sound of it, but I’d still try others and from the sound of it ya have already.
Aside from the PnC kit being the problem or something in the wiring there that has me a little puzzled, but I’ve yet to see any of the CG boards start having issues, this could just be the first of them is all. I’ve seen all kinds of issues with the older Matrix ones and fixed more than a few that would have went to the bin, but the CG seems to be a pretty good board so far as reliability goes.
You’ve tried another unopened, confirmed working PnC cable? I noticed from the sticks build thread ya pretty much kept the board and PnC setup fairly intact, and I know ya mentioned the PnC kit, so plugging in another one wouldn’t be to big a deal.
Any way ya can plug up another Wireless controller to the PnC kit in the stick for a test there as well?
The PnC cable seems the most likely culprit to me, that or the wiring/connectors of it somewhere. It’s pretty much just a 3.3v regulator and a voltage comparator to know when the thing is charged and change the color of the LED once the battery is full, so it thinking the battery is full too soon really points more to it being bad, though the problem could still be on the controller board somewhere, I haven’t gotten into that circuit on the CG board like I have on the Matrix one, yet.
If it doesn’t resolve itself, really would doubt that, though I’ve seen weirder things, and ya decide to replace it and the new board works let me know about the old one, I’d be interested in taking a look at it to see if the problem still exists in another setting and what it may be.