I have fought this same problem, thought it was resolved, and found it 
again.  I think the authoritative answer is in this TI app note: 
https://www.ti.com/lit/an/slva901/slva901.pdf?ts=1597613555964&ref_url=https%253A%252F%252Fwww.google.com%252F

Cutting to the chase, either ground the BAT terminal with  1K-ish resistor 
or power your product exclusively through the BAT terminal.  In my case, I 
tried to use both Vin and VUSB with an external battery and charger, 
plugging and unplugging the charger would cause a brief brownout condition 
that would lock up the PMIC and require the power to be removed before you 
could turn it on again.  According to the TI doc, the PMIC was really 
designed for battery as the primary power source, so not having a battery 
plugged in leads to some imperfect results -- like not being able to turn 
the stupid thing on.  I'm now just using BAT and things appear to work.

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