We found that regardless of whether or not TPS65920 starts up correctly, the VIO output rail will rise to 0.6 to 0.8V soon after VBAT/VIN is applied. When the chip does start up correctly, VIO will then later (hundreds of ms) rise to it's correct output voltage of 1.8V. When it doesn't start correctly, VIO will remain around 0.8V.
When VIO remains in this 0.8V state, its output voltage tracks the VBAT/VIN voltage. The higher VBAT/VIN is, the higher VIO is.
If the chip does not power up properly, we discovered reducing the VBAT/VIN voltage below 3.3V will cause the chip to turn on. At the same time of reducing VBAT/VIN, VIO will reduce until it hits a threshold of 0.7V and it's at this point the chip seems to power on. Does this behavior make sense based on the internals of the IC? Is there an internal diode that could be latching on when it shouldn’t be?
We noted that if we lower the external power supply voltage to <3.3V and then apply power, the chip seems to power up correctly everytime. If we set the power supply voltage >3.3V and then apply power, the chip fails to power up, unless we subsequently reduce the input voltage to <3.3V. The ramp-up times for both the external power supply and the BFT power supply board are ~5-10 ms. We discovered that if we slowly turn up the power supply voltage by hand, the board starts up correctly as well.