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TPA3255: Output nearly-dead; advice on debugging steps

Part Number: TPA3255

The design uses the dual BTL  (M1 = 0, M2 = 0), and it is a revision ("second generation") of a previous design that was working ok.

This is the partial schematic  (most of the decoupling network not shown;  but it is essentially identical to what's suggested in the datasheet):

(notice, RT7 is the OC resistor, I set it to 22k;  RT8 is the FREQ_ADJ resistor, set to 10k for AM2 — 600kHz — PWM frequency)

I'm applying 30V to all PVDD voltages, and a 12V wall adapter (producing 12.1V as measured at pin 2 of the TPA3255).

I confirmed (via test points) that M1 and M2 are both set to 0.

The symptoms:

The output activates and produces exactly 10 pulses (i.e., if I look at one of the output pins; e.g., OUT_A) before it shuts off.  The frequency is dead-on:  6 pulses in exactly 10 μs.   At the time that the output dies, FAULT is asserted, just for a little while.  The process repeats maybe every 100ms or 200ms?  (I can see the FAULT LED blinking more or less fast)

The output does not seem shorted.  I check with an ohmmeter, and I get: between either one of the outputs (OUT_A, B, C, or D) and GND, approximately 250 kΩ;  between OUT_A and OUT_B, approx. 700 kΩ;  same thing between OUT_C and OUT_D.

At first, the output had no load whatsoever  (in the design, the LC output filter is on a separate board).  I connected a light resistive load just in case  (200 Ω between OUT_A and OUT_B, 200 Ω between OUT_C and OUT_D).  Did not change anything.

Additional "debugging information/hints" I measured:

  • Voltage at OSC_ADJ pin:  1 V
  • Voltage at FREQ_ADJ pin:  approx. 0.8 V
  • Voltage at C_START pin:  0 V

  • Pin 2:  12.1 V
  • Pin 1:  10.55 V
  • Pin 22:  11.5 V

  • Pin 11:  3.31 V
  • Pin 14:  7.82V

Any ideas of what else I should try / measure?  (or in any case, anyone recognizes the symptoms and can guess where the culprit may be?)

Thanks,
Carlos
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  • Hi Carlos,

    Do you know what was changed from this revision and the first? Was the layout changed as well?

    Also what is the LC filter that you are using? What's the current limit of your power supplies? 

    Regards,

    Robert Clifton

  • > Do you know what was changed from this revision and the first? Was the layout changed as well?

    Mostly the input.  First generation has a DSP (an ADAU1701) with its DAC outputs going to the TPA3255 inputs.   This "second generation" has a CS4398 DAC to make the board essentially a two-channel power amplifier with I2S input.

    The layout for the amplifier was slightly changed, since I also decided to put a larger heatsink, w.r.t. the previous design.   Still, the schematics did not change (the TPA part, that is) at all, and KiCAD reports that the layout has no errors, so I am somewhat confident that the changes in the layout should not be the culprit.

    > Also what is the LC filter that you are using? What's the current limit of your power supplies?

    For the "debugging", I am not connecting any LC filter.  (I mentioned this in passing, see above — I ended up loading the outputs with a 200 Ω 10W resistor, for testing purposes).   As for the power supplies, I tried with a MeanWell LRS-100-36, which is rated 2.8A, and this morning I tried with a bench-top power supply and set the current limit to 3A.

    For any current "spikes"/peaks, in addition to the 1μF decoupling capacitors next to the TPA pins, the board has, for each PVDD, two 68μF aluminum-polymer bulk capacitors in parallel  (total four 68μF capacitors).

    Thanks,
    Carlos
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  • Hi Carlos,

    As it seems to be quick long discussion, it is recommended to discuss it offline by emailing to Robert. 

    But anyway, it is determined by you and Robert. 

    Thanks,

    Alix Wan.

  • Looks like the problem was a mundane case of a "fried" TPA3255. 

    I just assembled a whole new board  (as in, the exact same board, from the same five units I had ordered from the PCB fab), and it looks like it's working perfectly.  I have not put a speaker at the output  (or the LC filter, for that matter), but I inject tones through the I2S input, and I see the PWM at the output moving.  The FAULT indicator remains off, and the 600kHz at the output don't go away.

    There was probably a (temporary) unintended connection/short with the heatsink, since some of the caps underneath it were a bit too tall, so they may have made contact with the heatsink and burn something inside the TPA.

    I'm closing this one, and if anything I will ask a related question if there's something else that's not working as expected.

    Thanks, and sorry for the "false alarm" !

    Carlos
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