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TAS6422-Q1: TAS6422 Overcurrent Issue

Part Number: TAS6422-Q1

Hello TI Team,

This is an continuation of the same case from last year. We finally got around to improve the cooling, replace the output inductors and more, but the tas6422 still goes into overcurrent on channel 2 if we have both speakers connected and the sound is going full blast.

Just to give the full picture: We have an application where we use the tas6422 in a car setting (14.4V) providing sound to two 2Ohm speakers. If we have both speakers connected and the amplifier in 15V gain, then channel two will go into overcurrent error when we reach a volume of about 210. The sound, which is played is mono, so both speakers should get the same signal.
No error will happen if we only have 1 speaker connected, or if we reduce the gain to 7.5V. But then the system is not as loud, which is ofcourse not good.
The last time we discussed this error, there was also some temperture error and some concerns regarding the inductors. So we improved that.

The registers in the error condition now show the following:
0 - 0x0
1 - 0x11
2 - 0x72
3 - 0x4
4 - 0x0
5 - 0xe5
6 - 0xe5
7 - 0xcf
8 - 0xcf
9 - 0x0
10 - 0x0
11 - 0x11
12 - 0x0
13 - 0x0
14 - 0x0
15 - 0x15
16 - 0x40
17 - 0x0
... (all zero)
33 - 0x88
34 - 0x1
35 - 0x14
36 - 0x3
37 - 0x0
38 - 0x2
39 - 0x60
40 - 0xa


For the temperature, we worked with fischer electronics to improve the temperature handling and according to them, we should have now enough cooling for the power delivered. If wanted i can also proved a pdf with their analysis.

The output inductors are now DFEH7030D-3R3M=P3 wich can handle more current.

Can you help us improve this issue ? Or somehow help to explain or debug this ?
What i dont really understand: According to the datasheet, overcurrent shutdown on OC LEvel 2 should happen with currents over 9 Amps. But with 14.4V and 2 Ohm speakers we should never be able to reach that ?