I have a design that is using two TUSB2077 USB hub chips. The schematic and card layout are identical. We have built about 75 cards now and I have found five cards that one of the TUSB2077 chips does not work. I noticed that the crystal was not oscillating and suspected the reset may not be held long enough after power was applied. This was not the case but I did notice that if the reset is pulled low on the non-worklng chip the crystal starts to run (6MHz). It is really puzzling that a few cards are failing and I can not detect anything different in the voltage levels of the input pins on the working versus the non-working part. Any suggestions on how to resolve this?
I have looked at the power rail ramp up. It is in spec, the MODE pin is pulled low with a 1K ohm resistor, EXTMEM_N pin is pulled up to 3.3v with a 1K ohm resistor, BUSPWR and EEDATA/GANGED_N are pulled up with 1K ohm resistors. Reset is driven low then high by the PPOWER_GOOD signal from the switching regulator 2ms after 3.3v is within 10%