This thread has been locked.

If you have a related question, please click the "Ask a related question" button in the top right corner. The newly created question will be automatically linked to this question.

TPS61220 vout too low

Other Parts Discussed in Thread: TPS61220

I am working on a power supply circuit, and am using a TPS61220 as one of the powering methods. Now the fact that its only one section of the power supply is less important, because even the fabricated test boards that have been made with just the charge pump have the same behavior. We are looking for it to take a single AA battery, and have the supplied voltage of 5.5V, with a nominal load current of approximately 1mA. The layout being used is the one from the "design considerations" section on page 15 of the datasheet. 

The first thing that we noticed: When the battery is initially connected (about 70% of the time) the current consumption from the battery is 80mA - 100mA, the output voltage is around 2V. Since the current supplied to the load is only around 700uA under these conditions (confirmed with ammeter), I can only assume that most of that current is being shunted straight to ground somehow. 

Once it has been pulled OUT of this first failure mode, (which takes a variety of odd steps, not always the same ones) and it starts operating "normally" (meaning only consuming about 5mA-7mA of current) it still only provides around 3.6V, and ballpark of 800uA to the load. Since this is an order of magnitude lower than its rated maximum current, it seems like it should be allot closer to 5.5V

The design uses a 4.7uH inductor although a 10uH has been tried also. The capacitors are each 10uF, and the feedback resistors are 1M and 100k.  

It can be noted that unloaded, it does provide the correct voltage, but when a pot is added to simulate a resistive load, voltage drops precipitously with just a few hundred uA of load current.

Is this something anyone has seen before, or knows where one might start troubleshooting this problem? This is not an isolated incident, every one of the demonstration boards that has been made up has had the same problems. And the components have been changed quite radically just to see if it would make any difference (100uH inductor for example to see if it was the switching frequency that was somehow limiting the output power, it wouldn't even turn on with this size inductor, but it was worth a shot).

Is this the wrong component for this design? The datasheet seems to indicate that this is the ideal choice.

thank you in advance for your time

  • It sounds like noise is getting into your circuit.  Could you post your schematic and layout?  Even though it is similar to the datasheet, small changes can have a drastic impact on performance.

    Also, how are you driving the EN pin?  What voltage is it at?

    Could you send a scope capture of Vin, Vout, and L?

    What inductor are you using?

    You can try adding more input capacitance to overcome the impedance of the battery.

  • Thank you for your help Chris. 

      here is the schematic of the circuit. 

    The only omission from it compared to the prototype board I'm currently using is that there is an extra inductor between C3 and C1. I was just trying to isolate some HF noise going to the load, since this is the power circuit for a microphone, and noise is literally audible. 

    The switch (the J177) is designed to take a high voltage, and switch off the charge pump if that high voltage is detected. This has been shown to work perfectly, and I have tried directly connecting the Vin and En lines together, and experience the same behavior explained in my original post.

    I will note that the failure mode where it consumes tremendous current is not exclusively, but sometimes accompanied by the inclusion of the Fluke 45 current monitoring. It has a relatively small burden voltage (.14V in the range I'm trying to measure) and you can get it out of the failure mode with the Fluke 45 still connected in series with the battery. 

     This is the output of the Fluke 45 during failure, and  is when through adjusting the load and taking the battery in and out of the circuit repeatedly it finally entered a stable operating mode. The 1.2mA seems quite high, as there is no load between J2 and J5, but working better than 51mA. 

    The EN input   and Vin

    These both stay quite stable. There is a drop in voltage during the high current failure mode, where both lines drop to about 1.2V peak, and some noise is visible, which is understandable just from the ESR of the battery with those kind of currents being drawn through it. 

    Now is the interesting stuff: The output completely unloaded, 4.88V. Not the 5.5V that is supposed to be the max, but decent. 

     What is interesting, that by connecting a 10k trimpot between J2 and J5, when its at its maximum value, this is how Vout looks The output voltage immediately drops to 3.12V. Since this is only 312uA of current delivered to this load, that seems like a shockingly low value to drag Vout down so far. 

     and this is what the inductor L pin output looks like. I suspect this may be the heart of the problem, as I was expecting this to be a far more continuous signal, not nearly as periodic as its appearing, but it seems to always do this unless its in its high current failure mode.  this is the L pin during the high current failure mode. Obviously something is wrong, but I threw it in for illustration of my suspicion that the normal operation of the L pin should be far more periodic. 

     

    The inductor in the circuit is a 4.7uH Murata 0805 surface mount http://www.mouser.com/ProductDetail/Murata/LQM21DN4R7N00D/?qs=sGAEpiMZZMukHu%252bjC5l7YVznKgN%252bnMmGc9h9b4wxHqA%3D

    The tech who made the original board will be fabricating me a new version this weekend which will include a space for a larger capacitor on the input to compensate for the impedance of the battery as you suggest. 

    If its possible can you share with me what the voltage output of the L pin should look like under these conditions? Is the Icoil on the datasheet on page 8 the signal that should be present there? 

    Thank you again for your time. 

     

  • Thank you for your detailed reply.  Figures 21 and 22 show what the L node should look like.  Obviously, yours is different.  A few things to try:

    Use an inductor that is rated for a higher current.  As figure 22 shows, even at a very light load, the peak current in the inductor will be relatively high--150 mA.  Your inductor needs to have a saturation rating higher than this.  The inductance versus current graph for your inductor doesn't even go to 100 mA, so this inductor is very undersized.

    It could also be your board layout.  Could you post yours?

    I would really recommend ordering the EVM and testing your circuit on it.  The board design and components are proven to work with this IC.

    Can you try powering your circuit with just a lab supply set to 1.2V and no current meter?

    Finally, can you replace your Cin and Cout with ceramics? 

  • Chris, thank you for your timely reply. 

    I think that you are exactly right about the saturation rating of the inductor I'm using. It has a max current rating of 30mA, as I did not see the division markers on the PDF of figure 22. I will get the specific coilcraft inductor that is specified in the datasheet, then try again. Also, the capacitors currently being used are tantalum polarized. Is there a particular reason you say ceramic? I know that the datasheets example uses X5R's, and of course power supply bypass caps usually care less about temperature tolerances, we just have the tantalum ones already so that;s why we use them. 

    I will leave this for now while I wait for the larger inductor to come in, and the new board to get fabricated which will use that larger unit. If I'm still having trouble when I get everything in, I will post on here again. 

    Thank you for your help

     

  • Yes, testing with the inductor in the datasheet would be a good start.

    Ceramics are cheaper and smaller typically.  But more importantly for power supplies, they have much much less impedance (ESR).  How much ESR do your tantalums have?  With power supplies switching at very high frequencies, they need pulses of current from these caps in very short times.  If the caps can't deliver these current pulses, then the bus sags due to the drop across the impedance.

    I highly recommend using ceramics on the input and output.  You can keep the tantalums in parallel if you want.