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BQ25611D: my µC resets when I plug a charger

Part Number: BQ25611D
Other Parts Discussed in Thread: TPS63031, INA230

Hello,
I am facing a really strange issue that I was not able to diagnose. I'm just posting a message here if someone has better ideas to fix it.

Here is my schematic:

power pcb schematic.pdf

Here is my board layout (far from being perfect, I know):
power pcb board - top.pdfpower pcb board - bottom.pdf

On my previous board revision everything works properly. Here is what I changed since:

  • Switching from TPS631000DRLR to TPS63031DSKR due to inventory issues. I'm using this chip to get a 3.3V power supply to my RP2040 µC. These chips are using the SYS output of the BQ25611D to get power
  • Adding the missing 1µF capacitor very close to the charger input, I did forget it in my previous board revision
  • Fixing INT wiring. In my previous board revision, it was plugged incorrectly to 3.3V instead of a proper µC input

On this new board revision everything is working too except when I plug a power source to the BQ25611D chip, my µC resets. It was not the case before.

Here is what I tried to diagnose:

  • Disabling charging (by setting /CE to HIGH): it stops resetting, but I need charging to work. When the RP2040 resets, it won't reset again until I enable back charging
  • Monitoring 3.3V output from my TPS63031 with a scope: perfectly stable, even when plugging/unplugging the charger
  • Monitoring the internal 1.1V from my RP2040 with a scope: perfectly stable too
  • Monitoring the RUN input (where the RESET button is plugged too): perfectly stable to 3.3V too, even if my pull up resistor and my decoupling cap is a bit too far from the RP2040. I did manage to plug my probe directly to the RP2040 RUN pin and can confirm it's rock stable
  • Monitoring voltage/current pulled from USB to my BQ25611D: nothing special, steady 5V with 0.01A to 0.1A load depending on the situation. Something is weird though: when I'm using a laptop to provide USB power, sometimes it cuts the USB power, like if there were a short circuit for a very bried period of time. But when I'm using a lab bench PSU, I'm not seeing any current spike and the issue still occurs.
  • Using a very basic "Blink" Arduino sketch to confirm it was not a firmware issue: when blinking a LED with charging disable it works, when setting /CE to LOW, it resets again continiously
  • Using a basic Arduino sketch to get the last reset reason: work still in progress but it looks like the reset reason is the same as when pressing the reset button. But as I said earlier, the RUN input is perfectly stable

Any ideas are welcome!

  • Hello,

    My schematic review is as follows:

    1. We recommend pulling STAT up with 10 kOhm resistor. With a 1kOhm you are close to the ABS MAX of 6 mA on the STAT pin.

    For the layout, can you please send the gerbers? It will greatly help me to identify any possible layout issues.

    Can you please capture 2 waveforms: First of VBUS, VSYS, VBAT, and IBUS, second of VBUS, VSYS, SW, and IBAT? Do this whenever the behavior is observed.

    I am noting that the change in the 3.3 V PSU goes from 2 A capability to 800 mA capability. How much current is projected to be drawn from SYS?

    Regards,

    Mike Emanuel

  • Hello Mike,

    Thank you for your reply. You will find in attachment my gerbers. 0216.gerber.zip My layout is not perfect at all. I'm not sure how much my bad layout can be related to my issue.

    I will try to replace my 1k resistor to a 10k one. But as mentionned, on other boards that I made (with the previous revision design) it worked like a charm.

    I do not have proper test equipment with me to show you the 2 waveforms, I will post them back as soon as I can.

    Yes I did choose a 3.3V PSU with way lower capability. If I'm not wrong, I'm still pretty far from 500mA. The only three things that are plugged to it are my RP2040 (should use less than 50mA), its W25Q32 flash (should use less than 5mA) and my INA230 (should use less than 350µA). Everything else draws current from SYS or directly from the battery itself.

    Best regards,

    Gauthier

  • Hello Gauthier,

    Please keep in mind there are no via markers so my layout review is limited (especially on the GND connection). My layout review is as follows:

    1. VBUS C41 is very far away from the VBUS pin. Please move VBUS capacitor closer to IC pin.

    2. PMID C33 is far away from the PMID pin. Please move PMID capacitor closer to IC pin. This is the number 1 layout guideline and the most important.

    3. BATSNS does not seem like is connected to the positive terminal of the battery pack, rather the connector on the way to the battery pack.

    Awaiting your waveforms.

    Regards,

    Mike Emanuel