Hi team
So i've been using the LM3481 for a sepic converter for a while and i have had problems with the board (Please refer to the previous thread: https://e2e.ti.com/support/power-management-group/power-management/f/power-management-forum/1257300/lm3481-mosfet-heating/4846543#4846543)
Right now, when i was testing a few new boards im running into new issues.
The board is having the following configuration:
Vin: 7S Li-ion (20V to 30V)
Vout: 24V/1A.
I was testing the board at a load of 0.5A when i started encoutering the issue. The board was running fine for around 2mins during testing and later on the voltage at the output dropped off to 0V and it kept trying to restart. During this restart attempt the board kept losing output regulation and after a while the diode shorted out and i ended up having a board with VOUT and GND dead short. Replaced the diode and did the same test and i again ended up shorting the diode. This kept happening and this behaviour was observed on multiple boards. Can somebody please help me figure out why this might be happening? I can share my PCB files and schematic on private chat for a review.
(Please note: At a load of 0.5A, the inductor heats upto about 77 deg.C (which is around 46 deg.C above ambient.))
Im attaching a text file for the the testing values:
2/1/2024 12:04:57 PM 24.132V 0.0000A 2/1/2024 12:04:57 PM 24.132V 0.0000A 2/1/2024 12:04:58 PM 24.131V 0.0000A 2/1/2024 12:04:58 PM 24.130V 0.0000A 2/1/2024 12:04:59 PM 24.132V 0.0000A 2/1/2024 12:04:59 PM 24.040V 0.1930A 2/1/2024 12:05:00 PM 24.046V 0.4991A 2/1/2024 12:05:00 PM 24.049V 0.4988A 2/1/2024 12:05:01 PM 24.052V 0.4988A 2/1/2024 12:05:01 PM 24.055V 0.4988A 2/1/2024 12:05:02 PM 24.056V 0.4988A 2/1/2024 12:05:02 PM 24.055V 0.4988A 2/1/2024 12:05:03 PM 24.057V 0.4988A 2/1/2024 12:05:03 PM 24.060V 0.4988A 2/1/2024 12:05:04 PM 24.060V 0.4988A 2/1/2024 12:05:05 PM 24.060V 0.4988A 2/1/2024 12:05:05 PM 24.061V 0.4988A 2/1/2024 12:05:06 PM 24.062V 0.4988A 2/1/2024 12:05:06 PM 24.063V 0.4988A 2/1/2024 12:05:07 PM 24.058V 0.4988A 2/1/2024 12:05:07 PM 24.057V 0.4988A 2/1/2024 12:05:08 PM 24.059V 0.4988A 2/1/2024 12:05:08 PM 24.059V 0.4988A 2/1/2024 12:05:09 PM 24.064V 0.4988A 2/1/2024 12:05:09 PM 24.064V 0.4988A 2/1/2024 12:05:10 PM 24.064V 0.4991A 2/1/2024 12:05:10 PM 24.065V 0.4988A 2/1/2024 12:05:11 PM 24.065V 0.4988A 2/1/2024 12:05:11 PM 24.066V 0.4988A 2/1/2024 12:05:12 PM 24.067V 0.4988A 2/1/2024 12:05:12 PM 24.069V 0.4988A 2/1/2024 12:05:13 PM 24.069V 0.4988A 2/1/2024 12:05:14 PM 24.070V 0.4988A 2/1/2024 12:05:14 PM 24.071V 0.4991A 2/1/2024 12:05:15 PM 24.071V 0.4988A 2/1/2024 12:05:15 PM 24.073V 0.4988A 2/1/2024 12:05:16 PM 24.073V 0.4991A 2/1/2024 12:05:16 PM 24.077V 0.4988A 2/1/2024 12:05:17 PM 24.083V 0.4988A 2/1/2024 12:05:17 PM 24.080V 0.4988A 2/1/2024 12:05:18 PM 24.084V 0.4988A 2/1/2024 12:05:18 PM 24.087V 0.4988A 2/1/2024 12:05:19 PM 24.087V 0.4991A 2/1/2024 12:05:19 PM 24.088V 0.4988A 2/1/2024 12:05:20 PM 24.088V 0.4988A 2/1/2024 12:05:20 PM 24.088V 0.4991A 2/1/2024 12:05:21 PM 24.088V 0.4988A 2/1/2024 12:05:21 PM 24.084V 0.4988A 2/1/2024 12:05:22 PM 24.082V 0.4988A 2/1/2024 12:05:23 PM 24.082V 0.4988A 2/1/2024 12:05:23 PM 24.079V 0.4988A 2/1/2024 12:05:24 PM 24.085V 0.4991A 2/1/2024 12:05:24 PM 24.087V 0.4988A 2/1/2024 12:05:25 PM 24.088V 0.4988A 2/1/2024 12:05:25 PM 24.089V 0.4988A 2/1/2024 12:05:26 PM 24.090V 0.4988A 2/1/2024 12:05:26 PM 24.088V 0.4991A 2/1/2024 12:05:27 PM 24.084V 0.4988A 2/1/2024 12:05:27 PM 24.086V 0.4988A 2/1/2024 12:05:28 PM 24.083V 0.4988A 2/1/2024 12:05:28 PM 24.082V 0.4988A 2/1/2024 12:05:29 PM 24.087V 0.4988A 2/1/2024 12:05:29 PM 24.087V 0.4988A 2/1/2024 12:05:30 PM 24.087V 0.4988A 2/1/2024 12:05:30 PM 24.087V 0.4988A 2/1/2024 12:05:31 PM 24.088V 0.4988A 2/1/2024 12:05:32 PM 24.087V 0.4988A 2/1/2024 12:05:32 PM 24.085V 0.4988A 2/1/2024 12:05:33 PM 24.079V 0.4988A 2/1/2024 12:05:33 PM 24.085V 0.4988A 2/1/2024 12:05:34 PM 24.088V 0.4991A 2/1/2024 12:05:34 PM 24.077V 0.4988A 2/1/2024 12:05:35 PM 24.072V 0.4988A 2/1/2024 12:05:35 PM 24.076V 0.4988A 2/1/2024 12:05:36 PM 24.076V 0.4988A 2/1/2024 12:05:36 PM 24.077V 0.4988A 2/1/2024 12:05:37 PM 24.079V 0.4988A 2/1/2024 12:05:37 PM 24.077V 0.4988A 2/1/2024 12:05:38 PM 24.080V 0.4988A 2/1/2024 12:05:38 PM 24.077V 0.4988A 2/1/2024 12:05:39 PM 24.080V 0.4988A 2/1/2024 12:05:39 PM 24.082V 0.4988A 2/1/2024 12:05:40 PM 24.082V 0.4988A 2/1/2024 12:05:40 PM 24.079V 0.4988A 2/1/2024 12:05:41 PM 24.077V 0.4988A 2/1/2024 12:05:42 PM 24.083V 0.4991A 2/1/2024 12:05:42 PM 24.082V 0.4991A 2/1/2024 12:05:43 PM 24.082V 0.4988A 2/1/2024 12:05:43 PM 24.082V 0.4988A 2/1/2024 12:05:44 PM 24.080V 0.4988A 2/1/2024 12:05:44 PM 24.078V 0.4988A 2/1/2024 12:05:45 PM 24.077V 0.4988A 2/1/2024 12:05:45 PM 24.079V 0.4988A 2/1/2024 12:05:46 PM 24.078V 0.4988A 2/1/2024 12:05:46 PM 24.080V 0.4988A 2/1/2024 12:05:47 PM 24.072V 0.4988A 2/1/2024 12:05:47 PM 24.070V 0.4988A 2/1/2024 12:05:48 PM 24.069V 0.4988A 2/1/2024 12:05:48 PM 24.067V 0.4988A 2/1/2024 12:05:49 PM 24.066V 0.4988A 2/1/2024 12:05:49 PM 24.066V 0.4988A 2/1/2024 12:05:50 PM 24.072V 0.4988A 2/1/2024 12:05:50 PM 24.072V 0.4988A 2/1/2024 12:05:51 PM 24.068V 0.4988A 2/1/2024 12:05:52 PM 24.068V 0.4988A 2/1/2024 12:05:52 PM 24.071V 0.4988A 2/1/2024 12:05:53 PM 24.069V 0.4988A 2/1/2024 12:05:53 PM 24.067V 0.4988A 2/1/2024 12:05:54 PM 24.063V 0.4988A 2/1/2024 12:05:54 PM 24.062V 0.4988A 2/1/2024 12:05:55 PM 24.058V 0.4988A 2/1/2024 12:05:55 PM 24.059V 0.4988A 2/1/2024 12:05:56 PM 24.062V 0.4988A 2/1/2024 12:05:56 PM 24.066V 0.4988A 2/1/2024 12:05:57 PM 24.055V 0.4988A 2/1/2024 12:05:57 PM 24.040V 0.4988A 2/1/2024 12:05:58 PM 24.045V 0.4988A 2/1/2024 12:05:58 PM 24.060V 0.4988A 2/1/2024 12:05:59 PM 24.043V 0.4988A 2/1/2024 12:05:59 PM 24.068V 0.4988A 2/1/2024 12:06:00 PM 24.072V 0.4988A 2/1/2024 12:06:00 PM 24.062V 0.4988A 2/1/2024 12:06:01 PM 24.039V 0.4988A 2/1/2024 12:06:02 PM 24.039V 0.4988A 2/1/2024 12:06:02 PM 24.038V 0.4988A 2/1/2024 12:06:03 PM 24.042V 0.4988A 2/1/2024 12:06:03 PM 24.042V 0.4988A 2/1/2024 12:06:04 PM 24.038V 0.4988A 2/1/2024 12:06:04 PM 24.037V 0.4988A 2/1/2024 12:06:05 PM 23.986V 0.4988A 2/1/2024 12:06:05 PM 23.998V 0.4988A 2/1/2024 12:06:06 PM 24.033V 0.4988A 2/1/2024 12:06:06 PM 24.062V 0.4988A 2/1/2024 12:06:07 PM 24.051V 0.4988A 2/1/2024 12:06:07 PM 24.062V 0.4988A 2/1/2024 12:06:08 PM 24.064V 0.4988A 2/1/2024 12:06:08 PM 24.047V 0.4988A 2/1/2024 12:06:09 PM 24.051V 0.4988A 2/1/2024 12:06:09 PM 23.922V 0.4988A 2/1/2024 12:06:10 PM 24.052V 0.4988A 2/1/2024 12:06:10 PM 24.048V 0.4988A 2/1/2024 12:06:11 PM 23.863V 0.4988A 2/1/2024 12:06:12 PM 23.955V 0.4988A 2/1/2024 12:06:12 PM 23.974V 0.4988A 2/1/2024 12:06:13 PM 23.901V 0.4988A 2/1/2024 12:06:13 PM 23.886V 0.4988A 2/1/2024 12:06:14 PM 24.005V 0.4991A 2/1/2024 12:06:14 PM 23.945V 0.4988A 2/1/2024 12:06:15 PM 24.007V 0.4991A 2/1/2024 12:06:15 PM 23.919V 0.4988A 2/1/2024 12:06:16 PM 24.036V 0.4988A 2/1/2024 12:06:16 PM 24.027V 0.4988A 2/1/2024 12:06:17 PM 24.004V 0.4988A 2/1/2024 12:06:17 PM 24.035V 0.4988A 2/1/2024 12:06:18 PM 23.896V 0.4988A 2/1/2024 12:06:18 PM 24.009V 0.4988A 2/1/2024 12:06:19 PM 24.007V 0.4988A 2/1/2024 12:06:19 PM 23.980V 0.4988A 2/1/2024 12:06:20 PM 23.974V 0.4988A 2/1/2024 12:06:20 PM 24.002V 0.4988A 2/1/2024 12:06:21 PM 24.023V 0.4988A 2/1/2024 12:06:22 PM 24.028V 0.4988A 2/1/2024 12:06:22 PM 24.011V 0.4988A 2/1/2024 12:06:23 PM 24.037V 0.4988A 2/1/2024 12:06:23 PM 24.042V 0.4988A 2/1/2024 12:06:24 PM 24.056V 0.4988A 2/1/2024 12:06:24 PM 24.064V 0.4988A 2/1/2024 12:06:25 PM 24.068V 0.4988A 2/1/2024 12:06:25 PM 24.063V 0.4988A 2/1/2024 12:06:26 PM 24.042V 0.4988A 2/1/2024 12:06:26 PM 24.031V 0.4988A 2/1/2024 12:06:27 PM 24.055V 0.4988A 2/1/2024 12:06:27 PM 24.061V 0.4988A 2/1/2024 12:06:28 PM 24.051V 0.4988A 2/1/2024 12:06:28 PM 24.063V 0.4988A 2/1/2024 12:06:29 PM 24.061V 0.4988A 2/1/2024 12:06:29 PM 24.052V 0.4988A 2/1/2024 12:06:30 PM 24.065V 0.4988A 2/1/2024 12:06:31 PM 24.049V 0.4988A 2/1/2024 12:06:31 PM 24.065V 0.4988A 2/1/2024 12:06:32 PM 24.056V 0.4988A 2/1/2024 12:06:32 PM 24.057V 0.4988A 2/1/2024 12:06:33 PM 24.062V 0.4988A 2/1/2024 12:06:33 PM 24.065V 0.4988A 2/1/2024 12:06:34 PM 24.064V 0.4988A 2/1/2024 12:06:34 PM 24.061V 0.4988A 2/1/2024 12:06:35 PM 24.069V 0.4988A 2/1/2024 12:06:35 PM 24.066V 0.4988A 2/1/2024 12:06:36 PM 24.065V 0.4988A 2/1/2024 12:06:36 PM 24.053V 0.4988A 2/1/2024 12:06:37 PM 24.055V 0.4988A 2/1/2024 12:06:37 PM 24.054V 0.4988A 2/1/2024 12:06:38 PM 24.055V 0.4988A 2/1/2024 12:06:38 PM 24.049V 0.4988A 2/1/2024 12:06:39 PM 24.051V 0.4988A 2/1/2024 12:06:39 PM 24.050V 0.4988A 2/1/2024 12:06:40 PM 24.049V 0.4988A 2/1/2024 12:06:41 PM 24.048V 0.4988A 2/1/2024 12:06:41 PM 24.043V 0.4988A 2/1/2024 12:06:42 PM 24.038V 0.4988A 2/1/2024 12:06:42 PM 24.042V 0.4988A 2/1/2024 12:06:43 PM 24.034V 0.4988A 2/1/2024 12:06:43 PM 24.030V 0.4988A 2/1/2024 12:06:44 PM 24.030V 0.4988A 2/1/2024 12:06:44 PM 24.029V 0.4988A 2/1/2024 12:06:45 PM 24.003V 0.4988A 2/1/2024 12:06:45 PM 23.987V 0.4988A 2/1/2024 12:06:46 PM 23.967V 0.4991A 2/1/2024 12:06:46 PM 23.965V 0.4988A 2/1/2024 12:06:47 PM 23.945V 0.4988A 2/1/2024 12:06:47 PM 23.909V 0.4988A 2/1/2024 12:06:48 PM 23.889V 0.4988A 2/1/2024 12:06:48 PM 23.864V 0.4988A 2/1/2024 12:06:49 PM 23.862V 0.4991A 2/1/2024 12:06:49 PM 23.855V 0.4988A 2/1/2024 12:06:50 PM 23.836V 0.4988A 2/1/2024 12:06:51 PM 23.808V 0.4988A 2/1/2024 12:06:51 PM 23.790V 0.4988A 2/1/2024 12:06:52 PM 23.780V 0.4988A 2/1/2024 12:06:52 PM 23.721V 0.4988A 2/1/2024 12:06:53 PM 23.719V 0.4988A 2/1/2024 12:06:53 PM 23.706V 0.4988A 2/1/2024 12:06:54 PM 23.701V 0.4988A 2/1/2024 12:06:54 PM 23.694V 0.4991A 2/1/2024 12:06:55 PM 23.684V 0.4988A 2/1/2024 12:06:55 PM 23.634V 0.4988A 2/1/2024 12:06:56 PM 23.627V 0.4988A 2/1/2024 12:06:56 PM 23.614V 0.4988A 2/1/2024 12:06:57 PM 23.599V 0.4991A 2/1/2024 12:06:57 PM 23.542V 0.4988A 2/1/2024 12:06:58 PM 23.530V 0.4988A 2/1/2024 12:06:58 PM 23.514V 0.4988A 2/1/2024 12:06:59 PM 23.532V 0.4988A 2/1/2024 12:06:59 PM 23.498V 0.4991A 2/1/2024 12:07:00 PM 23.481V 0.4988A 2/1/2024 12:07:01 PM 23.491V 0.4988A 2/1/2024 12:07:01 PM 23.492V 0.4988A 2/1/2024 12:07:02 PM 23.493V 0.4988A 2/1/2024 12:07:02 PM 23.494V 0.4988A 2/1/2024 12:07:03 PM 23.495V 0.4988A 2/1/2024 12:07:03 PM 23.492V 0.4988A 2/1/2024 12:07:04 PM 23.482V 0.4988A 2/1/2024 12:07:04 PM 23.465V 0.4988A 2/1/2024 12:07:05 PM 23.458V 0.4988A 2/1/2024 12:07:05 PM 23.452V 0.4988A 2/1/2024 12:07:06 PM 23.424V 0.4988A 2/1/2024 12:07:06 PM 23.418V 0.4988A 2/1/2024 12:07:07 PM 23.412V 0.4988A 2/1/2024 12:07:07 PM 23.405V 0.4988A 2/1/2024 12:07:08 PM 23.403V 0.4988A 2/1/2024 12:07:08 PM 23.403V 0.4988A 2/1/2024 12:07:09 PM 23.400V 0.4988A 2/1/2024 12:07:10 PM 23.397V 0.4988A 2/1/2024 12:07:10 PM 23.394V 0.4988A 2/1/2024 12:07:11 PM 23.389V 0.4988A 2/1/2024 12:07:11 PM 23.393V 0.4988A 2/1/2024 12:07:12 PM 23.390V 0.4991A 2/1/2024 12:07:12 PM 23.383V 0.4988A 2/1/2024 12:07:13 PM 23.380V 0.4988A 2/1/2024 12:07:13 PM 23.380V 0.4988A 2/1/2024 12:07:14 PM 23.388V 0.4988A 2/1/2024 12:07:14 PM 23.396V 0.4988A 2/1/2024 12:07:15 PM 23.394V 0.4988A 2/1/2024 12:07:15 PM 23.384V 0.4988A 2/1/2024 12:07:16 PM 23.381V 0.4988A 2/1/2024 12:07:16 PM 23.378V 0.4991A 2/1/2024 12:07:17 PM 23.379V 0.4988A 2/1/2024 12:07:17 PM 23.364V 0.4988A 2/1/2024 12:07:18 PM 23.349V 0.4988A 2/1/2024 12:07:18 PM 23.318V 0.4988A 2/1/2024 12:07:19 PM 23.309V 0.4988A 2/1/2024 12:07:20 PM 23.305V 0.4988A 2/1/2024 12:07:20 PM 0.0000V 0.4988A 2/1/2024 12:07:21 PM 23.288V 0.4988A 2/1/2024 12:07:21 PM 0.0000V 0.0010A 2/1/2024 12:07:22 PM 0.0000V 0.4991A 2/1/2024 12:07:22 PM 0.3310V 0.4988A 2/1/2024 12:07:23 PM 0.3310V 0.1405A 2/1/2024 12:07:23 PM 0.3310V 0.1405A 2/1/2024 12:07:24 PM 0.3310V 0.1405A 2/1/2024 12:07:24 PM 23.334V 0.4991A 2/1/2024 12:07:25 PM 0.0000V 0.0025A 2/1/2024 12:07:25 PM 23.345V 0.4991A 2/1/2024 12:07:26 PM 0.0000V 0.0020A 2/1/2024 12:07:26 PM 23.340V 0.0957A 2/1/2024 12:07:27 PM 1.0293V 0.0957A 2/1/2024 12:07:27 PM 1.0293V 0.0957A 2/1/2024 12:07:28 PM 1.0293V 0.4991A 2/1/2024 12:07:28 PM 0.0368V 0.0303A 2/1/2024 12:07:29 PM 23.325V 0.4991A 2/1/2024 12:07:30 PM 23.294V 0.4988A 2/1/2024 12:07:30 PM 23.294V 0.0743A 2/1/2024 12:07:31 PM 0.2352V 0.1760A 2/1/2024 12:07:31 PM 0.0262V 0.4991A 2/1/2024 12:07:32 PM 1.1926V 0.3081A 2/1/2024 12:07:32 PM 0.4986V 0.1171A 2/1/2024 12:07:33 PM 23.359V 0.1171A 2/1/2024 12:07:33 PM 0.1996V 0.0556A 2/1/2024 12:07:34 PM 0.1996V 0.0556A 2/1/2024 12:07:34 PM 0.3153V 0.1704A 2/1/2024 12:07:35 PM 23.352V 0.4991A 2/1/2024 12:07:35 PM 1.1956V 0.1935A 2/1/2024 12:07:36 PM 1.1956V 0.4991A 2/1/2024 12:07:36 PM 0.5002V 0.4991A 2/1/2024 12:07:37 PM 0.5002V 0.1917A 2/1/2024 12:07:37 PM 23.345V 0.4991A 2/1/2024 12:07:38 PM 0.2568V 0.3127A 2/1/2024 12:07:38 PM 0.4346V 0.1248A 2/1/2024 12:07:39 PM 23.792V 0.0000A 2/1/2024 12:07:40 PM 23.974V 0.0000A 2/1/2024 12:07:40 PM 24.728V 0.0000A 2/1/2024 12:07:41 PM 24.328V 0.0000A 2/1/2024 12:07:41 PM 23.715V 0.0000A 2/1/2024 12:07:42 PM 23.408V 0.0000A 2/1/2024 12:07:42 PM 24.023V 0.0000A 2/1/2024 12:07:43 PM 23.434V 0.0000A 2/1/2024 12:07:43 PM 23.107V 0.0000A 2/1/2024 12:07:44 PM 23.436V 0.0000A 2/1/2024 12:07:44 PM 25.525V 0.0000A 2/1/2024 12:07:45 PM 24.027V 0.0000A 2/1/2024 12:07:45 PM 23.959V 0.0000A 2/1/2024 12:07:46 PM 24.510V 0.0000A 2/1/2024 12:07:46 PM 23.389V 0.0000A 2/1/2024 12:07:47 PM 23.455V 0.0000A 2/1/2024 12:07:47 PM 22.819V 0.0000A 2/1/2024 12:07:48 PM 23.710V 0.0000A 2/1/2024 12:07:49 PM 23.457V 0.0000A 2/1/2024 12:07:49 PM 23.306V 0.0000A 2/1/2024 12:07:50 PM 24.873V 0.0000A 2/1/2024 12:07:50 PM 23.632V 0.0000A 2/1/2024 12:07:51 PM 24.063V 0.0000A 2/1/2024 12:07:51 PM 24.335V 0.0000A 2/1/2024 12:07:52 PM 24.035V 0.0000A 2/1/2024 12:07:52 PM 24.830V 0.0000A 2/1/2024 12:07:53 PM 22.706V 0.0000A 2/1/2024 12:07:53 PM 23.503V 0.0000A 2/1/2024 12:07:54 PM 24.466V 0.0000A 2/1/2024 12:07:54 PM 24.546V 0.0000A 2/1/2024 12:07:55 PM 24.124V 0.0000A 2/1/2024 12:07:55 PM 23.980V 0.0000A 2/1/2024 12:07:56 PM 24.792V 0.0000A 2/1/2024 12:07:56 PM 23.556V 0.0000A 2/1/2024 12:07:57 PM 23.924V 0.0000A 2/1/2024 12:07:57 PM 24.320V 0.0000A 2/1/2024 12:07:58 PM 23.314V 0.0000A 2/1/2024 12:07:59 PM 22.811V 0.0000A 2/1/2024 12:07:59 PM 14.001V 0.0000A 2/1/2024 12:08:00 PM 10.474V 0.0000A 2/1/2024 12:08:00 PM 8.2461V 0.0000A 2/1/2024 12:08:01 PM 5.6298V 0.0000A 2/1/2024 12:08:01 PM 4.7927V 0.0000A 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