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BQ25703A: MOSET switching irregularities causing board failure

Part Number: BQ25703A

Tool/software:

We are using the BQ25703A in a production board, and during testing we have had board failures with the following behaviour:

  • Low input current draw when idle (much lower than usual: 10mA instead of usual ~45mA)
  • Output voltage is low (11.1V instead of lower limit of 11.6V)
  • We can see that the MOSFET switching is made up of lots of short pulses instead of one smooth pulse as seen on a passing board:
    Healthy passing board:

    Failing board:

We have not been able to isolate this problem to any faulty components.

We have looked at the switching components, the input filter components, as well as the current sense components.

Replacing the BQ25703A did not resolve this behaviour.

Can anyone please advise what might be causing the BQ25703A to behave this way?