Other Parts Discussed in Thread: TPS2546,
Dear All,
One of my customer using TPS54260DGQR part for 48V to 5V,2.5A Mobile Charger, they produced about 7000 boards and faced issue in about 300-400 boards.
I’m attaching the photograph of two failed modules,schematic for your information and mentioned customer observations below.
1. First, the bulk converter IC fails causing the output 5V gets short circuited
2. The resultant short circuit allows high current through the fuse and the fuse immediately cuts off the current path
3. The fuse used is PTC type (60V, 100A, trip current of 0.5A to 1A) whose resistance tends to increase with temperature caused by high current and thus blocks more current and radiates as heat.
4. This generated heat keeps on heating the entire board and gradually at some point of time when the fuse fails with a spark may cause the entire board to catch fire easily.
Kindly review and suggest if there is any other cause for it & to resolve the issue.CHARGER SCHEMATICS.pdf
Rgds,
Aravind.
