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TPS54231: TPS54231 Hanging issue

phanendra k
Intellectual 430 points
Part Number: TPS54231
Other Parts Discussed in Thread: LM317

Hi,

I have a query on the TPS54231,we are using this circuit for a CCTV camera supply.

We are operating with a Li-Ion 14.8V,5.2Ah battery and are charging with Solar Panel.
This Li-Ion battery is acting as input source for the TPS54231.
We have adjusted UVLO voltage at 13.8V for TPS54231 and Output voltage at 11.5V.

The camera at startup spikes to around 300mA to 340mA and settles down to 120mA to 130mA.
The normal operating voltage&current for CCTV is 11.5V/120to160mA respectively.

During the battery is full condition the CCTV camera is working fine and there is no issue.

But due to cloudy weather conditions sometimes the battery reaches LowerCutoff(LCO)
& during night time and camera gets shut off.

At this point the next day during Day time the Solar panel charges the battery,and it reaches from LCO to UVLO point of TPS54231,
during this transition then the CCTV camera functionality is inconsistent(some times it works and some time it gets hang),

CCTV camera is in Hanging condition means it doesn't work even it gets correct Voltage.

During startup CCTV camera compulsory needs 100mA to 180mA but its not happening.
What could be the reason for this hanging condition ?
Previously we have used LM317 same hanging problem occured there the chance of hanging is 90% but after switching to TPS54231 the chance of hanging went to 50% but we want to completely eliminate thia hanging problem.

As we are installing these Solar based CCTV at customer locations but facing these issues.

Please guide us,quick reply would help us.  

Kind Regards,

K.S.S.Phanendra,
 


 

  • 0
    TI__Genius 10070 points
    Hi,

    "some times it works and some time it gets hang", is this the same equipment? Could you please share the schematic? Let's review the schematic to see if there is any issue.
    And please double check the UVLO point.

    Shawn
  • 0 in reply to phanendra k
    Intellectual 430 points
    Hi Shawn Nie,

    Please find the schematic above in our supply board we are using only Vcc &GND from the header and LED and other pins are not used in the Header 2X2 diagram.

    In the schematic we are using the below components,The components that are not mentioned are NC in the circuit.

    R3 = 1.5Kohms
    R2 = 20Kohms
    R4,R6,R7 = 10Kohms
    R1 = 100Kohms
    R5 = 30Kohms
    C5 = 1000pF/16V
    C1,C8,C9 = 100nF/16V
    C3 = 0.1uF/50V
    C7 = 100pF/50V
    C2,C4 = 100uF/63V
    U2.4 & U2.8
    on J1
    D1 = SS14-E3/61T
    D2 = PMEG6010EP,115
    L1 =47uH/2A
    U1 = TPS54231DR
  • 0 in reply to phanendra k
    TI__Genius 10070 points
    Hi,

    The values are invisible.

    And when the battery is charged to 14.8V, still TPS54231 can't start up?

    Shawn
  • 0 in reply to phanendra k
    TI__Genius 10070 points
    Hi,

    The device will start when the battery's voltage is higher than 13.8+0.7=14.5V, you need to ensure the battery's voltage can be charged to 14.5V.

    Shawn
  • 0 in reply to Shawn Nie
    Intellectual 430 points

    Hi ,

    In the below reply after schematic , i have given in the list of values,please check it.

  • 0 in reply to phanendra k
    Intellectual 430 points
    Hi Shawn,

    Even the voltage is 16.4 for the battery full condition and have enough current there is still hanging.
    When 16.4V (Battery Full condition) is reached from the LCO point then this happens.(some times hangs and some times works)
  • 0 in reply to Shawn Nie
    Intellectual 430 points

    Hi Shawn,

    Can you please clarify regarding it.

  • 0 in reply to phanendra k
    TI__Genius 10070 points
    Hi,

    For the same board, some times hangs and some times works, right? Or some boards work, and the other boards didn't work?
    Have you checked the voltage of input pin when the battery is reached to 16.4V and the equipment didn't work? Please double check the voltage of input pin to ensure it is higher than 13.8V.
    In addition, could you please share the layout? Let's review it.

    Shawn
  • 0 in reply to Shawn Nie
    Intellectual 430 points

    Hi Shawn,

    For the same board, some times hangs and some times works, right?

    Yes

    Or some boards work, and the other boards didn't work?

    No its the problem in every board.


    Have you checked the voltage of input pin when the battery is reached to 16.4V and the equipment didn't work?

    Yes, as the battery gradually reaches from LCO point to 16.4V this problem arises and it hangs like 40% to 50% of times.

    If the voltage is above 13.8V and if it reaches 16.4V then there will be no issue of hanging.

    Please double check the voltage of input pin to ensure it is higher than 13.8V.
    In addition, could you please share the layout? Let's review it.

    Do you need the component layout or track layout of the schematic as it is a double sided Board.?

     

    Regards,

    K.S.S.Phanendra

  • 0 in reply to phanendra k
    TI__Genius 10070 points
    Hi,

    You can share the pictures of two layers, or the file of layout.

    "If the voltage is above 13.8V and if it reaches 16.4V then there will be no issue of hanging." I can't understand it clearly, you mean when the input voltage is above 13.8V, there is no issue right?

    Shawn
  • 0 in reply to Shawn Nie
    Intellectual 430 points

    Hi Shawn,

    Please find the layout ,

    My point is,

    When the voltage of battery reaches 16.4V(battery full) from the LCO point then the hanging problem occurs.

    If the voltage of the battery is at 14V and if it reaches to 16.4V(battery full) then the hanging problem doesn't occur.

  • 0 in reply to phanendra k
    TI__Genius 10070 points
    Hi

    "When the voltage of battery is lower than 13.8V, the device shut down because of UVLO, and then the battery is charged to 16.4V, and the voltage still can't start up. When the voltage of battery is higher than 14V, the device works normally, and then the battery is charged to 16.4V, the device is still working." Right?

    Please check the voltage of input pin when the hanging issue occurs, I want to confirm if the voltage is higher than 13.8V, because there is voltage drop on the diode and PCB resistance. Please test the voltage of input pin to GND pin of IC.

    For the layout, it is not clear, could you please capture two pictures, the top layer and bottom layer.

    Shawn
  • 0 in reply to Shawn Nie
    Intellectual 430 points

    Hi,

    "When the voltage of battery is lower than 13.8V, the device shut down because of UVLO, and then the battery is charged to 16.4V, and the voltage still can't start up. When the voltage of battery is higher than 14V, the device works normally, and then the battery is charged to 16.4V, the device is still working." Right?

    Ph : Exactly right.


    Please check the voltage of input pin when the hanging issue occurs, I want to confirm if the voltage is higher than 13.8V, because there is voltage drop on the diode and PCB resistance. Please test the voltage of input pin to GND pin of IC.

    Ph : Yes it is above 14V when measured w.r.t GND

    For the layout, it is not clear, could you please capture two pictures, the top layer and bottom layer.

    Ph: Please find the attached

  • 0 in reply to phanendra k
    TI__Genius 10070 points

    Hi,

    Please try to disconnect the battery and power up with external power supply, increase the input voltage from 12V to 15V slowly to check whether there still has the same issue.

    For the layout, the traces are invisible, so it is hard for me to tell if there's an issue. But the input capacitors are far away from the IC, the spike of SW would be large.

    Shawn