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BQ25570: PCB not working as expected

Part Number: BQ25570

Taking the answers you provided, I designed a PCB with the BQ25570, which you can find here: https://www.dropbox.com/s/4lwgx6h46k4pvoo/BQ25570%20interface.rar?dl=0

Unfortunately, the circuit is not working as expected. To be specific, when I connect the PCB with a small solar cell I use, VStor (and after CHgen, Vbat as well) start charging, but they never reach the supposed overvoltage level (4.2V). What actually happens is that charging stops at around 3 Volts and then the behaviour of the circuit is undetermined and not the expected, with voltage levels fluctuating around random values that change every once in a while (for example, it may drop down to 2 volts, or increase to 3.3 volts and stay there for some time).

What I would like is, if possible, to take a look at the PCB design (pcb kicad file, provided in the link above) to point out any potential errors, as well as to check the values in the component list I have placed below, in order to find out the potential cause of the problem.

  • Capacitors
  1. Cin 4.7uF -  X7R
  2. Cstor 4.7uF - X7R
  3. Cbyp 0.1uF - Z5U
  4. Cout 22uF - X5R
  5. Cref 10nF - X7R
  • Resistors
  1. Rout1 = 3.16MΩ
  2. Rout2 = 10MΩ
  3. Rov1 = 5.1ΜΩ
  4. Rov2 = 6.8MΩ
  5. Rok1 = 5.1MΩ
  6. Rok2 = 6.49MΩ
  7. Rok3 = 1.3MΩ

The expected voltage levels are as a result:   Vout =5.039V,   Vbat_ov = 4.235V,   Vbat_ok,hyst = 3.0582V,   Vbat_ok,prog = 2.74978V

  • Inductors
  1. L1 (Lboost) is wurth elektronik 744031220 - 22uH
  2. L2 (Lbuck) is wurth elektronik 744029100 - 10uH
  • Storage element

Simple Electrolytic capacitor 6600uF, 6.3V

Let me know if I can provide any more information that might be useful to debug my problem.

EDIT: I am attaching photos of the schematic and the PCB, if kicad files do not work for someone:

Schematic

PCB:

  • Hi Nick,

    Regarding VOUT=5V but VBAT_OV=4.235V, the buck converter can only step down its voltage from VSTOR=VBAT=4.235max.  Was the VOUT=5.0V a typo?  From the layout, how does the CBYP capacitor ground get back to VSS pin?  It appears that the path is broken by the connection to LBOOST.  This capacitor filters switching noise that has been known the alter the regulation points. Also, at PCB assembly, are the large mega ohm resistors carefully installed and then the board washed to remove solder flux?  As explained in the datasheet section 10.1, page 34, solder flux residue can form parasitic resistors in the large mega ohm range that can alter the regulation points.

    Regards,

    Jeff