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TL783: regulator outputting low voltage after a couple years in the field

Part Number: TL783

Hi team,

i have a customer using the TL783 for 48V input and 20V output. and they have seen abnormal behavior where the LDO outputs low voltage after some time in small cases.

the soldering was confirmed good and the two voltage setting resistors measured correctly. the voltage across pins 1-2 was around 0.5V instead of the expected ~1.27V. based off datasheet equation, this 0.5V correlates with their low output voltage (8V) so the suspect is the internal reference of the chip is low.

they ran a test on the bench where they powered on the regulator to compare the bad chip (Figure 2 & 3) with a good one (Figure 1). the waveforms are attached below.

blue trace is input voltage and yellow is output voltage. normal output should be 20V. when ramping the input voltage up on the bad chip, they noticed that the reference voltage would be fine at 1.24V until 38V. after 38V, the reference voltage collapses to < 1V. if they ramp the input voltage back down, the reference voltage will not return to 1.24V until the input voltage falls under 25V.

the behavior is seen whether the IC is powered on in the normal manner when the product powers on, or when they feed DC from the bench supply to the IC. in this case, there is no switching going on, so the regulator should only see its own voltage setting resistors as a load.

do you know what could be causing this strange behavior?

they also found that they could "fix it" by touching the tab (VOUT) of the TL783 with a soldering iron. why would applying heat for a couple seconds to the tab fix it?

Thanks,

Kevin 

  • Hi Kevin, 

    I am sending you an email for schematics and we will take our support from there.

    Regards, 
    Jason Song

  • Hi Kevin, 

    I have reviewed the schematic and I don't see any red-flag there. How many failures have they found? Have they applied "ABA" swap to confirm this is indeed a device issue? You mentioned the failure happened after a couple of years in the field, what's the percentage of the failure? 

    Regards, 

    Jason Song

  •  

    1. Try testing by replacing the bad device with a good device on the failing board.

     

    In the beginning few months ago (I don’t remember exact the date) on other unit we removed the U4 (thinking the component was damaged) and used a new U4 and the problem disappeared but I asked my team to use again the original component on the board and it also worked fine so that’s why after that point for other units we started re applying heat to the TAB using a soldering iron and the problem disappears (In the beginning we monitored the unit turned on at 120VA during 96 hours and the problem never came back again).

     

    1. Try testing by replacing the good device with the bad device on the good board.

     

    We have never put any of those presumable damaged U4’s on a Good Power Supply.

  • Hi Kevin, 

    Thanks for confirming additional details. Based on the feedback below, it does not seem to be a device issue. 

    In the beginning few months ago (I don’t remember exact the date) on other unit we removed the U4 (thinking the component was damaged) and used a new U4 and the problem disappeared but I asked my team to use again the original component on the board and it also worked fine so that’s why after that point for other units we started re applying heat to the TAB using a soldering iron and the problem disappears (In the beginning we monitored the unit turned on at 120VA during 96 hours and the problem never came back again).

    Please confirm how many failures the customer has identified so far, and we would need to confirm the ABA swap to confirm a failure before we can comment further. 

    Regards, 
    Jason Song