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Hot Swap Buffer Capability

Other Parts Discussed in Thread: TPS2595, TPS25200, TPS24751, TCA4311A

One of our project, we have a host PCB & some Add-on PCB's. In the initial customer requirement, there was no requirement of live plugging on ADD-on PCB's. Now the customer has changed the specification to add the live plugging option of ADD-on PCB. We tried the live plugging with an existing Host & add-on PCB. In some cases, we found that the controller is damaged. Can you suggest  us a solution to avoid this from your experience . I/O Hot swap buffers are enough for this?

Case Scenario:

  1. The add-on connector in the host PCB is connected direct I/O pins from the controller. Voltage tolerance is about 3.3V. 
  2. There are 4 I/O pins( input & output ) ,1 x UART TX & 1 xUART RX signals.
  3. Add-on PCB controller I/O  tolerance is 3.3V itself.
  4. 12V also connected to the Host add-on connector for powering the ADDAD_on PCB. Inside the ADDAD_on PCB, there are DC-DC regulator to get the 3.3V for add-on controller.

Can you suggest us a best solution to avoid issues related to live plugging, since our host controller is damaging in random plugging s.

BR
Sharvy