LT8490 24V design not working

The schematic looks OK from a functional viewpoint. There are a few things like no cap across CSP/CSN but nothing that would cause it not to function. What do you have for a load? The Output battery voltage needs to be above 35% of the VS2 setting before the LT8490 will charge. See table 3 on page 17 of the datasheet.

If you want to use a bench power supply on the input, VINR needs to be tied to GND before applying voltage to disable the MPPT function.

Thanks for your reply, I will connect the motor control board at the load (24V 5A).

Currently, my battery voltage is 23V, and I have set the VS2 at 29.6V. 

Is it necessary to disable MPPT?

I have observed that at SWEN, the voltage is 0.7V.

Do you need any additional details?

Thanks a lot for your valuable time.

SWEN should not be toggling and it appears from your spreadsheet that it is toggling. Look at your timer settings and Stage 0 threshold as well as Stage 0 and Stage 2 voltage thresholds. Ensure the input voltage stays well above the minimum operating voltage. If the SS pin never goes above a few millivolts then the LT8490 is continuously resetting. If you are seeing noise on the CLKOUT but you do see ~200KHz clock then there may be a layout issue assuming you are using a very local GND on your scope probe. The layer below the IC should be a GND plane.

Input Settings: I have set the maximum input current as 5 A with a 10mohm sense resistor. Vx1 is 6V, and Vx2 is 53V.

Output Settings: Iout Max is 2.5 A, Iout(MaxS0) is 0.625 A; I have used a 20mohm sense resistor. VS2 is 29 V. 

Do you think there is any issue with this? Do I need to increase the current limit?

I am using a 24V 7Ah lead acid battery. 

I have tested the MOSFET, they are working. 

I am not sure about the battery's internal thermister, Is IC restarting because of the temp sense pin? Is R28 10K resistor creating an issue?

I don't see any timer expiration on fault led. IC blinks the status LED once at 3.5S, and the fault LED is OFF.

May I share my PCB layouts with you?

Thanks a lot for your valuable time and efforts.

Rsense2 is too large for 7A. Target a voltage drop across the sense resistor of 0.0497V at max desired current. At 7A, a 7 milliohm resistor would be appropriate. With this value of sense resistor R_IMONOUT = 274K and RIOW = 26.7K.

Until you get it working properly, disable the temperature sensor.

I have changed the Sense resistor and R_IMONOUT; still, SWEN is varying between 0.6 to 3V, the status LED flashes every 3.5 sec, and the fault LED is off.

Is there anything else that I can check for the reason behind restarting IC?

I recommend using a power supply on the input and a resistive load on the output until you find the issue. Tie the VINR pin to GND and apply a 36V power supply that is not current limited. On the output, use a power resistor with a resistance that provides approximately 2A of current. For a 24V output this would be a resistance of approximately 12 ohms. Connect a power supply across the power resistor and set the voltage to approximately 20V. You can now disable the current limits by tying IMON_IN and IMON_OUT to GND. To disable the temp sense have a 11.5k pull up on the TEMPSENSE pin to LDO33 and a pulldown on the TEMPSENSE pin of 10K. Ensure a 100nF cap is in parallel with the pulldown resistor. Ensure no other components are on the TEMPSENSE pin. The LT8490 should now regulate to the set output voltage. If it does not, look at each pin of the LT8490 with a scope focusing on the inputs to find the problem. Once you get it operating properly in this mode, enable the features one at a time until you get back to the application circuit desired.

Can you please go through the layout? battery-charging-board-f44ed38c8fa00fd6fed66bea247621df94e71434 (1).zip

Is there any way to find out why SWEN or SWENO is varying between 0.6V to 3V?

SWENO is an output. SWEN is an input. SWENO is going low because one of the inputs is going out of range for delivering output current. If you have made the modifications described earlier, it will make it easier to find the input that is causing SWENO to go low.

Thanks for your reply. I have connected IMONIN and IMONOUT pins to the ground.

Case 1: Vin 28V (Power Source) >> Vout 24V (Battery) 

Status and Fault LED flashes, and SWEN Pin varies between 0.6V to 3 V. 

M2 is ON, M1, M3, and M4 are OFF.

Case 2: Vin 0V (Power Source) >> Vout 24V (Battery)

Status LED flashes every 3.5 seconds with 250ms ON time. SWEN pin is high with 3.3V, and CLKOUT is at 1.2V.

M1 gate voltage = 13V, M2 gate voltage = -1.1mV, M3 gate voltage = 4.5V, M4 gate voltage = -480mV.

It also sends 6V reverse to the input in case 2.

I have used both input and output sense resistors as 10mohm. R_IMON_OUT = 97.6K and R_IOW = 32.4K.

One more observation,

I have connected IMONOUT to the ground and IMONIN as it is. If I don't connect the battery, the status LED blinks 3 times, SWEN 3.3V. If I connect the battery again, it looks like it is charging the battery, however, SWEN is varying in this case, and sometimes fault LED also blinking. 

Is there any issue with current feedback? I have gone through the datasheet of LT8490. However, I didn't get enough information to solve this issue. I have designed 5 boards, your support means a lot to me. 

If using a power source, did you tie VINR to ground? Is SHDN staying a logic high? Are INTVCC, GATEVCC and LDO33 at the proper voltages? Is CLKOUT toggling at the proper frequency? If these are good, the next step is to probe each pin one at a time with a scope to ensure they are at the proper voltage levels. You can also get a DC2069A eval board to compare voltages. The major inputs to verify are Vin, FBIN, FBOUT,  and TEMPSENSE but even an output that can't reach its intended logic state can cause it not to operate. 

If using a power source, did you tie VINR to ground? Is SHDN staying a logic high? Are INTVCC, GATEVCC and LDO33 at the proper voltages? Is CLKOUT toggling at the proper frequency? If these are good, the next step is to probe each pin one at a time with a scope to ensure they are at the proper voltage levels. You can also get a DC2069A eval board to compare voltages. The major inputs to verify are Vin, FBIN, FBOUT,  and TEMPSENSE but even an output that can't reach its intended logic state can cause it not to operate.