Hello Tomas,
thank you for the swift reply.
Test conditions when these failures have been found is a surrounding temperature at about 4-8C, and power up tests are performed with a Debian 8 (Jessie) OS.
The failures are very temperature dependent, and intermittent, from a few failures per 12 hours at 35 starts per hour at the above temperatures, to several failures per hour at lower temperatures.
If the environment temperature is lowered further, the failures become more frequent, and if lowered to -20C, the chip sometimes does not respond on the SMBUS as all, but that might be baecause it is then too far off spec.
We are aware that the chip is only 0-70C, so these lower temperatures are only used to make the fault show itself as fast as possible,
If the temperature is raised to about 30C, the problems do not appear.
This is an OK dump:
i2cdump -y 0 0x60
No size specified (using byte-data access)
0 1 2 3 4 5 6 7 8 9 a b c d e f 0123456789abcdef
00: 00 ff ff ff ff ff ff 00 0c f4 1a 00 01 00 00 00 ........???.?...
10: 28 12 01 03 80 00 00 00 ee 00 00 00 00 00 00 00 (????...?.......
20: 00 00 00 af c0 00 45 40 01 01 01 01 01 01 01 01 ...??.E@????????
30: 01 01 01 01 01 01 00 0f 20 e0 30 58 19 20 18 48 ??????.? ?0X? ?H
40: 12 00 00 00 00 00 00 18 00 00 00 10 00 32 78 1e ?......?...?.2x?
50: 32 05 00 0a 20 20 20 20 20 20 00 00 00 fe 00 63 2?.? ...?..
60: 6f 6e 67 61 74 65 63 20 41 47 0a 20 00 00 00 0e ....... .:? ...?
70: 00 00 00 00 00 00 00 00 00 00 00 00 00 10 00 d8 .............?.?
80: 00 23 0b 04 01 00 00 00 01 fe 00 00 08 00 0f 0c .#???...??..?.??
90: 07 ff 1d 0a 14 00 01 02 01 02 00 00 00 00 00 00 ?.???.????......
a0: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 ................
b0: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 ................
c0: 04 00 00 03 00 c0 00 00 00 00 00 00 00 00 00 00 ?..?.?..........
d0: 00 00 00 00 00 00 00 00 01 02 03 04 05 06 07 08 ........????????
e0: 09 0a 0b 0c 0d 0e 0f 10 01 00 00 00 12 34 56 78 ?????????...?4Vx
f0: ff ff ff ff ff ff ff ff ff ff ff ff ff ff ff ff ................
And this is a failed dump:
i2cdump -y 0 0x60
No size specified (using byte-data access)
0 1 2 3 4 5 6 7 8 9 a b c d e f 0123456789abcdef
00: 00 ff ff ff ff ff ff 00 0c f4 1a 00 01 00 00 00 ........???.?...
10: 28 12 01 03 80 00 00 00 ee 00 00 00 00 00 00 00 (????...?.......
20: 00 00 00 af c0 00 45 40 01 01 01 01 01 01 01 01 ...??.E@????????
30: 01 01 01 01 01 01 00 0f 20 e0 30 58 19 20 18 48 ??????.? ?0X? ?H
40: 12 00 00 00 00 00 00 18 00 00 00 10 00 32 78 1e ?......?...?.2x?
50: 32 05 00 0a 20 20 20 20 20 20 00 00 00 fe 00 63 2?.? ...?..
60: 6f 6e 67 61 74 65 63 20 41 47 0a 20 00 00 00 0e ....... ..? ...?
70: 00 00 00 00 00 00 00 00 00 00 00 00 00 10 00 d8 .............?.?
80: 00 23 0b 04 01 00 00 00 01 fe 00 00 08 00 0f 0c .#???...??..?.??
90: 07 ff 1d 0a 14 00 01 02 01 02 00 00 00 00 00 00 ?.???.????......
a0: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 ................
b0: 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 ................
c0: 00 00 00 00 00 c0 00 00 00 00 00 00 00 00 00 00 .....?..........
d0: 00 00 00 00 00 00 00 00 01 02 03 04 05 06 07 08 ........????????
e0: 09 0a 0b 0c 0d 0e 0f 10 01 00 00 00 12 34 56 78 ?????????...?4Vx
f0: ff ff ff ff ff ff ff ff ff ff ff ff ff ff ff ff ................
As you can see, the difference is in 0xC0 and 0xC3.
I have verified the startup conditions regarding reset signal, time to first access (~180ms, 2x90ms), rise times of both power supplies and the pullup/down resistors, and they are all correct.
I cannot replicate the actual fault symptoms by blocking the diff pairs on either the AUX or any of the two DP channels, so that is probably not the cause of the failures.
In the Linux drm logs i have, it looks like the chip is not responding to AUX contact tries, but it never goes further than that when it fails.