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BQ34z110 Optimization cycle, OCVTAKEN after charging won't set

Other Parts Discussed in Thread: BQ34Z110, BQ34Z100-G1

Hi,

I am currently running a optimization cycle with a bq34z110 in combination with a 40Ah (current scale 1/2) sealed lead acid battery.

-I started with a fully loaded and relaxed battery,
-Send IT enable
-After 20min OCVTAKEN was set
-Discharged at c/8 rate
-Made a few extra discharge cycles at the end to overcome the voltage bounce problem
-OCVTAKEN was set after a really long time
-Charged the battery till current < 200mA
-And the battery is currently relaxing 

The battery has been relaxing(step 6) for almost 24 hours and counting and still no OCVTAKEN.

Can someone tell me what is wrong please?

I also have been searching this forum for hours to find some kind of summary of all the things that should be taken into account when running a optimization cycle,
But with no results, I also find a lot of contradictions in different posts and pdf files from TI...

The logging and settings are attached.
Note: I have changed the extension to txt because the original weren't valid for upload  (.log and .gg)

Thanks in advance

Kind regards,
Kris

optim cycle log - Copy.txt 

Settings data flash export.txt
[Header]
bq EVSW Version = 0.9.90	
DeviceName = bq34z110 v0.04
Time = 8/12/2014 9:52:49	


[Safety(Configuration)]
OT Chg = 55.0
OT Chg Time = 2
OT Chg Recovery = 50.0
OT Dsg = 60.0
OT Dsg Time = 2
OT Dsg Recovery = 55.0
[Charge Inhibit Cfg(Configuration)]
Chg Inhibit Temp Low = 0.0
Chg Inhibit Temp High = 45.0
Temp Hys = 5.0
[Charge(Configuration)]
Suspend Low Temp = -5.0
Suspend High Temp = 55.0
Chg Eff = 100
Chg Eff Temp Comp = 25
Chg Eff Drop Off % = 96
Chg Eff Reduction Rate = 10
Maintenance Current = 0
[Charge Termination(Configuration)]
Taper Current = 200
Min Taper Capacity = 25
Cell Taper Voltage = 100
Current Taper Window = 40
TCA Set % = 99
TCA Clear % = 95
FC Set % = 100
FC Clear % = 98
DODatEOC Delta T = 10.0
[Data(Configuration)]
Rem Cap Alarm = 100
Design Cell Voltage = 2000
Initial Standby = -12
Initial MaxLoad = -500
Manuf Date = 01-jan-1980
Ser. Num. = 0001
Cycle Count = 0
CC Threshold = 900
Design Cell Capacity = 20000
Design Cell Energy = 8000
SOH Load I = -400
TDD SOH Percent = 90
Cell Charge Voltage T1-T2 = 2300
Cell Charge Voltage T2-T3 = 2300
Cell Charge Voltage T3-T4 = 2300
Charge Current T1-T2 = 10
Charge Current T2-T3 = 50
Charge Current T3-T4 = 30
JEITA T1 = 0
JEITA T2 = 10
JEITA T3 = 45
JEITA T4 = 55
ISD Current = 10
ISD I Filter = 127
Min ISD Time = 7
Design Energy Scale = 1
Device Name = bq34z110
Manufacturer Name = Texas Inst.
Device Chemistry = PbA
[Discharge(Configuration)]
SOC1 Set Threshold = 150
SOC1 Clear Threshold = 175
SOCF Set Threshold = 75
SOCF Clear Threshold = 100
Cell BL Set Volt Threshold = 1800
Cell BL Set Volt Time = 2
Cell BL Clear Volt Threshold = 1850
Cell BH Set Volt Threshold = 2450
Cell BH Volt Time = 2
Cell BH Clear Volt Threshold = 2400
[Manufacturer Data(Configuration)]
Pack Lot Code = 0000
PCB Lot Code = 0000
Firmware Version = 0000
Hardware Revision = 0000
Cell Revision = 0000
DF Config Version = 0000
[Integrity Data(Configuration)]
Static Chem DF Checksum = 5823
[Lifetime Data(Configuration)]
Lifetime Max Temp = 30.0
Lifetime Min Temp = 20.0
Lifetime Max Chg Current = 0
Lifetime Max Dsg Current = 0
Lifetime Max Pack Voltage = 1500
Lifetime Min Pack Voltage = 32500
[Lifetime Temp Samples(Configuration)]
LT Flash Cnt = 0
[Registers(Configuration)]
Pack Configuration = 0940
Pack Configuration B = FE
Pack Configuration C = 30
LED_Comm Configuration = 00
Alert Configuration = 0000
Number of series cell = 6
[Lifetime Resolution(Configuration)]
LT Temp Res = 1.0
LT Cur Res = 100
LT V Res = 25
LT Update Time = 60
[LED Display(Configuration)]
LED Hold Time = 4
[Power(Configuration)]
Flash Update OK Cell Volt = 1000
Sleep Current = 10
FS Wait = 0

[Manufacturer Info(System Data)]
Block A 0 = 00
Block A 1 = 00
Block A 2 = 00
Block A 3 = 00
Block A 4 = 00
Block A 5 = 00
Block A 6 = 00
Block A 7 = 00
Block A 8 = 00
Block A 9 = 00
Block A 10 = 00
Block A 11 = 00
Block A 12 = 00
Block A 13 = 00
Block A 14 = 00
Block A 15 = 00
Block A 16 = 00
Block A 17 = 00
Block A 18 = 00
Block A 19 = 00
Block A 20 = 00
Block A 21 = 00
Block A 22 = 00
Block A 23 = 00
Block A 24 = 00
Block A 25 = 00
Block A 26 = 00
Block A 27 = 00
Block A 28 = 00
Block A 29 = 00
Block A 30 = 00
Block A 31 = 00

[IT Cfg(Gas Gauging)]
Load Select = 3
Load Mode = 0
Max Res Factor = 15
Min Res Factor = 3
Ra Filter = 500
Fast Qmax Start DOD % = 92
Fast Qmax End DOD % = 96
Fast Qmax Start Volt Delta = 100
Cell Terminate Voltage = 1800
Cell Term V Delta = 25
ResRelax Time = 200
User Rate-mA = 0
User Rate-Pwr = 0
Reserve Cap-mAh = 0
Reserve Energy = 0
Max Scale Back Grid = 4
Cell Max DeltaV = 100
Cell Min DeltaV = 0
Max Sim Rate = 2
Min Sim Rate = 20
Ra Max Delta = 44
Qmax Max Delta % = 5
Cell DeltaV Max Delta = 10
Fast Scale Start SOC = 10
Charge Hys V Shift = 40
[Current Thresholds(Gas Gauging)]
Dsg Current Threshold = 30
Chg Current Threshold = 38
Quit Current = 20
Dsg Relax Time = 60
Chg Relax Time = 60
Quit Relax Time = 1
Cell Max IR Correct = 400
[State(Gas Gauging)]
Qmax Cell 0 = 20000
Cycle Count = 0
Update Status = 00
Cell V at Chg Term = 2300
Avg I Last Run = -299
Avg P Last Run = -1131
Cell Delta Voltage = 2
T Rise = 20
T Time Constant = 1000

[OCVa Table(OCV Table)]
Chem ID = 0807

[R_a0(Ra Table)]
Cell0 R_a flag = FF55
Cell0 R_a 0 = 10
Cell0 R_a 1 = 7
Cell0 R_a 2 = 7
Cell0 R_a 3 = 7
Cell0 R_a 4 = 7
Cell0 R_a 5 = 7
Cell0 R_a 6 = 7
Cell0 R_a 7 = 8
Cell0 R_a 8 = 8
Cell0 R_a 9 = 8
Cell0 R_a 10 = 9
Cell0 R_a 11 = 10
Cell0 R_a 12 = 11
Cell0 R_a 13 = 28
Cell0 R_a 14 = 153
[R_a0x(Ra Table)]
xCell0 R_a flag = FFFF
xCell0 R_a 0 = 10
xCell0 R_a 1 = 7
xCell0 R_a 2 = 7
xCell0 R_a 3 = 7
xCell0 R_a 4 = 7
xCell0 R_a 5 = 7
xCell0 R_a 6 = 7
xCell0 R_a 7 = 8
xCell0 R_a 8 = 8
xCell0 R_a 9 = 8
xCell0 R_a 10 = 9
xCell0 R_a 11 = 10
xCell0 R_a 12 = 11
xCell0 R_a 13 = 28
xCell0 R_a 14 = 153

[Data(Calibration)]
CC Gain = 11.265
CC Delta = 11.243
CC Offset = -0.71
Board Offset = 0.18
Int Temp Offset = -3.3
Ext Temp Offset = -3.4
Voltage Divider = 16918
[Current(Calibration)]
Deadband = 15

[Codes(Security)]
Sealed to Unsealed = 36720414
Unsealed to Full = FFFFFFFF
Authen Key3 = 01234567
Authen Key2 = 89ABCDEF
Authen Key1 = FEDCBA98
Authen Key0 = 76543210

  • bq34z110_V0_04_modified2.zipKris,

    I reviewed your files. There is a bug in the firmware that limits the passed under some conditions and it looks like you have encountered it. The maximum Passed Charge during discharge will have to be lower than 16384mAh. You can see that the Passed Charge counter froze at this value. You can scale the current and capacities to keep under this limit. Other than that, the profile looks okay. I attached a senc file that you can use to make it easier to pass the optimization cycle. That way, you do not have to enable the second discharge to keep the voltages from relaxing to a higher voltage.

    Tom

  • Hi,

    To make things clear,
    The edidet file you have send me, is a solution to make the discharge cycle more easy (the voltage bounce).
    But it is no solution to the bug in firmware I encountered?
    If I scale the current and capacities, what values do you suggest?
    And wouldn't it affect the result?

    Kris
  • You would take the Design Capacity of your pack and divide it by 16384. Then, round up the number. This would be your minimum scaling factor. e.g. 40000/16384 = 2.44 (round up to 3) you then divide all of your current and capacity parameters by 3x. The gauge will then report all current and capacity values as divide-by-3 and you will have to multiply them by 3x to get the true values.

  • Greetings Tom,

    I'm also unable to get a ocvtaken flag and Update_Status 4 on relaxation of the first charge cycle of an Enersys cyclone 2s 2500mAh pack (Chem ID 803).

    I've tried a few times now.  Much difficulty and uncertainty in piecing together dozens of varied chemistry TI docs and community posts to formulate a detailed set of steps for the BQ34Z110 optimization cycle.  I'm mostly using a combination of SLUSB55B, SLUA597 and forum threads like this one.  These two SLU docs are contradictory in the first step.

    (1) Am I to start with the battery in a high or low SOC? or does it matter?

    (2) Most posts are for higher capacity packs.  What tips might you suggest for a successful cycle with low capacity packs?

    (3) What do you think I need to do differently? gg & log files attached

    (4) Does a sleep flag indicate a failed learning cycle?

    Thank you in advance.

    Rom

    CycloneD-2S-B.gg.txt
    [Header]
    bq EVSW Version = 0.9.90	
    DeviceName = bq34z110 v0.04
    Time = 12/17/2014 2:44:34 AM	
    
    
    [Safety(Configuration)]
    OT Chg = 55.0
    OT Chg Time = 2
    OT Chg Recovery = 50.0
    OT Dsg = 60.0
    OT Dsg Time = 2
    OT Dsg Recovery = 55.0
    [Charge Inhibit Cfg(Configuration)]
    Chg Inhibit Temp Low = 0.0
    Chg Inhibit Temp High = 45.0
    Temp Hys = 5.0
    [Charge(Configuration)]
    Suspend Low Temp = -5.0
    Suspend High Temp = 55.0
    Chg Eff = 100
    Chg Eff Temp Comp = 25
    Chg Eff Drop Off % = 96
    Chg Eff Reduction Rate = 10
    Maintenance Current = 0
    [Charge Termination(Configuration)]
    Taper Current = 100
    Min Taper Capacity = 25
    Cell Taper Voltage = 100
    Current Taper Window = 40
    TCA Set % = 99
    TCA Clear % = 95
    FC Set % = 100
    FC Clear % = 98
    DODatEOC Delta T = 10.0
    [Data(Configuration)]
    Rem Cap Alarm = 100
    Design Cell Voltage = 2000
    Initial Standby = -10
    Initial MaxLoad = -500
    Manuf Date = 01-Jan-1980
    Ser. Num. = 0001
    Cycle Count = 0
    CC Threshold = 900
    Design Cell Capacity = 2500
    Design Cell Energy = 5000
    SOH Load I = -400
    TDD SOH Percent = 90
    Cell Charge Voltage T1-T2 = 2550
    Cell Charge Voltage T2-T3 = 2450
    Cell Charge Voltage T3-T4 = 2380
    Charge Current T1-T2 = 10
    Charge Current T2-T3 = 50
    Charge Current T3-T4 = 30
    JEITA T1 = 0
    JEITA T2 = 10
    JEITA T3 = 45
    JEITA T4 = 55
    ISD Current = 10
    ISD I Filter = 127
    Min ISD Time = 7
    Design Energy Scale = 1
    Device Name = bq34z110
    Manufacturer Name = Texas Inst.
    Device Chemistry = PbA
    [Discharge(Configuration)]
    SOC1 Set Threshold = 150
    SOC1 Clear Threshold = 175
    SOCF Set Threshold = 75
    SOCF Clear Threshold = 100
    Cell BL Set Volt Threshold = 1800
    Cell BL Set Volt Time = 2
    Cell BL Clear Volt Threshold = 1850
    Cell BH Set Volt Threshold = 2450
    Cell BH Volt Time = 2
    Cell BH Clear Volt Threshold = 2400
    [Manufacturer Data(Configuration)]
    Pack Lot Code = 0000
    PCB Lot Code = 0000
    Firmware Version = 0000
    Hardware Revision = 0000
    Cell Revision = 0000
    DF Config Version = 0000
    [Integrity Data(Configuration)]
    Static Chem DF Checksum = 0000
    [Lifetime Data(Configuration)]
    Lifetime Max Temp = 30.0
    Lifetime Min Temp = 20.0
    Lifetime Max Chg Current = 0
    Lifetime Max Dsg Current = 0
    Lifetime Max Pack Voltage = 1500
    Lifetime Min Pack Voltage = 32500
    [Lifetime Temp Samples(Configuration)]
    LT Flash Cnt = 0
    [Registers(Configuration)]
    Pack Configuration = 0161
    Pack Configuration B = FF
    Pack Configuration C = 30
    LED_Comm Configuration = A3
    Alert Configuration = 0000
    Number of series cell = 2
    [Lifetime Resolution(Configuration)]
    LT Temp Res = 1.0
    LT Cur Res = 100
    LT V Res = 25
    LT Update Time = 60
    [LED Display(Configuration)]
    LED Hold Time = 4
    [Power(Configuration)]
    Flash Update OK Cell Volt = 1000
    Sleep Current = 10
    FS Wait = 0
    
    [Manufacturer Info(System Data)]
    Block A 0 = 00
    Block A 1 = 00
    Block A 2 = 00
    Block A 3 = 00
    Block A 4 = 00
    Block A 5 = 00
    Block A 6 = 00
    Block A 7 = 00
    Block A 8 = 00
    Block A 9 = 00
    Block A 10 = 00
    Block A 11 = 00
    Block A 12 = 00
    Block A 13 = 00
    Block A 14 = 00
    Block A 15 = 00
    Block A 16 = 00
    Block A 17 = 00
    Block A 18 = 00
    Block A 19 = 00
    Block A 20 = 00
    Block A 21 = 00
    Block A 22 = 00
    Block A 23 = 00
    Block A 24 = 00
    Block A 25 = 00
    Block A 26 = 00
    Block A 27 = 00
    Block A 28 = 00
    Block A 29 = 00
    Block A 30 = 00
    Block A 31 = 00
    
    [IT Cfg(Gas Gauging)]
    Load Select = 1
    Load Mode = 0
    Max Res Factor = 15
    Min Res Factor = 3
    Ra Filter = 500
    Fast Qmax Start DOD % = 92
    Fast Qmax End DOD % = 96
    Fast Qmax Start Volt Delta = 100
    Cell Terminate Voltage = 1800
    Cell Term V Delta = 25
    ResRelax Time = 200
    User Rate-mA = 0
    User Rate-Pwr = 0
    Reserve Cap-mAh = 0
    Reserve Energy = 0
    Max Scale Back Grid = 4
    Cell Max DeltaV = 100
    Cell Min DeltaV = 0
    Max Sim Rate = 2
    Min Sim Rate = 20
    Ra Max Delta = 44
    Qmax Max Delta % = 5
    Cell DeltaV Max Delta = 10
    Fast Scale Start SOC = 10
    Charge Hys V Shift = 40
    [Current Thresholds(Gas Gauging)]
    Dsg Current Threshold = 60
    Chg Current Threshold = 75
    Quit Current = 40
    Dsg Relax Time = 60
    Chg Relax Time = 60
    Quit Relax Time = 1
    Cell Max IR Correct = 400
    [State(Gas Gauging)]
    Qmax Cell 0 = 2500
    Cycle Count = 0
    Update Status = 00
    Cell V at Chg Term = 2464
    Avg I Last Run = -299
    Avg P Last Run = -1131
    Cell Delta Voltage = 2
    T Rise = 20
    T Time Constant = 1000
    
    [OCVa Table(OCV Table)]
    Chem ID = 0800
    
    [R_a0(Ra Table)]
    Cell0 R_a flag = FF55
    Cell0 R_a 0 = 83
    Cell0 R_a 1 = 66
    Cell0 R_a 2 = 56
    Cell0 R_a 3 = 51
    Cell0 R_a 4 = 47
    Cell0 R_a 5 = 47
    Cell0 R_a 6 = 49
    Cell0 R_a 7 = 56
    Cell0 R_a 8 = 59
    Cell0 R_a 9 = 64
    Cell0 R_a 10 = 72
    Cell0 R_a 11 = 83
    Cell0 R_a 12 = 150
    Cell0 R_a 13 = 267
    Cell0 R_a 14 = 275
    [R_a0x(Ra Table)]
    xCell0 R_a flag = FFFF
    xCell0 R_a 0 = 83
    xCell0 R_a 1 = 66
    xCell0 R_a 2 = 56
    xCell0 R_a 3 = 51
    xCell0 R_a 4 = 47
    xCell0 R_a 5 = 47
    xCell0 R_a 6 = 49
    xCell0 R_a 7 = 56
    xCell0 R_a 8 = 59
    xCell0 R_a 9 = 64
    xCell0 R_a 10 = 72
    xCell0 R_a 11 = 83
    xCell0 R_a 12 = 150
    xCell0 R_a 13 = 267
    xCell0 R_a 14 = 275
    
    [Data(Calibration)]
    CC Gain = 10.124
    CC Delta = 10.147
    CC Offset = -0.7
    Board Offset = 0
    Int Temp Offset = 0.0
    Ext Temp Offset = 0.0
    Voltage Divider = 5000
    [Current(Calibration)]
    Deadband = 5
    
    [Codes(Security)]
    Sealed to Unsealed = 36720414
    Unsealed to Full = FFFFFFFF
    Authen Key3 = 01234567
    Authen Key2 = 89ABCDEF
    Authen Key1 = FEDCBA98
    Authen Key0 = 76543210
    
    CycloneD-2S-B.log.txt

  • I made a few updates to your gg file and attached it to this message. I also attached a modified senc file that will make it easier to pass the optimization cycle. Try using these steps and run a log file during the entire process.

    1) Load the attached senc file.

    2) Load the attached gg file.

    3) Load ChemID 803. (Note that you normally load the gg file abq34z110.zipfter the ChemID, but your gg file has ChemID 800 data in it.)

    4) Issue the Reset (41) command.

    5) Issue the IT Enable (21) command.

    6) Charge the pack until the FC bit is set.

    7) Remove the charger and let the pack rest until the OCVTAKEN flag gets set.

    8) Discharge the pack at a C/8 rate to the 3500mV and remove the load.

    9) Let the pack rest until the OCVTAKEN flag gets set. OMax should update and Update Status should increment to 05.

    10) Go back to Step 6) and continue though Step 9) Also export gg files every 60 seconds during this process.

    Note: If Update Status does not increment to 05 in Step 9) in the first cycle, then stop and send the log file to me.

  • Hi Tom,

    The suggested steps helped but not sure if successful because OVCTAKEN flag was not set in first or second charge relaxation periods, only in the discharge relaxation periods.

    I allowed 3 hour relaxation after first charge cycle and just over 5 hours after the second.

    QMax was updated and update status was incremented to 05 (Step 9) in the first cycle, but no change after the second cycle.


    Also, I confirmed that ChemID 803 is not being written to the DF or GG file after selecting ChemID803 and clicking on the "Update" button per step 3.

    I manually updated it in the DF:OCV Table screen before proceeding to step 4.

    I need to resolve a discrepancy between the C/8 discharge rate  set for the load portion, and the fuel gauge measure of C/6.

    The gauge was calibrated before starting.

    Attached are gg, log and autolog files.

    Would appreciate if you would take a look.

    Note I had stopped the log &auto logging after the second charge relaxation and then started the second discharge with only the log file for second discharge.

    Thank you

    Rom

    Reply1.zip

  • Rom,

    You pack still had ChemID 800 loaded. You cannot just change the ChemID number to replace the chemistry data and I am not sure why you had the problem with loading it. I completed the golden cycle for you and all of the data in in the attached file.

    • Load this file into your device.
    • Issue a Reset (41) command.
    • Issue an IT Enable (21) command.

    Run a couple of cycles to check performance.

    Good luck, 

    Tom

    CycloneD golden.senc

  • Tom,

    Thank you, Its running now.

    Before loading I noticed Qmax and Update Status was updated to 6. It must have updated in the few hours since I sent my data and didn't notice until now.

    (1) Could these updates be occurring some time after the OCVTAKEN flag sets during the discharge relaxation?

    (2) Where did you see ChemID 800? It was 803 in the GG files after I edited the Data Flash within EQSW.

    (3) Can I conclude that a OCVTAKEN set after a long charge relaxation, is not needed for a successful learning cycle?

    Thanks again,
    Rom
  • The OCVTAKEN flag will set after the cells have stabilized to a point where an OCV can be measured. Events could have occurred that prevented Qmax from updating. Also, while the Ra table is updated during discharge, it does not get saved until the OCVTAKEN flag gets set during the rest period. The Ra table in your gg file is the one for ChemID 800. Changing the ChemID number manually does not update the chemistry data in the memory. If you want to export a senc file from your pack, then I can check the chemistry data in it to verify what is loaded.

  • Thats helpful, thank you Tom.

    So the only way to know if the chemistry in memory is right, is to know its Ra table?

    How can I view the chemsitry Ra table before loading so I can compare?

    Or if I export a senc file, how do you verify the chemistry data?

    This would be helpful since I will be working on a few other battery times after this one.
    Thanks again,
    Rom
  • You can know that the chemistry data is correct by checking the ChemID parameter after updating the chemistry to a new device. You can also check the default Ra table data, because it will have been updated. You can then load you gg file to the device and it will update the golden Ra table. I check the chemistry data by reading the OCV table in the device. The OCV table is hidden, so you will not be able to read it.
  • Thanks Tom.

    I understand how to check for a successful update now, but not an alternative to using the bqChem feature in the software should it fail.

    I'll repeat the process to see if problems persist  with the ChemID update feature.

    Its unfortunate that the bqChem programming feature executes without an indication of success or failure.

    Are there any precautions or special conditions that  might prevent a successful ChemID update?

    Thank you  for seeing me through on this.

    The test cycles look good so far.

  • There are no special precautions to take when updating parameters other than turning scanning off. I have seen it cause communications errors when the flash memory is updating.
  • Good to know.
    Thanks again. I really appreciate your help.
  • Hi Thomas,

    A while ago you have send me an adapted senc file, that would make it easier to pass the optimization cycle.
    Should I keep these settings when I create my 'golden image"?
    Or should I replace them with the defaults again?

    Kind regards,

    Kris

  • You can keep these setting as they adjusted the parameters to align with the bq34z100-G1 parameter set.