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BQ40Z50: Battery charge and discharge issue

Eric Chu
Prodigy 60 points
Part Number: BQ40Z50
Other Parts Discussed in Thread: BQSTUDIO

Tool/software:

Hello,

Our customer has faced some issues with the battery pack using BQ40Z50-R5 fuel gauge.

They performed some drop test and temperature cycle test with a fully charged battery. After the tests, the battery was unable to charge or discharge anymore.

Here is a screenshot of the Bit Registers values:


And here is the gg file of the battery:
Defective_test.gg.csv


I also asked them to provide the log file while trying to discharge the battery:

Fullscreen Defective_test_20240827.txt Download 
Tue Aug 27 08:47:04 CEST 2024

Device Version Info = 4500_5_03
BQZ Device Name = bq40z50R5_tooltips
BQZ Firmware Version = V5_03_BLD88

Design Capacity = 6700
Design Voltage = 10800
Specification Info = 0x0031
Manufacturer Date = 2024-4-10
Serial Number = 0x0001
Manufacturer Name = L
Device Name = 1
Device Chemistry = LION

Sample,DateTime,ElapsedTime,ManufAccess,RemCapAlarm,RemTimeAlarm,BattMode,@Rate(@),@TimeFull,@TimeEmpty,@RateOK,Temperature,Voltage,Current,AvgCurr,MaxErr,RSOC,ASOC,RemCap,FullChgCap,RunTimeEmty,AvgTimeEmty,AvgTimeFull,ChgCurr,ChgVolt,BattStat,CycleCnt,MaxTurboPwr,SusTurboPwr,MaxTurboCurr,SusTurboCurr,TurboRhf,TurboVx,TurboQpass,TurboIsim,TurboVloadCell1,TurboVloadCell2,TurboVloadCell3,TurboVloadCell4,TurboVloadStack,TurboVloadSystem,TurboReffCell1,TurboReffCell2,TurboReffCell3,TurboReffCell4,TurboReffStack,TurboReffSystem,TurboSPPCCell1,TurboSPPCCell2,TurboSPPCCell3,TurboSPPCCell4,TurboSPPCStack,TurboSPPCSystem,TurboRhfCell,SoH,OpStatA,OpStatB,TempRange,ChgStat,GaugeStat,ITStat,MfgStat,SafetyAlertAB,SafetyStatAB,SafetyAlertCD,SafetyStatCD,PFAlertAB,PFStatAB,PFAlertCD,PFStatCD,CellVolt1,CellVolt2,CellVolt3,CellVolt4,vBAT,vPACK,CellCurr1,CellCurr2,CellCurr3,CellCurr4,CellPower1,CellPower2,CellPower3,CellPower4,Power,AvgPow,IntTemp,TS1Temp,TS2Temp,TS3Temp,TS4Temp,CellTemp,FETTemp,GaugeTemp,GaugeTemp,TMP468IntTemp,TMP468Remote1Temp,TMP468Remote2Temp,TMP468Remote3Temp,TMP468Remote4Temp,TMP468Remote5Temp,TMP468Remote6Temp,TMP468Remote7Temp,TMP468Remote8Temp,UnCompCellVolt1,UnCompCellVolt2,UnCompCellVolt3,UnCompCellVolt4,FiltCellVolt1,FiltCellVolt2,FiltCellVolt3,FiltCellVolt4,FiltCellCurr1,FiltCellCurr2,FiltCellCurr3,FiltCellCurr4,FiltTemp,FltRemQ,FltRemE,FltFullChgQ,FltFullChgE,NoLoadRemCap,TrueRemQ,TrueRemE,InitialQ,InitialE,TrueFullChgQ,TrueFullChgE,T_sim,T_ambient,RaScale1,RaScale2,RaScale3,RaScale4,CompRes1,CompRes2,CompRes3,CompRes4,PackGrid,LStatus,CellGrid1,CellGrid2,CellGrid3,CellGrid4,StateTime,DOD0_1,DOD0_2,DOD0_3,DOD0_4,DOD0 Passed Q,DOD0 Passed E,DOD0 Time,DODEOC_1,DODEOC_2,DODEOC_3,DODEOC_4,QMax1,QMax2,QMax3,QMax4,QMaxDOD0_1,QMaxDOD0_2,QMaxDOD0_3,QMaxDOD0_4,QMaxPassedQ,QMaxTime,Tk,Ta,RawDOD_1,RawDOD_2,RawDOD_3,RawDOD_4,CBTime1,CBTime2,CBTime3,CBTime4,CBDOD_1,CBDOD_2,CBDOD_3,CBDOD_4,CBTotalDODChg,BalStat,SOH_FC_Q,SOH_FC_E,AccumT,AccumQ,LogRowTime(ms),LogStatus
1,2024-08-27 08:47:09,4.008,0x0387,670,10,0x0001,0,65535,65535,1,25.0,12308,0,0,1,96,98,6540,6858,65535,65535,65535,3400,12600,0x00C0,0,0,0,0,0,0,0,0,-1185,4045,4056,4051,0,12152,12152,0,0,0,0,0,0,-32767,-32767,-32767,-32767,-32767,-32767,0,100,0x0387,0x0000,0x04,0x0008,0x50,0x0814,0x02B8,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,4103,4103,4101,0,12227,2272,0,0,0,0,0,0,0,0,0,0,27.6,25.0,196.5,196.7,196.5,25.0,27.6,25.0,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,410.3,410.3,410.1,0.0,4103,4103,4101,0,-17,9,8,0,25.0,6540,7003,6858,7394,6540,6540,7003,318,391,6858,7394,25.0,24.8,1000,1000,1000,0,0,0,0,0,0,0x06,0,0,0,0,379,864,864,928,0,0,0,1,112,112,176,0,6990,6934,6933,6700,0,0,0,0,0,1,9.53,18000,864,864,928,0,0,0,0,0,0,0,0,0,0,0x00,6933,7480,0,0,1533,SUCCESS
2,2024-08-27 08:47:13,8.019,0x0387,670,10,0x0001,0,65535,65535,1,25.0,12308,0,0,1,96,98,6540,6858,65535,65535,65535,3400,12600,0x00C0,0,0,0,0,0,0,0,0,-1185,4045,4056,4051,0,12152,12152,0,0,0,0,0,0,-32767,-32767,-32767,-32767,-32767,-32767,0,100,0x0387,0x0000,0x04,0x0008,0x50,0x0814,0x02B8,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,4103,4103,4101,0,12226,8,0,0,0,0,0,0,0,0,0,0,27.6,25.0,195.7,195.0,196.7,25.0,27.6,25.0,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,410.3,410.3,410.1,0.0,4103,4103,4101,0,-17,10,8,0,25.0,6540,7003,6858,7394,6540,6540,7003,318,391,6858,7394,25.0,24.8,1000,1000,1000,0,0,0,0,0,0,0x06,0,0,0,0,383,864,864,928,0,0,0,1,112,112,176,0,6990,6934,6933,6700,0,0,0,0,0,1,9.53,18000,864,864,928,0,0,0,0,0,0,0,0,0,0,0x00,6933,7480,0,0,1569,SUCCESS
3,2024-08-27 08:47:17,12.023,0x0387,670,10,0x0001,0,65535,65535,1,25.0,12307,3,0,1,96,98,6540,6858,65535,65535,65535,3400,12600,0x00C0,0,0,0,0,0,0,0,0,-1185,4045,4056,4051,0,12152,12152,0,0,0,0,0,0,-32767,-32767,-32767,-32767,-32767,-32767,0,100,0x0387,0x0000,0x04,0x0008,0x50,0x0814,0x02B8,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,4103,4103,4101,0,12228,8,0,0,0,0,0,0,0,0,0,0,27.6,24.9,196.3,195.4,196.3,24.9,27.6,24.9,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,410.3,410.3,410.1,0.0,4103,4103,4101,0,-17,10,8,0,25.0,6540,7003,6858,7394,6540,6540,7003,318,391,6858,7394,25.0,24.8,1000,1000,1000,0,0,0,0,0,0,0x06,0,0,0,0,386,864,864,928,0,0,0,1,112,112,176,0,6990,6934,6933,6700,0,0,0,0,0,1,9.53,18000,864,864,928,0,0,0,0,0,0,0,0,0,0,0x00,6933,7480,0,0,1582,SUCCESS
4,2024-08-27 08:47:21,16.031,0x0387,670,10,0x0001,0,65535,65535,1,25.1,12308,0,0,1,96,98,6540,6858,65535,65535,65535,3400,12600,0x00C0,0,0,0,0,0,0,0,0,-1185,4045,4056,4051,0,12152,12152,0,0,0,0,0,0,-32767,-32767,-32767,-32767,-32767,-32767,0,100,0x0387,0x0000,0x04,0x0008,0x50,0x0814,0x02B8,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,4103,4103,4101,0,12228,9,0,0,0,0,0,0,0,0,0,0,27.6,25.0,194.9,196.0,196.5,25.0,27.6,25.0,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,410.3,410.3,410.1,0.0,4103,4103,4101,0,-17,10,8,0,25.0,6540,7003,6858,7394,6540,6540,7003,318,391,6858,7394,25.0,24.8,1000,1000,1000,0,0,0,0,0,0,0x06,0,0,0,0,390,864,864,928,0,0,0,1,112,112,176,0,6990,6934,6933,6700,0,0,0,0,0,1,9.53,18000,864,864,928,0,0,0,0,0,0,0,0,0,0,0x00,6933,7480,0,0,1527,SUCCESS
5,2024-08-27 08:47:25,20.033,0x0387,670,10,0x0001,0,65535,65535,1,25.0,12308,0,0,1,96,98,6540,6858,65535,65535,65535,3400,12600,0x00C0,0,0,0,0,0,0,0,0,-1185,4045,4056,4051,0,12152,12152,0,0,0,0,0,0,-32767,-32767,-32767,-32767,-32767,-32767,0,100,0x0387,0x0000,0x04,0x0008,0x50,0x0814,0x02B8,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,0x0000,4103,4103,4101,0,12228,2263,0,0,0,0,0,0,0,0,0,0,27.6,25.0,195.6,196.1,195.6,25.1,27.6,25.1,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,-273.2,410.3,410.3,410.1,0.0,4103,4103,4101,0,-17,10,8,0,25.0,6540,7003,6858,7394,6540,6540,7003,318,391,6858,7394,25.0,24.8,1000,1000,1000,0,0,0,0,0,0,0x06,0,0,0,0,394,864,864,928,0,0,0,1,112,112,176,0,6990,6934,6933,6700,0,0,0,0,0,1,9.53,18000,864,864,928,0,0,0,0,0,0,0,0,0,0,0x00,6933,7480,0,0,1599,SUCCESS



I noticed the PACK pin voltage is abnormal, so I was guessing that maybe there are some issues with the power MOSFETs or the fuse, but I did not see any of the related bits being set.

Can you tell what the problem might be that the battery is unable to charge and discharge?

Thank you in advanced!

Best regards,
Eric

  • 0
    TI__Mastermind 37761 points

    Hello Eric,

    Can the customer physically measure the PACK pin on the IC with a multimeter and report what voltage is being read. This is very strange behavior since both chg and dsg fets are on according to the register settings.

    Regards,

    Adrian

  • 0 in reply to Adrian
    Prodigy 60 points

    Hello Adrian,

    Unfortunately, the customer cannot measure the PACK pin voltage on the IC. They however measured the PACK pin voltage with a multimeter, and it was similar to the value in bqStudio (~2.5V).

    Do you think it is possible that the power MOSFETs are damaged or if there is something else? Because I cannot think of anything abnormal on the FW side.

    Thank you!

    Best regards,
    Eric

  • 0 in reply to Eric Chu
    TI__Mastermind 37761 points

    Hello Eric,

    Thank you for the additional information. Therefore, my first hypothesis would be the same that you are thinking, it is very likely something wrong with the power MOSFETs.

    Regards,

    Adrian