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BQ78350-DEVICE-FW: Cell Balancing at Rest not working

Part Number: BQ78350-DEVICE-FW
Other Parts Discussed in Thread: BQSTUDIO, BQ78350

Tool/software:

Hello!

I have a problem with cell balancing at rest with bq78350R3. I have a 15S LiFePO4 battery where cell balacing at rest is necessary.
* bqz Device Number 1E9B
* bqz Firmware Version 3.00
* bqz Build Number 31

It is activated in the balancing configuration. When using the Read-Word Function 0xB1, it returns 1, so it is actived. I also tried to deactivate and activate again with this command, but nothing changed. I also tried the Reset-Command and Power-On-Reset. The command always returns 1 but it doesn't work.

This is the Cell Balancing Configuration and the current Cell Voltages:

I can't see a reason why the cells are not balanced. On the PCM, there are LEDs added to the balancing resistors, that it's visible if cells are balanced. This works normally during charging, but not at rest. I also checked that the current is below Quit Current and Chg Relax Time has passed.

As shown in https://e2e.ti.com/support/power-management-group/power-management/f/power-management-forum/1289639/bq78350-device-fw-r3-cell-balancing-at-rest I have also treid CB_TEST_EN by setting it in Mfg Status Init or with CellBalanceToggle() (0x001B).

I've checked all points to this topic that I found in the E2E Forum but couldn't find a solution. Please help me solving this problem.

Thank you!

  • Hello Georg,

    This question has been assigned and we are working on the solution.

    Thank you,
    Alan

  • The gauge checks the CB_REST bit during boot after reset and it will set an internal flag that controls if it will allow balance in rest. If you set this bit in Balancing Configuration (as you show) then you do not need to send command 0xB1. Nor do you need to use SB_TEST_EN.

    If this internal flag is set (which it will be, if you set CB_REST) *and* the gauge is in relax state (which is controlled by Quit Current Threshold and the relax time (see 9.1.2 in the TRM)) then the gauge will run the balancing code (every 10 seconds with your interval settings).

    It calculates a threshold = min cell voltage + Cell Balance Min = 3389mV + 20mV = 3409mV (using your screenshot values).

    It checks, if the difference between max and min cell voltage is > Cell Balance Min. The max difference is 3457mV - 3389mV = 68mV so this will pass.

    It will then add the cells that exceed this threshold to a list of cells that need to be balanced. However, it will not allow cells on adjacent pins that exceed this threshold to be balanced.

    So the last restriction is likely the reason why you do not see balancing in action.

  • Thank you for your reply!

    The way I understand the implemented function is that adjacent cells may not be balanced at the same time, so if both need to be balanced, it will be switched automatically between both of them. If they are never balaced, it would mean that if two adjacent cells have higher values once, it's most likely that they will never be balanced again, because for every charging cycle, they may be the highest cells again. This would completely prevent balancing for a battery if two cells next to each other are the highest once. I don't think that it is implemented in this way.

    For the other conditions, as you calculated, I also don't see any reason why it shouldn't work. I also had situations where the differences in voltages were higher than in this screenshot, but since I'm testing, I've never seen Balancing in Rest working.

  • I can't diagnose this remotely. Everything that you presented should start cell balancing in relax.

    The main suspicious part is: "I also tried to deactivate and activate again with this command, but nothing changed.". This should toggle if you use this command so something goes wrong when you try issuing this command. Can you check if this command is actually sent on the smbus? 

  • With "nothing changed" I meant cell balancing still don't work, independend of what I tried. I made sure that SMBus communication is working and the commands are actuelly send.
    I used Write Word in Advanced Comm SMB in bqStudio. When I wirte 0 or 1 to 0xB1 I can read back the same value successfully. When I use Write Block 0x001B (Write Block 1B 00 to 0x44) the CB_TEST bit toggles in Manufactoring Status.

  • I have additional information that may help identifying the problem.

    When reading 0xB1 (Read Word in Advanced Comm SMB), I get 1 which should tell that Cell Balancing At Rest is actived. As already mentioned in my first post, I can successfully writing and reading back 0 or 1 to 0xB1.

    In the Registers tab, in the last group of registers, there are two entries "Cell Balance At Rest" that both show 0x00. When I try to overwrite the values here, they show 1 until I click Refresh. It looks like the value is not actually written to the processor. I also don't understand why here the value is 0x00, while reading the address 0xB1 returns 0x0001. Which command/register value is actually displayed on this position in bqStudio? When clicking on this register, there is "address 0xb1" which would sound right, but then it das to return the same value as ReadWord 0xB1. Why is there a difference?

    In https://e2e.ti.com/support/power-management-group/power-management/f/power-management-forum/1299701/bq78350-bq78350-r3-cell-balancing-at-rest-can-not-set you said "need to send the CB TEST command (0x001b) for the CB_TEST flag to set". In the TRM Addendum for R3 (sluucm2.pdf), only CB_R_TEST is mentioned as ManufacturerAccess() 0x0019. When sending this command, nothing changes, but when sending the 0x001b command, CB_TEST toggles. Which one is the actual bit or command to set?

    Do you have any example configuration / srec-file where Cell Balancing at Rest ist working? Then I cound try this as basis.

    Thank you for your help!

  • Please attach the .bqz file that you use for your version bq78350. I just searched through the R3 version for some of the items that you listed and some don't exist in the R3 .bzq file that I have. I need to know what exactly your bqStudio installation fetches for this gauge. This file is in the config folder. Please attach the files that start with 1E9B_3.

  • I have the 1E9B_3_00-bq78350R3.bqz in the config folder that I got when (re)installing bqStudio a few months ago (BatteryManagementStudio-1.3.127_Build3-windows-installer.exe). A few days ago I installed bq78350R3FirmwareBundle-3.00-windows-installer.exe because I thought it may be a newer firmware, but are the same. At least for the bqz-file, I generated and compared hash codes.
    It was not possible to attach a .bqz file, but after renaming it to .txt it was. I hope this works.

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    The firmware bundle is installed in a different folder, so I think the config folder is the one that is used?

    I got the .srec file from the firmware bundle (bq78350R3_v3_00_build_31.srec) bq78350R3_v3_00_build_31.txt

    Do you have any example srec-file with implemented cell balancing at rest?

  • Do you need any additional information to identify this problem?

    I also have a question to REST and RELAX. In which of these states should the balancing start? For us, it is important that balancing is possible that it starts directly after the end of the charing process. How can we set the configuration that it starts as fast as possible?

  • I saved the text file as 1E9B_3_00-bq78350R3_E2E.bqz but get an error message from bqStudio:

    Looks like the encoding to text removed information necessary to open the files inside the .bqz file (it's a password protected zip file originally).

    About RELAX and REST:

    RELAX is a gauging state. It is the state of a state machine with state transitions governed by measured current and time. See 9.1.2 in the TRM.

    REST is a battery state. The gauge, when it is in RELAX state, monitors cell voltages and if they are stable (which will take some time, depending on cell chemistry, previous load and temperature) then it considers the cell to be in REST.

    The cell balancing code, if cell balancing in RELAX is enabled, runs when the gauge took an OCV measurement.

    The gauge is very careful before it allows an OCV measurement. Here are the conditions that must be met:

    1. gauging state = RELAX

    2. charge termination detected with every cell voltage >= upper voltage threshold for the chemistry's flat zone (this depends on what chemistry you chose).

    #2 is over-ruled if the gauge was in RELAX for at least 48 hours.

    3. the gauge monitors cell voltage by averaging it over a 100 second window. The absolute difference of subsequent averages must be less than 10mV for every cell.

    #3 is over-ruled, after 5 hours after #2 was met.

    4. the gauge will start cell balancing 25 seconds after #3 was met.