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bq34z100 difficulty in achieving a learning cycle

Michael Behrens
Prodigy 140 points
Other Parts Discussed in Thread: BQ34Z100, BQEVSW

I am attempting to perform a learning cycle on a 1p8s 15Ah LiFePO4 pack of headway cells but am not able to get the FC bit to set and thus progress to 0x05 in the IT flags.


Attached are screenshots of the RAM after clearing the IT flag, sending a reset command (0x41) and then resting,

as well as, immediately after enabling IT (command 0x21).

Also attached is the gg file of the flash before and after enabling IT.

Fullscreen 5700.BatteryFlash28042014.txt Download 
[Header]
bq EVSW Version = 0.9.90	
DeviceName = bq34z100 v0.06
Time = 28/04/2014 2:50:47 PM	


[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
[Charge Termination(Configuration)]
Taper Current = 700
Min Taper Capacity = 25
Cell Taper Voltage = 500
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
Initial Standby = -10
Initial MaxLoad = -500
Manuf Date = 01-Jan-1980
Ser. Num. = ABCD
Cycle Count = 323
CC Threshold = 900
Design Capacity = 15000
Design Energy = 5400
SOH Load I = -400
TDD SOH Percent = 90
Cell Charge Voltage T1-T2 = 3650
Cell Charge Voltage T2-T3 = 3650
Cell Charge Voltage T3-T4 = 3550
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 = bq34z100
Manufacturer Name = Texas Inst.
Device Chemistry = LION
[Discharge(Configuration)]
SOC1 Set Threshold = 150
SOC1 Clear Threshold = 175
SOCF Set Threshold = 75
SOCF Clear Threshold = 100
Cell BL Set Volt Threshold = 2800
Cell BL Set Volt Time = 2
Cell BL Clear Volt Threshold = 2900
Cell BH Set Volt Threshold = 3700
Cell BH Volt Time = 2
Cell BH Clear Volt Threshold = 3600
[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 = 51D2
[Lifetime Data(Configuration)]
Lifetime Max Temp = 30.0
Lifetime Min Temp = 20.0
Lifetime Max Chg Current = 6843
Lifetime Max Dsg Current = -3056
Lifetime Max Pack Voltage = 28744
Lifetime Min Pack Voltage = 3500
[Lifetime Temp Samples(Configuration)]
LT Flash Cnt = 39
[Registers(Configuration)]
Pack Configuration = 0971
Pack Configuration B = FF
Pack Configuration C = 30
LED_Comm Configuration = 93
Alert Configuration = 0000
Number of series cell = 8
[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 = 3200
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 = 200
Cell Terminate Voltage = 2750
Cell Term V Delta = 50
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 = 200
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 = 70
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 = 15000
Cycle Count = 0
Update Status = 00
Cell V at Chg Term = 3650
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 = 0400

[R_a0(Ra Table)]
Cell0 R_a flag = FF55
Cell0 R_a 0 = 47
Cell0 R_a 1 = 35
Cell0 R_a 2 = 35
Cell0 R_a 3 = 33
Cell0 R_a 4 = 34
Cell0 R_a 5 = 38
Cell0 R_a 6 = 38
Cell0 R_a 7 = 43
Cell0 R_a 8 = 45
Cell0 R_a 9 = 48
Cell0 R_a 10 = 51
Cell0 R_a 11 = 50
Cell0 R_a 12 = 54
Cell0 R_a 13 = 65
Cell0 R_a 14 = 810
[R_a0x(Ra Table)]
xCell0 R_a flag = FFFF
xCell0 R_a 0 = 47
xCell0 R_a 1 = 35
xCell0 R_a 2 = 35
xCell0 R_a 3 = 33
xCell0 R_a 4 = 34
xCell0 R_a 5 = 38
xCell0 R_a 6 = 38
xCell0 R_a 7 = 43
xCell0 R_a 8 = 45
xCell0 R_a 9 = 48
xCell0 R_a 10 = 51
xCell0 R_a 11 = 50
xCell0 R_a 12 = 54
xCell0 R_a 13 = 65
xCell0 R_a 14 = 810

[Data(Calibration)]
CC Gain = 2.027
CC Delta = 2.023
CC Offset = -0.64
Board Offset = 0.33
Int Temp Offset = 0.0
Ext Temp Offset = 0.0
Voltage Divider = 37527
[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

Fullscreen 2350.BatteryFlash28042014afterIT.txt Download 
[Header]
bq EVSW Version = 0.9.90	
DeviceName = bq34z100 v0.06
Time = 28/04/2014 3:02:42 PM	


[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
[Charge Termination(Configuration)]
Taper Current = 700
Min Taper Capacity = 25
Cell Taper Voltage = 500
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
Initial Standby = -10
Initial MaxLoad = -500
Manuf Date = 01-Jan-1980
Ser. Num. = ABCD
Cycle Count = 323
CC Threshold = 900
Design Capacity = 15000
Design Energy = 5400
SOH Load I = -400
TDD SOH Percent = 90
Cell Charge Voltage T1-T2 = 3650
Cell Charge Voltage T2-T3 = 3650
Cell Charge Voltage T3-T4 = 3550
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 = bq34z100
Manufacturer Name = Texas Inst.
Device Chemistry = LION
[Discharge(Configuration)]
SOC1 Set Threshold = 150
SOC1 Clear Threshold = 175
SOCF Set Threshold = 75
SOCF Clear Threshold = 100
Cell BL Set Volt Threshold = 2800
Cell BL Set Volt Time = 2
Cell BL Clear Volt Threshold = 2900
Cell BH Set Volt Threshold = 3700
Cell BH Volt Time = 2
Cell BH Clear Volt Threshold = 3600
[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 = 51D2
[Lifetime Data(Configuration)]
Lifetime Max Temp = 30.0
Lifetime Min Temp = 20.0
Lifetime Max Chg Current = 6843
Lifetime Max Dsg Current = -3056
Lifetime Max Pack Voltage = 28744
Lifetime Min Pack Voltage = 3500
[Lifetime Temp Samples(Configuration)]
LT Flash Cnt = 39
[Registers(Configuration)]
Pack Configuration = 0971
Pack Configuration B = FF
Pack Configuration C = 30
LED_Comm Configuration = 93
Alert Configuration = 0000
Number of series cell = 8
[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 = 3200
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 = 200
Cell Terminate Voltage = 2750
Cell Term V Delta = 50
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 = 200
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 = 15000
Cycle Count = 0
Update Status = 04
Cell V at Chg Term = 3650
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 = 0400

[R_a0(Ra Table)]
Cell0 R_a flag = FF55
Cell0 R_a 0 = 47
Cell0 R_a 1 = 35
Cell0 R_a 2 = 35
Cell0 R_a 3 = 33
Cell0 R_a 4 = 34
Cell0 R_a 5 = 38
Cell0 R_a 6 = 38
Cell0 R_a 7 = 43
Cell0 R_a 8 = 45
Cell0 R_a 9 = 48
Cell0 R_a 10 = 51
Cell0 R_a 11 = 50
Cell0 R_a 12 = 54
Cell0 R_a 13 = 65
Cell0 R_a 14 = 810
[R_a0x(Ra Table)]
xCell0 R_a flag = FFFF
xCell0 R_a 0 = 47
xCell0 R_a 1 = 35
xCell0 R_a 2 = 35
xCell0 R_a 3 = 33
xCell0 R_a 4 = 34
xCell0 R_a 5 = 38
xCell0 R_a 6 = 38
xCell0 R_a 7 = 43
xCell0 R_a 8 = 45
xCell0 R_a 9 = 48
xCell0 R_a 10 = 51
xCell0 R_a 11 = 50
xCell0 R_a 12 = 54
xCell0 R_a 13 = 65
xCell0 R_a 14 = 810

[Data(Calibration)]
CC Gain = 2.027
CC Delta = 2.023
CC Offset = -0.64
Board Offset = 0.33
Int Temp Offset = 0.0
Ext Temp Offset = 0.0
Voltage Divider = 37527
[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

Can you please have a look to see if there is any parameters which I have not set correctly. I have not been able to find any solutions on the forums which seem to work for me.

Some things to note about the system: I am using the EVM but have changed the sense resistor to 2 mohm to facilitate a higher current operation. The charger I am using charges at about 6.8A and cuts off when the current draw falls below approximately 450mA.

I am currently logging data during a charging cycle and can post it when it is done if it is helpful.

Thanks


Edit: also attached is the log file of the charge

2086.LearningCycleLog.log

  • 0
    TI__Guru 73830 points

    Michael, 


    The FC bit is not setting, because you did not meet the charger termination criteria. (pg 20 of the datasheet) The AverageCurrent must drop below the Taper Current for two consecutive  Current Taper Windows (set to 40 sec in your gg file) You will need to allow charge below the 700mA Taper Current threshold. I would let it charge to the 450mA cut-off current that you mentioned.

    Also, you are using the default LiFePO4 ChemID. Have you verified that this ChemID is a good match for your cells? If not, you can follow the guidelines in the attached document to collect data and I can help with the analysis. I will need the data by tomorrow, as I will be out of the office starting Wednesday.


    I also noticed that you Cycle Count is high. You can set the CC Threshold closer to 15000 to increment Cycle Count one time per full discharge.

    Tom

    Chemistry selection.pdf
  • 0 in reply to ThomasCosby
    Prodigy 140 points

    Thanks Tom,


    I don't have any control over when the charger cuts off so I cannot hold the charging current at 450mA for the required 80 seconds. Would increasing the Taper Current Threshold to 2000mA achieve the same result? Also, in the document "configuring the bq34z100 data flash" it mentions that the "FO set %" affects whether the FC bit is set based on the taper current or the SOC. Is this true for the learning cycles too? Should I set this parameter to -1?

    I am doing a discharge test for the ChemID at the moment, I only had a whole pack charged and rested. Hopefully this will be good enough. I am preparing a single cell today too just in case but I won't be able to start the discharge test until the pack has finished so it will be unlikely to be ready before you leave.

    Michael

  • 0 in reply to Michael Behrens
    TI__Guru 73830 points

    Michael ,

    I would not increase the taper current. The current does not have to be at 450mA for 80 seconds, but it needsto be below 700mA for 80 seconds. If you let the pack charge until the current reaches 450mA, then you should meet this criteria. You can set the FC set % to -1 and the FC bit will get set after the charger termination criteria have been met and it does apply to the optimization cycles as well.

    Tom

  • 0 in reply to ThomasCosby
    Prodigy 140 points

    Thanks Tom,

    I will change the FC set % to -1 and see what happens. I was under the impression that the charge current needed to be below the the taper current threshold but above zero for the two measurement periods. In my case the system cuts off the charge current shortly after reaching 450mA so the charge current falls to zero. I'm not sure if this is caused by the cell over voltage protection or by the charger itself, either way I don't have any control over this behavior in the current implementation.


    Michael

  • 0 in reply to Michael Behrens
    Prodigy 140 points

    Attached is the battery discharge log for ChemID verification.

    6014.BatteryDischarge.log

  • 0 in reply to Michael Behrens
    TI__Guru 73830 points

    Michael,

    The closest match is ChemID 410, but it is not close enough to be considered to be acceptable. You should submit cells for characterization to create a new ChemID.


    Tom

  • 0 in reply to ThomasCosby
    Prodigy 140 points

    Tom,


    What is involved in submitting cells for characterization? Do I need to send you a cell/set of cells or do I just follow the discharge test procedure for a single cell and send you the data?

    Also, changing the FC set % to -1 but leaving the taper current threshold at 700mA didn't allow the FC bit to set.

    Michael

  • 0 in reply to Michael Behrens
    Prodigy 140 points

    At the risk of sounding like a broken record... I still haven't been able to get the FC bit to set and thus achieve a learning cycle. Attached is a log of the most recent charge cycle. At the conclusion of the charge cycle the CHG bit is cleared (green) which didn't happen before but the FC bit still does not set.

    1488.LearningCycleLog01052014.log

    Since the last time I uploaded the flash contents I have changed the chemistry to 410, changed the FC set % to -1 and changed the taper current to 1000 mA (the highest allowed)

    Any further guidance would be appreciated.

    Michael

  • 0 in reply to Michael Behrens
    TI__Guru 73830 points

    Michael,

    Have you verified that you meet the Charge Termination requirements discussed on page 20 of the datasheet. The log file shows that the charging current is only tapering to 1325 mA. is this lower than the taper current?


    Tom

  • 0 in reply to ThomasCosby
    Prodigy 140 points

    Tom,

    I believe the accumulated charge per window is above the 0.25mAh required and the pack voltage is above the taper voltage threshold. The taper current threshold is set as high as the software will allow me to set it but it still appears to be insufficient. I think previous logs may have shown average currents or ~450mA at cut-off due to averaging.

    As I said earlier, I don't have any control over the taper current cut-off from the charger, so unless there is a way to increase the taper current threshold I don't see any way of correctly configuring this device in my application.


    Michael

  • 0 in reply to Michael Behrens
    TI__Guru 73830 points

    Michael,

    You can edit the gg file and set the Taper Current to a larger value and then import it into the device. This will bypass the bqEVSW parameter limits.

    Tom