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bq78PL114S12 Discharge Complete state not "sticking" and DFET turning back on

When doing a 2C discharge with a 4S Li-Ion pack the voltage drops to my Discharge Completion (DC) voltage, 11600mV, and the DFET turns off after the Discharge Completion Time (2sec) and Discharge Completion FET Activation Time (2sec) have elapsed. It then stays off after this point. So far, so good.

When doing a 7.5C discharge, the pack reaches the DC voltage, the two timers elapse and the DFET turns off. After a fraction of a second to several seconds, the DFET turns back on and the pack starts discharging again until the DC voltage is reached. The DFET turns off again, etc. This repeats until the PUV or CUV point is reached where, finally, the DFET stays off (I have the recovery voltages set pretty high for PUV and CUV).

What could be causing this?

At first I thought the problem might have been related to a particular timer or rebound voltage level but a read of the Tech Manual seems to indicate that there's no timer or voltage affecting the clearing of the DC bit. Just a charge current or the discharge current essentially stopping before the Discharge Completion FET Activation Time timer elapses. But, I successfully reach the DC point and the DFET turns off so the timers shouldn't matter.

I've attached two screen captures. The first shows the 7.5C discharge and how the DFET keeps turning back on. The second shows a 2C discharge done right after the 7.5C discharge reached the DC voltage. Both discharge current levels show the DFET turning back on after different voltage and timer intervals.

Since the rebound voltage level, and rate of increase, is much higher after a 7.5C discharge reaches the DC voltage level, could this somehow be the cause? This is the only difference I can think of between the 2C discharge (all the way from 100% SOC to the DC voltage) and the 2C discharge I did immediately after the 7.5C discharge reached the DC voltage.

  • You may need to set PUV and CUV recovery threshold. Once you remove load from the battery, battery voltage jump up. And BQ detect safe condition and try to discharge again. Set your PUV and CUV recovery threshold much higher than PUV and CUV threshold. This will solve your issue.

     

  • That's what I thought might be happening but there's no mention of this association in the Tech Ref Manual and the pack never reached any of the CUV/PUV/EUV thresholds. But, you could be right. :)

    I set the recovery voltage thresholds to very high levels and tried another 7.5C discharge:

    CUV Threshold = 2600, CUV Recovery = 3500

    PUV Threshold = 10800, PUV Recovery = 14000

    EUV Threshold = 2700,  EUV Recovery = 3500

    Below is plot of the end of the 7.5C discharge. The turning back on of the DFET still occurs but, as before, at different voltage levels and seemingly different times (after reaching the DC voltage). I'm sure it's something obvious, but I'm stumped.

  • Is there any clue in safety history ??

  • Good idea, but unfortunately there's no indication of anything going on there.

    It appears to be an interaction between the certain firmware settings, our discharge current level, and the Discharge Complete voltage. We're trying out a bunch of variations of them to try to narrow it down.