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BQ20Z95: Battery gauge goes wrong after if left unused for 2 months

Part Number: BQ20Z95

Hello TI experts,

My customer designed battery pack with BQ20Z95 and sell it since 2014, and recently they got a complain from end customer.

end customer says that when they use battery pack with normal condition(charging and discharging with equipment), there was no problem.

but if they do not use battery and just store it about 2 months, when they attach the battery to equipment they see that the remaining capacity of battery is 25%.

(they sell and buy the battery that remains approximately 50%.)

and when they try to charge the battery with external charger, LED turns red to green immediately.

and they discharge and charge to full with this fault battery, the gauge turns to normal.

I think that gg file have some errors somewhere.

could you check this gg file for this fault situation? I know that this IC is old device, but i need your help.

and I have one more question, I could not find the known chemistry ID in bq Gas Gauge Evaluation software even though I updated ChemicalUpdater-848.

if you have known chemical ID for us, please let me know. the cell is ICP544382A,2300mAh, Samsung SDI, 3S1P.

please check these issues. Thanks.

Best regards,

Chase

[Header]
bq EVSW Version = 0.9.64	
DeviceName = bq20z95 v1.50
Time = 2020-02-06 ���� 7:17:35	


[Voltage(1st Level Safety)]
COV Threshold = 4250
COV Time = 1
COV Recovery = 4100
COV Delta = 0
COV Temp. Hys = 10.0
POV Threshold = 13000
POV Time = 0
POV Recovery = 12000
CUV Threshold = 3000
CUV Time = 2
CUV Recovery = 3200
PUV Threshold = 8250
PUV Time = 0
PUV Recovery = 9000
[Current(1st Level Safety)]
OC (1st Tier) Chg = 2800
OC (1st Tier) Chg Time = 2
OC Chg Recovery = 100
OC (1st Tier) Dsg = 2800
OC (1st Tier) Dsg Time = 2
OC Dsg Recovery = 200
OC (2nd Tier) Chg = 3100
OC (2nd Tier) Chg Time = 2
OC (2nd Tier) Dsg = 2950
OC (2nd Tier) Dsg Time = 2
Current Recovery Time = 32
AFE OC Dsg = 00
AFE OC Dsg Time = 0A
AFE OC Dsg Recovery = 10
AFE SC Chg Cfg = F3
AFE SC Dsg Cfg = F3
AFE SC Recovery = 5
[Temperature(1st Level Safety)]
Over Temp Chg = 60.0
OT Chg Time = 1
OT Chg Recovery = 55.0
Over Temp Dsg = 70.0
OT Dsg Time = 1
OT Dsg Recovery = 65.0
[Host Comm(1st Level Safety)]
Host Watchdog Timeout = 0

[Voltage(2nd Level Safety)]
SOV Threshold = 13050
SOV Time = 0
Cell Imbalance Current = 5
Cell Imbalance Fail Voltage = 500
Cell Imbalance Time = 5
Battery Rest Time = 1800
Min CIM-check voltage = 3000
PFIN Detect Time = 1
[Current(2nd Level Safety)]
SOC Chg = 4200
SOC Chg Time = 0
SOC Dsg = 4200
SOC Dsg Time = 0
[Temperature(2nd Level Safety)]
SOT Chg = 80.0
SOT Chg Time = 0
SOT Dsg = 80.0
SOT Dsg Time = 0
Open Thermistor = -33.3
Open Time = 0
[FET Verification(2nd Level Safety)]
FET Fail Limit = 100
FET Fail Time = 20
[AFE Verification(2nd Level Safety)]
AFE Check Time = 10
AFE Fail Limit = 100
AFE Fail Recovery Time = 20
AFE Init Retry Limit = 6
AFE Init Limit = 20
[Fuse Verification(2nd Level Safety)]
Fuse Fail Limit = 2
Fuse Fail Time = 5

[Charge Inhibit Cfg(Charge Control)]
Chg Inhibit Temp Low = -20.0
Chg Inhibit Temp High = 55.0
Temp Hys = 1.0
[Pre-Charge Cfg(Charge Control)]
Pre-chg Current = 200
Pre-chg Temp = 0.0
Pre-chg Voltage = 2750
Recovery Voltage = 2750
[Fast Charge Cfg(Charge Control)]
Fast Charge Current = 1400
Charging Voltage = 12600
Delta Temp = 0.0
Suspend Low Temp = -20.0
Suspend High Temp = 60.0
[Pulse Charge Cfg(Charge Control)]
Turn ON Voltage = 5000
Turn OFF Voltage = 5000
Max ON Pulse Time = 60.00
Min OFF Pulse Time = 0.00
Max OFF Voltage = 5000
[Termination Cfg.(Charge Control)]
Maintenance Current = 0
Taper Current = 170
Taper Voltage = 300
Current Taper Window = 60
TCA Set % = 100
TCA Clear % = 94
FC Set % = 100
FC Clear % = 94
[Cell Balancing Cfg(Charge Control)]
Min Cell Deviation = 6250
[Charging Faults(Charge Control)]
Over Charging Voltage = 500
Over Charging Volt Time = 0
Over Charging Current = 500
Over Charging Curr Time = 0
Over Charging Curr Recov = 100
Depleted Voltage = 6000
Depleted Voltage Time = 0
Depleted Recovery = 6500
Over Charge Capacity = 400
Over Charge Recovery = 2
FC-MTO = 36000
PC-MTO = 10800
Charge Fault Cfg = 30

[Data(SBS Configuration)]
Rem Cap Alarm = 280
Rem Energy Alarm = 3080
Rem Time Alarm = 10
Init Battery Mode = 0081
Design Voltage = 11550
Spec Info = 0031
Manuf Date = 25-Mar-2015
Ser. Num. = 055A
Cycle Count = 0
CC Threshold = 5310
CC % = 90
CF MaxError Limit = 100
Design Capacity = 2800
Design Energy = 32340
Manuf Name = 3S-1P
Device Name = EGENS
Device Chemistry = LION
[Configuration(SBS Configuration)]
TDA Set % = 0
TDA Clear % = 10
FD Set % = 0
FD Clear % = 20
TDA Set Volt Threshold = 9000
TDA Set Volt Time = 0
TDA Clear Volt = 10000
FD Set Volt Threshold = 9000
FD Volt Time = 0
FD Clear Volt = 10000

[Manufacturer Data(System Data)]
Pack Lot Code = 0000
PCB Lot Code = 0000
Firmware Version = 0151
Hardware Revision = 0001
Cell Revision = 0001
[Manufacturer Info(System Data)]
Manuf. Info = 123456789ABCDEF
[Lifetime Data(System Data)]
Lifetime Max Temp = 30.0
Lifetime Min Temp = 5.8
Lifetime Max Cell Voltage = 4253
Lifetime Min Cell Voltage = 2750
Lifetime Max Pack Voltage = 12749
Lifetime Min Pack Voltage = 8250
Lifetime Max Chg Current = 22562
Lifetime Max Dsg Current = -2043
Lifetime Max Chg Power = 225580
Lifetime Max Dsg Power = -22300
Life Max AvgDsg Cur = -2006
Life Max AvgDsg Pow = -2009
Lifetime Avg Temp = 12.3
[Lifetime Temp Samples(System Data)]
LT Temp Samples = 36524

[Registers(Configuration)]
Operation Cfg A = 0229
Operation Cfg B = 6CF8
Operation Cfg C = 0005
Permanent Fail Cfg = 5FED
Non-Removable Cfg = 0000

[LED Cfg(LED Support)]
LED Flash Rate = 2.000
LED Blink Rate = 1.000
LED Delay = 48.8
LED Hold Time = 4
CHG Flash Alarm = 10
CHG Thresh 1 = 0
CHG Thresh 2 = 26
CHG Thresh 3 = 51
CHG Thresh 4 = 76
CHG Thresh 5 = 100
DSG Flash Alarm = 10
DSG Thresh 1 = 0
DSG Thresh 2 = 26
DSG Thresh 3 = 51
DSG Thresh 4 = 76
DSG Thresh 5 = 100
Sink Current = 3

[Power(Power)]
Flash Update OK Voltage = 7800
Shutdown Voltage = 7800
Shutdown Time = 20
Cell Shutdown Voltage = 2850
Cell Shutdown Time = 20
Charger Present = 12600
Sleep Current = 10
Bus Low Time = 30
Cal Inhibit Temp Low = -20.0
Cal Inhibit Temp High = 60.0
Sleep Voltage Time = 60
Sleep Current Time = 20
Wake Current Reg = 02

[IT Cfg(Gas Gauging)]
Load Select = 1
Load Mode = 1
Term Voltage = 8250
User Rate-mA = 0
User Rate-mW = 0
Reserve Cap-mAh = 0
Reserve Cap-mWh = 0
[Current Thresholds(Gas Gauging)]
Dsg Current Threshold = 100
Chg Current Threshold = 100
Quit Current = 50
Dsg Relax Time = 1
Chg Relax Time = 60
[State(Gas Gauging)]
Qmax Cell 0 = 2800
Qmax Cell 1 = 2800
Qmax Cell 2 = 2800
Qmax Cell 3 = 2800
Qmax Pack = 2800
Update Status = 06
Avg I Last Run = -2006
Avg P Last Run = -2009
Delta Voltage = 13

[R_a0(Ra Table)]
Cell0 R_a flag = 0055
Cell0 R_a 0 = 220
Cell0 R_a 1 = 216
Cell0 R_a 2 = 245
Cell0 R_a 3 = 247
Cell0 R_a 4 = 286
Cell0 R_a 5 = 297
Cell0 R_a 6 = 357
Cell0 R_a 7 = 458
Cell0 R_a 8 = 539
Cell0 R_a 9 = 646
Cell0 R_a 10 = 917
Cell0 R_a 11 = 3106
Cell0 R_a 12 = 6409
Cell0 R_a 13 = 9616
Cell0 R_a 14 = 25384
[R_a1(Ra Table)]
Cell1 R_a flag = 0055
Cell1 R_a 0 = 213
Cell1 R_a 1 = 209
Cell1 R_a 2 = 238
Cell1 R_a 3 = 242
Cell1 R_a 4 = 282
Cell1 R_a 5 = 293
Cell1 R_a 6 = 351
Cell1 R_a 7 = 450
Cell1 R_a 8 = 528
Cell1 R_a 9 = 631
Cell1 R_a 10 = 881
Cell1 R_a 11 = 2884
Cell1 R_a 12 = 5949
Cell1 R_a 13 = 8924
Cell1 R_a 14 = 23559
[R_a2(Ra Table)]
Cell2 R_a flag = 0055
Cell2 R_a 0 = 221
Cell2 R_a 1 = 217
Cell2 R_a 2 = 247
Cell2 R_a 3 = 246
Cell2 R_a 4 = 290
Cell2 R_a 5 = 303
Cell2 R_a 6 = 366
Cell2 R_a 7 = 475
Cell2 R_a 8 = 559
Cell2 R_a 9 = 649
Cell2 R_a 10 = 914
Cell2 R_a 11 = 3013
Cell2 R_a 12 = 6212
Cell2 R_a 13 = 9315
Cell2 R_a 14 = 24603
[R_a3(Ra Table)]
Cell3 R_a flag = FF55
Cell3 R_a 0 = 298
Cell3 R_a 1 = 292
Cell3 R_a 2 = 306
Cell3 R_a 3 = 314
Cell3 R_a 4 = 283
Cell3 R_a 5 = 301
Cell3 R_a 6 = 379
Cell3 R_a 7 = 481
Cell3 R_a 8 = 576
Cell3 R_a 9 = 722
Cell3 R_a 10 = 1026
Cell3 R_a 11 = 2014
Cell3 R_a 12 = 4153
Cell3 R_a 13 = 6230
Cell3 R_a 14 = 16451
[R_a0x(Ra Table)]
xCell0 R_a flag = 0000
xCell0 R_a 0 = 220
xCell0 R_a 1 = 216
xCell0 R_a 2 = 245
xCell0 R_a 3 = 247
xCell0 R_a 4 = 286
xCell0 R_a 5 = 297
xCell0 R_a 6 = 357
xCell0 R_a 7 = 458
xCell0 R_a 8 = 539
xCell0 R_a 9 = 611
xCell0 R_a 10 = 867
xCell0 R_a 11 = 2938
xCell0 R_a 12 = 6062
xCell0 R_a 13 = 9095
xCell0 R_a 14 = 24009
[R_a1x(Ra Table)]
xCell1 R_a flag = 0000
xCell1 R_a 0 = 213
xCell1 R_a 1 = 209
xCell1 R_a 2 = 238
xCell1 R_a 3 = 242
xCell1 R_a 4 = 282
xCell1 R_a 5 = 293
xCell1 R_a 6 = 351
xCell1 R_a 7 = 450
xCell1 R_a 8 = 528
xCell1 R_a 9 = 598
xCell1 R_a 10 = 835
xCell1 R_a 11 = 2733
xCell1 R_a 12 = 5638
xCell1 R_a 13 = 8457
xCell1 R_a 14 = 22327
[R_a2x(Ra Table)]
xCell2 R_a flag = 0000
xCell2 R_a 0 = 221
xCell2 R_a 1 = 217
xCell2 R_a 2 = 247
xCell2 R_a 3 = 246
xCell2 R_a 4 = 290
xCell2 R_a 5 = 303
xCell2 R_a 6 = 366
xCell2 R_a 7 = 475
xCell2 R_a 8 = 559
xCell2 R_a 9 = 635
xCell2 R_a 10 = 894
xCell2 R_a 11 = 2948
xCell2 R_a 12 = 6078
xCell2 R_a 13 = 9114
xCell2 R_a 14 = 24072
[R_a3x(Ra Table)]
xCell3 R_a flag = FFFF
xCell3 R_a 0 = 298
xCell3 R_a 1 = 292
xCell3 R_a 2 = 306
xCell3 R_a 3 = 314
xCell3 R_a 4 = 283
xCell3 R_a 5 = 301
xCell3 R_a 6 = 379
xCell3 R_a 7 = 481
xCell3 R_a 8 = 576
xCell3 R_a 9 = 722
xCell3 R_a 10 = 1026
xCell3 R_a 11 = 2014
xCell3 R_a 12 = 4153
xCell3 R_a 13 = 6230
xCell3 R_a 14 = 16451

[Device Status Data(PF Status)]
PF Flags 1 = 0000
Fuse Flag = 00
PF Voltage = 0
PF C4 Voltage = 0
PF C3 Voltage = 0
PF C2 Voltage = 0
PF C1 Voltage = 0
PF Current = 0
PF Temperature = 0.0
PF Batt Stat = 00
PF RC-mAh = 0
PF RC-10mWh = 0
PF Chg Status = 0000
PF Safety Status = 0000
PF Flags 2 = 0000
[AFE Regs(PF Status)]
AFE Status = 00
AFE Output = 00
AFE State = 00
AFE Function = 00
AFE Cell Select = 00
AFE OLV = 00
AFE OLT = 00
AFE SCC = 00
AFE SCD = 00

[Data(Calibration)]
CC Gain = 5.6
CC Delta = 5.6
Ref Voltage = 1221.50
AFE Pack Gain = 720.49
CC Offset = -0.297
Board Offset = -41.5
Int Temp Offset = 7.4
Ext1 Temp Offset = -6.5
Ext2 Temp Offset = 0.0
[Config(Calibration)]
CC Current = 3000
Voltage Signal = 12600
Temp Signal = 298.0
CC Offset Time = 250
ADC Offset Time = 32
CC Gain Time = 250
Voltage Time = 1984
Temperature Time = 32
Cal Mode Timeout = 300
[Temp Model(Calibration)]
Ext Coef 1 = -28285
Ext Coef 2 = 20848
Ext Coef 3 = -7537
Ext Coef 4 = 401.2
Ext Min AD = 0
Ext Max Temp = 401.2
Int Coef 1 = 0
Int Coef 2 = 0
Int Coef 3 = -11136
Int Coef 4 = 575.4
Int Min AD = 0
Int Max Temp = 575.4
[Current(Calibration)]
Filter = 239
Deadband = 4
CC Deadband = 10.0

  • Hello Chase,

    They should have found the best fit ID using the GPCCHEM tool to upload to the gauge. Do they put the gauge in shutdown or sleep mode when the battery sits for a couple months?

    Sometimes the gauge will correlate incorrectly when the gauge is stored for a long time and a new cycle will correct the error.

    Sincerely,

    Wyatt Keller

  • Hello Wyatt,

    Thank you for your reply.

    1. can I use GPCCHEM? as I said it is NRND part. I thought that It is only for recent parts with bqStudio.

    2. I found something relative with shutdown and sleep mode in gg file. in it I can see it goes to sleep or shutdown mode after 20 seconds each, and 20 sec is not the effective time for this fault situation. it only occurs after much more long time. you can see the parameters in attached gg file.

    3. I asked to customer that do the learning cycle once again with Bq Gas Gauge Evaluation Software.

    what I wonder is, would it be okay to apply new gg file with only 2 learning cycle? the program(bq gas gauge evaluation program) guides the steps like this.

    and as i said I think this IC cannot use GPCCHEM because it is old product.

    please check this issues. Thanks.

    Best regards,

    Chase

  • Hello Chase, 

    You can still use the GPCCHEM tool, there is a chemistry updater on the bq20z95 product page.

    Is the gauge in sleep mode or shutdown when it's being stored? This could affect the quiescent current and how the gauge correlates SOC.

    They should do the GPCCHEM tool first before learning cycle.

    Sincerely,

    Wyatt Keller

  • Hello Wyatt,

    I am little confused about the process, can you check this step is right or not?

    1. first I have to get chemistry ID using GPCCHEM. to get this, I use default chemistry ID on bq Gas Gauge Evaluation Software, then I run the cycle mentioned as the document SLVA725A.

    2. I upload 2 files as zip to GPCCHEM, then I can get new chemistry ID for my new battery.

    3. I flash chemistry ID to the new battery, and I do 2 learning cycles on bq Gas Gauge Evaluation Software.

    4. I can get golden pack. (gg file)

    if there are some misunderstanding, please let me know. Thanks.

    Best regards,

    Chase

  • Hello Chase,

    Those steps are correct. For step 1 it doesn't matter what chemID is programmed or if IT is enabled, you're only logging the current, voltage, temperature information.

    Sincerely,

    Wyatt Keller

  • Hello Wyatt,

    Thank you for your kind response.

    Here is more questions,

    1. is it enough to do 2 learning cycles after flash new chemID on battery? or is it better to do more learning cycle for more accuracy ?

    2. what is the recommended time for sleep and shutdown mode? now I have 20 seconds for both mode.

    Thank you in advance.

    Best regards,

    Chase

  • Hello Chase,

    Doing 1 learning cycle is enough for the gauge to learn the battery.

    The sleep/shutdown time depends on your application and what you need.

    Sincerely,

    Wyatt Keller

  • Hello Wyatt,

    I am sorry that I have too many questions. because this is my first development of fuel gauge.

    anyway, i have few more questions,

    1. when I learn a cycle for chemistry ID, Should I do with a single cell? or assembled cells? (like 3s2p) or complete battery pack with default firmware?

    2. if the cell is changed of the structure or changed (ex. 3s2p to 2s1p) should I get new chemistry ID and do a new learning cycle?

    3. can I use fuel gauge with dummy battery made by ac adapter or power supply? how about battery tester?

    can I run a cycle for chemistry ID and learning cycle in this situation?

    Best regards,

    Chase

  • Hi Chase,

    1. complete battery pack 
    2. If the cell is changed it may need a different chemID. Changing pack config you will need to rerun a learning cycle
    3. For testing purposes this is ok

    Best regards,

  • Hello Nick,

    maybe Wyatt is busy :)

    we still have some errors for setting the environments.

    can i attach power supply directly to positive and negative electrodes of complete battery pack? the voltage is 12.6V, and the current limit is 1.4amps as the specification.

    or should we use individual charger containing charge IC?

    1) Power supply ----- (12.6V, 1.4A) -----> battery pack

    2) Power supply ----- (DC input 19V) -----> charger ----- (regulated and controlled 12.6V) -----> battery pack

    which one is right for getting ChemID and golden image?

    Best regards,

    Chase

  • Hello Wyatt, Hello Nick,

    Now i am in process of learning cycle with my customer.

    there is many problems now because this is the first time of learning cycle both me and my customer.

    1. anyway i got chemistry id successfully but in first learning cycle, charging and rest 2 hours, i cannot see the VOK flag clear. even we rest over 12 hours, the result is the same. can you give me some advice for this?

    2. i have to use command for unseal and full access mode with every step. if i do something like read registers or calibrate something, SS and FAS flag come back to set. i want to know this is normal operation.

    3. can i disable overvoltage and undervoltage protection completely forever using command? (not setting the range of voltage value, just disable)

    please check this issues. Thanks.

    Best regards,

    Chase

  • Hello Chase,

    Can you share the GPCCHEM report for the chem ID, just so I can verify it's a good match? This could be a reason for the VOK not toggling, VOK indicates if the voltage was good for a Qmax.

    You should perform the learning cycle with a gauge that hasn't been previously sealed, has this gauge been sealed before?

    I'm not aware of a command for disabling the protections permanently on the bq20z95.

    Sincerely,

    Wyatt Keller

  • Hello Wyatt,

    thank you for your reply.

    I upload GPCCHEM report.

    and I don't know exactly what you mean, just when we attach the battery to bqsw using EV2300, SS and FAS flag is always set. so we have to clear SS and FAS flag before we use any command. so i think the battery pack has been sealed for the mass production.

    and based on your saying, it is right operation that clear SS and FAS flag if I want to use any commands every time.

    let me know if you need more information for analysis. Thanks.

    Best regards,

    Chase

    EGEN_210113-report.zip

  • Hello Chase,

    The GPCCHEM report looks good for chemID 1169.

    Right, it would be best to do a learning cycle on a gauge that has not been sealed before because then you don't need keep unsealing it.

    Were you able to upload chemID 1169?

    Sincerely,

    Wyatt Keller

  • Hello Wyatt,

    first i am sorry that you are answering 2 different threads for 1 issue.

    yes, i upload chemID 1169 successfully. but i think the process is not perfect.

    because sometimes i can upload chemID  with no problem and other files like default DFI file, basic pack information and calibration data before uploading chemID.

    but sometimes I have an error message, and have to clear FAS and SS flag to upload something each step.

    I don't know this is just unstable program or i have some mistake.

    and i am asking you again, what is the reason that I cannot see the VOK flag cleard even I rest very enough time after charging? (i rest over 12 hours.)

    please give me some advice for this. Thanks.

    Best regards,

    Chase

  • Hello Chase,

    I think we can combine the two threads.

    If you upload an .srec of a sealed gauge, the gauge you upload it to will become sealed as well.

    As defined in the TRM, VOK indicates if the OCV taken is good for a Qmax, something is disqualifying the OCV for a Qmax.

    Sincerely,

    Wyatt Keller