Hello Onyx,
We have requested the unseal codes from the battery manufacturer, so we can look at all of the fail codes from the pack.
We do already have a gg file which the manufacturer supplied, and is used to program the pack. I have attached the gg file for you to have a look at. This has been renamed from the .gg extension normally used to .txt, so that it can be attached in this forum. I have also copied below.
Note that the normal charge current is 1.46A supplied by the LTC4006-6 charger IC.
Thanks,
Simon
Gas gauge file:
[Header]
bq EVSW Version = 0.9.65
DeviceName = bq20z75 v1.81
Time = 4/15/2011 1:15:51 PM
[Voltage(1st Level Safety)]
COV Threshold = 4300
COV Recovery = 4100
CUV Threshold = 2700
CUV Time = 1
CUV Recovery = 3000
[Current(1st Level Safety)]
OC (1st Tier) Chg = 2300
OC (1st Tier) Dsg = 9430
OC (1st Tier) Dsg Time = 2
Current Recovery Time = 8
AFE OC Dsg = 14
AFE OC Dsg Time = 0F
AFE SC Chg Cfg = 20
AFE SC Dsg Cfg = 96
[Temperature(1st Level Safety)]
Over Temp Chg = 55.0
OT Chg Recovery = 50.0
Over Temp Dsg = 62.0
OT Dsg Recovery = 55.0
[Voltage(2nd Level Safety)]
SOV Threshold = 18000
SOV Time = 0
Cell Imbalance Current = 5
Cell Imbalance Fail Voltage = 1000
Cell Imbalance Time = 0
Battery Rest Time = 1800
Min CIM-check voltage = 3000
PFIN Detect Time = 0
[Current(2nd Level Safety)]
SOC Chg = 10000
SOC Chg Time = 0
SOC Dsg = 10000
SOC Dsg Time = 0
[Temperature(2nd Level Safety)]
SOT Chg = 65.0
SOT Chg Time = 0
SOT Dsg = 75.0
SOT Dsg Time = 0
[FET Verification(2nd Level Safety)]
FET Fail Time = 0
[AFE Verification(2nd Level Safety)]
AFE Fail Limit = 10
[Charge Inhibit Cfg(Charge Control)]
Chg Inhibit Temp Low = -2.0
Chg Inhibit Temp High = 47.0
Temp Hys = 5.0
[Pre-Charge Cfg(Charge Control)]
Pre-chg Current = 200
Pre-chg Temp = 12.0
Pre-chg Voltage = 2900
Recovery Voltage = 3000
[Fast Charge Cfg(Charge Control)]
Fast Charge Current = 2000
Charging Voltage = 8400
Suspend Low Temp = -2.0
Suspend High Temp = 47.0
[Termination Cfg.(Charge Control)]
Taper Current = 220
Taper Voltage = 300
TCA Clear % = 95
FC Clear % = 98
[Cell Balancing Cfg(Charge Control)]
Min Cell Deviation = 1350
[Charging Faults(Charge Control)]
Over Charge Capacity = 400
[Data(SBS Configuration)]
Rem Cap Alarm = 400
Rem Energy Alarm = 2960
Rem Time Alarm = 10
Init Battery Mode = 0081
Design Voltage = 7400
Spec Info = 0031
Manuf Date = 15-Apr-2011
Ser. Num. = FFFF
Cycle Count = 0
CC Threshold = 3600
CF MaxError Limit = 100
Design Capacity = 4000
Design Energy = 29600
Manuf Name = TouchStar
Device Name = HawkII
Device Chemistry = LION
[Configuration(SBS Configuration)]
TDA Set % = 6
TDA Clear % = 8
FD Set % = 2
FD Clear % = 5
TDA Set Volt Threshold = 0
TDA Set Volt Time = 0
TDA Clear Volt = 0
[Manufacturer Info(System Data)]
Manuf. Info = 0100xxxx
[Lifetime Data(System Data)]
Lifetime Max Temp = 0.0
Lifetime Min Temp = 50.0
[Registers(Configuration)]
Operation Cfg A = 0121
Operation Cfg B = 24D8
Operation Cfg C = 0001
Permanent Fail Cfg = 0000
Non-Removable Cfg = 0000
[AFE(Configuration)]
AFE.State_CTL = 00
[Power(Power)]
Flash Update OK Voltage = 6000
Shutdown Voltage = 5000
Shutdown Time = 10
Cell Shutdown Voltage = 2500
Cell Shutdown Time = 10
Charger Present = 3000
Sleep Current = 10
Wake Current Reg = 00
[IT Cfg(Gas Gauging)]
Load Select = 3
Load Mode = 1
Term Voltage = 6000
User Rate-mA = 0
User Rate-mW = 0
Reserve Cap-mAh = 0
Reserve Cap-mWh = 0
[Current Thresholds(Gas Gauging)]
Dsg Current Threshold = 50
Chg Current Threshold = 25
Quit Current = 10
[State(Gas Gauging)]
Qmax Cell 0 = 4216
Qmax Cell 1 = 4227
Qmax Cell 2 = 4000
Qmax Cell 3 = 4000
Qmax Pack = 4216
Update Status = 02
Avg I Last Run = -802
Avg P Last Run = -604
Delta Voltage = 5
[R_a0(Ra Table)]
Cell0 R_a flag = 0000
Cell0 R_a 0 = 116
Cell0 R_a 1 = 120
Cell0 R_a 2 = 134
Cell0 R_a 3 = 146
Cell0 R_a 4 = 116
Cell0 R_a 5 = 119
Cell0 R_a 6 = 139
Cell0 R_a 7 = 121
Cell0 R_a 8 = 129
Cell0 R_a 9 = 142
Cell0 R_a 10 = 137
Cell0 R_a 11 = 149
Cell0 R_a 12 = 155
Cell0 R_a 13 = 317
Cell0 R_a 14 = 463
[R_a1(Ra Table)]
Cell1 R_a flag = 0000
Cell1 R_a 0 = 145
Cell1 R_a 1 = 150
Cell1 R_a 2 = 163
Cell1 R_a 3 = 174
Cell1 R_a 4 = 146
Cell1 R_a 5 = 150
Cell1 R_a 6 = 171
Cell1 R_a 7 = 155
Cell1 R_a 8 = 161
Cell1 R_a 9 = 176
Cell1 R_a 10 = 174
Cell1 R_a 11 = 189
Cell1 R_a 12 = 203
Cell1 R_a 13 = 384
Cell1 R_a 14 = 559
[R_a2(Ra Table)]
Cell2 R_a flag = FF55
Cell2 R_a 0 = 160
Cell2 R_a 1 = 166
Cell2 R_a 2 = 153
Cell2 R_a 3 = 151
Cell2 R_a 4 = 145
Cell2 R_a 5 = 152
Cell2 R_a 6 = 176
Cell2 R_a 7 = 204
Cell2 R_a 8 = 222
Cell2 R_a 9 = 254
Cell2 R_a 10 = 315
Cell2 R_a 11 = 437
Cell2 R_a 12 = 651
Cell2 R_a 13 = 1001
Cell2 R_a 14 = 1458
[R_a3(Ra Table)]
Cell3 R_a flag = FF55
Cell3 R_a 0 = 160
Cell3 R_a 1 = 166
Cell3 R_a 2 = 153
Cell3 R_a 3 = 151
Cell3 R_a 4 = 145
Cell3 R_a 5 = 152
Cell3 R_a 6 = 176
Cell3 R_a 7 = 204
Cell3 R_a 8 = 222
Cell3 R_a 9 = 254
Cell3 R_a 10 = 315
Cell3 R_a 11 = 437
Cell3 R_a 12 = 651
Cell3 R_a 13 = 1001
Cell3 R_a 14 = 1458
[R_a0x(Ra Table)]
xCell0 R_a flag = 0055
xCell0 R_a 0 = 116
xCell0 R_a 1 = 120
xCell0 R_a 2 = 134
xCell0 R_a 3 = 146
xCell0 R_a 4 = 116
xCell0 R_a 5 = 119
xCell0 R_a 6 = 139
xCell0 R_a 7 = 121
xCell0 R_a 8 = 129
xCell0 R_a 9 = 142
xCell0 R_a 10 = 137
xCell0 R_a 11 = 149
xCell0 R_a 12 = 155
xCell0 R_a 13 = 361
xCell0 R_a 14 = 527
[R_a1x(Ra Table)]
xCell1 R_a flag = 0055
xCell1 R_a 0 = 145
xCell1 R_a 1 = 150
xCell1 R_a 2 = 163
xCell1 R_a 3 = 174
xCell1 R_a 4 = 146
xCell1 R_a 5 = 150
xCell1 R_a 6 = 171
xCell1 R_a 7 = 155
xCell1 R_a 8 = 161
xCell1 R_a 9 = 176
xCell1 R_a 10 = 174
xCell1 R_a 11 = 189
xCell1 R_a 12 = 203
xCell1 R_a 13 = 413
xCell1 R_a 14 = 601
[R_a2x(Ra Table)]
xCell2 R_a flag = FFFF
xCell2 R_a 0 = 160
xCell2 R_a 1 = 166
xCell2 R_a 2 = 153
xCell2 R_a 3 = 151
xCell2 R_a 4 = 145
xCell2 R_a 5 = 152
xCell2 R_a 6 = 176
xCell2 R_a 7 = 204
xCell2 R_a 8 = 222
xCell2 R_a 9 = 254
xCell2 R_a 10 = 315
xCell2 R_a 11 = 437
xCell2 R_a 12 = 651
xCell2 R_a 13 = 1001
xCell2 R_a 14 = 1458
[R_a3x(Ra Table)]
xCell3 R_a flag = FFFF
xCell3 R_a 0 = 160
xCell3 R_a 1 = 166
xCell3 R_a 2 = 153
xCell3 R_a 3 = 151
xCell3 R_a 4 = 145
xCell3 R_a 5 = 152
xCell3 R_a 6 = 176
xCell3 R_a 7 = 204
xCell3 R_a 8 = 222
xCell3 R_a 9 = 254
xCell3 R_a 10 = 315
xCell3 R_a 11 = 437
xCell3 R_a 12 = 651
xCell3 R_a 13 = 1001
xCell3 R_a 14 = 1458
[Device Status Data(PF Status)]
PF Flags 1 = 0000
PF Flags 2 = 0000
[Data(Calibration)]
CC Gain = 10.105
CC Delta = 10.105
Ref Voltage = 1225.00
AFE Pack Gain = -500.52
CC Offset = -0.269
Board Offset = -31.6
Int Temp Offset = 4.4
Ext1 Temp Offset = 12.0
Ext2 Temp Offset = 0.0
[Config(Calibration)]
CC Current = 3000
Voltage Signal = 16800
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 = -30052
Ext Coef 2 = 22160
Ext Coef 3 = -7843
Ext Coef 4 = 403.9
Ext Min AD = 0
Ext Max Temp = 403.9
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 = 3
CC Deadband = 10.0