CBC (configurable battery charger) programming module for Lead Acid batteries

CBC (configurable battery charger) programming module for Lead Acid batteries

Configurable battery chargers offer users the flexibility to adjust charging parameters for increased optimisation and compatibility. Every Mascot CBC is ready for immediate use without the need for configuration. However, they can also be optimised for specific applications.

All Mascot Lead Acid (LA) battery chargers marked with this CBC symbol can be configured through the output cable using a toolkit consisting of a CBC module, a USB cable and Mascot’s config software. Our config software allows for the optimisation of 22 independent parameter settings and 7 additional enable/disable functions.

Figure 1 - All configurable parameters for LA chargers

Figure 2 - On/Off Mode Flags for LA chargers

All our chargers are designed for exceptional reliability, accurately following pre-configured CC/CV charging profiles. Once the charger has finished charging the battery at a constant voltage (while the current drops), a float charge is applied.

So, what is a float charge? A float charge applies a lower voltage charge, allowing batteries to be stored with optimal charge levels. Our config software provides the ability to select ‘float charge only’. When this is selected, the charger will only use float voltage to charge the battery. Mascot chargers offer a unique feature: the option to include current pulses during the float charge. Tests conducted by us have shown that these current pulses have a positive effect on the battery and may significantly increase its lifespan. These current pulses are limited (small), ensuring there is no risk of overcharging the battery. However, this feature can also be disabled to accommodate our customers’ requirements.

The chargers feature automatic diode detection, automatically detecting diodes in series, and compensate for the voltage change. By default, the voltage is increased by 0.2V when diodes are detected. Customers may adjust this to a higher or lower value as needed.

If temperature readings are required, LA chargers with a positive temperature coefficient (PTC) sensor are available, allowing the charger to automatically adjust the voltage according to the ambient temperature. Customers can set temperature limits for protection, including hot, cold, and charge pause++ settings. These limits can be set as either a pause, where charging resumes when the temperature reaches a safe level, or a hard cutoff, which halts charging and triggers an error code.

Figure 3: Model 4040 with PTC

Customers can disable the temperature compensated charge voltage by checking the ‘NO PTC’ box. Mascot’s standard is that PTC is not required. Therefore, if the PTC shorts or is removed the charger will ignore PTC reading and continue charging the battery with a fixed voltage. The charger will also use these voltages if the charger does not have a PTC sensor.

Our CBC adjustability can help to prevent overcharging, overheating and other potential issues that can affect a battery’s performance and lifetime. Once our customers have found their optimum configuration, we can then manufacture chargers matching their exact specification. The chargers can be password protected for reading and writing, this can be used to protect the chargers’ configuration. The fact that there is no master password means our customer's intellectual property is secure.

Using the config tool, various timers can be implemented:

Timer

Explanation

Soft start timer

Deeply discharged batteries are carefully charged with a low current until normal voltage is reached. In the event of charging a wrong or faulty battery, the charger will enter error mode when the timer expires.

Charge timer

In boost CV-mode, the current is decreased to the cut-off level. The charge timer limits the maximum time in this stage, which is useful if a parallel load is present.

Safety timer

This timer prevents overcharging and damage to the battery cells.

The Mascot CBC chargers, in conjunction with our config software, enable samples to be made efficiently. The updated software also offers code verification for research and development, making developers’ workflows more streamlined. By utilising the config software, users can review the last 10 charging cycles of the battery. This monitoring of battery performance permits the troubleshooting of any issues that may arise during the charging process – this can be used directly by our customers to identify if the fault is genuine or caused by misuse.

Figure 4 - Example of a charge log

Detailed setup instructions for our config software can be found in this guide or in video tutorials available here. More information about Mascot products can be found at www.mascot.no