CBC (configurable battery charger) programming module for LiFePO4 batteries

CBC (configurable battery charger) programming module for lithium iron phosphate battery (LiFePO4) 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 lithium iron phosphate (LFP) 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 (https://www.mascot.no/downloads/4099-config-tool/). Our config software allows for the optimisation of 21 independent parameter settings and 8 additional enable/disable functions.

Figure 1 - All configurable parameters for LFP chargers

Figure 2 - On/Off Mode Flags for LFP chargers

All of 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. This is particularly useful in standby applications with a load connected in parallel with the battery. However, some LFP datasheets specify that a float charge is not required. In such cases, the float charge can be turned off.

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.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.

The charger is designed to work with an NTC thermistor in the battery pack for temperature monitoring. If the temperature moves out of operational range, the charger responds differently based on set limits. For a low or high temperature warning, the charger will automatically resume operation once the temperature returns to the acceptable range. In the case of a high-temperature error, the charger will not resume even if the temperature normalises; the battery or mains supply must be disconnected and reconnected to resume charging. The system is adaptable to different NTC thermistors, allowing users and customers to input the nominal resistance value and β value (The correlation between resistance and temperature) using the configuration tool.

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. In Power supply (PS) mode, the charger operates without logic, functioning like a standard power supply. To use the charger as a power supply, simply enable PS mode and set the desired voltage.

If “float charge only” is selected (in addition to PS mode) the voltage is set with parameter 39 instead.

Using the config tool, various timers can be implemented:

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