Safe LiFePO4 high-performance battery pack launched

13th May 2021
Alex Lynn

With the new BP-LFP-2725, Bicker Elektronik has introduced an intrinsically safe ten year battery pack for emergency power supply and DC UPS systems. The lithium iron phosphate energy storage device with an integrated battery management system (BMS) is designed for applications that place the highest demands on quality, safety and reliability.

The compact BP-LFP-2725 with high energy density is designed for more than 6000 full cycles and is therefore ideally suited for use in particularly demanding applications in the industrial environment and medical technology. The battery pack is tested and certified according to IEC62133-2 and UN38.3.

Maximum safety and durability

Due to the built-in high-performance LiFePO4 cells in combination with our innovative high current BMS system, the compact BP-LFP-2725 reliably delivers its full performance even at high operating temperatures up to +55°C (max. 15A continuous current) and when frozen at -20°C (max. 6A continuous current).

The battery management system perfectly protects the cells from almost all harmful influences and ensures a permanently high capacity. Complex power saving modes prevent the battery pack from discharging quickly when not in use.

Low total cost of ownership (TCO) compared to traditional lead-acid batteries

In contrast to the supposedly cheaper lead-acid/gel/AGM batteries, high-quality lithium iron phosphate cells have an approx. Fifteen to twenty times longer service life and cycle stability. In addition, 100% of the full nominal capacity of the LiFePO4 battery pack can be continuously withdrawn. Lead-acid batteries have significant limitations in terms of the depth of discharge and number of cycles, too.

When calculating the TCO (Total Cost of Ownership) over the entire period of use of at least ten years, there is a clear cost advantage compared to lead-acid batteries, especially since the effort for maintenance and battery replacement for LiFePO4 is eliminated during this period.

LiFePO4: the particularly safe and long-lasting lithium-ion battery technology

The LiFePO4 battery pack BP-LFP-2725 impresses in safety-relevant applications with a particularly stable battery chemistry, a long service life of at least 10 years and more than 6000 full charge and discharge cycles. For all high-performance battery packs, Bicker Elektronik consciously relies on the particularly safe lithium iron phosphate chemistry, which makes thermal runaway almost impossible.

Only brand high-performance cells from LithiumWerks are used for the BP-LFP-2725, which clearly stand out from other manufacturers on the market due to their long service life and high cycle stability. The automated production of the high-performance cells ensures consistently high quality. Combined with the specially developed battery management system (BMS), Bicker Elektronik can guarantee the highest level of product safety and reliability.

Integrated high-performance battery management system (BMS)

The battery management system (BMS) of the BP-LFP-2725 monitors and controls the entire charging and discharging process of each battery cell in the energy storage system. At the same time, the BMS protects the battery pack from dangers such as short circuit, overcurrent, overtemperature, overcharging and deep discharge.

A balancing IC permanently measures and controls the cell voltages as well as the current flow and can react to critical changes within microseconds. The LiFePO4 energy storage system also has electronic overcurrent and short circuit protection so that the battery pack is not damaged in the event of an assembly error.

The same applies to overvoltage and undervoltage in the cells. In addition to the MOSFET safety circuit on the battery management system, a special thermal fuse protects the battery pack from the risk of overcharging as a second safety level. A 20A fuse is also installed as a second safety level in the event of a short circuit.

System present function for increased safety

With the system present function, the output of the battery pack remains deactivated (output voltage=0V) until it is connected to the DC UPS unit via the communication connector (BAT-DATA) and enabled.

Since the components on the BMS board run in standby mode, this power-saving function increases the shelf life of the (charged) battery pack.

Effective 'cell balancing' for long-term high performance

The integrated cell balancing ensures a balanced and uniform charge of all cells, so that the full capacity of the lithium-ion battery pack remains permanently usable. Intelligent balancing algorithms continuously control the LiFePO4 cells.

In the event of deviations, the individual cells are adjusted to one another with a balancing current of ~100mA during the charging process. This has a particularly positive effect on the service life, number of cycles and capacity of the energy storage device.

Available design versions for modular DC UPS and emergency power

The intrinsically safe LiFePO4 energy storage device is available in two versions: Compact and shrunk for flexible system integration as BP-LFP-2725 and in a robust aluminum housing for DIN rail mounting as BP-LFP-2725D.

In combination with the matching DC UPS units UPSI-2412 or UPSI-2412D, modular and powerful 24V emergency power supply solutions can be implemented (Backup times: ~70min@50W load / ~33min@100W load / ~18min@240W load).

Comprehensive service and support

In particular, applications with a long runtime benefit from optimal investment protection through the use of the particularly long-lasting and safe LiFePO4 energy storage devices of the BP-LFP series.

Combined with individual design-in advice and first-class service and support, Bicker Elektronik offers extensive value-added services for system developers and customers around the world. Upon request, the power supply specialist's development engineers can also implement customer-specific special and special solutions.

Bicker BP-LFP-2725 features

  • Ten-year battery pack with LiFePO4 high-performance cells.
  • Safe lithium iron phosphate technology.
  • 100% free from lead and cadmium.
  • Extended temperature range of -20 to +55°C.
  • Fifteen to twenty times longer service life than lead-acid batteries.
  • Integrated high-performance BMS system.
  • Advanced charging algorithms and cell balancing.
  • Redundant protection functions (intrinsic safety).
  • Integrated protection against deep discharge, overcurrent, overvoltage and short circuit.
  • Increased safety in the event of overcharging and short-circuiting of the battery pack.
  • Compact and shrunk design.
  • IEC 62133-2 safety approval.
  • UN 38.3 transport certification.

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