Varta EasyPack XL (LIP-009)

Overview

The Varta EasyPack XL (LIP-009) is a lithium‑polymer (LiPo) rechargeable battery pack built for compact devices that require long, stable runtime. Its slim profile and high energy density make it a strong fit for handheld medical instruments, industrial measurement tools, scanners, and pro AV equipment where space and weight are tight.

When to Choose It

• You need extended runtime without increasing device size or weight.
• Your device supports Li‑ion/Li‑polymer charging (CC/CV profile) and appropriate cutoff thresholds.
• You are designing enclosed, portable equipment with moderate continuous current draw (typical of sensors, scanners, monitors, or handheld terminals).

Avoid or Reconsider If

• Your device sees high ambient heat or frequent operation above ~45°C; consider chemistries with better high‑temperature tolerance.
• You need very high surge currents for motors or RF power amps without ample headroom and thermal design.
• Mechanical shock, puncture risk, or flexing cannot be mitigated—pouch cells require protective housings.

Compatibility and Integration Notes

• Voltage: Many single‑cell Li‑polymer packs are nominally ~3.7 V and charge up to ~4.2 V per cell. Confirm the exact nominal and maximum charge voltage in the LIP‑009 datasheet and ensure your device tolerances match.
• Charging: Use a dedicated Li‑ion/Li‑polymer CC/CV charger. Set charge current and termination according to the datasheet; if unsure, a conservative setting (≤0.5C) reduces stress and heat.
• Protection: Verify over‑charge, over‑discharge, over‑current, and short‑circuit protection are present (either integrated with the pack or on your device’s PCB). Never operate without proper protection.
• Connectors & leads: Match polarity, connector type, and wire gauge to your design. Avoid direct soldering to pouch tabs; use approved connectors or pre‑terminated leads.
• Mechanical: Mount securely to prevent flexing or puncture. Provide clearance for slight cell swelling at end of life, and avoid compressive forces.
• Regulatory: For shipping, obtain the manufacturer’s UN 38.3 test summary. Assess applicable safety standards (e.g., IEC 62133, UL/IEC 62368-1) for your end product.

Runtime Estimation

Estimate runtime using your device’s average current draw and the pack’s rated capacity from the datasheet.

1. Find rated capacity (mAh) on the LIP‑009 label/datasheet.
2. Measure or estimate your device’s average current draw (mA).
3. Runtime (hours) ≈ Capacity (mAh) ÷ Load (mA). Consider 10–20% overhead for inefficiencies and cutoff.

Example calculation (illustrative only)

If your device averages 600 mA and the pack is rated 4000 mAh, then 4000 ÷ 600 ≈ 6.7 hours. Accounting for overhead, plan for ~5.5–6.0 hours. Use your actual datasheet capacity and measured load for accuracy.

Charging and Safety

• Charge only with a Li‑ion/Li‑polymer CC/CV charger set to the correct voltage per the datasheet.
• Typical safe charge temperature window is around 0–45°C; do not charge below freezing or in high heat. Discharge windows are usually wider; always confirm in the datasheet.
• Do not short, crush, puncture, or bend the pack. Keep away from conductive debris and liquids.
• Provide thermal monitoring in designs with sustained high load or limited airflow.
• For storage over 3 months: store at ~30–60% state of charge, in a cool (15–25°C), dry place. Top up every 3–6 months.

Pros and Cons

• Pros: High energy density; slim and lightweight; stable voltage profile for electronics; supports compact enclosures.
• Cons: Sensitive to mechanical damage; prefers moderate temperatures; may not suit very high surge currents without careful design; requires strict charging control.

Common Applications

• Handheld medical diagnostics and patient monitoring
• Industrial measurement, data logging, and calibration tools
• Barcode scanners, mobile POS, and portable terminals
• Professional audio/video transmitters, mixers, and recorders

Alternatives to Consider

• Cylindrical Li‑ion (e.g., 18650 packs): Better mechanical robustness and potentially higher cycle life; typically larger volume.
• NiMH packs: More tolerant of cold and some abuse; lower energy density and higher self‑discharge.
• Primary lithium (non‑rechargeable): Long shelf life for low‑duty devices; not rechargeable and limited peak power.

FAQ

What charger do I need?

A Li‑ion/Li‑polymer CC/CV charger matched to the pack’s rated charge voltage and current. Always follow the LIP‑009 datasheet settings.

How do I size runtime correctly?

Measure average current draw during typical operation, apply the runtime formula, and add 10–20% margin for conversion losses, aging, and cut‑off thresholds.

Can I use it in high‑temperature environments?

Extended operation or charging in high heat reduces life and can be unsafe. Improve cooling, reduce load, or consider chemistries with better high‑temperature tolerance.

Is a protection circuit required?

Yes. Over‑charge, over‑discharge, and over‑current protection are essential. Some packs include protection; verify and add system‑level safeguards as needed.

What about shipping compliance?

Request the UN 38.3 test summary from the manufacturer and follow applicable transport regulations for lithium batteries.