Ryobi40V

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This is a basic analysis of how a Ryobi 40V smart charger (model number OP403) communicates with the battery's BMS to enable the charging FET.

Electronics

Pictures of the charger PCB are below:

PCB top side.
PCB bottom side.

The wall wart adapter is a 42V 1.5A rated switching converter, listed at 84W max from AC (though output is max 63W). The wall wart does the necessary CC/CV current limiting, with a ~44.15V open circuit voltage output when no battery is connected. Output is switched to the battery though a "GS3MR HCH" diode, switched by a AP9575GH-HF P-channel MOSFET (60V 15A 90mΩ @12A).

Charging Sequence:

Battery insertion to charging start sequence.

Data detail:

Data packet detail.

The charger includes a 5V 1.5A buck based on a MP2487 (4.5-55V in, 220mOhm PFET, 1.5A max). The sticker claims 5V 2.1A output.

There is also a resistor bank of 10 ohms effective (5p 130 ohms SMD series 5p 130 ohms SMD, in parallel with 5p 62 ohms 3-5W through hole), which is switched on to the pack to test IR, through a SW088R06VT N-channel MOSFET (60V 40A 9.2mΩ @20A).

The charger is controlled by an NXP LPC824M201JHI33E 32-bit 30 MHz Cortex M0 MCU.