Revolectrix Dual PowerLab 8x2 User Manual
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Revolectrix Dual PowerLab 8x2 User Manual

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Dual PowerLab 8x2
User's Guide
firmware ver 1.02 or newer
© 2013, 2014 FMA,Inc.
Updated: 09/02/2014

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Summary of Contents for Revolectrix Dual PowerLab 8x2

  • Page 1 Dual PowerLab 8x2 User’s Guide firmware ver 1.02 or newer © 2013, 2014 FMA,Inc. Updated: 09/02/2014...

  • Page 2: Table Of Contents

    Contents Contents ......................2 About this User’s Guide ...................... 4 About Dual PowerLab 8x2 ....................5 Using Dual PowerLab 8x2 ....................7 Quick reference ........................7 Set Smart Power Management .................... 9 Set options ......................... 11 Connect packs: basic ......................12 Connect packs: advanced ....................
  • Page 3 NiMH Fast Charge with Trickle ........................74 NiCd/NiMH 24 Hr Trickle Charge ......................... 74 Lead 12V SLA or Gel Cell ..........................74 Specifications: ........................75 Troubleshooting ......................... 77 Support options ......................... 80 REVOLECTRIX limited warranty ..................81 Limits and exclusions ..........................81...

  • Page 4: About This User's Guide

    About this User’s Guide The text and illustrations in this User’s Guide focus primarily on single channel operation. However, the Dual PowerLab is a dual channel Battery Workstation. Channels 1 and 2 operate identically but completely independent of one another, unless the DPL is set up for Expansion Channel Mode Operation.

  • Page 5: About Dual Powerlab 8X2

    About Dual PowerLab 8x2  Simple to operate: just connect Dual PowerLab 8x2 between a power source and a pack, select a pack-specific preset and start charging, discharging, cycling or monitoring. No jumpers, plugs or dials to set! During Auto Charge, Dual PowerLab 8x2 automatically determines pack capacity and sets optimal current, then dynamically adjusts charge rate as needed.
  • Page 6   takes advantage of the Dual PowerLab 8x2’s high power output. Parallel charging After connecting packs using Safe Parallel Adapters, simply tell Dual PowerLab 8x2 how many packs are attached—charge/discharge rates are automatically divided among the packs.  ...

  • Page 7: Using Dual Powerlab 8X2

    DC power supply or battery. You can also specify cutoffs in the CCS Supply tab. This quick reference lists common Dual PowerLab 8x2 tasks. What do you want to do? To do this… Do this… 1. Apply power.
  • Page 8 Connect up to 16 batteries of same chemistry, cell count and capacity in parallel by stacking banana plugs. Charge as above, but enter number of packs at Parallel Packs? question (e.g., 2P, 3P, 4P). Dual PowerLab 8x2 multiplies preset’s current setting by the number of “P” selected.

  • Page 9: Set Smart Power Management

    Because the Dual PowerLab 8x2 is capable of high power output, it is strongly recommended that you configure Smart Power Management before you use the Dual PowerLab 8x2 for the first time, and set it again any time you significantly change the power source - either DC power supply or Lead Acid battery.
  • Page 10 Smart Power Management setup is now complete. Repeat the above procedures for both DPL channels. The next time you cycle power to the Dual PowerLab 8x2, it will prompt you to select either DC Power Supply or Battery as the power source, but it will use the settings you entered to manage power from the selected source.

  • Page 11: Set Options

    14. At the Preset Changes Always Save? screen, press INC or DEC to select Y or N, then press ENTER. (Y = changes made to a User Preset at Dual PowerLab 8x2 are always saved to the loaded preset and uploaded to the Charge Control Software.

  • Page 12: Connect Packs: Basic

    Connect the pack to Dual PowerLab 8x2’s Output jacks, Balance Port or both. The Balance Port accepts a 9-pin Cellpro balance connector, which supports packs up to 8s. If the pack has a different style balance connector, REVOLECTRIX offers a variety of adapters for most popular connector types and brands (visit the Cellpro Adapters section in the REVOLECTRIX Web site).
  • Page 13 If stock REVOLECTRIX adapters don’t work for your packs, you can make your own adapters using the CPBP9P-10 Cellpro battery pigtail 10", 9 position, which consists of a “CellPro 9-pin connector with un-terminated wires. See Balance connector wiring and the Battery Wiring Diagram”...

  • Page 14: Connect Packs: Advanced

    Connect packs: advanced The table below lists several common Dual PowerLab 8x2 charging configurations. Find the configuration that most closely matches how you want to charge, then click the “Details” link for more information. Connect Number of Number Number of Ch’s...

  • Page 15: Configuration A

     1 standard adapter or Safe Adapter   Optional FUIM3 for computer support  Dual PowerLab 8x2 mode (Normal or Expansion Channel): Normal. Dual PowerLab 8x2 maximum charge power: up to 1344W charge to one pack (8s) using 40VDC/1700W power source.

  • Page 16: Configuration B

     Optional FUIM3 for computer support  Dual PowerLab 8x2 mode (Normal or Expansion Channel): Normal. Dual PowerLab 8x2 maximum charge power: up to 672W charge to each of two packs charged in parallel using 40VDC/1700W power source. Constraints:  1 pack per adapter (unless using MPA) ...
  • Page 17 See also Charge packs in parallel...

  • Page 18: Configuration C

     Optional FUIM3 for computer support  Dual PowerLab 8x2 mode (Normal or Expansion Channel): Normal. Dual PowerLab 8x2 maximum charge power: up to 672W charge to each of two packs charged in parallel using 40VDC/1700W power source. Constraints:  1 pack per adapter ...

  • Page 20: Configuration D

     Dual PowerLab 8x2 mode: Expansion Channel. Dual PowerLab 8x2 maximum charge power: up to 1344W to each pack (8s) using 40VDC/3400W power source. Standard house circuit would likely not provide enough power; would require 240VAC power supply for full power. Optionally, power each...
  • Page 21 See also Expansion Channel Mode...

  • Page 22: Power Supplies

    To achieve this, even on an 8 cell Li battery, it must boost the input voltage. This means the Dual PowerLab 8x2 may draw up to 1600W from the input power supply. To take advantage of Dual PowerLab 8x2’s full power capability, the power source should be 39.53V DC (higher voltage does not improve output power), and capable of...

  • Page 23: Charge/Discharge/Cycle/Monitor A Pack

    DC power supply or battery. 1. Connect Dual PowerLab 8x2 to a 10–48V DC power supply or 12–48V battery. 2. Press any button to display the Power Source? screen. Then: a.
  • Page 24 Edit a User Preset change the number of cycles or any other aspect of the preset. 6. Dual PowerLab 8x2 displays CHECKING PACK to see whether a pack is connected. If a pack is connected, then... 7. Dual PowerLab 8x2 displays the preset’s chemistry (for example, LiPo) and prompts you to verify it is the same as the pack’s chemistry (which should also be, for...

  • Page 25: Start Faster

    That enables you to specify exactly what operations Dual PowerLab 8x2 will perform. If all you want to do is Charge a battery, and once you have a preset configured properly, two...

  • Page 26: Charge/Discharge/Cycle Packs In Parallel

    Charge/discharge/cycle packs in parallel Dual PowerLab 8x2 can charge, discharge or cycle up to 16 LiPo or A123 packs in parallel. Parallel operations can save a lot of time, but you must follow these rules:  Always use Safe Parallel Adapters or the MPA (available at the REVOLECTRIX Web sites).

  • Page 27: Expansion Channel Mode

    Configuration D, for example). 2. Designate one channel of the Dual PowerLab 8x2 as the primary unit, and assign the other a unique Expansion Channel address. On each Dual PowerLab 8x2 channel: a. Press INC+DEC to display the Options menu (Choose TASK?).
  • Page 28  Press INC or DEC on the Primary unit to view charging data. Data will be displayed on each Dual PowerLab 8x2 for the pack connected to that unit. Tip: You can also monitor charging data, and view data in graphs, in the Charge Control Software.

  • Page 29: Regenerative Discharge

    Regenerative discharge routes most of the energy from the pack being discharged back into the Lead Acid battery powering the Dual PowerLab 8x2. This feature is only available when the Dual PowerLab 8x2 is powered from a Lead Acid battery.

  • Page 30: Modify A Preset

    Modify a preset You can change many preset properties directly on Dual PowerLab 8x2. Use this procedure at any time, but it’s essential when Dual PowerLab 8x2 isn’t connected to the Charge Control Software. Tip: You can also use the Charge Control Software’s...

  • Page 31: Manage Presets

    Copy a Library Preset Dual PowerLab 8x2 is equipped with up to 50 Library Presets. A Library Preset (which you can’t change) is a starting point for creating your own User Preset (which you can change). FMA configures Library Presets with optimal charge characteristics for a variety of battery chemistries and charging strategies.
  • Page 32 1. In the User Preset menu, use INC or DEC to select the slot where you want the new preset. Selecting an EMPTY PRESET is usually better unless you are intentionally overwriting an existing preset. Press and hold INC or DEC to scroll rapidly. 2.

  • Page 33: Using The Charge Control Software

    The free Dual PowerLab 8x2 Charge Control Software (CCS) gives you unparalleled ability to customize the Dual PowerLab 8x2. In order to connect the Dual PowerLab 8x2 to the computer and use the CCS, you are required to use one of the FMA PC USB Interfaces; either the FUIM2 or the FUIM3.

  • Page 34: Installing The Ccs

    Installing the CCS Install the Charge Control Software (CCS) from the Dual PowerLab 8x2 Software Install page (in the REVOLECTRIX Web site) using one of the methods detailed there. Once the software is installed, it will automatically check the Web site for updates in the background each time it is started.

  • Page 35: Cells Tab

    Dual PowerLab 8x2 operations in this tab. Operating from the Cells tab 1. Connect the pack to the Dual PowerLab 8x2. 2. In the Cells tab, open the User Preset menu (near the bottom of the tab), then select the preset you want to use for charging.

  • Page 36: Helpful Hints

      10. When the operation is complete, Dual PowerLab 8x2 will “beep beep beep” several times. Note: NiMH, NiCd and Lead Acid User Presets may switch to trickle charge (depending on how the preset is configured) when charging is complete.

  • Page 37: Internal Resistance Tab

    Use the Dual PowerLab 8x2 as a tool, measuring and recording the internal resistance of your packs over time. Look for trends that would indicate the IR of a cell or a pack is increasing over time.

  • Page 38: Supply Tab

     Current Limit: Set to match (or lower than) power supply’s maximum current. If the charge rate is set higher than the input current allows, the Dual PowerLab 8x2 will draw no more than the level set here, which may limit output current to the pack.

  • Page 39: Expansion Channel Section

     Battery Max Amps Out: Set for maximum supply battery current draw. If the charge rate is set higher than the input current allows, the Dual PowerLab 8x2 will draw no more than the level set here, which may limit output current to the pack. If Battery Max Amps Out is set too high, the battery’s output voltage may drop below the...

  • Page 40: Firmware Tab

    Firmware tab The Firmware tab enables you to:  Determine the firmware currently installed in the Dual PowerLab 8x2: it is displayed in the center of the tab. (Firmware version is also displayed in the Dual PowerLab 8x2 power-on “welcome” screen.) ...

  • Page 41: Full Firmware And Preset Update Process

    Tip: Factory Restore will replace all of the Library and User presets in the DPL with the latest factory defaults. If you have custom presets designed, back them up one at a time to your HD for recall later, or consider using the Update Library tool if you just want the latest Library Presets available in an update.

  • Page 42: Options Tab

    No matter what you choose for this option, you can always over-ride charge and discharge rate on-the-fly at the Dual PowerLab 8x2 after a charge is started by pressing ENTER. This method never saves the changes to the preset in use.

  • Page 43: Save And Load Options

    Tip: If you always use the same power source, specify the power source in Supply tab, then uncheck the Choose Power Source at Startup option. This will save you a step each time you power up the Dual PowerLab 8x2. Save and load options To save a set of options on your computer: Click the Save to File...

  • Page 44: Presets Tab

    The Charge Control Software gives you almost total control over User Presets, including which ones are available in Dual PowerLab 8x2, the order in which they are displayed, charging characteristics and the content and order of data screens displayed during charging.

  • Page 45: Save, Load, Backup And Restore User Presets

    5. Click the Open button. 6. Modify the preset as needed. 7. Click the Update button to download User Presets to Dual PowerLab 8x2. To load a preset from a saved graph: 1. In the Presets tab, click the User Preset location where you want the loaded preset to reside.

  • Page 46: Advanced Properties

    3. Click the archive file. 4. Click the Open button. 5. Click the Update button to download User Presets to Dual PowerLab 8x2. Tip: Use the Backup and Restore commands when you want to completely change the Dual PowerLab 8x2’s operations. For example, you might have one Dual PowerLab 8x2 set up as your Lithium-only charger and another Dual PowerLab 8x2 set up as your NiCd/NiMH-only charger.

  • Page 47: Errors Tab

    Errors tab The Errors tab lists preset errors detected by the CCS. If there are no preset errors, the tab is labeled No Errors. If there are preset errors present in the current CCS preset list, the tab is labeled X Errors, where X is the total number of errors found in all loaded presets.

  • Page 48: Graphs

    Graphs CCS graphs enable you to see how battery performance changes over time during charging and discharging operations. When you start a charge, CCS opens a dialog in which you can name the graph. Enter a descriptive name, then click OK. Note: At this point, the graph is being recorded in your computer’s memory.

  • Page 49: Exporting Graph Data

     Tab-delimited text. This format exports all data recorded by CCS, including data that was not displayed in the graph. Some of this data is purely technical and relates to Dual PowerLab 8x2 operation. Other data, such as supply voltage, can provide useful insights.

  • Page 50: Generate A Custom Fuel Table

    Generate a custom fuel table Dual PowerLab 8x2 calculates the fuel level in a battery based on a lookup table for a particular cell manufacturer or chemistry. Even two LiPo batteries from different eras or different brands from the same era can have vastly different voltage-versus-time characteristics during charging.

  • Page 51: Run Multiple Ccs Instances

    You can run multiple instances of CCS on one computer to support both channels of the Dual PowerLab. Here’s how: 1. Connect Channel 1 of the Dual PowerLab 8x2 to the computer using an FUIM3. 2. Launch CCS. Waiting to Start should appear at the top of the CCS window.

  • Page 52: Other Information

    Cells in an older pack may be more out of balance, but Dual PowerLab 8x2 will still balance them to within 6mV by the end of charge. For this reason, it may take longer to balance older packs.

  • Page 53: Storing Packs

    1.5V to activate charging. If an A123 pack is below this voltage, do not try to repair the pack by boosting voltage. Even if you manage to repair the pack, it will not have many cycles left and Dual PowerLab 8x2 will reject it for multiple reasons (as indicated by displayed Safety Codes)....

  • Page 54: How Auto Current Mode Works

    Dual PowerLab 8x2 adjusts charge current at one minute intervals throughout the charge cycle. When charging starts, it takes a short time for Dual PowerLab 8x2 to determine the correct parameters, so it may “hunt” for up to 30 minutes before it settles on the optimum current.

  • Page 55: Estimating Performance Factors

    Estimating performance factors If you don’t have a way to directly measure your propulsion system’s electrical parameters, Dual PowerLab 8x2 enables you to estimate them using before-and-after flight measurements. Note: The calculations outlined below work best when the pack is charged using a custom fuel table.

  • Page 56: Fma Wiring Mode Vs. Xh/Eh Wiring Mode

    PowerLab also supports the popular XH/EH Wiring mode for the balance connector. In the FMA Wiring mode, the Dual PowerLab 8x2 always expects pack + on pin 9 of the PowerLab’s balance port on the front of the unit. When switched to XH/EH mode, the PowerLab will look for pack + on the last wire connected to the battery pack without any empty pins in between.

  • Page 57: Balance Connector Wiring

    (REVO PN CPBP9P-10-US) must be wired to an 8s, 7s, 6s, 5s, 4s, 3s, 2s, and 1s battery pack when the Dual PowerLab 8x2 is set to FMA Wiring mode (Factory default). Whether the following is accomplished via the available adapters, or by physically...
  • Page 58 7s Pack Pack positive (red), 25.9V* Cell 7 Node 6, 22.2V* Pack positive Cell 6 Node 5, 18.5V* Node 6 Cell 5 Node 5 Node 4, 14.8V* Node 4 Cell 4 Node 3 Node 3, 11.1V* Node 2 Cell 3 Node 1 Pin 1 Node 2, 7.4V*...
  • Page 59 5s Pack Pack positive (red), 18.5V* Pack positive Cell 5 Node 4, 14.8V* Node 4 Cell 4 Node 3 Node 3, 11.1V* Node 2 Cell 3 Node 1 Pin 1 Node 2, 7.4V* Pack negative Black Cell 2 Node 1, 3.7V* Cell 1 Pack negative (blk), 0V...
  • Page 60 3s Pack Pack positive (red), 11.1V* Pack positive Node 2 Cell 3 Node 1 Pin 1 Node 2, 7.4V* Pack negative Black Cell 2 Node 1, 3.7V* Cell 1 Pack negative (blk), 0V * Nominal voltage with respect to pack negative FMA Cellpro Connector/FMA Wiring Mode 2s Pack Pack positive...
  • Page 61 FMA Cellpro Connector/FMA Wiring Mode 1s Pack Pack positive (red), 3.7V* Pack positive Pin 1 Pack negative Black Cell 1 Pack negative (blk), 0V * Nominal voltage with respect to pack negative FMA Cellpro Connector/FMA Wiring Mode...

  • Page 62: When Using Xh/Eh Wiring Mode

    PN CPBP9P-10-US) must be wired to an 8s, 7s, 6s, 5s, 4s, 3s, 2s, and 1s battery pack when the Dual PowerLab 8x2 is set to XH/EH Wiring mode. You may choose to set the Dual PowerLab 8x2 to XH/EH MODE and splice the 9 pin Cellpro pigtail to an XH/EH adapter you already own.
  • Page 63 7s Pack Pack positive, 25.9V* Cell 7 Node 6, 22.2V* Cell 6 Pack positive Node 5, 18.5V* Node 6 Cell 5 Node 5 Node 4, 14.8V* Node 4 Cell 4 Node 3 Node 3, 11.1V* Node 2 Cell 3 Node 1 Pin 1 Node 2, 7.4V* Pack negative...
  • Page 64 5s Pack Pack positive, 18.5V* Cell 5 Pack positive Node 4, 14.8V* Node 4 Cell 4 Node 3 Node 3, 11.1V* Node 2 Cell 3 Node 1 Pin 1 Node 2, 7.4V* Pack negative Black Cell 2 Node 1, 3.7V* Cell 1 Pack negative (blk), 0V...
  • Page 65 3s Pack Pack positive Pack positive, 11.1V* Node 2 Cell 3 Node 1 Pin 1 Node 2, 7.4V* Pack negative Black Cell 2 Node 1, 3.7V* Cell 1 Pack negative (blk), 0V * Nominal voltage with respect to pack negative FMA Cellpro Connector/XH and EH Wiring Mode 2s Pack Pack positive...
  • Page 66 1s Pack Pack positive Pin 1 Pack negative Black Pack positive, 3.7V* Cell 1 Pack negative (blk), 0V * Nominal voltage with respect to pack negative FMA Cellpro Connector/XH and EH Wiring Mode...

  • Page 67: Open Architecture Presets

    User Preset for the REVO Red brand, for example, you are also selecting a Fuel Table tailored for that brand. The Dual PowerLab 8x2 uses the Fuel Table to adjust current to maintain the specified C charge rate. Given a brand-specific Fuel Table, the Fuel Level display and Auto charge modes are highly accurate.

  • Page 68: Lipo Factory Presets

    LiPo factory presets LiPo Generic Accurate Charge Basic LiPo preset can be used for any LiPo battery. Fuel Table is optimized for generic LiPo batteries from C discharge ratings up to 20C. Selectable charge rates include 1C, 2C, 3C AUTO or 10 mA to 10.0A manual. Optimization is for the most accurate charging with termination settings of C/20 and max of 30 min timeout for C.V.

  • Page 69: Lipo Generic Small Balanced

    Special LiPo preset designed for charging small Park Flier type batteries that are not equipped with balance connectors. Be cautious when charging any LiPo battery non- balanced. Dual PowerLab 8x2 is not capable of detecting imbalance between cells. Never charge unattended using this preset. This preset is recommended for battery sizes as small as 10 mAh and up to 2000 mAh.

  • Page 70: A123 Factory Presets

    A123 factory presets A123 2300 mAh Accurate Charge Optimized for balance charging A123, 2300 mAh battery packs (requires balance wires on the pack). Fuel Table is optimized for this specific battery type and capacity. Selectable charge rates include 1C, 2C, 3C, 4C, 5C AUTO or 10 mA to 10A manual. Optimization is for the most accurate charging with termination settings of C/20 and max of 30 min timeout for C.V.

  • Page 71: A123 2300 Mah Non Bal 8S Fixed

    “Cells” parameter found in the “Detection” tab of the CCS. Otherwise, you may find an A123, fixed cell preset already designed for your battery in the Preset Library of the Dual PowerLab 8x2 or within the CCS. Other defaults: discharge rate setting is 2.25A, discharge voltage 2.8V/cell.

  • Page 72: A123 1100 Mah Non Bal. 1-5S

    “Cells” parameter found in the “Detection” tab of the CCS. Otherwise, you may find an A123, fixed cell preset already designed for your battery in the Preset Library of the Dual PowerLab 8x2 or within the CCS. Other defaults: discharge rate setting is 1A, discharge voltage 2.8V/cell.

  • Page 73: A123 Store Non Bal. 1-5S

    “Detection” tab of the CCS. Otherwise, you may find an A123, fixed cell preset already designed for your battery in the Preset Library of the Dual PowerLab 8x2 or within the CCS. Other defaults: discharge rate setting is 10A, charge voltage...

  • Page 74: Nimh, Nicd And Lead Acid Factory Presets

    NiMH, NiCd and Lead Acid factory presets NiCd Fast Charge with Trickle Basic NiCd Fast Charge with Delta Peak Cutoff and Trickle Charge. Requires manual charge rate setting of between 10 mA and 20A, with default value of 1A. Can charge from 1 to 21 cell packs.

  • Page 75: Specifications

    Specifications: Dual PowerLab Specifications: Specifications per channel; Dual PowerLab is a two channel Battery Workstation. For Battery types: Lithium Polymer (1s to 8s balanced, 1s to 2s unbalanced), Lithium Ion (1s to 8s balanced, 1s to 2s unbalanced), Lithium Manganese (1s to 8s balanced, 1s to 2s unbalanced), A123 (LiFePO4) (1s to 8s balanced, 1s to 9s unbalanced), NiCd (1s to 21s), NiMH (1s to 21s), 6v, 12v, 24v Lead Acid batteries (Flooded, Gel, AGM, SLA) Pack capacity: 20 mAh to 360Ah.
  • Page 76 Cooling fans: 13 CFM, 50mm diameter Heat sink: Internal 120W aluminum, thin finned Output battery connector: “Cellpro” compatible, JST PA series, 9 position LCD: 2 line, 16 character, light grey/blue backlit Footnotes: * Please note, for safety reasons, available charger current may be limited for certain battery types and/or charging modes, e.g., non-balanced charge of Li ** Please click here...

  • Page 77: Troubleshooting

    Troubleshooting Operating errors appear as safety codes in the display. If possible, correct the error. If errors continue, contact REVOLECTRIX Customer Service. Safety Code/Message Problem NiCd/NiMH charging can’t maintain constant current Increase Supply Supply <10 Volts Supply voltage is too low Supply >32 Volts...
  • Page 78 Bananas Removed The bananas were removed when charging Negative Amps Check the supply wiring Chg. Not Allowed The preset will not allow charging Cell V. Too Hi/L The cell voltage is out of range Pack Below 3.0V The pack voltage is too low. Check the preset Flag Bad Pack setting REPLACE BAD PACK Check the preset Flag Bad Pack setting Exp.
  • Page 79 Safety Code #119 Bananas connected while charging Safety Code #120 Cell count not verified Safety Code #121 Shunt FET off while CHG/DSCHING Safety Code #122 Unknown chemistry Safety Code #123 No next charge screen to show Safety Code #124 Bad run screen number Safety Code #125 Cell count is zero Safety Code #126...

  • Page 80: Support Options

    (301) 798 2770 For Sales or Technical Support on "Other Brands" in the REVO Store: Email: brandsupport@revolectrix.com To request information about a REVOLECTRIX product you are considering purchasing: Email: info@revolectrix.com or phone: (301) 798 2770 Support is also available for any of the following areas:...

  • Page 81: Revolectrix Limited Warranty

    REVOLECTRIX limited warranty REVOLECTRIX warrants this product to be free of manufacturing defects for the term of one year from the date of purchase. Should any defects covered by this warranty occur, the product shall be repaired or replaced with a unit of equal performance by REVOLECTRIX or an authorized REVOLECTRIX service station.

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