Blueshape Energy inside PWS-RUGGED User manual

www.blueshape.net Printed in Malta 2019
POWER STATION
FOR V-LOCK AND 3-STUD LITHIUM ION BATTERIES ONLY
Models
PWS-RUGGED
PWS-RUGGED 3S
OPERATING INSTRUCTIONS
Revision 1.0

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Please read these instructions concerning your safety
BLUESHAPE POWER STATIONS have been designed to provide a
superior performance by efficiently managing a high power output
during their operation without overheating or becoming unstable.
With the high output power capability of the PWS-RUGGED, it is
expected and very normal that the internal electronics generate
some heat and the internal temperature rises to a controlled extent.
The unit is designed to withstand operation with the lid closed during
power delivery (discharge) but needs to be kept with the lid open
during charging. It is important not to obstruct the fan intakes and
ventilation openings of the enclosure.
Moreover, please follow the safety instructions below.
- The equipment is designed to IP65 standards. It is advisable to
protect the equipment from rain and extreme humid
environments. Preferably, avoid excess contact with water or
other fluids as much as possible. . Refrain to use if any liquid
has been accidentally spilled inside the equipment. Contact
qualified service personnel for inspection or repair
- Clean only by using a dry cloth
- Remove on-board batteries when not in use
- Read the supplied instructions thoroughly and keep handy
- Avoid setting up near heat sources such as fire places,
radiators, stoves or other heat generating equipment
- If the equipment develops a fault, have it repaired by qualified
service personnel only
- NEVER attempt to close the lid, block the ventilation openings
or obstruct cooling fan air flow during charging
- Use only as instructed by the manufacturer
- Do not dismantle the apparatus. No user-serviceable parts
inside
IT IS STRONGLY RECOMMENDED TO
USE BLUESHAPE BATTERIES TO
OPERATE THIS UNIT
Although this unit can also run on 3r
d
party batteries, it
is not advisable to use any of these since:
only BLUESHAPE batteries are able to communicate
and dialogue with the unit. The unit was designed for
the BLUESHAPE battery protocol
BLUESHAPE batteries are renowned for their high
discharge capabilities and can guarantee:
Up to 9A for the standard series
Up to 12A or more for the HD/HDplus series

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Package contents
- PWS RUGGED Power Station
- Power cable (according to region)
- Operating manual
The unit IS resistant to IP 65*1standard but IS NOT being
declared as waterproof and not intended for usage in
submerged in water conditions or heavy direct rainfall
*1
Explanation of IP65 (Ingress protection rating)
IP 6 5
Ingress Protection First digit
Solids protection
Second digit
Liquids protection
RATED EXTENT
No ingress of dust;
complete
protection against
contact.
Water projected by
a nozzle (6.3mm)
against enclosure
from any direction
shall have no
harmful effects.

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PWS-RUGGED graphic description – exterior
1. Watertight 2-step latches
2. Swivelling and ergonomic handle
3. 14V outlet (max 340W) over two paired 4 pin XLR sockets,
protected with rubber caps
4. 28V outlet (max 560W) over two paired 3 pin XLR socket,
protected with rubber caps
5. 48V outlet (max 560W) over two paired 3 pin XLR socket,
protected with rubber caps

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PWS-RUGGED graphic description – interior
6. AC socket used in battery charging
7. LCD Display showing the state of charge and the actual current
delivered by each battery, the voltage of each battery and the
total power delivered by PWS-RUGGED
8. Illuminated power On/Off switch
9. Dual USB output socket, 5V 3A - 15W max/each
10. 28V - 48V output selector. When the 28V output is selected, the
48V outlets are totally disconnected. Conversely, when the 48V
output is selected, the 28V outlets are totally disconnected
11. Data socket for computer testing, debugging and calibration
12. Battery bay #1 and bay #2*
13. Battery bay #3 and bay #4*
*Note:
V-Lock adapter plates are installed on PWS-RUGGED
3-Stud adapter plates are installed on PWS-RUGGED 3S

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Introduction
The BLUESHAPE Power Station concept is a convenient system to
integrate the power of multiple V-lock batteries into a unique source
that can be tapped anywhere, anytime as a simultaneous dual DC
voltage output. Moreover, the PWS-RUGGED doubles up as a
powerful battery charger capable of charging 4 batteries
simultaneously at 4A each (65W). A user can carry the unit on the
field during the day and power up his equipment indefinitely if an
adequate supply of batteries is available. Later on or at night time,
he can re-charge his batteries, 4 at a time in the comfort of his hotel,
office or studio.
Depending on which batteries are installed, the quad PWS-
RUGGED system can supply power as follows:
- Up to 560W out with 4x HD or HDplus models
- Up to 490W out with 4x standard models
The internal electronics are highly efficient operating at not less than
90% especially when delivering full loads. Such efficiency permits
the PWS-RUGGED to remain cool even after hours of continuous
operation. This feature ensures a safe and prolonged system
reliability and lifetime.
The batteries on channels 1-4 are hot-swappable and enable the
unit to provide uninterrupted power even when a battery becomes
empty. The user will just need to monitor the capacity decrease of
the batteries through the LCD display provided and replace as
necessary without needing to switch off the unit.
Power is available from the 6 side XLRs as follows:
Selectable: 28V
- 2 x 3 pin female XLRs for 28V/ 560W max output (20A)
Selectable: 48V
- 2 x 3 pin female XLRs for 48V/ 560W max output (10A)
Always present
- 2 x 4 pin XLRs for 14V 340W max output (24A)
Inside (lid open) there is also a twin USB charger for mobile phone
top-up.
The display on the PWS-RUGGED will show each battery's
individual state of charge and the total real time power being
generated by the unit. This display makes it therefore, very easy to
monitor the unit during operation and understand what output, it is
delivering.

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Details on PWS-RUGGED operation
The unit must be operated with lid open when it is being used as a
charger but can be operated with the lid closed when it is only
supplying output from the on-board batteries.
AC connection is not necessary to have a DC output at 14V and
28V or 48V. The unit needs to be plugged to AC when it is to be
used in charger mode.
If AC is connected, the unit starts to charge any on-board batteries
immediately even if the main power switch is OFF.
If AC is connected but no battery is installed, then no DC output will
be available. At least one battery needs to be present to obtain a
DC output.
If batteries are installed and the device is turned ON, the DC outputs
become available even if AC is not connected. No harm is done to
the unit if loads are being powered by the various outputs while at
the same time, AC is being supplied. The unit will manage the DC
power distribution by itself and can also augment the output power
by up to 60W per battery channel, making use of the additional
power being derived from the mains.
For example:
If a battery (1 station) needs to release 100W in total, 60W will be
provided by AC, whereas the remainder is provided by the battery.
The unit can operate with even just 1 battery on board. It all
depends on the amount of power required by the user. Ideally
however, all 4 should be installed. Each battery is individually
stepped up to 28V-48V, so the total output is the combination of the
outputs of all the batteries installed. It would be desirable to have
the load, evenly distributed on all 4 batteries for these never to be
become overstressed.
Every station is hot swappable and can be monitored from the
display. It is easy to determine how the power is being supplied and
balance the requirement accordingly.
If a battery becomes empty or goes in an overload state, that battery
is excluded from the total output (the user is notified on the display)
We strongly suggest the usage of BLUESHAPE HD and HDplus
batteries because of their high current draw capabilities.

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Explanation of the DC outputs
1. Two outputs are available at all times - a regulated 14V
(always available) and a regulated 28V or 48V (user selectable)
2. A total of 6 x XLR outputs are installed on the PWS-RUGGED
side panel. These are divided as 2 sockets for each voltage (ie:
in parallel)
3. The 28V and 48V are each splitted on 2 x 3-pin female XLRs
4. The 14V is always available on 2 x 4-pin female XLRs
5. The 28V or 48V are alternative and user selectable through a
switch. When 28V is selected, the 48V output is disabled. If 48V
is selected, the 28V output is disabled
6. If there is an overload on any of the 3 different outputs, all the
outputs are automatically disconnected and the yellow RESET
button is lit. To reactivate the device, the user needs to remove
the overload condition and then press the RESET button
7. The instant power released from the 14V and 28V~48V output
is always shown on the display
Properties of the PWS-RUGGED
- Powerful 28V/48V selectable @ 20A/10A and 14V/24A
continuous output capability
- High speed charging of 4 batteries simultaneously at 4A (65W)
- Heavy duty, water resistant, rugged design. Ideal for harsh
outdoor environments
- 5V twin USB output for charging mobile devices
- Sophisticated internal electronics with highly efficient DC-DC
converters and the acclaimed BLUESHAPE 'QUICKCHANGER'
technology featuring on all 4 channels for hot swapping of
batteries.
- Can operate with as little as one battery on board (though not
recommended since the unit will not be able to reach its full
performance capabilities)
- Accurate data display obtained by the direct dialogue between
unit and the batteries (BLUESHAPE batteries only)
- Data communication outlet (useful for firmware upgrades/
testing and calibration purposes at factory or even for future
user software applications)

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Interpretation of the Display
Upon switch on (at least one battery on any channel must be
present), the display lights up, showing the installed Firmware
versions.
From then onwards, the screen will interchange between 2 different
data displays. The interval between screen interchanges is
approximately 3 seconds.
The first screen will display as follows:
Column #1
Battery no. (1 through 4)
An asterisk is shown when batteries are not
communicating with the unit
Column #2 Battery remaining capacity in percentage
(100%=full, 0%=empty)
Column #3
8 bar current contribution meter
The bars represent the PERCENTAGE
contribution of the channel versus a maximum
possible of 10A for that channel
Column #4
Actual power mode selected, 28V/48V and
power outputs for 24V/48V and 14V supplies
simultaneously
The state of charge of each installed battery is shown in percentage.
When BLUESHAPE batteries are powering the unit, this value is
very accurate and is read and updated in real time through the
dialogue between the battery and the unit since they are using the
same protocol. It therefore represents a true value of the remaining
capacity.

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When 3rd party batteries are in use, the capacity value may not be
as accurate since this is an estimation that unit makes based on the
battery voltage
The second screen will display as follows:
Column #1
Battery no. (1 through 4)
An asterisk is shown when batteries are not
communicating with the unit
Column #2 Battery Voltage
Column #3 Current demand per battery
Column #4
Actual power mode selected, 28V/48V and
power outputs for 24V/48V and 14V supplies
simultaneously
Notes:
1. If an on-board battery is:
< 10% state-of-charge (for battery types that are communicative)
or
Its voltage is less than 13 Volts (for batteries that do not
communicate
then,
column 2 flashes in the appropriate row of the battery in caption
2. If a battery on any station is missing (not installed), the
appropriate row will show blanks.
The above is applicable for both screen 1 and screen 2.

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Usage with BLUESHAPE batteries
PWS-RUGGED Recommendations
Recommended
1 = least
5 = most
BATTERY MODEL Capacity (Wh) Max. Discharge (A)
12345
BV095 Mini 65Wh 7A 
BV090 90Wh 7A 
BV100HDplus 100Wh 20A 
BV140 Mini 140Wh 12A 
BV150 150Wh 9A 
BV180 180Wh 9A 
BV190HDplus 190Wh 20A 
BV270HD 270Wh 12A 
BV290HDplus 290Wh 20A 

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XLR Polarity
14V 28V / 48V
Accessories
A number of cable accessories are available for connecting the
PWS-RUGGED with the most popular cameras on the market.
Examples:
PWC33: XLR 3 pole to XLR 3 pole
PWC34: XLR 3 pole to XLR 4 pole
PWC44: XLR 4 pole to XLR 4 pole
PWCAL: XLR 3 pole to Fisher 2 pole for ARRIALEXA
Please visit the BLUESHAPE website for more details:
www.blueshape.net
PLEASE NOTE THAT THE MAXIMUM OUTPUT
POSSIBILITY IS SHARED BETWEEN THE TWIN
XLRs FOR EACH OUTPUT VOLTAGE
The maximum power output for the 48V supply is 560W total
The maximum power output for the 28V supply is 560W total
The maximum power output for the 14V supply is 340W total
CE certification is pending.

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Technical specifications:
Parameter Value
Charging section 4 x 16.7V/65W charging units
Charging type simultaneous
AC 110V to 240V , 50/60Hz
Power Source Uninterruptable by battery hot swapping
Output Voltage #1 48V (selectable) +/- 3% on no load
Outlet [external] 2 x 3pin female XLR
Maximum output #1 560W (outputs from both 48V XLRs combined)
Output Voltage #2 28V (selectable) +/- 5% on no load
Outlet [external] 2 x 3pin female XLR
Maximum output #2 560W (outputs from both 28V XLRs combined)
Output Voltage #3 14V (always available) +/- 5% on no load
Outlet [external] 2 x 4pin female XLR
Maximum output #3 340W (outputs from both 14V XLRs combined)
Output Voltage #4 5V (always available)
Outlet [internal] Twin USB socket
Maximum output #4 15W (3A) total output
Over current protection of
outputs Available on all outlets
Short circuit protection of
outputs Available on all outlets
Over temperature protection Available
Display 20 column x 4 rows backlit white characters/ blue
background
Number of battery positions
(channels) 4 (1 to 4)
Position type Hot-swappable on all 4 channels
Conversion efficiency of DC-
DC converters >= 90%
Operating temperature range 0°C - 50°C (32°F - 122°F)
Storage temperature range -20°C - 65°C (-4°F - 149°F)
Operating/Storage humidity 5% to 90% RH
Dimensions 434 x 371 x 193 mm (17.09" x 14.61" x 7.60")
Weight 5.5 Kg (12.13 lbs) excluding batteries

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NEW CELL TOP Srl
VIA LIGURIA 4-6,
42124 REGGIO EMILIA, ITALY
TEL. [phone]
FAX. [phone]
WEB: www.blueshape.net
EMAIL: [email protected]
Warranty
BLUESHAPE Power Stations are warranted to be free from defects
in materials, workmanship and functionality for a period of 18
months commencing from the date of purchase.
This warranty shall not apply to any products or parts of, that have
been subjected to misuse, negligence, accidental or abnormal
conditions of operation.
The buyer should always contact the place of purchase for any
return of defective product. It is important that the buyer provides us
with as much information as possible about the failure being
claimed.
In the event of product failure for which warranty applies, we will
repair or replace the product free of charge. In these cases, all
expenses including transport charges will be borne by us.
In the case where the failure has been caused by one of the causes
explained above, repairs should be billed at a nominal cost. Prior to
the carrying out of any repairs, we will inform the customer of the
estimated costs of these repairs.
These warranty conditions are the only ones applicable to our
products and overrule any other expressed or implied warranties.
We shall not be held liable for any damages resulting from warranty
statements other than those contained in this declaration.
In all warranty claims, the buyer must reproduce the original
purchase invoice.