PowerBox Systems PowerPak Series User manual

Instruction Manual
PowEr PAk
PowerPak 2.5X2 ECO | PowerPak 2.5X2 PRO
PowerPak 5.0X2 PRO | PowerPak 2.5X3 PRO

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PowerBox-Systems − World Leaders in RC Power Supply Systems
Dear PowerBox pilot,
We are delighted that you have chosen a power supply system from the Po-
werPak series. These high-quality energy storage units combine maximum
power density and security in a rugged, compact case. PowerPaks are very
exible: thanks to the mounting frame supplied as standard, they are easy to
install, and can be swapped between models.
The PowerPaks 2.5X2 are available in two versions: ECO and PRO. The two
variants differ only in the charging technology – the performance of the cells
is always the same. The PRO version features integral charging circuitry and
a voltage monitor, whereas the ECO version is charged using a conventional
Li-Ion charger. Balancers are standard in both versions.
The self-discharge feature originally tted is to be discontinued as of Winter
2018, this function is now handled by the supplied BattLife Guard!
We hope you have years of pleasure and success with your PowerPak.
FEATURES:
integral charge / security electronics (PRO version)
can be charged using mains PSU or 12 V adapter (PRO version)
integral voltage monitor using external LED (PRO version)
Packs assembled using the latest generation of high-current
Li-Ion batteries
two different versions: ECO and PRO
two different output voltages: 8.4 V and 12.6 V
maximum discharge current 30 A
for use as receiver power supplies or turbine batteries
integral balancer
integral charge socket
rugged case protects cells from external inuences
Packs are held securely in the standard mounting frame with
quick-release latch
Batteries can remain in the model for charging
easy, swift battery swapping
economical cell exchange service

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1. INSTALLATION, CONNECTIONS
PowerPaks are installed in the model using the mounting frame, which
should be attached to a surface in the model which is as rigid as possible. Fit
the rubber grommets and brass spacers as shown in the illustration below:
TIP: For best
support put the
atten side down!
top
bottom
CONTENT
1. Installation, connections .......................................................................................3
2. Charging ...................................................................................................................5
3. Cell care ...................................................................................................................7
4. Voltage indicator, PRO version ............................................................................7
5. Cell exchange, Service ...........................................................................................8
6. Specication ............................................................................................................8
7. Dimensions...............................................................................................................9
8. Set contents .......................................................................................................... 10
9. Service.................................................................................................................... 10
10. Guarantee conditions ....................................................................................... 10
11. Liability exclusion .............................................................................................. 11

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PowerBox-Systems − World Leaders in RC Power Supply Systems
It is important to bear in mind that high G-forces and severe vibration can
occur in our models. This means that the mounting surface has to be capable
of withstanding several times the weight of the battery. The three-point arran-
gement of the mounting frame’s retaining screws allows the PowerPak to be
installed on surfaces which are not absolutely at.
The PowerPak is connected to the consumer unit using the patch leads (MPX
/ JR or MPX / MPX) supplied in the set. It is important that no substantial
length of cable should lie loose in the model, as this could place mechanical
strain on the connections.
Connections for the two versions - ECO (left) and PRO (right):
Note: PowerPaks are available in 2s form for receiver power supplies, and in
3s form for turbine power supplies.
Do not confuse the two versions! If you accidentally connect a PowerPak x3
to a receiver, the high voltage will destroy the electronics. To help you diffe-
rentiate between the versions, the front of the PowerPak x3 is marked red.
2. CHARGING
PowerPak 2.5X2 is available in two versions: PRO and ECO; the basic diffe-
rence between the types is the method of charging. The PRO version has its
own integral charge circuit, matched specically to the installed cells, whe-
Charge
+-
external LED
+-

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reas the ECO version is designed to be charged using an external LiIon / LiPo
charger.
Both versions feature integral balance circuits which ensure that individual
cells are not overcharged, as even Li-Ion cells are extremely vulnerable to this
state. Unbalanced cells can drift apart in condition, leading to loss of capacity;
accurate balancing also effectively eliminates this danger.
2.1 CHARGING THE PRO VERSION
To charge the PRO version you can use either the 110 / 220 V mains PSU or
the 12 V car adapter, either of which we can supply separately; both units can
be used to charge two PowerPaks simultaneously. The batteries are simply
plugged in like any conventional mobile phone, after which the charge pro-
cess is completed fully automatically.
When the charge lead is plugged in, the circuit rst checks the battery’s state
of charge before initiating the charge process. The integral LED - and the ex-
ternal LED, which can be plugged in if you wish - glows red when the battery is
on charge, and green when the charge process is complete.
A ashing red LED indicates an error, such as exceeding the maximum per-
mitted charge duration. If this should happen, please disconnect the battery
from the charger, then plug it in again. This causes the electronics to recheck
the state of the battery, and the charge process will restart if necessary.
Our accessory range also includes charge lead extensions (e.g. Order No.
5460), which can be useful for recharging batteries which are installed in in-
accessible locations.
Note re. Turbine PowerPak 3x PRO: you may nd that the charge process
does not conclude in the normal way with this PowerPak when using the 12 V
car adapter. The reason for this is that the voltage of the car battery may not
be sufcient, depending on its state of charge. In our experience the battery
is 95% fully charged at this point, but the LED remains red. Nevertheless the
battery can then be used in the normal way.
2.2 CHARGING THE ECO VERSION
To charge the ECO version you will need a charger intended for LiIon or LiPo
batteries. It is essential to set the charger correctly to suit the PowerPak you
wish to charge.

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PowerBox-Systems − World Leaders in RC Power Supply Systems
CAUTION: It is absolutely essential to set the correct nal charge vol-
tage (cut-off voltage)! If you charge these batteries with the cut-off
voltage set too high, the result could be a re!
PowerPak x2 batteries are charged at a nominal voltage of 7.4 V, correspon-
ding to a nal charge voltage of 8.4 V.
The optimum charge rate for the ECO version is 0.5C. If you are using a Power-
Pak 2.5 this means a charge current of 1.25 A. This rate of charge guarantees
a long useful life for the battery. However, it is permissible to charge at 1C (2.5
A) in exceptional cases.
Connect the PowerPak to your battery charger using the charge lead (Order
No. 2505) which is available separately. Check that polarity is correct at the
charger. The Uni connector on the PowerPak can be plugged in either way
round, as the positive (+) terminal is always in the centre.
CAUTION: Important information regarding PowerBox battery backers
and other dual power supplies:
1) All dual power supply units currently available commercially control
the charge current on the negative side.
2) All dual power supply units currently available commercially feature
a permanent connection between the negative terminals of the two
batteries.
These two facts make it impossible to charge two batteries simulta-
neously while they are plugged into a dual power supply unit! The follo-
wing options are available:
a) Disconnect one of the two batteries from the dual power supply unit
for charging
b) Charge the batteries in turn, i.e. one after the other
If you ignore the points stated above, the short-circuit situation may da-
mage the battery charger! These points do not apply to the PRO version
if the integral charge circuit is used.

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3. CELL CARE
The useful life of PowerPaks can be extended signicantly by handling them
correctly; this also enhances the safety of the cells.
The self-discharge circuit built into earlier PRO versions is to be discontinued
as of Winter 2018; the new version can be identied by a yellow dot on the
underside. This feature required a micro-controller whose idle current in many
cases caused cells to be deep-discharged if the battery was stored for a long
period. The circuit also proved to be incompatible with the charging electro-
nics of turbine generators.
The following applies to the PRO and ECO versions:
The self-discharge rate of our PowerPaks is very low, which means that, after
a ying session, it is best to store the model with the batteries part-dischar-
ged, and then recharge them before the next outing.
In both versions the useful life of the cells can also be extended by dischar-
ging the cells to storage voltage (approx. 7.6 to 7.8 V) before any protracted
period of storage. This can be carried out using a Li-Ion / LiPo charger, as
most modern battery chargers now feature a “storage mode”. Take care to
set the correct number of cells, otherwise they may be discharged too deeply.
Note: A frequently asked question is this: “how can I tell whether the battery
is still in good condition?”
With Lithium cells this is very easy to determine: give the pack a full charge,
then discharge it to 3.0 V per cell using a suitable LiIon / LiPo battery charger.
If the measured capacity is greater than 80% of its nominal capacity, the Po-
werPak is still in usable condition. If the discharged capacity falls below this
level, then please refer to Point 5.
4. VOLTAGE INDICATOR, PRO VERSION
In addition to the integral charge and the balancers, the PRO version features
an integral voltage indicator. When the PowerPak PRO is in the charged state,
the internal and external LEDs are switched off. The red LED lights up as soon
as the battery capacity falls to 30%.

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PowerBox-Systems − World Leaders in RC Power Supply Systems
5. CELL EXCHANGE, SERVICE
If, after a period of a several years, the cells in a PowerPak are exhausted, we
offer an economical cell exchange service combined with a check of the elec-
tronics. Simply send the PowerPak to our Service address (site 11).
All PowerPaks have passed rigorous testing to gain certication in accor-
dance with UN38.3, and the manufacturing process is monitored by the
quality management team. Thanks to this procedure these batteries can
legally be shipped by air freight.
For current and additional information on this subject please visit our support
forum: www.forum.powerbox-systems.com
Note: For reasons of safety it goes without saying that batteries which have
clearly suffered mechanical damage must not be sent back to us. If this ap-
plies to you, please contact us to discuss further action.
6. SPECIFICATION
Battery type PowerPak
2.5x2
PowerPak
5.0x2
PowerPak
2.5x3
Nominal capacity 2500mAh 5000mAh 2500mAh
Nominal voltage 7,4V 7,4V 11,1V
Charge cut-off voltage 8,4V 8,4V 12,6V
Charge voltage (PRO) 9 - 17V 9 - 17V 13,5 - 17V
Weight 125g 235g 191g
Weight of mounting frame 8g
Discharge temperature range 0°C to 60°C
Charge temperature range 0°C to 40°C

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7. DIMENSIONS
87,50
43
156
43
2.5X2
5.0X2 + 2.5X3
10
66
53,20
Height: 26 mm

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PowerBox-Systems − World Leaders in RC Power Supply Systems
8. SET CONTENTS
- PowerPak
- Mounting frame
- 1 x MPX / JR connecting lead
- 1 x MPX / MPX connecting lead
- 4 x rubber grommets
- 4 x brass tubular spacers
- 4 x screws
- BattLife Guard
- Operating instructions
9. SERVICE
We are anxious to offer good service to our customers, and to this end we
have set up a Support Forum which deals with all queries concerning our
products. This relieves us of a great deal of work, as it eliminates the need to
answer frequently asked questions time and again. At the same time it gives
you the opportunity to obtain help quickly. All the answers are provided by the
PowerBox Team, which guarantees that the information is correct. Please
use the Support Forum before you telephone us.
You can nd the forum at the following address:
www.forum.powerbox-systems.com
10. GUARANTEE CONDITIONS
At PowerBox-Systems we insist on the highest possible quality standards
in the development and manufacture of our products. They are guaranteed
“Made in Germany”!
That is why we are able to grant a 36 month guarantee on the electronics
of our PowerPaks, and a 12 month guarantee on the battery cells, from the
initial date of purchase.
The guarantee covers proven material faults, which will be corrected by us
at no charge to you. As a precautionary measure, we are obliged to point
out that we reserve the right to replace the unit if we deem the repair to be
economically unviable. Repairs which our Service department carries out for
you do not extend the original guarantee period. The guarantee does not co-

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ver damage caused by incorrect usage, e.g. reverse polarity, excessive vibra-
tion, excessive voltage, damp, fuel, short-circuits, etc. The same applies to
defects due to severe wear. We accept no liability for transit damage or loss
of your shipment. If you wish to make a claim under guarantee, please send
the device to the following address, together with proof of purchase and a
description of the defect:
SERVICE ADDRESS
PowerBox-Systems GmbH
Ludwig-Auer-Straße 5
D-86609 Donauwoerth
Germany
11. LIABILITY EXCLUSION
We are not in a position to ensure that you observe our instructions regarding
installation of PowerPaks, full the recommended conditions when using the
unit, or maintain the entire radio control system competently. For this reason
we deny liability for loss, damage or costs which arise due to the use or opera-
tion of PowerPaks, or which are connected with such use in any way. Regard-
less of the legal arguments employed, our obligation to pay compensation is
limited to the invoice total of our products which were involved in the event,
insofar as this is deemed legally permissible.
We wish you every success with your new PowerPak.
Donauwoerth, March 2019

PowerBox-Systems GmbH
certied according to DIN EN ISO 9001
Ludwig-Auer-Straße 5
D-86609 Donauwoerth
Germany
[phone]
[phone]
www.powerbox-systems.com
03/2019