Rev Electrix Cellpro 10XP User manual

Cellpro 10XP Charger
User’s Guide
© Copyright 2011, 2014 FMA, Inc.
Updated 09/02/2014

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Table of Contents
Table of Contents..................................................................................................................... 2
Description............................................................................................................................... 3
Features.................................................................................................................................... 3
Precautions.............................................................................................................................. 5
Parts.......................................................................................................................................... 5
Charger terminology................................................................................................................ 6
Pack terminology and configurations .................................................................................... 7
REVOLECTRIX Cellpro branded 5s battery packs...................................................................................7
REVOLECTRIX Cellpro branded 2s, 3s, and 4s battery packs................................................................7
REVOLECTRIX Cellpro branded 6s-9s battery packs..............................................................................8
Understanding the Cellpro 10XP Charger.............................................................................. 9
Auto Charging vs. Manual Current Settings..............................................................................................9
Power and Charging Speed......................................................................................................................9
About Factory Presets............................................................................................................................. 11
Power Management Feature...................................................................................................................11
Connecting packs to the charger...........................................................................................12
General information.................................................................................................................................12
Connecting non-Cellpro packs................................................................................................................12
Connecting one 1s to 10s REVOLECTRIX Cellpro pack ......................................................................13
Connecting two 1s to 5s Cellpro packs.................................................................................................13
Applying power to the charger...............................................................................................15
Introduction to presets.............................................................................................................................15
Operating the charger.............................................................................................................16
Overview of button operations: ...............................................................................................................16
Performing Common Tasks:...................................................................................................17
Selecting a preset ...................................................................................................................................17
Changing a preset...................................................................................................................................17
Charging a pack or packs .......................................................................................................................19
Options Menu Explained.........................................................................................................................20
Alternate charging modes.......................................................................................................................23
Using the Charge Control Software.......................................................................................24
Installing the Charge Control Software ...................................................................................................24
Launching the Charge Control Software.................................................................................................24
Connecting the charger to your computer...............................................................................................24
Monitoring charging operations...............................................................................................................24
Limiting charger input current .................................................................................................................25
Defining presets ......................................................................................................................................25
Setting charger options...........................................................................................................................26
Recording charge data............................................................................................................................26
Updating charger firmware......................................................................................................................27
Balance connector wiring.......................................................................................................28
When using FMAWIRING mode (Factory Default Setting)....................................................................28
When using XH/EH WIRING mode.........................................................................................................30
Estimating performance factors ............................................................................................32
Collect data .............................................................................................................................................32
Calculate performance factors................................................................................................................32
Evaluate results.......................................................................................................................................32
Specifications..........................................................................................................................33
Quick start for the Cellpro 10XP Charger..............................................................................34
Troubleshooting......................................................................................................................35
Support options......................................................................................................................37
REVOLECTRIX limited warranty ............................................................................................38

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Description
Model LC10S15ADC-MC, for use with LiPo, Li-Ion, A123, NiCd, NiMH, and Pb battery packs
10s Multi-Chemistry, 15 Amp, 600W model for automatic and manual charging with available high-power
balancing, overcharge protection, and automatic charge/discharge to storage (for Li batteries)
Features

Charges Lithium Polymer, Lithium Ion, A123, NiCd, NiMH, and Pb packs. Charges any brand of
pack.
Supports high-power balance charging of Li or A123 battery packs. Balance charges one 1s to 10s
pack, or two 1s to 5s LiPo packs simultaneously. When two packs are connected, the balance
connections and pack main discharge wires are wired in series by the charger.
Equipped with Cellpro brand (JST PA series times two, 6 position) balance connectors which enable
the charger to monitor and independently charge each cell to its optimum level (balance charge
operation).
Accepts Cellpro 10s Adapters for plug-and-play compatibility. Cellpro 10s Adapters support from 2s
to 6s battery packs (all brands). For more information on REVO adapters, visit
http://www.revolectrix.com/cellpro_adapters.htm
Backward-compatibility with older Cellpro 4s adapters is assured using the available 6-pin to 5-pin
adapter(s) (REVO PN: CP10S-5S/4S-ADP-US) for charging 2s to 4s Cellpro packs having 5-pin
balance connectors.
Also supports customer-selectable, XH mode. JST XH/EH balance connectors and wiring are
growing to be the dominant scheme in the industry. Switching to XH mode, the CP10XP can support
existing XH style adapters you may already own. Splice in REVO PN: CPBP6P-10-US battery
pigtails to the wires on existing adapters and you are good to go!
Supports non-balanced charge of Li (up to 2s), Ni (up to 28 cells), Pb (up to 24V), A123 (up to 12s).
Accepts 10-32 VDC input.
Up to 15A max charge current.
Maximum 25A input current
720W max continuous input and 605W max continuous output at 30V DC input. Charger will achieve
rated output to a 10s LiPo using 30V DC input. Increasing input voltage beyond 30V does increase
power output, but only if the charger’s output voltage exceeds 42V; e.g., when charging 12s non-
balanced A123 packs. However, 32V DC input is a maximum rating. It is recommended to utilize
input voltage slightly below the absolute maximum.
Supports AUTO rate charging (1.0C, 2.0C, and 3.0C charge rate) using Advanced Fuel Gauging
technology, or manual set currents of 0.10A –15A in 0.10A increments.
Industry’s largest 1A proportional integrated balancers
Power-balance-charge packs through balance connectors in tandem with the main discharge wires of
the battery pack(s). Unit does not support balance-connector only charging.
Compensates for balance wire lengths up to six feet with 1mV accuracy.
Displays individual cell internal resistance to 0.1milliohm, for estimating pack quality, health, and
performance.
Storage Preset available to charge or discharge Li batteries to appropriate per-cell storage levels; 3.8v
(LiPo), 3.0v (A123).

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During discharge to storage, the CP10XP incorporates 1A-per-cell (nominal) discharge rate using the
charger’s integrated balancing circuitry to provide up to 42W (at 10s) discharge power.
Light-grey, 2 line, 16 character backlit LCD display provides easy readability.
One button, Charge Optimization can be set for an Accurate 1mV cell balance and (C/20 termination)
or for Faster Charging (less balancing accuracy and C/10 termination) using the Charge Control
Software or at the CP10XP interface.
Protects your Pb input source from over-discharge by providing an audible warning when input
voltage of your Pb battery approaches 50% state of charge.
Intelligent controller performs extensive checks to prevent damage to packs and power supply. This
makes it virtually impossible to damage the charger or the batteries from incorrect connections or
wiring; including, but not limited to reverse polarity.
Input reverse-polarity protection.
Simple, effective, 2-button interface allows instant access to presets, preset parameters, and starting
and stopping charger operations.
Access pre-defined, named presets by clicking the MODE button.
Hold the MODE button to access the Main Menu operations: Choose Chg. Amps, Choose Chemistry,
Show Help Screen, Exit. Use the charger’s Main Menu to alter basic settings of presets on-the-fly, or
make the adjustments using the free PC Charge Control Software (CCS).
Press and hold the START/STOP button to start charger operation or cancel/end a charging session.
Press and hold MODE button during power up to access Options Menu; choose input amps limit and
supply low voltage setting (Power Management feature), alternate between FMA or XH balance
wiring schemes, and set quiet charging (no speaker beeps during charging).
Supports Bi-directional, optional PC interface (REVO PN: FUIM2-US or FUIM3-US) which enables
extensive charger setup using the CCS. Configure up to 10 custom presets, adjust speaker volume,
set LCD contrast and control many other settings.
CCS automatically checks for software and charger firmware updates in the background. Update
charger firmware reliably with the click of your mouse button, and without sending the charger back
to the factory. Keep up-to-date with the latest enhancements and bug fixes.
6 different, available Fuel Gauge lookup tables (fuel tables) may be assigned to independent presets
to match the characteristics of different Li battery chemistries. This feature only available using the
CCS.
Works with a wide range of power supplies, even those not rated for high power. Easily changes
from moderate current bench supply at home to car battery at the field using the Power Management
feature. Set Input supply amps limit and supply low voltage settings using the CCS or at the charger
interface, to prevent damage to your input source.

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Precautions
Follow all instructions in this manual to assure safe operation.
IMPORTANT: Do not disconnect or connect packs while the charger is charging.
Always watch LiPo packs while they are charging. Never leave LiPo packs unsupervised during
charging.
See additional warning sheets provided with your battery packs.
Follow all guidelines for charging, discharging, handling and storing LiPo cells.
Minor arcing may occur when discharge wires are connected to the charger before charging. This is
normal.

Parts
Cellpro 10XP Charger
Removable input plier clips (red/black) for connecting the CP10XP to a DC power source
Optional: FUIM2-US or FUIM3-US PC USB Adapter (required for using the Charge Control
Software)
Optional: Cellpro 6-pin to 5-pin Adapter(s)
Optional: Cellpro 10s Adapters (brands other than REVOLECTRIX Cellpro)
Optional: CP10S-BP12-2PK-US, Cellpro 10s Banana Plug Output Cables (2 pack) –solder the
mating end of the connector you use on your battery’s discharge wires to these cables
Notes:
You may have already received some of the optional items listed above with the purchase of a Combo.
Unless otherwise stated, REVOLECTRIX part numbers found within this manual assume purchase was or
will be made within the United States. If ordering from the International website, drop the “-US” from
the part number.

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Charger terminology
To DC
Power
Supply
DisplayConnect FUIM2 or FUIM3
PC USB Interface here when
connecting to Charge Control Software
(black wire toward outside wall of case)
Channel 1 Channel 2
Banana jacks for discharge
wires when charging
2 packs at the same time
Use two outer banana jacks for discharge
wires when charging only one pack.
Never connect pack discharge wires
across the two yellow banana jacks.
This will result in blowing the internal fuse.
Note the skull and crossbones
warning between the yellow jacks!
MODE button
START/STOP button
Channel 2
balance connector
Channel 1
balance connector

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Pack terminology and configurations
REVOLECTRIX Cellpro branded 5s battery packs
Balance connector,
Cellpro brand
(JST PA series)
6 position
Discharge wires:
Red = Pack positive
Blk = Pack negative
5s REVOLECTRIX packs like
the one shown above will connect
directly to the Cellpro 10XP charger
without requiring any additional adapter
REVOLECTRIX Cellpro branded 2s, 3s, and 4s battery packs
Balance connector,
Cellpro brand
(JST PA series)
5 position
Discharge wires:
Red = Pack positive
Blk = Pack negative
2s to 4s REVOLECTRIX packs like
the one shown above require the
5s-to-4s adapter for interconnection
to the Cellpro 10XP charger
(REVO PN: CP10S-5S/4S-ADP-US)

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REVOLECTRIX Cellpro branded 6s-9s battery packs
Balance connector,
Cellpro brand
(JST PA series)
5 position
Discharge wires:
Red = Pack positive
Blk = Pack negative
6s-9s REVOLECTRIX packs like
the one shown above require the
5s-to-4s adapter for one of the
balance connectors for inter-
connection to the Cellpro 10XP charger
Balance connector,
Cellpro brand
(JST PA series)
6 position
Note: Other brands of batteries will require Cellpro 10XP Adapters. For more information on REVO
adapters, visit http://www.revolectrix.com/cellpro_adapters.htm

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Understanding the Cellpro 10XP Charger
Auto Charging vs. Manual Current Settings
When balance charging Li batteries, you can set the Cellpro 10XP Charger’s charge rate to one of three
AUTO modes—1.0C, 2.0C or 3.0C—as appropriate for the pack(s) being charged. When one of these
rates is selected, the charger determines the pack’s capacity (over time) and automatically sets the
correct output current using FMA’s advanced Fuel Gauging technology. The accuracy of AUTO
charging depends on how well your battery’s charge curve matches up with the fuel table being used by
the CP10XP. Six different fuel tables are available to support different Li battery chemistries and may
be assigned to individual presets using the Charge Control software. Factory presets for LiPo batteries
are set up for a generic, 15C battery profile. AUTO charging using the default presets may or may not
be accurate for your batteries. The advantage to using AUTO charging is that you do not need to think
about or even know the true capacity of your batteries. You can charge different capacity batteries at
different times without having to adjust the charge rate setting and the charge will automatically adjust
to choose the appropriate charge rate. You just tell the CP10XP how fast you want to charge, and it
does the work for you. For safety reasons, AUTO charging current is capped at 6A, regardless of the
size of the pack being charged. You can also manually set charge current to any value between 0.1A
and 15A in 0.1A increments. Finally, you can select Storage Charge mode which automatically charges
or discharges to the appropriate per-cell storage voltage for LiPo or A123 batteries.
Power and Charging Speed
Cellpro 10XP Charger Power Chart
576
720
768
484
605
645
300
345
393
234
269
306
150
250
350
450
550
650
750
850
+12 +13.8 +15.7 +24 +30 +32
Input Voltage (VDC)
Power (Watts)
Continuous Input (Watts) Continuous Output (Watts)
When one pack is connected to the charger, the pack is initially charged at the selected charge rate (or
the maximum charge rate possible). Using Ohm’s law, the maximum charge rate (Amps) is derived
from the maximum power (Watts) the charger can produce without overheating.
Maximum output power will normally reach approximately 605W when charging a 10s LiPo battery
using a 30V DC input power source, and assuming the input source can deliver a maximum of 720W of

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clean power to the charger input. Maximum power depends on many factors including pack imbalance
during charge, input (supply) voltage, output (charge) voltage, DC/DC converter efficiency, which
varies between 80% and 95% depending on the relationship of supply voltage-to-charge voltage,
ambient temperature, and internal operating temperature. From the graph, you can see that Increasing
input voltage beyond 30V does increase power output, but only if the charger’s output voltage exceeds
42V; e.g., when charging 12s non-balanced A123 packs. However, 32V DC input is a maximum rating.
It is recommended to utilize input voltage slightly below the absolute maximum.
When the pack reaches about 95% capacity, the charger enters balance charge mode. Charge current
tapers off, but will remain at 1A or higher until the pack voltage slows the current to 1/20th C (Constant
Voltage Mode). When the pack reaches 99% capacity, the charger beeps three times. The pack can be
removed to use, or allowed to continue charging until it is 100% full and the charger displays “Charge
Complete.”
During the entire charge process, the charger power balances the pack using 1A current until all cell
voltages are within 1mV of each other. Power balancing is the process of beginning the balancing
process early in the charge cycle using high-current shunts to drain excess cell voltage while other cells
in the pack have a chance to catch up. Power balancing means the pack tops off faster and the total
charge time is greatly reduced. This is possible because the balance circuitry is internal to the charger.
Automatic temperature control and an integral fan ensure the charger never exceeds maximum safe
operating temperature under any conditions. The result is faster, safer charging.
When charging two packs, the packs are connected in series (the balance connections as well as the
main charge wires). In effect, the charger treats the two packs as a single pack. For example, if you
connect a 3s pack and a 4s pack, the charger operates on them as one 7s pack. If the pack capacities are
different for the two packs connected, the charge rate should be selected based on the lower capacity
pack. Initially, the packs are charged at the selected charge rate (or the maximum charge rate possible)
until one pack becomes fully charged—however, the charger can handle cell balancing of the two packs
completely independently. The second pack continues to charge at a minimum 1A rate until it is full
and balanced.
Notice that one of the packs in a simultaneously-charged pair is always topped off at a minimum rate of
1A (dictated by the maximum balance current available). If the packs have the same capacity, and were
discharged to about the same level, both packs will charge in less than 30 minutes at 3C. However, if
the packs have different capacities, or were discharged to different levels, charging for the pair could take
longer than expected. Since the charger supports a high power balance current of 1A, all other things
being equal, the charger still outperforms competing brands. In most instances, by the time the first pack
is fully charged, the second pack is already approaching constant voltage charge mode; the battery pack
itself is the limiting factor in charge time, not the charger.
Example 1: You are powering an aircraft with two 4s 2100mAh packs connected in series.
Because those packs have the same capacity, and were discharged to about the same level
during flight, you can expect them to charge in about the same time. It would be appropriate
to charge them simultaneously using the Cellpro 10XP Charger.
Example 2: You are powering one aircraft with a 3s 500mAh pack, and other aircraft with a
5s 5000mAh pack. If you charge these packs simultaneously using the Cellpro 10XP Charger,
it would probably take a long time (the 500mAh pack would become full first, then the
charger would switch to its 1A balancing rate to fill up the 5000mAh pack, which could take
several hours). In this case, it would be faster to charge these packs separately because the
charger can then apply optimum (and substantially different) charge currents to each pack.
In some cases, such as Example 2, it will be faster to charge two packs separately rather than
simultaneously. It’s up to you to decide, based on what you know about their respective capacities and
discharge states.