Revolectrix Cellpro 4s GOLD User manual

Features
n  Simpletooperate:justconnecttheCellpro4schargerbetweenapowersourceandapack.
Nojumpers,plugsordialstoset!Chargerautomaticallydeterminespackcapacityandsets
optimalcurrent,thendynamicallyadjustschargerateasneeded.Manualchargeratesof
0.25Ato4A(in0.25Aincrements)allowforspecialsituations.
n  ChargesLithiumPolymer,LithiumIon,LithiumManganeseandA123©chemistries.Adapt-
ersareavailablefromFMADirect.
n  Eachcellischargedindependently,providingexceptionalchargingsafetyandelevatingRC
packstothesafetylevelofcellphones.
n  ChargesLiPopackshavingonetofourcellsandanycapacityupto24Ah.Typicalpacksof
upto3Ahcapacitychargein50minutesorlessusingcharger’s1.4CAutoCurrentMode.
n  Multifunctiondisplayshowsoperatingmode,individualcellvoltages,chargecurrent,supply
voltage,andamountofcharge(mAh)putintopack.Plus,theuniqueFueldisplayshowsper-
centcapacityremaininginapack.
n  Viewersoftware(afreedownload)displaysreal-timedataandgraphs.
n  Latesttechnologyprovidestheultimateinsafety.Evenchargespackshavinghiddenphysical
damagewithoutdangerofre.Apackwillnotchargeifindividualcellvoltagesdon’tequal
totalpackvoltage.
n  Cellbalancingto10mVandautomaticoverchargeprotectionassurelongestpacklife.Auto-
matictemperaturemonitoringpreventspackoverchargingatlowambienttemperaturesand
chargerdamageathighambienttemperatures.
n  LowVoltageRestorefeatureautomaticallyattemptstorepairoverdischargedpacks.Cells
dischargedaslowas0.5Vmayberepairedtoasmuchas98%ofcapacity.
n  ColdWeatherChargestopschargingat4.10V/cellwhentemperatureisbelow55°Ftoprevent
celldamage.
n  Operatesfromany10–16VDCpowersource.Inputsandoutputsareprotectedagainstre-
versepolarity.
Precautions
n  Followallinstructionsinthismanualtoassuresafeoperation.
n  AlwayswatchLiPopackswhiletheyarecharging.NeverleaveLiPopacksunsuperviseddur-
ingcharging.
n  SeeadditionalwarningsheetsprovidedwiththischargerandFMALiPopacks.
n  Followallguidelinesforcharging,discharging,handlingandstoringLiPocells.
Cellpro 4s Gold Charger
Model LIPOCH4S04-GOLD, for use with LiPo, Li-Ion
and A123 battery packs with node connectors
Automatic and manual charging at up to 4A with cell
balancing and overcharge protection
FMA, Inc.
5713 Industry Lane, Suite 50
Frederick, MD 21704
Sales: [phone]
 Technical: [phone]  www.fmadirect.com

2
Connecting the charger
Connecting packs with a Cellpro connector
 ConnectCellproPacksasshowninthisdiagram:
Connect to 10–16 VDC
(e.g., gel cell or power supply)
Optional connection to PC
using FMA FSIM1 cable
Cellpro 4s Charger
Node Connector
Mode
Button
Power
Connector
(not used
during
charging)
1s to 4s
LiPo or A123
Pack
Data display
CAUTION: When two LiPo packs are connected in series, do not connect them to two
separate chargers that are wired to a single power source. This sets up the dangerous
condition in which the series-connected packs are being charged in parallel (the power
source provides a common ground). One or both chargers, as well as the packs,
will be damaged. This condition will be avoided if the chargers are driven from two
unconnected power sources (e.g., two lead acid batteries). For safest charging of
series-connected packs, disconnect the packs from each other before connecting them
to chargers.
Connecting non-Cellpro packs
 FMADirectoffersplug-and-playadaptersforchargingLiPopacksequippedwithnodecon-
nectorsmadebyothervendors.ChecktheCellprosectionatwww.fmadirect.comforthelat-
estadapters.
 Ifanadapterisn’tavailableforthepackyouwanttocharge,orifthepackdoesn’thavea
nodeconnector,theFMACPBP7LiPoPackNodeConnectorcableassemblywillmakethe
packcompatiblewiththeCellpro4sCharger.ThediagramsbelowshowhowtheNodeCon-
nectorattachestopacksofvariouscongurations.Additionalassemblyinformationispro-
videdwiththeNodeConnector.

Pin 1
FMA CPBP7 LiPo Pack
Node Connector
Red
Black
Pack positive
Node 3
Node 2
Node 1
Pack negative
Cell 4
+
–
Cell 3
+
–
Pack positive
(red), 14.8V*
Pack negative
(blk), 0V
Node 3, 11.1V*
Cell 2
+
–
Node 2, 7.4V*
4s Pack
Cell 1
+
–
Node 1, 3.7V*
Cell 3
+
–
Cell 2
+
–
Node 2, 7.4V*
3s Pack
Cell 1
+
–
Node 1, 3.7V*
Pack postive
(red), 7.4V*
Pack negative
(blk), 0V
Pack postive
(red), 11.1V*
Pack negative
(blk), 0V
Cell 2
+
–
2s Pack
Cell 1
+
–
Node 1, 3.7V*
* Nominal voltage with respect to pack negative.

3
Charging modes
TheCellpro4sChargerprovidesseveralchargingmodes.Pleasebecomefamiliarwiththem
beforechargingpacks.
Normal charging modes
 TheCellpro4sChargerprovidesbothautomaticallycontrolledandxedchargingcurrent
modes:
n  In4.00A A123 3.60V Mode,cellsareindividuallychargedto3.60Vpercell.Thisisfor
A123brandofhighcurrentLithiumIoncellsthathandlechargeratesupto5C.Charge
currentisxedat4.0Aorthemaximumchargeroutputcurrent.
Important: Only one mode is available for charging A123 packs. The 4.00A A123
3.60V Mode charges A123 chemistry to 3.6V per cell. Do not attempt to use any other
mode to charge A123 packs. Other modes will overcharge A123 packs to 4.2V per cell.
n  In1.0C LiPo 4.20V Mode,LiPo/Li-Ioncellsareindividuallychargedto4.2Vpercell.
Thechargermeasurespackparametersandsetsanoptimalchargecurrent.
n  In1.4C LiPo 4.20V Mode,LiPo/Li-Ioncellsareindividuallychargedto4.2Vpercell.
Chargecurrentisslightlyhigherthan1.0CLiPo4.20VMode.Packssmallerthan3Ah
willchargecompletelyinabout50minutes.
n  InSTORE LiPo @ 50% Mode,LiPo/Li-Ioncellsareindividuallychargedto3.842Vor
50%capacity.Thisisagoodchargelevelforlongtermstorageorshippingbymail.
n  In0.25A thru 4.00A LiPo 4.20V Mode,LiPo/Li-Ioncellsareindividuallychargedatthe
currentyouselect.Chargevoltageis4.2Vpercell.
 Whenrstconnectedtoapowersource,thechargerissetfor3.00AA1233.60VMode(the
factorydefault).YoucanchangetoanothercurrentsettingatanytimebyholdingtheMode
Button.Thechargerremembersthechargingmodeandcurrentsettingwhendisconnected
fromthepowersource,andwillstartinthatcongurationthenexttimeitisused.
 The1.4CAutoCurrentrateisabreakthroughforLiPocharging.FMAhasconductedexten-
sivetestingat1.4Cwithitscell-balancingchargersandcompatibleLiPopacks.Noevidence
ofsafetyissuesorcyclelifedegradationhasbeenfound.
CAUTION: Only FMA balancing chargers can safely charge packs at 1.4C. Other char-
gers don’t charge individual cells, and are limited to a 1.0C rate. Charging at greater
than 1.0C with those chargers increases the risk of re. Always follow charger and pack
manufacturers’ recommendations for maximum charge rate.
Other charging modes
n  InLow Voltage Restore Mode,thechargerautomaticallyattemptstorepairoverdis-
chargedpacks.Cellsdischargedaslowas0.5Vmayberepairedtoasmuchas98%of
capacity.
n  InSafety Charging Mode,thechargerdetectsthatatleastonecellisseriouslyoutofbal-
ance,andautomaticallylowerschargecurrentto0.5A.TodisableSafetyChargingMode,
disconnectthepack,thenreconnectit.
CAUTION: When the charger’s display shows SAFETY CHARGING, the connected
pack is damaged. Treat damaged packs with caution. Do not charge them on a am-
mable surface, and do not charge them unattended.
n  InCold Weather Balancing Mode,chargingautomaticallystopsat4.10V/cellwhentem-
peratureisbelow55°Ftopreventcelldamage.

4
How to charge a pack
Tip: Because FMA’s cell balancing technology monitors individual cells, you don’t need
to cool a pack before charging it. Go from ying to charging to ying again without wait-
ing. FMA cell-balancing chargers are the only ones that can charge a pack immediately
after discharge without damaging the pack.
1. Connectthechargertoapowersourceandapackasshownonthepreviouspage.
2. Ifyouwantadifferentchargingmodeorcurrent:
a. PressandholdtheModeButton.Thedisplaywillcyclethroughavailablecharging
modesandcurrents.
b. ReleasetheModeButtonwhenthedesiredchargingmodeorcurrentisdisplayed.
Tip: More information about the display —and how to navigate it—is provided on the
next page.
Note: You can change charger modes at any time, whether or not a battery is con-
nected to the charger. However, be careful. If you are charging an A123 pack (in 3.00A
A123 3.60V Mode, of course), you shouldn’t enter the menu (by pressing and holding
the Mode Button). Doing this could put the charger into a LiPo mode, which would over-
charge the pack. If you do change modes when a pack is connected, always make sure
the chemistry shown in the display (LiPo or A123) matches the connected pack.
 3. Undernormalconditions,thechargerwillbeepatthefollowingtimes:
n  Whenpackhasbeenchargedto90%ofcapacity.
n  Whenpackhasbeenchargedto100%ofcapacity.

5
About the data display
Thediagrambelowexplainsthedatadisplay,howtoviewdataaboutthepackbeingcharged,and
howtomanuallysetthechargecurrent.
Hold to set Mode
0.25A
LiPo 4.20V
1=3.88V 2=3.88V
3=3.88V
4=3.91V
0.019 Ah added
Charging
@ 0.60A
15.52V Fuel= 49%
LiPo FAST
CHARGE
Batt V Fuel=Lev%
LiPo
Checking V.
Batt V Fuel=Lev%
LiPo
Chgr. Ready
Start
Connect charger
to power source
Connect pack
to charger
Press
Mode Button
Charger status:
LiPo FAST CHARGE
LiPo
BALANCING
LiPo
LOW RESTORE
LiPo
SAFETY CHG.
LiPo
Cold W. BAL
LiPo
CHARGE DONE
LiPo
Checking V.
Press
Mode Button
Press and hold
Mode Button,
then...
release
Mode Button
when desired
current appears
To set specific charge mode
and current (at any time)
Note: In A123 Mode, "A123" will appear
where "LiPo" appears in these examples.
Press
Mode Button
Total pack voltage
Available capacity (as a
percent of total pack capacity)
Capacity added to pack
during this session
Individual cell voltages
Charge current sequences from
0.25A to 4.0A in 0.25A increments,
displays 1.0C, 2.0C, 3.0C, STORE
and A123 then repeats
This line shows
Charge current Chemistry Charge Voltage
Charging current
Tip: The charger stores the latest current setting.

6
Practical information about the Cellpro Charger
General information
n  Cellsinapackhavedifferentvoltageswhentheyaredischarged.TheCellpro4sChargerbal-
ances(equalizes)cellvoltageswhileitischargingthepack.
n  Duringcharging,cellsthatchargethefastestaretheweakestcellsinthepack.Attheendof
charging,cellswiththehighestvoltageareweakest.Thishappensbecauseweakercellshave
lowercapacity,andtheychargefasterthanstrongercells.
n  IftheCellproChargerdisplaysLOWVOLTRESTORE,thepackwasoverdischargedduring
itslastuse.ThechargerwillattempttorepairLiPocellsmeasuringbetween0.5Vand2.7V,
orA123cellsmeasuring0Vto2.0V.Toavoidadditionaldamagetorestoredcells,donot
overdischargearepairedpack.
n  Bydenition,endoflifeforaLiPocelliswhenthecellcanonlybechargedto80%ofits
originalcapacityrating.Thenumberofcharge/dischargecyclesacellundergoesbefore
reachingendoflifedependsonseveralfactors,includingcellquality,dischargerate,internal
heatgeneratedduringuse,andotherparameters.Cellsinanolderpackmaybemoreout
ofbalance,buttheCellpro4sChargerwillstillbalancethemtowithin10mVbytheendof
charge.Forthisreason,itmaytakelongertobalanceolderpacks.Thechargermayshow
FUEL=99%forseveralhourswhileitisbalancingahighcapacity(3Ahandup)“veteran”
packthatisseverelyoutofbalance.
Charging packs
n  Youcantopoffpacks,orremovethemwhentheyarepartiallycharged.Thereisnowayto
damageapackwhenusingtheCellpro4sCharger.
n  Ifapackisat80%orlessofitscapacitywhenconnectedtoanauto-detectspeedcontroller,
thecontrollermayloweritscut-offvoltage.Thiscouldoverdischargethepackduringthe
ight.Auto-detectspeedcontrollersshouldproperlysetcut-offvoltageifpacksarecharged
toatleast90%.
n  Tosavetime,stopchargingwhenthepackreachesabout95%ofcapacity.Thatlast5%takes
thelongest.
n  Somecellsmaysag0.10Vwithinanhouraftercharging.Thisisnormalaspacksage.
n  WhencharginganA123packthathasbeendischargedverylow,thechargerinitiallymay
notbeabletoaccuratelycountcellsinthepack.Toeliminatethepossibilityofaninaccurate
count,thechargerappliescurrentto“wakeup”thecells,thenrecounts.
n  OverdischarginganA123packbelow2.0V/cellwilldamagethecells(contrarytosomere-
ports).TheCellpro4sChargerrequiresaminimumpackvoltageof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thechargerwillrejectit
formultiplereasons(asindicatedbydisplayedsafetycodes).
Storing packs
n  Forbestresults,packs(exceptA123packs)shouldbestoredat50%ofcapacity.Usethe
charger’sStore Mode.
n  A123packscanbestoredat100%ofcapacity(fullycharged).Inthischemistry,thebreak-
downvoltageishigherthanthefully-chargedvoltage.
CAUTION: Do not use the charger’s Store Mode for A123 packs. Store Mode applies
3.84V per cell, which will damage A123 cells.
n  Packschargedto100%shouldnotbecooledbelowroomtemperature.Cellsat90%orless
capacitycanbecooledbelow32ºF(0ºC).

7
How Auto Current Mode works
 TheCellpro4sCharger’sAutoCurrentModepreciselymonitorsindividualcellfuellevels
(cellvoltages)inapack.Ifthechargerdeterminesitischargingtoofast,itslowsdown.
Likewise,ifitischargingtooslow,itspeedsup.Thechargeradjustschargecurrentatone
minuteintervalsthroughoutthechargecycle.
 Whenchargingstarts,ittakesashorttimeforthechargertodeterminethecorrectparameters,
soitmay“hunt”foruptoveminutesbeforeitsettlesontheoptimumcurrent.Thisisnor-
mal,anddoesn’tharmthepack.Thelongerthecharge,themoreaccuratethecalculation.
 TheplotbelowshowshowAutoCurrentModeadjuststhecharger’scurrentwhencharginga
1.25Ahpackat1.0C.Initially,thechargecurrentishigherthan1.0C.Withinafewminutes
thechargeradjuststhecurrentdownward,anditeventuallyreaches1.0C(1.25Ainthiscase).
Currentdropsasthepackreachesfullcharge.Whenchargecurrentdropstoabout0.1C,the
packisfullycharged.
 
 SinceAutoCurrentModealwaysstartsatthelastcurrentcalculatedduringtheprevious
chargecycle,thechargerdetectsandadjustsforanovercurrentcondition:ifanycell’svolt-
ageincreasesmorethan10%duringthersttwominutesofcharging,AutoCurrentMode
defaultsto0.5A.Thispreventsovercurrentifthepreviouslychargedpackhadasubstantially
largercapacity.
 Withthe1.0CAutoCurrentMode,afullydischargedpackischargedtoitsnominalcapacity
inaboutonehour.AutoCurrentModetakesintoaccountapack’sstartingchargelevel,so
toppingoffa50%dischargedpacktakesonlyaboutone-halfhour.

8
Estimating performance factors
Ifyoudon’thaveawaytodirectlymeasureyourpropulsionsystem’selectricalparameters,the
Cellpro4sChargerenablesyoutoestimatethemusingbefore-andafter-ightmeasurements.
1. Collect data
a. Chargepack.
b. Whenchargingisnished,recordFuel %andtotal pack voltage(i.e.sumofcellvolt-
ages).
c. Flyplane(ortestontheground).Recordight time in minutes.
d. Connectpacktocharger.RecordFuel %andtotal pack voltage.
2. Calculate performance factors
(Fuel % before ight) – (Fuel % after ight)
100 x (Pack capacity, Ah) = Capacity consumed during ight, Ah
(Capacity consumed during ight, Ah) x 60
(Flight time, minutes) = Average current during ight, A
(Pack voltage before ight, V) + (Pack voltage after ight, V)
2= Average voltage during ight, V
(Average voltage during ight, A) x (Average current during ight, V) = Average power during ight, Watts
 The“LiPoPerformanceEstimator”spreadsheet,whichsimpliesthesecalculations,canbe
downloadedfromwww.fmadirect.com/tech_data/techdocs/.
3. Evaluate results
n Average current during ightgivesyouaroughideawhethersystemcomponents—ESC,
motor,connectorsandwiring—areoperatingwithintheircurrentratings.Keepinmindthat
peakcurrentduringightmaygreatlyexceedtheaveragecurrentyoucalculated.
n Watts per poundisanapproximateindicatorofaircraftperformance(otherfactorsinuenc-
ingperformanceincludelift,dragandmotortype).Herearesomeguidelines:
  25to30wattsperpound:levelight.
  40to50wattsperpound:takeofffromsmoothsurface,climb.
  50to75wattsperpound:takeofffromgrass,sportaerobatics.
  75to125wattsperpound:patternaerobatics.
  Over125wattsperpound:3D.
Tip: For more direct electrical measurements, consider these FMA products:
n 60A Current Shunt (Model DVM-SHUNT-60)
n Digital Multimeter (Model DVM-VC890D)
(Average power during ight, Watts)
(Model weight, pounds) = Watts per pound

9
Charger Viewer Software
Installing the Charger Viewer Software
FordetailedinformationoninstallingtheCellpro4sGoldChargerViewerSoftware,pleasegoto
www.fmadirect.com/downloads.html,scrolldowntotheSoftware Updatessection,thenclickthe
linkfortheCellpro4sGoldViewerSoftware.
Using the Charger Viewer Software
UsetheChargerViewerSoftwaretomonitorpack
voltage,cellvoltages,chargecurrentandsafetycodes
onyourPC.
1. ConnecttheChargertoapackandtoapower
supply.
3. ConnecttheChargertoaPCusinganFMA
FUIM2orFUIM3adapter.Plugtheadapter’s
3-pinconnectorintothejackontheCharger’sleft
side.Theblackwireshouldbetowardthetopof
theCharger’spanel.
4. OnthePC,launchtheChargerViewerprogram.
Theprogramchecksportsuntilitndscharger
data,oropentheCommlistandselectaport.
n To add notes:View > Battery Notes.
n To see voltage versus time:
View > Graphs.TheninGraphwindow,View >
Charge VoltageorView > Discharge Voltageas
needed.

Tip: Resize the Graph window to see more detail.

10
Updating the Charger’s Firmware
1. Disconnectanypacksfromthecharger.
2. ConnecttheChargertothePCusinganFMAFUIM2orFUIM3adapter.Plugtheadapter’s
3-pinconnectorintothejackontheCharger’sleftside.Theblackwireshouldbetowardthe
topoftheCharger’spanel.
3. Applypowertothecharger.
4. OnthePC,launchtheChargerViewerSoftware.
5. IntheChargerViewer,Help > Update Charger Firmware.TheFirmwareUpdateutility
opensinanewwindow.
6. IntheFirmwareUpdateutility:
a. Selectthermwareversionyouwanttoinstall.
b. ClicktheUpdate Firmwarebutton.
7. Wait—anddonothingtothePC,chargerandinterconnection—untilupdatingiscomplete.
IMPORTANT: During rmware downloading, do not disconnect the charger from power,
do not disconnect the charger from the computer, and do not exit the rmware update
program.