Revolectrix Dual PowerLab 8x2 User manual

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

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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................................................................................................. 14
Configuration A.................................................................................................................. 15
Configuration B.................................................................................................................. 16
Configuration C.................................................................................................................. 18
Configuration D.................................................................................................................. 20
Power supplies................................................................................................................... 22
Charge/discharge/cycle/monitor a pack .......................................................................... 23
Start faster..................................................................................................................................................... 25
Charge/discharge/cycle packs in parallel........................................................................ 26
Expansion Channel Mode ................................................................................................. 27
Regenerative discharge..................................................................................................... 29
Modify a preset................................................................................................................... 30
Manage presets.................................................................................................................. 31
Clear a User Preset....................................................................................................................................... 31
Copy a Library Preset................................................................................................................................... 31
Using the Charge Control Software............................................................... 33
About the CCS.................................................................................................................... 33
Installing the CCS .............................................................................................................. 34
Cells tab.............................................................................................................................. 35
Operating from the Cells tab........................................................................................................................ 35
Helpful hints .................................................................................................................................................. 36
Internal Resistance tab...................................................................................................... 37
Supply tab........................................................................................................................... 38
DC Power Supply section ............................................................................................................................ 38
Supply Status section .................................................................................................................................. 38
Battery Power Source section..................................................................................................................... 38
Expansion Channel section......................................................................................................................... 39
Firmware tab....................................................................................................................... 40
Full firmware and preset update process................................................................................................... 41
Options tab......................................................................................................................... 42
Visual Settings section................................................................................................................................. 42
Preset Settings section ................................................................................................................................ 42
Audio Settings section................................................................................................................................. 42
Start Settings section................................................................................................................................... 42
Save and load options.................................................................................................................................. 43
Presets tab.......................................................................................................................... 44
Edit a User Preset ......................................................................................................................................... 44
Information about properties....................................................................................................................... 44
Save, load, backup and restore User Presets............................................................................................ 45

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Advanced properties .................................................................................................................................... 46
Errors tab............................................................................................................................ 47
Errors in custom presets ............................................................................................................................. 47
Graphs ................................................................................................................................ 48
Exporting graph data.................................................................................................................................... 49
Generate a custom fuel table............................................................................................ 50
About fuel tables........................................................................................................................................... 50
Run multiple CCS instances ............................................................................................. 51
Other information............................................................................................ 52
Charging tips...................................................................................................................... 52
General information...................................................................................................................................... 52
Charging packs............................................................................................................................................. 52
Storing packs ................................................................................................................................................ 53
How Auto Current Mode works......................................................................................... 54
Estimating performance factors....................................................................................... 55
FMA Wiring mode vs. XH/EH Wiring mode...................................................................... 56
Switching to XH/EH mode at the DPL:........................................................................................................ 56
Switching to XH/EH mode using the CCS:................................................................................................. 56
Balance connector wiring ................................................................................................. 57
When using FMA Wiring mode (Factory Default Setting)......................................................................... 57
When using XH/EH Wiring mode................................................................................................................. 62
Open architecture presets................................................................................................. 67
LiPo factory presets........................................................................................................... 68
LiPo Generic Accurate Charge.................................................................................................................... 68
LiPo Generic Faster Charge......................................................................................................................... 68
LiPo Generic High Power............................................................................................................................. 68
LiPo Generic Long Life (4.1V)...................................................................................................................... 68
LiPo Generic Small Balanced...................................................................................................................... 69
LiPo 1s/2s Small Non Balanced .................................................................................................................. 69
LiPo All Brands Storage Charge ................................................................................................................. 69
A123 factory presets.......................................................................................................... 70
A123 2300 mAh Accurate Charge ............................................................................................................... 70
A123 2300 mAh Faster Charge .................................................................................................................... 70
A123 2300 mAh High Power......................................................................................................................... 70
A123 2300 mAh Non Bal. 1-5s...................................................................................................................... 70
A123 2300 mAh Non Bal 8s Fixed ............................................................................................................... 71
A123 1100 mAh Accurate Charge ............................................................................................................... 71
A123 1100 mAh Faster Charge .................................................................................................................... 71
A123 1100 mAh Non Bal. 1-5s...................................................................................................................... 72
A123 1100 mAh Non Bal 8s Fixed ............................................................................................................... 72
A123 All Cpcty Storage Charge................................................................................................................... 72
A123 Store Non Bal. 1-5s ............................................................................................................................. 73
A123 Store Non Bal 8s Fixed ....................................................................................................................... 73
NiMH, NiCd and Lead Acid factory presets ..................................................................... 74
NiCd Fast Charge with Trickle..................................................................................................................... 74
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

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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.

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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. Alternatively, select manual charge rates
from 10mA to 40A.

Supports both balanced (depending on chemistry) and non-balanced charging (with
certain safety limitations) of the following chemistries:
LiPo (1s to 8s balanced, 1s to 2s unbalanced; maximum charge rate of 2.0A for
unbalanced charging).
Li-Ion (1s to 8s balanced, 1s to 2s unbalanced; maximum charge rate of 2.0A for
unbalanced charging).
A123©/LiFePO4 (1s to 8s balanced, 1s to 10s unbalanced; maximum charge
rate of 20A for unbalanced charging).
LiMn (1s to 8s balanced, 1s to 2s unbalanced; maximum charge rate of 2.0A for
unbalanced charging).
NiCd (1s to 21s; maximum charge rate of 20A).
NiMH (1s to 21s; maximum charge rate of 20A).
6V, 12V, 24V Lead Acid (Flooded, Gel, AGM, SLA).
Holds up to 25 user configurable presets (User Presets), optimized for the different
chemistries, providing charging strategies for most common RC charging needs. Also
holds up to 50 Library Presets. When using the free Charge Control Software, the
number of custom presets is virtually unlimited and will grow over time to meet
industry needs. Replace and customize presets to match your battery inventory.
During balanced charging, each cell is balanced independently, providing exceptional
charging safety and elevating RC packs to the safety level of cell phones. Typical
packs of up to 4Ah capacity charge in 40 minutes or less using charger’s 3C Auto
Current Mode.
Latest technology provides the ultimate in safety—even charges packs having hidden
physical damage without danger of fire. A pack will not charge if individual cell
voltages don’t equal total pack voltage.
Cell balancing to 78μV accuracy with a tolerance of 6mV and automatic over-charge
protection assure longest pack life. Automatic temperature monitoring prevents pack
over-charging at low ambient temperatures and charger damage at high ambient
temperatures. Cold weather settings adjustable per preset. 
Selectable modes: charge only, discharge only, cycle (charge/discharge any number
of times) and monitor (no charge or discharge, just measure pack voltage).
Selectable discharge: 

Internal discharge 10mA to 10A, 95W max.
Regenerative discharge 10mA to 40A, 1344W maximum when powering the
Dual PowerLab 8x2 from a Lead Acid battery. Regenerative discharge takes
most of that energy and puts it back into the input battery. For example, when
you discharge a LiPo pack for storage, you will be recharging your Lead Acid
input battery.
Multifunction backlit display lets you select presets, replace default presets from a
library and shows charging data such as individual cell voltages, charge current,

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supply voltage, and amount of charge (mAh) put into pack. Plus, the unique Fuel
display shows percent capacity remaining in a pack.
Dual PowerLab 8x2 Charge Control Software (CCS), a free download, allows you to
customize, save and load presets (including data displays), and view real-time
charging data and graphs. CCS also manages firmware updates to keep Dual
PowerLab 8x2 operating smoothly, and to keep you up-to-date with the latest features
and enhancements.
Parallel charging takes advantage of the Dual PowerLab 8x2’s high power output.
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.
Smart Power Management, once configured, prevents damage to your power supply
or storage battery.
Operates from any 10–48V DC power source. Inputs and outputs are protected
against reverse polarity.
Expansion Channel Mode enables multiple Dual PowerLab 8x2 channels to be inter-
connected, for highly efficient charging of multiple packs of the same chemistry. The
primary Dual PowerLab 8x2 channel communicates with the enhancement channel,
sends selected preset configurations over the network, and controls all aspects of
charging and balancing for the expansion channel.

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Using Dual PowerLab 8x2
Quick reference
This quick reference lists common Dual PowerLab 8x2 tasks. What do you want to do?
To do this…
Do this…
Select power
source type*
1. Apply power.
2. Press any button.
3. At the Power Source? screen, use the INC or DEC button to select Battery
or DC Power Supply (i.e., what is currently powering the Dual PowerLab
8x2).
4. Press ENTER to display User Preset menu.
Navigate the
menus
In the User Presets menu: Press INC and DEC to scroll through User
Presets. Press and hold INC or DEC to scroll rapidly.
In the User Presets menu: Press ENTER to set up to charge with the
displayed preset.
In menus: Press INC and DEC to scroll through options. Press and hold INC
or DEC to scroll rapidly.
In menus: Press ENTER to select the displayed option and move to the next
screen.
Press BACK to go back one screen.
Press and hold BACK to go directly to the User Presets menu from any
location.
Press INC+DEC (i.e., simultaneously) to access Preset Settings, Charger
Options, Manage Presets and Button Help functions.
Connect a pack
Details
For balanced charging at any current: Attach pack discharge wires to Output
jacks using banana cable, attach 9-pin connector to Balance Port (may
require adapter).
For non-balanced charging: Attach pack discharge wires to Output jacks
using banana cable.
IMPORTANT: To prevent damage to the power source, you must specify the
power source’s voltage and current cutoffs before charging for the first time
with a DC power supply, and before charging for the first time from a battery.
After that, update the power source’s operating characteristics any time you
change to a different DC power supply or battery. You can also specify cutoffs
in the CCS Supply tab.

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Charge,
discharge, cycle
or monitor a
pack
1. Apply power and select power source (see above).
Details
2. Connect pack.
3. Press INC or DEC to select desired User Preset, then press ENTER.
4. For each question, press INC or DEC to select correct answer, then press
ENTER.
5. CHECKING PACK indicates Dual PowerLab 8x2 is attempting to detect
attached pack.
6. Screen displays preset’s chemistry. If this matches pack’s chemistry, press
ENTER to start. (If they don’t match, just wait for the next prompt, then press
ENTER to return to the User Preset menu.)
7. During the operation:
Press INC or DEC to view data.
Press ENTER to change charge current.
Press and hold ENTER to stop the operation.
8. “Beep beep beep” indicates the operation is complete. Display shows
elapsed time. Press INC/DEC to review data. Operation is complete, but
“session” remains open so you can review collected data. Press and hold
ENTER to terminate session (this erases session data).
9. Disconnect pack.
10.Press ENTER to return to User Preset menu.
Charge packs in
parallel
To ensure safety, only use REVOLECTRIX Safe Parallel Adapters and stackable
safety banana plugs or the MPA when charging/discharging/cycling packs in
parallel. 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.
Details
*Assumes Choose Power Source at Startup is enabled in the CCS.

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Set Smart Power Management
You can set a variety of operating options, including the very important power source
voltage and current limits. You can set Smart Power Management either at the Dual
PowerLab 8x2 (described below) or in the CCS Supply tab (which is easier).
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.
The Dual PowerLab 8x2 stores two Smart Power Management profiles: one for a DC
power supply and one for a Lead Acid battery. When you apply power to the Dual
PowerLab 8x2, the first thing you do is select the profile that matches the power source
you are using. This makes it easy to change the Smart Power Management profile from
a DC power supply at home to a Lead Acid battery at the field.
If you don’t configure Smart Power Management to match your power source(s), these
are the default settings:
DC supply power source: 
Voltage lower limit: 10V 
Current upper limit: 25A

Battery power source: 
Voltage lower limit: 11V 
Current upper limit: 25A

Regenerative discharge, when enabled (it is disabled by default): 
Regenerative voltage upper limit into Lead Acid battery: 14.40V
Regenerative current upper limit into Lead Acid battery: 10A

The following procedure sets Smart Power Management for both a DC power supply and
a Lead Acid battery.
1. Connect Dual PowerLab 8x2 to a 10–48V DC power supply or Lead Acid battery.
2. Press any button on Dual PowerLab 8x2’s panel.
3. At the Power Source? screen, use the INC or DEC button to select Battery or DC
Power Supply (i.e., what is currently powering the Dual PowerLab 8x2).
4. Press ENTER to display the User Preset menu.
5. Press INC+DEC (i.e., press both INC and DEC at the same time) to display the
Options menu (Choose TASK?).
6. Press INC or DEC until you see Charger Options, then press ENTER.
7. The Charger Address? screen should display PRIMARY CHANNEL (unless you are
IMPORTANT: To prevent damage to the power source, you must specify the
power source’s voltage and current cutoffs before charging for the first time
with a DC power supply, and before charging for the first time from a battery.
After that, update the power source’s operating characteristics any time you
change to a different DC power supply or battery.
Note: All of the above parameters can be adjusted directly on the Dual
PowerLab 8x2, except Regenerative Amps and Regenerative Voltage, which
must be set using CCS.

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running in Expansion Channel mode). If it doesn’t, press INC or DEC until you see
PRIMARY CHANNEL. Press ENTER.
8. At the Power Source? screen, press INC or DEC to select DC Power Supply, then
press ENTER.
9. At the Supply Current Limit? screen, press INC or DEC to specify the current limit
appropriate for your DC power supply, then press ENTER. (Cutoff current should be
slightly less than the power source’s maximum output current capability. To protect
your power supply from damage, Dual PowerLab 8x2 will never draw more current
than you specify here, but charge current may not reach the preset or manually set
value.)
10. At the Low Sply Limit? screen, press INC or DEC to specify the cutoff voltage,
then press ENTER. (Cutoff voltage should be about 50% lower than the power
supply’s nominal output voltage. Example: For a 24V power supply, set the cutoff
voltage to 12V. To protect your power supply, charging stops if the power
supply’s voltage drops below the value you set here.)
11. At the Use Regenerative Discharge? screen, press and hold the BACK button, as
this feature does not apply to DC Power Supply setup. You will be returned to the
User Preset menu. You have now successfully set Smart Power Management for
your DC power supply. Next, repeat the process for your Lead Acid battery.
12. Press INC+DEC (i.e., press both INC and DEC at the same time) to display the
Options menu (Choose TASK?).
13. Press INC or DEC until you see Charger Options, then press ENTER.
14. At the Power Source? screen, press INC or DEC to select Battery, then press
ENTER.
15. At the Battery Current Limit? screen, press INC or DEC to specify the current
limit appropriate for your Lead Acid battery, then press ENTER. (Maximum
output current capability of Lead Acid batteries varies widely. Generally, a
standard flooded Lead Acid car battery might deliver 25A continuously and 50A
for short periods. An AGM style might not have any trouble delivering 50A
continuously without suffering substantially shortened life. To protect your battery
from damage, Dual PowerLab 8x2 will never draw more current than you specify
here, but charge current may not reach the preset or manually set value.)
16. At the Bat. Low Cutoff? screen, press INC or DEC to specify the cutoff voltage, then
press ENTER. (Cutoff voltage should be no lower than 11V for a 12V Lead Acid
battery. Lower cutoff will provide longer Dual PowerLab 8x2 operating time at the
expense of Lead Acid battery life. If you are using two 12V batteries in series for 24V
operation, Dual PowerLab 8x2 will automatically double the cutoff voltage you set
here. To protect your power supply, charging stops if the power supply’s voltage
drops below the value you set here.)
17. At the Use Regenerative Discharge? screen, press INC or DEC to enable or
disable this feature, then press ENTER. Regenerative discharge puts energy back
into a battery power source during pack discharge cycles.
18. Press and hold the BACK button to return to the User Preset menu.
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.
See also
CCS Supply tab