Revolectrix PowerLab Touch Series User manual

PowerLab Touch Series Battery Workstations
User’s Guide
BUMP Firmware v4.06 and later
APPLIES TO THE FOLLOWING MODELS:
POWERLAB 6 TOUCH (PN: LC06S40AT-MC)
DUAL POWERLAB 6 TOUCH (PN: LC06S40ATDIC-MC)
POWERLAB 8 TOUCH (PN: LC08S40AT-MC)
DUAL POWERLAB 8 TOUCH (PN: LC08S40ATDIC-MC)
© 2015, 2016, 2017 FMA,Inc.
Updated: 12/18/2017

2
Contents
Contents............................................................................................................. 2
About PowerLab Touch Battery Workstations.................................................................. 3
About BUMP Technology.................................................................................................... 3
PowerLab Touch Battery Workstation Features ............................................................... 4
Cabling and Installation – The Basics................................................................................ 6
............................................................................................................................................... 6
Connecting External CellPro PowerLabs........................................................................... 7
Configuring CellPro PowerLabs for BUMP Control........................................................ 10
Connecting Packs.............................................................................................................. 11
General info ................................................................................................................................................... 11
Single Pack Balanced LiPo Charge/Discharge.......................................................................................... 12
Single Pack Unbalanced Charge/Discharge .............................................................................................. 12
Safe Parallel Balance Charge (Lithium Only)............................................................................................. 13
Operation – Overview of User Interface........................................................................... 14
Operation – Battery Workstation Setup........................................................................... 19
Operation – Using BumpTags........................................................................................... 20
Operation – Using Battery Presets................................................................................... 24
Operation – Using Manual Operation............................................................................... 25
Settings............................................................................................................................... 26
Settings – Power Supplies ................................................................................................ 27
Settings – Feature Controls .............................................................................................. 29
BumpTag Installation......................................................................................................... 30
BumpTag Configuration.................................................................................................... 31
Upgrading Firmware.......................................................................................................... 38
Revolectrix CCS Mobile App............................................................................................. 39
Troubleshooting................................................................................................................. 41
Support options ................................................................................................................. 43
REVOLECTRIX limited warranty....................................................................................... 44
Limits and exclusions .................................................................................................................................. 44

3
About PowerLab Touch Battery Workstations
Decades in the making, the new PowerLab Touch series of Battery Workstations from Revolectrix
combines the amazing POWER, RELIABILITY, FLEXIBILITY, and INTUITIVE OPERATION of
the original Cellpro PowerLab series with integrated BUMP Technology (for more about BUMP
Technology, see below). Countless hours of Research and Development, refining and improving
legacy hardware, writing new firmware and software, as well as a six-month beta test program,
has resulted in four new and amazing PowerLab models; PowerLab 6 Touch, Dual PowerLab 6
Touch, PowerLab 8 Touch, and Dual PowerLab 8 Touch. These flagship products represent the
best REVO has to offer; 6s or 8s capable, Multi-Chemistry, Single or Dual Channel Charging
"engines" based on time-proven reliable power circuit designs, married to a powerful, color touch
LCD user interface; the best of what the original BUMP Controller has to offer, including NFC
BUMPTag operation, Preset, or Manual Control of all Battery Management functions; on-screen
real-time monitoring of all important data, integrated USB, and integrated Bluetooth 4LE for
Android and iOS Devices.
About BUMP Technology
BUMP is an exclusive Revolectrix concept for Battery Management. BUMP technology utilizes
Near Field Communication (NFC) technology to communicate with any battery equipped with a
BUMP Compliant Tag, or “BumpTag”. BumpTags are pre-installed and pre-configured on most
Revolectrix batteries, but are also available separately, so a customer can configure them for use
with any battery of his choosing. Once a BumpTag is programmed for a given battery, a simple
“BUMP” of the battery on a Revolectrix BUMP-compliant charger or controller and it is ready to
charge. The Revolectrix PowerLab Touch chargers have BUMP support built in, while BUMP
support may be added to any legacy (or up to 4 of legacy) Cellpro PowerLab BatteryWorkstations
by connecting a BUMP Controller which takes complete control of the PowerLab Workstations.
Unlike conventional methods of battery maintenance which require adjusting settings for every
operation, with BUMP technology, packs only need to be configured one time – when the
BumpTag is configured, then…
Charging is as simple as BUMP, CONNECT, and GO !

4
PowerLab Touch Battery Workstation Features
FEATURES:
•Simple, intuitive color touchscreen user interface
•Complete charger setup with a simple "bump" of the battery ... just bump, connect,
and press Go
•Optimizes charger settings for each individual battery, speeds up the charging setup
process
•Reduces accidental mistakes that could lead to expensive (and potentially
dangerous) battery damage
•Automatic calculation for parallel charging, even for different battery capacities and
C-ratings
•Each BumpTag contains the full factory ratings of the battery (write-once), as well as
user preferences and settings that can be changed at any time
•Each BumpTag contains a unique ID which enables automatic battery history and
performance tracking – battery cycle history is automatically cached and uploaded to
the mobile app whenever it connects via Bluetooth
•Flexible charger setup with BumpTags, Battery Presets, or Manual operations
•Unlimited number of BumpTags can be used with a single workstation, and across
multiple workstations
•Up to 99 Battery Presets, fully configurable directly from the PL Touch interface
•Manual operation mode for quick, simple one-off battery maintenance operations
•External control ports (PL Ports 3 and 4) work with legacy Cellpro PowerLab 6,
PowerLab 8v2, and Dual PowerLab (8x2) Battery Workstations
•Supported Chemistries: LiPo (including LiHV), LiFe, Li-Ion, NiMH, NiCd, and Pb
•Supported Operations: Accurate Charge, Normal Charge, Fastest Charge,
Discharge, Storage Charge, Trickle Charger, and Analyze Cycle
•Analyze Cycle allows battery performance characteristics (Fuel Table, actual
capacity, IR, etc.) to be stored back to the BumpTag for accurate fuel level and cycle
time estimates
•Designed to be easily mounted “under-deck” with the user interface exposed in a
simple rectangular cutout, allowing chargers and electronics to be completely hidden
inside a charging case or beneath charging tables/benches – ideal for integrated
charging solutions for consumer or commercial purposes
•Feature Controls settings allow the capabilities and user interface to be tailored to
specific use-cases – ideal for integration into commercial charging systems such as
drone operations

5
HARDWARE CAPABILITIES:
CONTROLLER INTERFACE
•High-brightness, 2.8" QVGA TFT LCD with resistive touchscreen
•Integrated BUMP wireless interface for configuring and reading BumpTags on batteries
•Integrated Bluetooth 4.0/LE support for wireless real-time monitoring, control, and firmware
upgrades (Android, Apple iOS, and Windows (future) mobile devices)
•Integrated USB On-The-Go (OTG) port for direct connection to Windows PC for firmware
updates, as well as powering/charging mobile devices
•Powerful 32-bit ARM Cortex-M3 main processor, plus co-processors for Bluetooth and NFC
•Two (2) external data ports for controlling legacy CellPro PowerLab Battery Workstations
CHARGER ENGINES
•Dedicated main and safety supervisor processors for each unit/channel
•Standard JST-XH balance connectors capable of direct connect of any cell count
(8S 9-pin connector on PowerLab 8 Touch, 6S 7-pin connector on PowerLab 6 Touch)
•Independent, variable per-cell balancing of up to 1000 mA per cell
•Reverse polarity protection on all inputs and outputs (when using properly fused main
charge leads)
•Regenerative Discharge allows full power “green” discharge back into Pb battery power
source
MODEL COMPARISONS:
Model Charger
Channels Max Cells Supported
Input
Voltage
Range
Input
Amps
Max
Output
Amps/Watts
Per
Channel
Internal
Discharge
Amps/Watts
Per
Channel
Regen
Discharge
Amps/Watts
Per
Channel
PowerLab 6
Touch
1
LiXX - 6s
NiXX- 19s
Pb 12V
10-32V
40A
40A
1000W
8A
50W
40A
1000W
Dual
PowerLab 6
Touch
2
80A
PowerLab 8
Touch 1 LiXX - 8s
NiXX- 21s
Pb 12V 10-48V
40A 40A
1350 W 10A 95W 40A 1350W
Dual
PowerLab 8
Touch
2 80A

6
Cabling and Installation – The Basics

7
Connecting External CellPro PowerLabs
SINGLE EXTERNAL CELLPRO POWERLAB, SINGLE POWER SOURCE
CAUTION: ALWAYS INTERCONNECT THE POWER
CONNECTIONS FIRST BEFORE APPLYING POWER TO ANY OF
THE POWERLAB TOUCH OR EXTERNAL CELLPRO POWERLAB
CHARGERS.
Failure to comply with the above may result in damage to the
PowerLab Touch and/or the external CellPro PowerLabs which
would not be covered under warranty.
POWER
SOURCE

8
TWO EXTERNAL CELLPRO POWERLABS, SINGLE POWER SOURCE
TWO EXTERNAL CELLPRO POWERLABS, MULTIPLE POWER SOURCES
COMMON GROUND
POWER
SOURCE
POWER
SOURCE 1
POWER
SOURCE 2

9
•The PowerLab Touch must always have a common power ground (negative) connection to all
externally connected CellPro PowerLabs. If the common ground connection does not exist at
the instant when the positive power wire is connected, excessive current may flow through the
CellPro PowerLab port(s) and damage the PowerLab Touch and/or CellPro PowerLab(s).
•Since the positive pin of the EC-5 input power connector may touch a split-second before the
negative pin, this ground-fault problem can occur even when just plugging in the EC-5
connection to the PowerLab Touch.
•To avoid this risk, make sure you always interconnect the PowerLab Touch and external CellPro
PowerLab power cables first (typically using EC5 Y-cables), then apply power to that common
cable - this ensures the common ground connection is established before the positive
connection is made and current starts flowing through the system.
•The PowerLab Touch and its external CellPro PowerLab(s) MAY use separate power supplies,
however, all of those power supplies must share a common ground connection which is capable
of handling high current loads, and that ground connection must remain connected as long as
any one of the power supplies is active. It's okay to turn on one power supply (and CellPro
PowerLab) at a time, as long as all of the common ground connections are established prior to
ANY power being connected. The common ground connection must remain interconnected until
all power is disconnected from the system.
•Finally, whenever possible, and at least the first time you connect up system components, it is
also recommended that the PowerLab Touch and any/all external CellPro PowerLabs are
powered up and running prior to connecting the ECM communication wires (labeled P3-P4 on
the back of the PowerLab Touch) to the external CellPro PowerLab data ports (on the back of
each CellPro PowerLab) using the supplied JR style male-to-male extensions. After the
PowerLab Touch boots up, you will then see a graphic on the display which illustrates the
proper polarity for these interface cables when plugging them into the PowerLab Touch ports.
Always ensure you make port interconnections at the PowerLab Touch using proper polarity
(black/ground wire to the right when viewed from above). Proper polarity for each external
CellPro PowerLab data port side of the cable (listed as “TO PC”) is illustrated on every CellPro
PowerLab top panel label and varies from model-to-model.

10
Configuring CellPro PowerLabs for BUMP Control
The PowerLab Touch series chargers are capable of controlling legacy CellPro PowerLab series chargers
(PowerLab6, PowerLab8v2, and Dual PowerLab8x2) via the 3-wire data port interface.
The PowerLab Touch chargers have two (2) external data ports available for external chargers.
These data ports use Expansion Channel Mode (ECM) for control which uses unique addresses to identify each
device for communication and, by default, all CellPro PowerLab chargers will have the ECM address set to zero
which makes it the PRIMARY. In order to control the CellPro PowerLabs externally, the ECM address must be
changed to the address which matches the physical port number of the PowerLab Touch data port to which it is
connected – either 3 or 4.
To change the ECM Address of the CellPro PowerLab, perform the following steps:
1. Press INC+DEC to display the Options menu (Choose TASK?).
2. Press INC or DEC until you see Charger Options, then press ENTER.
3. In the Charger Address? screen, select EXPANSION CH. n , where ‘n’ is equal to the port number where
you will connect this CellPro PowerLab (either 3 or 4), then press ENTER.
4. Press and hold BACK to exit options.
NOTE: The Expansion Channel Address of the CellPro PowerLab
must match the physical port number to which it is attached.