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Old Jul 30, 2013, 09:08 AM
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Howard Matos's Avatar
Frederick, MD
Joined May 2002
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New Product
Introducing the NEW Cellpro Dual PowerLab 8x2 from Revolectrix




Introducing the NEW Cellpro Dual PowerLab 8x2 from Revolectrix


The next step in the PowerLab progression! Built on a proven field tested platform.

INTRODUCTION:

Welcome to the new thread dedicated entirely to an open discussion about the new FMA/REVOLECTRIX Cellpro Dual PowerLab 8x2 Battery Workstation (DPL). The DPL is a dual independent channel work station. You are invited to ask technical questions or inquire about available features to your heart’s content. Answers will be supplied by FMA staff members who performed in-house alpha testing or beta test team members who have logged hours with prototypes of the DPL. Before you start asking questions, take a quick look at the specifications and the feature set of the DPL:

Dual PowerLab Specifications:

Specification per channel

For Battery types: Lithium Polymer (1s to 8s balanced, 1s to 2s unbalanced), Lithium Ion (1s to 8s balanced, 1s to 2s unbalanced), Lithium Manganese (1s to 8s balanced, 1s to 2s unbalanced), A123 (LiFePO4) (1s to 8s balanced, 1s to 9s unbalanced), NiCd (1s to 21s), NiMH (1s to 21s), 6v, 12v, 24v Lead Acid batteries (Flooded, Gel, AGM, SLA)

Pack capacity: 20 mAh to 360Ah.

Input voltage: 10-48VDC, reverse polarity protected. Each channel may be operated on separate power supplies using 110V/15A isolated circuits for best results. Additionally both channels may be operated on one power supply provided packs on each channel are isolated.

Input current: 1A to 40A, software limited

Power conversion: Synchronous DC/DC converter, supports multiple switcher frequencies of 31.25 kHz, 62.5 kHz, 125 kHz; user selectable by preset, 85% to 93% efficiency depending on output current

Output battery charge current: Adjustable range 10mA to 40A, limited by 40A input current*

Output battery discharge current: Internal discharge 10mA to 10A, 95W max
Regenerative discharge 10mA to 40A, 1344W max**

Continuous max output power: 408W @ +12VDC input, 1344W @ +39.53VDC

Cell balancing: Resolution 78uV (16 bit) for 1s-8s Li or A123 (LiFePO4) balanced charging

Voltage calibration: Cell voltage measurements are factory calibrated to a standard traceable to NIST; calibration is to +/- 6 mV

Current calibration: Charge current is factory calibrated on a 4A standard; calibration is to +/- 1mA

Measurement accuracy:
Voltage resolution: 78uV (16 bit)
Voltage tolerance: +/- 6mV
Charge current: +/- 1%
Capacity added to pack: +/- 1%
Percent capacity (“Fuel”): +/- 5% (with accurate fuel table defined for battery being charged)

Serial data output: 19.2kbps, 8 bits, 1 start bit, 1 stop bit, no parity

Data integrity: Checksum, CRC checking

Size: 10.24 in. (260mm) L x 5.55 in. (141 mm) W x 3.03 in. (77 mm) H

Cooling fans: 13 CFM, 50mm diameter

Heat sink: Internal 120W aluminum, thin finned

Output battery connector: “Cellpro” compatible, JST PA series, 9 position

LCD: 2 line, 16 character, light grey/blue backlit

Footnotes:
* Please note, for safety reasons, available charger current may be limited for certain battery types and/or charging modes, e.g., non-balanced charge of Li
** Please check bullet number 8 in the section titled “Major Features” below for a detailed description of Regenerative Discharge

Dual PowerLab Feature Set:

Major Features:
• Selectable charge rates range 10mA to 40A per channel
• Continuous maximum output power rating, 1344W @ +39.53VDC input voltage, 408W @ +12VDC input voltage
• Using +40VDC to +48VDC input, 1344W output will deliver full current rating (40A) over the full range of output voltage up to 33.6V
• Smart power management allows customer to select between programmable input power sources. Using the Charge Control Software (CCS), choose from several templates to get you in the ballpark, then fine tune the settings. Available settings include power supply input current limit, input low voltage limit, regenerative discharge rate and voltage limit. Dual PowerLab stores 1 set-up for Power Supply per channel and 1 set-up for Battery per channel and asks for verification one time on start-up
• Dual PowerLab does not support charging through node wires only
• Initiate charge, discharge, monitor, and multiple cycles at the DPL or via remote control from the CCS. Graph all major operations when using CCS
• Open Architecture presets allow for customization of any User Preset including show/hide presets on unit, preset name editing, up to 100 parameters control how presets are displayed and charging/discharge/cycling parameter associated with particular batteries and/or charging strategies. Unit includes 25 user preset banks pre-loaded for most major battery type/chemistries, plus 50 library presets
• 0.1mohm voltage resolution allows accurate four point internal resistance measurement of each cell
• Environmentally friendly, regenerative discharge capability of up to 1344W. Unlike traditional methods of discharge, which deplete the output battery’s energy in the form of heat across a transistor, regenerative discharge takes most of that energy and puts it back into the input battery. In other words, when you discharge your LiPo for storage, you will be re-charging your Lead Acid input battery. The total amount of power that you can achieve is limited only by the amount of current that your input battery can accept, or 1344W, whichever is lower
• DPL is also equipped with a traditional, 95W internal discharge capability which is non-regenerative
• Over-sized internal heat sink
• Twin (per channel) 12AWG silicon input power cables with EC5 connectors
• Sendust core toroid capable of 40A continuous input current requirement for maximum output specifications

Other Features:
• Supports Cellpro (FMA) and JST-XH wiring modes
• Adapters available for all popular R/C battery brands
• 2 line, 16 character backlit LCD per channel
• Available opto-isolated PC interface and free Charge Control Software (CCS)
• Intuitive 4 button user interface per channel
• Sleek and attractive high-impact ABS enclosure for maximum airflow efficiency
• Sturdy Aluminum top panel with reliable, recessed tactile buttons
• Quick “preset over-ride access” to common charging parameters like setting charge and discharge current and operational modes of charge/discharge/monitor/cycle(s)
• Additional advanced options menu for adjusting in-depth charging parameters and global options at the unit
• GUI PC software (CCS) allows access to 25 User Presets and 50 Library Presets per channel stored in the unit or available in unlimited number on the P.C. When using both channels, launch two independent instances of the CCS
• Free and reliable firmware updates for the life of the product using the CCS. Firmware updates accomplished on each channel independently
• Automatic Low voltage restore for recovering damaged or over-discharged packs
• Programmable options allow speaker ON/OFF or volume, LCD contrast, customized welcome screen, and much more
• Cold weather mode reduces end-charge voltage; parameters adjustable by customer including ON/OFF, end-charge voltage offset reduction, and temperature
• Expansion Channel mode whereby one DPL primary (master channel 1) can control the expansion channel 2, send over preset information, control all aspects of charging and balancing. This feature is perfect for charging multiple packs of same chemistry and capacity using multiple devices such as split packs connected in series during operation all at unbelievable rates
• Auto charge mode available utilizing advanced fuel gauging technology
• Customizable fuel table lookup values based on presets. Fuel tables can be created using a Fuel Table Wizard in the CCS and applied to individual battery brands by presets for improved accuracy
• Industry’s first Safe Parallel adapters available to maximize available power potential. P.C. software supports up to 9 packs in parallel per channel depending on adapters used. The DPL supports parallel, charge, discharge, cycle, or monitor on each channel. Adapters are peripheral products, available separately, or included as a part of DPL combos

Please note: all specifications and features listed above subject to change prior to delivery.

Retail price for the basic unit currently $369.95 on the REVO USA webstore:

http://www.usastore.revolectrix.com/...ual-PowerLab_4

and $359.95 on the REVO Singapore webstore:

http://www.store.revolectrix.com/Pro...ual-PowerLab_3

The Cellpro PowerLab 8x2 will be available for pre-orders in mid August, 2013 (watch for future announcements) with first production run units available late September, 2013.
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Last edited by Howard Matos; Aug 02, 2013 at 09:17 AM.
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Old Jul 31, 2013, 02:14 PM
Major Electron Addiction
USA, NC, Wilmington
Joined Aug 2006
574 Posts
If I series connect 4-12.2 volt server supplies I'll end up with 28.8 volts. Will this voltage be a problem? Another option would be 24.4 volts to each channel. Which option would you prefer?
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Last edited by rodsmith123; Jul 31, 2013 at 02:19 PM.
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Old Jul 31, 2013, 04:17 PM
AR-15 BRD!
Howard Matos's Avatar
Frederick, MD
Joined May 2002
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Quote:
Originally Posted by rodsmith123 View Post
If I series connect 4-12.2 volt server supplies I'll end up with 28.8 volts. Will this voltage be a problem? Another option would be 24.4 volts to each channel. Which option would you prefer?
Hi,

You are good to go with 4 x 12.2 = 48.8 volts. We will update the maximum input voltage after we complete further testing.

What is the chemistry and cell count of the packs you are looking to charge?
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Old Jul 31, 2013, 05:00 PM
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Seattle
Joined Sep 2007
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Quote:
Originally Posted by rodsmith123 View Post
If I series connect 4-12.2 volt server supplies I'll end up with 28.8 volts. Will this voltage be a problem? Another option would be 24.4 volts to each channel. Which option would you prefer?
If you are charging 6s packs, 36v or 48v would be better than 24v. This is to avoid the buck/boost transitions common to all chargers with DC-DC converters.
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Old Jul 31, 2013, 08:22 PM
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Australia
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Quote:
Originally Posted by Howard Matos View Post
You are good to go with 4 x 12.2 = 48.8 volts. We will update the maximum input voltage after we complete further testing.

It will be good to know what the actual absolute maximum allowable input voltage will be.

Many 48v supplies/inverters etc which are commonly available are designed for battery charging systems. These generally output around 54v or so for float charging etc. So when used as a stand alone supply [ie not for charging batteries] their output is around 53 to 54v rather than 48V DC.

It would be very handy if we can use these types of supplies to power the Dual PL8.
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Last edited by Costas_; Aug 01, 2013 at 03:07 AM.
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Old Aug 01, 2013, 09:17 AM
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United States, MN
Joined Feb 2011
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I still want to see some side by side photos for size comparison
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Old Aug 02, 2013, 02:27 PM
Major Electron Addiction
USA, NC, Wilmington
Joined Aug 2006
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Quote:
Originally Posted by Gregor99 View Post
If you are charging 6s packs, 36v or 48v would be better than 24v. This is to avoid the buck/boost transitions common to all chargers with DC-DC converters.
I charge a lot of 6s packs currently with my PL8 with a 24.4 volt power supply. Never had a hiccup with this setup.
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Old Aug 02, 2013, 02:35 PM
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Seattle
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Quote:
Originally Posted by rodsmith123 View Post
I charge a lot of 6s packs currently with my PL8 with a 24.4 volt power supply. Never had a hiccup with this setup.
Not all 6s charge scenarios are going to be affected. For example if your loaded supply voltage is on the lower side and you don't discharge your packs to 80%, the DC-DC convert may stay in boost mode the entire time. Loaded supply voltage must be viewed in the CCS graph in the supply section, not on the console. Also if you are not looking at the graphs, or current display and not charging from a generator that uses ECO mode, you may miss it.

If you want to send me one of your charge graphs I can tell you more about your specific scenario. PM me for my email address.
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Old Aug 05, 2013, 08:04 PM
ltc
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United States, MA, Mendon
Joined Mar 2010
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These appear to be more than just 2 PL8's bolted together.
The input voltage range has been extended to 48V, up from 32V on the current PL8.. Is this correct?

Does this mean newer versions of the PL8 and PL6 will have this same input voltage range?
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Old Aug 05, 2013, 10:19 PM
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Seattle
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Its $110 cheaper than 2 Powerlabs in a smaller lighter case.
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Old Aug 06, 2013, 07:24 AM
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USA
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Any idea when an Online Power Calculator (http://www.revolectrix.com/Calculators_main.htm) will be available for the DPL8?
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Old Aug 06, 2013, 03:38 PM
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USA
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Aside from the hardware differences does the new DPL8 have the same UI and firmware version as the current PL8? Will the DPL8 have its own version of the CCS?
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Old Aug 06, 2013, 04:35 PM
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Seattle
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There will be a different revision of the CCS and firmware revs for the DPL. The UI will be very familiar to Powerlab6 and Powerlab8 users.
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Old Aug 09, 2013, 09:35 AM
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USA
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Does the DPL8 have one or two FUIM3 interface ports?

Does it have two microcontrollers (one for each side) or is there one microcontroller shared between both charge components?
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Old Aug 09, 2013, 11:41 AM
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Seattle
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Quote:
Originally Posted by Ohmic View Post
Does the DPL8 have one or two FUIM3 interface ports?

Does it have two microcontrollers (one for each side) or is there one microcontroller shared between both charge components?
Two FUIM interfaces, two sets controls, two displays, not internally connected. They can be operated as two separate chargers, or as a single unit with the expansion mode by connecting two FUIM data ports together and enabling expansion mode.
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