FMA PowerLab 6 User manual

PowerLab 6

User’s Guide

For firmware ver. Starting at 1.05

Updated: 09/02/2014

Contents

Contents............................................................................................................. 2

About PowerLab 6................................................................................................................ 5

Using PowerLab 6 ............................................................................................. 7

Quick reference.................................................................................................................... 7

Set Smart Power Management............................................................................................ 9

Set options ......................................................................................................................... 11

Connect packs: basic........................................................................................................ 12

Connect packs: advanced................................................................................................. 14

Configuration B.................................................................................................................. 15

Configuration C.................................................................................................................. 16

Configuration D.................................................................................................................. 18

Configuration E.................................................................................................................. 20

Configuration F .................................................................................................................. 21

Configuration G.................................................................................................................. 22

Configuration H.................................................................................................................. 24

Power supplies................................................................................................................... 26

Charge/discharge/cycle/monitor a pack .......................................................................... 27

Start faster..................................................................................................................................................... 29

Charge/discharge/cycle packs in parallel........................................................................ 30

Expansion Channel Mode ................................................................................................. 31

Regenerative discharge..................................................................................................... 33

Modify a preset................................................................................................................... 34

Manage presets.................................................................................................................. 35

Clear a User Preset....................................................................................................................................... 35

Copy a Library Preset................................................................................................................................... 35

Using the Charge Control Software............................................................... 37

About the CCS.................................................................................................................... 37

Installing the CCS .............................................................................................................. 38

Cells tab.............................................................................................................................. 39

Operating from the Cells tab........................................................................................................................ 39

Helpful hints .................................................................................................................................................. 40

Internal Resistance tab...................................................................................................... 41

Supply tab........................................................................................................................... 42

DC Power Supply section ............................................................................................................................ 42

Supply Status section .................................................................................................................................. 42

Battery Power Source section..................................................................................................................... 42

Expansion Channel section......................................................................................................................... 43

Firmware tab....................................................................................................................... 44

Full firmware and preset update process................................................................................................... 45

Options tab......................................................................................................................... 46

Visual Settings section................................................................................................................................. 46

Preset Settings section ................................................................................................................................ 46

Audio Settings section................................................................................................................................. 46

Start Settings section................................................................................................................................... 46

Save and load options.................................................................................................................................. 47

Presets tab.......................................................................................................................... 48

Edit a User Preset ......................................................................................................................................... 48

Information about properties....................................................................................................................... 48

Save, load, backup and restore User Presets............................................................................................ 49

Advanced properties .................................................................................................................................... 50

Errors tab............................................................................................................................ 51

Errors in custom presets ............................................................................................................................. 51

Graphs ................................................................................................................................ 52

Exporting graph data.................................................................................................................................... 53

Generate a custom fuel table............................................................................................ 54

About fuel tables........................................................................................................................................... 54

Run multiple CCS instances ............................................................................................. 55

Other information............................................................................................ 56

Charging tips...................................................................................................................... 56

General information...................................................................................................................................... 56

Charging packs............................................................................................................................................. 56

Storing packs ................................................................................................................................................ 57

How Auto Current Mode works......................................................................................... 58

Estimating performance factors....................................................................................... 59

FMA Wiring mode vs. XH/EH Wiring mode...................................................................... 60

Switching to XH/EH mode at the PL6: ........................................................................................................ 60

Switching to XH/EH mode using the CCS:................................................................................................. 60

Balance connector wiring ................................................................................................. 61

When using FMA Wiring mode (Factory Default Setting)......................................................................... 61

When using XH/EH Wiring mode................................................................................................................. 65

Open architecture presets................................................................................................. 69

LiPo factory presets........................................................................................................... 70

LiPo Generic Accurate Charge.................................................................................................................... 70

LiPo Generic Faster Charge......................................................................................................................... 70

LiPo Generic High Power............................................................................................................................. 70

LiPo Generic Long Life (4.1V)...................................................................................................................... 70

LiPo Generic Small Balanced...................................................................................................................... 71

LiPo 1s/2s Small Non Balanced .................................................................................................................. 71

LiPo All Brands Storage Charge ................................................................................................................. 71

A123 factory presets.......................................................................................................... 72

A123 2300 mAh Accurate Charge ............................................................................................................... 72

A123 2300 mAh Faster Charge .................................................................................................................... 72

A123 2300 mAh High Power......................................................................................................................... 72

A123 2300 mAh Non Bal. 1-5s...................................................................................................................... 72

A123 2300 mAh Non Bal 8s Fixed ............................................................................................................... 73

A123 1100 mAh Accurate Charge ............................................................................................................... 73

A123 1100 mAh Faster Charge .................................................................................................................... 73

A123 1100 mAh Non Bal. 1-5s...................................................................................................................... 74

A123 1100 mAh Non Bal 8s Fixed ............................................................................................................... 74

A123 All Cpcty Storage Charge................................................................................................................... 74

A123 Store Non Bal. 1-5s ............................................................................................................................. 75

A123 Store Non Bal 8s Fixed....................................................................................................................... 75

NiMH, NiCd and Lead Acid factory presets ..................................................................... 76

NiCd Fast Charge with Trickle..................................................................................................................... 76

NiMH Fast Charge with Trickle.................................................................................................................... 76

NiCd/NiMH 24 Hr Trickle Charge ................................................................................................................. 76

Lead 12V SLA or Gel Cell............................................................................................................................. 76

Specifications: ................................................................................................................... 77

Troubleshooting................................................................................................................. 79

Support options ................................................................................................................. 82

REVOLECTRIX limited warranty....................................................................................... 83

Limits and exclusions .................................................................................................................................. 83

About PowerLab 6

Simple to operate: just connect PowerLab 6 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, PowerLab 6 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 6s balanced, 1s to 2s unbalanced; maximum charge rate of 2.0A for

unbalanced charging).

Li-Ion (1s to 6s balanced, 1s to 2s unbalanced; maximum charge rate of 2.0A for

unbalanced charging).

A123©/LiFePO4 (1s to 6s balanced, 1s to 8s unbalanced; maximum charge rate

of 20A for unbalanced charging).

LiMn (1s to 6s balanced, 1s to 2s unbalanced; maximum charge rate of 2.0A for

unbalanced charging).

NiCd (1s to 19s; maximum charge rate of 20A).

NiMH (1s to 19s; 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 8A, 50W max.

Regenerative discharge 10mA to 40A, 1000W maximum when powering the

PowerLab 6 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,

supply voltage, and amount of charge (mAh) put into pack. Plus, the unique Fuel

display shows percent capacity remaining in a pack.

PowerLab 6 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 PowerLab 6

operating smoothly, and to keep you up-to-date with latest features and

enhancements.

Parallel charging takes advantage of the PowerLab 6’s high power output. After

connecting packs using Safe Parallel Adapters, simply tell PowerLab 6 how many

packs are attached—charge/discharge rates are automatically multiplied by the

number of “P” selected.

Smart Power Management, once configured, prevents damage to your power supply

or storage battery.

Operates from any 12–32V DC power source. Inputs and outputs are protected

against reverse polarity. 

Expansion Channel Mode enables multiple PowerLab 6 units to be inter-connected,

for highly efficient charging of multiple packs of the same chemistry. The primary

PowerLab 6 communicates with the enhancement units, sends selected preset

configurations over the network, and controls all aspects of charging and balancing for

the expansion units.

Using PowerLab 6

Quick reference

This quick reference lists common PowerLab 6 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 PowerLab 6).

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

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).

Details

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.

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 PowerLab 6 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 when charging/discharging/cycling packs in parallel.

Connect up to 9 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). PowerLab 6 multiplies preset’s

current setting by the number of “P” selected.

Details

*Assumes Choose Power Source at Startup is enabled in the CCS.

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

PowerLab 6 (described below) or in the CCS Supply tab (which is easier).

Because the PowerLab 6 is capable of high power output, it is strongly recommended

that you configure Smart Power Management before you use the PowerLab 6 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 PowerLab 6 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 PowerLab 6, 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 PowerLab 6 to a 10–32V DC power supply or Lead Acid battery.

2. Press any button on PowerLab 6’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 PowerLab 6).

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 PowerLab

6, except Regenerative Amps and Regenerative Voltage, which must be set

using CCS.

running multiple PowerLabs 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, PowerLab 6 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, PowerLab 6 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 PowerLab 6 operating time at the expense of

Lead Acid battery life. If you are using two 12V batteries in series for 24V operation,

PowerLab 6 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. The next time you cycle power to the

PowerLab 6, 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.

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