mini-box Open-UPS User manual

OPENUPS
6-30V Intelligent Uninterruptible Power Supply
Installation Guide
Version 1.0f
P/N OPENUPS-06
Before you start…
Ple se t ke moment nd re d this m nu l before you inst ll the OPENUPS.
Often times, rushing into inst lling the unit c n result in serious d m ge to your OPENUPS
bo rd, computer. Always double check the polarity of your wires with voltmeter.
Introduction
Th nk you for purch sing the OPENUPS Uninterruptible power supply.
The OPENUPS w s designed to provide user specified regul ted power output from wide
input volt ge, b ttery b ckup, multi-chemistry ch rging nd cell b l ncing in single PCBA.
OpenUPS fe tures include:
-USB interf ce, works with Windows devices (Linux API pl nned)
-SMBUS sl ve nd I2C m ster
-Input between 6-30V
-Progr mm ble volt ge thresholds,
-Gener te ny output volt ge between 6-24V,
-Supports multiple b ttery chemistry
-B l nces up to 6 series b tteries.
-Ch rge volt ge between 6-30V, ch rge current up to 3A, b ttery b l ncing up to 6 cells,
-Coulomb counting (fuel g uge)
-Motherbo rd ON/OFF pulse control*

-Windows detects device s “B ttery”, no speci l drivers required **
*MotherBo rd ON/OFF control: The device is ble to send ON/OFF 'pulse sign ls' to
motherbo rd b sed on coulomb counter nd/or b ttery volt ge level, or b sed on input volt ge
level or when st rting.
**Windows “no driver support”: Inst lls itself s b ttery in Windows, using the Windows hid
driver without ny driver inst ll tion, visible s n icon in tr y b r.
OPENUPS onnection diagram
Power Input/Output Connectors:
J1: Input volt ge, (4pin mini-FIT JR)
J4: B ttery positive (+) nd B ttery neg tive (-) (2 pin mini-FIT JR)
J3: Output volt ge (4 pin mini-FIT JR)
B l ncing he der:
j6: cells 1 to 5, cell6 lre dy connected to B ttery (+) (JST PH connector, 5pin)
Interf ce connectors:
J9: Mini-USB connector (mini-USB)
J10: Motherbo rd ON/OFF control (0.1” he der)
J5: I2C m ster
(JST PH connector, 4pin)
J7: SMBUS sl ve (JST PH connector, 4pin)
J8: START/STOP button (0.1” he der)
J2: Progr mming he der, bootlo der jumper, MCU reset (0.1” pitch)
Displ y:
M in LED (see st tus M in LED below)
B ttery LED (see B ttery LED st tus below)

Bootloader Mode
The device c n st rt in bootlo der mode so firmw re upd tes re possible without using the
progr mming he der. Pl ce jumper between J2.4 nd J2.5, th n connect the unit to USB to
enter bootlo der mode.
St rt the HIDBootLo der.exe softw re provided to fl sh the new firmw re.
Reseting the M U
Pl cing shortly jumper between J2.1 nd J2.2 will reset the intern l MCU relo ding your
reconfigured p r meters nd rest rting the UPS. C re should be t ken when using this fe ture.
Getting Started…
Before you st rt you would need to connect the unit to USB nd configure:
- b ttery type nd c p city (def ult is PbSO4 nd 7000mAh)
- number of cells connected to the b l ncing he ders (def ult is CELLS=1)
- ch rge volt ges nd currents, (def ult is 14.1V nd 1700mA when f st ch rging)
- output volt ge (def ult is 12V)
- input st rt/stop volt ge thresholds ( def ult st rt t 11V, stop t 6V)
- other dv nced p r meters if needed
NOTE: The device needs to be rest rted so the new configur tion becomes ctive.
Simply remove the power nd disconnect USB c ble to shut down, settings will be
perm nently s ved.
Warning: Improper configur tion (ex: wrong under-volt ge, over-volt ge, reverse
pol rity) c n le d to b ttery d m ge or your system d m ge (ex: wrong output v lue)
Battery onfigurations:
This device is multi chemistry device. Multiple b tteries (up to 6 cells, 4.2V m x) c n
be connected in series (1S, 2S, 3S, 4S, 5S, 6S configur tion). P r llel configur tions
re lso supported but not recommended due to possible decre se in lifesp n.
It is possible to connect b ttery with more th n 4.2V/cell but in this c se only 1 cell
should be configured (CELLS=1). B l ncing is dis bled in this c se. This is typic l
ex mple of 12V SLA b ttery.
Connect your m in b ttery termin ls to the J4 connector. Alw ys double check the
pol rity of the connections.
Connect the intern l cells to the b l ncing he der J6, if needed. If more th n 1 cell nd
less th n 6 cells re used connect the neg tive termin l of the b ttery to the next free
pin on the J6 he der.
NOTE: If no b l ncing wires re connected through the J6 he der the CELLS
p r meter should be set to 1.
Ex mple: connecting 4 cells( cells 6, 5, 4 nd 3)
- The “highest” cell, cell_6, is lw ys connected to the power termin l BAT+ (no need

to connect nywhere)
- connect cell_5 to position 5 on J6 he der
- connect cell_4 to position 4 on J6 he der
- connect cell_3 to position 3 on J6 he der
- connect the b ttery's neg tive termin l(or GND) to position 2 on J6 he der
Starting and Stopping with battery power….
If everything correctly configured pressing shortly the J8 button will turn on the output
nd your UPS will be st rted, energy will be flowing from b ttery to the output.
Long pressing (5 sec) J8 button will initi te shut down of the UPS. A pulse is sent to
the motherbo rd th n the UPS w its predetermined UPS_HARDOFF_TOUT (60s by
def ult) before the output volt ge is turned off.
The motherbo rd's st te is sensed by me suring the output power vi . If the
motherbo rd w s shut down by the OS no pulse will be sent. The output power
thresholds c n be set by setting the POU_LO nd POUT_HI p r meters. If the
motherbo rd consumes more th n the POUT_HI threshold (me ning motherbo rd is
not shut down by OS) the pulse will be sent in c se shutdown conditions re fulfilled.
onnecting D input power….
Connect proper input volt ge source to the J1 connector.
If input volt ge is present (configur ble by thresholds), openUPS will en ble the proper
power p th nd energy will be flowing from input to output nd, if necess ry, b ttery
ch rging is st rted. E ch cell is c refully monitored so th t in c se of n under-
volt ge
or over-volt ge event proper ctions re t ken.
Operating modes:
-Auto rest rt when Input Power is Present=YES
Output nd ch rging is st rted once the input power is present.
-Auto rest rt when Input Power is Present=NO
Only ch rging is st rted once the input power is present. The output will be st rted
once the St rt button is pressed.
Main LED blink modes:
1) 5 x (30ms ON,30ms OFF) quick blinks during 750ms period repe tedly: initi l
del y
2) 500ms ON , 500ms OFF: UPS is in st ndby (w iting for proper st rting
conditions).
The unit will st y in this st te if one of the following conditions does not fulfill:
-Improper b ttery configur tion
-Cell under-volt ge nd input volt ge is not present
3) Ste dy ON: UPS is running from Input
4) 500msec ON, 2.5 sec OFF: UPS is running on B ttery
5) 1 sec ON, 1 sec OFF: OFFDELAY (time between shutdown condition fulfilled
nd the off pulse is sent to the motherbo rd) set by the
UPS_VBAT_UVP_OFF_TOUT p r meter.

6) 3x(500ms ON,500ms OFF) + 3 sec OFF repe tedly: H rdw re OFF del y (time
between the off pulse is sent nd cut off of the output volt ge) set by the
UPS_HARDOFF_TOUT, entering deep sleep
Status of Battery LED:
-F st blinking: incorrect configur tion of the cell numbers, or wrong connections on
the b l ncing he der.
-Toggle every 1 sec: B ttery is being ch rged
-Ste dy ON: B ttery is fully ch rged (100%)
-Ste dy OFF: (together with m in LED's 500msec ON, 2.5 sec OFF:) System is
running on b ttery
All LEDS OFF:
Unit is in Deep sleep mode consuming very little power. MCU is not powered. C n be
w ked up by shorting J8 or if input volt ge is present.
Setting Power plans under Windows Operating Systems:
Ex:Vist ,Win7
-Right click on the b ttery icon from the tr yb r then choose power options from the
context menu. Altern tively you c n choose Power Options lso from Control P nel
Items.
-Select/cre te power pl n or modify existing ones.
-In the “Ch nge Adv nced power settings” section the critic l nd low b ttery levels
nd ctions c n be lso modified

OPENUPS haracteristics
Minimum Input Oper ting. volt ge 6V
M ximum input Oper ting volt ge 30V
Deep-Disch rge shutdown threshold configur ble
Input current limit (fuse protected) Mini-bl de 10A
Deep Sleep Current Consumption. < 50uA
Stor ge nd oper ting temper ture -40 to +85 degrees Celsius (stor ge), -40 – 65C (oper ting)
MTBF 50K Hrs @ 85C, >200K Hrs t 65 (projected)
Efficiency (Input 10-16V) >80-95% (95% m x), depending on lo d V(in) nd V(out)
Input connectors Mini-Fit JR
Output Connector Mini-Fit JR
Output/Input Rail Output urrent (buck/boost converter):
M ximum input current: 6A*
Pe k Input current: 10A (<30 seconds)
M ximum output current: 6A*
Pe k output Current: 10A (<30 seconds)
*NOTE: When oper ting t high volt ge (input or output) or/or oper ting t elev ted
temper tures de-r ting up to 30% might be necess ry, forced ventil tion required. For long life
oper tion, ple se ensure th t hottest component on-bo rd is kept below 65C.
Support and warranty: St nd rd H rdw re W rr nty 1Ye r / US, 2 Ye r EU.

P r meter List:
NAME DES RIPTION
OPENUPSMODE OPENUPS mode
0- Auto rest rt when Input Power is
Present=YES
1- Auto rest rt when Input Power is
Present=NO
UPS_CONFIG Configur tion register. Used for en bling
dis bling modules. LSB bit is b0.
b6- Stop impulse
b5- St rt impulse
b4- Coulomb counter
b3- A/D Low p ss Filter module
b2- B l nce module
b1- Ch rge module
b0- Output module
Def ult is ll en bled
UPS_INIT_DELAY_TOUT[s] Initi l del y before st rting the UPS.
Def ult is 1 sec.
UPS_VIN_MAX_SHUTDOWN[V] M x llowed input volt ge. In c se input
volt ge exceeds predefined v lue
shutdown will be initi ted.
Def ult is 35V.
UPS_VIN_MIN_START [V] If input volt ge is bove this threshold the
UPS will st rt nd t ke power from the
input.
Def ult is 11V.
UPS_VIN_MIN_STOP [V] If input volt ge is below this threshold the
UPS will try to run on b ttery.
Def ult is 6V.
UPS_VCELL_MIN_START [V] If Vin is not present nd ll the b ttery
cells re bove this threshold the UPS
c n st rt nd runs on b ttery
Def ult is 11.7V
UPS_VCELL_MIN_STOP [V] If VIN is not present nd one of the
b ttery cells is less th n this threshold
during the time period specified by
UPS_VBAT_UVP_OFF_TOUT p r meter
the UPS will initi te shut down procedure.
Def ult is 11.4V
UPS_VBAT_UVP_OFF_TOUT [s] During this period b ttery cells re
checked g inst
UPS_VCELL_MIN_STOP. If cell volt ge
exceeds UPS_VCELL_MIN_STOP the
timer is re rmed so it c n filter unw nted
noise in the system.

Def ult is 5 sec.
UPS_HARDOFF_TOUT[s] After UPS_VBAT_UVP_OFF_TOUT
p ssed motherbo rd is sign led to shut
down. The UPS will w it this period so
th t the Motherbo rd c n shut down
gr cefully, th n cut power nd enter deep
sleep. This period should not be too long
to prevent b ttery dr in.
Def ult is 60 sec.
UPS_SWITCHOVER_VBAT_TOUT[ms] After UPS switches to b ttery, c n switch
b ck to Vin only fter this time el pses.
Def ult is 1000ms.
UPS_SWITCHOVER_VIN_TOUT[ms] After UPS switches to input, c n switch
b ck to b ttery only fter this time
el pses.
Def ult is 1ms.
DCHG_IMAX[mA] M x llowed disch rge current. In c se
disch rge current exceeds this threshold
shutdown will be initi ted.
Def ult is 10000 mA.
CAPACITY[mAh] B ttery C p city.
Def ult 7000mAh.
CHG_BAT_TYPE The b ttery chemistry to be ch rged.
0- PbSO4 (flo t ch rge is pplied)
1- LiFePO4 (flo t ch rge is not pplied)
2-LiPO(flo t ch rge is not pplied)
Other (flo t ch rge is not pplied)
Def ult is 0.
CHG_VCOND[V] Conditioning/Pre-ch rge volt ge. Ch rge
current is limited to CHG_ICOND until cell
volt ge exceeds this v lue nd for t le st
CHG_TCOND time .
Def ult is 11.2V.
CHG_ICOND[mA] Conditioning/Prech rge current. Ch rge
current is limited to this v lue until cell
volt ge exceeds CHG_VCOND v lue nd
for t le st CHG_TCOND time .
Def ult is 100mA.
CHG_TCOND [s] Conditioning/Prech rge time. Ch rge
current is limited to CHG_ICOND v lue
until cell volt ge exceeds CHG_VCOND
v lue nd it is pplied during this time.
Def ult is 30 sec.
CHG_IBULK[mA] F st ch rge current limit (const nt current
mode)
Def ult is 1750mA.
CHG_BULK_STOP_VOLTAGE[V/cell] M ximum llowed bulk ch rge

volt ge/cell during const nt
current/const nt volt ge ch rging
Def ult is 14.1V
CHG_HYSTERESIS[V/cell] An over-volt ge v lue
(CHG_BULK_STOP_VOLTAGE
+CHG_HYSTERESIS ) th t it is llowed
when ch rging.
If one of the cells exceeds this v lue
ch rging is immedi tely stopped.
Def ult is 100mV/cell.
CHG_START_VOLTAGE [V/cell] If cell volt ge is below this v lue ch rging
c n be st rted. For PbSO4 b ttery this
lso sets the flo ting ch rge volt ge.
Def ult is 13.5V/cell
CHG_IMIN [mA] If ch rge current in CV mode is less th n
this v lue
PbSO4: enter m inten nce mode nd
pply the flo t ch rge
volt ge(CHG_START_VOLTAGE)
LiFePO4,LiPO: cut off the ch rge volt ge
Def ult is 290mA
CHG_IFLOAT Ch rge current limit in flo t ch rge mode
for PbSO4 b tteries.
Def ult is 100mA.
CHG_GLOBAL_TOUT Glob l ch rge timeout.
Def ult is 1260 minute.
CHG_TOPPING_TIMER For Lithium b sed b tteries fter n
overvolt ge condition is detected for cell
resting period is set by this timer before
pplying sm ll topping ch rge in c se
other cells re still not ch rged.
Def ult is 1800s.
CHG_TEMP_PCB[°C] Ch rge current is limited by
CHG_ILIMIT_TEMP_PCB mount every
30s,if bo rd temper ture exceeds this
v lue. C n limit the ch rge current till
CHG_IBULK/4 v lue.
Def ults is 60°C.
CHG_ILIMIT_TEMP_PCB [A] Limit ch rge current with this mount if
bo rd temper ture exceeds
CHG_TEMP_PCB.
Def ult is 50mA.
CHG_FREQUENCY[kHz] The working frequency of the ch rger
buck-boost converter
Def ult is 333kHz.
CELLS[pcs] Number of configured cells to
ch rge/b l nce

Def ult is 1pcs.
BAL_VCELL_MIN[V] B l ncing is llowed if cell volt ges re
bove this v lue.
Def ult is 3V
BAL_VCELL_DIFF_START [V] If the volt ge difference between cells
exceeds this v lue st rt b l ncing the
cells.
Def ult is 70mV.
BAL_VCELL_DIFF_STOP[V] If the volt ge difference between cells is
less th n this v lue stop b l ncing the
cells.
Def ult is 40mV.
OUT_VOLTAGE[V] The output volt ge.
Def ult is 12V.
OUT_FREQUENCY[kHz] The working frequency of the output
buck-boost converter.
Def ult 300kHz
OUT_MAX_REGULATOR_STEP[nr] M ximum llowed regul tion step number
for output module (0-255)
Def ult 100.
MOB_ONOFF_TOUT[ms] The power switch on the motherbo rd(if
connected) will be shorted this period to
turn the Motherbo rd ON or OFF
Def ult is 500ms
POUT_LO[W] Output power low threshold for
motherbo rd live sensing. If output
power is lower th n this threshold shut
down impulse will NOT be sent to the
motherbo rd when shut down conditions
re fullfilled.
Def ult is 2W.
POUT_HI[W] Output power high threshold for
motherbo rd live sensing. If output
power is higher th n this threshold shut
down impulse c n be sent to the
motherbo rd when shut down conditions
re fullfilled.
Def ult is 6W.
OCV_SOC0 Open Circuit Volt ge St te Of Ch rge
detection for initi l 0% fuel g uge
estim tion.
Def ult is 11.8V
OCV_SOC10 Open Circuit Volt ge St te Of Ch rge
detection for initi l 10% fuel g uge
estim tion.
Def ult is 11.9V