mini-box Open-UPS Installation Manual

OPENUPS

6-30V Intelligent Uninterruptible Power Supply

Installation Guide

Version 1.0f

P/N OPENUPS-06

Before you start…

Please take a moment and read this manual before you install the OPENUPS.

Often times, rushing into installing the unit can result in serious damage to your OPENUPS
board, computer. Always double check the polarity of your wires with a voltmeter.

Introduction

Thank you for purchasing the OPENUPS Uninterruptible power supply.

The OPENUPS was designed to provide user specified regulated power output from a wide
input voltage, battery backup, multi-chemistry charging and cell balancing in a single PCBA.

OpenUPS features include:

-USB interface, works with Windows devices (Linux API planned)

-SMBUS slave and I2C master

-Input between 6-30V

-Programmable voltage thresholds,

-Generate any output voltage between 6-24V,

-Supports multiple battery chemistry

-Balances up to 6 series batteries.

-Charge voltage between 6-30V, charge current up to 3A, battery balancing up to 6 cells,

-Coulomb counting (fuel gauge)

-Motherboard ON/OFF pulse control*

-Windows detects device as “Battery”, no special drivers required **

*MotherBoard ON/OFF control: The device is able to send ON/OFF 'pulse signals' to
motherboard based on coulomb counter and/or battery voltage level, or based on input voltage
level or when starting.

**Windows “no driver support”: Installs itself as a battery in Windows, using the Windows hid
driver without any driver installation, visible as an icon in tray bar.

OPENUPS Connection diagram

Power Input/Output Connectors:

J1: Input voltage, (4pin mini-FIT JR)
J4: Battery positive (+) and Battery negative (-) (2 pin mini-FIT JR)
J3: Output voltage (4 pin mini-FIT JR)

Balancing header:

j6: cells 1 to 5, cell6 already connected to Battery (+) (JST PH connector, 5pin)

Interface connectors:

J9: Mini-USB connector (mini-USB)
J10: Motherboard ON/OFF control (0.1” header)
J5: I2C master

(JST PH connector, 4pin)
J7: SMBUS slave (JST PH connector, 4pin)
J8: START/STOP button (0.1” header)
J2: Programming header, bootloader jumper, MCU reset (0.1” pitch)

Display:

Main LED (see status Main LED below)
Battery LED (see Battery LED status below)

Bootloader Mode

The device can start in bootloader mode so firmware updates are possible without using the
programming header. Place a jumper between J2.4 and J2.5, than connect the unit to USB to
enter bootloader mode.

Start the HIDBootLoader.exe software provided to flash the new firmware.

Reseting the MCU

Placing shortly a jumper between J2.1 and J2.2 will reset the internal MCU reloading your
reconfigured parameters and restarting the UPS. Care should be taken when using this feature.

Getting Started…

Before you start you would need to connect the unit to USB and configure:

- battery type and capacity (default is PbSO4 and 7000mAh)

- number of cells connected to the balancing headers (default is CELLS=1)

- charge voltages and currents, (default is 14.1V and 1700mA when fast charging)

- output voltage (default is 12V)

- input start/stop voltage thresholds ( default start at 11V, stop at 6V)

- other advanced parameters if needed

NOTE: The device needs to be restarted so the new configuration becomes active.
Simply remove the power and disconnect USB cable to shut down, settings will be
permanently saved.

Warning: Improper configuration (ex: wrong under-voltage, over-voltage, reverse
polarity) can lead to battery damage or your system damage (ex: wrong output value)

Battery Configurations:

This device is a multi chemistry device. Multiple batteries (up to 6 cells, 4.2V max) can
be connected in series (1S, 2S, 3S, 4S, 5S, 6S configuration). Parallel configurations
are also supported but not recommended due to possible decrease in lifespan.

It is possible to connect a battery with more than 4.2V/cell but in this case only 1 cell
should be configured (CELLS=1). Balancing is disabled in this case. This is a typical
example of a 12V SLA battery.

Connect your main battery terminals to the J4 connector. Always double check the
polarity of the connections.

Connect the internal cells to the balancing header J6, if needed. If more than 1 cell and

less than 6 cells are used connect the negative terminal of the battery to the next free
pin on the J6 header.

NOTE: If no balancing wires are connected through the J6 header the CELLS
parameter should be set to 1.

Example: connecting 4 cells( cells 6, 5, 4 and 3)

- The “highest” cell, cell_6, is always connected to the power terminal BAT+ (no need

to connect anywhere)

- connect cell_5 to position 5 on J6 header

- connect cell_4 to position 4 on J6 header

- connect cell_3 to position 3 on J6 header

- connect the battery's negative terminal(or GND) to position 2 on J6 header

Starting and Stopping with battery power….

If everything correctly configured pressing shortly the J8 button will turn on the output
and your UPS will be started, energy will be flowing from battery to the output.

Long pressing (5 sec) J8 button will initiate shut down of the UPS. A pulse is sent to

the motherboard than the UPS waits a predetermined UPS_HARDOFF_TOUT (60s by

default) before the output voltage is turned off.

The motherboard's state is sensed by measuring the output power via. If the
motherboard was shut down by the OS no pulse will be sent. The output power
thresholds can be set by setting the POU_LO and POUT_HI parameters. If the
motherboard consumes more than the POUT_HI threshold (meaning motherboard is
not shut down by OS) the pulse will be sent in case shutdown conditions are fulfilled.

Connecting DC input power….

Connect a proper input voltage source to the J1 connector.

If input voltage is present (configurable by thresholds), openUPS will enable the proper

power path and energy will be flowing from input to output and, if necessary, battery
charging is started. Each cell is carefully monitored so that in case of an under-

voltage

or over-voltage event proper actions are taken.

Operating modes:

-Auto restart when Input Power is Present=YES
Output and charging is started once the input power is present.

-Auto restart when Input Power is Present=NO
Only charging is started once the input power is present. The output will be started
once the Start button is pressed.

Main LED blink modes:

1) 5 x (30ms ON,30ms OFF) quick blinks during 750ms period repeatedly: initial
delay

2) 500ms ON , 500ms OFF: UPS is in standby (waiting for proper starting
conditions).
The unit will stay in this state if one of the following conditions does not fulfill:

-Improper battery configuration

-Cell under-voltage and input voltage is not present

3) Steady ON: UPS is running from Input

4) 500msec ON, 2.5 sec OFF: UPS is running on Battery

5) 1 sec ON, 1 sec OFF: OFFDELAY (time between a shutdown condition fulfilled
and the off pulse is sent to the motherboard) set by the
UPS_VBAT_UVP_OFF_TOUT parameter.