Replacing a UPS Battery With Super-Capacitors

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Introduction: Replacing a UPS Battery With Super-Capacitors

Got tired of replacing the lead-acid battery in a UPS (Uninterruptible Power Supply), so put together a super-capacitor array to go in its place.

Such units are now commercially available
http://www.marathon-power.com/EN/UPSProducts/SupercapacitorUPS/SupercapacitorUPS.html

Step 1: Super-Capacitor Array

Started with six used 2600F 2.5V Maxwell super-capacitors that I found for $70 with postage and cross-bars included (from www.goldmine-elec.com, but they no longer stock them). The six are wired in series to allow for the voltages seen by a 12V battery; fortunately the array was found to be so well balanced by itself, that no extra circuitry was needed to ensure that no capacitor experienced an over-voltage. A UPS that trickle charges its battery will overcharge such an array, so a protective Zener diode would need to be added; the UPS I used it with did not have this problem, so there was no need for any extra components.

Step 2: Carrier Design

Designed a wood carrier that would take the place of the lead-acid battery. Tried to keep the design simple, and got it down to two dowels and two end-plates that needed holes drilled. The carrier is glued together permanently for strength, but still allows the capacitors to be removed and replaced. The two central dowels hold things together and stop the capacitors moving around; added a final cross-bar of wood across the output for physical strength.

Step 3: Possible Alternative Configuration

Considered the possibility of reconfiguring the array if the space available was narrower but higher; in my case the original design fitted well and was preferred for the support the inner dowels gave. In both designs the bolt heads reside part way into the end-plates, ensuring that the array cannot unfold.

Step 4: Final Product

Made the carrier of oak; a tough wood to work with, and not cheap (the ends were made from a plank sold for stair steps). The array is equivalent to a 1Ah 12V battery, and can hold up an average computer for a couple of minutes, more than enough to carry it through short glitches, and should endure a lot longer than the lead-acid battery it replaced. One can see here how the capacitor bolts are accessed through holes in the carrier end-plates (for assembly and dis-assembly). The rear plate is taller than the front to match the original battery mounts.

Super-capacitors can hold a lot of charge, so a disclaimer is necessary, and one must proceed at ones own risk.

Step 5: In Situ

Fortunately there was enough room inside my UPS to house the capacitor array.

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Just a note here ..... Cars use the batteries to start the car that's it then the battery gets recharge by the alternator.

If you turn the radio on while the car is not running a discharce will occur at your batteries and if use capacitors will discharge quicly so a combination of Capacitors and small Lithium battery (Hibrid) will be great and very powerful

I just finished a project like that. I ended up with a small lead acid battery though.

https://youtu.be/7llC0ZB-Rf8

Adding to my comment ..... have a look this video ...

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Sorry the only way will work is in a picture you may have to type this sites into your browsers I am sure you will like this ones

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Yes, but the lithium battery might not like charge scheme for lead acid batteries.

The UPS is designed to charge a lead acid battery, so will not be suited to charging a lithium battery; and the capacitors will no longer serve a purpose (just use the lithium battery). The other problem is the lithium battery may not be happy being discharged so quickly.

Yes UR correct but the lithium battery and the capacitors could replace the car battery complete there are a few videos on this subject.

Anyway the Caps are great to support batteries cranking power and will help the battery life on the long run.

I have a solar design using 10 x 2.5 volts connected in series giving me a total of 24 Volts and 35 Farads they are connected to my battery pack of 4 x 12 Volts batteries and 100 Watts each (2 x 2 in Series then in parallel) to obtain a total of 24 volts and 400 watts more than sufficient for my home run at the moment but I am ready to increase the power this year.

I only use the Caps to assist in the initial crank of my Fridge and some power tools that I use from time to time.

All this is connected with a 2 x 200 watts panels 12 each in series = 24 Volts and 400 Watts then to a MPPT 30 amp Power controller also use a Pure sine 3000 watts inverted and a few breakers along the way

All this works very well ... I check the Caps and Batteries when I crank my grinder and other power tools and the Caps discharged and charge in seconds ..... so my batteries are relax he he he

I am preparing a 18650 power wall as backup support for my solar installation as back up and have a petrol generator for emergencies (I have average 5 to 6 Hr sunshine every day all year) - similar as telsa wall pack ..... will see how I go

Thanks for your input

Yes, for a car application the hybrid makes sense; but not for the UPS application being discussed here.

How does your fridge run at night?

No problems I have a reserve of 3 days on Battery power so is ok I check every morning to be sure the batteries are fully charge and the Caps as well.

All running Ok I have the new Samsung fridge that takes low power so is Ok

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