Repurposing a Dead UPS in to a CNC Motor Controller Enclosure

15,927

39

13

Posted in TechnologyCnc

Introduction: Repurposing a Dead UPS in to a CNC Motor Controller Enclosure

Just for clarification, I did not make a CNC motor controller out of a UPS; I’m only using the UPS housing as an enclosure for a commercial motor controller.

I purchased a table top CNC router from eBay, and the controller came mounted on a board.  I didn’t pay a much for it so it wasn’t too big of a deal.  But I soon found that the motor controller would be much better off in a protective case.   It would also be nice to have an on/off switch.   I initially planned on creating my own custom box using my router but I figured this would be more time effective and more durable.

This project is pretty easy but does require some soldering, drilling, and cutting.
I completed this project in about 4 hours, for a cost of about $5.00.

Step 1: Tools & Materials Needed.

The Tools Required for this project are pretty basic.

Multi-meter for finding out the pin-outs of the switches, and double checking wiring.

Screwdriver you may need both a Philips and a flat.

A Utility knife (razor blade) for cutting the Sintra.

Wire strippers these will get a lot of use in this project 4 wires X 3 motors  X 3 connections

Step Drill (or a regular drill bit) for drilling the vent holes and any necessary mounting holes.

Cordless Drill (optional) this makes taking apart the UPS very easy and quick.

A soldiering iron. 

Step 2: Tearing Down the UPS

Important!  REMOVE THE BATTERY FIRST, after all the whole purpose of a UPS is to produce 110V even when it's unplugged.  There is usually a compartment that opens up to allow access for replacing the battery, usually on the bottom or possibly under the front cover.

This step is pretty easy just remove all of the items inside the box.  Keep any parts that will be needed to maintain the enclosures shape.   I won't go into too much detail because each UPS will be slightly different.  Make sure you leave enough of the enclosure to put it back together solid.  The most this should require is unplugging wires and removing screws.




Step 3: Adding the Power Supply.

The power supply fits nicely into the enclosure but make the Power supply easier to mount I installed a piece of Sinra (expanded PVC) to the bottom.  I first cut it to size and then attached it with 4 screws up from the bottom.

I then used screws to screw down the power supply through existing holes in the power supply housing.

I left the power supply wiring as complete as possible as to make it easier to wire when that step comes.

Step 4: Adding the Motor Controller.

This width of the UPS ended up being a little tighter than I planned and I didn't have a lot of room to work with.  I explored some options with Sinatra, but in the end I went with the simplest solution and just mounted it to the side of the power supply.

The Motor Controller has 4 mounting holes but the power supply case didn't have any good mounting holes so on the inside of the power supply case I add two strips of Sintra for the screws to anchor into.

Of course I also used plastic standoffs so the motor controller wouldn't short circuit on the metal case beneath it.




Step 5: Creating the Custom Back Plate

This Particular UPS has a back panel that can be removed, by undoing a couple of screws. This made it pretty easy to measure and cut a piece of Sintra for the new back panel.

I first cut it to size and attached it to the existing back panel, then checked to make sure I had it the right size for the case to fit properly. I did have to trim the corners to fit the bent metal corners of the case.

I then laid out all of the components that needed to attach to the back panel, and traced there locations. Once I had my lay out finished I could see that I wasn't going to be able to use the existing holes. I used a grinder (for lack of having a better tool available) and removed the inner part of the existing back panel.

With the metal cut out of the way and the new back panel in place I made the openings necessary to fit the connectors. The round holes I drilled with a Step Drill (if you don’t have one GET ONE) the square holes I cut with a razor blade.

Step 6: Wiring

There really isn't much to the wiring; all you are really doing is adding the connector’s inline to the motor wires, and adding a switch to the AC power cord.

I used the power cord from the UPS and also used the original grommet to secure it.  I drilled a big enough hole in the new back plate to install it.  Once in place I ran the ground wire and the White wire to their appropriate terminals on the new power supply.  
Then I added a longer lead to the black cable so it could connect to the front power switch.   I then ran the other lead from the switch back to the corresponding terminal on the power supply, completing the circuit.

 I first labeled the motor wires, 1,2 and 3 and then cut about 10" off the end to wire the inside of the enclosure.  I soldered the ends to the female connectors on the inside of the back plate and then connected the existing green pin connectors which connect to the motor controller.

The only thing left was to add the male connectors on to the wires connected to the motors.






Step 7: Finished!

I love it when a project comes together! Now my motor controller is safe, cool and quiet. It’s also nice to have a power switch to turn it on and off, instead of having to unplug it each time.

As future add-ons; I plan on putting some decals on it so someone doesn't make the mistake of thinking it's a UPS. I want to also add an emergency halt button on the top of it, and possibly incorporate spindle control into the back panel, using the original plug as the power connector.

Share

    Recommendations

    • Spotless Contest

      Spotless Contest
    • Microcontroller Contest

      Microcontroller Contest
    • Space Challenge

      Space Challenge
    user

    We have a be nice policy.
    Please be positive and constructive.

    Tips

    Questions

    13 Comments


    ----- Original Message -----
    From: conexups
    Sent: Wednesday, February 27, 2013 1:31 PM
    Subject: PRICE LIST FOR UPS , INVERTERS ,SOLAR UPS & Laboratory / Educational Kits For Engineering / Medical College Students -CONEX SYSTEM- www.conexups.com



    To,
    Purchase / Project / Maintenance Department:---

    Dear Sir,

    We Conex System,Pune, India www.conexups.com are leading manufacturer & service provider for following products for Last 20 Years.---

    Inverters & UPS (Online and Offline) UP TO 450KVA
    Solar Inverters, UPS (On grid & Off grid) -- UP TO 200KVA
    PWM And MPPT Charge Controllers 12V to 360V.
    STABALIZERS UP TO 1000KVA
    Tubular Lead Acid Batteries .
    Solar Panels
    Solar Home / Street Lighting System ( CFL and LED )
    Battery Chargers and Load Banks.
    LED Lighting ,MNRE APPROVED SOLAR STREET LIGHTS
    C.V.C.F./Static Frequency Converter
    Lift/ Elevator Inverter,
    D.C. Power Supply , C.V.T.,
    Laboratory / Educational Kits For Engineering / Medical College Students
    WE HAVE INSTALLATION UP TO 450KVA UPS IN DIFFERENT LOCATIONS IN INDIA & WORD FOR CNC MACHINE, MEDICAL EQUIPMENTS, CALL CENTRES, DEFENCE EQUIPMENTS & OTHER CRITICAL LOAD

    WE HAVE INSTALLATION UP TO 450KVA UPS IN DIFFERENT LOCATIONS IN INDIA & WORD FOR CNC MACHINE, MEDICAL EQUIPMENTS, CALL CENTRES, DEFENCE EQUIPMENTS & OTHER CRITICAL LOAD---WE HAVE ALSO INSTALLED 50 Hz. TO 400Hz. STATIC FREQUENCY CONVERTER FOR AIRCRAFT REPAIRS/MAINTENCE, DEFENCE, RADAR TEST FACILITY APPLICATION & HIGH CURRENT POWER SUPPLY FOR SUBMARIN APPLICATION ALL OVER INDIA & WORD.


    Conex System, Mr.Nilesh Tilak ,Pune- State- Maharashtra-- India ;Phone- +912027111666 , Mobile- +919822068763 & +919421058306 ; Email: info@conexups.com ; nile5637@gmail.com www.conexups.com

    PRICE LIST FOR PURE SINE WAVE ON LINE UPS WITH ISOLATION TRANSFORMER. in Rs.





    2 KVA 1 Ph - 1Ph 144V 28600 ; 2KVA- 1PH 48 / 72V -rs.29700

    3 KVA 1 Ph - 1 Ph 144V 31900;3KVA-72/96/120V --34500

    5 KVA 1 Ph - 1Ph 144 / 180V --39000 120V --40700

    7.5 KVA 1 Ph - 1 Ph 180 / 240V -46500 & 120V --49500

    10 KVA 1 Ph -1 Ph 180V --55000 & 240V --60500

    10 KVA 3 Ph -1 Ph 240V --71500

    15 KVA 3 Ph -1 Ph 240V --99600 & 360V--94500

    15 KVA 3 Ph -3 Ph 240V -116600 & 360V-112200

    20 KVA 3 Ph -1 Ph 300V--123500 & 360V--119000

    20 KVA 3 Ph -3 Ph 300V -141000 & 360V -135000

    25 KVA 3 Ph -1 Ph 360V - 141000

    25 KVA 3 Ph - 3 Ph 360V --153000

    30 KVA 3 Ph - 1Ph 360V --146000

    30 KVA 3 Ph - 3Ph 360V --158000

    40 KVA 3 Ph - 3 Ph 360 V -199500

    50 KVA 3 Ph - 3 Ph 360 V --242000

    60 KVA 3 Ph - 3 Ph 360 V -299000

    80 KVA 3 Ph - 3 Ph 360 V --399000

    100 KVA 3PH-3PH 360 V --512000

    120 KVA 3PH -3PH 360 V -585000

    150 KVA 3PH-3PH 360 V --735000

    180 KVA 3PH-3PH 360 V --1090000


    3Ph - 3Ph INVERTERS/ UPS FOR LIFTS, AIR-CONDITION etc. without Battery

    6 KVA 72/144/180v. --rs.55000

    8 KVA 72/144/180v.--64000


    10 KVA 144 / 180v. --75000


    12 KVA 144 / 180 v.--79000


    15 KVA 180 / 240v. --88000


    20 KVA 180 / 240 v. -109000


    30 KVA 240 / 360v.--129000


    35 KVA 240 / 360 v. ---139500

    40 KVA 240 / 360 v.--151000






    1PH-1PH INVERTERS/ UPS FOR HEAVY LOAD LIKE AIR-CONDITION etc. without Battery

    5KVA 120/180V
    34,000

    6KVA 120/180V
    38,000

    7.5KVA 120/180V
    43,000

    10KVA 180V
    49,000

    12KVA 192V
    52,000


    #Wide range of Input Supply Voltage to suit conditions
    #Custom built design is possible as per User Specifications
    #Latest Technology
    #Compact size
    #True ON-LINE topology
    #High Performance; High Efficiency with near unity power factor
    #Excellent Voltage Regulation and Transient Response
    #Comprehensive and User friendly LCD Display with Mimic
    #Support all types of Battery Systems
    #Extended Run Time Facility
    #Diesel Gen set Compatible
    #Optional Intelligent Computer Interface
    #Optional Auto By-pass facility
    #Optional N + 1 (Parallel Redundant / Hot standby) Configuration UPS Systems


    ON LINE UPS Range

    1KVA – 10 KVA (1Ph - 1Ph)
    10 KVA – 30 KVA (3Ph - 1Ph)
    15KVA – 500 KVA (3Ph - 3Ph)

    Services we can offer


    Our Presales Services include Actual Load study and Sizing of Equipment and Battery ratings.

    We undertake repairs / up gradation of Preexisting systems on mutually agreed terms

    We undertake Disposal / Buy back of systems against new purchase

    We can Design and Manufacture Custom built systems for a specific application. We can offer consultancy for devising the specifications for such requirements.

    We have Designed and Supplied following Custom built Equipment other than our standard products


    For Defense applications
    400Hz Static Frequency Converter for Radar Test Facility
    DC Power Supply 220 V – 80A for Submarine application

    For Industrial Applications
    Plate Formation Rectifier
    Variable Power Supply 5 – 600V for Capacitor Manufacturing Plant
    Battery Charger and Dischargers
    Charge Controllers for Solar and Wind Power applications
    Designed and Supplied 75KVA Inverter for Wind Power Generator
    Other Products


    Off Line Ups Systems



    Range
    1 KVA - 12 KVA (1Ph – 1Ph)
    6 KVA – 150 KVA (3Ph – 3Ph) -- (FOR LIFT, AIR-CONDITIONS & OTHER HEAVY LOAD.)



    Home Sine wave Inverter/Ups Systems

    Range---650 VA – 4.8 KVA



    STABALIZERS UP TO 2000KVA, ISOLATION TRANSFORMER, C.V.C.F., D.C. POWER SUPPLY, C.V.T., LED / SOLAR LIGHTING SYSTEMS



    Conex System, Pune( India) Nilesh Tilak - Mobile no--- +91- 9822068763 & 9421058306 ; Skypee- nile5637

    Email: info@conexups.com ; nile5637@gmail.com www.conexups.com




    hi
    what motor controller is that??
    where did you buy it?how much?
    thanks

    3 replies

    I got a Univelop 3axis controller pretty cheap.

    http://www.cncgeeker.com/index.php?main_page=product_info&cPath=1&products_id=1&zenid=84b768e2953c7e6f4a14ac0cdc7771d

    Bought the stepper motors on E-bay.
    Power supply from an old pc.

    I've seen those on E-bay, what do you think of it? My controller was a little expensive so I was looking to build another CNC machine using that controller. Let me know what you think please.

    So far so good. Easy to set up. Just hook the red, yellow and 2 blacks to it for power.

    now you need to use sugar cubes to remove the "APC" logo off the front panel.

    3 replies

    u can remove logo's with sugar cubes?????????

    yep you can!
    https://www.instructables.com/id/How-to-remove-Logos-from-your-PDA--cell-phone-wit/#step1

    i wish i knew this alot earlier

    I'm interests because i want to build a mini cnc

    I'm interests because i want to build a mini cnc

    Good idea and great Instructable. Could you tell me the name of the connectors used for the motor connection?

    1 reply

    Nevermind on the question, I found the answer.