Ups for Routers

In developing countries, power shutdowns is common... We have electricity power generator as backup, but there is a small time interval of 20 seconds during change overs.

My router gets restarted and takes 3 to 5 minutes to reconnect..

And if you are in a meeting, it becomes annoying...

Regular UPS, needs 100 to 300W to run, a modem or router is hardly 5 to 10W..

In this instructable, I will share, how to assemble simple DC UPS

Features
- Input : 5v 1A
- Output : 8v 600 mA
- Runtime : approx 1hr
- Led indicator

If you like this instructable, please press the vote button...

Update

I have been making and using DC Lithium ion battery UPS for few years now. Based on requests from friends and family, I have been modifying these circuits to support different setup and I think after 3 years, I have all the combinations as below, depending on your power requirement you can choose which version you want to make...

• Version 1 :This Page (5W)
  • Single Output 9V and 0.5A
  • Can be modified to set output to 5V, but not 12V
• Version 2:Link (15W)
  • Dual Output 9V/0.5A and 5V/1.5A
  • Can be modified to supply two 5V outputs
• Version 3: Link (24W)
  • Single output 12V/2A
  • Can be modified to step-down to 5 or 9V
• Version 4 : Link (36W)
  • Dual Output 12V and 5V
  • Output can be modified to both 5V or 9V
  • Or Single output at 12V

Step 1: What Do We Need ?

Material
- Old laptop batteries
- TP4056 Lithium ion battery charger with protection
- Step up voltage module
- 4mm MDF board
- 20X 7mm wooden strip
- Super glue
- Wires
- DC jack
- Switch

Tools
- Soldering iron
- Multi meter
- Saw
- Drilling machine

Step 2: Battery From Old Laptop

I have extracted my batteries from old laptop battery.

- Gently break open the outer shell
- Carefully disconnect batteries from circuit and each other
- Test battery voltage , it should be above 3v

I have used batteries that were around 2.5 v and yet worked fine

I will do a separate instrucable, on how to test lithium ion batteries ...

Step 3: Circuit

- Connect +B and -B from TP4056 to Lithium ion battery
- Connect the +Vout via switch to +Vin of step up module
-Connect -Vout directly to -Vin of step up module
- Adjust the variable resistor to set Output voltage to 8V
- Caution : donot make this circuit without TP4056 protection module

My router has 9v 600mA as input...
Since we are stepping up voltage from 3.7 to 9, it can cause high load on battery. So reduced it to 8v..

This circuit will work for Routers from 5v to 9v only. do not try it for 12v.

I am working on 12v UPS. Will share once completed...

Step 4: Enclosure

I choose 4mm MDF board, because I got it from packaging of one furniture, I ordered recently

Box Dimensions
85mmx 28mm x 55mm

- cut pieces as per above dimensions
- Make slots for TP4056 and output wire
- Hold the pieces together using paper tape
- Using super glue, glue all pieces except top cover
- Let it dry
- Fix top cover, using tiny screws
- Smoothen edges using sand paper

Step 5: Finishing

- Reassemble circuit inside the enclosure
- Use hot glue or double side take to secure modules and battery in place
- Do not leave anything loose inside
- I am using good copper wire

- Paint the enclosure using black acrylic paint
- Add logo

Step 6: Connect to Router

- Charge the lithium ion using a standard OEM mobile charger (5v 1A)
- Wait for the led light to go blue
- Now connect the ups to router, lights will turn red

Features
- Input : 5v 1A
- Output : 8v 600 mA
- Runtime : approx 1hr

Future
- 12v 2A UPS

If you like this instructable, please press the vote button...

https://youtu.be/k4wvL4V8HAA

Comments

[SanmoyR]

This is not a UPS. This is a power bank.

[Amit_Jain]

All UPs are power banks, you store power in batteries and then use it when needed... In this we are not converting the output to 220v AC...

This is a DC ups based on powerbank components. Can be used as powerbank too.. but not all power banks will work as ups

Ups is meant to supply power without interruption....

Many power banks can either charger or discharge at any given point...

Let's say you have a power bank that can charge and discharge at sametime,

and let's say it can supply 5v2a, the output is 10w. And the power adapter that you are using is also 5v 2a or lower. Once this is fully charged, it should be able to support device max at 10w

But with Output at 15w, a simple power bank will not work out, We need to design a bigger power bank

[saadland]

I tried to build exactly the same UPS but it do not work as expected. Once I turn on my Router, the voltage drop to 4v. I have a TP link router rated 9v, so I set up the step up converter to 8v as you. I tryed each component separatly. I tried to connected 5v to the step up converter, and out 8v, it work ok. but then when I fuse it with the TP4056, again output drop to 4v, and it is just anough to light up the main led off the router, so router is not working as supposed. I even tried different 18650s, same issue.
Dont know what more to try :(

[saadland]

very nice and easy UPS, for different 5v/12v devices!
The batterie is not always charging and supplying the device?? cause the point of a UPS is to have the battery kick in when there is a power loss to have the device (ex: Router), still on. If I may say it is a ON line UPS that you made, the battery is always supplying the device, power loss or not. So is it safe for the battery to be always working??
Hope I made myself understable...

[Amit_Jain]

It is the battery protection chip that allows this to work as a Online ups

As soon as the main source gets disconnected, the battery starts suppling and the reason could be the battery is keep at 4.2volts but no current is being supplied to battery

Tey this link

https://youtu.be/Qw4psECqpwI

[saadland]

thx very much for ur enlightenment ;)
thats small and easy to make UPS is gona be very useful for a lot of us .

[Amit_Jain]

https://www.instructables.com/id/Router-Ups-V2/

Also look at my version 2 for higher amps

[saadland]

without to have to say anything I already visited all ur instructables :D
v2 seems more approprieted since I am planning to make a UPS for a 12v device, but with only 1 step up module, not 2 like you did... maybe in future I ll have to make a 2 in 1 as u did, but for now I ll go for the 1 in 1 UPS.
Thx ;)
Edit: Finally my router, is 9V / 850mA. So not 12V as I thought...
So I will replicate exactly you UPS v1, and of course lower the exit power to 8V as you recommended ;)
I saw another able, same components as yours, but used for device 12V...
https://www.instructables.com/id/DIY-Mini-UPS-for-Router-Modem/

[Amit_Jain]

Thanks.
One point, this ups will not supply more than 400mili amps. As tp4056 can handle 5v at 1 amps as input

I am working on a 12v 2amp ups for a friend, will post it once i test it

[rosekreuze]

have you made it? 12v 1amp will also be good enough for me

[Amit_Jain]

Yes, i have. You should be able to see all my ups blogs

[rosekreuze]

sorry for the noob question but, you dont need a charger for this bms board? or the router powerbrick (not a charger) would be safe?

[Amit_Jain]

We need charger or smps that coverts 220v to 5v or 8.4 or 12.6 v based how many batteries you use

Most of the times, the original charger is not enough as we have to charge batteries and have load

Check my upsv3

https://www.instructables.com/id/UPS-for-Wifi-Routers-V3/

[rosekreuze]

i used lm317 step down board to reach my target voltage of 12.6v. everything seems fine except in an event of power lose. the charger seems pulling around 0.8amps on the battery. how do we deal with this battery power loss without adding a breaker or switch to prevent the charger from drawing power on the battery?

[rosekreuze]

i also thought of adding a w1209 thermostat controller. they are so cheap these days. the buck converter is unbearably hot when it starts charging the batteries. so w1209 might help

[Amit_Jain]

Please charge the battery and then connect... Also add a heatsink....
Or get a convertor with better amps rating... How often does the power failure lasts

[rosekreuze]

not really often, but usually lasts for quite some time. oh about the charger, my 3s usually lasts 2hours during testing. that being said i think the batteries could last even longer if the charger isnt drawing current from the battery. i search the internet and found that the batteries are experiencing a reverse discharge phenomenal when the charger is constantly plugged to the battery during power failures or if the isnt plugged to the power source. anyway ill see if a diode on the charger side could fix my issues

[Amit_Jain]

https://www.instructables.com/id/UPS-for-Wifi-Routers-V3/

[saadland]

thx a lot for the support, and also for sharing ur projects ;)

[bdmsoft]

Hi,

I too have tried same. But I am getting an issue, when routers Wifi getting on unit restarts. It keeps on happening. please help on that.