Introduction: 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

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

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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 ?

- 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

- 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

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

- 12v 2A UPS

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