Router Ups V2

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About: I am IT professional, living in Bangalore, India. As new gadgets come out everyday, we indulge in spending significant time and money on these gadgets. And our kids are learning from us, they know how to use...

Hi All,

Few months back I had made my first UPS for Routers using lithium ion battery 18650, I had made two UPS, One for my router and one for my fibre converter. It was bit of mess with two power adaptor. It was in my to do list to make single UPS with dual output...

Making this my main challenge was that

  • Single 5V charger, cannot provide enough power
  • Single Li ion battery cannot supply enough current
  • Solution was to use battery in 2S mode but TP4056 cannot be used

So in this instructable, I will share how I made my UPS with avaliable modules

Step 1: What Do We Need ?

Material

  • 2 Lithium Ion 18650 batteries ( extracted from old laptop)
  • 2S battery protection board Aliexpress link
  • CC CV Step down XL4015 Aliexpress link
  • DC Step up volt MT3608 Aliexpress Link
  • Step Down LM2596 Aliexpress link
  • Male Power connector- 5.1x2.3mm, 5.1x2.1mm
  • Female Power connector - 5.1 x 2.1mm
  • Switch
  • Wires ( Using copper wire with multi strands)
  • Case ( I made my own wooden case)
  • 12V 1.5A DC adaptor

Tools

  • Soldering Iron

Step 2: Circuit Design

We do not have any 2s lithium ion battery charging boards, like TP4056 that can supply constant voltage, current and provide battery protection on single module.

So have to break this into two

  • WH 2S80A: 2 S 18650 battery protection, capable to divide voltage across two batteries, overcharge protection, short circuit protection etc. Battery once charged does not draw current and this module will prevent overcharging. This is key for this circuit to work as UPS
  • XL4015 : To work as CC of 1.3A and CV of 8.4V
    • Green light : When Battery is completely charged
    • Blue light : Battery not charged or supplying constant current

Step 3: Setting Up XL4015

The XL4015 is a step down with adjustable CC and CV, using onboarded variable resisters .

To charge 2s lithium battery, we must set CV as 8.4 and ideal charging current upto 2A. Based on the your lithium ion batteries, these value may vary. please check datasheet before setting these value

My Charger could not supply 2A, so i set it to the max current it could supply without tripping

Anticlock : reduces voltage / current

Clockwise : increases voltage / current

If the variable resistors do not respond, disconnect power and turn clockwise till you hear "click" sound or the end. Note that now you have max current (5A), make sure your ammeter can take more than 5A . Turn anticlock to set the desired voltage with no load and then current

Step 4: 2s Battery

  • Connect the battery protection board to 2 lithium ion batteries in 2S config
  • Charge the batteries
    • Note that while charging the Blue led on XL4015 should be on, this ensures the batteries are getting requires charging current
    • When the batteries are completely charged the Green led will be on and Blue led will be off
    • If the Green and blue leds are toggling that means the power adaptor is not able to supply enough current and we must either change to new adaptor or reduce constant current

Step 5: Circuit and Testing

Build the circuit as per the circuit diagram. I added a switch to disconnect battery when I want.

You need to charge the batteries before you connect any output. Set the MT3608 to 9V and LM2956 to 5V ( this is the voltage i need for my modem. You could adjust them )

Idf you want a 12V UPS,

  • set the value MT3608 to 12V
  • Replace power supply that can supply required current
  • remove LM2956 from the circuit

Step 6: Finishing

I build my case using 4mm MDF sheet and added my logo to it.

I am adding a video to demo, UPS working

Please share your comments and suggestions

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    37 Discussions

    0
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    Amit_Jainankurg36

    Answer 27 days ago

    No, lithium Ion battery needs contant voltage and constant current. It may catch fire if over current is passed

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    ankurg36

    Question 4 weeks ago on Introduction

    Hi,
    sorry for bothering again and again. i ordered XL4015 again from amazon. it snot working . i think i am doing some mistake to check that. please help. i just connect the 12v 2amp adapter in input and check voltage at output. the output doesnt change even i rotate the screw (variable). this is 3rd time i ordered.

    seeking for your guidance.
    this is what i have from amazon.
    https://www.amazon.in/xcluma-Lithium-Battery-Charger-Step-Down/dp/B0714D9N5D/ref=sr_1_1?ie=UTF8&qid=1539747139&sr=8-1&keywords=xcluma+xl4015

    2 more answers
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    Amit_Jainankurg36

    Answer 4 weeks ago

    From the Amazon listing

    Common Problem: Output Voltage is not adjusting: Turn CC Potentiometer anticlockwise 30 rounds, before adjusting Voltage. Caution: When using this product, the input ground and output ground of the module should not be together, which will cause the current sampling resistor on the back of the board to be bypassed, so that the module can not adjust the output current, it is easy to connect the load. Burn the power chip on the module .

    0
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    Amit_JainAmit_Jain

    Reply 4 weeks ago

    Also see which one is for current and and which one for voltage

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    ankurg36

    Question 4 weeks ago on Introduction

    Hi,
    Why can't we use XL6009, in place of MT3608.?

    I oredered XL4015 thrice from Amazon, but that module is not working..how to check that ..I may doing some mistake. Can you share your experience with XL4015?

    1 more answer
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    Amit_Jainankurg36

    Answer 4 weeks ago

    Yes. Turn the variable resistor, in clock wise till you hear clicks. Then turn anti clock to adjust voltage...

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    ankurg36

    Question 4 weeks ago on Step 1

    Hi Amit,
    Can I use 12V 2A power adapter...I am not able to find 12v 1.5 A in market. One I have is 12V 0.5 A.

    2 more answers
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    Amit_Jainankurg36

    Answer 4 weeks ago

    Yes
    First charge the batteries full
    Then only connect the modem

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    ankurg36Amit_Jain

    Reply 4 weeks ago

    Thanks for quick response...I will make with 2A

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    saadland

    5 weeks ago

    Hi, nice instructable! The 2S battery Board is always necessary?? I tryed to connect 2 battery 18650 in serie and I get 7v which is what I need. I plan to use TP-4056 Module, which by what I saw over the net, you can connect flew 18650 battery in parallel, without the 2S module, just do a 6 pack in parallel and connect to TP-4056.
    What do you thing??

    1 reply
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    Amit_Jainsaadland

    Reply 4 weeks ago

    This will not work as ups. You can charge and then use.

    Batteries cannot be used and charged in parallel and series. If you do. It will short circuit

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    ankurg36

    Question 7 weeks ago on Step 6

    Hi Amit,
    i am really impressed with your work. Need some assistance as i am also trying to make the same.
    why cannot we replace XL4015 with LM2596?
    Why cannot we replace MT3608 with XL6009?

    I Tried the above thing,and y 12v 0.5A adaptor stopped working. i am not much sure about the reason.

    3 more answers
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    Amit_Jainankurg36

    Answer 7 weeks ago

    You need 2.5amp out to charge lithium ion battery in 2s config. Plus load. Since your adapter could not supply, it got burnt

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    ankurg36Amit_Jain

    Reply 7 weeks ago

    Thanks, but why can't I use xl6009 is place of MT3608?
    Can you share some link from where I can get XL4015. I ordered from amazon.the product is not working properly and giving constant voltage as of input(12v)

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    Amit_Jainankurg36

    Answer 7 weeks ago

    And you need contant voltage contstant current to charge lithium Ion battery. Simple voltage stepdown will not help

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    CelvinKetzer

    Question 2 months ago

    Hi
    I have a question about the WH 2S80A. I'm using the same in one of my projects. Now during testing of the unit I got a problem: If I connect the "MB" connector as you did I end up getting 0V out of P+ P-. On the other hand if I remove that connection the output goes up to the expected ~7V. There is also a voltage of about 3.7V at P+ to MB and P- to MB. I'm not sure if my wiring or general logic is faulty or if it is the WH 2S80A.
    I'd appreciate any help.

    1 more answer
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    Amit_JainCelvinKetzer

    Answer 7 weeks ago

    Sorry for delay, i missed your message.

    On the board due to some circuits, i also did not get proper voltage when i connect only my batteries.

    But if i connect P+ ans P- i do get 4.2v for each output

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    cvillaseñor

    8 weeks ago

    I badly need a backup PS for my modem. And this was the answer! Super easy to built and use, and very unexpensive. My modem needs 12V, so I adjust the MT3608 to 12V and leave the LM2956 at 5V for USB charging. Thanks for posting this!

    1 reply