Router Ups V2

8,377

71

54

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

Share

    Recommendations

    • 1 Hour Challenge

      1 Hour Challenge
    • Sensors Contest

      Sensors Contest
    • Pets Challenge

      Pets Challenge

    54 Discussions

    0
    None
    namnai49

    2 months ago on Step 2

    hellow amit, that some nice instructable.
    i am completely new to
    this but very much interested to make my own router UPS, my router and
    media converter adapter rating is (both) 12v 0.5A, and i want to run my
    UPS off grid 3-4 hours(more is better) as my country has the worst
    loadsheding problem,.

    considering above would u add anything new to your build ? what charging circuit do i need to charge 4 or 5 li-io battery.
    Thanks.

    3 replies
    1
    None
    Amit_Jainnamnai49

    Reply 2 months ago

    Hello Namnai49,
    You could use the attached circuit, with 3s config, connect both device in parallel to it.

    Use a smps that is 12v and 3a, this circuit when fully charged should provide 12v at 1amps for 3 hrs minimum.

    I am recommending 3a input so that the batteries could charge at 2a faster as you electricity is not available

    I have built this circuit for a friend and it working good for last few months

    Thanks
    Amit

    F9YXHKJJT4TSYP8.LARGE.jpg
    0
    None
    namnai49Amit_Jain

    Reply 2 months ago

    Many thanks.. I will try it and definitely let you know the results. :)

    0
    None
    JijoJ6namnai49

    Reply 2 months ago

    Hi Amit,
    I want to make the same 12v 0.5A for my Airtel Broadband modem. Found all the above components and my 3s charging setup need 4.2x3= 12.6v/1.3x3=4A. But if I use the same setup as above and connect XL4015 output to my modem may burn because of the 4A current. How can I reduce the current ? which circute I use to stepping down amp from 4A to .5 A?. Thanks.- Jijo

    0
    None
    DracG

    3 months ago

    Hello Amit, so during mains supply, XL4015 will supply 8.4 V to LM2956 (O/p 5V) and MT3068 (O/p 9V). When on batteries, the voltage will be 7.4V from your batteries at full charge. Will LM2956 and MT 3068 be able to output what is desired, now that input voltage is different from batteries? I thought that they have been configured first for 8.4 V to output 5V and 9V and will 7.4, it will not work with the same output.

    8 replies
    0
    None
    Amit_JainDracG

    Reply 3 months ago

    Hi DracG,
    When fully charged the batteries are also at 8.4v. At cut off voltage 7.4v the dc boost converter will still supply 9v and step down 5v

    Regards
    Amit

    0
    None
    DracGAmit_Jain

    Reply 3 months ago

    Hi Amit,

    My circuit requirement is 12v, 2A and I am sure LM2596 will not be able to sustain long term at 2A though their ratings may say that.

    1. Will XL4015 sustain through continuous 3A? do we need any heat sink?
    2. What board would you recommend for stepping down from 19V 3A to 12V 2A?

    I plan to go for 3S arrangement, where I will have 14V from XL4015 to charge 12.6V for 3 18650

    Thanks

    0
    None
    DracGDracG

    Reply 3 months ago

    Hi Amit, can you respond to above?

    0
    None
    Amit_JainDracG

    Reply 3 months ago

    Hi DracG

    I recommend using 3s config for battery. You should buy xl4015 that supports upto 5a... Mine did, without any heat sink

    I recently made 12v 2a circuit using a 12v 4a smps, XL4015 and 3s bms
    The smps has variable voltage adjust, so I set it at 13v, then i set XL4015 at 12.6v and 3A... Connected to a 3S BMS and out to load

    Hope this helps, I can draw a circuit diagram using above and share

    0
    None
    DracGAmit_Jain

    Reply 3 months ago

    Ok, but the main concern remains for LM2596. I checked the datasheet and found that it will not sustain long at 2A. What did you use? did it work for continuous run? My supply is 19.6v, 3A - old laptop power supply.

    Circuit dia will surely help

    0
    None
    Amit_JainDracG

    Reply 3 months ago

    My 3S UPS diagram attached,
    LM2596 will not work at 2A, I used it uptill 1.5A not at 2A

    3S UPS.png
    0
    None
    Amit_JainDracG

    Reply 3 months ago

    Hi DracG,

    I recommend using 3s config for battery. You should buy xl4015 that supports upto 5a... Mine did.

    I recently made 12v 2a circuit using a 12v 4a smps, XL4015 and 3s bms

    The smps has variant voltage option, so i set it at 13v, then i set XL4015 at 12.6v and 3A...

    Hope this helps

    0
    None
    DracGAmit_Jain

    Reply 3 months ago

    Thanks Amit, you didn't mention on LM2596 as it would need a step down from batter to router. Did it sustain at 2A?

    0
    None
    gkns

    Question 3 months ago

    Hi, good article.
    What is the back-up time you are getting out of 2 batteries?

    Can I charge 3S with this CV charging module?

    1 answer
    0
    None
    Amit_Jaingkns

    Answer 3 months ago

    Hi GKNS,

    No, charging lithium ion batteries should be with CC and CV
    I have recently made a UPS for a friend with 3S config

    I used a 3S BMS 4A with XL4015 as CC CV
    I have set CV as 12.6V and CC at 3A


    Regards
    Amit

    0
    None
    ankurg36

    Question 7 months ago on Introduction

    Hi,
    Xl4015 still not working..
    Can I use L2596 step down with 12v 2amp adaptor to charge batteries??

    1 answer
    0
    None
    Amit_Jainankurg36

    Answer 7 months ago

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

    0
    None
    ankurg36

    Question 8 months 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