Router Ups V2

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Introduction: Router Ups V2

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 a…

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

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 :Link (5W)
    • Single Output 9V and 0.5A
    • Can be modified to set output to 5V, but not 12V
  • Version 2:This Page (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

  • 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

1 Person Made This Project!

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73 Discussions

0
smadhwal
smadhwal

Question 3 months ago

Hi Amit,

Great project & explanation!

Would any of the options work for my 12V,1.5Amp router? I have a 12V, 3Amp adapter available

(i) 12V, 3Amp=>XL4015=>2S BMS+Battery=>MT3608=> output router
(a) Would this work?
(b) Would it be possible to use 4 LiPo's, 2S2P? If yes what would be the current setting on XL4015

(ii) Another option I am considering is adapter output straight to router through a diode. This adapter also supplies (in parallel) the XL4015=>BMS+Battery=> MT3608=> diode => output
I adjust the MT voltage to be lower than the parallel circuit. This way when ever power is available the router is fed directly.

I am not really keen on investing more on another adapter. I have a pile of components already and am running out of space....besides the money!

The battery time required is typically 30-60 seconds, 5 times a day.

Look forward to your advise.

Thank you
0
Amit_Jain
Amit_Jain

Answer 3 months ago

Hi Smadhwal,
I just published a new version of the router
https://www.instructables.com/id/UPS-for-WiFi-Router-V4/

To Answer you,
1. Use 3S battery config and your 12V adaptor to charge the 3S battery via a BMS and XL4015
2. You can use 2s2P config, with 8.4V & 3 to 3.5 amps, as your supply is 12V 3A, It will charge bit slow. At full charged, this will give you over 12Hr of backup. In my view 2S 1P is enough..
3. Diode can be used, share your diagram. As there is approx 1V drop on a the diode, so the final output may be lesser than 11v, Your router may or may not work.
4. Alternately, you could use a relay to switch... The coil is power by the original power adapter, The Router at common, The NO ( Normaly Open ) to Original Power and NC to UPS/battery that you have fully charged.
- Once a week, take out the batteries and charge them
- Or use the same power supply at higher ratings to charge them
0
saadland
saadland

Reply 9 days ago

Your option 4 is exactly what I am about to do but for UPS v1!! cause I only need 8.5V.
Why add a relay to the build?? Because when the battery is full the leds of the TP4056 are both blinking!! Maybe because the battery is draining at the same time!! So this way, the battery will be charged without to be disturbed, and when completed the TP4056 will light up Blue and the Router is supplied by its original charger.
And when the power goes off the state of relay change, and at this time, the basttery start draining!!!
All that because I want the TP4056 to behave as it is supposed to.
And of course I will stepDown the 9v >> 5v for the TP4056!

0
manu_reddy123
manu_reddy123

Question 8 weeks ago on Step 4

When it is not connected to the router.. and want to use it after power is gone.. Would it work

0
rishi.pandey
rishi.pandey

Question 4 months ago

Hi Amit, thanks for the detailed instructions. I'm planning to make a UPS for my internet router 12v 1.5A. I plan to use 3s charging board for 3x18650 batteries along with XL4015 (5A). My question is should I use my original router adapter 12v 1.5A for the main power source or do I need another one with higher capacity? Using 3 batteries is sufficient or can I do with 2 or 4 as well. I'm looking for a backup time of max 15 mins. so that's not an issue. If you could help me with the circuit design it would be great. Thanks !

1
Amit_Jain
Amit_Jain

Answer 4 months ago

Hi Rishi,
Each battery needs approx1a to charger. So in 3s you would need 3a + 1.5a= 4.5a
If you charge all batteries then the required current is lesser than the peak or max...

Your current charger is not enough, as the batteries need to be charged sometimes ....

So my recommendation is using 3s and a smps 12v 4a, set smps to 12.6v. and then on XL4015 just set current at 3.5a

0
rishi.pandey
rishi.pandey

Reply 4 months ago

Thanks Amit. I did not wanted to add extra components so what if I use 1s or 2s battery and a step up coverter. Would it be fine? In your answer did you mean to set the output current as 4.5 and not 3.5?

0
Amit_Jain
Amit_Jain

Reply 4 months ago

1s will not be able to provide 12v 1.5amps... even with a step up.your power supply will burnout

For 2s, you need 8.4v and 2a for battery plus another 18 w for your router

You can use a supply between 3.5 and 4.5a for 12v in 3s

0
simeoudakis
simeoudakis

6 months ago

is mt3608 connected at right polarity in diagram?

0
Amit_Jain
Amit_Jain

Reply 6 months ago

I made mistake in the diagram

0
dashawk
dashawk

Question 9 months ago

Hi Amit,

I am so inspired by this instructible. I am just wondering if I could put a schottky diode based in your image? I am not sure where to put it.

ups-with-smps.jpg
0
Amit_Jain
Amit_Jain

Reply 9 months ago

May be at the output in series, to avoid overcurrent drwan by the load

0
saadland
saadland

Answer 9 months ago

why do you want to add the schottky diode exactly??
Anyway, diode must be added on (+) outpout, so yellow line, on your image.

0
DracG
DracG

1 year 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.

0
Amit_Jain
Amit_Jain

Reply 1 year 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
DracG
DracG

Reply 1 year 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
Amit_Jain
Amit_Jain

Reply 1 year 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
DracG
DracG

Reply 1 year ago

Hey Amit,

I finished this circuit and it was running fine while testing i.e. there is no router reset when i switch off the main power.

However, during the actual main power failure, router remains on with internet status turns off. Internet status turns on when power comes back. This doesnt happen while testing when i switch off the power supply. Any idea?

0
Amit_Jain
Amit_Jain

Reply 1 year ago

This means there is power failure at your isp or at the fibre switch distribution in your apartment

0
DracG
DracG

Reply 1 year ago

You may be right... will check on this. The other observation is that blue LED on XL4015 remains switched on (battery charging) when load is connected. It will be green when there is no load and is in test mode. Did you get this observation as well?