Ups for Routers

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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...

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...

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

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    28 Discussions

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    saadland

    3 months ago

    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...

    6 replies
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    Amit_Jainsaadland

    Reply 3 months ago

    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

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    saadlandAmit_Jain

    Reply 3 months ago

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

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    saadlandAmit_Jain

    Reply 3 months ago

    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 dd, but for now I ll o for a 1 in 1 UPS.
    Thx ;)

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    Amit_Jainsaadland

    Reply 3 months ago

    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

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    saadlandAmit_Jain

    Reply 3 months ago

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

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    bdmsoft

    1 year ago

    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.

    1 reply
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    Amit_Jainbdmsoft

    Reply 1 year ago

    hi, my circuit will not work for 12v 1.2A... one lithium ion battery is not enough i supply this much power....

    Please share your circuit i can suggest a variant to my circuit using 2s or 3s battery pack

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    Cekpi7

    1 year ago

    Good idea, except you should add original 8v supply, and then switch to battery when there is no power (using relay or mosfets), if you use it like you made it, you battery will be constantly in charge mode (since you are drawing current and mt3606 thinks battery is not charged up) so it may damage battery

    6 replies
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    Amit_JainCekpi7

    Reply 1 year ago

    hi,

    Yes, the tp4056 module runs constantly to provide 1A. but there is a MOSFET on the module that cuts off current to battery. So over charge , over current is prevented...

    I charged the lithium ion battery, to avoid heating. once the battery is fully charged, tp4056 does not get hot.

    I did try putting relays and MOSFET, but all of them failed as the input voltage did not die for 2secs on power failure. Adding decay resistor did not help

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    Cekpi7Amit_Jain

    Reply 1 year ago

    Usually tp4056 recognizes cutoff at 4.2v, since you are drawing 1A from battery voltage should drop under 4.2v, dont know if it works as i think, since i have some components left i might try to do something like this (only for fun, i rarely get power blackouts)

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    Amit_JainCekpi7

    Reply 1 year ago

    So TP4056 does what you say... but this one has a protective circuit with DW01 and mosfets, which does the job. it took me some time to understand as well

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    Cekpi7Cekpi7

    Reply 1 year ago

    chargin module* not mt3606

    also you are using whole time 1A from that charger, which is maximum current it can deliver so it may overheat, also i had some problems with step up module when i used more than 1A on input on longer periods

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    Cekpi7Cekpi7

    Reply 1 year ago

    sorry for spam, but also you can power up router with 5v, i tried on 3 routers that i have and it works on all of them :)

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    Amit_JainCekpi7

    Reply 1 year ago

    good video, but when you add load, the power consumption will go high... in isolation it can work...

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    BruceF11

    1 year ago

    Can you say more about the "Step up voltage module" That's pretty generic.

    Overall I like the concept.

    2 replies
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    gowri

    1 year ago

    Good idea.kindly make a viedio and upload if possible.voted good luck.