Long Backup 🔋 WIFI Router UPS Making for Lead Acid Lithium Battery: A Step-by-Step Guide

Long Backup 🔋 WIFI Router UPS Making for Lead Acid Lithium Battery

Are you tired of your WiFi router going offline during power outages? In today’s hyper-connected world, losing your internet connection can be a major disruption, especially when you’re working from home or streaming your favorite content. A cost-effective and efficient solution is to build your own Long Backup WiFi Router UPS using lead acid or lithium batteries and an LM2596S-ADJ voltage regulator. This DIY guide will take you through the process of creating a stable UPS that supports 12V, 9V, and 5V outputs.

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Why Build Your Own WiFi Router UPS?

A UPS for your router ensures you remain connected to the internet during power outages, enabling uninterrupted work, entertainment, or communication. Pre-built router UPS units can be costly, so building your own system is a cost-effective, customizable solution. With this guide, you’ll get the chance to design your own PCB to make the project more compact, neat, and durable.

Key Components for Your WiFi Router UPS

Here’s a list of components needed to build this DIY project:

LM2596S-ADJ Buck Converter: For adjustable output voltage (12V, 9V, 5V).
Schottky Diode (1N5822): Prevents reverse current flow.
PNP Transistor (S8550): For automatic switching between AC power and battery backup.
Lead Acid/Lithium Battery: 12V, 7Ah or higher for backup.
AC 2-pin Terminal Block: To connect the AC input power.
14.4V Power Supply: Input power to charge the battery and supply power to the router.
Output Terminals: For connecting to the WiFi router.

Circuit Diagram: Explanation

Below is a detailed description of how the components interact:

Power Input (AC Source) & Battery Charging:
- The AC power source (14.4V) is connected through the AC 2-pin terminal block to power the router and simultaneously charge the battery.
- When AC power is available, it powers the WiFi router directly via the LM2596S-ADJ buck converter, while also charging the battery for future use.
Voltage Regulation with LM2596S-ADJ:
- The LM2596S-ADJ buck converter steps down the 14.4V input to the desired output voltages (12V, 9V, or 5V) needed by the WiFi router. The output voltage is adjustable using the onboard potentiometer of the LM2596S-ADJ.
- A multimeter is used to set the exact voltage your router requires.
Automatic Changeover with PNP Transistor & Schottky Diode:
- The Schottky diode (1N5822) ensures there’s no reverse current flow from the battery back into the power supply.
- The PNP Transistor (S8550) is used for automatic changeover between AC power and battery backup. When AC mains power is present, the PNP transistor switches to supply power directly to the router. When the AC mains power fails, the PNP transistor switches to battery power seamlessly.
Battery Backup:
- The 12V lead-acid or lithium battery provides backup power during an outage. The battery gets charged via the same power input when the mains is available.
Output to Router:
- The output from the LM2596S-ADJ buck converter is connected to the router, and depending on the router’s input requirement, you can set the voltage to 12V, 9V, or 5V.

Circuit Diagram

Here’s the circuit diagram for the WiFi Router UPS:

The Schottky diode (1N5822) is placed to prevent reverse current, and the PNP transistor (S8550) handles automatic changeover. The LM2596S-ADJ provides the regulated voltage to your router.

PCB Design on PCBWay

Step 1: Design the PCB Layout

To simplify the wiring process and give your project a professional look, you can create a PCB (Printed Circuit Board) using PCBWay.

Use PCB Design Software: You can use tools like Eagle, KiCAD, or EasyEDA to design the PCB layout. Arrange the components such as the LM2596S-ADJ module, Schottky diode, PNP transistor, and input/output terminals as per the circuit diagram.
PCB Layout Tips:
- Keep the power lines (14.4V, ground) thick for high current handling.
- Place the Schottky diode near the battery for reverse polarity protection.
- Position the PNP transistor close to the battery and AC input to enable fast switching.
Schematic to PCB: Once your schematic is ready, generate the PCB layout, route the traces, and verify all connections.

Step 2: Upload Your PCB Files to PCBWay

Once your design is complete, follow these steps to get your custom PCB made by PCBWay:

Generate Gerber Files: Your PCB design software will allow you to generate Gerber files. These are the files needed by PCB manufacturers to produce your board.
Create an Account on PCBWay: Go to PCBWay.com and sign up for a free account if you don’t have one.
Upload Your Gerber Files: On the PCBWay website, navigate to the PCB Instant Quote page and upload your Gerber files. This will give you an immediate quote for manufacturing your custom PCB.
Select Board Options:
- Choose 2 layers for this simple design.
- Opt for standard thickness (1.6mm) and copper weight (1oz) for durability.
- You can select a green solder mask for standard appearance or customize the color based on your preference.
Submit Your Order: Review your design and submit the order. PCBWay will manufacture the PCB and ship it to you.

Step 3: Assemble the PCB

Once you receive your PCB from PCBWay, solder the components onto the board:

Start by soldering the smaller components such as the Schottky diode and PNP transistor.
Next, solder the LM2596S-ADJ buck converter.
Connect the input/output terminals and the AC 2-pin terminal block.
Lastly, connect the battery and WiFi router to the respective outputs.

Video Reference:

Conclusion

By designing your own WiFi Router UPS using the LM2596S-ADJ, a Schottky diode, and a PNP transistor, you can ensure uninterrupted internet during power outages. The addition of a custom PCB from PCBWay will make the setup more robust, professional, and compact.

This DIY solution provides flexible voltage outputs (12V, 9V, or 5V) and automatic switching between AC power and battery backup, ensuring that your router stays online even when the lights go out. Enjoy the reliability and customizability of your homemade UPS system!

Start your project today and stay connected, no matter what happens!