🚀 DIY Long Backup Mini DC IPS | Make at Home Using a UPS Transformer! 💡

$5 10pcs 1-2 layer PCB Order from PCBWay: https://www.pcbway.com/?from=technology4power 💡 PCBWay 7th Project Design Contest: https://www.pcbway.com/activity/7th-project-design-contest.html

Introduction

Building a Mini DC IPS (Instant Power Supply) at home can be a rewarding project that equips you with a backup power solution for low-power DC appliances. This tutorial will guide you step-by-step through the process of creating a 10A Mini DC IPS using readily available components. With a well-designed circuit and attention to detail, you’ll have a reliable DC power backup system in no time.

Whether you’re an electronics enthusiast or just starting out, this guide provides comprehensive instructions and insights to ensure success.

Key Features of the Mini DC IPS

Compact and Portable: Small enough for home or DIY workshop use.
High Current Capacity: Delivers up to 10A output, suitable for most DC devices.
Relay-Controlled Load Management: Ensures seamless switching and control of connected loads.
LED Indicators: Provides real-time feedback on power and load status.
Safe Design: Includes protection features to prevent component damage.
Easy-to-Build Circuit: Designed with simplicity and efficiency in mind, perfect for DIYers.

Detailed Components Required

Component	Specification	Quantity	Purpose
Diodes	6A10	5	Rectification and flyback protection
Capacitors	1000µF, 680nF	2	Smoothing and filtering voltage
Resistors	1kΩ	3	Current limiting for LEDs and relay
Relay	5V SPDT	1	Switching load on/off
LED Indicators	5mm Red LEDs	3	Status indication (Power, NC, NO)
Flyback Diode	1N4007	1	Protection for relay
Connectors	2P/3P connectors	4	Easy input/output connections
PCB	Universal or Custom	1	Circuit mounting
Wires	Multi-strand wires	As needed	Connections between components
Transformer	AC 220V to 12V	1	Primary voltage conversion

Understanding the Circuit Diagram

Below is an overview of the circuit's main sections, designed for simplicity and efficiency. The attached schematic diagram will help you follow along as you assemble the components.

Bridge Rectifier:
- Four diodes (D1–D4) form a bridge rectifier, converting the AC input (220V) to DC voltage.
- This is essential for powering the relay and other DC components in the circuit.
Voltage Filtering and Smoothing:
- Capacitors (1000µF and 680nF) stabilize the rectified DC, reducing voltage fluctuations.
- This ensures a clean power supply for the relay and connected devices.
Relay Operation:
- The 5V relay (LOAD1) manages the connection between the DC load and the power source.
- Resistors control current flow to the relay and LED indicators, while the flyback diode (1N4007) protects the circuit from voltage spikes.
LED Indicators:
- Three LEDs provide status feedback:
  - Power LED (PWR): Lights up when the system is powered.
  - NC LED: Indicates the normally closed state of the relay.
  - NO LED: Indicates the normally open state of the relay.
Load and Battery Connections:
- Clear terminals are provided for the DC load and battery input, making the system user-friendly.

$5 10pcs 1-2 layer PCB Order from PCBWay: https://www.pcbway.com/?from=technology4power 💡 PCBWay 7th Project Design Contest: https://www.pcbway.com/activity/7th-project-design-contest.html

Step-by-Step Assembly Instructions

Gather Your Tools and Components:
- Tools required: Soldering iron, multimeter, wire cutter, and a small screwdriver.
- Double-check all components to ensure they meet the required specifications.
Set Up the Bridge Rectifier:
- Arrange the four diodes (D1–D4) in a bridge configuration.
- Connect the AC input to the rectifier and verify the DC output using a multimeter.
Add Filtering Capacitors:
- Solder the 1000µF and 680nF capacitors to the rectifier output.
- Ensure correct polarity for the electrolytic capacitor (1000µF).
Wire the Relay and Flyback Diode:
- Connect the relay coil to the DC supply through a 1kΩ resistor.
- Place the flyback diode (1N4007) across the relay coil to prevent voltage spikes.
Install the LED Indicators:
- Connect the LEDs to the respective points in the circuit.
- Use resistors to limit current and prevent LED damage.
Test the Circuit:
- Power the circuit and check for LED illumination.
- Verify relay operation by connecting a small DC load (e.g., a 12V LED light or fan).
Secure on a PCB:
- After testing, transfer the circuit to a PCB or custom board for a durable setup.

Common Issues and Troubleshooting

Problem: LEDs do not light up.
Solution: Check for loose connections or incorrect polarity of components.
Problem: Relay does not activate.

Solution: Verify the voltage at the relay coil and check the flyback diode orientation.
Problem: Output voltage fluctuates.
Solution: Ensure the capacitors are properly soldered and functional.

Applications of the Mini DC IPS

Emergency Power Supply: Provides backup for low-power DC appliances like LED lights and fans.
Portable Electronics: Perfect for powering small electronics in off-grid scenarios.
DIY Hobby Projects: Acts as a power source for experimenting with DC devices.

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Video Reference:

$5 10pcs 1-2 layer PCB Order from PCBWay: https://www.pcbway.com/?from=technology4power 💡 PCBWay 7th Project Design Contest: https://www.pcbway.com/activity/7th-project-design-contest.html

Conclusion

This DIY Mini DC IPS project is a simple yet effective way to gain hands-on experience with electronics. With minimal components and straightforward assembly, you can create a reliable backup power system for your home or workshop. By following this detailed guide and using the provided circuit diagram, you’ll have a functional and efficient IPS ready in no time.

Don’t forget to share your experience and improvements in the comments!