🔋 How to Make a Hybrid Solar-Based WiFi Router/ONU UPS

Are you tired of internet disconnections during power failures? In this detailed guide, we’ll show you how to build a Hybrid Solar-Powered UPS system for WiFi Routers and ONU devices, supporting 12V, 9V, and 5V outputs using a lead-acid battery. This smart DIY UPS not only switches automatically between power sources but also supports solar charging, making it perfect for off-grid or unreliable-grid areas.

✅ What is a Hybrid WiFi Router UPS?

A Hybrid WiFi Router UPS is an uninterrupted power supply system that automatically powers your router using:

A DC adapter (when available),

• A DC adapter (when available),

A 12V Lead Acid Battery during power cuts,

• A 12V Lead Acid Battery during power cuts,

And solar power using an external solar charge controller.

• And solar power using an external solar charge controller.

It provides regulated outputs for 12V, 9V, and 5V devices, suitable for most routers, ONUs, microcontrollers, or USB-powered devices.

🧠 How It Works – Circuit Overview

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This DIY circuit, titled "WiFi UPS LEAD ACID BATTERY" and designed using EasyEDA, uses a smart MOSFET-based switching system combined with LM2596 buck regulators.

⚙️ Power Input:

DC Adapter Input (9V–12V)

• DC Adapter Input (9V–12V)

Battery Input (12V Sealed Lead Acid)

• Battery Input (12V Sealed Lead Acid)

Solar Panel Charging (via external solar controller)

• Solar Panel Charging (via external solar controller)

🔁 Auto Changeover:

The IRF9540 MOSFET detects whether adapter power is available.

• The IRF9540 MOSFET detects whether adapter power is available.

If the adapter is present, the MOSFET blocks battery use.

• If the adapter is present, the MOSFET blocks battery use.

When the adapter is absent, the MOSFET automatically switches to battery power.

• When the adapter is absent, the MOSFET automatically switches to battery power.

1N5822RLG Schottky Diodes ensure no backfeed and protect each section.

• 1N5822RLG Schottky Diodes ensure no backfeed and protect each section.

⚡ Voltage Regulation:

LM2596T-5.0 outputs 5V for USB or microcontrollers.

• LM2596T-5.0 outputs 5V for USB or microcontrollers.

LM2596T-ADJ configured to output 9V for ONUs.

• LM2596T-ADJ configured to output 9V for ONUs.

Another LM2596T-5.0 provides a stable 12V output for routers and cameras.

• Another LM2596T-5.0 provides a stable 12V output for routers and cameras.

Each regulator uses 470uH inductors and 220uF capacitors for stable ripple-free DC.

• Each regulator uses 470uH inductors and 220uF capacitors for stable ripple-free DC.

🧰 Component List (Line by Line)

1 × LM2596T-5.0 (Fixed 5V Buck Converter)

• 1 × LM2596T-5.0 (Fixed 5V Buck Converter)

1 × LM2596T-ADJ (Adjustable Buck Converter – Set to 9V)

• 1 × LM2596T-ADJ (Adjustable Buck Converter – Set to 9V)

1 × LM2596T-5.0 (Fixed 12V Buck Converter)

• 1 × LM2596T-5.0 (Fixed 12V Buck Converter)

1 × IRF9540 P-Channel MOSFET

• 1 × IRF9540 P-Channel MOSFET

9 × 1N5822RLG Schottky Diodes

• 9 × 1N5822RLG Schottky Diodes

4 × 470uH Inductors

• 4 × 470uH Inductors

8 × 220uF Capacitors

• 8 × 220uF Capacitors

1 × 10kΩ Resistor

• 1 × 10kΩ Resistor

1 × 330Ω Resistor

• 1 × 330Ω Resistor

1 × 1kΩ Resistor

• 1 × 1kΩ Resistor

1 × 220Ω Resistor

• 1 × 220Ω Resistor

1 × DC Jack (FIX9V/FIX12V DC-072-165A)

• 1 × DC Jack (FIX9V/FIX12V DC-072-165A)

1 × 2-Pin Battery Connector (TH-2P-5.00)

• 1 × 2-Pin Battery Connector (TH-2P-5.00)

1 × USB Type-A Female Port

• 1 × USB Type-A Female Port

3 × 2-Pin Header Output Terminals (12V, 9V, 5V)

• 3 × 2-Pin Header Output Terminals (12V, 9V, 5V)

1 × 10V Zener Diode

• 1 × 10V Zener Diode

1 × 12V Lead Acid Battery

• 1 × 12V Lead Acid Battery

1 × Solar Charge Controller (External, for solar input)

• 1 × Solar Charge Controller (External, for solar input)

Wires, PCB or Perfboard, Heatsinks (optional)

• Wires, PCB or Perfboard, Heatsinks (optional)

🛠️ Step-by-Step Assembly

🔧 1. Prepare Your PCB or Perfboard

Use EasyEDA to print your PCB or arrange components on a perfboard following the schematic.

🔧 2. Solder the Power Input Section

Connect DC jack and battery connector.

• Connect DC jack and battery connector.

Add the protection diodes (1N5822RLG) and IRF9540 MOSFET.

• Add the protection diodes (1N5822RLG) and IRF9540 MOSFET.

🔧 3. Install the Buck Converters

Each LM2596 module should have its own inductor, capacitors, and diode.

• Each LM2596 module should have its own inductor, capacitors, and diode.

Adjust the LM2596-ADJ for 9V output using a multimeter.

• Adjust the LM2596-ADJ for 9V output using a multimeter.

🔧 4. Connect Output Terminals

Use pin headers or terminals to route 12V, 9V, and 5V outputs.

• Use pin headers or terminals to route 12V, 9V, and 5V outputs.

Add the USB Type-A port for 5V output.

• Add the USB Type-A port for 5V output.

🔧 5. Final Testing

Power the circuit from the adapter and check outputs.

• Power the circuit from the adapter and check outputs.

Disconnect adapter and ensure it switches to battery backup.

• Disconnect adapter and ensure it switches to battery backup.

☀️ Solar Panel Integration (Optional)

This circuit does not include a charge controller. To integrate solar charging:

Use a 10W–20W solar panel (depending on load).

• Use a 10W–20W solar panel (depending on load).

Connect it to an external solar charge controller.

• Connect it to an external solar charge controller.

Route the controller’s battery output to the battery terminal of this circuit.

• Route the controller’s battery output to the battery terminal of this circuit.

💡 Tips & Safety Notes

Use a fused adapter line to avoid short circuits.

• Use a fused adapter line to avoid short circuits.

Ensure heat dissipation using heatsinks on LM2596 ICs.

• Ensure heat dissipation using heatsinks on LM2596 ICs.

Mount the circuit in a plastic enclosure with ventilation holes.

• Mount the circuit in a plastic enclosure with ventilation holes.

Use a 12V 7Ah battery for best performance with routers/ONUs.

• Use a 12V 7Ah battery for best performance with routers/ONUs.

📥 Download the Circuit Diagram

✅ Designed in EasyEDA by Estiakkhan

• ✅ Designed in EasyEDA by Estiakkhan

✅ Version: V1.1

• ✅ Version: V1.1

✅ Date: 2024-11-21

• ✅ Date: 2024-11-21

📌Video Reference:

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📌 Conclusion

Creating your own Hybrid WiFi Router UPS can save you from internet interruptions and also reduce electricity costs if you integrate a solar system. This DIY project is ideal for students, engineers, and hobbyists looking to learn power management and renewable energy integration.

Stay online, save power, and learn electronics – all at once!