🧠 Introduction

Power cuts in off-grid areas can disrupt internet connectivity. With the rise of solar systems, a Hybrid WiFi Router UPS offers a smart solution by powering your router using solar energy and battery backup. In this post, you'll find the complete schematic, components, and a working explanation to build your own DIY solar-powered UPS for routers.

🔍 What is a Hybrid WiFi Router UPS?

1. A Hybrid WiFi Router UPS is an intelligent backup system that:
2. Runs your WiFi router, ONU, or modem without interruption
3. Uses solar power, battery backup, and grid power smartly
4. Automatically switches power source based on availability
5. Keeps your internet online during loadshedding or power failure
6. Unlike commercial UPS systems, this DIY solar-powered UPS is cost-effective, customizable, and perfect for remote or off-grid locations where stable power isn’t always available.

🖼️ Circuit Diagram (Schematic Overview)

This well-designed schematic includes multiple power sources (solar, adapter, battery) with automatic switching logic controlled by a P-Channel MOSFET (IRF9540) and a set of Schottky diodes (1N5822) for low voltage drop and fast recovery.

The power is stabilized and regulated using LM2596 Buck Converter ICs, each responsible for delivering reliable outputs like 5V, 9V, and 12V – suitable for various routers, ONUs, and IoT devices.

🔧 Components Used

1. Here's the component list from the circuit:
2. LM2596T-5.0, LM2596-ADJ: Buck converter ICs for 5V, 9V, and 12V output regulation.
3. IRF9540 P-MOSFET: Controls switching between adapter and battery.
4. 1N5822 Diodes: Schottky diodes for low voltage drop and reverse current protection.
5. 470uH Inductors, 220uF Capacitors: Used for buck converter filtering.
6. USB Output Port: For powering WiFi Router or ONU.
7. DC Jacks (DC-072-165A): Adapter and Output ports.
8. Resistors, Potentiometers: Voltage control & biasing.

⚙️ How the Circuit Works – Step-by-Step

1. Dual Input Power Source

DC Adapter and Solar Panel feed power into the system.

Diodes D1, D2 ensure isolation between sources.

The IRF9540 MOSFET intelligently selects between Adapter and Battery.

2. Battery Charging Logic

When DC input is present, it charges the 12V Lead-Acid Battery.

Schottky Diodes block reverse current from battery to input.

Capacitors filter noise and ripples for stable charging.

3. Auto Power Switch to Battery During Blackout

When DC input fails, the MOSFET allows battery to take over automatically.

There’s no relay used, so the switching is instant and silent.

4. Output Voltage Regulation

LM2596-5.0: Provides stable 5V for USB devices or router input.

LM2596-ADJ: Tunable for 9V or 12V routers.

Optional XL6009 can be used if boosting is needed beyond input voltage.

5. USB Output

The final power output is through a USB-A port or DC pin for connecting WiFi Router, ONU, or IP Camera.

🛠️ DIY Build Instructions

1. Solder Components as Per Schematic
2. Use a clean PCB or a veroboard
3. Test All Power Rails
4. Ensure correct voltage outputs from LM2596 modules
5. Connect Battery with Fuse
6. Add 2A or 5A fuse inline with the battery for safety
7. Connect Router or ONU to USB Port
8. Check the voltage your router needs (5V/9V/12V)
9. Final Enclosure
10. Place all components in a ventilated plastic/metal box

Video Reference:

⚠️ Safety Tips

1. Use only lead-acid or LiFePO4 batteries (NOT Li-ion without protection)
2. Always check polarity before powering the circuit
3. Use heat sinks with LM2596 if current >1A
4. Keep away from water, dust, and excess heat
5. Add battery overcharge protection module if needed (optional)

📦 Application Areas

1. WiFi Routers, ONU Devices
2. Mini Surveillance Systems
3. IoT Gateway Devices
4. Raspberry Pi or ESP32 Offline Projects
5. Remote Internet Monitoring
6. Rural or Disaster Recovery Networks

🗣️ Final Thoughts

Creating your own Hybrid WiFi Router UPS for Solar System is not only a rewarding DIY project but also a lifesaver during power cuts. This system ensures your router and internet stay live using clean solar energy and affordable components.

Whether you’re a hobbyist, tech enthusiast, or someone living off-grid, this project will save money, reduce power dependency, and give you peace of mind.