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In this project, I demonstrate how to breathe new life into an old, discarded UPS chassis by converting it into a custom Portable Power Station. Using a 12V 20Ah LiFePO4 battery pack and a custom Pure Sine Wave inverter circuit, this station provides clean, reliable 220V power for your portable electronics and DIY projects.Project OverviewThis DIY power station is designed to be a budget-friendly and compact solution for off-grid power needs. By repurposing an old UPS enclosure, we benefit from built-in AC sockets and a rugged frame, while upgrading the internals for significantly better performance and capacity.Key FeaturesOutput: 200W Continuous Pure Sine Wave (clean power for sensitive electronics).Storage: 12V 20Ah LiFePO4 battery pack.Recycled Design: Reuses existing UPS hardware for a professional finish.Modular: Easily serviceable and upgradeable.Hardware & ComponentsComponent PurposeOld UPS Chassis Housing, AC sockets, and power cable management. 12V 20Ah LiFePO4 BatteryHigh-density energy storage.Pure Sine Wave Inverter PCB Custom design for clean 220V output.
JLCPCB FabricationHigh-quality PCB manufacturing and SMT assembly.Wiring/HardwareConnectors, switches, and heat-shrink tubing. How It WorksThe system follows a straightforward architecture:1. Energy Storage: The 12V 20Ah LiFePO4 pack acts as the reservoir.2. Inversion: The custom inverter PCB takes the 12V DC input and converts it into a stable, 50Hz/60Hz 220V pure sine wave.3. Distribution: The output is routed through the original UPS chassis outlets, maintaining a clean look and high safety standards.Implementation StepsStep 1: Chassis PreparationStrip the old internal electronics from the UPS shell. Keep the AC power input and output terminals intact to save time on fabrication.
Step 2: Battery AssemblyConstruct the 12V 20Ah LiFePO4 battery pack. Ensure proper busbar connections and add a BMS (Battery Management System) to protect against overcharging and short circuits.
Step 3: PCB Design & Fabrication with JLCPCB Step 3: PCB Design & Fabrication with JLCPCB
To achieve a reliable and compact inverter, I designed a custom PCB. I used JLCPCB for high-quality manufacturing and SMT assembly, which ensures the board can handle the current loads safely and reliably. I also use JLCONE (JLCPCB's official desktop platform) to order my PCB and track my orders
Pro Tip: Use the JLCONE Desktop to streamline your workflow. It is a unified platform for managing your JLCPCB services-including PCB fabrication, PCBA, 3D printing, and CNC machining. It offers one-tap ordering, real-time tracking, and in- app support to make your prototyping journey much faster and more efficient.
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Step 4: Final AssemblyMount the battery and the inverter board inside the chassis. Wire the battery to the inverter input and the inverter output to the chassis sockets. Ensure all high-voltage wiring is properly insulated.
ResourcesFor the schematics, and detailed assembly tutorials, please refer to the links below:[Tutorial: Building the 12V 20Ah LiFePO4 Battery Pack]
https://youtu.be/A74iqOS0jmo?si=T19hF4nLa6qJHkAA[Tutorial: 12V Battery Charger from Laptop Adapter]https://youtu.be/JL5s0cf7t2o?si=wf9mgTOLOLpJoPv1Watch the full build video here:https://www.youtube.com/watch?v=wQPwWRxXzWsTips for BuildersSafety First: Always test your inverter output with a multimeter before plugging in any sensitive appliances.Cooling: If you are running the load near the 200W limit, ensure the UPS chassis fan is connected to the 12V rail to keep the inverter cool.Did you build this? Share your results and modifications! If you have questions about the circuit design, feel free to drop a comment on the video or reach out via my channel.*
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