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BackupPowerWithModifiedUPS

WARNING: MY MODIFIED UPS HAS STOPPED WORKING - LOOKS LIKE I DAMAGED IT!!
Actually, the unit is "working" but the modified sine wave output is messed up which is apparently detected
by the unit and causes it to shutdown. Here is a picture:

From the left, the levels should be: +164 0 -164 0 +164 0 -164 0 +164 but there is a leading transient
at the beginning of each level change that should not be there. (See the modified sine wave picture near the bottom of the page).
My guess is that there is an open or shorted capacitor in the unit. I suspect this happened when I was on the
VHF SKYWARN net on Monday night. There are some long unshielded wires connecting the modified UPS to the battery and
there is a lot of RF in the room!

I suspect I could repair the unit but I have no circuit diagram.
So, I ordered a battery charger and will order an inverter to replace the functions of the modified UPS.
Good Idea,
Bad Result !!

SUMMARY:
I took an old UPS (uninterruptible power supply) and replaced the 5 Amp-hour SLA (sealed lead-acid) battery in it with a marine 180 reserve power lead-acid battery (recommended by Bill, KQ1S).
A 180 reserve power battery can run 1800 minutes (3 hours) while delivering 25 amps before the battery voltage drops to 10.5 volts.

Features of the modified UPS during normal, line-powered operation:
Provides surge protection to all outlets.
Trickle charges the battery. Maintains nearly full charge as long as transmit periods are short.
A built-in relay switches input power to the UPS outlets - no battery power is required for UPS outlets.

During power outage or when you take the modified UPS out into the field:
UPS provides 110V "modified sine wave" AC power to the UPS outlets - can power a computer, etc.
Battery provides power for 110V AC and 12V DC for the transceivers.
Also note that you can connect your automobile battery to the modified UPS instead of the marine battery or internal battery for field use.

FUTURE PLANS:
This is a start at getting serious about emergency backup.
I also plan to add some solar cells for long term operations.
Ron, KG7OH provided me with his emergency backup and field operations setup. I will put some of that material here or ask Ron to provide that information.
I also have a 4KW propane or gasoline generator that has never been used. This was a requested birthday present for Bobbi, W6HQJ.
When I get around to it, this unit is capable of operating our furnace, well pump and refrigerators with power to spare.

Ron's (KG7OH) Battery Backup and Solar Cell Notes:
I use a home brew 12 volt 18 amp hour battery pack as backup. It is built into an ammo case (Harbor Freight $3). Everything is fitted with Power Pole connections. This includes my power supply, battery backup, radios, solar panels, marine battery and more. See the pictures below. It is kept under my station desk with a trickle charger on it.
In Munds Park I have two 100 watt solar panels and a marine deep cycle battery for field use. I recommend these solar panels. They are made by Grape Solar and sold at Home Depot. The cost is currently $72. I paid $99 each a couple of years ago for mine. They are fairly light and have a nice frame. These are identical to the ones that Ken, W7SS installed on the CARC trailer and the NADXA trailer.
The charge controller I use was recommended by a friend, Jay, W5DC. It is a SunForce 12 Volt, 30 Amp. Jay did extensive research and testing and claims this one to have the lowest RF noise level output. I use the single controller with either one or two solar panels and have been happy with the set up.

MODIFICATION:
I added banana plug/binding post terminals to the UPS unit, two red, two black. The original battery wires are connected to one set of terminals; the external battery is connected to these terminals. The other red terminal and the black terminal are connected to the internal battery. The other black terminal is not connected to anything; it can be used for other components. To switch to the internal battery, disconnect the external battery and connect the two red terminals with a jumper.
Below - Modified UPS on left with internal battery (removed from case) above it.
External battery on right. Sorry about the mess!

CAUTIONS:
Modifying the UPS unit voids its warranty. It is possible that the AC-to-DC portion of the UPS may overheat or fail to maintain external battery voltage if you do a lot of transmitting. The AC waveform supplied by typical UPS units during power outage is a "modified sine wave". For most modern equipment, this should not be a problem- but see discussion below.

DISCUSSION:
In a nutshell: In my "office", I have a UPS, a computer, a 12 V power supply to run my transceivers, a UHF/VHF transceiver and an HF transceiver. While working on my power supply (bad fan) and UPS units (bad batteries), I noticed that the batteries in those UPS units are 12 volt batteries. So, why do I need a $170 (MFJ 4245) power supply when the UPS unit has a 12 volt battery that could run my transceivers directly (at least for a short time)?

Here's what happens: The UPS is plugged into house AC power. It converts the 120V AC to 12V DC to charge the internal battery. Then it converts the DC back to 120V modified sine-wave AC to power other units. The AC output goes to the power supply which converts the AC back to 12 volt DC that powers the transceivers.

Of course, I need the 120V AC from the UPS to power the computer so that the computer can convert it back to DC to power the computer components.

The transceivers are designed to run on 12V DC so that you can power them from your car battery when you operate mobile.

You will have noticed that there are a lot of power-wasting operations going on there. Asking computer manufacturers to build equipment that operates on 12 V DC is a bit of a stretch. But junking that $170 power supply is a savings.

So, I went looking for a UPS that also had a 12V DC output terminal and I couldn't find one. Why? Probably because it wouldn't normally be used by non-Ham people and a variable-voltage 11-14V DC output (the battery voltage will vary with charge and configuration) would be hard to specify. Also, you would probably want to add a fuse and possibly some additional filtering to clean up any hash in that battery output. Anyway, I'll be looking into a number of issues in the next few days.

One issue is that the battery in the UPS will not operate the equipment for long on that 9 amp-hour battery - about 7 minutes at half-rated-power or 3 minutes at full-rated-power. But an automotive battery could be attached and would last a long time, especially when you realize that those transceivers are typically only transmitting a small fraction of the time. The UPS serves as a trickle charger.

Here's a list of power requirements that matches my office needs fairly well.
To this list, add charging cell phones and running the internet connection and router.

If I were manufacturing a UPS/DCpower unit, I would think about adding other things like additional DC filtering and USB charging outputs. Time to get out the oscilloscope and see what's going on in those UPS units!

New info on power backup for office and ham gear. Well, it works - sort of. I did some rewiring and moved the battery out of the UPS and attached my UHF/VHF radio to it. I was able to receive for an extended period of time and also transmit briefly.

However, the UPS got warm and the battery voltage dropped several volts during transmit. I was using a small 5 amp-hour battery; a large 80 amp-hour battery should solve the voltage-drop "problem".

One question was - why did the UPS get warm? The answer is because the UPS does not actually generate DC and then convert back to AC when attached to a 120V power source. There is a relay in there that connects the input AC to the output AC when 120V input is present. The UPS only generates DC to charge the internal battery for use when the AC input goes out. That's fine for small power loads for a short period of time but probably not o.k. for generating power for a 100W transmitter for long periods of time.

Another "problem" is that when generating AC from the battery, this UPS does not generate a sinusoidal output, it generates a "modified sinusoidal output". Here's a picture from https://www.dougv.com/2010/03/active-pfc-enabled-psus-are-not-compatable-with-most-low-end-ups/

The "modified sinewave" (in red) might be more accurately described as a "modified squarewave". So, when power goes off, that is what is fed to your computer, etc. The question is does it matter? And I think the answer is - not really for most equipment. The days of large, heavy 60 Hz transformers and vacuum tubes and giant high-voltage filter capacitors are mostly gone. Today's AC-to-DC power converters typically chop up the input waveform at a 25 KHz rate so that they can use small tranformers (inductance is proportional to frequency) to lower the voltage down to e.g. 12 Volts. So the "modified sinewave" lookis like a 25 KHz, 50% duty cycle square wave at a 120 Hz rate after the chopper. This might require a little more filtering to get to 12 VDC than would be necessary for the chopped 60 Hz sinewave but the difference is probably not noticeable. The problem (as mentioned in the referenced article) would occur if the equipment receiving the modified sinewave detected the anomalous input and shut itself down, defeating the UPS function!

Some inexpensive UPS units advertise that they generate a pure sinewave output. It might be better to buy one of those in case you have some equipment that will not tolerate the "modified sinewave" input.

So, I think this will work as long as we are using the UPS as a DC source and a trickle charger for a high-capacity battery.

But, I probably still need my power supply for normal operations.
I'm sure if I am lucky the back-ordered fan will arrive real soon now!

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Page last modified on February 20, 2021, at 06:10 AM