Portable Power 200W Sine Wave 220VAC Output With 20Ah Battery

Powerful Portable Power Station 200W

DIY Portable Power Station: 200W Pure Sine Wave Output

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.

This 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.

Output: 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.

Old UPS Chassis

Housing, AC sockets, and power cable management.

12V 20Ah LiFePO4 Battery

High-density energy storage.

Pure Sine Wave Inverter PCB

Custom design for clean 220V output.

JLCPCB Fabrication

High-quality PCB manufacturing and SMT assembly

Wiring/Hardware Connectors, 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.

Step 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 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.

Pro-Tip: Use the JLCONE desktop/mobile application 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.

App: https://jlcpcb.com/download?from=JLA

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.

Resources For 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=wf9mgTOLOLpJoPv1

**Watch the full build video here:**https://www.youtube.com/watch?v=wQPwWRxXzWs##

Tips for Builders

Safety First: Always test your inverter output with a multimeter before plugging in any sensitive appliances.

Prototyping:

Download the JLCONE app for Windows, macOS, or mobile to get started with your PCB projects easily. New users can often take advantage of special coupons!

Download here: https://jlcpcb.com/download?from=JLA

**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.*