Bill Collis-
1Wiring Instructions
Wiring Reference
All wiring is 16AWG. See voltage-drop-analysis.md for resistance and drop calculations.
Fuse Locations and Ratings
Fuse Rating Location Purpose F1 10A fast-blow PSU output Protects PSU output circuit F2 10A fast-blow Battery positive INSTALL FIRST — protects battery circuit F3 2A fast-blow BP-65 OUT → HA Green Protects HA Green load circuit F4 5A fast-blow BP-65 OUT → XB7 Modem Protects Xfinity Modem load circuit Install F2 before connecting the battery to any other part of the circuit. This is the primary short-circuit protection for the battery.
Component Mounting
Component Mounting Method Mean Well HDR-60-12 PSU Velcro to enclosure base, stabilize to wall Victron BatteryProtect BP-65 Velcro to enclosure base Pololu Ideal Diode Float — secure with wire ties Shelly Plus Uni Float — secure with wire ties Lever Nuts Float — secure with wire ties Wiring Cable clips as needed for strain relief Wiring Connections — From/To Reference
AC Input → PSU
From To Notes Power Cord — Black (Hot) PSU Pin 1 AC/L Power Cord — White (Neutral) PSU Pin 2 AC/N Power Cord — Green (Ground) N/A green ground is cut back, capped with a wire nut, and taped, because the HDR-60-12 is a Class II double-insulated PSU → Ideal Diode
From To Notes PSU Pin 4/5 DC Output V− Ideal Diode GND (V−) PSU Pin 6/7 DC Output V+ Ideal Diode VIN (V+) Via F1 (10A) Ideal Diode → Terminal Block
From To Notes Ideal Diode GND (V−) Input 2 (−) Terminal Block has 2 inputs Ideal Diode VOUT (V+) Input 2 (+) Terminal Block has 2 inputs Battery → Terminal Block
From To Notes Battery (V−) Input 1 (−) Terminal Block has 2 inputs Battery (V+) Input 1 (+) Via F2 (10A) Terminal Block → Victron BatteryProtect BP-65
From To Notes Terminal Block + BP-65 IN terminal Terminal Block − BP-65 GND terminal Use included 1.5mm² wire Victron BP-65 OUT → Loads
From To Notes BP-65 OUT terminal F3 input (2A) HA Green load circuit F3 output HA Green barrel plug (center +) 5.5mm × 2.1mm, center-positive BP-65 OUT terminal F4 input (5A) Xfinity Modem load circuit F4 output XB7 Modem barrel plug (center +) 5.5mm × 2.1mm, center-positive Terminal Block − HA Green barrel plug (sleeve) Common return Terminal Block − XB7 Modem barrel plug (sleeve) Common return Shelly Plus Uni Monitoring
From To Notes Battery + (Terminal Block) Shelly Pin 1 (V+) Module power in (+) Battery − (Terminal Block) Shelly Pin 2 (GND) Module power in (−) Battery + (Terminal Block) Shelly Pin 3 (Analog In) Bridge to Pin 1 — battery voltage sense; primary shutdown trigger at 12.2V DS18B20 Yellow/White (Data) Shelly Pin 5 (Data) 1-Wire temperature data DS18B20 Black (GND) Shelly Pin 6 (Sens. GND) Temperature sensor ground DS18B20 Red (VCC) Shelly Pin 7 (3.3V Out) Temperature sensor power Enclosure Layout
See https://github.com/wkcollis1-eng/DIY-LiFePO4-UPS/blob/main/assets/UPS_Layout_with_12_Volt_Regulator.png for the assembly drawing image.
The enclosure is a LeMotech IP65 ABS junction box (9.6″×7.6″×4.5″ interior). Key layout decisions:
- PSU occupies the left side; battery occupies the center. Physical separation provides AC/DC segregation and reduces EMI coupling.
- Cable glands (1/2" NPT) on the bottom face: AC input on the left, DC output barrel jacks on the right.
- Victron BP-65 mounts on the right side wall. Terminal block sits between battery and BP-65.
- Shelly and ideal diode float above the battery, secured with wire ties.
- All 16AWG runs are kept to approximately 6" segments to hold voltage drop 41mV at typical load and 63mV at peak.
DIY UPS for Home Assistant Green & Xfinity XB7 Mod
DIY 12V LiFePO4 UPS for Home Assistant Green and Xfinity XB7 modem. Victron BP-65 LVD, MOSFET ideal diode, 13.3V float, Shelly Plus Uni
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Simplified - Removed the Lever Nuts. Allows for stacking Ring Connectors on the "Out" of the Victron BP-65 to the Barrel Connectors. Saves $5.00 USD
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