We are talking about a very convenient board with a charge controller based on TP4056. The board additionally has protection for li-ion 3.7V batteries.

Suitable for converting toys and household appliances from batteries to rechargeable batteries.
This is a cheap and efficient module (charging current up to 1A).

Although a lot has already been written about modules on the TP4056 chip, I will add a little from myself.
More recently, I learned about, which cost a little more, are slightly larger in size, but additionally include a BMS module () to control and protect the battery from overdischarge and overcharge based on the S-8205A and DW01, which turn off the battery when the voltage on it is exceeded .


The boards are designed to work with 18650 cells (mainly due to the charging current of 1A), but with some alteration (soldering the resistor - reducing the charging current) they are suitable for any 3.7V batteries.
The layout of the board is convenient - there are solder pads for input, output and for the battery. Modules can be powered by Micro USB. The charging status is displayed by the built-in LED.
Dimensions are approximately 27 by 17 mm, the thickness is small, the “thickest” place is the MicroUSB connector


Specifications:
Type: Charger module
Input Voltage: 5V Recommended
Charge Cut-off Voltage: 4.2V (±)1%
Maximum Charging Current: 1000mA
Battery Over-discharge Protection Voltage: 2.5V
Battery Over-current Protection Current: 3A
Board Size: Approx. 27*17mm
Status LED: Red: Charging; Green: Complete Charging
Package Weight: 9g

The link in the header sells a lot of five pieces, that is, the price of one board is about $0.6. It's slightly more expensive than a single charging board on the TP4056, but without protection - these are sold in packs for a dollar and a half. But for normal operation, you need to buy a separate BMS.

Briefly about adjusting the charging current for TP4056

TP4056 charge controller module + battery protection
Provides overcharge, overdischarge, triple overload and short circuit protection.
Max Charging Current: 1A
Maximum D.C. discharge: 1A (peak 1.5A)
Charging voltage limit: 4.275 V ±0. 025 V
Limitation (cutoff) of discharge: 2.75 V ±0. 1 V
Battery protection, chip: DW01.
B+ connects to the positive terminal of the battery
B- connects to the negative terminal of the battery
P- is connected to the negative terminal of the load and charge connection point.

There is R3 on the board (marking 122 - 1.2 kOhm), to select the desired charging current for the element, select the resistor according to the table and solder it.


Just in case, a typical inclusion of TP4056 from the specification.



The lot of TP4056 + BMS modules is taken not for the first time, it turned out to be very convenient for hassle-free alterations of household appliances and toys to batteries.

The dimensions of the modules are small, just less than two AA batteries in width, flat - they are great for installing old batteries from cell phones.


For charging, a standard 5V source from USB is used, the input is MicroUSB. If the boards are used in cascade, you can solder to the first one in parallel, the photo shows the minus and plus contacts on the sides of the MicroUSB connector.


There is nothing on the reverse side - this can help when attaching to glue or tape.


MicroUSB connectors are used for power supply. Old boards on the TP4056 had MiniUSB.
You can solder the boards together at the input and only connect one to USB - this way you can charge 18650 cascades, for example, for screwdrivers.


Outputs - extreme pads for connecting the load (OUT +/-), in the middle BAT +/- for connecting the battery cell.


The fee is small and convenient. Unlike just modules on the TP4056, there is battery cell protection here.
For cascading, you need to connect the load outputs (OUT +/–) in series, and the power inputs in parallel.


The module is ideal for installation in various household appliances and toys that are powered by 2-3-4-5 AA or AAA cells. This, firstly, brings some savings, especially with frequent replacement of batteries (in toys), and, secondly, convenience and versatility. You can use for power elements taken from old batteries from laptops, cell phones, disposable electronic cigarettes, and so on. In case there are three elements, four, six and so on, you need to use the StepUp module to increase the voltage from 3.7V to 4.5V/6.0V, etc. Depending on the load, of course. Also convenient is the option on two battery cells (2S, two boards in series, 7.4V) with a StepDown board. As a rule, StepDown are adjustable, and you can adjust any voltage within the supply voltage. This is an extra volume to place instead of AA / AAA batteries, but then you don’t have to worry about the electronics of the toy.


Specifically, one of the boards was designed for an old IKEA mixer. Very often it was necessary to replace the batteries in it, and it worked poorly on batteries (in NiMH 1.2V instead of 1.5V). The motor doesn't care if it is powered by 3V or 3.7V, so I did without StepDown. It even turned a little more vigorously.


The 08570 battery from an electronic cigarette is almost ideal for any alterations (capacity is about 280mAh, and the price is free).


But in this case, it's a bit long. The length of the AA battery is 50 mm, and this battery is 57 mm, did not fit. You can, of course, make a “superstructure”, for example, from polymorph plastic, but ...
As a result, I took a small model battery with the same capacity. It is highly desirable to reduce the charging current (up to 250 ... 300 mA) by increasing the resistor R3 on the board. You can heat the regular one, bend one end, and solder any available 2-3 kOhm.

On the left, I brought a picture according to the old module. On the new module, the placement of the components is different, but all the same elements are present.


We connect the battery (Solder) to the terminals in the middle of BAT +/–, solder the motor contacts from the contactor plates for AA batteries (we remove them altogether), solder the motor load to the board output (OUT +/–).
You can cut a USB hole in the lid with a Dremel.


I made a new cover - the old one was completely thrown out. The new slots are thought out for placing the board and a hole for MicroUSB.


Gif of the mixer from the battery - it spins briskly. The 280mAh capacity is enough for a few minutes of work, you have to charge it in 3-6 days, depending on how often you use it (I rarely use it, you can plant it at once if you get carried away.). Due to the decrease in charging current, it charges for a long time, a little less than an hour. But any charging from a smartphone.


If you use a StepDown controller for RC cars, then it's better to take two 18650 and two boards and connect them in series (and the charging inputs in parallel), as in the picture. Where the common OUT is placed any step-down module and adjusted to desired voltage(e.g. 4.5V/6.0V) In this case, the car will not drive slowly when the batteries run out. In the event of a discharge, the module will simply turn off abruptly.

The module on the TP4056 with built-in BMS protection is very practical and versatile.
The module is designed for a charging current of 1A.
If you connect in a cascade, take into account the total current when charging, for example, 4 cascades to power the batteries of a screwdriver will “ask” 4A for charging, and this is a charger from cell phone will not stand.
The module is convenient for remaking toys - radio-controlled cars, robots, various lamps, remote controls ... - all possible toys and equipment where you have to change batteries often.

Update: if the minus is through, then everything is more complicated with parallelization.
See comments.

The product was provided for writing a review by the store. The review is published in accordance with clause 18 of the Site Rules.

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How tightly entered our lives Li-ion battery s. The fact that they are used in almost all microprocessor electronics is already the norm. So radio amateurs have long adopted them and use them in their homemade products. I contribute to this significant advantages of Li-ion batteries, such as small size, large capacity, big choice executions of various capacities and forms.

The most common battery is 18650, its voltage is 3.7 V. For which I will make a discharge indicator.
Probably, it’s not worth telling how low their discharge is harmful to the crane batteries. And for batteries of all varieties. Proper maintenance of rechargeable batteries will extend their life several times and save you money.

Charging indicator circuit


The circuit is quite versatile and can operate in the range of 3-15 volts. The response threshold can be adjusted with a variable resistor. So the device can be used for almost any battery, be it acid, nickel-cadmium (nicd) or lithium-ion (Li-ion).
The circuit monitors the voltage and as soon as it falls below a predetermined level, the LED will light up, signaling a low battery discharge.
The circuit uses an adjustable one (link where I took it). In general, this zener diode is a very interesting radio element that can make life easier for radio amateurs when building circuits based on stabilization or threshold operation. So take it into service, especially when building power supplies, current stabilization circuits, etc.
The transistor can be replaced by any other NPN structure, the domestic analogue of KT315, KT3102.
R2- adjusts the brightness of the LED.
R1- variable resistor rating from 50 to 150 kOhm.
The value of R3 can be added up to 20-30 kΩ to save power if a high gain transistor is used.
If you do not have an adjustable TL431 stabilizer, then you can use a proven Soviet two-transistor circuit.


The operating threshold is set by resistors R2, R3. Instead, one variable can be soldered to allow adjustment and reduce the number of elements. Soviet transistors can be replaced with BC237, BC238, BC317 (KT3102) and BC556, BC557 (KT3107).


The circuit can be assembled on the board or surface-mounted. Put on a heat shrink tube and blow it with a hot air gun. Attach with double sided tape to the back of the case. I personally installed this board in a screwdriver and now I don’t drive its batteries to a critical discharge.
You can also connect a buzzer (tweeter) in parallel with a resistor with an LED, and then you will definitely know about critical thresholds.

If you open any cell phone battery, you will find that a small printed circuit board is soldered to the terminals of the battery cell. This is the so-called protection scheme, or Protection IC.

Due to their characteristics, lithium batteries require constant monitoring. Let's take a closer look at how the protection scheme is arranged, and what elements it consists of.

Ordinary charge controller circuit lithium battery is a small board on which is mounted electronic circuit from SMD components. The controller circuit of 1 cell (“bank”) at 3.7V, as a rule, consists of two microcircuits. One microcircuit is a control one, and the other is an executive one - an assembly of two MOSFET transistors.

The photo shows a 3.7V battery charge controller board.

A microcircuit marked DW01-P in a small package is essentially the “brain” of the controller. Here is a typical wiring diagram for this chip. In the diagram, G1 is a cell of a lithium-ion or polymer battery. FET1, FET2 are MOSFET transistors.

Sokolevka, appearance and pin assignment of the DW01-P chip.

MOSFET transistors are not included in the DW01-P chip and are made as a separate chip assembly of 2 MOSFET transistors N-type. The assembly marked 8205 is usually used, and the package can be either 6-pin (SOT-23-6) or 8-pin (TSSOP-8). The assembly can be labeled as TXY8205A, SSF8205, S8205A, etc. You can also find assemblies marked 8814 and similar.

Here is the pinout and composition of the S8205A chip in the TSSOP-8 package.

Two FETs are used to separately control the discharge and charge of the battery cell. For convenience, they are made in one case.

The transistor (FET1) that is connected to the OD pin ( Overdischarge) DW01-P chips, controls the battery discharge - connects / disconnects the load. And the one (FET2) that is connected to the OC pin ( over charge) – connects/disconnects the power supply (charger). Thus, by opening or closing the corresponding transistor, it is possible, for example, to turn off the load (consumer) or stop charging the battery cell.

Let's look at the logic of the control chip and the entire protection circuit as a whole.

Overcharge protection.

As you know, overcharging a lithium battery over 4.2 - 4.3V is fraught with overheating and even an explosion.

If the cell voltage reaches 4.2 - 4.3V ( Overcharge Protection VoltageVOCCP), then the control chip closes the FET2 transistor, thereby preventing further battery charging. The battery will be disconnected from the power source until the voltage on the cell drops below 4 - 4.1V ( Overcharge Release VoltageVOCR) due to self-discharge. This is only if there is no load connected to the battery, for example, it is removed from a cell phone.

If the battery is connected to the load, then the FET2 transistor opens again when the cell voltage drops below 4.2V.

Overdischarge Protection.

If the battery voltage drops below 2.3 - 2.5V ( Overcharge Protection VoltageVODP), then the controller turns off the FET1 MOSFET transistor - it is connected to the DO pin.

There are very interesting condition . Until the voltage on the battery cell exceeds 2.9 - 3.1V ( Overdischarge Release VoltageVODR), the load will be completely disconnected. The controller terminals will be 0V. Those who are not familiar with the logic of the protective circuit may take this state of affairs for the “death” of the battery. Here is just a small example.

Miniature Li-polymer battery 3.7V from an MP3 player. Composition: control controller - G2NK (series S-8261), assembly of field-effect transistors - KC3J1.

The battery is discharged below 2.5V. The control circuit disconnected it from the load. At the output of the controller 0V.

At the same time, if you measure the voltage on the battery cell, then after the load was turned off, it slightly grew and reached the level of 2.7V.

In order for the controller to reconnect the battery to the “outside world”, that is, to the load, the voltage on the battery cell must be 2.9 - 3.1V ( VODR).

This raises a very reasonable question.

The diagram shows that the drain terminals (Drain) of transistors FET1, FET2 are connected together and are not connected anywhere. How does the current flow through such a circuit when the overdischarge protection is triggered? How can we recharge the “bank” of the battery again so that the controller turns on the discharge transistor again - FET1?

If you rummage through datasheets for Li-ion / polymer protection chips (including DW01-P, G2NK), then you can find out that after the deep discharge protection is triggered, the charge detection circuit is in operation - Charger Detection. That is, when connected charger the circuit will detect that the charger is connected and allow the charging process.

Charging to a level of 3.1V after a deep discharge of a lithium cell can take a very long time - several hours.

To restore a lithium-ion / polymer battery, you can use special tools, for example, the Turnigy Accucell 6 universal charger. I already talked about how to do this here.

It was with this method that I managed to restore a Li-polymer 3.7V battery from an MP3 player. Charging from 2.7V to 4.2V took 554 minutes and 52 seconds, which is more than 9 hours! That's how long a "recovery" charge can last.

Among other things, the functionality of lithium battery protection circuits includes overcurrent protection ( Overcurrent Protection) and short circuit. Overcurrent protection is triggered in the event of a sharp drop in voltage by a certain amount. After that, the microcircuit limits the load current. In the event of a short circuit (short circuit) in the load, the controller completely turns it off until the short circuit is eliminated.

Li-ion battery controller circuit
Scheme of the controller of a lithium-ion battery Device and principle of operation of the protective controller Li-ion / polymer battery If you open any battery from a cell phone, you can


Probably, for most radio amateurs, over the years, a box is put into which they are folded “for later” lithium batteries from the untimely deceased (drowned, fallen from the balcony, gnawed by Druzhok) mobile phones and cameras. They lie in a box and wait in the wings .. And the hour still does not come. The reason is simple - to use battery in the same flashlight you need to do it charge controller, and for some reason they didn’t deliver charging chips at the local radio store .. Yes, a problem.

And what's a poor radio amateur to do? Everything is very simple - you can get by with "pasture" using what is hidden from the eyes of the average user. Namely, the protection board, which is carefully hidden inside each lithium ion or lithium polymer battery. Without it, they are not allowed to use accumulators in household appliances due to the exceptional activity of lithium. If you disassemble battery from mobile phone , we will find such a simple device inside:

That's what it is battery protection board. This board has a two-level comparator chip and field-effect transistor. When the voltage drops to accumulator below 3v or rise above 4.25v this comparator turns off the transistor and isolates battery from the outside world, thereby protecting from damage.

I had an idea to try to use these properties of the protection board to control the process phone battery charging from standard USB ports computer (which has a 500mA current limiter as a bonus). So we get soup from an ax. More precisely, charging “out of nothing”. It remains to somehow display the progress (and completion) of the process to the user charging. Below is scheme this node.

Works very simply. When connected to USB port at charging starts and lights up Light-emitting diode. The charge current is limited by the computer port and resistors on the board. Upon reaching the voltage accumulator 4.25v triggers the comparator of the protection board and breaks the charge circuit. The LED will turn off. In the first charging option, I used the button to start the charging process. But it turned out that a 100nF capacitor was enough for the initial opening field effect transistor. The circuit is very simple and starts working without adjustment.
The board file can be downloaded from the section "File Catalog"

If, while repeating this design, you have any questions or ideas for improving it, write to me online your thoughts on this.

How to charge a lithium ion battery without a controller
How to charge a lithium-ion battery without a controller Probably, for most radio amateurs, over the years, a box is put into which lithium batteries from


If you are interested in how to charge a lithium-ion battery, then you have come to the right place.

Modern mobile devices require offline source nutrition.

And this is true both for “high technologies” like smartphones and laptops, and for more simple devices, say, electric drills or multimeters.

There are many different types of batteries. But for portable equipment, Li-Ion is most often used.

The relative ease of production and low cost led to such a wide distribution.

This was facilitated by excellent performance, plus low self-discharge and a large margin of charge-discharge cycles.

Important! For greater convenience, most of these batteries are equipped with a special control device that prevents the charge from passing critical levels.

During a critical discharge, this circuit simply stops supplying voltage to the device, and during excess acceptable level charge cuts off the incoming current.

At the same time, after reaching the nominal 100%, charging should last another one and a half to two hours.

This is necessary because the actual battery will be 70-80% charged.

When charging from a laptop or desktop computer Please note that the USB port is unable to provide sufficient high voltage, therefore, the process will take more time.

Alternating full and partial (80-90%) charge cycles will extend the life of the device.

Despite such a smart architecture and general unpretentiousness, following some rules for using batteries will help extend their life.

So that the battery of the device does not “suffer”, it is enough to follow simple recommendations.

Rule 1: Don't let your battery drain completely

Lithium-ion batteries of modern designs do not have a “memory effect”. Therefore, it is better to charge them before the moment of complete discharge comes.

Some manufacturers measure the life of their batteries by the number of charge cycles from zero.

The highest quality products can withstand up to 600 such cycles. When charging a battery with 10-20% remaining, the number of cycles increases to 1700.

Rule 2. A complete discharge still needs to be taken every three months.

With unstable and irregular charging, the average statistical marks of the maximum and minimum charges in the previously mentioned controller go astray.

This leads to the fact that the device receives incorrect information about the amount of charge.

Preventive discharge will help prevent this. At full discharge battery, minimum value charge in the control circuit (controller) will be reset.

After that, it is necessary to charge the battery "to the eyeballs", having kept from eight to twelve hours in a state connected to the network.

This will update the maximum value. After such a cycle, the battery will be more stable.

Rule 3. An unused battery must be stored with a small amount of charge

Before storage, it is better to charge the battery by 30-50% and store at a temperature of 15 0 C. In such conditions, the battery can be stored for quite a long time without much damage.

A fully charged battery will lose a significant amount of capacity during storage.

And completely discharged after a long storage, it remains only to give it for processing.

Rule 4. Charging must be done only with original devices

It is noteworthy that the charger itself is built into the design of a mobile device (phone, tablet, etc.).

The external adapter in this case acts as a rectifier and voltage stabilizer.

The use of third-party "charging" can adversely affect their condition.

Rule 5. Overheating is detrimental to Li-Ion batteries

High temperatures have an extremely negative effect on the design of batteries. Low ones are also fatal, but to a much lesser extent.

This must be remembered when using lithium-ion batteries.

The battery must be protected from direct sunlight and used at a distance from heat sources.

The permissible temperature range is between -40 0 C and +50 0 C.

Rule 6

It is not safe to use non-certified chargers. In particular, common Chinese-made "frogs" often ignite during the charging process.

Before using such a universal charger, you should check the maximum allowable values ​​indicated on the packaging.

So, attention must be paid to the maximum capacity.

If the limit is less than the capacity of the battery, then at best it will not fully charge.

When the battery is connected, the corresponding indicator on the frog body should light up.

If this does not happen, then the charge is critically low or the battery is out of order.

When the charger is connected to the network, the connection indicator should light up.

Another diode is responsible for achieving the maximum charge, which is activated in appropriate conditions.

Tips for using Li-ion batteries

How to charge and maintain a lithium-ion battery: 6 simple rules

How to charge and maintain a lithium-ion battery: 6 simple rules
How to charge and maintain a lithium ion battery: 6 simple rules If you are wondering how to charge a lithium ion battery, then you have come to the right place. Modern mobile devices

Everyone knows the advantages of lithium batteries - first of all, this is a high energy density, low weight and the absence of a "memory effect". It is also worth noting that the potential of one lithium battery. (3.6V) is three times that of a single NiCd or NiMH battery (1.2V).

However, lithium batteries have a number of features that do not allow their safe use without special control systems. These systems are called charge and discharge controllers. In today's industry, there are highly integrated microcircuits ready to perform these functions. But, as it turned out, they are not available for mass use. They are not sold in radio parts stores by the piece. They must be ordered from companies specializing in the supply electronic components for enterprises and repair shops. And the minimum lot in this case is from 10 pieces (this is at best).

All this prompted us to develop our controller on discrete elements available in any provincial radio store.

When discharging a lithium battery. you need to control its voltage and current strength in the circuit.

The voltage on a charged lithium battery. is 4.2V, not 3.6V as it says on it. Up to 3.6V, it drops under a load close to the capacity of the battery. Voltage control is not to give the battery. discharge below 3V. This threshold varies within 0.5 V depending on the chemical composition and geometric shape of the battery. Battery discharge. below 3V, leads to irreversible chemical processes inside the battery, which makes it unsuitable for further use.

To control the current strength in the circuit, it is necessary to provide a shutdown mechanism similar to the machine that is in the electrical panel in each apartment. Those. it must protect against short circuits and turn off when a certain current in the circuit is exceeded. In general, the maximum discharge current that a battery can deliver. equal to its capacity. For example, accum. with a capacity of 2A h can safely deliver a current of 2A. Battery work at currents exceeding its capacity, it is possible in short-term modes, or in normal mode, if this is indicated in the documentation by the battery manufacturer. In the event of a short circuit, the lithium battery might explode! Be careful!

More about chemical processes, charge and discharge modes of lithium batteries. can be read here Panasonic Lithium Ion Handbook (in English).

It all started with the fact that the battery in my laptop turned off. The laptop was two years old, from the battery. it almost did not work - it was always connected to the network. As I was later told, this could be the cause of the battery failure. Those. it was not a slow dying battery. with a decrease in capacity, on the contrary, the laptop worked from it for five hours, just one fine day, it did not turn on from the battery and that's it. The battery is no longer detected in Windows, and I concluded that the built-in battery controller burned out. batteries. Having disassembled the battery, we saw 6 elements, combined 2 into 3 cells with a series-parallel connection.

By measuring the voltage on each cell, we made sure that they were charged. This once again confirmed the version of the controller failure. During external inspection of the controller, no visible damage was found. I rejected the idea of ​​\u200b\u200brepairing the controller as difficult (on the forums, people wrote about soldering and programming the controller processor). In general, the complexity of this controller made a strong impression. Who knows what really burned out there?

That's why I ordered new battery, but I decided to do this later. But in vain!

I took care of them two months later. I tore the elements out of the case, disconnected them from the controller, measured the voltage on them and was very surprised - 4 elements were completely discharged! And on the other two, the voltage was about 1V. Apparently the damaged controller completely discharged 2 cells through itself.

According to the instructions, battery. discharged below 3V, it was necessary to charge with a current of 0.1 from the capacity. These 4 elements could not be charged. No tambourine dancing, freezing and thawing, tapping, etc. didn't help. I had to throw them out. This is the deep overdischarge that kills lithium batteries. The remaining two elements were charged successfully.

The elements were labeled Sanyo UR18650FM 2.6AH. It is immediately clear that the capacity of the element is 2.6 Ah and it is produced by the Japanese corporation Sanyo. Searching the corporation's website led us to a document called . Only the letter M at the end is missing. The document turned out to be very interesting. It contained specifications battery with a capacity of 2.5 Ah, the dimensions coincided with ours.

Deciding to use this document as a guide to action, we set about designing our discharge controller.

From the “Discharge rate characteristics” graph (characteristics of the discharge dynamics), it became clear that the element allows a discharge of up to 2.7V and a current of 2C, i.e. double capacity. Accordingly, our element with a capacity of 2.6A h can produce 5.2A.

discharge controller

Having comprehensively analyzed this document and other reference literature, Skvortsov Vladimir Nikolaevich (not to be confused with Starling) created a controller for working with one or two lithium cells. The controller protects the cells from short circuits and overdischarge.

The controller circuit shown in the figure provides load disconnection when the battery voltage drops to 6V (3V for each element). A short circuit is considered a current strength above 4A.

To use a controller with one element (shutdown at 3V), you need to select (increase) the resistor R1 - it is responsible for the response threshold when the voltage drops. You also need to take into account the individual characteristics of the transistor VT1 (tolerance% deviation).

To control the current strength, a resistor R7 is selected. The smaller its value, the more current the controller passes.

As a transistor VT3, you can use any powerful field-effect transistor with a current margin of 3 times the battery capacity, for example 15N03.

The principle and modes of operation of the controller

Power on, normal mode

When a battery of two charged batteries (8.4V) is connected, the VT4 transistor opens. Due to the base current through R4, the voltage at the VT4 emitter becomes about 0.7V. Also, resistor R4 keeps VT2 closed.

When VT4 is opened, a current begins to flow through the R1-R2 divider, which creates a voltage drop across R1, and VT1 opens. The voltage on its drain becomes close to the voltage on the battery. Through the resistor R3, it is fed to the gate VT3 and it opens. In this case, the "-" battery through R7 and open VT3 is connected to the output terminal "-". The controller turned on.

Overdischarge protection

When the battery voltage the battery reaches 6V (3V on each element), the voltage at the R1-R2 divider decreases, the voltage at the VT1 gate also decreases to the closing threshold, VT1 closes. The shutter VT3 is connected through R5 to the "-" battery. batteries, so VT3 also closes. The load is turned off. To bring the controller into the initial state you need to disconnect the load and charge the battery.

When testing assembled circuit you need to connect at least some minimum load to it, for example, LEDs. The protection mechanism works only with the connected load, in addition, the LEDs will clearly indicate the disconnection of the load.

Short circuit protection

The short circuit current is set by R7. The smaller its value, the more current the controller passes. The circuit in Figure 1 uses a 0.1 ohm resistor. With such a resistor, the controller allows current up to 4A, more current is considered a short circuit. When working at high currents, the resistor R7 must be of sufficient power - at least 1W.

When exceeding admissible current, voltage drop at R7 + voltage drop at the source - the drain of VT3 increases to the opening level of VT2. Open VT2 connects the VT3 gate to the "-" battery, VT3 closes. The drain VT3 as well as the base VT4 and the gate VT2 are connected to the “+” of the battery through the load. VT4 closes, the voltage on the divider R1-R2 is about 0, VT1 also closes. The load is turned off. To bring the controller to its original state, you need to disconnect the load.

Printed circuit board

The printed circuit board in Sprint-Layout 4 format can be downloaded in rar, 5Kb.

If you do not have this program, you can download it in rar, 1Mb.

The dimensions of the device (30 x 16mm) were chosen for the possibility of its installation in the end of the battery. batteries.

Device photos

Please note that the base of the transistor VT4 (KT3107) and the gate VT2 (2SK583) are conductors on the reverse side printed circuit board.

Battery preparation

Do not use batteries in the same device different types and stamps. It is better and safer to find identical elements.

When using two elements, you need to balance their initial potential - i.e. they should have the same voltage. To do this, connect their negative poles (minuses) directly, and the positive ones through a 30 Ohm resistor. The power of the resistor is 1 or 2 watts. Then you need to measure the voltage at the terminals of the resistor. If it is more than 10 millivolts, you need to wait. You have to wait about a day. It turns out that a more charged battery is slowly discharged through a resistor to a less charged one. That. voltage equalizes. Balanced elements can be connected directly without a resistor - in series or in parallel.

A little clarification about the serial connection. Factory integrated discharge controllers monitor the voltage on each of the series-connected elements. Our controller only controls the total output voltage. Measurements have shown that when using balanced cells, the voltage difference across the cells is 5 - 8 millivolts. This is perfectly acceptable. Therefore, there is no need to install a separate controller on each element.

charge theory

Factory charge controllers control voltage, current and charge time, select normal or gentle mode. If the voltage on the cell is above 3V, it is charging normally. The charging process in this case goes in 2 stages:
Stage 1 - charging with direct current (Constant current - CC);
Stage 2 - charging with constant voltage (Constant voltage - CV).

The maximum charge current depends on the capacity (C) of the battery, as a rule it is 0.7C or 1.0C. For our cells, the charge current was indicated in the document, and was equal to 0.7C. Charge voltage 4.2V (for one cell).

The power supply for charging one battery must have a voltage of 4.2V and provide a current of 0.7C (where C is the battery capacity, in our case 2.6 0.7 \u003d 1.82A). If the elements are connected in series, then the charge voltage doubles - 8.4V. If in parallel, the current strength doubles 2 0.7C \u003d 1.4C, and the voltage remains 4.2V.

The Charge characteristics graph shows both stages of charging. At the first stage, through the battery. pass a current of 0.7C. The main thing here is not to let the current rise above this value. At the same time, the voltage on the element gradually increases from 3 to 4.2V. This stage is called constant current (CC), which means that while the voltage rises, the current remains constant.

The first stage ends when the voltage on the element reaches 4.2V. This is indicated by the red number 1 on the graph. From this moment, the second stage begins - constant voltage (CV). This means that the voltage remains constant at 4.2V, and the current gradually decreases to a vanishingly small value. The moment of the beginning of the decrease in the current strength is indicated on the graph by the red number 2.

As can be seen from the graph, 80% of the capacity gain falls on the first stage.

Factory controllers consider charging complete when the current drops to a predetermined value - as a rule, this is 0.1C. In our graph, this is 50 milliamps. Also, some factory controllers monitor charging time. If the battery has not been fully charged within a certain time (the current has not dropped to the desired value), the controller also stops charging. The charge time depends on the capacity and charge current, and is indicated in the documentation. For our battery, this is 3 hours at a current strength of 0.7C.

The gentle charge mode is selected by the controller if the voltage on the battery was below 3V. Such an element is considered to be deeply discharged, and it must be charged carefully. In this case, charging starts from the Precharge stage. At this stage, the charge current is set to 0.1 of the capacity (0.1C). With this current, the voltage on the element is slowly raised to 3V. And then everything is as usual.

If you use serviceable elements and do not discharge them below 3V, you can completely get by with improvised means. To do this, you need a power supply with a voltage of 4.2 or 8.4V and current limiting. The end of the charge can be tracked by current strength or not tracked at all, but turn off the power supply after 2 or 3 hours.

In the near future, we will publish ways to refine conventional power supplies to meet the above characteristics.

To be continued…

Development of the device and printed circuit board - Skvortsov Vladimir Nikolaevich
Statement of the problem, submission and design of the material - Ugreninov Vitaly
Tyumen-Kosmopoisk, 2009

Sources used

Mini - USB charging Joint technical group TEGIR. expeditionary energy.

Lithium Ion Handbook Panasonic industrial

UR18650F Specifications SANYO Mobile Energy Company

Lithium ion Battery lineup SANYO Mobile Energy Company


Progress is moving forward, and lithium batteries are increasingly replacing the traditionally used NiCd (nickel cadmium) and NiMh (nickel metal hydride) batteries.
With a comparable weight of one cell, lithium has a large capacity, in addition, the cell voltage is three times higher - 3.6 V per cell, instead of 1.2 V.
The cost of lithium batteries has begun to approach conventional alkaline batteries, the weight and size are much smaller, and besides, they can and should be charged. The manufacturer says 300-600 cycles can withstand.
There are different sizes and choosing the right one is not difficult.
The self-discharge is so low that they lie for years and remain charged, i.e. the device remains operational when it is needed.

"C" stands for Capacity

Often there is a designation of the form "xC". This is just a convenient notation for the charge or discharge current of a battery in fractions of its capacity. It is formed from the English word "Capacity" (capacity, capacity).
When talking about charging with a current of 2C, or 0.1C, they usually mean that the current should be (2 × battery capacity) / h or (0.1 × battery capacity) / h, respectively.
For example, a battery with a capacity of 720 mAh, for which the charge current is 0.5C, must be charged with a current of 0.5 × 720mAh / h = 360 mA, this also applies to the discharge.

And you can make yourself a simple or not very simple charger, depending on your experience and capabilities.

Diagram of a simple charger on the LM317


Rice. 5.


The circuit with the application provides a fairly accurate voltage stabilization, which is set by the potentiometer R2.
Current stabilization is not as critical as voltage regulation, so it is enough to stabilize the current using a shunt resistor Rx and an NPN transistor (VT1).

The required charging current for a particular lithium-ion (Li-Ion) and lithium-polymer (Li-Pol) battery is selected by changing the resistance Rx.
The resistance Rx approximately corresponds to the following ratio: 0.95/Imax.
The value of the resistor Rx indicated in the diagram corresponds to a current of 200 mA, this is an approximate value, it also depends on the transistor.

It is necessary to provide a radiator depending on the charge current and input voltage.
The input voltage must be at least 3 volts higher than the battery voltage for normal operation of the stabilizer, which for one bank is? 7-9 V.

Diagram of a simple charger on the LTC4054


Rice. 6.


You can solder the LTC4054 charge controller from an old cell phone, for example, Samsung (C100, C110, X100, E700, E800, E820, P100, P510).


Rice. 7. This small 5-leg chip is labeled "LTH7" or "LTADY"

I will not go into the smallest details of working with the microcircuit, everything is in the datasheet. I will describe only the most necessary features.
Charge current up to 800 mA.
The optimal supply voltage is from 4.3 to 6 Volts.
Charge indication.
Output short circuit protection.
Overheating protection (reduction of charge current at temperatures above 120°).
Does not charge the battery when the voltage on it is below 2.9 V.

The charge current is set by a resistor between the fifth output of the microcircuit and ground according to the formula

I=1000/R,
where I is the charge current in amperes, R is the resistance of the resistor in ohms.

Lithium battery low indicator

Here simple circuit, which lights the LED when the battery is low and its residual voltage is close to critical.


Rice. eight.


Transistors are any low-power ones. The ignition voltage of the LED is selected by a divider of resistors R2 and R3. It is better to connect the circuit after the protection unit so that the LED does not drain the battery at all.

The nuance of durability

The manufacturer usually claims 300 cycles, but if you charge lithium just 0.1 volts less, up to 4.10 V, then the number of cycles increases to 600 or even more.

Operation and Precautions

It is safe to say that lithium-polymer batteries are the most “gentle” batteries in existence, that is, they require mandatory compliance with a few simple but mandatory rules, due to non-observance of which troubles happen.
1. Charge to a voltage exceeding 4.20 volts per can is not allowed.
2. Do not short circuit the battery.
3. It is not allowed to discharge with currents exceeding the load capacity or heating the battery above 60 ° C. 4. A discharge below a voltage of 3.00 Volts per jar is harmful.
5. Battery heating above 60°C is harmful. 6. Battery depressurization is harmful.
7. Harmful storage in a discharged state.

Failure to comply with the first three points leads to a fire, the rest - to a complete or partial loss of capacity.

From the practice of many years of use, I can say that the capacity of the batteries changes little, but the internal resistance increases and the battery starts to work less in time at high consumption currents - it seems that the capacity has fallen.
Therefore, I usually put a larger capacity, which the dimensions of the device allow, and even old cans, which are ten years old, work pretty well.

For not very high currents, old cell batteries are suitable.


You can pull out a lot of perfectly working 18650 batteries from an old laptop battery.

Where do I use lithium batteries

I have long converted a screwdriver and an electric screwdriver to lithium. I use these tools on a regular basis. Now even after a year of non-use, they work without recharging!

I put small batteries in children's toys, watches, etc., where there were 2-3 "tablet" elements from the factory. Where exactly 3V is needed, I add one diode in series and it turns out just right.

I put in LED flashlights.

Instead of the expensive and low-capacity Krona 9V, I installed 2 cans in the tester and forgot all the problems and extra costs.

In general, I put it wherever it turns out, instead of batteries.

Where do I buy lithium and usefulness on the topic

Are on sale. At the same link you will find charging modules and other useful things for DIYers.

At the expense of capacity, the Chinese usually lie and it is less than written.


Honest Sanyo 18650