DIY LiPo Charge/Protect/5V Boost Circuit
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DIY LiPo Charge/Protect/5V Boost Circuit

December 31, 2019

During a previous Project video Series of mine I showed you how to create this Battery-powered Raspberry Pi Handheld game console Which is still a ton of fun to play With Nevertheless I’m Currently Working on a successor though that most Importantly Should Be smaller and Lighter That is Why I will have to scrap the idea of using Nickel Metal Hydride batteries and Instead focus on lithium Polymer Battery as the Main Power Source Only problem is that the Nominal voltage of 3.7 volts of a Lipo Battery is not sufficient for the system So we would at Least Need a Circuit that can Boost the battery voltage Up to 5 volts and Deliver Up to 1 amp of Current. But It Would make sense to also integrate a constant Current constant voltage Charge circuits as Well as an Over discharge and Short-Circuit Protection Circuits. I already Tested a Potential candidate for Such a Circuit in a previous video, Which Unfortunately lack the Protection Features and could not provide enough current. Other Candidates on Aliexpress lack Electric Protection Features as Well and reusing a Power Bank circuits Would be novical at least in my opinion. So to solve this dilemma I will show you in this video how I designed created My own Lipo charge Protect Boost circuits that Fulfils all my Listed Requirements Let’s Get started. [music plays] As You might Know i’ve Been using the free online circuit design software called Easy eda for quite a While now and Since It can Also Transform Schematics Into Port Layouts i Will be using it for this Project and To make Things even Simpler for us we can use their partner component store Called lcSc Which are only offers Very low prices but also has its component database integrated into easy eda Which means that Not Only the schematic Symbols are available but also The Layout of the components for the port design Which Will save us a Lot of time and to conclude This trinity of Convenience we Can Let our Directly Export The board design to the easy eda pcB Manufacturing service Which is Actually Handled By The Company Jlc pcb Not Only are They the sponsor of This video but also offer Ridiculously Low prices and an overall Very Pleasing pcB quality But more about that Later for Now Let’s search for suitable charge ic as You can See here this selection Is quite big but there’s one i see a the Tpu 4056 Which i utilized before Without Any problems so Let’s Go with This one According to its data Sheets It Is a constant Current constant voltage a single cell lithium ion charge ic Which thus obviously also Works with a lipo cell and at The end of the data Sheets we Can See a typical application Schematic Which will pretty Much Only have to rebuild Within the Ez eda software By Utilizing The passive components of the database The Only Thing We Have to add By Ourselves so far is a Microusb Port For The Power inputs and a two kilo ohm resistor to set the charge current to 580 milliamps Next We Need a Protection Ic The first Entry The Dw 01 Pretty Much offered all the Protection Features i care about So i chose it without wasting any Time Again a Typical application Circuit Was present whose Rebuilding and the software was no problem at All but The two mandatory Mosfets were still missing a Simple Search for Dual n Channel Mosfet IC quickly look at me at the fs 8205 IC though Which can Withstand 20 volts 6 amps and has a Low gate voltage of Only 0.45 volts Perfect So I integrated this IC into the schematic and Edit solder Pads Full lipo Battery Which means we Were Pretty Much done with the charge and protect Part of the circuit. Next I added a Small Toggle switch to later Turn on and off The 5v boost Function and Started Searching For a suitable Boost converter ic What i found was the sdb628 Which according to its Datasheet has a Low input voltage a high efficiency and delivers Up to two amps There was also an Example circuits But This time Without Values for the components To determine them we have to look a Bit further down in the data Sheets Firstly we Can Set The output voltage By Utilizing in this formula. I went with the Values of 7.5 kilo ohm and 1 kilo ohm for the feedback Resistors Which Sets the output voltage to 5.1 volts Next the Datasheet Recommends an inductor value Between 4.7 and 22 micro Henry went with the biggest value and Continued By Adding input and output Capacitors with a value of 22 micro Farad’s and a suitable Schottky Diodes All of Course according to the Datasheet And After Adding Solder Pads For The 5 volts and Ground Outputs It Was time to push the convert project to pcB button and Start Designing the board Layouts What i came up with at the end looked something Like This Which Was Certainly not the best Solution But more about that in a Second for Now i click the fabrication output button Change the pcB quantity to ten boards and order them all for Only two Dollars But You can also Directly order Pcbs from Jlc PcB By Uploading Your cover files there and you would still Get this Insanely Low price Even With a Bull time of Only 48 Hours Any Way one Week after i ordered my pcBs I received them and Once I was done inspecting them all I did not notice any Kind of problem of them So i gathered all The Required smd components and started soldering them to the pcb and if you Have no clue how I did that then make sure to have a look at my How to solder properly video. Once I was done the soldering i hooked Up a Lipo battery and Connected five volt power to the micro usb Inputs as you can See the Red led lighted Up and the battery started Charging But with the current of Only 300 milliamps since the Battery Was already almost completely Charged Up After a Couple of Minutes of Charging though The led turned Green at a Cut-Off voltage of Around 4.209 Volts Which Seemed reasonable So it Was time to flip the toggle switch and measure the voltage at if i put outputs Which Revealed That the Boost circuits did in fact Work Well At Least Until i connected a Load of 6.9 ohms according To ohm’s Law a Current of 732 milliamps Should Have Flown but Instead the output voltage Broke down which means that Was a Problem That is Why i unsold Out the boost converter Ic and replaced It Over until year three 608 Ic Which Pretty Much Has the same pin out and Datasheet as the previous boost converter ic The Only differences that I have used this boost converter before and never had problems But Sadly Though This modification did not solve the Breakdown of the output voltage Which means there Was something Wrong With my board Design So i enlarged the boost converter copper traces and Rearranged a Couple Of The components Which Resulted in an overall Smaller size of The Board’s 4.3 centimeter By 1.9 centimeter to be exact After Once Again Waiting for Week i received the new version of My pcbs to Which i immediately soldered all of the components but I did not Only use the mt R3608 IC year as the only new Ic i Also Utilize The Fs 312f Protection ic Once Again The data Sheets of The olds and new Protection ics are Pretty Similar But The difference in which led me to this Icea is the higher over this charge protection voltage of two point Nine volts Instead of The old 2 Point 4 volts Which is pretty Low for lipo Battery Anyway after Finishing The soldering of The components i Added a Lipo Battery to the circuits and tested Out the charging feature Which like Before Worked Without a problem more Importantly though Was Whether the voltage Would Break down again Which it did not so i unsoldered the lipo battery and connected My lab Bench Power Supply instead to simulate different battery voltages and thus test the Board properly First off i Connected its Outputs to my diy power Logger and Connected a Variety of different Loads While Utilizing three different input Voltages in order to calculate the overall efficiency of the Boost converter As you can see in this diagram The average efficiency is Around 80% but a low input voltage and a Higher output current amounts can decrease This value a bit What is more important is that The output current Limit of the Boost converter is Around 1amp Since the output voltage Does Break down a Bit While lowering the input voltage to a value of 3 point 4 volts Not Perfect but It still fulfilled My requirement for the circuit Next i lower the input voltage Steadily Until i reached a value of Two point nine volts Which deactivated the Boost converter Even increasing The voltage to a normal value WouLd did not reactivate it only a Charged Impulse from the tpu 4056 allow the reactivating of The five volt Outputs Which means that the over discharge protection Worked Flawlessly Last But Not least i Showed a T5 Word Outputs of the circuits Which immediately It turned off the Boost converter Which means the short circuit Protection feature also Worked Like a Charm And My lipo Chart Protect Boost circuits Passed all my Tests and Due to its low quest and current of Only 4.7 micro amps Without the boost converter it can Also Safely Be used Even with small lipo batteries and if you a Need for such a circuits then you can Check out the video description you can Find the Gerber files and The easy eda Project Which you can utilize to for Example order Through Jl Cpcb Who made This project possible to begin With AnyWay i hope You enjoyed Watching This video if so don’t forget to like share and subscribe Stay Creative and i will see you next time

Only registered users can comment.

  1. How can I change the output power of the Boost Circuit to 12v? Can I just use an Boost-Converter in the end? Or do I need to redesign the Circuit?

  2. I purchased the battery charger / protection board from Amazon. Pretty much what you did except no boost converter. First test I did was under voltage where below 2.9 volts the charger IC should only put out a trickle charge of about 130ma or so. Well, it put out a little over an amp at a battery voltage of 2.7V. Pretty dangerous as the li-ion can swell up and explode. I bought 10 boards and they all failed that test.

  3. What changes would be needed to modify this design to output 3.3v.
    I’m interested in using this design as a base power/charging circuit for 3.3v projects.
    It would be nice to buck/boost the output power as required by the project.
    I would be willing to pay for a design, are you available in

  4. Wow. 3 in one board
    Edit: forgot to finish my comment lol. Anyway, I used your easy Eda schematic in a project of mine and added the traces to a single board. It’s impressive. Works perfect and now I have a complete. Present for my 10 year old brother. Thx man. This is the type of channel I like on YouTube.

  5. Hi, can I use it for Li-ion baterries as same as for LiPo as you presenting in the video? Thank you for all your videos, *thumbs up

  6. The DW01 has a low voltage turnoff at 2.4V, which is way too low. Am I right? So how can we make sure the circuit stops at 3 to 3.2V instead?

  7. I would love to watch a video about the casting design and manufacturing. A lot of people don't know how to bring their designs to live because of the mechanical designs (enclosures or cases)

  8. Can this circuit charge and discharge at the same time? I've seen power path management designs that use a p-channel mosfet as a one of a pair of diodes in an or'ing circuit. Would there be any benefit to including that in this project?

  9. !!!! DUDE !!!!

    !!!! YOU ARE AWESOME !!!!


    Please keep up the VERY inspiring open-source tinkering, designing, innovating and help you give the world !!

    YOU ROCK !!!!

  10. This is extremely neat, can this be used with a larger battery? I saw a 10000mah battery on AliExpress I want to buy for a project.

  11. Hi, my Xiaomi 10000mah power bank with a li-po battery stopped working after it took a hard drop. I've a couple of Power bank circuit board with me. Can I use any of those board to charge the li-po battery? Please let me know. Thanks in advance.

  12. Can anyone recommend an alternative to TP4056? If possible in an SOP8 package too.
    LCSC no longer have TP4056 in stock, and I can't find any other sellers of the chip.

  13. So if I wanted to add a small solar panel as the input (instead of USB) I could do this at the USB connection point instead of adding the USB port. Also instead of having a manual switch to allow load to draw, how could you charge and draw at the same time? Possible I may have missed something here…. Also, want to give you a great plug – I've learnt a lot more from watching your videos – thanks so much!

  14. I've worked with bare b628 ICs and can tell you that they are unpredictable (maybe datasheet omits some imp info) and they often smoke and burn out

  15. Im making a hand held too as my next project…. I hope you dont mind me borrowing your circuit. I really know very little about power circuits and intergrating your design in to my board would help me tons 🙂

  16. A premade powerbank PCB would be An overkill, so I created my own circuit, designed a PCB and let it ship from China!

  17. I made a modified version of this circuit, with a few additional features. Any expert willing to have a quick look and see if you spot anything dumb…?|785b91c961fb4abbaf7e3d4dfbbb8129|d44a65ea2f884457a981bd6d6c3ddf31

  18. ⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻⸻ says:

    question is
    when do we get the rpi in a gameboy sp video

  19. So mah question is (powerbank) the lipo charges ur phone faster than the li ion and the li ion dies faster than the lipo right? If its right it i will buy for 60$ a lipo powerbank with 12000 mah with Qualcomm quick charge 3.0 with a usb c connecter + normal usb from cellularline (is that company good?)

  20. Hi greatscott another nice video. This circuit doesnt have reverse polarity protection right? I did same circuit with small difference but its not working

  21. Hi, how did it solve @ 8:04 ?
    Just by changeing the copper trace ? What did you put the width as ?

  22. A big thing that helped me building buck/boost converters is knowing the ideal values of the inductor without needing to reference the datasheet each time (especially with general purpose switch controllers that might not have the specifics for inductors). I found an equation online for estimating the required value of the coil in a buck/boost converter, I then plugged this equation into a spreadsheet so if I need to build anything all I need is the input voltage, output voltage, frequency, and max current. This helps save space on the board and money in your pocket rather than going straight for the largest reasonable value. Not a huge savings unless you make a lot of boards but it's still helpful for making good buck/boosts. The value in henrys is L=((vin-vout)*vout)/(vin*Imax*hz*0.35). Thanks again for yet another awesome video Great Scott!

  23. I wanna make this exact board but I need a stronger boost. I need 5v but more like up to 5 amps maybe less if I can figure out better leds to use instead of 3 64×64 matrices

  24. Hi, GreatScott, i only recently found this video and fell in love with it. Can i ask something? why did you choose 0603 component sizes and not bigger… lets say 0805?(i want stock up myself on lcsc, so i am creating BOM) is it okay to solder this small packages with 5x magnification, or do you consider it hard? (handsolder or hot air). also have you experince with traces between 0603 pads? Thank you! 🙂

  25. if anyone interested, I have redesigned PCD for my own needs:

  26. Can someone tell me the values of the resistors for boost the voltage to 12v? I will be very happy 😊 :3

  27. Hi i am thinking or using a pijuice hat to providing portable power however what i want to do is parellele wire two 12000mah battereas together and I am looking for a ciruit or board that will allow charging of two batteries like the pijuice. Would you consider doing a video on this on making your own or improving on tje original to allow duel charging

  28. Is it possible to not have the switch there? as im planning on using this with a pi 0 and it runs on 5v so i wouldnt need to turn the booster off?

  29. Hallo do you have a DIY video for an electronic interface that can monitor the charging cycle for a tablet, or a smart/ iphone? one that would show the beginning
    battery voltage, the charging current, and ending (fully charged) voltage? Danke! great videos too😃

  30. hello GreatScott, or any other commenter
    I have a question,
    Well, i do not understand why you used a Button to turn the circuit of when charging, as far as i can see, this is only optional.
    Is there a important reason?

  31. Hello. In your board, it looks like the GND of C1 and U4 are separate from the rest of the grounds and ground plane. Is this on purpose? Trying to figure out why my version of this board isn't working. Thanks!

  32. Hi 😀
    I want to make my usb c lipo charger pcb.. but I am having problems on understanding how type C usb release power.. has somebody worked with type C usb power? (I don't need to communicate, so I can't understand if CC pins are useless). (I'll attach it only to a wall adapter)

  33. I know this is a old video but thought of a question. Which is more efficient, the boost or the buck converter? Curious because if you go with 1s you need the boost or go with 2s need a buck.

  34. Hello this video is really good.
    sorry for my english

    Is it possible to use the 5volts during charging time?
    i'll try to explain my question…
    I use an alarm system (with Arduino) and i want to have a power rescue. If i loose main power voltage i need a battery to maintain my arduino ON in order to send an alarm.
    i think i just need to caculate the capacity of battery with the time i need my system run without main power supply.

    Is it possible with this circuit ?
    Thanks a lot
    have a nice day

  35. Great scott …. Can youhelp me i need output of 3.3volt 1amp from lithium polymer 5000mah also need to charge the polymer battery after discharging. Any 2in 1 module you can suggest

  36. Are you open to a partnership, and if not where do i find someone with your skillset, or where do i go to learn this myself?

  37. Does your Power Management IC get hot? I just got one board that use "TC4056A" IC and that thing just go insane hot after a few seconds I start to charge my battery 🙁

  38. Great videos! Q: Why can't LiPo batteries simply be charged with a fixed voltage level @ let's say .5 VDC below their fully charged level?
    Example: I purchased a 50000 mAh power bank, which has 19 VDC charge input (I want to use 19V 40W PV panels for charging), USB-C & USB-A (to power RPi 3B+ or VIM3 SBC), and 5.2mm barrel w/selective outputs (12 VDC for small tracking motors). Perfect… except, the power bank shuts down when the sun doesn't shine.😣 So, I need to replace its 'brains'.
    The power bank contains 8 x 3.7V LiPo batteries (4 banks of parallel pairs in series), which measured 16.5 VDC fully charged (with mfr's charger & circuitry). But, I have reconfigured them into 2 series banks of 4 parallel batteries which reduces the fully charged voltage to 8.4 VDC (7.4V rating), so that I could use a buck converter with a lower input voltage to accommodate times of lower PV output. Another buck converter replaces the 5VDC output and a boost converter replaces the 12VDC output.
    What would be wrong with simply setting the charging buck converter to 8 VDC for a constant ~12 hr daily charge cycle with ~12 hr nightly discharge cycle?
    Thanks for your time.

  39. I'm not really an expert in pcb design, but I always use planes in the power sections to avoid drop power problems. Thanks for the video, everything is really well explained.

  40. Please update LiPoChargeProtectBoost's Bom, plenty of the parts are discontinued and referring the wrong parts.

    The website lists 17 parts and in the Bom it lists 21 parts.

    I want to build it is there a way to make output current variable aka adjustable that would be awesome to support more lipo and liion battery's.

    GreatScott aka Back To The Future ahahaah

  41. Why is the switch necessary?
    without it, if you want 5V then connect the load to 5V pin and if you dont want it, to B+, right?

  42. Excellent video. Many thanks. Did you mean to attach final schematic? That would help towards a full and detailed understanding.

  43. How can I connect an external battery in mobile? (Replaced two Battery already) What board to use that doesn't damage my phone?

  44. Seems like a lot of work to do a pretty basic thing. I would imagine this circuit being a good candidate for integration in a single IC.

  45. Thank you so much for your links, I've created an advanced solution out of them with possibility to measure the current and the battery voltage to monitor my system. Now i have to test it.

  46. Great tutorial! I have watched a few of your other video and have now subscribed to your channel. You should do a tutorial on creating your own controller pcb for the gameboy zero.

  47. Made this circuit myself and I'm getting a wired error I can't figure out.. when connected to the charger the green LED lights up (even though battery voltage is 3.5v) and the red LED lights up very dimly. No such mention in the datasheet for this error closest match is for blinking red LED which says add 10uf cap to battery pin. I've tried this to no effect.. any ideas??

  48. This is exactly the content I've been looking for. Explanation that is deep enough and doesn't waste time or beat you over the head just to make a video longer. Keep it up man! I love it.

  49. do you know that the battery shown in this video has its own BSM with built in over-charge and discharge protection? I've used that exact battery in a project and it does work.

  50. Ur awesome bro!! I wish I could be ur student I love electronics , when I was a child my dream was to become a electronic engineer but I never learned enough it's my passion to pay attention but I made alot of mistakes so I am trying so hard to get back on my toes!!! I appreciate ur videos very much thanks

  51. Fantastic video! I must incorporate this design into my WonderSwan portable RetroPie build. That protection circuit is something I really need! Any hopes of seeing a battery build for the Pi4?

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