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TP4056 Lipo Charger testing notes

Q: TP4056 keep shorting / dropping voltage when connected to XL6009. I found 2 solutions, which one is the best?

David McTravordHere is the electronics, I took the picture after I cut the wires, the measurement being done before the wires being cut. Basically, the voltage keeps dropping on C, from supposedly 4V to only 1V when I connect it to XL6009, without connecting the fan. Based on few searching, I discovered this p…

voltage tp4056 short

tlfong01

tlfong01

7445

Are you using XL6009 from HaoYu or XLsemi? XLSemi is the best. XL6009 180KHz 60V 5A Switching Current Boost DC/DC Converter Datasheet – HaoYu/ XLSemi (1) haoyuelectronics.com/Attachment/XL6009/… (2) xlsemi.net/datasheet/XL6019%20datasheet-English.pdf

Did you get your TP4056 from eBay or AliEx/Amazon? (1) aliexpress.com/w/…, TP4056 1A Standalone Linear Li-lon Battery Charger with Thermal (2) Regulation in SOP-8 – NanJing Top Power ASIC tp4056.com/d/tp4056.pdf

Why you use TP4056? XL6009 already has built in over voltage and over current protection. I think you can forget TP4056 and use a polyFuse for extra short circuit/over current. protection.

XL6009 4A is an overkill. I would suggest to instead use the popular cheapy LM2596 3A LM2596 module aliexpress.com/w/wholesale-lm2596-module.html

David McTravord

David McTravord

33

@tlfong01 I don’t know, the local seller didn’t specify where they bought it and what kind of brand it belongs.

@tlfong01 and for the module, then how can I charge the battery with? I use TP4056 for charging. And the LM2596, I’ll look into it.

@PStechPaul here the diagram imgur.com/a/EtQtYi1

tlfong01

tlfong01

Ah, there seems some misunderstanding somewhere. PStechPaul’s diagram is good to clarify things. Let me look at the whole picture and give you a quick reply, perhaps during weekend.

David McTravord

Sat 21:19

Alright, don’t worry, I also still waiting for the replacement XL6009 to arrived, in case if mine is defective, or the marking actually flipped. If you need any more information, just chat me here, or if you have a discord, chat me there McTee261#6133

15 hours later…

tlfong01

tlfong01

7445

Sun 11:52

A quick reply.

Your questions:

Q1 – @tlfong01 I don’t know, the local seller didn’t specify where they bought it and what kind of brand it belongs. – David McTravord 16 hours ago
Q2 – @tlfong01 and for the module, then how can I charge the battery with? I use TP4056 for charging. And the LM2596, I’ll look into it. – David McTravord 16 hours ago

My quick answers:

A1 – Your hardware setup diagram is not very clear. We need to use some reference for discussion. Perhaps we can use the following AliEx ad.

5V 1A 18650 TP4056 Lithium Battery Charger Module/Board With Protection Dual Functions Micro/Type-C USB – TZT 5-Star Store, AliExpress HK$10/(5pcs)
aliexpress.com/item/…

(see full text)

tlfong01

tlfong01

7445

Sun 12:30

AliEx TZT Lipo charger has two versions: with or without protection IC (HW01).

Now references for HW01:

(1) i.stack.imgur.com/SqNtn.jpg

(2) DW01 One Cell Lithium-ion/Polymer Battery Protection IC Datasheet – PingJing Semi
datasheet.lcsc.com/lcsc/…

tlfong01

tlfong01

Sun 13:07

Now I assume your TP4056 modules has HW01 built in. Pls let me know otherwise.

2 hours later…

tlfong01

tlfong01

7445

Sun 14:58

Now HW01 is control the dual N-channel power mosfet for charge/discharge current limiting. So we need to study the mosfet datasheet.

FS8205A Dual N-Channel Enhancement Mode Power MOSFET FortuneSemi
ic-fortune.com/upload/…

tlfong01

tlfong01

7445

Sun 15:14

If the OP’s TP4056 has no built in HW01 current protection cct, then I would recommend thi one from AliExpress:

1S 3.7V 4A li-ion BMS PCM 18650 Battery Protection Board PCB for 18650 lithium Battery Double MOS – $2.3
aliexpress.com/w/…

tlfong01

tlfong01

Sun 15:31

TZT’s TP4056 module recommends weak MT3608 boost converter and not the heavy duty XL6009. To play safe, I would start with MT3608 and perhaps LM2596 step down converter later.

7 hours later…

tlfong01

tlfong01

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Sun 22:34

I am drafting a block diagram for the single 3.7V Lipo battery charger.

user image

13 hours later…

tlfong01

tlfong01

7445

Mon 11:06

The OP is using a XL6009 boost converter without an on board DVM. I would suggest one with DVM, as shown below.

user image

XL6009 references:

DC-DC XL6009 Digital Boost Step Up Power Supply Module Adjustable 4.5 – 32V to 5-52V Step-up Voltage Regulator With LED Voltmeter HKD17.65
aliexpress.com/item/…

(see full text)

5 hours later…

tlfong01

tlfong01

7445

Mon 15:44

Warning to the OP:

(1) Why 18650 Battery Would Explode – DNK Power
dnkpower.com/…

(2) Should you be worried about exploding Lithium Ion batteries? – Aries RC 2016
youtube.com/…

1 hour later…

tlfong01

tlfong01

7445

Mon 16:53

More 1S protection board for double safety:

1S 3.7V 3A li-ion BMS PCM Battery Protection Board DC 4.2`5V CC/CV PCM for 18650 Lithium Ion Li Battery – AliExpress HK7/5pcs
aliexpress.com/item/…

(see full text)

4 hours later…

tlfong01

tlfong01

7445

Mon 20:33

Now I am going to test the TP4056 module with protection circuit.

user image

1 hour later…

tlfong01

tlfong01

7445

Mon 21:37

TP4056 Cheat Sheet

TP4056 1A Standalone Linear Li-lon Battery Charger with Thermal Regulation in SOP-8 Datasheet – NanJing Top Power ASIC
dlnmh9ip6v2uc.cloudfront.net/…

user image

tlfong01

tlfong01

Mon 21:50

DW01 Troubleshooting Cheat sheet.

DW01 One Cell Lithium-ion/Polymer Battery Protection IC Datasheet – PingJinSemi
datasheet.lcsc.com/lcsc/…

tlfong01

tlfong01

7445

Mon 22:43

user image

15 hours later…

tlfong01

tlfong01

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yst 13:14

There are two kinds of 18650 batteries: without or with built in IC (DW01) protection. I am going to test the one without protection.

Nitecore NL1835 NL835HP rechargeable battery 18650 3.6V Li-ion 3500mAh Output 2A (no built in protection) – AliExpress HK$132 (US$17)
aliexpress.com/item/…

user image

1 hour later…

tlfong01

tlfong01

7445

yst 14:41

Now I am charging up 4 NiteCore 2A, no protect 18650 samples for preliminary testing. These 4 things have charge in the range 4.18V~4.20V. So I guess they are almost fully charged.

user image

Now I am reading the user manual:

NiteCore DigiCharger D4 User Manual – NiteCore
charger.nitecore.com/Uploads/…

tlfong01

tlfong01

yst 15:22

Electric Danger of Lithium Ion 18650 – Battery Fires Exposed – Possible DIY Solution
youtube.com/…

3 hours later…

tlfong01

tlfong01

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yst 18:39

Now all 4 lipo batteries have finished charging. All measured 4.20V. Next step is testing the boost module XL6009.

user image

tlfong01

tlfong01

7445

yst 19:31

XL6009 Step up/Boost Converter Troubleshooting Warning.

The OP seems to connect output of TP4056 (18650) max 4.2V to the input of XL6009 boost converter to step upto 12V to drive a 12V BLDC motor. WARNING However, the minimum input voltage to XL6009 is 5V. So there is no guarantee that XL6009 should work.

Perhaps we should try MT3608 with input minimum voltage of 2V.

(1) XL6009 Datasheet – HaoYue
haoyuelectronics.com/…

(2) XL6009 Step-up Power Module DC-DC Converter – ICStation
instructables.com/…

(3) MT3608 1.2MHz 2A Step Up Converter – AeroSemi
olimex.com/Products/…

(4) LM2596 3A Step-Down Switching Regulator Datasheet – OnSemi
onsemi.com/pdf/datasheet/…

(see full text)

3 hours later…

tlfong01

tlfong01

7445

yst 22:09

More Lipo Experiments:

(5) Will China’s 18650 Battery Beat LG, Samsung, Sony & Panasonic? Let’s find out!
youtube.com/…

(6) Li-Ion battery short circuit, overcharge, undervoltage EXPERIMENT
youtube.com/…

tlfong01

tlfong01

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yst 22:59

Now I am testing if XL6009 specified min 5V input can work with Lipo output 3.7V to 4.2V.

user image

13 hours later…

tlfong01

tlfong01

11:39

Before my 18650 lab testing, I am watching more videos on how others are doing.

How to TEST 18650 cells (Samsung, LG, China OEM, …)
youtube.com/…

2 hours later…

tlfong01

tlfong01

7445

13:37

Now I am going to do a stretch stretch test on the boost converter XL6009. The AliEx user guide seems not very clear, so I need to google the Chinese version to clarify.

user image

2 hours later…

tlfong01

tlfong01

7445

15:41

New XTW6009 vs Old XL6009 Boost Converter:

So I googled for the XL6009 module user guide. I had a pleasant surprise! My XL6009 module is actually updated to XTW6009 with a wider input range of 3V ~ 32V!

In other words, my original conclusion that XL6009 not good for 3.7V Lipo cell input was wrong! This saves me much time of using my digital storage PSU (Riden RD6006) to verify XL6009 for oust of spec calibration/verification.

XTW6009 Boost Converter Chinese User Guide:

penzu.com/p/a81e30fd

tlfong01

tlfong01

16:32

***3V ~ 32V*** input to 5V~40V output DC-DC Step Up Power Supply Module XL6009 [XTW6009] Adjustable Boost Regulator Module Super LM2577 – AliExpress
aliexpress.com/item/…

6 hours later…

tlfong01

tlfong01

7445

22:19

The OP’s 12V 0.4A BLDC motor has the following spec:

I think it is similar to the following:

(1) Gdstime 7525 (75x50mm) DC12V 0.4A 2-pin Sleeve Bearing Brushless Sleeve Blower Cooling Fan

I think it is just an ordinary blower fan. So I will just get an common DC12V 2-pin computer cooling fan for testing.

tlfong01

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